SM - E215b Japan Hs Afme - en

HYDRAULIC EXCAVATOR
MAINTENANCE SPECIFICATIONS
SHOP E215B
MANUAL model E215BLC
(HS Engine)
INDEX
1 SPECIFICATIONS SECTION
SYSTEM
2 MAINTENANCE SECTION
3 SYSTEM SECTION
4 DISASSEMBLY SECTION
DISASSEMBLING
5 TROUBLESHOOTING
6 ENGINE SECTION
7 PROCEDURE E / G TROUBLESHOOTING
OF INSTALLING
OPTIONS SECTION OPT.
Book Code No. 87731204

0-1
GENERAL SAFETY INFORMATION 3) CAUTION- Indicates a potentially hazardous
situation which, if not avoided, may result in mi-
nor or moderate injury. It may also be used to
alert against possible damage to the machine
Do not operate or perform any maintenance on this and its components and is represented as fol-
machine until all instructions found in the OPERA- lows:
TOR’S MANUAL and this MANUAL have been thor-
oughly read and understood.
Improper operation or maintenance of this machine (4) It is very difficult to forecast every danger that may
may cause accidents and could result in serious in- occur during operation. However, safety can be en-
jury or death. sured by fully understanding proper operating pro-
Always keep the manual in storage. cedures for this machine according to methods
If it is missing or damaged, place an order with an recommended by Manufacturer.
authorized our Distributor for a replacement. (5) While operating the machine, be sure to perform
If you have any questions, please consult an autho- work with great care, so as not to damage the ma-
rized our Distributor. chine, or allow accidents to occur.
(1) Most accidents, which occur during operation, are (6) Continue studying the manual until all Safety, Oper-
due to neglect of precautionary measures and safe- ation and Maintenance procedures are completely
ty rules. Sufficient care should be taken to avoid understood by all persons working with the ma-
these accidents. Erroneous operation, lubrication chine.
or maintenance services are very dangerous and
may cause injury or death of personnel. Therefore
all precautionary measures, NOTES, DANGERS,
WARNINGS and CAUTIONS contained in the man-
ual and on the machine should be read and under-
stood by all personnel before starting any work with
or on the machine.
(2) Operation, inspection, and maintenance should be
carefully carried out, and safety must be given the
first priority. Messages of safety are indicated with
marks. The safety information contained in the
manual is intended only to supplement safety
codes, insurance requirements, local laws, rules
and regulations.
(3) Messages of safety appear in the manual and on
the machine : All messages of safety are identified
by either word of "DANGER", "WARNING" and
"CAUTION".
1) DANGER- Indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury and is represented as
follows:
2) WARNING- Indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury and is represented as
follows:
0-2
SAFETY PRECAUTIONS stands, capable of supporting the machine, before
performing any disassembly.
The proper and safe lubrication and maintenance

for this machine, recommended by Manufacturer, Do not operate this machine unless you have
are outlined in the OPERATOR’S MANUAL for the read and understand the instructions in the OP-
machine. ERATOR’S MANUAL. Improper machine opera-
Improper performance of lubrication or mainte- tion is dangerous and could result in injury or
nance procedures are dangerous and could result death.
in injury or death. Read and understand the MAN-
(6) Relieve all pressure in air, oil or water systems be-
UAL before performing any lubrication or mainte-
fore any lines, fittings or related items are discon-
nance.
nected or removed. Always make sure all raised
The serviceman or mechanic may be unfamiliar with components are blocked correctly and be alert for
many of the systems on this machine. This makes it possible pressure when disconnecting any device
important to use caution when performing service work. from a system that utilizes pressure.
A knowledge of the system and or components is im- (7) Lower the bucket, dozer, or other attachments to
portant before the removal or disassembly of any com- the ground before performing any work on the ma-
ponent. chine. If this cannot be done, make sure the bucket,
Because of the size of some of the machine compo- dozer, ripper or other attachment is blocked correct-
nents, the serviceman or mechanic should check the ly to prevent it from dropping unexpectedly.
weights noted in this manual. Use proper lifting proce- (8) Use steps and grab handles when mounting or dis-
dures when removing any components. Weight of com- mounting a machine. Clean any mud or debris from
ponents table is shown in the section ; steps, walkways or work platforms before using.
SPECIFICATIONS. Always face to the machine when using steps, lad-
The following is a list of basic precautions that must al- ders and walkways. When it is not possible to use
ways be observed. the designed access system, provide ladders, scaf-
folds, or work platforms to perform safe repair oper-
(1) Read and understand all Warning plates and decal
ations.
on the machine before Operating, Maintaining or
Repairing this machine. (9) To avoid back injury, use a hoist when lifting com-
ponents which weigh 20kg (45lbs) or more. Make
(2) Always wear protective glasses and protective
sure all chains, hooks, slings, etc., are in good con-
shoes when working around machines. In particu-
dition and are the correct capacity. Be sure hooks
lar, wear protective glasses when using hammers,
are positioned correctly. Lifting eyes are not to be
punches or drifts on any part of the machine or at-
side loaded during a lifting operation.
tachments. Use welders gloves, hood/goggles,
apron and the protective clothing appropriate to the (10)To avoid burns, be alert for hot parts on machines
welding job being performed. Do not wear loose fit- which have just been stopped and hot fluids in
ting or torn clothing. Remove all rings from fingers, lines, tubes and compartments.
loose jewelry, confine long hair and loose clothing (11)Be careful when removing cover plates. Gradually
before working on this machinery. back off the last two capscrews or nuts located at
(3) Disconnect the battery and hang a "Do Not Oper- opposite ends of the cover or device and carefully
ate" tag in the Operators Compartment. Remove ig- pry cover loose to relieve any spring or other pres-
nition keys. sure, before removing the last two capscrews or
nuts completely.
(4) If possible, make all repairs with the machine
parked on a firm level surface. Block the machine (12)Be careful when removing filler caps, breathers and
so it does not roll while working on or under the ma- plugs on the machine. Hold a rag over the cap or
chine. Hang a "Do Not Operate" tag in the Opera- plug to prevent being sprayed or splashed by liq-
tors Compartment. uids under pressure. The danger is even greater if
the machine has just been stopped because fluids
(5) Do not work on any machine that is supported only
can be hot.
by lift, jacks or a hoist. Always use blocks or jack
0-3
(13)Always use the proper tools that are in good condi- (21)Do not operate a machine if any rotating part is
tion and that are suited for the job at hand. Be sure damaged or contacts any other part during opera-
you understand how to use them before performing tion. Any high speed rotating component that has
any service work. been damaged or altered should be checked for
(14)Reinstall all fasteners with the same part number. balance before reusing.
Do not use a lesser quality fastener if replacements (22)Be careful when servicing or separating the tracks
are necessary. (crawlers). Chips can fly when removing or install-
(15)Repairs which require welding should be per- ing a track (crawlers) pin. Wear safety glasses and
formed only with the benefit of the appropriate ref- long sleeve protective clothing. Tracks (crawlers)
erence information and by personnel adequately can unroll very quickly when separated. Keep away
trained and knowledgeable in welding procedures. from front and rear of machine. The machine can
Determine type of metal being welded and select move unexpectedly when both tracks (crawlers)
correct welding procedure and electrodes, rods or are disengaged from the sprockets. Block the ma-
wire to provide a weld metal strength equivalent at chine to prevent it from moving.
least to that of the parent metal. Make sure to dis-
connect battery before any welding procedures are
attempted.
(16)Do not damage wiring during removal operations.
Reinstall the wiring so it is not damaged nor will be
damaged in operation of the machine by contacting
sharp corners, or by rubbing against some object or
hot surface. Do not connect wiring to a line contain-
ing fluid.
(17)Be sure all protective devices including guards and
shields are properly installed and functioning cor-
rectly before starting a repair. If a guard or shield
must be removed to perform the repair work, use
extra caution and replace the guard or shield after
repair is completed.
(18)The maintenance and repair work while holding the
bucket raised is dangerous due to the possibility of
a falling attachment. Don’t fail to lower the attach-
ment and place the bucket to the ground before
starting the work.
(19)Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not bend
or strike high pressure lines or install ones which
have been bent or damaged. Inspect lines, tubes
and hoses carefully. Do not check for leaks with
your hands. Very small (pinhole) leaks can result in
a high velocity oil stream that will be invisible close
to the hose. This oil can penetrate the skin and
cause personal injury. Use card-board or paper to
locate pinhole leaks.
(20)Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are in-
stalled correctly to avoid excessive heat, vibration
or rubbing against other parts during operation.
Shields that protect against oil spray onto hot ex-
haust components in event of a line, tube or seal
failure must be installed correctly.
0-4
E215B
NHK Middle East (HS Engine) INDEX E215BLC
Book Code No. Index
Title
Distribution Year–Month No.
MAINTENANCE SPECIFICATIONS
S5YN0118E01
2007-7
OUTLINE 1
S5YN0225E01
2007-7
SPECIFICATIONS 2
S5YN0322E01
ATTACHMENT DIMENSIONS 3
2007-7
S5YN1122E01
TOOLS 11
2007-7
S5YN1221E01 STANDARD MAINTENANCE
2007-7
12
TIME SCHEDULE
S5YN1318E02 MAINTENANCE STANDARD
2007-7
13
AND TEST PROCEDURE
S5YN2122E01 MECHATRO CONTROL
2007-7
21
SYSTEM
S5YN2223E01
2007-7
HYDRAULIC SYSTEM 22
S5YN2324E01
SYSTEM
2007-7
ELECTRIC SYSTEM 23
S5YN2422E01
2007-7
COMPONENTS SYSTEM 24
S5YN2518E02
2007-7
AIR-CONDITIONER SYSTEM 25
_
S5YN3118E01 DISASSEMBLING
DISASSEMBLING
2007-7 & ASSEMBLING

31
S5YN3218E02
ATTACHMENT 32
2007-7
S5YN3322E01
2007-7
UPPER STRUCTURE 33
S5YN3421E01
2007-7
TRAVEL SYSTEM 34
E / G TROUBLESHOOTING
S5YN4618E02
2007-7
BY ERROR CODES 46
S5YN4718E01
2007-7
BY TROUBLE 47
S5YN4818E01
2007-7
TROUBLE DIAGNOSIS MODE 48
_
S5YN5123E01
ENGINE 51
2007-7
_
YN11-45001~
YQ11-06001~ APPLICABLE MACHINES
0-5
NOTE:
This Manual is prepared as a technical material in This Manual may be properly revised due to the im-
which the information necessary for the maintenance provement of products, modification of specifications,
and repairing services of our hydraulic excavators are etc. And there are cases where the system on actual
collected, and is categorized into 7 Chapters, Specifica- machine and a part of the contents of this manual may
tion, Maintenance, System, Disassembly, Trouble- differ due to the variations of specification by countries.
shooting, Engine, and Installation Procedures for For the section in which the description is hardly under-
Optional Attachment. stood, contact our distributor.
• The Chapter "Specification" describes the specifi- The number is assigned to every part handled in this
cations for entire machine and material, which are Manual on account of the description, but the parts,
instructive for replacement and repairing of attach- which cannot be supplied as service parts are con-
ments. tained. Therefore, the order must be placed with re-
spective formal number with due confirmation on the
• The Chapter "Maintenance" describes the material,
Parts Manual for applicable machine.
which is helpful for maintenance service and adjust-
ments for entire machine.
• The Chapter "System" describes the operating sys-
tem like hydraulic system, electric system, compo-
nents, and so on.
• The Chapter "Disassembly" describes the removal
and installing of assembly mounted on the upper
structure and undercarriage, and the assembling
and disassembling of the associated hydraulic
equipment.
• The Chapter "Troubleshooting" describes how to
find the fault equipment.
• The Chapter "Engine" describes the engines mak-
ing use of the "Maintenance Manual" provided by
the suppliers.
• The Chapter "Installation Procedures for Optional
Attachment" describes the supplements added on
request as required.
0-6
1
1. OUTLINE
TABLE OF CONTENTS
1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS ......................................................1-3

1.1.1 PREPARATION BEFORE DISASSEMBLING ..........................................................1-3
1.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING ........................................1-3
1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT .......................1-3
1.1.4 ELECTRICAL EQUIPMENT .....................................................................................1-4
1.1.5 HYDRAULIC PARTS ................................................................................................1-5
1.1.6 WELD REPAIR .........................................................................................................1-5
1.1.7 ENVIRONMENTAL ISSUES.....................................................................................1-5
1.2 INTERNATIONAL UNIT SYSTEM .....................................................................................1-6
Book Code No. S5YN0118E01
1-1
1. OUTLINE
Issue Date of Issue Applicable Machines Remarks

SK330-8 : LC10-07001~ S5YN0118E01
First edition July, 2006 K
SK350LC-8 : YC10-03501~ (ASIA, OCE)
SK200-8 : YN11-45001~ ↑
↑ August, 2006 K
SK210LC-8 : YQ11-06001~ (ASIA, OCE)
SK250-8: LQ12-06001~ ↑
↑ October, 2006 K
SK260LC–8 : LL12-05001~ (ASIA, OCE)
↑ December, 2006 SK850LC: LY01-00101~ ↑ K
E235BSR : YF05-02001~ ↑
↑ February, 2007 K
E235BSR(N)LC : YU05-02001~ (NHK)
↑
↑ ↑ SK235SRLC-2 : YU05-02001~ K
(North America)
E215B : YN11-45001~ ↑
↑ March, 2007 K
E215BLC : YQ11-06001~ (NHK Russia)
SK235SR-2 : YF05-02001~ ↑
↑ April, 2007 K
SK235SRLC-2 : YU05-02001~ (OCE)
SK200-8 : YN11-45001~ ↑
↑ ↑ K
SK210LC-8 : YQ11-06001~ ASIA (HS Engine)
SK250-8: LQ12-06001~ ↑
↑ May, 2007 K
SK260LC–8 : LL12-05001~ ASIA (HS Engine)
E225BSR : YB05-03001~ ↑
↑ June, 2007 K
E225BSRLC : LA05-02001~ (NHK)
↑
↑ ↑ SK215SRLC : LA05-02001~ K
(North America)
E135BSR : YY05-12001~ ↑
↑ July, 2007 K
E135BSRLC : YH05-07001~ (NHK)
SK225SR : YB05-03001~ ↑
↑ ↑ K
SK225SRLC : LA05-02001~ (OCE)
SK460-8: LS10-02001~ ↑
↑ ↑ K
SK480LC–8 : YS10-01501~ (ASIA, OCE)
E215B : YN11-45001~ ↑
↑ ↑ K
E215BLC : YQ11-06001~ (NHK Middle East)
E265B : LQ12-06001~ ↑
↑ ↑ K
E265BLC : LL12-05001~ (NHK Russia)
E215B : YN11-45001~ ↑
↑ ↑ K
E215BLC : YQ11-06001~ (NHK Russia) HS Engine
↑
↑ ↑ ↑ K
(NHK Middle East) HS Engine
E385B : LC10-07001~ ↑
↑ August, 2007 K
E385BLC : YC10-03501~ (NHK Middle East)
1-2
1. OUTLINE
1.1 GENERAL PRECAUTIONS FOR 2) Attach "Don’t operate" tag to control lever, and
begin a meeting before starting the work.
MAKING REPAIRS
3) Before starting inspection and maintenance
1.1.1 PREPARATION BEFORE stop the engine.
DISASSEMBLING
4) Confirm the position of first-aid kit and fire
extinguisher, and also where to make contact
Read Operator's Manual
for emergency measure and ambulance to
before disassembling
prepare for accidents and fire.

(1) Knowledge of operating procedure
5) Choose a hard, lever and safe place, and put
Read Operator’s Manual carefully to understand
attachment on the ground without fail.
the operating procedure.
6) Use hoist, etc. to remove parts of heavy weight
(2) Cleaning machines
(23kg [50 lb] or more).
Clean machines of soil, mud, and dust before
carrying into the service shop. 7) Use proper tools, and change or repair
Carrying a soiled machine into the service shop, defective tools.
causes making less efficient work and damage of 8) Machine and attachment required to work in the
parts. lifting condition should be supported with
(3) Inspecting machines supports or blocks securely.
Confirm the disassembling section before starting 1.1.3 DISASSEMBLING AND ASSEMBLING
work, determine the disassembly procedure taking HYDRAULIC EQUIPMENT
the conditions in work shop into account, and
request to procure necessary parts in advance.
(4) Recording
Record the following items to keep contact and (1) Removing hydraulic equipment assy
prevent malfunction from recurring. 1) Before removing pipes, release the pressure of
1) Inspecting date, place hydraulic oil tank, or open the cover on the
2) Model name, Serial number and Record on return side to tank, and take out the filter.
hour meter 2) Drain the oil in the removed pipes into pan to
3) Trouble condition, place, cause prevent the oil from spilling on the ground.
4) Visible oil leak, water leak and damage 3) Pipes with plugs or caps to prevent oil leaking,
entry of dust, etc.
5) Clogging of filters, oil level, oil quality, oil
contamination and looseness. 4) Clean the outside surface of equipment, etc.
before disassembling, and drain hydraulic oil
6) Examine the problems on the basis of monthly
and gear oil before putting them on working
operation rate with the last inspection date and
bench.
records on hour meter.
(2) Disassembling hydraulic equipment
(5) Arrangement and cleaning in service shop
1) Since performance and function of hydraulic
1) Tools required for repair work.
equipment after disassembly and assembly
2) Prepare the places to put the disassembled
results in immunity from responsibility on the
parts.
manufacture’s side, disassembly, assembly
3) Prepare oil pans for leaking oil, etc. and modification without permission are strictly
prohibited.
1.1.2 SAFETY WHEN DISASSEMBLING AND
ASSEMBLING 2) If it is unavoidably necessary to disassemble
and modify, it should be carried out by experts
or personnel qualified through service training.
WARNING
3) Make match mark on parts for reassembling.
(1) Safety 4) Before disassembling, read Disassembling
1) Wear appropriate clothing, safety shoes, safety Instruction in advance, and determine if the
helmet, goggles, and clothes with long sleeves. disassembly and assembly are permitted or
not.
1-3
1. OUTLINE
5) For parts which are required to use jig and

tools, don’t fail to use the specified jig and tools.
6) For parts which can not be removed in the
If hydraulic oil and lubricating oil are not
specified procedure, never force removal. First
filled and also air bleed is not performed,
check for the cause.
the hydraulic equipment may be damaged.
7) The removed parts should be put in order and
tagged so as to install on proper places without 3) For air bleed of hydraulic pump and swing
confusion. motor, loosen drain plug on the upper part, start
8) For common parts, pay attention to the quantity engine, and run in low idling, then bleed air until
and places. hydraulic oil is comes out. After completion of
comes, tighten plug securely.
(3) Inspecting parts
4) For air bleed of travel motor and hydraulic
1) Check that the disassembled parts are free
cylinder, starts engine and operate it for 10
from adherence, interference and uneven
minutes or more at no-load and low speed.
working face.
2) Measure the wear of parts and clearance, and
record the measured values.
3) If an abnormality is detected, repair or replace For cylinder, don’t move it to the stroke end
the parts. at beginning.
(4) Reassembling hydraulic equipment
5) Air in pilot circuit can be bleed out by only
1) During the parts cleaning, ventilate the room. operating digging, swing and traveling motions
2) Before assembly, clean parts roughly first, and thoroughly.
then completely. 6) Check hydraulic oil level.
3) Remove adhering oil by compressed air, and Move attachments to hydraulic oil check
apply hydraulic oil or gear oil, and then position, and check hydraulic oil level of tank.
assemble them. Refill oil if the oil level is lower than the specified
4) Replace the removed O-ring, back-up rings and level.
oil seal with new ones, and apply grease oil on How to check oil level of hydraulic oil tank
them before assembling.

5) Removes dirt and water on the surface on
which liquid sealant are applied, decrease LEVEL GAUGE
Oil level of hydraulic oil tank.
them, and apply liquid sealant on them. If the indicator is within
level marks, the oil quantity
6) Before assembling, remove rust preventives on is acceptable.
new parts.
7) Use special tools to fit bearings, bushing and oil 1.1.4 ELECTRICAL EQUIPMENT
seal.
8) Assemble parts matching to the marks.
9) After completion, check that there is no
(1) The disassembly of electrical equipment is not
omission of parts.
allowed.
(5) Installing hydraulic equipment
(2) Handle equipment with care so as not to drop it or
1) Confirm hydraulic oil and lubrication oil.
bump it.
2) Air release is required in the following cases ;
(3) Connector should be removed by unlocking while
1. Change of hydraulic oil holding the connector.
2. Replacement of parts on suction pipe side Never stress in tension to the caulked section by
3. Removing and attaching hydraulic pump pulling wire.
4. Removing and attaching swing motor (4) Check that connector is connected and locked
completely.
5. Removing and attaching travel motor
(5) Engine key off before removing and connecting
6. Removing and attaching hydraulic cylinder
connector.
1-4
1. OUTLINE
(6) Engine key off before touching terminals of starter (2) Flexible hose (F hose)
and alternator. • Even if the connector and length of hose are the
(7) Remove battery grounding terminal before same, the parts differ according to the
beginning work close to battery and battery relay withstanding pressure. Use proper parts.
with tools. • Tighten it to the specified torque, and check that
(8) Wash machine with care so as not to splash water it is free from twist, over tension, interference,
on electrical equipment and connector. and oil leak.
(9) When water has entered in the waterproofed
1.1.6 WELD REPAIR
connector, the removing of water is not easy. So
(1) The weld repair should be carried out by qualified
check the removed waterproofed connector with
personnel in the specified procedure after
care to protect it from entry of water. If moisture
disconnecting the grounding cable of battery. If the
adheres on it, dry it completely before connecting.
grounding cable is not disconnected, the electrical
equipment may be damaged.
(2) Remove parts which may cause fire due to the
Battery fluid is dangerous. entry of spark beforehand.
The battery fluid is dilute sulfuric acid, and causes (3) Repair attachments which are damaged, giving
scald and loss of eyesight by adhering on eyes, particular attention to the plated section of piston
skin and clothes. When the fluid has adhered on rod to protect it from sparks, and don’t fail to cover
them, take an emergency measure immediately and the section with flame-proof clothes.
see a doctor for medical advice.
1.1.7 ENVIRONMENTAL ISSUES
• When it has adhered on skin ;
Wash with soap and water. (1) Engine should be started and operated in the place
where air can be sufficiently ventilated.
• When it has got in eyes ;
Wash in water for 10 minutes or more (2) Waste disposal
immediately. The following parts follows the regulation.
Waste oil, waste container and battery
• When it has spilled out in large quantity ;
Use sodium bicarbonate to neutralize, or wash (3) Precautions for handling hydraulic oil
away with water. Hydraulic oil may cause inflammation of eyes.
Wear goggles to protect eyes on handling it.
• When it was swallowed ;
Drink milk or water. • When it has got in eyes ;
Wash eyes with water until the stimulus is gone.
• When it has adhered on clothes ;
Wash it immediately. • When it was swallowed ;
Don’t force him to vomit it, but immediately
1.1.5 HYDRAULIC PARTS receive medical treatment.
• When it has adhered on skin ;
Wash with soap and water.
(4) Others
(1) O-ring For spare parts, grease and oil, use KOBELCO
• Check that O-ring is free from flaw and has genuine ones.
elasticity before fitting.
• Even if the size of O-ring is equal, the usage
differs, for example in dynamic and static
sections, the rubber hardness also differs
according to the pressure force, and also the
quality differs depending on the materials to be
seated. So, choose proper O-ring.
• Fit O-ring so as to be free from distortion and
bend.
• Floating seal should be put in pairs.
1-5
1. OUTLINE
1.2 INTERNATIONAL UNIT SYSTEM (4) Derived Units bearing Peculiar Designations
Introduction Table1-4
Although this manual uses the SI units system. Outline QUANTITY UNIT SYMBOL FORMULA
of SI units system is described here. Frequency hertz Hz 1Hz=1/s
Given hereinunder are an excerpt of the units that are Force newton N kg • m/s 2
related to this manual : Pressure and
pascal Pa N/m2
1. Etymology of SI Units Stress
English : International System of units Energy, Work
2. Construction of SI Unit System and Quantity of joule J N•m
heat
Base units Power watt W J/s
Table 1-1
Derived units Quantity of
of base units
coulomb C A•s
Supplemen electricity
SI units tary units Table 1-3
SI unit Table 1-2 Electric
system Derived units potential
Derived bearing peculiar
designations difference,
units volt V W/A
Table 1-4 Voltage, and
Electromotive
Prefixes of SI
(n-th power of 10, where n is an integer) force
Table 1- 5 Quantity of
static electricity
(1) Basic Units farad F C/V
and Electric
Table1-1 capacitance
Electric
QUANTITIES DESIGNATION SIGN ohm V/A
resistance
Length Meter m
celcius
Mass Kilogram kg Celcius
degree or C
° (t+273.15)K
Time Second s temperature
degree
Current Ampere A
Thermodynamic Kelvin K Illuminance lux lx l m/m2
temperature
(5) Prefixes of SI
Gram molecule Mol mol
Luminous intensity Candela cd Table1-5
PREFIX
(2) Supplementary Units POWER
DESIGNATION SIGN
Table1-2 Giga G 109
QUANTITIES DESIGNATION SIGN Mega M 106
Plain angle Radian rad Kilo k 103
Solid angle Steradian sr Hecto h 102
Deca da 10
(3) Derived Units of Basic Units
Deci d 10–1
Table1-3 Centi c 10–2
QUANTITIES DESIGNATION SIGN Milli m 10–3
Area Square meter m2 Micro μ 10–6
Volume Cubic meter m3 Nano n 10–9
Velocity Meter per second m/s Pico p 10–12
Acceleration Meter per second / second m/s2
Density Kilogram per cubic meter kg/m3
1-6
1. OUTLINE
(6) Unit Conversion Table
QUANTITIES JIS SI REMARKS

Mass kg kg
Force kgf N 1kgf=9.807N
Torque kgf•m N•m 1kgf•m=9.807N•m
Pressure kgf/cm2 MPa 1kgf/cm2=0.098MPa
Motive power PS kW 1PS=0.7355kW
Revolution r.p.m min –1 1r.p.m=1min–1
1-7
1. OUTLINE
[MEMO]
1-8
2
2. SPECIFICATIONS
TABLE OF CONTENTS
2.1 NAME OF COMPONENTS................................................................................................2-3

2.2 GENERAL DIMENSIONS ..................................................................................................2-4
2.2.1 E215B/E215BLC
[5.65m (18ft-6in) Boom+2.94m (9ft-8in) Standard Arm+0.80m3 (1.05cu•yd) Bucket Shoe] ....2-4
2.2.2 E215B/E215BLC
[5.65m (18ft-6in)+2.4m (7ft-10in) Short Arm+0.93m3 (1.22cu•yd) Bucket Shoe] ......2-4
2.2.3 E215B/E215BLC
[5.65m (18ft-6in) Boom+3.5m (11ft-6in) Long Arm+0.70m3 (0.92cu•yd) Bucket Shoe] ..........2-5
2.3 WEIGHT OF COMPONENTS............................................................................................2-6
2.4 TRANSPOTATION ............................................................................................................2-8
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER ........................................2-8
2.4.2 DIMENSIONS OF ATTACHMENT ...........................................................................2-9
2.5 SPECIFICATIONS AND PERFORMANCE .......................................................................2-11
2.5.1 SPEED AND CLIMBING CAPABILITY.....................................................................2-11
2.5.2 ENGINE ....................................................................................................................2-11
2.5.3 HYDRAULIC COMPONENTS ..................................................................................2-11
2.5.4 WEIGHT ...................................................................................................................2-11
2.6 TYPE OF CRAWLER.........................................................................................................2-12
2.7 TYPE OF BUCKET ............................................................................................................2-12
2.8 COMBINATIONS OF ATTACHMENT................................................................................2-13
2.9 ENGINE SPECIFICATIONS ..............................................................................................2-14
2.9.1 SPECIFICATIONS....................................................................................................2-14
2.9.2 ENGINE CHARACTERISTIC CURVE (HINO J05E-TG) ..........................................2-15
2-1
2. SPECIFICATIONS

E215B : YN11-45001~ S5YN0225E01
↑
↑ ↑ ↑ K
2-2
2. SPECIFICATIONS
2.1 NAME OF COMPONENTS

ARM CYLINDER
ARM
BOOM
BOOM CYLINDER
BUCKET
CYLINDER
CAB
SLEWING BEARING
IDLER LINK
SLEWING MOTOR
SWIVEL
JOINT FUEL TANK
HYDRAULIC TANK
BUCKET LINK
CONTROL VALVE
GUARD
MUFFLER
HYDRAULIC
PUMP
BUCKET
MONITOR PANEL
SHOE AND TRACK LINK
FRONT IDLER
ENGINE
IDLER ADJUST
COUNTER WEIGHT
UPPER ROLLER
AIR CLEANER TRACK GUIDE

RADIATOR AND OIL COOLER
ROTALY MULTI CONTROL VALVE
(OPTION)
LOWER ROLLER BATTERY

TRAVEL MOTOR
2-3
2. SPECIFICATIONS
2.2 GENERAL DIMENSIONS

2.2.1 E215B/E215BLC [5.65m (18ft-6in) Boom+2.94m (9ft-8in) Standard Arm+0.80m3 (1.05cu•yd) Bucket
Shoe]
1315 (4'4")
Unit : mm(ft-in)
43 (1.7")
2710 (8'11")
1395 (4'7")
R2
75
0
(9
')
9450 (31')
2750 (9')
3030 (9'11")
2980 (9'9")
*1060
(3'6")
450
(17.1")
600 (23.6")
4170 (13'8") [4450 (14'7")]
2800 (9'2")
4840 (15'11") [4980 (16'4")] [2990] (9'10")
Dimensions marked * do not include the height of the shoe lug.

[ ] include LC specifications.
2.2.2 E215B/E215BLC [5.65m (18ft-6in)+2.4m (7ft-10in) Short Arm+0.93m3 (1.22cu•yd) Bucket Shoe]
9530 (31'3") Unit : mm(ft-in)

3980 (13'1")
2750 (9')
3160 (10'4")
*1060 (3'6")
4170 (13'8") [4450 (14'7")]

4840 (15'11") [4980 (16'4")]
2-4
2. SPECIFICATIONS
2.2.3 E215B/E215BLC [5.65m (18ft-6in) Boom+3.5m (11ft-6in) Long Arm+0.70m3 (0.92cu•yd) Bucket
Shoe]
9520 (31'3") Unit : mm(ft-in)
2750 (9')
3180 (10'5")
*1060 (3'6")
4170 (13'8") [4450 (14'7")]
4840 (15'11") [4980 (16'4")]
Dimensions marked * do not include the height of the shoe lug.

[ ] include LC specifications.
2-5
2. SPECIFICATIONS
2.3 WEIGHT OF COMPONENTS

Unit ; kg (lb)
Model
E215B E215BLC
Item
Machine complete 20,200 (44,500) 20,600 (45,400)
1. Upper frame assy (Assembly of following :) 9,500 (21,000) ←
1.1 Upper frame 1,770 (3,900) ←
1.2 Counter weight (Semi-weighted) 4,640 (10,230) ←
1.3 Cab 260 (570) ←
1.4 Engine *540 (1,190) ←
1.5 Hydraulic oil tank *150 (330) ←
1.6 Fuel tank *110 (240) ←
1.7 Slewing motor (including reduction unit) *210 (460) ←
1.8 Control valve *230 (510) ←
1.9 Boom cylinder *170 (375) × 2 ←
1.10 Pin (for mounting boom) 70 (150) ←
1.11 Pump *130 (290) ←
1.12 Radiator (including intercooler) *90 (200) ←
2. Lower frame assy (Assembly of following :) 6,730 (14,840) 7,130 (15,720)
2.1 Lower frame 2,260 (4,980) 2,420 (5,340)
2.2 Slewing bearing 250 (550) ←
2.3 Travel motor (including reduction unit) 260 (570) × 2 ←
2.4 Upper roller 20 (44) × 2 ←
2.5 Lower roller 30 (66) × 14 30 (66) × 16
2.6 Front idler 110 (240) × 2 ←
2.7 Idler adjuster 100 (220) × 2 ←
2.8 Sprocket 50 (110) × 2 ←
2.9 Swivel joint *30 (66) ←
2.10 Track link with 600mm (23.6in) shoes assy 1,260 (2,780) × 2 1,350 (2,980) × 2
Track link with 700mm (27.6in) shoes assy 1,470 (3,240) × 2 1,560 (3,440) × 2
Track link with 800mm (31.5in) shoes assy 1,600 (3,530) × 2 1,700 (3,750) × 2
2.10.1 Track link assy 510 (1,120) × 2 540 (1,190) × 2
3. Attachment (Assembly of following / STD :) 3,420 (7,540) ←
{5.65m (18ft-6in) Boom + 2.94m (9ft-8in) Arm + 0.80m3 (1cu•yd) Bucket}
3.1 Bucket assy (STD) 640 (1,410) ←
3.2 STD Arm assy (Assembly of following :) 1,050 (2,315) ←
3.2.1 STD Arm 660 (1,455) ←
3.2.2 Bucket cylinder *140 (310) ←
3.2.3 Idler link 20 (44) × 2 ←
3.2.4 Bucket link 90 (198) ←
3.2.5 Pin (2pcs. for mounting bucket cylinder / 2pcs. for mounting bucket) 100 (220) ←
3.3 Boom assy (Assembly of following :) 1,730 (3,815) ←
3.3.1 Boom 1,310 (2,890) ←
3.3.2 Arm cylinder *255 (560) ←
3.3.3 Pin (Mounting arm • Mounting arm cylinder) 80 (180) ←
2-6
2. SPECIFICATIONS
Unit ; kg (lb)
Model
E215B E215BLC
Item
4. Lubricant and water (Assembly of following :) 550 (1,210) ←
4.1 Hydraulic oil 200 (440) ←
4.2 Engine oil 20 (44) ←
4.3 Fuel 310 (680) ←
4.4 Water 20 (44) ←
Marks * show dry weight.
2-7
2. SPECIFICATIONS
2.4 TRANSPOTATION
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER
(1) 5.65m (18ft-6in) Boom+2.94m (9ft-8in) Arm+0.80m3 (1.05cu•yd) Bucket
Model
E215B E215BLC
Item
Width 600mm (23.6in) shoes 2,800 (9ft-2in) 2,990 (9ft-10in)
Weight 20,200kg (44,500 lbs) 20,600kg (45,400 lbs)
Unit : mm (ft-in)
9470 (31'1") 2260 (7'5")
3080 (10'1")
3780 (12'5")
138 (5.43") [*145 (5.71")]
(3.94")
100
(27.6")
700
80
(3.15")
72 (2.83") 90 (3.54")
[*54 (2.13")] [*83 (3.27")]
SECTION AA
* marks indicate LC specifications.
2-8
2. SPECIFICATIONS
2.4.2 DIMENSIONS OF ATTACHMENT

(1) BOOM
Type
5.65m (18ft-6in) Boom
Item
Length×Height×Width 5.86 × 1.57 × 0.67
m (ft-in)
L×H×W (19'3"× 5'2"× 2'2")
Weight kg (lbs) 1,670 (3,680)
(2) ARM AND BUCKET
Type 2.4m (7ft-10in) Arm + 2.94m (9ft-8in) Arm + 3.5m (11ft-6in) Arm +
0.93m 3(1.22cu•yd) Bucket 0.80m 3 (1.05cu•yd) Bucket 0.70m 3 (0.92cu•yd) Bucket
Item
Length×Height×Width 4.75 × 0.9 × 1.33 5.29 × 0.9 ×1.16 5.88 × 0.9 × 1.08
m (ft-in)
L×H×W (15'7"×2'11"×4'4") (17'4"×2'11"×4') (19'3"×2'11"×3'7")
Weight kg (lbs) 1,740 (3,840) 1,680 (3,700) 1,880 (4,150)
(3) Arm
Type
2.4 m (7ft-10in) Arm 2.94 m (9ft-8in) Arm 3.5 m (11ft-6in) Arm
Item
Length×Height×Width 3.40 × 0.86 × 0.56 3.94 × 0.86 × 0.56 4.53 × 0.87 × 0.56
m (ft-in)
L×H×W (11'2"×2'10"×1'10") (12'11"×2'10"×1'10") (14'10"×2'10"×1'10")
Weight kg (lbs) 1,020 (2,250) 1,044 (2,300) 1,260 (2,780)
2-9
2. SPECIFICATIONS
(4) Bucket
Type Hoe bucket

Length×Height×Width 1.37 × 1.26× 0.87 1.37 × 1.26× 1.07 1.37 × 1.26× 1.16 1.37 × 1.26× 1.33
m (ft-in
L×H×W (4'6"×4'2"×2'10") (4'6"×4'2"×3'6") (4'6"×4'2"×3'10") (4'6"×4'2"×4'4")
Weight kg (lbs) 520 (1,150) 630 (1,390) 640 (1,410) 710 (1,560)
Bucket capacity m cu•yd
3
0.51 (0.67) 0.70 (0.92) STD 0.80 (1.05) 0.93 (1.22)
Type Hoe bucket Slope finishing bucket

Length×Height×Width 1.37×1.26×1.16 1.25×0.90×2.20
m (ft-in
L×H×W (4'6"×4'2"×3'10") (4'1"×2'11"×7'3")
Weight kg (lbs) 750 (1,650) 890 (1,960)
Bucket capacity m3 cu•yd 0.80 (1.05) HD 0.82 (1.07)
Hoe bucket Slope finishing bucket
2-10
2. SPECIFICATIONS
2.5 SPECIFICATIONS AND PERFORMANCE

2.5.1 SPEED AND CLIMBING CAPABILITY
Area & Model

E215B E215BLC
Item
Swing speed min-1 {rpm} 12.5 {12.5}
Travel speed (1-speed/2-
km/h (mile/h) 3.6 / 6.0 (2.2 / 3.7)
speed)
Gradeability % (degree) 70 (35)
2.5.2 ENGINE
Engine model HINO J05E-TG

Water-cooled, 4 cycle 4 cylinder direct injection type diesel engine
Type
with inter cooler turbo-charger
4 -ø112 mm × 130 mm
Number of cylinders—Bore×Stroke
(4.41 in × 5.12 in)
Total displacement 5.123 L (312.61 cu•in)
Rated output / Engine speed 114 kW (155 PS) / 2,000 min-1
Maximum torque / Engine speed 572 N•m (422 lbf•ft)/ 1,600 min-1
Starter 24 V / 5.0kW
Alternator 24 V / 1.2kW
2.5.3 HYDRAULIC COMPONENTS
Hydraulic pump Variable displacement axial piston pump × 2 + gear pump × 1

Hydraulic motor (swing) Axial piston motor × 1
Variable displacement axial piston motor × 2
Hydraulic motor (travel)
(with counterbalance valve)
Control valve 8-spool control valve × 1
Cylinder
Double action cylinder
(Boom, Arm, Bucket)
Oil cooler Air-cooled type
2.5.4 WEIGHT
Unit : kg (lbs)
Fully equipped weight 20,200 (44,500) 20,600 (45,400)
Upper structure 9,500 (21,000) ←
Lower machinery
6,730 (14,840) 7,130 (15,720)
(600mm grouser shoe)
Attachment
5.65m (18 ft-6in) Boom+2.94m (9ft-8in) Arm 3,420 (7,540) ←
+0.80m3 (1.05cu•yd) Bucket
2-11
2. SPECIFICATIONS
2.6 TYPE OF CRAWLER

Overall width of crawler Ground pressure kPa
Shape Shoe width mm (in)
mm (ft-in) (psi)
STD 2,800 (9'2") 45 (6.53)
Grouser shoe
600 (23.6)
LC 2,990 (9'10") 43 (6.24)
STD 2,900 (9'6") 40 (5.80)

700 (27.6)
LC 3,090 (10'2") 38 (5.51)
STD 3,000 (9'10") 35 (5.08)

800 (31.5)
46 LINKS LC 3,190 (10'6") 33 (4.79)
Use 600mm (23.6") grouser shoes on rough ground (areas covered with rocks and gravel). If you drive or excavate
with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, etc.)
2.7 TYPE OF BUCKET

Heaped Outer width mm (ft-in) Availability
Struck Number W or W/O Weight
Hoe bucket capacity With side Without side of face
m3(cu•yd) of tooth side cutter kg (lbs)
m3(cu•yd) cutter cutter shovel
0.39 520
0.51 (0.67) 870 (2'10") 770 (2'6") 3 W YES
(0.51) (1,150)
0.52 630
0.70 (0.92) 1,080 (3'6") 980 (3'3") 5 W YES
(0.68) (1,390)
[STD] 0.59 640
1,160 (3'10") 1,060 (3'6") 5 W YES
0.80 (1.05) (0.77) (1,410)
0.67 710
0.93 (1.2) 1,330 (4'4") 1,230 (4') 5 W YES
(0.88) (1,560)
2-12
2. SPECIFICATIONS
2.8 COMBINATIONS OF ATTACHMENT

Bucket Available Arm
Heaped capacity Struck 2.94m (9ft-8in) Arm 3.5m (11ft-6in) 2.4m (7ft-10in) Arm
Type
m3 (cu•yd) m3 (cu•yd) (STD) Arm (Long) +Arm (Short)
0.51 (0.67) 0.39 (0.51)

0.70 (0.92) 0.52 (0.68)
Hoe bucket [STD]
0.59 (0.77)
0.80 (1.05)
0.93 (1.2) 0.67 (0.88)
Breaker — —
Nibbler — —
Standard combination
General operation : Excavation or loading of sand, gravel, and clay
Light operation : Mainly loading or loose gravel (e.g., cultivation or loading of sand or gravel)
Prohibited combination : There are problems from the view points of strength and stability.
• Use the attachments recommended by NEW HOLLAND KOBELCO.

The trouble due to the use in the condition "Use not allowed" described in the above table is not included in our
responsibility
If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to the arm and
bucket may occur.
2-13
2. SPECIFICATIONS
2.9 ENGINE SPECIFICATIONS

2.9.1 SPECIFICATIONS
Applicable machine E215B, E215BLC

Engine model HINO J05E-TG
Water-cooled, 4 cycle 4 cylinder direct injection type
Type
diesel engine with inter cooler turbo-charger
Number of cylinder×Bore×Stroke mm (in) 4 × 112 × 130 (4.41 × 5.12)
Total displacement cc (cu•in) 5,123 (313)
Compression ratio 18.0
Rated output kW (PS) at min-1 114 (155) at 2,000
N•m (lb•ft) at
Maximum torque 572 (422) at 1,600
min-1
High idling min-1 2,000 ± 30
Low idling min-1 1,000 ± 30
Injection starting pressure MPa (psi) 50 (7,250)
Start/Full open
Thermostat action 350 (170) / 363 (194)
K (°F)
Firing order 1-3-4-2
MPa (psi)
Compression pressure 3.4~3.7 (493~537) at 280
at min-1
Fuel injection timing 0°
Valve clearance Open Close
14°before top 30°after bottom
Intake valve 0.3 mm at cool
Valve clearance dead point dead point
54°before bottom 13°after top dead
Exhaust valve 0.45 mm at cool
dead point point
Starter capacity V × kW 24 × 5.0
Generator capacity (Alternator) V×A 24 × 50
ø650 (25.6") × suction type 7 fans, V-belt drive,
Cooling fan drive method
pulley ratio Crank / Fan= 0.89
Full level 18.0 (4.76)
Engine oil quantity L (gal) Low level 15.0 (3.96)
Total 20.5 (5.42)
Dry weight kg (lbs) 580 (1,280)
Fuel consumption ratio g/kW•h (g/ps•h) 217 (160)
Allowable inclination
Front / Rear and Right / Left : 35°
(Limited by E/G lubrication)
Dimension (L×W×H) mm (in) 1,063 × 725 × 995 (3ft-5.86in × 28.5in × 39.2in)
Rotating direction Counterclockwise seeing from flywheel side
2-14
2. SPECIFICATIONS
2.9.2 ENGINE CHARACTERISTIC CURVE (HINO J05E-TG)
Condition to be measured: The net value is indicated, measuring with cooling fan.
marks show the rated point
SHAFT TORQUE
SHAFT OUTPUT
FUEL CONSUMPTION RATE
ENGINE SPEED (min-1)
Fuel consumption volume

Fuel consumption rate X kW X Load factor ( )
0.835 X 1000
217g/kW.h
X 114kW X
0.835 X 1000 : Standard load factor
. L/h (0.70~0.80)
29.6
Fuel consumption in regular operation
(load factor 0.70~0.80)
20.7 L/h~23.7 L/h
2-15
2. SPECIFICATIONS
[MEMO]
2-16
3
3. ATTACHMENT DIMENSIONS
TABLE OF CONTENTS
3.1 BOOM ................................................................................................................................3-3

3.1.1 BOOM DIMENSIONAL DRAWING...........................................................................3-3
3.1.2 BOOM MAINTENANCE STANDARD.......................................................................3-4
3.2 ARM ...................................................................................................................................3-6
3.2.1 ARM DIMENSIONAL DRAWING..............................................................................3-6
3.2.2 ARM MAINTENANCE STANDARD ..........................................................................3-7
3.3 BUCKET ............................................................................................................................3-10
3.3.1 BUCKET DIMENSIONAL DRAWING .......................................................................3-10
3.3.2 BUCKET DIMENSIONAL TABLE .............................................................................3-10
3.3.3 LUG SECTION DIMENSIONAL DRAWING .............................................................3-11
3.3.4 BOSS SECTION DIMENSIONAL DRAWING...........................................................3-12
3-1

E215B : YN11-45001~ S5YN0322E01
↑
↑ ↑ ↑ K
(NHK Russia) HS Engine
↑
↑ ↑ ↑ K
3-2
3.1 BOOM
3.1.1 BOOM DIMENSIONAL DRAWING

Fig. 3-1 Boom dimensional drawing
Unit : mm (ft-in)
STD —
5.65M (18ft-6in) BOOM
YN02B00403F1 —
No NAME DIMENSION
A Boom length 5,650 (18'6") —
B Boom foot width 670 (26.4") —
C Boom end inner width 347 (13.7") —
D Boom end outer width 482 (19") —
E Height of boom cylinder rod pin 1,008.5 (3'4") —
F Height of arm cylinder (head side) pin 1,203.5 (3'11") —
G Distance between pins of boss R2,589 (8'6") —
H Distance between pins of bracket R2,829.5 (9'3") —
I Arm cylinder (head side) inner width 126 (4.96") —
J Outer width of bracket on the arm cylinder (rod side) 468 (18.4") —
mounting
d1 Boom foot pin dia. ø 90 (3.54") —
d2 Boom cylinder (rod side) pin dia. ø 85 (3.35") —
d3 Pin dia. of boom end. ø 90 (3.54") —
d4 Arm cylinder (head side) pin dia. ø 85 (3.35") —
3-3
3.1.2 BOOM MAINTENANCE STANDARD

(1) Clearance of pin and bushing on boom section
A
C
Fig. 3-2 Clearance of pin and bushing on boom section
Unit : mm (in)
Standard value Clearance
Sym- Bushing Repaira
Item Pin part No. Pin dia. Standard Service Remedy
bol Pin dia. i.d. ble
tolerance value limit
tolerance level
+ 0.020 + 0.217 + 0.237
ø 90 (+0.0008) (+0.0085) (+0.0093)
A Boom foot YN02B01719P1
(3.5433) - 0.020 + 0.071 + 0.051
(-0.0008) (+0.0028) (+0.0020)
+ 0.243 + 0.283
0
Boom cylinder ø 85 (+0.010)
- 0.040
(0.011)
B YN02B01720P1
(Head side) (3.3465) + 0.085 + 0.085 More
(-0.0016) Replace
(+0.0033) (+0.0033) than 2.5
bushing
+ 0.247 + 0.267 2.0 (0.1)
or pin
Boom cylinder (+0.0097) (+0.0105) (0.08)
C YN02B01721P1
(Rod side) + 0.020 + 0.093 + 0.073
ø 85 (+0.0008) (+0.0037) (+0.0097)
(3.3465) - 0.020 + 0.252 + 0.272
Arm cylinder (-0.0008) (+0.0099) (+0.0107)
D YN02B01722P1
(Head side) - 0.099 + 0.077
(-0.0039) (+0.0030)
3-4
(2) Clearance in thrust direction on the boom cylinder installation section
D
D C
B A
SECTION C-C
SECTION D-D
SECTION A-A
SECTION B-B
Fig. 3-3 Clearance in thrust direction on the boom cylinder installation section
Unit : mm (in)
Clearance X adjusted with shim
Basic size Pin length
(total of both sides)
Sec. Item Remedy
Standard Repairable Service
No. Size No. Length
value level limit
670
Boom
(26.4) 0.5 (0.02) 831
A-A Boom foot L1 PL1
676 or less (32.7)
Upper frame
(26.6) 2.0 2.5
105 (0.08) (0.10)
Boom cylinder
Boom cylinder (4.13) 0.6~1.0 241
B-B L2 PL2
(Head side) 111 (0.02~0.04) (9.49)
Upper frame Shim
(4.37)
adjust
105
Boom cylinder L3 ment
Boom cylinder (4.13) 0.6~2.0 3.0 4.0 736
C-C PL3
(Rod side) 468 (0.02~0.08) (0.12) (0.16) (29.0)
Boom L3'
(18.4)
120
Arm cylinder
Arm cylinder (4.72) 0.6~1.0 2.0 2.5 260
D-D L4 PL4
(Head side) 126 (0.02~0.04) (0.08) (0.10) (10.2)
Boom
(4.96)
3-5
3.2 ARM
3.2.1 ARM DIMENSIONAL DRAWING
VIEW J
SECTION X-X
SECTION Y-Y SECTION Z-Z
Fig. 3-4 ARM DIMENSIONAL DRAWING
2.94m (9ft-8in) ARM YN12B00904F1 Unit : mm (ft-in)

Code NAME DIMENSION Code NAME DIMENSION
C Arm length 2,940 (9'8") N Bracket inner width 126 (4.96")
Distance between pins of boss
D R874 (34.4") O Bracket inner width 111 (4.37")
and bracket
D1 I.D of boss ø110 (4.33") P Idler link dimension 630 (24.8")
D2 I.D of boss ø85 (3.35") Q Bucket link dimension 610 (24")
Height between pins of boss and
D4 I.D of boss ø105 (4.13") R 31 (1.22")
center
E R2,169 (7'1") d1 Pin dia. ø80 (3.15")
and bracket
F R420 (16.5") d2 Pin dia. ø70 (2.76")
and boss
G 665.5 (26.2") d3 Pin dia. ø85 (3.35")
bracket
H 312 (12.3") d4 Pin dia. ø90 (3.54")
bracket
K Arm top end boss width 325 (12.8") d5 Pin dia. ø80 (3.15")
L Arm link section boss width 323 (12.7")
M Boss width 342 (13.5")
3-6
3.2.2 ARM MAINTENANCE STANDARD

(1) Clearance of pin and bushing
E F
D, D'
B
C
G
Fig. 3-5 Clearance of pin and bushing on arm section
Unit : mm (in)
Standard dimensions Clearance
No. Item Pin part No. Pin dia. Bushing i.d. Standard Repairable Service Remedy
Pin dia.
tolerance tolerance value level limit
+0.253 +0.313
(+0.0100) (+0.0123)
A Arm point
–0.020 +0.080 +0.100
ø80 (-0.0008) (+0.0031) (+0.0039)
YN12B02215P1
(3.1496) –0.060 +0.284 +0.364
Bucket link (-0.0024) (+0.0112) (+0.0143)
B
(Bucket side) +0.156 +0.0176
(+0.0061) (+0.0069)
+0.253 +0.293
Idler link
ø70 (+0.0100) (+0.0115)
C (Connected part YN12B02216P1
(2.7559) +0.194 +0.194
of arm) (+0.0076) (+0.0076)
0 +0.232 +0.272
Bucket link (0) (+0.009) (+0.0107)
D
(Idler link side) –0.040 +0.161 +0161
Replace
(-0.0016) (+0.0063) (+0.0063) 2.0 2.5
YN12B02217P1 bushing
+0.318 (0.08) (0.01)
or pin
Bucket cylinder ø80 (+0.0125)
D'
(Rod side) (3.1496) +0.278 +0.141
(+0.0109) (+0.0056)
+0.141 +0.298
Bucket cylinder (+0.0056) (+0.0117)
E YN12B02218P1
(Head side) +0.161
(+0.0063)
+0.020 +0.252 +0.272
Arm cylinder ø85 (+0.0008) (+0.0099) (+0.0107)
F YN02B01722P1
(Rod side) (3.3465) –0.020 +0.079 +0.059
(-0.0008) (+0.0031) (+0.0023)
+0.214 +0.234
Arm foot
ø90 (+0.008) (+0.0090)
G (Connected part YN12B02094P1
(3.5433) +0.067 +0.047
of boom)
(+0.003) (+0.0020)
3-7
(2) Clearance of arm and cylinder installing sections in thrust direction
E
D, D'
B
F
E
B C
D, D' F
A A
C G
G
X1 L1
X L3 PL5
X L6
X L5
PL1 PL3 PL6

SECTION A-A SECTION C-C SECTION E-E SECTION F-F
PL7
X2 L2 X7 L7
X L4
X4' L4'
PL2 PL4
SECTION B-B SECTION D-D
SECTION G-G
Fig. 3-6 Clearance of arm and cylinder installing sections in thrust direction
3-8
Unit : mm (in)
Clearance X adjusted with shim
Basic size Pin length
(total of both sides)
Sec. Item Remedy
Standard Repairable
No. Size Service limit No. Length
value level
325
Arm
(12.79) 1.0 (0.04) 2.0
A-A Arm point L1 PL1
326 or less (0.08)
Bucket
(12.83) 481
325 (18.9)
Link side
(12.79)
B-B Bucket link L2 — — PL2
327
Bucket
(12.87)
323 2.5
Idler link Arm 0.5 1.0
C-C L3 (12.72) (0.10) PL3
(Arm connection) (0.02) (0.04)
Link side -
Bucket link Rod side -
D-D (Idler link L4 323 427
Link side
connection) (12.72) (16.8)
0.6~1.0 2.0 Shim
105 PL4
Rod side (0.024~0.04) (0.08) adjust
Bucket link (4.13)
D’-D’ L4’ -ment
(Rod side) 111
Link side
(4.37)
105
Head side
Bucket cylinder (4.13) 235
E-E L5 PL5
(Head side) 111 (9.25)
Arm
(4.37) 0.6~2.0 3.0 4.0
120 (0.024~0.08) (0.12) (0.16)
Rod side
Arm cylinder (9.72) 260
F-F L6 PL6
(Rod side) 126 (10.2)
Arm
(4.96)
342
Arm
(13.46) 0.5 1.0 2.5 505
G-G Arm foot L7 PL7
347 (0.02) (0.04) (0.10) (19.9)
Boom
(13.66)
3-9
3.3 BUCKET
3.3.1 BUCKET DIMENSIONAL DRAWING
(1) Hoe bucket
Fig. 3-7 Bucket dimensional drawing
No. NAME No. NAME

A Distance between pin and bracket G Inner width of bucket bottom
B Distance between bucket pin and tooth end H Bucket outer width of front side
C Inner width of bucket top end I Pitch between teeth
D Inner width of lug Io Pitch between teeth
E Inner width of bracket d1 Outer dia. of bushing
F Outer width of side cutter d2 Pin dia.
3.3.2 BUCKET DIMENSIONAL TABLE
Unit : mm (ft-in)
Type Hoe bucket
[STD]
0.51 m3 0.70 m3 0.93 m3
Capacity 0.80 m3
(0.67 cu•yd)) (0.92 cu•yd)) (1.21 cu•yd))
(1.05 cu•yd)
Part No. YN61B00316F1 YN61B00287F1 YN61B00286F1 YN61B00288F1
A R430 (16.9") ← ← ←
B R1,440 (4'9") ← ← ←
C 1,003 (3'3") 712 (28") 925 (36.4") 1,176 (3'10")
D 399 (15.7") ← ← ←
E 327 (12.9") ← ← ←
F 1,157 (4') 868 (34.2") 1,079 (3'6") 1,330 (4'4")
G 863 (34") 572 (22.5") 785 (30.9") 1,036 (3'5")
H 1,057 (3'6") 766 (30.2") 979 (38.5") 1,230 (4')
I 224 (8.82") 300 (11.8") 203 (7.99") 266 (10.5")
IO 224 (8.82") 300 (11.8") 203 (7.99") 266 (10.5")
d1 ø 95 (3.74") ← ← ←
d2 ø 80 (3.15") ← ← ←
3-10
3.3.3 LUG SECTION DIMENSIONAL DRAWING
X B
J
A
BOSS
M
28 YB61B01002P1
(1.10) Apply rust prevention oil
19
(0.748)
3-G
B
F
N
D E
H
BOSS
SHIM 1 Insert this pin flush with surface YB61B01002P1
Five shims are installed
at shipping SECTION X-X
DETAIL B
Fig. 3-8 Dimension of lug section
Unit : mm (ft-in)
Lug plate thickness
Screw hole P.C.D

Boss outer dia.
Boss outer dia.

Spring pin dia.
Pin hole dia.
Boss width.
Boss width.
Screw dia.
Capacity of
Hole dia.
Type of Part No. of

bucket
bucket bucket
m3 (cu.yd)
A B D E F G H J M N
[STD]
0.80 (1.05) YN61B00316F1
Hoe
bucket 0.51 (0.67) YN61B00287F1 80 25 95 13 180 25 170 36 140
(3.15") (0.984") (3.74") (0.512") (7.09") M16 (0.984") (6.69") (1.42") (5.51")
0.70 (0.92) YN61B00286F1
0.93 (1.21) YN61B00288F1
3-11
3.3.4 BOSS SECTION DIMENSIONAL DRAWING
H 5
(0.197")
oG
oC
oD
oA
oB
15 (0.591")
Fig. 3-9 Dimension of boss section
Unit : mm (ft-in)
Type Capacity of
Part No. of Part No.
of bucket øA øB øC øD E F øG H I
bucket of boss
bucket m3 (cu•yd)
[STD]
0.80 (1.05) YN61B00316F1
Hoe 114.3 84 105.5 111.5 23 38 17 13 2.5
0.51 (0.67) YN61B00287F1 YB61B01002P1
bucket (4.50") (3.31") (4.15") (4.39") (0.91") (1.50") (0.669") (0.512") (0.098")
0.70(0.92) YN61B00286F1
0.93(1.21) YN61B00288F1
3-12
11. TOOLS
11
TABLE OF CONTENTS
11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS............................................11-3

11.2 SCREW SIZE...................................................................................................................11-5
11.2.1 CAPSCREW (BOLT) ..............................................................................................11-5
11.2.2 CAPSCREW (SOCKET BOLT) ..............................................................................11-5
11.2.3 SOCKET SET SCREW...........................................................................................11-5
11.3 TIGHTENING TORQUE FOR HOSE AND FITTING .......................................................11-6
11.3.1 JOINT (O-RING TYPE)...........................................................................................11-6
11.3.2 HYDRAULIC HOSE (30° FLARE TYPE) ................................................................11-6
11.3.3 JOINT (ORS TYPE)................................................................................................11-6
11.3.4 SPLIT FLANGE ......................................................................................................11-6
11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES...................................................11-7
11.5 PLUG ...............................................................................................................................11-8
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT ...................................................................11-8
11.5.2 PLUG FOR HYDRAULIC EQUIPMENT .................................................................11-9
11.6 SPECIAL SPANNER FOR TUBE ....................................................................................11-11
11.7 SPECIAL TOOLS.............................................................................................................11-12
11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND......11-14
11.9 SUCTION STOPPER.......................................................................................................11-15
11.9.1 COMPONENTS ......................................................................................................11-15
11.9.2 DIMENSION ...........................................................................................................11-15
11.9.3 APPLICABLE MODEL ............................................................................................11-15
11.10 COUNTER WEIGHT LIFTING JIG ..................................................................................11-16
11.11 UPPER FRAME LIFTING JIG..........................................................................................11-17
11.12 ENGINE MOUNTING PEDESTAL...................................................................................11-18
11.13 TRACK SPRING SET JIG ...............................................................................................11-19
11-1
11. TOOLS

E215B : YN11-45001~ S5YN1122E01
↑
↑ ↑ ↑ K
↑
↑ ↑ ↑ K
11-2
11. TOOLS
11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS

Tables Table11-1 and Table11-2 indicate tightening torques applicable to cases where no special note is given.
Overtightening of bolts may result in a twist-off and a fracture under load.
Insufficient tightening may lead to a loosening or loss of bolts. Always tighten bolts to proper torques.
Table11-1 Tightening torque for metric coarse threads (not plated)
Unit : N•m (lbf•ft)
Classification 4.8T 7T 10.9T
Nominal size No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
4.4±0.5 3.7±0.4 9.6±1.0 8.1±0.8 17.4±1.8 14.7±1.5
M6 P=1
(3.2±0.4) (2.7±0.3) (7.1±0.7) (6.0±0.6) (12.8±1.3) (10.8±1.1)
10.7±1.1 9.0±0.9 23.5±2.0 19.6±2.0 42.2±3.9 35.3±3.9
M8 P=1.25
(7.9±0.8) (6.6±0.7) (17.3±1.5) (14.5±1.5) (31.1±2.9) (26.0±2.9)
21.6±2.0 17.9±1.8 46.1±4.9 39.2±3.9 83.4±8.8 70.6±6.9
M10 P=1.5
(15.9±1.4) (13.2±1.3) (34.0±3.6) (28.9±2.9) (61.5±6.5) (52.1±5.1)
36.3±3.9 31.4±2.9 79.4±7.8 66.7±6.9 143±15 121±12
M12 P=1.75
(26.8±2.9) (23.2±2.1) (58.6±5.8) (49.2±5.1) (105±11) (89.2±8.9)
57.9±5.9 49.0±4.9 126±13 106±10 226±20 191±19
M14 P=2
(42.7±4.4) (36.1±3.6) (92.9±9.6) (78.2±7.4) (167±15) (141±14)
88.3±8.8 74.5±6.9 191±20 161±16 343±39 284±29
M16 P=2
(65.1±6.5) (55.0±5.1) (141±15) (119±12) (253±29) (209±21)
122±12 103±10 265±29 226±20 481±49 402±39
M18 P=2.5
(90.0±8.9) (75.8±7.2) (195±21) (167±15) (355±36) (297±29)
172±17 144±14 373±39 314±29 667±69 559±59
M20 P=2.5
(127±13) (106±10) (275±29) (232±21) (492±51) (412±44)
226±20 192±20 500±49 422±39 902±88 755±78
M22 P=2.5
(167±15) (142±15) (369±36) (311±29) (665±65) (557±58)
294±29 235±29 637±69 520±49 1160±118 941±98
M24 P=3
(217±21) (173±21) (470±51) (383±36) (856±87) (694±72)
431±39 353±39 941±98 765±78 1700±167 1370±137
M27 P=3
(318±29) (260±29) (694±72) (564±58) (1250±123) (1010±101)
588±59 490±49 1285±127 1079±108 2300±235 1940±196
M30 P=3.5
(434±44) (361±36) (948±94) (796±80) (1700±173) (1430±145)
794±78 667±69 1726±177 1451±147 3110±314 2610±265
M33 P=3.5
(586±58) (492±51) (1270±131) (1070±108) (2290±232) (1930±195)
1030±98 863±88 2226±226 1863±186 4010±402 3360±333
M36 P=4
(760±72) (637±65) (1640±167) (1370±137) (2960±297) (2480±246)
11-3
11. TOOLS
Table11-2 Tightening torques for metric fine threads (not plated)

Torque value Unit : N•m (lbf•ft)
Classification 4.8T 7T 10.9T
Nominal size No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
11.3±1.1 9.5±1.0 24.5±2.0 20.6±2.0 44.1±3.9 37.3±3.9
M8 P=1.0
(8.3±0.8) (7.0±0.7) (18.1±1.5) (15.2±1.5) (32.5±2.9) (27.5±2.9)
22.6±2.0 18.7±1.9 48.1±4.9 41.2±3.9 87.3±8.8 73.5±6.9
M10 P=1.25
(16.7±1.5) (13.8±1.4) (35.5±3.6) (30.3±2.9) (64.4±6.5) (54.2±5.1)
39.2±3.9 33.3±2.9 85.3±8.8 71.6±6.9 154±16 129±13
M12 P=1.25
(28.9±2.9) (24.6±2.1) (62.9±6.5) (52.8±5.1) (114±12) (95.2±9.6)
92.2±8.8 77.5±7.8 196±20 169±17 363±39 304±29
M16 P=1.5
(68.0±6.5) (57.2±5.8) (145±15) (125±13) (268±29) (224±21)
186±19 155±16 402±39 333±29 726±69 608±59
M20 P=1.5
(137±14) (114±12) (297±29) (246±21) (535±51) (448±44)
314±29 265±29 686±69 569±59 1240±118 1030±98
M24 P=2
(232±21) (195±21) (506±51) (420±44) (915±87) (760±72)
637±59 530±49 1390±137 1157±118 2500±255 2080±206
M30 P=2
(470±44) (391±36) (1030±101) (853±87) (1840±188) (1530±152)
853±88 706±70 1860±186 1550±155 3350±334 2790±275
M33 P=2
(629±65) (521±52) (1370±137) (1140±114) (2470±246) (2060±203)
1070±108 892±88 2330±226 1940±196 4200±422 3500±353
M36 P=3
(789±80) (658±65) (1720±167) (1430±145) (3100±311) (2580±260)
11-4
11. TOOLS
11.2 SCREW SIZE

11.2.1 CAPSCREW (BOLT)
Nominal B mm Nominal B mm
screw size screw size
Tool size Tool size
(d) (d)
M6 10 M36 55
M8 13 M42 65 d
M10 17 M45 70
M12 19 M48 75
(M14) 22 M56 85
M16 27 (M60) 90 B
(M18) 27 M64 95
M20 30 (M68) 100
(M22) 32 M72 105
M24 36 M76 110
(M27) 41 M80 115
M30 46
11.2.2 CAPSCREW (SOCKET BOLT)
screw size screw size
Tool size Tool size
(d) (d)
(M3) 2.5 M20 17
(M4) 3 (M22) 17 @
(M5) 5 M24 19
M6 5 (M27) 19
M8 6 M30 22
M10 8 M36 27
*
M12 10 M42 32
M14 12 (M45) 32
M16 14 M48 36
(M18) 14 M52 36
11.2.3 SOCKET SET SCREW
screw size screw size d
Tool size Tool size
(d) (d)
M2.5 1.27 M8 4
M3 1.5 M10 5
M4 2 M12 6
M5 2.5 M16 8 B
M6 3 M20 10
11-5
11. TOOLS
11.3 TIGHTENING TORQUE FOR HOSE AND FITTING

11.3.1 JOINT (O-RING TYPE)
Size Wrench Tightening torque

(PF) (mm) N•m (lbf•ft) O-RING O-RING
1/8 14 17±2 (13±1.5)
1/4 19 36±2 (27±1.5)
3/8 22 74±5 (55±4)
1/2 27 108±9.8 (80.0±7)
3/4 36 162±9.8 (119±7)
1 41 255±9.8 (188±7)
11.3.2 HYDRAULIC HOSE (30° FLARE TYPE)
Size Tightening torque

Wrench(mm) UNION NUT
(PF) N•m (lbf•ft)
1/8 17 15±2.0 (11±1.5)
1/4 19 29±4.9 (21±3.6)
3/8 22 49±4.9 (36±3.6)
1/2 27 78±4.9 (58±3.6)
3/4 36 118±9.8 (87±7.2)
1 41 137±15 (101±11)
11.3.3 JOINT (ORS TYPE)
Tightening Torque CONNECTOR O-RING FITTING

Unified screw size Opposing flats
N•m (lbf•ft)
1-14 UNS 30, 32 137±14 (101±10)
36 177±18 (131±13)
1 3 / 16-12 UN
41 206±26 (152±15)
41 206±26 (152±15)
1 7/ 16-12 UN
46 206±26 (152±15) NUT
11.3.4 SPLIT FLANGE
Tightening torque N•m (lbf•ft)

Standard pressure Hi pressure
Size Bolt Bolt
series series
size size
20.6 MPa 41.2 MPa
3/4 33.9±5.6 (25±4) M10 39.5±5.6 (29±4) M10
1 42.4±5.6 (31±4) M10 62.2±5.6 (46±4) M12
11/4 55.1±7.1 (41±5) M10 93.3±8.4 (69±6) M14
11/2 70.6±8.4 (52±6) M12 169±11 (125±8) M16
2 81.9±8.4 (60±6) M12 282±11 (208±8) M20
11-6
11. TOOLS
11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES

Table11-3 indicates standard tightening torques applicable to cases where no particular note is given.
Overtightening or undertightening of nuts and sleeves in FLARELESS JOINT may develop oil leaks through pipe
connections.
Always tighten nuts and sleeves to proper torques.
Table11-3
Working Tube size Opposing Tightening torque
pressure OD × thickness flats N•m (lbf•ft)
Manufacturer's name
MPa (psi) mm (in) (HEX)
mm
ø10×1.5
19 49.0±9.8 (36±7.2)
(0.394×0.059)
ø15×2.0
27 118±12 (87±8.7)
(0.591×0.079)
ø18×2.5
Nippon A.M.C. 29.4 (4270) 32 147±15 (110±11)
(0.709×0.098)
ø22×3.0
36 216±22 (160±16)
(0.866×0.118)
ø28×4.0
41 275±27 (200±20)
(1.10×0.157)
ø35×5.0
Ihara Koatu 29.4 (4270) 55 441±44 (330±33)
(1.38×0.197)
SLEEVE NUT
B
d
d
Tube size Parts No. Tube size Opposing Parts No.

ød Ihara Koatu Nippon A.M.C. ød flats Ihara Koatu Nippon A.M.C.
(HEX) mm
6 ZF93S06000 — 6 14 ZF93N06000 —
8 ZF93S08000 — 8 17 ZF93N08000 —
10 ZF93S10000 ZA93S10000 10 19 ZF93N10000 ZA93N10000
12 ZF93S12000 — 12 22 ZF93N12000 —
15 ZF93S15000 ZA93S15000 15 27 ZF93N15000 ZA93N15000
18 ZF93S18000 ZA93S18000 18 32 ZF93N18000 ZA93N18000
22 ZF93S22000 ZA93S22000 22 36 ZF93N22000 ZA93N22000
28 ZF93S28000 ZA93S28000 28 41 ZF93N28000 ZA93N28000
32 ZF93S32000 — 32 50 ZF93N32000 —
35 ZF93S35000 ZA93S35000 35 55 ZF93N35000 ZA93N35000
38 ZF93S38000 — 38 60 ZF93N38000 —
11-7
11. TOOLS
11.5 PLUG
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT
(1) Cap nut (Joint plug)
Applicable Cap nut parts Opposing flats

tube T screw
A
No.
O. D : A H1 H
6 ZF83H06000 M12 X 1.5 14 14
8 ZF83H08000 M14 X 1.5 17 17
10 ZF83H10000 M16 X 1.5 17 19
12 ZF83H12000 M18 X 1.5 19 22
H1 T screw H 15 ZF83H15000 M22 X 1.5 24 27
18 ZF83H18000 M26 X 1.5 27 32
22 ZF83H22000 M30 X 1.5 32 36
28 ZF83H28000 M36 X 1.5 38 41
(2) Plug (Tube plug)
Applicable
tube Plug parts No.
O. D : A
A
6 ZF83P06000
8 ZF83P08000
10 ZF83P10000
12 ZF83P12000
Sleeve Nut
Type 15 ZF83P15000
joint body 18 ZF83P18000
22 ZF83P22000
28 ZF83P28000
(3) Nut
Applicable
A
d screw tube Nut parts No. d screw Opposing flats

O. D : A
6 ZF93N06000 M12 X 1.5 14
8 ZF93N08000 M14 X 1.5 17
10 ZF93N10000 M16 X 1.5 19
12 ZF93N12000 M18 X 1.5 22
15 ZF93N15000 M22 X 1.5 27
18 ZF93N18000 M26 X 1.5 32
22 ZF93N22000 M30 X 1.5 36
28 ZF93N28000 M36 X 1.5 41
32 ZF93N32000 M42 X 1.5 50
35 ZF93N35000 M45 X 1.5 55
38 ZF93N38000 M48 X 1.5 60
11-8
11. TOOLS
11.5.2 PLUG FOR HYDRAULIC EQUIPMENT

(1) PF screw
B
O-ring
PF screw Plug parts No. B mm O-ring parts No. Nominal O-ring
PF1/4 ZE72X04000 19 ZD12P01100 1B P11
PF3/8 ZE72X06000 22 ZD12P01400 1B P14
PF1/2 ZE72X08000 27 ZD12P01800 1B P18
PF3/4 ZE72X12000 36 ZD12P02400 1B P24
PF screw PF1 ZE72X16000 41 ZD12P02900 1B P29
(2) PT screw
B
PT screw
PT screw Plug parts No. B mm
PT1/8 ZE82T02000 5
PT1/4 ZE82T04000 6
PT3/8 ZE82T06000 8
PT1/2 ZE82T08000 10
PT3/4 ZE82T12000 14
PT1 ZE82T16000 17
PT1 1/4 ZE82T20000 22
PT1 1/2 ZE82T24000 22
(3) Plug for (F) flare hose
PF screw
PF screw Plug parts No. B mm

PF1/4 2444Z2728D1 14
60
PF3/8 2444Z2728D2 17
PF1/2 2444Z2728D3 22
PF3/4 2444Z2728D4 27
Opposing flats B PF1 2444Z2728D5 36
PF screw Plug parts No. E mm F mm

PF PF1/4 2444Z2729D1 14 19
60
screw
PF3/8 2444Z2729D2 17 22
PF1/2 2444Z2729D3 23 27
PF3/4 2444Z2729D4 27 36
Opposing PF1 2444Z2729D5 36 41
Opposing
flats F PF1 1/4 2444Z2729D6 40 50
flats E
11-9
11. TOOLS
(4) Plug for ORS joints

Male

$%
&
) *

"

- .,/01

'$ +,) #
( ' +,) ! # !
( ' +,) #
Female
%!

! & '#()*
"#
"#$
"#
(5) Plug for half clamp
4-oH For standard pressure : 20.6 MPa (2990 psi)

Plug O-ring
Size part No. C mm D mm G mm H mm part No.
25.53~
1/2 ZE12Q08000 38.10 17.48
25.40 9 45Z91D2
C
31.88~
3/4 ZE12Q12000 47.63 22.23 31.75 11 ZD12P02600
ZE12Q16000 52.37 39.75~ ZD12P03400

1 26.19
39.62 11
44.58~
D 1 1/4 ZE12Q20000 58.72 30.18 44.45 11 ZD12P03800
For high pressure : 41.2 MPa (5970 psi)

Plug O-ring
G Size part No. C mm D mm G mm H mm part No.
25.53~
1/2 ZE13Q08000 40.49 18.24 9 2445Z831D1
25.40
31.88~
3/4 ZE13Q12000 50.80 23.80 11 ZD12P02600
31.75
ZE13Q16000 57.15 39.75~ ZD12P03400
1 27.76 13
39.62
44.58~
1 1/4 ZE13Q20000 66.68 31.75 15 ZD12P03800
44.45
11-10
11. TOOLS
11.6 SPECIAL SPANNER FOR TUBE

Applicable tube
diameter Part No. HEX (mm) Drawing of a special spanner mm (in)
mm (in)
70(2.76)
16 22
15 (0.591) 2421T160 27 (0.630) (0.315) (0.866)
40(1.57) 12.7 (0.500 )
70(2.76)
42(1.65)
19 22
18 (0.709) 2421T138 32 (0.748) (0.866)
12.7 (0.500 )
22(0.866)
70(2.76)
48(1.89) 11.5(0.453)
23 22
22 (0.866) 2421T130 36 (0.906) (0.866)
12.7 (0.500 )
109(4.29)
60(2.36)
14.5(0.571)
29 22
28 (1.10) 2421T115 41 (1.142) (0.866)
12.7 (0.500 )

28 (1.10) 2421T231 46

32 (1.26) 2421T232 50

81(3.19) 90(3.54)
20.5(0.807)
35 (1.38) 2421T314 55 41 PART-No. 45

(1.61) (1.77)
HEX55 19.05 (0.750 )
11-11
11. TOOLS
11.7 SPECIAL TOOLS

Table11-4
No. Tools name Tools No. Shape Applicable
Allen wrench
ZT22A10000 Pump
1 Nominal
suction
B : 10, C : 11.3
Commercial tool length (L1) - cut length = Required length

40 (1.57") - 10 (0.39") = 30 (1.18")
Spanner or
Pump
2 socket General tools
install
Nominal B : 17
CUT
Spanner ZT12A36000 Swing motor

3
Nominal S : 36 A,B port
Commercial tool outer width (D) - cut length = Required length

81 (3.19") - 16 (0.63") = 65 (2.56")
Additional M10 X 22
threading
for M10 eye bolt
Plug ZE72X12000 For slinging the
4
PF3/4 swing motor
O-ring
PF3/4
M12 Eye bolt
ZS91C01200
Eye bolt
or For slinging the
5 M12×22
commercial swing motor
equivalent
22
M12
M8 Eye bolt
Plug
ZF83P22000
(Nominal
tube dia. 22)
6 Reference nut Flare hose
Reference
ZS91C00800
Eye bolt
ZF93N22000 M8 X 18
Nut Addtional
threading for
M8 Eye bolt
11-12
11. TOOLS
Table11-4
M8 Eye bolt
M8 X 18
Plug Additional
YN01H01001P1
threading
Nominal
7 1-14UNS HEX 27 Flare hose
Eye bolt ZS91C00800

1-14UNS
M8 Eye bolt
M8 X 18
Additional
Plug YN01H01002P1 threading
Nominal
8 1 3/16-12UN HEX 36 Flare hose
Eye bolt ZS91C00800

1 3/16-12UN
M12 Eye nut
Plug ZE25F08000
PF1/2 For slinging the
9 Weld
Coupling swivel joint
half Coupling half
PF 1/2
TORX driver 5.49

(with tamper
For instrument
10 proof) — Point shape
panel cover (RH)
T30
(For M6)
11-13
11. TOOLS
11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING

COMPOUND
(1) For general use
Manufacturer
Service Features
Loctite Three-Bond
Low
#242 1360K
strength
Screw locking Middle
#262 1374
compound strength
High
#271 1305
strength
Sealing
#515 1215 Sealing
compound
(2) For specific location
No. Use Manufacturer Name Equivalent Applicable

(Manufacturer ; Loctite)
# 1901 Anti-seizure Cylinder
Three-Bond # 1215 gray # 5699 Swing motor
# 1211 white # 5301J Swing motor
# 1303B # 211 Main pump
(Manufacturer ; Three-
Bond)
Sealing Loctite
# 222 # 1344N Main pump
compound
1 # 277 # 1307N Pilot valve
&
adhesive (Manufacturer ; Three-
Bond)
Loctite Parmatex 98D # 1121 Hydraulic oil tank :
Sumitomo
Chemical Co., Cyano Bond PO-1 Hose
Ltd.
Shell
Shell Alvania EP2 New Molyknock Grease 2 Swing bearing grease bath
petroleum
11-14
11. TOOLS
11.9 SUCTION STOPPER

11.9.1 COMPONENTS
No. NAME PARTS No. Q'TY

SUCTION STOPPER ASSY 24100P978F2
1 ROD 2420T4660D1 1
1 Rod
2 NUT ZN16C08007 1
3 COVER 2414T2123D2 1
4 O-RING 45Z91D6 1
2 Nut
3 Cover
4 O-ring
Fig. 11-1 Components of suction stopper
11.9.2 DIMENSION
50
(1.97")
R8
O113 (4.45")
2
M8 NUT
O8 (1.315")
600 (23.6")
M8 O100 +0.5
0
(0.787")
(3.94 +0.0197
0 )
O108
20
(4.25")
ROD COVER
Fig. 11-2 Dimension of suction stopper
11.9.3 APPLICABLE MODEL

SK200-6ES
Applicable
SK115SR
SK135SR
SK235SR
SK200-6E
SK100-2
SK120-2
SK100-3
SK120-3
SK200-6
SK200-8
model
SK100
SK120
Part No.
24100P978F2
11-15
11. TOOLS
11.10 COUNTER WEIGHT LIFTING JIG

(1) Standard eye bolt
Size Vertical
Part No. lifting load
d L kg (lbs)
M8 15 ZS91C00800 80 (176)
M10 18 ZS91C01000 150 (331)
M12 22 ZS91C01200 220 (485)
M16 27 ZS91C01600 450 (992)
M20 30 ZS91C02000 630 (1390)
M24 38 ZS91C02400 950 (2090)
L
d
M30 45 ZS91C03000 1500 (3310)
M36 55 ZS91C03600 2300 (5070)
M42 65 ZS91C04200 3400 (7490)
M48 70 ZS91C04800 4500 (9920)
Fig. 11-3 Eye bolt
11-16
11. TOOLS
11.11 UPPER FRAME LIFTING JIG
Q'ty : 2 sets
Material : Mild steel
Fig. 11-4 Upper frame lifting jig
11-17
11. TOOLS
11.12 ENGINE MOUNTING PEDESTAL
245 (9.65) Material : Wood

Unit ; mm (inch)
6 1
175(6.89)
375 (14.8)
2
400 (15.7)
(4.72) (4.72)
240 (9.45)
750 (29.5)
120 120
375 (14.8)
175(6.89)
6 6
744 (29.3) 100
(3.94)
945 (37.2)
6 6
275 300
(10.8) (11.8)
2 X 1 piece 4 X 1 piece 1 X 1 piece

400 (15.7) 670 (26.4)
200 (7.9) 430 (16.9)
25
55 (0.98)120
(2.2) (4.72)
5(0.2)
50(2.0)
352 (13.9)
250(9.84)
0
213(8.39)
750 (29.5)
R5 .0)
200(7.87)
t 50 ( 2
(2.0) t 24 (0.95)
t 24 (0.95)
5 X 1 piece
3 X 1 piece 670 (26.4)
400 (15.7) 120
(4.72)
200 (7.87) 945 (37.2)
55 145
352 (13.9)
(2.2)
(5.71)
6 X 5 pieces
R5
352 (13.9)
100(3.94)
(2. 0
(3.5)
10(0.39)
90
t 24 (0.95) 0)
t 24
10(0.39)
(7.48)
(0.95)
190
t50
(2.0)
Fig. 11-5 Engine stand
11-18
11. TOOLS
11.13 TRACK SPRING SET JIG
M30
Retainer nut
Retainer plate
)
.6"
(12
(27.6")
Stand
(15.0")
Hydraulic jack
Base
Fig. 11-6 Track spring set jig
11-19
11. TOOLS
[MEMO]
11-20
12. STANDARD MAINTENANCE
TIME TABLE
12
TABLE OF CONTENTS
12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ...12-4
12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST
(TEMPORARY EDITION) ................................................................................................12-15
12.2.1 MEASURING METHOD .........................................................................................12-15
12.2.2 WORKING CONDITION .........................................................................................12-15
12.2.3 STANDARD TIME CONSTITUENT ........................................................................12-15
12.2.4 MEANING OF WORDS IN USE .............................................................................12-17
12-1
12. STANDARD MAINTENANCE TIME TABLE

E215B : YN11-45001~ S5YN1221E01
First edition March, 2007 K
↑
↑ July, 2007 ↑ K
(NHK Middle East)
↑
↑ ↑ ↑ K
↑
↑ ↑ ↑ K
12-2
PREFACE
(1) Working Conditions
1) Workers :
More than one worker shall be 1st class service technician (having five years or more of field experience and
having received training in the operation).
2) Equipment :
Jigs, tools, apparatuses and testers used in field service work shall be available commercially. The
maintenance plant shall be equipped with a service shop, a crane and inspection apparatuses necessary for
specific self inspection activities.
3) Place :
A flat land where work may be performed and to which a service car or a truck crane is accessible.
(2) Range of standard maintenance time
1) Standard maintenance time=Direct maintenance time×Preparation time
2) Direct maintenance time : Net time actually spent for maintenance
3) Spare time :
Time needed to move machines for service, prepare safety operations, discuss work, and process the needs
of the body.
(3) Extra time (not included in the standard service time)
1) Repair time :
Machining, sheet metal, welding, melt cutting, folding and extracting bolts, servicing parts, and painting.
2) Items excluded from service time because of uncertainty in time :
Receiving a vehicle into shop, transfer, delivery, inspection on completion, investigation of causes of faults,
diagnosis, and inspection.
3) Indirect time :
Time for ; field work, preparation of necessary parts before leaving for work, return for field work, waiting time
because of user’s convenience in the field, paper work after returning to shop, and preparation of bills.
4) Special time : Work at early morning, at midnight and on holidays are to be calculated separately.
5) Separate calculation : The operating time for service cars, trucks with a crane and crane trucks.
(4) Applicable machine for estimation of standard maintenance time
1) Standard machine
2) A well maintained and controlled machine with a standard combination of attachments which is used in a
general environment.
12-3
12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF

EXCAVATOR
(1) Standard maintenance time table
1) Units of working time : 6 minutes = 0.1 hour
2) Calculating method of standard maintenance time :
Maintenance time=Working time×Number of workers
(Working time=Maintenance time÷Number of workers)
3) When more than one operation is going on :
Add each standard service time. A pure time (readily started) is given except covers easily removed by hand.
Assy works include the following works marked with black dot •.
4) O/H : The removing and attaching time is not included.
5) Abbreviations in the table.
A/C : Air conditioner C/V : Control valve O/H : Over haul

ASSY : Assembly Cyl : Cylinder SOL : Solenoid
ATT : Attachment E/G : Engine SW : Switch
BRG : Bearing F hose : Flexible hose V : Valve
(2) Classification of working code
No. Group Remarks

01 Attachment Indicates installing, removing, replacement and overhaul.
02 Cab & Guard
03 Swing frame
04 Travel system
Electric Indicates the installing, removing and replacement of single items.
06
equipments
09 E/G relation Indicates overhaul of the single engine.
(Materials prepared by manufacturer )
(3) Conditions for standard service time of the engine

1) Tools designated by E/G maker are used
2) Genuine parts are changed
3) Correct working procedures are observed.
• The time required for works specified in this Chapter shows the total time for maintenance.
12-4
Work to be Unit :
Group Location Unit Remarks
done Hour
00 Bucket relation See 32.1.2
01 Bucket ASSY Detach/attach 1 pc. Include adjustment. 0.6
02 • Bucket attaching and detaching position Preparation 1 pc. 0.1
03 • Bucket attaching pin Detach/attach 1 Include stopper pin. 0.1
04 • Bucket drive pin Detach/attach 1 0.1
05 • Bucket sling and movement Preparation 1 pc. 0.2
06 Bucket (single) O/H 1 pc. Not include attaching and detaching 2.4
07 • Tooth Replace 1 pc. 0.6
08 • Side cutter Replace 1 pc. 1.2
09 • Bushing Replace 1 pc. 0.6
10 Arm relation See 32.1.3

11 Arm ASSY Detach/attach 1 pc. 1.2
12 • Bucket cylinder attaching and Preparation 1 pc. 0.4
detaching position and piping
13 • Bucket cylinder rod pin Detach/attach 1 pc. Include stopper pin 0.1
14 • Bucket cylinder head pin Detach/attach 1 pc. Include stopper pin 0.1
15 • Bucket cylinder assy Detach/attach 1 pc. 0.1
16 • Arm cylinder rod pin Detach/attach 1 pc. Include stopper pin 0.1
17 • Boom top pin Detach/attach 1 pc. Include wire stop pin. 0.1
01 Attachment
18 • Arm sling and movement Detach/attach 1 pc. 0.2
30 Boom relation See 32.1.4

31 Boom ASSY Detach/attach 1 pc. 1.4
32 • Boom attaching and detaching position Preparation 1 pc. 0.1
33 • Boom cylinder temporary slinging Preparation 2 pcs. 0.2
34 • Boom cylinder rod pin Detach/attach 2 Include two stopper pins. 0.2
35 • Boom cylinder piping Detach/attach 2 pc. 0.2
36 • Arm & bucket piping Detach/attach 1 pc. 0.2
37 • Boom assy temporary slinging Detach/attach 1 pc. 0.1
38 • Boom foot pin Detach/attach 1 Include stopper pin. 0.2
39 • Boom assy slinging Detach/attach 1 pc. 0.2
40 Arm cylinder attaching and detaching Detach/attach 1 pc. 0.4
41 • Arm cylinder piping Detach/attach 1 pc. 0.2
42 • Arm cylinder head pin Detach/attach 1 pc. Include stopper pin. 0.1
43 • Arm cylinder slinging Detach/attach 1 pc. 0.1
50 Boom cylinder attaching and detaching Detach/attach 2 pcs. 0.7
51 • Boom cylinder piping Detach/attach 2 0.3
52 • Boom cylinder head pin Detach/attach 2 pcs. 0.2
53 • Boom cylinder slinging Detach/attach 2 0.2
60 Bucket cylinder O/H 1 3.6
61 • Pin bushing Replace 1 Include seal. 1.2
70 Arm cylinder O/H 1 3.6
12-5
Work to be Unit :
done Hour
71 • Pin bushing Replace 1 set Include seal. 1.2
80 Boom cylinder O/H 2 7.0
01
81 • Pin bushing Replace 1 set Include seal. 1.2
10 Cab relation See 33.1.2

11 Cab ASSY Detach/attach 1 pc. 1.4
12 • Front lower glass, floor mat Detach/attach 1 pc. each 0.1
13 • Seat rear cover top, bottom Detach/attach 4 places 0.2
14 • Seat rear cover top, bottom Detach/attach 1 pc. each 0.2
15 • Right side panel (include A/C duct) Detach/attach 3 0.3
16 • Cable and harness (electric) Detach/attach 6 0.2
17 • Cab mounting bolt Detach/attach 8 pcs. 0.2
18 • Cab slinging Detach/attach 3 places 0.2
20 Guard relation See 33.1.4

21 Bonnet assy (11) Detach/attach 1 pc. 0.2
22 Guard (5) Detach/attach 1 pc. 0.2
24 Guard assy (3) Detach/attach 1 pc. 0.2
25 Stay (7) Detach/attach 1 pc. 0.2
02 Cab & Guard

27 Panel assy (21) Detach/attach 1 pc. 0.2
34 Pillar (11) Detach/attach 1 pc. 0.2
35 Beam (4) Detach/attach 1 pc. 0.2
41 Cover (2) Detach/attach 1 pc. 0.2
44 Plate (20) Detach/attach 1 pc. 0.2
45 Cover assy (1) Detach/attach 1 pc. 0.2
Note: The numbers in the parenthesis like guard (14) match the guard numbers on the upper structure.
12-6
Work to be Unit :
done Hour
50 Under cover relation See 33.1.5
02 Cab & Guard

60 Counterweight relation See 33.1.11

61 Counterweight ASSY Detach/attach 1 pc. 0.6
62 • Counterweight lifting eye bolt Detach/attach 1 set 0.1
63 • Counterweight temporary slinging Preparation 1 pc. 0.2
64 • Counterweight mounting bolt Detach/attach 1 pc. 0.2
65 • Counterweight slinging Detach/attach 1 pc. 0.1
10 Intake relation See 33.1.9

11 Air cleaner ASSY Detach/attach 1 pc. 0.4
12 • Hose (3) Detach/attach 1 0.1
13 • Air cleaner mounting bolt Detach/attach 1 set 0.2
14 • Element Replace 1 0.1
20 Exhaust relation See 33.1.10

21 Muffler ASSY Detach/attach 1 pc. 0.4
22 • U bolt Detach/attach 1 pc. 0.2
23 • Clamp ASSY Detach/attach 1 pc. 0.2
03 Swing frame
30 Radiator relation See 33.1.12

31 Radiator ASSY Detach/attach 1 pc. 4.0
32 • Coolant (LLC) Replace 1 pc. 0.3
33 • • Concentration of coolant Measuring 1 pc. 0.2
34 • A/C condenser Detach/attach 1 pc. 0.3
35 • Stay Detach/attach 1 pc. 0.1
36 • Bracket Detach/attach 1 0.3
37 • Sub tank hose Detach/attach 1 pc. 0.1
38 • Fan guard Detach/attach 1 pc. 0.3
39 • Water hose (radiator ~ E/G) Detach/attach 2 0.5
40 • Radiator mounting bolts removing Detach/attach 1 set 0.2
41 • Under cover Detach/attach 1 pc. 0.1
42 • Hydraulic oil tank suction stopper Detach/attach 1 pc. 0.2
43 • Hydraulic oil piping Detach/attach 1 pc. 0.6
Note: The numbers in the parenthesis like cover (2) match the guard numbers on the upper structure.
12-7
Work to be Unit :
done Hour
44 • Inter cooler hose & tube Detach/attach 2 pcs. 0.5
(E/G to inter cooler)
45 • Radiator lifting or hoisting Detach/attach 1 pc. 0.2
46 • Radiator inter cooler core & oil cooler Cleaning 1 pc. 1.0
50 Fuel relation See 33.1.6

51 Fuel tank ASSY Detach/attach 1 pc. 1.8
52 • Fuel Replace 1 pc. 0.3
53 • Hose (water separator side) Detach/attach 2 0.1
54 • Water separator Detach/attach 1 pc. 0.1
55 • Tube (tank side) Detach/attach 1 0.1
57 • Fuel tank installing bolts Detach/attach 1 pc. 0.3
58 • Tank slinging Detach/attach 1 pc. 0.3
Other necessary works Detach/attach 1 pc. Removing and installing guard 0.4
60 Hydraulic oil tank relation See 33.1.7

61 Hydraulic oil tank ASSY Detach/attach 1 pc. 3.0
65 • Cover Detach/attach 1 pc. 0.2
03 Swing frame
66 • Hydraulic oil Replace 1 pc. 0.5

68 • Pilot drain hose Detach/attach 1 pc. 0.2
69 • Pump suction hose Detach/attach 1 pc. 0.5
70 • Mounting bolt Detach/attach 1 pc. 0.2
71 • Hydraulic oil tank slinging Detach/attach 1 pc. 0.3
72 • Return filter Replace 1 0.2
73 • Suction filter Cleaning 1 0.2
80 Pump relation See 33.1.8

81 Pump ASSY Detach/attach 1 pc. 3.2
82 • Hydraulic oil tank cover Detach/attach 1 pc. 0.2
83 • Strainer & stopper Detach/attach 1 pc. 0.3
84 • Piping Detach/attach 1 set 1.0
85 • Guard Detach/attach 5 pcs. 1.0
86 • Pump slinging Detach/attach 1 pc. 0.5
87 • Cleaning Cleaning 1 pc. 0.1
88 • Vent air Adjust 1 pc. 0.1
89 Pump ASSY O/H 1 pc. 4.0
90 Swing motor unit relation See 33.1.18

91 Swing motor ASSY Detach/attach 1 pc. 2.4
94 • Unit slinging Detach/attach 1 pc. 0.5
95 • Cleaning and sealant Cleaning 1 set 0.2
12-8
Work to be Unit :
done Hour
96 Swing motor O/H 1 pc. 3.6
97 Swing reduction gear O/H 1 pc. 4.2
100 Swivel joint relation See 33.1.19

101 Swivel joint ASSY Detach/attach 1 2.6
102 • Piping (Top part only) Detach/attach 1 set 0.5
103 • Whirl stop bolt Detach/attach 1 0.2
104 • Cover Detach/attach 1 0.4
105 • Joint & elbow Detach/attach 1 set 0.4
106 • Mounting bolt Detach/attach 1 set 0.4
107 • Swivel joint slinging Detach/attach 1 0.4
108 • Cleaning Cleaning 1 set 0.3
109 Swivel joint O/H 1 set Removing and installing guard 3.6
Other necessary works Detach/attach 1 set Lower piping 0.6
120 Main control valve See 33.1.15

03 Swing frame
121 Main control valve ASSY Detach/attach 1 pc. 2.5

122 • Attach tag to port name of pipe Preparation 1 pc. 0.6
124 • Bracket mounting bolt Detach/attach 1 pc. 0.1
125 • Valve slinging Detach/attach 1 pc. 0.1
126 Main control valve ASSY Detach/attach 1 set 6.0
Other necessary works Detach/attach 1 set Guard 0.4
130 Valve relation OPT

131 Solenoid valve ASSY Detach/attach 1 1.0
132 • Attach tag to port name of pipe Preparation 1 0.2
134 • Mounting bolt Detach/attach 1 0.3
140 Engine (E/G) mounting relation See 33.1.13

141 Engine ASSY Detach/attach 1 pc. After removing pump & radiator 1.8
142 • Harness connector & grounding & Detach/attach 1 pc. 0.3
cable connection
143 • Fuel hose Detach/attach 1 pc. 0.1
144 • Others Detach/attach 1 set 0.5
146 • Engine slinging Detach/attach 1 set 0.2
12-9
Work to be Unit :
done Hour
148 Engine O/H 1 set Reference for engine (Chapter 51)
Other necessary works Detach/attach 1 set Removing and installing guard 0.6
Detach/attach 1 set Removing and installing Counterweight 0.6
Detach/attach 1 set Removing and installing pump 3.2
Detach/attach 1 set Removing and installing air cleaner 0.4
Detach/attach 1 set Removing and installing muffler 0.4
03 Swing frame
Detach/attach 1 set Removing and installing radiator 4.0
150 Upper frame See 33.1.20

151 Upper frame ASSY Detach/attach 1 pc. After removing swivel joint 1.3
152 • Mounting bolt Detach/attach 1 set 0.4
153 • Upper frame slinging Detach/attach 1 pc. 0.4
155 • Sealant Apply 1 pc. 0.2
Other necessary works Detach/attach 1 set Cab 1.4
Detach/attach 1 set Guard 0.4
Detach/attach 1 set Counterweight 0.6
Detach/attach 1 set Boom 1.4
00 Travel relation See 34.1.2

01 Track link ASSY Detach/attach One side Include adjustment of tension 1.5
02 • Track link attaching and detaching position Preparation One side 0.1
03 • Master pin Detach/attach One side 0.5
04 • Track link extending and winding Detach/attach One side 0.5
05 Shoe plate Replace 1 pc. 0.4
04 Travel system
10 Upper roller relation See 34.1.3

11 Upper roller ASSY Detach/attach 1 After removing track link 0.2
12 Upper roller O/H 1 1.0
20 Lower roller relation See 34.1.4

21 Lower roller ASSY Detach/attach 1 0.2
22 Lower roller O/H 1 1.5
30 Front idler relation See 34.1.5

31 Front idler ASSY Detach/attach One side After removing track link 0.6
32 Front idler ASSY slinging Detach/attach One side 0.3
33 Front idler ASSY Detaching One side 0.3
34 Idler ASSY O/H One side 1.0
35 Idler adjuster ASSY O/H One side Replace spring 2.4
36 • Grease cylinder O/H One side 0.6
12-10
Work to be Unit :
done Hour
40 Sprocket See 34.1.6
41 Sprocket Replace One side After removing track link 0.6
50 Travel motor relation See 34.1.7

51 Travel motor ASSY Detach/attach One side After removing track link 1.7
52 • Motor cover Detach/attach One side 0.1
53 • Hydraulic piping Detach/attach One side 0.9
54 • Motor mounting bolt Detach/attach One side 0.5
04 Travel system
55 • Motor slinging Detach/attach One side 0.1

56 Motor cleaning Cleaning One side 0.1
57 Travel motor O/H One side 3.6
58 Travel reduction gear O/H One side 3.6
60 Swivel joint relation

61 Pipe on swivel joint travel side Detach/attach 1 pc. Include bonnet assy removing and installing. 0.6
62 Swivel joint O/H 1 pc. See 33.2.6 3.6
70 Swing bearing See 34.1.8

71 Swing bearing ASSY Detach/attach 1 pc. After removing upper frame 0.7
72 Swing bearing mounting bolt Detach/attach 1 pc. 0.5
73 Swing bearing slinging Detach/attach 1 pc. 0.3
Controller
C-1 Controller (KPSS) Replace 1 0.5
C-2 Gauge cluster Replace 1 1.0
C-4 Air conditioner Amplifier Replace 1 2.0
Diode
06 Electric equipments
D-4 Diode Replace 1 0.3

12-11
Work to be Unit :
done Hour
Electric equipments
E-1 Fuse & relay box Replace 1 0.3
E-2 Alternator Replace 1 1.0
E-3 Hour meter Replace 1 0.3
E-5 Horn (High) Replace 1 0.3
E-6 Horn (Low) Replace 1 0.3
E-7 Tuner Replace 1 0.3
E-8 Speaker left Replace 1 0.3
E-9 Speaker right Replace 1 0.3
E-10 Receiver dryer Replace 1 Include gas sealing. 1.0
E-11 Air compressor Replace 1 Include Counterweight removing and installing. 1.0
E-12 Battery Replace 2 0.4
E-13 Travel alarm (Middle east) Replace 1 0.3
E-14 Cigarette lighter Replace 1 0.3

E-15 Fusible link Replace 1 0.2
E-22 DC-DC converter Replace 1 0.3
E-23 12V socket Replace 1 0.3
E-27 Accel redundant volume Replace 1 0.3
Light
L-1 Boom work light left Replace 1 Bulb 0.2
L-2 Work light right Replace 1 0.2
L-5 Room light Replace 1 0.2
L-6 Boom cylinder work light (right) Replace 1 0.2
L-7 Cab work light Replace 1 0.2
Motor
M-1 Starter motor Replace 1 Include Counterweight removing and installing. 1.0
M-3 Wiper motor Replace 1 0.5
M-4 Washer motor Replace 1 0.5
M-8 Grease motor (OPT) Replace 1 0.5
M-9 Skylight wiper motor (OPT) Replace 1 0.5
Proportional valve
PSV-A Arm variable recirculation proportional valve Replace 1 0.5
PSV-B P2 bypass cut proportional valve Replace 1 Include proportional valve block removing and installing. 0.5
PSV-C Travel straight proportional valve Replace 1 0.5
PSV-D P1 bypass cut proportional valve Replace 1 0.5
PSV-P1 P1 pump proportional valve Replace 1 0.5
PSV-P2 P2 pump proportional valve Replace 1 0.5
12-12
Work to be Unit :
done Hour
Relay
R-1 Battery relay Replace 1 0.3
R-2 Starter relay Replace 1 0.3
R-3 Glow relay Replace 1 0.3
R-4 Safety relay Replace 1 0.1
R-5 Horn relay Replace 1 0.1
R-6 Work light relay Replace 1 0.1
R-8 Travel alarm relay (Middle east) Replace 1 0.1
R-23 Auto idle stop relay 1 Replace 1 0.1
R-24 Auto idle stop relay 2 Replace 1 0.1
R-25 E/G emergency stop relay Replace 1 0.1
R-26 Safety lock lever relay Replace 1 0.1
R-28 Alternator relay Replace 1 0.1
R-29 Wiper motor relay (Normal rotation) Replace 1 0.1
R-30 Wiper motor relay (Reverse rotation) Replace 1 0.1

R-31 Wiper motor relay arc prevention relay Replace 1 0.1
R-32 Washer motor relay Replace 1 0.1
Sensor
SE-1 Pressure sensor : Bucket digging Replace 1 0.3
SE-2 Pressure sensor : Bucket dump Replace 1 0.3
SE-3 Pressure sensor : Boom up Replace 1 0.3
SE-4 Pressure sensor : Boom down Replace 1 0.3
SE-5 Pressure sensor : Swing Replace 1 0.3
SE-7 Pressure sensor : Arm in Replace 1 0.3
SE-8 Pressure sensor : Arm out Replace 1 0.3
SE-9 Pressure sensor : Travel right Replace 1 Include under cover removing and installing 0.5
SE-10 Pressure sensor : Travel left Replace 1 Include under cover removing and installing 0.5
SE-11 Pressure sensor : P2 side OPT. Replace 1 Include under cover removing and installing 0.5
SE-13 Engine speed sensor Replace 1 Include under cover removing and installing 0.5
SE-15 Engine water temperature sensor Replace 1 Include guard removing and installing 0.5
SE-16 Accel potentio Replace 1 0.5
SE-20 Pressure sensor : P1 side : P1 side (OPT.) Replace 1 Include under cover removing and installing 0.5
SE-22 Pressure sensor : P1 pump Replace 1 0.5
SE-23 Pressure sensor : P2 pump Replace 1 0.5
Solenoid
SV-1 Swing parking SOL Replace 1 Include proportional valve block removing and installing. 0.5
SV-2 Attachment boost pressure SOL Replace 1 Include proportional valve block removing and installing. 0.5
SV-3 2-speed travel SOL Replace 1 Include proportional valve block removing and installing. 0.5
SV-4 Safety lever lock SOL Replace 1 Include proportional valve block removing and installing. 0.5
12-13
Work to be Unit :
done Hour
Switch
SW-1 Key switch Replace 1 0.3
SW-4 Swing parking release switch Replace 1 0.3
SW-7 Engine oil pressure switch Replace 1 0.3
SW-8 Clogged air filter switch Replace 1 0.3

SW-10 Horn switch (left) Replace 1 0.3
SW-11 Safety lever lock switch Replace 1 0.3
SW-13 Travel alarm switch (For middle east) Replace 1 0.3
SW-19 Wiper interlock switch Replace 1 0.3
SW-20 Attachment power boost switch (right) Replace 1 0.3
SW-26 Cab work light switch Replace 1 0.3
SW-27 Engine cooling coolant level switch Replace 1 0.3
SW-55 Boom work light switch Replace 1 0.3
12-14
12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST

(TEMPORARY EDITION)
Preface
This standard working time is based on the work time required for service of engine like disassembly, check,
adjustment and assembly and so on under a following condition.
This standard working time is provided under the following conditions.
12.2.1 MEASURING METHOD

(1) The time from the worker beginning working at the regular position of machine to the returning to the regular
position after completion of the work is counted as working time.
(2) The measuring unit is in 0.1 minute, and then round up the fractions.
(3) The work is carried out by a couple of workmen as a general rule, and the man-hour of two workers is counted
as the working time. But light work which can be carried out easily by a person and the efficient is higher is
counted as a workman.
12.2.2 WORKING CONDITION
12.2.2.1 TOOLS, INSTRUMENT

(1) Hand tool ;
Tools which are commercially available and each workman usually carries
(2) Common tool ;
Tools which are commercially available and each workman do not usually carry but the storing place is specified
(3) Special tool ;
Tools especially prepared by HINO Motor’s Ltd. and the storing place is specified
(4) Machine tool ;
When measuring equipment and instrument are used, the time required to move parts to the specified place is
included but the time waiting for tool is not included as a general rule
12.2.2.2 WORKING PROCEDURE

The disassembly and assembly should be carried out according to working procedure prepared by HINO Motor’s
Ltd. Service Technical Dept. Training Group.
12.2.2.3 STANDARD WORKMAN QUALIFICATION

Workmen shall basically acquire 2~3 years of maintenance experience of HINO
12.2.3 STANDARD TIME CONSTITUENT
12.2.3.1 STANDARD WORKING TIME = NET WORKING TIME + STANDARD TIME + STANDARD
ALLOWANCE TIME
(1) Net working time
The time workman works actually and the time required for measurement, cleaning, and so on is included, but
the time required for troubleshooting is not included
(2) Standard time
Time required for preparation to the beginning of work, preparation of special tool, measuring equipment, parts
and so on, and for the work site clean-up.
(3) Standard allowance time
Calculate the allowance time directly required for workmen from the following equation.
Net standard time × HINO allowance rate
Allowance rate varies within the range of 0.15 ~ 0.75 according to the work difficulty, contents, working position
and so on.
12-15
12.2.3.2 ALLOWANCE RATE, STANDARD PREPARATION TIME
12.2.3.2.1 HINO allowance rate (0.15~0.75)

(1) Basic rate : 0.10
(2) Working posture allowance (Fatigue coefficient) : Take any one of the followings according to the work contents.
Standing work : 0.05
Work in bent posture : 0.10
Work while lying : 0.15
(3) Difficult work allowance : 0.30
(4) Seized rusted section (For new vehicle) : 0.50
Take any one of above (3) and (4).
Min. allowance rate = Basic allowance + standing work allowance = 0.1+ 0.05 = 0.15
Max. allowance rate = Basic allowance + work allowance in lying + seized rusted section = 0.1 + 0.15 + 0.5=0.75
12.2.3.2.2 STANDARD WORKING TIME

(1) Working standard time : 3 minutes
(One time for a set of works)
(2) Special tool standard time : 3 minutes
(3) Standard time of non-portable machine : 3 minutes
(For single work)
(4) Part standard time : 6 minutes (up to 10 items), 10 minutes (10 items or more)
(5) Test : 15 minutes
(6) Preparation time for chain block, measuring instrument, piston, heater and so on : 3 minutes
(7) General cleaning : 2 minutes
(8) Safety treatment like wheel stopper, and so on : 3 minutes
(9) Visual checks : 2 minutes
The preparation time is classified into as described above, and only items required for the every work are
selected, calculated and counted as preparation time of the work.
12-16
12.2.4 MEANING OF WORDS IN USE

• Completed machine :
When detaching, replacing and adjusting the specified parts, it means the time which is determined by
addition of the preparation time, net working time and standard allowance time of the work.
• Single unit :
When detaching, replacing and adjusting the specified parts, it means the time in which the preparation time
of the work is omitted and which is determined by addition and subtraction to/from the work for "Completed
machine".
• Removal and installation :
The work to remove specified parts from machine and to attach the parts, and then to perform necessary
adjustment
• Simultaneous replacement :
The work to remove specified parts in 2 types or more from machine and to attach the spare parts, and then
to perform necessary adjustment
• Adjustment :
The work to carry out necessary adjustment with the specified parts removed or attached :
• Overhaul :
The work to remove specified assembled parts from machine, disassemble and check them, and then to
attach the spare parts to machine and to perform necessary adjustment
• Include :
Explains the contents of work to make the specified work range clear
• Exclude :
Shows the work which is not included in the specified primary work
• Unit :
Time is shown by hour.
12-17
SK200-8 SK330-8
Work No. Work Work unit Works Q'ty

Adding hour 1 Adding hour
1
by 1 each by 1 each
Completed Timing adjustment

1 00101 Engine adjustment A set 2.3 2.5
machine Valve clearance adjustment
Completed
2 00103 Engine adjustment B set A set and nozzle adjustment — —
machine
Include; Engine warm-up, valve clearance
Completed
3 00111 Compression measuring adjustment, removing air cleaner element 3.4 4.3
machine
and battery specific gravity measurement
Replacing cylinder, block, piston, ring
8 99012 Single unit From engine is removed condition 27.4 31.6
and liner simultaneously
Replacing crank shaft, piston, ring
9 99013 Single unit From engine is removed condition 20.8 25.8
and liner simultaneously
From engine is removed condition
Include; Valve clearance adjustment
Replacing cylinder block Single unit 24.4 30
Exclude; Installing expansion plug knock
pin
11 00126 Replacing crank shaft Single unit From engine is removed condition 18.4 22.8
12 00127 Replacing crank shaft main bearing Single unit From engine is removed condition 18.4 22.8
Include; Adjustment of water pump, oil
pump, valve clearance, valve lapping and
15 00151 Engine overhaul Single unit measurement/cleaning 38.5 44.3
Exclude; Replacing of injection pump,
electrical equipment, water pressure test,
clutch overhaul and valve guide
16 00152 Compression measuring Single unit 2.3 3.1
From piston & connecting rod are
17 00153 Replacing piston Single unit 0.5 0.5 0.5 0.5
removed conditions
18 00154 Replacing piston ring Single unit 0.2 0.2 0.2 0.2
removed conditions
19 00155 Replacing cylinder liner Single unit 0.4 0.4 0.4 0.4
removed conditions
20 00157 Replacing connecting rod Single unit 0.3 0.3 0.3 0.3
removed conditions
From connecting rod is a single unit
21 00158 Replacing piston pin bushing Single unit condition 0.4 0.4 0.4 0.4
Include; Reaming
26 00165 Replacing expansion plug Single unit 0.4 0.4 0.4 0.4
Completed
41 00302 Valve clearance adjustment 1.7 2.0
machine
Replacing rocker chamber cover
42 00305 One set 1.3 1.4
upper
43 00306 One set Include; Removal and installing upper — 4.3
lower
44 00304 One set 1.3 1.4
gasket
Removal and installing rocker arm Completed
45 00312 2.6 3.3
and support machine
Completed
46 00313 Replacing rocker arm 2.6 3.4
machine
Completed
47 00314 Replacing rocker arm support 2.6 3.4
machine
Completed
48 00315 Replacing rocker arm shaft 2.6 3.4
machine
Completed Excluding; Removal and installing of nozzle
50 00322 Removal and installing cylinder head 8.2 10.4
machine holder or injector and injector sub harness
Completed Include; Valve lapping
51 00323 Replacing cylinder head 11.5 16.9
machine Exclude; Replacing of valve guide
12-18
SK200-8 SK330-8

1
by 1 each by 1 each
Include; Valve lapping

Completed Exclude; Replacing of valve guide,
52 00324 Overhaul of cylinder head 13.3 18.8
machine water pressure test and replacing
valve seat
Completed
53 00325 Replacing cylinder head gasket 8.2 10.4
machine
Completed
54 00326 Replacing valve Include; Valve lapping 10.2 15.6
machine
Completed Exclude; Removal and installing of
55 00327 Replacing valve spring 4.9 8.8
machine cylinder head
Completed Exclude; Removal and installing of
57 00328 Replacing valve stem seal 5.3 9.4
machine cylinder head
Removal and installing camshaft
61 00376 One set 1.2 0.2 1.6 0.2
housing plug
Removal and installing camshaft (with Completed
62 00377 2.6 3.4
camshaft gear) machine
With manifold and nozzle holder
Replacing cylinder head
Excluding; Removal and installing of
63 00352 (one piece and one set require same Single unit 6.1 6.5
cylinder head, replacing valve guide,
hour)
water pressure test and replacing
valve seat
Unit of 1
66 00355 Replacing valve guide 1.0 0.8 1.0 0.8
cylinder
72 00361 Replacing expansion plug Single unit 0.4 0.4 0.4 0.4
Replacing rocker arm
Unit of 1
73 00371 (one piece and one set require same 0.1 0.1
cylinder
hour)
Replacing rocker arm support
Unit of 1
74 00372 (one piece and one set require same 0.1 0.1
cylinder
hour)
Unit of 1
75 00373 Replacing rocker arm bushing 0.3 0.1 0.3 0.1
cylinder
From cylinder head is removed
Unit of 1
76 00374 Replacing valve condition 0.5 0.5 0.5 0.5
cylinder
Unit of 1 From cylinder head is removed
77 00375 Replacing valve spring 0.2 0.2 0.2 0.2
cylinder condition
Unit of 1 From cylinder head is removed
78 00330 Replacing valve stem seal 0.3 0.3 0.3 0.3
cylinder condition
81 00406 Removal and installing supply pump One set Include; Function check 2.3 2.3
84 00411 Tightening oil pan Single unit From engine is removed condition 0.5 0.5
85 00412 Removal and installing oil pan Single unit From engine is removed condition 0.5 0.5
86 00413 Replacing oil pan Single unit From engine is removed condition 0.7 0.7
87 00414 Replacing oil pan gasket Single unit From engine is removed condition 0.7 0.7
88 00421 Replacing oil pan drain cock Single unit From engine is removed condition 0.5 0.5
89 00422 Replacing oil pan drain cock gasket Single unit From engine is removed condition 0.5 0.5
92 00443 Replacing breather hose Single unit From engine is removed condition 0.3 0.2 0.3 0.2
93 00444 Replacing oil level gauge Single unit From engine is removed condition 0.1 0.1
94 00445 Replacing oil level gauge guide Single unit From engine is removed condition 0.2 0.2
95 00446 Replacing oil level gauge bracket Single unit From engine is removed condition 0.2 0.2
102 00512 Replacing fly wheel housing Single unit From engine is removed condition 3.4 3.4
103 00541 Replacing fly wheel housing gasket Single unit From engine is removed condition 5.4 5.4
104 00542 Replacing rear end plate Single unit From engine is removed condition 5.4 5.4
105 00543 Replacing rear end plate gasket Single unit From engine is removed condition 5.4 5.4
106 00515 Replacing crank shaft rear oil seal Single unit From engine is removed condition 5.4 5.4
12-19
SK200-8 SK330-8

1
by 1 each by 1 each
119 00552 Replacing crank shaft rear oil seal Single unit From fly wheel is removed condition 0.2 0.2
131 00613 Replacing intake manifold One set Include; Applying liquid gasket 2.0 2.3
132 00614 Replacing intake manifold gasket One set Include; Applying liquid gasket 2.0 2.3
Removal and installing intake pipe
133 00636 One set 1.3 1.6
(manifold side)
134 00637 Replacing intake pipe (manifold side) One set 1.3 1.6
135 00622 Replacing air intake hose One set 0.4 0.2 0.4 0.2
136 00623 Replacing air intake pipe One set 0.4 0.2 0.4 0.2
137 00626 Replacing air intake pipe One set Turbo charger to inter cooler 0.4 0.4
138 00627 Replacing air intake pipe One set Air cleaner to turbo charger 0.4 0.2 0.4 0.2
Completed
139 00675 Replacing silencer body 0.3 0.2 0.3 0.2
machine
Completed
142 00641 Tightening exhaust manifold 0.9 1.3
machine
Removal and installing exhaust Completed
143 00643 With insulator and stud bolt 2.8 3.2
manifold machine
Completed Include; Replacing stud bolt with new

144 00644 Replacing exhaust manifold 3.0 3.4
machine one and insulator (TI system)
Completed
145 00645 Replacing exhaust manifold gasket 2.8 3.2
machine
One side of
Removal and installing of turbo
146 00646 Replacing exhaust heat insulator completed 2.4 2.6
charger
machine
147 00651 Replacing exhaust pipe One set 0.8 0.8
148 00653 Replacing exhaust pipe gasket One set 0.6 0.6
164 00686 Removal and installing turbo charger One set 2.9 2.5
165 00687 Replacing turbo charger One set Include; Replacing stud bolt 2.6 2.5
Replacing turbo charger oil return Include; Removal and installing of
167 00689 One set 0.9 0.9
pipe lower insulator
Replacing air intake pipe upper
174 00624 One set 0.4 0.4
(cooler to manifold)
Removal and installing engine and From engine is removed condition
188 00701 timing gear cover Single unit Include; Removal and installing of 5.4 5.4
(fly wheel housing) cylinder head
Replacing timing gear cover
189 00711 Single unit Include; Removal and installing of 5.4 5.4
(fly wheel housing)
cylinder head
Replacing timing gear cover gasket From timing gear cover is removed
190 00712 Single unit 0.7 0.7
(fly wheel housing) condition
Replacing timing gear cover plate From timing gear cover is removed
191 00713 Single unit 1.0 1.0
(rear end plate) condition
Replacing timing gear cover plate
From timing gear cover is removed
192 00714 gasket Single unit 1.0 1.0
condition
(rear end plate gasket)
193 00725 Replacing idler gear (main) Single unit 0.2 0.2
condition
194 00736 Replacing idler gear (sub) Single unit 0.1 0.1
condition
195 00726 Replacing idler gear shaft (main) Single unit 0.2 0.2
condition
196 00737 Replacing idler gear shaft (sub) Single unit 0.1 0.1
condition
197 00724 Replacing crank shaft gear rear Single unit 0.4 0.4
201 00738 Replacing cam idle gear Single unit 0.4 0.4
condition
12-20
SK200-8 SK330-8

1
by 1 each by 1 each

202 00739 Replacing cam idle gear shaft Single unit 0.4 0.4
condition
203 00731 Replacing camshaft Single unit 0.8 0.8
condition
204 00732 Replacing camshaft gear Single unit 0.8 0.8
condition
205 00751 Replacing crank pulley One set 1.9 1.9
206 00754 Replacing crank dumper One set 2.8 2.8
207 00755 Replacing crank shaft front oil seal One set 2.2 2.2
Replacing crank shaft front oil seal
208 00757 One set 2.8 2.8
retainer
Replacing crank shaft front oil seal
209 00758 One set 2.8 2.8
retainer gasket
Completed
211 00801 Checking injection timing 0.3 0.3
machine
226 00834 Replacing priming pump One set 0.4 0.4
227 00835 Cleaning fuel feed pump strainer One set 0.4 0.4
228 00836 Replacing through feed valve One set 0.4 0.4
230 00838 Replacing fuel injection pipe One set 2.5 0.1 2.5 0.1
236 00851 Replacing fuel filter assembly One set 0.5 0.5
237 00857 Replacing fuel filter cartridge One set 0.3 0.3
253 00875 Replacing fuel hose One set 0.8 0.8
254 00876 Replacing fuel leakage pipe One set 0.8 0.8
276 00912 Replacing oil filter cartridge One set 0.4 0.4
Replacing oil filter relief valve (oil filter
277 00907 One set 0.3 0.3
regulator valve)
Replacing oil filter relief valve spring
278 00908 One set 0.3 0.3
(oil filter regulator valve)
279 00909 Replacing oil filter safety valve One set 0.3 0.3
280 00910 Replacing oil filter safety valve spring One set 0.3 0.3
00961(tim Removal and installing fly wheel
294 ing gear housing Single unit From engine is removed condition 6.1 6.1
cover) (timing gear cover)
295 00942 Replacing oil pump Single unit From engine is removed condition 6.3 6.3
296 00944 Replacing oil pump gear Single unit From engine is removed condition 6.5 6.5
297 00943 Overhaul of oil pump Single unit From engine is removed condition 6.5 6.5
298 00946 Replacing suction strainer One set 0.1 0.1
299 00947 Replacing suction strainer O-ring One set 0.1 0.1
301 00951 Replacing oil pipe One set 0.4 0.4 0.4 0.4
302 00954 Replacing oil hose One set 0.4 0.4 0.4 0.4
303 00971 Replacing cooling oil jet 1 0.2 0.2 0.2 0.2
327 01028 Removal and installing water pump One set Include; Filling engine coolant up 4.0 4.0
328 01029 Replacing water pump One set Include; Filling engine coolant up 4.0 4.0
329 01030 Overhaul of water pump Single unit 0.8 0.8
330 01031 Replacing water pump pulley Single unit 0.6 0.6
331 01032 Replacing water pump casing gasket One set Liquid gasket 4.0 4.0
332 01036 Replacing cooling fan One set 0.9 0.9
333 01037 Replacing fluid fan coupling One set 0.9 0.9
334 01044 Replacing thermostat casing One set Include; Filling engine coolant up 1.3 1.3
336 01046 Replacing thermostat casing cover One set Include; Filling engine coolant up 1.0 1.0
Replacing thermostat casing cover
337 01047 One set Include; Filling engine coolant up 1.0 1.0
gasket
Include; Checking for temperature at
338 01048 Replacing thermostat One set 1.0 1.0
valve start opening
12-21
SK200-8 SK330-8

1
by 1 each by 1 each
Include; Checking for temperature at

339 01049 Checking thermostat One set 1.0 1.0
valve start opening
341 01053 Replacing coolant hose One set 0.3 0.2 0.3 0.2
342 01054 Replacing radiator hose One set 0.3 0.2 0.3 0.2
343 01071 Replacing fluid fan coupling 1 0.3 0.3
344 01072 Replacing cooling fan 1 0.3 0.3
345 01073 Replacing water pump 1 From cooling fan is removed condition 1.7 1.7
346 01074 Overhaul of water pump 1 0.8 0.8
402 01401 Removal and installing alternator One set 0.8 0.8
403 01402 Replacing alternator One set 0.9 0.9
404 01406 Replacing alternator support bracket One set 1.0 1.0
405 01408 Replacing V-belt One set 0.3 0.3
438 01801 Removal and installing supply pump One set Include; Function check 3.0 3.0
439 01802 Replacing supply pump One set Include; Function check 3.0 3.0
Removal and installing common rail
assembly
440 01830 One set Include; Function check 3.8 3.8
(with pressure sensor, pressure
limiter)
Replacing common rail assembly
441 01804 (with pressure sensor, pressure One set Include; Function check 3.8 3.8
limiter)
Removal and installing injector Completed
442 01805 Include; Function check 2.9 3.5
assembly machine
Completed Include; Function check and

443 01806 Replacing injector assembly 3.4 4.0
machine reprogramming
Removal and installing injector
444 01807 One set Include; Function check 1.9 0.2 1.9 0.2
assembly
Include; Function check and
445 01808 Replacing injector assembly One set 2.4 0.2 2.4 0.2
reprogramming
Removal and installing injector sub
harness assembly
Replace injector sub harness
assembly
448 01811 Removal and installing flow dumper One set Include; Function check 1.2 0.3 1.2 0.3
449 01812 Replacing flow dumper One set Include; Function check 1.2 0.3 1.2 0.3
Removal and installing pressure
limiter
451 01814 Replacing pressure limiter One set Include; Function check 1.2 1.2
Replacing common rail pressure
sensor
453 01816 Replacing main engine speed sensor One set Include; Function check 1.2 1.2
454 01817 Replacing sub engine speed sensor One set Include; Function check 1.2 1.2
Replacing coolant temperature
sensor
456 01819 Replacing fuel temperature sensor One set Include; Function check 1.2 1.2
457 01820 Replacing accel sensor One set Include; Function check 1.5 1.5
460 01823 1 Include; Function check 0.3 0.3
sensor
461 01824 1 Include; Function check 0.3 0.3
limiter
463 01826 Replacing injection pipe One set Include; Function check 1.2 0.1 1.2 0.1
Replacing fuel pipe
464 01827 One set Include; Function check 1.2 0.1 1.2 0.1
(common rail to supply pump)
465 01828 Replacing fuel leakage pipe One set Include; Function check 1.7 1.7
469 01840 Checking leakage of pressurized fuel One set Include; Function check 1.2 1.2
12-22
SK200-8 SK330-8

1
by 1 each by 1 each
471 01901 Replacing main engine speed sensor One set Include; Function check 1.2 1.2
472 01902 Replacing sub engine speed sensor One set Include; Function check 1.2 1.2
Replacing coolant temperature
sensor
474 01904 Replacing accel sensor One set Include; Function check 1.5 1.5
475 01908 Removal and installing EGR valve One set Include; Function check 2.1 2.5
476 01909 Replacing EGR valve One set Include; Function check 2.1 2.5
479 01916 Removal and installing EGR cooler One set 1.8 1.8
480 01917 Replacing EGR cooler One set 1.8 1.8
Removal and installing closed
481 01918 One set 0.3 0.3
ventilator
482 01919 Replacing closed ventilator One set 0.3 0.3
12-23
[MEMO]
12-24
13. MAINTENANCE STANDARD AND
TEST PROCEDURE
TABLE OF CONTENTS 13
13.1 HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED ...13-3
13.2 PERFORMANCE INSPECTION STANDARD TABLE .....................................................13-4
13.3 MEASUREMENT OF ENGINE SPEED ...........................................................................13-6
13.3.1 MEASUREMENT OF ENGINE SPEED ..................................................................13-6
13.4 MEASUREMENT OF HYDRAULIC PRESSURE ............................................................13-7
13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE .......................................13-7
13.4.2 PLACE TO INSTALL PRESSURE GAUGE............................................................13-7
13.4.3 PRESSURE ADJUSTMENT POSITION.................................................................13-8
13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE.................................................13-10
13.5 MEASURING TRAVEL PERFORMANCES.....................................................................13-12
13.5.1 TRAVEL SPEED.....................................................................................................13-12
13.5.2 DEVIATION OF TRAVEL .......................................................................................13-12
13.5.3 PERFORMANCES OF PARKING BRAKE .............................................................13-13
13.5.4 DRAIN RATE OF TRAVEL MOTOR.......................................................................13-14
13.6 MEASURING SWING PERFORMANCES.......................................................................13-15
13.6.1 SWING SPEED ......................................................................................................13-15
13.6.2 PERFORMANCE OF SWING BRAKE ...................................................................13-15
13.6.3 PERFORMANCE OF SWING PARKING BRAKE ..................................................13-16
13.6.4 DRAIN RATE OF SWING MOTOR ........................................................................13-17
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES ....................................13-18
13.7.1 OPERATING TIME OF CYLINDERS .....................................................................13-18
13.7.2 OIL TIGHTNESS OF CYLINDERS .........................................................................13-19
13.8 MEASURING PERFORMANCES OF SWING BEARING ...............................................13-20
13.9 MECHATRO CONTROLLER...........................................................................................13-21
13.9.1 ENGINE CONTROL INPUT / OUTPUT ..................................................................13-21
13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT) ...13-21
13.9.3 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO
CONTROLLER .......................................................................................................13-27
13-1
13. MAINTENANCE STANDARD AND TEST PROCEDURE

SK200–8 : YN11-45001~ S5YN1318E01
First edition August, 2006 K
SK210LC–8 : YQ11-06001~ (ASIA, OCE)
S5YN1318E02
Revision February, 2007 ↑ K
(ASIA, OCE)
E215B : YN11-45001~ ↑
↑ March, 2007 K
SK200-8 : YN11-45001~ ↑
↑ April, 2007 K
E215B : YN11-45001~ ↑
↑ July, 2007 K
↑
↑ ↑ ↑ K
↑
↑ ↑ ↑ K
13-2
13.1 HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE

EXERCISED
(1) Application
1) When the machine is new ;
Confirm that the performances are in accordance with standard specifications as compared to the
performance standards.
2) At specific self inspection ; (Rule by country)
Use the data for the criterion, for the purpose of correction, adjustment and replacement.
3) When performances are deteriorated ;
Determine whether it is caused by a fault or end of service life after long hours of operation, to be used for
safety and economical considerations.
4) When main components are replaced ;
For example, use data to restore performances of pumps and others.
(2) Terminology
1) Standard values ;
Values to be used to condition or assemble a new machine. Where special notes are not given, these values
represent standard specifications (machine with standard attachments and standard shoes).
2) Reference values for remedy ;
Values at which readjustment is required. In order to ensure performance and safety it is strictly prohibited
to use the machine over the specified values.
3) Service limit ;
This is the limit value at which reconditioning is impossible without replacement of parts. If the value is
expected to exceed the service limit before next inspection and correction are performed, replace the parts
immediately. The operation over the specified values causes increase of damage and requires the down time
of machine, and also causes safety problems.
(3) Cautions to be Exercised at Judgment
1) Evaluation of measured data ;
Disagreement of measuring conditions, variations of data peculiar to a new machine, and measuring errors
are to be evaluated. Determine generally at what levels measured values are located, instead of determining
whether or not values fall within or run out of the reference values.
2) Determining correction, adjustment or replacement ;
Machine performances deteriorate with time as parts wear and some deteriorated performances may be
restored to new levels. Therefore, determine correction, adjustment or replacement, depending upon the
operating hours, kind of work and circumstances in which the machine is placed, and condition the machine
performances to its most desirable levels.
(4) Other Cautions to be Exercised
1) Parts liable to degrade ;
Rubber products, such as, hydraulic hoses,
O rings, and oil seals deteriorate with time ; replace them at regular intervals or at overhauls.
2) Parts requiring regular replacement ;
Out of critical hoses that are necessary to secure safety, we designate Very Important Parts (V.I.P) and
recommend that they should be replaced regularly.
3) Inspection and replacement of oils and greases ;
In performing maintenance, it is necessary for the user to familiarize himself with how to handle the machine
safely, cautions to be exercised and inspection/lubrication procedures. Refer to the operators manuals as
well.
13-3
13.2 PERFORMANCE INSPECTION STANDARD TABLE
Unless otherwise specified, measure it on "H" mode.
Table13-1
Measuring Position Standard Tolerance Adjusting Measuring
Inspection Item Unit
Position Size Port value Hi Lo Point condition
Class
NAS 9
Cleanliness of hydraulic oil Hydraulic oil in tank — — — Sampling
Standard Measuring condition
or less
Hydraulic oil temperature Tank surface 50 (122) + 5 (41) - 5 (23)
°C
— Atmospheric temp
50°C~-10°C
Water temperature Radiator surface 75 (167) + 15 (59) - 15 (5) (°F) — (122°F~14°F)
H mode Lo idle 1000 + 30 - 30 LOW throttle
Engine speed
not required
H mode Hi idle 2000 + 30 - 30 Full throttle (HI idle)
Adjustment
Measure the engine
B mode Hi idle 2000 + 30 - 30 Perform all
speed at multi display on min-1
A mode Hi idle 2000 + 30 - 30 measurement with
the gauge cluster.
Decel 1050 + 30 - 30 the air-conditioner
S mode Hi idle 1800 + 30 - 30 "OFF".
Pilot primary pressure circuit G pump a4 5.0 (725) + 0.5 (+73) 0 PR1 HI idle
valve pressure
P1 a1
Main relief
ATT 34.3 (4970) + 0.7 (+100) - 0.5 (-73) MR1 Boom up

P2 a2
P1 a1
Boost 37.8 (5480) + 1.0 (+145) - 0.5 (-73) MR1
P2 a2
R 37.8 (5480) 0 - 4.0 (-580) OR4 Boom down
Boom a1
High pressure circuit
H 39.7 (5760) 0 - 5.9 (-855) OR3 Boom up

Over load relief valve pressure
R 39.7 (5760) 0 - 5.9 (-855) OR8 Arm out

Main pump
Arm a2
H PF1/4 37.8 (5480) 0 - 4.0 (-580) MPa OR7 Arm in
R 37.8 (5480) 0 - 4.5 (-711) (psi) OR2 Bucket dump
Bucket a1
H 39.7 (5760) 0 - 5.9 (-855) OR1 Bucket digging
RH 29.0 (4205) + 6.0 (+870) 0 OR6 Swing RH
Swing a2
LH 29.0 (4205) + 6.0 (+870) 0 OR5 Swing LH
FW —
RH a1 34.3 (4970) + 0.7 (+100) - 0.5 (-73) Simultaneous
Travel
RV —
operation of travel
FW —
LH a2 34.3 (4970) + 0.7 (+100) - 0.5 (-73) RH and LH
RV —
13-4
Standard
Inspection item Unit
value
Sprocket revolution 1st speed 30.5 ~ 27.5
min-1
(RH,LH) 2nd speed 50.4 ~ 45.6
Up 2.5 ~ 3.1
Boom
Down 2.2 ~ 2.8
Operating speed
Operating time of In 3.0 ~ 3.6

Arm sec (At no load)
cylinder Out 2.3 ~ 2.9
Digging 2.2 ~ 2.8
Bucket
Dumping 1.7 ~ 2.3
RH
Swing speed 4.2 ~ 5.4 sec / 1 rev
LH
1st speed Iron shoe 19.5 ~ 21.5
Travel speed sec / 20 m
2nd speed Iron shoe 11.9 ~ 13.1
Amount of travel
2nd speed 0 ~ 240 mm / 20 m
deviation
Parking brake drift 15 degree gradient 0 mm / 5 min
Performance of Swing Neutral position after
Performance
55 ~ 75 degree
brake 180° full speed swing
Performance of Swing
15 degree gradient 0 mm
parking brake
Tip of the bucket tooth 160
ATT amount of drift Boom cylinder 14 mm / 10min (At no load)
Arm cylinder 11
Amount of horizontal play at the bucket tooth 30 ~ 50 mm
The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation numbers in
advance.
(1) Bucket digging, (2) Bucket dump, (3) Boom up, (4) Boom down
(5) Swing left, (6) Swing right, (7) Arm in, (8) Arm out

13-5
13.3 MEASUREMENT OF ENGINE SPEED

13.3.1 MEASUREMENT OF ENGINE SPEED
(1) Warming up of engine
Start engine to raise the coolant temperature of
engine to 60 to 90°C (140 to 194°F) at surface of
radiator upper tank.
The E/G coolant tem-perature gauge is used to
measure. The range in white color shows the
temperature of approx. 65 to 105°C (149 to 221°F),
so confirm that the pointer indicates the
temperature within the white range.
(2) Engine speed measured value through service

diagnosis (See Fig. 13-2)
1) Turn "ON" the starter switch with the buzzer stop
switch pressed.
2) A program No. and an actual engine revolution
are displayed as the No.2 Item.
3) The screen advances like No.2, No.3....each
time the "Wiper switch" on the gauge cluster is

pushed.

4) The screen returns like No.45, No.44....each
time the "Washer switch" is pushed.
5) The display does not disappear unless the

starter switch is turned to"OFF".

Fig. 13-1 Switch for E/G speed indication
NO.2 ENG
G-3 SPEED SET 2205
MEAS 1 2201
MEAS 2 2201
G-5 ENG OIL PRS. LIVE
WATER TEMP. 100 OF
F
MODE HM
H-1 ACCEL. VOLT. 4.2V
POS 100%
ECU OUTPUT 0.5V
Fig. 13-2 Service diagnosis for E/G speed

measuring (Example)
13-6
13.4 MEASUREMENT OF HYDRAULIC PRESSURE

13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE
(1) Hydraulic equipment
6.9 MPa (1000psi) pressure gauge : 1unit
49 MPa (7100psi) pressure gauge : 2 units A3 a5
Pressure measuring equipment and instrument for
analysis : 1 set A2
PSV2 (A1)
(2) Measuring cleanliness of hydraulic oil (PSV1)
Dr3
B3
B1
After releasing air in the hydraulic oil tank, open the
cover and sample oil in the hydraulic tank, and a1 a2
measure with the instrument for analysis. If the
Fig. 13-3 Gauge port on main pump
measured value is higher than the standard value,
replace the return filter or change the hydraulic oil.
13.4.2 PLACE TO INSTALL PRESSURE GAUGE

(1) Main circuit
After releasing the pressure in hydraulic oil tank
and system, replace plugs PF1/4 of main pump
gauge ports (a1) (a2) with plugs for pressure
measurement, and attach pressure gauge 49 MPa
(7100 psi).
(2) Pilot circuit
Replace pilot gauge plug (a5) with plug PF1/4 for
pressure measurement, and attach pressure gauge
6.9 MPa (1000 psi).
13-7
13.4.3 PRESSURE ADJUSTMENT POSITION

(1) Main control valve
PLUG FOR
OR8 : ARM (R) OPTIONAL RELIEF
MACHINE
FRONT
MR1 : MAIN RELIEF OR3 : BOOM (H) OR2 : BUCKET (R)

(ATT & TRAVEL)
VIEW FROM THE TOP OF THE MACHINE
OR4 : BOOM (R) OR1 : BUCKET (H)
MACHINE
FRONT
OR7 : ARM (H) PLUG FOR OPTIONAL RELIEF
VIEW FROM THE BOTTOM OF THE MACHINE
Fig. 13-4 Relief valve position on main control valve
13-8
(2) Pilot relief valve

The pilot relief valve PR1 is located on the gear pump that is attached to the main pump.
A3
a5
Dr3
B3
PR1 ADJUST SCREW
FOR PILOT RELIEF
Fig. 13-5 Pilot relief valve position

(3) Swing over load relief
The swing motor is equipped with plugs PA,PB for pressure measurement, but the measurement is carried out
using gauge ports (a1) and (a2). (See Fig. 13-3)

Fig. 13-6 Swing over load relief position
13-9
13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE

(1) Pilot relief valve
Adjust it with adjust screw (311).
: 24 mm,
Tightening torque : 29.4 N•m (22 lbf•ft)
: 6 mm
No. of turns of adjust screw Pressure change MPa (psi)

1 turn Approx. 2.1 (305)
Fig. 13-7 Pilot relief valve
(2) 2-stage main relief valve
(Commom for travel and ATT sections) 0-:! 0-:'
Start from the boosting side, first. Loosen nut (1),

adjust the pressure with adjusting screw (2) and
tighten nut (1) after completion of the adjustment on
the boosting side.
Then, loosen nut (3), adjust the pressure on the
standard side with adjusting screw (4) and tighten
" !
nut (3) after completion of the adjustment. 0-:
: 32 mm, Fig. 13-8 Main relief valve
Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft) (Travel section, ATT common section)
: 22 mm,
Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft)
: 19 mm, Adjust screw
: 6 mm

Boosting side 1 turn Approx. 17.6 (2560)
STD side 1 turn Approx. 17.6 (2560)
(3) Over load relief valve

(Boom, bucket, arm sections)
Loosen lock nut (1) and adjust it with adjust screw
(2).
: 22 mm,
Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft)

: 6 mm 0-:
Fig. 13-9 Over load relief valve
No. of turns of adjust screw Pressure change MPa (psi) (Boom, bucket, arm sections)
1 turn Approx. 17.7 (2560)
13-10
(4) Over load relief valve (Swing) 0-:!& 0-:!

When the adjustment of pressure is required,
loosen lock nut (1) and adjust the pressure with cap
(2).
: 30, 38 mm,
Tightening torque : 118 N•m (87 lbf•ft)
4 !
: 12 mm Fig. 13-10 Swing over load relief valve

1 turn Approx. 10 (1450)
(5) Travel over load relief valve

This valve was adjusted by valve maker. Do not
replace any inner parts except for O-ring.
Fig. 13-11 Travel over load relief valve
13-11
13.5 MEASURING TRAVEL PERFORMANCES

13.5.1 TRAVEL SPEED
(1) Purposes
Measure the travel sprocket revolution and confirm
the performances between the hydraulic pump and
the travel motor of the travel drive system.
(2) Conditions
Hydraulic oil temperature ;
45~55°C (113~131°F)
Crawler on the right and left sides are tensioned
evenly.
(3) Preparation
Attach the reflection panel with a magnet to the Fig. 13-12 One side lifted position
travel motor cover.
Swing the swing frame through 90°as shown in Fig.
13-12 and make the crawler on one side take off the REFLECTION
ground, using the attachment. PANEL
(4) Measurement
Engine revolution; Hi idle
2-speed travel switch; 1st speed and 2nd speed
Measuring points ; Right and left
Method, example 1 ;
Measure revolution with a stroboscope
Fig. 13-13 Adhering position of reflection panel
Method, example 2 ;
Measure the revolutions per minute visually. Sprocket revolution Unit min-1
Measurement item Standard Reference value Service
value for remedy limit
RH H mode 1st speed 30.5~27.5 23.8~21.5 19.4 or less
&
LH H mode 2nd speed 50.4~45.6 39.3~35.6 32.2 or less
13.5.2 DEVIATION OF TRAVEL

(1) Purpose
Measure the amount of deviation at 20m (66ft) BOOM FOOT PIN
travel and confirm the horizontal balance between
the hydraulic pump and the travel motor of the
travel drive system.
(2) Condition
Hydraulic oil temperature ; ARM TOP PIN
45~55°C (113~131°F)
RH and LH crawler are tensioned evenly.
Firm, level ground Fig. 13-14 Travel position
13-12
(3) Preparation
1) Straight course more than 30m (108ft)
2) Travel position in which the bottom of the bucket
is lifted by about 30cm (1ft). A
(4) Measurement 20m (66ft)
1) Measure the max. deviation distance of the
circular arc in the 20m (66ft) length, excluding
Fig. 13-15 Measuring method
the preliminary run of 3~5m (10~16ft).
2) Operate the travel lever at the same time. Travel deviation Unit : mm (in) / 20m (66ft)
Measuring Reference value
position Standard value for remedy Service limit
A 240 (9.45) or less 480 (18.9) 720 (28.4)
13.5.3 PERFORMANCES OF PARKING BRAKE

(1) Purpose
Confirm that the parking brake holds a stopped
condition of the machine in a no-load travel position
and on a 15 degree slope.
(2) Condition BOOM FOOT PIN
A slope with (Approx. 15 deg) gradient and a
stopped condition in a no-load travel position
ARM TOP PIN
(3) Preparation
Place an angle meter on the shoe plate and confirm
that it makes an angle more than 15 degree. 15 degree slope
Hang a perpendicular in parallel with the guide
frame rib on the track frame and put a mark Fig. 13-16 Parking brake operating position
(matching mark) on the shoe plate.
(4) Measurement
Five minutes after the engine stops, measure the
movement distance of the matching mark.
C
GUIDE FRAME
Fig. 13-17 Method of measurement
Parking brake Unit : mm(in)/5min

C 0 1 (0.04) 2 (0.08)
13-13
13.5.4 DRAIN RATE OF TRAVEL MOTOR

(1) Purpose FORWARD 90 o 10
To measure the drain rate of the travel motor and to (3.54") (0.394")
confirm the performances of the travel motor. o 22 PIPE 40

(0.866") (1.57")
(2) Conditions
Hydraulic oil temperature ; RIB "A" 150
STOPPER (5.91")
45~55°C (113~131°F) "B"
(3) Preparation o 80
(3.15")
ROTARY DIRECTION
1) Place a stopper under the RH and LH travel
sprockets. Fig. 13-18 Location of stopper applied to travel
2) Stop the engine and release pressure from the sprocket
hydraulic circuit.
3) Connect a hose with the drain port of the travel
motor and take drain in a container.
(4) Measurement ; at Travel Lock
Unless you observe the rotary force direction at

travel lock, rib "A" may be broken by stopper "B" in
some cases. (See Fig. 13-18)
1) Start the engine and relieve pressure at the full

stroke of the travel lever. Fig. 13-19 Method of measuring the drain rate of
2) Measure the drain rate for 30 seconds of travel motor
relieving.
Travel deviation Unit : L(gal)/30sec
Drain rate 9 (2.4) 16 (4.2) 23 (6.1)
13-14
13.6 MEASURING SWING PERFORMANCES

13.6.1 SWING SPEED
(1) Purpose
Measure the swing time and confirm the
performances between the hydraulic pump and the
swing motor of the swing drive system.
(2) Conditions
45~55°C (113~131°F)
Firm, level ground
(3) Preparation
Put the bucket empty and extend the boom, arm
and bucket cylinder fully. Fig. 13-20 Swing speed measuring position (at the
And the machine becomes a position of minimum min. reach)
reach.
(4) Measurement
Swing the machine by bringing the swing lever to its
full stroke. Measure the time required to make two
turns after one turn of preliminary run and calculate
the time required for one turn.
13.6.2 PERFORMANCE OF SWING BRAKE

(1) Purpose Swing speed Unit : sec/rev
Confirm the braking torque performances by the Measuring
Standard value
Reference value
Service limit
position for remedy
swing relief valve. Swing speed at
min. reach 4.2~5.4 5.4~6.9 7.2~
(2) Conditions
45~55°C (113~131°F) ARM TOP BOOM FOOT
PIN PIN
Firm, level ground
(3) Preparation
1) Put the bucket empty, retract the arm cylinder
fully and extend the bucket cylinders fully. And
move the boom so that the arm top pin is
positioned at same height with boom foot pin. Fig. 13-21 Swing brake performance measuring
2) Put a matching mark on the outer circumference position
of the swing bearing of the upper frame side and
of the track frame side. Place two poles (flags)
on the front and back of the extended line of the
matching mark.
13-15
(4) Measurement MEASURING THE LENGTH OF THE ARC OVER

THE OUTER CIRCUMFERENCE OF OUTER RACE
1) When operating in regular swing speed, by
MATCHING MARKS ON
shifting lever to neutral position at pole position
OUTER RACE
the swing operation stops.
2) Calculate the swing drift angle by the following
equation, after the upper swing body stops,
using the amount of deflection (m) of the
matching marks on the swing race and the length
MATCHING MARKS
(m) of the circumference of the swing race : ON INNER RACE

Fig. 13-22 Measuring position of swing brake
performances

Swing brake performance Unit : degree
Swing 180 75 85 90
13.6.3 PERFORMANCE OF SWING PARKING BRAKE

(1) Purpose
To confirm the mechanical performances of the
swing parking brake that is fitted to the inside of the
swing motor.
(2) Conditions
On a slope of 15 degree incline.
Stop the machine at right angles with the slope. Put
the bucket empty, retract the arm cylinder fully and
extend the bucket cylinder fully. And move the
boom so that the arm top pin is positioned at same
height with boom foot pin.
Fig. 13-23 Swing parking brake performance
measuring position
(3) Preparation MEASUREING THE LENGTH OF THE ARC OVER
Put the angle meter on the shoe plate and make THE OUTER CIRCUMFERENCE OF OUTER RACE
MATCHING MARKS ON
sure that the angle is more than 15 degree. OUTER RACE
Put a matching mark on the outer race side and on
the inner race side.
(4) Measurement
When five minutes has passed after the engine
stops, measure the length of the movement of the
MATCHING MARKS
matching marks. ON INNER RACE
Fig. 13-24 Measuring position of swing parking

brake performances
Performance of swing parking brake Unit : mm(in)/5min

C 0 1 (0.04) 2 (0.08)
13-16
13.6.4 DRAIN RATE OF SWING MOTOR

(1) Purpose
Measure the drain rate of the swing motor and
confirm the performances of the swing motor.
(2) Conditions
Hydraulic oil temperature ; 45~55°C (113~131°F)
Firm, level ground
(3) Preparation
1) Stop the engine.
2) Release pressure from inside the hydraulic
circuit.
3) Disconnect the swing motor drain hose from its
end returning to the hydraulic oil tank and take
oil in a container.
4) Put a plug to the tank side.
(4) Measurement ; at Swing Lock Fig. 13-25
1) Start the engine and put the side faces of bucket
Travel deviation Unit : L(gal)/30sec
against the inside of the right or left shoe plates. Measuring Reference value
2) Relieve the swing motor at full stroke of the
swing motion. Drain rate 2.1 (0.55) 5.2 (1.4) 6.2 (1.6)
3) Collect the amount of drained oil in a container

for 30 seconds.
13-17
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES

13.7.1 OPERATING TIME OF CYLINDERS
(1) Purpose
Measure the operating time of the boom, arm and
bucket and confirm the performances between the
hydraulic pump and the cylinder of the attachment
drive system.
(2) Condition
Hydraulic oil temperature ; 45~55°C (113~131°F) Fig. 13-26 Measuring position for bucket digging
Engine revolution; Hi idle and dump
Operating time excluding the cushion stroke

(3) Preparation

Firm level ground with the bucket empty
(4) Measurement 1 ; Boom up and down
With the boom operating lever at full stroke,
measure the required operating time of the bucket
between the ground surface and its highest
position.
Fig. 13-27 Measuring position for boom up and
down motions
When lowering the boom, allow the bucket onto a

soft ground or cushioning such as rubber tires ;
never put the bucket against concrete or other
solid material.
30cm (1ft)
Measurement 2 ; Arm in and out, bucket digging
and dump Fig. 13-28 Measuring position for arm in and out
In a position in which the tooth of the bucket rises to motions
a level of about 30cm (1ft) above ground, measure
Cylinder Operating time Unit : sec
the full stroke operating time required with the arm
and bucket operating levers at full stroke. position Standard value for remedy Service limit
2.2~2.8 2.8~3.6 3.8~
1.7~2.3 2.2~2.9 3.0~
2.5~3.1 3.2~4.0 4.2~
2.2~2.8 2.8~3.6 3.8~
3.0~3.6 3.8~4.6 5.0~
2.3~2.9 2.9~3.7 3.9~
13-18
13.7.2 OIL TIGHTNESS OF CYLINDERS

(1) Purpose B
Confirm that the cylinder oil tight by checking the BOOM FOOT PIN
moving length of the cylinder rods. C
(2) Condition A
Hydraulic oil temperature ; 45~55°C (113~131°F)
Firm, level ground ARM TOP PIN
D
After cylinders are replaced, bleed off air from the
cylinders, before checking for oil tightness. Fig. 13-29
Retract the arm cylinder rod 50mm (2in) from stroke
end so that the piston does not match a same range Oil tightness of cylinder Unit : mm(in)/5min
of the cushioning mechanism. Measuring
Standard value
Reference value
Service limit
position for remedy
(3) Preparation A 7 (0.28) 11 (0.43) 14 (0.55)
Put the bucket empty. Extend the arm cylinder rod B 6 (0.24) 9 (0.35) 11 (0.43)
50mm (2in) from the most retracted position. And C - - -
extend the bucket cylinders fully. Then hold the D 80 (3.1) 120 (4.7) 160 (6.3)
boom so that the arm top pin is positioned at same
height with boom foot pin.
(4) Measurement
Measure the items five minutes after the engine is
turned off.
13-19
13.8 MEASURING PERFORMANCES OF SWING BEARING

(1) Purpose
LOCATION OF BEARING
Measure the gap between the lower frame and the MOUNTING BOLTS
bottom face of the swing bearing and estimate the
degree of wear of the swing bearing.
SWING BEARING
(2) Condition A
Firm, level ground
The swing bearing mounting bolts are not
DIAL INDICATOR
loosened.
The swing bearing is lubricated well, not making LOWER FLAME
abnormal sound during turning.
Fig. 13-30 How to measure the axial play of swing
bearing
(3) Preparation
1) Install a dial indicator to the magnetic base and
fix it to the lower frame.
90 ~100
2) Direct the upper swing body and the lower frame
toward the travel direction, bring the probe of the
dial indicator in contact with the bottom surface
of the outer race on the swing body side and set 30cm (1ft)
the reading at zero. Fig. 13-31 Measuring position 1

(4) Measurement 1 (Measuring position 1 and 2)
1) Measure the displacement of the outer race in ARM TOP BOOM FOOT
PIN PIN
the axial direction in position 1 [The arm at
90°~110° and the crawler front is lifted by
attachment about 30cm (1ft)] and in position 2,
using a dial indicator.
Fig. 13-32 Measuring position 2
Axial play of swing bearing Unit : mm (in)

0.8~1.8 2.3~3.3 3.6~
A (0.03~0.07) (0.09~0.13) (0.14)
(5) Measurement 2 (Measuring position 3)

1) Retract the arm cylinder fully and extend the ARM TOP BOOM FOOT
PIN PIN
bucket cylinder fully. And move the boom so that
the arm top pin is positioned at same height with
boom foot pin. Then swing the bucket right and
left by man power.
But in this case, the gap of the attachment is
included.
Fig. 13-33 Measuring position 3
Right and left movement of the tip of bucket Unit : mm (in)

Bucket 30~50 (1.18~1.97) 80 (3.15) 120 (4.72)
13-20
13.9 MECHATRO CONTROLLER

13.9.1 ENGINE CONTROL INPUT / OUTPUT
E-27:
C-8: EMERGENCY
ACCEL
ENGINE CONTROLLER
INJECTOR
E-1:
C-2: FUSE&RELAY
GAUGE CLUSTER BOX
ENGINE
ENGINE SPEED
SENSOR
PUMP
PROPORTIONAL
C-1: VALVE
STARTER ACCEL MECHATRO CONTROLLER
SWITCH POTENTIO METER
Fig. 13-34 INPUT / OUTPUT
13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT)
13.9.2.1 PURPOSE OF THE ADJUSTMENT

There are 3 kinds of adjustment of mechatro controller as shown below; every adjustment is an essential function
to ensure performance of machine.
(1) Adjustment of engine ("A" adjustment)
This adjustment is performed to set the relation between the acceleration command voltage output from
mechatro controller to engine controller and the engine speed.
(2) Adjustment of pump ("B" adjustment)
This adjustment is performed to correct the output variation by coordinating the output hydraulic pressure with
engine rated output.
(3) Adjustment of unloading valve ("C" adjustment)
This adjustment is performed to correct the open variation of unloading valve to improve the operability further.
13.9.2.2 IN CASES WHERE THE ADJUSTMENT OF MECHATRO CONTROLLER IS REQUIRED;

When the following parts are replaced or repaired, carry out the adjustment without fail.
(1) Mechatro controller
(2) Engine or engine controller
(3) Hydraulic pump or hydraulic pump proportional valve
(4) Unloading proportional valve, spool of unloading valve
13-21
13.9.2.3 PREPARATION
(1) Raise the oil temperature to about 50°C (122°F) to warm up the engine.
(2) Turn the air-con OFF.
(3) Turn the starter key switch OFF to stop the engine.
When the mechatro controller was replaced, the following error code is displayed because the adjustment data
is not entered.
A215, A225, A015, A025, A035
As the error codes other than those shown above may suggest failures of machine, repair the machine into the
ordinary operating condition according to Error Code List.
For machines equipped with lifting magnet, turn the generator OFF.
13-22
13.9.2.4 ADJUSTING PROCEDURE
MULTI DISPLAY
BUZZER STOP SWITCH WORK MODE SELECT SWITCH
WASHER SWITCH
WIPER SWITCH
SELECT SWITCH
Fig. 13-35 Gauge cluster

(1) Adjustment of engine ("A" adjustment)
Procedure
1) Turn starter key switch ON keeping the work mode selector switch on the

gauge cluster pressed, and hold it for 5~10 seconds, and then release it. (If
the engine is started, the following indication is not displayed. Therefore do not
start the engine.)

2) Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release
ADJUST
it and the screen for selecting adjustment is displayed. When adjustment data
READY
is not entered in mechatro controller, "READY" is indicated. If the adjustment FEED
operation is once performed, "FIN" is indicated.
And the lever lock solenoid is automatically released, disabling all operations.
3) Press selector switch on gauge cluster to display "START ENG".

"Engine SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration

command voltage) are indicated.

4) After starting engine, press selector switch on gauge cluster, and "MEMORY

ENG" is displayed, the engine speed is automatically increased, and the

adjustment of engine is performed.

(When trying to limit engine speed, press selector switch on gauge cluster at

the speed as it is, and the adjustment of engine is terminated. The torque
adjustment and unloading adjustment required later are not performed, and
default value is written.)
5) When normal HIGH idling speed is detected, the adjustment is completed. And
FINISH ENG
"FINISH ENG" is displayed. ENGINE SPEED
2000rpm
(Press the buzzer stop switch on gauge cluster while this display is appeared, PUMP PRESSURE
C-1 2.0M C-2 2.0M
STEP
and the adjustment of engine is completed. The torque adjustment and 400
unloading adjustment required later are not performed, and default value is
written.)
13-23
(2) Adjustment of pump ("B" adjustment)

Procedure
1) The adjustment automatically shifts from engine to pump, the speed shifts

from LOW idling to HIGH idling. And "MEMORY PUMP" is displayed. And the

unloading proportional valve and pump proportional valve actuate, accordingly

the loading of pump is increased.

The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 pump
"PROPO-VALVE" current (command value) are indicated.
2) After detection of the engine rated speed, the adjustment of pump is
FINISH PUMP
automatically completed. And "FINISH PUMP" is displayed. ENGINE SPEED
2000rpm
(Press the buzzer stop switch on gauge cluster while this display is appeared PUMP PRESSURE
C-1 35.0M C-2 35.0M
PROPO-VALVE
and the adjustment is completed. The unloading adjustment required later is E-1 300mA E-2 300mA
not performed, and default value is written.)
(3) Adjustment of unloading valve ("C" adjustment)

Procedure
1) The adjustment shifts from pump to unloading, and the unloading valve
MEMORY UNLOAD
actuates, accordingly the pump pressure is detected. And "MEMORY ENGINE SPEED
2000rpm
UNLOAD" is displayed. PUMP PRESSURE
C-1 2.0M C-2 2.0M
PROPO-VALVE
The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 "PROPO- D-1 300mA D-2 300mA
VALVE" voltage (command value) are indicated.
2) When the unloading valve operates to the specified value, the adjustment of

unloading proportional valve is automatically terminated. And "FINISH

UNLOAD" is displayed.

The speed is shifted to the speed corresponding to acceleration potentiometer.

The adjusting current value is indicated on the display of current of P1, P2

unloading proportional valves. The adjusting range is usually 520~635mA.
Stop the engine. (The adjusted data is automatically stored.)
(4) Corrective actions taken when the adjustment can not be performed;
ERROR ENG.
1) In cases where the adjustment of engine can not be performed; And ERROR ENGINE SPEED
2000rpm
PUMP PRESSURE
ENG" is displayed. C-1 2.0M C-2 2.0M
STEP
Judging condition: The read engine speed is 50rpm lower than the last value. 400
It is conceived that the error is caused by the speed read error, pump load
applied to the engine and unusual acceleration command voltage applied to
the engine controller in the course of adjustment.
a. Checking speed sensor: Check that it is free from wrong reading of speed
due to engine vibration.
b. Checking load applied to pump: Check that it is free from abnormal
increase of pump pressure during adjustment of engine through
adjustment screen.
c. Checking acceleration command voltage: Measure the acceleration
command voltage output from mechatro controller to engine controller.
Check that signal is regularly input to the engine controller by actual
measurement of voltage or with failure diagnosis tool of engine controller.
13-24
2) In cases where the adjustment of pump can not be performed; And "ERROR
ERROR PUMP
PUMP" is displayed. ENGINE SPEED
2000rpm
Judging condition 1: PUMP PRESSURE
C-1 35.0M C-2 35.0M
PROPO-VALVE
P1 and P2 average pump pressure at the time when the adjustment is E-1 300mA E-2 300mA
completed is 25MPa or less.
Judging condition 2:
The adjustment does not complete although the pump proportional valve
current reaches to the specified value.
The P1 and P2 pump pressures usually increase to 33~38MPa.

When the pressure does not increase;
a. Identify the reason why the pressure does not increase,
• Check that the relief valve operates normally.
• Check that the hydraulic circuit is free from leak of pressure.
• Check that the pressure sensor functions normally.
And so on.
b. Identify the reason why the actual flow rate does not increase,
• Check that the pump proportional valve operates normally.
• Check that the pump regulator operates normally.
And so on.
3) In cases where unloading valve can not be performed; And "ERROR
ERROR UNLOAD
UNLOAD" is displayed. ENGINE SPEED
2000rpm
Judging condition 1: PUMP PRESSURE
C-1 2.0M C-2 2.0M
PROPO-VALVE
The pump pressure does not increase up to the pressure in the range of the D-1 300mA D-2 300mA
specified adjustment. Or the increased pressure is held as it is.
Judging condition 2:
Pressure sensor of either P1 pump or P2 pump is failed.
Normally the pump pressures of P1 and p2 pumps gradually increase to

10~25MPa.
(It may be affected by operating oil temperature.)
When the pump pressure does not increase;

a. Identify the reason why the pressure does not increase,
• Check that the relief valve operates normally.
• Check that the hydraulic circuit is free from leak of pressure.
• Check that the pressure sensor functions normally.
And so on.
(5) Other precautions:
1) In the event of a failure, there is case where the adjustment may not be
performed normally.
First serve the machine, and perform the adjustment work.
2) In the condition where large load is constantly applied to engine, the
adjustment could not be performed normally.
For machines equipped with lifting magnet, turn the generator OFF.
13-25
(6) When the adjustment of unloading valve only is performed; ("C" adjustment)
In the event where only unloading valve and unloading proportional valve are
replaced, perform the adjustment of unloading valve only.
Procedure
1) Turn starter switch ON keeping the work mode selector switch on the gauge

cluster pressed, and hold it for 5~10 seconds, and then release it.
(If the engine is started, the following indication is not displayed. Therefore do
not start the engine.)

2) Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release
ADJUST
it and the screen for selection of adjustment type is displayed. And "ADJUST"
READY
is displayed. FEED
When adjustment data is not entered in mechatro controller, "READY" is
indicated. If the adjustment operation is once performed, "FIN" is indicated.
And the lever lock solenoid is automatically released, disabling all operations.
3) Change the adjusting items with washer switch ( ) and wiper switch ( ), and

select "ADJUST UNLOAD". (See Fig. 13-35)
Like the output adjustment, when adjustment data is not entered in mechatro
controller, "READY" is indicated. If the adjustment operation is once
performed, "FIN" is indicated.
4) Press selector switch on gauge cluster to display "START ENG".

"ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration

command voltage) are indicated.

5) After starting engine, press selector switch on gauge cluster and "MEMORY
MEMORY UNLOAD
UNLOAD" is indicated, the engine speed is automatically increased and the ENGINE SPEED
2000rpm
adjustment of unloading valve is performed. PUMP PRESSURE
C-1 2.0M C-2 2.0M
PROPO-VALVE
"ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "PROPO-VALVE" D-1 300mA D-2 300mA
(acceleration command current) are indicated.
6) When the unloading proportional valve operates to the specified value, the

adjustment of unloading proportional valve automatically completes. "FINISH

UNLOAD" is indicated.

The speed is shifted to the speed corresponding to acceleration potentiometer.

The value of adjusting current is indicated on the display of current of P1 and

P2 unloading proportional valves. The adjusting range is usually 520~635mA.
Stop the engine. (The adjusted data is automatically stored.)
13-26
13.9.3 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO CONTROLLER

(1) Engine emergency mode
When the trouble occurs and the control of engine is impossible, the engine speed can be controlled by operating
emergency acceleration (E-27) provided on the seat rear side. (See Fig. 13-34)
Operating procedure:
1) Set the emergency acceleration to NORMAL position.
2) Start engine.
3) Turn the emergency acceleration to HI side and control the engine speed.
4) When stopping the engine, set the emergency acceleration to NORMAL position before stopping.
Never increase the engine speed immediately after starting engine. It is dangerous.
To avoid this danger, repeat the above procedure, or the engine speed does not increase.
When the machine does not operate, set the emergency acceleration to NORMAL position.
(2) Pump emergency mode

In the event where a failure of P1 or P2 pump proportional valve represented in items of self diagnosis is
indicated on multi display provided on the gauge cluster, the full power control of pump and positive control
through mechatro controller are unavailable. Then the P1 and P2 pumps are automatically switched to
emergency mode, making the operation with the power shift control of pump and the constant power control by
means of self-pressure possible. But be careful that, at emergency mode, the accuracy of inching becomes poor,
the frequency of engine down is increased, and the engine stalls in LOW speed condition.
The emergency mode should be used in only case of emergency. We recommend that the defective section is
repaired by troubleshooting as early as possible.
13-27
[MEMO]
13-28
21. MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS
21.1 SUMMARY OF MECHATRO CONTROL SYSTEM.........................................................21-4

21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL ..................................................21-4
21.1.2 UNLOAD VALVE CONTROL..................................................................................21-6
21
21.1.3 POSITIVE CONTROL & P-Q CONTROL ...............................................................21-7
21.1.4 BOOM UP CONFLUX CONTROL ..........................................................................21-9
21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL.............................................21-10
21.1.6 ARM-IN ANTI-CAVITATION CONTROL ................................................................21-12
21.1.7 ARM-OUT CONFLUX CONTROL ..........................................................................21-13
21.1.8 BUCKET DIGGING (DUMP) CONFLUX CONTROL ..............................................21-14
21.1.9 BUCKET DIGGING ANTI-CAVITATION CONTROL ..............................................21-15
21.1.10 SWING PRIORITY CONTROL ...............................................................................21-17
21.1.11 TRAVEL STRAIGHT CONTROL ............................................................................21-18
21.1.12 PRESSURE RELEASE CONTROL ........................................................................21-20
21.1.13 N&B SWITCH CONTROL (OPTION) .....................................................................21-21
21.1.14 OPTION CONFLUX CONTROL (OPTION) ............................................................21-22
21.2 MECHATRO CONTROLLER...........................................................................................21-23
21.2.1 SUMMARY OF MULTI DISPLAY ...........................................................................21-23
21.2.2 SELF DIAGNOSIS DISPLAY..................................................................................21-28
21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION .......................................................21-30
21.2.4 TROUBLE HISTORY DIAGNOSIS .........................................................................21-40
21.2.5 TROUBLE DIAGNOSIS MODE ..............................................................................21-41
21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE ...........................................21-42
21.2.7 ADJUSTING PROCEDURE OF DISPLAY .............................................................21-43
21.2.8 MECHATRO CONTROL EQUIPMENT ..................................................................21-47
21-1

E215B : YN11-45001~ S5YN2122E01
↑
↑ ↑ ↑ K
↑
↑ ↑ ↑ K
21-2
PREFACE
This manual explains only those related to the electro hydraulic conversion as mechatro control. This manual
summarizes the mechatro system and the function of the mechatro controller related apparatuses. Regarding the
conditions before and after each conversion, refer to the hydraulic system and the electric system.
21-3
21.1 SUMMARY OF MECHATRO CONTROL SYSTEM

21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL
%
% %

% % %%
%
% %

% %
%
% %
%%
(
)

% % *+
'

%

%

% %,
' ',

*-- %

'
'
%
%% %

%
%

% %

$%

%

!"#

$% %
& %

' %
%% !"# % !"#

%
%%% %
% %

21-4
MAIN CONTROL VALVE

L1
SE-29
ARM OUT DUMP DOWN FORWARD FORWARD LEFT ARM OUT

(8) (2) (4) (3) (6) (8) SV-13
P1 UNLOAD
ATTACHMENT BOOST
SELECTOR VALVE
CONFLUX
BOOM UP
BOOM LOW SPEED
TRAVEL RIGHT
ARM 2 SPEED
ARM 1 SPEED
TRAVEL LEFT
N&B
BUCKET
P2 UNLOAD
OPTION
STRAIGHT
SWING
TRAVEL
PL1
SOL
P1 P2
(1) (3) (5) (7)
DIGGING UP REVERSE REVERSE RIGHT ARM IN
L2 SOLENOID VALVE
L3
L4
SWING MOTOR PARKING RELEASE
TRAVEL MOTOR 1,2 SPEED SELECT
BOOM CYLINDER
BOOM DOWN RECIRCULATION
BOOM CONFLUX
SWING PARKING BRAKE
SAFETY LOCK LEVER

ATTACHMENT BOOST
TRAVEL 1,2 SPEED

TRAVEL STRAIGHT
ARM IN 2 SPEED
L5
P1 UNLOAD
P2 UNLOAD
ARM CYLINDER
ARM OUT CONFLUX
ARM IN CONFLUX
PSV PSV PSV PSV SV SV SV SV
-A -D -C -B -2 -3 -1 -4
(7)
ARM IN
L6 BUCKET CYLINDER
DIGGING / DUMP CONFLUX
L7
PROPORTIONAL VALVE
SOLENOID VALVE ) BLOCK
21-5
21.1.2 UNLOAD VALVE CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
VALVE
SWING
BOOM
STRAIGHT
SOLENOID
TRAVEL
P2 UNLOAD
P2 P1
PILOT PILOT
(LEFT) (RIGHT) VALVE VALVE
OPTIONAL
PILOT VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
SE-11 PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
(1) On starting any one of operations, the control pilot secondary pressure switches spools and enters in respective
low pressure sensors.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes
pilot signal and outputs command according to the input voltage to each unload pressure proportional valve.
(3) Each unload pressure proportional valves output pilot secondary pressure according to the command output by
mechatro controller and switches each unload spools.
(4) With this operation, the bleed opening according to lever manipulated movement is obtained, consequently the
pump pressure which is used to actuate each actuators are delivered and makes each actuator start operating.
21-6
21.1.3 POSITIVE CONTROL & P-Q CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
OPTIONAL
PILOT VALVE
P2 P1
SE-23 SE-22
SE-11
(LEFT) (RIGHT) PILOT PILOT

VALVE VALVE
PILOT VALVE
FOR TRAVEL
LOW LOW
PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8
pi
PILOT SIGNAL
PROCESS P2 PUMP P2 PUMP
PROPORTIONAL PROPORTIONAL
VALVE COMMAND VALVE PSV-P2
pi
pi
P1 PUMP P1 PUMP
PROPORTIONAL PROPORTIONAL
PILOT SIGNAL VALVE COMMAND VALVE PSV-P1
PROCESS
PILOT SECONDARY PRESSURE MECHATRO
CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
21-7
(1) Positive control

1) On starting any one of operations, pilot secondary pressure switches each spool and is input to each low
pressure sensor.
2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to each unload pressure
proportional valve.
3) Each pump proportional valve outputs pilot secondary pressure according to the command output by
mechatro controller and changes the tilting angle of each pump and controls the delivery rate.
4) With this operation, the delivery rate according to lever manipulated movement is fed to the actuator, and
consequently the working speed according to the lever manipulated movement will be obtained.
(2) P-Q control
1) The output voltage of high pressure sensor provided on each pump line is input to mechatro controller and
the mechatro controller processes pilot signal and operates the command according to the input voltage
(load pressure).
2) The lower value between command values calculated by positive control and operated value found by P-Q
control {operated value found in item 1)} is selected and is output to each pump proportional valve as
command value.
3) Each pump proportional valve outputs pilot secondary pressure according to the command output by
mechatro controller and changes tilting angle of each pump and controls the delivery rate.
4) With this operation, the delivery rate according to lever manipulated movement is fed to actuator and
consequently working speed will be obtained according to lever movement.
POSITIVE CONTROL P-Q CONTROL
PILOT SIGNAL PROCESS PILOT SIGNAL PROCESS

SECONDARY PRESSURE
SECONDARY PRESSURE
PUMP PROPORTIONAL
PUMP PROPORTIONAL
PILOT PRESSURE PUMP DELIVERY PRESSURE
21-8
21.1.4 BOOM UP CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-3
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER
pi : PROPORTIONAL VALVE
BOOM UP PILOT SECONDARY PRESSURE SECONDARY PRESSURE
(1) On starting boom up operation, boom up operating pilot pressure switches boom spool and boom up conflux
spool and is input to low pressure sensor.
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and
P2 unload proportional valves.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure
control valve.
(4) With original hydraulic pressure command, boom main spool and boom up conflux spool are switched, and also
with the command by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched and
consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during boom up operation.
21-9
21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
N&B
SELECTOR
BUCKET
OPTION
SWING
BOOM
VALVE
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
LOW
PRESSURE
PRESSURE
SENSOR
SE-1~6 SENSOR
SE-7
CONTROL PROCESS
FOR 2 SPEED
pi PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
ARM IN PILOT SECONDARY PRESSURE
P1 PUMP
PROPORTIONAL
VALVE PSV-P1

PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P1 UNLOAD
pi PROPORTIONAL
VALVE PSV-D
pi
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
VALVE CONTROL VALVE FOR ARM
PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
ARM PILOT SECONDARY
PRESSURE
P2 PUMP PRESSURE MECHATRO pi : PROPORTIONAL VALVE

CONTROLLER SECONDARY PRESSURE
21-10
(1) Recirculation and conflux (Low loading)

1) On starting arm-in operation, arm-in operating pilot secondary pressure is input to arm 1 spool, arm 2 spool
and low pressure sensor.
2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller
processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves,
P1 and P2 unload proportional valves and reverse proportional valve for arm-in 2 spool.
In case of combined operation, the pilot pressure other than arm-in operation is input to low pressure sensor
and the output voltage is input to mechatro controller. And the mechatro controller processes pilot signal
according to the combined operation and outputs command, which is different from the arm-in independent
operation, to P1 pump proportional valve, P1 unload proportional valve and reverse proportional valve for
arm-in 2 spool.
3) Primary pressure of reverse proportional valve for arm-in 2 spool is arm-in pilot secondary pressure and it
switches arm 2 spool by proportional secondary pressure according to command. (Arm 2 spool controls
recirculation rate and conflux rate.)
The other proportional valves output proportional secondary pressure according to command from mechatro
controller. These proportional valves change the delivery rate of P1, P2 pump, and switch P1, P2 unload
valve.
4) The arm 1 spool is switched according to original oil pressure command, and P1, P2 pumps, P1, P2 unload
spools and arm 2 spool are switched according to the command output by mechatro controller, and
consequently the return oil from the arm cylinder rod side is recirculated in P1 and P2 pumps delivery oil
during arm operation.
(2) Recirculation cut
The voltage output by high pressure sensor on P2 side is input to mechatro controller, and when the load is
raised during arm operation the mechatro controller processes pilot signal processing according to the pressure
detected by high pressure sensor and outputs command to cut recirculation into reverse proportional valve for
arm-in 2 spool.
The reverse proportional valve for arm-in 2 spool outputs pilot secondary pressure according to the command
output by mechatro controller and switches arm 2 spool to recirculation cut position, and consequently
recirculation passage is blocked.
21-11
21.1.6 ARM-IN ANTI-CAVITATION CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE ACCEL
SENSOR POTENTIO
SE-7
pi pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

pi PILOT SIGNAL
PROCESS REVERSE PROPORTIONAL
VALVE CONTROL PROCESS
FOR ARM 2 SPOOL PSV-Bpi

pi
VALVE FOR ARM VALVE FOR ARM 2 SPOOL
2 SPOOL COMMAND PSV-A pi
ENGINE SPEED (COMMAND VALUE) MECHATRO

CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
(1) On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and is input to low
pressure sensor.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
(3) Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller processes pilot
signal processing and outputs command according to the input voltage to P2 pump proportional valve and P2
unload proportional valve.
(4) And also outputs command according to input pressure output by potentiometer to reverse proportional valve
for arm 2 spool.
(5) Each proportional valves output pilot secondary pressure according to each command output by mechatro
controller, and consequently since the reverse proportional valve for arm 2 spool is controlled to spool stroke
according to engine speed and changes recirculation rate to prevent the cavitation from occurring even if pump
delivery rate is low due to low engine speed.
21-12
21.1.7 ARM-OUT CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT P2 P1
VALVE
LOW
PRESSURE
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
ARM OUT PILOT SECONDARY PRESSURE

pi
P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER
SECONDARY PRESSURE
(1) On starting arm-out operation, arm-out operating pilot pressure switches arm 1 spool and arm 2 spool and is
input to low pressure sensor.
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and
P2 unload proportional valves.
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure
control valves.
(4) With original hydraulic pressure command, arm 1 spool and arm 2 spool are switched and also with the
command output by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched, and
consequently the delivery oil on P2 pump side confluxes delivery oil on P1 pump side during arm-out operation.
21-13
21.1.8 BUCKET DIGGING (DUMP) CONFLUX CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
PILOT
VALVE P2 P1
LOW
PRESSURE
SENSOR
SE-1(2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

pi
PILOT SIGNAL
PROCESS TRAVELSTRAIGHT
PROPORTIONAL
VALVE PSV-C
MECHATRO
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
(1) On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure switches bucket
spool and is input to low pressure sensor.
pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and
P2 unload proportional valves and travel straight proportional valve.
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and
travel straight valve of the control valve.
(4) The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump delivery
oil confluxes P2 pump delivery oil because of P2 unload valve switched.
21-14
21.1.9 BUCKET DIGGING ANTI-CAVITATION CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED
ARM 2 SPEED
N&B
SELECTOR
BUCKET
OPTION
SWING
BOOM
VALVE
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
PILOT
VALVE
P2 P1
LOW
PRESSURE
SENSOR
SE-1 (2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
BUCKET DIGGING PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
ACCEL VALVE PSV-B
POTENTIO
pi PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

pi
PILOT SIGNAL
PROCESS TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C

PILOT SIGNAL
pi PROCESS
BUCKET ATT BOOST
ANTI-CAVITATION SOLENOID VALVE
PROCESS SV-2
ENGINE SPEED (COMMAND VALUE)
MECHATRO
CONTROLLER
P1 PUMP PRESSURE pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
21-15
(1) On starting bucket digging (dump) operation, bucket digging operating pilot pressure switches bucket spool and
is input to low pressure sensor.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
P2 unload proportional valves and travel straight proportional valve.
travel straight valve of control valve.
(5) The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump delivery
oil confluxes P2 pump delivery oil because of P2 unload valve switched.
(6) ATT boost solenoid valve turns the solenoid valve on according to the engine speed, and outputs secondary
pressure, and actuate stroke limiter and then controls the stroke of bucket spool.
The control of spool stroke makes the prevention of cavitation possible even if engine speed is low and pump
delivery rate is low.
(7) When P1 pump pressure was raised at cylinder stroke end, etc. the solenoid valve is closed according to the
pump pressure, and when the pump pressure is high, the boost solenoid valve does not work to control the
stroke limit of bucket spool.
21-16
21.1.10 SWING PRIORITY CONTROL
BOOM UP CONFLUX
P1 UNLOAD
PILOT
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
VALVE
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
LOW
PRESSURE
SENSOR
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
ARM IN PILOT SECONDARY PRESSURE PROPORTIONAL
pi PILOT SIGNAL VALVE PSV-P1
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
P1 UNLOAD
PROPORTIONAL
ARM IN PILOT SECONDARY PRESSURE VALVE PSV-D
pi
TRAVEL STRAIGHT TRAVEL STRAIGHT
PROPORTIONAL COMMAND
VALVE COMMAND PROPORTIONAL
VALVE PSV-C
SWING PILOT SECONDARY PRESSURE VALVE CONTROL VALVE FOR ARM
pi PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
MECHATRO pi : PROPORTIONAL VALVE

SWING PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE
(1) During arm-in operation, arm operating pilot secondary pressure switches arm spool and is input to low pressure
sensor on starting swing operation (or arm-in operation during swing operation), and swing operation pilot
secondary pressure switches swing spool and is input to low pressure sensor.
pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves, P1 and P2
unload pressure proportional valves, travel straight valve and reverse proportional valve for arm 2 spool.
by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload spool, travel
straight spool, arm 2 spool.
(4) With original hydraulic pressure command, arm 1 spool and swing spool are switched and also with the
command by mechatro controller, P1 and P2 unload spools, travel straight spool and arm 2 spool are switched
enabling for two pump flow rates to be supplied to the arm cylinder head side, and consequently the return oil
on arm cylinder rod side is recirculated into arm cylinder head side.
(5) Because the return oil on the arm rod side is recirculated, the working pressure is raised and pump delivery rate
is used for swing operation by priority, and operated by the recirculated oil, making the operation with minimum
speed drop possible.
21-17
21.1.11 TRAVEL STRAIGHT CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
OPTIONAL
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PILOT VALVE N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
P2 UNLOAD
SOLENOID
TRAVEL
(LEFT) (RIGHT) PILOT PILOT
VALVE VALVE P2 P1
PILOT VALVE
FOR TRAVEL
SE-11 LOW
SE-10 SE-9
PRESSURE
SENSOR
TRAVEL STRAIGHT SIGNAL
pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROPORTIONAL
VALVE PSV-C

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
PILOT SECONDARY PRESSURE CONTROLLER
SECONDARY PRESSURE
21-18
(1) Judgment travel straight

1) During travel operation (right and left), pilot pressure switches each spool and is input to low pressure sensor
on carrying out attachment system operation.
2) Mechatro controller decides as travel straight on receiving the input according to the combination shown in
the table from the low pressure sensor and turns travel straight signal on.
3) On turning travel straight signal on, the following commands are output to each proportional valve.
(2) Operation of each proportional valve
(Basically attachment operation is actuated by P1 pump and travel operation is actuated by P2 pump in travel
straight condition.)
1) Travel straight proportional valve
Outputs switching pressure according to the high priority select pressure in the attachment system operating
(Boom, arm, bucket, swing, option) pilot pressure during operation.
2) P1 unload proportional valve
pilot pressure during operation.
3) P2 unload proportional valve
Outputs switching pressure according to the high priority select in the travel operating pilot pressure during
operation.
4) P1 pump proportional valve
pilot pressure during operation.
5) P2 pump proportional valve
Outputs switching pressure according to the high priority select in the travel operating pilot pressure during
operation.

21-19
21.1.12 PRESSURE RELEASE CONTROL
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
GAUGE CLUSTER PILOT
VALVE
P2 P1
SE-23 SE-22
ENGINE
PRESSURE
RELEASE
CONTROL ENGINE SPEED
CONTROL
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1
pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B
pi
PILOT SIGNAL
P1 UNLOAD
VALVE PSV-D
MECHATRO
CONTROLLER SECONDARY PRESSURE
(1) Change mechatro controller to "PRESSURE DRAINING MODE" by operating switch on gauge cluster.
For detail of changing mode method, refer to "How to switch to "Pressure release mode"" on item 22.11.1.
(2) Once mechatro controller decides it as pressure release control, regardless of each input signal (operating pilot,
accel potentiometer, etc.) the mechatro controller;
1) Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump to minimum
tilt angle.
2) Outputs command of pressure release and outputs command of pressure release control to ECU and fixes
engine speed to pressure release control speed.
3) Outputs maximum command to P1 and P2 unload valves and each pilot secondary pressure fixes P1 and
P2 unload valves to the maximum opening.
(3) Mechatro controller senses output voltage from the main pump high pressure sensor, decides the pump
pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on gauge cluster.
(4) Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure) to
be released by operating each control lever and switching spool with the unload valve opened.
21-20
21.1.13 N&B SWITCH CONTROL (OPTION)
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
PRESSURE SENSOR N&B
FOR BREAKER SELECTOR
BUCKET
OPTION
SE-29
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
TRAVEL
P2 P1
A MODE
B MODE
GAUGE CLUSTER
pi
B MODE SWITCH MECHATRO

CONTROLLER
pi : OUTPUT OF N&B SELECTOR SOLENOID
(1) Nibbler circuit

1) Select A mode through gauge cluster.
2) Nibbler display appears on gauge cluster.
3) The return oil from the nibbler passes through selector valve and option spool and led to tank line of main
control valve.
4) When selecting A mode through gauge cluster, the breaker pressure sensor has not function to output.
It is in normal when there is no output from sensor in A mode, and in cases of other than above, error display
is output to gauge cluster.
(2) Breaker circuit
1) Select B mode through gauge cluster.
2) Breaker display appears on gauge cluster.
3) The return oil from the breaker passes through selector valve and directly returns into hydraulic oil tank.
4) When selecting B mode through gauge cluster, the breaker pressure sensor outputs signal.
It is in normal when there is an output from sensor in B mode, and in cases of other than above, error display
is output to gauge cluster.
21-21
21.1.14 OPTION CONFLUX CONTROL (OPTION)
BOOM UP CONFLUX
P1 UNLOAD
TRAVEL RIGHT
ARM 1 SPEED
ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR
BUCKET
OPTION
SWING
VALVE
BOOM
STRAIGHT
SOLENOID
P2 UNLOAD
PILOT VALVE
TRAVEL
P2 P1
SINGLE / CONFLUX
LOW
SWITCH
PRESSURE
SENSOR
SE-11
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
P1 UNLOAD
VALVE PSV-D

pi
PILOT SIGNAL
PROCESS TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C
MECHATRO pi : PROPORTIONAL VALVE
OPTION PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE
(1) Select the Conflux with the aid of Conflux/Single switch.

(2) On starting option operation, option operating pilot pressure switches option spool and is input to low pressure
sensor.
P2 unload pressure proportional valves and travel straight proportional valve.
(4) Each proportional valves output pilot proportional valve secondary pressure according to the command output
travel straight valve of the control valve.
(5) The parallel passage on P2 side is connected to P1 port because of the travel straight valve switched and P1
pump delivery oil confluxes P2 pump delivery oil because of the P2 unload valve switched.
21-22
21.2 MECHATRO CONTROLLER

21.2.1 SUMMARY OF MULTI DISPLAY
Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.
(1) Controls
EMERGECY ACCEL DIAL

SWING PARKING
BRAKE RELEASE
GAUGE SWITCH
CLUSTER
SAFETY
LOCK
LEVER
RIGHT
CONTROL
LEVER
WITH ATT
BOOST SW.
FUSE &
STARTER SWITCH RELAY BOX
ACCEL DIAL
DETAIL A
(2) Gauge cluster
No. Name
11 1 Engine coolant temperature gauge
2 Fuel level gauge
22:00
3 Screen change switch
H
4 Buzzer stop switch
5 Work mode select switch
1
6 Washer switch
7 Wiper switch
2
3 8 Travel high speed, low speed select switch
9 Auto accel switch
10 10 Select switch
6
4 9 8 5 7 11 Multi display (LCD)
21-23
(3) Screen selection by work mode select switch

Press the work mode selector switch ( ) in order, and "S" → "H" → "B" → "A" mode can be selected.
Select the effective work mode according to the work condition and working target from the table shown below.
For the selected work mode, refer to the table shown below.
• S mode: For standard excavating work

• H mode: For heavy duty excavating work
• B mode: For works with breaker
• A mode: For demolition works with crusher
(Nibbler)
10:25
S
• The initial setting (default) of work mode had been set
to "S" mode at factory.
As for the work mode after the engine starts, the
mode that was used the last time engine was stopped
is automatically set.
Check that the selected mode conforms to the work
before starting work.
• Check that the attachment in use conforms to the
work mode before starting work. If not conformed,
select proper mode with the work mode select switch.
• The operation under improper work mode may cause
damage to machine.
Work mode Display Contents
S mode
10:25 "S mode"is suitable for standard digging and loading works and is in
fuel saving and is maintained well-balanced relations with workload.
H mode
10:25 "H mode"is suitable for heavy duty digging work which gives priority
to the workload at the high speed.
B mode
10:25 For the work with breaker, select "B mode" without fail.
A mode
10:25 For the work with crusher (nibbler), select "A mode".
For the work with breaker, select "B mode" without fail.
The work with breaker in any mode other than "B mode" may cause damage to the hydraulic equipment and
breaker.
21-24
1) Pump flow rate adjustment (A mode /B mode)

No. Switches 1 2 3 4
3 KPSS work mode select switch
4 Washer switch
5 Wiper switch
6 Travel speed select switch
7 Auto accel switch 5
8 Select switch 8 7 6
Fig. 21-1
According to some kind of attachment, it is required to change the flow rate for service circuit. Change the flow rate
in accordance with the procedure mentioned below.
In this machine, last set flow rate has been stored and the initial flow rate is 220L/min. The adjustment (increase or
decrease) of flow rate is changeable by 10L/min step.
Main screen Attachment mode (A mode)
10:25 Flow
rate 220 L/m
Flow
rate 100 L/m
Flow
rate 100 L/m
Enter
H A A
(a) (b) (d)
Increase/Decrease
In Breaker mode (B mode)
Flow Flow Flow

rate 220 L/m rate 100 L/m rate 100 L/m
Enter
B B
(c) (d)
Screen in Attachment/Breaker mode Increase/Decrease
A mode B mode When the conflux switch is tuned
on, the double flow rate is displayed.
Flow Flow
rate 220 L/m rate 220 L/m
A B
(b) (c)
1. Turn starter key switch on and display main screen (a).

2. The display on the left lower corner of screen is changed in order of "S" → "H" → "B" → "A" each time the
"MODE" switch (3) is pressed under the condition where main screen (a) is displayed.
3. Select "A" and A mode screen is displayed, and select "B" and B mode screen is displayed.
4. Press select switch (8) in A/B mode display screens (b)/(c) and the value of flow rate reverses in black and
the screen (d) is displayed. In this condition, press FEED (4)/ (5) and the flow rate value increases or
decreases.
5. Select the desired setting value and then press select switch (8) and the flow rate is set to the desired value.
21-25
(4) MAINTENANCE SCREEN DISPLAYS

This screen displays the remaining time to the end of recommended replacement/change interval specified for
filter/oil.
For the initial set value of recommenced replacement/change time, see the following table.
Replacement interval
Item Default
Engine oil 500 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
MIDDLE EAST 2,000 Hr
Hydraulic oil
RUSSIA 5,000 Hr
This menu is available for confirmation of the following items.

The maintenance screen changes each time the screen change switch is pressed.
1. Remaining time display to the engine oil change

This display shows the remaining time to the coming engine oil change. 492Hr
ENGINE OIL
H
2. Remaining time display to the coming fuel filter replacement

This display shows the remaining time to the coming engine fuel filter 492Hr
replacement. FUEL FILTER
H
3. Remaining time display to the coming hydraulic oil filter replacement

This display shows the remaining time to the coming hydraulic oil filter 992Hr
replacement. HYD. FILTER
H
4. Remaining time display to the coming hydraulic oil change

This display shows the remaining time to the coming hydraulic oil 1992Hr
change. HYD. OIL
H
• The display automatically changes to the main screen, if switch is not operated for 30 seconds.
• For the setting procedure of maintenance time to be performed to the coming oil change in each type and
filter replacement, see the 21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE.
21-26
(5) Gauge cluster display

After key is switched on and logo mark display disappears, screen for operator is displayed on multi screen. The
display functions of multi display are explained below.
CLOCK DISPLAY
SELF DIAGNOSIS / WARNING
MACHINE CONDITION
H
MULTI DISPLAY INDICATIONS
1) Display function for operator ......... Screen usually displayed during operation
1.1 Clock display function ......... Current time is displayed.
1.2 Self-diagnosis display ......... When abnormality is detected on mechatro system like sensor, proportional
valve, etc., this displays error code.
1.3 Warning display ......... When machine was thrown into dangerous state, or was failed, displays warning
contents with the symbol and statement. (For warning contents, see items
shown below.)
1.4 Machine condition display ......... Displays machine operating condition.
2) Display function for maintenance ......... Displays remaining time up to replacement/change of following
items.
(1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil
3) Failure history display function ......... Stores abnormality occurred on mechatro system in the past and
displays in order of recent occurrence.
4) Mechatro adjustment display ......... Displays procedure for adjustment of mechatro system like output
adjustment and unload adjustment, etc.
5) Service diagnosis display ......... Displays information like pressure sensor sensed value, proportional valve
command, etc. output by mechatro controller
6) Failure diagnosis mode display function ......... Specifies failed section automatically for failures which are
not detected by self diagnosis and displays the results.
. Warning These descriptions indicate error codes.
CAUTION LOW ENG OIL

W009 W005 PREHEAT W011
ATTACHMENT PRESS.
HIGH ENG
AUTO IDLE STOP WATER TEMP.
W006 CHARGE ERROR
POWER BOOST LOW ENG WATER

ON LEVEL
W004 LOW FUEL LEVEL
WARM FINISH WARM-UP DRAIN WATER SEPA W010 WARM AUTO WARMING UP
DATA
CPU COMMUNICATION CLOGGED AIR FLTR W008 CHANGE ENG OIL
ERROR
SWING BRAKE
ENGINE STOP
DISENGAGED
Error codes were stored as trouble history, and displayed on the monitor by the trouble history display function.
21-27
21.2.2 SELF DIAGNOSIS DISPLAY

(1) Outline
This function identifies abnormality of control I/O signal like pressure, proportional valve, etc. during machine
operation through self diagnosis. The failed items are displayed on multi display of gauge cluster. For connector
No. and pin No., refer to the section "C-1 Mechatro controller" explained later. Electric circuit diagram or harness
is available to identify wire No. and wire color.
(2) I/O configuration
!"

(3) Self diagnosis display items

As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure type with
the aid of error code.
)&#* #-(# $*#% !"# '--!""#(/

0* +( +( "( (.* 1)#-# #( #-*'+/
0* (.* 1)#-# !"# *$)#/
2 2 !"# $%&' () $#( %! *+#'! $ ,* #""'" -'(# (!"+. !"# (.+'/

0* 8 '+*"' #" 0', )"#!"# . )"#!"# "')'"*'+ "')'"*'+ 1' #+'( 1)##( #+'" '*#+*'%#*#" '%%!+-*'+ **#"$ "# $ +.+# 5 # $ '!*)!*
(.* %#%'"$ #+'" #+'" 6 6# '" 6 6# 6 6# '" )!%) 6 6# #*-
+.+# ''% !) )!%) !+ '( )!%) &''* --# #"*'+ **#"$ "# $ 9)#" "7
(3!* (* )"#6#+*'+ "# $
'"4!# ''% (',+ )!%) !+ '( )!%) 1,+. )"7+. ''% +. # 9)#" "7 '","(
(3!* (* "'**'+ "# $
5+ '( "% '!* ''% #( "6# *".* "6# 8 +. # #+'" "% +. # 9)#" "7 "#6#"#
(3!* (* )##( '" '6# "'**'+ "# $
''% !) "% + ''% "'( 2)*'+ +. # #+'" '" 9#" %'*'"
(3!* (* # #-*'" '6# ; 5
"% + !-7#* !-7#* *"'7#
(3!* (* (..+. %*
"% '!* !-7#* "% )''
(3!* (* (!%) '" "% +
1,+.

"6# ".* !# #+'"

"6# #*
##" *' +#=* ).# >+.+#?

1# #-*'" )'*'+ :
(#*#-*'+ -'%%!+-*'+

1,+. #"
".* "# $
1,+. #"
#* "# $
"6# "%
"# $
(# ')*'+ 1 "# $

(# ')*'+ +.+# *')
"# $
1#*$ '-7
#6#" "# $

(3!*%#+* 1#*$ "# $
(* #-*'"
(3!*%#+*
(* #-*'"
'!"%#*#"
#-*'"
'!"%#*#"
#-*'"
"')'"*'+
6 6# (3!* (*
!*#"
-'%%!+-*'+
##" *' +#=* ).# >+.+#?
0".#" *+ 0".#" *+

+'"% "+.# +'"% "+.#
"+*'" 2 : #""'"
!"# < "'!+(+.
'"* -"-!*
9"'+. '!*)!* 9"'+. '!*)!* "+*'" "+*'" 26#" "!+
2: !"# 2: !"#
-'++#-*'+ -'++#-*'+ -'++#-*'+ -'++#-*'+ "+*'" 2: -'++#-*'+ -'++#-*'+ %# '6#"
!"# <
-'++#-*'+
',#" '!"-# ',#" '!"-# ',#" '!"-# '+*-* )'+* ',#" '!"-#
'"* -"-!* '"* -"-!* '"* -"-!* %# *#( +( (#"#( '"* -"-!*

21-28
Note)
The numbers in the column of "page for reference" show the related page in Chapter 51 Engine.
21-29
21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION

The current service diagnosis is displayed on multi display based on the data received from mechatro controller. This
section explains the operating procedure and examples of each screen. The values in display changes according to
the conditions like engine speed, attachment position, etc.
(1) Service diagnosis display screen operating procedure
1) Turn starter switch ON keeping buzzer stop switch pressed.

2) After logo mark is displayed, the screen changes in service diagnosis mode.
The service diagnosis screen "Mode No.1", "Screen No.1" is displayed first.
The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in
"Screen No.1".
The screen number each mode can display differs. The screen number displayed by each mode is as
follows.
• Mode No.1 : Screen No.1~No.30
• Mode No.2 : Screen No.1, Screen No.31~No.40
• Mode No.3 : Screen No.1, Screen No.41~No.50
3) The screen changes each time each switch is pressed from now on.
Washer switch: Screen gains by 1 in order. (No.2→No.3→No.4→...)
Wiper switch: Screen loses by 1 in order. (No.24→No.23→No.22→...)
Auto idling switch: Service diagnosis number advances from No.1 to No.3, and then returns to No.1.
(No.1→No.2→No.3→No.1→...)
Travel 1, 2 speed switch: Service diagnosis number advances from No.3 to No.1, and then returns to
No.3. (No.3→No.2→No.1→No.3→...)
4) Turn key switch OFF and the display of service diagnosis mode is closed.
21-30
(2) Service diagnosis display screen (Example)

The service diagnosis display screen list is shown below. The conditions for display are H mode, engine low
speed and lever to neutral position.)
1) Service diagnosis mode No.1
No. Displays Contents No. Displays Contents
1 4
NO.1 NO.4 RELAY
MAIN CONT. P/N
YN22E00001F1 P/No. indication K-1 AIS RELAY 2 OFF Indicated value
PROGRAM VERSION K-2 SAFETY RLY OFF Indicated value
1-VER 11.11 Program version indication K-3 ENG STOP OFF Indicated value
2-VER 00.00 MERIT controller program version KEY SWITCH OFF Key switch
START SWITCH OFF Starter switch
SERVICE DIAG 1 Service diagnosis mode CHARGE LIVE Alternator
K-4 LOCK LEVER OFF Indicated value
SWITCH OFF Switch
2 5
NO.2 ENG NO.5 PRESS.SENSOR
G-3 SPEED SET 2205 No load setting rpm B-1 BOOM RAISE
MEAS1 2201 Actual rpm 1 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS2 2201 Actual rpm 2 (Engine controller) B-2 BOOM LOWER
G-5 ENG PRS. LIVE Engine oil pressure 3.5V 2.6M Sensor voltage / Pressure converted value
WATER TEMP 100 OFF Coolant temperaturre sensor B-3 ARM OUT
MODE HM Work mode 3.5V 2.6M Sensor voltage / Pressure converted value
H-1 ACCEL VOLT. 4.2V Potentiometer voltage B-4 ARM IN
POS. 100% Voltage % indication 3.5V 2.6M Sensor voltage / Pressure converted value
ECU OUTPUT 0.5V Accel output voltage to engine B-5 BUCKET DIG
controller 3.5V 2.6M Sensor voltage / Pressure converted value
B-6 BUCKET DUMP
3.5V 2.6M Sensor voltage / Pressure converted value
3 6
NO.3 SOL.VALVE NO.6 PRESS.SENSOR
F-1 POWER BOOST B-7 SWING
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-9 TRAVEL(R)
SWITCH OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
F-2 SWING-BRAKE B-10 TRAVEL(L)
MEAS. OFF Measured value B-16 P1 OPT.
RELEASE SW OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
F-3 1/2-TRAVEL B-17 P2 OPT.
MEAS. OFF Measured value B-18 DOZER 1
SWITCH OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
B-19 DOZER 2
3.5V 2.6M Sensor voltage / Pressure converted value
21-31
7 16
NO.7 P.SENSOR PROPO-V NO.16 PRESS.SENSOR
C-1 PUMP P1 B-11
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
C-2 PUMP P2 B-12
C-3 BOOM-HEAD B-13
C-4 BOOM-ROD B-14
PROPO-VALVE B-15
E-3 OPT RELIEF 1 Set value in computer / Converted value from pressure 3.5V 12.6M Sensor voltage / Pressure converted value
COMP. 600mA 14.5M Measured value / Converted value from pressure B-20
MEAS. 600mA 14.5M 3.5V 12.6M Sensor voltage / Pressure converted value
E-4 OPT RELIEF 2 Set value in computer / Converted value from pressure
COMP. 600mA 14.5M Measured value / Converted value from pressure
8 NO.8 PROPO-VALVE
18
NO.18 DIGITAL INPUT
D-1 P1 UN-LOAD(BP-CUT) DI1 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI2 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI3 OFF ON/OFF indication
D-2 P2 UN-LOAD(BP-CUT) DI4 OFF ON/OFF indication
See
D-3 S-TRAVEL DI7 OFF ON/OFF indication
Mechatro
controller
connector
D-6 ARM IN-2-SPEED DI10 OFF ON/OFF indication
DI13 OFF ON/OFF indication
9 19 NO.19 DIGITAL INPUT
NO.9 PROPO-VALVE
E-1 P1 PUMP DI15 OFF ON/OFF indication
POWER SHIFT 100mA Power shift DI18 OFF ON/OFF indication
FLOW RATE 100L Flow rate of pump P1 DI19 OFF ON/OFF indication
E-2 P2 PUMP DI20 OFF ON/OFF indication
POWER SHIFT 100mA Power shift DI23 OFF ON/OFF indication
FLOW RATE 100L Flow rate of pump P2 DI24 OFF ON/OFF indication
10 20
NO.10 SENSOR,SWITCH NO.20 DIGITAL INPUT
H-9 FUEL LEVEL DI29 OFF ON/OFF indication
4.5V 90 Fuel level DI30 OFF ON/OFF indication
H-10 HYD.OIL TEMP DI31 OFF ON/OFF indication
4.5V 30 Hydraulic oil temperature DI32 OFF ON/OFF indication
GLOW OFF Glow switch DI33 OFF ON/OFF indication
AIR FILTER LIVE Air filter clogging DI34 OFF ON/OFF indication
WATER SEPA. LIVE Water separator clogging DI35 OFF ON/OFF indication
ENG OIL FILTER LIVE Engine oil filter clogging DI36 OFF ON/OFF indication
FRONT WINDOW OFF Front window open/close switch DI37 OFF ON/OFF indication
DOUBLE FLOW ON Conflux/Single flow select switch DI38 OFF ON/OFF indication
KPSS SW OFF KPSS switch DI39 OFF ON/OFF indication
HEATER OFF Command from air heater DI40 OFF ON/OFF indication
ENG OIL LEVEL LIVE Engine oil level DI41 OFF ON/OFF indication
COOLANT LEVEL LIVE Coolant level DI42 OFF ON/OFF indication
11 21
NO.11 SOL.VALVE NO.21 DIGITAL OUTPUT
F-4 OPT SELECT DO1 COMP. OFF Set value in computer
COMP. OFF Set value in computer MEAS. OFF Measured value
MEAS. OFF Measured value (Feed back value) DO2 COMP. OFF Set value in computer
MEAS. OFF Measured value
SPOOL POS. NIB Spool position DO3 COMP. OFF Set value in computer
SELECT SWITCH NIB Mode of selector valve MEAS. OFF Measured value
F-5 FAN PUMP DO4 COMP. OFF Set value in computer
COMP. OFF Set value in computer MEAS. OFF Measured value
MEAS. OFF Measured value DO5 COMP. OFF Set value in computer
F-6 MEAS. OFF Measured value
COMP. OFF Set value in computer DO6 COMP. OFF Set value in computer
MEAS. OFF Measured value MEAS. OFF Measured value
DO7 COMP. OFF Set value in computer
12 22
NO.12 POTENTIO. NO.22 DIGITAL OUTPUT
H-2 BOOM DO8 COMP. OFF Set value in computer
3.5V 137 Sent value from sensor / Converted value from angle MEAS. OFF Measured value
H-3 ARM DO9 COMP. OFF Set value in computer
3.5V 137 Sent value from sensor / Converted value from angle MEAS. OFF Measured value
21-32

23 27
NO.23 DIGITAL OUTPUT NO.27 MERIT SYSTEM
MEAS. OFF Measured value COMMUNICATION OFF Status of communication in MERIT controller
DO16 COMP. OFF Set value in computer 4
DO18 COMP. OFF Set value in computer 0412051200
24 28
NO.24 DIGITAL OUTPUT NO.28 ENG CONT.
DO22 COMP. OFF Set value in computer TRANS.COUNT. 100 Counted number of transmission error
MEAS. OFF Measured value RECEIVE COUNT. 100 Counted number of reception error
DO23 COMP. OFF Set value in computer DIAG STATUS 9 Diagnosis status
MEAS. OFF Measured value NUMBER OF DIAG 100 Numbers of error
DO24 COMP. OFF Set value in computer BOOST PRESS. 100 Boost pressure
MEAS. OFF Measured value BOOST TEMP. -100 Boost temperature
DO25 COMP. OFF Set value in computer BAROMETRIC P. 100 Atmospheric pressure
MEAS. OFF Measured value FUEL TEMP. -100 Fuel temperature
DO26 COMP. OFF Set value in computer FUEL CONS. 200 Fuel consumption
MEAS. OFF Measured value INTAKE TEMP. -100 Intake air temperature
DO27 COMP. OFF Set value in computer ENG PRESS. 300 Engine oil pressure
MEAS. OFF Measured value GLOW OFF Glow output from ECU
DO28 COMP. OFF Set value in computer ENG STOP OFF Engine stop command from ECU
MEAS. OFF Measured value TORQUE 1000 Calculated torque of ECU
25
NO.25 WIPER SYSTEM
WIPER SW OFF Wiper switch
RISEUP SW OFF Wiper rise-up switch
REVERSE SW OFF Wiper reverse rotation switch
PREVENT ARC OFF Wiper motor ark prevention
CW MOTOR RLY OFF relay
CCW MOTOR RLY OFF Wiper normal rotation relay
WASHER SW OFF Wiper reverse rotation relay
MOTOR RELAY OFF Washer switch
Washer motor relay

1 33
NO.1 NO.33 BUCKET
MAIN CONT. P/N C-1 P1-PRES 13.9M Pump pressure sensor
YN22E00001F1 P/No. indication C-2 P2-PRES 13.9M Pump pressure sensor
PROGRAM VERSION E-1 P1-PSV 600mA Command current
1-VER 11.11 Program version indication E-2 P2-PSV 600mA Command current
2-VER 00.00 MERIT controller program version D-1 P1-UL(BPC) 600mA Command current
D-2 P2-UL(BPC) 600mA Command current
SERVICE DIAG 2 Service diagnosis mode D-3 S-TRAVEL 600mA Command current
B-5 BUCKET DIG 1.9M Bucket digging pressure sensor
B-6 BUCKET DUMP 1.9M Bucket dump pressure sensor
G-3 ENG SPEED 2205 Engine actual speed
POWER SHIFT 100mA Power shift current
31 NO.31 BOOM
34
NO.34 TRAVEL
C-1 P1-PRES 13.9M Pump pressure sensor C-1 P1-PRES 13.9M Pump pressure sensor
E-1 P1-PSV 600mA Command current E-1 P1-PSV 600mA Command current
D-1 P1-UL(BPC) 600mA Command current D-1 P1-UL(BPC) 600mA Command current
B-1 BOOM RAISE 1.9M Boom up pressure sensor D-3 S-TRAVEL 600mA Command current
B-2 BOOM LOWER 1.9M Boom down pressure sensor B-9 TRAVEL(R) 13.9M Travel right pressure sensor
G-3 ENG SPEED 2205 Engine actual speed B-10 TRAVEL(L) 13.9M Travel left pressure sensor
POWER SHIFT 100mA Power shift current Pi-P1 13.9M Pilot pressure at travel straight (P1 side)
Pi-P2 13.9M Pilot pressure at travel straight (P2 side)
G-3 ENG SPEED 2205 Engine actual rpm
POWER SHIFT 100mA Power shift current
32 35
NO.32 ARM,SWING NO.35 OPT
D-3 S-TRAVEL 600mA Command current D-3 S-TRAVEL 600mA Command current
D-6 ARM-IN-2 600mA Command current E-3 OPT RELIEF 600mA Command current
B-3 ARM OUT 13.9M Arm out pressure sensor B-16 P1 OPT 1.9M P1 side option pressure sensor
B-4 ARM IN 13.9M Arm in pressure sensor B-17 P2 OPT 1.9M P2 side option pressure sensor
B-1 BOOM RAISE 13.9M Boom up pressure sensor F-4 OPT SELECT NIB Optional selector SOL (Nibbler line)
B-7 SWING 13.9M Swing pressure sensor DOUBLE FLOW SW NIB Conflux/ Single selector switch
G-3 ENG SPEED 2205 Engine actual speed G-3 ENG SPEED 2205 Engine actual rpm
POWER SHIFT 100mA Power shift current POWER SHIFT 100mA Power shift current
21-33

1 43
NO.1 NO.43 MACHINE-INFORM.
MAIN CONT. P/N HOUR METER 3550 Hour meter of controller
YN22E00001F1 P/No. indication TRIP METER 3500 Trip meter of controller
PROGRAM VERSION OPERATION 3300 All accumulated operating time
1-VER 11.11 Program version indication TRAVEL 300 All accumulated traveling time
2-VER 00.00 MERIT controller program version SWING 3000 All accumulated swing time
HAMMER 100 All accumulated breaker operating time
SERVICE DIAG 3 Service diagnosis mode CRANE 100 All accumulated high-reach crane operating time
STARTER 1200 All accumulated starter operating time
41 44
NO.41 ADJUSTMENT 1 NO.44 MACHINE-INFORM.
ENG PUMP PRESS.
HI-IDLE 2205 Engine speed high idle TOTAL 10Hr Pump pressure distribution (%)
PUMP LEVEL1 24% 22% Total / In the last 10 hours
ACT I 515mA Current at pump adjustment LEVEL2 50% 50% Total / In the last 10 hours
15mA Current correction at pump adjustment LEVEL3 25% 25% Total / In the last 10 hours
PUMP P 35.0M Pressure at pump adjustment LEVEL4 1 % 3% Total / In the last 10 hours
ESS N 2040 Engine speed sensor rpm
UN-LOAD WATER TEMP.
P1 600mA P1 unload corrective current TOTAL 10Hr Coolant temperature distribution (%)
P2 600mA P2 unload corrective current LEVEL1 24% 22% Total / In the last 10 hours
BOOM 137 137 Angle adjustment LEVEL2 50% 50% Total / In the last 10 hours
ARM 137 137 Angle adjustment LEVEL3 25% 25% Total / In the last 10 hours
OFFSET 137 137 Angle adjustment LEVEL4 1 % 3% Total / In the last 10 hours
INTER-B 137 137 Angle adjustment
21-34
(3) Service diagnosis data list

Preface and precaution
The following is the data decided as normal status after service diagnosis for every operation. Use these data
to decide normal/abnormal status.
• The values in following display are reference values with standard attachment attached machine.
• The value of pressure sensor is calculated taking variation into accounts. When compared to performance
check reference criteria, measure it with the aid of calibrated measuring instrument.
• The current of proportional valve is not the measured value, but command value. The measured value
should be confirmed by the value in the displayed value for each proportional valve.
• The current value of pump proportional valve is reference value because it varies according to pump
pressure and adjusted torque value.
• The value in display during operation shows the value in steady state, rather than, at start of operation.
• Check on machine after sufficiently warming up machine.
• The value in display may differ according to software version. Contact our dealer/distributor.
Operation No.1 : No operation Operation No.2 : No operation

H mode Hi idle S mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 750 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1770~1830
POWER SHIFT 0 mA POWER SHIFT 0 mA
Operation No.3 : Boom up in full lever operation & relief Operation No.4 : Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.31 BOOM No.31 BOOM

C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 11.0~16.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 11.0~16.0 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 560~750 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 560~750 mA
B-2 BOOM LOWER 0.0 M B-2 BOOM LOWER 0.0 M
21-35
Operation No.5 : Boom down in full lever operation & in

operation
H mode Hi idle
No.31 BOOM
C-1 P1-PRES 12.5~16.0 M
C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 600~617 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 427~477 mA
D-2 P2-UL(BPC) 750 mA
B-1 BOOM RAISE 0.0 M
B-2 BOOM LOWER 3.0 M
G-3 ENG SPEED 1970~2060
POWER SHIFT 0 mA
Operation No.6 : Arm-in in full lever operation & relief Operation No.7 : Arm-in in full lever operation & in operation
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 12.5~16.5 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 12.5~16.5 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 550~750 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 550~750 mA
21-36
Operation No.8 : Operation No.9 :

Arm-out in full lever operation & relief Arm-out in full lever operation & in operation
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 15.0~22.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 15.0~22.0 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 488~677 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 488~677 mA
* Measure the values after a lapse of 5 minutes or after * Measure the values after a lapse of 5 minutes or after
release of low temperature mode release of low temperature mode

Swing in full lever operation & relief Swing in full lever operation & in operation
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 28.0~35.8 M C-2 P2-PRES 10.0~15.0 M
E-2 P2-PSV 528~750 mA E-2 P2-PSV 750 mA
21-37

Bucket digging in full lever operation & relief Bucket digging in full lever operation & in operation
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 4.0~8.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 4.0~8.0 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 650~750 mA
E-2 P2-PSV 415~525 mA E-2 P2-PSV 540~563 mA
B-5 BUCKET DIG 3.0 M B-5 BUCKET DIG 3.0 M
B-6 BUCKET DUMP 0.0 M B-6 BUCKET DUMP 0.0 M

Bucket dump in full lever operation & relief Bucket dump in full lever operation & in operation
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 6.0~15.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 6.0~15.0 M
E-1 P1-PSV 415~525 mA E-1 P1-PSV 577~750 mA
E-2 P2-PSV 415~435 mA E-2 P2-PSV 415~435 mA
B-5 BUCKET DIG 0.0 M B-5 BUCKET DIG 0.0 M
B-6 BUCKET DUMP 3.0 M B-6 BUCKET DUMP 3.0 M
21-38

P2 side option in full lever operation & relief P2 side option in full lever operation & relief
A mode Hi idle B mode Hi idle
No.35 OPT No.35 OPT
C-1 P1-PRES 22.5~26.0 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 22.5~26.0 M C-2 P2-PRES 22.5~26.0 M
E-1 P1-PSV 459~584 mA E-1 P1-PSV 500 mA
E-2 P2-PSV 459~584 mA E-2 P2-PSV 665~750 mA
E-3 OPT RELIEF 0 mA E-3 OPT RELIEF 0 mA
B-16 P1 OPT 0.0 M B-16 P1 OPT 0.0 M
B-17 P2 OPT 2.0~2.6 M B-17 P2 OPT 2.0~2.6 M
F-4 OPT SELECT NIB F-4 OPT SELECT BRK
DOUBLE FLOW SW. ON DOUBLE FLOW SW. OFF
* Conflux switch is ON. Relief set pressure is value of * Conflux switch is OFF. Relief set pressure is value of
shipping. shipping.

Travel right in full lever operation & travel idling Travel left in full lever operation & travel idling
No.34 TRAVEL No.34 TRAVLE
C-1 P1-PRES 5.0~12.0 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 5.0~12.0 M
B-9 TRAVEL(R) 2.0~2.5 M B-9 TRAVEL(R) 0.0 M
B-10 TRAVEL(L) 0.0 M B-10 TRAVEL(L) 2.0~2.5 M
Pi-P1 0.0 M Pi-P1 0.0 M
Pi-P2 0.0 M Pi-P2 0.0 M
21-39
21.2.4 TROUBLE HISTORY DIAGNOSIS

The items of error detected by mechatro controller self diagnosis function are stored in mechatro controller as one
of history. And the errors are able to be indicated on the multi display.
The warning content is record partially in "Travel history screen".
The error code for self diagnosis is stored.
(1) How to display

1) Turn starter switch on.
2) Press buzzer stop switch for 10 seconds continuously 5 times and the trouble history screen is displayed.
(Example)
No errors NO ERROR
Error detected in the past
3) Transmit trouble history data (One or many) and hour meter to gauge cluster.
• Hour meter and 4 failure data are displayed on screen.
• In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
4) Paging (Up and down)
• Press washer switch ( ), and the item moves upward.
• Press wiper switch ( ), and the item moves downward.

5) Turn starter switch off, and the display is disappeared.
(2) How to delete contents of trouble history

1) Display trouble history screen.
2) Press work mode change switch and buzzer stop switch simultaneously for 10 seconds or more.
3) When "NO ERROR" is displayed, the deletion is completed.
4) Turn starter switch off.
All the stored items are erased. It is impossible to erase data partially.
21-40
21.2.5 TROUBLE DIAGNOSIS MODE

The recent control system includes many electrical systems and it makes troubleshooting very difficult.
The failure diagnosis mode is used to automatically specify the failed sections for the failures which can not be
detected through the use of self diagnosis function (the failure can be specified through the use of error code) like
disconnection and abnormal output. This is useful to save the time for troubleshooting.
(1) Function
There are two types of trouble diagnosis mode.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and
engine system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not moved, both directional valve and proportional valve are automatically
actuated, the sensor detects the machine status and the mechatro controller identifies the normal condition
or failed condition of the system.
For details of how to use, refer to "Chapter 46 TROUBLESHOOTING TROUBLE DIAGNOSIS MODE".
21-41
21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE

This machine is equipped with multi-display which allows confirmation of remaining time to the coming replacement/
change time of engine oil, fuel filter, hydraulic oil filter and hydraulic oil, therefore when the remaining time reaches
to Zero (0), replace or change engine oil, fuel filter, hydraulic filter, hydraulic oil, etc. and perform the initial setting
by the following order.
Screen change Buzzer stop KPSS work mode

switch switch select switch
Interval of replacement of parts is mentioned below. Washer

switch
• Engine oil : 500 Hr
• Fuel filter : 500 Hr
Select Wiper
• Hydraulic filter : 1,000 Hr switch switch
Auto accel Travel speed
• Hydraulic oil : 2,000 Hr (MIDDLE EAST) switch select switch
5,000 Hr (RUSSIA)
Procedure Operating Procedure Display on Multidisplay
After several seconds,

display is changed to 10:25
1 Turn starter key switch on.
clock autmatically.
H
Press " " switch press once display

change switch on the switch panel once. And 10:25 Press screen change 250 Hr
2 ENGINE OIL
the clock display changes to the display of switch once more.
remaining time for coming engine oil change. H H
Press " " switch press once select

switch once and the display for the engine 250 Hr Press select switch 250 Hr
3 ENGINE OIL ENGINE OIL
oil change reverses. once more.
H
When required to adjust the interval to the coming

Replacing interval is
4
change time by 10 hours, press " " switch 250 Hr changed with each 500 Hr
and the time to the coming engine oil change is ENGINE OIL ENGINE OIL
pressing of switch.
added. Press " " switch and the time to the
coming engine oil change is reduced.
When desired to return to the initial set time,

press " " buzzer stop switch once. 500 Hr To set the desired interval, 500 Hr
5 Press " " select switch once and the set ENGINE OIL press the select switch ENGINE OIL
time is stored. H
1. After displaying the display for setting by pressing the display change switch, set the respective maintenance
time for fuel filter, hydraulic oil filter and hydraulic oil while repeating the procedure 2 to 5.
2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does not
sound.
21-42
21.2.7 ADJUSTING PROCEDURE OF DISPLAY

(1) For operator
1) Auto idling stop

No. Switchs 1 2 3 4
3 KPSS work mode select switch
4 Washer switch
5 Wiper switch
6 Travel speed select switch
7 Auto accel switch 5
8 Select switch 8 7 6
Fig. 21-2
Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST
H
(a) (b)
AUTO IDLING STOP
(d)
AUTO WARM-UP AUTO IDLE STOP AUTO IDLE STOP
OFF OFF ON
FEED FEED FEED
(c)
(e)
AUTO IDLE STOP AUTO IDLE STOP
OFF ON
OFF ON OFF ON
1. Press select switch (8) in main screen (a) for operator and display "SWITCH STATUS CLOCK/CONTRAST"
select screen (b).
2. Press select switch (8) again and display "AUTO WARM-UP OFF" screen (c).
3. In operation of FEED (4), the "AUTO IDLE STOP OFF" screen (d) is displayed.
4. In operation of FEED (4), the color of "OFF" portion reverses and the "AUTO IDLE STOP OFF" screen
(e) is displayed.
5. Switch from "OFF" to "ON" in operation of FEED (4) and set it by pressing selector switch (8).
6. When auto idling is functioning, the "AUTO IDLE STOP" is displayed on the multi-display.
7. Turn starter key switch off once and store the auto idling stop setting as a memory.
21-43
2) Clock Adjustment Switches

1 Screen Change Switch
2 Buzzer Stop Switch
3 KPSS Work Mode Select Switch
4 Washer Switch
5 Wiper Switch
6 Travel Speed Select Switch
7 Auto Accel Switch
5
8 Select Switch 8 7 6
Main screen (a)

SWITCH STATUS
10:25 CLOCK/CONTRAST 13:15
H H
(a) (b)
(c) (d) (e)

SWITCH STATUS ADJUST CLOCK Y M D H M Enter
CLOCK/CONTRAST ADJ CONTRAST 06 04 01 13 15
Select Year/Month/Day/Hour/Minute Increase/Decrese
1. Turn starter key switch on and display main screen (a) for operator, and then press select switch (8) and
display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).
2. In operations of FEED (4) and FEED (5), move cursor to "CLOCK/CONTRAST" screen (c) and then
press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed.
3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK" and then press select
switch (8) and the "ADJUST CLOCK" screen (e) is displayed.
4. Select any of "Y•M•D•H•M" in operation of FEED (4) and FEED (5) and vary the values in operations
of FEED (4) and FEED (5).
5. After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting is
completed, and then the screen returns to main screen (a).
21-44
3) Contrast Adjustment Switches

1 Screen Change Switch
2 Buzzer Stop Switch
3 KPSS Work Mode Select Switch
4 Washer Switch
5 Wiper Switch
6 Travel Speed Select Switch
7 Auto Accel Switch
5
8 Select Switch 8 7 6
Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST
H
(a) (b)
(c) (d) (a)

SWITCH STATUS ADJUST CLOCK
CLOCK/CONTRAST ADJ CONTRAST 10:25
H
(e) (f)
ADJUST CLOCK ADJ CONTRAST Enter
ADJ CONTRAST 55555
Adjustable range
11111~99999 Increase/Decrease
(Default 55555)
1. Turn starter key switch on and display main screen (a), and press select switch (8) and display "SWITCH
STATUS CLOCK CONTRAST" select screen (b).
2. In operations of FEED (4) and FEED (5), move cursor to "SWITCH STATUS CLOCK CONTRAST"
screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is
displayed.
3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK ADJ CONTRAST" and then
press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (e) is displayed.
4. Press select switch (8) and the "ADJ CONTRAST 55555" screen (f) is displayed.
5. Vary the values by pressing the desired figure in operations of FEED (4) and FEED (5).
The available setting range is in 9 steps from "11111" to "99999".
[Example] 11111 (faint) → 99999 (clear) * The initial set value is 55555.
6. Press select switch (8) and the adjusted values are stored as a memory and the contrast adjustment is
completed, and then the screen returns to main screen (a).
21-45
(2) Function for service

Following items are provided for adjustment of service function.
Item CONTENTS
Language Language selection
Rise-up wiper Wiper control change (When cab is changed)
Idle stop ON/OFF of auto idle stop (ON/OFF of adjustment for user) and time adjust
P1 option pressure sensor ON/OFF of self diagnosis for P1 option pressure sensor
P2 option pressure sensor ON/OFF of self diagnosis for P2 option pressure sensor
Swing alarm ON/OFF of swing alarm (ON/OFF of adjustment for user)
Left pedal for rotation of option Does left rotation pedal use?
attachment (Unload valve does not actuate because P4 pump is equipped in EU.)
Optional flow rate limitation, relief pressure limitation, combination of return
Setting of optional equipment
selector adjustment)
Engine speed ON/OFF of engine rpm display
Adjustment the type of the engine speed of auto deceleration runs up
Auto acceleration
abruptly.
Change of starter mode Change of start mode
Low temperature mode forcible
Low temperature mode release
release
Cylinders calibration Injection adjust mode of engine
Pressure release For pressure release
21-46
21.2.8 MECHATRO CONTROL EQUIPMENT

(1) C-1 Mechatro controller
1) Outside view
2 1 6 2 1 4 2 1 8 2 1
10
16
26
34
27 22 18 16 12 28 22
CN101 CN102 CN103 CN104
CN105 CN106 CN107 CN108 CN109

9 21 7 2 16 21 9 21 7 21
21
31 10 16 8 12 7 28 10 22 8
22 24 17 17 13 19 20 15 16
2) List of connectors
Connector No. Pin No. Port name Function Input/putput Signal level
CN101 1 GA 0V
2 A1 Boom up Input 0.5~4.5V
3 +5VA Power output 5V
5 A2 Boom down Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A3 Arm in Input 0.5~4.5V
11 A4 Arm out Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A5 Bucket digging Input 0.5~4.5V
17 A6 Bucket dump Input 0.5~4.5V
18 GA 0V
19 TXD1 Gauge cluster Transmission RS232C communication
20 RXD1 Reception RS232C communication
21 GP 0V
22 SHG1 Shield GND
23 TXD3 Down load Transmission RS232C communication
25 DL EARTH / OPEN(5V
26 GP 0V
27 CANH1 E/G ECU CAN communication
28 CANL1 E/G ECU CAN communication
29 DO 20 Spare Output EARTH/OPEN
30 DO 21 Safety relay Output EARTH/OPEN
31 DO 22 Spare Output EARTH/OPEN
32 DO 23 Rotary light (yellow) Output EARTH/OPEN
33 DO 24 Rotary light (green) Output EARTH/OPEN
34 DI 36 Heavy lift Input EARTH/OPEN
21-47
CN102 1 GA 0V
2 A8 Travel right Input 0.5~4.5V
5 A9 Travel left Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A10 Accelation Input 0.5~4.5V
11 A13 P1 option Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A14 P2 option Input 0.5~4.5V
17 A27 Spare Input 0.5~4.5V
18 GA 0V
19 GA 0V
22 D1 37 Spare Input GND / OPEN
CN103 1 GA 0V
2 A Swing Input 0.5~4.5V
5 A11 P1 pump Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A12 P2 pump Input 0.5~4.5V
11 A15 Boom angle Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A16 Arm angle Input 0.5~4.5V
16 Reserved
21-48
CN104 1 GA 0V
2 A17 Boom head Input 0.5~4.5V
5 A18 Boom rod Input 0.5 4.5V
6 GA 0V
7 GA 0V
8 A19 Extra pressure source Input 0.5~4.5V
12 GA 0V
14 GA 0V
15 A22 Fuel level Input 0.5~4.5V
16 GP 0V
18 GA 0V
19 GA 0V
20 A24 Selector detection Input 0.5~4.5V
24 GA 0V
25 GA 0V
28 DI 1 Cab slow up and down Input GND / OPEN
CN105 1 +24V Battery relay output side 20~32V
2 +24V Battery relay output side 20~32V
(sensor analog output)
3 +24V Battery relay output side 20~32V
4 DO 7 Travel 1,2 speed select valve Output 24V/OPEN
5 DO 8 Swing P/B select valve Output 24V/OPEN
6 DO 9 Travel 1,2 speed select valve Output 24V/OPEN
7 DO 11 Attachment boost select valve Output 24V/OPEN
8 GND Battery (-) 0V
10 D10+ OPT changeable relief 1 Output +0~800mA
11 D1+ P1 unload Output +0~800mA
12 D1- -0~800mA
13 D2+ P2 unload Output +0~800mA
14 D2- -0~800mA
15 D3+ Travel straight Output +0~800mA
16 D3- -0~800mA
17 D4+ Arm in Output +0~800mA
18 D4- -0~800mA
19 D5+ P1 pump Output +0~800mA
20 D5- -0~800mA
22 D10- OPT changeable relief 1 Output -0~800mA
23 D6+ P2 pump Output +0~800mA
24 D6- -0~800mA
25 D7+ Cab slow stop valve Output +0~800mA
26 D7- -0~800mA
27 D8+ Boom cushion Output +0~800mA
28 D8- -0~800mA
29 D9+ Arm cushion Output -0~800mA
30 D9- +0~800mA
31 +24V Battery direct connection 20~32V
21-49
CN106 1 +24V Battery relay secondary side 0 20~32V
2 SHGF Shield GND
3 F1+ Accel motor A phase (spare) Output +24V 1.5A
4 F1- Accel motor A phase (spare) Output +24V 1.5A
5 F2+ Accel motor B phase (spare) Output +24V 1.5A
6 F2- Accel motor B phase (spare) Output +24V 1.5A
7 OIL Oil level (spare) 0
8 OILG
9 D11+ OPT changeable relief 2 Output +0~800mA
10 D11- -0~800mA
11 D12+ Spare Output +0~800mA
12 D12- -0~800mA
14 D13- -0~800mA
16 D14- -0~800mA
19 D12- -0~800mA
20 E1+ E/G speed sensor Input XX~XXVp-p
21 E1- 0V
22 SHG3 Shiled GND
23 CANH2 Proportional vlave expand unit CAN communication
24 CANL2 CAN communication
CN107 1 DI 3 Key switch (GLOW) Input +24V/OPEN
2 DI 8 Water separetor Input EARTH / OPEN
3 DI 9 E/G oil pressure Input EARTH / OPEN
4 DI 10 Air filter Input EARTH / OPEN
5 DI 11 Stroke end check Input EARTH / OPEN
6 DI 12 Spare Input EARTH / OPEN
7 DI 13 E/G coolant level Input EARTH / OPEN
10 DI 20 ECU main relay Input EARTH / OPEN
12 DI 32 Hand control nibbler Input EARTH / OPEN
13 DI 38 Quick coupler Input EARTH / OPEN
14 DI 39 Extra pressure Input EARTH / OPEN
17 Reserved
21-50
CN108 1 DI 2 Key switch (ON) Input +24V / OPEN
2 DI 4 Spare Input +24V / OPEN
3 DI 5 Swing P/B release Input GND / OPEN
4 DI 6 E/G start Input +24V / OPEN
5 DI 7 High reach hoisting at fixed position Input GND / OPEN
6 DI 16 Wiper rise up Input GND / OPEN
7 DI 17 Wiper reverse Input GND / OPEN
8 DI 18 ATT boost Input GND / OPEN
9 DI 19 Nibbler open check SW Input GND / OPEN
10 DI 21 Elevator cab up check Input +24V / OPEN
12 DI 23 Lever lock Input +24V / OPEN
13 DI 24 Hand control rotation / Input
clamp open or close GND / OPEN
14 DI 25 Front window open or close Input GND / OPEN
15 DI 26 Hand control breaker Input GND / OPEN
16 DI 27 Conflux/single select Input GND / OPEN
17 DI 29 Overload select Input GND / OPEN
18 DI 30 High reach (hoist at travel) Input GND / OPEN
19 Reserved
20 GP
21 DI 33 Charge Input ~12V / 12V~
24 Reserved Reserved
25 H1+ Accel signal 1 0~5V
26 H2- 0V
27 H2+ Accel signal 2 0~5V
28 H2- 0V
CN109 1 DO 1 Wiper arc prevention Output GND / OPEN
2 DO 2 Wiper normal moving Output GND / OPEN
3 DO 3 Wiper reserve moving Output GND / OPEN
4 DO 4 Washer motor Output GND / OPEN
5 DO 5 Bucket move limitation Output GND / OPEN
6 DO 6 Reserved Output GND / OPEN
7 DO 12 Rotary light (RH) Output GND / OPEN
8 DO 13 Swing flasher (RH) Output GND / OPEN
9 DO 14 Swing flasher (LH) Output GND / OPEN
10 DO 15 Travel alarm Output GND / OPEN
11 DO 16 Auto idle stop relay Output GND / OPEN
12 DO 17 Engine stop Output GND / OPEN
13 DO 18 Lever lock Output GND / OPEN
14 DO 19 Extra pressure release Output GND / OPEN
15 Reserved
16 GP IT controller 0V
17 TXD2 Tranmission RS232C communication
19 RTS Spare RS232C communication
20 CTS Spare RS232C communication
21 SHG2 Shiled GND
22 DO 10 Cab up and down switching valve SV 24V/OPEN
21-51
(2) Gauge cluster (symbol C-2)

1) General view
MULTI
DISPLAY LCD
COOLANT
TEMPERATURE
GAUGE
FUEL LEVEL
GAUGE
MATED SIDE
AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
SCREEN CHANGE
SWITCH ETC.
BUZZER STOP SWITCH WORK MODE SWIHCH
2) Connector CN-600 (Harness side)
No. Item name Wire color No. Item name Wire color
Gauge cluster → Mechatro
GND source (+24V Battery Yellow /
1 controller (RS232C White 5
direct connection) Black
communication)
Mechatro controller → Gauge
2 cluster (RS232C Red 6 GND Black
communication)
Source (+24V starter switch
3 Reserved — 7 White
ON)
GND (RS232C
4 Reserved — 8 Black
communication)
3) Function
a. It processes signals by communication between the gauge cluster and the mechatro controller, displays
them in lamps, displays them in LCDs and actuates the buzzer.
b. It outputs coolant temperature signals, fuel level signals and panel switch signals to the mechatro
controller through the communication port.
4) Summary of display and drive item
No. Item Remarks

1 Monitar display LCD dot 120×168
2 Gauge display (Coolant temp., Fuel level) Stepping motor
3 —
4 Buzzer Piezo-electricity type
7 Work mode select switch
8 Back light LED
21-52
(3) Relay & fuse box (symbol E-1)

1) General view
(Overhead view of box)

LABEL INSIDE
Note) These circles indicate the parts

which are used in standard specification
1 10
1 14 1 14 1 12 1 3 1 3
CN16 CN17
20 20 CN4-1 17 CN5 15 6 2 6
CN2-1 CN2-2 2
11 22 1 3 1 3
13 26 13 26 9 20 CN14 CN15
1 13 1 7 2 6 2 6
1 9
CN4-2 1 3 1 3
17
CN3-1 CN3-2 12
6 12 3 CN12 CN13
1
2 6 2 6
12 24 8 16 1 CN1
1 2 1 2 CN2-3 2 1 2
CN8 CN9 2 4 CN10
3
LOCATION OF CONNECTORS (Seen from backside)
LOCATION OF RELAY & FUSE
LABEL OF RELAY & FUSE BOX

No. CODE IN CIRCUIT PARTS NAME
21-53
2) Circuit diagram
21-54
21-55
21-56
(4) High pressure sensor : YN52S00048P1
ECONOSEAL SERIES MARK (+)> SPECIFICATION :

3POLES CAP
MATING HOUSING174357-2 PRESSURE RANGE : 0 50 MPa (0 7110 psi)
POWER SOURCE VOLTAGE : 5.0+0.5V DC
COMMON OUTPUT : 1/10Vs-9/10Vs
OUTPUT (+) (Vs=5V DC 0.5 4.5V DC)
POWER SOURCE (+) INSURANCE RESISTANCE : 100M OR MORE
HOUSING (BETWEEN CASING AND ALL IN/OUT
TERMINAL
TERMINALS AT 50V DC MEGGER)
PLASTIC POTTING CONDENSER
COVER
ELECTRIC CONNECTING DIAGRAM
DIE
CASING (Ex. Construction of internal controller)
FLEXIBLE BOARD
CIRCUIT DIAPHRAGM
O-RING P14 PIPE

JIS B2401 CLASS1B
THREAD
PF 3/8
Tightening torgue STRUCTURE
73.5N.m (54.2lbf.ft)
(5) Low pressure sensor : LC52S00019P1
A AMP MQS CONNECTOR 3 POLE (B TYPE)

OPPOSITE CONNECTOR (FEMALE)
HOUSING 2-967642-1
TERMINAL (GOLD PLATED) 965906-5
CONNECTOR TERMINAL POSITION

TERMINAL No.
1 COM
2 OUT PUT (+)
3 POWER (+)
VIEW A
19 21.9 HEX
O-RING P11
PF1/4 Tightening torgue
34.3N.m (25.3lbf.ft)
DETAIL OF SENSOR CONNECTOR SPECIFICATION :

PRESSURE RANGE : 0 3.0 MPa (0 448 psi)
RATED VOLTAGE : 5.0+0.5V DC
INSURANCE RESISTANCE : 100M OR MORE
(BETWEEN BODY AND EACH TERMINAL AT
50V DC MEGGER)
21-57
[MEMO]
21-58
22. HYDRAULIC SYSTEM
TABLE OF CONTENTS
Paste here
22
Book Code No. S5XX220XJ0X
22-1

SK200–8 : YN11-45001~ S5YN2223E01
First edition April, 2007 K
SK210LC–8 : YQ11-06001~ ASIA (HS Engine)
22-2
22.1 SUMMARY
The hydraulic circuits are built up with the following functions and features in order to achieve easy operability, safety, mass volume handling and low fuel consumption.
Table22-1
Perfor- Device
mance Function Features
Travel straight Travel straight at combined operation

Travel 2-speed change & Auto 1st (low) speed return 1-2 travel speed change and low speed / high torque at heavy duty
Travel
Auto parking brake Automatic braking when parking

Motor overrun protection Prevents overrunning of travel motor on the down hill slope.
Travel pilot operation Prevents hunting by the built in travel shockless mechanism
Reverse rotation protective function Easy positioning to protect it from swinging back when stops swinging.
Swing priority circuit Easy operation of stable swing speed, arm slanted leveling,
Swing
(simultaneous operation of arm in and swing motions) swing press digging

Easy operability and safety
Automatic swing parking brake Swing parking brake when operating at on a slope
Attachment
Hydraulic pilot control system Light action with operating lever

Pilot safety lock system Cut out of pilot circuit by safety lock lever.
Lock valve (boom / arm) Protect boom and arm from unexpected drop (Natural fall).
Holding valve for boom (Option) Prevention of boom falling when boom head side piping breaks
Pressurized hydraulic oil tank To prevent hydraulic oil from entering dust and to
promote self suction ability of pump
Suction strainer Remove dust on suction side.
Line filter ; pilot circuit To prevent pilot operating circuit from malfunctioning
Others
Return circuit To prevent hydraulic oil from contamination

Cooling hydraulic oil by oil cooler To prevent hydraulic oil from being deteriorated.
Pressure draining circuit To release the main circuit pressure for piping repair work.
Main control valve with optional valve Optional piping and additional work are easy
Switching of return line for N&B machine in the cab Switching of return line for N&B machine is able to
(Option) change with a switch in the cab
Electric flow controlled variable displacement pump Pump delivery rate control by a current command to the
Mass handling capability
solenoid proportional valve of the variable displacement pump

Pump
Positive flow rate control Flow control by positive pilot control pressure
Hydraulics backup control Backup control by hydraulic when the electric flow controlled
variable displacement pump fails.
Boom up conflux circuit Speed up of boom up operation
Attachment
Arm conflux circuit Speed up of arm operation

Bucket conflux circuit For speed-up of bucket operation (digging & dump)
Optimum operation by work mode select (H,S,A,B) Efficient operation in all work modes
consumption
Auto accel Reduce fuel consumption and noise by lowering engine

computer
Low fuel
Micro
speed when control lever is in neutral position.
22-3
22.2 HYDRAULIC CIRCUITS AND

COMPONENTS
STD. SCHEMATIC HYD. LINES YN01Z00185P1 (SE.Asia) / YN01Z000161P1 (Oceania)
Item Component name Part No. Model No.
YN10V00036F1 K3V112DTP (SE.Asia : without PTO.)
1 Hyd. pump assy
YN10V00040F1 K3V112DTP (SE.Asia : with PTO.)
2 Control valve (main) YN30V00101F1 KMX15YD
3 Swing motor unit YN15V00036F1 M5X130-CHB
4 Travel motor unit YN15V00037F1 GM38VB
5 Boom cylinder (RH & LH) YN01V00151F1 ø85×ø120×1355
YN01V00175F2 ø95×ø135×1558 (SE.Asia)
6 Arm cylinder
YN01V00175F1 ø95×ø135×1558 (Oceania)
YN01V00153F2 ø80×ø120×1080 (SE.Asia)
7 Bucket cylinder
YN01V00153F1 ø80×ø120×1080 (Oceania)
8 Swivel joint YN55V00053F1
9 Pilot valve (ATT) YN30V00111F1 PV48K2
10 Pilot valve (travel) YN30V00105F1 6TH6 NRZ
11 Inline filter YN50V00020F1 Y-457400
12 Suction strainer YW50V00004F7 Y-501400
13 Solenoid valve assy YN35V00047F1 8KWE5A-30
14 Return filter YN52V01008F3 FZ1F183A012A
15 Air breather YN57V00004F1 AB0210GA008A
Multi control valve (lever less) YN30V00113F1 Australia : STD
16
Multi control valve (with lever) YN30V00117F1 New Zealand : STD
17 Restrictor YN21V00005F1 07381-00000
The part numbers may be changed due to modification,

so use only the numbers for references.
22-4
22.2.1 STANDARD
SE22 SE23 P MB MB P
P P
MAIN PUMP PSV1 a1 A1 A2 a2 PSV2
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT
a3
8
a4
Dr
5.0MPa
M A B
a5
114kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPT.) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM
P P P P P P
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 16 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT
A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)
A8 ARM2
PSV-A 16
T2 P2 YN01Z00185P1 01
13
22-5
22.2.2 N&B SPECIFICATION (OPTION)
N&B specification YN01Z00162P1

NO. PARTS PART No. MODEL No.
50 SELECTOR VALVE YN30V00104F1 VBY-174B
51 STOP VALVE 24100P3133F1
52 PILOT VALVE YN30V00080F1 16030-00000
53 RELIEF VALVE YN22V00021F1 KRX16EK22
P2 P1 T1 T2
NOTE:
PTb 1. THIS HYDRAULIC CIRCUIT IS USED TO ADD TO STANDARD CIRCUIT.
TRAVEL 2. SELECTION CONDITION AND PROPORTIONAL VALVE COMMAND WHEN ANY OF NIBBLER SINGLE & CONFLUX FLOW OR BREAKER IN SERVICE.
P1 UNLOAD PRIORITY
PCb
COMMAND SIGNAL OF SOLENOID PROPORTIONAL VALVE
SELECTION
(W: , W/O: )
M CONFLUX / SINGLE FLOW ELECTROMAGNETIC COMMAND SIGNAL P1 P2 TRAVEL
P2 UNLOAD CHANGEOVER SWITCH OF SELECTOR VALVE (ITEM 50)(W:O,W/O:-) PUMP PUMP STRAIGHT P1 UNLOAD P2 UNLOAD
MAIN PUMP CONFLUX FLOW OF NIBBLER CONFLUX "ON"

PCa SINGLE FLOW OF NIBBLER CONFLUX "OFF"
BREAKER CONFLUX "OFF"
3. WHEN USING NIBBLER, ACCORDING TO SPECIFICATION OF NIBBLER INSTALLED,

CHOOSE CONFLUENCE OR SINGLE FLOW BY CONFLUENCE FLOW CHANGEOVER SWITCH.
4. ADJUST OVERLOAD RELIEF VALVE OF OPTIONAL PORT TO CUSTOMIZE SPECIFICATION ORDINARY SET PRESSURE.
51
LEFT
NIBBLER
NOTE 4
HYD.TANK 53 RIGHT
BREAKER
PBo 52
OPTION
PAo NIBBLER & BREAKER
PILOT VALVE
24.5MPa Ao
Bo T
P
24.5MPa
B C1 C2 A
SOL/V BLOCK LEVER
A1 LOCK P
SE-11
50 SV-13
Ps C PL
P
SE-29
YN01Z00162P1 01
22-6
This page is blank for editing convenience.
22-7
22.3 COLOR CODING STANDARD 22.4 NEUTRAL CIRCUIT 22.4.3 PUMP POSITIVE FLOW CONTROL resulting in the reduction of tilt angle. Similarly,
(1) Type : when the servo piston moves rightward, the
FOR HYDRAULIC CIRCUITS This section describes the following.
Electric flow controlled variable displacement spool (652) is moved leftward by the feedback
Blue (1) Bypass cut valve and unload valve control
pump. lever.
Feed, drain circuit (2) Safety lock lever and pilot circuit The operation is maintained until the opening of
less than 0.44 MPa (64 psi) (2) Principle :
(3) Pump positive flow control spool sleeve is closed.
Green The current command I to the pump’s solenoid
(4) Pump P-Q (Pressure-Quantity) curve control proportional valve controls the delivery rate of the
Return, make up circuit, 22.4.4 PUMP P-Q CURVE CONTROL
0.44~0.59 MPa (64~86 psi) pump. OPERATION
22.4.1 OPERATION OF BY-PASS CUT VALVE
Purple AND UNLOADING VALVE HOUSED IN (3) Operation : (1) Type :
Secondary pilot pressure, CONTROL VALVE 1) Flow rate rise operation (Eg. P1 pump) Electrical flow control type variable pump
(including proportional vlave) By operating any of control levers, the
(1) By-pass cut valve (2) Principle :
0.59~5 MPa (86~725 psi) operating secondary pressure of pilot valve
On starting engine, P1 and P2 unloading Perform an operation of the value from pump high
Red rises, and the rising pressure is transformed to
proportional valves (PSV-D, PSV-B) output pressure sensor to P-Q curve control value, and
Primary pilot pressure, the rise of output voltage corresponding to the
secondary pressure according to the command send a command to the pump solenoid proportional
(including proportional vlave) pressure input by the low pressure sensor.
output by mechatro controller, and this pressure valve.
5 MPa (725 psi) Mechatro controller signal-processes this
exerts on PBp1 and PBp2 ports, and consequently (3) Operation :
Orange change of voltage, resulting in rise of command
the by-pass cut spool is switched to CLOSE side. The pump high pressure sensor converts the
Main pump drive pressure, current value I to the pump proportional
The by-pass cut spool is usually held on CLOSE pressure to the output voltage corresponding to the
5~34.3 MPa (725~4970 psi) solenoid valve and consequently the pump flow
side after the engine started. And it is switched to pump delivery pressure.
Blue tone rate rises. This is called "Positive Control
OPEN side only when failure occurred on pump The mechatro controller converts the voltage output
At valve operation System".
proportional valve and mechatro controller. by the high pressure sensor to the P-Q curve
Red valve As the pump command current value rises, the
(2) Unloading valve control value. On the other hand, select the pump
When solenoid proportional valve (reducing) secondary pressure of proportional solenoid
On starting engine, like by-pass cut valve, the positive control command current value from the
is operating valve also rises. On the regulator attached on
secondary pressures output by P1 and P2 low pressure sensor in lower order, and the values
Red solenoid the pump, the spool (652) through piston (643)
unloading proportional valves (PSV-D, PSV-B) are output to respective pump proportional valve as
In active and exciting is pushed leftward, and stops at the position
exert on PCb and PCa ports, consequently the P1 a command current.
Displaying the flow circuit and standby circuit when where being in proportion to the force of pilot
and P2 unloading valves are switched to OPEN With this operation, the pump power is controlled so
operating. spring (646).
side. as not to be exceed the engine power, therefore
Regarding the electrical symbols in this manual, refer to The tank port connected to the large bore of
engine dose not stall.
the electric circuit diagram. 22.4.2 SAFETY LOCK LEVER AND PILOT servo piston (532) opens, and the piston
CIRCUIT moves leftward by delivery pressure P1 of the
(1) Purpose : small bore resulting in the increase of tilt angle
To protect attachment from unexpected movement ( ).
for safety. The servo piston and spool (652) are
connected to feedback lever (611). Therefore
(2) Principle :
when servo piston moves leftward, the spool
Cut pressure source of pilot valve for operation.
(652) also moves rightward by means of
(3) Operation : feedback lever. With this movement, the
If the safety lock lever (red) is pushed forward after opening of spool sleeve closes gradually, and
the engine starts, the limit switch (SW-11) is turned the servo piston stops at the position the
on. The timer relay is actuated one second later opening closed completely.
which causes the solenoid (SV-4) of the solenoid
2) Flow rate reduction operation
valve block (13) to be energized and makes the
As the current value I of mechtro controller
pilot operating circuit to stand by.
reduces, the secondary pressure of solenoid
proportional valve reduces, and spool (652) is
moved rightward by the force of pilot spring
(646). With the movement of spool, the delivery
pressure P1 usually flows into the large bore of
piston through the spool.
The delivery pressure P1 flows in the small
bore of servo piston, but the servo piston
moves rightward due to the difference of area,
22-8
SE22 SE23 P MB MB P
P P
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
651
652 M
1 29.0MPa
611 D MA MA D
PB PA
643
a3
532 8
646 a4
Dr
5.0MPa
M A B
a5
114kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPT.) 2
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PCb PAL
BL
12 CT2 CP2
BOOM
P P P P P P
T3
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
P T
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 16 Ao
Bo
3 6 4
P SE9
1 5 2
P SE10
PSV-C CUT CUT
A7 P1UNLOAD
(P3) (P4)
A8 ARM2
PSV-A 16
T2 P2 YN01Z00185P1 01
13
Fig. 22-1 NEUTRAL CIRCUIT : Positive control function at safety lock lever down (unlocked position)
22-9
22.5 TRAVEL CIRCUIT 22.5.2 2-SPEED TRAVEL SOLENOID COMMAND

CIRCUIT AND AUTO 1st SPEED RETURN
This section describes the following.
FUNCTION
(1) Travel forward pilot simultaneous operation circuit
(1) Purpose :
(2) 2 speed travel solenoid command circuit and auto
Change travel motor speed with switch.
1-speed return function
(2) Principle :
(3) Travel main circuit
If the switch is turned, an electric signal is issued. It
(4) Travel motor function excites the 2-speed travel solenoid which in turn
converts the primary pilot pressure and the self
22.5.1 TRAVEL FORWARD PILOT
pressure to a tilting angle of the variable
SIMULTANEOUS OPERATION CIRCUIT
displacement motor.
(1) Purpose :
(3) Operation :
Light operating force and shockless operation
If the rabbit marked switch on the gauge cluster is
(2) Mechatronics :
pressed, the solenoid (SV-3) of the proportional
1) If the travel lever with damping mechanism is valve block (13) is excited and changes the
operated for travel right, left and forward proportional valve. Then the solenoid command
motions, the secondary pilot proportional pressure is issued from port A3, enters the P port of
pressure comes out of the 3, 1 ports of P/V (10). the travel motor (4), opens the oil passage to the
The higher of the pressures is selected, comes 2nd speed select piston, and causes the motor to
out of the 6, 5 ports and acts upon the low run in the 2nd speed tilting mode by its self
pressure sensors (SE9) (SE-10). pressure. However, when the main circuit pressure
2) The pilot secondary pressure flows to PAr and rises above 28 MPa (4060 psi), the motor’s self
PAL ports of the control valve (2), moves the pressure pushes the 2nd speed select piston back
travel spool, and switches the main circuit. to the 1st speed.
3) The low pressure sensor output voltage is input
22.5.3 TRAVEL MAIN CIRCUIT
into mechatro controller. The mechatro
(1) Operation :
controller performs signal processing and
The delivery oil from Pump A1 and A2 ports by
outputs current corresponding to the increase
changing the travel spool with the operation of
of flow rate to P1 pump proportional valve
travel pilot flows in each VA port on the left side of
(PSV-P1) and P2 pump proportional valve
travel motor (4) through C,D ports of swivel joint (8)
(PSV-P2), and at the same time the command
from AL, AR ports of C/V, and rotates the travel
current is output to P1 unloading valve (PSV-D)
motor.
and P2 unloading valve (PSV-B).
4) The secondary pressures output by P1 pump 22.5.4 TRAVEL MOTOR FUNCTION
proportional valve (PSV-P1) and P2 pump (1) Function :
proportional valve (PSV-P2) exert on pump
1) Prevents the motor from over running on a
regulator, actuating the pump on the delivery
slope.
flow rate increase side.
2) Check valve that prevents cavitation of the
5) The secondary pressure delivered in P1
hydraulic motor.
unloading valve (PSV-D) and P2 unloading
3) Shockless relief valve and anti cavitation valve
valve (PSV-B) is fed to PBp1, Pcb, PBp2 and
when inertia force stops.
PCa ports provided in control valve (2).
The secondary pressure from proportional 4) High/Low 2 step speed change mechanism and
valve which has exerted on PBp1 and PBp2 auto 1st speed return at high load.
ports holds the by-pass cut spool on CLOSE 5) Travel parking brake.
side, like the operation in the lever neutral
position.
The secondary pressure from proportional
valve which has exerted on PCb and PCa ports
switches the unloading spool in CLOSE side.
22-10
SE22 SE23 P MB MB P
P P
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
a3
8
a4
Dr
5.0MPa
M A B
a5
114kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPT.) 2
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PCb PAL
BL
12 CT2 CP2
BOOM
P P P P P P
T3
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
P T
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 16 Ao
Bo
3 6 4
P SE9
1 5 2
P SE10
PSV-C CUT CUT
A7 P1UNLOAD
(P3) (P4)
A8 ARM2
PSV-A 16
T2 P2 YN01Z00185P1 01
13
Fig. 22-2 TRAVEL CIRCUIT : Travel 2nd speed, RH & LH simultaneous operation.
22-11
22.6 BUCKET CIRCUIT 5) The secondary pressure delivered in travel 3) With the function of pilot circuit, the oil flow is
straight proportional valve (PSV-C) is led to switched from bucket spool, and is fed into
This section describes the following.
PTb port provided in control valve (2) and shifts bucket cylinder head side through AC port of C/
(1) Bucket digging pilot circuit
the travel straight valve one stage. V (2). On the other hand, the return oil from
(2) Auto accel operation cylinder rod (R) side is throttled by bucket spool
22.6.2 AUTO ACCELERATION OPERATION
(3) Flow control in the work mode and returns to tank circuit from BC port of C/V
(1) Principle : (2).
(4) Bucket digging travel straight main circuit
Auto acceleration actuates according to signals
(5) Bucket spool stroke limiter References :
from low pressure sensor.
• In bucket dumping operation, the travel straight
22.6.1 PILOT CIRCUIT FOR BUCKET DIGGING (2) Operation :
valve also switches like digging operation,
(1) Mechatronics : <When lever is set to neutral position>
resulting in confluence with travel straight.
In the event where the sensor does not receive
1) When the operation for bucket digging is • When the bucket operation and other operation
signal for 4 seconds or more even though the
performed, the pilot proportional secondary are simultaneously performed, the travel straight
acceleration dial is set to MAX position, the engine
pressure is delivered through port 1 of the right valve does not actuate, resulting in single flow of
speed should be raised to 1000rpm.
pilot V (9), flows to PAc port, and acts on the low bucket circuit.
<When lever is operated>
pressure sensor (SE-1), and at the same time
When the pressure 0.6MPa (87psi) is input to low 22.6.5 BUCKET SPOOL STROKE LIMITER
the bucket spool is switched.
pressure sensor in STD specification (travel,
2) The voltage output by low pressure sensor (1) Purpose :
bucket, swing, arm), proportional voltage from low
inputs in mechatro controller. The mechatro To secure simultaneous operability of boom and
pressure sensor inputs in mechatro controller, and
controller performs signal processing and arm on boosting up attachment pressure (Pump
then the engine speed returns to the dial set
outputs current corresponding to the increase flow rate decreases.) and to prevent cavitations at
position corresponding to the lever operation.
of pump flow rate to pump proportional valves low engine speed
(PSV-P1) and (PSV-P2) on the P1 and P2 22.6.3 STAND-BY CURRENT CONSTANT (2) Operation :
pump sides, and at the same time the CONTROL On boosting up attachment pressure, pilot primary
command current is output to P1 unloading (1) Principle : pressure exerts on PCc port of C/V(2) through
valve (PSV-D), P2 unloading valve (PSV-B) and When the engine speed is intermediate speed or attachment booster solenoid valve, operates stroke
travel straight proportional valve (PSV-C). lower, command current value to have the pump limiter of bucket spool, and throttle oil path of spool.
In the following pages, the relation of operation delivery rate constant is output. As a result, P1 pump pressure increases, making
of low pressure sensor to both the increase of the simultaneous operation of boom up and bucket
(2) Operation :
pump flow rate and unloading proportional digging possible.
Even if the engine speed specified by acceleration
valve is the same. Therefore the explanation is Even though the engine speed is low, similarly the
potentiometer is low speed, as the delivery rate
omitted. cavitations can be prevented by actuating the
corresponds to the intermediate speed, the
3) The secondary pressure output by P1 pump stroke limiter.
actuator moves earlier than the movement
proportional valve (PSV-P1) and P2 pump equivalent to the control lever angle rate in light
proportional valve (PSV-P2) exerts on pump load operation.
regulator, actuating the pump onto the delivery
flow increase side. 22.6.4 BUCKET DIGGING AND TRAVEL
STRAIGHT CONFLUENCE (CONFLUX)
4) The secondary pressure delivered in P1
MAIN CIRCUIT
unloading valve (PSV-D) and P2 unloading
valve (PSV-B) is led to PBp1, PCb, PBp2 and (1) Operation :
PCa ports provided in control valve (2). 1) The oil delivered through A1 port of P1 pump
The secondary pressure from proportional goes into P1 port of C/V (2), opens load check
valve which has exerted on PBp1 and PBp2 valve LCc through parallel circuit and enters in
ports holds the by-pass cut spool on CLOSE bucket spool.
side, like the operation in the lever neutral 2) On the other hand, the oil delivered through P2
position. port of P2 pump goes into P2 port of C/V (2),
The secondary pressure from proportional confluences with oil from P1 pump through
valve which has exerted on PCb and PCa ports travel straight valve, and goes into bucket
switches the unloading spool in CLOSE side. spool. (Confluence of oil from 2 pumps)
22-12
SE22 SE23 P MB MB P
P P
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
a3
8
a4
Dr
5.0MPa
M A B
a5
114kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPT.) 2
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PCb PAL
BL
12 CT2 CP2
BOOM
P P P P P P
T3
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
P T
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 16 Ao
Bo
3 6 4
P SE9
1 5 2
P SE10
PSV-C CUT CUT
A7 P1UNLOAD
(P3) (P4)
A8 ARM2
PSV-A 16
T2 P2 YN01Z00185P1 01
13
Fig. 22-3 BUCKET CIRCUIT : Bucket digging (Travel straight conflux), Auto-accelation and Standby flow rate constant control
22-13
22.7 BOOM CIRCUIT

This section describes the boom raise conflux
operation.
(1) Boom up pilot circuit
(2) Boom up 2 pumps conflux main circuit in C/V
22.7.1 BOOM RAISE PILOT CIRCUIT

(1) Operation :
1) If boom up operation is performed, the
secondary pilot proportional pressure from the
right pilot valve (10) gets out of port 3 and acts
upon the low pressure sensor (SE3). At the
same time, the pressure acts upon the PAb and
PB1 ports.
2) The secondary pressure which enters the PAb
port of C/V (2) shifts the boom spool. The
secondary pressure which enters the PB1 port
shifts the boom conflux spool.
22.7.2 BOOM UP 2 PUMPS CONFLUX MAIN

CIRCUIT IN C/V
(1) Purpose :
Boom up speed up
(2) Principle :
Confluxing oil from 2 pumps
(3) Operation :
1) The oil delivered through A1 port of P1 pump
flows into C/V (2) P1 port, and branches into
bypass circuit and parallel circuit. Since P1
unloading valve is closed, the boom spool is
moved and bypass circuit is closed, the oil
opens load check valve LCb through parallel
circuit and flows into boom spool.
2) Then the oil passes through boom spool, opens
lock valve of boom lock valve CRb, and is led
into H side of boom cylinder through C/V (2) Ab
port.
3) Meanwhile, the oil delivered from the A2 port of
the P2 pump enters the P2 port of C/V (2) and
due to shut off the P2 unloading valve, the oil
then passes through the parallel circuit and via
the restrictor on the circumference of the boom
conflux spool, pushes the load check valve
CCb open from the boom conflux circuit, and
combines the oil delivered by the P1 pump
internally.
4) The return oil from boom cylinder R side flows
into tank circuit through boom spool from C/V
(2) Bb port.
22-14
SE22 SE23 P MB MB P
P P
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
a3
8
a4
Dr
5.0MPa
M A B
a5
114kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPT.) 2
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PCb PAL
BL
12 CT2 CP2
BOOM
P P P P P P
T3
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
P T
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 16 Ao
Bo
3 6 4
P SE9
1 5 2
P SE10
PSV-C CUT CUT
A7 P1UNLOAD
(P3) (P4)
A8 ARM2
PSV-A 16
T2 P2 YN01Z00185P1 01
13
Fig. 22-4 BOOM CIRCUIT : Boom up operation, Confluence function.
22-15
This section describes boom lower operation. 22.7.5 CONSTANT RECIRCULATION FUNCTION
(1) Boom down pilot circuit OF BOOM DOWN MAIN CIRCUIT
(2) Prevention of natural fall by lock valve and (1) Purpose :
actuation at lowering Prevention of cavitation during boom
lowering motion.
(3) Constant recirculation function of boom down main
circuit (2) Principle :
The oil returning from the boom cylinder head (H) is
22.7.3 BOOM DOWN PILOT CIRCUIT recirculated to the rod (R).
(1) Operation : (3) Operation :
1) If the boom down operation is performed, the When the oil is supplied to the boom cylinder rod
secondary pilot proportional pressure comes (R) side during boom down operation, the boom
out of portáC of the right pilot valve (9) and acts moves faster than it should do in some cases by the
upon the low pressure sensor (SE-4). self weight of the attachment.
At the same time, the pressure acts upon the On that occasion, the circuit pressure on the rod (R)
PBb port of C/V (2). side is on the negative side.
2) The voltage output of the low pressure sensor The oil supplied to the boom cylinder rod (R) flows
(SE-4) enters the mechatro controller and into the A1 port of the P1 pump and the P1 port of
processed in it. C/V. The oil then passes through the boom spool
and goes out of the Bb port.
3) Then, the proportionl secondary pressure fed
On that occasion, the oil returning from the head
into C/V (2) PBb port and branches off in two
(H) goes through the recirculation path in the boom
lines and switches boom spool and releases
spool, pushes the check valve in the spool open, is
boom lock valve.
recirculated to the Bb port and is supplied to the rod
22.7.4 PREVENTION OF NATURAL FALL BY (R). When the (R) pressure is larger than the head
LOCK VALVE AND ACTUATION AT (H) pressure, the check valve in spool closes.
LOWERING Thereupon, the recirculation is stopped.
(1) Purpose :
Prevention of natural fall when the lever is neutral
(2) Principle :
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
(3) Operation :
In the boom down action, the selector valve is
changed over by the secondary proportional
pressure of PBb port. Then the poppet spring
chamber of the lock valve CRb gets through the
drain line (Dr) and makes the lock valve poppet
open.
When the boom lever is at neutral, the drain line on
the lock valve CRb poppet spring chamber is
closed which causes the poppet closed.
The result is that the oil returning from the boom
cylinder head (H) to the boom spool is held and
makes the leak from the boom spool zero.
Thus the boom cylinder is prevented from making a
natural fall.
22-16
SE22 SE23 P MB MB P
P P
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
a3
8
a4
Dr
5.0MPa
M A B
a5
114kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPT.) 2
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PCb PAL
BL
12 CT2 CP2
BOOM
P P P P P P
T3
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
P T
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 16 Ao
Bo
3 6 4
P SE9
1 5 2
P SE10
PSV-C CUT CUT
A7 P1UNLOAD
(P3) (P4)
A8 ARM2
PSV-A 16
T2 P2 YN01Z00185P1 01
13
Fig. 22-5 BOOM CIRCUIT : Boom down operation & Prevention of natural boom falling.
22-17
22.8 SWING CIRCUIT 22.8.2 SWING AUTO PARKING BRAKE

This section describes the following operations. (1) Purpose :
Swing lock in neutral position and parking
(1) Swing left pilot circuit
(2) Principle :
(2) Swing auto parking brake
Release mechanical brake only when required to
(3) Swing main circuit
operate swing and arm in.
(4) Swing motor circuit
(3) Operation :
22.8.1 PILOT CIRCUIT FOR LEFT SWING 1) The swing parking system excites the swing
(1) Operation : parking SOL (SV-1) usually if the key switch is
turned on and works by the action of the
1) When the left swing operation is performed, the
mechanical brake.
pilot proportional secondary pressure is
delivered through port (5) of left pilot V (9), and 2) The mechanical brake is released if the swing
the secondary pressure acts on PBs port of C/ parking solenoid is de-excited only when the
V (2), and simultaneously flows out from Pss secondary operating pressure in the swing and
port of C/V and acts on low pressure sensor arm in actions acts upon any of the low
(SE-5). pressure sensors (SE-5, 7).
2) The voltage output by the low pressure sensor 3) The swing parking solenoid (SV-1) is excited
is input in the mechatro controller, and is signal- five seconds after the pressure of the swing low
processed. pressure sensors (SE-5) is reduced to zero.
In the case of arm in operation, the swing
3) Then, the secondary pressure led into PBs port
parking solenoid (SV-1) is excited the moment
of C/V (2) switches the swing spool.
the pressure of the arm in low pressure sensor
(SE-7) is reduced to zero. This causes the
mechanical brake to operate.
22.8.3 SWING MAIN CIRCUIT

(1) Operation :
The oil delivered from the A2 port of the P2 pump
enters the P2 port of C/V (2) and is branched off into
the bypass line and the parallel circuit. However,
since the bypass line is closed as the swing spool
is shifted, the oil pushes the load check valve LCs
open through the parallel circuit, enters the B port
of the swing motor via the Bs port of C/V (2), and
rotates the swing motor counterclockwise.
22.8.4 SWING MOTOR CIRCUIT

(1) Anti cavitation circuit at swing deceleration
(2) Shockless relief valve that prevents the swing
motor from being reversed.
22-18
SE22 SE23 P MB MB P
P P
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
a3
8
a4
Dr
5.0MPa
M A B
a5
114kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPT.) 2
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PCb PAL
BL
12 CT2 CP2
BOOM
P P P P P P
T3
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
P T
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 16 Ao
Bo
3 6 4
P SE9
1 5 2
P SE10
PSV-C CUT CUT
A7 P1UNLOAD
(P3) (P4)
A8 ARM2
PSV-A 16
T2 P2 YN01Z00185P1 01
13
Fig. 22-6 SWING CIRCUIT : Swing operation (LH)
22-19
22.9 ARM CIRCUIT with P2 pump delivery oil in the valve section,
and then is flowed into arm cylinder head (H)
This section describes the following operations.
side through Aa port of C/V (2).
(1) Arm in, light-load operating pilot circuit
3) The return oil from arm cylinder (R) side flows
(2) Arm in, light-load variable normal recirculation main
in Ba port of C/V (2) and passes through the Ba
circuit / internal conflux main circuit
port because the arm lock valve CRar is open,
22.9.1 ARM IN, LIGHT-LOAD OPERATING PILOT and is flowed into arm 2 spool through arm 1
CIRCUIT spool.
(1) Purpose : 4) Because arm 2 spool is switched to normal

Speed-up and Anticavitation when the arm is at recirculation position, causing restriction of
light loaded. passage to tank, the return oil from arm cylinder
(R) side flows into arm cylinder (H) side.
(2) Principle :
The oil returning from the arm cylinder rod (R) is • Because, at light load, the pressure in
recirculated variably to the head (H) at arm 2 spool cylinder rod (R) side is higher than that in
in C/V. the head (H) side, it opens the check valve
housed-in arm 2 spool and is recirculated in
(3) Operation :
the head (H) side, resulting in the speed up
1) When the arm in operation is performed, the
of arm-in operation at light load.
secondary pilot proportional pressure gets out
5) Cavitations prevention control in arm-in
of port 7 of the left pilot valve (9) and acts upon
operation
the low pressure sensor (SE-7).
Command current is output to arm 2 solenoid
At the same time, the pressure is branched off
proportional valve by signal processing of E/G
in two flows, acts upon the Paa1 port and the
speed and arm-in pilot pressure, accordingly
PLc2 port, changes over the arm spool and the
the arm 2 spool is switched to neutral
arm lock valve CRar. releases.
(cavitations prevention) position, resulting in
2) The output voltage by the low pressure sensor
cavitations prevention.
is input into mechatro controller, and is pilot
signal-processed, and is output to P1, P2 pump
Position of arm 2 spool
proportional valve (PSV-P1), (PSV-P2) and arm
2 inverse proportional valve (PSV-A). Neutral position
(Anticavitation position)
3) The secondary pressure from pilot proportional Normal recirculation position
valve, which is reduced by arm 2 inverse Recirculation
proportional valve (PSV-A) switches arm 2
spool.
From arm out
22.9.2 ARM-IN, LIGHT-LOAD VARIABLE
P/V
From arm 2 inverse
NORMAL RECIRCULATION, INTERNAL proportional valve
CONFLUX MAIN CIRCUIT
Reference :
(1) Operation : In light-load arm-in operation (normal recirculation,
1) The P2 pump delivery oil flows in travel left conflux), when the attachment to which the circuit in
section through P2 port of C/V (2) and is P1 pump side is applied is operated, the meter-in
branched off in by-pass circuit and parallel path of arm 2 spool is closed, resulting in single flow
circuit, but because arm 1 spool is switched, the operation.
delivery oil which goes through parallel circuit
opens load check valve LCa and is flowed into

arm 1 spool.

2) On the other hand, P1 pump delivery oil flows in

P1 port of C/V (2), and the flows in travel

straight section and travel right tandem path.
Then because arm 2 spool was switched, the
delivery oil opens load check valve LCAT2,

goes through arm 2 spool, and confluences
22-20
SE22 SE23 P MB MB P
P P
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
a3
8
a4
Dr
5.0MPa
M A B
a5
114kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPT.) 2
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PCb PAL
BL
12 CT2 CP2
BOOM
P P P P P P
T3
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
P T
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 16 Ao
Bo
3 6 4
P SE9
1 5 2
P SE10
PSV-C CUT CUT
A7 P1UNLOAD
(P3) (P4)
A8 ARM2
PSV-A 16
T2 P2 YN01Z00185P1 01
13
Fig. 22-7 ARM CIRCUIT : Arm in (Light load) operation, Arm variable recirculation & Anti cavitation function
22-21
This section describes the following operations. 4) The return oil returns directly into tank circuit
(3) Arm in, heavy load operating pilot circuit because arm 2 spool is switched to
(recirculation cut) recirculation cut position.
(4) Arm in, heavy load operating sequence confluxed
main circuit
Neutral position Recirculation cut position
22.9.3 ARM IN, HEAVY LOAD OPERATING
PILOT CIRCUIT
From arm out
(1) Operation :
P/V
1) In arm-in operation, when the heavy loading is
From arm 2 inverse
applied to arm and the P2 pump pressure proportional valve
increases to the set pressure, the voltage
output by P2 pump pressure sensor (SE-23) is
converted to signal (signal processing) by
mechatro controller, consequently the current
of arm 2 solenoid proportional valve is
controlled according to the load pressure and
the arm variable recirculation is cut.
When the recirculation is cut, internal
confluence is held similarly to that in light load
operation.
2) Left pilot valve actuation due to arm-in
operation is equivalent to that at light load
operation.
22.9.4 ARM IN, HEAVY LOAD OPERATING

RECIRCULATION CUT MAIN CIRCUIT
(1) Purpose :
Speed up for arm in operation
(2) Principle :
Cut the recirculation and reduce rod pressure.
(3) Operation :
1) P2 pump delivery oil flows in the travel left
section through P2 port of C/V (2) and
branched off in by-pass circuit and parallel
circuit. Consequently the arm spool is switched
and pushes and opens load check valve LCa
through parallel circuit, and flows in the arm
spool.
2) On the other hand, P1 pump delivery oil flows in
P1 port of C/V (2), and flow in travel right
tandem passage through travel straight section.
Then because arm 2 spool was switched, the
delivery oil opens load check valve LCAT2, and
confluences with P2 pump delivery oil in the
valve section, and is flowed into arm cylinder
head (H) side through Aa port of C/V(2).
3) The return oil from arm cylinder (R) side flows
in Ba port of C/V(2) and is flowed to arm lock
valve CRar, but because the arm lock valve
CRar is open, the return oil goes through arm
lock valve CRar and flows in arm 2 spool.
22-22
SE22 SE23 P MB MB P
P P
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
a3
8
a4
Dr
5.0MPa
M A B
a5
114kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPT.) 2
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PCb PAL
BL
12 CT2 CP2
BOOM
P P P P P P
T3
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
P T
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 16 Ao
Bo
3 6 4
P SE9
1 5 2
P SE10
PSV-C CUT CUT
A7 P1UNLOAD
(P3) (P4)
A8 ARM2
PSV-A 16
T2 P2 YN01Z00185P1 01
13
Fig. 22-8 ARM CIRCUIT : Arm in (Heavy load) operation, Arm confluence & recirculation cut function
22-23
This section describes the following operations. 22.9.7 NATURAL FALL PROTECTION WITH ARM
(5) Arm out pilot circuit LOCK VALVE
(6) Arm out 2 pumps conflux main circuit (1) Purpose :
To prevent the arm from falling naturally by the
(7) Natural fall protection with arm lock valve
weight of the arm and bucket.
22.9.5 ARM OUT PILOT CIRCUIT (2) Principle :
(1) Operation : Complete seat of the return circuit against the arm
1) When the arm out operation is performed, the spool of the arm cylinder (R) side circuit.
secondary pilot proportional pressure gets out (3) Operation :
of port 8 of the left pilot valve (9), and acts upon 1) When the secondary pressure for arm
the low pressure sensor (SE-8). At the same operation disappears and the arm cylinder
time, the oil is branched off in two flows and act stops, the pressure on the rod (R) side passes
upon the PBa1 and Pba2 ports of C/V (2). through the selector of the lock valve from the
2) The operating proportional secondary pressure Ba port of C/V, acts the back pressure on the
flowed in Pba1 port of C/V (2) switches the arm lock valve CRar and seats the lock valve.
1 spool. 2) Since the oil flow into the arm spool from the
3) Then, the operating secondary pressure flowed lock valve is shut off completely, natural fall of
in PBa2 port of C/V (2) switches the arm 2 spool the arm due to oil leaks through the arm spool
valve. is prevented.
22.9.6 ARM OUT 2 PUMPS CONFLUX MAIN

CIRCUIT
(1) Purpose :
Arm out operation speed up.
(2) Principle :
The oil delivered by the P1 pump is confluxed with
that delivered by the P2 pump in C/V (2).
(3) Operation :
1) P1 pump delivery oil opens load check valve
(LCAT2) by switching arm 2 spool and
confluxes with P2 pump delivery oil just short of
the arm lock valve.
2) And, P2 pump delivery oil flows through arm 1
spool and confluences with P1 delivery oil,
opens lock valve of arm lock valve CRar with
free flow and is flowed into arm cylinder rod (R)
side through Ba port of C/V(2).
3) On the other hand, the return oil from arm
cylinder (H) side flows in Aa port, and returns
into tank circuit through arm 1 spool and arm 2
spool.
The return line which does not pass through
boost check valve is used for this return circuit
to reduce the pressure loss.
22-24
SE22 SE23 P MB MB P
P P
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
a3
8
a4
Dr
5.0MPa
M A B
a5
114kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPT.) 2
34.3MPa
37.8MPa SWING LEFT
BOOST
15 14 PL
CMR1
CHECK ARM OUT
ARM IN
PCb PAL
BL
12 CT2 CP2
BOOM
P P P P P P
T3
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
P T
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 16 Ao
Bo
3 6 4
P SE9
1 5 2
P SE10
PSV-C CUT CUT
A7 P1UNLOAD
(P3) (P4)
A8 ARM2
PSV-A 16
T2 P2 YN01Z00185P1 01
13
Fig. 22-9 ARM CIRCUIT : Arm out operation, Confluence function
22-25
22.10 COMBINED CIRCUIT 22.10.2 BOOM UP / TRAVEL, MAIN CIRCUIT

This section describes only the difference in combined (1) Purpose :
operation. To insure straight travel movement during travel
operation even if the attachment is operated.
(1) Boom up / travel, pilot circuit
(2) Principle :
(2) Boom up / travel, main circit
The travel action and the attachment action are
22.10.1 BOOM UP / TRAVEL, PILOT CIRCUIT actuated by separate pumps.
(1) Operation : (3) Operation :
<Operation: Different point of pilot circuit from 1) P1 pump delivery oil flows through P1 port of C/
independent operation > V(2) and branches off in P1 parallel circuit and
1) The mechatro controller outputs command travel straight spool.
current to travel straight solenoid proportional P2 pump delivery oil flows through P2 port of C/
valve after signal processing, and the solenoid V(2) and branches off in P2 tandem circuit and
valve outputs secondary pressure and acts on travel straight spool.
PTb port of C/V (2). 2) The delivery oil flowed into P1 parallel circuit of
2) Then the pressure of PTb port switches the P1 pump opens check valve CT1 and LCb and
travel straight valve one step. flows in boom spool, which exerts on boom up
operation.
The delivery oil flowed into travel straight spool
of P1 pump opens check valve CT2 because
the travel straight spool is shifted, and flows in
boom conflux spool and exerts on boom up
operation with the internal oil conflux.
(In travel straight operation, P1 pump delivery
oil exerts on swing operation of attachment.)
3) The delivery oil flowed into P2 tandem circuit of
P2 pump flows in left travel spool to travel
leftward.
The delivery oil flowed into travel straight spool
of P2 pump flows in right travel spool because
the travel straight spool is shifted and exerts on
the right travel operation.
(In travel straight operation, P2 pump delivery
oil exerts on travel operation.)
4) However, a portion of the flow is led to the travel
straight spool notch restriction. The speed of
attachments like travel, boom, etc. is adjusted
by the circuit of restriction.
22-26
SE22 SE23 P MB MB P
P P
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
a3
8
a4
Dr
5.0MPa
M A B
a5
114kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPT.) 2
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PCb PAL
BL
12 CT2 CP2
BOOM
P P P P P P
T3
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
P T
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 16 Ao
Bo
3 6 4
P SE9
1 5 2
P SE10
PSV-C CUT CUT
A7 P1UNLOAD
(P3) (P4)
A8 ARM2
PSV-A 16
T2 P2 YN01Z00185P1 01
13
Fig. 22-10 COMBINED CIRCUIT : Boom up & Travel forward 1st speed operation, Travel straight function.
22-27
In this section, the independent operation is omitted 22.10.4 SWING / ARM IN, SWING PRIORITY MAIN
and describes difference in combined operation. CIRCUIT
(3) Swing / Arm in light load, pilot circuit (1) Purpose :
(4) Swing / Arm in, swing priority main circuit Stable swing speed.
(2) Principle :
22.10.3 SWING / ARM IN LIGHT LOAD, PILOT
Raise the oil pressure flowing to arm cylinder, and
CIRCUIT
give a priority of the delivery of P2 pump to swing
(1) Operation : operation.
1) On operating swing (left) and arm in motions (3) Operation :
simultaneously, mechatro controller outputs
1) The swing main circuit operates with P2 pump
command current to travel straight solenoid
flow. But on P2 pump circuit side, the flow goes
proportional valve (PSV-C) and arm 2 solenoid
to the swing circuit and arm circuit
inverse proportional valve according to signal
simultaneously because the swing circuit and
processing, and this proportional valve outputs
arm circuit are parallel. Then since the return oil
secondary pressure, which acts on PTb port
from arm cylinder rod (R) side is restricted in
and PAa2 port of C/V(2).
the arm 2 spool because the arm 2 spool is
2) PTb port pressure switches the travel straight switched to forced recirculation position, the
spool 2 steps, and the PAa2 port pressure pressure of return oil is raised, causing the rise
switches the arm 2 spool to the forced of circuit pressure on the arm cylinder head (H)
recirculation position. side.
2) At the same time meter-in of arm 2 spool closes
and arm in conflux is therefore cancelled, and
delivery oil from P2 pump and P1 pump are
combined in the parallel circuit on P2 pump side
because the travel straight spool was switched.
The conflux oil of P1 and P2 delivery oil in high
pressure flows in swing side taking priority over
all others.
This operation is called "Swing Priority Circuit".
Position of forced recirculation
Neutral position Meter-in passage

(Close)
From From arm 2

arm out inverse
P/V proportional valve
Normal recirculation opsition
Arm 2 spool
22-28
SE22 SE23 P MB MB P
P P
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
a3
8
a4
Dr
5.0MPa
M A B
a5
114kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPT.) 2
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PCb PAL
BL
12 CT2 CP2
BOOM
P P P P P P
T3
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
P T
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
LCAP2
SV-2 PBa2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 16 Ao
Bo
3 6 4
P SE9
1 5 2
P SE10
PSV-C CUT CUT
A7 P1UNLOAD
(P3) (P4)
A8 ARM2
PSV-A 16
T2 P2 YN01Z00185P1 01
13
Fig. 22-11 COMBINED CIRCUIT : Swing / Arm in operation, swing priority function
22-29
22.11 PRESSURE DRAINING (3) Operation :

(RELEASING) CIRCUIT 1) Pump proportional valve reduces the pump flow
rate to the minimum.
This section describes the following operations.
2) Unloading proportional valves (PSV-D, PSV-B)
(1) Pressure drain (releasing) pilot circuit
output secondary pressure and the secondary
(2) Pressure drain (releasing) main circuit
pressure flows in PCb, PCa ports of C/V(2) and
22.11.1 PRESSURE RELIEVING PILOT CIRCUIT switches the P1, P2 unloading valves to OPEN
position.
(1) Purpose :
To release the pressure in main circuit for piping 22.11.2 PRESSURE RELEASE MAIN CIRCUIT
repair works.
(1) Operation :
(2) Principle :
After the mode is switched to "Pressure Relief
Mode" with switch on gauge cluster, mechatro
controller outputs the following commands. When the hydraulic pressure releasing is
1) Minimum tilting command value to pump performed, make sure to place bucket on the
proportional valve (PSV-P1, PSV-P2). ground.
2) Output "Pressure relief control speed command When the operating lever is shifted to neutral during
value" at ECU. (Electric system) engine running, "DRAINING HYD. PRESS." is
3) Stand-by command value to P1, P2 unloading displayed on the gauge cluster while the mode
proportional valves switch is changed to pressure relieving mode. In
this time the intermittent buzzer sounds
How to switch to "Pressure release mode"
continuously. When right and left operating levers
1) Select the service diagnosis mode. are operated 4 or 5 times to their full stroke,
(Keeping pressing of the "BUZZER STOP pressure is relieved.
SWITCH" [ ] on gauge cluster, turn the starter After draining pressure is completed, turn off the
key on.) starter key and buzzer sound stops. If the pump
2) Select the service adjustment mode 1. pressure is determined to be more than 1 MPa (145
(Under the condition that "Screen No.1" of psi) by the output value of the high pressure sensor
"Service diagnosis mode 1" is indicated, or the high pressure sensors (SE-22,23) are
keeping pressing of the "BUZZER STOP broken, "FAIL DRAIN HYD. PRESS" is displayed
SWITCH", press the selector switch [ ] 3 and the buzzer sounds continuously. In that case,
times. When "LANGUAGE/LOGO", also the buzzer is not stopped unless the engine
"ADJUSTING MODE 1" and "PRESET BY key is turned to OFF. Repeat the pressure releasing
FACTORY" are displayed, press [ ] or [ ] procedure once again.
switch, and highlight "ADJUSTING MODE 1", (2) Hydraulics :
and then press "Selector Switch" again.) If the travel straight valve is turned to the pressure
3) When "ADJUSTING MODE 1" screen is release position, the oil delivered by each pump is
displayed, press [ ] or [ ] switch, and "DRAIN unloaded to the tank passage. If the spools are
HYD. OFF" screen appears. switched by pilot operation, the remaining pressure
from the actuators may be relieved to the tank
4) Press "Selector Switch" and highlight "OFF",
circuit, i.e. the main circuit pressure may be
and press [ ] switch to change to "DRAIN
released.
HYD. ON", and then press "Selector Switch"
again.
22-30
SE22 SE23 P MB MB P
P P
PH1 PH2
PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING
PG
VA VA DB
REG REG
1 29.0MPa
D MA MA D
PB PA
a3
8
a4
Dr
5.0MPa
M A B
a5
114kw B1
/2000min-1 B3 Dr3 A3
PTO
(OPT.) 2
34.3MPa
37.8MPa SWING LEFT
15 14 PL
CMR1
ARM OUT
ARM IN
PCb PAL
BL
12 CT2 CP2
BOOM
P P P P P P
T3
PAr CT1 PB1
BR CP1
AR PCa
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs
As
(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
P T
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 16 Ao
Bo
3 6 4
P SE9
1 5 2
P SE10
PSV-C CUT CUT
A7 P1UNLOAD
(P3) (P4)
A8 ARM2
PSV-A 16
T2 P2 YN01Z00185P1 01
13
Fig. 22-12 PRESSURE DRAIN (RELEASE) CIRCUIT : At pressure release mode.
22-31
[MEMO]
22-32
23. ELECTRIC SYSTEM
TABLE OF CONTENTS
Paste here
23
Book Code No. S5XX230XJ0X
23-1
23. ELECTRIC SYSTEM

E215B : YN11-45001~ S5YN2322E01
23-2
23. ELECTRIC SYSTEM
23.1 ELECTRIC CIRCUIT DIAGRAM (HS ENGINE)
DC-DC CONVERTER,
ROOM LIGHT TUNER
CIGARETTE LIGHTER
HORN, HORN RELAY
FUEL SUPPLY PUMP

ENG. CONTROLLER
ENG. CONTROLLER
RELAY, HOUR METER
KEY SW. STARTER RELAY

ACTUATOR POWER
APPLICABLE YN11-45001-
GAUGE CLUSTER
IT CONTROLLER
MACHINE No. YQ11-06001-
AUTO GREASE
CONTROLLER
CONTROLLER
CONTROLLER
LEVER LOCK
LC10-07001-
BATTERY RELAY
MECHATRO
MECHATRO
C-8 : ENGINE CONTROLLER ENG. HARNESS
YC10-03501-
BACK UP
BACK UP
SUPPLY
TUNER
LQ12-06001-
LL12-05001- ENG. SPEED SENSOR
FOR ECU
SH7 SHIELD
E-1 : FUSE & RELAY BOX
R-26 :
LEVER LOCK RELAY
SOLENOID,
HIGH REACH,
LMN/BH
AIR CON.
AIR CON.
RADIATOR COOLANT
LEVEL CONTROLLER,
FLASHER, REAR WORK
LIGHT, TRAVEL ALARM,
ONE WAY CALL
DC-DC CONVERTER
WORK LIGHT
GAUGE CLUSTER
WIPER, WASHER
CAB WORK LIGHT
CAB WORK LIGHT
ROOF WIPER
OPT. BUCKET CONTROL

OPT. 4
OPT. 1
OPT. 3
OPT. HAND CONTROL
AIR CON. (AMP.)
ENGINE CONTROLLER INJECTOR 1

CHECK CONNECTOR
SH1 SHIELD
INJECTOR 2
E-12 : E-12 :
BATTERY BATTERY SH2 SHIELD
STARTER CABLE
INJECTOR 3
SH3 SHIELD
E27 :
R-1 : ACCEL REDUNDANT
E-15 : BATTERY RELAY VOLUME INJECTOR 4
FUSIBLE LINK
SH4 SHIELD
R-23 :
AUTO IDLE STOP RELAY 1 R-24 : R-25 : INJECTOR 5
AUTO IDLE ENG. EMERGENCY
STOP RELAY 2 STOP RELAY SH5 SHIELD
KEY ON
POSITION
INJECTOR 6
PREHEATING
SH6 SHIELD
START
TERMINAL
ENGINE START
ACC
OFF
ON
IN THE CASE OF
R-3 : SK330-8, E385
GLOW RELAY GLOW
CYLINDER
DISCRIMINATION
G SENSOR
SW-1 : BOOST SENSOR

KEY SW.
E-2 :
ALTERNATOR
M-1 : C-1 :
STARTER MOTOR MECHATRO CONTROLLER COMMON RAIL
(TCO-60-2) PRESS. SENSOR
R-4 :
SAFETY RELAY
SUCTION
CONTROL VALVE
(FUEL PUMP (SCV))
C-6 :
AUTO GREASE CONTROLLER
R-2 : E-3 : HOUR METER
STARTER RELAY SHIELD FUEL PUMP SENSOR
CHARGE
KEY ON
PREHEATING
WATER TEMP SENSOR
C-5 :
CONTROL : (SENSOR POWER RADIATOR COOLANT SW-27 :
SOURCE, CPU) LEVEL CONTROLLER RADIATOR COOLANT LEVEL SW.
OUT SOURCE :
(PSV, SOL. MOTOR)
R-28 : ALTERNATOR RELAY
CONTROL : (SENSOR POWER

SOURCE, CPU)
WATCH IC TO 2/4
SW-28 :
(1/4)
WATER SEPARATOR SW.
LC03Z00036P1 03
23-3
23. ELECTRIC SYSTEM
C-1 : MECHATRO CONTROLLER (TCO-60-2)

FROM 1/4
SE-16 : ACCEL POTENTIO

PRESS. SENSOR
SE-1 : BUCKET DIGGING
C-8 : ENG. CONTROLLER

SE-2 : BUCKET DUMP
ENG. HARNESS
SE-3 : BOOM UP
POSITION
INJECTOR 1
SE-4 : BOOM DOWN
RELEASE
NORMAL
SW-4 :
TERMINAL SWING PARKING BRAKE RELEASE SW.
INJECTOR 2 SE-7 : ARM IN SV-1 :
SWING PARKING BRAKE SOL.
SE-8 : ARM UP
INJECTOR 3 SV-3 : TWO SPEED SELECT SOL.
SE-5 : SWING
SV-2 : POWER BOOST SOL.
IN CASE OF
INJECTOR 4 E215B, SE-9 : TRAVEL RIGHT PSV-B : P2 UNLOAD
E265B, PROPORTIONAL SOL.
SK210-8,
SK260-8,
SE-10 : TRAVEL LEFT PSV-C : TRAVEL PRIORITY
PROPORTIONAL SOL.
SE-22 : PUMP P1
PSV-D : P1 UNLOAD
PROPORTIONAL SOL.
SE-23 : PUMP P2
PSV-A : ARM TWO-SPEED INVERSE
PROPORTIONAL SOL.
SE-20: P1 OPT. PSV-P1 : PUMP P1

PROPORTIONAL SOL.
C-2 : GAUGE CLUSTER
SE-11 : P2 OPT.
PSV-P2 : PUMP P2
PROPORTIONAL SOL.
ENG. WATER TEMP INDICATOR

PSV-E : OPT RELIEF ADJUSTMENT
PROPORTIONAL SOL. 1
SE-15 : FUEL SENSOR PSV-H : ARM CUSHION

FUEL METER
PROPORTIONAL SOL.
PSV-I : OPT RELIEF ADJUSTMENT

PROPORTIONAL SOL. 2
OPT
SW-20 : POWER BOOST SW. RIGHT
SE-13 : ENG. SPEED SENSOR

SHIELD
SHIELD
DISPLAY BUZZER MODE WASHER

SELECT SW. STOP
ENTER DECEL TRAVEL WIPER

TO 3/4
2-SPEED
(2/4)
LC03Z00036P1 03
23-4
23. ELECTRIC SYSTEM

E-22 : DC-DC CONVERTER
FROM 2/4
E-23 : 12V SOCKET
R-17 : EXTRA RELEASE RELAY

SW-7 : ENG. OIL PRESS SW.
SV-11 :
SW-8 : AIR FILTER CLOGGING SW. EXTRA RELEASE SOL
RUSSIA / EU
R-5 : HORN RELAY

SE-28 : EXTRA PRESS
E-5 : HORN HIGH
E-5 : HORN LOW
EXTRA RELEASE SW-10 : HORN SW. LEFT
EU(OPT)
(WIPER RELAY)
SW-15 : R-31 :
CONFLUX/SINGLE SELECT SW. PREVENT SPARK RELAY SW-5 : HORN SW. RIGHT
R-29 :
WIPER MOTOR RELAY OPT.
OPT
M-3 : WIPER MOTOR
L-5 : ROOM LIGHT

R-30 :
WIPER MOTOR REVERSING RELAY
SW-44 :
EXTRA PRESS. SW.
EU
R-32 : E-14 : CIGARETTE LIGHTER

WINDOW WASHER MOTOR RELAY M-4 : WASHER MOTOR
SW-11 : R-26 : SV-4 :
LEVER LOCK LEVER LOCK CONTROL LEVER LOCK SOL. E-10 : E-11 :
SW. RELAY RECEIVER DRIER AIR COMPRESSOR CLUTCH
STOP R-6 :
REVERSE WORK LIGHT RELAY
GROUND
OUTPUT AIR CON.
AMP.
SW-19 : WIPER INTERLOCK SW.
SW-35 : HEAVY LIFT SW.
EU
COOLING
UNIT
SE-29 : R-8 : TRAVEL ALARM RELAY

OPT. SELECTOR DETECT SENSOR
E-13 :
TRAVEL ALARM
SV-13 : OPT. SELECTOR SOL.

SW-13 : TRAVEL ALARM SW.
OPT MIDDLE EAST
SW-12 :
OVER LOAD ALARM SELECT SW-17 : ROOF WIPER SW.
POSITION
SW. E-7 : TUNER
M-9 : ROOF WIPER MOTOR

OFF
ON
TERMINAL E-8 : SPEAKER LEFT

SE-26 :
PRESS. SENSOR : BOOM HEAD
EU(FOR OVER LOAD ALARM)
E-9 : SPEAKER RIGHT
(BACK-UP)
EU
ROOF WIPER
TO 4/4
(3/4)
LC03Z00036P1 03
23-5
23. ELECTRIC SYSTEM
C-1 : MECHATRO CONTROLLER (TCO-60-2) C-1 : MECHATRO CONTROLLER (TCO-60-2)
FROM 3/4
C-6 : AUTO GREASE CONTROLLER

R-26 : SV-6 :
LEVER LOCK RELAY SW-33 : REVOLUTION
SE-24 : REVOLUTION RIGHT SOL
PRESS SENSOR : BOOM HEAD R-12 :
REVOLUTION RIGHT SW.
RIGHT RELAY
M-8 : GREASE MOTOR
SE-25 :
PRESS SENSOR : BOOM ROD E-2 :
ALTERNATOR
SV-7 :
SW-34: REVOLUTION
SE-17 : BOOM POTENTIO. R-13 : REVOLUTION LEFT SOL
REVOLUTION LEFT SW.
OPT. LEFT RELAY
AUTO GREASE
SE-19 : ARM POTENTIO. REVOLUTION N&B
L-6 : BOOM WORKING LIGHT

R-6 : WORK LIGHT RELAY RIGHT OPT.
L-1 : BOOM WORKING LIGHT
LEFT
L-2 : DECK WORKING LIGHT
R-36 : C-4 : AIR-CON AMP RIGHT SV-9 :
SW-29 : NIBBLER OPEN
ROTARY LIGHT RELAY (RED) NIBBLER OPEN
L-19 : R-15 : SOL
HIGH REACH THREE NIBBLER OPEN SW.
COLORS ROTARY LIGHT SW-55 :
BOOM, DECK WORKING LIGHT SW. RELAY
(CASE OF HAND CONTROL
NIBBLER CONNECT WITH 571)
R-36 :
ROTARY LIGHT RELAY
(YELLOW) L-3 :
R-19 : FLASHER RELAY SWING FLASHER LEFT & WORKING LIGHT
(CASE OF HAND CONTROL

BRAKER CONNECT WITH 572)
R-38 :
ROTARY LIGHT RELAY (GREEN)
OPT.
L-10 : SV-10 :
SW-30 : NIBBLER CLOSE
HIGH REACH ROTARY LIGHT NIBBLER CLOSE SOL
R-16 :
SV-5 : NIBBLER CLOSE SW.
BUCKET DUMP CUT SOL. RELAY
POSITION
EASY OPERATING NIBBLER

TRAVEL
FIXED
SW-41 :
OFF
TERMINAL
HIGH REACH
CRANE SW.
(FIXED)
(TRAVEL)
OPT.
HIGH REACH CRANE
SV-14 :
QUICK COUPLER OPERATION SOL. L-4 :
SWING FLASHER RIGHT & WORKING LIGHT 9P CONNECTOR
SWING FLASHER & WORKING LIGHT
SW-59 :
QUICK COUPLER SW-37 :
OPERATION SW. TRAVEL INDEPENDENT SW.
EU OPT. USA
QUICK COUPLER
DOWNLOAD
(4/4)
LC03Z00036P1 03
23-6
23. ELECTRIC SYSTEM
23.2 ELECTRICAL EQUIPMENT LIST

GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No.
MECHATRO CONTROLLER YN22E00214F1 L-1 BOOM WORK LIGHT (LH) YW80S00001F1 PRESSURE SENSOR : LC52S00019P1
C-1 SE-1
(TCO-60-2) (HARD) L-2 BOOM WORK LIGHT (RH) YT80S00002F2 BUCKET DIGGING
(C) CONTROLLER
C-2 GAUGE CLUSTER YN59S00021F2 SWING FLASHER (LH) & REAR PRESSURE SENSOR :
L-3 YM80S00001F1 SE-2
AIR-CON CONTROLLER WORK LIGHT BUCKET DUMP
C-4 AIR CON ACCESSORY
(L) LIGHT
(INCLUDING PANEL) SWING FLASHER (RH) & REAR SE-3 PRESSURE SENSOR : BOOM UP
L-4 YM80S00001F2
ENGINE COOLANT LEVEL WORK LIGHT PRESSURE SENSOR :
C-5 ENGINE ACCESSORY SE-4
(SE) SENSOR
CONTROLLER L-5 ROOM LIGHT YT80S00001P1 BOOM DOWN
C-8 ENGINE CONTROLLER ENGINE ACCESSORY L-6 BOOM WORK LIGHT (RH) YW80S00001F1 SE-5 PRESSURE SENSOR : SWING
L-7 CAB WORK LIGHT YT80S00002F2 SE-7 PRESSURE SENSOR : ARM IN
D-4 DIODE HARNESS ACCESSORY SE-8 PRESSURE SENSOR : ARM OUT
D-5 DIODE ACCESSORY OF RELAY BOX SE-9 PRESSURE SENSOR : TRAVEL RH
D-6 DIODE M-1 STARTER MOTOR ENGINE ACCESSORY SE-10 PRESSURE SENSOR : TRAVEL LH
(M) MOTOR
D-9 DIODE M-3 WIPER MOTOR YN53C00012F2 SE-11 (PRESSURE SENSOR : P2 OPT.)
D-10 DIODE M-4 WASHER MOTOR YN54C00001F1 SE-13 E/G SPEED SENSOR ENGINE ACCESSORY
(D) DIODE
D-12 DIODE SE-15 FUEL SENSOR YN52S00045F1

D-13 DIODE SE-16 ACCEL POTENTIOMETER YN52S00032P1
D-14 DIODE SE-20 (PRESSURE SENSOR : P1 OPT.) LC52S00019P1
D-16 DIODE ARM 2 SPEED SE-22 PRESSURE SENSOR : PUMP P1 YN52S00048P1
D-17 DIODE PSV-A INVERSE YN35V00049F1 SE-23 PRESSURE SENSOR : PUMP P2
D-25 DIODE HARNESS ACCESSORY PROPO.VALVE SWING PARKING
(P) PROPORTIONAL
SV-1 YN35V00051F1
SOLENOID VALVE
P2 UNLOAD (YN35V00047F1) BRAKE SOL.
(SV) SOLENOID
PSV-B YN35V00048F1
PROPO.VALVE SOLENOID POWER BOOST
SV-2 (YN35V00047F1) YN35V00050F1
TRAVEL STRAIGHT VALVE ASSY SOL
PSV-C SOLENOID
E-1 FUSE AND RELAY BOX YN24E00016F2 PROPO.VALVE TWO SPEED
SV-3 VALVE ASSY
E-2 ALTERNATOR ENGINE ACCESSORY P1 UNLOAD SELECT SOL
PSV-D
E-3 HOUR METER YT58S00006P1 PROPO.VALVE SAFETY LOCK
SV-4
E-5 HORN HIGH LC53S00001D1 P1 PUMP LEVER SOL
PSV-P1 YN35V00052F1
E-6 HORN LOW LC53S00001D2 PROPO.VALVE SW-1 KEY SWITCH YN50S00026F1
PUMP ACCESORY
E-7 TUNER - P2 PUMP SWING PARKING BRAKE RELEASE
PSV-P2 SW-4 YN50S00047P1
E-8 SPEAKER LEFT YN54S00006P1 PROPO.VALVE SWITCH
E-9 SPEAKER RIGHT R-1 BATTERY RELAY YN24S00008F1 SW-5 HORN SWITCH (RH) YN50E00017P1
E-10 RECEIVER DRYER YN54S00041P1 R-2 STARTER RELAY ENGINE ACCESSORY SW-7 E/G OIL PRESSURE SWITCH ENGINE ACCESSORY
E-11 AIR-CON COMPRESSOR YX91V00001F1 R-3 GLOW RELAY ENGINE ACCESSORY SW-8 AIR FILTER CLOGGING SWITCH YR11P00008S005
E-12 BATTERY YN72S00016P1 R-4 SAFETY RELAY YN24S00010P1 SW-10 HORN SWITCH (LH) YN50E00017P1
(E) ELECTRIC FITTINGS
E-13 TRAVEL ALARM (For Middle east) YN53S00004F1 R-5 HORN RELAY SW-11 SAFETY LOCK LEVER SWITCH YN50S00041F1
E-14 CIGARETTE LIGHTER YN81S00003P1 R-6 WORKING LIGHT RELAY SW-13 TRAVEL ALARM SWITCH YN50S00040DF
E-15 FUSIBLE LINK LC13E01175S002 R-8 TRAVEL ALARM RELAY CONFLUX/SINGLE SELECT
SW-15 YN50S00040D3
E-22 DC-DC CONVERTER YT77S00001P1 R-9 CAB WORKING LIGHT RELAY SWITCH
(SW) SWITCH
E-23 12V SOCKET YN81S01002P1 R-19 FLASHER RELAY YY24S00001P1 SW-17 SKYLIGHT WIPER SWITCH YN50S00040D9
E-27 ACCEL REDUNDANT VOLUME YN52S00052P1 R-23 AUTO IDLE STOP RELAY 1 YN24S00010P1 SW-19 WIPER INTERLOCK SWITCH YT50S00004P1
(R) RELAY
R-24 AUTO IDLE STOP RELAY 2 SW-20 POWER BOOST SWITCH (RH) YN50E00017P1
R-25 ENGINE EMERGENCY STOP RELAY SW-21 POWER BOOST SWITCH (LH)
R-26 LEVER LOCK RELAY SW-26 CAB WORK LIGHT SWITCH YN50S00040D4
R-28 ALTERNATOR RELAY SW-27 COOLANT LEVEL SWITCH ENGINE ACCESSORY
WIPER MOTOR RELAY SW-28 WATER SEPARATOR SWITCH ENGINE ACCESSORY
R-29 YN24S00012P2
(NORMAL ROTATION) SW-55 BOOM WORK LIGHT SWITCH YN50S00040D1
WIPER MOTOR RELAY
R-30
(REVERSE ROTATION)
WIPER MOTOR RELAY
R-31 (ARC PREVENTION)
R-32 WASHER MOTOR RELAY
NOTE : The parts number may be changed due to the improvement of machine, so use the number for reference only. LC03Z00036P1 03
23-7
23. ELECTRIC SYSTEM
23.3 HARNESS
23.3.1 HARNESS LIST
DIVISION DRAWING No. HARNESS

REMARKS
POSITION ITEM NAME ASSEMBLY No. CODE No. NAME DRAWING No.
3.2 INSTRUMENT PANEL ASSY YN17M00069F1

3.3 CONTROLLER INSTALL (ENGINE) YN22E00220F1
CONTROLLER INSTALL YN22E00219F1
CONVERTER YN77S00028F1
3.4 UPPER ELEC ASSY LC03E00008F1
3.5 UPPER HARNESS ASSY YN13E00095F1 1 HARNESS YN13E01446P7 UPPER
UPPER FRAME
2 CABLE YN13E01417P1 BATTERY TO RELAY

3 CABLE YN13E01441P2 BATTERY TO BATTERY
4 CABLE LC13E01144P1 BATTERY TO GROUND
5 CABLE YN13E01442P1 STARTER
6 HARNESS YN13E01482P1 ECU HARNESS
36 CABLE LE13E01006P1 FLOOR HARNESS
37 CABLE LC13E01180P2 GLOW RELAY TO STARTER RELAY
38 CABLE LQ13E01100P1 ENGINE GROUND
52 HARNESS LC13E01193P1 AIR CLEANER
3.6 ENGINE HARNESS ASSY LQ16E00010F1 1 HARNESS LQ16E01015P1 ENGINE SUB
3.7 UPPER HARNESS ASSY LC13E00032F1 1 HARNESS YN13E01449P3 FLOOR
(FLOOR PLATE) 4 HARNESS LC13E01186P1 CAB SUB
9 CABLE LE13E01005P1 FLOOR GROUND
3.8 CAB HARNESS LC14E00023F1 1 HARNESS YN14E01102P3 CAB
CAB
6 HARNESS YN14E01106P1 KEY SWITCH GROUND

BOOM 3.9 BOOM HARNESS ASSY YN15E00003F4 1 HARNESS YN15E01042D1 BOOM LIGHT
LIGHT
3.10 BOOM LIGHT INSTALL YN80E00011F1 BOOM LIGHT

3.11 DECK LIGHT INSTALL YN80E00049F1 DECK LIGHT
FUEL
PUMP 3.12 FUEL PUMP ASSY YN22P00024F1
ALARM 3.13 ALARM ASSY YN53E00015F1
The parts number may be changed due to the improvement of machine, so use the number for reference only.
23-8
23. ELECTRIC SYSTEM
23.3.2 INSTRUMENT PANEL ASSY
TIGHTENING TORQUE
INSTRUMENT PANEL ASSY YN17M00069F1 (01)
1.5N.m (1.1lbf.ft)
TIGHTENING TORQUE SEMS BOLT TIGHTENING TORQUE
ITEM PART NAME PART No. Q'TY REMARKS 5.2N.m (3.8lbf.ft) 5.2N.m (3.8lbf.ft)
3-2 POTENTIO METER YN52S00032P1 1 2 PLACES INSTALL TO CAB
TAPPING SCREW
TAPPING
3-11 KEY SWITCH YN50S00026F2 1 K250 SEMS BOLT DUCT ASSY SCREW
4-2 CIGARETTE LIGHTER YN81S00003P1 1 2 PLACES
TIGHTENING TORQUE TAPPING SCREW
5-2 HOUR METER YT58S00006P1 1 2.8N.m (2.1lbf.ft) TIGHTENING TORQUE
5.2N.m (3.8lbf.ft)
10 GAUGE CLUSTER YN59S00021F3 1
SECTION BB SECTION DD SECTION EE
46-3 SPEAKER YT54S00006P1 2
TIGHTENING TORQUE TIGHTENING TORQUE

TIGHTENING TORQUE 5.0N.m (3.7lbf.ft) 8.5N.m (6.3lbf.ft)
TIGHTENING TORQUE 5.0N.m (3.7lbf.ft) INSTALL SEMS BOLT
5.0N.m (3.7lbf.ft) INSTALL SEMS BOLT TO CAB
INSTALL SEMS BOLT
INSTALL SEMS TO CAB
TIGHTENING TORQUE TO CAB
4.1N.m (3.0lbf.ft) BOLT TO CAB
2 PLACES
SEMS BOLT
TIGHTENING TORQUE
4.1N.m (3.0lbf.ft)

23.5N.m (17.3lbf.ft) 5.0N.m (3.7lbf.ft)
3 PLACES
SEMS BOLT
SECTION AA
VIEW
SEMS BOLT
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
TIGHTENING TORQUE
TIGHTENING TORQUE 0.43N.m (0.32lbf.ft) TIGHTENING TORQUE
. .
8.5N m (6.3lbf ft) 8 PLACES 5.0N.m (3.7lbf.ft)
5.0N.m (3.7lbf.ft) TIGHTENING TORQUE 4 PLACES
5.0N.m (3.7lbf.ft) 4.9N.m (3.6lbf.ft) SEMS BOLT TAPPING SCREW
SEMS BOLT TIGHTENING TORQUE INSTALL SEMS BOLT
SEMS BOLT
12.0N.m (8.9lbf.ft) TO CAB
INSTALL
SEMS BOLT
TO CAB
SEMS BOLT
4 PLACES
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
SECTION CC
TIGHTENING TORQUE
5.2N.m (3.8lbf.ft)
SEMS BOLT VIEW
INSTALL TAPPING SCREW TIGHTENING TORQUE
TO A/C 5.0N.m (3.7lbf.ft)
23-9
23. ELECTRIC SYSTEM
23.3.3 CONTROLLER INSTALL
CONTROLLER INSTALL(ENGINE) YN22E00220F1 (03) CONVERTER YN77S00028F1 (01)
ITEM PART NAME PART No. Q'TY REMARKS ITEM PART NAME PART No. Q'TY REMARKS
1 CONTROLLER ENGINE ACSSESSORY 1 C8:ECU TIGHTENING TORQUE 1 CONVERTER YT77S00001P1 1
1.7N.m (1.3lbf.ft)
5 CONTROLLER ENGINE ACSSESSORY 1 C5:COOLANT LEVEL ASSEMBLE WITH THE
NUT OF ACCESSORY
CONTROLLER INSTALL YN22E00219F1 (07) TIGHTENING TORQUE

12N.m (8.9lbf.ft)
ITEM PART NAME PART No. Q'TY REMARKS ASSEMBLE WITH THE
NUT OF ACCESSORY
2 SWITCH YN50S00047P1 1 SLEWING PARKING RELEASE
7 POTENTIO METER YN52S00052P1 1 ENGINE EMERGENCY MODE
TIGHTENING TORQUE
9.60N.m (36.9 lbf.ft)
SEMS BOLT
INSTALL THE CONER

IN THIS DERECTION
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
2 3 PLACES
SEMS BOLT RELAY BOX ASSY
UPPER
HEXAGON NUT
TOOTHED LOWER
HEXAGON NUT
LOCK WASHER
HORN WASHER
SECTION AA
SEMS BOLT
TIGHTENING
TORQUE
2.8N.m (2.1lbf.ft)
VIEW
TIGHTENING TORQUE
2.8N.m (2.1lbf.ft)
SEMS BOLT
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
SEMS BOLT
SEMS BOLT
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
23-10
23. ELECTRIC SYSTEM
23.3.4 UPPER ELECTRIC ASSY
UPPER ELECTRIC ASSY LC03E00008F1 (02)
ITEM PART NAME PART No. Q'TY REMARKS

1 BATTERY RELAY YN24S00008F1 1
2 HORN LC53S00001D1 1 HIGH
3 HORN LC53S00001D2 1 LOW
AFTER INSTALLING GLOW RELAY AND STARTER RELAY

TO BRACKET (A), ASSEMBLE THIS BRACKET
TIGHTENING TORQUE SEMS BOLT
23.5N.m
GLOW RELAY
HORN (LOW)
BRACKET
HORN (HIGH) SEMS BOLT

TIGHTENING TORQUE
15.5N.m (11.4 lbf.ft)
STARTER RELAY
B TERMINAL
BATTERY RELAY BOX C TERMINAL
NUT
TIGHTENING TORQUE
17.5N.m (12.9 lbf.ft) 2 PLACES
SEMS BOLT
TIGHTENING
TORQUE
10.7N.m (7.9 lbf.ft)
TIGHTENING TORQUE
10.7N.m
CONNECT SEMS BOLT
AFTER CHECKING CONNECT HARNESS AS SHOWN
GROUND
NO PAINT IS HERE TO AVOID SHORT CIRCUIT ON
SEMS BOLT HORN (HIGH)
POWER SOURCE WIRING
CONNECT HARNESS AS SHOWN HORN (LOW)
TO AVOID SHORT CIRCUIT ON SEMS BOLT
INSTALL BOLT FROM POWER SOURCE WIRING TIGHTENING TORQUE
FRONT SIDE 11.7N.m
MAX
(BLACK) (BLACK)
(GREEN ORANGE) (GREEN ORANGE)
SECTION BB (BATTERY RELAY BOX)

VIEW (COVER INSTALL)
VIEW VIEW
23-11
23. ELECTRIC SYSTEM
23.3.5 UPPER HARNESS ASSY (1/6)

SE-28 : SE-5 : FIX WHITE TAPING SW-28 :
UPPER HARNESS ASSY YN13E00095F1 (16) L-2 : PRESS SENSOR : PRESS SENSOR : POSITION
SV-11 : WATER SEPARATOR SW.
FRAME WORKING LIGHT RIGHT EXTRA PRESS (OPT) SWING CLIP
ITEM PART NAME PART No. Q'TY REMARKS CLIP EXTRA PRESS SOL (OPT) TO TRAVEL ALARM (OPT)
SE-15 :
1 HARNESS YN13E01446P6 1 UPPER FUEL SENSOR
FIX WHITE TAPING POSITION
2 CABLE YN13E01417P1 1 BATTERY - RELAY
PUMP 2 PROPORTIONAL SOL.
3 CABLE YN13E01441P2 1 BATTERY - BATTERY
SE-23 : PRESS SENSOR : PUMP P2
4 CABLE LC13E01144P1 1 BATTERY - GROUND
5 CABLE YN13E01442P1 1 STARTER SE-22 : PRESS SENSOR : PUMP P1
6 HARNESS YN13E01482P1 1 ECU HARNESS PSV-P1 : PUMP 1

PROPORTIONAL SOL.
36 CABLE LE13E01006P1 1 FLOOR GROUND CLIP
37 CABLE LC13E01180P2 1 GROW RELAY - STARTER RELAY E-6 : HORN LOW
SE-13 :
38 CABLE LQ13E01100P1 1 ENGINE GROUNDING E-5 : HORN HIGH ENGINE SPEED SENSOR
52 HARNESS LC13E01193P1 1 AIR CLEANER
TO HARNESS OF
CLIP
ENGINE
UPPER HARNESS
INSTALL THE CABLES TO TERMINALS STARTER CABLE
SO AS TO AVOID INTERFERENCE STARTER CABLE
WITH CAP AND BRACKET EARTH CONNECT SEMS BOLT AFTER
BATTERY CHECKING NO PAINT IS HERE
FIX WHITE TAPING
NOTE 2
SEMS BOLT POSITION
TO ATT HARNESS
CLIP
UPP HARNESS
BATTERY RELAY INSERT HARNESS IN
CABLE SLIT OF INSULATION
FLOOR
GROUNDING TO RADIATOR COOLANT
CABLE LEVEL SW.
BATTERY CABLE NOTE 1 TO ENG ROOM RIGHT
FLOOR HARNESS GROUND E-10 :

GROUNDING
TRAVEL INDEPENDENT CHANGE SWITCH NOTE 5 RECEIVER DRIER
CABLE
NIBBLER OPEN PRESSURE SWITCH BATTERY RELAY BOX
DETAIL OF BATTERY LEFT ROTATING SWITCH
HORN SWITCH (LH) CLIP CLIP TO CAB TO SOLENOID TO AIR FILTER
ATTACHMENT BOOST SWITCH (LH) BLOCK CLOGGING SW.
DC-DC CONVERTER
CLIP
WASHER MOTOR
FIX A HARNESS TO PRESS SENSOR : SWING
IT CONTROLLER
TO THE PLATE
NIBBLER OPEN SWITCH
NIBBLER CLOSE SWITCH UPP HARNESS
NOTES:
(1) TIGHTENING TORQUE OF
CLIP BATTERY TERMINALS ARE 3.4N-M.
CLIP TO ATT HARNESS (2) TIGHTENING TORQUE OF
FIX WHITE TAPING TO ENGINE GROUNDING CABLES ARE 10.7N-M.
POSITION (3) UNLESS OTHERWISE SPECIFIED
TO HARNESS OF ENGINE TIGHTENING TORQUE IS SHOWN BELOW.
CLIP M8 : 23.5N.m
FIX WHITE TAPING
M10 : 46.1N.m
TO ENGINE SPEED SENSOR POSITION
(4) UNLESS OTHERWISE SPECIFIED, THE
CLIP INSTALLING PROCEDURE IS SHOWN BELOW.
FLOOR GROUNDING
(5) PLACE THE SLIT OF CORRUGATED TUBE
CABLE
DOWNWARD AND INSTALL IT.
CLIP
GROUND
CONNECT SEMS BOLT UPPER HARNESS TO RECEIVER DRIER TO BATT RELAY BOX HARNESS
SEMS BOLT AFTER CHECKING
CLIP NO PAINT IS HERE CLIP ENGINE GROUNDING CABLE
CLIP
NOTE 2
SECTION AA ECU HARNESS FIX WHITE TAPING POSITION
23-12
23. ELECTRIC SYSTEM
F TERMINAL TIGHTENING TORQUE 3.43N.m (2.5 lbf.ft)

USE NUT OF ATTACHED
S TERMINAL GLOW RELAY
SV-11 :
EXTRA PRESS SOL. (OPT) FIX WITH HARNESS
SE-29 :
IN THE ELBOW
GLOW RELAY - STARTER RELAY TIE UP HARNESS PRESS SENSOR :
GLOW RELAY SELECTOR DETECTION
WITH SOLENOID VALVE
CONNECT TO USING PLASTIC TIE
2P CONNECTOR
SV-13 :
FOR HARNESS OF C TERMINAL TIGHTENING TORQUE 3.8N.m OPT SELECTOR SOL
ATTACHED USE NUT OF ATTACHED
GLOW RELAY B TERMINAL STARTER RELAY
TO ENG ROOM LIGHT

FIX WITH THE CLIP SE-28 :
PRESS SENSOR :
EXTRA PRESS (OPT)
CLIP
FIX WITH THE CLIP
STARTER RELAY
CLIP INSTALL THE LOCK OF

THE FUSE BOX COVER UPWARD
BATTERY RELAY
FIX WITH THE CLIP CLIP
WHEN THERE IS NO OPTION
FIX WHITE TAPING POSITION OF SE-28, 29, SV-13,
SEMS BOLT CLIP TIE UP THIS HOSE HERE
FIX FUSE BOX
WITH THE BRACKET
CONNECT THIS
CONNECT THIS VIEW
TERMINAL WITH
TERMINAL WITH
BATTERY CABLE
STARTER CABLE DETAIL A (EXTRA SOL. INSTALL)
TIGHTENING TORQUE
TIGHTENING
7.8N.m MAX
TORQUE
7.8N.m MAX
(5.8 lbf.ft) FIX A CONNECTOR
TO THE BRACKET
TIGHTENING TORQUE
PSV-P1 :
25.5N.m
UPPER HARNESS PUMP P1
SEMS BOLT
PROPORTIONAL SOL.
CLIP FIX A HARNESS
TO PUMP FIX WHITE TAPING POSITION ON GUARD
PROPORTIONAL SOL CLIP
CLIP FIX A HARNESS SO THAT
PASS CENTER OF CUTTING
HOLE OF GUARD.
STARTER CABLE
PSV-P2 :
PUMP P2 CLIP
BATTERY RELAY CABLE PROPORTIONAL SOL.
BATTERY RELAY ENGINE SIDE
UPPER HARNESS
CLIP
TIE UP CORRUGATED PART OF
HARNESS WITH SOLENOID VALVE
FIX CONNECTOR USING PLASTIC TIE
TO THE BRACKET SE-22 : SE-23 :
PRESS SENSOR : PRESS SENSOR :
PUMP P1 PUMP P2
CLIP
TIE UP CORRUGATED PART OF
FUSE BOX
HARNESS WITH PRESSURE SENSOR TO WATER SEPARATOR SW
USING PLASTIC TIE VIEW
VIEW (PUMP P1, P2 PROPORTIONAL SOL. INSTALL)

VIEW
(PRESS SENSOR : PUMP P1, P2 INSTALL)
23-13
23. ELECTRIC SYSTEM
CONNECT CONNECTOR WITH "CN4-1" CONNECT CONNECTOR WITH "CN5"

TAG OF ITEM 1 : HARNNESS TAG OF ITEM 6 : HARNNESS
E-1 :
C-8 : ENGINE CONTROLLER
E-1 : FUSE & RELAY BOX FUSE & RELAY BOX
C-1 :
MECHATRO CONTROLLER
34P CONNECTOR 32P CONNECTOR 31P CONNECTOR C-8 :

CONNECT THE "CNT-2" TAGGED
WITH "CN-1F" TAG WITH "CN-3F" TAG WITH "CN-5F" TAG ENGINE CONTROLLER
CONNECTOR WITH FLOOR HARNESS
35P (A) CONNECTOR 35P (B) CONNECTOR
WITH "CN-2F" TAG WITH "CN-4F" TAG
VIEW
C-1 : MECHATRO CONTROLLER CONNECT CONNECTOR CONNECT CONNECTOR

WITH "CN4-2" WITH "CN1"
TAG OF ITEM 1 : HARNNESS TAG OF ITEM 1 : HARNNESS CONNECT WITH
CAB SUB HARNESS BLUE CONNECTOR TO
VIEW ACCELERATION
SET A WHITE TAPING PART OF UPPER HARNESS
TO WHITE TAPING PART OF FLOOR HARNESS, EMERGENCY VOLUME
AND FIX TO FLOOR HARNESS CLIP
16P CONNECTOR 31P CONNECTOR 17P CONNECTOR CONNECT 1P CONNECTOR TO

CAB SUB HARNESS
R-19 :
28P CONNECTOR 24P CONNECTOR FLASHER RELAY
VIEW FIX WHITE TAPING POSITION OF UPPER HARNESS AND
ECU HARNESS TO THE FLOOR HARNESS WITH CLIP
CLIP
CLIP
FLOOR HARNESS
TIE UP UPPER HARNESS,
FLOOR HARNESS,
ECU HARNESS AND
C-8 : CAB SUB HARNESS
ENGINE CONTROLLER
ECU HARNESS GROUND

FIX WHITE TAPING GROMMET C-5 :
ECU HARNESS,
POSITION RADIATOR COOLANT
UPPER HARNESS GROUND
CLIP LEVEL CONTROLLER
TIGHTEN SEMS BOLT AFTER CHECKING
SEMS BOLT NO PAINT IS HERE
ECU HARNESS 6 PLACES CLIP
NOTE 2 FIX UPPER HARNESS AND
FLOOR HARNESS PUT WHITE TAPING FLOOR HARNESS TO THE
POSITION HERE STAND IN CASE OF
UNCONNECTION, TIE UP
GROMMET HARNESS AND FIX
CONNECT 1P CONNECTOR HARNESS
TO CAB HARNESS (GND) UPPER HARNESS ENGINE CONTROLLER
CHECK CONNECTOR
ECU HARNESS GROUND
UPPER HARNESS ENGINE CONTROLLER UPPER HARNESS GROUND
ECU HARNESS GROUND
CHECKER (FOR OUTSIDE MONITOR) UPPER HARNESS GROUND
MECHATRO CONTROLLER CLIP
ECU HARNESS FIX WHITE TAPING
POSITION
UPPER HARNESS GROUND UPPER HARNESS GROUND FIX THE CONNECTOR
FUSE & RELAY BOX
WITHOUT INTERFERENCE
LEVER LOCK SOLENOID
IN AIR-CON DUCT
FLASHER RELAY ATT. BOOST SOLENOID
UPPER HARNESS GROUND TRAVEL 2 SPEEDS SOLENOID
PUT WHITE TAPING POSITION HERE "CNT-1" WITH TAG, CONNECTOR OF DECK WORK LIGHT (RH) SWING PARKING SOLENOID
RADIATOR COOLANT LEVEL SWITCH FUEL PUMP
CONNECT TO FLOOR HARNESS ENGINE ROOM LIGHT
AIR FILTER CLOGGING SWITCH GREASE PUMP
SWING FLASHER (LH) & REAR WORK LIGHT
ECU HARNESS GROUND SWING FLASHER (RH) & REAR WORK LIGHT UPPER HARNESS GROUND
VIEW ENGINE CONTROLLER WATER SEPARATOR SWITCH BATTERY RELAY (COIL)
RADIATOR COOLANT LEVEL CONTROLLER
TRAVEL ALARM DIODE D4
PRESSURE RELEASING SOL. FOR EXTRA GLOW RELAY (COIL)
FUSE & RELAY BOX CONNECTION
23-14
23. ELECTRIC SYSTEM
ENGINE ROOM LIGHT
SW-27 :
RADIATOR COOLANT LEVEL SW

CLIP
CLIP
FIX A CONNECTOR ON BRACKET

BATTERY RELAY BOX
CLIP
UPPER HARNESS
SW-8 :
AIR FILTER CLOGGING SW
TO BATTERY RELAY BOX
UPPER HARNESS
TIE UP CORRUGATED PART OF HARNESS VIEW
CLIP WITH SWITCH USING PLASTIC TIE
RADIATOR COOLANT LEVEL SW. INST
CONNECT HARNESS OF TO AIR FILTER

AIR FILTER CLOGGING SW CLOGGING SW
FIX TO CONNECTOR
CLIP
E-10 :
RECEIVER DRIER
CLIP
FIX A HARNESS OF
CLIP ON GUARD
CLIP
CLIP FIX HARNESS TO THE HOSE
FIX WHITE TAPING POSITION FIX TO THE CLIP
AIR FILTER CLOGGING SW. INST VIEW
23-15
23. ELECTRIC SYSTEM
ENGINE ACCESSORIES
ENGINE ACCESSORIES
HARNESS
HARNESS
ENGINE GROUND CABLE
GROUND
GLOW
ENGINE TIGHTEN AFTER
NUT CHECKING NO PAINT IS HERE
ALTERNATOR (B) NOTE 2
TIGHTENING TORQUE UPPER HARNESS
3.3~4.4N.m CLIP
(2.4~3.3 lbf.ft)
PART OF ALTERNATOR CLIP
B TERMINAL
ENGINE SUB HARNESS
CLIP
UPPER HARNESS
TO ALTERNATOR
CLIP
FIX WHITE TAPING
POSITION
STARTER CABLE ENGINE SUB HARNESS
CLIP
ECU HARNESS
UPPER HARNESS
CLIP
FIX A CONNECTOR ON BRACKET
VIEW
ECU HARNESS
TO BATTERY RELAY BOX
UPPER HARNESS ENGINE ACCESSORIES HARNESS
ENGINE SUB HARNESS (USE THE CLIP OF ENGINE) FIX A CONNECTOR

VIEW DETAIL OF ALTERNATOR CLIP CLIP BY ENGINE HARNESS
PLACE CLIP INWARD AS SHOWN IN DRAWING, ATTACHMENT CLIP ON BRACKET
AND CLAMP HARNESS AT WHITE TAPING
TO STARTER MOTOR AND GLOW

INSTALL THE RUBBER CAP DETAIL OF E
ON UPPER SIDE TIGHTENING TORQUE ENGINE GROUND CABLE
TIGHTENING TORQUE GLOW 23.5N.m (17.3 lbf.ft)
51.9N.m (38.3 lbf.ft) CLIP
SEMS BOLT ENGINE GROUND CABLE NUT
FIX WHITE TAPING
POSITION
CLIP
FIX WHITE TAPING

POSITION
CLIP
TO GLOW
UPPER HARNESS
CLIP ECU HARNESS
SEMS BOLT STARTER CABLE
FIX WHITE TAPING
NUT POSITION
12~15N.m (8.9~11 lbf.ft) 25.5N.m (18.8 lbf.ft) VIEW
FIX A HARNESS BY SE-13 :
CLIP ON BRACKET ENGINE SPEED SENSOR
M-1 : STARTER MOTOR
CLIP CLIP FIX A CONNECTOR TO BRACKET
TIGHTENING TORQUE
UPPER HARNESS
3.5~5.5N.m (2.6~4.1 lbf.ft)
STARTER CABLE C TERMINAL
CLIP UPPER HARNESS
FIX WHITE TAPING CLIP
POSITION FIX WHITE TAPING
POSITION M-1 : STARTER MOTOR
DETAIL C DETAIL D DETAIL OF ENGINE SPEED
23-16
23. ELECTRIC SYSTEM
E-13 :
CLIP
TRAVEL ALARM
(OPT)
L-2 :
INSTALL THE "ALARM"
DECK WORK
TAGGED CONNECTOR
LIGHT (RH)
CLIP ON BRACKET
CLIP FIX A CONNECTOR TO

THE BRACKET
SE-15 : FIX WHITE TAPING POSITION
FUEL SENSOR CLIP
CONNECT A HARNESS
INSIDE OF CAP
UPPER FLAME
CLIP
CLIP
CLIP
SW-28 :
WATER SEPARATOR SW.
VIEW (DETAIL OF TRAVEL ALARM INSTALL)
VIEW
PSV-D :
P1 UNLOAD
PSV-D :
SV-3 : PSV-C : PROPORTIONAL SOL.
P2 UNLOAD
TWO-SPEED SELECT SOL. TRAVEL STRAIGHT PSV-A :
PROPORTIONAL SOL.
PROPORTIONAL SOL. ARM TWO-SPEED INVERSE
SV-1 : SV-2 :
PROPORTIONAL SOL.
SWING PARKING BRAKE SOL. POWER BOOST SOL.
SV-4 :
LEVER LOCK SOL.
CLIP
CLIP
DETAIL B (DETAIL OF PSV BLOCK)
23-17
23. ELECTRIC SYSTEM
23.3.5-1 UPPER HARNESS (1/4) : YN13E01446P7
23-18
23. ELECTRIC SYSTEM
23-19
23. ELECTRIC SYSTEM
23-20
23. ELECTRIC SYSTEM
23-21
23. ELECTRIC SYSTEM
23.3.5.2 BATTERY RELAY CABLE : YN13E01417P1 23.3.5.5 STARTER CABLE : YN13E01442P1
TERMINAL
TERMINAL
CAP INSTALL DOUBLE CORRUGATE

YAZAKI 7034-1283
TERMINAL WHITE TAPING INSTALL CORRUGATE TUBE

TERMINAL CAP
CAP
YAZAKI 7034-1283
SUPPLY CAP TO BE
TAPED IN TWO TURNS WITH SLOW BLOWN INSTALLED
TERMINAL FUSE 100A CAP
23.3.5.3 BATTERY CABLE : YN13E01441P2 WIRE No.35 YAZAKI 7034-1283
TAPED DOUBLY
TERMINAL TAPING
WIRE No.36
CORRUGATE TUBE TWO TERMINALS ARE IN TOUCH WITH

TO BE INSTALLED CAP EACH OTHER TO THEIR BACK AND
BUNDLED BY TAPING, CAP TO BE INSTALLED
TERMINAL TERMINAL
DETAIL A
(JIS D5403) (JIS D5403)
CAP
23.3.5.4 BATTERY GROUNDING CABLE : LC13E01144P1
TERMINAL
TERMINAL
CAP TAPED IN TWO TURNS
23-22
23. ELECTRIC SYSTEM
23.3.5-6 ECU HARNESS (1/2) : YN13E01482P1
DOUBLE DOUBLE DOUBLE SEALING PLUG

SPLICE SPLICE SPLICE
ACCELERATION WHITE TAPING

EMERGENCY
TO FUSE & RELAY BOX

TO ENGINE
CONTROL
WHITE TAPING
SEALING HARNESS
WHITE TAPING PLUG
SEALING PLUG
INSTALL DOUBLE CORRUGATE
TAPING
TO HARNESS FLOOR
SUPPLY WITH SEALING

SUMITOMO 6409-0075 PLUG
SUPPLY WITH
SUMITOMO 6409-0071 TAPING
WHITE TAPING
SHIELD UNCONNECTED
WHITE TAPING
C-6 : ENGINE CONTROLLER
23-23
23. ELECTRIC SYSTEM
23.3.5-6 ECU HARNESS (2/2) : YN13E01482P1 23.3.5-36 FLOOR GROUNDING CABLE : LE13E01006P1
100 (3.94")
LA308 5B E E 5B E
1PAM
YAZAKI 7122-3010
23.3.5-37 RELAY CABLE : LC13E01180P2
TAPED DOUBLY
180 (7.09")
CAP TO BE INSTALLED
CAP
YAZAKI 7034-1280
TERMINAL TERMINAL
HEAT SHRINKAGE TUBE TO BE INSTALLED
23.3.5-38 ENGINE GROUNDING CABLE : LQ13E01100P1
TERMINAL TERMINAL
CORRUGATED TUBE TO BE INSTALLED
23.3.5-52 AIR CLEANER HARNESS : LC13E01193P1
SW-8 :
AIR FILTER CLOGGING
SWITCH
WHITE TAPING
23-24
23. ELECTRIC SYSTEM
23.3.6 ENGINE HARNESS ASSY
E-11 : HARNESS (ECU)

ENGINE HARNESS ASSY LQ16E00010F1 (03)
AIR COMPRESSOR ENGINE ACCESORY
CLUTCH
1 HARNESS LQ16E01015P1 1 ENGINE SUB
M-1 :
STARTER CABLE STARTER MOTOR
TIGHTENING TORQUE
23.5N.m (17.3 lbf. ft)
SEMS BOLT
B TERMINAL
M-1 :
STARTER MOTOR HARNESS (UPPER)
REMOVE AND CANCEL THE HARNESS OF
ATTACHMENT FOR SC TERMINAL
TIGHTENING TORQUE
23.5N.m (17.3 lbf. ft)
SEMS BOLT DETAIL A
STARTER CABLE
HARNESS (UPP)
ENGINE GROUND CABLE
COOLANT THERMO SENSOR (ECU) COOLANT THERMO SENSOR (ECU)
ALTERNATOR (L, R)
TIGHTENING TORQUE
TIGHTENING TORQUE 9.6N.m (7.1 lbf. ft)
3.3~4.4N.m (2.4~3.3 lbf. ft) CLIP
FIX A HARNESS WITH CLIP ALTERNATOR (B) SEMS BOLT
ON BRACKET OF
ENGINE ACCESSORY
CLIP
HARNESS (ENGINE SUB)
FIX A WHITE TAPING
SW-7 : HARNESS (UPP) TIGHTENING TORQUE
SEMS BOLT 3.3~4.4N.m (2.4~3.3 lbf. ft)
FIX THE PLATE TO ENGINE OIL PRESS SW
CLIP
ENGINE BRACKET SEMS BOLT
TIGHTENING TORQUE
25.5N.m (18.8 lbf. ft)
ENGINE SUB HARNESS

UPPER HARNESS
ALTERNATOR
E-2 :
ALTERNATOR
VIEW CONNECT UPP HARNESS
DETAIL OF ALTERNATOR
23-25
23. ELECTRIC SYSTEM
23.3.6.1 ENGINE SUB-HARNESS : LQ16E01015P1
E-2 : ALTERNATOR
SW-7 :
ENGINE OIL PRESS. SW.
SEALING PLUG
ENGINE COOLANT
THERMO SENSOR (FOR ECU)
WHITE TAPING
SEALING PLUG
TO UPP HARNESS
23-26
23. ELECTRIC SYSTEM
23.3.7 UPPER HARNESS ASSY (FLOOR PLATE) (1/2)
UPPER HARNESS ASSY LC13E00032F1 (10) NOTE : 1. ATTACHMENT OF WELDING CLIP WITHOUT DIRECTIONS IS
MADE INTO THE FOLLOWING.
CLIP
1 HARNESS YN13E01449P3 1 FLOOR
HARNESS
4 HARNESS LC13E01186P1 1 CAB SUB HARNESS
9 CABLE LE13E01005P1 1 FLOOR HARNESS GROUND
SW-1 :
FIX A HARNESS ON KEY SW.
SENSOR BLOCK BY CLIP
CLIP SW-16 :
TO WASHER MOTOR ACCEL POTENTIO
SW-1 : KEY SWITCH
CLIP CLIP
USE THE HOLE OF SEAT CAB HARNESS
SE-16 :
STAND AND FIX HARNESS
ACCEL POTENTIO
WITH CLIP
FIX WHITE TAPING SE-1 :
POSITION PRESS SENSOR :
BUCKET DIGGING
TO WASHER MOTOR
SE-8 : SE-2 :
ARM OUT BUCKET DUMP
SE-7 : SE-4 : SE-3 :
PRESS SENSOR : PRESS SENSOR : PRESS SENSOR : FIX A HARNESS TO CLIP OF
ARM IN BOOM DOWN BOOM UP CAB SIDE COVER
DETAIL A : A CASE SENSOR TOWER VIEW

PUSH CONTROL LEVER MOST FRONTWARD
AND FIX THIS SLACK HARNESS WITH CLIP
SW-12 :
SW-35 : OVER LOAD ALARM SELECT SW.
HEAVY LIFT SW. CONNECT SWITCH TO TAGGED
CONNECT SWITCH "OVER L" CONNECTOR
TO TAGGED "HEAVY"
SW-13 : CONNECTOR
TRAVEL ALARM SW.
IN CASE OF TRAVEL SW-40 :
ALARM SPEC., ROTARY LIGHT SW.
CONNECT SWITCH TO CONNECT SWITCH TO TAGGED "ROTARY"
FIX A CORRUGATERD TAGGED "ALARM" CONNECTOR
TUBE NOT CONTACT CONNECTOR
M-CONNECTOR LOCK OF CONNECTOR. CLIP
SENSOR FIX A HARNESS
OF SW. SIDE
CLIP CLIP
FIX A HARNESS PART OF CLIP
SE-20 : PRESS SENSOR : P1 OPT WHITE TAPING OF CLIP FIX A CLIP ON HOLE
OF STAND SIDE
TIGHTENING TORQUE 10.7N.m (7.9lbf.ft)
TIGHTEN AFTER CHECKING NO PAINT HERE CLIP
FIX A CLIP ON HOLE SW-20 :
NUT
FLOOR HARNESS GROUND OF STAND SIDE POWER BOOST SW. RIGHT
TO PRESS SENSOR, FASTEN FLOOR HARNESS
TUNER CONNECT WITH EARTH MULTI, (YELLOW TAPING)
CABLE OF UPPER WITH LEVER SW.
OVER LOAD ALARM SW. WASHER MOTOR SW-33 :
FRAME HARNESS
HEAVY LIFT SW. REVOLUTION RIGHT SW. (OPT)
TOGETHER
(RED TAPING)
TRAVEL INDEPENDENT CHANGE SW.
SE-10 : SW-5 :
ATT BOOST SW. (RH)
PRESS SENSOR : HORN SW. RIGHT (OPT) (BLUE TAPING)
HORN SW. (RH)
TRAVEL LEFT
ATT BOOST SW. (LH)
SE-9 :
HORN SW. (LH) PRESS SENSOR :
DC-DC CONVERTER TRAVEL RIGHT E-7 :
WASHER MOTOR TUNER CLIP
SE-11 : CLIP FIX WHITE TAPING
PRESS SENSOR : FIX WHITE TAPING POSITION
P2 OPT CLIP FIX A CLIP ON HOLE
POSITION
FIX WHITE TAPING OF SEAT SIDE
THROUGH THE HARNESS
POSITION
AT SEAT SIDE OF BRACKET
CLIP
FIX WHITE TAPING POSITION TO THE FRONT SIDE OF FLOOR PLATE
23-27
23. ELECTRIC SYSTEM
23.3.7 UPPER HARNESS ASSY (FLOOR PLATE) (2/2)
SW-10 : E-1 :
HORN SW. LEFT (OPT) (BLUE TAPING) FUSE & RELAY
SW-21 : BOX C-1 :
POWER BOOST SW. LEFT (OPT)
MECHATRO CONNECT THE "CNT-2" TAGGED
(YELLOW TAPING) C-8 : ENG. CONTROLLER CONTROLLER CONNECTOR WITH "UPPER HARNESS"
SW-34 :
REVOLUTION LEFT SW. (OPT)
(RED TAPING) CONNECT TO SWING
PARKING RELEASE SW.
CONNECT THE "CNT-4" TAGGED

CONNECTOR OF CAB HARNESS E-22 :
SW-11 : WITH "ITEM 1 HARNESS" DC-DC CONVERTER
LEVER LOCK SW.
CLIP
CONNECT TO CAB HARNESS
PUSH CONTROL LEVER

MOST FRONTWARD
AND FIX THIS SLACK CLIP
HARNESS WITH CLIP CONNECT TO
DC-DC CONVERTER
CLIP TO FLOOR PLATE
CLIP BACK SIDE
DETAIL OF WASHER MOTOR CONNECTION
CLIP TO RIGHT
FIX WHITE TAPING INST-PANEL
POSITION
CLIP
USE CLIP TO TIE UP WHITE TO UNDER
TAPING PART OF HARNESS FLOOR
WITH PILOT HOSE TOGETHER TO LEFT
VIEW INST-PANEL
TO IT CONTROLLER
CONNECT THE "CNT-1" TAGGED HARNESS
CONNECTOR WITH "ECU HARNESS"
C-1 :
CONNECT THE "CNT-3" TAGGED E-1 :
MECHATRO CONTROLLER
CONNECTOR OF CAB HARNESS CLIP FUSE & RELAY
WITH "UPPER HARNESS" BOX
CONNECT THE "CN2-1" CONNECT THE "CN2-2" CLIP
TAGGED CONNECTOR WITH TAGGED CONNECTOR WITH CLIP FIX WHITE TAPING POSITION
TIE UP "ITEM 1 HARNESS" WITH
"ITEM 1 HARNESS" "ITEM 1 HARNESS" TO THE PLATE WITH CLIP
"ITEM 12 HARNESS" USING CLIP
TO THE PLATE WITH CLIP CAB SUB HARNESS
CONNECT TO SWING
DETAIL OF FUSE & RELAY BOX CONNECTION PARKING RELEASE SW.
FIX TO THE UPPER PART CONNECT THE "CNT-2"

OF PLATE WITH CLIP TAGGED CONNECTOR
WITH "UPPER HARNESS"
CONNECT THE "CN3-2" TAGGED

CONNECTOR WITH "ITEM 4 HARNESS" CONNECT THE "CN2-3"
TAGGED CONNECTOR WITH
CONNECT THE "CN3-1" "ITEM 1 HARNESS"
TAGGED CONNECTOR WITH
"ITEM 4 HARNESS"
VIEW
FLOOR HARNESS
FIX TO THE LOWER PART

OF PLATE WITH CLIP
34P CONNECTOR 22P CONNECTOR 28P CONNECTOR 22P CONNECTOR TO UNDER

VIEW FLOOR
SECTION AA
23-28
23. ELECTRIC SYSTEM
23.3.7-1 FLOOR HARNESS (1/3) : YN13E01449P3
SE-9 :
PRESS SENSOR :
TRAVEL RIGHT
SW-1 :
KEY SW.
WHITE TAPING SUPPLY WITH

SW-39 :
NIBBLER OPEN AMP 1565123-1
WHITE TAPING
PRESSURE SW.
SUPPLY WITH
SUPPLY TAPING AFTER TAPING AFTER

WITH BUNDLED BUNDLED
SUPPLY WITH SUMITOMO 6409-0603
SE-11 :
PRESS SENSOR : WHITE TAPING
SEALING PLUG TO BE P2 OPT
INSERTED IN TO ALL
WHITE TAPING
TAPING
SE-10 :
PRESS SENSOR :
TRAVEL LEFT
SE-20 :
PRESS SENSOR : SE-16 :
P1 OPT ACCEL POTENTIO
TAPING AFTER
BUNDLED TO ECU HARNESS
WHITE TAPING
TAPING
WHITE TAPING WHITE TAPING
WHITE TAPING TAPING
SUPPLY WITH
WHITE TAPING
SUPPLY WITH DOUBLE TO UPPER HARNESS
SPLICE
AMP 1565123-1 WHITE TAPING
DOUBLE
SPLICE
SW-43 :
JIB PRESS SW.
TO FRAME GND. M-4 :
WASHER MOTOR
TAPING
SEALING PLUG TO BE
INSERTED IN TO ALL
SW-4 :
SWING RELEASE SW.
SE-8 : SE-1 :
ARM OUT BUCKET DIGGING
SE-7 : SE-2 : E-1 :

PRESS SENSOR : PRESS SENSOR : FUSE & RELAY BOX
ARM IN BUCKET DUMP
SE-4 : SE-3 :
BOOM LOWERING BOOM RAISING
23-29
23. ELECTRIC SYSTEM

#
!
%

$

"

#!"#

!

23-30
23. ELECTRIC SYSTEM
23-31
23. ELECTRIC SYSTEM
23.3.7.2 CAB SUB-HARNESS : LC13E01186P1
TO HARNESS (UPPER)
E-1 :
FUSE & RELAY BOX
TO CAB HARNESS
23.3.7.3 FLOOR GROUNDING CABLE : LE13E01005P1
100 (3.94")
1PAF
YAZAKI 7123-3010
23-32
23. ELECTRIC SYSTEM
23.3.8 CAB HARNESS ASSY
CAB HARNESS ASSY LC14E00023F1 (07)

E-1 :
1 HARNESS YN14E01102P3 1 CAB FUSE & RELAY BOX
C-1 :
6 HARNESS YN14E01106P1 1 KEY S/W GROUND MECHATRO CONTROLLER
CAB SUB HARNESS
E-23 :
12V SOCKET
E-9 :
SPEAKER RIGHT
CONNECT TO
FLOOR HARNESS
TIGHTENING TORQUE 4.4N.m (3.2 lbf.ft) CONNECT TO

FIX WHITE CONNECT WITH CAB WORK LIGHT
TIGHTEN SEMS BOLT AFTER CAB SUB HARNESS
TAPING CONNECT WITH ROOM LIGHT
CHECKING NO PAINT IS HERE
POSITION
SEMS BOLT
FIX WHITE CLIP CONNECT WITH WIPER INTERLOCK SW. CLIP
CAB HARNESS GROUND TAPING
E-14 :
GAUGE CLUSTER POSITION FIX TO CLIP ON THE DUCT
CAB WORK LIGHT SW. CIGARETTE
CAB HARNESS
AIR-CON UNIT LIGHTER
UPPER HARNESS (GND)
CLIP FIX WHITE TAPING
BOOM DECK WORK LIGHT SW.
CAB WORK LIGHT FRONT POSITION
WIPER INTERLOCK SW. SW-15 :
HOUR METER CONFLUX / SINGLE
WIPER MOTOR SELECT SW. E-8 :
CIGARETTE LIGHTER SPEAKER LEFT
12V POWER SOURCE SOCKET SW-55 : FLOOR HARNESS
SKY ROOF WIPER (OPT) BOOM , DECK
CONFLUX / SINGLE CHANGE SW. WORKING LIGHT SW. CAB SUB CONNECT TO
CAB WORK LIGHT HARNESS UPPER HARNESS
SW-1 :
KEY SW. TO AIR
6 CONNECT WITH
CONDITIONER UNIT
CAB WORK LIGHT
FLOOR HARNESS CLIP
UPPER HARNESS
1
C-2 :
GAUGE CLUSTER
DETAIL A
CLIP
SW-41 :
HIGH REACH CRANE SW.
CLIP CONNECT THE SWITCH
WITH "CRANE" TAGGED
E-3 : BLACK CONNECTOR
HOUR METER SW-17 : SW-26 :
ROOF WIPER SW. CAB WORK LIGHT SW.
CONNECT THE SWITCH CONNECT THE SWITCH WITH "CAB LIGHT"
M-3 : WITH "WIPER" TAGGED TAGGED NATURAL COLOR CONNECTOR
SW-55 :
WIPER MOTOR NATURAL COLOR
BOOM , DECK WORKING LIGHT SW. E-4 :
CONNECT THE SWITCH WITH "BOOM, DECK" CONNECTOR
CIGARETTE LIGHTER
TAGGED BLUE CONNECTOR
E-4 :
CIGARETTE
LIGHTER
TO AIR
CONDITIONER UNIT
FIX TO THE
BRACKET
FIX WHITE TAPING CLIP
POSITION
TIE UP FLOOR HARNESS WITH
CLIP
CAB HARNESS USING CLIP
SW-15 : SW-1 :
CONFLUX / SINGLE KEY SWITCH
SELECT SW.
CONNECT THE SWITCH
WR B
WITH "CONFLUX" TAGGED
GREEN CONNECTOR
DETAIL B VIEW II
DETAIL OF HOUR METER VIEW I
23-33
23. ELECTRIC SYSTEM
23.3.8.1 CAB HARNESS (1/2) : YN14E01102P3
E-8 : SPEAKER LEFT
DOUBLE
WHITE TAPING SPLICE
DOUBLE
TAPING AFTER SPLICE
BUNDLED
TO CAB WORKING LIGHT
TO CAB WORKING LIGHT
DOUBLE
SPLICE E-9 :
DOUBLE
SPLICE SPEAKER RIGHT
WHITE TAPING
TO ROOF WIPER
E-23 : SHIELD UN-CONNECTED
12V SOCKET
TAPING TAPING C-2 :
GAUGE CLUSTER
L-5 : ROOM LIGHT

TAPING WHITE TAPING
M-3 : WIPER METER
DOUBLE
SW-19 : SPLICE
WIPER INTERLOCK SW. E-3 :
DOUBLE SW-17 : HOUR METER
TO CAB GND. SPLICE ROOF WIPER
SW-41 : SW-15 :
SW.
HIGH REACH CONFLUX / SINGLE
CRANE SW. SELECT SW.
TO ROTALY LIGHT C-4 : E-14 :
TO HARNESS (FLOOR) CIGARETTE LIGHTER
AIR CONDITIONER UNIT WHITE TAPING SW-55 :
TO HARNESS (UPP)
DOUBLE BOOM, DECK
SPLICE
WORKING LIGHT SW.
SW-26 :
CAB WORK LIGHT
SW.
DOUBLE
SPLICE
WHITE TAPING
TAPING TAPING AFTER TAPING AFTER
BUNDLED BUNDLED
TAPING
TO CAB HARNESS
23-34
23. ELECTRIC SYSTEM
23.3.8.1 CAB HARNESS (2/2) : YN14E01102P3 23.3.8-6 KEY SWITCH GROUND HARNESS : YN14E01106P1
23-35
23. ELECTRIC SYSTEM
23.3.9 BOOM HARNESS ASSY 23.3.10 INSTALLING BOOM LIGHT
BOOM HARNESS ASSY YN15E00003F4 (07) INSTALLING BOOM LIGHT YN80E00011F1 (04)
5 HARNESS YN15E01042D1 1 BOOM LIGHT 1 LIGHT YW80S00001F1 1
CLAMP AT
TAPING POSITION
CLIP
TO UPPER
HARNESS
POINT THIS LAMP TO BUCKET BOTTOM CENTER.
INSTALL THE LAMP SO THAT THE LIGHT BEAM POINTS THE
23.3.9.1 BOOM HARNESS : YN15E01042D1
BOTTOM OF BUCKET, IN THE CONDITION THAT AREM IS
4250 EXTENDED FULLY (ARM OUT) AND BUCKET IS CLOSED FULLY.
1
980
Y Y
CB104
CAP : 170889-1 1MA-CNA
TERMINAL : 170003-5 T-AV0. 85sq WHITE TAPING YAZAKI 172127-1
(YELLOW) TERMINAL : 170340-1
TIGHTENING TORQUE : 18.6N.m

(13.7 lbf.ft)
SECTION AA
23-36
23. ELECTRIC SYSTEM
23.3.11 INSTALLING UPPER LIGHT
INSTALLING UPPER LIGHT YN80E00049F1 (01)

1 LIGHT YT80S00002F2 1
NOTE :
ITEM 1, TIGHTENING TORQUE 18.6N.m (13.7 lbf.ft)
MAIN HARNESS
NUT (SUPPLIED WITH LIGHT)
HOW TO INSTALL LIGHT AT RIGHT SIDE DECK
23-37
23. ELECTRIC SYSTEM
23.3.12 FUEL PUMP ASSY 23.3.12-1 FUEL PUMP ASSY
FUEL PUMP ASSY YN22P00024F1 (01) FUEL PUMP ASSY YF22P00008F1 (01)
1 FUEL PUMP ASSY YF22P00008F1 1 1 FUEL PUMP YF22P00009P1 1
12 LEVEL SENSOR YF52S00004P1 1
RUBBER PLUG : AMP 172888-2

HOUSING : AMP 174259-2
12
BLACK GREEN
TIGHTENING TORQUE
0"
) 147N.m (108 lbf.ft)
.1 HOSE
(1
RED WHITE
CONTACT : AMP 173706-1 LOCK PLUG : AMP 174260-7

SECTION CC
CLIP
TIGHTENING TORQUE
6.86N.m (5.06 lbf.ft) CAPSCREW
TIGHTENING TORQUE
23N.m (17.0 lbf.ft)
HOSE
SEMS BOLT
(1
TIGHTENING TORQUE
.1
0"
)
80N.m (59.0 lbf.ft)
DETAIL aa
12
C
C
1 CLIP
GROMMET
PF3/4
SEMS BOLT
TIGHTENING TORQUE
80N.m (59.0 lbf.ft)
NOTE :
1) MAKER : JABSCO CO. LTD
2) NAME : 50L PUMP ADD AUTOMATIC STOP DEVICE
23-38
23. ELECTRIC SYSTEM
23.3.13 TRAVEL ALARM ASSY
ALARM ASSY YN53E00015F1 (01)

1 ALARM YN53S00004F1 1
3 SWITCH YN50S00040DF 1
4 RELAY YN24S00010F1 1
TIGHTENING
TORQUE
23.5N.m
(17.3lbf.ft)
SEMS BOLT
E-13 :
TRAVEL ALARM
1
UPP
HARNESS
VIEW
SW-13 :
TRAVEL ALARM SW.
CONNECT WITH NAME TUBE OF "ALARM"
3
4
TRAVEL ALARM RELAY
DETAIL OF FUSE & RELAY BOX
RIGHT CONSOLE BOX
23-39
23. ELECTRIC SYSTEM
[MEMO]
23-40
24. COMPONENTS SYSTEM
TABLE OF CONTENTS
24.1 HYDRAULIC COMPONENTS .........................................................................................24-3

24.1.1 HYDRAULIC PUMP • REGULATOR ......................................................................24-3
24.1.2 CONTROL VALVE..................................................................................................24-21
24.1.3 PILOT VALVE (ATT)...............................................................................................24-59
24.1.4 PILOT VALVE (TRAVEL) .......................................................................................24-63
24.1.5 SWING MOTOR UNIT ............................................................................................24-65
24.1.6 TRAVEL MOTOR ...................................................................................................24-75
24
24.1.7 SWIVEL JOINT.......................................................................................................24-89
24.1.8 CYLINDER..............................................................................................................24-91
24.2 ELECTRIC EQUIPMENT.................................................................................................24-97
24.2.1 ELECTRIC EQUIPMENT LIST ...............................................................................24-97
24.2.2 SPECIFICATION OF ELECTRIC EQIUPMENTS...................................................24-100
24-1

E215B : YN11-45001~ S5YN2422E01
↑
↑ ↑ ↑ K
↑
↑ ↑ ↑ K
24-2
24.1 HYDRAULIC COMPONENTS

24.1.1 HYDRAULIC PUMP • REGULATOR
24.1.1.1 SUMMARY
(1) Outside view and Hydraulic port
5
EYE BOLT (M10)
a3 PSV2
Dr
A3 2X4-M12
Depth 22
A1 A2
B3
a4 VIEW
PSV1
MAX. FLOW RATE ADJUSTING SCREW
PH1 PH2
4 PSV1 4
PSV2 PSV2
MIN. FLOW MIN. FLOW RATE

2 2 ADJUSTING SCREW
RATE
ADJUSTING a3
SCREW
PH1 PH2 PH2 PH1
a4
a1 3 a1
a2
a2 B3
B3
B1
Dr B1
A3
Dr3 a5
A1 A2 5
1 A2
Dr3
Hydraulic ports
No. Parts Q'TY Code Ports name Size
1 Main pump assy 1 A1,2 Delivery port SAE 6000psi 1"
2 Regulator assy 2 B1 Suction port SAE 2500psi 2 1/2"
3 Gear pump assy (for pilot) 1 Dr Drain port PF3/4-20
4 Solenoid proportional reducing valve 2 PSV1,2 Servo assist port PF1/4-13
5 PTO unit (OPT.) 1 PH1,2 Pressure sensor port PF3/8-17
a1~a4 Gauge port PF1/4-15
a5 Gauge port PF1/4-14
A3 Delivery port of gear pump PF1/2-19
B3 Suction port of gear pump PF3/4-20.5
Dr3 Drain port of gear pump PF3/8-15
Fig. 24-1 Hydraulic pump • regulator
24-3
(2) Hydraulic circuit diagram
(FRONT) PSV1 a1 A1 PH1 PH2 A2 a2 PSV2 (REAR)

(KDRDE5K) (KR3G-YTOK-HV) (KR3G-YTOK-HV) (KDRDE5K)
Solenoid proportional Solenoid proportional

reducing valve (PSV-1) reducing valve (PSV-2)
Regulator Regulator
a3 Dr a4
Engine Gear pump for pilot
a5
Main pump
B1 B3 Dr3 A3
PTO gear case

(OPT.)
Fig. 24-2 Hydraulic circuit diagram of pump

(3) Specifications
Item Main pump Gear pump

Pump assy YN10V00036F1 -
Parts No.
Single Pump YN10V00043F1 YN10V00014F3
Pump model K3V112DTP1K9R-YT0K-HV ZX10LGRZ2-07G
Max.displacement capacity cm3 110 X 2 10
Revolution Rated min-1(Clockwise seen from shaft end) 2000
Rated 34.3 (4980)
Pressure MPa (psi) 5.0 (725)
ATT boost pressure 37.8 (5480)
Max. flow L/min (gal/min) 220 (58) X 2 at 7.8MPa (1130 psi) 21 (5.5)
Max. input horse power kW (PS) 114 (155) 3.4 (4.6)
Max. input torque N.m (lbf.ft) 544 (401) 14.7 (10.8)
Part No. YN10V01009F1
Model KR3G-YTOK-HV
Regulator Electric flow control, positive flow control,
Control function
total power control at emergency mode and power shift control
Others With solenoid proportional reducing valve (KDRDE5K-31/30C50)

Weight kg (lb) 141 (310)
24-4
24.1.1.2 HYDRAULIC PUMP
24.1.1.2.1 CONSTRUCTION
(1) Main pump
953 806 789 532 Apply adhesive (Three Bond No.1305N) 724 901 808 954 717 151 152 211
886 214 548 531 702 792 534 A
535 732
717
261
406
824
774
111
B B
127
123
710 04
212
401 251 490 271 153 156 157 468 313 124 710 116 467 466 312 885 314 141 271 113
728 727 725
Tightening torque 05
Tightening torque
Item number Thread size
N.m (lbf.ft) 546
401 M20 430 (317) 414 326
406 M8 29 (21) 725
407 M6 12 (8.9) 727
414 M10 57 (42)
466 PF 1/4 36 (27)
467 PF 3/8 74 (55)
468 PF 3/4 170 (125)
490 NPTF1/16 8.8 (6.5)
531,532 M24X2 240 (177) 407 325
806 M16 130 (96) SECTION B-B SECTION B-B
VIEW A
808 M20 240 (177) (OPT.)
No. Parts Q'ty No. Parts Q'ty No. Parts Q'ty
111 Drive shaft (F) 1 314 Valve plate (L) 1 724 O-ring ; 1B P8 16
113 Drive shaft (R) 1 325 Sensor block 1 725 O-ring ; 1B P11 9
116 Gear #1 1 326 Cover 1 727 O-ring ; 1B P14 3
123 Roller bearing 2 401 Socket bolt ; M20X210 8 728 O-ring ; 1B P24 4
124 Needle bearing 2 406 Socket bolt ; M8X20 4 732 O-ring ; 1B P18 2
127 Bearing spacer 3 407 Socket bolt ; M6X55 3 774 Oil seal 1
141 Cylinder block 2 414 Socket bolt ; M10X20 4 789 Back up ring ; P18 2
151 Piston 18 466 VP plug ; PF1/4 2 792 Back up ring ; G35 2
152 Shoe 18 467 VP plug ; PF3/8 2 806 Nut ; M16 2
153 Retainer plate 2 468 VP plug ; PF3/4 4 808 Nut ; M20 2
156 Spherical bushing 2 490 Plug ; NPTF1/16 32 824 Snap ring 2
157 Cylinder spring 18 531 Tilting pin ; M24X2 2 885 Valve plate pin 2
211 Shoe plate 2 532 Servo piston ; M24X2 2 886 Spring pin 4
212 Swash plate 2 534 Stopper(L) 2 901 Eye bolt ; M10 2
214 Tilting bushing 2 535 Stopper(S) 2 953 Socket screw ; M16X35 2
251 Swash plate support 2 546 Spacer 2 954 Set screw ; M20 2
261 Seal cover (F) 1 548 Feed back pin 2 04 Gear pump 1
271 Pump casing 2 702 O-ring ; 1B G35 2 05 PTO unit 1
312 Valve block 1 710 O-ring ; 1B G95 2
313 Valve plate (R) 1 717 O-ring ; 1B G145 4
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Fig. 24-3
24-5
(2) Gear pump (For pilot)
700 354 351

Suction port : PF3/4 433
Tightening torque : 73.5N.m
(54.2 lbf.ft)
434
Delivery port : PF1/2

Tightening torque :
53N.m (39.1 lbf.ft)
311
312
732 307 850
434 355
Drain port : PF3/8 310 308 309 466
725
710 435 361 353 Tightening torque :
34.3N.m (25.3 lbf.ft)
No. Parts Q’ty No. Parts Q’ty

307 Poppet 1 361 Front case 1
308 Seat 1 433 Flange socket; M8×40 2
309 Ring 1 434 Flange socket; M8×55 2
310 Spring 1 435 Flange socket; M8×20 4
311 Adjust screw 1 466 VP plug ; PF1/4 1
312 Lock nut ; M14×1.5 1 700 Ring 1
351 Gear case 1 710 O-ring ; 1B G95 1
353 Drive gear 1 725 O-ring ; 1B P11 1
354 Driven gear 1 732 O-ring ; 1B P16 1
355 Filter 1 850 Locking ring 1
24-6
(3) PTO gear case (OPT.)
125
711 468
118 825 710 728
117
126
326 262
115
128
826
414
435
886
885

115 Idle shaft 1 435 Flange socket ; M10×20 4
117 2nd gear 1 468 VP plug ; PF3/4 1
118 3rd gear 1 710 O-ring ; 1B G80 1
125 Ball bearing 2 711 O-ring ; 1B G85 1
126 Roller bearing 1 728 O-ring ; 1B P24 1
128 Bearing spacer 2 825 Snap ring 1
262 Cover 2 826 Snap ring 1
326 Gear case 1 885 Sprig pin 1
414 Capscrew ; M10×20 4 886 Pin 2
24-7
24.1.1.2.2 OPERATION
The pump assy is equipped with two pumps
arranged on the same axis that are connected with
gear (116) and distribute the rotating power to the REGULATOR
gear trains on a different axis. Thus the engine
rotation is transmitted to front shaft (111) that drives
the two pumps and, at the same time, drives the
auxiliary pump (OPT) arranged on another shaft. 116
The pump assy consists largely of the rotary group,
the main part of the pump that makes rotary on; the 111
swash plate group that changes the delivery rate;
the valve block group that selects between oil
suction and delivery ; and the PTO group (OPT)
that transmits the drive power to the auxiliary pump.
(1) Rotary group
PTO GEAR CASE
The rotary group consists of shaft(111), cylinder
(OPT)
block (141), piston (151), shoe (152), plate (153), AUXILIARY PUMP
spherical bushing (156), and cylinder spring (157). (OPT)
The shaft is supported by bearings (123) and (124) Fig. 24-4 Construction of hydraulic pump
at its both ends. The shoe, which is caulked to the
piston, forms a spherical joint and relieves it of
thrust force that is generated by load pressure.
Further, the piston is provided with a pocket so it
moves lightly on shoe plate (211), taking hydraulic
balance.
The sub group of the piston-shoe is pressed
against the shoe plate by the cylinder spring, via the
retainer plate and the spherical bushing, so that it
moves smoothly over the shoe plate. The cylinder
block (141) is also pressed against valve plate
(313) by the action of cylinder spring (157).
313
124
312
111
116
124
314
141
157
156
151
. 153
152
211
Fig. 24-5 Rotary group
24-8
(1) Swash plate group 532

The swash plate group consists of swash plate
(212), shoe plate (211), swash plate support (251),
531
tilting bushing (214), tilting pin (531), and servo 214 211
piston (532). The swash plate is the cylindrical part 212
that is formed on the opposite side of the shoe
sliding surface and is supported by the swash plate
support. 251
The hydraulic force controlled by the regulator
flows into the hydraulic chamber that is provided on
both sides of the servo piston. This moves the
servo piston to the right and left. The result is that
the swash plate swings on the swash plate support
via the spherical part of the tilting pin and changes
Fig. 24-6 Swash plate group
the tilting angle (a).
(2) Valve block group
The valve block group consists of valve block (312),
valve plates (313 or 314), and valve plate pin (885). 313
312
The valve plates having two crescent-shaped ports
are installed to valve block (312) to feed oil and
recycle it from cylinder block (141). The oil switched 116
over by the valve plate is connected with the 111
external pipe by way of the valve block. 314
141
885
Fig. 24-7 Valve block group

(3) PTO group (OPT) 117
The PTO group is composed of 1st gear (116), 2nd
gear (117) and 3rd gear (118). The 2nd and the 3rd 126
gear are supported by bearings (125) and (126)
respectively and installed to the valve block.
Now, if the shaft is driven by the engine, the cylinder
block rotates together by the spline linkage. If the
swash plate is inclined, the pistons arranged in the
cylinder block make reciprocating motion with
respect to the cylinder while rotating with the 118
cylinder block. If we keep an eye on a single piston,
125
it makes a motion away from the valve plate (oil
suction process) in the first 180°and a motion
toward the valve plate (oil delivery process) in the
125
remaining 180°. If the swash plate is not inclined
(zero tilting angle), the piston does not stroke i.e.
Fig. 24-8 PTO group
delivers no oil.
The shaft rotation is taken up by the 1st gear (116)
and transmitted to the 2nd gear (117) and the 3rd
gear (118), in that order, to drive the gear pump that
is linked to the 3rd gear.
24-9
24.1.1.3 REGULATOR
PSV B PSV 418

413
079
757 D
439
438
725
730
a3
656 643
438 924
D
801
722 543 755 545 541 724 B 466, 755 708 644 646 645 728
VIEW C SECTION B-B
641 655 654 836 651 652 601

624
734 629
612 897 876 874 755 858 653
A 630
615 814
412 628
614 631 627

C
613
898 802
875
A 732
611 753
733
756
622 621 623 625 626 887 763
SECTION A-A
At start and
emergency mode
Tightening torque
662 642 Tightening torque
Item No. Thread size
N.m
543 545 541
466 412,413 M8 29
At normal
438,439 M6 12
755 E 418 M5 6.9
466 PF 1/4 36
496 NPTF1/16 8.8
496 630 M30X1.5 160
755 E
801 M8 16
802 M10 19
SECTION E-E SECTION D-D
Fig. 24-9
24-10

412 Socket bolt ; M8X50 2 628 Adjusting screw (C) 1 732 O-ring ; 1B P16 1
413 Socket bolt ; M8X70 2 629 Cover (C) 1 733 O-ring 1
418 Socket bolt ; M5X12 2 630 Lock nut ; M30X1.5 1 734 O-ring ; 1B G25 1
438 Socket bolt ; M6X20 8 631 Sleeve (For PF) 1 753 O-ring ; 1B P9 1
439 Socket bolt ; M6X25 5 641 Pilot cover 1 755 O-ring ; 1B P11 7
466 VP plug ; PF1/4 3 642 Spool 1 756 O-ring ; 1B P26 1
496 Plug ; NPTF1/16 17 643 Pilot piston 1 757 O-ring ; 1B P12.5 1
541 Seat 2 644 Spring seat (Q) 1 763 O-ring ; 1B G35 1
543 Stopper 1 2 645 Adjusting stem (Q) 1 801 Nut ; M8 1
545 Ball 2 646 Pilot spring 1 802 Nut ; M10 1
601 Casing 1 651 Sleeve 1 814 Snap ring 1
611 Feed back lever 1 652 Spool 1 836 Snap ring 1
612 Lever (1) 1 653 Spring seat 1 858 Snap ring 2
613 Lever (2) 1 654 Return spring 1 874 Pin ; 4X11.7L 1
614 Fulcrum plug 1 655 Set spring 1 875 Pin ; 4X8L 2
615 Adjusting plug 1 656 Block cover 1 876 Pin ; 5X8L 2
621 Compensating piston 1 662 Spring 1 887 Pin 1
622 Piston case 1 708 O-ring ; 1B G75 1 897 Pin ; 5X19L 1
623 Compensating rod 1 722 O-ring ; 1B P6 3 898 Pin ; 11.5X11.8L 1
624 Spring seat (C) 1 724 O-ring ; 1B P8 8 924 Socket screw ; M8X20 1
625 Outer spring 1 725 O-ring ; 1B P10 1 041 Sub-check valve 2
626 Inner spring 1 728 O-ring ; 1B P18 1 079 Solenoid proportional reducing valve 1
627 Adjusting stem (C) 1 730 O-ring ; 1B P22 1
The codes in a rectangle represent adjust screws.
Do not tamper with the adjust screws as much as possible.
24-11
(1) Control function
Control function …… Electric flow control.
•Positive flow control.
•Total horsepower control.
Emergency mode control.
•Hydraulic positive control.
•Hydraulic total horsepower control
(2) Summary
The regulator KR3G-YTOK for the in-line type axial piston pump K3V series is composed of the control
mechanism as mentioned below:
1) Electric flow control and positive flow control
The tilting angle of the pump (delivery rate) is controlled by controlling the current command value of the
solenoid proportional reducing valve attached to the regulator. The regulator makes positive flow control
(positive control) that increases the delivery rate as the secondary pressure of the solenoid proportional
reducing valve rises. Since this function permits the output power of the pump to be varied, it is possible to
attain optimum power according to the operating condition. Also, since the pump delivers only the necessary
oil flow, the machine does not consume excessive power.
2) Constant power control at emergency mode

When the electromagnetic proportional pressure-reducing valve cannot output the secondary pressure due
to the trouble, the spool for emergency mode is switched automatically, and the control is switched from
electric control to hydraulic control (emergency mode).
In emergency mode, the power shift command pressure Pf shifts the power set value. The power shift
pressure (secondary pressure of electromagnetic proportional pressure-reducing valve) is led to power
control section of regulator on each pump through pump inside passage and shifts respective control to the
same power set value.
In the power shifted condition, as self pump delivery pressure Pd1 rises, the pump tilt angle (delivery rate) is
automatically reduced; consequently the input torque is controlled to the constant value or less. (When the
speed is constant, the input power is also constant.)
This pump is controlled by Pd1 only regardless of another delivery pressure. Condition where the power is
controlled, the regulator of each pump is controlled to the different tilt angle (delivery rate). Consequently in
the condition where the power is controlled, the overloading of engine is automatically prevented regardless
of the loading of pump 2. And in normal condition, because the power shift pressure is 0MPa, the power
control is not worked.
With this mechanism, it is possible to obtain proper power for the working condition.
This regulator is made up of the above two kinds of control system, but when both controls are actuated
together, the low tilt angle (low delivery rate) command precede on mechanical operation described later.
(3) Explanation of operation

1) Flow rate electrical control
Delivery flow rate Q
The pump delivery rate is controlled according to

the command current value corresponding to the
movement of control devices. This relation is
shown in right figure.
Command current I
Fig. 24-10
24-12
a. Flow rate increase (See Fig. 24-11)

CL port :
As the command current value I rises, the Connect with large
diameter chamber of
secondary pressure P2 of electromagnetic servo piston
proportional pressure-reducing valve rises, and 652
by pressing pilot piston (643) in (A) direction it 646
stops at the position the secondary pressure P2 B 613
balances the pilot spring force (646). The D 876 F 897
movement of pilot piston is transferred to lever 2 875
(613) through pin (875), and rotates at (B) A 611
643
fulcrum in arrow direction. Furthermore the lever C
2 movement is transferred to feedback lever
(611) through pin (897) and rotates at (C) fulcrum E 532
in the same arrow direction as (B). Consequently (KDRDE5K) Psv A
the spool (652) connected to feedback lever

moves towards (D). When the spool moves
towards (D), the port CL connected to tank port
is open and the pressure in servo piston large
bore diameter chamber is released,
consequently the servo piston (532) moves
towards (E) according to delivery pressure Pd1
in small bore diameter piston chamber, resulting Pd1
in the rise of flow rate. Since the feed back lever CL port
is connected to the servo piston and spool, the a3
feed back lever rotates at (F) fulcrums with the Hydraulic circuit diagram
B
movement of the servo piston towards (E),
consequently the spool is returned to the original Fig. 24-11
position. With this movement, the opening of
spool sleeve gradually closes, and the servo
piston stops at the position the opening closes
completely.
24-13
b. Flow rate decrease (See Fig. 24-12)

As the command current value I is reduced, the

secondary pressure P2 of electromagnetic

proportional pressure-reducing valve is reduced, #
and by pressing pilot piston (643) in (G) direction
it stops at the position the pilot spring force (646) !
balances the secondary pressure P2. The %
movement of pilot piston is transferred to lever 2
(613) through pin (875), and rotates at (H)
fulcrum in arrow direction. Furthermore the lever
$
2 movement is transferred to feedback lever "

(611) through pin (897) and rotates at (I) fulcrum
in the same arrow direction as (H). Consequently (")*)+", - .
the spool (652) connected to the feedback lever
moves towards (J). When the spool moves
towards (J), the delivery pressure Pd1 is led in
servo piston large bore diameter chamber
through spool and port CL. The servo piston
small bore diameter chamber constantly
receives delivery the pressure Pd1,
consequently the servo piston moves towards -
(K) according to the difference of area resulting

in the reduction of tilt angle, and finally the flow
rate is reduced. Since the feed back lever is !&' '
connected to servo piston and spool, the feed /
back lever rotates at (L) fulcrum with the Fig. 24-12
movement of servo piston towards (K),
consequently the spool is returned to the original
position. With this movement, the opening of
spool sleeve gradually closes, and the servo
piston stops at the position the opening closes
completely.
2) Power control (In emergency mode)
When the load pressure rises, the pump tilt angle
is reduced preventing the overloading of engine
as shown in Fig. 24-13.

The operation of power control is the same as
the flow rate control, and is explained below.
Delivery output (Pd1)

Fig. 24-13
24-14
a. Overload prevention operation (See Fig. 24-14)

Because the delivery pressure Pd1 acts on the

compensating rod stepped section with the rise

of self pump delivery pressure Pd1 the %
compensating rod (623) is pushed towards (M),
and moves to the position the delivery pressure "
!
Pd1 balances the spring force of outer spring
' $
(625) and inner spring (626). The movement of
(
compensating rod is transferred to lever 1 (612)

through pin (875), and rotates at (N) fulcrum in
&
arrow direction. Furthermore the lever 1 (612)
#
movement is transferred to feedback lever (611) (
through pin (897) and rotates at (O) fulcrum in +,--.,/ ' 0
the same arrow direction as (N). Consequently
the spool (652) connected with feedback lever
moves towards (P). When the spool moves
towards (P), the delivery pressure Pd1 is led in
servo piston large bore diameter chamber
through spool and CL port. Since the delivery
pressure Pd1 is constantly led to servo piston
large bore diameter chamber, the servo piston '
moves towards (Q) according to the difference of

area, resulting in the reduction of tilt angle, (
consequently the flow rate is also reduced. Since ")* *
1
the feed back lever is connected with servo
piston and spool, the feed back lever rotates at Fig. 24-14
(R) fulcrum with the movement of the servo
piston towards (Q), consequently the spool is
returned to the original position. With this
movement, the opening of spool sleeve
gradually closes, and the servo piston stops at
the position the opening closes completely.
24-15
b. Flow rate recovery operation (See Fig. 24-15)

897 876 625
Because the compensating rod (623) is pushed X 612 626
CL port : T S
towards (S) with the force of outer spring (625) Connect with large
diameter chamber of
and inner spring (626) with reduction of self servo piston G
pump delivery pressure Pd1, and moves to the 652
position the spring force of outer spring (625) H
and inner spring (626) balances the delivery
V J 875
pressure Pd1. The movement of compensating
623
rod is transferred to lever 1 (612) through pin 621
611
(875), and rotates at (T) fulcrum in arrow
direction. U
W
Furthermore the lever 1 (612) movement is
532
transferred to feedback lever (611) through pin (KDRDE5K) Psv A
(897) and rotates at (T) fulcrum in the same
arrow direction as (N). Consequently the spool
(652) connected to feedback lever moves
towards (V).
As the spool moves towards (V), CL port is open
and connected to tank port, the pressure of servo
piston large bore diameter chamber is released
and the servo piston (532) moves towards (W) Pd1
with delivery pressure Pd1 in small bore CL port
diameter chamber, and consequently the flow a3
rate is raised. Since the feed back lever is Hydraulic circuit daigram
connected to servo piston and spool, the feed B
back lever rotates at (X) fulcrum with the Fig. 24-15

movement of the servo piston towards (W),
consequently the spool is returned to the original
position.
With this movement, the opening of spool sleeve
gradually closes, and the servo piston stops at
the position the opening closes completely.
3) Priority mechanism of low tilt angle (low flow
rate) command
As the said explanation, the tilting commands of
flow rate control and power control are
transferred to feedback lever (611) and spool
(652) through the large bore section of lever 1
(612) and lever 2 (613), but because the pin (dia
5) is extruded in large bore (dia 9), pin (897) on
the side where making tilt angle smaller contacts
with it, consequently the bore (dia 9) of lever on
the side where larger tilt angle command is given
is free without contact with pin (897). In this
mechanical selecting manner, the command on
the side of low tilt angle of the flow rate control
and power control has a priority.
24-16
4) Power shift control

As shown in Fig. 24-16, the pump set power is
controlled according to the movement of control

by power shift pressure Pf.
As power pressure Pf rises, the compensating
rod (623) moves rightward through pin (898) and
compensating piston (621). Consequently like
the overloading prevention operation of power
control, the pump tilt angle becomes smaller and
the power setting value is reduced. Conversely,
if the power shift pressure Pf is reduced, the Delivery pressure (Pd1)
power set value is raised. Fig. 24-16
The power shift pressure Pf of this pump is
ordinary set to 0MPa, but in emergency mode,
the power shift pressure Pf is raised to 4.9MPa.
24.1.1.3.3 ADJUSTING THE REGULATOR

The regulator may be adjusted in terms of maximum
flow, minimum flow, horsepower (at emergency mode
control) control characteristics, flow control
characteristics using the adjust screw.
(1) Adjusting the maximum flow (See Fig. 24-3)
Adjust the maximum flow by loosening nut (808)
and by tightening set screw (954) (or loosening it).
Tightening set screw (954) decreases the delivery

rate, as indicated in Fig. 24-17.
Only the maximum flow varies, but other control
characteristics remain unchanged.
Adjust screw no. 954

No. of turns for tightening 1/4
Pilot pressure Pi (Input current I) No change Input current I (Pilot pressure Pi)
Fig. 24-17 Adjusting the max. delivery flow
Min. increase in delivery flow L/min (gal/min) 5.8 (1.5)
(2) Adjusting the minimum flow (See Fig. 24-3)

Adjust the minimum flow by loosening nut (806) and
by tightening socket screw (953) (or loosening it).
Tightening socket screw increases the delivery

rate, as indicated in Fig. 24-18.
Other control characteristics remain unchanged in
the same way as maximum flow adjustment, care
should be used of the fact that overtightening may
increase a required power at the maximum delivery
pressure (at relieving action).
Input current I (Pilot pressure Pi)
Fig. 24-18 Adjusting the min. delivery flow
Pilot pressure Pi (Input current I) No change
Min. increase in delivery flow L/min (gal/min) 4.6 (1.2)
24-17
(3) Adjusting the input horsepower

(At emergency mode)
Since the regulator is of total horsepower control
type, turn the adjust screws of both the front (No.1)
and rear (No.2) pumps when changing horsepower
set values. Adjust the horsepower settings of both
pumps to a same level. The pressure change
values by adjustment are based on two pumps
pressurized at the same time, and the values will by
halved when only one pump is loaded.
1) Adjusting the Outer Spring (See Fig. 24-9)
(At emergency mode)
Adjust it by loosening lock nut (630) and by

tightening adjust screw (628) (or loosening it).
Tightening the adjust screw shifts the control
chart to the right and increases the input
horsepower, as indicated in Fig. 24-19.
Since turning the adjust screw C (628) by N turns
changes the setting of the inner spring (626),
return the adjust screw C (627) by NX1.48 turns
at first. Delivery pressure (Pd1)
Fig. 24-19 Adjusting the input horsepower (1)
Increase delivery pressure MPa (psi) 2.06 (299)
Increase in input torque N.m (lbf.ft) 50 (36.9)
2) Adjusting the Inner Spring (See Fig. 24-9)

(At emergency mode)
Adjust it by loosening nut (802) and by adjust
screw (C) (627) (or loosening it). Tightening the

adjust screw increases the flow and then the
input horsepower, as indicated in Fig. 24-20. And
the input torque raises.

Increase inflow L/min (gal/min) 12 (3.2) Delivery pressre (Pd1)
Fig. 24-20 Adjusting the input horsepower (2)
Increase in input torque N.m (lbf.ft) 58.7 (43.3)
(4) Adjusting the flow control characteristics (See Fig.

24-9)
Adjust them by loosening nut (801) and socket bolt
(924) (or loosening it). Socket bolt causes the

control chart to move to the right as shown in Fig.
24-21.

Increase Pilot pressure MPa (psi) 0.18 (26)
Input current I (Pilot pressure Pi)
Decrease in delivery flow L/min (gal/min) 18.5 (4.9)
Fig. 24-21 Adjusting the flow control
characteristics
24-18
24.1.1.3.4 CAUSES OF FAULT RESULTING FROM REGULATOR

When trouble due to this regulator occurs, disassemble
and inspect it referring to "Chapter YN33-II"
(1) When the engine is overloaded,
Load every unit of pump, and check on pumps on
the right and left sides for possible damages. When
pumps on both sides are failed, check on them for
the following failures 1), 2). When pump on the one
side is failed, start checking from para. 3).
1) Check that the power shift command current I is
normal.
2) The power shift pressure is low.
• Check the dither of amp.
• Replace solenoid proportional reducing
valve.
3) Stick of compensating piston (621) and
compensating rod (623)
• Disassemble and clean it.
4) Stick of pin (898)
(2) The max. flow rate is not delivered.
1) Check that pilot differential pressure Pi is normal.
2) Stick of pilot piston (643)
3) Stick of spool (652)
4) Stick of pin (898)
Note : When the damage of part is severe, replace the
part with new one.
24-19
24.1.1.4 CONTROL CURVE OF PUMP

250 [1] 99kW H mode at traveling or optional working
[2] 83kW H mode at operating attachment Input revolution ;2000 min-1
Q 2000min-1: [3] 75kW S mode at operating attachment
Input horse power ;114 kW
(H mode) Input torque ;544 N.m
200 1800min-1:
(S mode) [2] [1] Reference value in ( )
Two pumps are loaded at the same time

Delivery flow rate Q [ L/min ]
150
[3]
100
50
Min.Flow(at 2000min-1)
0 5 10 15 20 25 30 35 40
Delivery pressure Pd [MPa]
250
[4] 91kW : At emergency mode
718mA Input revolution ;2000 min-1
Q 2000min-1 220L Input horse power ;114 kW
300mA Input torque ;544 N.m
200 Reference value in ( )
Two pumps are loaded at the same time

Pf:Power shift pressure (Reference value)
Delivery flow rate Q [ L/min ]
[4]
150 1471
(P
At f=4
em .9M
er Pa
ge )
nc
y
100 m 981
od
e
I-Q Curve
Pd=7.8MPa at Qmax
50 490
Input torque
Tin N.m
Min.Flow(at 2000min-1)
400mA
Tin 30L
0 5 10 15 20 25 30 35 40
Delivery pressure Pd [MPa]
0 1 2 3 4 [MPa]
Pilot pressure Pi
24-20
24.1.2 CONTROL VALVE
24.1.2.1 SPECIFICATIONS
24.1.2.1.1 OUTSIDE VIEW

PTb
PBL
P2 CT2
CP2
CT1
P1
Pcb PAL
CT1 T1
PTb T2
P1 unload CT2
PCb PAL
Travel PL PCb PAL Travel left PBL
AL BL
straight P2 unload
CMR1 CMR2 Ar CP2
USE FOR YN30V00101
Br PAr PCa
Travel PB1 Boom
F1
PBr PAr PB1

1
Ab right conflux CCb Bs
PAb CP1 (HEAD) As
PBs Swing
Bb Boom PBb PBs PAs
(ROD) PBb Aa
LCb CRb Pss LCs
PC PCc PBa1 Pss
PAc Bucket PLc2 (HEAD)
Ac Bc PBc PBa1 Arm 1 CRa PAa1
(HEAD) (ROD) Ba
LCc LCa
PCAP2 LCAT2 MU PBa2 PAo (ROD)
PAa2 Arm 2 PBa2 PAo Option PBo
Ao Bo
LCo
PBp1 PBp2
(P3) (P2)
PBa2 PAo
PBp1 PBp2
PAa2
Arm 2 Option
PBo
PAc PAa1
Bucket Arm 1
(P4) PAa
(P3) PAb
Boom Swing
PBr PCa
Travel right P2 unload
(T3)
PTb
Travel PBL Travel left
straight
PAa2 PBo
A
VIEW A
Fig. 24-22 Outside view
24-21
24.1.2.1.2 PORTS
Port size Tightening torque Ports Description

PF3/4 150~180 N•m (111~133 lbf•ft) MU
(T3) Pluged
PF1/2 98~120 N•m (72~89 lbf•ft) (P3) Pluged
(P4) Pluged
PF3/8 69~78 N•m (51~58 lbf•ft) PAa1 Arm 1 (in) pilot port
PBa1 Arm 1 (out) pilot port
PAb Boom (up) pilot port
PBb Boom (down) pilot port
PAc Bucket (digging) pilot port
PBc Bucket (dump) pilot port
PAL Travel left (forward) pilot port
PBL Travel left (reverse) pilot port
PAr Travel right (forward) pilot port
PBr Travel right (reverse) pilot port
PAs Swing (right) pilot port
PBs Swing (left) pilot port
PAa2 Arm 2 (in) pilot port
PBa2 Arm 2 (out) pilot port
PAo Option pilot port
PBo Option pilot port
DR Drain port
PF1/4 34~39 N•m (25~29 lbf•ft) Pss Swing pilot high pressure select port
PLc2 Lock valve select pilot port
PBp1 Bypass cut valve (P1 side) pilot port
PBp2 Bypass cut valve (P2 side) pilot port
PL Attachment boost port
PB1 Boom (up) conflux pilot port
PTb Travel straight pilot port
PCa Unload valve (P2 side) pilot port
PCb Unload valve (P1 side) pilot port
PCc Bucket (digging) stroke limiter pilot port
M12 83~110N•m (61~81 lbf•ft) P1 Pump port (P1 side)
P2 Pump port (P2 side)
T1 Tank port 1
T2 Tank port 2
M10 49~65 N•m (36~48 lbf•ft) Ar Right travel motor port (forward)
Br Right travel motor port (reverse)
AL Left travel motor port (forward)
BL Left travel motor port (reverse)
As Swing motor port (right)
Bs Swing motor port (left)
Ab Boom cylinder head side port (up)
Bb Boom cylinder rod side port (down)
Aa Arm cylinder head side port (in)
Ba Arm cylinder rod side port (out)
Ac Bucket cylinder head side port (digging)
Bc Bucket cylinder rod side port (dump)
24-22
Port size Tightening torque Ports Description

Ao Optional pilot port
Bo Optional pilot port
24.1.2.1.3 SPECIFICATIONS
Item Specifications
Model KMX15YD/B44001
Maximum flow rate [L/min (gal/min)] 220 (58)×2
Maximum set pressure [MPa (psi)] 37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)
Main relief valve set pressure [MPa (psi)] Std 34.3 (4970) [at 70×2L/min (18.5×2gal/min)]
When power boost pressure 37.8 (5480) [at 60×2L/min (15.9×2gal/min)]
Overload relief valve set pressure
39.7 (5760) [at 30L/min (8gal/min)]
(Boom head, Bucket head, Arm rod) [MPa (psi)]
Overload relief valve set pressure
37.8 (5480) [at 30L/min (8gal/min)]
(Boom rod, Bucket rod, Arm head) [MPa (psi)]
24-23
24.1.2.2 CONSTRUCTION AND OPERATION
(1) Control valve
J
154 164 101
P2
T2 T1
PAL PBL
YT1 J
PB1 PCa
YBG1
P2-20
PBs PAs
YS1
Pss
PBa1 PAa1
YA1
PAo PBo
YP1
(P4)
163 162 163 169 155 162
SECTION A-A
154 164
P1
102
973 973
PTb PCb
P1-20
973 973
PBr PAr
YT1
973
PAb PBb
YB1
973 973
PBc PCc
PAc
YK1
974 973
PAa2 PBa2
YAG
1
974
(P3)
162 162 169 155 163 162
SECTION B-B
Fig. 24-23 Section (1/6)
24-24
T2
H 273x10 273x10 H
PCb PAL
P1 unload
Travel left
(Travel straight)
C C
USE FOR YN30V00101F1

977 PAr
PB1 Boom conflux
Travel right (P2 unload)
D 978x2 D
PBs
Boom Swing
E PCc
PBb E
PBa1 Pss
Bucket
Arm 1
F F
PBa2 PA
PAo
Arm 2 MU Option
G G
K PBp1 PBp2
K
(P3) B A
PBa2 PAo
PBp1 PBp2
274x4
275x4
213
(P4)
(P3)
212
PAa2 PBo
273x10 273x10
24-25
%"$. '($ $(#,

'($ -,)*+,

'($ )*+, !"#$%&

%"$.

24-26
Swing
204
203 PBs
333 Boom 333
331 Pss
336 331
322
321 336
603 AbR
331 322
211
261 321
266 266
160
160 331
514 261
303
524 As 161
CRb
556 162
164 Ab 163
511 511
521 523
LCb LCs
551 556
164 164
Bb 162
Bs
161
301
266
264
264
602 PAb
160 PAs
206
205 BbR
SECTION E-E
164 551
Bucket
209
PCc
216 201
333 Arm 1 333
PBa1
331 331
PBc
336 336
322 322
321 321
BaR
602 BcR 603
331 331
261 261
211
304 160
514
524
CRar
Bc 556
Ba 164
511 511
521 521
LCc LCa
551 551
164 164
Ac
162 Aa
161
264 302
603 PAc PAa1 264
205 AcR 205
SECTION F-F AaR 605
24-27
201
333 Arm 2 Option 201
331 PBa2 PAo 333
340
328 331
321
336
331
324
261
AoR 323
604
MU 331
308
162 261
162 311
162
511 Ao
521
LCAT2 511
551
164 521
515 LCo
521 LCAP2 551
551 164
164
Bo
162
161
604
BoR
264 264
PAa2 PBo
205
205
SECTION G-G
T2
161
P1
T1
511
521 163
CT1
551
163
164
162
P2 511
521
CT2
551
164
SECTION H-H
24-28
PBp1 PBp2
207
160 606 606
278x5 266
264 264
527 528 163

T2 T1
517
518
SECTION J-J
SECTION K-K
24-29
Tightening torque Tightening torque

N•m (lbf•ft) N•m (lbf•ft)
101 Casing A 1 321 Spring 5
102 Casing B 1 322 Spring 4
220~250 (162~184) 154 Plug PF3/4 3 323 Spring 3
110~130 (81~96) 155 Plug PF1/2 2 324 Spring 3
20~24 (15~18) 159 Plug PT1/4 MEC (Pre-coat bolt) 1 325 Spring 1
7.8~9.8 (5.8~7.2) 160 Plug PT1/16 MEC (Pre-coat bolt) 5 326 Spring 1
161 O-ring 7 327 Spring 3
164 O-ring 19 331 Spring seat 24
16~18 (11.8~13.3)
169 O-ring 2 333 Spacer bolt 12
Loctite #262
201 Cover 5 336 Stopper 10
204 Sub cover 1 511 Poppet 11
205 Cover 7 512 Poppet 2
207 Back pressure check valve cover 1 515 Poppet 1
9.8~14 (7.2~10.3) 211 Lock valve selector sub 2 518 Poppet 1
212 Plate 1 521 Spring 11
216 Piston 1 523 Spring 1
25~34 (18~25) 273 Socket bolt 40 230~260 (170~192) 551 Plug 13
98~120 (72~89) 274 Socket bolt 4 130~150 (96~111) 552 Plug 2
98~120 (72~89) 275 Socket bolt 4 230~260 (170~192) 556 Plug 3
25~34 (18~25) 278 Socket bolt 5 562 O-ring 2
301 Boom spool sub 1 69~78 (51~58) 601 Main relief valve 1
302 Arm 1 spool 1 69~78 (51~58) 602 Port relief valve 2
303 Swing spool 1 69~78 (51~58) 603 Port relief valve 3
304 Bucket spool 1 69~78 (51~58) 604 Relief valve plug assy 2
305 Boom conflux spool 1 69~78 (51~58) 605 Overload relief valve 1
306 Travel spool 2 98~120 (72~89) 606 Bypass cut valve 2
307 Travel straight spool 1 140~180 (103~133) 973 Socket bolt 8
308 Arm 2 spool sub 1 140~180 (103~133) 974 Socket bolt 2
309 P1 unload spool 1 977 Name plate 1
310 P2 unload spool 1 978 Rivet 2
311 Option spool 1
24-30
(2) Main relief valve (Two step relief) (601)
Fig. 24-29 Main relief valve (Two step relief)

69~78 (51~58) 103 Plug ; M27 1 562 Back up ring 1
104 Adjust screw 1 611 Poppet 1
121 C-ring 1 613 Stopper 1
122 Spacer 1 614 Piston 1
123 C-ring 1 621 Spring 1
124 Filter stopper 1 652 Adjust screw 1
125 Filter 1 661 O-ring 1
163 O-ring 1 663 O-ring 1
512 Plunger 1 664 O-ring 1
521 Spring 1 28~31 (21~23) 671 Lock nut ; M14 1
541 Seat 1 46~52 (34~38) 673 Lock nut ; M24 1
561 O-ring 1 1
24-31
(3) Over load relief valve (602,603,605)
Fig. 24-30 Over load relief valve
Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
69~78 (51~58) 101 Body ; M27 1 541 Seat 1
69~78 (51~58) 102 Plug ; M27 1 561 O-ring 1
161 O-ring 1 562 Backup ring 1
162 O-ring 1 563 O-ring 1
123 C-ring 1 564 Backup ring 1
124 Filter stopper 1 611 Poppet 1
125 Filter 1 612 Spring seat 1
511 Plunger 1 651 Adjust screw 1
521 Spring 1 661 O-ring 1
522 Spring 1 28~31 (21~23) 671 Lock nut ; M14 1
24-32
(4) Arm 2 spool (308)
371 361 340 319 308 317 340 361 371 350
351
Fig. 24-31 Arm 2 spool
Tightening
Tightening torque
torque No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft)
N•m (lbf•ft)
308 Spool 1 16~18 (33~35) Loctite #638 350 Plug 1
317 Plunger 1 16~18 (33~35) Loctite #638 351 Plug 1
340 Spring 2 371 Buckup ring 2
(5) Boom spool (301)
301 317 340 361 371 350

Fig. 24-32 Boom spool
Tightening
Tightening torque
N•m (lbf•ft)
N•m (lbf•ft)
301 Spool 1 16~18 (12~13) Loctite #638 350 Plug 1
340 Spring 1 371 Buckup ring 1
24-33
(6) Lock valve selector (211)
101
164
171
201
321
PLc A B Dr
166 541 167 511 161
Fig. 24-33 Lock valve selector
Tightening
Tightening torque
N•m (lbf•ft)
N•m (lbf•ft)
101 Casing 1 10~14 (7.4~10.3) 171 Socket bolt 3
161 O-ring 4 49~59 (36~44) 201 Plug 1
166 O-ring 1 511 Spool 1
167 O-ring 1 541 Sleeve 1
24-34
(7) Bypass cut valve (606)
! ! " "
2 2E
6 ,H

Fig. 24-34 Bypass cut valve

98~120 (72~89) 101 Plug 1 301 Plunger 1
201 Poppet 1 69~78 (51~58) 401 Plug 1
202 Spring 1 402 O-ring 1
24-35
(8) Swing shuttle valve cover (204)

Fig. 24-35 Swing shuttle valve cover
Tightening
Tightening torque
N•m (lbf•ft)
N•m (lbf•ft)
166 O-ring 1 542 Seat 1
202 Cover 1 25~29 (18~21) 554 Plug 1
541 Steel ball 1 7.9~9.8 (5.9~7.2) 555 Plug 1
24-36
(9) Boost check valve (517)
104
107
102
101
Fig. 24-36 Boost check valve
Tightening
Tightening torque
N•m (lbf•ft)
N•m (lbf•ft)
101 Poppet 1 20~29 (15~21) Loctite #262 104 Plug 1
102 Poppet 1 107 Spring 1
24-37
24.1.2.2.2 HYDRAULIC CIRCUIT DIAGRAM

P1 T1 T2 P2
CMR1
PL CMR2
PTb PBL
Travel straight
PCb PAL Travel left
P1 unload
AL
CT2 CP2 BL
CT1
(T3) Boom conflux
Travel right PAr PCa
P2 unload
CP1
Br
Ar PB1
PBr CCb
PBs
Dr
LCb LCs Pss
Boom PAb PAs Swing

As
Bs
(ROD) Bb
PBa1
CRb LCa
(HEAD) Ab
PAa1 Arm 1
PBb
LCc Aa (HEAD)
Bucket PAc
CRa
(ROD) Bc PLc2
(HEAD) Ac
Ba (ROD)
PCc
PBc
LCAT2
LCAP2 LCo
Arm 2 PAa2 PAo Option
Ao
Bo
PBa2 PBo
MU
PBp1 PBp2
(P3) (P4)
Fig. 24-37 Hydraulic circuit diagram
24-38
(1) In neutral position
The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through unloading
valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through
tank port T1. And when the operation of unloading valve is impossible due to failure of electric control system,
because the by-pass cut valve (606) located on the downstream of center by-pass passage (52) opens, the
hydraulic oil through hydraulic pump P1 port passes through travel straight spool (306), and then flows though
the center by-pass passage (52) which passes through travel right, boom, bucket and arm 2 and the by-pass cut
valve (606) on P1 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to
the hydraulic tank through tank port T1.
The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure circuit
(D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to the hydraulic
oil from hydraulic pump P1. And when the operation of unloading valve is impossible, because the by-pass cut
valve (606) located on the downstream of center by-pass passage (55) opens, the hydraulic oil through hydraulic
pump P2 port passes through main passage, and then flows though the center by-pass passage (55) which
passes through travel left, swing, arm 1 and option and the by-pass cut valve (606) on P2 side, and flows into
low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.

!"! #!"# $
# %#&
Fig. 24-38 In neutral position
24-39
(2) Actuation in travel operation

1) In travel independent operation
On starting travel operation (forward) started, the hydraulic oil delivered by hydraulic pump P1 is fed into
travel right motor, and the hydraulic oil delivered by hydraulic pump P2 is fed into travel left motor. The pilot
pressure enters ports PAr and PAL, and the right and left travel spools (306) move rightward the force of
springs (323)(324) and the secondary pressure of solenoid proportional valves [X1] and [X2] acts on ports
PCb and PCa and switches unloading spools (309) (310).
The hydraulic oil delivered by hydraulic pump P1 passes through travel straight spool (307) and flows into
main circuit, and flows through between the perimeter of right travel spool (306) and casing and is fed into
A side of right travel motor through port Ar. The hydraulic oil delivered by hydraulic pump P2 flows through
between the perimeter of left travel spool (306) and casing and is fed into A side of left travel motor through
port Ar similarly to the stream of hydraulic oil delivered by hydraulic pump P1.
But in the meantime, the return oil from the B sides of left and right travel operations passes through between
the perimeter of right and left travel spools (306) and casing through ports Br and BL and flows into low
pressure circuit (D), boost check valve (517), and then returns to the hydraulic tank through tank port T1. On
traveling reverse (at the time when the pilot pressure actuates on ports PBr and PBL of control valve), the
actuation is similar to that in forward travel operation.

Fig. 24-39 In left reverse travel (at PBL is pressurized)
24-40
2) In travel straight operation

When actuator other than travel operation and the travel operation are operated simultaneously in the said
item 1) "In travel independent operation" the pilot signal from the outside acts on port PTb and the travel
straight spool (307) moves upward.
With this operation, the hydraulic oil delivered by hydraulic pump P1 mainly flows from P2 to A and is used
for each actuator, and the hydraulic oil delivered by hydraulic pump P2 mainly flows from P2 to B and into
main passage, and is used for right and left travel operations as hydraulic oil realizing the actuator and travel
simultaneous operation. (Travel straight function) At circuit (I) position, a part of hydraulic oil delivered by
hydraulic oil P1 passes through circular notch on travel straight spool (307) and enters from P1 to B enabling
the hydraulic oil to be supplied from actuator side to travel side. And at circuit (II) position, the circular notch
on travel straight spool (307) closes and the pump line on the travel sides is independent from pump line on
actuator.

Fig. 24-40 Movement of travel straight spool
24-41
(3) Actuation in bucket operation

1) In bucket digging operation
On starting bucket digging operation, the pilot pressure enters port PAc, bucket spool (304) moves leftward
the force of springs (321)(322), and simultaneously the secondary pressure of solenoid proportional valve
[XI] acts on port PCb and switches unloading spool (309).
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load
check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through
U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ac).
In the meantime, the return oil from bucket cylinder rod side (R) passes through between the perimeter of
bucket spool (304) and casing, flows through low pressure circuit (D) and boost check valve (517), and
returns to the hydraulic tank through tank port T1.
And when the flow rate of hydraulic oil delivered by hydraulic pump P1 with engine running in low idling is
low, the pilot signal from the outside enters port PCc and piston (216) moves rightward. With this actuation,
the maximum leftward stroke of bucket spool (304) is limited, consequently the area of passage between the
perimeter of bucket spool (304) and casing minimizes. Consequently the flow rate of return oil from bucket
cylinder rod side (R) reduces and bucket cylinder moving speed is limited preventing cavitation which may
be occurred on bucket cylinder head side (H). (Stroke limiter ON)
53
216
PAc
PCc PBc
Bc Ac
LCc
321 (D)
322 304 511
(R) (H)
Fig. 24-41 In bucket digging operation (Stroke limiter ON)
24-42
2) In bucket dumping operation

On starting bucket dumping operation, the pilot pressure enters port PBc and bucket spool (304) moves
rightward the force of springs (321)(322), and simultaneously the secondary pressure of solenoid
proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered by
hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and flows
through between the perimeter of bucket spool (304) and casing through U-shaped passage, and supplied
to bucket cylinder rod side (R) through port (Bc).
In the meantime, the return oil from bucket cylinder head side (H) passes through between the perimeter of
bucket spool (304) and casing and flows through low pressure circuit (D), and returns to the hydraulic tank
through tank port T1. The return oil does not pass through boost check valve (517).
Downstream of boost check valve

! "#"

Fig. 24-42 In bucket dumping operation
24-43
(4) Boom
1) In boom up operation
On starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves rightward
against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional
valve [XI] acts on port PCa and switches unloading spool (309).
And the pilot pressure enters port PB1 and boom conflux spool (305) is switched against the force of springs
(325) (326) and the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches
unloading spools (310).
check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing through
U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ab).
In the meantime, the return oil from boom cylinder rod side (R) passes through between the perimeter of
boom spool (301) and casing, flows through low pressure circuit (D) and boost check valve (517), and
returns to the hydraulic tank through tank port T1.

Fig. 24-43 In boom up operation (Boom spool)
24-44
2) In boom up conflux operation

The hydraulic oil delivered by hydraulic pump P2 passes through travel left spool and enters parallel passage
(56), and pushes and opens load check valve CP2, and flows through between the perimeter of boom
conflux spool (305) and casing from the A side of U-shaped passage, and pushes and opens conflux check
valve CCb (511) and enters port Ab through conflux passage inside of casing and confluents the hydraulic
oil from the hydraulic pump P1 side.

Fig. 24-44 In boom up conflux operation (Boom conflux spool)
24-45
3) In boom down operation

On starting boom down operation, the pilot pressure enters port PBb and boom spool (301) moves leftward
against the force of springs (321) (322) and the secondary pressure of solenoid proportional valve [X1] acts
on PCb and switches unloading spool (309). And simultaneously the spool of lock valve selector (211) is
switched, and the poppet (514) is released because the spring chamber of lock valve poppet CRb (514) is
connected to the drain circuit.
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), and pushes and opens
load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing
through U-shaped passage, and is supplied to boom cylinder rod side (R) through port (Bb).
In the meantime, the return oil from boom cylinder head side (H) enters the control valve through port (Ab).
Because the retention of lock valve poppet CRb (514) which is located on this side of boom spool (301) is
released, the lock valve poppet (514) pushes and opens. And then the return oil enters BH chamber and
passes through between the perimeter of boom spool (301) and casing, and flows through low pressure
circuit (D) and boost check valve (517), and the returns to the hydraulic tank through tank port T1. And a part
of the return oil flows into the inside of boom spool (301) through circular notch of boom spool (301). Since
the return oil contains sufficient pressure with the self weight of boom, arm, etc. the return oil passes through
inside passage of boom spool (301) and pushes and opens poppet (317) leftward as shown in the figure and
flows through the circular notch, and then supplied to boom cylinder rod (R) side again through port Bb.
(Boom recirculation function)

Fig. 24-45 In boom down operation
24-46
(5) Arm operation

1) In arm out operation
On starting arm out operation, the pilot pressure enters ports PBa1 and PBa2, and arm 1 spool (302) moves
rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid
proportional valve [X2] acts on port PCa and switches unloading spool (310).
And the pilot pressure also enters PBa2, and arm 2 spool (308) is switched against the force of springs (321)
(328) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and switches
unloading spools (309).
check valve LCa (511), and flows into AR chamber through between the perimeter of arm 1 spool (302) and
casing through U-shaped passage.
In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass passage (52)
and pushes and opens load check valve LCAT2 (511) and enters U-shaped passage, and pushes and opens
load check valve LCAP2 (515) provided with orifice, and flows into U-shaped passage. And then the
hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing, and enters AR chamber
through casing inside passage (RR) and confluences the hydraulic oil from hydraulic pump P2 side.
The conflux hydraulic oil opens lock valve poppet CRar (514) and is supplied to arm cylinder rod side (R).
In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of arm
1 spool (302) and casing and passes though low pressure circuit (D’) and casing inside passage (HH) and
then flows into low pressure circuit (D’) through between the perimeter of arm 2 spool (308) and casing.
The return oil in low pressure circuit (D’) returns to hydraulic tank through tank port T1 without passing
through boost check valve (517).
'

)

!"

!#"$ %$ &
"&

(
'(
Fig. 24-46 In arm out operation
24-47
2) In arm in operation (At light load: arm recirculation function)

On starting arm in operation, the pilot pressure enters ports PAa1 and PLc2, and arm 1 spool (302) moves
leftward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid
proportional valve [X2] acts on port PCa and switches unloading spool (310). At the same time, since the
spool of lock valve selector (211) is switched, the spring chamber of lock valve poppet CRar (514) is
connected to the drain circuit and the retention of poppet (514) is released.
And the pilot pressure enters PAa2 through solenoid proportional valve [XR], and arm2 spool (308) moves
leftward against the force of springs (321) (328) and the secondary pressure of solenoid proportional valve
[X1] acts on port PCb and switches unloading spools (309). But in light load operation, because the solenoid
proportional valve [XR] actuates and arm 2 spool (308) stays in the position of circuit (I).
check valve LCa (511), and flows into port (Aa) through between the perimeter of arm 1 spool (302) and
casing through U-shaped passage. In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows
through center by-pass passage (52) and pushes and opens load check valve LCAT2 (511) and enters U-
shaped passage, and also the oil from parallel passage (53) pushes and opens load check valve LCAP2
(515) provided with orifice and flows into U-shaped passage. And then the hydraulic oil flows through
between the perimeter of arm 2 spool (308) and casing from U-shaped passage and enters port (Aa) through
casing inside passage (HH) and confluences the hydraulic oil from hydraulic pump P2 side.
The conflux hydraulic oil is supplied to arm cylinder head side (H) through port (Aa).
In the meantime, the return oil from arm cylinder rod side (R) enters the control valve through port (Ba).
Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1 spool (302) is
released, the return oil pushes and opens lock valve poppet CRar (514) and enters AR chamber. The return
oil in AR chamber is led to arm 2 spool (308) through arm 1 spool (302) and casing inside passage (RR), but
because arm 2 spool (308) does not connect to low pressure passage (D) at circuit (I), the entire flow rate
flows into arm 1 spool (302).
The return oil from chamber AR passes through the perimeter of arm 1 spool (302) and casing, and flows
through casing inside passage (RH) and is led to the inside of arm 2 spool (308) through circular notch (a)
of arm 2 spool (308). In light load operation, since the return oil contains higher pressure than that of arm
cylinder head side (H) with the self weight of arm, etc. the hydraulic oil inside of arm 2 spool (308) passes
through check valve (317) and flows into casing inside passage (HH) and the supplied to arm cylinder head
side (H) again. (Arm recirculation function)
And a part of the return oil which was led to arm 2 spool (308) passes through check valve (319), and flows
through boost check valve (517) through load pressure circuit (D) and returns to the hydraulic tank through
tank port T1.
AR (R) (H) 302

322 321 chamber 514
211 CRar
511 LCa
Ba Aa
56
PBa1 P1
PAa1
(D')
(D) LCAT2 LCAP2
Arm 1 P1
(D')
PAa2 PBa2
RR 52 RH Dr
(D) HH Dr
Arm 2
(a) To arm 1 spool
Aa (HEAD)
PBa2 PAa2 Ba
[XR]
(ROD)
53 To pilot cut valve
MU Circuit (I)
317
328 515
321 308319(D)511 LCAT2
LCAP2
Fig. 24-47 In arm in operation (At light load: arm recirculation function)
24-48
3) In arm in operation (In heavy load operation)

The arm recirculation function is effective in actuating arm cylinder quickly in light load operation, but in
heavy load operation (work required large power); the function causes the power loss. This control valve
selects the presence of recirculation function in light and heavy load operation with solenoid proportional
valve [XR]. (Variable recirculation function)
The flow path of hydraulic oil in heavy load operation, the path on the supply side to arm cylinder is the same
as that in light load operation, differs from that of return oil. In heavy load operation, solenoid proportional
valve [XR] actuates and arm 2 spool (308) is positioned to circuit (II). The return oil from arm cylinder rod
side (R) enters the control valve through port (Ba). Because the retention of lock valve poppet CRar (514)
which is located on this side of arm 1 spool (302) is released, the return oil pushes and opens lock valve
poppet CRar (514) and enters AR chamber. The return oil in AR chamber is led to arm 2 spool (308) through
arm 1 spool (302) and casing inside passage (RR). But because arm 2 spool (308) is connected to low
pressure passage (D) at circuit (áU), almost all the return oil passes through between the perimeter of arm
2 spool (308) and casing and flows through boost check valve (517) through low pressure (D) and returns
to the hydraulic tank through tank port T1.
The return oil from AR chamber passes through between the perimeter of arm 1 spool (302) and casing and
flows through casing inside passage (RH) and then is led to the inside of arm 2 spool (308) through circular
notch (a) of arm 2 spool (308). In heavy load operation, since the pressure on arm cylinder head side (H) is
higher than the rod side, the hydraulic oil in arm 2 spool (308) does not flow into casing inside passage (HH),
but flows through check valve (319) and passes through boost check valve (517) through low pressure (D)
and returns to the hydraulic tank through port T1.
(R) (H) 302
AR
322 321 chamber 514
211 CRar
511 LCa
Ba Aa
56
PBa1 PAa1 P1
(D')
(D) LCAT2 LCAP2
Arm 1 (D') P1
(D) RR 52 RH
HH
PAa2
Dr
PBa2
Dr
Arm 2
(a) To arm 1 spool
PBa2 PAa2 Aa (HEAD)
[XR] Ba
53 (ROD)
To pilot cut valve
MU
Circuit (II)
317
328 515
308 (D)
321 319 511 LCAT2 LCAP2
Fig. 24-48 In arm in operation (In heavy load operation)
24-49
(6) Swing operation

On starting swing operation, the pilot pressure enters ports PAs or PBs, and swing spool (303) moves leftward
or rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid
proportional valve [X2] acts on port PCa and switches unloading spool (310).
At the same time, in the event that the pilot pressure acts on port PAs, the pilot pressure flows through shuttle
valve inside of cover (204) through the inside passage and then is led to port Pss. When the pilot pressure acts
on port PBs, the pilot pressure also flows through shuttle valve inside of cover (204) and then is led to port Pss.
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check
valve LCs (511) and flows through between the perimeter of swing spool (303) and casing through U-shaped
passage and is supplied to swing motor A side or B side through port (As) or (Bs).
In the meantime, the return oil from swing motor A side or B side passes through between the perimeter of swing
spool (303) and casing through port (Bs) or (As) and flows through low pressure circuit (D) and boost check valve
(517), and then returns to the hydraulic tank through tank port T1.

Fig. 24-49 Swing operation
24-50
(7) Spool actuation for operation in option

This spool is used to control the attachment in option like Nibbler (Crusher), etc.
Where the pilot pressure acts on port PAo on operating the attachment in option, the pilot pressure enters ports
PAo, and option spool (311) moves against the force of springs (323) (324), and simultaneously the secondary
pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
The hydraulic oil delivered by hydraulic pump P2 flows through parallel passage (56) and pushes and opens
load check valve LCo (511), and flows through between the perimeter of option spool (311) and casing through
U-shaped passage and is supplied to actuator for attachment through port (Ao).
In the meantime, the return oil from actuator for attachment swing passes through between the perimeter of
option spool (311) and casing through port (Bo) and flows through low pressure circuit (D) and boost check valve
(517), and then returns to the hydraulic tank through tank port T1.
The operation where the pilot pressure acts on PBo port is the same as the above.
* The oil passage is branched toward the end side of control valve at the mid course from option spool (311) to
port Ao, but when N&B (Nibbler and Breaker) selector valve is provided on the end side of control valve, this
oil passage is used as passage to connect to N&B selector valve.

Fig. 24-50 Spool actuation for operation in option
24-51
(8) Lock valve operation

The lock valve is housed in between each port of the control valve connected to arm cylinder rod side (R) and
arm cylinder head side (H) and the arm spool and boom spool, and reduces the leaking due to holding pressure
caused by each cylinder.
1) At boom spool neutral position (Arm spool makes the same operation.)
When boom spool (301) is set to neutral position, spool (511) of lock valve selector is held on the left side
as shown in the figure. At this position, passages Sa and Sb are connected each other at the inside of
bushing (541) and on the perimeter of spool (511). Therefore in spring chamber (RH) of lock valve poppet,
the holding pressure receiving from boom cylinder head side (H) passes from passage Sa to bushing (541)
spool (511) and is connected through passage Sb, consequently the lock valve poppet (514) is kept pressed
the lower side as shown in the Fig. 24-51 and restricts the leaking to the minimum.
%& ' ()

) *'&+ , +

!"# $

Fig. 24-51 Lock valve operation (At boom spool neutral position)
24-52
2) In boom down operation ((In arm in operation)

Pilot pressure PBb for boom down operation acts on port PLc of lock valve selector, and the spool (511)
moves rightward as shown in the Fig. 25-52. After the spool (511) was moved, orifice (a) of bushing (541)
first closes and then passages Sa and Sb are blocked, and therefore the holding pressure receiving from
boom cylinder head side (H) does not act on spring chamber (RH) of lock valve poppet (514).
And after spool (511) was moved, the inside of bushing (541) is connected from port Dr to passage DR
through spring chamber (321).
With this actuation, spring chamber (RH) of lock valve poppet (514) is connected from orifice (b) of bushing
(541) to drain passage Dr through passage Sb, and the force which pushes lock valve poppet (514) down
as shown in the Fig. 24-52 is released. And since lock valve poppet (514) receives holding pressure from
boom cylinder head side (H) to the pressure receiving section in ring type which is made up of guide diameter
and seat diameter of lock valve poppet (514), lock valve poppet (514) is pushed upward and is open.
The said operation, in boom down operation, is performed before making the opening (meter out opening)
which is used to return the return oil from the boom cylinder head side of boom spool (301) to the tank open,
the operation has no effect on the operability of boom down operation.
In case of arm-in operation, the operation is the same.
Return oil from RH CHAMBER

boom cylinder head
514 Lock valve selector
511
BH CHAMBER 541
Sb
CRb PLc
Ab Dr
(a) (b) 321
A A PLc Sa Sb Dr
SECTION A-A
Sa
321 322
PBb
(D)
301
Dr
Fig. 24-52 Lock valve selector operation (At boom down operation)
24-53
(9) By-pass cut valve

This by-pass cut valve is located on the most downstream of center by-pass passage (52) on P1 side and center
by-pass passage (55) on P2 side. And this by-pass cut valve controls the flow rate of hydraulic oil from each
center by-pass passage to low pressure passage (D).
1) In normal operation
On starting the engine, the secondary pressure of solenoid proportional valves [X1] and [X2] act on pilot
ports PBp1 and PBp2 of by-pass cut valve (606). This secondary pressure is the same as that actting on
pilot port PCb of P1 unloading spool (309) and pilot port PCa of P2 unloading spool (310).
The following explains the by-pass cut valve on P1 side, the operation of by-pass cut valve on P2 side is the
same. The secondary pressure of solenoid proportional valve [X1] enters PBp1 and plunger (301) moves
downward against the force of spring (302). The taper section at the top end of plunger (301) is seated on
the seat of plug (101), shutting off the spring chamber of poppet (201) and spring chamber (b) of plug (101).
The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and enters
spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring chamber (b) of
plug (101) are disconnected, spring chamber (a) of poppet (201) is the same pressure as center by-pass
passage (52) and poppet (201) is pushed the seat section of casing shutting off center by-pass passage (52)
and low pressure passage (D).
Consequently, in normal operation, center by-pass passage (52) is always disconnected from low pressure
passage (D) and the hydraulic oil delivered by hydraulic pump P1 does not flow through center by-pass
passage (52), but returns to the hydraulic tank through P1 unloading spool (309).
[X1]
PBp1
301 302
(b)
(C)
Dr
201 101
(a)
(D)
52
Fig. 24-53 By-pass cut valve (In normal operation)
24-54
2) At the time when failure occurred

When the electric system is failed and consequently the secondary pressure of solenoid proportional valves
[X1] and [X2] is not produced, plunger (301) is moved upward by the force of spring (302). Since the taper
section at the top end of plunger (301) is lifted up from the seat section of plug (101), spring chamber (a) of
poppet (201) and spring chamber (b) of plug (101) are connected each other.
The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and enters
spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring chamber (b) of
plug (101) are connected each other, the hydraulic oil in spring chamber (a) of poppet (201) passes through
from seat section of plug (101) to spring chamber (b) and flows into passage (Dr) through passage (c).
Consequently the pressure in spring chamber (a) of poppet (201) lowers, poppet (201) receives the pressure
of center by-pass passage (52) and is lifted up against the force of spring (202), and the hydraulic oil from
center by-pass passage (52) flows into low pressure passage (D) through poppet (201) of by-pass cut valve
(606). Therefore when the electric system is failed, P1 unloading spool (309) is shifted to the neutral position
and the passage to low pressure passage (D) is cut off, but because center by-pass passage (52) is
connected to low pressure passage (D) through by-pass cut valve (606), the abnormal rise of the pump
pressure is prevented.
PBp1
302
301
(b)
(C)
Dr
201 101
(a)
(D)
202
52
Fig. 24-54 By-pass cut valve (In condition of failure)
24-55
(10)Boost check valve, By-pass check valve

1) Boost check valve
The boost check valve is located between low pressure passage (D) and tank port T1 and generates boost
pressure necessary for the low pressure passage.
a. In normal operation
The hydraulic oil from low pressure passage (D) moves the boost check valve (517) upward against the
force of spring (527), and returns to the hydraulic tank through tank port T1. At this time, the pressure
generated by spring (527) is used as the boost pressure for the low pressure passage.
But the return oil used for the arm out and bucket dumping operation does not pass through boost check
valve (517), but returns from low pressure passage (D’) to hydraulic tank through tank port T1.
b. In make up operation
When supplying to make up the flow rate through low pressure passage (D) after the swing operation is
suspended, if the hydraulic oil quantity in low pressure passage (D) is not enough, the deficient hydraulic
oil is made up from hydraulic tank into low pressure passage (D).
When the deficient hydraulic oil in low pressure passage (D) is not sufficient, the pressure of low pressure
passage (D) is lowered. If the pressure of low pressure passage (D) is lowered to the pressure at tank port
T1, poppet (102) housed in boost check valve (517) receives the pressure at tank port T1 on the receiving
section in ring type which is made up of guide diameter and seat diameter of poppet (102), and is pushed
upward and opens, and the hydraulic oil flows from the hydraulic tank to low pressure passage (D) to make
up the deficient flow rate.

Fig. 24-55 Boost check valve operation
24-56
2) By-pass check valve

Even if the pressure at tank port T1 goes up due to the sudden change of return flow rate, the by-pass check
valve actuates and prevents the pressure at tank port T1 from going up higher than the specified pressure,
and consequently the oil cooler and filter located between tank port T1 and the hydraulic tank are protected
from possible damage.
When the pressure at tank port T1 goes up to the pressure added by spring (528), by-pass check valve (518)
is pushed and opens against the force of spring (528), and the hydraulic oil in tank port T1 directly returns
to the hydraulic tank through tank port T2.
527
528
(D') T2
518
T1
102
517
(D)
Fig. 24-56 By-pass check valve operation
24-57
24-58
24.1.3 PILOT VALVE (ATT)
24.1.3.1 OUTLINE
(1) Outside view
5-PF3/8
Single operating angle Single operating angle T=49.0 (36.1)
(Port 2, 4) (Port 1, 3)
The adjust nut

(opposing flats : 22) :
Fix adjust nut
(opposing flats : 22)
when the lever is installed by PF1/4
means of spanner or the like. T=29.4 (21.7)
Then tighten the mating lock
nut to 41 + 3 N.m (302.2 lbf.ft). T=Tightening torque
: N.m (lbf.ft)
VIEW A

Model PV48K2004
Operating torque Refer to the curve below
Max. primary pressure 6.9 MPa (1000 psi)
Primary pressure 5.0 MPa (725 psi)
Rated flow 20 L/min (5.3gal/min)
Weight Approx. 1.9 kg (4.2 lbs)
A
PORT 1, 3 PORT 2, 4
(580)4.0 4.0(3.0) (580)4.0 4.0(3.0)

Secondary pressure [MPa (psi)]
Secondary pressure [MPa (psi)]

Operation torque [N.m (lbf.ft)]
Operation torque [N.m (lbf.ft)]

(464)3.2 (464)3.2
(435)3.0 3.0(2.2) (435)3.0 3.0(2.2)
SINGLE OPERATING TORQUE SINGLE OPERATING TORQUE
2.21(1.63) 2.29(1.69)
(290)2.0 2.0(1.5) (290)2.0 2.0(1.5)
SECONDARY PRESSURE SECONDARY PRESSURE
(145)1.0 1.0(0.74) (145)1.0 1.0(0.74)

0.94(0.69) 0.94(0.69)
(87)0.6 (87)0.6
0 0 0 0
0 1.1 2 4 6 7 0 1.12 4 6 8 9.4
PUSH ROD STROKE (mm) PUSH ROD STROKE (mm)
0 5 10 15 19 0 5 10 15 20 25
Operating angle (deg.) Operating angle (deg.)
P T
1 3 2 4
HYDRAULIC SYMBOL
24-59
24.1.3.2 CONSTRUCTION
Apply Loctite #277

312
302
501 Apply grease on
301 rotating and sliding sections.
Be careful the
Apply grease on top section
assembling direction
212
213
151
*246
*218-2
211
214
*218-1
216-2 216-1
241-2 241-1
201-2
Secondary 201-1
pressure 217
adjusting shim
101 221
PORT 2,4 PORT 1,3
Fig. 24-57 Pilot valve (ATT)
torque No. Name Q’ty torque No. Name Q’ty
101 Casing 1 *218-1 Seat 2
151 Plate 1 *218-2 Seat 2
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
212 Push rod 4 *246 Spring 4
213 Seal 4 47.1 (34.7) 301 Joint : M14 1
214 O-ring : 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (50.6) 312 Adjust nut : M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4
Note) The parts marked * may not be equipped depending on valve type.
24-60
24.1.3.3 OPERATION
(1) Lever in neutral (See Fig. 24-58)
The action of spring (509) (for secondary pressure
setting) that determines the output pressure of the
pilot valve does not act upon spool (201).
Therefore, spool (201) (for return) is pushed up by
spring (221) [spring seat (216)]. The output ports
(2,4) connect with the T port. The result is that the
output pressure is equal to the tank pressure.
216
509
221
201
PORT (2,4) PORT (1,3)
Fig. 24-58 Lever in neutral

(2) When the pilot lever is tilted (See Fig. 24-59 )
When the lever is tilted and the push rod (511)
strokes, the spool (201) [spring seat (216)] moves
downward to make the port P to connect with the
port 2, 4, with the result that the oil of the pilot pump
flows to the port 2 ,4 to produce a pressure.

Fig. 24-59 When the lever is tilted
(3) Lever held (See Fig. 24-60)
When the pressure at ports (2,4) rises to a level
equivalent to the action of spring (509) that is set by
tilting the lever, the hydraulic pressure balances the
spring action. When the pressure of ports (2,4)
rises above a set value, ports (2,4) and the P port
close while ports (2,4) and the T port open. When
the pressure at ports (2,4) falls below a set value, 509
ports (2,4) and the P port open while ports (2,4) and
the T port close. Thus the secondary pressure is
T PORT
kept constant.
P PORT
PORT (2,4) PORT (1,3)

Fig. 24-60 When the lever is held
24-61
(4) Operation in the area where the tilting angle of the

lever is large.
(varies with the model)
If the lever is inclined beyond a certain angle on
certain models, the top end of the spool contacts
the bottom of the bore of the push rod. This keeps
the output pressure connected with the P port
pressure.
Furthermore, on a model in which a spring seat and
a spring are built in the push rod, the bottom of the
bore of the push rod contacts the spring if the lever
is turned beyond a certain angle. This causes the
secondary pressure gradient to change by the
spring action. Thereafter, the bottom of the bore of
the push rod contacts the top end of the spring seat,
keeping the output pressure connected with the P
port.
24-62
24.1.4 PILOT VALVE (TRAVEL)
24.1.4.1 OUTLINE
(1) Outside view
Tightening torque
Port size N.m (lbf.ft) Port name Function
1 LH travel forward port
2 LH travel reverse port
PF3/8 30 (22) 3 RH travel forward port
4 RH travel reverse port
T Tank port
5 LH travel pressure sensor port
PF1/4 16.7 (12.3) 6 RH travel pressure sensor port
P Pilot primary pressure port
(2) Specifications
P T
Item Specifications
Type 6TH6NRZ
Primary pressure 4.9MPa (711psi)
Secondary pressure 0.54~2.35MPa (78~341 psi)
Rated flow 25 L/min (6.6 gal/min)
Weight Approx. 8kg (18 lbs)
1 5 2 3 6 4
Hydraulic symbol
(3) Performance characteristics

Secondary pressure
[MPa (psi)] Secondary pressure
2.35 + 0.15
(340 + 22)
0.54 + 0.1
(78 + 15) 0
1 30' 11 30' Pedal angle (degree)
(4.7 + 0.5) 2 30' 12 30'
6.4 + 0.64
7.7 + 0.77
(5.7 + 0.6)
12.7 + 1.27
(9.4 + 0.9)
Operating Operating torque
torque
[N.m (lbf.ft)] Control diagram
24-63
24.1.4.2 Construction and operation

The hydraulic remote control valve in TH6NR type is operated with directly-operated pressure-reducing valve.
The pilot control equipment TH6NR in double foot pedal type is made up of the actuating section which is
equipped with 2 foot supports (1), 4 pressure-reducing valves (11), 4 damper system (12) and body (6).
Every pressure-reducing valve is made up of control spool (2), control spring (3), return spring (4) and plunger
(5).
The dumper system is made up of plunger (8), orifice (9) and return spring (10).
In stationary condition, the pedal is held in neutral position by return spring (10).
In operation, the foot pedal pushes the plunger (5) used for pressure-reducing valve and plunger (8) used for
dumper system.
The hydraulic oil fed into damper chamber is restricted in the orifice (9) by the pressure corresponding to the
operating speed. [Similarly, when the foot pedal returns to the neutral position with the return spring, the
hydraulic oil trapped in the damper chamber is forced out. Consequently the return speed is controlled by the
flow rate of hydraulic oil led through orifice (9).]
Simultaneously, the plunger (5) is pushed against return spring (4) and control spring (3). The control spring (3)
first moves the control spool (2) downwards, and then closes the passage between control port and the return
pipe to tank port (T). At the same time, the control port is connected to passage (7). When the control spool
reaches to the position the force of control spring (3) balances the pressure of control port (1 or 2), it starts
retaining the condition.
The pressure of control port is proportional to the stroke of plunger (5) and the position of pedal (1) according to
the mutual relations between the control spool (2) and control spring (3).
The closed circuit pressure control makes proportional control of selector valve and high responsibility of
hydraulic pump and motor possible in relation with the characteristics of foot pedal (1) position and control spring
(3).
5
3
8 10
3
11 12
4
10
9
9
7 6
2
control ports 1-3 P line control ports 2-4

T line
24-64
24.1.5 SWING MOTOR UNIT
24.1.5.1 SPECIFICATION
(1) General view
THREAD FOR
Port Tightening torque
M L
Symbol Port name EYE BOLT 2-M10
size N.m (lbf.ft) PB DEPTH 18
A,B Main port PF3/4 167 (123) RELIEF VALVE
B
(B PORT SIDE)
DB Drain port PF3/8 74 (55)
M Make-up port PF3/4 167 (123)
PA,PB Pressure measuring port PF1/4 36 (27) (SH)
PG Parking brake release port PF1/4 36 (27)

L Gear oil level gauge PT1/2 65 (48) IP
IP Gear oil filling port PT3/4 98 (72) PG
RELIEF VALVE
A (A PORT SIDE)
DB
PA
PB PA ANTI-REACTION VALVE BLOCK

M DB
A,(B)
PG IP
PG FILLING PORT
PT3/4
DB
PA PB
Grease
fitting
A B
Hydraulic diagram
24-65
(2) Specifications
Swing motor unit part No. YN15V00036F2

Type M5X130CHB-10A-41C/295
Hydraulic motor
Displacement cm (in )
3 3 129.2 (7.88)
Working pressure MPa (psi) 32.4 (4700)
Max. flow L/min (gal/min) 220 (58)
Braking torque N•m (lbf•ft) 655 (483)
Release pressure MPa (psi) 2.5~5.0 (362~725)
Relief set pressure MPa (psi) 29 (4205)
Weight kg (lbs) 49 (108)
Anti- Type 2KAR6P72/240-712
reaction valve
Weight kg (lbs) 2.5 (5.5)
block
Hydraulic motor assy weight kg (lbs) 51.5 (114)
Part No. YN32W00022F1
Speed reduction type Planetary 2-stage
Reduction unit
Reduction ratio 15.38

Lubicate oil Gear oil SAE90 (API class GL-4 grade)
Lubicate oil volume L (gal) 3 (0.8)
Grease Extreme pressure lithum base #2 grease
Grease volume kg (lbs) Approx. 1 (2.2)
Weight kg (lbs) 145 (320)
Total weight kg (lbs) Approx. 197 (434)
24-66
(1) Swing motor
993
VALVE CASING SECTION
702 712
ANTI
CAVITATION
PLUNGER
351 Arrangement of brake spring
355
051 RELIEF VALVE
469
051-1
488 ANTI-REACTION
VALVE BLOCK 401
052 151
303 162 171 161
985
163 985 444 984 131 451
712 A A
472 390 391
VIEW I
702
707
706
100
980
743
742
400-1
111
400-2 052
121
400
123 994 SECTION A-A
122
114 301
124 443 491 101
24-67

Anti-reaction valve ; M22-
177 (130) 051 Relief valve ; M33-P1.5 2 69 (51) 400 2
P1.5
051-1 O-ring ; 1B G30 2 400-1 O-ring ; 1B P20 2
052 Anti-reaction valve sub 1 400-2 Backup ring 2
Casing for anti-reaction
100 1 431 (318) 401 Socket bolt ; M20×45 4
valve
101 Drive shaft 1 443 Roller bearing 1
111 Cylinder 1 444 Roller bearing 1
114 Spring plate 1 451 Pin 2
121 Piston 9 334 (246) 469 ROMH plug; M30-P1.5 2
122 Shoe 9 472 O-ring ; W1516,WG40 1
123 Set plate 1 488 O-ring ; 1B P28 2
124 Shoe plate 1 491 Oil seal 1
131 Valve plate 1 702 Brake piston 1
36 (27) 151 Plug ; PF1/4 2 706 O-ring ; W1516,WG38 1
161 O-ring ; 1B P11 2 707 O-ring ; W1516,WG41 1
162 O-ring ; 1B P12 2 712 Brake spring 18
163 O-ring ; 1B P6 2 742 Friction plate 3
29 (21) 171 Socket bolt ; M8×55 4 743 Separator plate 4
301 Casing 1 0.9 (0.66) 980 Plug ; PF1/4 1
303 Valve casing 1 1.7 (1.2) 984 Plug ; PF3/8 1
351 Plunger 2 4.4 (3.2) 985 Plug ; PF3/4 3
355 Spring 2 65 (48) 993 Plug ; PT1/2 1
390 Name plate 1 98 (72) 994 Plug ; PT3/4 1
391 Rivet 2
24-68
(2) Swing reduction unit

Be careful about installation Punch here 2 portions
direction of retaining ring. near hole to prevent
Apply Three Bond #1360 item 22 (spring pin)
or equivalent. coming out.
OIL FILLING PORT PT3/4
LEVEL PORT PT1/2
Apply Loctite #515.
SURFACE OF
LUBE OIL Be careful about
installation direction
of spring pin.
VIEW (II) (4 places)
Apply Loctite #515.
Be careful about
of retaining ring. Drive this spring pin
into 1mm lower than
the surface of spider.
Apply Loctite #515.
Install the filling port Tightening torque

of this fitting toward 69.1+4.4 N.m
motor side. (51.0+3.2 lbf.ft)
Apply seal tape or
Loctite #577.
Fill up this space

with grease.

1 Pinion shaft 1 17 Needle bearing 4
2 #1 sungear 1 18 Washer 8
3 #1 pinion 3 19 Retaining ring 1
4 #2 sungear 1 20 Retaining ring 1
5 #2 pinion 4 21 Sleeve 1
6 Ring gear 1 22 Spring pin 4
7 Spider assy 1 181 (134) 23 Capscrew ; M14X135 11
8 Spider 1 24 Cap 2
9 Shaft 4 25 Tube L=112 1
10 Spherical bearing 1 26 Elbow 1
11 Spherical bearing 1 69.1 (51) 27 Plug 1
12 Oil seal 1 28 Retaining ring 3
13 Housing 1 30 Oil seal 1
15 Thrust Washer 6 31 Grease fitting 1
16 Needle bearing 3 32 Relief fitting 1
24-69
24.1.5.3 OPERATION
24.1.5.3.1 OPERATION OF HYDRAULIC MOTOR

If the high pressure oil flows into the cylinder
through the inlet port (a) of valve plate (131), as Cylinder block (111)
shown on the figure on the right, the hydraulic

pressure acts upon piston (121) and creates force F2
F in the axial direction. F1
The force F may be divided into force F1 vertical to F

shoe plate (124) via shoe (122) and force F2 at right
angles with the shaft.
The force F2 is transmitted to cylinder block (111) Drive shaft (101)
via pistons (121) and causes drive shaft to turn so

as to produce a rotating moment.
The cylinder block (111) has nine pistons equally
arranged. Rotating torque is transmitted to drive
Valve
shaft by turns by pistons connected to inlet port of plate
high pressure oil. Shoe (131)
Shoe Piston
plate
If the oil supply and discharge directions are (122) (121)
(122)
reversed, the drive shaft rotates in the opposite
direction. Low pressure oil High pressure oil
Theoretical output torque T can be given by the

following equation.
P X q P ; Effective differential pressure MPa OUTLET INLET (a)
T=
2X q ; Displacement per revolution cc/rev
Fig. 24-61 Operation of hydraulic motor
24.1.5.3.2 VALVE CASING SECTION

(1) (1)Operation of anti-cavitation check plunger
Since the system using this type of motor is not
equipped with a valve having a counterbalance 351
function, the motor is rotated beyond the oil feed
rate in some cases.
The system has check plunger(351) and sucks in
deficient oil, in order to prevent cavitation from
occurring due to oil deficiency. M port
(Make-up port)
DIRECTIONAL VALVE
Fig. 24-62 Operation of anti-cavitation check

plunger
24-70
(2) Operation of relief valve Chamber h

Orifice m Spring (321) Piston I (302)
1) Consider where the relief valve is pressurized.
The pressure at the P, R ports is equal to the tank
pressure at the beginning, as shown in Fig. 24-
63. P
The relief valve begins to operates when the
hydraulic pressure that is determined by the Pressure R Chamber g
product of the pressure-receiving area A1 of receiving Plunger(301) A3 A2 Orifice n A4
area A1
plunger(301) and the pressure P balances the Fig. 24-63 Functional explanation of relief valve (1)
hydraulic pressure that is determined by the
product of the pressure-receiving area A2 of the Orifice m Spring (321) Chamber h
Pin (303) Piston I (302)
plunger(301) and the pressure Pg of chamber g.
Thereafter, the pressure of chamber g rises and
the piston 1 (302) begins to stroke. The load to
spring (321) increases by this movement of the P
piston.
As the result, the relief pressure P is raised and R
controlled in the pressure boost time t1 from P1 Plunger(301) Orifice n Chamber g
till Ps. Fig. 24-64 Functional explanation of relief valve (2)
This process is explained in the following in the
relationships between the movements of the Orifice m Spring (321) Chamber h
Pin (303) Piston I (302)
components shown in (2) to (4) of Fig. 24-
64~Fig. 24-66and the relief pressure :
a. Condition shown in Fig. 24-64.
P
If the P port of the relief valve is pressurized,
pressure is built up in chamber g via the
R
restrictor m of plunger (301). Orifice n
The hydraulic pressure acting on plunger Plunger(301) Chamber g
(301) increases and when it balances the load Fig. 24-65 Functional explanation of relief valve (3)
Fsp of spring (321), the relief valve performs Orifice m Spring (321) Pin (303) Piston I (302)
relieving action by the pressure P1.
This relationship is expressed as :
P1×A1=FSP1+Pg1×A2
where FSP1 : P
primary set load value of spring (321)
b. Condition shown in Fig. 24-65. R
The pressure of chamber g acts upon the Plunger(301) Orifice n Chamber g
pressure-receiving area A3-A4 of piston 1
Fig. 24-66 Functional explanation of relief valve (4)
(302). When the hydraulic pressure rises
above the load of spring (321), the piston 1
begins to move to the left.
On that occasion, since the machine turns to
the left while discharging the oil of chamber h
arranged between piston 1 and adjust plug
(401) into chamber g via orifice n provided in
piston 1 (302), chamber h serves as a
dumping chamber.
The load of the spring increases slowly till Fig. 24-67 Pressure boost characteristics
piston 1 reaches the end of the adjust plug.
The relief pressure P rises smoothly.
24-71
c. Condition shown in Fig. 24-66.

The machine does not travel to the left further
when piston 1 (302) arrives at the end of
adjust plug (401). Therefore, the relief valve
keeps its normal relieving action whereby the
relief pressure is held at P2.
In the processes 1 to 3 above, the relief
pressure changes as shown in Fig. 24-67.
2) Function when the relief valve pressure is
reduced
Let us consider the pressure of the P port is
reduced.
When the pressure at port P is reduced to zero,
the pressure of chamber g falls to the tank
pressure level. The result is that the plunger
(301) which is now open moves to the left and is
seated on seat (341). At the same time, the
piston 1 (302) moves to the right by the action of
spring (321) and returns to the condition of Fig.
24-63.
(3) Operation of anti-reaction valve
Fig. 24-68 Hydraulic circuit diagram for anti-

reaction valve.
1) Neutral condition :
Fig. 24-68 illustrates the relationship between
the neutral condition of the anti-reaction valve
and the hydraulic circuits. Now, let us consider a
L
braking condition in which brake pressure
generates on the AM port side.
k
322 313 321 311
Fig. 24-69 Neutral condition
2) When brake pressure occurs : m n
If pressure (P) generates at the AM port, it
passes through the passage L, the hole on the
shaft of seat (313) and the passage m of plunger P=PS
(311) and is led to the n chamber.
L
When the pressure P rises above a value (Ps)
set by spring (321), plunger (311) compresses
spring (321) and shifts it to the left. 322 313 321 311
Seat (313) compresses weak spring (322) as
Fig. 24-70 When brake pressure occurs
pushed by plunger (311) and moves to the left.
24-72
3) At anti-reaction action p t
When inertia load stops moving (point Y Fig. 24-
72), brake pressure (P) tries to fall.
When P<Ps, plunger (311) moves toward the P<PS
right return side by the action of spring (321). L
Seat (313) tries to move to the right by the action
of spring (322), but since chamber p provides k
damping action by orifice g, the return of the seat 322 313 g r 321 311
makes a time delay with regard to the return of
Fig. 24-71 At anti-reaction action
the plunger.
Consequently, seat t opens. This makes a P Y
passage connecting the AM port and BM ports or
PS
both ports of the hydraulic motor by way of
→t→r→k. The result is that the pressures at the
AM and BM ports become equal (Pb), falling into PB
X
the condition at point Z in Fig. 24-72. Z
T
This prevents the hydraulic motor from swing
shock by the closing pressure of the AM port. Fig. 24-72 Pressure change diagram of anti-
reaction operation
24.1.5.3.3 OPERATION OF BRAKE SECTION

The cylinder (111) is jointed by drive shaft (101) and a
712
spline. Separator plate (743) is fixed in its
circumferential direction by circular grooves provided in
casing (301).
Now, if the friction plate (742) splined to the outer 702
circumference of the cylinder is pressed against casing 712 743
(301) via separator plate (743) and brake piston (702)
702 742
by the action of brake spring (712), frictional force is
created between friction plate (742) and casing (301)
111 301
and between separator plate (743) and brake piston
(702). The frictional force bounds the drive shaft to 743 742 301 101
brake the motor.
Fig. 24-73 Operation of swing brake
In the meantime, when brake release pressure applied
to the oil chamber formed between brake piston (702)
and casing (301) overcomes the spring force, the brake
is released as brake piston (702) moves till friction plate
(742) is separated from casing (301).
24-73
24.1.5.3.4 SWING REDUCTION UNIT

The swing reduction unit is used to reduce the rotating Ring gear (Fixed) Planetary shaft
speed which is transmitted by the hydraulic motor and
to convert it to the strong turning force (torque).
This swing speed reduction unit is equipped with
Spider
planetary speed reducing mechanism.
The planetary mechanism is made up of sun gear, Sun gear
planetary pinion, planetary shaft, spider and ring gear,
as shown in Fig. 24-74.
For the operation of the 1st stage planetary, the

hydraulic motor rotates #1 sun gear (2). Sun gear (2) is
Planetary pinion
engaged with planetary pinion (3) and rotates, but since
ring gear (6) is fixed, planetary pinion (3) revolves about Fig. 24-74 Planetary mechanism
sun gear (2) with the planetary shaft and spider (7). Swing motor
The role of spider is to hold the planetary pinion and 3 2
planetary shaft and transmits the power from the 6
planetary pinion to the spider through the planetary
shaft. 7
The #1 spider (7) is linked with #2 sun gear (4) by the 4
involute spline, and transmits the power to the 2nd 8
stage planetary mechanism.
For the operation of the 2nd stage planetary, the power 13
is transmitted to sun gear (4)→planetary pinion 5
(5)→spider (8) similarly to the 1st stage. The #2 spider 10
(8) is linked with pinion shaft (1) by the involute spline,
and pinion shaft (1) is engaged with the swing gear
fixed on the undercarriage (lower frame) and rotates.
11 1
Fig. 24-75 Function of reduction unit
24-74
24.1.6 TRAVEL MOTOR
24.1.6.1.1 General view

[A] PF 1
O-ring port
[D] PF 1/2
O-ring port
[P] PF 1/4 [B] PF 1

O-ring port O-ring port
24.1.6.1.2 SPECIFICATIONS
Model
GM38VB
Item
Rated output torque N.m (lbf.ft) 20100 / 34200 (14800 / 25200)
Working revolution min-1 48.2 / 29.6
Reduction ratio 1 / 55.617
Max. displacement cm3/rev. (cu.in/rev) 78.8 / 130.8 (4.81 / 7.98)
Hydraulic Max. revolution min-1 2680 / 1648
motor Max. pressure MPa (psi) 34.3 (4970)
2 speed chamber pilot pressure MPa (psi) 2.94~5.88 (426~853)
Parking Breke torque N.m (lbf.ft) 470 (347)

brake Release pressure MPa (psi) 1.49 (216)
24-75
SECTION B-B
C C
SECTION C-C
SECTION A-A
24-76
No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty

1 Hub 1 Piston assy 1 Rear flange assy
3 Carrier [1] 1 161 •Piston 1 301 •Rear flange 1
4 Sun gear[1] 1 163 •Seal 1
5 Planetary gear[1] 3 162 Steel ball 1 •Spool assy 1
6 Carrier pin [1] 3 102 Shaft 1 323 ••Spool 1
7 Carrier [2] 1 326 ••Plug 2
8 Sun gear[2] 1 Swash plate kit 1 327 ••Valve 2
9 Planetary gear[2] 3 103 •Swash plate 1 328 ••Spring 2
10 Carier pin[2] 3 167 •Pivot 2 331 ••O-ring 2
11 Thrust washer[1] 6 107 Retainer plate 1 324 •Plug 2
12 Thrust washer[2] 6 108 Thrust ball 1 325 •Spring retainer 2
13 Thrust plate 1 109 Timing plate 1 329 •O-ring 2
14 Cover 1 112 Piston 1 330 •Spring 2
15 Cupling 1 113 Spring 8 363 •Spool 1
16 Parallel pin [1] 3 114 Spring 9 364 •Connector 1
17 Parallel pin [2] 3 115 Friction plate 3 365 •Pin 1
22 Lock washer 2 116 Separator plate 4 366 •Spring 1
23 Shim 1 119 Shim 1~2 367 •Spring retainer 1
24 Angular bearing 2 132 Oil seal 1 368 •G (PF) 1/4 plug 2
Needle-roller bearing
27 3 133 C-ring for hose 1 369 •O-ring 2
with cage
Needle-roller bearing
28 3 135 D-ring 1 370 •G (PF) 3/8 plug 1
with cage
29 Floating seal 1 139 D-ring 1 371 •O-ring 2
30 Plug 3 149 Tapered-roller bearing 1 372 •Orifice 2
31 O-ring 3 150 Tapered-roller bearing 1 373 •Orifice spring 2
35 Socket bolt 18 374 •G (PF) 1/8 plug 5
36 C-ring for hole 1 Relief valve assy 375 •O-ring 6
201 •Valve seat 2 376 •M6 orifice 3
101 Spindle 1 202 •Valve 1 377 •Check valve 3
137 Socket plug 1 203 •Sleeve 1 378 •Check valve spring 3
138 Expander 1 204 •Plug 1 379 •O-ring 1
205 •Spring retainer 1 380 •O-ring 1
Piston kit 1 206 •Piston 1 341 •Parallel pin 1
•Piston kit 9 207 •Spring 1 343 •Socket bolt 8
105 ••Piston 1 208 •Piston seal 1 345 •Socket plug 15
106 ••Shoe 1 209 •Piston seal 1
104 Cylinder block 1 210 •O-ring 1 399 Name plate 1
24-77
24.1.6.3 OPERATION
24.1.6.3.1 HYDRAULIC MOTOR SECTION (BRAKE VALVE, PARKING BRAKE, HIGH-LOW 2 SPEED
CHANGE MECHANISM)
(1) Function
1) Function of hydraulic motor
This hydraulic motor is swash plate type axial piston motor and functions to convert the force of oil pressure
from the pump to rotary motions.
2) Function of brake valve
a. When trying to stop travel motor, this brake valve controls the force of inertia meant to rotate the travel
motor with the inertia of body so as to stop the rotation with smooth braking.
b. Function like check valve used to prevent cavitation of hydraulic motor.
c. This brake valve opens the port used to releases the force of parking brake when the travel motor is
operated and closes it when the travel motor stops.
3) Function of parking brake
This parking brake functions to prevent power shovel from runaway at the time when parking or stopping on
slope and from slipping with the friction disk type braking mechanism, and is integrated into hydraulic motor
section.
4) Function of high and low 2 speed change mechanism
This mechanism varies the tilt angle of swash plate with functions of selector valve and control piston, and
changes the speed in 2 steps, high speed-low torque rotation and low speed-high torque rotation.
(2) Working principle and explanation of functions
1) Hydraulic motor
The hydraulic oil delivered by hydraulic pump enters rear flange (301) of GM motor, passes through brake
valve and is led to the inside of cylinder block (104) through timing plate (109). This hydraulic oil flows
through only one side of [Y1-Y2] linked from the upper dead point to the lower dead point after piston (105)
stroke. The hydraulic oil flowed into one side of the cylinder block pushes each piston (4 or 5 pieces) and
produces force (F kg=P MPa×A cm2 ). This force acts on swash plate (103), and is separated into (F2, F3)
because the swash plate is fixed having angle (a degree) to motor shaft (102) line. The radial force of the
separated force (F3) generates torque (T= F3×ri) to [Y1-Y2]. This combined force [T= (F3×ri)] makes the
cylinder block rotate using the piston as turning effort. This cylinder block transmits torque by making the
motor shaft rotate because the motor shaft and spline are linked each other.
24-78
2) Brake valve
a. When starting operation and in operation
When the hydraulic oil is supplied from the control valve to port A, the hydraulic oil opens valve (327)
and enters port P2 on the suction side of hydraulic motor and tries to rotate the hydraulic motor. And
simultaneously the hydraulic oil pushes and opens orifice (372) located on section X-X through passage
(a) and enters chamber (e). This hydraulic oil acts on the end face of spool assembly (323A) and
generates force, and slides the spool on the neutral condition slide rightward with the force of spring
(330). At this time the hydraulic oil pushed out of chamber (f) passes through passage b1 and is
discharged into port B through the orifice of throttle valve located on section Y-Y. Because the hydraulic
oil flows through the orifice, the damper functions resulting in slow movement of spool assembly and
consequently the shock caused when starting is reduced.
When spool assembly slides, passage g is formed between rear flange (301) and spool assembly with
the spool groove. Port PS located on the passage on the return side of hydraulic motor and port B on
the other side are connected to this passage and consequently because the return oil returns to the
control valve enabling the hydraulic motor to rotate.
And because the spool assembly slides, the hydraulic oil enters port C1 through passage c. The
hydraulic oil entered in port C1 actuates piston (112) of parking brake and releases parking brake force.
(For details, see 24.1.6.3.1 (2)-3.)
In the event that the hydraulic oil is supplied to port B, the right valve in pair opens, and the spool
assembly moves leftward resulting in reverse rotation of hydraulic motor.
X Y
SECTION X-X SECTION Y-Y
X
Y
24-79
b. When slowing down the speed and in traveling down on slope

On reducing the oil flow rate supplied from control valve to port A to slow down the travel speed, the
pressure at port A and port P2 lowers because the force of inertia is applied to the hydraulic motor.
Consequently the hydraulic pressure which is used to push spool assembly (323A) in chamber (e) is
cancelled, and the spool assembly which has been shifted rightward tries to return to the neutral position
with the force of spring (330). At this time passage g is restricted and the flow rate from port P3 to port
B is limited. With this actuation, the pressure is generated on port P3 and the pressure gives the braking
force to the hydraulic motor which is tried to continue rotating with the force of inertia to slow down the
speed. When reaching to the target speed, the pressure at port A and port P2 rises and the spool
assembly slides rightward to the former position and restores the operation in the former state.
And when the spool assembly tries to return to the neutral position, the hydraulic oil in chamber (e) is
discharged into port A side through passage b2. At the same time, the hydraulic oil passes through
passage b and pushes and opens orifice (372) located on the section Y-Y and is supplied to chamber (f)
to prevent cavitation generating in chamber (f).
On traveling on slope, the force acts on hydraulic motor to increase the speed from the outside.
Consequently the pressure at port A and port P2 lowers, like the actuation when slowing down the
speed, the hydraulic pressure in chamber (e) is cancelled, and the spool assembly which has been
shifted rightward tries to return to the neutral position. At this time passage g is restricted to limit the flow
rate from port P3 to port B, and the pressure is generated on port P3 and the braking force is supplied
to the hydraulic motor. This braking force resists the external force used to increase the speed of
hydraulic motor, and prevents self traveling of hydraulic motor. And also in cases where hydraulic oil is
supplied to port B, because the spool assembly which has been pushed leftward tries to return to the
neutral position, the braking force is supplied to the hydraulic motor to prevent the speed from slowing
down and self traveling.
X Y
SECTION Y-Y
X Y
24-80
c. When parking and stopping

When the hydraulic oil supplied from control valve to port A is cut off to stop operating, the pressure at
port A and port P2 lowers. Consequently because the hydraulic pressure which has pushed spool
assembly (323A) is cancelled, the spool assembly which has been shifted rightward returns to the
neutral position with the force of spring (330). At this time passage g is closed and the flow rate from port
P3 to port B is cut off. With this actuation, the pressure is generated on port P3 and gives the braking
force to the hydraulic motor which is tried to continue rotating with the force of inertia to reduce the speed
and to stop operating. Because relief valve (202A) is provided on between port P3 and port P2 and
restricts the pressure generated on port P3, the hydraulic motor is protected from being broken by
excess pressure and the shock caused by stopping motion is reduced.
And when the spool assembly tries to return to the neutral position, the hydraulic oil in chamber (e) is
discharged into port A side through passage b2. At the same time, the hydraulic oil passes through
passage b and pushes and opens throttle valve (372) located on the section Y-Y and is supplied to
chamber (f) to prevent cavitation generating in chamber (f).
And when the spool assembly returns to the neutral position, port C1 and drain port D are connected
with the passage provided on the spool assembly, and the hydraulic oil which is used to slide piston (112)
of parking brake is discharged to drain port D through passage c. With this operation, the released
parking brake actuates again and gets back the braking force.
X Y
SECTION Y-Y
X
Y
24-81
3) Parking brake
a. When starting operating and in operation
The hydraulic oil is supplied from the brake valve to port C1 when starting operating and then flows into
cylinder chamber (a), which is made up of spindle (101) and piston (112). When the pressure in cylinder
chamber (a) increases until the force reaches over the force of spring (113), the piston moves toward
rear flange (301) side. With the movement of this piston, the piston pushing force the separator plate
(116) and the friction plate (115) is cancelled, consequently the movement of friction plate fitted on
cylinder block (104) of hydraulic motor is in a free state and the braking force to the cylinder block is
released.
24-82
b. When parking and stopping

When spool assembly (202) of brake valve returns to the neutral position after stopping the operation,
port C1 is connected to the drain and the pressure in cylinder chamber (a) lowers. When the pressure
in cylinder chamber (a) reduces lower than the force of spring (113), piston (112) is pushed back by the
force of spring and pushes separator plate (116) and friction plate (115) in free state to spindle (101), and
consequently frictional force is generated between the separator plate and friction plate and fixes
cylinder block (104) which is linked to the friction plate with spline. With this operation, and also in cases
where the force (torque) for rotation is applied to the traveling motor used for parking on slope and
digging work from the outside, the motor is prevented rotating.
The torque of parking brake is set to 60% of output force of motor, if the external torque over the
parking braking torque is applied to, the motor rotates.
24-83
4) Explanation of auto 2-speed change mechanism

a. In low speed operation
When the pilot pressure is not supplied through port P, spool (383) is pushed rightward by the force of
spring (366) and the hydraulic oil is blocked at port P1 and the hydraulic oil in chamber (h) is bled into
drain port D through spool. Consequently swash plate (103) turns into the maximum tilt angle 1, and
the cylinder capacity of hydraulic motor reaches to the maximum and the speed changes in the low
speed operation.
24-84
b. In high speed operation

When the pilot pressure is supplied through port P, the force overcomes the force of spring (366) and the
hydraulic oil pressure supplied into chamber (k) inside of spool through port A (or port B) and port C1
and spool (363) is pushed leftward. Consequently the hydraulic oil which is the highest of oil pressures
at port P, P2 and P3 is led from port P1 to chamber (h) through the spool and port C1. Piston (161) is
then pushed and held by the hydraulic pressure which has been led into chamber (h) until swash plate
(103) strikes stopper face m provided on spindle (101). At this time the swash plate turns into the
minimum tilt angle, 2, and the cylinder capacity of hydraulic motor reaches to the minimum and the
speed changes in the high speed operation.
24-85
c. Auto change to low speed operation while operating it at high speed

As the load increases during high speed operation, the hydraulic pressure at port A (or port B) increases,
and the spool slides rightward when the force in combination of the force of spring (366) and the force
in chamber (k) inside of spool (363) overcomes the pressure at port P. Consequently the hydraulic oil in
chamber (h) which has pushed the swash plate to face m is fed into drain port D through spool (363). At
this time the swash plate strikes spindle face n and turns into the maximum tilt angle 1, and the speed
changes in low speed operation.
And when the load lowers and the hydraulic pressure at port A (or port B) lowers, the cylinder capacity
turns into the minimum and the high speed operation is restored by the operation in previous item "b. In
high speed operation".
24-86
24.1.6.3.2 Reduction unit

(1) Function
This reduction unit is made up of 2 step planetary gearing (epicycle gear, sun and planet gear) mechanism and
functions to reduce the high speed rotation supplied from hydraulic motor, to convert it into the low speed high
torque and to obtain hub (1) (casing) rotation.
(2) Explanation of actuation
The hydraulic motor axis rotation motion is transmitted to sun gear 1 (4) located on the 1st stage which is linked
to shaft (102) with spline. At this time planetary gear 1 (5) on the 2nd stage stays in mesh with sun gear 1 (4),
and planetary gear 1 (5) is engaged with hub (1) rotating on its axis and starts revolving. This revolution makes
carrier (3) fixed to planetary gear 1 (5) and sun gear 2 (8) on the 2nd stage linked with the carrier rotate.
This rotation is transmitted to hub (1) (ring gear) through planetary gear 2 (9) on the 2nd stage fixed on the
column of spindle, and turns into output rotation motion of the reduction unit. (The rotation is transmitted by
planetary gear1 (5) on the 1st stage, too.)
Column Planetary gear 2 Planetary gear 1
Sun gear1
Shaft
Input Out put
Spindle
Sun gear 2
Carrier
Hub (Ring gear)
24-87
24-88
24.1.7 SWIVEL JOINT
24.1.7.1 GENERAL VIEW

Fig. 24-76 General view of swivel joint
Item Specifications
Assy parts No. YN55V00053F1
Working pressure 34.3 MPa (4970 psi)
High pressure ports
Max. impact pressure 51.5 MPa (7470 psi)
A, B, C, D
Rated flow 255 L/min (67 gal/min)
Low pressure ports Working pressure 0.5 MPa (73 psi)
E Rated flow 50 L/min (13 gal/min)
Low pressure ports Working pressure 5 MPa (725 psi)
F Rated flow 30 L/min (8 gal/min)
Revolution speed 15 min-1 (15 rpm)
A, B, C, D (Body) PF1
A, B, C, D (Stem) PF3/4
Ports size
E PF1/2
F PF1/4
Length : L 368 mm (14.5")
Weight 25 kg (245 lbs)
24-89

! !"

#$!#$ !%&
' () (" * () +,(,!-
.!#! )

#$!#$ !%&
' () (" * () +,(,!-
.!#! )
Fig. 24-77 Construction
No. Name Q’ty No. Name Q’ty

1 Body 1 7 O-ring(G95 1A) 1
2 Stem 1 8 Capscrew (M8×20) 2
3 Thrust plate 1 9 Capscrew (M8×30) 3
4 Cover 1 12 Plug 1
5 Seal 5 13 O-ring 1
6 Seal 1
24.1.7.4 OPERATION
The swivel joint consists mainly of body (1) and stem (2) that rotate mutually, thrust plate (3) preventing both
components from falling off, cover (4) closing one side of body (1), seal (5) that partitions off the circuits and seal
assy (6) and O-ring (7) that prevent external leaks.
Four ports for the travel main circuits are provided on body (1) and stem (2). Further, four oil passing grooves are
arranged in the inner surface of body (1), with seal (5) fixed above and below the circumferential groove.
The body (1) and the stem (2) rotate mutually. The oil flowing in from body (1) or stem (2) keeps on flowing to stem
(2) or body (1) past the circumferential groove between body (1) and stem (2) ; the oil flow is never shut off because
of rotation. Further, an oil groove for lubrication that connects with the drain port is provided, in order to prevent the
body (1) from seizure with the stem (2).
This construction keeps on connecting the circuits between the swing bodies by means of a swivel joint.
24-90
24.1.8 CYLINDER
(1) General view
B A
n gth gth
n
d le d le
de te
xten rac
ly e et
Fu
l l ly r
Fu
Part No. and Manufacturing No.

Stamp position
Fig. 24-78 General view of cylinder

(2) Specifications
Unit : mm (ft-in)
Center distance of pins

Part No. of Cylinder bore / Dry weight
Use Stroke Full extend B / Full Cushion
cylinder assy Rod Dia. kg (lbs)
retract A
ø120 / ø85 1,355 3,199 / 1,844 With cushion on
Boom YN01V00151F1 166 (366)
(4.72" / 3.34") (4-5) (10-6 / 6-1) rod side R-50
ø135 / ø95 1,558 3,637/ 2,079 With cushion on

Arm YN01V00175F2 249 (549)
(5.32" / 3.74") (5-1) (11-11 / 6-10) both sides H-40,R-60
ø120 / ø80 1,080 2,675 / 1,595 With cushion on

Bucket YN01V00153F2 149 (329)
(4.72" / 3.15") (3-7) (8-9 / 5-3) rod side R-50
24-91
24.1.8.2 CONSTRUCTION AND FUNCTION
(1) Boom cylinder
T= Tightening torque ; N.m (lbf.ft)

23 22 12 T=267 (197) 22 23
B
-0.5
-0.5
105 0
105 0
PS1/8
PT1/4
With hole
DETAIL B (1 place) DETAIL C
T=5460 (4027)
9 8 7 6 3 4 5 11 10 2 1 13 14 16 17 18 19 15 20 21
Slit
Orientation of cut off part
of cushion bearing (13)
Fig. 24-79 Construction of boom cylinder
P/No YN01V00151F1
1 Cylinder tube 1 9 Wiper ring 1 17 Buckup ring 2
2 Piston rod 1 10 O-ring 1 18 Slide ring 2
3 Rod cover 1 11 Buckup ring 1 19 Slide ring 2
4 Bushing 1 12 Socket bolt; M16×75 12 20 Set screw; M12 1
5 Snap ring 1 13 Cushion bearing 1 21 Steel ball 1
6 Buffer ring 1 14 Cushion seal 1 22 Pin bushing 2
7 U-ring 1 15 Piston 1 23 Wiper ring 4
8 Buckup ring 1 16 Seal ring 1
24-92
(2) Arm cylinder

T=367 (271)
27 26 12 26 27
B
-0.5
-0.5
120 0
120 0
PT1/4
PS1/8
With hole
DETAIL B (1 place) DETAIL C T=7890 (5820) T=56.9 (42)
9 8 7 6 3 4 5 11 10 2 1 13 14 16 17 18 19 15 20 21
Orientation of cut off part Slit

25 23 22 24
Slit
Fig. 24-80 Construction of arm cylinder
P/No YN01V00175F2
1 Cylinder tube 1 10 O-ring 1 19 Slide ring 2
2 Piston rod 1 11 Buckup ring 1 20 Set screw; M12 1
3 Rod cover 1 12 Socket bolt; M18×80 12 21 Steel ball 1
4 Bushing 1 13 Cushion bearing 1 22 Cushion bearing 1
5 Snap ring 1 14 Cushion seal 1 23 Cushion seal 1
6 Buffer ring 1 15 Piston 1 24 Stopper 2
7 U-ring 1 16 Seal ring 1 25 Snap ring 1
8 Buckup ring 1 17 Buckup ring 2 26 Pin bushing 4
9 Wiper ring 1 18 Slide ring 2 27 Wiper ring 4
24-93
(3) Bucket cylinder
22 21 12 T=267 (197) 21 22
B
-0.5
-0.5
105 0
105 0
PS1/8
PS1/8
With hole
DETAIL B (1 place) DETAIL C
T=6200 (4573) T=56.9 (42)
9 8 7 6 3 4 5 11 10 2 1 13 15 16 17 18 14 19 20
Orientation of cut off part

Fig. 24-81 Construction of bucket cylinder
P/No YN01V00153F2
1 Cylinder tube 1 9 Wiper ring 1 17 Slide ring 2
2 Piston rod 1 10 O-ring 1 18 Slide ring 2
3 Rod cover 1 11 Buckup ring 1 19 Set screw; M12 1
4 Bushing 1 12 Socket bolt; M16×75 12 20 Steel ball 1
5 Snap ring 1 13 Cushion bearing 1 21 Pin bushing 4
6 Buffer ring 1 14 Piston 1 22 Wiper ring 4
7 U-ring 1 15 Seal ring 1
8 Buckup ring 1 16 Buckup ring 2
24-94
HYDRAULIC CYLINDER CONSTRUCTION (See Fig. 24-79)

By construction the hydraulic cylinder consists mainly of cylinder tube assy (1), piston rod assy (2) that takes out the
motion of pistons reciprocating in the cylinder tube assy, and cylinder head (3) that serves as both a lid and a guide.
Cylinder tube assy (1) is equipped with a pin mount (clevis) that connects piston rod assy (2) with other parts.
In addition to these main components, seal ring (16) and back-up ring (17) are located between cylinder tube assy
(1) and piston rod assy (2); buffer ring (6), U-ring (7) back-up ring (8) and wiper ring (9) are located between piston
rod assy (2) and cylinder head (3); and an O-ring (10) and a back-up ring (11) are placed between cylinder tube assy
(1) and cylinder head (3)
If pressurized oil is fed alternatively to the oil inlet and Cushion bearing (13) Chamber "A" Passege "B"
outlet provided in the cylinder, force acts on the piston Tank
which in turn causes the piston rod (2) to extend and Piston (15)
Rod (2)
retract.
Rod side
Head side
(1) Operation of cylinder with cushion
1) Cushion on rod side
The cushion mechanism is provided to prevent Rod cover (3)
Cushion stroke
the generation of shock when the moving speed
of piston (15) is not reduced and strikes cylinder Fig. 24-82 Cushion mechanism on the rod side
head (3).

An oil in chamber "A" returns to the tank by
passing through passage "B" at a fixed flow rate
in a intermediate stroke state (Fig. 24-82) of
pressing head side. Next, in a state of just before
stroke end (Fig. 24-83), cushion ring (13)
plunges into passage "B".
At this time, an oil in chamber "A" passes
clearance "D" and mouth gap "C", an oil flow
volume returning to tank suddenly drops and the
piston part movement slows down. Fig. 24-83 Cushioning action on the rod side
2) Cushion on head side (See Fig. 24-84)

This construction is similar to the one of cushion

on rod side. In a state of intermediate stroke

pressing rod side, an oil in chamber "A" returns
to tank by passing through passage "B" at a fixed
flow rate.
Next, in a state of just before stroke end, cushion
bearing (22) plunges into passage "B". At this
time, the oil in chamber "A" flows only through
clearance "D" and mouth gap "C" of cushion seal

(23). So the returning oil volume drops suddenly

and the piston movement slows down.

Fig. 24-84 Cushion mechanism on the head side
24-95
24-96
24.2 ELECTRIC EQUIPMENT

24.2.1 ELECTRIC EQUIPMENT LIST
Group Code Name Parts No.

C - 1 Mechatro controller YN22E00214F1
(C) Controller
C - 2 Gauge cluster YN59S00021F2

C - 4 Air-con controler (including panel) YN20M01468P1
C - 5 Engine coolant level controller VHS834701230
C - 8 Engine controller VH89661E0010
D - 4 Diode Harness accessory
D - 5 Diode Accessory of relay box
D - 6 Diode ↑
D - 9 Diode ↑
↑
(D) Diode
D - 10 Diode
D - 12 Diode ↑
D - 13 Diode ↑
D - 14 Diode ↑
D - 16 Diode ↑
D - 17 Diode ↑
D - 25 Diode Harness accessory
E - 1 Fuse and Relay box YN24E00016F2
E - 2 Alternator VH270402192A
E - 3 Hour meter YT58S00006P1
E - 5 Horn high LC53S00001D1
E - 6 Horn low LC53S00001D2
E - 7 Tuner —
(E) Electric fittings
E - 8 Speaker left YN54S00006P1

E - 9 Speaker right ↑
E - 10 Receiver dryer YN54S00041P1
E - 11 Air-con compressor YX91V00001F1
E - 12 Battery YN72S00016P1
E - 13 Travel alarm (For Middle east) YN53S00004F1
E - 14 Cigaratte lighter YN81S00003P1
E - 15 Fusible link LC13E01175S002
E - 22 DC-DC converter YT77S00001P1
E - 23 12V socket YN81S01002P1
E - 27 Accel redundant volume YN52S00052P1
L - 1 Boom work light (LH) YW80S00001F1
(L) Light
L - 2 Deck work light (RH) YT80S00002F2

L - 5 Room light YT80S00001P1
L - 6 Boom work light (RH) YW80S00001F1
L - 7 Cab work light —
24-97

(M) Motor
M - 1 Starter motor VHS281002894A

M - 3 Wiper motor YN53C00012F2
M - 4 Washer motor YN54C00001F1
Arm 2 speed inverse propo.
PSV - A YN35V00049F1
(P) Proportional
valve
solenoid valve
(YN35V00047F1)
PSV - B P2 unload propo. valve YN35V00048F1
Solenoid valve assy
PSV - C Travel straight propo. valve ↑
PSV - D P1 unload propo. valve ↑
PSV - P1 P1 pump propo. valve (YN10V00023F1) YN35V00052F1
PSV - P2 P2 pump propo. valve Pump ↑
R - 1 Battery relay YN24S00008F1
R - 2 Starter relay VHS283001271A
R - 3 Glow relay VHS286201420A
R - 4 Safety relay YN24S00010P1
R - 5 Horn relay ↑
R - 6 Working light relay ↑
R - 8 Travel alarm relay ↑
(R) Reray
R - 9 Cab working light relay ↑

R - 23 Auto idle stop relay 1 YN24S00010P1
R - 24 Auto idle stop relay 2 ↑
R - 25 Engine emergency stop relay ↑
R - 26 Lever lock relay ↑
R - 28 Alternator relay ↑
R - 29 Wiper motor relay (Normal rotation) YN24S00012P2
R - 30 Wiper motor relay (Reverse rotation) ↑
R - 31 Wiper motor relay (Arc prevention) ↑
R - 32 Washer motor relay ↑
SE - 1 Pressure sensor : Bucket digging LC52S00019P1
SE - 2 Pressure sensor : Bucket dump ↑
SE - 3 Pressure sensor : Boom up ↑
SE - 4 Pressure sensor : Boom down ↑
SE - 5 Pressure sensor : Swing ↑
SE - 7 Pressure sensor : Arm in ↑
(SE) Sensor
SE - 8 Pressure sensor : Arm out ↑

SE - 9 Pressure sensor : Travel RH ↑
SE - 10 Pressure sensor : Travel LH ↑
SE - 11 Pressure sensor : P2 OPT. ↑
SE - 13 E/G speed sensor VHS894101290A
SE - 15 Fuel sensor YN52S00045F1
SE - 16 Accel potentiometer YN52S00032P1
SE - 20 Pressure sensor : P1 OPT. LC52S00019P1
SE - 22 Pressure sensor : Pump P1 YN52S00048P1
SE - 23 Pressure sensor : Pump P2 ↑
24-98

(SV) Solenoid SV - 1 Swing parking brake SOL. YN35V00051F1
SV - 2 Power boost SOL (YN35V00047F1) YN35V00050F1
SV - 3 Two speed select SOL Solenoid valve assy ↑
SV - 4 Safety lock lever SOL ↑
SW - 1 Key switch YN50S00026F1
SW - 4 Swing parking brake release switch YN50S00047P1
SW - 5 Horn switch (RH) YN50E00017P1
SW - 7 E/G oil pressure switch VHS835301471D
SW - 8 Air filter clogging switch YR11P00008S005
SW - 10 Horn switch (LH) YN50E00017P1
SW - 11 Safety lock lever switch YN50S00041F1
(SW) Switch
SW - 13 Travel alarm switch (For Middle east) YN50S00040DF

SW - 15 Conflux/single select switch YN50S00040DD
SW - 17 Skylight wiper switch YN50S00040D9
SW - 19 Wiper interlock switch YT50S00004P1
SW - 20 Power boost switch (RH) YN50E00017P1
SW - 21 Power boost switch (LH) ↑
SW - 26 Cab work light switch YN50S00040D4
SW - 27 Coolant level switch VHS834601510A
SW - 28 Water separator switch VHS233002800A
SW - 55 Boom work light switch YN50S00040D1
24-99
24.2.2 SPECIFICATION OF ELECTRIC EQIUPMENTS
File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
C-1
Maker Sinko Electric Co. Ltd
Controller
Rated voltage DC24V
YN22E00214F1
Weight 4.2 kg (9.3 lbs)
Mechatro controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
C-2
Maker Nippon seiki Co., Ltd
Controller
Rated voltage DC24V
YN59S00021F2
Insulation More than 3M at 500V megger
Gauge cluster
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
C-4
Controller
YN20M01468P1

Air-con Controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
24-100
File No.
Name of part
Use
Applicable Machine
C-5
Rated voltage DC24V
Controller
Maker's (Hino) P/No. S8347-01230
VHS834701230
Controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
Hino P/No. : 82580-8050A

(YAZAKI : 7382-1680)
Hino P/No. : 82580-8870A
(YAZAKI : 7283-1080)
Measurement circuit Pin arrangement
C-8
Controller 89661-E0010
VH89661E0010 Maker's P/No. SOFTWARE
P/No.89663-E0750
Engine controller Rated voltage 24V (DC)
YN11 - 45001 ~ Working voltage 16~32V (DC)
YQ11 - 06001 ~ Operating voltage
(at starter ON) 9~32V (DC)
LC10 - 07001 ~ Back-up source
(reference value) 5mA MAX (BAT=24V)
YC10 - 03501 ~
Connector 167 pins Male
24-101
File No.
Name of part
Use
Applicable Machine
E-1
Fuse capacity and circuit
Fuse & Relay box
YN24E00016F2
Fuse & Relay
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
Front side of machine
E-2
Alternator M6
B terminal
VH270402192A
Generator
YN11 - 45001 ~
YQ11 - 06001 ~
4 pin connector (Water proof)

Terminal arrangement Hino P/No. 82560-2390
(Eqivalent to sumitomo 6188-0631 )
VIEW A
Connector
Hino P/No. 82560-8640
(Eqivalent to sumitomo 6189-0351)
E-3
Hour meter Movement Quarts
Operating voltage 10~80VC GM terminal : 2962447
YT58S00006P1
GM connector : 2962448
Service meter
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
24-102
File No.
Name of part
Use
Applicable Machine
E - 5, 6
Type Bottom L : Low sound
Horn H : High sound
Rated voltage DC24V STAMP
LC53S0001D1 (High)
Operating voltage range DC20~30V
LC53S0001D2 (Low)
Sound level 113+5dB(A)/2m
Warning sound
420+20Hz high sound
YN11 - 45001 ~ Basic frequency 350+20Hz low sound
YQ11 - 06001 ~ Insulation resistance More than 3M /DC500V
LC10 - 07001 ~
YC10 - 03501 ~ o 8.5
E - 8, 9
Speaker
YN54S00006P1

Radio

YT02 - 04001 ~
!
YT03 - 05293 ~
YT04 - 07001 ~
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
E - 10
Maker Sanden Corp.
Receiver dryer
Airtight test pressure 3.5MPa (508 psi)
YN54S00041P1
Pressure proof test pressure 5.3MPa (769 psi)
Air-con
Breaking test pressure 9.8MPa (1420 psi) Outlet (To unit)
YN11 - 45001 ~ Desiccant moisture 17% or over than the
weight of desiccant
YQ11 - 06001 ~ adsorption capability (Include initial absorption 2%)
LC10 - 07001 ~ Refrigerant HFC-134a
YC10 - 03501 ~ Inner volume/Desiccant 578cm3/300g Inlet (From condenser)
24-103
File No.
Name of part
Use
Applicable Machine
E - 11
Air-con compressor
!"#$"###
YX91V00001F1

%&'
Air-con

'### (

)* +
YX03 - 01601 ~
YX04 - 01773 ~

$,!'
YX05 - 02001 ~
-.$&#/,!0
YN11 - 45001 ~

YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
E - 12
Type 115F51
Battery
Voltage 12V
YN72S00014P1
Capacity (5HR) 96Ah
Power
Weight (Incl. fluid) Approx. 26.5kg (58.4 lbs)
YN11 - 45001 ~
Electrolyte Approx. 6.7 L (1.77 gal)
YQ11 - 06001 ~
Negative Positive
LC10 - 07001 ~ terminal terminal
YC10 - 03501 ~
(0.67")
(0.67")
Taper
Taper
17
17
17.9 19.5
(0.705") (0.768")
502 (19.76")
180 (7.09")
255 (10")
210 (8.27")
24-104
File No.
Name of part
Use
Applicable Machine
E - 13 GND AV 0.5 Black
Model BA3111A
Alarm
Rated voltage DC 12V~36V Power AV 0.5 Red / Green
YN53S00004F1
AMP Econoseal J series Mark II water-proof
Travel alarm
Housing : 174354-2 Harness seal : 172888-2
(Middle east) Terminal : 171661-1 Retainer : 1-174355-1
YN11 - 45001 ~ VIEW A

YQ11 - 06001 ~
LC10 - 07001 ~ Vinyl tube
YC10 - 03501 ~
E - 14
Cigarette lighter !

"# $%
YN81S00003P1
&! - +
Cigarette lighter ./
YN11 - 45001 ~

' (
)&%
YQ11 - 06001 ~
LC10 - 07001 ~
* + (,$&
YC10 - 03501 ~
01 +
E - 15
Fusible link

LC13E01175S002
Fuse
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
E - 22
Input voltage DC 24V
DC-DC converter
Output voltage DC 12V
YT77S00001P1
Output current 2.5A Max
DC24V→DC12V
Ground Negative
YN11 - 45001 ~ YV
WG YB
YQ11 - 06001 ~ OL
Fix the wire B
with tape
HOUSING YAZAKI 7122-2262
TERMINAL YAZAKI 7114-2020
VIEW A
A
24-105
File No.
Name of part
Use
Applicable Machine
E - 23
Power supply For 12V
12V socket
Max. current Less than 10A
YN81S00001P1
Insulation resistance More than 10M /500v megger
Power socket
YN11 - 45001 ~
GROUND TERMINAL
YQ11 - 06001 ~
Open and shut

POSITIVE TERMINAL direction
980-10760
E - 27
Resistance 2
Rated voltage DC 5V
Accel redundant volume
Resistance 2 TOCOS
YN52S00052P1 Parts E-27 RA30YME20FB202
Accel redundant volume
YN11 - 45001 ~ After soldering,
insulate this part
YQ11 - 06001 ~ with heat shrinkable tube
Clip
LC10 - 07001 ~
Adhesive
YC10 - 03501 ~
Fix this resistance with tape HOUSING : 172131-5

PVC tube (Black) TERMINAL : 170340-1
Dial
VIEW I
L - 1, 6
Light (Halogen)

YW80S00001F1
Boom work light (LH, RH)
LC08 - 06201 ~
YC08 - 03001 ~
LC09 - 06201 ~
YC09 - 03701 ~
YN11 - 45001 ~

YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
L-2
Light (Halogen) Type BL84-200
Bulb DC 24V,70W
YT80S00002F2
Effective area of lens 71cm2
Deck work light
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
24-106
File No.
Name of part
Use
Applicable Machine
L-5
Bulb 24V,5W Body
Light
Note) Equivalent to 2456Z322F1 Lens
YT80S00001P1
Room light
YT02 - 04001 ~
YT03 - 05293 ~
YT04 - 07001 ~ Bulb
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ SECTION A-A Door
Switch
YC10 - 03501 ~
M-1 B Terminal : M8X1.25
Rated output DC 24V, 15kW A
Motor
Yazaki P/No.
VHS281002894A Terminal : 7114-6047
Pinion gear
Connector : 7282-3013-30 (Black)
Starter motor Hino P/No. : 82580-6720
YN11 - 45001 ~ Mating connector
Hino P/No. : 82580-6730
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
VIEW A
M-3
159800-5710
Motor Denso corp. P/No. (Motor only)
YN53C00012F2 Rated voltage 24V
Wiper motor Swing angle Applox. 80
YN11 - 45001 ~ Controller
YQ11 - 06001 ~ Wiper motor 24V
LC10 - 07001 ~
YC10 - 03501 ~
Wiper sw
OFF-Stop
Stop signal ON-Start
Reverse signal
Electric diagram
M-4
Rated voltage DC 24V
Motor (Reservoir)
Injection flow 600cc (0.16 gal) / min or more
YN54C00001F1
Capacity 1.5L (0.4 gal)
Window washer
Injection pressure 88.3 kPa (12.8 psi) or more
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
24-107
File No.
Name of part
Use
Applicable Machine
R-1
At start 24V2000A(0.1 sec) Terminal A
Relay Rated voltage / current At charge 28V120A(Continuous) VIEW A
YN24S00008F1 Exciting current 0.4A or less / 24V
Lock section
Battery relay Contact pressure 37.2N {8.4 lb} or more Terminal A
YN11 - 45001 ~ Closed circuit voltage 16V or less VIEW I
Terminal B
YQ11 - 06001 ~ Open circuit voltage 7V or less HOUSING AMP
GND terminal
174359-2
LC10 - 07001 ~ Insulation resistance 3M or more/500V megger RETAINER AMP
1-174360-7
YC10 - 03501 ~ TERMINAL AMP
171661-1
WIRE PROOF PLUG AMP
172888-2
VIEW Z Terminal L
Flowing direction of
main current F HOUSING YAZAKI
o 9 X 30L
Terminal A Terminal B Terminal B Heart shrinkage tube 7123-4210-30
AVS 1.25G
F TERMINAL YAZAKI
AVS 1.25B 7116-3251*
z GND wire
WIRE PROOF PLUG
I Terminal B Terminal L 7157-3580-60
F HOUSING YAZAKI AVS 1.25L Terminal B
7123-4220-30
F TERMINAL YAZAKI
P coil 7116-3251
REAR HOLDER YAZAKI
7157-6801-30
H coil WIRE PROOF PLUG
7157-3580-60
Bracket groud
Circuit diagram
o 7.0 X 150L
Corrugete tube (Black)
Fusible link assy B o 7.0 X 150L

Fusible link assy A Corrugete tube (Black)
R-2 Length of coupler harness

Hino P/No. S2830-01271A
Relay (From outlet to coupler)
Rated voltage DC24V L=215mm
VHS283001271A
Rated time 30 sec 18 o4 MAX
Starter relay Vynil tube (Red)
Exciting current 3A or more (at 20 )
YN11 - 45001 ~
Min operating voltage DC18V or less (at 20 )
YQ11 - 06001 ~
Insulation resistance 1M or more
LC10 - 07001 ~
YC10 - 03501 ~ Black
Blue
Vynil tube (Red) M6
Terminal C Terminal B
Electric diagram
E (AVX 0.85mm2 Black)

E (AVX 0.85mm2 Blue)
Tape
M6
24-108
File No.
Name of part
Use
Applicable Machine
R-3
Hino P/No. S2862-01420A
Relay
VHS286201420A
Rated load 100A flow
Glow relay
Min. operating voltage DC 18V or less
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
S terminal
YC10 - 03501 ~
(Red)
Name plate
F terminal
Connector
090 II Non water-proof male 2P blue
SW terminal Hino P/No. 82580-7320A
Yazaki P/No. 7282-1020-90
Mating connector
090 II Non water-proof female 2P
Hino P/No. 82580-7330A
L terminal Yazaki P/No. 7383-1020-**
Electric diagram
R - 4,5,6,8,9,23,24,25,
26,28 Maker Tyco Electronics
Maker's p/No. V23074-A2002-A403
Relay
Type Micro relay A
YN24S00010P1
Safety relay
Horn realy Contact 1C
Work light relay * Accessory of relay box
Travel alarm relay
Cab working light relay
Auto idle stop relay 1, 2
Engine emergency stop relay Pin assignment
Lever lock relay
Alternator relay
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
Terminal arrangement
24-109
File No.
Name of part
Use
Applicable Machine
R - 29,30,31,32
Maker's P/No. V23134-A0053-C643
Relay
Parts name Relay
YN24S00012P2
Rated voltage DV 24V
Wiper motor relay
Washer motor relay Contact 1C
YN11 - 45001 ~ * Accessory of relay box
YQ11 - 06001 ~
Pin assignment
SE - 1 ~ 5, 7 ~ 11,20
Pressure sensor
(Low pressure)

! " !
LC52S00019P1
Bucket dig and dump,
) *+ ,- . #%%. ,#
Boom up and down, ( ,- .

# #+,. #%%. ,#
/.)0.
Swing, ,.
%)0 % #%%. ,#% 1#2+%& 3 4$56764$'
,.
%)0 3 5656$
Arm in and out, ' # 1.8 '5 &#0 0),.
Travel RH and LH and other 4 #2, 2, 1)
%.++ +.)0 3 56767$'
YN11 - 45001 ~ #9.

YQ11 - 06001 ~ #$
%&
'( '' /'"
SE - 13
Output voltage 2.8V or more
Speed sensor
Clearance 1.0mm
VHS894101290A Sumitomo : 090-II (4P : B)
E/G speed sensor P/No. : 6188-0265
Hino. P/No.
YN11 - 45001 ~ Sensor side : 82580-6120A (B)
Harness side : 82580-6130A (B)
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
M16 x 1 Hex. : 17
Hex. : 22
Tightening torque : 47N.m (34.7 lbf.ft)
24-110
File No.
Name of part
Use
Applicable Machine
SE - 15
Float operation
Fuel sending unit
Float Resistance
YN52S00045F1 +0.1
FULL 10 -0.6
Fuel level
3/4 (19)
YN11 - 45001 ~
1/2 32+5
YQ11 - 06001 ~
1/4 (49.5)
LC10 - 07001 ~
EMPTY 85 +10
0
YC10 - 03501 ~
Machine side controller
Float
Electric diagram VIEW A
SE - 16
Total resistance value
Potentio meter
Effective electric angle
YN52S00032P1
Number of notches
Accel dial
Source voltage
YT02 - 04001 ~
Notch part
YT03 - 05293 ~
YT04 - 07001 ~ Potentio
YN11 - 45001 ~ 3MA JM II + AMP
Bracket
YQ11 - 06001 ~ HOUSING : 174359-2
TERMINAL : 171661-1
LC10 - 07001 ~
YC10 - 03501 ~ Dial
SE - 22, 23 Electric diagram (Arrangement)

Pressure range 0~50MPa (7250 psi)
Pressure sensor
Max. allowable press. 120MPa (17400 psi)
(High pressure)
Operating source voltage 5+0.5V DC
YN52S00048P1
100M or more/DC50V megger
P1 pump Insulation resistance
(Between casing and terminal)
P2 pump
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ Source (+)
P3/8
YC10 - 03501 ~ Tightening torque Output (+) Econo seal J series
: 73.5 N.m O ring P14 Common (+) (Mark II (+)
(54.2 lbf.ft) JIS B2401 3 pole
24-111
File No.
Name of part
Use
Applicable Machine
PSV - A, B, C, D
Proportional solenoid valve
Hydraulic solenoid valve
Hydraulic symbol A5 to A8
(YN35V00047F1)
YN35V00048F1
YN35V00049F1
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
HYDRAULIC SYMBOL
Arm 2 speed
P1 unload
Travel straight
P2 unload
Attachment boost
Travel 1,2 speed
Swing parking
Lever lock
PSV - P1, P2
Solenoid Type KDRDE-5K AMP MARK II
Max. feed press 13.7MPa (1987 psi) HOUSING : 174354-2
YN35V00052F1 TERMINAL : 173706-1
Rated feed press 5.0MPa (725 psi) Orifice Spring
HEX 10
Pump P1, P2
Allowable back press 1MPa (145 psi) Spool T=7.4N.m
proportional valve (5.5lbf.ft)
Control pressure range 0~2.7MPa (392 psi)
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
Sleeve O-ring Solenoid Seal nut
1B P20
SV - 1, 2, 3, 4
Rated pressure 5.0 MPa (725 psi)
Solenoid directional
Solenoid directional
pressure Rated voltage DC 24V
valve (8 spool) assy
Hydraulic symbol Solenoid proportional Dither current 100Hz,200mA P-P P1, P2, T, A1, A8 port PF3/8
valve Coil resistance 17.5 (at 20C)
A1 to A4 A2~A7 port PF1/4
AMP MARK II AMP MARK II
(YN35V00047F1) Connector specification HOUSING 174354-2
TERMINAL 173706-1
YN35V00050F1
YN35V00051F1
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
24-112
File No.
Name of part
Use
Applicable Machine
SW - 1 Auto return
Switch
Connection
YN50S00026F1 Terminal
Position
Starter switch
Auto return
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ VIEW A Terminal
YC10 - 03501 ~ arrangement
SW - 4
Type ST110D Insulation tape
Switch
Rated DC30V, 10A R B W
YN50S00047P1
Insulation resistance
Swing parking brake
release
Vinyl tube
YN11 - 45001 ~ YAZAKI
T No.
YQ11 - 06001 ~ Contact construction : Position Red (2) 7122-2237
7114-2020
Swing parking release
Normal
White (3) Blue (1)
SW - 5, 10, 20, 21
*+ ,-
Switch -

).

YN03M01861F1
(Right grip)
!" #$ $%
&
& '
YN03M01862F1 (%" )
(Left grip)
Horn, ATT Power boost
YN11 - 45001 ~
YQ11 - 06001 ~ )) ) - /012-, 34+# 5! )6
LC10 - 07001 ~ )) ) - &$7-, 8!#+9!8!
7 5)) ) : ( #6
YC10 - 03501 ~
SW - 7
Type Normal close
Switch
Working pressure 39.2~58.8kPa (5.7~8.5psi)
VHS835301471D
Rating DC 24V/12W
E/G oil pressure switch More than 100M / 090 II Water proof connector
Insulation resistance DC500V megger
YN11 - 45001 ~ Color : Black
Hino P/No. : 82580-6830
YQ11 - 06001 ~ Yazaki P/No. : 7383-1114
LC10 - 07001 ~
YC10 - 03501 ~
24-113
File No.
Name of part
Use
Applicable Machine
SW - 8
Switch

YR11P00008S005

Air cleaner
Clogging switch !
YT02 - 04001 ~
YT03 - 05293 ~
YT04 - 07001 ~
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
SW - 11
Switch

YN50S00041F1

Lock lever
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~ ! "
! "

#$
SW - 13
Switch
Single pole single throw
YN50S00040DF Type (alternate)
Travel alarm More than 1M /
Insulation resistance DC500V megger UP
(Middle east)
YN11 - 45001 ~ Terminal connector
YQ11 - 06001 ~ Position
Connector
LC10 - 07001 ~
YC10 - 03501 ~
SW - 15
Switch
YN50S00040DD Type (alternate)
Conflux / single flow More than 1M /
switching (OPT)
Connector
LC10 - 07001 ~
YC10 - 03501 ~
24-114
File No.
Name of part
Use
Applicable Machine
SW - 17
Switch
YN50S00040D9 Type (alternate)
Roof window wiper More than 1M /
switch (OPT)
Connector
LC10 - 07001 ~
YC10 - 03501 ~
SW - 19
Switch
YT50S00004P1
Rated load 1A
Voltage drop 0.2V or less
Wiper inter lock
Insulation resistance 5M or more
YN11 - 45001 ~
Operation force Initial motion 0.8+0.3
0 kg
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
Max. stroke
SW - 26
Switch
YN50S00040D4 Type (alternate)
Cab work light switch More than 1M /
YN11 - 45001 ~
YQ11 - 06001 ~ Terminal connector
LC10 - 07001 ~ Position
Connector
YC10 - 03501 ~
SW - 27
Purpose Coolant level detection
Switch
Working temperature -40 ~130
VHS834601510A
Coolant level switch Hino P/No. : 82580-71708
Sumitomo P/No. : 6188-0110
YN11 - 45001 ~
Electrode side
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~ CONNECTOR
Housing side
(To ground) Mating connector
M18, P=1.5 Hino P/No. : 82580-71808
Sumitomo P/No. : 6189-0189
24-115
File No.
Name of part
Use
Applicable Machine
SW - 28
Switch
VHS233002800A
Fuel filter
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ Fuel outlet
Fuel inlet
YC10 - 03501 ~
Deposit container
Drain
Water proof connector

Yazaki 7383-7028-40
SW - 55
Switch

YN50S00040D1
!
"## &%
Boom work light switch $

YN11 - 45001 ~
YQ11 - 06001 ~ $
LC10 - 07001 ~
%
YC10 - 03501 ~
24-116
25. AIR-CONDITIONER SYSTEM
TABLE OF CONTENTS
25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER).........................25-3

25.1.1 AIR CYCLE.............................................................................................................25-3
25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE ....................................................25-4
25.2 COMPONENT AND CONSTRUCTION ...........................................................................25-5
25.2.1 COMPONENT ........................................................................................................25-5
25.2.2 CONSTRUCTION ...................................................................................................25-6
25.3 PIPING.............................................................................................................................25-9
25.3.1 AIR CONDITIONER................................................................................................25-9
25.3.2 AIR DRYER ASSY..................................................................................................25-11 25
25.4 FUNCTION ......................................................................................................................25-12
25.4.1 MECHANISM OF COOLING CIRCUIT...................................................................25-12
25.4.2 COOLING CIRCUIT................................................................................................25-14
25.4.3 COMPONENT PARTS ...........................................................................................25-15
25.5 DISASSEMBLY AND ASSEMBLY...................................................................................25-19
25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION .........................................25-19
25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT ..........................................................25-20
25.6 CHARGING REFRIGERANT...........................................................................................25-24
25.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION .........................................25-24
25.6.2 OPERATING PROCEDURE...................................................................................25-25
25.6.3 CHARGING PROCEDURE ....................................................................................25-26
25.7 ELECTRIC CIRCUIT........................................................................................................25-32
25.7.1 WIRING DIAGRAM AND CONNECTORS .............................................................25-32
25.7.2 STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION ...25-34
25.8 TROUBLESHOOTING.....................................................................................................25-37
25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL ..............................................25-44
25.9.1 POSITION OF INDICATION FOR FAILURE. .........................................................25-44
25.9.2 EXPLANATION OF INDICATION FOR FAILURE. .................................................25-44
25.9.3 EXPLANATION OF MONITOR MODE ...................................................................25-46
25-1

SK200–8 : YN11-45001~ S5YN2518E01
SK210LC–8 : YQ11-06001~ (ASIA, OCE)
S5YN2518E02
(ASIA, OCE)
E215B : YN11-45001~ ↑
↑ March, 2007 K
E215B : YN11-45001~ ↑
↑ July, 2007 K
↑
↑ ↑ ↑ K
↑
↑ ↑ ↑ K
25-2
25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER)

Air-conditioner is the unit which places evaporator and heater core parallel, and unifies a blower fan and an inside /
outside air switching unit. And this unit changes hot air to cool air.
25.1.1 AIR CYCLE

• Heater
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is
performed with hot air (heating) at the heater core of air-con unit, and then the heated air blows off from grille
through duct.
• Cooler
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is
performed with cold air (dehumidifying and cooling) at the evaporator of air-con unit, and then the cooled air
blows off from grille through duct.
• Heater system
The heater recycles (circulates) the cooling water in the engine, and the hot water delivered by the engine flows
in the heater core of air-con unit and then heat exchange is performed.
The intake air is heated and the heated air blows off from the grille provided on the inside of cab.
The blow off air temperature is controlled by the temperature control switch on the control panel, and the
operation is controlled by air mixing damper on the air-con unit.
25-3
25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE
AIR CONDITIONER CONTROL PANEL
COMPRESSOR
SOLAR RADIATION SENSOR COMPRESSOR DRIVE SOURCE
REFRIGERANT
AIR MIXED DAMPER SIGNAL PRESSURE SWITCH
AIR-CON BLOWER REVOLUTION SIGNAL
AIR OUTLET SWITCHING SIGNAL CONTROLLER
INNER AIR SENSOR
EVAPORATION SENSOR
INNER AIR AND OUTER AIR
SWITCHING SIGNAL
OUTER AIR INTAKE

MOTOR
VENT ACTUATOR
INNER AIR
MOTOR
ACTUATOR
AIR CONDITIONER UNIT FACE
FOOT MOTOR BLOWER

ACTUATOR CONTROLLER
25-4
25.2 COMPONENT AND CONSTRUCTION

25.2.1 COMPONENT
27
33 30
27-1
40
32
39
27-3 27-4
27-2
35
35-7 35-6
35-1
35-2 35-5
34 35-8
35-10 35-9
Fig. 25-1 Air-conditioner group
A/C ASSY YN20M00104F1 (12)

27 Air-conditioner assy 1 33 Pulley 1 35–7 L hose 1
27–1 Air-conditioner unit 1 34 Condenser 1 35–8 L hose : Ø 15.5 1
27–2 Hose 2 35 Air dryer assy 1 35–9 S tube : Ø 16 1
27–3 Clamp 2 35–1 Receiver dryer 1 35–10 L tube : Ø 8.5 1
27–4 Filter 1 35–2 Bracket 1 39 Filter 1
30 Panel assy 1 35–5 S hose : Ø 24.5 1 40 Solar radiation sensor 1
32 Compressor 1 35–6 D hose 1
25-5
25.2.2 CONSTRUCTION
(1) Air conditioner unit
49
47
48
46 44
31
42 31
41
50
3 1
45 1
A
1 32 43
39
37
38
36
40
B
2
33
Fig. 25-2 Air conditioner unit (1/2)
25-6
14 16
6 1 1 31
1
5
15
1
31
62
1 3
1 1
D
E 4
7
28 1
A 1 1
27
1
20
26
13
C 60
11
29
23
21 22
24 82
24
83
51 54 79
9 63
78 23 C 84 61
17
E
18
31
D
B
10
19
12
1 25
3
31
77
Fig. 25-3 Air conditioner unit (2/2)
25-7

1 Screw M5×16 23 21 Expansion valve 1 44 MA mode lever 1
2 Main harness 1 22 O-ring 1 45 Foot lever 1
3 MA air mix 3 23 O-ring 1 46 Face lever cam 1
4 Blower controller 1 24 Screw M5×40 2 47 Vent lever cam 1
5 Upper casing 1 25 Thermistor 1 48 Face rod 1
6 Air mix door 1 26 Thermistor holder 1 49 Vent rod 1
7 Air mix lever 1 27 Heater core 1 50 Foot rod 1
8 Lower casing 1 28 Pipe holder 1 51 Plate 1
9 Air mix door sub 1 29 Thermistor 1 54 Screw 1
10 Air mix lever sub 1 31 Screw M4×30 9 60 Casing packing A 1
11 Blower 1 32 Upper casing 1 61 Casing packing B 1
12 Lever MA air mix 1 33 Lower casing 1 63 O-ring 1
13 Intake door 1 36 Foot door 1 77 Packing 1
14 MA intake lever 1 37 Vent door 1 78 Tube 1
15 Intake lever 1 38 Face door 1 79 Tube 1
16 Intake rod 1 39 KK box upper packing 1 82 Tube 1
17 Air mix rod 1 40 KK-box lower packing 1 83 Bracket 1
18 Air mix rod sub 1 41 Vent lever 1 84 Lower casing 1
19 Relay 2 42 Face lever 1
20 Evaporator 1 43 Foot joint lever 1
(2) Receiver dryer
REFRIGERANT 2
INLET
REFRIGERANT
OUTLET
2-M6
1
No NAME Q'TY
1 PRESSURE SWITCH 1
3 2 SIGHT GLASS 1
4 3 DESICCANT 1
4 SUCTION PIPE 1
5 5 FILTER 1
6 RECEIVER TANK 1
Fig. 25-4 Receiver dryer
25-8
25.3 PIPING
25.3.1 AIR CONDITIONER
30
40
NOTE
1. Apply oil for refrigerant R134a to the
27 8 O-rings of all air-conditioner hose fittings.
8 2. Refrigerant volume : 900 50g
3. T : Tightening torque N.m(lbf.ft)
8 58
25 6
24
8
6
24
5
8
A
12
55
2
13
6 INITIAL BELT TENSION
24 When the belt is pushed by the
54 force of 28N, adjust the 25
deflection of L part to be 6mm.
39 4
8 22
51
JAM NUT FOR 18
TENSION PULLEY 20
T=46.1(33) 25
5
2 10
11 21
16
3
6 L
59
9
25 10
25 33
49 23
A 25
9 1
32 10
15
35 52 50
53
5
7 13
25
25
8 25
17 25
3 12
6
56 14
57
23
34 56
57
Fig. 25-5
25-9
Air conditioner YN20M00104F1

1 Hose : L = 3550 1 24 Clip 3
2 Hose : L = 2950 1 25 Clip 15
3 Bracket 2 27 Air conditioner assy 1
4 V-belt 1 30 Panel 1
3.92~4.9 (2.9~3.6) 5 Clip 4 32 Compressor assy 1
6 Sems bolt : M10×25 5 33 Pulley assy 1
7 Sems bolt : M6×20 2 34 Condenser 1
8 Sems bolt : M8×20 9 35 Air dryer assy 1
9 Capscrew : M8×100 4 39 Filter 1
10 Washer 6 40 Solar radiation sensor 1
23.5 (17.3) 11 Capscrew : M8×25 2 49 Clip 1
12 Tube for heater : L = 2400 1 50 Connector 1
13 Tube for heater : L = 1500 1 51 Bracket 1
14 Tube for D hose : L = 2350 1 52 Clip 1
15 Tube for S hose : L = 2050 1 53 Sems bolt : M10×20 1
16 Bracket 1 54 Grommet 1
17 Tube for L hose : L = 1800 1 55 Grommet 1
18 hose : L = 90 1 4.4 (3.2) 56 Capscrew : M6×50 4
20 Clip 2 57 Washer 4
21 Bracket 1 58 Tube for L hose 1
46.1 (34.0) 22 Sems bolt : M10×40 2 59 Clip 1
23.5 (17.3) 23 Sems bolt : M8×25 4
UNIT CONNECTION TUBE ASSY COMPRESSOR CONNECTION BOLT
UNIT CONNECTION BOLT

S TUBE (9)
27 AIR CONDITIONER ASSY D HOSE (6)

S
32 COMPRESSOR ASSY
RECEIVER CONNECTION BOLT

S HOSE (5)
L TUBE (10)
L HOSE (8) L HOSE (7) 34 CONDENSER

Note : 35 RECEIVER DRYER
Numbers in ( ) shows the number in Fig. 25-6. RECEIVER DRYER MOUNTING BRACKET
25-10
25.3.2 AIR DRYER ASSY
&
#
! )
"
'
"
!
%
) ,
#
, *
+ $
+
*
Fig. 25-6
Air dryer assy YN96V00024F1 (02)
1 Receiver dryer 1 6 D hose 1
2 Bracket 1 7 L hose 1
3 Capscrew 2 8 L hose 1
4 Capscrew 2 9 S tube 1
5 S hose 1 10 L tube 1
25-11
25.4 FUNCTION
25.4.1 MECHANISM OF COOLING CIRCUIT
(2) Mechanism of Cooling
Item HFC-134a (R134a)
In the cooling process, the refrigerant that flows
Chemical formula CH2FCF3
through the cooling circuit changes its phases from Molecular weight 102.03
liquid to gas and vice versa during which process Boiling point -26.19 (-15.14 )
heat is transferred from the low temperature part Critical temperature 101.14 (214.05 )
Critical pressure 4.065 MPa (41.45kgf/cm2 1)
(compartment) to the high temperature part
Critical density 511 kg/m3 (31.9lb/ft3)
(outside of the vehicle). Density of saturated
1206 kg/m3 (75.3lb/ft3)
1) Kind of Refrigerant liquid[25 (77.0 )]
Many kinds of refrigerants that change in that Specific volume of saturated
0.0310 m3/kg (0.496ft3/lb)
vapor [25 (77.0 )]
way are available, but the following requirements Latent heat of
are needed for use in such applications: 197.5 KJ/kg {47.19kcal/kg}
vaporization [0 (32 )]
• Latent heat of vaporization (heat of Flammability Nonflammable
Ozone destruction
vaporization) is large. coefficient 0
• It is easy to liquefy (condense). (It dose not 1 : 1MPa (mega pascal) equals 10.1972kgf/cm2
require very high pressure for condensation.) (145psi)
• It is easy to gasify (evaporate). (It evaporates
sufficiently at not too low pressure, i.e. cools
down an object.)
• It has small specific heat. (Since the
refrigerant itself is cooled by the expansion
valve, the loss resulting from it must be held
down to a minimum.)
• It has a high critical temperature and a low
solidification point.
• It is stable chemically and does not corrode
and permeate into the circuit parts.
• It is free from toxicity, objectionable odor,
flammability and explosiveness and excels in
thermal conductivity and electric insulation.
• It has small specific volume.
• It is easy to find out leakage.
Out of refrigerants meeting the above-
mentioned requirements, ones having
characteristics that suit the intended cooling
unit are chosen and used. If a refrigerant
other that those designated is used,
sufficient refrigeration will not be performed
or the equipment in which the refrigerant is
used may be broken. Therefore, always use
a designated refrigerant for the cooling unit.
Table shows the principal characteristics of
the R134a refrigerant that is used in this
machine.
25-12
(3) Characteristics of Refrigerant (Fig. 25-7) PRESSURE

In general, the fluid (general term of gas and liquid) MPa(psi)
R134a
has the following qualities: 4(580)
1) As a gas under certain pressure is cooled down,

3(435)
it begins to condensate at a certain temperature LIQUID
to take a liquid state. The temperature at which
2(290)
condensation begins is unique to each
substance (fluid) at a given pressure. The 1(145) GAS
temperature determined by a given pressure is 0.5(75)
TEMPERATURE
called saturation temperature. [ ( )]
0 0 15 18 35 50 100
(32) (59)(64) (95) (122) (212.0)
2) Inversely to 1) above, the pressure at which a
gas condenses for a temperature is determined. Fig. 25-7 Pressure-temperature characteristics of
This pressure is called saturation pressure. R134a
Fig. 25-7 illustrates the relationships between
the saturation temperature and the saturation
pressure in the case of refrigerant R134a used in
the air-conditioner. At the temperature and the
pressure on the lower righthand side of the curve
in Fig. 25-7 the refrigerant take a gaseous state,
while at the temperature and the pressure on the
upper lefthand side of the curve, the refrigerant
takes a liquid state.
Let us think of a case where an air-conditioner is
operated in the midst of summer. As the
refrigerant evaporates, it absorbs evaporation
heat from the air of the compartment. In order to
cool the inside of the compartment down to 25°C
(77°F), the refrigerant must transform
(evaporate) from a liquid to a gaseous state at a
lower temperature. It can be seen from Fig. 25-7
that R134a under a pressure above the
atmospheric pressure is capable of cooling the
inside of the compartment sufficiently. (If a
refrigerant that requires a pressure below the
atmospheric pressure to cool it to a required
temperature is used, air is mixed into the circuits,
thereby deteriorating the performance of the
cooling unit.) In the process in which gaseous
refrigerant is brought back to a liquid state, the
refrigerant is cooled and condensed by the outer
air exceeding 35°C (95°F).
Accordingly the refrigerant is capable of
condensing at a pressure exceeding 1 MPa
(145psi), as seen from Fig. 25-7.
25-13
25.4.2 COOLING CIRCUIT

Fig. 25-8 illustrates the cooling circuit of the car air-
conditioner.
In this circuit diagram, the portion that cools the air of INSIDE OF COMPARTMENT(CAB)
the compartment is the evaporator. The object air is
cooled off by utilizing the fact that the refrigerant takes
heat off the surrounding area as evaporation heat as it
evaporates in the cooling circuit. Since the part at which EVAPORATOR EXPANSION
BLOWER VALVE
vaporization of the refrigerant takes place is the
evaporator, cooled air is constantly delivered to the
circumference of the evaporator by the blower fan. In INSIDE OF ENGINE
the meantime, liquid refrigerant (slightly wet vaporized S D ROOM
refrigerant) is fed into the evaporator, when "cooling" COMPRESSOR COOLING FAN
effect is attained.
For instance, in order to cool the air to 15°C (59°F), the
refrigerant can not absorb evaporation heat from the air RECEIVER
DRYER
unless it evaporates at a temperature lower that 15°C
(59°F). For that purpose, it can be seen from Fig. 25-7 CONDENSER
that the pressure of the refrigerant in the evaporator
must be less than 0.51 MPa (74psi). Fig. 25-8 Construction of cooling circuit
Furthermore, the cooling effect deteriorates unless the
feed rate of the refrigerant is controlled so that all of the
refrigerant supplied to the evaporator vaporizes and
turns into dry vapor.
Consequently, the cooling circuit is so constructed that
the evaporator can cool down an object (air in this case)
sufficiently (i.e. so as to decrease the pressure in the
evaporator) and that an adequate amount of refrigerant
can be fed to the evaporator.
The feed rate of the refrigerant is controlled by the
expansion valve, but the pressure in the evaporator is
held low by the throttling action of the expansion valve
and the suction action of the compressor. The
compressor acts as a pump that allows the refrigerant
to circulate. The compressive action of the compressor
and the heat exchange (heat radiation) action of the
condenser transform the refrigerant in a dry vapor state
back to a liquid state.
25-14
25.4.3 COMPONENT PARTS

(1) Evaporator (See Fig. 25-9.)
The evaporator is an important heat exchanger that
EVAPORATOR
absorbs the heat of the compartment air (object) by
the utilization of the latent vaporization heat of the
low-temperature, low-pressure liquid-state
refrigerant. Therefore, it is necessary that
satisfactory heat transfer between the object and
the refrigerant take place in the evaporator.
O-RING
To that end, the evaporator is equipped with fins on
the air side in order to increase the heat transfer
area of the air side and thereby perform excellent
thermal transfer between the refrigerant and the air.
The humidity in the air condenses as the air cools
down and adheres to the outside of the evaporator EXPANSION VALVE
as water drops. The cooling effect deteriorates if
the water drops freeze. Therefore, how to
discharge water is an important point. SOCKET BOLT M5X40(2 PCS.)
The amount of refrigerant supplied to the
evaporator is controlled by the expansion valve Fig. 25-9
which is described in the following. In order to attain
proper control, it is necessary to reduce the
pressure drop of the refrigerant of the evaporator.
Accordingly, reducing the pressure drop is one
element that makes the evaporator attain its full
performances.
(2) Expansion Valve
In order for the evaporator to fulfill its performances,
a proper amount of low-pressure low-temperature
liquid refrigerant must be fed to the evaporator.
If the feed rate is too low, the refrigerant completes
vaporization early in the evaporator which results in
deterioration of the cooling effect. If the feed rate is
too high, unvaporized liquid refrigerant returns to
the compressor (liquid back). This not only
deteriorates the cooling effect, but also damages
the compressor valves.
The expansion valve feeds the flowing high-
pressure high-temperature liquid refrigerant to the
evaporator as low-pressure low-temperature liquid
refrigerant (damp vapor of low dryness). The
expansion valve controls the feed rate of the
refrigerant at the same time.
25-15
Fig. 25-10 shows how the block type expansion

valve is constructed. The temperature sensing
DIAPHRAGM
part is provided in the shaft of the expansion
valve to directly detect the refrigerant
temperature at the outlet of the evaporator.
The diaphragm contains R134a in saturated REFRIGERANT
state. The pressure in the diaphragm changes EVAPORATOR OUTLET
SIDE
according to the temperature detected by the
sensor. The change in the pressure causes the SHAFT
force acting upon the diaphragm to vary
accordingly.
The high-pressure high-temperature liquid
refrigerant that is fed from the receiver side REFRIGERANT
INLET
reduces the pressure abruptly as it passes
through the valve (throttling action). On that
BALL
occasion, part of the refrigerant evaporates by VALVE
the very heat of the refrigerant and cooled off. SPRING
The result is that low-pressure low-temperature
damp refrigerant vapor is fed to the evaporator. Fig. 25-10 Block type expansion valve
The opening of the valve is determined by the
equilibrium between the pressure (low) of the
evaporator side, the action of the adjust spring
and the pressing force of the diaphragm (the
temperature of the refrigerant at the outlet of the
evaporator to be sensed by the thermowell). The
feed rate is controlled automatically so that
under the pressure in the evaporator, the
refrigerant is properly overheated (3~8 degrees
C) and goes out of the evaporator. This action is
carried out by sensing the refrigerant
temperature at the outlet of the evaporator as
against the inlet pressure of the evaporator and
consequently controlling the feed rate of the
refrigerant.
This means that if the refrigerant pressure drop
in the evaporator is excessive, it is difficult to
control the overheating or the feed rate of the
refrigerant. For this reason, the smaller the
pressure drop of the evaporator, the better.
The expansion valve senses the pressure and
the temperature at the outlet of the evaporator
and controls the overheating of the refrigerant
and the refrigerant supply to the evaporator more
Fig. 25-11 Expansion valve outside view
securely. The air-conditioner of this machine
adopts a block type expansion valve.
25-16
(3) Compressor (See Fig. 25-12.)

D HOSE
The compressor performs the following three
functions in the cooling circuit:
1) Suction action
S HOSE
2) Pumping action
3) Compressive action
1) The suction action, as combined with the
throttling action, works to decrease the
refrigerant pressure in the evaporator. This
permits the refrigerant to vaporize at low
temperature in order to perform cooling effect.
2) The pumping action serves to cause all the
refrigerant to circulate in the cooling circuit. This
enables enables continuous cooling.
3) The compressive action, as combined with the Fig. 25-12
action of the condenser which is mentioned
hereunder, transforms vaporized refrigerant
back to a liquid state again.
The saturation temperature gets higher as the
pressure increases. For instance, it becomes
possible to cool down the refrigerant by the use
of an outer air of 35°C (95°F) and liquefy it. The
compressive action of the compressor works to
turn low pressure vaporized refrigerant to high
pressure vapor refrigerant. The condenser then
serves to cool down the refrigerant. However,
since the compressive action takes place only for
a short period, the refrigerant hardly exchanges
heat with outer air. That is to say, it takes a near
form of thermally insulated compression, so that
the refrigerant discharged by the compressor
turns into high-temperature high-pressure vapor
and is delivered to the condenser.
(4) Condenser ( See Fig. 25-13.)
This is a heat exchanger that cools the vaporized
refrigerant at high temperature and high pressure
by the use of outer air and condenses the
refrigerant. The direction in which heat moves is
from the refrigerant to air, the opposite to the case
of the evaporator. Fins are equipped on the outer
air side to improve thermal transfer. If the
refrigerant is not cooled well by the condenser, the
air in the compartment can not be cooled
sufficiently by the evaporator. For that purpose, it is
necessary to secure ventilation required for the
cooling of the refrigerant.
Fig. 25-13 Condenser
25-17
(5) Receiver dryer ( See Fig. 25-14.)

REFRIGERANT SIGHT GLASS
1) Receiver Tank INLET
On the air-conditioner, the revolution of the REFRIGERANT
compressor varies greatly which causes the OUTLET
proper flow of refrigerant in the cooling circuit to
vary. It is the receiver tank that receives the
variations. When the cooling circuit does not
need much refrigerant, the receiver tank stores
extra refrigerant temporarily and supplies it when
the cooling circuit needs much refrigerant. The
PRESSURE SWITCH
receiver tank also stores an extra amount of
refrigerant to be used for filling balance and
supplement small amounts of leakage of the
refrigerant through penetration into rubber
hoses.
2) Dryer
If water is mixed in the cooling circuit, it
deteriorates the compressor valves and oil, DESICCANT
corrodes the metallic parts of the circuit or clogs
the circuit as the water freezes in the expansion SUCTION
valve. It is desirable that the amount of water PIPE
mixed in the refrigerant should be held below a
concentration of 30ppm. The air-conditioner
uses a molecular sieve as desiccant suited for FILTER
the circuit, in order to absorb water content that
intrudes into the circuit when the dryer is
installed or when refrigerant is charged.
3) Sight Glass
This is a inspection window with which the
refrigerant level in the circuit is determined, the RECEIVER
TANK
only means of confirming the inside of the circuit
visually.
4) Filter
5) Pressure Switch
This machine employs pressure switches of
high/low pressure type.
The pressure switch protects the circuit by Fig. 25-14
cutting off the power supply to the compressor
when high pressure increases abnormally high
[more than 3.14MPa (460psi) ].
The pressure switch also detects the leakage of
refrigerant by cutting the power supply to the
compressor when the pressure of the circuit falls
below 0.2MPa (28psi).
25-18
25.5 DISASSEMBLY AND ASSEMBLY

25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION
(1) Special Refrigerator Oil
Unit : N.m (lbf.ft)
This air-conditioner uses special refrigerator oil
SP20 for use with new refrigerant R134a. Oils other PIPE FASTENING PART TIGHTENING TORQUE
than SP20 may not be used. Since SP20 tends to
D hose and compressor (M8 bolt) 19.6~24.5 (14~18)
absorb moisture and may corrode paint and resin,
the following points must be noted: D hose and condenser 19.6~24.5 (14~18)
1) Do not keep open all pipe connections on a new L hose and condenser 11.8~14.7 (8.7~11)
compressor and the component parts of the
L hose and receiver dryer (M6 bolt) 7.8~11.8 (5.8~8.7)
installed refrigeration circuit
(Remove valves and caps at the pipe openings L hose and air-conditioner unit 11.8~14.7 (8.7~11)
of the compressor, just before connecting pipes. S hose and air-conditioner unit 29.4~34.3 (22~25)
If you have removed a pipe joint for repair, put a
cap to both ports immediately.) Expansion valve 1.96~2.45 (1.4~1.8)
2) Use care so SP20 does not adhere to the

painted surface and resin parts. In case SP20 Unit : N.m (lbf.ft)
has adhered to such surfaces, wipe it off SCREW SIZE TIGHTENING TORQUE
immediately.
N4,T4 machine screw, M4 0.78~1.18 (0.58~0.87)
(2) The receiver dryer is filled with desiccant to absorb
moisture in the circuit. Therefore, remove the valve N5,T5 machine screw, M5 1.96~2.45 (1.4~1.8)
at the pipe port immediately before connecting M6 (mounting part of L hose joint) 7.85~11.8 (5.8~8.7)
pipes.
M6 (except mounting part of L hose joint) 9.8~11.8 (7.2~8.7)
(3) Tightening Torque
M8 (mounting part of S,D hose joints) 19.6~24.5 (14~18)
1) Pipe Joints
When connecting pipe joints, coat the O-ring with M8 (mounting part of A/C unit) 9.8~11.8 (7.2~8.7)
special oil (SP20) and fasten to the tightening
M8 (other than those mentioned above) 11.8~15.7 (8.7~12)
torque indicated in the table, using a double
spanner. M10 39.2~53.9 (29~40)
2) Screws and Bolts

Fasten to the tightening torque indicated in the
table REPLACED PARTS AMOUNT TO BE FILLED IN
(4) Amount of Oil for Compressor
EVAPORATOR 40 cc (2.4cu.in)
The compressor SD7H (HD type) is filled with
135cc (8.2cu•in) of oil. If the oil volume is small, CONDENSER 40 cc (2.4cu.in)
seizure at high revolution and shortening of service
Drain out the volume of oil left in
life will occur. If the oil volume is large, the cooling
COMPRESSOR the compressor to be replaced,
ability will be deteriorated.
from the new compressor.
Once the air-conditioner is operated, part of the oil
is dispersed in the refrigeration circuit. Therefore,
RECEIVER DRYER 20 cc (1.2cu.in)
when replacing the parts in right Table, adjust the oil
level to that of table. HOSES 20 cc (1.2cu.in)
(5) Before performing operation, stop the engine and
turn off all power supplies to the equipment related
to the air-conditioner.
(6) After the operation is over, confirm that all faults
have been repaired completely, by operating the
air-conditioner.
25-19
25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT

(1) Removing inner air filter

Slide the inner air filter leftward and remove it from
the unit.

Fig. 25-15
(2) Removing selector box
MODE ACTUATOR PLUS SCREW
Remove 6 plus screws, remove connector MAIN HARNESS
connected to the mode actuator on mode selector
box, and separate the mode selector box from the
unit.
CONNECTOR
(3) Removing main harness SELECTOR BOX
Pull out 3 harness clamps from the unit, and UNIT
disconnect all connected connectors and remove
harness on the body from the unit.
Fig. 25-16
(4) Removing upper unit case AIR MIX LEVER PLUS SCREW
1) Remove air MIX rod and air MIX rod sub from air
MIX lever.
2) Remove 12 plus screws which are used to install
the upper and lower unit casings.
Pull out the upper unit casing upward giving
attention to the thermistor harness so as not to
UPPER UNIT
be caught by the casing. CASING
AIR MIX
ROD SUB
AIR MIX
ROD SUB
LOWER UNIT CASING
Fig. 25-17
25-20
(5) Replacing blower controller UPPER UNIT CASING

1) Remove 2 plus screws and remove the blower
controller from the upper unit casing.
2) Install new blower controller by the reverse
procedure of removal.
* Do not disassemble the blower controller.
PLUS SCREW BLOWER CONTROLLER
Fig. 25-18
(6) Removing heater core
PIPE CLAMP
1) After draining the coolant, remove heater hose HEATER CORE
PLUS SCREW
from the heater core.
2) Remove 1 plus screw, and remove pipe clamp EVAPORATOR ASSY
which is used to secure the heater core and then BLOWER MOTOR
remove the heater core from the lower unit
casing.
3) Install it by the reverse procedure of removal.
(7) Replacing blower motor

1) Disconnect connector which is connected to the
blower motor and remove the blower motor from
the lower unit casing.
* Do not remove the fan from the blower motor.
LOWER UNIT CASING

2) Install it by the reverse procedure of removal.
Fig. 25-19
(8) Replacing evaporator and expansion valve
1) Take the evaporator with expansion valve off
EVAPORATOR
from the lower casing.
2) Remove evaporator sensor with sensor holder
from the removed evaporator. SENSOR HOLDER
3) Insert the sensor holder into the new evaporator 105mm
at the position shown in Fig. 25-20 and install the (4.1 inch)
evaporator sensor again.
11TH ROWS OF FIN
EVAPORATION SENSOR
Fig. 25-20
25-21
4) Remove 2 socket bolts M5×40 with Allen wrench

(4mm) and remove the expansion valve from the
EVAPORATOR
evaporator.
5) Fit O-ring (NF O-ring 5/8 and 1/2 one each) to
A
new evaporator.
* When assembling again, fit O-ring paying

attention so as not to be caught with others. O-RING
(Socket bolt M5×40 (2 pcs.) Tightening torque :
6.9N•m (5.1lbf•ft)
* Do not apply undue force to pipe of evaporator

outlet. This undue stress causes the leak of
refrigerant from "A" part of evaporator. EXPANSION VALVE
Moreover, when tube (78), (79) (see Fig. 25-3)
connected with expansion valve is disconnected
SOCKET BOLT M5X40(2 PCS.)
from expansion valve, similar careful work is
necessary.
Fig. 25-21
(9) Replacing motor actuator

VENT ROD
1) Replacing mode actuator
FACE ROD
a) Remove connector connected to the motor
MA MODE
actuator. LEVER
CONNECTOR
b) Remove FACE rod and VENT rod which is PLUS SCREW
3PCS.
used to connect MA mode lever and mode
MODE
cam from the holder. ACTUATOR
c) Remove 3 plus screws and remove the
motor actuator with lever MA mode from the
unit.
d) Remove the lever MA mode from the
removed motor actuator, and install it on new Fig. 25-22
motor actuator by the reverse procedure of
removal.
2) Replacing air mixing actuator
AIR MIX ROD
a) Remove connector connected to the motor
MA AIR MIX LEVER
actuator.
b) Remove rod air MIX which is used to connect
the motor actuator and the lever MA air MIX. CONNECTOR

motor actuator with MA lever air MIX from the
unit.
d) Remove the MA lever air MIX from the
removed motor actuator, and install it on new
removal. AIR MIX ACTUATOR
PLUS SCREW 3PCS.
Fig. 25-23
25-22
3) Replacing inner and outer air switching actuator

a) Disconnect connector connected to the

motor actuator.

b) Remove intake rod from MA intake lever.

motor actuator with MA intake lever from the

unit.
d) Remove the MA intake lever from the
removed motor actuator, and install it on new
removal.

Fig. 25-24
25-23
25.6 CHARGING REFRIGERANT

25.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION
(1) Always assign a person in charge of handling refrigerant.
Refrigerant charge operation involves dangers as it handles high pressure gas. Always assign a person familiar
with how work is done for handling refrigerant.
• Wear protective goggles. (You may lose your sight if the refrigerant gets in your eyes.)
• The refrigerant in liquid state is at very low temperature [approx. -26°C (-15°F)]. Therefore, handle it
with care. (You may get a frostbite if the refrigerant is sprayed over your skin.)
(2) Storage and Transportation

1) Keep the service can (hereinafter called can) less than 40°C (104°F). Since high pressure gas of R134a is
filled in the can in a saturated liguefied state, the pressure in the can increases sharply as temperature rises.
The can may blast as the result.
It is for this reason why the can temperature must be kept below 40°C (104°F).
2) For storage, choose a cold dark place not exposed to direct sunlight.
3) If the can is placed near a fire source, it is subject to radiation heat and gets hot. This causes the inside
pressure to rise and may cause the can to blow out. Do not bring the can close to a fire.
4) The inside of the closed compartment gets very hot as the radiation heat of the sunlight enters the
compartment. The areas of the compartment which are exposed to direct sunlight may rise to a dangerous
temperature level. Do not bring the can into the compartment. Also, the inside of the trunk room may rise to
a dangerous temperature level even in the summer time. Use sufficient care, therefore, taking the above into
account.
5) Note that if the can has scratches, dents and distortion, the strength of the can will deteriorate.
1. Do not drop or knock on the can.
2. When transporting, loading or unloading cans and packages containing cans, do not throw or drop them.
6) Store cans beyond the reach of children.
(3) Charging
1) When warming the can in which refrigerant is charged, do not fail to open the service can valve and the low
pressure valve of the gauge manifold and warm the can in warm water of 40°C (104°F or below (to an extent
that you do not feel hot when you put your hand in the water.) If the can is put in hot water or heated by a
direct fire, the pressure of the can may rise sharply, thereby blowing off the can.
2) When charging refrigerant while running the engine, do not open the high pressure valve (HI) of the gauge
manifold in any case.
(4) Others
Reuse of service cans is prohibited by law; never use them again. Do not allow foreign matter to enter the air-
conditioner circuit. Air, water and dust are detrimental to the refrigeration cycle. Install the components of the air-
conditioner correctly and speedily. Pay full attention to the entry of water and dust.
• Be careful about overcharge of gas.

• Fasten pipes to a specified torque.
25-24
25.6.2 OPERATING PROCEDURE

(1) Refrigerant charge into the air-conditioner consists mainly of "vacuum making operation", and "gas charge
operation".
1) The "vacuum making operation" consists of removing water in the air-conditioner circuit. If only a little water
remains in the circuit, the small holes of the expansion valve are frozen during operation. This causes the
circuit to clog up or rust, resulting in a variety of malfunctions. Therefore, before filling refrigerant in the
circuit, make vacuum and allow the water in the circuit to boil and vaporize. Water in the circuit is thus
eliminated.
2) The "gas charging operation" consists of filling refrigerant in the circuit after forming vacuum. Filling gas not
only depends upon the cooling performances of the air-conditioner, but also affects the service life of the
component parts of the circuit. Extreme overcharge will make the circuit pressure extremely high and causes
the cooling performance to deteriorate. On the contrary, undercharge causes poor circulation of the
lubricating oil of the compressor and causes seizure of the moving parts of the compressor.
The gas filling operation involves handling of high pressure gas; filling gas according to incorrect operation
procedure is dangerous. Fill refrigerant correctly following the operation procedures and cautions stated in
this manual.
(2) Operation Chart
Vacuum making operation Refrigerant filling operation
More than Leave it as it is,

30 min. for five minutes.
Begin vacuum Stop vacuum Check Fill in Check for Fill in
making making air-tightness refrigerant gas leak refrigerant
Lower than
-750mmHg Gauge indicates
abnormality
Charge refrigerant gas to a gauge
Check and correct joints pressure of 0.1MPa (14 psi)
(3) Tools
No. Parts Q’ty Sketch Service No. Parts Q’ty Sketch Service
Low pressure
4 Quick joint 1
Gauge side
1 1
manifold For service can
5 T joint 1
valve
Red :
high pressure side
Charging Blue : Service can
2 3 6 2 For service can
hose low pressure side valve
Yellow :
vacuum pump side
Vacuum
High pressure For vacuum
3 Quick joint 1 7 pump 1
side pump
adapter
25-25
25.6.3 CHARGING PROCEDURE
25.6.3.1 VACUUM MAKING OPERATION

(1) Connecting gauge manifold (See Fig. 25-25)
HIGH
1) Close the high pressure valve (HI) and the low LOW PRESSURE PRESSURE GAUGE
pressure valve (LO) of the gauge manifold. GAUGE GAUGE MANIFOLD
(CLOSED)LOW HIGH PRESSURE
2) Connect the charging hoses (red and blue) with PRESSURE VALVE VALVE(CLOSED)
the service valves of the compressor. RED
BLUE
Red hose :
High pressure side (HI) of the gauge HIGH
PRESSURE YELLOW
manifold→high pressure side (DIS) of SIDE
compressor DIS
LOW
Blue hose : PRESSURE
Low pressure side (LO) of gauge manifold→low SIDE
SUC
pressure side (SUC) of compressor
COMPRESSOR VACUUM PUMP(STOP)
Fig. 25-25
• Do not mistake the high pressure hose for the low
pressure hose in any circumstances when
connecting them. Put the hose in firmly till a clicking

sound is heard.

3) Connect the center valve of the gauge manifold

with the charging hose of the vacuum pump.
Fig. 25-26 Connecting gauge manifold
Some kinds of gauge manifolds are not equipped with

an open/close valve in the center.
25-26
(2) Vacuum making (See Fig. 25-27)

LOW PRESSURE VALVE(OPEN) (CLOSE)
1) Open the high pressure valve (HI) and the low HIGH PRESSURE VALVE(OPEN) More than (CLOSE)
pressure valve (LO) of the gauge manifold. 30 min
2) Turn on the switch of the vacuum pump and
make vacuum for more than 30 minutes. GAUGE MANIFOLD
3) When vacuum making for a specified duration
is over (degree of vacuum : less than - 750
mmHg), close the high pressure valve and the
low pressure valve of the gauge manifold.
DIS
4) Then turn off the vacuum pump.
(3) Air-tightness Check
Close the high pressure valve and the low pressure
valve of the gauge manifold, leave it as it is for more SUC
than five minutes and make sure that the gauge
indication does not return toward 0.
Fig. 25-27 Vacuum making operation
If the gauge indication swings toward 0, there is

somewhere that is leaking. Retighten pipe joints, make
vacuum again and make sure of no leakage.
25-27
25.6.3.2 GAS CHARGING OPERATION

(1) Charging from high pressure side (See Fig. 25-28.)
1) After making vacuum repeatedly, change the
charging hose (yellow) of the gauge manifold
from the vacuum pump to the service can.
2) Air purge
Open the service can valve. (However, close the
high and low pressure valves of the gauge AIR PURGE
manifold.) Then push the gas valve of the side CLOSE
service port on the low pressure side of the
SCREW DRIVER OPEN SERVICE
gauge manifold, using a screw driver, in order to CAN VALVE
YELLOW
let out the air in the charging hose by the
pressure of the refrigerant. (See Fig. 25-28.)
BLUE RED
(The operation ends when a hissing sound is
heard.)
Fig. 25-28 Gas charging operation

3) Open the high pressure valve of the gauge
manifold and charge in refrigerant. [Charge in
gaseous refrigerant to a gauge pressure of
0.1MPa (14psi).] LOW PRESSURE HIGH PRESSURE VALVE
After charging, close the high pressure valve of VALVE(CLOSE) (OPEN) (CLOSE)
RED FILL IN 1~1.5 CANS
the gauge manifold and the service and valve. BLUE OF REFRIGERANT
(See Fig. 25-29.)
DIS
YELLOW
SERVICE CAN
VALVE
• Do not run the compressor during this work, (OPEN) (CLOSE)
CHARGE
(Otherwise the refrigerant flow in reverse
direction which causes the service can and the SUC
hoses to rupture. This is very dangerous.)
(2) Checking for gas leak (High pressure side)
Check for gas leak in the cycle, using a gas leak
detector (electric type). Retighten and correct
leaking points.
• Always use the leak tester for R134a. (Do not use
one for flon gas service as it provides poor
sensitivity.)
25-28
(3) Charging from low pressure side (See Fig. 25-30)

1) Make sure that the high-pressure and low-
pressure valves of the gauge manifold and the
service can valve are closed. LOW PRESSURE HIGH PRESSURE
VALVE VALVE(CLOSE)
2) Start the engine and run the revolution to OPEN CLOSE
WHEN AIR RED (CLOSE SECURELY)
1500±100rpm and fully close the cab door and BUBBLES IN THE
SIGHT GLASS
the windows. DISAPPEAR
YELLOW
DIS
3) Turn on the air-conditioner switch, set the fan BLUE
switch to Max and the temperature control switch
to cool Max. SERVICE CAN
VALVE(OPEN)
4) When charging gas, set the discharge pressure
SUC
of the compressor to 1.4~1.6 MPa (200~230psi).
COMPRESSOR SERVICE CAN
OPERATION (DO NOT TURN IT OVER)

(Low pressure side)
5) Open the low pressure valve of the gauge
SIGHT GLASS
manifold and the service can valve and fill in
refrigerant till air bubbles of the sight glass of the
receiver go away. (See Fig. 25-30)
[Total amount of gas to be charged :
900g±50g (2.0±0.11 lbs)]
6) When refrigerant charge is over, close the low
pressure valve of the gauge manifold and the
service can valve.
RECEIVER DRYER
• Do not open the high pressure valve of the

gauge manifold in any circumstances. Fig. 25-31 Receiver dryer
• Never place the service can upside down. (The
compressor valve may be scored because the
refrigerant is sucked in a liquid state.)
25-29
(4) Criterion for checking the amount of refrigerant

filled in
JUDGMENT OF REFRIGERANT LEVEL THROUGH THE SIGHT GLASS OF RECEIVER DRYER
After A/C is turned on, only a little

PROPER LEVEL bubbles are seen and thereafter light
milky white is seen.
After A/C is turned on,

OVERCHARGE no air bubbles are seen.
After A/C is turned on, continuous

UNDERCHARGE
air bubbles are seen.
• If the air-conditioner is run with poor refrigerant

R134a, it has adverse effect on the compressor.
• If the refrigerant is charged too much
(overcharged), the cooling performance is
deteriorated. Moreover, the circuit pressure
gets abnormally high : Always keep a proper
level.
(5) Removing Gauge Manifold

When the refrigerant level has been checked,
disconnect the charging hoses from the
compressor in the following manner :
1. Press the "L" shape metal fitting of the charging
hose (blue) on the low pressure side against the
service valve of the compressor so the
refrigerant does not leak out and loosen the nut.
As soon as the nut has been removed,
disconnect the charging hose from the service
valve.
2. Leave the high pressure side as it is till the high
pressure gauge reading falls. [below 1MPa
(140psi)].
3. Disconnect the charge hose (red) on the high
pressure side the same way as on the low
pressure side.
25-30
25-31
25.7 ELECTRIC CIRCUIT

25.7.1 WIRING DIAGRAM AND CONNECTORS
JAE : JAPAN AVIATION ELECTRONICS
JAE JAE INDUSTRY, LTD.
HOUSING : IL-AG5-22D-S3C1 HOUSING : IL-AG5-14D-S3C1
TERMINAL : IL-AG5-C1-5000 TERMINAL : IL-AG5-C1-5000
MAKER : YAZAKI CORP.

MAKER : YAZAKI CORP. HOUSING No. : 7122-6060
HOUSING No. : 7123-6060-40 REAR HOLDER : 7157-6260-30
TERMINAL : 7116-2871 TERMINAL : 7114-2871
NIPPON AMP KK
170889-1
170003-5
PRESSURE SWITCH
(RECEIVER DRYER)
MAKER : SUMITOMO
HOUSING No. : 6189-0094
MAKER : YAZAKI CORP. HARNESS SEAL : 7160-8234
7120-8019 TERMINAL : 1500-0110
CP3.96MA
FUSE 20A LIGHT SWITCH
POWER SUPPLY FOR
NIGHT LIGHTING
MAKER : YAZAKI CORP. MAKER : YAZAKI CORP. A/C MAIN POWER

HOUSING No. : 7123-2249 FUSE 5A
HOUSING No. : 7123-6020 MAIN KEY SW POWER SUPPLY FOR
TERMINAL : 17111 TERMINAL : 7116-2871 COMPRESSOR CLUTCH
FUSE 15A
FUSE 5A
MAKER : YAZAKI CORP. MAKER : YAZAKI CORP.

HOUSING No. : 7123-2237 HOUSING No. : 7123-2228
TERMINAL : 17111 TERMINAL : 17111 FUSE BOX
MAKER : YAZAKI CORP.

JAE IL-AG5-7S-S3C1 HOUSING No. : 7123-2228
TERMINAL : AG5-C1-5000 TERMINAL : 17111
COMPRESSOR
NIPPON AMP KK 174056-2 JAE IL-AG5-7S-S3C1

TERMINAL : 175062-1 TERMINAL : AG5-C1-5000
JAE IL-AG5-7S-S3C1
TERMINAL : AG5-C1-5000 MAKER : YAZAKI CORP.
HOUSING No. : 7123-2249
TERMINAL : 17111
NOTE) 1. THe double chain lines indicate the wiring

on the excavator side. MACHINE SIDE WIRING (PARTS)
2. The connector colors indicate the cord colors seen
from the connecting part.
P W B R Y G L Br Lg O
LIGHT
PINK WHITE BLACK RED YELLOW GREEN BLUE BROWN GREEN ORANGE
Fig. 25-32 Electric diagram (1/2)
25-32
CCU (OPERATION PANEL + CONTROLLER)
EVA SENSOR
AIR INLET SENSOR
SUN SENSOR
MOTOR ACTUATER
(FOR AIR MIX)
MOTOR ACTUATER
BLOWER OFF RELAY (FOR MODE)
BLOWER MOTOR
BLOWER AMP
MOTOR ACTUATER
(REC/FRESH)
COMPRESSOR RELAY
AIR CONDITIONER SIDE

WIRING (PARTS) IN THE CAB
Fig. 25-33 Electric diagram (2/2)
25-33
25.7.2 STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION
(1) Control panel and control unit
The control unit is integrated into control panel, and
processes the signal input by each sensor, etc. and
the signal input by each switch through control
panel with the function of the built-in micro
Fig. 25-34
computer, and comprehensively controls each
actuator (Inner and outer air flow select, air mix),
fan motor and compressor on the output side.
And the self-diagnosis performance is provided to
facilitate the trouble shooting.
(2) Blower controller (TKS-B215A1)

The power transistor shifts the fan motor into
variable speed with base current from the control B
unit.
TERMINAL NO.
CONTINUITY
1 2 3
CONTINUED Lg L
TESTER NOT CONTINUED
CONTINUED(DIODE PARALLEL
AND FORWARD DIRECTION FLOW)
In normal operation
1. Disconnect the connector of blower amplifier.
2. Check continuity between terminals on the
blower amplifier side.
Fig. 25-35
* The installing position is provided on the left side
of air-con unit.
25-34
(3) Relay
Four-electrode relay is used for the blower OFF
relay and compressor relay.
1) Blower OFF relay
The blower OFF relay turns on after receiving the
signal from the control amplifier.
When the blower OFF relay turns on, the source
voltage is supplied to the blower motor and the
blower motor starts running.
2) Compressor relay
The relay ON—OFF is tripped by the control
amplifier and electronic thermostat control. Fig. 25-36
3) Relay inspecting items
1. Relay (24-4PE)
2. Coil resistance: 320
3. Specified voltage: DC20V~30V
4. Be careful about the coil side of relay because
this relay has polarity.
5. Inspection: Inspect the continuity between 3
and 4 according to the conditions mentioned
below.
20~30V applied between terminals 1-2:
Continued
20~30V not applied between terminals 1-2: Not
continued
(4) Air mix actuator
Air mix actuator is installed at the center of air-con
unit, and opens and closes air mix damper through
the link.
The air mix actuator contains potentiometer which
is switched by being coupled to the shaft of
actuator.
When the target air mix door position is determined CONTROL AMPLIFIER MOTOR ACTUATOR
through the temperature control switch, the control LIMITER

COOL
unit reads the level of potentiometer of the actuator, POTENTIO 5V
POTENTIO
and determines the rotating direction of motor in POTENTIO GND
either normal rotation or reverse rotation. Then as

the motor rotates, the contact point is moved, and HOT
when the contact point is detached or the output

signal of control unit turns OFF, the motor stops
rotating. Fig. 25-37
25-35
(5) The actuator for inner and outer

The actuator for inner and outer air flow select is
installed on the blower intake unit, and opens and
closes inner and outer air damper through the link.
The actuator for inner and outer air flow select

contains position detection switch which is
switched with the movement of shaft of the
actuator. AMPLIFIER MOTOR ACTUATOR
When the inner and outer damper position is set by

the inner and outer switch on the control panel, the
control unit reads the signal of the position
detection switch in the actuator and determines the INNER AIR SIDE
rotation direction of motor in either normal rotation OUTER AIR SIDE
or reverse rotation. Then as the motor rotates, the LIMITER
position detection switch also rotates and makes it

stop at the set position of the inner and outer air Fig. 25-38
damper.
(6) Evaporator sensor
This sensor is used to control the evaporator outlet
temperature with the compressor ON-OFF to
protect the evaporator from freezing, and this
evaporator sensor functions as a sensor of this
control.
• Evaporator sensor inspecting items
(Specification)
Terminal resistance : Fig. 25-39
at 0 degree C : 7.2 k
at 25 degree C : 2.2k
(7) Dual pressure switch
This dual pressure switch is attached on L-hose
and is used to turn OFF the compressor, and
employs dual type (for high and low pressure
control) to protect the cooler cycle from possible
failure at the time when abnormal pressure was
generated on the high pressure side.
Fig. 25-40
SPECIFICATION OF DUAL PRESSURE SWITCH
0.02MPa(2.9psi) 0.59MPa(86psi)
ON
OFF
0.20MPa(29psi) 3.14MPa(455psi)
(LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)
(8) Solar radiation sensor

This solar radiation sensor, which is used to correct
the solar radiation to the auto air conditioner
detects the strength and solar orientation of
sunbeam after transforming them into current by
means of photo diode.
Inspection : Check for the continuity between
Fig. 25-41
terminals.
25-36
25.8 TROUBLESHOOTING
Air temperature does not fall. Note : M/A is motor

actuator
* is any of the
numbers 0 ~ 9.
If AUTO switch or A/C switch is pushed,
"HL.E" is indicated on the set temp. display of the panel.
NO YES
"HL.*" is shown on the set temp. . Connector for air mix M/A is
display of the panel. disconnected or in poor contact.
. Air mix M/A is failed.
NO YES . Main harness shows poor continuity.
A snow mark ( ) on A snow mark ( )
the panel is flashing. on panel is flashing. Inspect and correct or replace parts.
NO YES
. Inner air sensor or harness is disconnected or shorted. . Both inner air sensor and
. Inner air sensor connector is disconnected or in poor contact. evaporation sensor are
disconnected or shorted.
See section monitor mode. . Controller failed.
See section monitor mode.

Inspect and correct or replace parts.
A
NO YES
Blowout temp. falls if temp. is set . Evaporation sensor connector

at 18.0 (64.4 ) (COOLMAX) and the is disconnected or in poor contact.
blowout mode is changed to vent mode. . Evaporation sensor is disconnected or shorted.
NO YES Inspect and correct or replace parts.
Air mix damper is Cool air flowing

in COOLMAX. into inner air sensor Inspect and correct or replace parts.
NO YES
NO YES
If M/A is at stop halfway, Turn compressor clutch
eliminate cause, correct on and off. Inspect and
correct electric circuits. Controller is faulty Inspect duct or
and measure operating or inner air sensor eliminate cause for
force. (less than 14.7N : OK) is faulty. cool air intrusion.
Refer to Troubleshooting
for refrigeration cycle.
Inspect and replace.
NO YES
. Inspect, correct or replace M/A failed or controller

M/A lever link. is out of order.
. After cleaning lever link,
apply grease.
Replace.
25-37
Air temperature does not rise. Note : * is any of

the numbers 0 ~ 9.
HL.E is shown on the set temp. display of the panel.

NO YES
"HL. " is shown on the set temp.

* . Connector for air mix M/A is
display of the panel. disconnected or in poor contact.
. Air mix M/A is failed.
NO YES . Main harness shows poor continuity.
. Inner air sensor or harness is disconnected or shorted.
. Inner air sensor connector is disconnected or in poor contact. Inspect and correct or replace parts.
NO YES
NO YES
Blowout temp. rises at blowout
mode if temp. is set at
HOT MAX 32.0 (64.4 )
NO YES
Air mix damper is Warm air is flowing into

in HOT MAX. inner air sensor.
NO YES
NO YES
If M/A action is at stop, Inspect warm water piping.
eliminate cause, correct
Controller or Inspect duct or
and measure operating
force. (less than 14.7N : OK) inner air sensor eliminate causes
is out of order. for warm air entry.
NO YES
Inspect and replace.
. Inspect, correct or M/A failed or controller

replace M/A lever link. is out of order.
. Clean lever link and apply grease.
Replace.
25-38
Blower motor does not run.
At air flow HI, battery voltage acts across

Note 1) both terminals (+) and (-) of blower motor.
NO YES
Battery voltage acts across red Blower motor fails.

(+) and body of blower motor.
NO YES Replace.
Inspect blower motor relay. Blower motor Approx. 10V acts across light green wire
Note 2) rotates if white / red wire and red wire of and grounding of blower amplifier.
blower motor relay are direct connected.
NO YES
NO YES
Controller is out of order. Remove blower amplifier and check for

Wire harness is Replace continuity across light green wire
faulty. Inspect and black wires ; you get continuity.
and correct or replace.
NO YES
Battery voltage acts across white /

red wire and body of blower motor relay. Eliminate cause Inspect and
and replace repair harness.
NO YES blower amplifier.
Inspect and repair Blower turns if orange wire of blower motor relay
harness or replace. is connected with ground.
NO YES
Replace relay. Inspect and correct harness

or replace controller.
Note 1) Measure with connector set.

Note 2) Always turn off air-conditioner, starter key switch and light switch before work.
25-39
Blower motor speed does not change.
CASE (1)
Note) is any of the
"HL. " is shown on the set temp. display of the panel.
* *
numbers 0 ~ 9.
NO YES
Replace blower . Inner air sensor or harness is disconnected or shorted.

amplifier controller. . Inner air sensor connector is disconnected or in poor contact.
CASE (2)
Does not blower motor speed

change because the setting mode
is other face mode?
YES NO
Is door or front window open? See CASE (1).
YES NO
The limiting or control operation See CASE (1).

is actuated by door switch or
front window switch.
25-40
Magnet clutch does not engage.
Snow mark ( ) lights

if A/C switch is pressed.
No Yes
Snow mark ( ) flickers and E is Voltage acts upon clutch.

shown on panel display.
No Yes
To A On page 25-37. Voltage is applied to Clutch faulty.

pressure switch harness.
No Yes
Voltage acts across white / green wire and Pressure switch is faulty or refrigerant
Ground (Black) connector connected to excavator. gas is under charged or overcharged.
No Yes
Refer to troubleshooting
for refrigeration cycle.
Inspect clutch Inspect air-conditioner
fuses. harness. No fault.
No Yes
Replace harness. Replace controller.
Inner air and outer air do not change over.
Inner / outer air mode display on

operation panel is flickering.
No Yes
M/A lever includes foreign matter Connector of inner/outer air

or is broken. M/A is disconnected or in poor
No Yes contact.
Or M/A failed or main harness failed.
M/A failed Remove foreign matter

and replace parts. Inspect or replace.
Replace
25-41
Modes do not change.
Mode display (Mark of person)

on operating panel is flickering.
No Yes
M/A rod does not disengage. Mode M/A connector is

disconnected or in poor
No Yes
contact or M/A failed or main
harness is faulty.
Repair. Each damper lever does not disengage.
No Yes Inspect or replace.
Repair. When rod is removed and cam is operated

by hand, it is heavy. (more than 19.6N.)
No Yes
M/A or controller is out of order. . Cam or damper shaft includes

foreign matter or is broken
. Erroneous motion occurs due to
Replace. dirty grease.
. Remove foreign matter or replace parts.

. Clean cam and apply new grease.
25-42
Trouble with refrigeration cycle.
Both high and low pressures are lower.

Low pressure is higher.
NO YES
Air bubbles are seen in sight glass.
Air bubbles are seen in High pressure
sight glass. is lower.
NO YES
Cooling does not work Oil comes out from

if run at high speed. piping and parts. Compressor cylinder Compressor cylinder
does not get hot. gets very hot.
NO YES NO YES
Expansion valve Expansion valve Natural Gas leaks
is clogged or is frozen or leak from from pipe
maladjusted. intruded by water. hose. joints and Expansion valve is Compressor does
parts. maladjusted. not discharge well.
(too much open)
Adjust or replace After making
expansion valve. vacuum, refill Retighten
refrigerant Charge gas. or replace
and replace parts.
receiver. Replace Replace compres
expansion valve.
High pressure
is lower.
Air bubbles are seen in sight glass.
NO YES
High pressure gets Condenser is

lower slowly. fouled or clogged.
High pressure YES NO

circuit before
receiver is Air bubbles are hard to
clogged up. go out even if water
is poured on condenser.
Remove Clean
clogging or condenser. Air is mixed.
replace parts. Make vacuum and
refill refrigerant.
25-43
25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL

The failure of motor actuator and each sensor can be identified on the display of panel.
25.9.1 POSITION OF INDICATION FOR FAILURE.
The error is indicated on 3 digits segment.
25.9.2 EXPLANATION OF INDICATION FOR FAILURE.

(1) Failure of Motor Actuator
1) HL.E is indicated on 3 digits segment.
Check harness or connector to motor actuator

for the air mix damper for disconnection.
2) MODE is flickering.
Check harness or connector to motor actuator

for the air outlet damper for disconnection.
3) R/F is flickering.
Check harness or connector to motor actuator for the inner and outer
air damper for disconnection.
Note) The above indication and flickering does not function if the
harness and connector were disconnected under the condition
the panel ON/OFF switch is ON.
After the failure was occured, if the panel ON/OFF switch is
turned ON, it functions.
After correction of failure, if the main switch is not switched from
OFF to ON the error indication and flickering are not released.
25-44
(2) Failures of sensors

1) HL.* is indicated on 3 digits segment.
Check the inner air sensor or the harness for disconnection

and short circuit, and also connectors for disconnection.
(* is any of the numbers 0 to 9.)
2) **E and mark are flickering.
(** is displayed leaving the present set temperature value.)
Check evaporator sensor or the harness for disconnection

and short circuit, and also connectors for disconnection.
Note) The above displays in items 1) and 2) are indicated by 3 digits segment when error occurred under the
condition the panel ON/OFF switch is ON.
And, after correction of failure if the panel ON/OFF switch is switched from OFF to ON, the error indication is
released.
(3) Communication error of control amplifier and panel

1) E is indicated on the only use segment of display.

25-45
25.9.3 EXPLANATION OF MONITOR MODE

When error of 25.9.2 (2) sensors is displayed, the monitor mode is available to identify the sensor condition
(disconnection, short circuit).
(1) Position of monitor mode indication
SEGMENT FOR ONLY MONITOR INDICATION

3 DIGITS SEGMENT
(2) Operation of monitor mode
SPEED UP AND DOWN

INNER OR OUTER
SWITCH FOR BLOWER
AIR INLET SELECT
SWITCH (R/F)
ON/OFF SW
1) Press inner and outer air flow select switch and ON/OFF switch simultaneously for 1 second.
2) Press AUTO switch.
(After all segments are lit on for 1 second, the mode is switched into monitor mode.)
3) Any figures of figures from 0 to 9 or any letters of alphabet from A to F are displayed on the 3rd digit and 2nd
digit of segment in three digits. The 1st digit is indicated by "H".
4) Any digit indicated by one of figures 0 to 2 for the exclusive segment in three digits is selected by pressing
UP or DOWN of blower switch, and the required sensor is selected from the list below.
SEGMENT ASSIGNMENT LIST

0 INNER AIR SENSOR
1 EVAPORATOR SENSOR
2 SOLAR RADIATION SENSOR
(Excluding above mentioned indications, for example "from 3 to 9 and from B to F" are not used at service work.)
5) The monitor display is terminated by pressing the inner and outer air flow select switch (R/F) and ON/OFF
switch for 1 second again, or turning off the main switch of excavator.
Notes)
1. The air conditioner is turned off while the monitor mode is in operation, and all switches are not available for
operation and setting until the monitor mode is cancelled.
2. Even if each sensor is corrected while the monitor mode is in operation, the error display is memorized.
Therefore turn on ON/OFF switch again, and the error display is disappeared.
25-46
(3) Contents of monitor mode display

Refer to the list of segment display exclusively used for monitor and the list of segments in three digits.
1) Example 1
THIRD SEGMENT
SECOND SEGMENT
When the segment exclusively used for monitor indicates 0
(displays the inner air sensor condition),
since the segment indicates 3F, the sensor is in normal
operating condition according to the list of 3 segments.
--> The inner air sensor is in normal operating condition.
2) Example 2

(displays the evaporator sensor condition),
since the segment indicates 00, the sensor is
in disconnection condition according to the list of 3 segments
--> The evaporator sensor is in disconnection condition.
3) Example 3

(displays the solar radiation sensor condition), since the
segment indicates FF,the sensor is in short-circuiting condition
according to the list of 3 segments.
-->The solar radiation sensor is in short-circuiting condition.
4) List of 3 segments
SECOND SEGMENT
INNER AIR SENSOR DISCONNECTION (0CH0 INDICATED)

EVAPORATOR SENSOR DISCONNECTION (0CH1 INDICATED)
SOLAR RADIATION SHORT-CIRCUITING (0CH2 INDICATED)
THIRD SEGMENT
EACH SENSOR IS NORMAL
SOLAR SENSOR 5V SIDE SHORT-CIRCUITING (C7H2 INDICATED)
INNER AIR SENSOR SHORT-CIRCUITING (F6H0 INDICATED)

EVAPORATOR SENSOR SHORT-CIRCUITING (F6H1 INDICATED)
25-47
[MEMO]
25-48
31. DISASSEMBLING AND ASSEMBLING
TABLE OF CONTENTS
31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY ...........................31-3

31.1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY ..................................31-3
31.1.2 INDICATION OF TIGHTENING TORQUE .............................................................31-3
31
31-1

SK330–8 : LC10-07001~ S5YN3118E01
SK350LC–8 : YC10-03501~ (ASIA, OCE)
SK200–8 : YN11-45001~ ↑
↑ August, 2006 K
SK210LC–8 : YQ11-06001~ (ASIA, OCE)
SK250-8: LQ12-06001~ ↑
↑ October, 2006 K
SK260LC–8 : LL12-05001~ (ASIA, OCE)
↑ December, 2006 SK850LC: LY01-00101~ ↑ K
E235BSR : YF05-02001~ ↑
E235BSR(N)LC : YU05-02001~ (NHK)
↑
↑ ↑ SK235SRLC-2 : YU05-02001~ K
(North America)
E215B : YN11-45001~ ↑
↑ March, 2007 K
SK235SR-2 : YF05-02001~ ↑
↑ April, 2007 K
SK235SRLC-2 : YU05-02001~ (OCE)
SK200-8 : YN11-45001~ ↑
↑ ↑ K
SK250-8: LQ12-06001~ ↑
↑ May, 2007 K
E225BSR : YB05-03001~ ↑
↑ June, 2007 K
E225BSRLC : LA05-02001~ (NHK)
↑
↑ ↑ SK215SRLC : LA05-02001~ K
(North America)
E135BSR : YY05-12001~ ↑
↑ July, 2007 K
E135BSRLC : YH05-07001~ (NHK)
SK225SR : YB05-03001~ ↑
↑ ↑ K
SK225SRLC : LA05-02001~ (OCE)
SK460-8: LS10-02001~ ↑
↑ ↑ K
SK480LC–8 : YS10-01501~ (ASIA, OCE)
E215B : YN11-45001~ ↑
↑ ↑ K
E265B : LQ12-06001~ ↑
↑ ↑ K
E215B : YN11-45001~ ↑
↑ ↑ K
↑
↑ ↑ ↑ K
E385B : LC10-07001~ ↑
↑ August, 2007 K
31-2
31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY

31.1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY
This chapter is consist of 3-Section as follows.
(1) ATTACHMENTS .................................................................Chapter 32
1) Removing and Installing
2) Disassembling and Assembling
a. Cylinder
(2) UPPER STRUCTURE ........................................................Chapter 33
a. Hydraulic pump
b. Control Valve
c. Pilot Valve (ATT)
d. Pilot Valve (Travel)
e. Slewing Motor
f. Swivel Joint
(3) TRAVEL SYSTEM ..............................................................Chapter 34
a. Travel Motor
31.1.2 INDICATION OF TIGHTENING TORQUE

Tightening torque is indicated as follows, for example ;
T=98N•m(72 lbf•ft)
Tolerance is ±10% unless otherwise specified.
• Refer to "Chapter 11 TOOLS" for standard tightening torque.
31-3
[MEMO]
31-4
32. ATTACHMENT
TABLE OF CONTENTS
32.1 REMOVING AND INSTALLING.......................................................................................32-3

32.1.1 ATTACHMENT ASSY.............................................................................................32-3
32.1.2 BUCKET .................................................................................................................32-3
32.1.3 ARM........................................................................................................................32-6
32.1.4 BOOM.....................................................................................................................32-9
32.2 DISASSEMBLING AND ASSEMBLING...........................................................................32-13
32.2.1 CYLINDER..............................................................................................................32-13
32
32-1
32. ATTACHMENT

SK200–8 : YN11-45001~ S5YN3218E01
SK210LC–8 : YQ11-06001~ (ASIA, OCE)
S5YN3218E02
(ASIA, OCE)
E215B : YN11-45001~ ↑
↑ March, 2007 K
SK200-8 : YN11-45001~ ↑
↑ April, 2007 K
E215B : YN11-45001~ ↑
↑ July, 2007 K
↑
↑ ↑ ↑ K
↑
↑ ↑ ↑ K
PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of 2 sections. "Removing and Installing", and "Disassembling and Assembling".
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
(4) The removing and installing procedure does not completely cover all possible situations because of differences
of field condition and defective section.
(5) Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.
32-2
32. ATTACHMENT
32.1 REMOVING AND INSTALLING

32.1.1 ATTACHMENT ASSY
(D) ARM CYLINDER HEAD PIN (C) BOOM CYLINDER ROD PIN (A) BOOM FOOT PIN
4. BOOM
ARM CYLINDER
(F) BOOM TOP PIN
(E) ARM CYLINDER 2. BUCKET

ROD PIN
(G) BUCKET CYLINDER

HEAD PIN
BUCKET CYLINDER 3. ARM (J) BUCKET DRIVE PIN
(I) IDLER LINK PIN
IDLER LINK BUCKET LINK
(H) BOOM CYLINDER
(H) BUCKET CYLINDER ROD PIN (K) BUCKET ATTACHING PIN HEAD PIN
Fig. 32-1 Front attachment and position
32.1.2 BUCKET
32.1.2.1 REMOVING BUCKET

(1) Put the machine in position to remove bucket.
Fig. 32-2 Position to remove bucket

(2) Removing pin (2)
BOSS SECTION
Expand slit of ring (1) with screwdriver, and remove
it. Push out the pin (2) with flat-blade screwdriver . DRIVER
1 2
SECTION OF BOSS
Fig. 32-3 Removing pin (2)
32-3
32. ATTACHMENT
(3) Removing bucket attaching pin (K)

Lift up bucket, position it so that bucket attaching
pin (K) is not loaded, adjust bucket link, and pull out
K
bucket attaching pin (K).
Fig. 32-4 Removing bucket attaching pin

(4) Removing bucket drive pin (J)
Put bucket on the ground, position it so that the
bucket drive pin (J) is not loaded, adjust bucket link, J
and pull out pin (J).
Store the removed pin (J) in original position again.
Fig. 32-5 Removing bucket drive pin
32.1.2.2 ATTACHING BUCKET

(1) Attaching bucket drive pin (J)
Attach bucket drive pin (J) first, then continue in the
reverse procedure of removing.
J
• When aligning the pin holes, do not put your

finger in the pin holes, but align them visually.
• Check the seals for damaged and replace as
necessary.
• When inserting the pin, coat the shaft with
grease.
Fig. 32-6 Attaching bucket
32-4
32. ATTACHMENT
32.1.2.3 PROCEDURE FOR ADJUSTING CLEARANCE

Adjustment of clearance between bucket and arm Apply rust preventive oil +1.0 +0.039"
326 -0.5 (12.84 -0.020" )
(1) Shift O-ring (3) toward the bucket boss, using a New bucket
spatula. (a→b) B
12 : WASHER 3 : O-RING
11 : CAPSCREW b a
(2) When adjusting clearance (B), bring the non-
adjusting side of the bucket in contact with the arm.
(3) Measure clearance (B) and check that it is within

1.0mm (0.04in). 7 : BUSHING
8 : PLATE
(4) Adjust clearance (B) where it is more than 1.0mm
Install pin (10) until the top
(0.04in). 9 : SHIM 10 : PIN of pin is even surface
with bushing.
(5) An average of 5 shims (9) of 1mm (0.04in)

thickness are set in the plate (8) fixed by the three
capscrews (11). The clearance can be decreased
Fig. 32-7 Adjusting clearance between bucket and
by 1mm (0.04in) if one shim is removed.
arm
: 24mm,
Tightening torque : 279N•m (206 lbf•ft)
(6) After adjustment, tighten the capscrews evenly.

• The gap exceeding the specified dimension
causes early wear.
(7) Operate the bucket and confirm that the total sum
of both clearance is within 1.0mm (0.04in).
(8) Replace O-ring (3) on its original position.
• When shifting O-ring (3) by means of a spatula, use

care so as not to damage O-ring (3).
• Remove shims (9), push out bushing (7) rightwards
by means of three capscrews (11) and adjust
clearance (B) so it settles within the standard value
evenly all round.
32-5
32. ATTACHMENT
32.1.3 ARM
32.1.3.1 REMOVING ARM

(1) Put the machine in position to remove arm.
Extend the arm cylinder, retract the bucket cylinder
and bring the arm down on the ground.
Fig. 32-8 Position to remove arm

(2) Disconnecting piping of bucket cylinder
Release pressure of hydraulic tank, place oil pan to
prepare for oil leaking, and disconnect pipes.
Plug both end of disconnected pipes.

Plug : Tools section 11.5.2-(4)
Tools section 11.5.2-(5)
OIL PAN
When the removal of bucket cylinder is not
required, skip to procedure (6). Fig. 32-9 Disconnecting piping of bucket cylinder
(3) Removing bucket cylinder rod pin (H) After adjustment of shim, the total gap
Loosen nut (9), remove capscrew M16×140 (8), should be within 0.6~1.0mm (0.02~0.04in).
SHIM
and push out pin (H). 8
: 24mm
9
G A H SECTION D-D
H D A Install plastic shims
to bucket link side.
D
PLASTIC SHIM STEEL SHIM
Fig. 32-10 Detail of bucket cylinder rod pin (H)
(4) Removing cylinder head pin (G)
Install plastic shims
Loosen nut (3), remove capscrew M16×150 (2), to bucket link side.
and push out pin (G). 3 2
SHIM
After adjustment of
shim, the total gap
should be within
: 24mm 0.6~1.0mm (0.02~0.04in).
SHIM Apply grease
to inner wall
of bushing
G
SECTION A-A
Fig. 32-11 Detail of bucket cylinder head pin (G)
32-6
32. ATTACHMENT
(5) Removing bucket cylinder

Sling tube of bucket cylinder with nylon sling, and
remove it.
Bucket cylinder weight : 140 kg (310 lbs)
Fig. 32-12 Slinging bucket cylinder

(6) Removing arm cylinder rod pin (E)
Apply grease to inner wall
Put a wooden block between the arm cylinder and of bushing
the boom. Install plastic shims 2
Loosen nut (3), remove capscrew M16×150 (4), to bucket link side.
SHIM
and push out arm cylinder rod pin (E). E
: 24mm
Retract arm cylinder rod, and return pin (E) to the 3

SHIM
original position (hole). After adjustment of shim, the total gap
should be within 0.6~2.0mm (0.02~0.08in).
SECTION B-B
E
BLOCK Fig. 32-13 Detail of arm cylinder rod pin (E)
(7) Removing boom top pin (F)

Loosen capscrew M14×30 (2), and pull out boom Tightening torque 144N.m (106 lbf.ft)
Apply loctite #242 to bolt.
top pin (F). 2 1
: 22 mm SHIM
Install plastic
shims to arm
Insert pin (F) into the original hole. side.
SHIM Apply grease

to inner wall
After adjustment of of bushing
shim, the total gap
should be within
0.5mm (0.02in).
F
SECTION A-A
Fig. 32-14 Detail of boom top pin (F)
32-7
32. ATTACHMENT
(8) Slinging arm assy

Sling arm with nylon sling and remove it.
Arm weight : 660 kg (1,455 lbs)
Fig. 32-15 Slinging arm assy
32.1.3.2 ATTACHING ARM

Instal the arm in the reverse order of removing, paying
attention to the following :
1) When aligning the pin holes, do not put your
2) Check the seals for damage and replace as
necessary.
3) When inserting the pin, coat the shaft with
grease.
4) Pin lock nut handling procedure
(0.02")
CLEARANCE
: 24 mm
5) When installing the arm and the cylinder, inspect

the clearance in the thrust direction of the pins
and decide the thickness of shims by referring to
the Maintenance Standard.
6) Tightening torque
Tightening torque
Classfication Size
N.m lbf.ft
M14 144 106
Metric threads
M16 147 108
PF,PT threads 1/8" 16.7 12.3
32-8
32. ATTACHMENT
32.1.4 BOOM
32.1.4.1 PREPARATION FOR REMOVING AND ATTACHING BOOM

When removing and attaching boom in the position
shown in Fig. 32-16, to remove and attach boom foot
pin (A), removing and attaching of cab and guard are
required.
32.1.4.2 REMOVING BOOM

(1) Put the machine in position to remove boom.
Place top end of boom down on block, etc. giving
attention for arm cylinder rod not to be extended.
BLOCK
Fig. 32-16 Position to remove boom

(2) Lifting up boom cylinder temporarily
Remove the right and left boom cylinders one side
by one side according to the following procedure:
Lift up boom cylinder temporarily to prevent it from
A
dropping.
A
STAND
Fig. 32-17 Lifting up boom cylinder temporarily

(3) Press the boom cylinder rod pin (C)
Install plastic shim to cylinder side.
At the one side of pin (C), loosen nut (5), remove SHIM
capscrew (3) (M16X150), and remove boss (4). After adjustment of shim,
the total gap should be within
And push pin (C) to the end of boom boss. 0.6~2.0mm (0.02~0.08in).
SHIM
: 24 mm
4 3
(4) Preparing for disconnecting cylinder pipes

C
Retract the above mentioned cylinder rod, and 4
place one side of cylinder on stand. (See Fig. 32-
17) 5
SECTION A-A
Fig. 32-18 Detail of boom cylinder rod pin (C)
32-9
32. ATTACHMENT
(5) Disconnecting the arm cylinder and bucket cylinder

pipings
Release pressure from arm and bucket circuit and
bleed air in hydraulic tank, and then disconnect
A1
pipe at (A1), (A2), (A3), (A4) and hose (B1), (B2),
A4
(B3), (B10).
A3
A2
: 36, 41 mm
After disconnection of pipe, plug every pipe.

ORS Plug : See Tools 11.5.2-(4).
O-RING
B1
B3
O-RING BUCKET (H)
B2 BUCKET (R)
B10
ARM (H)
ARM (R)
Fig. 32-19 Boom piping disconnection

(6) Lifting up boom assy temporarily
Lift up boom cylinder with nylon sling so that boom
foot pin (A) is not loaded.
Weight of single boom : 1,310 kg (2,890 lbs)
A A
Boom assy temporary lift up procedure
(7) Removing boom foot pin (A) After adjustment of shim,

the total gap should be SHIM
1) Loosen nut (3) and remove capscrew (2) within 0.5mm (0.02in).
M20×175. 2
A
: 30 mm
2) Draw out pin (A). 3

Apply molybdenum addition
grease to inner wall of bushing.
SHIM
Install plastic shim to boom side.
SECTION A-A
Fig. 32-20 Details of boom foot pin (A) section
32-10
32. ATTACHMENT
(8) Hoisting boom assy

Hoist and remove boom assy.
Weight of single boom : 1,310 kg (2,890 lbs)
D
D
Boom assy hoisting procedure
(9) Completion of removal of front attachments

When the removing and attaching of cylinder are
not required, the work is finished. 2
(10)Removing and installing arm cylinder

F2
1) Lift up arm cylinder (2) with nylon sling so that
the head of cylinder is not loaded.
2) Disconnect hose (F1) and (F2) at position A. After adjustment of
After disconnection of hose, plug both ends of shim, the total gap
should be within F1
hose. 0.6~1.0mm (0.02~0.04in).
3 2 A
Install plastic shim to
Plug : TOOLS cylinder side. SHIM
11.5.2-(4) Plugs for ORS fitting SHIM
11.5.2-(5) Plugs for half clamp Apply grease
to inner wall
:36 mm of bushing
:12 mm
D
SECTION D-D
3) Removing arm cylinder head pin (D)
Fig. 32-21 Removing arm cylinder
Loosen nut (3), remove capscrew M16×150 (2)
and pull out pin (D).
: 24mm
4) Removing arm cylinder (2)

Weight of arm cylinder : 255 kg (560 lbs)
32-11
32. ATTACHMENT
(11)Removing and installing boom cylinder

1) Release pressure from boom circuit and bleed
air in hydraulic tank.
2) Sling boom cylinder (2) using nylon sling
temporally not to act the weight of cylinder upon
the cylinder head. 2
3) Disconnect each two hoses (C2) and (C3). And
plug their both ends. 2
B
Plug : TOOLS 11.5.2-(4) Plugs for ORS fitting
: 27,32,36,41mm C3
C2
C3
Fig. 32-22 Removing and installing boom cylinder
4) Removing boom cylinder foot pin (B) After adjustment of shim,
(See Fig. 32-23,Fig. 32-24) the total gap should be within Apply grease
0.6~1.0mm (0.02~0.04in). to inner wall
Loosen nut (5), remove capscrews M16×150 (3) SHIM of bushing
and pull out pin (B).
3
B
B
: 24mm
5) Remove boom cylinder (2).

5
Weight of boom cylinder : 170 kg (375 lbs) Apply grease to
inner wall of bushing
6) Remove another boom cylinder the same way. SHIM
Install plastic shim
SECTION B-B to cylinder side.
Fig. 32-23 Removing and installing boom cylinder
head pin (B)
32.1.4.3 ATTACHING BOOM

(1) Attaching boom foot pin (A)
First of all, insert boom foot pin (A) and install the
boom assy.
Attach it in the reverse procedure of removing,
paying attention to the following points.
A
1) When aligning the pin holes, do not put your
2) Check that the dust seals is not damaged and
replace as necessary.
3) When inserting the pin, coat the shaft with
grease.
4) Refer to paragraph 32.1.3.2 (page 32-8) about
B
installing of jam nut.
5) When installing boom and cylinder, check the
clearance of mounting section in thrust direction,
Fig. 32-24 Boom foot pin (A)
and decide the thickness of shim according to
the maintenance standard.
Install plastic shim first, and insert iron shim into
remaining gap.
Regarding the position of shim, refer to Fig. 32-
20.
32-12
32. ATTACHMENT
32.2 DISASSEMBLING AND ASSEMBLING

32.2.1 CYLINDER
32.2.1.1 PREPARATION BEFORE DISASSEMBLY

Before assembly, secure a dustfree workshop and necessary equipment and facilities.
32.2.1.1.1 WORK AREA

The following working area is required for disassembly:
(1) Ample space
For the disassembly of the hydraulic cylinder, the cylinder tube and the piston rod must be drawn out. For this
reason, the first condition is that the working area is long enough for the work. In terms of width, it is also
necessary to keep sufficient space to disassembly, cleaning and measuring equipment are placed and the work
can be performed.
(2) Suitable working environment
The hydraulic cylinder is a precision-machined product that uses seals and packings made of rubber and plastic
materials. For this reason full care should be exercised so the hydraulic cylinder is free from dust, dirt, and in
particular, such hard particles as sand, metal chips, and weld slag (spatter). If the hydraulic cylinder is
assembled with hard particles adhered on such components as the cylinder tube and the piston rod, the tube
inner surface and the rod surface are scratched as the cylinder operates, consequently disabling it in worst
cases. Damage to the piston seals and the rod seals will result in oil leaks. For this reason, grinding and welding
operation should not be performed in the neighborhood of the working area to keep it clean.
32.2.1.1.2 APPARATUS
The following equipment are required for disassembly:
(1) Hoist or crane
The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must also be capable
of making level and liner movement under load for retracting and extending the piston rod and the tube.
(2) Work bench
The work bench must have strength and rigi-dity capable of accommodating the total length of the cylinder in its
most retracted condition and of withstanding the repulsive force of the tightening torques of the cylinder head
and the piston nut. Since a vise is attached to the bench, the width of the work bench must be sufficiently large.
(3) Support stand
If the piston rod is fully extended in a free condition, the bushing and the seals may be damaged as the rod
bushing and the piston are twisted due to the weight of the rod. A stand is required to support the rod to prevent
damage of seals.
(4) Hydraulic source
A Hydraulic source is required for disassembly and assembly of the cylinder head and piston nut and for oil leak
tests after completion of assembly.
(5) Jet air source
It is used for drying after oil draining and cleaning of the cylinder.
(6) Cleaning bath, cleaning oil and detergent
(7) Oil pan and oil reservoir
An oil pan is necessary to contain oil drained from the cylinder and oil spilt during work.
An oil reservoir is required to collect oil spilt on the floor and waste oil.
(8) Others
Oil extracting hoses, wooden blocks, clean cloths and sawdust in which oil soaked are also necessary.
32-13
32. ATTACHMENT
32.2.1.1.3 NECESSARY TOOLS

Tools and jigs vary with types of cylinder, but it is necessary to prepare the tools in Table32-1 as a guideline.
Table32-1 List of Tools and Jigs
Tool / Jig Remarks Tool / Jig Remarks
Hammer 1. Steel hammer Spatula Metallic one with smooth corners.
2. Wooden or plastic mallet
Screwdriver A few types of large and small sizes Gimlet A sharp-point tool may be used in place of a
gimlet.
Chisel Flat chisel Special jig 1. For removing and press-fitting bushing.
(A), (D), (C)
2. For press-fitting wiper ring. (D)
3. For inserting and reforming seal ring.
(E),(F),(G),(H)
See para 32.2.1.9 for detail)
Vise One having an operation wide enough to Rust
hold cylinder head O.D. and tube remover
mounting pins (clevis)
Wrench 1. Eye wrench Measuring 1. Slide caliper
2. Allen wrench instruments 2. Micrometer
3. Extension pipe for wrenches
3. Cylinder gauge ( Fig. 32-25)
4. V-block
• For the details of special tools and jigs, refer to the back pages of this manual.
32.2.1.1.4 EXTERNAL CLEANING

The cylinder taken off the excavator has dust and
foreign matter, and grease is usually adhered to the
clevis part. For this reason, remove external soil and
contamination from the cylinder with water and steam Fig. 32-25 Cylinder gauge
before bringing it into the workshop.
• The following describes the construction of boom
cylinder. When disassembling and servicing the
cylinder, confirm the construction of cylinder
referring to Parts Manual.
32.2.1.1.5 DISCHARGING OIL

Place a wooden-block on the work bench and place the
WOODEN BLOCK
cylinder on it to prevent it from rotating. Charge air into
ports A and B alternately to actuate the piston rod till the
PORT B
hydraulic oil in the cylinder is drained out. At this time, V BLOCK
connect a suitable hose to each port so that the
hydraulic oil may not gush out. PORT A
AIR
OIL PAN
Fig. 32-26 Preparation
32-14
32. ATTACHMENT
32.2.1.2 CONSTRUCTION OF CYLINDER (GENERAL EXAMPLE OF CYLINDER)
25 24 12 24 25
PS1/8
PT1/4
SLIT 15
ONE HOLE
DETAIL 6 DETAIL B
DETAIL C
Piston with piston nut type
9 8 7 6 4 5 3 11 10 2 1 13 14 15 17 16 18 19 *20 *21 22 23
SLIT
C
Fig. 32-27 Construction of general cylinder
No. Parts name Q’ty No. Parts name Q’ty No. Parts name Q’ty
1 Cylinder tube 1 10 O-ring 1 19 Slide ring 2
2 Piston rod 1 11 Back-up ring 1 20 Shim *1
3 Rod cover 1 12 Socket bolt 12 21 Piston nut *1
4 Bushing 1 13 Cushion bearing 1 22 Setscrew ; M12 1
5 Snap ring 1 14 Cushion seal 1 23 Steel ball 1
6 Buffer ring 1 15 Piston 1 24 Pin bushing 2
7 U-ring 1 16 Seal ring 1 25 Wiper ring 4
8 Back-up ring 1 17 Back-up ring 2
9 Wiper ring 1 18 Slide ring 2
Note : In case of piston with piston nut type, the parts with * are not used.
32-15
32. ATTACHMENT
32.2.1.3 DISASSEMBLY
• When disassembling and servicing the cylinder,
check the construction and the availability of
service parts as well as necessary tools and jigs
on separate Parts Manual.
• The figures in parentheses after part names
correspond to those in Fig. 32-27.
• The following explanation and quantities are for
a general use cylinder which has separated
piston and piston nut.
In case that piston and piston nut are combined,
the construction differs from separated type,
refer to the sentence in parenthesis.
32.2.1.3.1 REMOVING ROD COVER AND PISTON ROD

(1) Hold the clevis section of the tube in a vise.
Use mouth pieces so as not to damage the machined

surface of the cylinder tube. Do not make use of the
outside piping as a locking means.
(2) Pull out piston rod (2) about 200mm (8in). Because
the piston rod is heavy, finish extending it with air
200mm
pressure after the above-mentioned oil draining (8")
operation.
(3) Loosen and remove socket bolts (12) of the rod
cover in sequence.
Fig. 32-28
Cover the extended piston rod (2) with cloths to prevent
it from being accidentally damaged during operation. ALLEN WRENCH 12
(4) Strike the corner of the rod cover flange by means

of a plastic mallet till rod cover (3) comes off.
Turn counterclockwise
3
Cover here with cloths
2
Fig. 32-29
32-16
32. ATTACHMENT
• At this time, the weight of piston rod (2) is loaded KNOCK THIS EDGE
on rod cover (3). Therefore, lift the top end of the WITH A PLASTIC MALLET.
LIFT HERE.
piston rod with a hoist to the extent that only the
rod weight may be held.
3
2
Fig. 32-30 Drawing out piston rod assy (2).
(5) Draw out the piston rod assy from cylinder tube (1). LIFT HERE. 1
PULL STRAIGHT
SIDEWAYS
Since the piston rod assy is heavy in this case, lift the HORIZONTALLY
tip of the piston rod (2) with a hoist and draw it out.
However, when piston rod (2) has been drawing out to
approximately two thirds of its length, lift it in its center OIL PAN
to draw it completely. However, since the plated surface
Fig. 32-31 Method of drawing out the piston rod
of piston rod (2) is lifted, do not use a wire rope which
assy
may score the surface, but use a strong cloth belt or a
rope.
(6) Place the removed piston rod on a horaizontal

wooden V-block.
PISTON ROD ASSY
• Cover a V-block with cloths.

WOODEN V-BLOCK
(PLACE CLOTHS)
Fig. 32-32 Method of placing the piston rod
(7) Remove slide ring (18) and (19) from piston (15). 15
Remove slide ring by
widening the slit toward
the arrow
19
18
Fig. 32-33 Remove slide ring (18) and (19)
32-17
32. ATTACHMENT
32.2.1.3.2 REMOVING PISTON ASSY

(1) Fix piston rod (2) by holding its clevis section in a 3 WOODEN BLOCK
vise. Fix the piston rod (2) securely as piston nut 2
(21) is tightened to a high torque. 15
21
• Note that the tightening torque differs with the type,

the working pressure and the mounting method of
the piston (15), though the rod diameter remains
the same.
• It is also necessary to place a suitable supporting
block near the piston (15). In case a V-block is
WOODEN V-BLOCK
used, put cloths or something over the rod to (PLACE CLOTHS)
prevent it from damage.
Fig. 32-34 How to loosen piston nut (21)
(2) Scrape off the caulked part of setscrew (22) of
22 DRILL
piston nut (21) by means of a hand drill and loosen
setscrew (22) and remove ball (23).
21
23
Fig. 32-35 Removing setscrew (22) and ball (23)

(3) Loosen and remove piston nut (21) or [piston (15)].
TURN COUNTER
• Since piston nut (21) is tightened to a high torque,
CLOCKWISE.
use a eye wrench suitable for the outside diameter 15
of piston nut (21). EYE WRENCH
21
• In case that piston and piston nut are combined,
Fig. 32-36 How to loosen piston nut (21)
apply the eye wrench to hexagonal part of piston
and loosen the piston directly.
(4) Remove piston (15) by tapping with plastic mallet,

supporting weight of piston (15) with hoist.
In case that piston and piston nut are combined, the

shim (20) is not used.
4 15
Fig. 32-37 Removing piston (15)
32-18
32. ATTACHMENT
(5) After removing cushion bearing (13) and cushion

LIFT WITH A HOIST. STRIKE WITH
seal (14), separate rod cover (3) from piston rod (2).
A PLASTIC MALLET.
If it is too hard to slide it, knock the flanged part of
PULL STRAIGHT.
rod cover (3) with a plastic mallet. But when
drawing it out, lift rod cover (3) by hoist and pull it
NOTE:
straight horizontally. DO NOT
DAMAGE
PISTON ROD
SURFACE.
Take care so rod bushing (4) and the lip of packings

(6,7,8,9) may not be damaged by thread of the piston
3 4 6 8,7 9 2
rod (2).
Fig. 32-38 Removing rod cover (3)
32.2.1.3.3 DISASSEMBLING PISTON ASSY

(1) Remove seal ring (16) and back-up ring (17).
HAMMER
Cut the seal ring (16) by tapping it with a screwdriver or SCREWDRIVER (OR CHISEL)
a chisel. Take care not to strike it too hard, otherwise
the groove may be damaged. BACK-UP RING SEAL
17 RING
16
USE CARE NOT

15 TO DAMAGE O-RING
THE GROOVE.
Fig. 32-39 Removing seal ring (16) and
back-up ring (17)
32-19
32. ATTACHMENT
32.2.1.3.4 DISASSEMBLING ROD COVER ASSY

(1) Remove O-ring (10) and back-up ring (11).
SPATULA
Remove back-up ring (11) and O-ring (10) in that
order. Remove back-up ring (11) and O-ring (10) by 10
pulling and stretching them with an spatula like
earpick. 11
Fig. 32-40 Removing the outer circumferential seal

of rod cover (3)
(2) Remove buffer ring (6), U-ring (7) and back-up ring GIMLET
(8). Each seal is fixed in the groove on the bore and
removing in flawless is impossible.
8
Stab each seal with a gimlet and pull it out of the
3 7
groove.
6
Take care in this operation not to damage the grooves.
Fig. 32-41 Removing the inner circumferential seal

of rod cover (3)
(3) Remove wiper ring (9). When taking out wiper ring HAMMER SCREW- 3
(9), fix rod cover (3) in a vise. DRIVER
WOOD PIECE
WOOD PIECE
VISE
Fig. 32-42 Removing wiper ring (9)

(4) Remove snap ring (5) and bushing (4).
PRESS HERE
Remove snap ring (5) first, and remove bushing (4). CHUCK ASSY TOOL A
But the bushing (4) is press fitted in rod cover (3),
so push it out by press with jig as shown in the
figure.
See para 32.2.1.9.3 (1) for removing. BUSHING 4
BLOCK TOOL C
Fig. 32-43 Removing rod bushing (4)
32-20
32. ATTACHMENT
32.2.1.3.5 REMOVING PIN BUSHING

(1) Apply driver to wiper ring (25) of cylinder tube (1)

and piston rod (2), and strike it by hammer lightly.
(2) Push out pin bushing (24) press fitted in cylinder
tube (1) and piston rod (2) with press.

Fig. 32-44 Drawing out pin bushing (24)
32.2.1.4 CLEANING
(1) After disassembly the cylinder, wash all parts with
commercial detergent.
Never use benzene(gasoline, thinner, etc.) because it

may be damage the rubber, etc.
(2) Do not use the used oil seal, O-ring, back-up ring,
etc. even if they are not damaged after inspection.
(3) After cleaning, dry all parts by compressed air, and
put them on the working bench taking care not to
damage them.
32.2.1.5 ASSEMBLING PIN BUSHING

Start assembling the following sub assy
• Cylinder tube assy
• Piston assy
• Rod cover assy
32.2.1.5.1 ASSEMBLING PIN BUSHING

(1) Press fit pin bushing (24) in cylinder tube (1) and PUSH WITH A PRESS
piston rod (2) respectively with press. 2
24
(2) Press fit wiper ring (25) in the upper and lower sides
of cylinder tube (1) and piston rod (2) respectively
with press.
• Before press fitting, apply grease on wiper ring and

boss hole. OIL HOLE LOCATION
• Before press fitting the pin bushing, align the Fig. 32-45 Press fitting of pin bushing (24)
position of oil hole.
32-21
32. ATTACHMENT
32.2.1.5.2 ASSEMBLING OF PISTON ASSY

(1) The fitting of seal ring (16) requires special tool as PRESS HERE METAL (G)
shown in Fig. 32-46. Seal ring (16) is pushed in by
PRESS JIG (E)
press, etc. with pushing in tool as shown in the
figure. (The O-ring of seal ring (16) and back-up
SLIDE JIG (F)
ring (17) on one side should be installed
beforehand.)
15
16 O-RING
Heat them, and they may be soften. But never heat
them over 100°C (212.0°F) or more.
17
(2) Fit back-up ring (17) on the other side. After fitting,
correct it immediately to prevent from expansion of Fig. 32-46 How to fit seal ring (16)
seal ring (16) with correcting jig (H) as shown in Fig.
PRESS HERE
32-47. 16 17
CORRECTIONAL
JIG (H)
• For piston, stop it once tentatively (for 3 to 5
seconds), and then push it in fully.
• After fitting, wind tape around seal ring (16) 2 or 3
times, and remove it immediately before piston (15)
is inserted in cylinder tube (1).
• Fit slide rings (18) (19) at the same time when
piston (15) is inserted in cylinder tube (1).
Fig. 32-47 Installing seal ring (16)
32.2.1.5.3 ASSEMBLING ROD COVER ASSY

(1) Press fit bushing (4) in rod cover (3) with bushing %$
% &'
press-fitting jig (A). Then, fit snap ring (5) in the
(

groove. Apply hydraulic oil on internal surface of
rod cover (3).

The snap ring (5) can not be fitted when the bushing (4)
) ! "
is not press-fitted fully to the stop end. #!$
(2) Apply grease to wiper ring (9), and fit wiper ring (9), PRESS HERE. (STRAIGHT DOWN)
directing the lip side toward the groove of retainer
tool (D). And set retainer tool (D) on rod cover (3) RETAINER TOOL (D)
and press fit wiper ring (9) with press.
U-RING GROOVE
Fig. 32-48 Press fitting of bushing (4)
32-22
32. ATTACHMENT
(3) Fit buffer ring (6), back-up ring (8) and U-ring (7) in INSERT U-RING INTO GROOVE FROM THIS SIDE.
their grooves in that order. Before setting packings,
coat them with hydraulic oil (or vaseline if not
available). If you forget the coating, the packings
may be scored. When attaching seals, deform them
in a heart shape as illustrated.
• U-ring (7) is harder than other packing and it would

be difficult to deform them in a heart shape. In such
a case, put a U-ring in the groove obliquely by hand Fig. 32-49 Inserting a seal into the inner
as deep as possible and push in the last part with a circumference of rod cover.
push bar till it is set with a click.
PUSH BAR (WOOD OR PLASTIC)
• Buffer ring (6) should be fitted taking care of the 10
fitting direction. The reverse fitting may cause
11
deformation, damage, etc. of the piston due to high Tube side
pressure generated between the buffer ring and U- 3
ring.
• If U-ring (7) is set upside down, the lip may be
damaged. Check that it is positioned correctly.
• Attach back-up ring (11) on the open air side of O-
ring (10). (See Fig. 32-50).
7
8
9
Fig. 32-50 How to fit U-ring (7)
32.2.1.5.4 INSERTING ROD COVER ASSY TO PISTON ROD

Inserting rod cover (3) to piston rod assy by the
following procedure. INSERT GUIDE JIG (I) 3
(1) Fix piston rod assy on working bench. PUSH
(2) Install rod cover (3) on piston rod (2) with inserting
guide jig (I) as shown in Fig. 32-51 paying attention
2
for the lip section of U-ring not to be caught on the
stepped section.
Fig. 32-51 Inserting rod cover (3)
• For the rod the outer diameter of piston installing

section is small, insert spacer on the faucet section
of rod first, and attach inserting guide jig.
• Apply hydraulic oil on the inserting guide jig and
outer surface of piston rod lightly to make the
insertion smooth.
32-23
32. ATTACHMENT
32.2.1.5.5 ASSEMBLING PISTON ASSY ONTO PISTON ROD

(1) Install cushion on the extraction side, cushion PISTON
bearing (13) and cushion seal (14) by the following 13
procedure. 14
1) Put cushion seal (14) on it, directing the slit

machined side toward the piston side.
2) Fit cushion bearing (13) on it directing the
flattening side as shown in Fig. 32-52.
FLAT SECTION
Direct slit toward

piston side
Fig. 32-52 Cushion mechanism on extension side
(2) When cushion is installed on the retraction side, fit
Direct slit toward
cushion bearing (13) and cushion seal (14) by the thread side
following procedure. THREADED PART
1) Fit cushion bearing before fitting piston nut. The

nut attached obstructs the fitting of cushion PISTON ROD
bearing.
2) Put cushion seal on it, directing the slit machined
side toward the piston side.
3) Fit cushion bearing on it directing the flattening
SNAP RING
side as shown in Fig. 32-53. CUSHION SEAL CUSHION STOPPER
(Slit 1 place) BEARING (Divide into 2 portions)
4) Put stopper in the groove. Push cushion bearing
to stopper fully, and drive snap ring. Use plastic Fig. 32-53 Cushion mechanism on retraction side
mallet in order not to damage the rod, cushion
bearing.
Cushion seal and cushion bearing should be fitted

taking care of the fitting direction. If they are fitted in
reverse directions, the cushion does not effective.
After installing cushion, be sure that the cushion
bearing moves up and down, and right and left.
32-24
32. ATTACHMENT
(3) Insert shim (20), and tighten piston nut (21) or 21

[piston (15)] till it gets tight.
Always tighten the piston nut (21) or [piston (15)] of
each piston to specified torque
(Refer to 32.2.1.7.3). EYE WRENCH
• In case that piston and piston nut are combined, the

Fig. 32-54 Tightening piston nut (21)
shim (20) is not used. Apply the eye wrench to
hexagonal part of piston and loosen the piston ANTI-LOOSENING
22 CAULKING 20
directly. 2
23
• Always correct the threads in piston nut (21) or
[piston (15)] before fixing piston nut, using a
tapping.
• Insufficient tightening torque causes an inner leak
and a damage of thread. And over tightening torque
causes a bulge of cushion bearing and a V-BLOCK
deformation of piston contacted surface. 21
• Clean and decrease (with solvent) the parts of Fig. 32-55 Attaching setscrew (22)
piston assembly, and dry it, then tighten this piston
22 18 19
assembly. 2
(4) Put steel ball (23) into hole and tighten setscrew
(22).
: 6mm
After tightening the setscrew to a specified torque,
caulk the two places of the thread of the piston nut 21 V-BLOCK
side to secure the setscrew.
Fig. 32-56 Attaching slide ring (18), (19)
See para 32.2.1.7.3 for torque.
(5) Attach two slide rings (18) and (19). Take off vinyl
tape wound around the perimeter of piston (15),
apply high-quality grease (or vaseline) to slide ring
(18), (19) and attach the slide rings in a manner that
they may be coiled around the groove. Set the slide
rings about 180 degrees apart with each other so
that the slits may not point to the same direction.
32-25
32. ATTACHMENT
32.2.1.5.6 OVERALL ASSEMBLY

(1) Place a V-block on a work bench (A wooden V-
1
block is preferable.). Place the cylinder tube assy
(1) on it and fix the assy by passing a wooden bar LIFT
through the clevis pin hole to lock the assy.
(2) Insert the piston rod assy into the cylinder tube
assy, while lifting and moving the piston rod assy
with a hoist. In this operation, apply hydraulic oil (or STRAIGHT
PREVENT TURNING
vaseline) to the inner surface of the tube mouth and WITH WOODEN BAR.
the circumference of the piston. Align the center of
the piston rod assy with the center of the cylinder
tube assy and put it in straight forward. When Fig. 32-57 Inserting piston rod assy
inserting, make sure that slide rings (18), (19) on
the perimeter of the piston is not out of the groove.
(3) Tighten socket bolt (12). Match the bolt holes of the 12
rod cover flange to the threaded holes in the
cylinder assy, and screw in socket bolts (12) one by PLACE CLOTH
one. Tighten the bolts to a specified torque, taking
care so the bolts may not be tightened unevenly.
See para. 32.2.1.7.3 for torque.
: 14 mm
ALLEN WRENCH
TURN CLOCKWISE
Fig. 32-58 Tightening socket bolts (12)
Take care so as not to damage the rod surface by

accidentally slip a wrench. Covering the rod surface
with cloth is recommended to prevent damage to it.
32-26
32. ATTACHMENT
32.2.1.6 INSPECTION AFTER ASSEMBLY

(1) No-load functional test
Place the cylinder level at no load, operate the
piston rod 5 to 6 strokes by the directional valve and DIRECTIONAL VALVE
make sure that it operates without failure. PUMP
• Do not raise the hydraulic pressure above the H R

maximum pressure of 37.8MPa (5480psi) for the
cylinder of the machine.
• Grease coated on the O-rings and the seals of the
HYDRAULIC CYLINDER
rod cover may come out. Wipe it off and retest the
Fig. 32-59 External leak test
cylinder in such a case.
(2) Leak test MEASURE THE

1) Apply a test pressure to the retracting and INTERNAL LEAK.
extending sides of the cylinder for three minutes
independently, and check that the rod section
and the welds have external leaks and
permanent deformation. For an internal leak test,
connect the cylinder with a test unit as shown in
Fig. 32-60. FROM DIRECTIONAL VALVE
Fig. 32-60 Internal leak test
2) After completing the test, apply a plug to each

port and store the cylinder. (Fig. 32-61)
• For storage, place the cylinder on wooden V-

blocks and bring the cylinder to the most
retracted condition. Fig. 32-61 How to store the cylinder
32-27
32. ATTACHMENT
32.2.1.7 MAINTENANCE STANDARDS
32.2.1.7.1 INSPECTION AFTER DISASSEMBLY

Visually inspect all parts after cleaning to see that excessive wear, crack and other damage that are detrimental to
use are not present.
(1) Inspection Item
Table32-2
Part Name Inspecting Section Inspection Item Remedy
1. Neck of rod pin Presence of crack Replace.
2. Weld on rod hub Presence of crack Replace.
3. Stepped part to which
Presence of crack Replace.
piston is attached
4. Threads Presence of seizure Recondition or replace
Measure degree of bend (See
5. Bend Refer to (Table32-3)
Fig. 32-62)
Piston rod 6. Plated surface Check that:
1) Plating is not worn off to 1) Replace or replate
base metal
2) Rust is not present on plating. 2) Replace or replate
3) Recondition, replate or
3) Scratches are not present.
replace.
7. Rod Wear of O. D. Recondition, replate or replace.
8. Bushing at mounting part Wear of I. D. Replace.
1. Weld on bottom Presence of crack Replace.
2. Weld on head Presence of crack Replace.
Cylindertube 3. Weld on hub Presence of crack Replace.
4. Tube interior Presence of damage Replace if oil leak is seen.
5. Bushing at mounting part Wear on inner surface Replace.
1. Bushing 1) Wear on inner surface 1) See para. 32.2.1.7.2
Rod cover 2) Replace if score is deeper than
2) Flaw on inner surface
coating.
(2) Repair method

Check all seals and parts to see that they do not show excessive damage and wear. For correction of scores on
the piston rod, observe the following procedure:
1) Correct very fine longitudinal scratches with an oilstone. Replace the piston rod if the scratch is so deep as
may be caught by your nail.
2) In case of a smooth indention, recondition by removing the sharp area around the indention with an oilstone.
If the score or the indention is excessive, replace or replate the damaged part.
• Always regrind after replating. The thickness of the plating must be maximum 0.1mm (0.004in).
• In case plating is removed to the base metal during reconditioning with an oilstone, do not fail to replate the
surface.
32-28
32. ATTACHMENT
32.2.1.7.2 LIMIT OF SERVICEABILITY

Serviceability limits represent the limits of wear on the
sliding surfaces of the cylinder tube and the rod that
have no such damage as may degrade the sealing
effect.
(1) Clearance between piston rod and rod bushing
Replace the bushing if the clearance between the
piston rod and the rod bushing exceeds 0.25mm
(0.01in).
(2) Bend of piston rod
The allowable bend of the rod is maximum 1mm /
1m (0.04"/3’3"). For measurement, support both
ends of the parallel section of the piston rod with V-
blocks, set a dial indicator in the center between the
two V-block turn the piston rod, and read the
difference between the maximum and minimum Fig. 32-62 Measuring Method
deflection on the dial indicator.
Table32-3 shows an example of measurement.
Table32-3 Example of Measurement

Distance between Deflection of the dial indicator
V-blocks in the middle of the rod. Remedy
m (ft-in) mm (in)
1 (3’3") 1 (0.04") Replace
Even if the bend is within the above limit, the cylinder

may not operate smoothly because of localized bend.
Beware of it during function test after assembly.
Replace the rod if the cylinder makes a squeaking
noise or dose not operate smoothly.
32.2.1.7.3 TIGHTENING TORQUE
B A C Unit : N.m (lbf.ft)

A B C
Cylinder Piston nut
or [Piston] Socket bolt Setscrew
Boom 5460 (4030) 267 (200) 56.9 (42)
Arm 7890 (5820) 367 (270) 56.9 (42)
Bucket 6200 (4570) 267 (200) 56.9 (42)
32.2.1.7.4 VOLUME OF OIL LEAK

The oil leak rates as mentioned in 1.6 (2) of Inspection after Assembly are as shown in INSPECTION AFTER
ASSEMBLY32.2.1.6 (2).
Cylinder Volume of Internal Oil Leak

Boom 1.0cc (0.06 cu•in) or below / 3min
Arm 1.0cc (0.06 cu•in) or below / 3min
Bucket 1.0cc (0.06 cu•in) or below / 3min
32-29
32. ATTACHMENT
32.2.1.8 TROUBLESHOOTING
Table32-4
Trouble Failed Parts Cause Remedy
1. Oil leak through sliding 1. Back-up ring 1. Foreign matter is trapped in the 1. Remove foreign matter.
surface of piston rod. Oil bore of back-up ring
ring is formed on piston 2. Lips on outer and inner diameter 2. Replace back-up ring.
rod, and the ring grows up surfaces of back-up ring are
to oil drops, and they drip. scored.
3. Other back-up ring are failed. 3. Replace back-up ring
2. U-ring 1. Foreign matter is trapped in the 1.Remove foreign matter.
OIL LEAKS FROM HERE bore of ring.
2. Score is present on the bore of ring. 2. Replace U-ring.
3. Other rings are failed. 3. Replace U-ring.
3. Buffer ring 1. Foreign matter is trapped in the 1.Remove foreign matter.
bore of ring.
2. Score is present on the bore of ring. 2. Replace buffer ring.
3. Other rings are failed. 3. Replace buffer ring.
4. Wiper ring 1. Foreign matter is trapped in the 1.Remove foreign matter.
bore of wiper ring.
2. Lip on the bore of wiper ring is 2. Replace wiper ring.
scored.
3. Another wiper ring is failed. 3. Replace wiper ring.
5. Piston rod 1. Score is present on the sliding 1.Smooth out the sliding surface with
surface of piston rod. an oilstone. If leakage occurs even
if the sliding surface is finished
below 1.6S, rod packings may be
scored. Disassemble and inspect it
and replace rod packings as
required.
If leak will not stop by that
treatment, replace piston rod.
2. Hard chromium plating has peeled 2. Replate.
off
2. Oil leaks from the 1. O-ring 1. O-ring is damaged. 1. Replace O-ring.
circumference of rod cover. 2. Backup ring 1. Back-up ring is damaged. 1. Replace back-up ring.
3. Cylinder tube 1. Swelling of cylinder tube. 1. Replace cylinder tube.
OIL LEAKS FROM HERE

3. Oil leaks from welds. 1. Cylinder tube 1. Welds of cylinder are broken. 1. Replace cylinder tube.
WELDS
4. Cylinder falls by it-self. 1. Piston seal 1. Foreign matter is trapped in the 1. Remove foreign matter
[When the rod is loaded with sliding surface of seal ring.
a static load equal to the 2. Score is present on the sliding
2. Replace seal ring..
maximum working pressure surface of seal ring.
multiplied by the area of the 1. Sliding surface of slide rings is
2. Slide ring 1. Replace slide ring.
cylinder bore, the maximum scored.
movement of the piston is 3. Piston rod 1. Elongation.Piston rod and piston 1. Replace piston rod.
more than 0.5mm (0.02") in are elongated. (Loose nut)
ten minutes.]
32-30
32. ATTACHMENT
32.2.1.9 JIGS LIST
32.2.1.9.1 SPECIAL JIG LIST (POSSIBLE TO SUPPLY)

When assembling, the following jigs are required.
Table32-5
Described
Application Shape
paragraph
A D
For removing and press 32.2.1.3.4,

fitting bushing EDGE OF C 32.2.1.5.2
CHUCK
D
For press fitting wiper
32.2.1.5.2
ring
E H
F
For correcting seal ring 32.2.1.5.2
INSERTING JIG CORRECTING JIG
I
For inserting rod cover 32.2.1.5.4
For above jigs, contact our dealer.

(The Jig No. List provided by cylinder maker is shown in the following page.)
32-31
32. ATTACHMENT
Special Jig No. List

(1) For jigs for rod cover, select jig corresponding to respective rod diameter.
(2) For jigs for piston, select jig corresponding to the cylinder bore.
Table32-6
Application rod diameter (mm) Kit No. of maker
65 3006J-56001
70 3007J-06001
75 3007J-56001
80 3008J-06001
85 3008J-56001
Jig for rod cover
90 3009J-06001
removing & installing
95 3009J-56001
100 3010J-06001
105 3010J-56001
110 3011J-06001
115 3011J-56001
120 3012J-06001
Application cylinder bore (mm) Kit No. of maker
95 3009J-51001
100 3010J-01001
105 3010J-51001
110 3011J-01001
115 3011J-51001
Jig for seal ring 120 3012J-01001
inserting & 125 3012J-51001
correcting 130 3013J-01001
135 3013J-51001
140 3014J-01001
145 3014J-51001
150 3015J-01001
160 3016J-01001
170 3017J-01001
32-32
32. ATTACHMENT
32.2.1.9.2 OTHER SPECIAL JIGS (PREPARED BY SERVICE SHOP)

(1) Bushing removing jig (Symbol J)
80 MATERIAL : Mild steel

50 15 15 Unit : mm (inch)
12-S
d D Cylinder Used
5
C2 R2 R0.2 80 94 Bucket
10 12-S
85 94 Arm
25-S 85 99 Boom
oD -0.2
-0.4
oD -0.5
oD -3-4
-1
Fig. 32-63 Bushing removing jig

(2) Wrench for piston nut or [piston]
Unit : mm (inch)
B Cylinder Used
110 Arm
95 Boom
95 Bucket
Fig. 32-64 Wrench for piston nut or [piston]
32-33
32. ATTACHMENT
32.2.1.9.3 SPECIAL JIG HANDLING PROCEDURE

(1) How to remove bushing from rod cover.
1) Attaching chuck assy tool
Insert tool in rod cover slowly until the edge top
end of chuck assy reaches to the end of bushing -,/-
(4).
• Special attention must be paid so that the

inner surface of rod cover is not damaged by
the edge of tool.
• Attach top on the position 5mm (0.2 in) from
the bushing end face so that the edge does
not protrude from the end face.
)
4
5 (0.197")
(CHUCK)
2) Tightening chuck assy tool temporarily

a. Fit allen wrench to the head of adjuster bolt on
the top end of tool, and insert lever in the
round hole on the rear end of tool.
b. Fix it with allen wrench and lever to the
position where the tool does not drop even if
the rod cover is raised, inclining it forward and
rearward.
• Move rod cover onto the working bench

holding tool attached.
• Be careful not to drop it on foots, etc.
32-34
32. ATTACHMENT
3) Attaching tools for retainer

Put retainer on the press bench directing the
wiper ring fitting section of rod cover upward, D
then put retainer tool (D) on the rod cover.
FLANGE
• Fit retainer tool as shown in the right figure
directing large diameter section (flange
section) upward.
• Clean the surface of press bench, and take
care for the tool bottom face not to be
damaged by foreign matter like dust, chip, etc.
4) Cutting into of the edge of chuck PRESS HERE

Press the upper section of retainer tool gradually
so that the edge of chuck tool (A) cuts into the
bushing surface.
Set the pressing force to 2~3 tons (4410~6615
lbs).
After completion of pressing, tighten adjuster bolt

again by hand.
• Press it with retainer tool (D).
CHUCKING JIG A
32-35
32. ATTACHMENT
5) Setting of tools for block

Prepare block (C), and put rod cover (3) on it
aligning them.
Select corresponding block (C) in shape,
dimensions, etc. from the table shown below.
oD
15 (0.59") 15 (0.59")
od 10
10
Unit : mm (inch)
Class
(Nominal size) d D h
o55 (2.17) 62 (2.44) 88 (3.46) 80 (3.15)
o60 (2.36) 67 (2.64) 96 (3.78) 80 (3.15)
o65 (2.56) 72 (2.83) 96 (3.78) 80 (3.15)
o70 (2.76) 77 (3.03) 100 (3.94) 80 (3.15)
o75 (2.95) 82 (3.23) 110 (4.33) 80 (3.15)
o80 (3.15) 87 (3.43) 112 (4.41) 80 (3.15)
o85 (3.35) 92 (3.62) 124 (4.88) 90 (3.54)
o90 (3.54) 97 (3.82) 135 (5.31) 90 (3.54)
o95 (3.74) 102 (4.02) 145 (5.71) 90 (3.54)
C
o100 (3.94) 107 (4.21) 145 (5.71) 90 (3.54)
o105 (4.13) 112 (4.41) 150 (5.91) 90 (3.54)
o110 (4.33) 117 (4.61) 165 (6.50) 90 (3.54)
o115 (4.53) 122 (4.80) 170 (6.69) 90 (3.54)
o130 (5.12) 137 (5.39) 190 (7.48) 90 (3.54)
6) Removing of bushing
a. Move block (C) and rod cover (3) with tool
under the press.
b. Press the upper part of retainer tool (D) slowly
until bushing (4) is take out from rod cover (3)
D
(until there is a sound that the chuck tool (A)
drops on the work bench)
• The force of 3 tons (6615 lbs or less) is
necessary to press it out.
The stroke of press ram is about 32~52mm
(1.26in~2.04in). (But it varies according to the
difference of dimension of cylinder head.)
• Press it with retainer tool (D).
When the block and rod cover assy are not

aligned, interrupt the work and align the block
and rod cover assy.
32-36
32. ATTACHMENT
7) Removing of rod cover

a. Remove block (C) with rod cover (3) near side,
remove retainer tool (D) from rod cover (3),
and then move rod cover (3) to other place.
b. Take out the chuck tool (A) with bushing from
block (C).
4
Do not work under the press because it is very
dangerous.
A
8) Removing of bushing
a. Place chuck tool (A) with bushing (4)
sideways, and loosen adjuster bolt with allen
wrench and lever.
b. Place the chuck tool (A) vertically and turn the
adjuster by hand until the wedge is raised
about 5mm (0.2 in).
c. Remove the wedge from the edge of chuck.

• Clean the surface of work bench, and be

careful for the tool not to be damaged by 4
foreign matters like dust, chips, etc.
32-37
32. ATTACHMENT
9) Tightening of adjuster bolt

Tighten the chuck tool (A) the bushing (4) is
removed to the extent that there is no gap

between the chuck and the wedge upper face,
turning the adjuster bolt by hand.

• This special tool differs according to the
corresponding piston rod diameter.
• The chuck edge is an important portion. Take
care of handling and storage.

32-38
32. ATTACHMENT
(2) Rod cover bushing press-fitting procedure

4
1) Temporary setting of head bushing
Put rod cover (3) on the press-working bench
directing the tube connection upward.
Set bushing (4) on the inner surface of rod cover

(3) temporarily.
• Make sure that the inner and outer surfaces of

bushing (4) are free from foreign matter.
2) Setting chuck assy tool (A)

Insert the chuck assy tool (A) in temporary-set
bushing (4) directing the flange downward, and
set it on rod cover (3).
A
• Be sure that the adjuster bolt is tightened to

the extent that there is no gap between
adjuster of chuck assy (A) and wedge.

32-39
32. ATTACHMENT
3) Attaching retainer tool

Put retainer tool (D) on the wedge stepped
section of chuck assy tool (A) slowly directing the
flange upward.
• Align chuck assy (A) and the wedge.

4) Preparation for press-fitting PRESS RAM

Move the rod cover on which chuck tool (A) and
retainer tools are attached under the press.
• Adjust it so that the press ram is centered to

the tool. RETAINER(D)
CHUCK(A)
BUSHING(4)
BUSHING PRESS-
FITTING PART
32-40
32. ATTACHMENT
5) Press-fitting of bushing
Push the head of retainer (D) with press, and
press fit bushing (4) to the specified position of
rod cover (3) slowly.
• The pressing force should be held 5 tons STEP OF WEDGE

(11025 lbs) or less, keeping the required force
for the press-fitting.
• Raise the pressure gradually adjusting the
force by means of pressure adjusting valve of
press unit.
• Be sure that the end face of bushing is located
on the interior of the groove for snap ring.
When it is located on near place, press fit and
adjust the location again.
LIFTING THREAD
RETAINER JIG (D)
ADJUSTER BOLT
WEDGE
CHUCK TOOL ASSY (A)
CHUCK
BLOCK TOOL (C)
Bushing removing and press fitting jig (For reference only)
32-41
32. ATTACHMENT
[MEMO]
32-42
33. UPPER STRUCTURE
TABLE OF CONTENTS

33.1.1 OPERATOR SEAT .................................................................................................33-3
33.1.2 CAB ........................................................................................................................33-4
33.1.3 BATTERY ...............................................................................................................33-6
33.1.4 GUARD...................................................................................................................33-7
33.1.5 UNDER COVER .....................................................................................................33-13
33.1.6 FUEL TANK ............................................................................................................33-14
33.1.7 HYDRAULIC TANK ................................................................................................33-16
33.1.8 HYDRAULIC PUMP................................................................................................33-20
33.1.9 AIR CLEANER........................................................................................................33-25
33.1.10 MUFFLER...............................................................................................................33-26
33.1.11 COUNTERWEIGHT................................................................................................33-28
33.1.12 RADIATOR & OIL COOLER ...................................................................................33-29
33.1.13 ENGINE ..................................................................................................................33-35
33.1.14 CONSOLE COVER ................................................................................................33-38
33
33.1.15 CONTROL VALVE..................................................................................................33-40
33.1.16 PILOT VALVE (FOR ATT) ......................................................................................33-43
33.1.17 PILOT VALVE (FOR TRAVEL) ...............................................................................33-44
33.1.18 SWING MOTOR UNIT ............................................................................................33-46
33.1.19 SWIVEL JOINT.......................................................................................................33-48
33.1.20 UPPER FRAME......................................................................................................33-51
33.2 DISASSEMBLING AND ASSEMBLING...........................................................................33-54
33.2.1 HYDRAULIC PUMP • REGULATOR ......................................................................33-54
33.2.2 CONTROL VALVE..................................................................................................33-80
33.2.3 PILOT VALVE (ATT)...............................................................................................33-111
33.2.4 PILOT VALVE (FOR TRAVEL) ...............................................................................33-121
33.2.5 SWING MOTOR UNIT............................................................................................33-130
33.2.6 SWIVEL JOINT.......................................................................................................33-157
33-1
33. UPPER STRUCTURE

E215B : YN11-45001~ S5YN3322E01
↑
↑ ↑ ↑ K
PREFACE
(1) This Manual describes all the procedures from removing to installing, arranging them by item.
(2) This Manual consists [Removing and installing], and [Disassembling and assembling].
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
(4) The removing and installing procedure does not completely cover all possible situations because of differences
(5) Recognize well that the service man must decide a work procedure before proceeding to repair. When deciding
the work procedure, choose an item that is needed, familiarize yourself with the contents of the work and itemize
the work procedure, before starting work.
(6) Disconnect the negative terminal of battery first, when the removing and the installing of the electric component
and wiring are performed.
(7) The explanatory note and figure of this manual may differ from the actual machine by the difference in
specification.
33-2
33. UPPER STRUCTURE

33.1.1 OPERATOR SEAT
33.1.1.1 REMOVAL
(1) Preparation for removal
1) Remove the head rest (A1-1) of the operator’s
seat (A1) to ease handling. A1-1
2) Move the whole control stand to its foremost A1

position.
3) Move the operator’s seat to its forward end.
4) Incline the reclining seat as forward as possible. B2
(2) Remove operator’s seat. (Include upper rail.) C1
1) With the above-mentioned condition, remove C2
C1
two cap screws (B2) M8×20 from the upper rail. C2
Then move the control stand to its rearmost end
and remove two capscrews (B2) M8×20.
: 6 mm
2) Remove the operator’s seat. [about 28kg (62
lbs).] 1
7
Carry out the following operations as required.
13
3) Remove seat belt (C1). 10
4) Remove armrest (A3)(A4).
5) Remove bracket assy (1), rail (7).
Fig. 33-1 Disassembling and Assembling seat
33.1.1.2 INSTALLATION
Install it in reverse procedure of removing according to A4
the tightening torque table.
A5
Allen
Tightening position wrench Tightening torque
HEX (mm) N·m (lbf·ft)
A6
Capscrew (B2) 6 23.5 (17.3) A1
Sems bolt (C2) 17 46.1 (34) A3 A2
Capscrew (A5) 13 23 (17)
Sems bolt (A6) 13 23 (17) A5
Reference : Movement on rail

Upper rail …… Fixed on lower surface of seat
[Forward 80mm (0.26in), backward 80mm (0.26in)]
Lower rail …… Fixed on seat stand.
[Forward 60mm (0.19in), backward 60mm (0.19in)]
Amount of adjustment of seat height Fig. 33-2 Disassembling and Assembling armrest
[Up; 23mm (0.07in), down; 37mm (0.16in)]
Suspension stroke
[Up; 37.5mm (1.48in), down; 37.5mm (1.48in)]
33-3
33. UPPER STRUCTURE
33.1.2 CAB
33.1.2.1 REMOVAL
(1) Remove floor mat.
A7
(2) Remove cover (A7)
Lift cover (A7) upwards and remove it. (Fixed with
2 clips)
(3) Remove cover assy (A1)
1) Loosen 4 sems bolts (A22) M6×16 and lift cover
assy (A1) up.
2) Disconnect each connector for both speakers.
Then remove cover assy (A1). A22
(4) Remove the harness connector (See Chapter 23) A1
1) Disconnect connectors of cab harness (CN-
515), (CN-518), (CN-71) (CN-72) and (CN-500)
at rear right of cab.
2) Disconnect antenna cable coming from backside
of tuner at rear left of cab. Fig. 33-3 Disassembly and assembly of cover (A7)
(5) Remove the plastic tube for the window washer and cover assy (A1)
from the rear left of cab.
(6) Remove the right panel of cab
1) Remove 2 caps (A29) loosen 2 sems bolts (A40)
M6×25 and 1 sems bolt (A39) M6×16. And right A3
A14
panels (A4) and (A4-2) are freed.
: TORX driver T30
2) Lift cover (A3) upwards and remove it. (Fixed
A22
with 3 clows and 2 clips)
B2
3) Unfix 3 harness clips (A4-8) of inside on right A4-8
A40
panel (A4-2). And free the harnesses connected A4
A29
to key switch.
A4-8 A39
4) With harnesses are connected condition, install A40
key switch cover (A3) to bracket (A1) of rear cab A4-8
temporally. (See Fig. 33-5)
5) Disconnect harness connectors of work light A29 A4-2
switch on right panel (A4), air conditioner panel
and cigarette lighter, and remove right panel (A4) A22
and (A4-2). (See Chapter 23)
6) Loosen sems bolts (A22) M6×16 and (A23)
M6×40 one each, and remove front panel (A5-2)
with air conditioner duct.
: Plus driver
A5-2
A23
Fig. 33-4 Disassembly and assembly of right panels
(A4-2), (A3) and (A5-2)
33-4
33. UPPER STRUCTURE
RELAY BOX
ASSY
Fig. 33-5 Move switch cover assy

(7) Remove cab attaching bolt
1) 5 capscrews (A1) M12×65 and 1 capscrew (A3)
M12×30. (Mark ) B4
2) 2 nuts (B4) M16 (Mark )

(8) Slinging cab
1) Remove two plastic plugs at the front of the
ceiling of the cab. Then place a wire sling with A3
eye rings and a hook around the cab, as shown
in Fig. 33-7.
A1
2) Then lift up slowly avoiding interference with
surroundings.
Fig. 33-6 Removing and installing cab mounting
Wire with hook ;
bolts.
Length 1.5m (4ft 11in)×Dia. 8mm
(0.315in)×3pcs.
Weight of cab ; Approx. 250kg (550 lbs)
Install it in reverse order of removing according to the
Tightening Torque Table.
Allen Tightening torque EYE BOLT
Tightening position wrench
N·m (lbf·ft)
M10
HEX
Nut M16 (B4) 24 191 (140)
Capscrew (A1)(A3) 19 79.4 (60
Torx driver
Sems bolt M6 (A39)(A40) (T30) 8.5 (6.3)
Sems bolt M6 (A22)(A23) Plus driver 5.0 (3.7)
Fig. 33-7 Slinging cab
33-5
33. UPPER STRUCTURE
33.1.3 BATTERY
33.1.3.1 REMOVING
(1) Open left panel assy (21).
1) Open it with starter key.
2) Open left panel assy (21).
3) Fix it with stay.
(2) Remove battery cover (1)

Loosen nut (6) M10 and remove battery cover (1).
: 17 mm
(3) Remove battery cable
1) Remove cable (A4) [between the earth and
battery (–)].
(Always remove (-) terminal first and install it at 21
last.)
Fig. 33-8
2) Cable (A3) [between battery (+) and (-)]
3) Cable (A2) [between battery (+) and battery 6
Tightening torque
relay] 15.7 N.m (11.6 lbf.ft)
: 13 mm
Follow the battery removal order.

Start removing battery from grounding side, and finish
attaching to grounding side. If this order is missed,
short-circuits may occur.
(4) Remove battery (B1)

1) Loosen 2 capscrews (3) M10×235.
A2
: 17 mm
A4
2) Remove plate (2). A3
3) Remove battery (B1). 2
3
B1
Fig. 33-9 Removing and installing battery
33.1.3.2 INSTALL
(1) Install the battery in the reverse order of removing.
Hold down plate (2) against battery (B1), and
tighten capscrew (3).
: 17 mm,
Tightening torque : 10.8N•m (8.0 lbf•ft)
(2) Installing grounding cable
Install grounding cable (A4) last. Especially care
must be taken that the grounding face is free from
painting, rust, etc.
: 13 mm
33-6
33. UPPER STRUCTURE
33.1.4 GUARD
33.1.4.1 PREPARATION FOR REMOVAL

(1) Remove guard in the following procedure. 7
Remove the guards in the order of 2
6
(11)→(5)→(6)→(7)→(2)→(21)→(23)→(3)→(4)→ 1
22
(22) and (1). 5
(2) All the locked cover, open them using starter key.
11
23
4
21
Fig. 33-10 Arrangement of guard assy
33.1.4.2 REMOVE GUARD

(1) Remove bonnet assy (11) 2
3
1) Unlock catches (2) and unlatch catches (2), (3), 11
and open bonnet (11).
2) Remove four nuts (7) M12.
3) Remove bonnet (11).
: 19 mm
Weight : 37kg (82 lbs)
7
7
Fig. 33-11 Removing bonnet assy (11)
(2) Remove guard (5) 41b
1) Remove 4 sems bolts (41a) M12×25 on upper
41a
side.
5
2) Remove 3 sems bolts (41b) M12×25 on the side.
3) Remove guard (5)
41a
: 19 mm
Weight :10kg (22 lbs) C
Fig. 33-12 Removing guard (5)
33-7
33. UPPER STRUCTURE
(3) Remove guard (6) and guard assy (3).

41a
1) Remove 4 sems bolts (35) M12×25. 35
2) Remove a sems bolt (41a) M12×25. 6
35
3) Remove guard (6).
4) Remove a sems bolt(41b) M12×25.
41b
5) Remove guard assy (3).
: 19 mm D
3
(4) Remove stay (7)
1) Remove 2 sems bolts (41) M12×25.
2) Remove 2 sems bolts (43) M12×40. 7
3) Remove stay (7). 41
: 19 mm
43
A
Fig. 33-14 Removeing stay (7)
(5) Remove guard (2)
41
2) Remove connector for right side deck light. 2
3) Remove guard (2).
Deck light
: 19 mm

(6) Remove panel assy (21) 21
1) Unlock panel assy (21).
2) Remove 4 nuts (4) M10.
3) Remove panel assy (21).
: 17 mm 4
Fig. 33-16 Removing panel assy (21)
33-8
33. UPPER STRUCTURE
(7) Remove panel assy (23)

23
2) Remove panel assy (23). 4
: 17 mm

(8) Remove panel assy (22)
22
1) Unlock and open panel assembly (22).
3) Remove panel assy (22).
: 17 mm

(9) Remove guard assy (16) and guard (14), (15), (17).
41
1) Remove 9 sems bolts (41) M12×25 and a sems 17
41
bolt (6A) M12×30 and guard assy (17), (15), (16),
41
(14) in order. 14 41
16 41
6A 41
: 19 mm 41
41
41
15
Fig. 33-19 Removing guard assy (16) and guard

(14), (15), (17).
(10)Remove pillar (11)
C
1) Remove 4 sems bolts (42) M12×30 and remove
pillar. 11
: 19 mm 42
Fig. 33-20 Removing pillar (11)
33-9
33. UPPER STRUCTURE
(11)Remove beam (4)

41
1) Loosen 6 sems bolts (41) M12×25.
2) Remove beam (4).
: 19 mm
Weight : 13kg (29 lbs) 4
10
12
Fig. 33-21 Removing and installing of beam (4)

(12)Remove pillar (10), (12)
Remove battery relay box in advance and remove
pillar (10). (See Chapter 23) 10

2) Loosen 2 sems bolts (43) M12×40. 12
3) Loosen a sems bolt (51) M12×35.
42
: 19 mm 51
43
4) Remove pillar (10), (12).
Weight : Pillar (10) : 12kg (26 lbs)
Fig. 33-22 Removing and installing of pillar (10),(12)

(13)Remove guard assy (18) and (13) 41
1) Loosen 4 capscrews (33) M12×20, and remove 19
guard assy (18).
2) Loosen 2 sems bolts (42) M12×20, and remove 18
guard assy (13). 13
E
33
: 19 mm
33
(14)Remove guard (19)

Loosen 6 sems bolts (41) M12×25, and remove
E
guard (19). 42
Fig. 33-23 Removing and installing of guard assy

and guard
33-10
33. UPPER STRUCTURE
(15)Remove cover (2)

1) While air cleaner is removed, loosen hose clamp 3
3-1
of engine intake and disconnect the hose.
2) Loosen 6 sems bolts (6) M12×25, and remove
cover (2).
: 19 mm 6
(16)Remove guard assy (1)

Loosen 4 sems bolts (6) M12×25, and remove 3-2
guard assy (1).
5
1-2 4
6 2-2 2
: 19 mm 1 2-1
1-1 6
(17)Remove guard assy (3)

6
guard assy (3).
6
: 19 mm
Weight : 15kg 6
Fig. 33-24 Removing and installing of cover and

guard assy
(18)Remove plate (20)
plate (20).
: 19 mm
Weight : 15kg (33 lbs) B
41
41
20
41
Fig. 33-25 Removing and installing of plate (20)
33-11
33. UPPER STRUCTURE
(19)Remove cover assy (1)

1) Disconnect the hose (14) which is connected to
fuel feed pump and fuel tank. And disconnect the
connector of harness for fuel pump.
(See Fig. 33-28)
2) Unlock the locks and open cover (1-2). 41
1-2
4) Remove cover assy (1).
: 19 mm
Weight : 30kg
(20)Remove other brackets, as required.
1
Fig. 33-26 Remove cover assy (1)
(1) Installing is done in the reverse order of removing.
(2) Tightening torque
Unit : N.m (lbf.ft)

Size Capscrew Sems bolt
M8 - 23 (17)
M10 - 46.5 (34.3)
M12 121 (90) 80 (59)
33-12
33. UPPER STRUCTURE
33.1.5 UNDER COVER
33.1.5.1 REMOVAL
(1) Remove under cover (1,2,3,4,5,6,7,8)
1) Remove attaching sems bolts (9) M12×30 and (10) M12×25.
2) Remove covers.
: 19 mm
8
1
4
10
10
2
10
9 3 10
10 7
5
9
6
Fig. 33-27 Under cover assy
(1) Install under cover (1,2,3,4,5,6,7,8)
: 19 mm
33-13
33. UPPER STRUCTURE
33.1.6 FUEL TANK

(1) Draining fuel. (See Fig. 33-30)
1) Unlock cap (B2) with a starter key and open it.
2) Loosen valve (A8) under the tank.
3) Draining fuel
Capacity of tank : 367L (97gal)
(2) Remove stay (7) and guard (2).
(See 33.1.4 GUARD)
(3) Remove the connector for level sensor (A4).
(See Fig. 33-30)
(4) Disconnect the connector of automatic fuel stop 8
switch (12). 12
CONNECTOR 14
(5) Removal of fuel feed hose
6 6
: 19 mm
2) Loosen clip (8) and disconnect hose (14).
3) Install the plug which fits to hose bore.
(6) Remove the connector of fuel feed pump (1) from 1

the tank.
Fig. 33-28 Removing fuel feed hose (14)
(7) Remove fuel hose
1) Loosen clip (16),(23) and draw out hoses (24)
and (7).
2) Put in plugs that match the hose bore.
14
21
27
7
Fig. 33-29 Removing fuel hose (7), (24)
33-14
33. UPPER STRUCTURE
33.1.6.2 REMOVAL
(1) Remove 4 capscrews (A1) M16×40.
B2
: 24 mm
(2) Hook the wire to the lifting eye on the fuel tank assy
A4
(C1) and remove the fuel tank.
Weight : 102kg (225 lbs) C1
A6
(3) Remove shim (A3).
Record the shim locations.
A3
A1
A8
Fig. 33-30 Removing fuel tank
Tank attaching bolt (A1) M16×40
: 24 mm, Apply Loctite #262

If the gap (looseness) between tank mount and frame

exceeds 1mm (0.04inch), adjust the gap with shim (A3)
and tighten capscrew (A1) to install the tank.
Tightening torque
No. Name Q'ty N.m (lbf.ft)
A1 Capscrew 4 191 (140)
A6 Machine screw 5 1.96 (1.4)
A8 Cock 1 34 (25)
6 Sems bolt 2 80 (59)
33-15
33. UPPER STRUCTURE
33.1.7 HYDRAULIC TANK

(1) Remove panel assy (2), guard (6) and other guards $
necessary to remove the hydraulic oil tank.
(See 33.1.4 GUARD.)
Fig. 33-31 Remove guard

(2) Release internal pressure of tank
Remove cap on air breather and push valve (head
of bolt) by your finger.

Keep pressing until the hissing stops.
Fig. 33-32 Bleeding internal pressure of tank
(3) Remove cover (C2).
C5
1) Remove 6 sems bolts (C5) M10×25. C5
: 17 mm C3
2) Remove cover (C2). C2

3) Remove suction strainer (B2).
(4) Remove cover (C3).

1) Remove 6 capscrews (C5) M10×25.
: 17 mm B
2) Remove cover (C3). B2
3) Remove filter element (B6). C
D
(5) Turn the handle of element assy (B), and B6 Air
breather
disassemble the removed filter element (B6). D
Disassemble parts : (B), (C), (D)×2, (E), (F)
E
(6) Draining hydraulic oil
F Hyd.tank
Place pump in tank and draw up hydraulic oil.
Capacity of tank : 146 L (39gal)
Fig. 33-33 Remove cover (C2), (C3)
33-16
33. UPPER STRUCTURE
33.1.7.2 REMOVAL
(1) Draw out the suction hose (A3)
Remove 2 clips (A19) of the tank side and pull out
hose (A3).
2 : Flat-blade screwdriver
A19
At installing suction hose, A3
apply PERMATEX to the
inner end of both hoses. A12
Fig. 33-34 Removing and installing the suction

hose
(2) Disconnecting the main pipe return hose
Remove sems bolt (15) M8×35 and remove return
hose (3).
9
: 17 mm 6
S/M
(3) Remove drain hose (6) of pump Dr
: 36 mm
C/V
T2 15
H/P
(4) Remove drain hose (9) of swing motor 3 Dr
Fig. 33-35 Removing main piping return hose

: 27 mm
(5) Disconnecting pilot return hose

1) Remove pilot hose (A1).
: 22 mm
A1
2) Remove pilot hose (A10).

C/V
: 22 mm DR A13
PT
T
3) Remove pilot hose (A13). S/V
T
A10
: 22 mm
Fig. 33-36 Remove pilot return hose
(6) Remove drain hose (2) of pilot pump
: 22 mm
Fig. 33-37 Removing pump drain hose
33-17
33. UPPER STRUCTURE
(7) Remove hydraulic tank attaching bolt

Remove 4 capscrews (A1) M16×40.
: 24 mm
(8) Slinging hydraulic oil tank

Place a wire sling, using the lifting plate on top of
the tank.
Tank weight : Approx : 140kg (310 lbs)
(9) Remove shim (A3). A3
A1
Fig. 33-38 Removing hydraulic tank
Record the shim locations.
(1) Cleaning hydraulic oil tank
(2) Cleaning suction hose
(3) Cleaning mount of tank.
Installing is done in the reverse order of removing.
(4) Install 4 mounting capscrews (A1) M16×40 with
Loctite #262. (See Fig. 33-38.)
: 24 mm, Apply Loctite # 262

If the gap (looseness) between tank mount and frame

exceeds 1mm (0.04inch), adjust the gap with shim (A3)
and tighten capscrew (A1) to install the tank.
33-18
33. UPPER STRUCTURE
(5) Connection of suction hose (A3)(See Fig. 33-34) O-RING

1) Apply PERMATEX on pipe side of hose
connection and insert it.
2) Put the hose with clip (A19).
Tightening torque : 5.39 N•m (4.0 lbf•ft)
C
(6) Assembling return element
Assemble filter element by the use of element kit
(B-100). (See Fig. 33-33,Fig. 33-39)
D
B2 SUCTION
1. Two elements (D) are used as one set. STRAINER
YW50V00004F7
2. Replace O-ring (C) and packing (F) with new ones F
respectively.
ELEMENT KIT
(7) Install return element. (See Fig. 33-33) YN52V01008R800
(8) Installing suction strainer (B2)
(9) Tighten sems bolts (C5) M10×25 that attach tank
covers (C2), (C3). Fig. 33-39 Element & suction strainer
M10 Tightening torque : 46.1 N•m (34 lbf•ft)
Replace O-ring fitted on the back side of tank cover with

new one.
33-19
33. UPPER STRUCTURE
33.1.8 HYDRAULIC PUMP

(1) Release pressure in hydraulic oil tank.
C5
(See 33.1.7HYDRAULIC TANK)
(2) Remove six capscrews (C5) M10×25.
C2
(3) Remove cover (C2)
Suction
: 17 mm stopper
(4) Take out suction strainer.

(5) Install suction stopper.
Suction
For suction stopper, see chapter 11. Tools. strainer
Hyd.tank
Fig. 33-40 Suction stopper installing

(6) Remove guards
1) Remove bonnet assy (1).
2) Remove guard (5), (14), (15), (17) and guard
assy (16).
1
3) Remove those parts that are required to remove
14 5
the hydraulic pump such as the fuel filter assy.
4) Remove drain hose at the bottom of the muffler. 17
16 15
Fig. 33-41 Removing guards
33-20
33. UPPER STRUCTURE
33.1.8.2 REMOVAL
(1) Loosen sems bolts (13) M12×40 and remove half A13
clamp (A10). And disconnect 2 hoses (A1), (A2) A1
from the delivery side. A10
A13 A2
: 17 mm
A10
(2) Remove pilot pump suction hose (1) C/V
P2 6
(See Fig. 33-43) A13
A2 A4
A10
: 36 mm
A1
(3) Remove suction hose (A3) and drain hose (6) A13 Dr
a2
1) Remove 4 capscrews (B2) M12×30. A10
a1
C/V
: 10 mm P1
A3
2) Remove elbow (B1) of suction hose (A3) from PH2
PH1
pump.
3) Remove drain hose (6) (Dr).
B1
: 36 mm
B2
Fig. 33-42 Removing hoses
(4) Removing other hoses
2 A3
1) Disconnect hoses of the following ports. Dr3
Hose
Port No. Tool Remarks
Dr3 3 22 Drain 3
B3
*Psv1 4 19 Pilot primary pressure P1 side Psv2
Psv1
*Psv2 2 19 Pilot primary pressure P2 side
B1 A11
Psv1 A11 22 Pilot pump delivery 1 SOL/V
P1
Fig. 33-43 Removing other hoses
Remove the parts marked * only if necessary.
2) Attach tags to hoses to identify.

3) Put a plug in the hoses and the pump.
33-21
33. UPPER STRUCTURE
(5) Remove connector Tightening torque 25.5N.m

Remove 4 connectors of all pressure sensors and PSV-P1: SEMS BOLT (19 lbf.ft)
P1 pump proportional valve
proportional valves.
PSV-P2:
Engine P2 pump
side proportional
valve
CLIP
SE-22: Using Zip-tie, clamp
Pressure sensor : the corrugated part of
P1 pump harness to the solenoid.
CLIP SE-23:
Using Zip-tie, clamp the corrugated Pressure sensor :
part of harness to the pressure sensor. P2 pump
Fig. 33-44 Removing connector
(6) Remove main pump 3 0
1) Put a wire sling on the hydraulic pump and
tension the wire sling a little. Loosen 8
capscrews (4) M10×30.
: 17 mm
2) Draw out the power take-off assy from the
flywheel housing slowly, adjusting the tension of 4
the wire rope.
On that occasion, the assembly is drawn out with
the insert NA (2-3) remaining on the flywheel 2-5
side. 2-4
3) Remove element (2-1) from the tip of the spline
shaft.
4) Remove 4 capscrews (2-5) M16×50 that fasten 2-6
insert R (2-4) and remove insert R (2-4).
2-2 1
: 14 mm
2-5
5) Remove hub (2-2)
If you loosen 2 set screws (2-6) M16×22, hub 2-3
2-7 2-1
comes off from the spline shaft of the pump.
Fig. 33-45 Removing pump
: 8 mm
6) Remove 4 capscrews (2-5) M16×45 that fasten
the insert NA (2-3) with the engine side flywheel,
as necessary. Then remove and spring pin (2-7)
from insert NA (2-3).
: 14 mm
7) Removing bracket (1)
Loosen 4 capscrews (3) M20×55, and remove
bracket (1) from pump (0).
33-22
33. UPPER STRUCTURE
(1) Installing bracket (1)
Tighten bracket (1) with capscrew (3) and install
bracket temporarily.
: 17 mm
Tightening torque : 431 N•m (318lbf•ft)
Apply Loctite #262
(2) Installing hub (2-2)
Put hub (2-2) into the pump spline till it enters 3mm
(0.12in) from the end face of the spline (See Fig.
33-46 Detail aa). Then install two set screws (2-6)
and fix them together.
: 8 mm
(3) Installing insert R (2-4)
Install insert R (2-4) into hub (2-2) by means of
capscrews (2-5).
: 14 mm
Tightening torque : 210~230 N•m (155~170 lbf•ft)
(4) Installing element (2-1)
Put element (2-1) into hub (2-2) and insert R (2-4).
(5) Installing insert NA (2-3)
Put spring pin (2-7) into insert NA (2-3) and install it
to the engine flywheel by means of capscrews (2-
5).
: 14 mm
Tightening torque : 210~230 N•m (155~170 lbf•ft)
(See Fig. 33-45 about above mentioned (1) ~ (5).)
33-23
33. UPPER STRUCTURE
(6) Installing the pump (See Fig. 33-45,Fig. 33-46)

Lift the pump with bracket (1). Place coupling (2) in
the groove of element (2-1) so as to receive insert

NA (2-3).
(7) Coat 8 capscrews (4) M10×35 with Loctite #262
and put them in place.

: 17 mm
Tightening torque : 64.7N•m (48 lbf•ft)

(8) Fasten hoses (A1), (A2) on the delivery side with
%
half clamp (A10) and sems bolt (A13) M12×40. 45&$
6 5$

.

(See Fig. 33-42)

: 17 mm " , -.
/ /0 . 1 0
2/ 1 .- ,3
Tightening torque : 62.2N•m (46 lbf•ft) %

(9) Install suction hose (A3) with 4 capscrews (B2)
M12×30. (SeeFig. 33-42)

: 10 mm !

(10)Install the hydraulic piping by referring to
"HYDRAULIC SYSTEM".
!
(11)Installing the hose (See Fig. 33-43) "&$
'(# )
"#$ *$#+ $

Fig. 33-46 Installing hydraulic pump
" !

! # #$
(12)Installing pressure sensor connector and
proportional valve connector.
(13)Remove suction stopper
(14)Install suction strainer
When the pump is replaced, replenish more than 1L

(0.26gal) of hydraulic oil from the drain port (Dr).
(15)Bleed air in pump

Dr
Bleed air by loosening the drain port (Dr).
(16)Check hydraulic oil level.
(17)Start engine and check it for oil leak and noise.
(18)Attach drain down pipe under engine muffler.
(19)Install guards
(See Fig. 33-41,Fig. 33-19)

Fig. 33-47 Bleed air port (Dr) in pump

33-24
33. UPPER STRUCTURE
33.1.9 AIR CLEANER

(1) Opening bonnet assy (21) and (23).
(See 33.1.4 GUARD)
(2) Open bonnet assy (11).
(See 33.1.4 GUARD)
(3) Remove Panel assy (3).
(See 33.1.4 GUARD)
(4) Unplug terminals on indicator (1-8) wiring. 31
(See Fig. 33-49)
3
23
21
Fig. 33-48 Preparation for removal
33.1.9.2 REMOVAL
(1) Pulling out hose (3).

1) Loosen clips (5), (6) on both sides of hose (3).

2) Pulling out hose (3)

: Flat-blade screw driver
(2) Remove air cleaner assy (1)

1) Remove 4 sems bolts (8) M10×25

: 17 mm

2) Remove air cleaner assy (1) from plate (4).

Fig. 33-49 Removing air cleaner
(1) Installing is the reverse order of removing with Replacing parts
attention paid to the following items:
1) Put in air hoses (2), (3) to the end as shown in
Fig. 33-49.
2) Tightening torque :
O RING (1-6)
No. Name Tightening torque N.m (lbf.ft) (YN11P00029S006)
1-8 Indicator 3.9 (2.9) FILTER ELEMENT (1-3)

(YN11P00029S003)
8 Sems bolt 39.2 (29) (Apply Loctite #262)
5,6,7 Clip 5.9 (4.4) FILTER ELEMENT (1-2)
(YN11P00029S002)
33-25
33. UPPER STRUCTURE
33.1.10 MUFFLER

(1) Remove bonnet assy (11) and guard (5).
11
(2) Remove panel assy (22). 5
(3) Remove guard (14), (15), (17) and guard assy (16). 22
(See Fig. 33-19)
33.1.10.2 REMOVAL
(1) Remove U bolt (4).
1 4
: 13 mm
2) Remove 2 U bolts (4).
(2) Remove clamp assy (5) 9
5
1) Remove 2 capscrews (9) M10×35
: 17 mm A
11 2 8
2) Separate clamp assy (5) from muffler (1). 10
10
(3) Removing other parts
Remove brackets (2) as necessary.
A
: 19 mm
Attach washer (12) to nut (11) side.

Tightening torque: 68.6~98 N.m (51~72lbf.ft)
Tighten nut (11) till the no gap is here between
plates of clamp.
12,11,9
10mm (0.4 in) from
the tip of muffler slit
B
C
A
Procedure of
fastening U bolt Installing clamp side (5)
Fig. 33-51 Removing and installing the muffler
33-26
33. UPPER STRUCTURE
Installing is the reverse order of removing with attention
paid to the following items:
(1) Procedure of fastening U bolt (4) (See Fig. 33-51)
1) Tighten 4 nuts (A) till there is no space and make
sure that the dimension C is even all around.
2) Tighten nuts (A) to specified torque and confirm
the C dimensions on the right and left once
again.
3) Tighten nuts (B) to specified torque and make
sure that U bolts are not inclined.
Nut A : 8.8 N•m (6.5 lbf•ft)
Nut B : 10.8 N•m (8.0 lbf•ft)
(2) Installing clamp assy (5)
1) Place the end of clamp (5) 10mm (0.40in) away
from the tip of the muffler slit so the joint of clamp
does not extend over the slit in the muffler. (See
Fig. 33-51)
2) Install the clamp assy (5) in the illustrated
direction.
(3) Tightening torque :

!"!
(4) Replacing parts

33-27
33. UPPER STRUCTURE
33.1.11 COUNTERWEIGHT
33.1.11.1 REMOVAL
(1) Lifting up counterweight temporarily
Hook wire rope to slinging plate, and lift it and
stretch wire rope to the degree where it is providing
no slack temporarily.
Weight of counterweight ;
Approx. 4,640kg (10,230 lb)
Wire more than ø16 (0.63 inch) ;
1.5m (5ft)×2 pcs.
(2) Removing counterweight
1) Remove 4 capscrews (A1) M27×355.
Fig. 33-52 Lifting up counterweight
: 41 mm
2) Remove shim (A3), (A4), (A5). (Select)
3) Remove counterweight (C1).
C1
A5
A4
A3
A2
A1
Fig. 33-53 Removing counterweight
(1) Install counterweight in the reverse order of
removing.
(2) Install shim (A3), (A4), (A5) as it was. (select)
(3) Slinging counterweight
Check that the attaching bolts can be screwed in by
hand. A3,A4,A5
(4) Apply Loctite #262 on capscrews (A1), and tighten
them with washers (A2).
: 41 mm
(5) Remove slinging tools.
A1,A2
Fig. 33-54 Fastening the counterweight attaching
capscrew
33-28
33. UPPER STRUCTURE
33.1.12 RADIATOR & OIL COOLER

(1) Bleed air from the hydraulic tank and install the
suction stopper.(See 33.1.7 and 33.1.8)
(2) Remove bonnet assy (11)
(See 33.1.4 GUARD)
(3) Remove battery (See 33.1.3 BATTERY)
4
(4) Remove beam (4). (See 33.1.4 GUARD)
(5) Open panel assy (21). (See 33.1.4 GUARD)
(6) Removing under cover installed on lower side of
radiator.
10
Fig. 33-55 Removing under cover (4)
2) Remove cover (4).
19
Clip 13
: 19 mm
19
(7) Drain down of radiator
Put container 18L (4.8gal) under drain valve hose 8 12
for draining water. 1
[Water capacity of radiator : 5.5L (1.5gal)]
(8) Remove hose from radiator sub tank (1) A
Remove clip of radiator cap side and disconnect
hose (8).
A
Fig. 33-56 Removing hose of sub tank (1)
Do not loosen the joints of the hoses related to the air-

conditioner. Otherwise the refrigerant leaks.
(9) Move air-conditioner condenser and receiver tank A
1) Loosen 2 sems bolts (23) M8×25 and 2 sems

bolts (6) M10×25.
: 13 mm, 17 mm
2) Move a set of air-conditioner condenser and
receiver tank. 23
34
(10)Disconnect connector of coolant level switch (B5).
(See Fig. 33-58)
Tightening torque
46.1N.m (34 lbf.ft)
6
35
Fig. 33-57 Moving condensers and receiver tank
33-29
33. UPPER STRUCTURE
33.1.12.2 REMOVAL
(1) Remove radiator stay (A1).
B10
1) Remove a sems bolt (A2) M12×35 and 3 sems
bolts (A3) M12×30.
: 19 mm
2) Remove 2 stays (A1). B5
A3
B9
(2) Remove water hose (2),(3) A1
B1
1) Loosen the hose bands (30) for water hose (2).
A
: Flat-blade screwdriver
2) Remove hose (2). A3 A3
A2
3) Loosen hose band (30) on water hose (3) and
A1
remove capscrew (22) M10×25.
A2 B
: 17 mm
4) Remove hose (3).
A
Fig. 33-58 Removing radiator assy

(3) Remove hoses (4)(5) for inter-cooler 11 17 23
15 C
1) Remove two fixing U-bolts (17) from tube (11). 6
30 19
23 17
: 13 mm D
19
2) Loosen sems bolt (21) M10×20. 21
C 30
: 17 mm 33
E
B 4
3) Loosen hose bands (30), (31) and remove hose
31
(4).
2
E 29
D 31
4) Loosen hose bands (30) and remove hose (6).
30
30 B 3
5
5) Loosen hose bands (31) and remove hose (5).
22
22
30
31
Fig. 33-59 Removing hose for radiator/inter-cooler

(4) Remove guard (12), (13) (See Fig. 33-56)
1) Remove 4 sems bolts M8×20.
2) Remove guard (12), (13).
: 13 mm
33-30
33. UPPER STRUCTURE
(5) Disconnecting hydraulic oil hose (1), (2)

1) Loosen 2 capscrews (16) M12×55 for attaching 15 OUT
clamp (13). 1 C/V
T2
2) Place an oil pan under the hose joint. Loosen 4 13 C/V
16
sems bolts (15) M12×35, and remove hoses (1) T1
and (2). 2
(6) Remove radiator assy. (See Fig. 33-58)
13
1) Remove 4 sems bolts (A2) M12×35. 16 A2
IN
: 19 mm 15
: 19 mm
Fig. 33-60 Removing hydraulic oil hose (1), (2)
2) When lifting the engine fan, shift the radiator so
it does not interfere with the engine fan.
3) Plug up pipe ends with clean cloth, etc.
4) Removing radiator
Place a wire sling in the lifting eyes of the radiator
assy and remove the assy by crane.
33-31
33. UPPER STRUCTURE
And removed clips of hose should be clamped at
original position.
(2) Install radiator assy
Place a wire sling in the lifting eyes of the radiator
Insert width Insert width
and move it to original position temporally. And of hose of hose
install hydraulic hose, radiator hose and hose of
(1.3
inter-cooler. Regarding Inserting width of hose. 35 8in)
(See Fig. 33-61) CLIP
)
(1.57in Torque
(3) Radiator attaching bolt 40
5.9N.m
(4.4 lbf.ft)
Apply Loctite #262 on 4 semsbolts (A2) M12×35.
: 19 mm
(1.77in)
45
(1.57in)
40
(4) Adjust the clearance between the fan and the Insert width
of hose
radiator shroud all around the circumference, as
below :
Circumferential direction: 40 (1.57in)
CLIP
Torque
20±5mm (0.8in±0.2in) 5.9N.m (4.4 lbf.ft)
39±5mm (1.5in±0.2in) Fig. 33-61 Inserting width of hose
(5) Clean the plastering area of the insulation

thoroughly before plastering it.

(6) Making up hydraulic oil and LLC (Long Life
Coolant)
After completion of other installation, make up
hydraulic oil and water.
Coolant volume of engine body : 9 L (2.4gal)
Coolant capacity of radiator : 5.5 L (1.5gal)
Hydraulic oil capacity of oil cooler : 2.4 L (0.63gal)
Fig. 33-62 Back-and-forth adjusting position of

radiator
33-32
33. UPPER STRUCTURE
33.1.12.4 PROCEDURE OF DISASSEMBLING AND ASSEMBLING THE RADIATOR/INTER COOLER CORE

(1) Preparation for disassembly and assembly
! ! ! ' '
1) Remove one under cover at the bottom of the
radiator.
2) Wait till the engine coolant cools down so you do
not get burned. Then remove the cap of the
radiator, discharge the coolant by opening the
drain valve located at the back bottom and
receive it in a container.
! "
* In case of removing inter cooler only, the above # $% %&

mentioned work is not necessary.
(2) Disassembly
1) Loosen each 2 bolts (30), (31) at head and
bottom of shroud, remove upper plate (27) and
lower plate (28).
2) Disconnect wiring connector of radiator coolant

level switch.
3) Loosen 4 sems bolts (9) M8×20 attaching plate
assy (10), remove plate assy (10).
4) Loosen 2 capscrews (15) M10×30 attaching
radiator core.
5) After confirming that the coolant has been
drained out completely, loosen and remove only
the radiator side of hose bands (30) at the top
and bottom of the radiator. (See Fig. 33-59)
*
++
6) Lift and remove radiator core using lifting eyes
and hoist on the radiator core.
Weight : 10kg (22lbs)
Confirm the missing of rubber bushing (14) )
under the radiator core.
* %
7) Loosen 2 capscrews (15) M10×30 attaching the " ,
top of the inter-cooler core.
8) Loosen and remove only the inter-cooler side of
hose bands (31) at the top and bottom of the
inter-cooler. (See Fig. 33-59)
9) Lift and remove inter-cooler using lifting eyes
and hoist on the inter-cooler.
Confirm the missing of rubber bushing (14)
(
under the inter-cooler.

+ -
Fig. 33-63 Removing radiator and inter-cooler
33-33
33. UPPER STRUCTURE
10) Disconnection of oil cooler hose

Disconnect hose (1), (2) from upper and lower of
cooler, and drain hydraulic oil. (See Fig. 33-60)
11) Lift cooler temporally using cooler head flange
for slinging.
12) Loosen 4 bolts (16) M8×25 attaching oil cooler.
13) Lift the oil cooler.
There is no predetermined sequential order in

removing radiator core, inter-cooler core and oil cooler.
Removing these components can be done as
necessary.
(3) Installing
33-34
33. UPPER STRUCTURE
33.1.13 ENGINE
33.1.13.1 PREPARATION FOR REMOVING

(1) Remove battery ground (See 33.1.3 BATTERY)
(2) Remove bonnet and guard (See 33.1.4 GUARD ) Remove under cover (See 33.1.5 UNDER COVER)
(3) Remove air cleaner hose (See 33.1.9 AIR CLEANER)
(4) Remove counterweight (See 33.1.11 COUNTERWEIGHT)
(5) Remove radiator hose and inter-cooler hose (See 33.1.12 RADIATOR & OIL COOLER)
(6) Remove fuel hose and heater hose, and if necessary disconnect air-con hose.
(7) If necessary, remove pump, muffler and radiator.
(8) Remove harness connector (Refer to ELECTRIC SYSTEM)
1) Remove E/G ground cable
2) Starter cable-Starter B terminal
3) Remove the connector that connects the upper harness with the engine and ECU harness.
4) Upper harness
CN-206-E/G sub harness
P5-Alternator B terminal
CN-136-E/G speed sensor
CN-141, CN142-Pump proportional valve
CN-139, CN-140-P1,P2 pump pressure sensor
CN-212-Glow
P3-Starter motor C terminal
Prepare a stand, which withstands the weight of the engine assy and can place the removed engine firmly. (Refer
to Tools)

Fig. 33-64 Outside view of engine
33-35
33. UPPER STRUCTURE
33.1.13.2 REMOVAL
27
27
14
14 Pin
11
17 10
2
* 25 11
12
3 26
C
B
16
27 10 23
25
14
11
* 12
14 20
27 11
36 20
10 5 26 12
3
20 A
25 A
10 23
12 20 22
28 30 16
A D
2
17 D
2
1
* 5
B C
Fig. 33-65 Dismantling and mounting engine

(1) Remove hose of engine oil filter
Place oil pan under the connection of filter (1), and disconnect hoses (2), (16), (17) at positions. (2) Plug
connector of filter side and hose.
: 17 mm, 41 mm
(2) Plug connector of filter side and hose.
(3) Loosen engine mounting bolt of frame
1) Loosen 4 nuts (20) M18.
: 27 mm
2) Loosen 4 capscrews (27) M18×150.
3) Remove 4 plates (14).
4) Remove upper rubber mounts (10) and (11) 2 each.
(4) Slinging engine body
Prepare a stand, which withstands the weight of the engine assy and can place the removed engine firmly. (Refer
to "Tool".)
1) Sling engine hooking wire to lifting lugs on the front and rear sides.
Weight: Approx. 580 kg (1,280 lbs)
Wire: ø6 (0.236")×1m (3ft 3in) - 2pcs.
(5) Position engine on the stand stably.
33-36
33. UPPER STRUCTURE
%!&'(!(&
)*
+
+ #$
+ ,,

!

"

!

"

!

"

!

"

!
"

!

"

!" #
!" #
$% !%# '( !$#
& )% !$#
33-37
33. UPPER STRUCTURE
33.1.14 CONSOLE COVER
33.1.14.1 REMOVAL
(1) Removing right-hand console cover
1) During pushing 4 locked claws of boot retaining
plate (4) with flat-blade screw driver, lift the plate
(4) and remove it.

: Plus screw driver
3) During lifting right upper console cover (3A) up;
disconnect connector of tuner and antenna.

Move boot (3) upwards and remove console
cover (3A).
• Removing of boot and lever is unnecessary. Fig. 33-66 Removing plate (4)
4) Loosen 3 sems bolts (16A) M6×15 and remove 16
lower console (4). 3A
: Plus screw driver 16
(2) Removing left-hand console cover 16A
16B
1) Remove the boot retaining plate (4) in the same
way as right-hand console cover. (See Fig. 33- 5 16B 4 16A
66) 16B
16C
2) Loosen 2 sems bolts (A6) M8×20 and remove left
armrest assy.
6
: 13 mm
3) Loosen 4 sems bolts (16B) M6×15.
: Plus screw driver
4) Remove the left upper console cover (5) in the
same way as right-hand console cover.
5) Loosen 2 sems bolts (16C) M6×15 while lifting
left under console cover (6) up, and remove left Fig. 33-67 Removing console covers
lower console cover.
Install it in reverse order of removing according to the
tightening torque table.
A6
Item Bolts Tightening torque N.m (lbf.ft)
16~16C Sems bolt M6 8.5 (6.3)

A6 Sems bolt M6 23.5 (17.3)
Fig. 33-68 Removing left armrest
33-38
33. UPPER STRUCTURE
33-39
33. UPPER STRUCTURE

(1) Remove guard (6)
(See 33.1.4 GUARD)
(2) Remove under cover (5).
(See 33.1.5 UNDER COVER)
(3) Install the suction stopper to the hydraulic oil tank. 1
(4) Remove the hoses in Fig. 33-70 and Fig. 33-71.
Tightening torque
Mark each hose with a port name before removing it. 284N.m(209 lbf.ft)
4 Tightening torque
235N.m (173 lbf.ft)
Fig. 33-69 Removing the standard main control

valve
33.1.15.2 REMOVAL
(1) Remove 3 capscrews (4) M16×45, and remove
control valve (1) by hoist.
: 24 mm
Weight :Approx. 232kg (512 lbs)
(1) Installing is done in the reverse order of remove.
1) Install control valve by tightening 3 capscrews (4) M16×45.
: 24 mm
2)
Connector / Bolt Hose nut
Tread
size Ports Opposing Tightening Opposing Tightening Remarks
Name torque torque
flats N.m (lbf.ft) flats N.m (lbf.ft)
Pss,PLc2,PBp1,PBp2,PL,
PF1/4 PB1,PTb,PCa,PCb,PCc 19 36 (27) 19 29 (21)
ORS Joint
PAa1,PBa1,Pab,PBb,Pac,
PBc,PAL,PBL,Par,PBr,Pas,
PF3/8 PBs,PAa2,PBa2,Pao,Pbo,DR 22 74 (55) 22 49 (36)
PF3/4 MU 36 162 (119) 36 118 (87)
Ar,Br,AL,BL,As,Bs,Aa,Ba,Ac,Bc 14 42.4 (31)
M10 Ab,Bb Sems bolt 14 57 (42)
P1,P2 17 62.2 (45)
M12 T1,T2 17 96 (70)
(2) Check for oil leak and operation.
33-40
33. UPPER STRUCTURE
Functions Ports Ports on upper sides Ports Functions

LEFT RIGHT
P2 bypass cut PBp2 PBp1 P1 bypass cut
Option PAo PBa2 Arm 2 in

Mu Make-up line
Arm (R) relief valve -
- Bucket (R)relief valve
Arm 1 out PBa1
PBb Boom down
Swing (LH) PBs
- Boom (H) relief valve
Boom conflux PB1 PAr Travel right forward
Travel left forward PAL - Main relief valve
Tank return T2 PCb P1 unload
Ports on rear sides (on machine)

LEFT RIGHT
P1 P1 pump
P2 P2 pump
Ports on right sides (on machine)

UPPER SIDE LOWER SIDE
Bucket dump BC
Bucket dump PBc
Bucket (H) stroke limit PCc AC Bucket digging
Boom up Ab Bb Boom down
Drain Dr BR Travel right reverse
Travel right forward AR
ATT power boost PL
Fig. 33-70 Control valve ports (1/2)
33-41
33. UPPER STRUCTURE
+!

+!
&'% * '%
()' ()'
!
#

!

# !

'+ ()' %(," ()'

$
!
$ !
"
%

!# "

!#

Fig. 33-71 Control valve ports (2/2)
33-42
33. UPPER STRUCTURE
33.1.16 PILOT VALVE (FOR ATT)

The removing procedure for right and left is the same,
so the preparation for left side is described here.
(1) Put attachment on ground, stop engine and release
pressure in tank.
(2) Remove left console cover (5), (6) assy referring to
Section 33.1.14CONSOLE COVER.
3
(3) Disconnect harness connector for horn at 2-1
position.
5
(4) Attach a tag to the hose to make assembly work
easier. *
Fig. 33-72 Installing and removing boot and lever

part
33.1.16.2 REMOVAL
(1) Remove hoses from your side to far side in order. !
: 19 mm, 22 mm
(2) Move the boot (3) up and loosen nut (5).
(See Fig. 33-72)

: 22 mm

(3) Turn and loosen lever (2-1) tightened in pilot valve,
and remove lever assy in a set. (See Fig. 33-72) *+, *!+
%& '
( ""'

(4) Remove 4 capscrews (A14) M6×25. (See Fig. 33- % ' ""'

73) % ' !
: 5 mm -%. /*/
(5) Remove pilot valve. *+, *!+
(6) Plug hose ends.
" ##
Plug PF1/4, PF3/8 )' '
( $

! 01 0 " ##
Fig. 33-73 Pilot valve connector
Install it in the reverse order of removal and tighten it. Front of machine
T Arm (R) Boom (R)
: 5 mm T = 11.8 N•m (11 lbf•ft) capscrew (Green) T (Gray)
(A14) Bucket (R)
Swing (R) (Blue)
(Red)
Swing (L)
(Gray)
Make sure the tightening torque for capscrews, Bucket (H) P

(Red)
because pilot valve is made of aluminum. Arm (H) (Blue) P
Boom (H) (Green)
LEFT SIDE RIGHT SIDE
Fig. 33-74 Pilot valve port position (from upper
side)
33-43
33. UPPER STRUCTURE
33.1.17 PILOT VALVE (FOR TRAVEL)

(1) Release pressure in hydraulic oil tank (See 33.1.7
HYDRAULIC TANK)
(2) Remove under cover (1) (See 33.1.5 UNDER
COVER)
A1
(3) Remove floor mat (B1). A8
A2 A7
A6
A7
A5
B1
A8
Fig. 33-75 Removing floor mat, pedal and and lever
33.1.17.2 REMOVAL
(1) Separate the two pressure sensors SE-9 (A9) and
SE-10 (A9) at the connector. %
4 () "56)
: 24 mm 27 &82*
0%
(2) Attach tag, and discount connectors and hoses .
(A2), (A3), (A4), (A5) 1.23 &*
% - 1/ &*
: 19 mm (P port)
: 22 mm (T port, 1~4 port) 0/
-

(3) Plug hose ends
1/ &*

"
Plug PF1/4, PF3/8

(4) Remove 4 sems bolts (A8) M8×20, and remove
+,
+/

right and left pedals (A5), (A6).
+,
: 13 mm +

(5) Remove 4 sems bolts (A7) M10×20 and remove
right and left lever (A1), (A2).

: 17 mm

(6) Remove 4 sems bolts (A11) M10×30.

: 17 mm % !"# $$
(7) Remove pilot valve lifting it upward.
(8) Stop up holes with plugs PF1/4.

&'( )"*
Fig. 33-76 Installing and Removing pilot valve
33-44
33. UPPER STRUCTURE
Install it in the reverse order of removal and tighten it.
Sems bolt (A11)
: 17 mm T = 37 N•m (27.3 lbf•ft)

Sems bolt (A7)
: 17 mm T = 46.1 N•m (34.0 lbf•ft)

Sems bolt (A8)
: 13 mm T = 23.5 N•m (17.3 lbf•ft)

Pressure sensor
: 24 mm T = 16.7 N•m (12.3 lbf•ft)
33-45
33. UPPER STRUCTURE

(1) Park machine on firm level ground and place
attachment on ground.
(2) Remove the guard (6).
(See 33.1.4 GUARD)
(3) Operate the switch on gauge cluster and select the
pressure release mode, and then release the inner
pressure in circuit by operating control lever. (See
22.11 HYDRAULIC SYSTEM PRESSURE
DRAINING(RELEASING) CIRCUIT)
(4) Bleed air from the hydraulic oil tank and attach to
each hose a tag showing port name and other
information.
33.1.18.2 REMOVAL
(1) Remove hose. 8
S/J 9
1) Remove hose (7) from the connector in the E
makeup port M. C/V

MU
H/D TANK
: 36 mm Dr
7
2) Remove 2 hoses (8), (9) from the Tee in the drain
port Dr. M
: 27 mm
3) Remove hose (3) from the elbow of the PG port
(For swing parking brake) (See Fig. 33-78)
B
A
: 19 mm
4) Remove 2 hoses (A4), (A7) from the connectors
of the A, B port.
A7
: 36 mm
A4 C/V
Put in plugs PF3/4, PF1/2, and PF1/4 into the Bs C/V
As
removed ports.
Fig. 33-77 Removing swing unit piping
2 2
1
PG
A17
A3
Fig. 33-78 Removing swing unit
33-46
33. UPPER STRUCTURE
(2) Removing the swing unit

Remove 13 capscrews (1) M20×55.
: 30 mm
1) Remove two plastic caps (2) M12 at the top of
the swing motor and install eye bolts.
2) Put a wire sling in the eye bolts and remove the
swing motor unit.
Weight of swing motor unit ;
Approx. 192kg (423 lbs) (Include reduction assy)
33.1.18.3 PREPARATION FOR INSTALL

(1) Clean mating surfaces of swing motor unit and upper frame.
Tools : spatula, wash oil
(2) Apply Loctite #515 on entire mounting surface of swing motor unit.
Install the swing motor unit in the reverse order of
Coat all the mounting surface of 1
disassembly, confirming the orientation of the swing the swing motor with Loctite #515
equivalent.
motor unit.
(1) Tighten 13 capscrews (1) M20×55.
: 30 mm Detail of swing motor unit assy mount

Tightening torque : 539N•m (400 lbf•ft) Apply Put sealing tape on the both sides
Loctite #262 of thread portion of filling tube.
Tightening torque 108 N.m (80 lbf.ft)
(2) Fill inside from motor drain port to casing with FILLING PORT Apply Loctite #262
hydraulic oil before piping for drain 1 equivalent.
Tightening torque
539N.m (400 lbf.ft)
LEVEL GAUGE
Put sealing tape on the thread
portion of tube for level gauge.
Tightening torque 69.1 N.m (51 lbf.ft)
Fig. 33-79 Installing swing motor unit
33.1.18.5 PREPARATION FOR DRIVE

(1) Before starting operation, check that gear oil #90 (API grade GL-4) level of swing reduction is sufficient.
Amount of oil : 3L (0.8gal)
(2) When starting operation, operate motor in low idling and at low speed for several minutes, and check it for
possible oil leak and noise.
33-47
33. UPPER STRUCTURE
33.1.19 SWIVEL JOINT

Remove boom piping hose
33.1.19.2 REMOVAL
(1) Remove travel motor hose and tube
1) Remove 2 hoses (A16). (E port : PF1/2)
: 27 mm, Tightening torque : 78.5 N•m (58 lbf•ft)

2) Remove tubes (A1), (A2). (C, D port : PF1)
: 41 mm, Tightening torque : 275 N•m (203 lbf•ft)

3) Remove tubes (A3), (A4). (A, B port : PF1)
: 41 mm, Tightening torque : 275 N•m (203 lbf•ft)

4) Remove 2 hoses (A7). (F port : PF1/4)
: 19 mm, Tightening torque : 29.4 N•m (22 lbf•ft)
(TRAVEL MOTOR) (TRAVEL MOTOR)

VB (LOWER) VA (LOWER)
(LH) REVERSE REVERSE (RH)
VA (UPPER) VB (UPPER)
FORWARD FORWARD
T : Tightening torque
of connector
A2 N.m (lbf.ft)
A4
SWIVEL JOINT
T=255
(188)
A7
T=255 (188) B2 T=36.3 (26.8)
A7
A3
A1
A16
T=108 (80)
T=108 (80)
A16
Fig. 33-80 Removing piping (lower side)
33-48
33. UPPER STRUCTURE
(2) Disconnecting the hoses on the top part of swivel

joint
)$
1) Remove drain hose (8). (E port : PF1/2)
: 27 mm
Tightening torque : 78 N•m (58 lbf•ft) &
2) Remove hoses (A8), (A5).
(A, C port : 1-3/16-12UN)
)'
: 36 mm
3) Remove hoses (A9), (A6).
(B, D port : 1-3/16-12UN)
: 36 mm
4) Remove hose (A7).
(Travel 2-speed change over port : PF1/4)
)#
)&
: 19 mm
)%
Fig. 33-81 Disconnecting the hoses on the top part

of swivel joint
(3) Remove whirl-stop of swivel joint.

1) Loosen the nut (36) M24.
2) Remove a capscrew (35)M124×130.
: 36 mm

!

Fig. 33-82 Removing whirl-stop nut & the capscrew

(4) Remove joint for piping (See Fig. 33-80,Fig. 33-81) Tightening torque
6.8N.m (5 lbf.ft) B9
1) Remove 2 connectors (B2). (F port)
2) Remove connector (1) (F port) for travel 2-speed Tightening torque
B8
change over. (PF1/4) 14.7N.m (11 lbf.ft)
To prevent from
entering water,
: 19 mm apply Loctite 572
(5) Remove seal (B4) or 577 around
this plate (B5).
1) Remove 6 capscrews (B8) M10×25. B5
: 17 mm
2) Remove clip (B9). B4
3) Remove seal (B4). Fig. 33-83 Removing seal (B4)
33-49
33. UPPER STRUCTURE
(6) Remove capscrew for installation

Attach eye bolt, lift it up temporarily, and remove 3
capscrews (C2) M12×25.
: 19 mm & '$
(See 11.7 SPECIAL TOOLS No.9 Plug)
$ %

!" #$!
Fig. 33-84 Removing capscrew for installation

(7) Slinging the swivel joint
Weight : Approx. 28kg (62 lbs)
Piping tightening torque
Tightening torque N.m (lbf.ft)

Size Tool.
PF HEX O-ring type Hydraulic hose
Connector
1/4 19 36 (27) 29 (22)
3/8 22 74 (54) 49 (36)
1/2 27 108 (80) 78 (58)
3/4 36 162 (120) 118 (87)
1 41 255 (180) 137 (100)
1-3/16-12UN 36 - 177 (130)
(2) Check for oil leak and the hydraulic oil level.
(3) Check for operating.
33-50
33. UPPER STRUCTURE
33.1.20 UPPER FRAME

(1) Remove attachment
(See chapter 32)
(2) Remove cab (See 33.1.2 CAB)
(3) Remove guard (See 33.1.4 GUARD)
(4) Remove counterweight

(See 33.1.11 COUNTERWEIGHT)

(5) Remove swivel joint
(See 33.1.19 SWIVEL JOINT)

Fig. 33-85 Temporarily lift upper frame
33.1.20.2 REMOVAL
(1) Lifting up upper frame temporarily

Insert two upper swing body lifting jigs and 2
counterweight fastening cap screws (A1) M27×335
into the counterweight mounting holes from above.
Attach 2 chain blocks to the boom foot side and lift
the upper frame at four points.
Wire rope ;
ø16 (0.630")×2.5m(8ft-2in), 2pcs.
ø16 (0.630")×1.5m(4ft-11in), 2pcs
Chain block ; For 2,000kg (4,410 lbs) 2pcs.
Fig. 33-86 Matching mark on swing bearing and
(2) Marking match marks on swing bearing
upper frame
Put match marks on upper frame and swing
bearing.
(3) Removing upper frame attaching bolts
Remove 32 capscrews M20×100 and a reamer bolt
(11) used to install swing bearing and upper frame.
: 30 mm
(4) Slinging upper frame
Sling according to Fig. 33-85, and remove upper
frame and put it on a stand.
Weight : Approx. 5ton (11,000lbs)
Fig. 33-87 Removing upper frame attaching bolts
33-51
33. UPPER STRUCTURE
(1) Installing is done in the reverse order of removing. Apply Loctite #515 to the race surface
(2) Cleaning mating surfaces of upper frame and swing over the whole circumference (shaded area)
on the inside of capscrew.
bearing.
(3) Apply Loctite #515 to the inside of the capscrews
on the contact surface.
(4) Slinging upper frame
Match marks and install it with a reamer bolt (11)
and a washer (12) temporarily.
Apply Loctite #262

equivalent.
T=392N.m (290 lbf.ft)
Confirm the reamer bolt positions referring to Fig. 33- 11,12
89.
Fig. 33-88 Bearing mount

: 30 mm Apply Loctite #262
Apply Loctite #262
(5) Install swing bearing
Install 32 capscrews (10) M20×100.
: 30 mm Apply Loctite #262

Install a reamer bolt (11).
: 30 mm
Fig. 33-89 Reamer bolt position (*) Apply Loctite to

shaded area
33-52
33. UPPER STRUCTURE
33-53
33. UPPER STRUCTURE
33.2 DISASSEMBLING AND ASSEMBLING

33.2.1 HYDRAULIC PUMP • REGULATOR
33.2.1.1 HYDRAULIC PUMP
33.2.1.1.1 Structural exploded view

(1) Main pump
983 531
981 . 534
548 792
702
B 532
732 X
789 Z
535 W
886 Y
953 A
806
728
468
113
127
123
127
824 271
325 808
717
04 490 954 546901
251 312
725
401 407 490
C
124
727 886
314
717 D
141 546
157 E
156
151 153 885 727
. 886
152 467
B 725
211 466
214 406
212 261 D
774 E
710
F
A
116
724 710
717
313 326
124 F 414 05
111
C
885
Fig. 33-90 Structural exploded view of main pump
33-54
33. UPPER STRUCTURE
Marks in Fig. 33-109 show the position where regulator is installed.
No. Name Q'ty No. Name Q'ty No. Name No.

111 Shaft(F) 1 314 Valve plate (L) 1 724 O-ring ; 1B P8 16
113 Shaft(R) 1 325 Sensor block 1 725 O-ring ; 1B P11 9
116 1st gear 1 326 Cover 1 727 O-ring ; 1B P14 3
123 Roller bearing 2 401 Socket bolt ; M20X210 8 728 O-ring ; 1B P24 4
124 Needle bearing 2 406 Socket bolt ; M8X20 4 732 O-ring ; 1B P18 2
127 Bearing spacer 3 407 Socket bolt ; M6X55 3 774 Oil seal 1
141 Cylinder block 2 414 Socket bolt ; M10X20 4 789 Backup ring P18 2
151 Piston 18 466 VP plug ; PF1/4 2 792 Backup ring G35 2
152 Shoe 18 467 VP plug ; PF3/8 2 806 Nut ; M16 2
153 Retainer 2 468 VP plug ; PF3/4 4 808 Nut ; M20 2
156 Spherical bushing 2 490 Plug ; NPTF1/16 32 824 Stop ring 2
157 Cylinder spring 18 531 Tilt pin ; M24X2 2 885 Valve plate pin 2
211 Shoe plate 2 532 Servo piston ; M24X2 2 886 Spring pin 4
212 Swash plate 2 534 Stopper (L) 2 901 Eye bolt ; M10 2
214 Tilting bushing 2 535 Stopper (S) 2 953 Socket screw ; M16X30 2
251 Swash plate support 2 546 Spacer 2 954 Set screw ; M20 2
261 Seal cover (F) 1 548 Feed back pin 2 04 Gear pump 1
271 Pump casing 2 702 O-ring ; 1B G35 2 05 PTO gear case 1
312 Valve block 1 710 O-ring ; 1B G95 2
313 Valve plate (R) 1 717 O-ring ; 1B G145 4
The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Tightening torque of bolt, plug, nut and servo piston

Tightening torque
No. Thread size
N.m (lbf.ft)
401 M20 430 (317)
406 M8 29 (21)
407 M6 12 (8.9)
414 M10 57 (42)
466 PF 1/4 36 (27)
467 PF 3/8 74 (55)
468 PF 3/4 170 (125)
490 NPTF1/16 8.8 (6.5)
531,532 M24X2 240 (177)
806 M16 130 (95)
808 M20 240 (177)
33-55
33. UPPER STRUCTURE
(2) Gear pump (For pilot)
700 354 351

Suction port : PF3/4 433
Tightening torque : 73.5N.m
(54.2 lbf.ft)
434
Delivery port : PF1/2

Tightening torque :
53N.m (39.1 lbf.ft)
311
312
732 307 850
434 355
Drain port : PF3/8 310 308 309 466
725
710 435 361 353 Tightening torque :
34.3N.m (25.3 lbf.ft)
Fig. 33-91

307 Poppet 1 361 Front case 1
308 Seat 1 433 Flange socket; M8×40 2
309 Ring 1 434 Flange socket; M8×55 2
310 Spring 1 435 Flange socket; M8×20 4
311 Adjust screw 1 466 VP plug ; PF1/4 1
312 Lock nut ; M14×1.5 1 700 Ring 1
351 Gear case 1 710 O-ring ; 1B G95 1
353 Drive gear 1 725 O-ring ; 1B P11 1
354 Driven gear 1 732 O-ring ; 1B P16 1
355 Filter 1 850 Locking ring 1
33-56
33. UPPER STRUCTURE
33.2.1.1.2 Disassembly and assembly of main pump

(1) Tools
The right list shows the tools required for remove

and install.

(2) Disassembling procedure #

1) Selecting a place for disassembly.
• Choose a clean place.
• Spread rubber sheet or cloth on work bench

to protect parts from damaging. $%

!"
&

2) Cleaning
'
( )*+
#
Remove dust and rust, etc. on pump surface with ,-
!"
wash oil. .
,

2* ,
3
)/
! +2
2 3,
0
,

3 -

+ 44
1*

3) Drain oil
REGULATOR
Drain out the oil in the pump casing by removing
drain port plug (466), (468).
: 19 mm, 36 mm
• Drain out oil from the plug of the front pump

and the rear pump.
4) Removing regulator and PTO gear casing

Remove the socket bolts [412, 413, 414 (See
Fig. 33-90, Fig. 33-109)]. Then remove the
regulator and the PTO cover (326).
: 6 mm, 8 mm
• Regarding the disassembly of the regulator,

refer to article of Regulator.
5) Remove gear pump

Remove the socket bolts (435). Then remove the
gear pump (04).
: 6 mm
6) Remove socket bolt (401)
Loosen socket bolts (401) that fasten swash
plate support (251), pump casing (271) and
valve block (312).
: 17 mm
Fig. 33-92 Remove socket bolt (401)
33-57
33. UPPER STRUCTURE
6) Disassembling the pump casing and the valve

312 271
block
Place the pump level on a work bench with its
mounting surface of the regulator facing down.
Then separate pump casing (271) and valve
block (312).
• When facing the mounting surface of the

regulator down, place a rubber sheet on a
work bench so as not to score the mounting
surface.
Fig. 33-93 Disassembling the pump casing (271)
• When the pump casing has been separated and the valve block (312)
from the valve block, draw out the 1st gear
(116) at the same time.
7) Drawing out the cylinder assy %
Draw out cylinder (141) out of pump casing (271)
"##%
in parallel to shaft (111). At the same time draw
out piston (151), plate (153), spherical bushing #!
(156) and cylinder spring (157). #$
• Use care so as not to score the sliding

surface of the cylinder, spherical bushing,
shoe and the swash plate.
Fig. 33-94 Drawing out the cylinder assy

8) Remove seal cover (F)
406
Remove socket bolt (406) M8 and seal cover F
(261). 261
: 6 mm
• The seal cover (F) may be drawn out with

ease if it is taken out by tightening bolts in the
tapped holes (M6 tap) of the seal cover (F).
• An oil seal is fitted to seal cover (F).
Therefore, use care so as not to score the oil
seal.
Fig. 33-95 Removing seal cover F (261)
33-58
33. UPPER STRUCTURE
9) Separating the swash plate support and the

pump casing %
Knock lightly on the mounting flange of swash
plate support (251) from the pump casing (271)
side and separate the swash plate support from #
the pump casing.
Fig. 33-96 Separating the swash plate (251) support

and the pump casing (271)
10) Remove shoe plate and swash plate
Draw out shoe plate (211) and swash plate (212)
%
from pump casing (271).

Fig. 33-97 Removing shoe (211) and swash plate

(212)
11) Drawing out the shaft
Tap lightly the shaft end (111, 113) by means of a #
plastic hammer and draw out the shaft from the
swash plate support.
!
Fig. 33-98 Drawing out the shaft (111), (113)
33-59
33. UPPER STRUCTURE
12) Remove valve plate

Remove valve plate (313, 314) from valve block
(312).
312
• The valve plate may come off during the
operation under 6).
314
(313 :
Opposite Side)
Fig. 33-99 Removing valve plates (313), (314)

13) Remove other parts 531
If necessary, remove stopper (L) (534), stopper
(S) (535), servo piston (532) and tilting pin (531)
from pump casing (271), and remove needle
534
bearing (124) from valve block (312). 806 535
532
• When removing the tilting pin, use care so as

not to score the head of the tilting pin, using
a jig. 808
• It is hard to separate the tilting pin from the
servo piston in some cases as Loctite is 124
312
coated on the mating part between them. 271
Use care so as not to score the servo piston

by applying undue force. 251
• Do not draw out needle bearings except
when their service life has ended.
• Do not loosen hex nuts (806),(808) of valve
block (312) and swash plate support (251). A
set flow rate changes.
Fig. 33-100 Removing other parts
33-60
33. UPPER STRUCTURE
(3) Installing procedure

1) Precautions to be exercised in installation
Assembly is a reverse order of disassembly, but
notice the following.
1. Repair scored parts at disassembly. Get
replacements ready beforehand.
2. Wash parts sufficiently in cleaning oil and dry
them with jet air.
3. Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
4. In principle, replace sealing parts such as O-
rings and oil seals.
5. Tighten socket bolts and plugs to specified
torques in this manual, using a torque
wrench.
6. Do not mix up front pump parts with rear
pump parts.
2) Installing swash plate support
%
Attach swash plate support (251) to pump casing
(271) by tapping the swash plate support lightly
with a plastic hammer.
• When the servo piston, the tilting pin, the

stopper (L) and the stopper (S) have been
removed, install them to the pump casing
beforehand.
• When tightening servo piston and tilting pin,
use a jig so as not to damage the head of the #
tilting pin and feedback pin.
Coat the screwed part with Loctite #262.
Fig. 33-101 Installing swash plate support (251)
3) Installing swash plate #
Place the pump casing with its mounting surface %#!
of the regulator facing down, insert the tilting
bushing of the swash plate into tilting pin (531),
and fit swash plate (212) to swash plate support
(251) properly.
• Confirm by the fingers of your both hands

that swash plate moves smoothly.
• The shaft be installed easily if grease is
applied to the sliding parts of swash plate
and swash plate support.
• Do not damage the sliding surface of shoe
plate. Fig. 33-102 Installing swash plate (212)
33-61
33. UPPER STRUCTURE
4) Installing shaft
Install shaft (111) fitted with bearing (123),
bearing spacer (127) and snap ring (824), to
swash plate support (251).
251
• Do not knock on the shaft with a hammer or

something. 123
• Fix the bearing by lightly tapping the outer
127,824
race of it by means of a plastic hammer and
set it exactly to the end by using a steel rod
and others.
111
Fig. 33-103 Installing shaft (111)

5) Installing seal cover
Assemble seal cover (F) (261) to pump casing
(271) and fix it with socket bolts (406). %
: 6 mm $
"$
• Coat the oil seal in seal cover (F) with a thin
film of grease.
• Handle the oil seal with sufficient care so it is
not scored.
Fig. 33-104 Installing seal cover F (261)

6) Inserting piston cylinder sub
Assemble the piston cylinder sub [cylinder block
141(151,152,157)
(141), piston (151), shoe (152), plate (153),
spherical bushing (156) and cylinder spring 156
(157)].
Align the spherical bushing with the cylinder 153
spline and insert them into the pump casing.
Fig. 33-105 Inserting piston cylinder sub

7) Installing valve plate
Install valve plate (313), (314) to valve block
(312) by aligning pin.
312
• Do not mistake the suction and delivery sides
of the valve plate.
314
(313 :
Opposite Side)
Fig. 33-106 Installing valve plates (313), (314)
33-62
33. UPPER STRUCTURE
8) Installing valve block 312 271

Install valve block (312) to pump casing (271) 401
and fasten them together with socket bolts (401).
: 17 mm
Tightening torque ; 430 N•m (320 lbf•ft)
• Work will be promoted if assembly is started

from the rear pump.
• Exercise care so as not to mistake the
direction of the valve block (312). (Install it so
Fig. 33-107 Installing valve block (312)
the regulator comes up as seen from the
front side and the suction flange comes on
the right.)
• Insert the 1st gear into the valve block
beforehand and connect it with the spline of
the shaft.
9) Installing gear pump REGULATOR
Install gear pump (04) and fasten them together
with socket bolts (435).
: 6 mm,
Tightening torque ; 17 N•m (12.5 lbf•ft)
10) Installing regulator and PTO cover

Pinch feedback pin of tilting pin in feedback lever
of the regulator and PTO cover (326), install the
regulator and fasten socket bolt.
(412)(413) (See Fig. 33-109] Fig. 33-108 Installing regulator and PTO cover
Socket bolt (412)(413) …… For regulator
: 6 mm,
Socket bolt (414) …… PTO Cover (326)
: 8 mm,
• Do not mistake the front regulator for the rear

regulator.
11) Installing drain port plug

The work is complete when drain port VP plugs
(466), (468) have been set.
: 19 mm, 36 mm
33-63
33. UPPER STRUCTURE
33.2.1.1.3 Maintenance standards

(1) Replacement standards for abrasive parts
Replace or readjust parts that exceed the following standards of wear.
However, always replace such parts that show excessive damage on appearance.
Recommended
Standard
Part name and inspection item value Remedy
dimension
forreplacement
Clearance between piston and cylinder
0.039 0.067
bore Replace piston or cylinder.
(0.0015 ) (0.0026 )
(D-d)
Gap between piston and caulked part of
shoe 0 ~ 0.1 0.3
Replace piston shoe assy.
(0.004 ) (0.012 )
( )
Thickness of shoe 4.9 4.7
Replace piston shoe assy.
(t) (0.193 ) (0.185 )
Free height of cylinder spring 41.1 40.3
Replace cylinder spring.
(L) (1.618 ) (1.587 )
Combined height of retainer plate and
23.0 22.0 Replace a set of spherical bushing or
spherical bushing
(0.906 ) (0.866 ) retainer plate.
(H-h)

(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face)
Valve plate (sliding section) Surface roughness requiring

3-Z
Swash plate (shoe plate face) correction
Cylinder (sliding section) Standard surface roughness
Less than 0.4Z (lapping)
Roughness of each surface (correction value)
33-64
33. UPPER STRUCTURE
33.2.1.1.4 Troubleshooting
(1) Locating causes of troubles
The pump is usually fitted with a regulator, auxiliary valves and auxiliary pumps, and this makes fault location
extremely difficult. However, faults would be found out easily if the following check items were attended to.
1) Inspecting the filter and drain oil
Inspect the filter element to check for abnormal contaminations. Some metallic particles will be deposited on
it as the shoe and the cylinder wear off. In case metallic particles are found in large quantity, the elements
may be damaged. In that case check the drain oil in the pump casing as well.
2) Checking for abnormal vibration and sound
Check that the pump does not vibrate and make an abnormal sound.
Check that the hunting of the regulator and the attached valveÅfs relief valve are of regular frequency. In
case vibration and sound are abnormal, the pump may be making a cavitation or internally broken.
3) When two pumps are used
In case two single pumps or motors are used or when a double pump is used. change pump pipelines. This
will make clear that the pumps are faulty or the circuit after the pumps is faulty.
4) Pressure measurements
If the problem is related to control functions, avoid disassembling the pumps carelessly, but look for causes
by measuring pressures.
(2) Troubleshooting
1) Overloading to engine
Cause Remedy Remarks

1. Revolution and pressure are higher 1) Set pressure to specified value.
than set values.
2. Regulator torque is set higher than 2) Readjust regulator. 2)Refer to Regulator Manual.
normal.
3. PumpÅfs internal parts are seized or 3) Replace damaged parts. 3) Check filter and drain oil to see if
broken. abnormal wear particles are present.
4. Regulator is piped incorrectly. 4) Pipe regulator correctly.
2) Pump’s oil flow rate is extremely low and delivery pressure is not available.

1. Regulator is out of order 1) Repair regulator. 1) Refer to Regulator Manual.
2. Pump’s internal parts are seized or 2)Replace damaged parts. 2)Check filter and drain oil.
broken.
3. Attached pump is out of order 3) Replace damaged parts. 3) Remove attached pump and check
shaft joint.
4. Attached valve is out of order. 4) Check attached valve. 4) Refer to Manual for Attached Valve.
Particularly poppet, seat and
spring.
5. Regulator is piped incorrectly. 5) Pipe correctly.
33-65
33. UPPER STRUCTURE
3) Abnormal Sound and Vibration

1. Cavitation 1) Prevent cavitation. 1-1) The boost pressure is low.
Check that hydraulic oil is not 1-2) The attached pump is in trouble.
clouded. 1-3) The suction pipe is inhaling air.
1-4) The suction resistance is high.
2. Caulked part of shoe is broken. 2)Replace piston shoe and shoe
plate.
3. Cylinder is cracked 3) Replace cylinder.
4. Pump is installed improperly. 4) Correct installation.
5. Regulator is hunting. 5) Repair regulator, 5) See Regulator Manual.
6. Relief valve in attached valve is 6) Repair attached valve. 6) See the Manual for Attached Valve.
hunting.
33-66
33. UPPER STRUCTURE
33-67
33. UPPER STRUCTURE
33.2.1.2 REGULATOR
626
625
624
753
627
623
621 D 728
B 645
611
622 F
874 646
733 613
732 875 644
631 612
898
652 875
A 643
651
836 G E
897 C
655
654
653
814
630
438
629
763
802
628
756
801
924
412
656 413
438 757
Y
W
Z D
418 079 E
041 876
755 X 615
601 755
722 858
466 496 734
755 G
887
708 F
A 876
662 B 724 614
439 C
642 730 725 8-724 755
858
041 755
755 466
466 755
641
Fig. 33-109 Structural exploded view of regulator
33-68
33. UPPER STRUCTURE
Marks in Fig. 33-90 show the position where regulator is installed.
No. Name Q'ty No. Name Q'ty No. Name No.

412 Socket bolt ; M8X50 2 628 Adjust screw (C) 1 732 O-ring ; 1B P16 1
413 Socket bolt ; M8X70 2 629 Cover (C) 1 733 O-ring 1
418 Socket bolt ; M5X12 2 630 Lock nut ; M30X1.5 1 734 O-ring ; 1B G25 1
438 Socket bolt ; M6X20 8 631 Sleeve (For PF) 1 753 O-ring ; 1B P9 1
439 Socket bolt ; M6X25 5 641 Pilot cover 1 755 O-ring ; 1B P11 7
466 VP plug ; PF1/4 3 642 Spool 1 756 O-ring ; 1B P26 1
496 Plug ; NPTF1/16 17 643 Pilot piston 1 757 O-ring ; 1B P12.5 1
541 Seat 2 644 Spring seat (Q) 1 763 O-ring ; 1B G35 1
543 Stopper 1 2 645 Adjust stem (Q) 1 801 Nut ; M8 1
545 Ball 2 646 Pilot spring 1 802 Nut ; M10 1
601 Casing 1 651 Sleeve 1 814 Snap ring 1
611 Feed back lever 1 652 Spool 1 836 Snap ring 1
612 Lever (1) 1 653 Spring seat 1 858 Snap ring 2
613 Lever (2) 1 654 Return spring 1 874 Pin ; 4X11.7L 1
614 Fulcrum plug 1 655 Set spring 1 875 Pin ; 4X8L 2
615 Adjust plug 1 656 Block cover 1 876 Pin ; 5X8L 2
621 Compensating rod 1 662 Spring 1 887 Pin 1
622 Piston case 1 708 O-ring ; 1B G75 1 897 Pin ; 4X19L 1
623 Compensating rod 1 722 O-ring ; 1B P6 3 898 Pin ; 7.5X11L 1
624 Spring seat (C) 1 724 O-ring ; 1B P8 8 924 Socket screw ; M8X20 1
625 Outer spring 1 725 O-ring ; 1B P10 1 041 Check valve sub 2
626 Inner spring 1 728 O-ring ; 1B P18 1 079 Solenoid proportional 1
627 Adjusting stem (C) 1 730 O-ring ; 1B P22 1 reducing valve
The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Tightening torque of bolt, plug and nut

Tightening torque
No. Thread size
N.m (lbf.ft)
412,413 M8 29 (21)
438,439 M6 12 (8.9)
418 M5 6.9 (5)
466 PF 1/4 36 (26)
496 NPTF1/16 8.8 (6.5)
630 M30X1.5 160 (118)
801 M8 16 (12)
802 M10 19 (14)
33-69
33. UPPER STRUCTURE
33.2.1.2.2 Disassembly and assembly

(1) Tools
and install.

(2) Disassembling procedure !
" #
"$
%
#
"$
• Choose a clean place. &

" #
"$

to protect parts from damaging. '(
,.
.
)

2) Cleaning *+
#
"$
Remove dust and rust, etc. on regulator surface
" "1
with wash oil.
, /00
"

- /0
3) Remove regulator (SeeFig. 33-109)

438 656 413 412
Remove socket bolts (412, 413) and separate
the regulator from the pump body.
629
: 6 mm
4) Remove port plate (See Fig. 33-109)

Remove socket bolt (438) and separate the port
438
plate (656).
601
: 5 mm
Fig. 33-110 Removing regulator

5) Remove cover (See Fig. 33-109)
Remove socket bolts (438) and remove cover
(C) (629).
: 5 mm
• The cover is equipped with adjust screws 624,625,626

(628), adjust stem (627), lock nut (630), hex 627
nut (801) and set screw (924). Do not loosen
801
those screws and nuts. If they are loosened,
preadjusted set pressure and flow values 629( 628 )
change.
630 924
Fig. 33-111 Removing cover (C) (629)
33-70
33. UPPER STRUCTURE
6) Remove compensating parts

M4 BOLT 645
(See Fig. 33-109 (D) section, See Fig. 33-111,
Fig. 33-112)
644,646
After removing the cover (C) (629) sub assy, take
out outer spring (625), inner spring (626) and
629
spring seat (624) from the compensating part.
Then take out adjust stem (645), pilot spring
(646) and spring seat (644) from the pilot part.
• Adjust stem (645) comes out easily if an M4

bolt is used.
Fig. 33-112 Removing compensating parts
7) Remove pilot cover and the set spring
Remove socket bolt (439) and pilot cover (641).
Once the pilot cover comes off, separate set
spring (655) from the pilot section.
(Fig. 33-109 (A) and (B) section)
: 5 mm
439
641
Fig. 33-113 Removing pilot cover (641) and set

spring (655)
8)Remove spring seat, return spring and sleeve
(Fig. 33-109 (A) section)
Remove snap ring (814). Then remove spring
814(653)
seat (653), return spring (654) and sleeve (651).
• Sleeve (651) is equipped with snap ring 654,

(836). 651(836)
• When removing snap ring (814), return
spring (654) comes out : Use care so as not
to lose it.
Fig. 33-114 Removing spring seat (653), return

spring (654) and sleeve (651)
9) Remove adjust plug (Fig. 33-109 (F),(G) section)
emove snap ring (858) and take out fulcrum plug
(614) and adjust plug (615). &#&
• Fulcrum plug (614) and adjust plug (615) $#

come off easily if a M6 bolt is used.
$"
Fig. 33-115 Removing adjust plug (615)
33-71
33. UPPER STRUCTURE
$"
Fig. 33-116 Removing fulcrum plug (614)

10) Remove lever (Fig. 33-109 (G) section)
Remove lever 2 (613).
Do not draw out pin (875).
• The work is eased if tweezers is used.
$!&%#
Fig. 33-117 Removing lever 2 (613)

11) Remove feedback lever
Draw out pin (874) and remove feedback lever &%"
(611).
• Push out pin (874) [pin dia : ø4mm (0.157in)]

from above with a slender steel rod so as not
to interfere with lever 1 (612). $
Fig. 33-118 Removing feedback lever (611) [1]
$
Fig. 33-119 Removing feedback lever (611) [2]
33-72
33. UPPER STRUCTURE
12)Remove lever (Fig. 33-109 (F) section)

Remove lever 1 (612). $
$
Do not draw out pin (875). &%"
&'%
&%# $!
13) Remove pilot piston and spool &%#
(Fig. 33-109 (C),(A) section)
Draw out pilot piston (643) and spool (652).
14) Remove piston casing, compensating piston

and compensating rod (Fig. 33-109 (B) section)
Draw out piston casing (622), compensating $"!
piston (621) and compensating rod (623).
• Piston casing (622) comes out from the $ !

opposite side of the piston casing if $ $
compensating rod (623) is pushed out. %!!
%!
$!
&'& $#
$#
&!$
$##
$#"
$#!
&"
Fig. 33-120 Part of exploded view of regulator

15) Remove spool (642) and spring (662)
"$$
Remove VP plug (466) from pilot cover (641),
and draw out spool (642) and spring (662).
This completes disassembly.

$$
$"
"$$
$"
33-73
33. UPPER STRUCTURE
(3) Installing procedure :

Assembly is the reverse order of disassembly. Do
the work paying attention to the following :
• Repair those parts that were damaged during
disassembly and prepare replacement parts
beforehand.
• If foreign matter enters, it causes malfunction;
clean parts thoroughly in cleaning oil, blow them
with jet air and assemble parts in a clean place.
• Always tighten bolts and plugs to the specified
torque. The tolerance of torque should be within
10%.
• Do not fail to coat the moving parts with clean
hydraulic oil, before assembly.
• In principle, replace seals such as O-ring.
1) Installing compensating rod (Fig. 33-109 (B)
section)

Assemble compensating rod (623) into the
compensating hole of casing (601).

2) Assembling lever
Put the pin pressed in lever 1 (612) into the
groove of the compensating rod (623). Then
assemble the lever to the pin (875) that is
pressed in the casing.
3) Assembling spool and sleeve (See Fig. 33-109
PIN (874)
(A) section)
Assemble spool (652) and sleeve (651) into the
spool hole of the casing.
• Make sure that the spool and the sleeve (652) SPOOL FEEDBACKLEVER(611
move smoothly in the casing.
• Beware of the direction of the spool. Fig. 33-123 Direction of the spool (652)
4) Assembling feedback lever

Assemble feedback lever (611). Then put pin
(874) into the pin hole of the feedback lever.
• The work is eased if the pin is put in the

feedback lever a little, beforehand.
• Take care so as not to mistake the direction
of the feedback lever.
Fig. 33-124 Assembling feedback lever (611)
33-74
33. UPPER STRUCTURE
5) Assembling pilot piston (See Fig. 33-109 (C)

section)
Assemble pilot piston (643) into the positive
control hole of the casing.
• Make sure that the pilot piston moves $!&%#

smoothly.
6) Assembling lever (See Fig. 33-109 (G) section)

Place pin (875) pressed in lever 2 (613) into the
groove of the pilot piston and assemble lever 2
(613). Fig. 33-125 Assembling lever 2 (613)
7) Installing fulcrum plug (See Fig. 33-109 (F)

section)
Assemble fulcrum plug (614) so pin (875) 614(875,858)
pressed in the fulcrum comes in the pin hole of
lever 2 (613). Then fit snap ring (858).
Fig. 33-126 Installing fulcrum plug (614)

8) Installing adjust plug (See Fig. 33-109 (G)
section)
Insert adjust plug (615) and fit a snap ring (858). &#&
• Use care so as not to mistake the holes into $#

which the fulcrum and adjust plug are
inserted. $"
• At this point, operate the feedback lever and
make sure that the gap is not large and that
the lever moves smoothly.
9) Installing return spring and the spring seat Fig. 33-127 Installing adjust plug (615)
(See Fig. 33-109 (A) section)
Assemble return spring (654) and spring seat
(653) into the spool hole and fit snap ring (814).

Fig. 33-128 Installing return spring (654) and spring

seat (653)
33-75
33. UPPER STRUCTURE
10) Assembling compensating parts (See Fig. 33-

109 (A),(B) section)
Assemble set spring (655) into the spool hole.
Place compensating piston (621) and piston
casing (622) into the compensating hole and
attach pilot cover (641). Then fasten them
together with socket bolts (438), (439).
: 5 mm
Tightening torque ; 12 N•m (8.7 lbf•ft) $ $
Fig. 33-129 Assembling compensating parts
11) Installing spool and spring
"$$
Assemble spool (642) and spring (662) into pilot
cover (641), and tighten VP plugs (466).
$$
$"
"$$
$"
Fig. 33-130 Assembling spool (642)
12) Assembling into the pilot hole and the
compensating hole
(See Fig. 33-109 (E),(D) section)
Put spring seat (644), pilot spring (646) and
adjust stem (645) into the pilot hole. Then
assemble spring seat (624), inner spring (626)
and outer spring (625) into the compensating
hole.
• Do not mistake the direction of the spring

Fig. 33-131 Assembling into the pilot hole and
seat.
compensating hole
13) Installing cover

Attach cover (C) (629) fitted with adjust screws
(628), (925), adjust stem (627), lock nut (630),
nut (801) and socket bolt (924). Then fasten
them with socket bolts (438).
: 5 mm

14) Installing block cover (See Fig. 33-110)

Attach block cover (656).
: 5 mm

Fig. 33-132 Installing cover (C) (629)
This completes assembly.
33-76
33. UPPER STRUCTURE
33.2.1.3 PTO GEAR CASING (For OCEANIA)
414
117 128
216 435
826 886 711
128 326
414
115
886 262
728
885 125 468
118
125
825
710 435
435
414
262
414

No. Parts name Q’ty No. Parts name Q’ty
115 Idle shaft 1 33 (25) 435 Flange socket ; M10×20 4
117 2nd gear 1 74 (54) 468 VP plug ; PF3/4 1
118 3re gear 1 710 O-ring ; 1B G80 1
125 Ball bearing 2 711 O-ring ; 1B G85 1
126 Roller bearing 1 728 O-ring ; 1B P24 1
128 Bearing spacer 2 825 Snap ring 1
262 Cover 2 826 Snap ring 1
326 Gear casing 1 885 Spring pin 1
33 (25) 414 Socket bolt ; M10×20 4 886 Pin 2
33-77
33. UPPER STRUCTURE
33.2.1.3.2 Disassembly and assembly

(1) Tools
Tool name Dimension
Allen wrench Opposing flats 8,10mm
and install.
For snap ring RR-20
(2) Disassembling procedure Plier
For snap ring RR-72
• Choose a clean place.
to protect parts from damaging.
2) Cleaning
Remove dust and rust, etc. on pump surface with
wash oil.
3) Drain oil
Drain out the oil in the pump casing by removing
drain port plug (468).
: 27 mm
• Drain out the oil from the plugs of the front
pump and the rear pump.
4) Remove cover FLANGE SOCKET (M10)
Remove the socket bolts (414). Then remove the Tightening torque : 33N.m (25 lbf.ft)}
cover (262).
: 8 mm
5) Remove PTO gear casing 414
Remove flange socket (435) and PTO gear
casing.
: 8 mm
262 COVER
PTO GEAR CASING
414
262 COVER
Fig. 33-133 Removing gear pump
HOLE FOR FLANGE

SOCKET (435)
PTO
GEAR CASING
Fig. 33-134 Removing PTO gear casing
33-78
33. UPPER STRUCTURE
6) Removing the 2nd gear, the roller bearing and HOLE FOR
the bearing spacer IDLE SHAFT (115)
Draw out the spring pin (885) and remove idle
shaft (115). Then draw out 2nd gear (117), roller
bearing (126) and bearing spacer (128). 117 (126,128)
• Roller bearing (126) can not be separated
from 2nd gear (117).
Fig. 33-135 Removing 2nd gear (117)

7) Removing the 3rd gear and the ball bearing
Remove snap ring (825) and draw out 3rd gear
(118) and ball bearing (125).
• Ball bearing (125) can not be separated from 125
3rd gear (118).
118
Fig. 33-136 Removing 3rd gear (118) and ball

bearing (125)
(3) Installing procedure
Assembly is a reverse order of disassembly, but
notice the following.
1) Repair scored parts at disassembly. Get
replacements ready beforehand.
2) Wash parts sufficiently in cleaning oil and dry
them with jet air.
3) Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
4) In principle. replace sealing parts such as O rings
and oil seals.
5) Tighten socket bolts and plugs to specified
torques in Service Standard, using a torque
wrench.
6) Do not mix up front pump parts with rear pump
parts.
33.2.1.3.3 Maintenance standards

In case a pitching (1 pit is more than 1mm (0.039in), while the area ratio is more than 5%.) is seen on the gear tooth
surface of 2nd gear (117) and 3rd gear (118), replace the gears. Replace the gears also in case they show excessive
damage.
33-79
33. UPPER STRUCTURE
33.2.2.1 SECTIONAL VIEW
J
154 164 101
P2
T2 T1
PAL PBL
YT1
J
PB1 PCa
YBG1
P2-20
PBs PAs
YS1
Pss
PBa1 PAa1
YA1
PAo PBo
YP1
(P4)
163 162 163 169 155 162
SECTION A-A
154 164
P1
102
973 973
PTb PCb
P1-20
973 973
PBr PAr
YT1
973
PAb PBb
YB1
973 973
PBc PCc
PAc
YK1
974 973
PAa2 PBa2
YAG
1
974
(P3)
162 162 169 155 163 162
SECTION B-B
33-80
33. UPPER STRUCTURE
T2
H 273x10 273x10 H
PCb PAL
P1 unload
Travel left
(Travel straight)
C C
USE FOR YN30V00101F1

977 PAr
PB1 Boom conflux
Travel right (P2 unload)
D 978x2 D
PBs
Boom Swing
E PCc
PBb E
PBa1 Pss
Bucket
Arm 1
F F
PBa2 PA
PAo
Arm 2 MU Option
G G
K PBp1 PBp2
K
(P3) B A
PBa2 PAo
PBp1 PBp2
274x4
275x4
213
(P4)
(P3)
212
PAa2 PBo
273x10 273x10
33-81
33. UPPER STRUCTURE
%"$. '($ $(#,

'($ -,)*+,

'($ )*+, !"#$%&

%"$.

33-82
33. UPPER STRUCTURE
Swing
204
203 PBs
333 Boom 333
331 Pss
336 331
322
321 336
603 AbR
331 322
211
261 321
266 266
160
160 331
514 261
303
524 As 161
CRb
556 162
164 Ab 163
511 511
521 523
LCb LCs
551 556
164 164
Bb 162
Bs
161
301
266
264
264
602 PAb
160 PAs
206
205 BbR
SECTION E-E
164 551
Bucket
209
PCc
216 201
333 Arm 1 333
PBa1
331 331
PBc
336 336
322 322
321 321
BaR
602 BcR 603
331 331
261 261
211
304 160
514
524
CRar
Bc 556
Ba 164
511 511
521 521
LCc LCa
551 551
164 164
Ac
162 Aa
161
264 302
603 PAc PAa1 264
205 AcR 205
SECTION F-F AaR 605
33-83
33. UPPER STRUCTURE
201
333 Arm 2 Option 201
331 PBa2 PAo 333
340
328 331
321
336
331
324
261
AoR 323
604
MU 331
308
162 261
162 311
162
511 Ao
521
LCAT2 511
551
164 521
515 LCo
521 LCAP2 551
551 164
164
Bo
162
161
604
BoR
264 264
PAa2 PBo
205
205
SECTION G-G
T2
161
P1
T1
511
521 163
CT1
551
163
164
162
P2 511
521
CT2
551
164
SECTION H-H
33-84
33. UPPER STRUCTURE
PBp1 PBp2
207
160 606 606
278x5 266
264 264
527 528 163

T2 T1
517
518
SECTION J-J
SECTION K-K
33-85
33. UPPER STRUCTURE

No. Parts name Q’ty No. Parts name Q’ty
101 Casing A 1 321 Spring 5
102 Casing B 1 322 Spring 4
220~250(162~184) 154 Plug PF3/4 3 323 Spring 3
110~130(81~96) 155 Plug PF1/2 2 324 Spring 3
20~24(15~18) 159 Plug PT1/4 (Capsule coating) 1 325 Spring 1
7.8~9.8(5.8~7.2) 160 Plug PT1/16 (Capsule coating) 5 326 Spring 1
164 O-ring 19 331 Spring seat 24
16~18(11~13)
169 O-ring 2 333 Spacer bolt 12
Loctite #262
204 Cover sub 1 511 Poppet 11
Back pressure check
207 1 515 Poppet 1
valve cover
9.8~14(7.2~13) 211 Lock valve selector sub 2 518 Poppet 1
25~34(18~25) 273 Socket bolt 40 230~260(170~192) 551 Plug 13
98~120(72~89) 274 Socket bolt 4 130~150(96~111) 552 Plug 2
98~120(72~89) 275 Socket bolt 4 230~260(170~192) 556 Plug 3
25~34(18~25) 278 Socket bolt 5 562 O-ring 2
301 Bom spool sub 1 69~78(51~58) 601 Main relief valve 1
302 Arm 1 spool 1 69~78(51~58) 602 Over load relief valve 2
303 Swing spool 1 69~78(51~58) 603 Over load relief valve 3
304 Bucket spool 1 69~78(51~58) 604 Plug assy for relief valve hole 2
305 Boom conflux spool 1 69~78(51~58) 605 Over load relief valve 1
306 Travel spool 2 98~120(72~89) 606 By-pass cut valve 2
307 Travel straight spool 1 140~180(103~133) 973 Socket bolt 8
308 Arm 2 spool sub 1 140~180(103~133) 974 Socket bolt 2
309 P1 unload spool 1 977 Name plate 1
310 P2 unload spool 1 978 Pakerrizing rivet 2
311 Option spool 1
33-86
33. UPPER STRUCTURE
33.2.2.2 PREPARATION FOR DISASSEMBLY

(1) General precautions
1) As all the hydraulic components are precisely machined, it is essential to carry out disassembly and
reassembly in an especially clean location.
2) When handling the control valve, take special care to prevent the entry of foreign matter, such as dust or
sand.
3) Cap each port of the control valve before removing the valve from the machine. Before disassembly, confirm
that each cap is in place and then clean the exterior of the assembly.
Use a workbench. Lay a clean sheet of paper or rubber mat over the workbench.
4) When carrying or moving the control valve, hold the body, and never put pressure on a lever, an exposed
spool, or the end cover. Handle the valve with care.
5) Tests(for relief characteristics, leaks, overload valve setting, flow resistance, etc.) that are desired after
disassembly and reassembly require hydraulic testing apparatus.
For this reason, do not disassemble hydraulic units that you are capable of disassembling but cannot test or
adjust.
Prepare beforehand washing fluid, hydraulic oil, grease, etc. .
(2) Tools
Prepare the following tools before disassembling the control valve.
No. Tools Q’ty Remarks

a Vise 1
Box end 1 of each
b 24mm, 27mm, 32mm
wrench size
1 of each
c Allen wrench 5mm, 6mm, 10mm, 12mm, 14mm, 22mm
size
d Spanner 1 32 mm
e Loctite #262 1
f Spatula 1
g Pincers 1
Adjustable
h 1
wrench
The figures in parentheses after part names in this
manual represent those item numbers in the structural
sectional drawing under Fig. 33-137 to Fig. 33-142.
(1) Place the control valve on a work bench so as to
locate back pressure check valve upwards.
Disassemble the valve in a clean place, and be careful

not to damage flange surfaces or plate mounting
surfaces.
Fig. 33-143 Preparation for disassembly
33-87
33. UPPER STRUCTURE
33.2.2.3.1 Disassembling P1 unload spool

(1) Loosen the socket bolts (273) and remove the
spring cover (202) and the O-ring (261) for P1
unload spool.
Fig. 33-144 Removing spring cover (202) for P1

unload spring cover
(2) Draw out, from casing B (102), as a assy of P1
unload spool (309), spring seat (331), springs
(327), (329), stopper (336) and bolt (333).
When drawing out the spool assy, use care so as not to

score casing B (102).
Fig. 33-145 Drawing out P1 unload spool assy (309)

(3) Fix the P1 unload spool assy with vise via a
protective plate (aluminum plate, etc.) and remove
bolt (333). Then separate spring seat (331), springs
(327), (329) and stopper (336) from P1 unload
spool (309).
Fig. 33-146 Disassembling P1 unload

spool assy (309)
33-88
33. UPPER STRUCTURE
33.2.2.3.2 Disassembling the travel spool (left travel and right travel)
spring cover (201) and the O-ring (261) for travel.
Fig. 33-147 Removing spring cover (201)

(2) Draw out the assy of travel spool (306), spring seat
(331), springs (323), (324), stopper (336) and bolt
(333) from casing A (101) or casing B (102).
When drawing out the spool assy, take care so as not

to score the casing A (101) or the casing B (102).
Fig. 33-148 Drawing out travel spool (306) assy

(3) Fix the travel spool assy with vise via a protective
plate (aluminum plate, etc.). Remove bolt (333) and
separate spring seat (331), springs (323), (324) and
stopper (336) from travel spool (306).
Fig. 33-149 Removing right travel spring cover

(201)
Fig. 33-150 Disassembling travel spool (306) assy
33-89
33. UPPER STRUCTURE
33.2.2.3.3 Disassembling the boom conflux spool

(1) Loosen socket bolts (273) and remove spring cover
(201) for boom conflux and O-ring (261).
(2) Draw out the assy of boom conflux spool (305),

spring seat (331), springs (325), (326), stopper
(339) and bolt (333) from casing A (101).

score casing A (101).
(3) Fix the boom conflux spool with vise via a protective
plate (aluminum plate, etc.) and remove bolt (333).
Then separate spring seat (331), springs (325),
(326) and stopper (339) from boom conflux spool
(305).
Fig. 33-152 Drawing out boom conflux spool (305)

assy
33.2.2.3.4 Disassembling the boom spool

(1) Loosen socket bolts (273) and remove spring cover
(203) for boom spool and O-ring (261), (266).
(2) Draw out the assy of boom spool (301), spring seat
(333) from casing B (102).

to score casing B (102).
33-90
33. UPPER STRUCTURE
(3) Fix the boom spool assy with vise via a protective
(322) and stopper (336) from boom spool (301). Do
not disassemble boom spool (301) further unless
there is special reason.
Fig. 33-154 Drawing out boom spool (301) assy
33.2.2.3.5 Disassembling the swing spool

spring cover sub (204) and the O-ring (261), (266)
for swing. Do not disassemble spring cover sub
(204) further unless there is special reason.
(2) Draw out the assy of swing spool (303), spring seat
(333) from casing A (101).
Fig. 33-155 Removing spring cover sub (204)

(3) Fix the swing spool assy with vise via a protective
(322) and stopper (336) from swing spool (303).
Fig. 33-156 Drawing out swing spool (303) assy
33-91
33. UPPER STRUCTURE
33.2.2.3.6 Disassembling bucket spool

(1) Loosen socket bolts (273) and remove bucket
spring cover (209) and O-ring (261).

(2) Draw out the assy of bucket spool (304), spring
seat (331), springs (321), (322), stopper (336) and
bolt (333) from casing B (102).

Fig. 33-158 Drawing out bucket spool (304) assy

(3) Fix the bucket spool assy with vise via a protective
(322) and stopper (336) from bucket spool (304).
(4) When needed to disassemble the spring cover of

bucket spool, loosen plug (551) with casing B (102)
installed. After removed cover (209) from casing B
(102), remove plug (551) and then take out piston
(216).
Fig. 33-159 Disassembling bucket

spring cover (209)
33-92
33. UPPER STRUCTURE
33.2.2.3.7 Disassembling arm 1 spool

(1) Loosen socket bolts (273), and remove spring
cover (201) and O-ring (261) of arm 1 spool.
(2) Draw out the assembly which is consist of arm 1

spool (302), spring seat (331), spring (321, 322),
stopper (336) and bolt (333) from casing A (101).

Fig. 33-160 Removing arm 1 spring cover (201)
(3) Fix the arm 1 spool assy with vise via a protective
plate (aluminum plate etc.) and remove bolt (333).
Then remove spring seat (331), spring (321, 322)
and stopper (336) from arm 1 spool (302).
Fig. 33-161 Disassembling arm 1 spool (302) assy
33.2.2.3.8 Disassembling arm 2 spool

cover (201) and O-ring (261) of arm 2 spool.
(2) Draw out the assembly which is consist of arm 2

stopper (340) and bolt (333) from casing B (102).

Fig. 33-162 Removing arm 2 spring cover (201)
(3) Fix the arm 2 spool assy with vise via a protective
and stopper (340) from arm 2 spool (308). Do not
disassemble arm 2 spool (308) further unless there
is special reason.
Fig. 33-163 Disassembling arm 2 spool (308) assy
33-93
33. UPPER STRUCTURE
33.2.2.3.9 Disassembling option spool

cover (201) and O-ring (261) of option spool.
(2) Draw out the assembly which is consist of option

stopper (336) and bolt (333) from casing A (101).

Fig. 33-164 Removing option spring cover (201)
(3) Fix the option spool assy with vise via a protective
and stopper (336) from option spool (311).
Fig. 33-165 Drawing out option spool assy (311)
33.2.2.3.10 Disassembling travel straight spool

spring cover (202) and the O-ring (261) for travel
straight.
(2) Draw out the assy of travel straight spool (307),

spring seat (331), springs (327), (329), stopper
(336) and bolt (333) from casing B (102).

Fig. 33-166 Drawing out travel straight spool (307)
to score the casing B (102).
assy
(3) Fix the travel straight spool assy with vise via a
protective plate (aluminum plate, etc.). Remove
bolt (333) and separate spring seat (331), springs
(327, 329) and stopper (336) from travel straight
spool (307).
33-94
33. UPPER STRUCTURE
33.2.2.3.11 Disassembling P2 unload spool

cover (202) of P2 unload spool and O-ring (261).
(2) Draw out the assembly which is consist of P2

unload spool (310), spring seat (331), spring (327,
329), stopper (336) and bolt (333) from casing A
(101).

Fig. 33-167 Removing P2 unload spring cover (202)
(3) Fix the P2 unload spool assy with vise via a

protective plate (aluminum plate etc.) and remove
bolt (333). Then remove spring seat (331), spring
(327, 329) and stopper (336) from P2 unload spool
(310).
Fig. 33-168 Drawing out P2 unload spool assy (310)
33.2.2.3.12 Removing spool covers

(1) Travel, boom, bucket, arm 1, arm 2 and option
Loosen socket bolts (273) and remove spool cover
(205) and O-ring (264).
(2) Swing
Loosen socket bolts (273) and remove spool cover
(206) and O-ring (264), (266). Do not disassemble
spool cover (206) further unless there is special
reason.
Fig. 33-169 Removing spool cover (205),(206)
33-95
33. UPPER STRUCTURE
33.2.2.3.13 Removing relief valve and plug assy for relief valve hole
(1) Remove the main relief valve (601) and overload
relief valve (602), (603) and (605) from the casing.
• Distinguish overload relief valve between (602),

(603) and (605) with a tag to prevent them from
being confused during reassembly, as they are the
same in appearance and shape but differ in
pressure setting.
• Regarding the disassembly of the relief valves
Fig. 33-170 Removing main relief valve (601)
themselves, do not disassemble it.
Fig. 33-171 Removing overload relief valve (602),

(603) and (605)
Fig. 33-172 Removing plug assy (604) for relief

valve hole
33-96
33. UPPER STRUCTURE
33.2.2.3.14 Removing by-pass cut valve

(1) Remove by-pass cut valve (606) from the casing.
Remove the by-pass cut valve, giving particular

attention to the poppet (606-201) and spring (606-202)
which may be remained on the inside of casing.
Fig. 33-173 Removing by-pass cut valve (606)
33.2.2.3.15 Removing lock valve selector valve sub

(1) Loosen socket bolt (211-171) and remove lock
valve selector valve sub (211) from the casing.
Further disassembly of the lock valve selector sub
is not allowed.
Fig. 33-174 Removing lock valve selector sub (211)
33.2.2.3.16 Removing back pressure check valve

(1) Loosen socket bolt (278) and remove back
pressure check valve (207) from the casing.
Fig. 33-175 Removing back pressure check valve

cover (207)
33-97
33. UPPER STRUCTURE
(2) Remove springs (527), (528), boost check valve

poppet sub (517) and by-pass check valve poppet
(518) from the casing. The further disassembly of
boost check valve poppet sub (517) is not allowed.
Replace control valve so that the spool cover face

directs downward.
When replacing, take care so as not to score the spool

cover.
Fig. 33-176 Removing boost check valve sub (517)
and by-pass check valve poppet (518)
33.2.2.3.17 Removing plate

(1) Loosen socket bolts (274), (275) and remove plates
(212), (213).
(2) After removing plates, remove all O-rings (162),
(163) remained on the casing side.
Fig. 33-177 Removing plate (212),(213)
33-98
33. UPPER STRUCTURE
33.2.2.3.18 Removing check valve

(1) Remove plugs of load check valve, conflux check
valve, etc. and then remove poppet (511) and
spring (521).
(2) Load check valve on the swing section
Remove plug (556) and then remove poppet (511)
and spring (523).
The plug and spring in use differ from the above (1). Do
not mix the parts when assembling parts again.
(3) Load check valve on arm 2 section Fig. 33-178 Removing plug (551),(556),(552)
and spring (521).
The poppet in use differs from the above (1). Do not mix
the parts when assembling parts again.
(4) Lock valve

and spring (524).
Fig. 33-179 Removing poppet (511),(512),(514),(515)
The plug, poppet and spring in use differ from the

above (4). Do not mix the parts when assembling parts
again.
(5) Main relief valve

and spring (522).
The plug, poppet and spring in use differ from the

above (5). Do not mix the parts when assembling parts
again.
The plugs in which the procedure for disassembly is not

included in the above procedure are usually used to
block auxiliary holes and holes caused by casting. Do
not disassemble further if unnecessary.
33.2.2.3.19 Disassembling casing

Further disassembly of the casing is not allowed.
33-99
33. UPPER STRUCTURE
33.2.2.3.20 Inspection after disassembly

Thoroughly clean all disassembled parts with wash oil, and dry them with jet air. Place each part on a clean sheet
of paper or cloth for inspection.
(1) Control valve
1) Inspect the entire surface of each part for burrs, scratches, cuts, and other defects.
2) Confirm that the O-ring groove surface of the casing or the block is free from foreign matter, dents or rust.
3) If the check valve seat of the casing or the block has dents or damage on its surface, smooth it by lapping.
Take care not leave lapping compound behind in the casing or block.
4) Confirm that O-ring or the outer circumference of the sliding part of a manual spool is free from scratches,
dents, and the like. Remove any small defects with an oil stone or lapping compound.
5) Manually confirm that all sliding and fitted parts move smoothly. Confirm that all grooves and passages are
free from foreign matter.
6) Replace any broken or deformed spring with new one.
7) Of a relief valve malfunctions, repair it by following the relief valve disassembly and reassembly procedures.
8) Replace all O-ring with new ones.
(2) Relief valve

1) Make sure that the poppet and the seat surface at the tip of the seat are without fault and that the contact
surface is even all over.
2) Manually confirm that the main poppet slides smoothly onto and off the seat.
3) Confirm that the outer circumference of the main poppet and the inner circumference of its seat are free from
defects such as scratches.
4) Confirm that each spring is free from breakage, deformation, and excessive wear.
5) Confirm that the orifices of the main poppet and its seat are not clogged.
6) Replace all O-rings with new ones. (Between casing and seal)
33.2.2.4 REASSEMBLY
(1) Here, only the reassembly procedures are described. Regarding drawings, refer to the disassembly procedures.
(2) Figures in parentheses after part names in this instruction represent those item numbers in the structural
sectional drawing. (Fig. 33-137 to Fig. 33-142)
(3) Precautions on reassembling O-ring
1) Confirm that O-rings are free from defects caused by poor handling.
2) Apply thin coat of grease or hydraulic oil to O-rings and their mating parts.
3) Do not stretch O-rings to the extent that they become permanently set.
4) When installing O-rings, do not roll them into place. Twisted O-rings do not easily untwist by themselves after
installation, and can cause oil leaks.
5) Use a torque wrench to tighten each attaching bolt. Tighten to the specified torque in "Maintenance
Standards."
33-100
33. UPPER STRUCTURE
33.2.2.4.1 Installing check valve

(1) Load check valve, conflux check valve, and so on
Attach poppet (511) and spring (521) in place, place O-ring (164) in plug (551) and tighten them to the specified
torque. (9 places)
(2) Load check valve of swing section
torque. (1 place)
(3) Load check valve of arm 2 section
torque. (1 place)
(4) Lock valve section
torque. (2 places)
(5) Main relief valve section
torque. (2 places)
Take care to prevent misassembling of parts and assembling position error because the parts in (1) to (5) are similar
in shape.
33.2.2.4.2 Assembling plate

(1) Place O-rings (162), (163) in casing.
(2) Attach plates (212), (213) and tighten socket bolts (274), (275) to the specified torque.
Replace control valve so that this plate face directs downward.
33.2.2.4.3 Assembling back pressure check valve

(1) Attach boost check valve poppet sub (517), by-pass check valve poppet (518) and springs (527), (528).
(2) Attach O-rings (264), (266) in back pressure check valve cover, attach it to casing A (101) and tighten socket
bolt (278) to the specified torque.
33.2.2.4.4 Assembling lock valve selector sub

(1) Attach lock valve selector sub (211) to the casing and tighten socket bolt (211-171) to the specified torque.
33.2.2.4.5 Assembling by-pass cut valve

(1) Attach by-pass cut valve (606) to casing and tighten it to the specified torque.
Take care to prevent drop of poppet (606-201) and spring (606-202) when attaching by-pass cut valve.
33-101
33. UPPER STRUCTURE
33.2.2.4.6 Assembling relief valve and relief valve hole plug assembly
(1) Tighten main relief valve (601), port relief valves (602), (603), (605) and relief valve hole plug assembly (604) in
respective place to the specified torque.
Assemble it giving attention to the label attached when disassembling to prevent mistake because the port relief
valves (602), (603), (605) are similar in shape.
33.2.2.4.7 Assembling p2 unload spool

(1) Hold the mid section of P2 unload spool (310) with vise provided with protection plate (aluminum plate, etc.), fit
spring seat (331), springs (327), (329) and stopper (336) and tighten bolt (333) to the specified torque.
• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform P2 unload spool (310) because of careless over clamping.
(2) Place P2 unload spool assembly in item (1) in casing A (101).
Place P2 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of P2 unload spool assembly and tighten
socket bolt (273) to the specified torque.
33.2.2.4.8 Assembling travel straight spool

(1) Hold the mid section of travel straight spool (307) with vise provided with protection plate (aluminum plate, etc.),
fit spring seat (331), springs (327), (329) and stopper (336) and tighten bolt (333) to the specified torque.

• Take care not to deform travel straight spool (307) because of careless over clamping.
(2) Place travel straight spool assembly in item (1) in casing B (102).
Place travel straight spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of travel straight spool assembly, and
tighten socket bolt (273) to the specified torque.
33-102
33. UPPER STRUCTURE
33.2.2.4.9 Assembling spool in option

(1) Hold the mid section of spool in option (311) with vise provided with protection plate (aluminum plate, etc.), fit

• Take care not to deform option spool (311) because of careless over clamping.
(2) Place spool assembly in option in item (1) in casing A (101).
Place option spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of spool assembly in option and tighten
33.2.2.4.10 Assembling arm 2 spool

(1) Hold the mid section of arm 2 spool (308) with vise provided with protection plate (aluminum plate, etc.), fit spring
seat (331), springs (321), (328) and stopper (340) and tighten bolt (333) to the specified torque.

• Take care not to deform arm 2 spool (308) because of careless over clamping.
(2) Place arm 2 spool assembly in option in item (1) in casing B (102).
Place arm 2 spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 2 spool assembly and tighten
33.2.2.4.11 Assembling arm 1 spool

(1) Hold the mid section of arm 1 spool (302) with vise provided with protection plate (aluminum plate, etc.) and fit

• Take care not to deform arm 1 spool (302) because of careless over clamping.
(2) Place arm 1 spool assembly in item (1) in casing A (101).
Place arm 1 spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 1 spool assembly, and tighten
33-103
33. UPPER STRUCTURE
33.2.2.4.12 Assembling bucket spool

(1) Hold the mid section of bucket spool (304) with vise provided with protection plate (aluminum plate, etc.), fit

• Take care not to deform bucket spool (304) because of careless over clamping.
(2) Place bucket spool assembly in item (1) in casing B (102).
Place bucket spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (209) with O-ring (261) attached to the spring side of bucket spool assembly and tighten
(4) Attach piston (216) to spring cover (209), place O-ring (164) in plug (551) and tighten to the specified torque.
33.2.2.4.13 Assembling swing spool

(1) Hold the mid section of swing spool (303) with vise provided with protection plate (aluminum plate, etc.), fit spring

• Take care not to deform swing spool (303) because of careless over clamping.
(2) Place swing spool assembly in item (1) in casing A (101).
Place swing spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover sub (204) with O-rings (261), (266) attached to the spring side of swing spool assembly and
33-104
33. UPPER STRUCTURE
33.2.2.4.14 Assembling boom spool

(1) Hold the mid section of boom spool (301) with vise provided with protection plate (aluminum plate, etc.), fit spring

• Take care not to deform boom spool (301) because of careless over clamping.
(2) Place boom spool assembly in item (1) in casing B (102).
Place boom spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (203) with O-rings (261), (266) attached to the spring side of boom spool assembly and
33.2.2.4.15 Assembling boom conflux spool

(1) Hold the mid section of boom conflux spool (305) with vise provided with protection plate (aluminum plate, etc.),
fit spring seat (331), springs (325)(326) and stopper (339) and tighten bolt (333) to the specified torque.

• Take care not to deform boom conflux spool (305) because of careless over clamping.
(2) Place boom conflux spool assembly in item (1) in casing A (101).
Place boom conflux spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of boom conflux spool assembly and
33.2.2.4.16 Assembling travel spool (travel right and left)

(1) Hold the mid section of travel spool (306) with vise provided with protection plate (aluminum plate, etc.), fit spring

• Take care not to deform travel spool (306) because of careless over clamping.
(2) Place travel spool assembly in item (1) in casing A (101) or casing B (102).
Place travel spool assembly in casing A (101) or casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of travel spool assembly and tighten
33-105
33. UPPER STRUCTURE
33.2.2.4.17 Assembling P1 unload spool

(1) Hold the mid section of P1 unload spool (309) with vise provided with protection plate (aluminum plate, etc.), fit

• Take care not to deform P1 unload spool (309) because of careless over clamping.
(2) Place P1 unload spool assembly in item (1) in casing A (101).
Place P1 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of P1 unload spool assembly and tighten
33.2.2.4.18 Assembling spool cover, and so on

(1) Travel, boom, bucket, arm 1, arm 2, option
Place O-ring (264) in spool cover (205) and tighten socket bolt (273) to the specified torque.
(2) Swing
Place O-rings (264), (266) in spool cover (206) and tighten socket bolt (273) to the specified torque.
33-106
33. UPPER STRUCTURE
33.2.2.5.1 Inspection of components
Part name Inspection item Criterion and remedy

Casing 1) Look for scratches, rusting and corrosion. 1) If any of the following parts are damaged,
replace the casing.
• Sliding part of casing hole and spool,
particularly the land, to which holding
pressure is applied.
• Area of sealing part that is in contact with
O-ring.
• Sealing and seating part of main or
overload relief valve.
• Area of seating part or sliding part of
poppet.
• Sealing part of plug.
• Defects of other parts that seem to
prevent normal function.
Spool 1) Look for scratches, galling, rusting and 1) If a detectable defect with your fingernail is
corrosion. found on the sliding part of the outer
circumference, replace the spool.
2) Insert the spool in the casing bore, and 2) If the spool damages the O-ring or does
move it while turning it. not move smoothly, repair or replace the
spool.
Poppet If spring is damaged, replace it.
1) Look for damage on the poppet and the 1) If the seat of poppet or spring are
spring. damaged, correct or replace it.
2) If the poppet moves lightly without
2) Insert the poppet in the casing, and move catching, it is normal.
it.
Spring and related parts 1) Look for rust, corrosion, deformation, and 1) If damaged heavily, replace.
breakage of the spring, spring seat,
stopper, spacer bolt and cover.
Main relief valve 1) Look for rust and damage on outer 1) Replace.
Port relief valve surface.
By-pass cut valve 2) Inspect the contact face of the valve seat. 2) If damaged, replace.
3) Inspect the O-ring, backup ring, and seal. 3) As a general rule, replace all parts with
new ones. (Between casing and seal)
33-107
33. UPPER STRUCTURE
(1) If an abnormal condition is noticed, check to see if the problem is with the control valve itself, one of the main
pumps, the gear pump, or a circuit. To this end, you will need to measure pilot pressure, pump delivery pressure,
load pressure, etc. If any part of the system is to be disassembled for inspection, follow the disassembly and
reassembly procedures in this manual.
(2) Dust is the enemy of hydraulic components. Pay strict attention to protection from dust. If any part of the system
is to be disassembled, take dust protection measures beforehand.
(3) Moving parts must be handled with care. If they are damaged, smooth the damage using an oil stone or the like.
(4) Take care not to damage the contact face of O-rings. A damaged contact face will certainly cause oil leaks.
33.2.2.6.1 Control valve
Trouble Cause Remedy

1. Travel does not 1) Malfunctioning main relief valve. 1) Check travel relief valve pressure
occur. • Foreign matter between main poppet • Disassemble and clean. If damaged
Slow to start up and seat. heavily, replace the assy as a unit.
(or poor power).
• Same as above.
Slow response.
• Foreign matter between poppet and • Correct sticking part with oil stone.
seat.
• Replace spring.
• Sticking main poppet.
• Remove foreign matter.
• Broken or deformed spring.
• Readjust, and tighten lock nut to
• Clogged main poppet throttle. specified torque.
• Loosened adjusting screw.
2. Machine does not 1) Malfunctioning travel straight valve. 1) Check pilot pressure.
move straight during • Sticking spool. • Correct sticking part with oil stone.
simultaneous
• Replace spring.
operation of travel
• Broken or deformed spring. • Remove foreign matter.
and attachment.
• Clogged small hole in spool.
2) Malfunctioning main relief valve. 2) Remove main relief valve.
33-108
33. UPPER STRUCTURE

3. Excessive natural 1) Excessive clearance between casing and 1) Replace spool.
falls of attachment spool.
under its own weight 2) Spool is not completely in neutral position. 2) Check secondary pilot pressure.
when spool is in • Foreign matter between casing and • Disassemble, clean and smooth
neutral. spool, or sticking spool. sticking part with oil stone.
• Broken or deformed spring. • Replace spring.
• Clogged pilot circuit. • Remove foreign matter.
3) Malfunctioning overload relief valve. Refer 3) Check overload relief valve pressure.
to item 1. 1) above. (See 33.2.2.3.20 (2))
(See 33.2.2.3.20 (2)) • Clean and check damage on seat
• Foreign matter between valve seat and surface.
casing.
4) Lock valve function is faulty. 4) Replace
(Arm, boom)
• Foreign matter between poppet seat • Disassemble, clean.
and casing. • Correct stuck part with oil stone or
• Poppet is stuck. replace.
• Replace spring.
• Broken or deformed spring. • Replace lock valve selector assy.
• Selector spool is stuck.
4. When raising 1) Malfunctioning load check valve. 1)
attachment, at first it • Foreign matter between poppet and • Disassemble and clean. If heavily
drops. casing. damaged, replace control valve.
• Correct sticking part with oil stone.
• Replace spring.
• Sticking poppet.
• Broken or deformed spring.

5. Bucket, boom, arm or 1) Malfunctioning main spool. 1) Check secondary pilot pressure.
swing does not • Excessive clearance between casing • Replace spool.
operate. and spool. • Disassemble and clean.
Slow to start up (or
• Foreign matter between casing and • Correct stuck part with oil stone.
poor power).Slow
spool.
response. • Replace spring.
• Sticking spool.
• Broken or deformed return spring.

• Clogged pilot circuit.
2) Malfunctioning main relief valve. Refer to 2) Check main relief valve pressure. Refer to
item 1. 1) above. item 1. 1) above.
(See 33.2.2.3.20 (2)) (See 33.2.2.3.20 (2))
3) Malfunctioning overload relief valve. Refer 3) Check overload relief valve pressure.
to item 1. 1) above. (See 33.2.2.3.20 (2))
(See 33.2.2.3.20 (2))
33-109
33. UPPER STRUCTURE

6. Boom conflux does 1) Malfunctioning conflux valve. 1) Measure pilot pressure.
not operate. • Excessive clearance between casing • Replace spool.
and spool. • Disassemble and clean.
• Foreign matter between casing and • Correct stuck part with oil stone.
spool.
• Replace spring.
• Sticking spool.
• Broken or deformed return spring.

• Clogged pilot circuit.
33.2.2.6.2 Relief valve

1.No pressure rise. Main or pilot poppet of relief valve is sticking Check for foreign matter on each poppet.
and valve is open, or there is foreign matter Confirm that each component slides
on valve seat. smoothly.
If failure is found, replace it in an assembly.
2. Unstable relief Main or pilot poppet of relief valve seat is If failure is found, replace it an assembly.
pressure. damaged.
3. Incorrect relief 1) Wear due to foreign matter. 1) Replace damaged assembly
pressure setting. 2) Loosened locknut or adjusting screw. 2) Adjust pressure.
4. Oil leak. Confirm that each component operates
smoothly. Replace damaged or worn
1) Damaged seat. component.
Damaged O-ring. 1) If failure is found, replace it an assembly.
2) Sticking component due to foreign matter. 2) Confirm that there are no scratches,
scores, or foreign matter present before
reassembling.
If failure is found, replace it an assembly.
33-110
33. UPPER STRUCTURE
33.2.3 PILOT VALVE (ATT)
33.2.3.1 CROSS-SECTIONAL VIEW
312
302
Apply grease on
rotating and
501
Apply grease on 301 sliding sections.
Be careful the
top section assembling
212 direction
213
151
* 246
* 218-2
211
214
* 218-1
216-2 216-1
241-2 241-1
201-2
201-1
217
Secondary
pressure 101 221
adjusting shim
Designed value
t=0.4 (0.061 in),
1 pc
PORT PORT
2,4 1,3
Fig. 33-180 Pilot valve (For ATT)
Apply loctite #277 to areas marked

101 Casing 1 *218-1 Seat 2
151 Plate 1 *218-2 Seat 2
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
212 Push rod 4 *246 Spring 4
213 Seal 4 47.1 (35) 301 Joint : M14 1
214 O-ring ; 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (51) 312 Adjust nut : M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4
Note) The parts marked * might not be equipped depending on valve type.
33-111
33. UPPER STRUCTURE
(1) Plug each port of pilot valve, and clean it with
kerosine. 501
P port : PF1/4
1~4 and T port : PF3/8
(2) Fix pilot valve with vise via a protective plate
(Alminum plate etc.), and remove boots (501).
Fig. 33-181 Removing boot (501)

(3) Remove adjusting nut (312) applying spanners to
adjusting nut (312) and circular plate (302).
312
: 22mm, 32mm
302
Fig. 33-182 Removing adjusting nut (312)

(4) Remove circular plate (302)
302
: 32mm
Fig. 33-183 Removing circular plate (302)
Fig. 33-184 Circular plate is removed
33-112
33. UPPER STRUCTURE
Fig. 33-185 Installing Jig A

(5) Turn joint (301) in counterclockwise with Jig A to
remove.
Jig A : See page 33-120.
: 24mm
301
When the force of return springs (221) is strong, never

loosen joint (301). If loosened, it might result in jumping
out of plate (151), plug (211) and push rod (212).
Remove joint (301) pressing plate (151) downward with
two fingers. Fig. 33-186 Removing joint (301)
(6) Remove plate (151)

• When the force of return springs (221) are 151
strong, press plate to let it come up slowly.
Fig. 33-187 Removing plate (151)

• When the force of return springs (221) are weak,
plug is left in casing (101) due to sliding
resistance of O-ring (214).
Pull plug (211) out with a driver.
To prevent personal injury, plug (211) must be removed

slowly and evenly until the return spring (221) force is
completely released.
211
Fig. 33-188 Removing plug (211)
33-113
33. UPPER STRUCTURE
(7) Remove push rod (212), plug (211), pressure

reducing valve assy (spool), return springs (221)
from casing (101). 212
211
Record combination of port holes on casing and the 221

pulled out parts. The stroke differs according to
direction.
101
Fig. 33-189 Removing push rod, plug, pressure

reducing valve and spring
(8) Push springs (241-1), (241-2) in the range of 7mm
(0.276in) that the movement of spring seats (216- 216-1
216-2
1), (216-2) and shift the seats (216) in a side
direction, and remove spools (201-1), (201-2)
through the larger hole of seat.
Never push down spring seat (216-1) in 7mm (0.276in)

or more. (For port 1,3)
201-1
Never push down spring seat (216-2) in 9.4mm
201-2
(0.370in) or more. (For port 2,4)
Fig. 33-190 Removing spool (201)
(9) Remove spool (201-1), (201-2), spring seats (216-
1), (216-2), spring (241-1), (241-2) and washer 241-1 216-1
(217). 241-2 216-2
217
201-1
201-2
Fig. 33-191 Disassembling pressure reducing valve

(10)Remove spring (*246), spring seat (*218-1), (*218-
2) from push rod (212). *218-1 *246 214
*218-2
The parts marked * might not be equipped depending

on valve type.
212
211
Fig. 33-192 Disassembling push rod
33-114
33. UPPER STRUCTURE
(11)Pull out push rod (212) from plug (211).

(12)Remove O-ring (214) from plug (211).
212
Fig. 33-193 Removing push rod (212)

(13)Remove inside seal (213) from plug (211) with
small driver.
213
Fig. 33-194 Removing seal (213)
33.2.3.3 CLEANING PARTS

(1) Clean parts with wash oil roughly.
(2) Clean parts with wash oil completely.
(3) Dry parts by swabbing clean rag.
(4) Apply rust preventives on parts.
33.2.3.4 ASSEMBLING
(1) Fit washer 2 (217), springs (241-1), (241-2), spring
seats (216-1), (216-2) to spool (201-1), (201-2). 201-1 241-1 216-1
216-2
201-2 241-2
217
Fig. 33-195 Assembling pressure reducing valve
33-115
33. UPPER STRUCTURE
(2) Push spring (241-1), (241-2) in the range of that the

movement of spring seats (216-1), (216-2) in a side 216-1
direction, and install spools (201-1) through the 216-2
larger hole of spring seat. (See Fig. 33-190)
Never push down spring seat (216-1) in 7mm (0.276in)

or more. (For port 1,3)
Never push down spring seat (216-2) in 9.4mm 201-1
(0.370in) or more. (For port 2,4) 201-2
Fig. 33-196 Installing spools (201-1), (201-2)

(3) Place spring (221) into ports 1,3 of casing (101),
and then install pressure reducing valve assy in it. PRESSURE REDUCING
VALVE ASSY
Place springs (221) into ports 2,4 and install it.
221
Install the removed respective assy into respective

holes. 101
Fig. 33-197 Installing pressure reducing valve assy

(4) Fit O-ring (214) and seal (213) into plug (211).
• Apply hydraulic oil on surface of push rod. 211
214 213
PLUG (211)
SEAL (213)
-RING (214)
PUSH ROD
(212) Apply hydraulic oil
For the assembling

direction of seal (213). Fig. 33-198 Installing O-ring (214) and seal (213)
(5) Insert push rod (212) in plug (211) and install spring
(*246) and spring seat (*218-1) to push rod (212) on
port 1,3 side.
And install spring seat (*218-2) to push rod on port
2,4 side.
The parts marked * might not be equipped depending

on valve type.
212 211 246 218-1
Fig. 33-199 Assembling push rod, spring (246) and
seat (218)
33-116
33. UPPER STRUCTURE
(6) Fit plug (211) assy to casing (101).

1) When the force of spring (211) is weak, it stops
at the position where it is pushed in by the sliding
resistance of O-ring (214).
101 211
Fig. 33-200 Installing plug assy

2) When the force of spring (221) is strong, attach
plate (151) and press 4 push rods by hand at the 301
same time, and tighten joint (301) temporarily.
• Install spool (201) straight and evenly into the
hole of casing (101).
• Take care so that plug (211) and plate (151) do
not jump out of casing (101).
151
Fig. 33-201 Installing plug assy and plate (151)

(7) Install joint (301) on casing (101) with jig A securely.
Jig A : See page 33-120.
Tightening torque : 47.1 N•m (35±2.2 lbf•ft)
101
A
Fig. 33-202 Installing joint (301)
33-117
33. UPPER STRUCTURE
(8) Install circular plate (302) to joint (301)
• Screw it in until it comes in contact with 4 push rods 312

(212) equally.
• The exceeding of screw in may cause malfunction
of machine. 302
(9) Screw adjusting nut (312) in until it touches circular

plate (302), and tighten it applying spanner to stop
circular plate returning.
Fig. 33-203 Installing circular plate (302)
: 32mm
: 22mm
• Apply Loctite #277 to threads of joint.
(10)Apply heat-resisting grease to joint (301) rotating
section and the top of push rod (212).
(11)Cover it with boots. GREASE
(12)Spray rust preventives through each port and

attach plug respectively.
301
212
Fig. 33-204 Applying grease to joint section and

push rod
33-118
33. UPPER STRUCTURE
Check item Standard Remarks

When leakage quantity reaches to 1000cc/ min.
or more where handle is set in neutral position,
Conditions
or to 2000cc/min. or more in operation, replace
Leakage Primary pressure 2.94 MPa (426 psi)
spool with new one.
Hydraulic oil viscosity 23 cSt
If leaked, even if the spool is replaced, replace
pilot valve assy with new one.
When the wear of sliding section is 10 more
This condition may be the same as the
Spool than the that of non sliding section, replace it
above.
with new one.
Push rod When the wear of top is 1mm (0.04in) or more, replace it with new one.
When looseness of 2mm (0.08in) or more on
In case of the looseness due to the
Looseness of control circular plate (302) on control section and joint
loosening on tightening section, adjust
section section (301) due to wear is produced, replace
it.
them with new ones.
When trouble such as noise, hunting, drop of
primary pressure, etc. has occurred in op-
eration, and it does not restore after taking
Stability of operation
corrective action according to below 33.2.3.6 (
TROUBLESHOOTING), replace pilot valve
assy with new one.
• O-ring, etc. should be replaced with new one at every disassembling.

• If socket bolt (125) was loosened, seal washer (121) should be replaced.
It is very difficult to find defective section. The following table explains the several estimated causes. For repair, refer
to the estimated causes and corrective actions.
The following table explains general phenomenon, estimated causes and corrective actions. However, most
machine problems are not caused by the failure of only one part, but involve relations with other parts. Therefore
corrective action other than those described in this table is often required. The following table does not cover causes
and corrective actions for all the troubles. So it may be necessary to perform further investigation of troubles and
causes.
Trouble Cause Remarks

1) Primary pressure is insufficient. 1) Secure primary pressure.
2) Secondary pressure springs (241) are
2) Replace with new ones.
broken or fatigued.
Secondary pressure
3) Clearance between spool (201) and
does not rise . 3) Replace spool (201).
cas-ing (101 ) is abnormally large.
4) Disassembly and reassembly or
4) Handle has a looseness.
replace handle section.
1) Sliding parts are caught. 1) Repair the unsmoothed section.
Secondary pressure is
2) Tank line pressure varies. 2) Bring pressure directly to oil tank.
unstable.
3) Air has mixed into pipeline. 3) Bleed air by operating it several times.
Secondary pressure is 1) Tank line pressure is high. 1) Bring pressure directly to oil tank.
high 2) Sliding parts are caught. 2) Correct.
33-119
33. UPPER STRUCTURE
33.2.3.7 JIG
(1) Jig for removing and installing joint (301)
(1)
Material ; SCM415 (N)
Carburizing and Quenching
(2) BUSHING
Material ; S45C
SECTION AA
A A
Installing condition on joint
* (1) and (2) are tight fitted
Sectional drawing of jig
Material ; SCM415 (N)

Carburizing and Quenching
Q'ty ; 2
Detail of bushing
33-120
33. UPPER STRUCTURE
33.2.4 PILOT VALVE (FOR TRAVEL)
T=Tightening torgue
N.m (lbf.ft) 12-o
12-o
7-h
12-o
12-y
5 12-y
12-x 12-x
13
6 8
f
d
Loctite 262 10
g
T=3
g
14
q 11
T=5 (3.7) r 15
u
t T=4 (3)
7-i T=30 (22)
15
7-k T=1.2 (0.9)
7-h u
15 t T=4 (3)
7-j t 14
u
r
q
17 21 T=5 (3.7)
Loctite 262 21
21
z
r 21
w' T=3~5 (2.2~3.7)
Fig. 33-205 Exploded view of pilot valve

5 Rubber boots 2 12-x Seal ø14×20×3 6
6 Foot pedal (Switch plate) (2) 12-y Wiper ring 6
6-d Switch plate 2 13 Damper spring 4
6-f Regulation screw M8×28 4 14 Check valve kit (2)
6-g Set screw M5×8 4 14-q Plug M8 2
7 Retaining plate kit (1) 14-r Ball M6, 35 2
7-h Plate 1 15 Orifice (4)
7-i Capscrew M10×20 2 15-u Plug M6 4
7-j Shaft 2 15-t Orifice M6, ø0.6 4
7-k Set screw M4×10 2 17 Shuttle valve kit (2)
8 Flange kit 4 17-w’ Shuttle valve & orifice 2
10 Control spool 4 17-r Ball M6, 35 2
11 Return spring 4 17-z Orifice M5, ø0.8 2
12 Damper flange kit (4) 21 Plug 4
12-o Damper plunger ø14 4
33-121
33. UPPER STRUCTURE
33.2.4.2 DISASSEMBLY AND ASSEMBLY

(1) Boot replacement

The pilot control unit does not need to be removed from

the machine to perform this operation.
1) Remove both faulty boots.

(using a flat screw driver if necessary)
2) Replace both boots with a new one.
* Reassembly :

• First fit the lower part of the rubber boot on
the retaining plate between the 2 switch
plates
• Then put the lower part in the external
groove of the retaining plate
• Finish by fitting the upper part of the rubber
boot on the switch plate.
Fig. 33-206
(2) Switch plate removal
1) Remove :

• The pilot control unit from the machine.
• Both rubber boots (See 33.2.4.2 (1))
2) Remove the screw locking the axis using a 2mm
socket wrench. (See Fig. 33-207 No.1)
* Reassembly :
• Apply a droplet of Loctite #262 on the

locking screw thread.
• Torque :1.2 N•m (0.89 lbf•ft)
3) Fit a M3 screw on the switch plate axis in order
to remove it
(Using pliers if necessary). (See Fig. 33-207
No.2)

* Reassembly :
• Position the axis so that the hole is aligned
with the locking screw as shown on the
picture (See Fig. 33-207 No.3)
4) Mark out the position of the switch plate before
removing it.
Fig. 33-207
5) Repeat the operation for the second switch plate.
6) Reassemble parts in reverse order.
33-122
33. UPPER STRUCTURE
(3) Switch plate adjustment
If the switch plate is replaced, it is necessary to adjust

the regulation screws.

1) Unscrew the 2 locking screws using a 2,5mm
socket wrench (See Fig. 33-208)
* Reassembly :
locking screw thread.
• Torque :3 N•m 2.2 (lbf•ft)
2) Set the switch plate horizontally.
3) Screw on simultaneously both regulation screws
using a flat screw driver (5,5×150) until feeling Fig. 33-208
some resistance.
Do not misadjust the two damping screws. (See Fig.

33-209)
Regulation Damping screws
screws to already adjusted
4) Tighten the locking screws to hold the regulation adjust and glued
screws in position.
5) Repeat the operation for the second switch plate
making sure both switch plates are parallel. (See
Fig. 33-208) SWITCH PLATE
The figure is shown
from the backside.
(4) Retaining plate removal
Fig. 33-209
1) Remove
• Both switch plates (See 33.2.4.2 (2))
2) Unscrew simultaneously both screws holding the
retaining plate using a 8mm socket wrench.
(See Fig. 33-210)
* Reassembly :
• Apply a droplet of Loctite #262 on the screw
thread.
• Torque :30 N•m (22 lbf•ft)
Fig. 33-210
33-123
33. UPPER STRUCTURE
3) Lift the retaining plate to remove it.

(See Fig. 33-211)
* Reassembly :
• Use the retaining plate to insert the 4 guides
into the body simultaneously and
perpendicularly.
(See Fig. 33-211 left side)
5) Drain the pilot control unit (See 33.2.4.3).
Fig. 33-211
(5) Damping plunger seals replacement
1) Remove
• Both rubber boots. (See 33.2.4.2 (1))
• The retaining plate (See 33.2.4.2 (4))
WIPER RING
2) Remove the wiper ring of the damping plunger
1 2 DAMPER PLUNGER
(1).
(See Fig. 33-212 No.1) Fig. 33-212
* Reassembly :
• Replace with a new wiper ring.

Always place the damping plunger prior to the wiper

ring, and make sure the wiper ring is correctly

positionned.

3) Remove the damping plunger (2).

(Fig. 33-212 No.2)
Fig. 33-213
4) Using a needle, remove the seal placed inside

the body (See Fig. 33-214 No.3, 4)

* Reassembly :
• Replace with a new seal and grease it.
3 4
Fig. 33-214
33-124
33. UPPER STRUCTURE
• Squeeze the seal between your fingers to

obtain a 8-shape.
(See Fig. 33-215 No.5)
• Insert the seal within the groove with your
fingers (lip in bottom position).
(See Fig. 33-215 No.6, 7)
• Push the seal against the side using the 5 6
round head of a small socket wrench. (Fig.
33-215 No.8)
During the reassembly, make sure the seal is correctly

positionned, and pay attention not to damage nor twist
it. 7 8
5) Repeat the operation for the other 3 assemblies. Fig. 33-215
6) Extract the damping springs from the body (using

flat nose pliers).
7) Inspect the damping springs. If defects are
detected, replace the 4 springs.
(6) Guide/plunger and regulation unit replacement
1) Remove
• The retaining plate (See 33.2.4.2 (4)) DAMPER
PLUNGER
2) Guide/plunger replacement :
BODY
• Insert the end of a thin screwdriver between
the guide and the body, carefully lift the guide
to remove it from the body.
Hold the guides with the other hand during the

extraction operation to limit the effect of the return
spring.
3) Remove the guide / plunger assembly.

4) Repeat the operation for the other 3 sub-
assemblies.
5) Visually check that the guides / plungers are in
good condition. If defects are present, replace
the 4 sub-assemblies.
Fig. 33-216
33-125
33. UPPER STRUCTURE
6) Guide/plunger and relulation unit replacement

• Extract the regulation units from the body
(using flat nose pliers).
• Inspect the regulation units. If defects are
detected on the parts, replace the 4 units.
7) Return spring replacement :
• Extract the return springs from the body
(using flat nose pliers).
Fig. 33-217
• Inspect the return springs. If defects are
detected, replace the 4 springs.
Fig. 33-218
(7) Throttle kit replacement
1) Remove
• The pilot control unit from the machine
• The retaining plate (See 33.2.4.2 (4))
• The damping plungers and springs (See
33.2.4.2 (5))
Fig. 33-219
33-126
33. UPPER STRUCTURE
2) Unscrew the screw using a 3mm socket wrench.

(See Fig. 33-219)
* Reassembly :
• Apply a droplet of Loctite #262 on the screw
thread
• Screw on until it sets just above the body.
(See Fig. 33-220)
3) Unscrew the throttle using a 3mm socket
wrench.
* Reassembly :
4) Repeat the operation for the other 3 assemblies.
SCREW
5) Replace with new screws and new throttles.
THROTTLE
Fig. 33-220
(8) Shuttle valve kit removal
1. Remove the pilot control unit from the machine
The pilot control unit does not need to be disassembled

to perform this operation.
2) Unscrew the shuttle valve using a 4mm socket

wrench. (See Fig. 33-221 and Fig. 33-222)
* Reassembly :
• Thoroughly clean the body to remove any
trace of loctite. Fig. 33-221

shuttle valve thread.
Wait for 8 hours before using the machine to let the

Loctite #242 dry completely.
Fig. 33-222
33-127
33. UPPER STRUCTURE
3) Put the body up-side-down to remove the shuttle

valve and the ball. (See Fig. 33-224)
4) Unscrew the throttle using a 2,5mm socket
wrench.
* Reassembly:
• Hand tighten.
5) Repeat the operation for the other
subassemblies.
6) Inspect the shuttle valves, balls and throttles. If
defects are detected, replace all the assemblies.
Fig. 33-223

Fig. 33-224
(9) Check valve kit removal
1) Remove the pilot control unit from the machine
The pilot control unit does not need to be disassembled

to perform this operation.
2) Unscrew the check valve plug using a 4mm

socket wrench.
(See Fig. 33-225)
* Reassembly :
• Drain the pilot control unit
(See 33.2.4.3)
Fig. 33-225
• Torque :5 N•m (3.7lbf•ft)
3) Put the body up-side-down to remove the ball.
4) Repeat the operation for the second check valve
kit.
5) Inspect the check valve plugs, O-rings and balls.
If defects are detected, replace all the
assemblies. (See Fig. 33-226)

Fig. 33-226
33-128
33. UPPER STRUCTURE
33.2.4.3 DRAIN OF HYDRAULIC PILOT CONTROL UNIT

(1) When removing the retaining plate, the throttle kit or
the shuttle valve kit, it is necessary to drain the pilot
unit.
(2) Reassemble the pilot unit control completely.
(3) Install the pilot unit control in the machine.
(4) Slightly unscrew the check valve plug using a 4mm
socket wrench. (See Fig. 33-227)
(5) Switch on the machine.
(6) Operate gently the pedal until the bubbles
disappear.
(7) Tighten the check valve plug.
• Torque : 5 N•m (3.7 lbf•ft)
(8) Repeat the operation for the other check valve plug.
Fig. 33-227
33-129
33. UPPER STRUCTURE
(1) Swing motor

()"
!

"
#
$%
&
$''

&"

*+ $
,
% %
'
% ' $$$ '$ $

$

%

'
$
$
$&

$&

$
$

&

$
$ $$ $
Fig. 33-228 Swing motor
33-130
33. UPPER STRUCTURE
177 (130) 051 Relief valve ; M33-P1.5 2 69 (51) 400 Anti-reaction valve ; M22-P1.5 2
051-1 O-ring ; 1B G30 2 400-1 O-ring ; 1B P20 2
052 Anti-reaction valve sub 1 400-2 Backup ring 2
100 Casing for anti-reaction valve 1 431 (320) 401 Socket bolt ; M20×45 4
101 Drive shaft 1 443 Roller bearing 1
111 Cylinder 1 444 Roller bearing 1
114 Spring plate 1 451 Pin 2
121 Piston 9 334 (250) 469 ROMH plug ; M30-P1.5 2
122 Shoe 9 472 O-ring 1
123 Set plate 1 488 O-ring ; 1B P28 2
124 Shoe plate 1 491 Oil seal 1
131 Valve plate 1 702 Brake piston 1
36 (27) 151 Plug ; PF1/4 2 706 O-ring 1
161 O-ring ; 1B P11 2 707 O-ring 1
162 O-ring ; 1B P12 2 712 Brake spring 16
163 O-ring ; 1B P6 2 742 Friction plate 3
29 (22) 171 Socket bolt ; M8×55 4 743 Separator plate 4
301 Casing 1 0.9 (0.65) 980 Plug ; PF1/4 1
303 Valve casing 1 1.7 (1.2) 984 Plug ; PF3/8 1
351 Plunger 2 4.4 (3.3) 985 Plug ; PF3/4 3
355 Spring 2 65 (48) 993 Plug ; PT1/2 1
390 Name plate 1 98 (72) 994 Plug ; PT3/4 1
391 Rivet 2
33-131
33. UPPER STRUCTURE
(2) Swing reduction unit

Be careful about installation
direction of retaining ring.
Apply Three Bond #1360 Caulk these 2 places
or equivalent. with punch.
OIL FILLING PORT PT3/4
LEVEL PORT PT1/2
Apply Loctite #515.
SURFACE OF Be careful about

LUBE OIL installation direction
of spring pin.
VIEW (II) (4 places)
Apply Loctite #515.
Be careful about
of retaining ring. Drive this spring pin
into 1mm lower than
the surface of spider.
Apply Loctite #515.
Install the filling port Tightening torque

of this fitting toward 69.1+4.4 N.m
motor side. (51.0+3.2 lbf.ft)
Apply seal tape or
Loctite #577.
Fill up this space

with grease.
Fig. 33-229 Sectional view of swing reduction unit

1 Pinion shaft 1 17 Needle bearing 4
2 #1 sun gear 1 18 Thrust washer 8
3 #1 pinion 3 19 Snap ring 1
4 #2 sun gear 1 20 Snap ring 1
5 #2 pinion 4 21 Sleeve 1
6 Ring gear 1 22 Spring pin 4
7 Spider assy 1 181 (134) 23 Socket bolt ; M14×135 11
8 Spider 1 24 Cap 2
9 Shaft 4 25 Tube ; L=112 1
10 Spherical bearing 1 26 Elbow 1
11 Spherical bearing 1 69.1 (51.0) 27 Plug 1
12 Oil seal 1 28 Snap ring 3
13 Housing 1 30 Oil seal 1
15 Thrust washer 6 31 Grease fitting 1
16 Needle bearing 3 32 Relief fitting 1
33-132
33. UPPER STRUCTURE
33.2.5.2 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR
33.2.5.2.1 Tools
Tools Remarks
Socket wrench Relief valve M33×P1.5 41mm
M8, M20 6,10,12,17mm
Allen wrench ROMH PLUG M30×P1.5 14mm
ROH PLUG PF1/4 6mm
Screwdriver Flat-bladed type, medium size 2 pcs.
10×8×200(0.39"×0.31"×7.87")
Steel bar
(key material) 1 pc.
Hammer Plastic hammer 1 pc.
10~45 (7.2~33)
Torque wrench N•m (lbf•ft) 40~180 (29~130)
120~480 (87~350)
Slide hammer bearing puller
14 (0.551")
85 (3.35")
75 (2.95")
30 (1.18")
15 (0.591")
35 (1.38") 5
2. 2")
R1 .49
M16 ( 0
Through
Brake piston drawing tool
100 (3.94")
44 (1.73")
8 (0.315")
M18
4
(0.158")
BRAKE PISTON
DRAWING TOOL
o 8 (0.315") BRAKE PISTON
CASING
33-133
33. UPPER STRUCTURE
33.2.5.2.2 Disassembly
(1) General cautions
1) Hydraulic components are precision products
and have small clearance. Therefore, assemble
and disassemble in a less dusty clean place. Use
clean tools and cleaning oil and handle
components with full care.
2) If a component is removed from the main body,
clean the area around the ports thoroughly and
plug them up so no dust and water do not enter.
When fitting them back to the body, do not
remove the plugs till piping is completed.
3) Study the structural drawing before the work
begins and prepare necessary parts according to
your purpose and the scope of work. Seals and
O-rings once removed can not be used again.
Some parts can not be supplied as single parts
and available only in sub assy. Prepare such
parts according to the parts manual.
4) The piston and the cylinder block are shop fitted
when new. If you intend to reuse them, put a
matching mark on the piston and the cylinder
block.
(2) Disassembly procedure

The figures in parentheses after part names in this
manual represent those item numbers in Fig. 33-
228
1) Draining oil
Remove the drain plug and drain hydraulic oil
from casing (301).
2) Preparation for removing the valve casing #
Fix the motor on a work bench so the drive shaft
(101) end comes down. On that occasion, put a !! #
matching mark on the mating parts of casing
(301) and valve casing (303). %
%
• Choose a clean place, and lay with a rubber
sheet or a cloth on a work bench. Handle the
valve casing with care so parts do not have
dents.
!
Fig. 33-230 Removing valve casing (303)
33-134
33. UPPER STRUCTURE
3) Loosen relief valve (051) and separate it from !#

valve casing (303).
: 41 mm
!##
!!
4) Loosen anti-reaction valve sub assy (052) and
remove from valve casing (303). (See Fig. 33-
230)
"$'
: 6 mm
5) Separate ROMH plug (469) from valve casing

(303) and draw out spring (355) and plunger
(351). " #
Fig. 33-231 Removing relief valve (651),
: 14 mm
anti-reactionvalve (052),
anti-cavitation plunger (351)
6) Loosen socket bolt (401) and separate valve
and valve casing (303)
casing (303) from casing (301). If the socket bolt
(401) are loosened, the valve casing floats off

casing (301) by the force of brake spring (712).
Then separate valve plate (131) from valve

casing (303).
: 17 mm
7) Draw out brake spring (712) from brake piston

(702).

8) Put the claw of the brake piston removing jig in
the concaved part of brake piston (702). Fig. 33-232 Removing brake piston (702)
Tighten 2 bolts of jig simultaneously, and draw
out the brake piston (702) with the jig, from the
!
casing.

9) Lay the motor on its side again and draw out

cylinder block (111) from drive shaft (101). Then "
draw out piston (121), set plate (123), spring
(114) and shoe plate (124).
Handle the parts with care so as not to score the sliding

surfaces of cylinder block (111) and shoe (122).
! %" %"!
Fig. 33-233 Drawing cylider block (111), piston sub

assy, friction plate (742) and separator plate
33-135
33. UPPER STRUCTURE
10) Draw out friction plate (742) and separator plate

(743) from casing (301). 301
11) Draw out drive shaft (101) from casing (301),

while lightly tapping the side face of valve casing
(303) in drive shaft (101), using a plastic mallet. PLASTIC
MALLET
• Do the following work as required.
101
a. Drawing the inner race of roller bearing (443)

from drive shaft (101), using a press. 443
• Do not reuse the removed bearing.

Fig. 33-234 Removing drive shaft (101)
b. Drawing out the outer race of roller bearing (443) PRESS
from casing (301), by lightly tapping the steel rod
101
from the oil seal (491) housing side.
(Do not reuse the bearing.)
c. Separate the outer race of roller bearing (444)

443
from valve casing (303), using a slide hammer
bearing puller.
Put the inner race

on the press bench.
Fig. 33-235 Removing inner race of

roller bearing (443)
33-136
33. UPPER STRUCTURE
33.2.5.2.3 Assembly
(1) General precautions
1) Repair those parts damaged after disassembly
and prepare replacement parts beforehands.
2) Clean all parts thoroughly in cleaning oil and dry
them with jet air.
3) Always coat the moving parts with clean
hydraulic oil, before assembly.
4) Replace such seals as O-ring and oil seal in
principle.
5) Tighten socket bolts and plugs to specified
torques, using a torque wrench.
(2) Assembly procedure OUTPUT SHAFT SIDE

The figures in parentheses after part names in this 101
manual represent those item numbers in the Fig.
33-228.
1) Preparation for assembly 443
Place casing (301) on a proper bench so its valve
casing (303) faces upward.
• This operation is necessary only when the

roller bearing is removed.
2) Shrinkage fit the inner race of roller bearing (443)

into drive shaft (101).
444
3) Shrinkage fit the inner race of roller bearing (444)
to drive shaft (101). Fig. 33-236 Assembling the inner race of bearings
(443), (444)
• This operation is necessary only when the oil
seal is removed.
Fit oil seal (491) to casing (301). On that
occasion, coat the lip of the oil seal with
grease and check the direction of it, before
fixing it.
4) Assemble the outer race of roller bearing (443)

into casing (301), by lightly tapping the steel rod.
5) Attach drive shaft (101) to casing (301).
""! "'
!
Fig. 33-237 Fitting oil seal (491), outer race of
roller bearing (443), and drive shaft (101)
33-137
33. UPPER STRUCTURE
6) Place casing (301) as shown in Fig. 33-238 and

insert shoe plate (124).
On that occasion, the shoe plate does not come
off if it is coated with grease.
The larger
chamfer side
124
443 301
101
Fig. 33-238 Inserting shoe plate (124)

7) Set the set plate (123) and spring (114), then set !
piston sub (121, 122) assy.
8) Assemble piston sub assy (121, 122) fixed in

retainer plate (123) into cylinder (111). Match it to
the spline of drive shaft (101) and insert it in
place.
"

Fig. 33-239 Inserting cylinder assy
9) Replace casing (301) with oil seal (491) facing
downward and assemble separator plate (743)
and friction plate (742) into casing (301), in that
order.
Assemble four separator plates and three friction
plates.

Assemble the same phases of four slits in the gears of

friction plate (742).
Assemble four slits in the four claws of separator plate
(743) in the position of Fig. 33-240.

Fig. 33-240 Installing of separator plate (743),
friction plate (742).
33-138
33. UPPER STRUCTURE
10) Fit O-rings (706), (707) to casing (301). In that

702
case, if the O-rings are coated with grease, they
are hard to tear off when brake piston (702) is
inserted.
11) Assemble brake piston (702) into casing (301).
12) Assemble brake spring (712) into brake piston

(702). In that case, make sure that a spring is
placed securely in the spot faced part of the
brake piston. SLIT (OPPOSITE SIDE)
PG PORT
• This operation is necessary only where roller Fig. 33-241 Assembling brake piston
bearing (444) is removed.
13) Insert the outer race of roller bearing (444) into

valve casing (303), while lightly tapping the steel
rod placed on the outer race, using a hammer.
14) Assemble valve plate (131) into valve casing

(303) and fit O-ring (472) in it.
15) Install valve casing (303) to casing (301) and

fasten them with socket bolts (401).
: 17 mm,
16) Fit plunger (351) and spring (355) to valve

casing (303). Then tighten ROMH plug (469)
fitted with O-ring (488) against valve casing
(303).
: 14 mm,
17) Fit relief valve (051) to valve casing (303).
: 41 mm,
18) Fit anti-reaction sub assy (052) to valve casing

(303).
: 6 mm,
33-139
33. UPPER STRUCTURE
33.2.5.3 DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT
33.2.5.3.1 Tools
Code Tool name Remarks
Material : Mild steel 412

270
a Stand
230
o 162
Material : Mild steel
22
Spherical bearing (10) 13-o 16
190
b (Position
removing jig (I) space equally)
P.C.D 146
VIEW X
X

Spherical bearing (11)
c
removing jig (II)

d
removing jig (I)
Material : Mild steel 150

Oil seal (30) 125
e
9
installing jig


f
press-fit jig

g
Oil seal (12)

installing jig


h
press-fit jig

33-140
33. UPPER STRUCTURE
Code Tool name Remarks

i Snap ring plier For shaft
j Torque wrench 200 N•m (148 lbf•ft) class
k Plastic hammer (Wooden mallet)
m Press 30 ton (66150 lb) class
n Flat-bladed screw driver
p General tools Allen wrench, Steel bar
Thread sealant Three Bond #1360K
q
Sealant Loctite #515
The numbers in parentheses correspond to the ones in
construction drawings Fig. 33-228.
(1) Preparation
1) Before disassembly, clean the outside of the
reduction unit thoroughly and check for no
damage and scoring.
2) Drain gear oil from the reduction unit.
3) Disconnect the drain tube.
4) Matching Mark
To facilitate the reassembly of the unit, put
matching mark on the joining parts of the housing
before disassembly.
(2) Disassembling swing motor from reduction unit

1) Preparation for disassembly
SWING MOTOR
Place the reduction unit assy on a stable work
bench as shown in Fig. 33-242, remove plug
23
(27), drain out oil and put a matching mark on the
matching surface of the figure on the right.
MATCHING
MARK n
2) Removing swing motor assy
Loosen all socket bolt (23) (M14). Attach eye
bolts (M10) in the lifting bolt holes in the top
surface of the swing motor and lift the assy by
crane.
27
If it is hard to remove the swing motor assy from
the reduction unit, float it by inserting a flat-blade Fig. 33-242 Removing swing motor assy
screwdriver in the groove of the flange. 7
2
: 12 mm
(3) Disassembling reduction unit 6

1) Remove #1 sun gear (2).
2) Removing #1 spider assy (7).

The spider assy (7) [consisting of thrust washer
13
(15), #1 pinion (3), needle bearing (16) and snap
ring (28)] can be removed from the spline easily
Fig. 33-243 Removing #1 sun gear and
if it is lifted up in that condition.
#1 spider assy
33-141
33. UPPER STRUCTURE
3) Removing ring gear (6)

Attach eye bolts (M10) to the top surface of ring
gear (6) and lift the ring gear lightly by a wire

sling.
Put a flat-blade screwdriver (n) into the matching
surface of ring gear (6) and housing (13) and
remove ring gear (6) by lightly tapping the outer
circumference of the ring gear with a plastic
mallet (k).
Fig. 33-244 Removing ring gear (6)

4) Remove #2 sun gear and #2 spider assy. 521,-4 )55;
Draw out #2 sun gear (4) and remove the #2
"
spider assy.
Regarding the disassembly of the #2 assy, refer
to par. (4) which will come up later.
Fig. 33-245 Removing #2 spider assy

• Particularly if no failure is found, the further
disassembly (under condition shown in Fig.
33-246) is not allowed.
Check on parts for possible failure according
to the inspection procedure shown in item
33.2.5.4.2 separately in this condition.
And we recommend that the pinion shaft and
housing assy are replaced together as one
set. But if it is unavoidably necessary to
replace a part of them, follow the procedure
shown below.
• If no failure is found in this step, the
disassembly later is not required.
Fig. 33-246
5) Remove retaining ring (20) from pinion shaft (1).
33-142
33. UPPER STRUCTURE
6) Pulling out pinion shaft

PRESS
Pull pinion shaft (1), sleeve (21), oil seal (30) and
spherical bearing (lower) (11) out by means of
10
press while supporting housing (13) as shown in
the figure. 12
• Spherical bearing (upper) (10) and oil seal 1

(12) are left in the housing.
13
JIG (a)
Fig. 33-247 Pulling out pinion shaft (1)

7) Removing spherical bearing (lower) (11)
PRESS
Pull oil seal (30), sleeve (21) and spherical
bearing (lower) (11) out by means of jigs (b) (c)
while supporting pinion shaft assy as shown in JIG (b)
the figure.
Press force : 30t
• Do not use the removed oil seal and bearing.
JIG (c)
21
30
11
Fig. 33-248 Removing spherical bearing (lower) (11)
33-143
33. UPPER STRUCTURE
8) Removing spherical bearing (upper)

Set housing (13) as shown in the figure, insert jig
(d) between bearing (10) and oil seal (12) and

remove bearing (10) by striking from the upper

side.
9) Remove oil seal (12) from housing (13).
• Do not use the removed oil seal and bearing.

Fig. 33-249 Removing spherical bearing

(upper) (10) and oil seal (12)
(4) Disassembling spider assy
7 3 28 16 15
1) Disassembling #1 spider assy
1. Remove retaining ring (28) with a plier (i).
2. Remove thrust washers (28) (15), pinion (3)
needle bearing (16). 15
Fig. 33-250 Disassembling #1 spider assy
• The shaft attached to spider assy (7) is caulked.

When replacing parts, replace the spider assy as a
set.
• Pinions (3) can not be replaced singly. Replace
them it in a set of three.
2) Disassembling #2 spider assy

9 18
1. Draw out spring pin (22).
2. Draw out shaft (9) from spider (8) and remove
17
thrust washer (18), pinion (5) and needle
bearing (17). 5
18
8 22
Pinions (5) can not be replaced singly. Replace them it
Fig. 33-251 Disassembling #2 spider assy
in a set of four.
33-144
33. UPPER STRUCTURE
33.2.5.3.3 Assembly
(1) Preparation
1) Sufficiently clean every part with wash oil and dry
it with compressed air.
2) Check on every part for failure.
(2) Assembling pinion shaft assy

1) Attaching oil seal
JIG (e)
Attach oil seal (30) to sleeve (21) by means of jig
(e).
30
Apply Loctite #515 21
Fig. 33-252 Attaching oil seal (30)

2) Inserting sleeve

Insert sleeve (21) and oils seal (30) assy in
pinion shaft (1).
!
3) Applying gear oil

Apply gear oil to the perimeter of axis of pinion

shaft (1) lightly to prevent seizure.
Fig. 33-253 Inserting sleeve in pinion shaft

4) Fitting spherical bearing (lower)
Seal sufficient grease in spherical bearing
(lower)(11) and force it in pinion shaft (1) by
means of jig (f).
Press force : 4~5t

• Since the bearing is formed with a partition at
the center section, seal grease in it from both
sides.
Fig. 33-254 Fitting spherical bearing (lower)
33-145
33. UPPER STRUCTURE
5) Apply sufficient grease to the pinion shaft assy.

Grease : Lithium extreme-pressure grease
(SHELL Albania EP2 or equivalent)
/4-)5-
(3) Placing pinion shaft assy in
1) Place housing (13) on level bench.
2) Attach eye bolt to screw (M10) at the axis end of
pinion shaft assy, and perpendicularly hang up
pinion shaft assy and place it in the housing.
• Horizontally orient the outer race of spherical

bearing and insert it in by striking lightly.
If the outer race is tilted, it is hard to insert Fig. 33-255 Apply grease
even if striking. Then do not force to insert it
in, but take it away once and horizontally
orient the outer race twice and insert it in
again.
!
Fig. 33-256 Placing pinion shaft assy in

3) Set housing assy so that the pinion directs
JIG (g)
downward.
4) Fit oil seal (12) in housing (13) by means of jig

(g). 12
• Apply Loctite #515 to the perimeter of oil 13

seal.
• Fill one third (1/3) of the space of the groove-
shaped section provided on the oil seal (12)
lip with grease.
• Insert it horizontally giving attention to the lip
of oil seal so as not be damaged.
Fig. 33-257
33-146
33. UPPER STRUCTURE
5) Press fit spherical bearing (upper) (10) in pinion
shaft (1) and housing (13) at the same time by

means of jig (h).

Fig. 33-258 Spherical bearing (upper) Press-fitting

6) Attach retaining ring (20).
20
Fig. 33-259 Attach retaining ring
33-147
33. UPPER STRUCTURE
(4) Assembling spider assy

7 3 28 16 15
1) Assembling #1 Spider assy
a. Coat the bore surface of pinion (3) with
grease. Put pinion (3) on thrust washer (15)
and assemble needle bearing (16) into the
15
bore surface
b. Fit thrust washers (15) and pinion (3) as in Fig. Fig. 33-260 Assembling #1 spider assy
33-261 and fit snap ring (28) by means of
pliers (i).
i
Fix the snap ring with the sharp edge on the motor side
(top side in the position of Fig. 33-261).
SNAP RING (28) 15

Motor side
7
28 3
Fig. 33-261 Fixing snap ring
2) Assembling #2 Spider assy GEAR SIDE SLIT

a. Coat the bore surface of pinion (5) with Caulk two
points with
grease. Put pinion (5) on thrust washer (18)
a punch.
and fit needle bearing (17) to the bore surface.
b. Fit thrust washer (18) and pinion (5) as in Fig.
33-262 insert shaft (9) into spider (8) and drive
spring pin (22).
6~7mm 6~7mm
(0.24~0.28 in) (0.24~0.28 in)
VIEW I (Direction of spring pin)
9 18
Insert shaft (6) into spider (8) so spring pin hole (22) is 17
aligned.
5
18
8 22
Fig. 33-262 Assembling #2 spider assy
(5) Installing #2 spider assy
#2 SPIDER ASSY
Insert #2 spider assy in spline axis of pinion shaft
(1).
Fig. 33-263 Assembling #2 spider assy
33-148
33. UPPER STRUCTURE
(6) Installing #2 sun gear (2)

2
Install #2 sun gear (2) directing the spline upward.
Fig. 33-264 Installing #2 sun gear (2)

(7) Installing ring gear (6)
Apply a thin film of sealant Loctite #515 to the
#2 SPIDER ASSY
matching surface of housing (13) and ring gear (6)
and assemble them, aligning the gear teeth and 6
Align
according to the matching marks given.
maching marks.
13
Fig. 33-265 Installing ring gear (6)

(8) Installing #1 spider assy

1) Mesh the #1 spider assy with ring gear (6) and
set them in place.
2) Mesh #1 sun gear (2) with #1 pinion (3) and set
them in place.
(9) Fit drain tube (25) and plug (27).
: 12 mm

(10)Filling Lube Oil
Fill in 3.0L (0.8gal) of gear oil SAE90 (API Service Fig. 33-266 Installing #1 spider assy
Grade GL-4).
(11)Installing swing motor assy

Attach eye bolts (M10) in the tapped holes of the
swing motor and put a wire sling in them
Coat the matching surface of ring gear (6) with M14X135
23
sealant Loctite #515, insert the spline joint of the
swing motor and match the matching marks.
Coat socket bolts (23) with sealant Three-Bond
MACHING
1360K and fasten them. MARKS
: 12 mm,
Fig. 33-267 Installing swing motor assy
33-149
33. UPPER STRUCTURE
33.2.5.4.1 Swing motor

(1) Replacement standards for parts
The following are the standards to determine whether or not parts may be reused from values taken at
disassembly. These are only general standards and in case the motor displays poor performance or parts shows
extreme damage and discoloration before disassembly, it is most important to determine how many parts should
be replaced, depending upon the purpose of disassembly and the remaining service life of the motor that the
user expects.
Recommended
Standard
Value for
Item Dimension Remedy
Replacement
mm (in)
mm (in)
Clearance between piston and
cylinder bore
(D-d)
0.027 0.052
Replace piston or cylinder.
(0.00160) (0.00205)
@ ,
Gap between piston and caulked part

of shoe ( )
0.3
0 Replace piston and shoe assy.
(0.0112)
Thickness of shoe (t)
5.5 5.3
Replace piston and shoe assy.
(0.217) (0.209)
J
Thickness of friction plate
2.0 1.8
Replace.
J (0.0787) (0.0709)
33-150
33. UPPER STRUCTURE
(2) Standard for correcting sliding surfaces

If the surface roughness of the sliding surface of parts exceeds the following standard, correct it or replace the
parts.
Standard for correcting sliding surfaces

Standard surface Surface roughness
Name of parts
roughness requiring correction
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)
• Lap each sliding surface to a standard roughness level or finer.

• If the spherical sliding surface of the spring (114) and cylinder (111) are roughened, replace parts in pairs.
33-151
33. UPPER STRUCTURE
33.2.5.4.2 Swing reduction gear

(1) Inspection at disassembly
1) Spacer and thrust washer
a. Inspect that the parts are not seized or worn abnormally or unevenly.
b. Inspect and measure the parts to see that the wear does not exceed the allowable values.
2) Gears
a. Inspect that the gear teeth do not show pitting and seizure.
b. Inspect by dye penetrant examination that the bottom of the teeth does not show cracks.
3) Bearing
Turn the bearing and check that it does not develop abnormal sound, catching and other faults.
Do not reuse spherical bearing
4) O-rings and oil seals

Do not reuse O-rings and oil seals; always replace them with new ones at reassembly.
(2) Inspection after assembly

1) Operation
Check to see that #1 sun gear (2) is not faulty when turned by hand.
2) Checking for oil leak and oil condition

Check for oil leak.
Check the oil level by level gauge and confirm that the oil is not dirty. If the oil is short, replenish gear oil
SAE90 (API Service Grade GL-4).
33-152
33. UPPER STRUCTURE
(3) Maintenance standards
G
A D
H LUBE OIL LEVEL E
Unit : mm (in)
Code Item Repairable level Service Limit Remedy
0
A Wear in #1 planetary shaft ø39 1.53 -0.0004 Replace entire spider assy.
No flaking
0
B Wear in #2 planetary shaft ø29 0.0787 -0.0079 Replace four shafts as a set.
There should be no pitting
Replace
Condition of tooth face exceeding 1.6mm (0.0630in) dia,
C Gears (Planetary pinion should be
abnormal wear or seizure.
replaced in a set of four.)
Condition of tooth flank There should be no cracks.
0
D Thickness of thrust washer 1.6 0.063 -0.0079 1.3 0.0512 Replace
0
E Thickness of thrust washer 2.0 0.0787 -0.0079 1.6 0.063 Replace
Wear in shaft
0
F (Diameter of part coming in contact ø95 0.0787 -0.003 ø94.9 3.736 Replace
with oil seal )
Apply Three-Bond 1360K and
G Socket bolt tightening torque M14— 181 N•m (130 lbf•ft)
tighten to specified torque.
Gear oil SAE90
H Lube oil 3.0 L (0.8 gal) Replenish or replace.
(API Service Grade GL-4)
33-153
33. UPPER STRUCTURE
33.2.5.5.1 Swing motor

(1) Hydraulic motor does not rotate.

Pressure does not rise. 1. Relief valve pressure in circuit is not 1. Set to correct value.
adjusted correctly.
2. Malfunction of relief valve. 2.
2-1. Sticking plunger.] 2-1. Correct the stuck areas or replace the
plunger.
2-2. Orifice on plunger is clogged. 2-2. Disassemble and clean.
3. Plunger seat is faulty. 3. Check the seat surface and replace the
plunger if scored.
4. Anti-reaction valve seat is faulty. 4. Replace the anti-reaction valve cartridge
or block.
Pressure rises 1. Overload. 1. Eliminate overload.
2. Moving parts are seized. 2. Inspect and repair piston, shoe and
cylinder valve plate.
3. Brake release pressure is not working on 3. Check circuit and correct it.
the motor
4. Brake piston is stuck. 4. Disassemble and check.
5. Spool for releasing brake is stuck. 5. Disassemble and check.
6. Friction plate is seized. 6. Disassemble, check and repair.
(2) Rotating direction is reverse.

Rotating direction is 1. Motor’s assembling direction is reversed. 1. Assemble correctly.
reverse. 2. Piping inlets and outlets are reversed. 2. Pipe correctly.
(3) Revolution does not rise to set value.

Revolution does not 1. Oil inflow is deficient. 1. Check pump’s delivery rate and circuits
rise to set value to motor.
2. Oil leaks are excessive due to high 2. Lower oil temperature.
temperature.
3. Sliding surfaces are worn or damaged. 3. Replace.
33-154
33. UPPER STRUCTURE
(4) Brake torque is insufficient.

Brake torque 1. Friction plate is worn. 1. Disassemble and check. Replace if wear
isinsufficient. is beyond standard value.
2. Brake piston is stuck. 2. Disassemble and check.
3. Brake release pressure is not released. 3. Check and correct circuit.
4. Break release spool is stuck. 4. Disassemble and check.
5. Spline of friction plate is damaged. 5. Disassemble and check. Replace
damaged part.
(5) The swing motor drifts much.

Check the drain rate of the hydraulic motor. If it is less than 4 L/min (1.1 gal/min), you should think that the motor
is not faulty.

The swing motor drifts 1.Relief valve malfunctions. 1. Replace.
much when it is Same as (1). Same as (1).
actuated by external 2. Plunger seat is faulty. 2. Replace.
torques. (e.g. Machine
3. Seat of the anti-reaction valve is no good. 3. Replace the anti-reaction valve cartridge
is on a slope.)
or block.
(6) Oil leaks

1) Oil leak from oil seal

Oil leaks from oil seal 1. Lip of seal catches contaminant and 1. Replace oil seal.
damaged.
2. Shaft is damaged or worn. 2. Shift the lip and shaft positions or replace
oil seal.
3. Casing inner pressure has risen 3. Repair drain piping if clogged up.
abnormally high, with the result that lip of
oil seal is flipped.
4. Shaft is rusted. 4. Disassemble and correct.
2) Oil leak from matching surface

Oil leak from matching 1. O-ring is missing. 1. Set O-ring correctly and assemble it.
surface 2. O-ring has a scratch. 2. Replace.
3. Seal surface has a scratch. 3. Disassemble and correct.
4. Bolt is loose or damaged. 4. Tighten to specified torque or replace.
33-155
33. UPPER STRUCTURE
33.2.5.5.2 Reduction unit

()

*)

# $

%

$

% & $

%

+)

!

"
'

33-156
33. UPPER STRUCTURE
33.2.6 SWIVEL JOINT
33.2.6.1 CONSTRUCTION VIEW

! !"

#$!#$ !%&
' () (" * () +,(,!-
.!#! )

#$!#$ !%&
' () (" * () +,(,!-
.!#! )
Fig. 33-268 Construction of swivel joint
No. Part name Q’ty No. Part name Q’ty

1 Body 1 7 O-ring (G95 1A) 1
2 Stem 1 8 Socket bolt (M8×20) 2
3 Thrust plate 1 9 Socket bolt (M8×30) 3
4 Cover 1 12 Plug 1
5 Seal 5 13 O-ring (P80) 2
6 Seal assy 1
33-157
33. UPPER STRUCTURE
33.2.6.2.1 Tools
No. Tool Name Used for Remarks

Hammer 1. Steel hammer
a
2. Wooden or plastic mallet
b Rubber mat Disassembly 750 mm (30in) square or more
Wrench Assembly 1. Allen wrench
c 2. Double-ended and single-ended wrench
3. Extension pipe
d Torque wrench Assembly 98 N•m (72 lbf•ft)
Pin Grind the tip of "a nail" to shape
as a screwdriver.
e Disassembly
Spatula Make from a hack-saw blade
Disassembly Approx. 120mm (4.72in)

f
Assembly
Remove the edge completely

Vinyl tape and make corner round smooth.
Disassembly
g Vise Vise movable over 150mm (6in)
Assembly
h Loctite # 242
i Lubricating oil Hydraulic oil or vaseline
j Cleaning oil
33.2.6.2.2 Apparatus
(1) Hoist or crane
The lifting device should be capable of lifting the swivel joint assy.
(2) Work bench
The work bench should have an area of 1.2m×1.5m (4ft×5ft).
(3) Others
Also prepare cloth, wooden block and oil pan.
33.2.6.2.3 Cleaning outside

Clean the swivel joint to be free from dirt and dust, using steam and cleaning oil.
• Keep all ports plugged up while cleaning.
33-158
33. UPPER STRUCTURE
The part numbers used in this disassembly procedure
correspond to those of a construction drawing in Fig.
33-268.

(1) Removing cover
1) Mark cover (4) and body (1) with matching marks
for convenient reassembly.
2) Place a V-block on a work bench, place a swivel
joint set on the side, fix it and loosen socket bolt

(9) by means of a pipe and wrench. Alternately,
the swivel joint may be fixed by holding stem (2)

in a vise.
: 6 mm Fig. 33-269 Removing cover (4)

3) Remove cover (4) from body (1) and draw out O-
ring (7) from cover (4).
%
"
Fig. 33-270 Removing O-ring (7)

(2) Removing thrust plate

Loosen socket bolt (8) fastening thrust plate (3), in
the same manner as the removing of the above-

mentioned cover.
: 6 mm

When removing thrust plate (3) by fixing body (1),

support stem (2) so it may not fall down.

Fig. 33-271 Removing thrust plate (3)

(3) Removing stem % &'
Place body (1) on a V-block. Put a wooden block !
against stem (2) via the body so about half of the " #$
stem is covered by the wooden block and knock it
out using a mallet.
By hitting out the stem over about 1/2 from the
body, it can be easily pulled out by hand.
Stem weight : 10.5 kg (23 lbs)

Fig. 33-272 Drawing out stem (2)
33-159
33. UPPER STRUCTURE
(4) Removing sealing parts

SPATULA (f)
1) Remove rings (13) of seal assemblies (6) and (5)
with spatula (f).
13
Pay attention to the body (1) not to be damaged by the

top edge of spatula (f).
Fig. 33-273 Removing O-ring (13)

2) Pierce slipper ring of seal assemblies (6) and (5)
with pin (e) and remove them from the seal SLIPPER RING
groove. Fig. 33-274 shows only one pin, but use
two pins to remove it securely.
BACKUP RING
DETAIL (6)
O-RING
GROOVE
SEAL (6) PIN (e) SEAL GROOVE

ASSY
OIL GROOVE
SEAL (5) SEAL GROOVE
Fig. 33-274 Removing out seal assy (5)(6)
33.2.6.2.5 Assembly
Prior to assembly, clean each parts (excluding the O-
ring and seal), and arrange in the sequence of
assembly.
Apply grease on the groove of seal to be installed on
seal assembly (6) and O-ring (13).
(1) Assembling seals to body
1) Apply hydraulic oil to O-ring (13) thinly and insert
it in O-ring groove.
Check the twist of O-ring
33-160
33. UPPER STRUCTURE
2) Slipper ring is assembled, after first inserting the

backup ring, by slightly-distorting the shape as
shown in Fig. 33-275. Also after inserting all of
the seals, be certain that these are installed in
the seal groove by use of the spatula.
3) Assemble seal (5) by the same procedure above
mentioned.
Fig. 33-275 Inserting slipper ring (6)

Remove grease, hydraulic oil and vaseline from the
groove of seal.
And insert seal (5).
Seals (5) have no back-up ring.
(2) Assembling stem

Press in by applying your weight by your hands.
Lightly coat the outer circumference of stem (2) and
the inner surface of body (1) with grease or vaseline
and slowly insert stem (2) into body (1).
2 STEM
• If stem (2) is pressed in too fast, the seal may be

damaged. Do it slowly. O-RING 13
• The clearance between body (1) and stem (2) is 1 BODY

SEAL ASSY 6
about 0.1mm (0.004in). Push stem straight along
the shaft center. SEAL 5
WORK BENCH
Fig. 33-276 Inserting stem (2)

(3) Assembling thrust plate
& !
1) While holding stem (2) and body (1), match the
hole of thrust plate (3) and the stem (2) hole.
2) Next, after removing any oil from the thread of
socket bolt (8), coat it with Loctite #242 and
tighten to stem (2).
: 6 mm,
Fig. 33-277 Tightening socket bolt (8)
33-161
33. UPPER STRUCTURE
(4) Assembling cover

1
After installing O-ring (7) to cover (4) and aligning MATCHING MARK
the matching marks of the cover (4) and body (1),
coat socket bolt (9) with Loctite #242 and tighten it 9
which will then complete assembly.
4
: 6 mm,
ALLEN WRENCH
PIPE
Fig. 33-278 Tightening socket bolt (9)
33-162
33. UPPER STRUCTURE
33.2.6.3.1 Inspection procedure and remedy
Interval Check Item Checking Procedure Remedy

Seal for oil leakage Replace O-ring or dust seal , if any oil
2,000hr Check oil leakage outside
outside leakage can be found.
4,000hr All sealing parts Replace all sealing parts such as slipper
In principle, seal with back-up ring and O-ring.
disassemble All sliding parts
and check re- Check abnormal wear, scoringor
Repair or replace referring to their
gardless of corrosion caused by foreignmatters or
limit of service.
oil leakage or seizure.
not.
When All parts Repair or replace referring to their limit of
Check them for seizure, foreignmatters,
disassembled service.
abnormal wear, anddefect of seals.
for repair O-rings and dust seal should be replaced.
33.2.6.3.2 Service limit of the parts
Parts Maintenance Standards Remedy

Sliding surface with
Plating worn or peeled due to seizure or contamination. Replace
sealing sections
Sliding surface between 1) Worn abnormally or damaged more than 0.1mm
Replace
body and stem other than (0.004in) in depth due to seizure or contamination.
Body, Stem sealing sections 2) Damaged less than 0.1mm (0.004in) in depth. Smooth with oilstone.
1) Worn more than 0.5mm (0.02in) or abnormality. Replace
Sliding surface with thrust 2) Worn less than 0.5mm (0.02in). Smooth
plate 3) Damage due to seizure or contamination repairable
Smooth
within wear limit 0.5mm (0.02in).
1) Worn more than 0.5mm (0.02in) or abnormality. Replace
Sliding surface with thrust 2) Worn less than 0.5mm (0.02in). Smooth
Cover
plate 3) Damage due to seizure or contamination
Smooth
repairable within wear limit 0.5mm (0.02in).
33-163
33. UPPER STRUCTURE
Parts Maintenance Standards Remedy

1) Protruded excessively from seal groove.

Replace
(With back-up ring)

2) Slipper ring 1.5mm (0.06in) narrower than seal groove,
or narrower than back-up ring.
Replace
Slipper ring
(With back-up ring)
1.5mm (0.02in)
(max.)
BACKUP RING
3) Worn unevenly more than 0.5mm (0.02in)

Replace

(With back-up ring)
33-164
33. UPPER STRUCTURE
33.2.6.3.3 Inspection after assembly

After completion of assembly, inspection for oil leakage,
pressure resistance, etc., using a device as shown in
Fig. 33-279.
(1) High pressure port (A,B,C,D and F port)
Install a directional valve and pressure gauge to the

stem side port and body side port respectively, and
while watching the pressure gauge (for high
pressure) installed on the body side and also by
regulating high pressure relief valve (7), gradually

increase the pressure and when the pressure has
reached 1.5 times the maximum working pressure,
close stop valve (3) and lock in the hydraulic oil in
the swivel. Keep stop valve (6) on the low pressure
relief valve side closed at this time.
Check that it is free from looseness, deformation,
breakage, etc. under three minutes pressurizing.
And, the oil leakage must be checked for the first 1
minute, and if there be a pressure drop for any
reason, the pressure drop should be in 10% of the
trapped pressure.

This checking must be carried out for every circuit.
Fig. 33-279 Hydraulic circuit for inspection

equipment
(2) Low pressure port (E port)

Similar to the high pressure port, install a directional
valve and pressure gauge on each port of the stem '$ ( )

side and body side. *(&
Open stop valve (6) on the side of low pressure !
relief valve (5) and while watching the pressure
"
gauge (for low pressure) connected to the body
# " # +
side and also by regulating low pressure relief valve
,&-. /
0
(5), gradually increase the pressure and check for
"
outside leakage with a color check at a pressure of
0.49MPa (71psi). # " #

$$ /1 2 &0
"
% &
33.2.6.3.4 Troubleshooting

1. External leakage of hydraulic oil Defective O-ring & seal Replace all seals.
2. Internal leakage of hydraulic oil 1) Defective slipper seal 1) Replace all seals.
2) Sliding face worn excessively 2) Replace assy.
3. Swivel stem seized 1) Stem and body seized 1) Grind and hone.
Replace assy, if stem and body are too loose
and causing oil leakage.
2) Inappropriate swivel stopper bracket 2) Reinstall
Secure 2~3mm (0.08~0.12in) allowance for
bolt stopper.
4. Loose swivel stem and cover Socket bolt tightened insufficiently. Retighten.
33-165
33. UPPER STRUCTURE
[MEMO]
33-166
34. TRAVEL SYSTEM
TABLE OF CONTENTS

34.1.1 TRAVEL SYSTEM .................................................................................................34-3
34.1.2 CRAWLER..............................................................................................................34-3
34.1.3 UPPER ROLLER ....................................................................................................34-7
34.1.4 LOWER ROLLER ...................................................................................................34-13
34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) ...........................................................34-21
34.1.6 SPROCKET ............................................................................................................34-30
34.1.7 TRAVEL MOTOR ..................................................................................................34-33
34.1.8 SWING BEARING ..................................................................................................34-35
34.2 REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT .......................................34-38
34.2.1 TRAVEL MOTOR ...................................................................................................34-38
34
34-1
34. TRAVEL SYSTEM

E215B : YN11-45001~ S5YN3421E01
First edition March, 2007 K
↑
↑ July, 2007 ↑ K
(NHK Middle East)
↑
↑ ↑ ↑ K
↑
↑ ↑ ↑ K
PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of first part. Removing and attaching, and sequel. Disassembling and assembling.
(3) The removing and attaching can be performed in the procedure specified in Table of Contents, but in view of
(4) The removing and attaching procedure does not completely cover all possible situations because of differences
(5) Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.
34-2
34. TRAVEL SYSTEM

34.1.1 TRAVEL SYSTEM
8. SWING BEARING
2. CRAWLER
7. TRAVEL MOTOR
5. FRONT IDLER 6. SPROCKET
GUARD LOWER FRAME
GREASE NIPPLE OF THE 3. UPPER ROLLER
TRACK SPRING ADJUSTER 4. LOWER ROLLER
Fig. 34-1 Designation and location of undercarriage
34.1.2 CRAWLER
34.1.2.1 REMOVING CRAWLER

(1) Position the machine to remove crawler.
(2) Pushing out master pin.
1) Find the master pin and place it in its removing/
fixing position in Fig. 34-3.
2) Loosen the grease nipple and slacken crawler.
: 19 mm
• When loosening the grease nipple of the adjuster,

Fig. 34-2 Crawler removing position
do not loosen it more than one turn.
• Where grease does not come out well, move the
machine back and forth. The over loosening of
grease nipple may cause it to jump out incurring
danger of injury. So be careful not to over loosen
the grease nipple.
3) Pushing out master pin

Apply jig on master pin and strike it out with a
mallet.
(Refer to Fig. 34-7 Press fitting of master pin)

When using a big hammer, wear protective goggles
Fig. 34-3 Removing/fixing position of master pin
and a long-sleeved uniform so you do not injure
yourself by flying objects.
34-3
34. TRAVEL SYSTEM
(3) Removing crawler

Put attachment on ground so that weight is not

loaded to the lower frame, and remove track link
assy rotating sprocket.
Crawler end section may fall on the ground just before

extending it on the ground incurring danger of injury.
Please keep well away from the equipment.
Fig. 34-4 Removing crawler
34.1.2.2 INSTALLING
(1) Checking crawler installation direction.
Place the track links on the ground so they
converge, facing the front idler, as shown in the

figure on the right.
(2) Installing crawler

1) Preparation for installation
Treat paint flaking protection with care not to
damage lower flame.
Fig. 34-5 Installing direction of crawler
2) Winding crawler
Insert a crowbar into the master pin hole, lift the
lower frame 1 to 2cm above the ground level by
holding it by hand so the machine body weight is
not exerted on the shoe. Retract the sprocket to
help push the back winding of the crawler.
(3) Preparation for press fitting master pin

1) Preparing for installation
Put square wood under the shoe plate.
2) Aligning master pin holes
Aligning master pin holes through fine Fig. 34-6 Winding crawler
adjustment turning sprocket.
• When using a big hammer, exercise care so you

are not injured by flying objects the same way as
when pushing out the master pin.
• Coat the master pin with molybdenum disulfide
grease, before pressing it in.
(4) Press fitting of master pin

Apply press fitting jig on master pin, and strike it

with a mallet to press fit. Fig. 34-7 Press fitting of master pin
34-4
34. TRAVEL SYSTEM
(5) Adjusting crawler tension (See Fig. 34-8)

After installing, adjust tension of crawler.
: 19 mm

A
Fig. 34-8 Adjusting crawler tension
FLAT SHOE
2
1-6
1-1
1-8
1-4
1-3 TRIANGLE SHOE
1-8 2 RUBBER PAD SHOE 3
1-7 2
1-1
4 3
1-7 1-5 3
1-2 1-2
Fig. 34-9 Track link assy and shoe plate
STD undercarriage LC undercarriage

Shoe assy
Shoe assy
YN60D00054F2 YN60D00055F2
YN60D00054F5 YN60D00055F4
YN60D00054F6 YN60D00055F5
No. NAME Q'TY No. NAME Q'TY
1 .LINK ASSY YN62D00017F1 1 1 1 1 .LINK ASSY YN62D00017F3 1 1 1
1-1 ..TRACK LINK R 46 46 46 1-1 ..TRACK LINK R 49 49 49
1-2 ..TRACK LINK L 46 46 46 1-2 ..TRACK LINK L 49 49 49
1-3 ..BUSHING 45 45 45 1-3 ..BUSHING 48 48 48
1-4 ..PIN 45 45 45 1-4 ..PIN 48 48 48
1-5 ..MASTER BUSHING 1 1 1 1-5 ..MASTER BUSHING 1 1 1
1-6 ..MASTER PIN 1 1 1 1-6 ..MASTER PIN 1 1 1
1-7 ..COLLAR 2 2 2 1-7 ..COLLAR 2 2 2
1-8 ..SEAL 90 90 90 1-8 ..SEAL 96 96 96
2 .SHOE 600mm 46 - - 2 .SHOE 600mm 49 - -
.SHOE 700mm - 46 - .SHOE 700mm - 49 -
.SHOE 800mm - - 46 .SHOE 800mm - - 49
3 .BOLT 2420Z1292 184 184 184 3 .BOLT 2420Z1292 196 196 196
4 .NUT 2420Z1293 184 184 184 4 .NUT 2420Z1293 196 196 196
34-5
34. TRAVEL SYSTEM
34.1.2.4 MAINTENANCE STANDARD
F E
D D G
B
Fig. 34-10
Unit : mm (in)
REPAIRAB SERVICE
No. ITEM STANDARD VALUE REMEDY
LE LEVEL LIMIT
A Link pitch 190 ± 0.1 (7.4803 ± 0.0039) 194 (7.64) 198 (7.80) Replace the link
B O.D. of bushing ø 58.78 (2.3142 ) ø 55 (2.17) ø 54 (2.13) assy if the service
C Height of link 106 ± 0.3 (4.1732 ± 0.0118) 100 (3.94) 98 (3.86) limit is exceeded
Basic
Tolerance Fit Fit
dimension
Interference between bushing + 0.11
D Interference
and link ø 58.78 (+0.0043) Interference
Shaft 0.05
(2.3142) - 0.05 0
(0.0020) Replace
(-0.0020)
+ 0.1
Interference
Interference between track pin ø 36.63 (+0.0039) Interference
E Shaft 0.05
and link (1.4421) - 0.05 0
(0.0020)
(-0.0020)
- 0.03
Interference
Interference between master ø 36.50 (-0.00118) Interference
F Shaft 0.05 Replace Link
pin and link (1.43701) - 0.088 0
(0.0020)
(-0.00315)
8 (0.32) 10 (0.39)
G Clearance between links 1.5 (0.06) (both side) Replace
(both side) (both side)
H Tightening torque of shoe bolt 853 N•m (629 lbf•ft) Reassembly
34.1.2.5 TOOLS AND JIGS

(1) Tightening tools
Unit : mm (in)
NAME OPPOSING FLATS
30 (1.2)
Socket
(2) Jig
NAME SHAPE
Master pin fixing jig for iron

crawler
34-6
34. TRAVEL SYSTEM
34.1.3 UPPER ROLLER
34.1.3.1 UPPER ROLLER ASSY
UPPER ROLLER ASSY No. YN64D00032F1

ITEM NAME Q’TY REMARKS
1 ROLLER ASSY 4 YN64D01068F1
2 CAPSCREW (SEMS SCREW) 4 M20×P2.5×100
3 NUT 4
4 WASHER 4
34.1.3.2 REMOVING
Remove crawler (Above mentioned). 3
4
(2) Removing upper roller (1)

2
1) Remove nuts on support tightening section, and
also remove capscrew (2) M20×100. 1
: 30 mm
Fig. 34-11 Removing upper roller
34.1.3.3 INSTALLING
(1) Inspection
Before reassembling, check it that it rotates smooth COUNTER-
manually and for leak. SINKING
(2) Installing upper roller (1)

1) To install the upper roller, turn up socket bolts (2)
toward the center of machine.
2) Insert it until collar comes in contact with support.
3) Fit it directing the countersinking mark of shaft

CENTER OF MACHINE
end upward.
4) Apply Loctite #262 on capscrew M20×100, and

tighten it to the specified torque.
: 30 mm
2 1 3,4
Fig. 34-12 Installing upper roller
34-7
34. TRAVEL SYSTEM

11 8 4 6 7 3 2

"#

"# $
%

!#
"#
!"#
1 10 5 9
Fig. 34-13 Construction of upper roller

(1) Disassembly '
1) Draining out oil "
Remove plug (10) and drain out oil.
&
: 6mm #

2) Removing snap ring (11)
Mount the end face inside upper roller (1) on
stand jig (f) and separate snap ring (11), using
snap ring pliers.
B
3) Removing cover (5)

Take off cover (5) upwards, utilizing the screwed
hole for the plug.
4) Removing O-ring (8)

Separate O-ring (8) from cover (5). Fig. 34-14 Construction of upper roller
5) Removing plate (4)

Loosen 2 socket bolts (9) and draw out plate (4)
D
from roller (1).
: 10mm
6) Removing shaft (2) %

Put the extrusion jig (h) against the end face of
!
shaft (2) and push shaft (2) with collar (3) for
floating seal (7), using a press or hammer.
B
Fig. 34-15 Extruding shaft
34-8
34. TRAVEL SYSTEM
7) Removing floating seal (7).

%
Take out floating seal (7) from roller (1).
Fig. 34-16 Taking out floating seal

8) Removing floating seal (7).
C
Remove from collar (3), floating seal (7) that is
located on the side from which shaft (2) was $
disassembled.
%
!
B
Collar (3) is press fitted into shaft (2). Therefore do not
disassemble it.
Fig. 34-17 Removing floating seal and extruding

bushing
9) Removing bushing (6)
Push with press (e)
Since the bushing is thin, machine it on a lathe or
scrape it off, take care so as not to damage the i
bore of roller (1).
If the bushing is not worn much, mount upper 6
roller (1) on jig (f), insert jig (g) into the end face
1
of bushing (6) and push it out with a press.
(2) Assembly
Assembly of the upper roller is done in the reverse f
order of disassembly.
1) Place upper roller (1) on the top end face of jig
(f), with its floating seal setting side facing down.
2) Confirm that the outer surface of bushing (6) is Fig. 34-18 Pushing in bushing
not scuffed and coat the outer surface of the
inserting side of the bushing, with molybdenum
disulfide grease. 2
7
3) Put jig (i) into bushing (6) and press it in, using
the bore of the bushing and the bore of the roller 7 1
as guides.
3
If you fail in this operation by pressing the bushing

unevenly, the bushing is distorted and gets
unserviceable. In that case, do not re-use the bushing Fig. 34-19 Fixing floating seal
as it may develop malfunctioning after assembly.
34-9
34. TRAVEL SYSTEM
4) Installing floating seals (7)

Two floating seals (7) make a pair. Attach one
floating seal to retainer fixed in shaft (2), and
another to the inside of upper roller (1). 2
• Prior to placing floating seal (7) in, apply 7

engine oil lightly to seal surface.
1
5) Inserting shaft (2)
Coat shaft (2) with a thin film of oil and insert it
into upper roller (1).
6) Installing plate (4) Fig. 34-20 Inserting shaft

Mount upper roller (1) on the stand jig (f) and
'
attach plate (4) to the end face of the shaft with &
bolt (9). #
: 10mm, "
7) Installing O-ring (8)

Fit O-ring (8) to the groove of cover (5).
• Apply grease to O-ring.
8) Installing cover (5) B

Attach cover (5) to upper roller (1). Use a press
in this operation as a press fit is used.
9) Installing snap ring (11)

Fix snap ring (11) into upper roller (1), using snap
ring pliers.
Fig. 34-21 Installing cover
10) Filling oil

Fill in 30cc (1.83cu•in) of engine oil API grade
#
CD #30 through the plug hole in cover (4).
11) Installing plug (10)

Wind seal tape around plug (10) and screw it into
the plug hole of cover (4).
: 6mm,
B
• After assembling the upper roller, confirm that
oil is not leaking from it and that it rotates
smoothly by hand.
Fig. 34-22 Filling oil
34-10
34. TRAVEL SYSTEM
C
A
E
F
D D
B
Unit : mm (in)
REPAIRABLE SERVICE
LEVEL LIMIT
A Dia. ø 140 (6.30) — —
B Width 150 (5.91) — —
Replace
C Tread dia. ø 120 (4.72) ø 107 (4.21) ø 105 (4.13)
D Tread width 33 (1.30) — —
Basic
Tolerance Fit Fit
dimension
Clearance between - 0.025
E
shaft and bushing (-0.00098) Clearance Clearance
ø 45 (1.772) Shaft
- 0.040 0.7 (0.028) 1.0 (0.039) Replace bushing
(-0.00157)
+ 0.030
Interference between Interference Clearance
F ø 50 (1.969) Hole (+0.00118)
roller and bushing 0 0.01 (0.0004)
0
Tightening torque of
G 115 N•m (85 lbf•ft)
socket bolt
Oil Engine oil API grade CD #30, 30cc (1.83cu•in) Refill
Roller rotation Roller rotates smoothly by hand. Reassembly
34-11
34. TRAVEL SYSTEM

Unit : mm
NAME OPPOSING FLATS
30
Socket
Allen wrench 6,8
(2) Jigs
Unit : mm (in)
No. NAME SHAPE
120 (4.72)
90 (3.54) 160 (6.30)
f Stand jig
52.5(2.07)
For extruding
g
(0.709)
bushing
18
49(1.93)
For extruding
h
(1.18)
shaft
+0.1
+0.1
60(2.36)
49.5 0
44.6
Bushing fixing
i
1.756 +0.004
1.949 +0.004
jig (1.26)32
0
(1.46)37 50(1.97)
87(3.43)
34-12
34. TRAVEL SYSTEM
34.1.4 LOWER ROLLER
34.1.4.1 LOWER ROLLER ASSY
B5 Apply Loctite #262

ROLLER
STD undercarriage YN64D00020F1

T=397N.m (290 lbf.ft)
ASSY
LC undercarriageYF64D00002F1
ITEM NAME Q'TY
1 LOW ROLLER : YN64D00019F1 - 14
LOW ROLLER : YF64D00001F1 16 -
2 CAPSCREW : M18X80(P=1.5) 64 56
2 1 B2
Apply Loctite #262
T=397N.m (290 lbf.ft)
Fig. 34-23 Lower roller assy and track guide
34.1.4.2 REMOVAL
1) Loosen the tension of the crawler, lift up the
lower frame by the front attachment and stop the
engine in that condition.
2) Place a safety block (wood) at the front and back
of the lower frame.

(2) Removing track guide

Remove capscrews (B5) and remove track guide Fig. 34-24 Preparation for removal
(B2).
: 27mm,
Weight of track guide : Approx. 25kg (55 lbs)
ROLLER
STD undercarriage YN01F00035F1

LOW
B2,B5
LC undercarriageYN01F00036F1 STD
ITEM NAME Q'TY
B2 TRACK GUIDE : YN63D00003P1 2 2
B5 CAPSCREW : M18X40(P=1.5) 8 8
(3) Remove lower roller

Remove capscrews (2) and remove lower roller (1). B2,B5
LC
: 27 mm, Fig. 34-25 Installing track guide
Weight of lower roller : Approx. 33kg (73 lbs)
Fig. 34-26 Installing lower roller
34-13
34. TRAVEL SYSTEM
(1) Installation of lower roller
Coat mounting capscrews (2) with Loctite #262 and
fasten all 4 capscrews temporarily. Then tighten
them to a specified torque.
: 27 mm,
(2) Installation of track guide
Capscrews (4) with Loctite #262 and fasten all 4
capscrews temporarily. Then tighten them to a
specified torque.
: 27 mm,
(3) Adjusting tension of crawler
Tighten grease nipple and fill it with grease.
: 19 mm,
34-14
34. TRAVEL SYSTEM
STD undercarriage YN64D00019F1 4 1 6 2 7 5

LOWER ROLLER 8
LC undercarriage YF64D00001F1
No. NAME Q'TY REMARKS
1 ROLLER 1
2 COLLAR 2
3 SHAFT 1
4 BUSHING 2 3
5 PIN 2
6 FLOATING SEAL 2 Fig. 34-27 Construction of lower roller
7 O RING 2 1A G60
8 PLUG 2 PT1/4

(1) Disassembly
1) Drain oil L
Remove plug (8) and drain out oil.
: 6mm 2
2) Removing pin (5) 5

Put both ends of lower roller assy on the V-
shaped blocks (K), apply push-out bar (L) on
upper end face of pin (5), and push pin (5) out
striking with mallet.
K
3) Removing collar (2), O-ring (7)

Put lower roller on jig (M) for repair stand so that
the shaft (3) is perpendicularly located, apply
Fig. 34-28 Pushing out collar fixing pin (5)
push-out jig (P) on shaft end on upper side, and
push shaft (3) until the O-ring (7) separate from
collar (2) with press or mallet, and take out collar
(2) and O-ring (7). JIG P
7
2
4) Removing shaft (3)
In addition, push out and remove shaft (3) 1
together with the lower collar (2) and O-ring (7).
3
JIG M
The shaft (3) extrusion operation may cause the
remaining lube oil to flow out. Prepare an oil container
beforehand.
Fig. 34-29 Removing shaft (3), collar (2), O-ring (7)
34-15
34. TRAVEL SYSTEM
5) Removing collar (2), O-ring (7)

Remove O-ring (7) from shaft (3) that was drawn $
out in the previous paragraph.
6) Removing floating seal (6)

Remove floating seal (6) from collar (2).
7) Removing floating seal (6)

Remove floating seal (6) from roller (1).
Fig. 34-30 Removing floating seal (6)
Fig. 34-31 Removing floating seal (6)

Since thickness of bushing (4) is thin [thickness
is 2.0mm (0.079in)], remove it through lathe or
N
strip it with care not damage inner hole of roller.
When the wear of bushing is not large, place
1
upper roller (1) on jig (M) for repair stand and
apply the end of push-out jig on the end face of
bushing (4) end, and push it out striking it with 4
mallet.
JIG M
Hammer the inside surface of roller lightly so as not to

damage the surface. Put the extrusion jig (N) uniformly Fig. 34-32 Extruding bushing (4)
over the circumference of bushing (4) and extrude it
perpendicularly little by little.
34-16
34. TRAVEL SYSTEM
(2) Installing % !
1) Attach O-ring (7) to one side
Install O-ring (7) to groove on shaft.
• Grease O-ring.
• Replace O-ring with new one without fail at Fig. 34-33 Attach O-ring (7) to one side
reassembling.
2) Press fitting bushing (4)

Align inner hole of roller (1) and bushing (4) and JIG Q
press fit it vertically in capacity of press fit load,
5ton (11000 lbs), in the condition that bushing 4
push-in jig (Q) is inserted into bushing (4).
• Apply molybdenum disulfide grease on press-

fit section of bushing, and press fit it in
ordinary temperature.
• Bushing which fails to press-fit because of the
one-side pressing should not be fitted. Fig. 34-34 Press fitting bushing (4)
3) Press fitting collar (2) PRESS

Fit O-ring (7) to the one side of shaft (3) mating
pin hole of collar (2) on which floating seal (6) is PIN HOLE
fit with pin hole of shaft (3) in advance. Use the 6
2
press of capacity 17 ton (37500 lbs) or more.
PIN HOLE
3 7
• Care should be taken not to damage O-ring
(7) while press-fitting collar (2) to shaft (3).
4) Inserting pin (5) Fig. 34-35 Press fitting collar (2)

Press-fit pin (5) to pin hole on aligning pin holes
of shaft (3) and collar (2).
6 5
7 2
Fig. 34-36 Inserting pin (5)
34-17
34. TRAVEL SYSTEM
5) Attach floating seal (6) to roller side

Fit floating seal (6) to inner holes on both ends of
roller (1).
1
6
• Check that the seal surface is free from flaws,
rusts, etc. before reusing the floating seal.
3
6) Inserting roller (1)
2
Insert roller (1) from the side where collar (2), 7
O-ring (7) is not press-fitted to the shaft (3).
Fig. 34-37 Inserting roller (1)
PRESS
Install O-ring (7) to groove on shaft.
PIN HOLE
• Grease O-ring.
2
• Replace O-ring with new one without fail at
reassembling. PIN HOLE
7
8) Press fitting collar (2)

Press-fit collar (2) to shaft (3).
3
• Press-fit collar (2) on aligning pin (5) hole.
9) Inserting pin (5)

Press-fit pin (5) in to the pin hole mating pin hole
of collar (2) with pin hole on the end side of shaft
(3).
Fig. 34-38 Installing O-ring (7), collar (2)

10) Filling oil
Remove plug (8) and fill in 160cc (9.8cu•in) of
engine oil API grade CD #30.
11) Check it for leakage 8
Before tightening plug (8), check it for leakage in TIGHTENING
TORQUE
the condition of air pressure 0.2 MPa (29 psi). 23N.m (17 lbf.ft)
12) Installing plug (8)
Apply oil resistant sealant on plug (8), and
tighten it in the plug hole on the collar (2) end 2
face.
: 6 mm,
Tightening torque : Fig. 34-39 Installing filling oil plug (8)
21.6~24.5 N•m (15.9~18.1 lbf•ft)
After assembling the lower roller, confirm that oil is not

leaking and that the roller rotates smoothly by hand.
34-18
34. TRAVEL SYSTEM
+ +
*
-
)
0
Fig. 34-40 Lower roller (Track roller)
Unit : mm (in)
REPAIRABLE SERVICE
LEVEL LIMIT
A O.D. of flange ø 185 (7.28) — — Reinforcement weld,
B Tread dia. ø 150 (5.91) ø 134 (5.28) ø 128 (5.04) repair or replace
C Flange width 23.5 (0.925) 18 (0.709) 16.5 (0.65)
Basic
Tolerance Fit Fit
dimension
Clearance between
- 0.060
D shaft and bushing
ø 65 (-0.00236) Clearance Clearance
(Wrapped bushing) Shaft
(2.55905) - 0.090 0.7 (0.276) 1.0 (0.394) Replace bushing
(-0.00354)
+ 0.030
Interference between ø 69 (+0.00118) Interference Clearance
E Hole
roller and bushing (2.71653) - 0.020 0 0.01 (0.0004)
(-0.00079)
F Oil Engine oil API grade CD #30, 160cc (9.8 cu•in) Refill
Execute air leak test at 0.2MPa (28psi)
H Plug (8)
before tightening the plug.
Roller rotation Rotates smoothly by hand. Reassembly
34-19
34. TRAVEL SYSTEM

Unit : mm
NAME OPPOSING FLATS
19, 27
Socket
Allen wrench 6
(2) Jig
Unit : mm (in)
No. NAME SHAPE
K V-block
100(3.94)
Pin (5)
(0.551)
L
14
extrusion rod
16 (0.630)
200(7.87)
Bushing
N
extrusion rod
290(11.4)
160(6.30)
M Stand jig
(4.92)
125
270(10.6)
Shaft
P
(2.52)
extrusion jig
64
(1.18)
30
86(3.39)
94.5(3.72)
64.5(2.54)
Bushing
Q
fixing jig
+0.1
64.6 0
(2.543 +0.004
0 )
34-20
34. TRAVEL SYSTEM
34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY)
34.1.5.1 FRONT IDLER ASSY
FRONT IDLER ASSY YN52D00034F1 APPLY LOCTITE #262 OR

EQUIVALENT
No. NAME Q'TY REMARKS T=279N.m(210 lbf.ft)
1 3 2
1 IDLER ASSY 2 YN52D00009F1
2 IDLER ADJUSTER ASSY 2 YN54D00014F1
3 CAPSCREW 4 M16X45
4 GREASE NIPPLE 2
Fig. 34-41 Front idler assy
34.1.5.2 REMOVING
Remove crawler. (Above mentioned)
(2) Removing idler assy

Sling idler assy, and push it forward with bar.
Weight of front idler assy : 210kg (463 lbs) BAR
Keep away from the front side of front idler.
(3) Installing
(4) Where idling assy (1) has to be separated

Loosen capscrew (3), and separate idler assy (1)
from idler adjuster assy (2).
Fig. 34-42 Removing and installation the front idler
: 24 mm

Weight of idler assy : 107kg (236 lbs)
Weight of idler adjuster assy : 103kg (227 lbs)
• The separated idler assy (1) should be placed on

square timbers.
! "
Fig. 34-43 Separating idler assy (1) from idler

adjuster
34-21
34. TRAVEL SYSTEM
34.1.5.3 IDLER ASSY

#

!

%
!"
#
"

&
#
$
#
"
"$

# #%
Fig. 34-44 Idler assy
34.1.5.3.2 REMOVING AND INSTALLING

(1) Removing 5
R
1) Drain oil
Remove plug (8) on the side of collar (3) to drain.
: 5 mm
2) Removing pin (5)

Apply pin push bar (jig R) to the top of pin, and
push out striking bar (jig R) lightly by hammer. Fig. 34-45 Removing pin (5)
PUSH WITH PRESS

3) Removing collar (3)
Put idler (1) on stand (U), apply push-out jig (S) S
6
on shaft (6), push out shaft (6) with collar (3), 3
then remove collar (3). 1
U
3
Fig. 34-46 Removing collar (3)

4) Removing collar (3) from shaft (6) PUSH WITH PRESS
If removal of collar (3) on the opposite side is
S
required, turn over front idler and proceed with
the procedure described in Par. 3). 6
3
Fig. 34-47 Removing collar (3)
34-22
34. TRAVEL SYSTEM

6
With idler (1) mounted on the stand, tap bushing
(2) lightly by hammer, while placing the bushing
drawing rod (T) against the end face of bushing
(2) evenly all round, till it comes out.
6) Removing floating seals (4)

Take out floating seals (4) from idler (1), collar
(3). If you intend to re-use floating seals (4), 7
confirm that there is no scoring and rusting on
the contact surface and store the floating seals
Fig. 34-48 Removing bushing (2)
in pairs by placing card board between the
sealing faces.
7) Removing O-ring (7)

Separate O-ring (7) from shaft (6).
(2) Assembly PUSH WITH
2 PRESS V
1) Pressing in bushing (2)
1
Align inner hole of idler (1) and bushing (2) and
press fit it vertically with press so that jig (V) for
bushing press-fitting is inserted into bushing (2).

Fit O-ring (7) to O-ring groove on shaft (6).
Fig. 34-49 Pressing in bushing (2)
• Apply grease to O-ring
3) Installing collar (3) (See Fig. 34-50) PRESSING

Press fit the O-ring (7) installed side of shaft (6)
into collar (3), and drive pin (5). 6
4) Installing floating seal (4)

3
Fit the half of floating seal (4) on each side of
5
collar (3) and idler (1).
5) Inserting idler (1)

Fig. 34-50 Installing collar (3), shaft (6)
Insert floating seal (4) fitted side of idler (1) into
shaft (6). $
"
6) Installing floating seal (4)
Fit floating seal (4) on the other side of idler (1).
Fig. 34-51 Inserting idler (1) and installing floating

seal (4)
34-23
34. TRAVEL SYSTEM
7) Installing collar (3)

Fit the half of floating seal (4) on the other collar & !
(3), press fit it in shaft (6), and drive pin (5) in with #
hummer.
8) Filling oil•Inspection
Fill in 200cc (12.2cu•in) of engine oil API grade
CD #30 through the plug hole of collar (3), wind
seal tape and tighten plug (8).
: 5 mm
Fig. 34-52 Installing collar (3) and filling oil
• After installing the idler assy to the idler
adjuster assy, make certain that no oil leaks
from floating seal and plug (8) and that idler
(1) rotates smoothly.
34.1.5.3.3 MAINTENANCE STANDARD

160(6.30)
C
F
D
E
B
A
Fig. 34-53 Front idler
Unit : mm (in)
REPAIRABLE SERVICE
LEVEL LIMIT
A Dia. of idler projection ø 535 (21.1) — —
B Tread dia. ø 497 (19.6) ø 490 (19.3) ø 487 (19.2) Replace
C Flange width 84 ± 0.5 (3.307±0.020) 78 (3.07) 76 (2.99)
Basic
Tolerance Fit Fit
dimension
Clearance between shaft and - 0.03
D
bushing ø 75 (-0.00118) Clearance Clearance
Shaft Replace
(2.95275) - 0.06 1.5 (0.059) 2.0 (0.079)
bushing
(-0.00236)
+ 0.035 Clearance
Interference between idler and ø 83 Interference
E Hole (+0.00138) 0.01
bushing (3.26771) 0
0 (0.0004)
F Oil Engine oil API grade CD #30, 200cc (12.2cu•in) Refill
Idler rotation Rotates smoothly by hand Reassemble
34-24
34. TRAVEL SYSTEM
34.1.5.3.4 TOOLS AND JIGS

Unit : mm
NAME OPPOSING FLATS
24
Socket
Allen wrench 5
(2) Jigs
Unit : mm (in)
No. NAME SHAPE
(0.591)
(1.18)
15
30
R Pin striking jig
(0.591)
105(4.13) 15
340 (13.4)
S Shaft push out jig

(2.91)
74
(0.630)
16
300(11.8)
T Bushing drawing rod
Approx.150
(5.91)
Approx.600
(23.6)
U Stand
Approx.
400
(15.7)
2
(0.787)
105(4.13)
20
90(3.54)
Bushing press fitting

70(2.76)
V
jig
+0.1
74.6 0
(2.937 +0.004
0 )
103(4.06)
W Collar press fitting jig
(1.18)
30
34-25
34. TRAVEL SYSTEM
34.1.5.4 IDLER ADJUSTER ASSY
IDLER ADJUSTER ASSY YN54D00014F1 " ! % # ' & $
No. NAME Q'TY REMARKS

1 GREASE CYLINDER 1
2 BRACKET 1
3 NUT 1
4 SPRING PIN 1 8X80
5 SPRING 1
6 PISTON 1

7 COLLAR 1
Fig. 34-54 Idler adjuster assy
8 O-RING 1 1B G80
9 U-PACKING 1
10 PIN 2
11 COVER 1
34.1.5.4.2 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
M30
HOLDING-DOWN NUT
1) Spring set special jig
Before disassembling and assembling the idler RETAINER PLATE
adjuster assy, prepare spring setting jig (V).
Capacity of hydraulic jack : more than 20 tons
(44000 lbs)
V
: 46 mm
HYDRAULIC JACK
Large power is needed to set the spring. Prepare a

BASE
special jig before disassembly and assembly.
Fig. 34-55 Spring set special jig (V)
2) Preparation for working
Place a hydraulic jack between the jig base and
the stand. 2
Loosen the holding-down nuts of the jig and draw

out the retainer plate upward.
: 46 mm
3) Draw out grease cylinder (See Fig. 34-54)
Draw out piston (6) from grease cylinder (1) of 5
the idler adjuster assy.
4) Removing U-packing (9), O-ring (8) (See Fig. 34-
54)
Remove U-packing (9) and O-ring (8) from
V
grease cylinder (1).
5) Slinging work idler adjuster Fig. 34-56 Slinging work idler adjuster
Set the idler adjuster assy on the stand of the jig,
with its bracket side facing up.
34-26
34. TRAVEL SYSTEM
6) Fixing idler adjuster assy

Fit retainer plate to bracket (2), tighten holding- 3
down nuts alternately, and secure idler adjuster
assy.
: 46 mm HOLDING-DOWN NUT
RETAINER PLATE
4
Fig. 34-57 Fixing idler adjuster assy
7) Compression of spring (5) #
Remove spring pin (4), press spring (5) lifting it
with jack so that nut (3) can be turned freely, and
remove nut (3).
: Bar ø7.5×120
: 80 mm
Fig. 34-58 Compression of spring (5)

8) Removing bracket (2)
Allow the hydraulic jack to retract slowly till the
spring is extended to its free length. Remove the
retainer plate and take off bracket (2), cover (11). RETAINER PLATE
The free length of the spring : 540.1 mm (21.3 in)
2
11
Fig. 34-59 Removing retainer plate, bracket (2)

9) Removing spring (5), grease cylinder (1)
Hook lifting eye nut (W) to screw M52×P3 on
9
grease cylinder (1) top end and hoist it. Then,
remove the set of grease cylinder (1) and spring
(5) using crane from the jig.
Remove spring (5), collar (7), grease cylinder
#
(1), in that order.
Fig. 34-60 Removing spring (5), grease cylinder (1)
34-27
34. TRAVEL SYSTEM
(2) Assembly
Assembly is done in the reverse order of W
disassembly. 1
1) Installing spring (5), grease cylinder (1)
Insert grease cylinder (1), collar (7) into spring
5
(5) and attach lifting eye nut (W) to screw
M52×P3 at the tip of the grease cylinder. Lift the
grease cylinder by crane and erect it in the
center of the jig stand upright.
Fig. 34-61 Attach spring (5) and grease cylinder (1)

2) Fixing idler adjuster assy
to the jig
Install bracket (2), cover (11) on top of spring (5).
Center the rod of grease cylinder (1) and the
holes in bracket (2). Attach the retainer plate and
four holding-down nuts. Fasten the nuts evenly
all round and fix the idler adjuster assy to the jig
body.
(See Fig. 34-65)
: 46 mm
3) Compressing spring (5) and tightening nut (3)
HOLDING-
Extend the hydraulic jack, compress spring (5) to DOWN NUT
a set length and screw in nut (3) to the screwed
part at the tip of grease cylinder (1). RETAINER
PLATE
Set length of the spring : 429mm (16.9in)
2
4) Installing spring pin (4)
4
Tighten nut (3) till the holes for locking spring 3
pins (4) are aligned. Then fit spring pin (4).
11 7
: 80 mm 1
Fig. 34-62 Compression of spring (5), and attaching

nut (3) and spring pin (4)
5) Removing idler adjuster assy
Remove idler adjuster assy from jig.
Fig. 34-63 Removing idler adjuster assy
34-28
34. TRAVEL SYSTEM
6) Installing U-packing (9), O-ring (8)

1 9 8 6
Fit U-packing (9) and O-ring (8) to grease
cylinder (1).
• Grease oil seal (9) and O-ring (8).
7) Filling grease cylinder(1) with grease.

Fill up grease in cylinder (1), remove the grease
nipple from piston (6) to discharge the inside air,
and press in the piston by hand. GREASE NIPPLE
• Direct grease nipple hole downward to make Fig. 34-64 Grease cylinder (1)
air discharge easier.
8) Installing grease nipple

Tighten grease nipple to piston (6).
: 19 mm,
34.1.5.4.3 MAINTENANCE STANDARD
No. ITEM STANDARD VALUE

A Installed length of spring 429mm (16.9 in)
B Free length of spring Approx. 540.1mm (21.3 in)
C Stroke 51.8mm (2.04in)
D Set length 716mm (28.2in)
E Outside view of piston Nor scoring and rusting
Tightening torque of
F 59N•m (43 lbf•ft)
grease nipple
X
E
C
A, B F
X D Y
INSTALL A SPRING WHOSE STARTING POINT AT BRACKET SIDE TO BE 35 DEGREE.
BRACKET
DETAIL Y
SECTION XX
Fig. 34-65
34-29
34. TRAVEL SYSTEM
34.1.6 SPROCKET
34.1.6.1 REMOVING
Remove crawler referring to "34.1.2 CRAWLER",
lift up crawler frame with attachment, and put it on
square timbers to float and stabilize.

(2) Removing sprocket
Loosen 26 capscrews (2) M16×45, for the
attaching of the sprocket by means of a socket and
remove the sprocket (1).
Weight of sprocket : 48kg (106 lbs)
: 24 mm
Fig. 34-67 Removing sprocket
34.1.6.2 INSTALLING
(1) Check before installing
Check the mating portion of the travel reduction unit
and the sprocket, eliminate burrs and
contamination thoroughly and install the sprocket.
(2) Installing sprocket temporarily

Coat the sprocket attaching capscrews with Loctite
#262 and fasten the sprocket temporarily.
(3) Installing sprocket completely

Remove the wooden blocks under the truck frame,
bring the machine down on the ground and tighten
the sprocket.
: 27 mm
Fig. 34-68 Installing sprocket completely
34-30
34. TRAVEL SYSTEM
34.1.6.3 MAINTENANCE STANDARD (YN51D01003P1)
96.07mm NUMBER OF
PITCH 21
(3.78in) TEETH
SPECIFICATION
ø58.72mm 644.602
ROLLER DIA. PITCH DIA.
(2.31in) (25.333in)
C
Fig. 34-69 Sprocket
Unit:mm (in)
REPAIRABLE SERVICE
No. NAME STANDARD VALUE REMEDY
LEVEL LIMIT
Reinforcement weld,
A O.D. of sprocket ø 659 (25.9) ø 651 (25.6) ø 649 (25.6)
repair or replace.
B Width of sprocket teeth 66±2 (2.520±0.079) 60 (2.36) 58 (2.28) Replace.
Reinforcement weld,
C O.D. of sprocket bottom ø 586 (23.1) ø 578 (22.8) ø 576 (22.7)
repair or replace.

(1) Tools
Unit : mm
NAME OPPOSING FLATS
24
Socket
34-31
34. TRAVEL SYSTEM
(2) Sprocket tooth profile gauge : W
Unit : mm (in)
)
6"
0 .23
( 6
R
.7823)
96.07(3
Fig. 34-70 Tooth profile gauge (Full scale)
34-32
34. TRAVEL SYSTEM
34.1.7 TRAVEL MOTOR
34.1.7.1 TRAVEL MOTOR

3
APPLY LOCTITE #262
OR EQUIVALENT
TIGHTENING TORQUE:
279 N.m(206 lbf.ft)
Fig. 34-71 Installing travel motor
34.1.7.2 REMOVING
Remove crawler, lift up crawler frame using
attachment, and put it on square timbers to float
and stabilize.
(2) Removing cover (1)
Remove sems bolt (6) M12×25 and also remove
covers (1).
$
: 19 mm

(3) Preparation of oil pan
(4) Removing hydraulic pipe
Release pressure from travel circuit, and bleed air Fig. 34-72 Removing and installing cover (1)
in hydraulic oil tank, then remove all pipes
connecting to travel motor. Then plug up all pipes
and joint section to protect them from entry of dust.
: 19mm, 27mm, 41mm

Refer to "Hydraulic pipe plug" 5.1
(See Chapter 11. TOOLS)
"Plug for flare hose" 5.2 (3) (See Chapter 11.
TOOLS)
Fig. 34-73 Removing and installing hydraulic pipe
34-33
34. TRAVEL SYSTEM
(5) Removing sprocket

Removing twenty two (one side) capscrews (2)
M18×55.
: 24 mm
Fig. 34-74 Removing and installing sprocket

(6) Loosening travel motor attaching bolts (3) REMOVE PIPES (DISCONNECT)
Apply match marks on travel motor and crawler
frame, and remove seventeen (one side)
capscrews (3) M20×60.
: 24 mm
Fig. 34-75 Removing and installing travel motor

attaching bolts
(7) Slinging travel motor assy
Sling travel motor with nylon sling applied on the
side close to sprocket installing section and remove
the motor.
Weight of motor : About. 260kg (573 lbs)
Fig. 34-76 Slinging travel motor
34.1.7.3 INSTALLING
Installing of the travel motor piping is performed in the

reverse order of removal.

1) Cleaning
"# "* $ '+ ) $"
.
Check that contact surface of travel motor and

crawler frame is free from burr and stain. "$ #) + #,* #%$ /#$#

"%" & "* - )*+$
"'# & +# - "),""%
Tighten capscrew and hydraulic pipes to the - #,&#%%
torque specified in "Tightening Torque".
! #' )"
3) Fill inside from motor drain port to casing with "() "* - #* )#" ,
hydraulic oil before piping for drain. When
"(# #, - ,' &&, *
"() "* - +$ +#,
starting operation, operate motor in low idling
"(# #, - "%''%
and at low speed for several minutes, and check
" )" - #&&"*%
it for possible oil leakage and noise.
34-34
34. TRAVEL SYSTEM
34.1.8 SWING BEARING
34.1.8.1 SWING BEARING ASSY

FRONT A A
INNER S ZONE POSITION OF

SWING BEARING
SECTION AA
Fig. 34-77 Swing bearing assy
34.1.8.2 REMOVING
(1) Matchmarks
SWING BEARING
Remove upper structure, apply matchmarks on
inner race of swing bearing and lower frame. OUTER RACE
INNER RACE
(2) Remove 36 capscrews (2) M20×65 for installation
inner race. MATCHMARKS
: 30 mm
(3) Removing grease

Remove grease in grease bath.
Fig. 34-78 Matchmarks
(4) Removing swing bearing SWING BEARING

Attach eyebolt on swing bearing and sling it. EYE BOLT
Weight of swing bearing : 243kg (536 lbs)
GREASE BATH
Fig. 34-79 Removing and installing swing bearing
34-35
34. TRAVEL SYSTEM
34.1.8.3 INSTALLING
(1) Cleaning
Clean it completely so that installing surfaces of
swing bearing and lower frame are free from dust
and dirt.
(2) Installing
Install swing bearing on lower frame meeting the

matchmarks and positioning the S mark on inner

race as shown in Fig. 34-80.
(3) Temporary fastening of inner race
Coat the threads of the capscrews (2) with Loctite
#262 and tighten all the capscrews (2) temporarily.
: 30 mm

(4) Regular tightening of inner race
Tighten the capscrews (2) at 180 degrees intervals Fig. 34-80 Location of S mark on swing bearing
alternately to a specified torque.
: 30 mm,
(5) Filling grease
Fill grease bath with 8.6kg (19 lbs) of grease NLGI-
2 (containing molybdenum disulfide) or equivalent.

!
Fig. 34-81 Removing and installing capscrew (2)
ASSY PART NO. YN40F00026F1 6

1 8
No. NAME Q'TY No. NAME Q'TY
9
1 OUTER RACE 1 6 SEAL 1
7
2 INNER RACE 1 7 TAPER PIN 1 3
3 BALL 120 8 PLUG 1 5
4 RETAINER 120 9 GREASE NIPPLE(PT1/8) 1 2
5 SEAL 1
Fig. 34-82 Sectional view of swing bearing

(1) Disassembly
1) Remove seal (5) fitted in the groove in the outer EYE BOLT
6 2
circumference under inner race (2) and seal (6) 7
fitted in the groove in the inner circumference on
1
top of outer race (1) and place them level on a
SQUARE WOODEN
square wooden block or something. BLOCK
2) Remove taper pin (7), using a hammer and an
extrusion rod. 8
3) Remove plug (8), utilizing an pull bolt inserted in 5
the screwed hole (M10) in the center of the plug
and using a puller. Fig. 34-83 Disassembling swing bearing
34-36
34. TRAVEL SYSTEM
4) While rotating outer race (1) little by little, take out 1

ball (3) and retainer (4) through plug hole, in that
order.
2
4
3
Fig. 34-84 Removing balls (3) and retainers (4)
(2) Installing
1) Thoroughly degrease the groove for seal (6)
located on the inner surface of outer race (1) and
the groove for seal (5) located on the outer
surface of inner race (2). Coat the grooves with 1
adhesive Cyano Bond PX-3000 equivalent, fit PUSH ROD 6
seal (5) and place it on a surface plate.
2) Lower outer race (1) to the position where upper 2
surface of inner race (2) and lower portion of seal SQUARE 3
WOODEN BLOCK 5
groove is mated, put adjusting washer under
outer race (1) so that outer raceway surface of Fig. 34-85 Fitting balls (3)
ball (3) aligns with inner raceway, and support it.
EYE BOLT
3) Insert ball (3) and retainer (4), on which grease
is applied, through plug (8) hole on outer race
(1), alternately.
HOOKED ROD
To insert ball (3) and retainer (4), use a push rod, etc.,
to protect persons from injury from inserting fingers into 4
plug hole. SQUARE
WOODEN BLOCK
4) Fit plug (8) to outer race (1) while checking it for Fig. 34-86 Fitting retainer (4)
direction and position of taper pin hole.
5) Coat seal (6) with adhesive Cyano Bond PX-
3000 equivalent and fit it in the groove of outer
race (1).
6) After completion of assembly, caulk the edge of
taper pin (7) by punching.
7) Check that grease nipple (9) is properly fitted,
and fill it with grease. Then, check bearing for
smooth rotation and flaws on seal lip portion.
• Shell Albania EP#2 ; 160cc (9.76cu•in)

Maintenance standard concerning wear of swing bearing is described in the section 13.6 MEASURING SWING
PERFORMANCES of "Maintenance Standard and Test Procedure" in this manual.
34-37
34. TRAVEL SYSTEM
34.2 REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT

34.2.1 TRAVEL MOTOR
34.2.1.1 CROSS-SECTIONAL VIEW
SECTION B-B
C C
SECTION C-C
SECTION A-A
34-38
34. TRAVEL SYSTEM

1 Hub 1 Piston assembly 1 Rear flange assembly
3 Carrier [1] 1 161 • Piston 1 301 • Rear flange 1
4 Sun gear [1] 1 163 • Seal 1
5 Planetary gear [1] 3 162 Steel ball 1 • Spool assembly 1
6 Carrier pin [1] 3 102 Shaft 1 323 •• Spool 1
7 Carrier [2] 1 326 •• Plug 2
8 Sun gear [2] 1 Swash plate kit 1 327 •• Valve 2
9 Planetary gear [2] 3 103 • Swash plate 1 328 •• Spring 2
10 Carrier pin [2] 3 167 • Pivot 2 331 •• O-ring 2
11 Thrust washer [1] 6 107 Retainer plate 1 324 • Plug 2
12 Thrust washer [2] 6 108 Thrust ball 1 325 • Spring retainer 2
13 Thrust plate 1 109 Timing plate 1 329 • O-ring 2
14 Cover 1 112 Piston 1 330 • Spring 2
15 Coupling 1 113 Spring 8 363 • Spool 1
16 Parallel pin [1] 3 114 Spring 9 364 • Connector 1
17 Parallel pin [2] 3 115 Friction plate 3 365 • Pin 1
22 Lock washer 2 116 Separator plate 4 366 • Spring 1
23 Shim 1 119 Shim 1~2 367 • Spring retainer 1
24 Angular ball bearing 2 132 Oil seal 1 368 • G (PF) 1/4 plug 2
27 Needle-roller bearing 3 133 Snap ring (for hole) 1 369 • O-ring 2
28 Needle-roller bearing 3 135 D ring 1 370 • G (PF) 3/8 plug 1
29 Floating seal 1 139 D ring 1 371 • O-ring 2
30 Plug 3 149 Taper roller bearing 1 372 • Orifice 2
31 O-ring 3 150 Taper roller bearing 1 373 • Orifice spring 2
35 Socket bolt 18 374 • G (PF) 1/8 plug 5
36 Snap ring (for hole) 1 Relief valve assembly 375 • O-ring 6
201 • Valve seat 2 376 • M6 orifice 3
101 Spindle 1 202 • Valve 1 377 • Check valve 3
137 Socket plug 1 203 • Sleeve 1 378 • Check valve spring 3
138 Expander 1 204 • Plug 1 379 • O-ring 1
205 • Spring retainer 1 380 • O-ring 1
Piston kit 1 206 • Piston 1 341 • Parallel pin 1
• Piston assembly 9 207 • Spring 1 343 • Socket bolt 8
105 •• Piston 1 208 • Piston seal 1 345 • Socket plug 15
106 •• Shoe 1 209 • Piston seal 1
104 Cylinder block 1 210 • O-ring 1 399 Name plate 1
34-39
34. TRAVEL SYSTEM
34.2.1.2 GENERAL FOR MAINTENANCE
34.2.1.2.1 Tools
(1) Standard tools
No. Tools Size Q'ty

3 (For M6), 4 (For PT1/16)
5 (For PF1/8), 6 (For PF1/4)
1 Allen wrench 1 each
8 (For M10 and PF3/8)
10 (For PF1/2), 14 (For M16)
Socket wrench
2 (Ratchet handle) 1
(JIS B 4641)
Dial type Approx. 50N•m (37lbf•ft)
3 Torque wrench 1 each
Nominal 32 (O.D. 44mm
4 Adapter for torque wrench (1.73inch) or less), 46 Socket, 1 each
Nominal 3,4,5,6,8,10,14 Hex key
5 Torque wrench (Wrench type) Opposing flats 21mm (0.83inch) 1
6 Extension bar 150mm (5.91inch) 1
7 Hammer Various size 1 each
8 Plastic mallet L= Approx. 400mm (15.7inch) 1
Flat-bladed screw driver Approx. 50mm (2 inch)
9 1 each
Approx. 150mm (6 inch)
For shaft 1
10 Snap ring
For hole 1
Lifting capacity 9800 N (7230 lbf) 1 set
Eye bolt for M16 (2)
11 Lifting tool Eye bolt for M10 (3)
Eye bolt for PF1/2 (2)
Wire with hook (1)
12 Leather gloves 1 set
(2) Apparatuses
Application item
Apparatus Size Remarks Q'ty
(Use or number of relevant parts)
Work bench for
Disassembly and assembly 1 set
general-use
For rough cleaning and
Cleaning the parts Cleaning bath 1 set
finish cleaning
Pressing capacity 9800 N
24 (Angular ball bearing) Work bench for press 1 set
(7230 lbf) or over
Pressure 0.29 to 0.49 MPa
Drying after cleaning Compressed air —
(42 to71 psi)
34-40
34. TRAVEL SYSTEM
(3) JIGS
Name: Work bench for travel motor

• This is used to disassemble and to assemble of travel motor
safely and securely.
Name: Fixing metal

• This is used to assemble spindle (101) and hub (1).
Name: Jig for installing lock washer

• Jig for installing lock washer (22) into groove of spindle
(101).
Name: Jig for press-fitting angular ball bearing

• Jig for press-fit angular ball bearing (24) into hub (1).
Name: Steel bar (I)

• This is used to remove angular ball bearing (24) from hub
(1).
34-41
34. TRAVEL SYSTEM
Name: Long eye bolts

• These are used to lift travel motor, spindle (101) and hub (1).

Name: Spatula
• This is used to remove timing plate (109) from rear flange
(301).
Name: Jig for installing floating seal (I)

• This is used to install floating seal (29) into hub (1).
Name: Jig for installing floating seal (II)

• This is used to install floating seal (29) into hub (1) and
spindle (101).
Name: Jig for installing floating seal (III)

• This is used to install floating seal (29) into spindle (101).
34-42
34. TRAVEL SYSTEM
34.2.1.2.2 Tightening torque
Number of Bolt / Nut

relevant parts Opposing flats Tightening torque
Q'ty
(In cross-sectional Name Size mm (inch) N•m (lbf•ft)
view)
98.1±19.6
30 Plug PF1/2 10 (0.394) 3
(72.4±14.5)
57.9±9.81
35 Socket bolt M10 (P1.5) 8 (0.315) 18
(42.7±7.24)
13.7±1.37
137 Socket plug PT1/16 4 (0.1575) 1
(10.1±1.01)
157~177
204 Plug M27 (P1.5) 32 (1.2598) 2
(116~131)
304~324
324 Plug M38 (P1.5) 46 (1.811) 2
(224~239)
49.0~58.8
364 Connector PF3/8 21 (0.8268) 1
(36.1~43.4)
29.4±2.94
368 Plug PF1/4 6 (0.2362) 2
(21.7±2.17)
49.0~58.8
370 Plug PF3/8 8 (0.315) 1
(36.1~43.4)
14.7±1.47
374 Plug PF1/8 5 (0.1969) 5
(10.8±1.08)
230±23.0
343 Bolt M16 14 (0.5512) 8
(170±17)
34.2.1.2.3 Weight of component
Number of relevant parts

Components Weight kg (lb)
(In cross-sectional view)
Travel motor assembly Approx. 277 (610)
1 Hub Approx.79 (175)
101 Spindle Approx. 60 (130)
3 and others Carrier (ÇP) Assy Approx. 27 (60)
7 and others Carrier (ÇQ) Assy Approx. 47 (105)
34-43
34. TRAVEL SYSTEM
34.2.1.3.1 Preparation
The following preparations must be made before disassembly.
(1) Preparing working bench
• Prepare work bench for travel motor.
• Prepare work bench which is sturdy for disassembly and assembly of the travel motor's inner parts and has
enough space to put the parts, and from which the possibility of the dropping and movement of parts is
eliminated.
• Cover the work bench with rubber sheet, vinyl sheet, etc.
(2) Preparing tools and materials.

Prepare the tools and materials which are specified in paragraph 34.2.1.2.1.
34.2.1.3.2 General cautions required to perform the work
The inner parts which are under disassembly may be easily slipped because they are coated by gear oil and
hydraulic oil.
Special attention must be given to the handling of parts which might fall and injure, and might be damaged.
When flammable like diesel oil or kerosene, etc. is used to wash and clean the removed parts, pay attention to the
handling so as not to start a fire and get burn because the flammable is tending to catch fire.
(1) Identify the items to be checked and the property of abnormalities detected rightly before disassembly, and carry
out the disassembly according to the specified procedure.
(2) Handle parts taking care so as not to collide each other and not to drop because the each part is precisely made.
(3) Do not strike or pry parts even if made by hard material, otherwise the assembly might be difficult due to burrs
and damage and may cause the deterioration of performance.
(4) If the parts removed or under disassembly are left, it may cause rusting of parts due to moisture and dusts. If it
is unavoidably necessary to suspend the work, do not fail to protect the parts form rust and dust.
(5) Mark the mating face of each part at the time of disassembly.
(6) Go ahead with the work while putting the removed parts in order so as not to damage or miss the parts during
disassembly.
(7) The removed seals, etc. must be replaced with new ones even if no damage is found. Prepare the spare parts
before starting disassembling.
(8) The pictures and figures carried in this document are taken by typical models. Even if a part of the picture and
figure differs from those of products in use, it has not an effect on the disassembling procedure.
34-44
34. TRAVEL SYSTEM
34.2.1.3.3 Disassembling procedure

(1) Cleaning travel motor
1) Tighten eye bolt to the tapped hole for spindle (2), hang up the travel motor with hoist and carry it to washing
bath.
Tighten two eye bolts to the tapped holes for spindle in such locations that they are symmetrical each other.
2) Clean each section of travel motor with car washing brush.
Carefully clean the space between hub (1) and spindle (101) (floating seal fitting section) because earth and
sand might be entered.
(2) Installing travel motor

1) Put travel motor on work bench.
Align the thread hole of hub (1) to the threaded hole of work bench and softly insert the travel motor in
attaching hole of work bench.
2) Attach the travel motor on the work bench in such locations that two socket bolts are symmetrical each other.
Securely tighten the socket bolt. If not, there is a possibility of injury due to the drop of travel motor when it
has been turned over.
(3) Draining lube oil.

1) Lay the travel motor horizontally. (Direct the drain port downward.)
2) Loosen oil filler plug (30) and release the pressure in the reduction unit, and then lightly tighten the plug
again.
If the pressure is applied to the inside of reduction unit, lubricating oil may be gushed out when loosening
the plug of drain port.
3) Put the oil pan under the top end of drain port and slowly loosen the plug of drain port and then drain
lubricating oil.
Prepare the oil pan of which the capacity is sufficient for the lubricating oil quantity specified to the reduction
unit, 5.3L.
34-45
34. TRAVEL SYSTEM
4) If it is hard to drain lubricating oil, slowly loosen and remove the plug of oil filler port.
5) Remove O-ring (31) from the removed plug.
Do not use the removed O-ring (31). It may cause oil leak.
(4) Removing cover

1) Turn over travel motor. (Direct reduction unit
upward.)
2) Loosen and remove bolt 18-M10.
3) Since the sealant is used on the mating faces of
cover (14) and hub (1), apply a protecting plate
to the cover obliquely and remove the cover
while striking it upward.
Be careful about the cover which might be sprung up

when striking the cover obliquely upward. Pay attention

to the cover which might be drop on foot, etc.
4) Attach eye bolt to the PF1/2 port and hang up

and move the cover from the hub.
(5) Removing 1st gear

1) Attach eye bolts to 3 tapped holes M10 for carrier
[1] (3) and hang up and move carrier [1]
assembly by hoist.
When lifting carrier [1] assembly, slowly lift it directing

center shaft of hub and carrier [1] assembly upright to
protect the internal gear of hub from being damaged by
the edge of planetary gear [1] (5).
2) Lift and remove sun gear [1] (4) by hand.
Pay attention to sun gear [1] in order not to drop

because it is slippery because of lubricating oil applied.
34-46
34. TRAVEL SYSTEM
(6) Removing 2nd gear

1) Attach eye bolts to 3 tapped holes M10 for carrier
[2](7) and lift and move carrier [2] assembly by
hoist.
When lifting carrier [2] assembly, slowly lift directing

center shaft of hub and carrier [2] assembly upright to
protect the internal gear of hub from being damaged by
the edge of planetary gear [2] (9).
2) Lift and remove sun gear [2] (8) from carrier [2]
assembly by hand.
Pay attention to sun gear [2] in order not to drop

because it is slippery because of lubricating oil applied.
(7) Removing coupling

1) Remove coupling (15) from shaft (102).
(8) Removing lock washer

1) Direct the spindle side upward.
2) Secure it in shaft direction with special jig to
protect the spindle from dropping out by making
use of threaded hole M16 of hub (1) and spindle
(101).
34-47
34. TRAVEL SYSTEM
3) Apply flat-blade driver or equivalent to the space

between two lock washers (22) and remove it
while striking the driver obliquely downward.
(9) Removing spindle

1) Direct the spindle side upward.
2) Remove the special jig used to secure hub and
spindle.

3) Attach eye bolt to spindle and lift the spindle by
hoist.
Slowly lift the spindle in parallel with the shaft of

hub. If the spindle is obliquely lift, a large force
which might cause the breakage of the hoisting
accessory, eye bolt, etc. is applied resulting in
injury by being hit by the hoisting accessory. When
it is hard to pull it out, do not be forced to lift, but
use press, etc. to pull it out safely.
(10) Removing floating seal

1) Touch the inner side of floating seal (29) by hand,
and remove it pushing upward.
There is a case where the edge of floating seal cuts

your finger. We recommend using glove when
removing it. And when it is stuck due to the intrusion of
mud, remove it using screw driver as a lever.

(11) Removing angular ball bearing
1) Apply iron bar to the inner ring of angular ball
bearing (24) and remove it little by little while
striking 3 or 4 points divided into equal divisions
on the circumference by hammer.
If the inner ring is struck, the raceway surface may be

damaged, and consequently the reuse of ball bearing
might be impossible. Therefore the angular ball bearing
should be removed only when required to be replaced.
34-48
34. TRAVEL SYSTEM
(12) Removing rear flange assembly

1) Directs rear flange (301) upward.
2) Loosen 8 socket bolts (348) and remove rear
flange.
3) Remove rear flange from spindle (101).
When the rear flange is removed by both hands, pay

attention to timing plate (109) and spring (113) so as not
to drop.
When disassembling the parts of rear flange section,

loosen each plug before loosening socket bolts used to
secure rear flange [operation of (12) 2] to facilitate
going ahead with the disassembly which is carried out
later.
34-49
34. TRAVEL SYSTEM
(13) Removing taper roller bearing

1) Secure sliding surface of cylinder block (104)
with fixing plate.
Insert rubber-like cushioning material between cylinder

block sliding surface and fixing plate giving attention to
the sliding surface of cylinder block so as not to
damage.
2) Apply puller axis to the center hole of shaft (102)

and hook claw to the inner ring of taper roller
bearing (150).
3) Pull the taper roller bearing out of the shaft while
slowly turning the axis of puller with spanner, etc.
Put rear flange (301) on work bench while
directing the mating face with spindle (101)
upward.
When the retainer (cage) of the taper roller bearing is

accidentally damaged by puller, replace the retainer
(cage) with new one.
(14) Disassembling parking brake

1) Pull the piston out making use of the threaded
hole M6 of piston (112).
2) Turn work bench sideways.

3) Remove separator plate (116) and friction plate
(115).
34-50
34. TRAVEL SYSTEM
(15) Disassembling rotary section

1) Pull out cylinder block, piston (105) and retainer
plate (107) together.
2) Remove swash plate (103).
3) Remove shaft (102).
Slowly pull the shaft out being care not to damage the
lip of oil seal (132).
(16) Removing piston

1) Apply cloth on piston (161), blow air through the
drilled hole and remove the piston of spindle
(101).
34-51
34. TRAVEL SYSTEM
34.2.1.4 SERVICE STANDARDS

Disassemble GM motor according to this standard. At this time do not damage the moving and sliding part.
34.2.1.4.1 Seals
Replace all seals (O-ring, oil seal, floating seal with new one) once used even if no damage is seen.
34.2.1.4.2 Wear parts maintenance standard

(1) Replace any part that shows damage on appearance.
(2) Replace such parts that show the following abnormalities, as well.
Reference Allowable
Item No. Parts Trouble
value value
• Severe damage to appearance.
(1) Hub • Pitting occurs on tooth surface of ring gear. — —
• Abnormal wear such as scoring is present.
• Severe damage to appearance.
(101) Spindle — —
• Abnormal wear such as scoring is present.
(3)
Carrier assembly • Abnormal wear such as scoring is present. — —
and other
(4) Sun gear 1
(8) Sun gear 2 • Pitting occurs on tooth surface of gear.
— —
(5) Planetary gear 1 • Flaking is seen on race of bearing.
(9) Planetary gear 2
(11) Thrust washer 1 • Discoloration and abnormal wear appears
— —
(12) Thrust washer 2 on the sliding surface.
• Dent is present.
(24) Angular ball bearing • Flaking is seen. — —
• Uneven wear is present.
• Pitting occurs on roller.
(27) Needle-roller
• Abnormal wear is present on the end of — —
(28) bearing
cage.
• Sliding part is damaged due to valve (263)
(301) Rear flange — —
motion.
• Contact face between shaft and oil seal
(102) Shaft (132) was worn. — —
• Spline was worn.
(103) Swash plate • Seizure is present. — —
• Spline is worn.
• Bore surface is worn badly.
(104) Cylinder block — —
• The face between sliding surface and timing
plate (109) was scored or worn unevenly.
Clearance on Clearance on
• Clearance is present in the axial direction
Piston assembly diameter 0 to diameter 0 to
(105) between piston and shoe.
piston shoe 0.05mm 0.2mm
(106) • Shoe is worn abnormally and unevenly.
(0.002inch) (0.008inch)
• Deformation is present.
(107) Retainer plate • The sliding surface between thrust ball (108) — —
and plate is scored and worn unevenly.
34-52
34. TRAVEL SYSTEM
Reference Allowable
Item No. Parts Trouble
value value
• The sliding surface between retainer plate
(108) Thrust ball (107) and spherical sliding part is worn — —
unevenly.
(109) Timing plate • Sliding surface is seized or worn unevenly. — —
• Both end face are worn unevenly. Braking torque Braking torque
(115) Friction plate
• Special torque can not be reached. 470N•m 470N•m
(116) Separator plate
• Seizure is seen. (347lbf•ft) (347lbf•ft)
(112) Piston
• Outer circumstance is scored.
(135) D ring — —
• Wear or nibbling are seen on D ring.
(139) D ring
• Dent is present.
(149)
Taper roller bearing • Flaking is seen. — —
(150)
• Uneven wear is present.
(161) Piston
• Wear or nibbling are seen on seal. — —
(163) Seal
(323) • Outer circumstance is scored.
Spool — —
(363) • Outer circumstance is worn unevenly.
34-53
34. TRAVEL SYSTEM
34.2.1.5 ASSEMBLY
The assembly is carried out by the reverse procedure of disassembly.
34.2.1.5.1 Preparation
Prepare work bench, tools and materials similarly to the disassembly specified in paragraph 34.2.1.3.
34.2.1.5.2 General caution necessary to perform the work

(1) Pay attention to the same general caution as the disassembly explained in paragraph 34.2.1.3.
(2) On assembling, remove metal chips and foreign matters from all parts and make sure that parts are free from
burr, dent, etc. If burr and dent are found, remove them by means of oil stone.
(3) Replace O-ring, oil seal and floating seal with new one.
(4) Remove adhesive left on the threaded hole of hub (1) by passing tap M10×P1.5 through the hole. Then clean
and degrease the threaded hole, and blow air to remove cleaning fluid.
Replace socket bolt (7) with new one.
(5) Use care about O-ring, oil seal and floating seal when fitting them so as not to damage. (Apply grease in small
amounts to smooth.)
(6) Be sure to apply clean hydraulic oil (NAS grade 9 or more) to the moving parts and sliding parts provided on the
hydraulic motor and valve before assembling.
(7) Do not use cloth glove during assembling work. (To prevent malfunction due to lint of fiber)
(8) Torque bolts and plugs to values specified in paragraph 34.2.1.2.2 "Table of Torque".
(9) At the time the assembly was completed, plug all ports to prevent dust entering.
(10)The pictures and figures carried in this document are taken by typical models. Even if a part of the picture and
figure differs from those of products in use, it has not an effect on the assembling procedure.
34.2.1.5.3 Assembling procedure
• Remove adhesive adhered on female thread hole M10 of hub (1) by means of tapping.
• Remove sealant adhered on mating surface of hub (1) and cover (14) with scraper, grindstone, etc.
• Sufficiently clean all parts in cleaning bath before assembling.
34-54
34. TRAVEL SYSTEM
(1) Assembling spindle

1) Set spindle (101) on work bench.
2) Fit outer ring of taper roller bearing (149) into the
center hole of spindle.
3) Place piston (161) in the cylinder hole of spindle.
4) Place steel balls (162) in piston hole.
Apply grease to the steel ball to fix on the piston hole to

be sure the steel ball does not drop out of the piston
during assembly which will be carried out later.
5) Attach L side of pivot (167) to the left side in the

picture.
6) Insert shaft (102).
Apply grease to spline of shaft and slowly insert it taking

care not to damage the lip of oil seal.
(2) Assembling rotary section

1) Apply grease to the sliding surface of swash
plate (103) and pivot.
2) Tilt the swash plate and place it in spindle.
• Make sure that the speed is changed in High and

Low smoothly while blowing air through the drilled
hole after assembling the swash plate in.
• Apply clean hydraulic oil to the sliding surface of
swash plate.

4) Set cylinder block (104), piston (105), spring
(114), thrust ball (108) and retainer plate (107)
and insert it in the shaft.
• Apply clean hydraulic oil to the sliding surface of

cylinder block, piston, thrust ball and shoe (106).
• On inserting cylinder block assembly in the shaft, fix
the reduction unit side of shaft first and the insertion
can be performed smoothly.
34-55
34. TRAVEL SYSTEM
(3) Assembling parking brake

1) Direct rear flange attaching face of piston
upward while turning the work bench.
2) Install separator plate (116), friction plate and
separator plate in that order.
3) Apply soft metal bar to piston (112) and insert it

in spindle (101) while striking the bar with a
hammer.
Strike 3 or 4 points divided into equal divisions on the

circumference of piston in order and assemble it in the
condition where the piston is held in level because the
sliding surface might be damaged if the piston is largely
tilted.
(4) Assembling taper roller bearing

1) Push taper roller bearing (150) on which the
outer ring has been removed against shaft (102),
and then apply metal bar to the inner race and
insert it while striking the bar with a hammer.
34-56
34. TRAVEL SYSTEM
(5) Adjusting clearance of taper roller bearing
When spindle (101), shaft (102), rear flange (301) or

taper roller bearing (149) (150) is replaced, adjust the
clearance of taper roller bearing. When the clearance is
improper, the life of taper roller bearing might be
shortened.
1) Direct the mating surface with the rear flange of

spindle (101) upward.
2) Press taper roller bearing (150) into shaft (102)
while striking it with plastic hammer.
3) Measure dimension A.
4) Measure dimension B of rear flange (301).
5) Subtract dimension A from dimension B, and
select shim (119) which makes the clearance to
0~0.17mm (0~0.0067in).
(6) Assembling rear flange

1) Place shim and outer race of taper roller bearing
(150) in the center hole of rear flange (301) in
that order.
2) Install timing plate to rear flange so that parallel
pin (341) which is press-fitted in the rear flange
aligns with the hole on the perimeter of timing
plate (109).
3) Install spring (113) into the hole of rear flange.
Apply grease to timing plate and spring to prevent the

parts from missing when the rear flange assembly is
assembled to the spindle.
4) Make sure those O-rings (375), (379), (380) are

fitted into O-ring grooves of rear flange.
34-57
34. TRAVEL SYSTEM

6) Install rear flange.
7) Tighten socket bolt (343) to the specified torque.
When the parts of rear flange are disassembled, tighten

each plug to the specified torque.
34-58
34. TRAVEL SYSTEM
(7) Assembling hub

1) Place hub (1) on press work bench. PRESS
2) Install angular ball bearing (24) in the hub, place
ball bearing press fitting jig on the outer race of HUB
angular ball bearing, and press fit it in the hub by JIG FOR PRESS-FITTING
ANGULAR BALL BEARING
means of press.
3) Turn over the hub.
4) Press fit angular ball bearing in the hub by the
same procedure as that described in above 2).
BALL BEARING
STAND
Pay attention to the direction of ball bearing (24) to be

attached.
JIG FOR
INSTALLING F/S (II)
5) Place the hub on work bench and fix it.
JIG FOR
INSTALLING F/S (I)
FROATING
SEAL (F/S) HUB
6) Apply grease to O-ring of floating seal (29), and

fit floating seal into floating seal groove of hub
(1).
7) Similarly, fit floating seal into floating seal groove
of spindle (101).
• When applying grease to O-ring of floating seal,

take O-ring out of floating seal and apply thin coat
of grease to perimeter of O-ring.
• Remove jig F/S (I) for installing floating seal and
make sure that spindle groove end face is in
parallel with floating seal surface within the range of
1mm. When it is not in parallel, it might cause
leaking oil and seizure. Perform the procedure from
the first again.
34-59
34. TRAVEL SYSTEM
(8) Adjust clearance of angular contact ball bearing
When hub (1), angular ball bearing (24) or spindle (101)

is replaced, do not fail to adjust the clearance. When
the clearance is improper, the life of angular ball
bearing might be shortened.
1) Temporarily attach lock washer (22) to spindle,

and measure dimension C.
2) Measure bearing width D of angular ball bearing

as shown in figure.
Turn hub and angular ball bearing several times to

make the bearing level.
3) Subtract dimension D from dimension C and

select shim (23) which makes the clearance
within -0.08~+0.02mm (-0.0031~+0.0008in).
(9) Assembling spindle :
1) Fit shim (23) in spindle (101) with grease.
2) Align the lifted spindle with the center shaft of
hub (1) and insert the spindle in angular ball
bearing (24) while lowering the spindle slowly.
3) Tighten and secure it with special jig making use

of the threaded hole M16 of hub and spindle.
4) Direct the reduction unit upward while turning
work bench.
5) Apply metal bar to the inner race of angular ball
bearing on the reduction side and strike it lightly
by means of hammer to make the inner race
level.
34-60
34. TRAVEL SYSTEM
6) Fit lock washer (22) to the groove of spindle.
7) Press lock washer into the groove of spindle by

means of jig.
Be sure to press lock washer into the groove bottom to

prevent the interference with the lock washer when
placing carrier [2] (7) in.
8) Direct spindle upward while turning work bench.

9) Remove special jig which is used to fix hub and
spindle.
10) Turn spindle several times.
The sliding surface of floating seal fits surface of hub

and spindle by turning the spindle. This results in
prevention of imitated oil leaks at test run.
(10)Assembling 2nd stage gear

1) Assemble coupling (15) to shaft (102).
2) Hoist carrier [2] assembly. And install it in hub (1).
When placing carrier [2] assembly in, align the center

shaft of carrier [2] assembly with the hub and lower it in
slowly giving attention to the internal tooth of hub in
order not to be damaged by the edge of planetary gear
[2] (9).
34-61
34. TRAVEL SYSTEM
Locate planetary gear [2] and the port of flange as

shown in the figure.
PLANETARY GEAR (2)
(11)Assembling 2nd stage gear

1) Hoist carrier [1] assembly. And install it in the hub
(1).
When placing carrier [2] assembly in, align the center

shaft of carrier [2] assembly with the hub and lower it in
slowly giving attention to the internal tooth of hub in
order not to be damaged by the edge of planetary gear
[1] (5).
2) Place sun gear [1](4) in while being matched to

the spline of coupling.
In cases where it is hard to place sun gear [1] in

because the spline of sun gear [1] interferes with the
gear tooth of planetary gear, lift carrier [1] assembly
once until the connection of coupling to sun gear [2](8)
comes off and place sun gear [1] in again.
3) Place thrust plate (13) in carrier [1](3).
34-62
34. TRAVEL SYSTEM
(12)Assembling cover
1) Apply sealant "Loctite #515" to the surface of
hub in contact with the cover.
Apply sealant throughout the end face of hub (1) as

shown in figure.
2) Place cover on hub to the position of bolt hole.
3) Tighten socket bolts (35) to the specified torque.
34-63
34. TRAVEL SYSTEM
(13)Lubricating
1) Fill lubrication oil through filling port.
2) Tighten plug (30) to the specified torque at

respective ports.
34-64
46. TROUBLE SHOOTING
(BY ERROR CODES)
TABLE OF CONTENTS
46.1 JUDGMENT OF ACTUAL THING AT SITE .....................................................................46-3

46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING .......................................46-4
46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER ....................................................46-4
46.4 TROUBLESHOOTING BY ERROR CODE......................................................................46-4
46
46-1
46. TROUBLE SHOOTING (BY ERROR CODES)

SK330-8 : LC10-07001~ S5YN4618E01
SK350LC-8 : YC10-03501~ (ASIA, OCE)
SK200-8 : YN11-45001~
↑ August, 2006 ↑ K
SK210LC-8 : YQ11-06001~
SK250-8 : LQ12-06001~
↑ October, 2006 ↑ K
SK260LC-8 : LL12-05001~
S5YN4618E02
(ASIA, OCE)
E215B : YN11-45001~ ↑
↑ March, 2007 K
SK200-8 : YN11-45001~ ↑
↑ April, 2007 K
E215B : YN11-45001~ ↑
↑ July, 2007 K
E265B : LQ12-06001~ ↑
↑ ↑ K
E215B : YN11-45001~ ↑
↑ ↑ K
↑
↑ ↑ ↑ K
46-2
Preface
Troubleshooting provides process locating for the
cause of trouble in the order that trouble occurred. This
manual describes how to solve the specific
phenomenon systematically as early as possible. For
troubleshooting concerning the inside of equipment,
refer to troubleshooting for each manual of equipment.
Fig. 46-1 Attending the field to verify actual thing.
46.1 JUDGMENT OF ACTUAL THING AT SITE

(1) Get to the site as quickly as possible.
Verify model, serial number, situation of trouble and
field, and notify person of arrival time.
(2) Verify background of trouble occurred
1) Model name and serial number
2) Kind of attachment
Check that the combination of attachment is
proper or that the operating method is not
unreasonable.
3) Operating time by hour-meter
4) History of trouble occurred and additional works.
5) Recurrence of past trouble, or problems on the
Fig. 46-2 Verifying background of trouble occurred.
additional works.
(3) How to diagnose trouble
1) Verify defective part
2) Make the condition of trouble again
3) Where defective parts can not be verified,
surmise causes systematically.
4) Verify reasons for surmise
5) Report methods, procedure, and period for
repairing to user.
(4) Explanation of the cause of trouble
1) Explain the cause of trouble to clients. For
example, oil leak through piston is caused by
Fig. 46-3 Confirm the symptoms of the trouble.
flaws on the piston rod. And the method of using
the machines should be explained so that the
same kind of trouble does not reoccur.
2) Treatment of damaged parts
The damaged parts to be claimed and returned
are evidence so they should be handled with
care. Protect them from entry of water, soils, etc.
into port of hydraulic unit, etc. and return them.
And also use care not to flaw and damage those Fig. 46-4 Diagnosing fail by means
surfaces. troubleshooting.
46-3
46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING

Classify failures into the following 3 types and carry out the troubleshooting.
No. Classes of failure Troubleshooting

A When error code after self-diagnosis is displayed Carry out troubleshooting according to the error
on gauge cluster code.
B When no failure is detected currently but error code When it is hard to recreate the failure situation, cancel
after self diagnosis is remained in trouble history the data in the history and reproduce the failed
situation or suppose the cause according to the
troubleshooting by error code, and then repair it.
C When error code after self diagnosis is not • Carry out troubleshooting according to instructions
displayed or is not remained in the history in Chapter 47 "TROUBLESHOOTING BY
TROUBLE".
• Carry out troubleshooting according to instructions
in Chapter 48 "TROUBLE DIAGNOSIS MODE".
46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER

If the fuse of mechatro controller has blown, the following display appears on the gauge cluster.
(1) The blown fuse of mechatro controller
a. Blown fuse 5A of mechatro controller :
"DATA COMMUNICATION ERROR" is displayed on the gauge cluster in the condition where the controller
program is not executed.
b. Blown fuse 20A of mechatro controller
The controller functions normally but the power supply applied when the controller drives the solenoid, etc.
stops.
Many error codes are displayed on the gauge cluster.
D013, D023, D033, D063,
E013, E023, F021
46.4 TROUBLESHOOTING BY ERROR CODE

When error code was displayed on the gauge cluster with the aid of self-diagnosis display function, carry out the
troubleshooting referring to applicable page in the contents of error codes.
Error Code Trouble Described

page
A015 Engine adjustment (A adjustment) is not adjusted yet or is failed. 46-7
A025 Pump propo. valve adjustment (B adjustment) is not adjusted yet or is failed. 46-7
A035 Unload valve adjustment (C adjustment) is not adjusted yet or is failed. 46-8
A215 Written data of ROM adjustment data is incorrect. 46-8
A225 Writing of ROM adjustment data is incorrect. 46-9
A235 Written data of ROM hour meter data is incorrect. 46-9
A245 Writing of ROM hour meter data is incorrect. 46-10
A255 Writing of proportional valve adjustment data is incorrect. 46-10
B012 Incorrect output of boom up pressure sensor 46-11
B013 Disconnection of boom up pressure sensor 46-11
B014 Short-circuit of boom up pressure sensor 46-12
B022 Incorrect output of boom down pressure sensor 46-12
B023 Disconnection of boom down pressure sensor 46-13
B024 Short-circuit of boom down pressure sensor 46-13
46-4

page
B032 Incorrect output of arm out pressure sensor 46-14
B033 Disconnection of arm out pressure sensor 46-14
B034 Short-circuit of arm out pressure sensor 46-15
B042 Incorrect output of arm in pressure sensor 46-15
B043 Disconnection of arm in pressure sensor 46-16
B044 Short-circuit of arm in pressure sensor 46-16
B052 Incorrect output of bucket digging pressure sensor 46-17
B053 Disconnection of bucket digging pressure sensor 46-17
B054 Short-circuit of bucket digging pressure sensor 46-18
B062 Incorrect output of bucket dump pressure sensor 46-18
B063 Disconnection of bucket dump pressure sensor 46-19
B064 Short-circuit of bucket dump pressure sensor 46-19
B072 Incorrect output of swing pressure sensor 46-20
B073 Disconnection of swing pressure sensor 46-20
B074 Short-circuit of swing pressure sensor 46-21
B092 Incorrect output of travel right pressure sensor 46-21
B093 Disconnection of travel right pressure sensor 46-22
B094 Short-circuit of travel right pressure sensor 46-22
B102 Incorrect output of travel left pressure sensor 46-23
B103 Disconnection of travel left pressure sensor 46-23
B104 Short-circuit of travel left pressure sensor 46-24
B113 Disconnection of pressure sensor of optional selector positioning 46-24
B114 Short-circuit of pressure sensor of optional selector positioning 46-25
B162 Incorrect output of P1 optional side pressure sensor 46-25
B163 Disconnection of P1 side optional pressure sensor 46-26
B164 Short-circuit of P1 side optional pressure sensor 46-26
B172 Incorrect output of P2 optional side pressure sensor 46-27
B173 Disconnection of P2 side optional pressure sensor 46-27
B174 Short-circuit of P2 side optional pressure sensor 46-28
C012 Incorrect output of P1 pump pressure sensor 46-28
C013 Disconnection of P1 pump pressure sensor 46-29
C014 Short-circuit of P1 pump pressure sensor 46-29
C022 Incorrect output of P2 pump pressure sensor 46-30
C023 Disconnection of P2 pump pressure sensor 46-30
C024 Short-circuit of P2 pump pressure sensor 46-31
C033 Disconnection of boom head pressure sensor 46-31
C034 Short-circuit of boom head pressure sensor 46-32
C043 Disconnection of boom rod pressure sensor 46-32
C044 Short-circuit of boom rod pressure sensor 46-33
D012 Failure of output transistor ON at P1 unload proportional valve 46-33
D013 Disconnection of P1 unload proportional valve 46-34
D022 Failure of output transistor ON at P2 unload proportional valve 46-34
D023 Disconnection of P2 unload proportional valve 46-35
D032 Failure of output transistor ON at travel straight proportional valve 46-35
D033 Disconnection of travel straight proportional valve 46-36
D062 Failure of output transistor ON at arm in high speed proportional valve 46-36
D063 Disconnection of arm in high speed proportional valve 46-37
E012 Failure of output transistor ON at P1 pump proportional valve 46-37
46-5

page
E013 Disconnection of P1pump proportional valve 46-38
E022 Failure of output transistor ON at P2 pump proportional valve 46-38
E023 Disconnection of P2 pump proportional valve 46-39
F011 Failure of output transistor OFF and GND short of attachment boost SOL valve 46-39
F013 Failure of output transistor ON and disconnection of attachment boost SOL valve 46-40
F021 Failure of output transistor OFF and GND short of swing parking SOL valve 46-40
F023 Failure of output transistor ON and disconnection of swing parking SOL valve 46-41
F031 Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve 46-41
F033 Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve 46-42
F041 Failure of output transistor OFF and GND short of optional selector SOL valve 46-42
F043 Failure of output transistor ON and disconnection of optional selector SOL valve 46-43
G032 Overrun of speed sensor of direct input Mechatro-controller 46-43
G033 Disconnection of speed sensor of direct input Mechatro-controller 46-44
G042 Overrun of speed sensor of direct input Mechatro-controller and received data from E/G controller. 46-44
G043 Disconnection of speed sensor of direct input Mechatro-controller and received data from E/G controller. 46-45
H013 Disconnection of acceleration potentio 46-46
H014 Power short-circuit of acceleration potentio 46-46
H023 Disconnection of boom angle potentio 46-47
H024 Power short-circuit of boom angle potentio 46-47
H033 Disconnection of arm angle potentio 46-48
H034 Power short-circuit of arm angle potentio 46-48
H091 Failure of GND short-circuit of fuel sensor 46-49
H093 Disconnection of fuel sensor 46-49
I111 Received error of CAN1 communication (passive error) 46-50
I113 Received error of CAN1 communication (time-out) 46-50
I313 Received error of cluster communication (time-out error) 46-51
K014 Adhesion of battery relay terminal 46-51
R014 Failure of arc prevention relay of wiper motor 46-52
R024 Failure of normal rotation relay of wiper motor 46-53
R034 Failure of reverse rotation relay of wiper motor 46-54
R044 Failure of washer motor relay 46-55
R134 Failure of swing flasher relay 46-55
R144 Failure of swing flasher relay 46-56
R154 Failure of travel alarm relay 46-56
R164 Failure of auto idling stop relay 2 46-57
R174 Failure of engine forcible stop relay 46-58
R184 Failure of lever lock relay 46-59
R214 Failure of safety relay 46-59
46-6
Table46-1
Error code A015
Trouble Not yet adjusted engine or failed adjustment of engine (A adjustment)
Judging Engine adjustment is missed. Or it is impossible to set the adjusting value within the adjusting
condition range.
Symptom Deviated from the reqired value, but no problem in normal operations.
Control in the
Rotate with the default engine
event of failure
Returned in
The engine adjustment is completed normally.
normal condition
Service Screen No. 2 G-3 SPEED SET
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 •Checking Carry out engine adjustment (A adjustment). When "ERROR ENG" was
displayed during adjustment, refer to the section "Adjustment procedure -
Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3
Table46-2
Error code A025
Trouble Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment)
Judging Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value within
condition the adjusting range.
Symptom Deviated from the rated output, but no problem in normal operation
Control in the
Workable with the default proportional valve output.
event of failure
Returned in
The pump proportional valve adjustment is completed normally.
normal condition
Service Screen No. 9 E-1 P1 PUMP
diagnosis Screen No. 9 E-2 P2 PUMP
1 •Checking Carry out pump adjustment (B adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"
3
46-7
Table46-3
Error code A035
Trouble Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment)
Judging The adjustment of unload valve is missed. Or the adjusting value can not be set in the adjusting
condition range.
Symptom It is not normal output, but no problem in normal operation
Control in the
Work with the aid of output by default proportional valve.
event of failure
Returned in
The adjustment of unload valve is completed normally.
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
diagnosis Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
1 •Checking Carry out adjustment of unload valve (C adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"
3
Table46-4
Error code A215
Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the content of memory is correct or not. (Trouble history only)
condition
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3
46-8
Table46-5
Error code A225
Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the data is correct or not.
condition
Control in the
Control can be done by default value.
event of failure
Returned in
normal condition
Service Screen No.
2
3
Table46-6
Error code A235
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is correct or not. (Trouble history only)
condition
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
normal condition
Service Screen No.
2
3
46-9
Table46-7
Error code A245
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is incorrect.
condition
Symptom The hour meter data which was judged as error is taken as 0 Hr. No problem in normal operation
Control in the
Normal control is available.
event of failure
Returned in
normal condition
Service Screen No.
2
3
Table46-8
Error code A255
Trouble The data of proportional valve adjustment is written incorrectly.
Judging
Check proportional valve adjustment data, and judge the data is incorrect.
condition
Control in the
Using fixed value of proportional valve correction data, usual control is done.
event of failure
Returned in
normal condition
Service Screen No.
2
3
46-10
Table46-9
Error code B012
Trouble Boom up pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The boom up operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-1 BOOM RAISE
1 • Boom up pressure sensor When B012 is cancelled and other error occurs by turning starter switch on
SE-3 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B012 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-126F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
Table46-10
Error code B013
Trouble Boom up pressure sensor’s wiring disconnects.
Judging
The input voltage from boom up pressure sensor is less than 0.1V.
condition
Symptom The boom up speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency
Control in the
mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
1 • Boom up pressure sensor When B013 is cancelled and other error occurs after exchanging the
SE-3 connector with other sensor.
2 • Wiring between boom up When B013 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-101F
46-11
Table46-11
Error code B014
Trouble Boom up pressure sensor’s power source is shortcut.
Judging
The input voltage from boom up pressure sensor is 4.7V or more.
condition
Symptom The boom up speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Returned in
normal condition
1 • Boom up pressure sensor When B014 is cancelled and other error occurs after exchanging the
2 • Wiring between boom up When B014 is displayed after the connector is exchanged with other sensor.
CN-101F
Table46-12
Error code B022
Trouble Boom down pressure sensor outputs error
Symptom The boom down operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 5 B-2 BOOM LOWER
1 • Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch on
2 • Wiring between boom down When B022 is displayed after turning the starter switch on after the connector
46-12
Table46-13
Error code B023
Trouble Boom down pressure sensor’s wiring is disconnecting.
Judging
The input voltage from boom down pressure sensor is 0.1V or less.
condition
Control in the
event of failure
Returned in
normal condition
1 • Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the
2 • Wiring between boom down When B023 is displayed after the connector is exchanged with other sensor.
CN-101F
Table46-14
Error code B024
Trouble Boom down pressure sensor’s power source is shortcut.
Judging
The input voltage from boom down pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition
1 • Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch on
2 • Wiring between boom down When B024 is displayed after turning the starter switch on after the connector
46-13
Table46-15
Error code B032
Trouble Arm-in pressure sensor outputs error
Symptom The arm-out operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 5 B-3 ARM OUT
1 • Arm-out pressure sensor When B032 is cancelled and other error occurs by turning starter switch on
2 • Wiring between arm-out When B032 is displayed after turning the starter switch on after the connector
Table46-16
Error code B033
Trouble Arm-out pressure sensor’s wiring is disconnecting.
Judging
The input voltage from arm-out pressure sensor is 0.1V or less.
condition
Symptom Shock at stopping of arm-out is great.
Control in the
event of failure
Returned in
normal condition
1 • Arm-out pressure sensor When B033 is cancelled and other error occurs after exchanging the
2 • Wiring between arm-out When B033 is displayed after the connector is exchanged with other sensor.
CN-101F
46-14
Table46-17
Error code B034
Trouble Arm-out pressure sensor’s power source is shortcut.
Judging
The input voltage from arm-out pressure sensor is 4.7V or more.
condition
Symptom Shock at stopping of arm-out is great.
Control in the
event of failure
Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode)
Returned in
normal condition
1 • Arm-out pressure sensor When B034 is cancelled and other error occurs by turning starter switch on
2 • Wiring between arm-out When B034 is displayed after turning the starter switch on after the connector
Table46-18
Error code B042
Trouble Arm-in pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the arm-in
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The arm-in operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 5 B-4 ARM IN
1 • Arm-in pressure sensor When B042 is cancelled and other error occurs by turning starter switch on
2 • Wiring between arm-in When B042 is displayed after turning the starter switch on after the connector
46-15
Table46-19
Error code B043
Trouble Arm-in pressure sensor’s wiring is disconnecting.
Judging
The input voltage from arm-in pressure sensor is 0.1V or less.
condition
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done
Symptom but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the
bucket bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1 and P2 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200mA.
Returned in
normal condition
1 • Arm-in pressure sensor When B043 is cancelled and other error occurs after exchanging the
2 • Wiring between arm-in When B043 is displayed after the connector is exchanged with other sensor.
CN-101F
Table46-20
Error code B044
Trouble Arm-in pressure sensor’s power source is shortcut.
Judging
The input voltage from arm-in pressure sensor is 4.7V or more.
condition
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done
Symptom but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the
bucket bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200mA.
Returned in
normal condition
1 • Arm-in pressure sensor When B044 is cancelled and other error occurs by turning starter switch on
2 • Wiring between arm-in When B044 is displayed after turning the starter switch on after the connector
46-16
Table46-21
Error code B052
Trouble Bucket digging pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket
condition digging pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The bucket digging operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 5 B-5 BUCKET DIG
1 • Bucket digging pressure sensor When B052 is cancelled and other error occurs by turning starter switch on
2 • Wiring between bucket digging When B052 is displayed after turning the starter switch on after the connector
Table46-22
Error code B053
Trouble Bucket digging pressure sensor’s wiring is disconnected.
Judging
The input voltage from bucket digging pressure sensor is 0.1V or less.
condition
Symptom The bucket digging speed slows down a little.
Control in the
event of failure
Returned in
normal condition
46-17
Table46-23
Error code B054
Trouble Bucket digging pressure sensor’s power source is shortcut.
Judging
The input voltage from bucket digging pressure sensor is 4.7V or more.
condition
Symptom The bucket digging speed slows down a little.
Control in the
event of failure
Returned in
normal condition
Table46-24
Error code B062
Trouble Bucket dump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket dump
Symptom The bucket dump operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 5 B-6 BUCKET DUMP
CN-125F
and repair it if necessary.
46-18
Table46-25
Error code B063
Trouble Bucket dump pressure sensor’s wiring is disconnected.
Judging
The input voltage from bucket dump pressure sensor is 0.1V or less.
condition
Symptom The bucket dump speed slows down a little.
Control in the
event of failure
Returned in
normal condition
Table46-26
Error code B064
Trouble Bucket dump pressure sensor’s power source is shortcut.
Judging
The input voltage from bucket dump pressure sensor is 4.7V or more.
condition
Symptom The bucket dump speed slows down a little.
Control in the
event of failure
Returned in
normal condition
46-19
Table46-27
Error code B072
Trouble Swing pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the swing
Symptom The swing operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 6 B-7 SWING
1 • Swing pressure sensor When B072 is cancelled and other error occurs by turning starter switch on
2 • Wiring between swing When B072 is displayed after turning the starter switch on after the connector
Table46-28
Error code B073
Trouble Swing pressure sensor’s wiring is disconnected.
Judging
The input voltage from swing pressure sensor is 0.1V or less.
condition
Control in the
event of failure
Returned in
normal condition
46-20
Table46-29
Error code B074
Trouble Swing pressure sensor’s power source is shortcut.
Judging
The input voltage from swing pressure sensor is 4.7V or more.
condition
Control in the
event of failure
Returned in
normal condition
Table46-30
Error code B092
Trouble Travel right pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel right
Symptom The travel right operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 6 B-9 TRAVEL (R)
1 • Travel right pressure sensor When B092 is cancelled and other error occurs by turning starter switch on
2 • Wiring between travel right When B092 is displayed after turning the starter switch on after the connector
46-21
Table46-31
Error code B093
Trouble Travel right pressure sensor’s wiring is disconnected.
Judging
The input voltage from Travel right pressure sensor is 0.1V or less.
condition
Symptom The Travel right operability becomes poor.
Control in the
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
normal condition
Table46-32
Error code B094
Trouble Travel right pressure sensor’s power source is shortcut.
Judging
The input voltage from Travel right pressure sensor is 4.7V or more.
condition
Symptom The Travel right operability becomes poor.
Control in the
event of failure
Returned in
normal condition
46-22
Table46-33
Error code B102
Trouble Travel left pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel left
Symptom The travel left operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 6 B-10 TRAVEL (L)
1 • Travel left pressure sensor When B102 is cancelled and other error occurs by turning starter switch on
2 • Wiring between travel left When B102 is displayed after turning the starter switch on after the connector
Table46-34
Error code B103
Trouble Travel left pressure sensor’s wiring is disconnected.
Judging
The input voltage from Travel left pressure sensor is 0.1V or less.
condition
Symptom The Travel left operability becomes poor.
Control in the
event of failure
Returned in
normal condition
46-23
Table46-35
Error code B104
Trouble Travel left pressure sensor’s power source is shortcut.
Judging
The input voltage from Travel left pressure sensor is 4.7V or more.
condition
Symptom The Travel left operability becomes poor.
Control in the
event of failure
Returned in
normal condition
Table46-36
Error code B113
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging
The input voltage from option selector position detect pressure sensor is 0.1V or less.
condition
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 16 B-11
1 • Option selector position When B113 is cancelled and other error occurs by turning starter switch on
detect pressure sensor after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option When B113 is displayed after turning the starter switch on after the connector
selector position detect is exchanged with other sensor.
CN-104F
46-24
Table46-37
Error code B114
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging
The input voltage from selector position detect pressure sensor is 4.7V or more.
condition
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 16 B-11
1 • Option selector position When B114 is cancelled and other error occurs by turning starter switch on
detect pressure sensor after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option When B114 is displayed after turning the starter switch on after the connector
selector position detect is exchanged with other sensor.
CN-104F
Table46-38
Error code B162
Trouble P1 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P1 side option operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 6 B-16 P1 OPT.
1 • P1 side option pressure sensor When B162 is cancelled and other error occurs by turning starter switch on
2 • Wiring between P1 side option When B162 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to
CN-304F the wiring checking procedure and repair it if necessary.
46-25
Table46-39
Error code B163
Trouble P1 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 side option pressure sensor is 0.1V or less.
condition
Symptom The P1 side option does not work.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
normal condition
Table46-40
Error code B164
Judging
The input voltage from P1 side option pressure sensor is 4.7V or more.
condition
Symptom The P1 side option does not work.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
normal condition
46-26
Table46-41
Error code B172
Trouble P2 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P2 side option operability becomes poor.
Control in the
Normal control
event of failure
pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to
CN-303F the wiring checking procedure and repair it if necessary.
Table46-42
Error code B173
Judging
The input voltage from P2 side option pressure sensor is 0.1V or less.
condition
Symptom The selection of conflux does not work.
Control in the
event of failure
Returned in
normal condition
46-27
Table46-43
Error code B174
Judging
The input voltage from P2 side option pressure sensor is 4.7V or more.
condition
Symptom The selection of conflux does not work.
Control in the
event of failure
Returned in
normal condition
Table46-44
Error code C012
Trouble P1 pump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1 pump
Symptom The P1 pump operability becomes poor.
Control in the
Normal control
event of failure
Service Screen No. 7 C-1 PUMP P1
1 • P1 pump pressure sensor When C012 is cancelled and other error occurs by turning starter switch on
2 • Wiring between P1 pump When C012 is displayed after turning the starter switch on after the connector
46-28
Table46-45
Error code C013
Trouble P1 pump pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 pump pressure sensor is 0.1V or less.
condition
Symptom The delicate operability of P1 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
normal condition
Table46-46
Error code C014
Trouble P1 pump pressure sensor’s power source is shortcut.
Judging
The input voltage from P1 pump pressure sensor is 4.7V or more.
condition
Returned in
normal condition
46-29
Table46-47
Error code C022
Trouble P2 pump pressure sensor outputs error.
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 pump
Symptom The P2 pump operability becomes poor.
Control in the
Normal control
event of failure
Table46-48
Error code C023
Trouble P2 pump pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 pump pressure sensor is 0.1V or less.
condition
Returned in
normal condition
46-30
Table46-49
Error code C024
Trouble P2 pump pressure sensor’s power source is shortcut.
Judging
The input voltage from P2 pump pressure sensor is 4.7V or more.
condition
Returned in
normal condition
Table46-50
Error code C033
Trouble Boom head pressure sensor’s wiring is disconnected.
Judging
The input voltage from boom head pressure sensor is 0.1V or less.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 7 C-3 BOOM-HEAD
1 • Boom head pressure sensor When C033 is cancelled and other error occurs by turning starter switch on
2 • Wiring between boom head When C033 is displayed after turning the starter switch on after the connector
46-31
Table46-51
Error code C034
Trouble Boom head pressure sensor’s power source is shortcut.
Judging
The input voltage from boom head pressure sensor is 4.7V or more.
condition
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 7 C-3 BOOM-HEAD
1 • Boom head pressure sensor When C034 is cancelled and other error occurs by turning starter switch on
2 • Wiring between boom head When C034 is displayed after turning the starter switch on after the connector
Table46-52
Error code C043
Trouble Boom rod pressure sensor’s wiring is disconnected.
Judging
The input voltage from boom rod pressure sensor is 0.1V or less.
condition
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 7 C-4 BOOM-ROD
1 • Boom rod pressure sensor When C043 is cancelled and other error occurs by turning starter switch on
2 • Wiring between boom rod When C043 is displayed after turning the starter switch on after the connector
46-32
Table46-53
Error code C044
Trouble Boom rod pressure sensor’s power source is shortcut.
Judging
The input voltage from boom rod pressure sensor is 4.7V or more.
condition
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 7 C-4 BOOM-ROD
1 • Boom rod pressure sensor When C044 is cancelled and other error occurs by turning starter switch on
2 • Wiring between boom rod When C044 is displayed after turning the starter switch on after the connector
Table46-54
Error code D012
Trouble P1 unload proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Option conflux can not be done.
Control in the
event of failure
Returned in
normal condition
1 • P1 unload proportional valve When D012 is cancelled and other error occurs by turning starter switch on
PSV-D after exchanging the connector with other sensor.
2 • Wiring between P1 unload When D012 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
46-33
Table46-55
Error code D013
Trouble P1 unload proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Option conflux can not be done.
Control in the
event of failure
Returned in
normal condition
PSV-D after exchanging the connector with other sensor.
Table46-56
Error code D022
Trouble P2 unload proportional valve and output transistor ON are failure.
Judging
condition
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
event of failure
Returned in
normal condition
PSV-B after exchanging the connector with other sensor.
46-34
Table46-57
Error code D023
Trouble P2 unload proportional valve’s wiring is disconnected.
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
event of failure
Returned in
normal condition
PSV-B after exchanging the connector with other sensor.
Table46-58
Error code D032
Trouble Travel straight proportional valve and output transistor ON are failure.
Judging
condition
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
normal condition
Service Screen No. 8 D-3 S-TRAVEL
1 • Travel straight proportional valve When D032 is cancelled and other error occurs by turning starter switch on
PSV-C after exchanging the connector with other sensor.
2 • Wiring between Travel straight When D032 is displayed after turning the starter switch on after the connector
46-35
Table46-59
Error code D033
Trouble Travel straight proportional valve’s wiring is disconnected.
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
normal condition
Service Screen No. 8 D-3 S-TRAVEL
1 • Travel straight proportional valve When D033 is cancelled and other error occurs by turning starter switch on
PSV-C after exchanging the connector with other sensor.
2 • Wiring between Travel straight When D033 is displayed after turning the starter switch on after the connector
Table46-60
Error code D062
Trouble Arm-in spool 2 proportional valve and output transistor ON are failure.
Judging
condition
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
normal condition
Service Screen No. 8 D-4 ARM IN-2-SPEED
1 • Arm-in spool 2 proportional valve When D062 is cancelled and other error occurs by turning starter switch on
PSV-A after exchanging the connector with other sensor.
2 • Wiring between Arm-in spool 2 When D062 is displayed after turning the starter switch on after the connector
46-36
Table46-61
Error code D063
Trouble Arm-in spool 2 proportional valve’s wiring is disconnected.
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
normal condition
Service Screen No. 8 D-4 ARM IN-2-SPEED
1 • Arm-in spool 2 proportional valve When D063 is cancelled and other error occurs by turning starter switch on
PSV-A after exchanging the connector with other sensor.
2 • Wiring between Arm-in spool 2 When D063 is displayed after turning the starter switch on after the connector
Table46-62
Error code E012
Trouble P1 pump proportional valve and output transistor ON are failure.
Judging
condition
Service Screen No. 9 E-1 PUMP P1
1 • P1 pump proportional valve When E012 is cancelled and other error occurs by turning starter switch on
PSV-P1 after exchanging the connector with other sensor.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P1 pump When E012 is displayed after turning the starter switch on after the connector
46-37
Table46-63
Error code E013
Trouble P1 pump proportional valve’s wiring is disconnected.
Table46-64
Error code E022
Trouble P2 pump proportional valve and output transistor ON are failure.
Judging
condition
46-38
Table46-65
Error code E023
Trouble P2 pump proportional valve’s wiring is disconnected.
Table46-66
Error code F011
Trouble ATT boost solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom ATT boost is not available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-1 POWER BOOST
1 • ATT boost solenoid valve When F011 is cancelled and other error occurs by exchanging the connector
SV-2 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between ATT boost When F011 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
46-39
Table46-67
Error code F013
Trouble ATT boost solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom ATT boost is not available or is leaving available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
1 • ATT boost solenoid valve When F013 is cancelled and other error occurs by exchanging the connector
2 • Wiring between ATT boost When F013 is displayed after the connector is exchanged with other solenoid
Table46-68
Error code F021
Trouble Swing parking solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging
condition
Symptom Swing parking is not available.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 3 F-2 SWING-BRAKE
1 • Swing parking solenoid valve When F021 is cancelled and other error occurs by exchanging the connector
SV-1 for other solenoid valve. Check solenoid valve unit for possible failure. If
failure found, replace it.
2 • Wiring between swing parking When F021 is displayed after the connector is exchanged with other solenoid
46-40
Table46-69
Error code F023
Trouble Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Judging
condition
Symptom Swing parking is not available or is leaving available.
Control in the
Normal control
event of failure
Returned in
normal condition
1 • Swing parking solenoid valve When F023 is cancelled and other error occurs by exchanging the connector
2 • Wiring between swing parking When F023 is displayed after the connector is exchanged with other solenoid
Table46-70
Error code F031
Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
circuit.
Judging
condition
Symptom Travel 2 speed is not obtainable.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 3 F-3 1/2-TRAVEL
1 • Travel 1, 2speed solenoid valve When F031 is cancelled and other error occurs by exchanging the connector
2 • Wiring between travel 1, 2speed When F031 is displayed after the connector is exchanged with other solenoid
46-41
Table46-71
Error code F033
Trouble Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Judging
condition
Symptom Travel 2 speed is not obtainable or is keeping 1 speed.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Service Screen No. 3 F-3 1/2-TRAVEL
1 • Travel 1, 2speed solenoid valve When F033 is cancelled and other error occurs by exchanging the connector
2 • Wiring between travel 1, 2speed When F033 is displayed after the connector is exchanged with other solenoid
Table46-72
Error code F041
Option selector solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
circuit.
Judging
condition
Symptom Option selector valve does not change to breaker side.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is ground level while exciting command is output.
normal condition
Service Screen No. 11 F-4 OPT SELECT
1 • Option selector solenoid valve When F041 is cancelled and other error occurs by exchanging the connector
2 • Wiring between option selector When F041 is displayed after the connector is exchanged with other solenoid
46-42
Table46-73
Error code F043
Trouble Option selector solenoid valve and output transistor ON are failure, and disconnection.
Judging
condition
Option selector valve does not change to breaker side or it does not change from breaker to
Symptom
nibbler.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is ground level while exciting command is not output.
normal condition
Service Screen No. 11 F-4 OPT SELECT
1 • Option selector solenoid valve When F043 is cancelled and other error occurs by exchanging the connector
2 • Wiring between option selector When F043 is displayed after the connector is exchanged with other solenoid
Table46-74
Error code G032
Trouble Mechatro controller direct input speed sensor is overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
2 • Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure
sensor and controller and repair it if necessary.
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
(Controller is broken by only applying power to grounding of signal.)
46-43
Table46-75
Error code G033
Trouble Mechatro controller direct input speed sensor, Disconnection
Judging
Voltage of alternator is 12V or more, and speed sensor indicates excess low engine rpm.
condition
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
normal condition
2 • Wiring between engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
CN-136F
CN-106F
Table46-76
Error code G042
Mechatro controller direct input speed sensor and received data from engine controller are
Trouble
overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Control in the
Normal control
event of failure
Returned in
normal condition
• Wiring between engine Check wiring for possible failure according to the wiring checking procedure
2
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure
pressure sensor and controller Especially check wiring for false disconnection and noise included.
Check that the error is corrected after replacement of controller.
4 • Mechatro controller
5 • Engine controller Check that the error is corrected after replacement of controller.
46-44
Table46-77
G043
When cranking is executed for five seconds or more, this error code might be displayed. In case
Error code that the engine does not start, check by the table of "Section 47.3 Engine related
Troubleshooting". Execute the following check when the error code G043 is displayed after
starting the engine.
Mechatro controller direct input speed sensor and received data from engine controller are
Trouble
disconnected.
Judging Voltage of alternator is 12V or more, and speed sensor and receipt data from engine controller
condition indicate excess low engine rpm.
Symptom Engine speed down may cause extension by abrupt loading.
Control in the
Enter 0 rpm for engine speed. Enter 0 for ESS power shift command.
event of failure
Returned in
normal condition
• Wiring between engine Check wiring for possible failure according to the wiring checking procedure
2
CN-136F
CN-106F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure
pressure sensor and controller
Check that the error is corrected after replacement of controller.
4 • Mechatro controller
5 • Engine controller Check that the error is corrected after replacement of controller.
46-45
Table46-78
Error code H013
Trouble Accel potentiometer is disconnected.
Judging
The input voltage from accel potentiometer is 0.1V or less.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
normal condition
Service Screen No. 2 H-1 ACCEL VOLT.
1 • Accel potentiometer Measure the resistance between terminals of speed sensor. 1.6~2.4k
SE-16 Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-402F
CN-102F
Table46-79
Error code H014
Trouble Accel potentiometer’s power source is shortcut.
Judging
The input voltage from accel potentiometer is 4.7V or more.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
normal condition
Service Screen No. 2 H-1 ACCEL VOLT.
1 • Accel potentiometer Measure the resistance between terminals of accel potentiometer.
SE-16 1.6~2.4k
Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel Check wiring for possible failure according to the wiring checking procedure
CN-402F
CN-102F
46-46
Table46-80
Error code H023
Trouble Boom angle potentiometer’s wiring is disconnected.
Judging
The input voltage from boom angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 12 H-2 BOOM
1 • Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0~6.0k
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between boom angle Check wiring for possible failure according to the wiring checking procedure
CN-702F
CN-103F
Table46-81
Error code H024
Trouble Boom angle potentiometer’s power source is shortcut.
Judging
The input voltage from boom angle potentiometer is 0.1V or less.
condition
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 12 H-2 BOOM
1 • Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0~6.0k
2 • Wiring between boom angle Check wiring for possible failure according to the wiring checking procedure
CN-702F
CN-103F
46-47
Table46-82
Error code H033
Trouble Arm angle potentiometer’s wiring is disconnected.
Judging
The input voltage from arm angle potentiometer is 0.1V or less.
condition
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 12 H-3 ARM
1 • Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-19 4.0~6.0k
2 • Wiring between arm angle Check wiring for possible failure according to the wiring checking procedure
CN-703F
CN-103F
Table46-83
Error code H034
Trouble Arm angle potentiometer’s power source is shortcut.
Judging
The input voltage from arm angle potentiometer is 0.1V or less.
condition
Control in the
Normal control
event of failure
Returned in
normal condition
Service Screen No. 12 H-3 ARM
1 • Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-19 4.0~6.0k
2 • Wiring between arm angle Check wiring for possible failure according to the wiring checking procedure
CN-703F
CN-103F
46-48
Table46-84
Error code H091
Trouble Fuel sensor grounding is short-circuited.
Judging
The input voltage from fuel sensor is 0.1V or less.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
normal condition
Service Screen No. 10 H-9 FUEL LEVEL
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ~ FULL 5
2 • Wiring between fuel Check wiring for possible failure according to the wiring checking procedure
CN-152F
CN-104F
Table46-85
Error code H093
Trouble Fuel sensor’s wiring is disconnection.
Judging
The input voltage from fuel sensor is 4.7V or more.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
normal condition
Service Screen No. 10 H-9 FUEL LEVEL
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ~ FULL 5
2 • Wiring between fuel Check wiring for possible failure according to the wiring checking procedure
CN-152F
CN-104F
46-49
Table46-86
Error code I111
Trouble Reception of CAN1 communication is abnormal. (Passive error)
Judging
Reception from engine controller can not receive correctly.
condition
Symptom It has been affected little.
Control in the
Keep the last receiving condition.
event of failure
Returned in
normal condition
Service Screen No.
1 • Wiring between ECU Check wiring for possible failure according to the wiring checking procedure
and controller and repair it if necessary.
CN-3F (There is a possibility of false disconnection.)
CN-101F
Table46-87
Error code I113
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Reception from gauge cluster can not receive correctly. It has been affected little.
condition
Symptom It has been affected little.
Control in the
It can be operated in condition that coolant temperature is 20°C.
event of failure
Returned in
normal condition
Service Screen No. 2 G-5 WATER TEMP
1 • Wiring between ECU Check wiring for possible failure according to the wiring checking procedure
CN-3F
CN-101F
46-50
Table46-88
Error code I313
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Reception from gauge cluster can not receive correctly.
condition
Symptom Switch operation of gauge cluster can not be done.
Control in the
Keep the condition after immediately key-on is operated.
event of failure
Returned in
normal condition
Service Screen No.
1 • Wiring between gauge cluster Check wiring for possible failure according to the wiring checking procedure
CN-600F
CN-101F
Table46-89
Error code K014
Trouble Battery relay contact welded
Judging The power 24V is continuously supplied to controller for 40 seconds or more while the key switch
condition ON signal turned OFF
The power on the battery relay secondary side does not turn OFF even if the key switch is turned
Symptom
OFF.
Control in the
Normal control with key switch OFF
event of failure
Returned in Turn key switch ON.
normal condition Or when the power supply 24V to mechatro controller is stopped
Service Screen No. 4 K-1 AIS RELAY 2
diagnosis Screen No. 4 K-3 KEY SWITCH OFF
1 • Battery relay Turn key switch off and disconnect the connector (CN-256F) on the battery
R-1 relay coil. If 24V power lives on battery relay secondary side, check on battery
CN-256F relay for failure and replace it if failed.
Turn off the key switch, and remove the connector (CN-256F) on the battery
• Auto idle stop relay 2 relay coil side. If power of battery relay on secondary side falls, remove either
R-24 auto idling stop relay 2 or alternator relay.
2
• Alternator relay The failure may be occurred in case where the power falls after the relay was
R-28 removed, and therefore check on the relay unit and replace it with new one if
failed.
3 • Wiring between auto idle stop When K014 is left displayed with the relay removed
relay/alternator relay and Check that no power 24V is produced on relay (-) line according to the wiring
controller checking procedure and replace it if necessary.
CN-109F, CN2-1 When no failure found after checking on wiring and K014 is left displayed
• Fuse& relay box Replace fuse/relay box.
E-1
46-51
Table46-90
Error code R014
Trouble Wiper motor arc prevention relay error
Judging The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the
condition power source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 PREVENT ARC
1 • Wiper motor arc prevention relay When error is cancelled after removing wiper motor arc prevention relay,
R-31 check relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor arc When R014 is left displayed with the relay removed
prevention relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-1 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R014 is left displayed
E-1
Replace fuse/relay box.
46-52
Table46-91
Error code R024
Trouble Wiper motor forward rotation relay error
Judging The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the
Symptom Wiper does not move.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 25 CW MOTOR RLY
1 • Wiper motor forward rotation When error is cancelled after removing wiper motor forward rotation relay,
relay check relay unit for failure, replace it with new one if failed.
R-29 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor When R024 is left displayed with the relay removed
forward rotation relay and Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-1 When no failure found after checking on wiring and R024 is left displayed
•Fuse & relay box
E-1
46-53
Table46-92
Error code R034
Trouble Wiper motor reverse rotation relay error
Judging The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the
Symptom Wiper does not move after forward rotation.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 25 CCW MOTOR RLY
1 • Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay,
relay check relay unit for failure, replace it with new one if failed.
R-30 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2 • Wiring between wiper motor When R034 is left displayed with the relay removed
forward rotation relay and Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-1 When no failure found after checking on wiring and R034 is left displayed
•Fuse & relay box
E-1
46-54
Table46-93
Error code R044
Trouble Washer motor relay error
Judging
The mechatro controller output line to washer motor relay is short-circuited with the power source.
condition
Symptom Washer motor does not move.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 25 MOTOR RELAY
1 • Washer motor relay When error is cancelled after removing washer motor relay, check relay unit
R-32 for failure, replace it with new one if failed.
2 • Wiring between washer motor When R044 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
•Fuse & relay box When no failure found after checking on wiring and R044 is left displayed
E-1 Replace fuse/relay box.
Table46-94
Error code R134
Trouble Swing flasher relay error
Judging
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
condition
Symptom Right swing flasher does not light.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 22 D13
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher relay,
When resistance between relays (HB) and (HC) is 0 , it is in abnormal condition.
2 • Wiring between swing flasher When R134 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F figure C) according to the wiring checking procedure and replace it if
necessary.
46-55
Table46-95
Error code R144
Trouble Swing flasher relay error
Judging
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
condition
Symptom Left swing flasher does not light.
Control in the
event of failure
Returned in
normal condition
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher relay,
When resistance between relays (HB) and (HC) is 0 , it is in abnormal condition.
2 • Wiring between swing flasher When R144 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F figure B) according to the wiring checking procedure and replace it if
necessary.
Table46-96
Error code R154
Trouble Travel alarm relay error
Judging
The mechatro controller output line to travel alarm relay is short-circuited with the power source.
condition
Symptom Travel alarm does not actuate.
Control in the
event of failure
Returned in
normal condition
1 • Travel alarm relay When error is cancelled after removing of travel alarm relay, check relay unit
2 • Wiring between travel alarm When R154 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
•Fuse & relay box When no failure found after checking on wiring and R154 is left displayed.
46-56
Table46-97
Error code R164
Trouble Auto idle stop relay 2 relay error
Judging The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power
condition source.
Power source for mechatro controller often turns off.
Symptom
Auto idle stop relay 2 does not actuate.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 4 K-1 AIS RELAY 2
1 • Auto idle stop relay 2 relay When error is cancelled after removing of auto idle stop relay 2, check relay
R-24 unit for failure, replace it with new one if failed.
2 • Wiring between auto idle When R164 is left displayed with the relay removed
stop relay 2 and controller Check that no power 24V is produced on relay (-) line according to the wiring
•Fuse & relay box When no failure found after checking on wiring and R164 is left displayed.
46-57
Table46-98
Error code R174
Trouble Engine forcibly stop relay error
Judging The mechatro controller output line to engine forcibly stop is short-circuited with the power
condition source.
When key switch is turned off but engine does not stop.
Symptom
Engine auto idle stop function does not actuate.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 4 K-3 ENG STOP
1 • Engine forcibly stop relay When error is cancelled after removing of engine forcibly stop relay, check
R-25 relay unit for failure, replace it with new one if failed.
2 • Wiring between engine When R174 is left displayed with the relay removed
forcibly Check that no power 24V is produced on relay (-) line according to the wiring
stop relay and controller checking procedure and replace it if necessary.
CN-109F, CN2-2 When no failure found after checking on wiring and R174 is left displayed.
• Fuse & relay box Replace fuse/relay box.
E-1
46-58
Table46-99
Error code R184
Trouble Safety lock lever relay error
Judging The mechatro controller output line to safety lock lever relay is short-circuited with the power
condition source.
Symptom Safety lock lever timer does not actuate.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 4 K-4 LOCK LEVER
1 • Safety lock lever relay When error R184 is cancelled after removing of safety lock lever relay, check
R-26 relay unit for failure, replace it with new one if failed.
2 • Wiring between safety lock When R184 is left displayed with the relay removed
lever relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
• Fuse & relay box When no failure found after checking on wiring and R184 is left displayed.
Table46-100
Error code R214
Trouble Safety relay error
Judging
The mechatro controller output line to safety relay is short-circuited with the power source.
condition
Symptom Safety relay does not actuate.
Control in the
event of failure
Returned in
normal condition
Service Screen No. 4 K-2 SAFETY RLY
1 • Safety lock lever relay When error R214 is cancelled after removing of safety relay, check relay unit
2 • Wiring between safety lock When R214 is left displayed with the relay removed
lever relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
• Fuse & relay box When no failure found after checking on wiring and R214 is left displayed.
46-59
[MEMO]
46-60
47. TROUBLESHOOTING
(BY TROUBLE)
TABLE OF CONTENTS
47.1 HYDRAULIC SYSTEM ....................................................................................................47-3

47.2 ELECTRIC SYSTEMS .....................................................................................................47-27
47.2.1 WIRING CHECKING PROCEDURE ......................................................................47-27
47.2.2 TROUBLE...............................................................................................................47-30
47.3 ENGINE RELATED TROUBLESHOOTING ....................................................................47-33
47
47-1
47. TROUBLESHOOTING (BY TROUBLE)

SK200–8 : YN11-45001~
First edition Augst, 2006 S5YN4718E01 K
SK210LC–8 : YQ11-06001~
SK250-8 : LQ12-06001~
SK260LC-8 : LL12-05001~
E235BSR : YF05-02001~ ↑
E235BSR(N)LC : YU05-02001~ (NHK)
E215B : YN11-45001~ ↑
↑ March, 2007 K
SK235SR-2 : YF05-02001~ ↑
↑ April, 2007 K
SK235SRLC-2 : YU05-02001~ (OCE)
SK200-8 : YN11-45001~ ↑
↑ ↑ K
SK250-8: LQ12-06001~ ↑
↑ May, 2007 K
E225BSR : YB05-03001~ ↑
↑ June, 2007 K
E225BSRLC : LA05-02001~ (NHK)
↑
↑ ↑ SK215SRLC : LA05-02001~ K
(North America)
E135BSR : YY05-12001~ ↑
↑ July, 2007 K
E135BSRLC : YH05-07001~ (NHK)
SK225SR : YB05-03001~ ↑
↑ ↑ K
SK225SRLC : LA05-02001~ (OCE)
E215B : YN11-45001~ ↑
↑ ↑ K
E265B : LQ12-06001~ ↑
↑ ↑ K
E215B : YN11-45001~ ↑
↑ ↑ K
↑
↑ ↑ ↑ K
47-2
47.1 HYDRAULIC SYSTEM

Preface:
The troubleshooting for the failures shown below is explained here.
Identify the failure and trouble and carry forward the troubleshooting in order of the failure item number.
(1) All controls do not function/slow

(2) Engine down/stalled
(3) Move at lever neutral position
(4) Poor fine operability
(5) Slow boom up, insufficient power
(6) Slow boom down, insufficient power for lifting up body
(7) Slow arm in, insufficient power
(8) Slow independent arm out (in the air)
(9) Slow bucket digging
(10)Slow bucket dumping
(11)Swing operation not functioned/slow
(12)Noise during swing operation
(13)Swing on a slope drifts when control lever is in neutral position
(14)Swing drifts when swing operation is stopped
(15)Slow travel speed/weak
(16)Travel deviation
(17)Travel 1st/2nd speed not changed
(18)Travel parking on a slope is not held
(19)Travel does not run straightly when both crawlers and attachment operated simultaneously.
(20)Slow breaker (crusher) operation, weak power
(21)Option selector valve malfunction: not switched to breaker circuit
(22)Option selector valve malfunction: not switched to nibbler (crusher) circuit
47-3
(1) All controls do not function/slow
No. Sections Contents/normal value Corrective action, others

1 Fuse Check fuse No.4 If the fuse is blown out, check on
(10A) the short-circuited section.
2 Safety lever lock Carry out service No.4 K-4 switch: Check action of switch by tester,
switch diagnosis Push down the lever and it turns on, push or check that the power voltage
up and it turns off. is lowered by pushing the lever
down.
3 Safety lever lock Check that the Measure both terminals of solenoid Check solenoid unit for possible
switching solenoid is switched connector. 24V by pushing the lever down, failure.
correctly 0V by pushing it up Check harness for possible
failure.
4 Safety lever lock relay Carry out service No.4 K-4 lock lever: Check action of relay by tester
diagnosis Push down the lever and it turns off, push
up and it turns on.
5 Pilot pressure sensor •Stop engine stop and key is on position. Check 5V power for controller
All pilot low pressure sensors are 0MPa to
0.1MPa.
6 Solenoid valve for Measure pressure of About 0MPa by pushing the lever up, and Replace solenoid valve
safety lock lever solenoid A1 port 4MPa or more by push it down.
7 Pilot line filter Disassemble and Check filter for clogging Clean filter
check it visually
8 Pilot gear pump Measure pilot primary Check that it is 4MPa or more in high idling Check gear pump and the relief
pressure at gear valve for possible failure
pump
9 Multi control valve (in Change position Since all are blocked due to poor switching
case that travel is performance, check that the lever select
operable) pattern is set to the proper position.
10 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.3 Boom up full lever & relief proportional valve and controller
for possible failure.
11 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of 0.5 to
proportional valve secondary pressure 1.2MPa in boom up full lever and high
directly at the ports A7 idling operation
and A5 of 8 sections
solenoid block
12 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis. E-2 P2 pump largely differed from the actually
pump proportional •See Service Diagnosis Data List measured value, check
valve Operation No.18 Travel right full lever & proportional valve and controller
idling for possible failure.
Operation No.19 Travel left full lever &
idling
13 Secondary pressure of Measure the pump Check that pump proportional valve Replace proportional valve
pump proportional proportional valve secondary pressure is 2.7MPa or more in
valve secondary pressure right (left) travel full lever and high idling
directly in idling operation
operation. (Ports a3, Right travel: P1 pump proportional valve
a4) Left travel: P2 pump proportional valve
47-4

14 Main relief pressure Carry out service •See Service Diagnosis Data List Measure the relief pressure
diagnosis Operation No.3 Boom up full lever & relief actually
15 Check set pressure Check that P1 and P2 pump pressures are Reset or replace
32MPa in boom up full lever, high idling
and H mode operation.
16 Pump regulator Visual check When removing, free from abnormal Replace
resistance against sliding.
Free from abnormal damage, etc on
outside surface
Spring free from breakage, damage, etc.
17 Pump Visual check When removing, inside parts (cylinder Replace
block, piston, valve plate, shaft, etc.) are
free from abnormal resistance against
sliding, abnormal damage, etc.
(2) Engine down/stalled

current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No. 1 Operation is nil proportional valve and controller
2 Secondary pressure of Measure the pump Check that P1/P2 pump proportional Replace proportional valve
P1, P2 pump proportional valve valve pressures are within the range of
proportional valve secondary pressure 0.5 to 1.0MPa in control lever neutral
directly (Ports a3, a4) and high idling operation.
3 Pressure sensor of P1, Check pressure •See Service Diagnosis Data List Check pressure sensor and
P2 pump Operation No. 1 Operation is nil replace it if necessary
Operation No.3 Boom up full lever &
relief
resistance against sliding
outside surface
Spring free from breakage, damage,
etc.
block, piston, valve plate, shaft, etc.)
are free from abnormal resistance
against sliding, abnormal damage, etc.
(3) Move at lever neutral position

1 Pilot pressure sensor Carry out service Check that targeted pilot pressure of Check remote control valve
diagnosis sensor is 0MPa in high idling
2 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
3 Main spool Check targeted spool Check that spool is free from abnormal Replace
visually damage and spring is free from
breakage
4 Over load relief valve Check targeted spool Free from dust entered in port relief Replace
visually valve. Seat is free from abnormality
47-5

5 Lock valve poppet Check targeted poppet Seat is free from abnormality Replace
(in case of boom and visually
arm)
6 Lock valve selector Exchange lock valve Check that the trouble is reversed Replace
(in case of boom and selector of boom/arm
arm) and boom/arm
7 Holding valve spool for Check that smooth Free from abnormal resistance against Replace
boom sliding of spool in sleeve sliding Do not pull spool out of sleeve
(in case of boom) forcibly.
8 Holding valve relief Check targeted spool Filter free from abnormal Replace
valve for boom visually contamination
(in case of boom)
9 Cylinder Check targeted cylinder Make sure of no problem of seals by Replace cylinder or seals
visually disassembling and investigation
(4) Poor fine operability

1 Pressure sensor Carry out service •See Service Diagnosis Data List Replace pressure sensor
diagnosis Operation No. 1 Operation is nil
•All low pressure sensors are 0MPa to
0.1MPa
valve Operation No. 1 Operation is nil proportional valve and controller
3 Secondary pressure of Measure the Check that P1/P2 unloads secondary Replace proportional valve
unload proportional proportional valve pressures is within the range of
valve secondary pressure 2.7MPa or more in control lever neutral
directly at the ports A7 and high idling operation
solenoid block
Operation No. 1 Operation is nil proportional valve and controller
P1, P2 pump proportional valve valve pressures are within the range of Check regulator
proportional valve secondary pressure 0.5 to 1.0MPa in control lever neutral
directly. (Ports a3, a4) and high idling operation
6 Slow return check valve Visual check Check that slow return check valve Clean and replace
of pilot line installed on pilot line is free from dust
(in case of boom up or entered
arm out)
47-6
(5) Slow boom up, insufficient power

1 Boom up pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.3 boom up full lever and sensor
relief Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
control pressure of in boom up full lever and high idling When equipped with multi
boom up operation control valve, check it while
changing lever pattern
3 Pump pressure sensor Carry out service •See Service Diagnosis Data List When there is difference
diagnosis for P1, P2 Operation No.4 boom up full lever and between P1 and P2 pump
pump pressures in in operation pressures, check high pressure
operation. sensor.
valve Operation No.3 Boom up full lever & proportional valve and controller
relief for possible failure.
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure 0.5~1.2MPa in boom up full lever and
directly at the ports A7 high idling operation
solenoid block
Operation No.4 boom up full lever & in proportional valve and controller
operation for possible failure.
proportional valve secondary pressure 1.8 to 3.0MPa in boom up full lever and
directly (Ports a3, a4) high idling operation
8 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean and replace
<Trouble> poppet and no contamination on orifice
Only P2 pressure is low. No problem for sliding ability of internal
piston (Check it through PBp2 port.)
breakage
10 Lock valve poppet Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Both P1 and P2 Free from abnormal damage, etc on damage)
pressures are low. outside surface
11 Conflux check valve Visual check When removing, free from abnormal Replace
Only P2 pressure is Free from abnormal damage, etc on damage)
high. outside surface
12 Holding valve for boom Visual check When removing, free from abnormal Replace
(poppet) resistance against sliding (Check on the casing side for
<Trouble> Free from abnormal damage, etc on damage)
Both P1 and P2 outside surface
pressures are high.
47-7

13 Boom spool Visual check When removing, free from abnormal Replace
Only P1 pressure is Spring is free from breakage. damage)
high.
14 Check boom spool and Disassembly and Free from abnormal resistance against Replace spool assembly
recirculation investigation sliding
<Trouble> Spring is free from breakage.
Only P1 pressure is low.
15 Conflux spool Visual check When removing, free from abnormal Replace
Only P2 pressure is Spring is free from breakage. damage)
high. Free from abnormal damage, etc on
outside surface
16 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 boom up full lever and
Relief pressure is low. relief
17 Over load relief valve Visual check (Head Pressure is 32MPa or more in boom up When only relief pressure of
<Trouble> side) full lever and high idling. Free from boom up is low, replace valve
Relief pressure is low. dust entered in over load relief valve.
Seat is free from abnormality
(6) Slow boom down/insufficient power for lifting up body

1 Boom down pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.5 boom down full lever sensor.
& in operation Check remote control valve.
2 Remote control valve Measure remote control Check that pressure is 3.0MPa or more Check remote control valve
pressure of boom down in boom down full lever and high idling When equipped with multi
directly operation control valve, check it while
changing lever pattern.
3 Actual measuring Carry out service P1 unload valve (cut valve) In case where the reading is
current value of P1 diagnosis •See Service Diagnosis Data List largely differed from the actually
unload proportional Operation No.5 boom down full lever & measured value, check
valve in operation proportional valve and controller
4 Secondary pressure of Measure the Check that P1 unload secondary Replace proportional valve
P1 unload proportional proportional valve pressures are within the range of 0.8 to
valve secondary pressure 1.2MPa in boom down full lever and
directly at the ports A7 of high idling operation
8 sections solenoid
block.
pump proportional valve Operation No.5 boom down full lever measured value, check
& in operation proportional valve and controller
6 Secondary pressure of Measure the pump Check that P1 pump proportional valve Replace proportional valve
P1 pump proportional proportional valve pressures are within the range of 2.0 to
valve secondary pressure 2.5MPa in boom down full lever and
47-8

7 Actual measuring Carry out service Check that the value is not change •Check pressure sensor of
current value of travel diagnosis regardless of operation travel
straight proportional •See Service Diagnosis Data List •In case where the reading is
valve Operation No. 1 Operation is nil largely differed from the
Operation No.18 Travel right full lever actually measured value, check
& idling proportional valve and
Operation No.19 Travel left full lever & controller for possible failure.
idling
8 Travel straight Measure directly the High idling pressure is 0.8MPa or less Replace proportional valve
proportional valve travel straight regardless neutral/operation
secondary pressure proportional valve
secondary pressure.
breakage
10 Lock valve poppet Visual check When removing, free from abnormal Replace
Boom down is low. Free from abnormal damage, etc on damage)
outside surface
11 Holding valve (poppet) Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding Free from (Check on the casing side for
Boom down is slow. abnormal damage, etc on outside damage)
surface
12 Boom spool Visual check When removing, free from abnormal Replace
Boom down is slow. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
13 Check boom spool and Disassembly and Free from abnormal resistance against Replace spool assembly
Machine can not be
lifted by supporting with
boom.
15 Over load relief valve Visual check Free from dust entered in port relief Replace
<Trouble> valve.
Machine can not be Seat is free from abnormality
lifted by supporting with
boom.
(7) Slow arm in, insufficient power

1 Arm in pressure sensor Carry out service •See Service Diagnosis Data List Check and replace pressure
diagnosis Operation No.6 arm in full lever and sensor
pressure control pressure of arm in arm in full lever and high idling When equipped with multi
in operation control valve, check it while
47-9

diagnosis for P1, P2 Operation No.7 arm in full lever and in between P1 and P2 pump
pump pressures in operation pressures, check high pressure
operation. sensor
valve Operation No.6 Arm in full lever & proportional valve and controller
proportional valve secondary pressure 1.2MPa in arm in full lever and high
directly at the ports A7 idling operation.
solenoid block.
Operation No.7 Arm in full lever & in proportional valve and controller
P1, P2 pump proportional valve valve pressures are 2.0MPa or more in
proportional valve secondary pressure arm in full lever and high idling
directly. (Ports a3, a4) operation. (Secondary pressure is
affected by oil temperature and
attachment weight)
8 Actual measuring Carry out service •See Service Diagnosis Data List In case where the reading is
current value of arm in diagnosis Operation No. 1 Operation is nil largely differed from the actually
spool 2 proportional Operation No.6 Arm in full lever & measured value, check
valve relief proportional valve and controller
Operation No.7 Arm in full lever & in for possible failure.
operation
9 Secondary pressure of Measure directly the Check that secondary pressure of Replace proportional valve
arm in spool 2 proportional valve proportional valve secondary
proportional valve secondary pressure at pressures are within the range of
the ports A8 (arm 2 following
spool) of 8 sections Lever neutral: 0MPa
solenoid block. Motion in the air: 1.7 to 2.2MPa
Arm in relief: 2.5MPa or more
idling
11 Secondary pressure of Measure directly the 0.8MPa or less in high idling operation Replace proportional valve
travel straight proportional valve regardless of neutral/operation
proportional valve secondary pressure at
the ports A6 (travel
straight) of 8 sections
solenoid block
47-10

breakage
14 Over load relief valve Visual check (Head Pressure is 32MPa or more in arm in When only relief pressure of arm
<Trouble> side) and relief. in is low, replace valve
P1, P2 pressure is low. Free from dust entered in over load
relief valve.
Seat is free from abnormality
15 Over load relief valve Visual check (Rod side) Pressure is 32MPa or more in arm out When only relief pressure of arm
<Trouble> and relief. out is low, replace valve
relief valve.
Seat is free from abnormality.
16 Arm 1 spool Visual check When removing, free from abnormal Replace
P1, P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
P1, P2 pressure is high Free from abnormal damage, etc on damage)
or low. outside surface
18 Check arm 2 spool and Disassembly and Free from abnormal resistance against Replace spool assembly
Arm in power is poor.
19 Check lock valve poppet Visual check Free from abnormal resistance against Replace
<Trouble> sliding (Check on the casing side for
Both P1, P2 pressures Free from abnormal damage, etc on damage)
are high. outside surface
(8) Slow independent arm out (in the air)

1 Arm out pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.8 arm out full lever and sensor
control pressure of arm in arm out full lever and high idling When equipped with multi
out operation control valve, check it while
diagnosis for P1, P2 Operation No.9 arm out full lever and between P1 and P2 pump
pump pressures in in operation pressures, check high pressure
operation. sensor
valve Operation No.8 Arm out full lever & proportional valve and controller
47-11

proportional valve secondary pressure 1.2MPa in arm out full lever and high
directly at the ports A7 idling operation
solenoid block
Operation No.9 Arm out full lever & in proportional valve and controller
proportional valve secondary pressure 1.5 to 2.7MPa in arm out full lever and
(Secondary pressure is affected by oil
temperature and attachment weight)
idling
the ports A6 (travel
solenoid block
breakage
12 Over load relief valve Visual check (Rod side) Pressure is 32MPa or more in arm out When only relief pressure of arm
<Trouble> and relief. out is low, replace valve
relief valve. Seat is free from
abnormality
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
outside surface
47-12

15 Check arm 2 spool and Disassembly and Free from abnormal resistance against Replace spool assembly
recirculation investigation (spring sliding
<Trouble> side) Spring is free from breakage.
Both P1, P2 pressures
are low.
16 Check lock valve poppet Visual check Free from abnormal resistance against Replace
<Trouble> sliding (Check on the casing side for
(9) Bucket digging is slow

1 Bucket digging pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.12 bucket digging full sensor
lever and relief Check remote control valve
control pressure of in bucket digging full lever and high When equipped with multi
bucket digging idling operation control valve, check it while
diagnosis for P1, P2 Operation No.13 Bucket digging full between P1 and P2 pump
pump pressures in lever and in operation pressures, check high pressure
operation. sensor
valve Operation No.12 Bucket digging full proportional valve and controller
lever & relief for possible failure.
proportional valve secondary pressure 1.2MPa in bucket digging full lever and
directly at the ports A7 high idling operation
solenoid block
Operation No.13 Bucket digging full proportional valve and controller
lever & in operation for possible failure.
P1, P2 pump proportional valve pressures is 2.7MPa or more and P2
proportional valve secondary pressure pump proportional valve pressure is
directly (Ports a3, a4) 1.6 to 2.2MPa in bucket digging full
lever and high idling operation.
8 Attachment boost Carry out service No.3 POWER BOOST Check harness
solenoid command diagnosis Bucket digging COMP OFF, MEAS Replace solenoid valve
OFF
9 Attachment boost Measure switching Check that pressure is 0MPa in bucket Replace solenoid valve
solenoid secondary valve secondary digging full lever and high idling
pressure pressure operation
47-13

current value of travel diagnosis Operation No.12 Bucket digging full largely differed from the actually
straight proportional lever & relief measured value, check
valve proportional valve and controller
11 Secondary pressure of Measure directly the Check that travel straight secondary Replace proportional valve
travel straight proportional valve pressure is 2.7MPa or more in bucket
proportional valve secondary pressure at digging full lever and high idling
the ports A6 (travel operation
solenoid block
12 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean or replace
13 Check stroke limiter Visual check When piston is removed from cover, it Replace
<Trouble> is free from abnormal resistance (Check on the casing side for
Both P1, P2 pressures against sliding damage.)
are high. Free from abnormal damage, etc on
outside surface
breakage
Operation No.3 Boom up full lever and
relief
16 Travel straight spool Visual check When removing, free from abnormal Replace
outside surface
17 Bucket spool Visual check When removing, free from abnormal Replace
18 Over load relief valve Check targeted spool Free from dust entered in over load Replace
visually relief valve.
(10)Bucket dump is slow

1 Bucket dump pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.14 Bucket dump full sensor
control pressure of in bucket dump full lever and high When equipped with multi
bucket dump idling operation control valve, check it while
diagnosis for P1, P2 Operation No.15 Bucket dump full between P1 and P2 pump
pump pressures in lever and in operation pressures, check high pressure
operation. sensor
47-14

valve Operation No.14 Bucket dump full proportional valve and controller
lever & relief for possible failure.
proportional valve secondary pressure 0.5~1.2MPa in bucket dump full lever
directly at the ports A7 and high idling operation. Replace
and A5 of 8 sections proportional valve
solenoid block
Carry out service Operation No.15 Bucket dump full proportional valve and controller
diagnosis. lever & in operation for possible failure.
P1, P2 pump proportional valve pressures is 2.7MPa or more and P2
proportional valve secondary pressure pump proportional valve pressure is
directly (Ports a3, a4) 0.9 to 1.4MPa in bucket dump full lever
and high idling operation.
current value of travel diagnosis Operation No.14 Bucket dump full largely differed from the actually
straight proportional lever & relief measured value, check
valve proportional valve and controller
travel straight proportional valve pressure is 2.7MPa or more in bucket
proportional valve secondary pressure at dump full lever and high idling
solenoid block
10 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean and replace
piston (Check it through PBP2 port.)
11 Check stroke limiter Visual check Free from abnormal damage and wear Replace
<Trouble> on outside of piston inside cover (Check on the casing side for
Pilot pressure is low. damage.)
breakage
<Trouble> Operation No.3 Boom up full lever and
outside surface
15 Bucket spool Visual check When removing, free from abnormal Replace
47-15

visually relief valve.
(11)Swing does not move/slow

1 Swing pressure sensor Carry out service •See Service Diagnosis Data List Check and replace pressure
diagnosis Operation No.11 Swing full lever and sensor
in operation Check remote control valve
control pressure of in boom up full lever and high idling When equipped with multi
swing operation control valve, check it while
3 Swing parking brake Carry out service No.3 F-2 SWING-BRAKE Check swing pressure sensor
solenoid diagnosis Lever neutral: COMP ON, MEAS ON Check harness
Swing: COMP OFF, MEAS OFF
Swing parking brake Measurement of Lever neutral: 0MPa Replace solenoid valve
4
solenoid solenoid valve A2 port In operation: 4MPa or more
5 Shuttle valve Visual check No contamination on spool cover Clean or replace
<Trouble> (short side) and orifice
Pilot pressure is low. No damage on spool cover (long side)
and shuttle
6 Pump pressure sensor Carry out service •See Service Diagnosis Data List Check high pressure sensor
diagnosis for P2 pump Operation No.11 Swing full lever and
pressures in operation in operation
unload proportional Operation No.11 Swing full lever & in measured value, check
valve operation proportional valve and controller
8 Secondary pressure of Measure the Check that P2 unload secondary Replace proportional valve
P2 unload proportional proportional valve pressures are within the range of 0.5 to
valve secondary pressure 1.2MPa in swing full lever and high
directly at the ports A5 of idling operation
8 sections solenoid
block
current value of P2 diagnosis largely differed from the actually
Operation No.11 Swing full lever & in proportional valve and controller
P2 pump proportional proportional valve pressure is 2.7MPa or more in swing
valve secondary pressure full lever and high idling operation
directly (Ports a3, a4)
(Check this trouble by Operation No.18 Travel right full lever actually measured value, check
only swing operation) & idling proportional valve and
idling
47-16

(Check this trouble by the ports A6 (travel
only swing operation) straight) of 8 sections
solenoid block
breakage
P2 pressure is low. Free from abnormal damage, etc on damage)
outside surface
15 Swing spool Visual check When removing, free from abnormal Replace
outside surface
16 Swing relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.10 Swing full lever and
17 Swing motor Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be free from
abnormal resistance against sliding.
outside surface (brake plate etc)
18 Swing reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
swing reduction gear metal powder. reduction gear
drain
19 Swing reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
(12)Noise occurred at swing operation

Swing: COMP OFF, MEAS OFF
2 Measurement of Lever neutral: 0MPa Replace solenoid valve
solenoid valve A2 port In operation: 4MPa or more
3 Boost check valve Visual check When removing, free from abnormal Replace
(Sound of cavitation at resistance against sliding
stopping) Spring is free from breakage.
4 By-pass check valve Visual check When removing, free from abnormal Replace
(Sound of cavitation at resistance against sliding
stopping) Spring is free from breakage.
5 Swing motor Visual check Disassemble and inspect abnormal Replace
(Brake valve/friction wear and scuffing
plate)
6 Swing motor piston Visual check When removing, free from abnormal Replace
47-17

7 Swing reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
swing reduction gear metal powder. reduction gear
drain.
8 Swing reduction Visual check Tooth surface has no abnormally worn Replace
and chipped.
(13)Swing drifts on a slope while swing control lever is in neutral position

1 Swing pressure sensor Carry out service •Engine stop & starter key ON Check and replace pressure
diagnosis All pilot low pressure sensors are sensor
within range of 0 to 0.1MPa.
breakage
Swing: COMP OFF, MEAS OFF Check parking brake release
switch
4 Measurement of Lever neutral: 0MPa Replace solenoid valve
solenoid valve A2 port In operation: 4MPa or more
5 Swing motor Visual check Disassemble and inspect abnormal Replace
(Brake valve/friction wear and scuffing
plate)
6 Parking brake Visual check Piston and friction plate do not have Replace
abnormal resistance against sliding
Free from spring damage
(14)Swing drifts at stopping

1 Shuttle valve Visual check No contamination on spool cover Clean or replace
<Trouble> (short side) and orifice. No damage on
Pilot pressure is low spool cover (long side) and shuttle.
2 Swing pressure sensor Carry out service •Engine stop & starter key ON Replace pressure sensor
diagnosis All pilot low pressure sensors are
within range of 0 to 0.1MPa.
3 Swing relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.10 Swing full lever and
4 Anti-reaction valve Visual check Free from dirt entering Clean or replace
Sliding part should be free from foreign
matter entering, abnormal damage and
wear.
breakage
6 Swing motor Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be free from
abnormal resistance against sliding.
47-18
(15)Travel speed is slow/poor

1 Travel right and left Carry out service •See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.18 Travel right full lever sensor
and idling Check remote control valve
Operation No.19 Travel left full lever
and idling
control pressure of in travel right (left), forward (reverse)
travel right and left full lever and high idling operation
valve Operation No.18 Travel right full lever proportional valve and controller
& idling for possible failure.
idling
proportional valve secondary pressure followings in travel right (left), forward
directly at the ports A7 (reverse) full lever and high idling
and A5 of 8 sections operation
solenoid block Travel right (P1 unload): 0.5 to 1.0MPa
Travel left (P2 unload): 0.5 to 1.0MPa
Operation No.18 Travel right full lever proportional valve and controller
idling
6 Secondary pressure of Measure the pump Check that P1/P2 unload secondary Replace proportional valve
P1, P2 pump proportional valve pressures are within the range of
directly (Ports a3, a4) (reverse) full lever and high idling
operation
Travel right (P1 pump): 2.7MPa or
more
Travel left (P2 pump): 2.7MPa or more
7 Actual measuring Carry out service Check that the value is not change •Check voltage of low pressure
current value of travel diagnosis regardless of operation sensor other than sensor for
straight proportional •See Service Diagnosis Data List travel
valve Operation No. 1 Operation is nil •In case where the reading is
Operation No.18 Travel right full lever largely differed from the
& idling actually measured value, check
Operation No.19 Travel left full lever & proportional valve and
idling controller for possible failure
proportional valve secondary pressure
breakage
Check sealing ability of shuttle valve
and entry of dust in orifice
47-19

outside surface
11 Travel spool Visual check of targeted When removing, free from abnormal Replace
<Trouble> spool resistance against sliding (Check on the casing side for
Pump pressure is high. Free from abnormal damage, etc on damage)
outside surface
12 Travel motor relief valve Check set pressure Check P1 and P2 pump pressures are If P1 is low, right travel motorÅfs
32MPa or more in right and left travel relief valve is failed.
levers full lever (relief operation at If P2 is low, left travel motorÅfs
locked crawler belt) and high idling relief valve is failed.
13 Travel motor Visual check Inner parts (piston, cylinder block, Replace
valve plate, brake valve spool) are to
be free from abnormal resistance
against sliding.
14 Parking brake in travel Visual check When removing, free from abnormal Replace
motor resistance against sliding
No sticking on friction plate and
separator plate
15 Travel reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
travel reduction gear metal powder. reduction gear
drain
16 Travel reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
(16)Travel deviation

1 Travel right and left Carry out service •See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.18 Travel right full lever sensor
and idling Check remote control valve
Operation No.19 Travel left full lever
and idling
control pressure of in travel right (left), forward (reverse)
travel right and left full lever and high idling operation
3 Actual measuring Carry out service Check that the value is not change •Check voltage of low pressure
current value of travel diagnosis regardless of operation sensor other than sensor for
straight proportional •See Service Diagnosis Data List travel
valve Operation No. 1 Operation is nil •In case where the reading is
Operation No.18 Travel right full lever largely differed from the
& idling actually measured value, check
Operation No.19 Travel left full lever & proportional valve and
idling controller for possible failure.
proportional valve secondary pressure
47-20

valve Operation No.18 Travel right full lever proportional valve and controller
idling
directly at the ports A7 (reverse) full lever and high idling
and A5 of 8 sections operation
solenoid block Travel right (P1 unload): 0.5 to 1.0MPa
Travel left (P2 unload): 0.5 to 1.0MPa
Operation No.18 Travel right full lever proportional valve and controller
idling
8 Secondary pressure of Measure the pump Check that P1/P2 unload secondary Replace proportional valve
P1, P2 pump proportional valve pressures are within the range of
directly (Ports a3, a4) (reverse) full lever and high idling
operation
Travel right (P1 pump): 2.7MPa or
more
Travel left (P2 pump): 2.7MPa or more
9 Exchange P1 for P2 Exchange delivery pipe Check the direction of deviation If the direction is changed,
of P1 for P2 inspect a pump. If the direction
is not changed, inspect a valve
and travel unit.
breakage
Check sealing ability of shuttle valve
and entry of dust in orifice
outside surface
Spring is free from breakage
12 Travel spool Visual check of targeted When removing, free from abnormal Replace
<Trouble> spool resistance against sliding (Check on the casing side for
Pump pressure is high. Free from abnormal damage, etc on damage)
outside surface
13 Travel motor relief valve Check set pressure Check P1 and P2 pump pressures are If P1 is low, right travel motorÅfs
32MPa or more in right and left travel relief valve is failed.
levers full lever (relief operation at If P2 is low, left travel motorÅfs
locked crawler belt) and high idling relief valve is failed.
Replace as necessary
47-21

14 Travel motor Visual check Inner parts (piston, cylinder block, Replace
valve plate, brake valve spool) are to
be free from abnormal resistance
against sliding.
15 Travel reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
travel reduction gear metal powder. reduction gear
drain
16 Travel reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
outside surface
etc.
block, piston, valve plate, shaft, etc.)
are free from abnormal resistance
against sliding, abnormal damage, etc.
(17)Travel 1/2 speed cannot be switched

(In case of the traveling under heavy loading (for example traveling on a slope or traveling on a soft ground), the
speed may sometimes does not change from 1st to 2nd because this machine equips the function of automatic
speed change.)

1 Travel 1/2 speed Carry out service Switch travel 1/2 speed to 2nd speed Check pressure sensor
switching solenoid diagnosis No.3 F-3 1/2-TRAVEL Check harness
Lever neutral COMP OFF, MEAS OFF Check travel 1/2 speed switch
Travel operation COMP ON, MEAS on gauge cluster
ON
2 Travel 1/2 speed Measure A3 port Lever neutral: 0MPa Replace solenoid valve
switching solenoid pressure on solenoid In operation: 4MPa or more
valve
3 1/2 speed switching Visual check Check that spool is free from abnormal Replace
spool in travel motor damage and spring is free from (Check on the casing side for
breakage damage)
4 1/2 speed switching Visual check Free from entry of dust Remove dust or replace
orifice in travel motor
5 Tilting piston in travel Visual check Free from abnormal wear on piston Replace
motor and seal (Check on the casing side for
damage)
(18)Machine does not stay on a slope in traveling

1 Pilot pressure sensor Carry out service •Engine stop & starter key switch is ON Check pressure sensor and
diagnosis Targeted pilot low pressure sensor is replace as necessary
in range of 0 to 0.1MPa Check remote control valve
breakage
47-22

3 Parking brake in travel Visual check When removing, free from abnormal Replace
motor resistance against sliding
etc.
4 Orifice of passage for Visual check Free from entry of dust Remove dust or replace
parking brake in travel
motor
(19)Machine does not travel straight in simultaneous operation of traveling and attachment

1 Actual measuring Carry out service No.8 D-3 S-TRAVEL is should be •Check voltage of low pressure
current value of travel diagnosis COMP 590mA and MEAS 560 to sensor other than travel sensor
straight proportional 620mA in both travel full lever and in •In case where the reading is
valve boom up full lever at high idling largely differed from the
actually measured value, check
proportional valve and
controller for possible failure.
2 Secondary pressure of Measure directly the Check secondary pressure is within Replace proportional valve
travel straight proportional valve range of 1.8 to 2.2MPa in both travel
proportional valve secondary pressure full lever and in boom up full lever at
high idling
resistance against sliding (Check on the casing side for
Free from abnormal damage, etc on damage)
outside surface
(20)Breaker works slowly and power is poor (In case of conflux, check p1 unload/pump and travel straight)

1 Pressure sensor for Carry out service •See Service Diagnosis Data List Check and replace pressure
optional attachment diagnosis Operation No.16 P2 side OPT full senso
2 Remote control valve Measure directly remote Check that pressure is 2.1MPa or more Check remote control valve0
control pressure of in optional attachment full lever and
travel right and left high idling operation
3 Actual measuring Carry out service •See Service Diagnosis Data List •In case where the reading is
current value of P1/P2 diagnosis Operation No.16 P2 side OPT full largely differed from the
unload proportional lever and relief actually measured value, check
valve proportional valve and
proportional valve secondary pressure 1.2MPa
directly at the ports A7
solenoid block
5 Actual measuring Carry out service •See Service Diagnosis Data List •Check voltage of low pressure
current value of travel diagnosis Operation No.16 P2 side OPT full sensor other than sensor for
straight proportional lever & relief optional attachment
valve •In case where the reading is
largely differed from the
actually measured value, check
proportional valve and
47-23

travel straight proportional valve pressure is 2.7MPa or more in optional
proportional valve secondary pressure at attachment full lever and high idling
solenoid block
7 P1 by-pass cut valve Visual check No problem for sliding ability of main Clean or replace
8 Relief pressure Check set pressure •See Service Diagnosis Data List Reset or replace
Operation No.16 P2 side OPT full
lever and relief
(Set value of factory shipment is
24.5MPa.)
9 Remote control valve Check targeted remote Check sealing ability of shuttle valve Replace
control valve and entry of dust in orifice.
outside surface
11 Spool for optional Visual check When removing, free from abnormal Replace
attachment resistance against sliding (Check on the casing side for
<Trouble> Free from abnormal damage, etc on damage)
P1, P2 pressures are outside surface
high. Spring is free from breakage.
visually relief valve
(21)Selector valve for option malfunctions: Breaker circuit is not obtained.

(Indication of failure is displayed. For reference, see "Table47-1 Action of optional selector solenoid valve")

1 N&B selector spool Visual check When removing, free from abnormal Replace
outside surface
2 N&B selector solenoid Screw for emergency Check that the error indication is Replace solenoid valve
disappeared by turning emergency
screw
3 N&B selector solenoid Carry out service •No.11 F-4 Option selector is B mode Check solenoid valve
diagnosis COMP ON, MEAS ON Check harness
Spool position BRK
Selector switch BRK
4 N&B selector pressure Carry out service •No.16 B-11 Check pressure sensor
sensor diagnosis Data List Check harness
3.0MPa at B mode and 0.0MPa at A
mode
47-24
(22)Selector valve for option malfunctions: Nibbler circuit is not obtained.

(Indication of failure is displayed. For reference, see "Table47-1 Action of optional selector solenoid valve")

1 N&B selector spool Visual check When removing, free from abnormal Replace
outside surface
2 N&B selector solenoid Carry out service •No.11 F-4 Option selector is A mode Check solenoid valve
diagnosis COMP OFF, MEAS OFF Check harness
Spool position NIB
Selector switch NIB
47-25
Table47-1 Action of optional selector solenoid valve

Optional Selector
Safety lock Safety lock selector valve
Engine Work Spool Failure diagnosis
No. lever SW's lever relay's valve detecting Warning display
condition mode position display
input output COMP. pressure
MEAS. sensor
1 Running ON OFF A OFF Nibbler Normal — —
2 "SELECTOR VALVE [F042] displayed
Running ON OFF A ON Breaker Normal
FAILURE" simultaneously
3 "SELECTOR VALVE
Running ON OFF A OFF Breaker Normal —
FAILURE"
4 Running ON OFF A ON Nibbler Normal — [F042] displayed
5 Running ON OFF B ON Breaker Normal — —
6 "SELECTOR VALVE [F043] displayed
Running ON OFF B OFF Nibbler Normal
FAILURE" simultaneously
7 "SELECTOR VALVE
Running ON OFF B ON N&B Normal —
FAILURE"
8 Running ON OFF B OFF Breaker Normal — [F043] displayed
9 "SELECTOR VALVE
Running ON OFF — — — Failure [B113] displayed
FAILURE"
10 Stopping — — — — — — — —
11 — OFF — — — — — — —
12 — — ON — — — — — —
47-26
47.2 ELECTRIC SYSTEMS

47.2.1 WIRING CHECKING PROCEDURE
Check for continuity between connector terminals, CONNECTOR
presence or absences of short-circuit with other wires,
and presence or absences of short-circuit with machine
body grounding.
WIRE
(1) Checking for disconnection between connectors.
(When both ends measurement is easy because of
TESTER
short distance between connectors,)
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is zero (0), it is in normal
condition.
(When both ends measurement is difficult because

of long distance between connectors,)
Measure the resistance using tester. JUMPER
Pull out opposite connector first. WIRE
Where the resistance is zero (0), if the terminal on
one side is connected to frame body grounding with TESTER
jumper wire, it is in normal condition. FRAME BODY GROUNDING
The resistance is 1M or more when the terminal
on one side is not connected to frame body
grounding with jumper wire, it is in normal condition.
(2) Checking for presence or absence of short-circuit

with machine body
When the resistance is 1M or more, it is in normal
condition.
TESTER
FRAME BODY GROUNDING
(3) Checking for presence or absence of short-circuit

between wirings.
When the resistance is 1M or more, it is in normal
condition. TESTER
47-27
(4) Checking connector terminal for contact

Insert male terminal into female terminal unit, and INSERT
then check that the inserting force is equivalent to
other female terminals. MALE TERMINAL FEMALE TERMINAL
If looseness is there, replace the female terminal
with new one.
Clean the dirt terminal.
Do not insert the male terminal the thickness differs. It

may cause loose connection.
(5) Caution which should be paid in measuring voltage

When measuring the power supply to electric
equipment at connector position with the grounding
terminal contained inside of connector, measure
the voltage between grounding inside of connector
and power terminal.
When measuring the voltage between frame body
grounding and power source, the disconnection of
wiring to grounding inside of connector cannot be
identified.
Since the voltage may vary between with connector
connected and with connector not connected.
Measure the voltage with each connector
connected whenever possible.
(6) Checking the general view of connector CRIMPED
PART
a. Check the terminal crimped condition.
Pull one electric cable with the about 3kg force,
RUBBER
and make sure that the cable does not come out PLUG
RECEPTACLE.
of the terminal. CONTACT
When came out, replace the terminal and crimp PLUG

SEALING
it again. (is housed in plug)
b. Check connector for imperfect insertion DOUBLE LOCK

PLATE FOR PLUG
Check that all top ends form a line on the same DOUBLE LOCK
PLATE FOR CAP
position as seen from the connector engaged
side. CAP
When moved along, push it in further through TAB.CONTACT

wire inserting hole. RUBBER PLUG
c. Check connector for intruding of water.

Pull out the connector and check that the inside
is free from intruding of water.
When water intruding is found, check rubber plug
for damage and also that the sealing is fitted
properly.
47-28
(7) When abnormality occurs at intervals

When the abnormality situation can not be
reoccurred during checking operation, try the
following operations.
a. Check that variable of display exists or not on the
service diagnosis screen while shaking the
harness or giving shock by operating the
machine.
b. Check that variables of resistance and voltage
exist or not using tester while shaking the
harness.
c. Turn starter switch on and apply electricity
continuously, and check it again after the
temperature of wiring and equipment was raised.
(8) Checking on body grounding
Check attaching bolts of grounding terminal for
loosening.
And also check that there is no loose connection
due to corrosion.
There are multiple groundings like centralized

grounding box shown in the figure and battery
grounding, engine grounding, horn grounding fixed
together with horn, body grounding placed on
attaching section of boom working light.
Block of grounding is located
under floor plate of cab.
47-29
47.2.2 TROUBLE
(1) Engine does not stop.
(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
(3) Auto accel does not actuate. (The engine speed does not automatically slow down.)
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
(5) Wiper does not function.
47-30
(1) Engine does not stop.

1 Starter key switch Check signal of starter No.4 K-3 Key switch Check continuity between
key switch ON by OFF at starter key switch OFF position terminals of starter switch using
carrying out service ON at starter key switch ON position tester
diagnosis.
2 Engine forcible stop When ON is displayed No.4 K-3 Key switch Check on engine forcible stop
relay with the starter switch OFF at starter key switch OFF position relay
OFF, then pull out R-25 ON at starter key switch ON position
engine forcible stop
relay and carry out the
service diagnosis.
3 Wiring Voltage between line 0V when starter switch is OFF Check harness
No.62 among starter Check diode D-9 between
switch, engine forcible starter switch and auto idling
stop relay, mechatro stop relay 1
controller and the body
grounding
(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.

1 Fuse No.1 fuse (5A) Not blown fuse Check harness
Replace fuse
2 Mechatro controller Accel control Engine speed varies according to Check mechatro controller and
accel potentiometer operation. replace as necessary
(Use remote control because the auto
accel function is working.)
3 Wiring Transmission circuit line See "WIRING CHECKING Repair wiring
No.770 from mechatro PROCEDURE"
controller to gauge
cluster
4 Gauge cluster Gauge cluster Replace gauge cluster
(3) Auto accel does not actuate. (The engine speed does not automatically slow down).

1 Engine coolant Check engine coolant No.2 G-5 WATER TEMP Replace engine coolant sensor
temperature temperature by carrying Auto accel does not work in the
out service diagnosis. temperature -15°C or less.
Warm up and raise the coolant
temperature to – 15°C or more
2 Gauge cluster Indication of auto accel Mark "Display/not display" for auto Replace gauge cluster
accel switches by auto accel switch
operation on gauge cluster.
3 Low pressure sensor Service diagnosis Each control pressure of No.5 and Check low pressure sensor
No.6 is in the range of 0~0.1MPa at
control lever neutral position.
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)

1 Low pressure sensor Service diagnosis Each control pressure of No.5 and Check low pressure sensor
No.6 is raised with control lever
operated.
47-31
(5) Wiper does not function
Wiping range of
forward and
reverse movements
Wiper motor
Rise up (storing) position Rise up limit switch's ON range
Upper reversing position Reverse limit switch's ON range
Lower reversing position

1 Fuse Check fuse No.20 Replace fuse
2 SW-19: Service diagnosis No.19 D125 Check wiper interlock switch
Wiper interlock switch Wiper switch display (D125) is OFF with front window closed. and repair it if necessary
Check according to "WIRING
CHECKING PROCEDURE" and
repair it if necessary
3 Rise up limit switch built- Service diagnosis No.25 Wiper system Check according to "WIRING
in wiper motor CHECKING PROCEDURE"
Reverse limit switch Switch action in operation
Normal condition
Rise up limit switch ON OFF OFF
Reverse limit switch ON ON OFF
4 R-31: Service diagnosis No.25 Wiper system

Arc prevention relay When started by forward rotation: STOP START (STOP) (REVERSE) (STOP) (FORWARD)
R-29: Arc prevention relay OFF ON ON ON ON OFF ON ON ON OFF ON
Forward rotation relay Forward rotation relay OFF ON ON ON ON OFF OFF OFF OFF OFF ON
Reverse rotation relay OFF OFF OFF OFF OFF OFF ON ON ON OFF OFF
R-30:
Check that the relay is worked as shown in the table. Check that the relay is excited.
Reverse rotation relay * When the limit switch does not change in OFF after 4 seconds Check relay & fuse box and replace it
from the wiper startup, turn OFF all relay's outputs. if necessary.
47-32
47.3 ENGINE RELATED TROUBLESHOOTING
Checking
Filters Liquid Leak, clogging
Air leak between turbocharger and intake manifold

Factors
Leak, clogging of fuel system and intruding of air

Contamination of water and fuel with oil
Breather hose crushed or clogged
Fan belt slipped, fan pulley worn
Poor or deteriorated battery

Shortage of fuel level
Improper fuel in use

Air cleaner clogged
Fuel filter clogged
Oil level of oil pan

Oil filter clogged
Muffler clogged
Engine oil leak
Coolant level
Trouble
Poor start ability (Take a long time)

Faulty starting
Faulty engine starting/engine does not rotate.

Faulty engine starting/engine rotates but no
exhaust gas (No fuel injection)
Faulty engine starting/exhaust gas is emitted

but engine does not start (With fuel injection)
Poor output Insufficient
Engine poor run-up (Low follow-up ability)

rotation
Rotation in bad condition (hunting)

Engine stalled during operation.
Output is lowered.
Overheating
Exhaust smoke is black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Other failures
Early contamination of oil

Larger fuel consumption
Intruding of oil in coolant, back flow, reduction
of coolant quantity
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Vibration
47-33
Checking Electric equipment

Shovel side Shovel side Engine side
Loose mounting bolts, damage of mounting rubber

Factors
Radiator core clogged/fin clogged and crushed

Peeling of space insulation around radiator
Loose connection of battery cable terminal

Failure of radiator pressure cap
Failure of hydraulic system

Startup circuit wiring
Starter switch key
Hydraulic switch
Starter motor
Battery relay
Safety relay
Glow relay
Glow plug
Alternator
Trouble

Faulty starting



rotation

Output is lowered.
Overheating
Other failures

of coolant quantity
Vibration
47-34
Intake and Lubrication Cooling

Fuel system exhaust system system
system
Factors
Seizing and interference of turbocharger

Seal of turbocharger worn, damaged
Turbocharger oil drain tube clogged
Leak and crush of hydraulic piping
Failure of thermostat (Not open)

Fuel leak into the head cover
Improper fuel injection time
Failure of regulator valve
Damage of water pump

Damage of EGR cooler
Failure of supply pump
Failure of relief valve

Failure of oil pump
Failure of injector
Trouble

Faulty starting



rotation

Output is lowered.
Overheating
Other failures

of coolant quantity
Vibration
47-35
Engine body
Factors
Wear and damage of rear oil seal and seal surface

Damage and seizing of piston and connecting rod
Damage of engine oil cooler core and O-ring
Damage of cylinder head and head gasket
Wear and failure of valve and valve guide
Wear of piston ring and liner, ring stick

Strainer clogged, damage of oil pipe
Failure of injection holder sleeve
Damage of flywheel gear

Hole due to cavitation
Damage of dumper
Trouble

Faulty starting



rotation

Output is lowered.
Overheating
Other failures

of coolant quantity
Vibration
47-36
48. TROUBLESHOOTING
(TROUBLE DIAGNOSIS MODE)
TABLE OF CONTENTS
48.1 TROUBLE DIAGNOSIS MODE .......................................................................................48-3
48
48-1
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

SK330–8 : LC10-07001~ S5YN4818E01
SK350LC–8 : YC10-03501~ (ASIA, OCE)
SK200–8 : YN11-45001~
↑ August, 2006 ↑ K
SK210LC–8 : YQ11-06001~
SK250-8 : LQ12-06001~
SK260LC-8 : LL12-05001~
E235BSR : YF05-02001~ ↑
E235BSR(N)LC : YU05-02001~ (NHK)
E215B : YN11-45001~ ↑
↑ March, 2007 K
SK235SR-2 : YF05-02001~ ↑
↑ April, 2007 K
SK235SRLC-2 : YU05-02001~ (OCE)
SK200-8 : YN11-45001~ ↑
↑ ↑ K
SK250-8: LQ12-06001~ ↑
↑ May, 2007 K
E225BSR : YB05-03001~ ↑
↑ June, 2007 K
E225BSRLC : LA05-02001~ (NHK)
↑
↑ ↑ SK215SRLC : LA05-02001~ K
(North America)
E135BSR : YY05-12001~ ↑
↑ July, 2007 K
E135BSRLC : YH05-07001~ (NHK)
SK225SR : YB05-03001~ ↑
↑ ↑ K
SK225SRLC : LA05-02001~ (OCE)
E215B : YN11-45001~ ↑
↑ ↑ K
E265B : LQ12-06001~ ↑
↑ ↑ K
E215B : YN11-45001~ ↑
↑ ↑ K
↑
↑ ↑ ↑ K
E385B : LC10-07001~ ↑
↑ August, 2007 K
48-2
48.1 TROUBLE DIAGNOSIS MODE

The trouble diagnosis mode is used to automatically specify the failed sections for the troubles which can not be
detected by auto diagnosis function (the trouble can be specified by error code) like disconnection, abnormal output.
(1) Function
There are two types of trouble diagnosis mode.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and
engine system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not operated, both selector valve and proportional valve are automatically
actuated, the sensor detects the machine condition and the mechatro controller identifies the normal
condition or failed condition of the system.
(2) How to use and flow chart
The operation is performed through gauge cluster.
No.1 Select service adjustment select screen.
(Switch starter key on while pressing buzzer stop switch and press select switch three times while pressing
buzzer stop switch on the service diagnosis screen No.1.)
No.2 Select Trouble diagnosis mode
(Move the cursor to the desired position with screen change switch " ", and press the select switch.)
No.3 Select either "DIAG MODE 1" or "DIAG MODE 2"
(Move the cursor to the desired position with screen change switch " ", and press the select switch.)
No.4 Go ahead the operation according to the instructions on the screen of cluster gauge.
No.1 No.2 No.3

SELECT SWITCH
LANGUAGE/LOGO 8 FAULT DIAG MODE DIAG MODE 1
BUZZER STOP SWITCH
ADJUSTING MODE 1 DIAG MODE 2
PRESET BY FACTORY
FEED SCREEN CHANGE SWITCH
CASE OF DIAG MODE 1
SENSOR CHECK START ENG LOWER BOOM DIAG MODE 1

ENGINE SPEED
RELEASE LOCK In diagnosis
CHECK 0000 rpm
PRESSURE
C-1 00.0M C-2 00.0M
TO GROUND LEVER START operation
PROPO-VALVE About 15 minutes
E-1 005mA E-2 005mA
D-1 300mA D-2 300mA
For the diagnosing items, see Table 48-1.

When required to stop in diagnosis
Turn engine on operation, press the buzzer stop switch
manually. BACK TO No.3 and the operation is forcedly stopped.
The data at the time of judgment

can be confirmed with the select
RESULT OF DIAGNOSIS RESULT OF DETAIL switch.
When
DIAG MODE 1 not failed, DIAG MODE 1 1 P1 UNLOAD
ENGINE SPEED
0000 rpm
END ENGINE STOP OK O K PRESSURE
C-1 00.0M C-2 00.0M
PROPO-VALVE
E-1 005mA E-2 005mA
DATA END FEED D-1 300mA D-2 300mA
The other judgments can be

Engine stops confirmed with the feed button.
automatically. RESULT OF DIAGNOSIS
When failed,
DIAG MODE 1 RESULT 1 1 P1 UNLOAD
ENGINE SPEED
P1 UN-LOAD PSV NG 0000 rpm
P1 UN-LOAD SPOOL NG NG PRESSURE

C-1 00.0M C-2 00.0M
PROPO-VALVE
DATA END FEED DATA END FEED E-1 005mA E-2 005mA
D-1 300mA D-2 300mA
The suspected trouble sections are displayed in order of

possibility. The suspected three sections in maximum are
BACK TO No.3 displayed. When desired to see other suspected trouble sections,
press feed " " button. For diagnosis results and corrective
actions to be taken, see Table 48-2.
Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the
attachment and it causes injury or death.Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis
mode after making sure of the bucket-grounded condition.
2. Before executing the trouble diagnosis mode, check each pressure sensor proportional valve and select valve for possible abnormality.
Check that the commands of proportional valve and select valve do not largely differ from the actually measured values through the service diagnosis.
The preliminary investigation of electric system makes the time saving and high precision diagnosis possible.
3. For the diagnosis results and the corrective actions to be taken, usually occurred troubles are taken as an example. When multiple troubles are occurred at the same time, there is a
case no accordance of diagnosis obtained. In this case, contact our dealer/distributor.
4. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring
to the trouble history.
48-3
No.4 CASE OF DIAG MODE 2
SENSOR CHECK START ENG

ENGINE SPEED
LOWER BOOM DIAG MODE 2
CHECK 0000 rpm
PRESSURE
C-1 00.0M C-2 00.0M
TO GROUND START
PROPO-VALVE
E-1 005mA E-2 005mA
D-1 300mA D-2 300mA
Turn engine on
Example: Case of boom up
manually. AT CONTROL LEVER IS
NEUTRAL WHEN FINISHING OF
DIAGNOSIS IS REQUIRED.
BOOM UP BOOM UP
OK BACK TO No.3
PRESSURE 0.0 MPa PRESSURE 1.5 MPa PRESSURE 3.0 MPa
SEARCHABLE OPERATION
Boom up
Boom down
In the normal condition, OK is
Bucket digging displayed when the control
lever is moved to stroke end.
Bucket dump
Arm in
Arm out
Swing
Travel right
Travel left
P1 side option
P1 side option
Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the
attachment and it causes injury or death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis
mode after making sure of the bucket-grounded condition. Place the bucket on the ground between both crawlers.
2. In the case of "DIAG MODE2", pump pressure is unloaded with unload valve in order not to actuate attachment.
When trouble diagnosis is performed, if the pump pressure is generated, the engine stops and "UN-LOAD PSV NG" is displayed. Check the troubled section according to indication.
3. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring
to the trouble history.
Table48-1 Failure diagnosis Mode-1/Diagnosis item

No. Display Contents of diagnosis
Is normal pressure generated in the condition that the flow rate at P1 side is minimum and
1 1 P1 UNLOAD
the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the minimum flow rate is relieved at P1
2 2 P1 UNLOAD
side?
Is normal pressure generated in the condition that the unload valve is fully opened, and P1
3 3 P1 UNLOAD
side flow rate is minimum?
Is normal pressure generated in the condition that the unload valve is in emergency position,
4 1 P2 UNLOAD
and P2 side flow rate is minimum?
Is normal pressure generated in the condition that the minimum flow rate is relieved at P2
5 2 P2 UNLOAD
side?
Is normal pressure generated in the condition that the unload valve is fully opened, and P2
6 3 P2 UNLOAD
Is normal pressure generated in the condition that the flow rate at P1 side is emergency and
7 1 P1 PUMP
Is normal pressure generated in the condition that the unload valve is emergency, and P1
8 2 P1 PUMP
9 3 P1 PUMP
and P1 side flow rate is maximum?
Is normal pressure generated in the condition that the flow rate at P2 side is emergency and
10 1 P2 PUMP
Is normal pressure generated in the condition that the unload valve is emergency, and P2
11 2 P2 PUMP
12 3 P2 PUMP
and P2 side flow rate is maximum?
48-4
Table48-1 Failure diagnosis Mode-1/Diagnosis item

No. Display Contents of diagnosis
Is normal pressure generated in the condition that P1 side flow rate is minimum, unload
13 1 TRAVEL-S
valve is emergency position and travel straight is stroked fully?
Is normal pressure generated in the condition that P2 side flow rate is minimum, unload
14 2 TRAVEL-S
valve is emergency position and travel straight is stroked fully?
Is rated engine speed obtained in the condition that P1 side flow rate increases little by little
15 1 P1 ENGINE
when P1 side flow rate is relieved?
Is rated engine speed obtained in the condition that P2 side flow rate increases little by little
16 2 P2 ENGINE
when P2 side flow rate is relieved?
When pump regulator does not have "Total power control of Emergency mode", "1 P1 PUMP" of No.7 and "1 P2
PUMP" of No.10 are not given a diagnosis.
Table48-2 Failure diagnosis Mode-1/Diagnosis and Remedy

Diagnosis (Display) Possible cause Remedy
Check each pressure sensor by
SENSOR CHECK Disconnection of pressure sensor, Short
service diagnosis and replace it if
NG circuit, Abnormal output
necessary
Secondary pressure is excessive high against
the command Check P1 unload proportional valve
P1 UN-LOAD PSV NG
Secondary pressure is excessive low against and replace it if necessary
the command
Stuck at full-stroke side Check P1 unload spool and replace it
P1 UN-LOAD SPOOL NG
Stuck at neutral side if necessary
the command Check P2 unload proportional valve
P2 UN-LOAD PSV NG
the command
Stuck at full-stroke side Check P2 unload spool and replace it
P2 UN-LOAD SPOOL NG
Stuck at neutral side if necessary
Stuck at closing side Check P1 by-pass cut valve and
P1 B-P CUT NG
Stuck at neutral side replace it if necessary
Stuck at closing side Check P2 by-pass cut valve and
P2 B-P CUT NG
the command Check P1 pump proportional valve
P1 PUMP PSV NG
the command
Delivery rate is excessive large against the Check P1 pump regulator and replace
command it if necessary.
P1 PUMP NG
Delivery rate is excessive small against the Check P1 pump and replace it if
command necessary.
the command Check P2 pump proportional valve
P2 PUMP PSV NG
the command
48-5
Table48-2 Failure diagnosis Mode-1/Diagnosis and Remedy

Diagnosis (Display) Possible cause Remedy
Delivery rate is excessive large against the Check P2 pump regulator and replace
command it if necessary.
P2 PUMP NG
Delivery rate is excessive small against the Check P2 pump and replace it if
command necessary.
the command Check travel straight proportional
S-TRAVEL PSV NG
Secondary pressure is excessive low against valve and replace it if necessary
the command
Stuck at full-stroke side Check travel straight spool and
S-TRAVEL SPOOL NG
PUMP 1 PRESS. SENSOR Check P1 high pressure sensor and
Pressure is recognized lower than it is
NG replace it if necessary
PUMP 2 PRESS. SENSOR Check P2 high pressure sensor and
Pressure is recognized lower than it is
NG replace it if necessary
Set pressure decreases Check main relief valve and replace it
MAIN RELIEF NG
Set pressure increases if necessary
Check engine and replace it if
ENGINE NG Output is lowered
necessary
Check engine speed sensor and
E/G R SENSOR NG Characteristics is misaligned
replace it if necessary
48-6
51. ENGINE
PREFACE
This service manual explains the single engine. Note that this manual is edited without
modification by based on the service manual of HINO MOTOR.
51
51-1
51. ENGINE

SK200–8 : YN11-45001~ S5YN5123E01
First edition April, 2007 K
SK210LC–8 : YQ11-06001~ ASIA (HS Engine)
E215B : YN11-45001~ ↑
↑ July, 2007 K
↑
↑ ↑ ↑ K
51-2
HINO DIESEL ENGINE
WORKSHOP MANUAL
J05E-TG
(HS Engine)
KSS-SMJ5-E011E
2007.4
GENERAL 1
STANDARD VALUE 2
PARTS TO BE PREPARED 3
ENGINE ASSEMBLY/DISASSEMBLY 4
FUEL SYSTEM 5
EMISSION CONTROL 6
ELECTRICAL 7
INTAKE 8
ENGINE MECHANICAL 9
EXHAUST 10
COOLING 11
LUBRICATION 12
STARTING AND CHARGING 13
TURBOCHARGER 14
AIR COMPRESSOR 15
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS 16
ENGINE DIAGNOSIS CODE 17
For your information:
This documentation does not contain any descriptions in

regard to the hatched part
"6. Emission Control".

"15. Air Compressors".
GENERAL 1–1
ENGINE
1
1 GENERAL
General information
Warning................................................................... 1-2
How to read this manual ........................................ 1-3
Precautions for work ............................................... 1-7
Tightening of engine bolts and nuts ...................... 1-10
Tightening of chassis bolts and nuts..................... 1-12
Tightening of flare nuts and hoses........................ 1-14
Taper thread sealant for piping ............................. 1-15
Assembly of joints and gaskets for piping ............. 1-16
Handling of liquid gasket....................................... 1-18
Failure diagnosis table for each problem .............. 1-19
Failure diagnosis using HinoDX ............................ 1-20
Connection method of HinoDX ............................. 1-23
Chassis number and engine number ................... 1-23
1–2 GENERAL
Warning
JP31199010102001
Observe the following precautions to work safely and to prevent damage to customers' vehicles.
This manual is prepared for qualified service engineers who are recognized as technical expert. Those who are not
qualified, who are not appropriately trained, who performs service without appropriate tool or equipment, or who
perform service with the way not specified in this manual may not only damage the vehicle, but also put service
engineers and surrounding people in danger.
• Appropriate service and repair are essential to ensure safety of service engineers and safety and reliability of
vehicles. Be sure to use Hino genuine parts for replacement of parts. Do not use deteriorated parts in quality.
• Items described in this manual are the procedures to be observed in service and repair. For service and repair
according to this procedure, be sure to use the special tools designed for each purpose.
• If a method or a tool not recommended is used, safety of service engineers, and safety and reliability of vehicles
may be impaired. Never use a method or tool not recommended.
• This manual shows “Warning” and “Caution” for items that need to be observed so that accidents may not occur
during service or repair, or that damage to vehicle due to improper method may not impair safety and reliability of
vehicles. These instructions cannot give warning for all possible hazards. Note that items with “Warning” or
“Caution” are not absolute for safety.
GENERAL 1–3
How to read this manual

JP31199010102002
1. Scope of repair work

(1) Repair work is classified into three large categories of "Diagnosis", "Mounting/removal, replacement,
assembly⋅disassembly and inspection⋅adjustment" and "Final inspection".
(2) This manual describes "Diagnosis" in the first process and "Mounting/removal, replacement,
assembly⋅disassembly and inspection⋅adjustment" in the second process. Explanation of "Final inspection"
in the third process is omitted here.
(3) Although the following work is not described in this manual, it should be performed in actual work.
a. Jacking and lifting
b. Cleaning and washing of removed parts as required
c. Visual inspection
2. Standard value
(1) Standard value, limit, action and tightening torque described in the text are summarized in tables.
3. Items to be prepared
(1) Items to be prepared before work are SST, tools, gauges and lubricant, etc. These are listed in the list
section of items to be prepared. Items such as general tools, jack, rigid rack, etc. that are usually
equipped in general service shop are omitted.
4. How to read sections and titles

(1) Sections are classified according to J2008, SAE standard.
(2) For areas that show system names like "Engine control system", "Inspection", "Adjustment",
"Replacement", "Overhaul", etc. of components are described.
(3) For areas that show part names like "Injection pump", "Mounting/removal and disassembly" is described.
(4) Illustrations of the parts catalog are shown for part layout. (Part codes in the parts catalog are described in
the illustration. Major names and tightening torque are listed in the table.)
! CAUTION The part layouts in this manual are inserted based on illustrations and part numbers of the
parts catalog CD-ROM issued in march, 2007. (Some areas do not show exploded view. They
will be additionally issued when the parts catalog CD is revised.) Be sure to use the parts
catalog for confirmation of illustrations and part numbers and for ordering parts.
1–4 GENERAL
5. How to read troubleshooting

(1) Failure diagnosis in this manual describes Step 2 and Step 3 below :
Hear from customers for conditions and environments

(1) Question "Step 1"
of failures and check the fact.
Perform diagnosis inspection, status inspection,

(2) Pre-inspection function inspection and basic inspection. Check the
"Step 2"
(3) Reproduction method failure status. If it is difficult to reproduce the problem
with status inspection, use the reproduction method.
(4) Troubleshooting for each Summarize inspection results obtained from Step 2.
diagnosis code Perform inspection systematically according to
"Step 3"
(5) Troubleshooting for each failure troubleshooting procedures for each diagnosis code or
status failure status.
Check if failure occurs again after repair. If it is difficult

(6) Confirmation test "Step 4" to reproduce a failure, perform the confirmation test
under the conditions and environment of the failure.
(2) Pre-inspection
• Pre-inspection is performed in the following steps :

Diagnosis inspection→Diagnosis deletion→Failure status check (Use the reproduction
method if not reproduced.)→Diagnosis reconfirmation
• Estimate the failure system before the reproduction test. Attach a tester and evaluate
estimated failure together with failure status. Refer to the troubleshooting chart for
Pre- estimated cause of a failure.
inspection • An error code is displayed if a failure occurs instantaneously. If any specific failure is not
found, perform troubleshooting using the reproduction method.
• Failure status check
If failure is reproduced, perform Step 2 → Step 3 → Step 4.
If failure is not reproduced, use the reproduction method (simulation of external
conditions or check of each wire harness and connector, etc.)
GENERAL 1–5
6. How to read explanation details

(1) Part layout
Example
ENGINE MECHANICAL [J08E] 9–17
Timing Gear Cover and Flywheel Housing

Part layout
JP04117090402003
Part name code
Part catalog Fig. No.
SAPH041170900182
11308 Flywheel housing 11390 End plate

Description of
11309 Oil seal retainer 9828A Front oil seal* part name code
11357 Gasket* 9828B Rear oil seal*
11357A Gasket*
*Parts not to be reused.

Left: Part name code (nut)
Tightening torque
9069H M14 : 171.5N m{1, 750kgf cm} 9419A M16 : 196N m{2, 000kgf cm}
9069J M12 : 97N m{990kgf cm} 9419B M16 : 196N m{2, 000kgf cm}
Service procedure
Overhaul item
SAPH311990100001
✩:It is the ID number for parts to prepare electronic data. It is not required for repair work.
1–6 GENERAL
7. Definition of terms
Terms in this manual are defined as follows :
(1) Direction
a. Individual unit
Front/back direction
The power input side is front and the output side is back.
Rotating direction
When viewed from the rear, the clockwise direction is right rotation and the counterclockwise direction is
left rotation.
Vertical direction
With a unit mounted on the vehicle (chassis), the upward direction is upper and the downward direction is lower.
Left/right direction
When viewed from the rear, the left direction is left and the right direction is right.
(2) Standard value ⋅⋅⋅⋅⋅⋅⋅Basic dimension excluding tolerance and clearance generated by tolerances when two
parts are joined
(3) Repair limit⋅⋅⋅It is the value requiring repair. Symbol of + or - with the value means increase or decrease to
the standard value.
(4) Service limit⋅⋅⋅It is the value requiring replacement. Symbol of + or - with the value means increase or
decrease to the standard value.
(5) Warning⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅It is an item that may result in risk of human life or serious injury by incorrect handling.
(6) Caution⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅It is an item that should not be performed including inhibited work or an item that require
attention in working procedures.
(7) Reference⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅⋅It is supplementary explanation in work.
8. Unit
(1) SI unit is used in this manual. SI unit is the international unit to unify the conventional different international
units into one unit per quantity and to promote smooth technical communications.
(2) This manual shows both the SI unit and conventional units. The conventional units are shown in { }.
Convent Conversion value*1 Convent Conversion value*1

SI unit ional (1[Conventional SI unit ional (1[Conventional unit]
unit unit] = X [SI unit]) unit = X [SI unit])
Spring 1kgf/mm=980665N/
Force N kgf 1kgf=9.80665N N/mm kgf/mm
constant mm
1kgf⋅cm=0.0980665
Torque*2 N⋅m kgf⋅cm Volume L cc 1cc=1mL
N⋅m
1kgf/
2 cm2=98.0665kPa
kgf/cm Efficiency W PS 1PS=0.735499kW
Pressure Pa =0.0980665MPa
1mmHg=0.133322k Calorific
mmHg W⋅h cal 1kcal=1.163W⋅h
Pa value
r/min 1rpm=1r/min Fuel

Rotational 1g/PS⋅h=1.3596g/
rpm consumpt g/W⋅h g/PS⋅h
speed min-1 1rpm=1min-1 kW⋅h
ion rate
*1
: X means the value when 1 [Conventional unit] is converted to the SI unit.
It is used as the conversion factor from the conventional unit to the SI unit.
*2
: The conversion value of the torque may vary depending on the unit.
Observe the standard values described for each unit.
GENERAL 1–7
Safety information
Precautions for work

JP31199010101001
1. General precautions
To ensure safety in work and to prevent accidents, observe the following items :
(1) Appearance
a. Wear safety goggles.
b. Do not wear watch, necktie, ring, bracelet, necklace, etc. to prevent accident before work.
c. Bind long hair at the back.
d. Be sure to wear a cap and safety shoes.
(2) Safety work
a. Do not touch radiator, muffler, exhaust pipe, tail pipe, etc. after stop of the engine to prevent burn.
b. Do not put your clothes or tools near the rotating part (in particular, cooling fan or V–belt) during
operation of the engine.
c. Remove the starter key when the engine is not started.
d. Start the engine at a well ventilated place so that carbon monoxide may not be filled.
e. Since gas from the fuel or the battery is flammable, do not spark a fire or smoke a cigarette near the area.
f. Since the battery fluid is poisonous and corrosive, be careful for handling.
g. Do not short-circuit the cable of the battery or starter. Otherwise, the cable may be burned or burn may
occur.
h. If a tool or rag is left in the engine compartment, it may be bounced with a rotating part of the engine,
resulting in injury.
i. To tow a failure machine, refer to "Towing" in the "Operation manual" of the machine.
2. Precautions for service work

Pay attention to the following points before service work
(1) Preparation before disassembly
a. Prepare general tools, special tools and gauges before work.
b. To disassemble a complicated area, put a stamp or match mark on the location not functionally affected
to ease assembly. To repair the electric system, disconnect the cable from the minus terminal of the
battery before work.
c. Perform inspection according to the procedure in the text before disassembly.
(2) Inspection during disassembly
Every time parts are removed, check the area where the parts are assembled and check for deformation,
damage, wear or scratch.
(3) Arrangement of disassembled parts
Place removed parts neatly in order. Separate parts to be replaced from parts to be reused.
(4) Washing of disassembled parts
Clean and wash parts to be reused well.
(5) Inspection and measurement
Inspect and measure parts to be reused as required.
(6) Assembly
a. Keep the specified standard values (tightening torque, adjusting values, etc.) and assemble correct
parts in the correct order.
b. Be sure to use genuine parts for parts to be replaced.
c. Use new packing, gasket, O–ring and cotter pin.
d. Use seal gaskets for some areas where gaskets are used. Apply specified oil or grease to sliding areas
where application of oil is required, and apply specified grease to the oil seal lip before assembly.
(7) Check of adjustment
Make adjustments to the service standard values using a gauge or tester.
1–8 GENERAL
3. Precautions for electric system

(1) Removal of battery cable
a. In an electric system, remove the cable from the

battery minus (-) terminal to prevent burnout due to
short-circuit.
b. When the battery cable is removed, the battery
Loosen
terminal may be damaged. Loosen the nut completely
and never pry it for removal.
SAPH311990100002
(2) Handling of electronic parts
a. Do not give impact on electronic parts such as

computer and relay.
b. Do not place electronic parts at a high temperature and
humidity area.
c. Do not expose electronic parts to water in washing of a
vehicle.
SAPH311990100003
(3) Handling of wire harness
a. Mark clamps and clips to prevent interference of a wire

harness with body edge, sharp edge and bolts. Be sure
to reassemble it to the original position.
b. When parts are assembled, be careful not to pinch a
wire harness.
SAPH311990100004
GENERAL 1–9
(4) Handling of connector
a. When a connector is removed, hold the connector (as

shown by the arrow in the left) and pull it out. Do not pull
the wire harness.
b. Unlock the locking connector before pulling.
c. Insert the locking connector completely until it clicks.
d. To insert a test lead into the connector, insert it from the
back of the connector.
e. If it is difficult to insert a test lead from the back of the
connector, prepare a harness for inspection.
SAPH311990100005
4. Precautions for electric welding

Inadvertent electric welding on a cab or chassis may cause reverse welding current from the grounding
circuit, resulting in damage to electric and electronic parts. Observe the following items for electric
welding.
(1) Turn "OFF" the starter switch.
(2) Make sure that switches are "OFF".
(3) Disconnect the minus (-) terminal of the battery according to the removal procedure of the battery cable.
(4) Disconnect connectors of each computer.
(5) Remove all fuses. (For locations of fuses, refer to "Electrical System Chapter".)
(6) Be sure to connect grounding of the electric welding machine near the welding area.
Connect grounding from a bolt (plated bolt) or a frame near the welding area.
Remove paint of the frame for connection of grounding from the frame.
(7) Other precautions
a. Put a cover on rubber hoses, wire harnesses, pipes, tires, etc. around the welding area so that they
may not be exposed to spatter.
b. Perform welding under appropriate conditions and minimize heat effect in the peripheral area. Also
maintain welding quality.
(8) After welding, connect and assemble in the order of the fuse and the minus terminal of the battery
disassembled. When paint is removed from a frame or cab, apply rust preventive coating with the same
color.
(9) After reassembly, check the function if it operates correctly.
General information
1–10 GENERAL
Tightening of engine bolts and nuts

JP31199010102003
1. Tightening torque of general standard bolts

(1) For bolts with seatings
Unit : N⋅m{kgf⋅cm}
Screw diameter x Pitch 7T 9T
M8 x 1.25 (Coarse thread) 28.5{290} 36{370}
M10 x 1.25 (Fine thread) 60{610} 74.5{760}
M10 x 1.5 (Coarse thread) 55{560} 68.5{700}
M12 x 1.25 (Fine thread) 108{1, 100} 136{1, 390}
M12 x 1.75 (Coarse thread) 97{990} 125{1, 280}
M14 x 1.5 (Fine thread) 171.5{1, 750} 216{2, 210}
M14 x 2 (Coarse thread) 154{1, 570} 199{2, 030}
Remark Bolt with number “7” on the head Bolt with number “9” on the head
! CAUTION • 8T bolt is in accordance with 7T bolt.
(2) For bolts with washers

Screw diameter x Pitch 4T 7T 9T
M6 x 1 (Coarse thread) 6{60} 10{100} 13{130}
M8 x 1.25 (Coarse thread) 14{140} 25{250} 31{320}
M10 x 1.25 (Fine thread) 29{300} 51{520} 64{650}
M10 x 1.5 (Coarse thread) 26{270} 47{480} 59{600}
M12 x 1.25 (Fine thread) 54{550} 93{950} 118{1, 200}

M12 x 1.75 (Coarse thread) 49{500} 83{850} 108{1, 100}
M14 x 1.5 (Fine thread) 83{850} 147{1, 500} 186{1, 900}
M14 x 2 (Coarse thread) 74{750} 132{1, 350} 172{1, 750}
Bolt with number “4”on

the head Bolt with number“7”on
Bolt with number “9”on
Remark Projection bolt Stud the head Stud with C
the head
with R surface at free surface at free end
end
! CAUTION • 8T bolt is in accordance with 7T bolt.
R surface (4T) C surface (7T)
SAPH311990100006
GENERAL 1–11
2. Precoated bolt
Precoated bolt is the bolt with an application of a seal lock
agent at the thread.
(1) When re-application of lock agent is required

a. When precoated bolts are removed
b. When precoated bolts are moved due to tightening
Seal Lock Agent check (for loosening or tightening)
NOTICE • Check torque with the lower limit of the

SAPH311990100007 tightening torque allowable value. If
movement is found, tighten the bolt
according to the procedure below.
(2) Re-use method of precoated bolt lock

a. Clean bolt and screw holes. (Clean screw holes for
replacement.)
b. Dry completely by blowing air.
c. Apply the specified seal lock agent to the thread of the
bolt.
3. Plastic region tightening method (angle method)

One turn by 90°
(1) Precautions
Some engines are tightened with the plastic region
Tighten it 90°
tightening method.
Since it is different from the conventional method, tighten
it according to the instruction in the text.
SAPH311990100008
(2) Parts tightened

One turn by 90° Tighten it 45°
One turn by 45° (Second time) Cylinder head bolt, crankshaft main bearing cap bolt,
connecting rod bearing cap bolt, etc.
Tighten it 90°
(First time)
! CAUTION • Measure the overall length of the bolt before
assembly and replace the bolt if the length
exceeds the service limit.
Apply engine oil to bolt seating and bolt
thread in assembly.
SAPH311990100009
(3) Tightening method after tightening to seating torque

Two turns by 90° Tighten it 90°
(Second time) Tightening of 90 °, 135 °(90 °once and 45 °once) and
Tighten it 90° 180 °(90 °twice) is available.
(First time)
SAPH311990100010
1–12 GENERAL
Tightening of chassis bolts and nuts

JP31199010102004
1. Tightening torque of general standard bolts and nuts

(1) Selection method of tightening torque
a. Find the applicable strength zone from the table below and select the bolt tightening torque from the
table described later.
b. Select the nut tightening torque from the mating bolt as described above.
(2) Identification method of bolt strength zone
a. Identification method with product
Hexagonal bolt
Strength zone of hexagonal bolts is, in principle, indicated with recession, relief, surface depression
and upset on the head with the symbol in the table.
Strength zone 6T 7T 8T 9T 10T 11T 12T
Identification symbol for part 6 7 8 q*1 10 11 12
(*1) : 9 may be misread with 6. It is expressed in q.
Depression Relief Base depression Upset
SAPH311990100011
Hexagonal nut
Symbol example for identification of the strength zone of the hexagonal nut is shown in the table below :
Formula
(3) Types of general standard bolts and nuts
Standard seating Seating A with flange Seating B with flange

GENERAL 1–13
(4) Standard tightening torque table of general standard bolts and nuts
(Representative standard seating is described)
Strength
zone
Bolt 4T 7T 9T
diameter
(mm)
4.5±1.8{50±20}
(Cab)
M6 9.0±1.8{90±20} 11.5±2.0{117±23}
5.5±1.1{60±10}
(Chassis)
14.0±3.5{140±40}
(Cab)
M8 22.0±4.0{220±40} *2 29.0±5.5{300±60} *2
17.0±3.0{170±30}
(Chassis)
43.0±8.5{440±90} *2 57.0±11.0{580±110} *2
(Cab) (Cab)
M10 27.0±5.0{276±55}
51.5±10.0{530±100} 68.5±13.5{700±140}
(Chassis) (Chassis)
76.0±15.0{776±150} *2 100.0±20.0{1, 020±200} *2

(Cab) (Cab)
M12 48.0±9.5{490±98}
91.0±18.0{930±180} 120.0±24.0{1, 220±240}
(Chassis) (Chassis)
M14 77.0±15.0{786±157} 120.0±24.0{1, 220±240} 160.0±32.0{1, 630±326}
M16 120.0±24.0{1, 220±244} 190.0±38.0{1, 940±390} 250.0±50.0{2, 550±510}

M18 165.0±33.0{1, 680±336} 260.0±52.0{2, 650±530} 345.0±69.0{3, 520±704}
M20 235.0±47.0{2, 400±480} 370.0±74.0{3, 770±750} 490.0±98.0{5, 000±1, 000}
M22 320.0±64.0{3, 270±654} 505.0±100.0{5, 150±1, 030} 670.0±130.0{6, 840±1, 370}
M24 405.0±81.0{4, 130±826} 640.0±125.0{6, 530±1, 310} 845.0±165.0{8, 620±1, 720}
! CAUTION • Use the tightening torque value for seating A with flange except for *2 in the table larger by
10% than the tightening torque value in the table.
• Use the tightening torque value for seating B with flange of *2 in the table larger by 20%
than the tightening torque value in the table.
The tightening torque value of M8 for seating B with flange remaines unchanged.
• Seating B with flange of *2 in the table is interchangeable with the standard seating in
pairs. Use the standard seating for the tightening torque value.
1–14 GENERAL
Tightening of flare nuts and hoses

JP31199010102005
1. Tightening torque of pipe flare nut

Pipe outer
diameter φ4.76 φ6.35 φ8 φ10 φ12 φ15
Material
Steel pipe 15±5{150±50} 25±5{250±50} 36±5{370±50} 52±7{530±70} 67±7{680±70} 88±8{900±80}
2. Tightening torque of hoses

Hose outer diameter

Hose outer diameter Hose outer diameter
φ13, φ20, φ22, fitting at
φ10.5 fitting PF3/8 fitting
packing
21.5±1.5{215±15}
Air hose Only meter gauge 41.5±2.5{425±25} —
10{100}
Packing
Brake hose — —
51.5±7.5{525±75}
3. Lock nut tightening torque of brass joint

Screw nominal
M12 M16 M20 M27
size
Tightening
15±2{150±20} 66±6{670±60} 97±9{990±90} 209±19{2130±190}
torque
GENERAL 1–15
Taper thread sealant for piping

JP31199010102006
The taper thread of the air pipe joint has application of sealant
[Loctite # 575 (by Japan Loctite)]. Follow the procedures below for
connection or disconnection of pipes.
1. For disconnection
Removal of joint (Example: Use of magnetic valve)
Magnetic valve
(1) The sealant ( # Loctite 575) has strong sealing feature.
Frame Air pipe (Flare joint) The return torque of the taper joint is increased about 1.5
(No application of sealant) times the initial tightening torque. When the joint is
disconnected, use a long wrench for disconnection.
Since sealant is
applied to this area, (2) When a joint at a poorly accessible area is replaced,
remove accessories
with the joint remove accessories first and disconnect the joint.
attached and
Air hose
remove the joint.
SAPH311990100016
2. For connection
1/4 turn
(1) For application of sealant ( # Loctite 575), wipe the
Amount of application: 0.1 g/piece
sealing area completely with a rag or thinner. Apply
sealant directly to about three ridges for quarter round
3 threads
with offset of one ridge from the end. Tighten it according
1 thread
to the tightening torque in the table below.
Remove dirt completely from the mating part (female)
before tightening.
SAPH311990100017 ! CAUTION • If your eye or skin comes in contact with

sealant, wash it off immediately with water.
Tightening torque of taper joint Unit : N⋅m{kgf⋅cm}
Screw
diameter 1/4 3/8 1/2
Material
Steel 49±10{500±100} 64±15{650±150}
Aluminum,
25±5{250±50} 34±5{350±50} 44±5{450±50}
brass
(2) When a sealing tape is replaced with sealant, remove the

tape completely first as in (1).
! CAUTION • Be careful to prevent entry of dirt or foreign

matter in the pipe.
(3) If air leak is found after assembly with application of

sealant, air leak cannot be stopped with additional
tightening. Assemble the part again according to (1) and
(2).
1–16 GENERAL
Assembly of joints and gaskets for piping

JP31199010102007
1. Tightening torque of joints

Metal sealing method
Sealing method
Gasket sealing method (Flare pipe type, nipple connector type)
Tightening screw (Aluminum + Rubber or Copper)

Type A Type B
size
M8 13{130}
M10 20{200} 11{110}
M12 25{250} 20{200}
M14 25{250} 31{320}
M16 29{300} 39{400}
M18 39{400} 59{600}
M20 *39{400} 64{650} 20{200}
M24 69{700}
M28 *127{1300}
2. Joint assembly procedure and subsequent inspection

(1) Before assembly, make sure that there is no dirt or burr on the seating surface (mating part, pipe joint,
gasket, etc.).
(2) Since pipes have some degrees of freedom for assembly, the seating surface tends to incline. Tighten
pipes finally after temporary tightening to prevent leak.
(3) After tightening, apply the specified pressure to each pipe joint to ensure that there is no leak.
(4) Observe the values above for each tightening torque.
*When assembled soft washer # 4840FR-N (aluminum and rubber carbon pressure bonding) is loosened
or removed, be sure to replace it with a new part. This is not necessary for normal retightening.
GENERAL 1–17
3. Examples of joint methods in various pipes
Metal sealing method

Gasket sealing method Type A Type B
(Flare pipe type) (Nipple connector type)
Joint bolt Sealing surface: 3 places

Flare pipe
Gasket Connector
Flare nut Nut
Joint bolt Connector nipple
Sealing surface
: 4 places
Flare connector
Gasket
One piece eye joint Gasket
with sleeve Gasket Sealing surface
Gasket : 5 places Sealing surface: 5 places
Joint bolt Nut

Lock washer Bracket
Nut
Sealing surface
: 8 places
Connector nipple
Sealing surface: 1 place Sealing surface: 1 place

Flare connector
Nut Lock washer

Box nut
3-way joint
Sealing surface
: 8 places
Joint pipe
Bracket
Sealing surface
: 3 places
One piece eye joint without sleeve
Joint bolt
Sealing surface: 4 places
Joint bolt
Joint pipe
Sealing surface: 6 places

1–18 GENERAL
Handling of liquid gasket

JP31199010102008
1. Application of liquid gasket and part assembly procedure

(1) Remove old liquid gasket on each part and mating part completely. Clean the parts with a rag to prevent
deposit of oil, moisture, dirt, etc.
Be sure to overap parts at the beginning and at the end of application.
(2) Be careful for offset with the mating part when a part applied with liquid gasket is assembled. Apply the
liquid gasket again if offset occurs.
(3) Assemble parts within 20 minutes after application of the liquid gasket.
If 20 minutes has passed, remove the liquid gasket and apply it again.
(4) Start the engine at least 15 minutes or more after assembly of parts.
2. Removal of parts
(1) When parts are removed, do not pry one place only. Remove parts by prying each other using collar or
clearance on the flange. When gasket is removed, be careful to prevent entry of gasket offal into the
engine.
3. Others
(1) When the liquid gasket is contained in a tube, use the accompanying winding tool. When it is contained in
a cartridge, use the application gun.
Winding tool
Application gun
Tube: 150 g Cartridge type: 300 g
For a tube, desired application width may be obtained from the cut position at the nozzle end.
1 : Approx. 2 mm at the 1st section cut

2 : Approx. 5 mm at the 2nd section cut
Nozzle of tube
General information
Description of function
GENERAL 1–19
Failure diagnosis table for each problem

JP31199010301001
Engine mechanical Causes and actions are described for each item.
JP03Z01020601001
Status Cause Action

Engine overheat (coolant) Insufficient coolant Replenish coolant
Faulty thermostat Replace thermostat
Water leak from cooling system Correction
Faulty coolant pump Repair or replace
Faulty head gasket Replace head gasket
Engine overheat Clogging of radiator Cleaning of radiator
(radiator) Corrosion of cooling system Clean and repair cooling system
Clogging of radiator core front part Clean radiator
Faulty radiator cap Replace radiator cap
Engine overheat (compression Non-synchronous injection timing Adjust injection timing.
pressure) Faulty fuel injection pressure Adjust injection pressure
Faulty fuel Replace with correct fuel
Faulty injector Replace injector
Engine overheat (lubrication Deterioration of engine oil Replace engine oil
unit) Faulty oil pump Replace oil pump
Insufficient engine oil Replenish engine oil
Large engine oil consumption Wear of piston ring and cylinder Replace piston ring and cylinder
(piston, cylinder liner and piston liner liner
ring) Damage to piston ring Replace piston ring and cylinder
liner
Faulty fixing of piston ring Replace piston ring and cylinder
liner
Faulty assembly of piston ring Replace piston ring and cylinder
liner
Faulty engine oil Replace engine oil
Faulty piston ring joint Reassemble piston ring
Large engine oil consumption Wear of valve stem Replace valve and valve guide
(valve and valve guide) Wear of valve guide Replace valve guide
Faulty assembly of valve stem seal Replace stem seal
Excessive oil lubrication to rocker Inspection of clearance between
arm rocker arm and rocker arm shaft
Large engine oil consumption Faulty oil level gauge Replace with correct level gauge
(others) Excessive filling of engine oil Fill with appropriate amount of oil.
Leak of engine oil Repair or replace the part of oil
leak.
Piston seizure (in operation) Sudden stop of engine Perform warm-up before stop of
engine
Piston seizure (lubrication unit) Insufficient engine oil Replenish engine oil
Deterioration of engine oil Replace engine oil
Incorrect engine oil Replace with correct engine oil.
Low oil pressure Inspection of lubrication unit
Faulty oil pump Replace oil pump
Piston seizure Abnormal combustion Refer to overheat section.
Piston seizure Cooling unit Refer to overheat section.
SAPH311990100031
1–20 GENERAL
Failure diagnosis using HinoDX

JP31199010301002
! CAUTION • HinoDX is used for inspection and adjustment

of the system in addition to failure diagnosis.
1. HinoDX
(1) With HinoDX, failure of the common rail fuel injection

system can be diagnosed. The interface box (Hino-Bowie)
and the special cable are required for connection to the
vehicle.
Special tool : 09121-1040 Hino-Bowie
SAPH311990100032
09042-1220 Cable between vehicle and
Hino-Bowie
CD-ROM HinoDX
! CAUTION • Install the software of the Hino Diagnostic

eXplorer (HinoDX) in the PC. For the
installation method, refer to the instruction
manual accompanying the CD.
2. List of failure diagnosis tools
Part name Part No. External shape General description and function
PC • Operating system (OS) : Windows95,

(DOS/V standard) Windows98(IE5.0 or later),
Windows2000(SP3, IE5.0 or later),
WindowsXP(SP1a, IE6.0 or later)
— • CPU and memory : Conditions that
assure operation of the above operating
system
• Display : 800 x 600, 256 colors or
more
Hino-Bowie 09121 - 1040 • PC interface

(Interface box) Cable between
vehicle and Hino-
Bowie (09042 -
1220)
Signal check 09049 - 1080 Interrupting installation between vehicle

harness (for common rail fuel harness and ECU allows inspection with a
injection system) tester rod while the power is supplied.
GENERAL 1–21
3. Deletion of past failures

(1) To delete past failures of the engine ECU, use HinoDX on
the PC. (Refer to "HinoDX operation manual".)
SAPH311990100032
4. Connection of signal check harness
(1) To prevent damage to the ECU connector and to improve

accessibility, connect the signal check harness and put a
testing rod on the signal check connector of the signal
check harness for meaurement.
a. Disconnect the connector from the ECU.
Unit harness ! CAUTION • Do not break the locking tab of the connector.
Signal check harness
b. Connect the signal check harness to the machine
harness and the ECU.
Test lead Signal check harness
(for common rail fuel injection system)
Part No.
09049-1080
Signal check connector
SAPH311990100036
1–22 GENERAL
(2) Terminal No.

For the signal check harness connector, the ECU terminal number in the text is treated as follows :
ECU unit
Signal check
harness
ECU side Unit side
SAPH311990100038
GENERAL 1–23
Connection method of HinoDX

JP31199010301003
1. Connection of HinoDX
(1) Remove the left side cover at the rear of the driver's seat
and connect the failure diagnosis connector with a PC
which installed HinoDX through the interface box.
Special tool : 09121-1040 Hino-Bowie (Interface box)

09042-1220 Connecting cable
Engine ECU CD-ROM HinoDX
(2) Set the starter key to "ON" and start HinoDX.
Failure diagnosis
connector
SAPH311990100039
Failure diagnosis connector
Hino-Bowie
Connect to the failure diagnosis Connecting cable

connector at the unit side.
SAPH311990100040
Setup layout
Layout
Chassis number and engine number

JP31199010401001
1. Engine type and engine number

(Example)
(1) Engine type and engine number are stamped at the left
Stamp position cylinder block when viewed from the cooling fan. For order
of parts, information of this number will facilitate
procedures smoothly.
Ex. J05E TA10101
SAPH311990100041
STANDARD VALUE 2–1
ENGINE
2 STANDARD VALUE 2
Specification
System drawing
(performance)
Engine Body................................................................ 2-2

Standard value........................................................ 2-2
Tightening torque .................................................... 2-2
Fuel System ................................................................ 2-2
Electrical...................................................................... 2-3
Standard value........................................................ 2-3
Intake ........................................................................... 2-3
Engine Mechanical ..................................................... 2-4
Standard value........................................................ 2-4
Tightening torque .................................................. 2-11
Exhaust...................................................................... 2-12
Cooling ...................................................................... 2-12
Standard value...................................................... 2-12
Lubrication ................................................................ 2-12
Standard value...................................................... 2-12
Starting and Charging.............................................. 2-14
Standard value (Alternator 50A) .......................... 2-14
Tightening torque (Alternator 50A) ....................... 2-15
Standard value (starter) ........................................ 2-15
Tightening torque (starter) .................................... 2-16
Turbocharger............................................................. 2-16
Standard value...................................................... 2-16
2–2 STANDARD VALUE
Engine Body
Standard value
JP31199020205001
MPa {kgf/cm2, lbf/in.2}
Repair Service
Inspection item Standard value Action
limit limit
Compression pressure 3.4-3.7 2.7

—
(Engine revolution per cylinder: 150 r/min) {35-38, 493-237} {28, 392}
Tightening torque
JP31199020205002
Unit:N⋅m{kgf⋅cm, lbf⋅ft}
Tightening area Tightening torque Remark
7.8 - 8.8
Starter B terminal
{80 - 110, 5.8 - 6.5}
3.3 - 4.4
Alternator B terminal
{33 - 45, 2.4 - 3.2}
Oil pan drain cock 41 {420, 30}
4.5 - 5.0
Radiator hose band
{45 - 50, 3.3 - 3.7}
Fuel System
Tightening torque
JP31199020205003
Unit : N⋅m{kgf⋅cm, lbf⋅ft}
Injector clamp 25 {250, 18}
Supply pump - Bearing holder case 28.5 {290, 21}
Bearing holder case - Pump drive 28.5 {290, 21}
Supply pump coupling flange mounting nut 63.7 {650, 47}
Injector harness 2.2 {22, 1.6}
Fuel filter air bleeding bolt 1.7 - 2.6 {17.3 - 23, 1.2 - 1.9}
Electrical
Standard value
JP31199020205018
Inspection item item item Standard value Remark

8 - 10mm {0.3152 - 0.394in.} Compression
Deflection (Reference push force 98N gauge (09444-
{10kgf, 22lbf}) 1210) is used.
When installing Belt tension
a new belt gauge (95506-
490 - 570 N
Tension 00090 Denso
{50 - 58 kgf, 110 - 128 lbf}
part No.) is
V-belt tension used.
adjustment 10 - 12mm {0.394 - 0.472in.} Compression
Deflection (Reference push force 98N {10kgf, gauge (09444-
22lbf}) 1210) is used.
At the time of Belt tension
inspection gauge (95506-
320 - 400 N
Tension 00090 Denso
{33 - 41 kgf, 72 - 90 lbf}
part No.) is
used.
Tightening torque
JP31199020205019

Starter mounting bolt 154 {1,570, 114}
Starter mounting nut 171.5 {1,750, 126}

Battery cable mounting nut 16 - 22 {165 - 225, 11 - 16}
Alternator through bolt 83 {850, 61}
E terminal bolt 3.2 - 4.4{33 - 45, 2 - 3}
Fixing bolt at brace 51{520, 38}
Outside B terminal mounting nut 3.2 - 4.4{33 - 45, 2 - 3}
Through bolt 7.8 - 9.8{80 - 99, 6 - 7}
Intake
Tightening torque
JP31199020205005

Intake manifold mounting bolt 28.5 {290, 21}

Engine Mechanical
Standard value
JP31199020205006
Unit : mm {in.}
Inspection item Standard value Repair limit Service limit Action
IN 0.30 {0.0118} — —
Valve clearance (cold)
EX 0.45 {0.0177} — —
0.01 - 0.08
Cylinder liner protrusion — —
{0.003 - 0.003}
Cylinder liner flange width 8 {0.314} — —
Cylinder block flange width 8 {0.314} — —
117 - 117.008
A — —
{4.6063 - 4.6066}
117.008 - 117.014
Cylinder block inner diameter B — —
{4.6066 - 4.6068}
117.014 - 117.022
C — —
{4.6068 - 4.6072}
116.982 - 116.99
A — —
{4.6056 - 4.6059}
116.99 - 116.996
Cylinder liner outer diameter B — —
{4.6059 - 4.6061}
116.996 - 117.004
C — —
{4.6061 - 4.6064}
Clearance between cylinder liner and 0.01 - 0.026
— —
cylinder block {0.0003 - 0.0010}
Cylinder
112.15
Cylinder liner inner diameter 112 {4.4094} — Replace
{4.4154}
liner
Piston outer diameter

111.9±0.006
(Pin hole 23mm{0.9 in.} above the lower — —
{4.4089±0.0002}
end of the skirt Square direction)
Cylinder
0.088 - 0.112 Liner
Piston clearance — —
{0.0034 - 0.0044} Replace
piston
Approx. 11.5
Top — —
{0.4527}
Free joint clearance
Approx. 14
Second — —
{0.5512}
0.3 - 0.40
Top — 1.5 {0.0591}
{0.0118 - 0.0157}
Gap between ends 0.75 - 0.9 Replace

Second — 1.2 {0.0472}
Piston of piston ring {0.0295 - 0.0354} piston ring
ring 0.15 - 0.3
Oil — 1.2 {0.0472}
{0.0059 - 0.0118}
–0.1
Top 2.5 {0.0984} —
{–0.0039}
Ring width B –0.1 Replace

Second 2 {0.0787} —
dimension {–0.0039} piston ring
–0.1
Oil 4 {0.1574} —
{–0.0039}
+0.2
Top 2.5 {0.0984} —
{+0.0079}
+0.2 Replace
Piston ring groove Second 2 {0.0787} —
{+0.0079} piston
+0.1
Oil 4 {0.1574} —
{+0.0039}
0.09 - 0.13
Top — —
{0.0035 - 0.0051}
Clearance between Replace
0.04 - 0.08
piston ring and Second — — piston ring
{0.00016 - 0.0031}
Piston piston ring groove or piston.
0.02 - 0.06
Oil — —
{0.0008 - 0.0024}
–0.04 Replace
Piston pin outer diameter 37 {1.4567} —
{–0.0015} piston pin
+0.05 Replace
Piston boss inner diameter 37 {1.4567} —
{+0.0020} piston
–0.002T - 0.025L
{0.0000 - 0.0010} Replace
Clearance between piston pin 0.05
(T : Tightening — piston pin
and piston boss {0.0020}
allowance, or piston
L : Clearance)
Replace
+0.1
Connecting rod bushing inner diameter 37 {1.4567} — connecting
{0.0039}
rod bushing
Replace
piston pin
0.015 - 0.036 0.08
Connecting rod bushing oil clearance — or
{0.0006 - 0.0014} {0.0031}
connecting
rod bushing
Replace the
63.8
Crank pin outer diameter 65 {2.5590} — crankshaft.
{2.5118}
(Note 1)
Thickness of connecting rod

2.0 {0.0787} — —
bearing
Replace
bearing for
0.031 - 0.082
Connecting rod oil clearance 0.2 {0.0079} — clearance of
{0.0012 - 0.0032}
0.3 or more
(Note 2)
Crank
78.8 Replace
Crank journal outer diameter 80{3.1496} —
{3.1024} shaft (Note
1)
Cranks Thickness of main bearing 2.5 {0.2342} — —
haft
Replace
0.051 - 0.102
Crankshaft oil clearance 0.2 {0.0079} — bearing
{0.0020 - 0.0040}
(Note 2)
+1.00 Replace
Center journal width 36 {1.4173} —
{+0.039} crankshaft.
Thickness of thrust bearing 2.5 {0.2342} — —
Replace
0.050 - 0.219 0.50 1.219 thrust
Crankshaft end play
{0.0020 - 0.0086} {0.0020} {0.0480} bearing or
crankshaft
0.15 Ground to
Crankshaft runout — —
{0.0059} under-size
+0.8 Replace
Crank pin width 34 {13.386} —
{+0.0315} crankshaft
Note 1 : Correction with re-grinding for eccentric wear of 0.10 or more. Re-grinding for wear of 0.20 or
more. Replace crankshaft for wear of 1.20 or more.
Note 2 : Under-size bearing values are 0.25, 0.50, 0.75 and 1.00.
Replace
–0.8
Connecting rod large end width 34 {1.3386} — connecting
{–0.0315}
rod
Replace
0.20 - 0.52 connecting
Connecting rod end play — 1.0 {0.0394}
{0.0079 - 0.0205} rod or
crankshaft
Camshaft journal outer –0.15 Replace
40 {1.5748} —
diameter {–0.0059} camshaft
Bearing
Camshaft bearing inner +0.15
40 {1.5748} — Replacemen
diameter {+0.059}
t
Replace
Camshaft bearing oil 0.020 - 0.063
— — camshaft or
Clearance {0.0008 - 0.0025}
bearing
IN 50.067 {1.9711} — –0.08 Replace

Camsha Cam height
EX 52.104 {2.0513} — {–0.0031} camshaft
ft
IN 8.067 {0.3175} — –0.08 Replace
Cam lift
EX 10.104 {0.3978} — {–0.0031} camshaft
Camshaft journal width

33 {1.2992} — —
(Rear journal)
0.100 - 0.178 Replace

Camshaft end play — —
{0.0039 - 0.0070} camshaft
0.04 Replace
Camshaft runout — 0.1 {0.039}
{0.0016} camshaft
–0.08 Replace
Rocker shaft outer diameter 22 {0.8661} —
{–0.0031} rocker shaft
+0.08 Replace rocker

Rocker arm bushing inner diameter 22 {0.8661} —
{+0.0031} arm bushing
0.030 - 0.101 0.15

Rocker arm oil clearance —
{0.00012 - 0.0040} {0.0059}
IN 7 {0.2756} — — Replace
Valve stem outer diameter
EX 7 {0.2756} — — valve
IN 7 {0.2756} — — Replace
Valve guide inner diameter
EX 7 {0.2756} — — valve guide
0.023 - 0.058
IN — — Replace
Oil clearance between valve guide {0.0009 - 0.0020}
valve or
and valve stem 0.050 - 0.083
EX — — valve guide
{0.0020 - 0.0033}
0.55 - 0.85
IN — 1.1 {0.0433} Replace
{0.0217 - 0.0335}
Valve sink valve and
1.15 - 1.45
EX — 1.7 {0.0669} valve seat
{0.0453 - 0.0571}
IN 30° Allowable angle 30° - 30°35'

Valve seat angle
EX 45° Allowable angle 45° - 30°30'
Correction
IN 30° Allowable angle 29°30 - 45°
Valve face angle
EX 45° Allowable angle 44°30 - 45°
44.8
Set length — —
{1.764}
129N
Set load — —
{13.1kgf, 29lbf}
Inner
64.6 –3.0 Replace
Free length —
{2.5433} {–0.3543} spring
2.0 Replace
Squareness — —
Valve {0.0787} spring
spring 46.8
Set length — —
{1.8252}
314N
Set load — —
{32.0kgf, 70lbf}
Outer
75.7 –3.0 Replace
Free length —
{2.9803} {–0.3543} spring
2.0 Replace
Squareness — —
{0.0787} spring
0.030 - 0.167 0.30

Crank - Main idle —
{0.0012 - 0.0066} {0.0012}
Main idle - Pump 0.032 - 0.096 0.10
—
drive idle {0.0013 - 0.0038} {0.00393}
Pump drive idle - 0.020 - 0.083 0.10

—
Pump drive {0.0008 - 0.0033} {0.00393}
Backla 0.030 - 0.113 0.30 Gear

Main idle - Sub-idle —
sh {0.0012 - 0.0044} {0.0012} replacement
0.030 - 0.113 0.30

Sub-idle - Oil pump —
{0.0012 - 0.0044} {0.0012}
0.050 - 0.218 0.30
Sub-idle - Cam idle —
{0.0020 - 0.0086} {0.0012}
0.030 - 0.253 0.30

Cam idle - Cam —
{0.0012 - 0.0100} {0.0012}
Shaft outer diameter 57 {2.2441} — —
Bushing inner
57 {2.2441} — —
diameter
Timing Replace
Clearance between 0.030 - 0.090 0.20
gear — shaft or
Main shaft and bushing {0.0012 - 0.0084} {0.0079}
bushing
idle
Gear width 44 {1.7322} — —
Shaft length 44 {1.7322} — —
Replace
0.114 - 0.160 0.30
End play — shaft or
{0.0045 - 0.0063} {0.0012}
gear
Bushing inner
50 {1.9685} — —
diameter
Replace
— shaft or
Sub- shaft and bushing {0.0010 - 0.0030} {0.0079}
bushing
idle
Gear width 22 {0.8661} — —
Shaft length 22 {0.8661} — —
Replace
0.040 - 0.120 0.30
End play — shaft or
{0.0016 - 0.0047} {0.0012}
gear
Bushing inner
34 {1.3386} — —
diameter
Replace
— shaft or
Cam shaft and bushing {0.0002 - 0.0030} {0.0079}
bushing
idle
Gear width 22 {8.6614} — —
Shaft length 22 {8.6614} — —

Replace
0.040 - 0.120 0.30
End play — thrust plate
Timing {0.0016 - 0.0047} {0.0012}
or gear
gear
Bushing inner
34 {1.3386} — —
diameter
Replace
Pump Clearance between 0.025 - 0.075 0.10
— shaft or
drive shaft and bushing {0.0002 - 0.0030} {0.0039}
bushing
idle
Gear width 28.5 {1.1220} — —
Shaft length 28.5 {1.1220} — —
0.016 - 0.22
End play — —
{0.0006 - 0.0087}
Grinding is
inhibited
Longitudinal because
direction 0.06 backlash
Flatness under cylinder head 0.20
{0.0024} — between
Flatness above cylinder block {0.0079}
Square direction cam idle –
0.03 {0.0012} sub-idle
gears is
changed.
0.15
Surface runout of flywheel — —
{0.0060}
Camshaft gear mounting bolt — — 31 {1.2205} Replacement
Bearing cap bolt (Crankshaft mounting) — — 108 {4.2520} Replacement
Connecting rod bolt — — 68.0 {2.6772} Replacement
187.5
long — — Replacement
{7.3819}
156.5
Head bolt middle — — Replacement
{6.1614}
126.5
short — — Replacement
{4.9803}
Valve timing
Exhaust valve open (before BDC) 54°
Exhaust valve close (after TDC) 13°
Intake valve open (before TDC) 14°
Intake valve close (after BDC) 30°
Tightening torque
JP31199020205007

Crankshaft pulley mounting bolt 118 {1,203, 87}
Head cover mounting bolt 28.5 {290, 21}
Camshaft bearing cap mounting bolt 28.5 {290, 21}
Union bolt of leakage pipe 13.5 {135, 10}
Injector harness mounting nut 28 {290, 21}
Camshaft gear mounting bolt 59 {600, 44}+90°
Rocker arm and crosshead adjusting screw lock

25 {250, 18}
nut
Rocker arm support bolt 59 {600, 44}
Head bolt 59 {600, 44}+90°+90°
Cam idle gear shaft mounting bolt 108 {1,100, 80}
Main bearing cap mounting bolt 69 {700, 51}+90°+45° Refer to the main text.
Connecting rod cap mounting bolt 69 {700, 51}+90°+45°

Oil check valve 22 {220, 16}
Sub-idle gear shaft mounting bolt 108 {1,100, 80}
Main idle gear shaft mounting bolt 172 {1,750, 127}
Flywheel mounting bolt 186 {1,900, 137}
196 {2,000, 145} M16
Flywheel housing mounting bolt 55 {560, 41} M10
36 {370, 27} M8
Flywheel housing stay - Flywheel housing 171.5 {1, 750} M14
Rear end plate torx bolt 55 {560, 41}
Supply pump bearing case mounting bolt 28.5 {290, 21}

Exhaust
Tightening torque
JP31199020205008
Exhaust manifold mounting stud bolt 30 {300, 22}
Exhaust manifold mounting nut 53 {540, 40}
Cooling
Standard value
JP31199020205009
Standard Repair Service

Inspection item Action
value limit limit
74.5 - 78.5°C
Thermostat valve open temperature {166.1 - — — Replacement
173.3°F}
10mm
Thermostat valve lift
{0.3937 in.} or — — Replacement
(Set temperature 95 °C)
more
Lubrication
Standard value
JP31199020205010
Unit : mm {in.}
Repair Service
limit limit
39kPa
Hydraulic alarm switch operation pressure {0.4kgf/cm2, — —
5.66lbf/in.2 }
Repair Service
limit limit
Outer diameter of drive gear 54 {2.1260} — —

Cylinder block side
54 {2.1260} — —
Oil pump chamber inner diameter
Clearance between drive gear and 0.100 - 0.202 0.30 Replace drive
—
cylinder block {0.0039 - 0.0080} {0.0118} gear or oil pump
Drive gear width 28.5 {1.1220} — —
Cylinder block side

28.5 {1.1220} — —
Depth of oil pump chamber
0.049 - 0.113 0.15 Replace drive

Drive gear end play —
{0.00193 - 0.0044} {0.059} gear or oil pump
Outer diameter of driven gear shaft 18 {0.7087} — —
Cylinder block hole diameter 18 {0.7087} — —
Clearance between drive gear shaft outer

Oil 0.040 - 0.099 Replace drive
diameter and bushing inner diameter at — —
pump {0.0016 - 0.0039} gear or bushing
cylinder block side
Cylinder block hole diameter 18 {0.7087} — —
Clearance between driven gear shaft

0.030 - 0.075 Replace oil
outer diameter and cylinder block hole — —
{0.0012 - 0.0030} pump
diameter
Inner diameter of driven gear bushing 18 {0.7087} — —
Clearance between driven gear shaft Replace oil

0.040 - 0.083 0.15
outer diameter and gear bushing inner — pump or
{0.016 - 0.0033} {0.059}
diameter bushing
Backlash between drive gear and driven 0.072 - 0.277 0.30 Replace oil
—
gear {0.0028 - 0.0109} {0.0118} pump
Tightening torque
JP31199020205011

Oil pan mounting bolt 30 {300, 22}
Oil strainer 31 {320, 23}
Oil pan drain cock 41 {420, 30}
Oil pump mounting bolt 28.5 {290, 21}
M14 24.5±4.9 {250±50, 18±4}
M20 24.5±4.9 {250±50, 18±4}

Oil circuit spring plug
Oil cooler M22 29.4±4.9 {300±50, 22±4}
M24 34.3±4.9 {350±50, 25±4}
Coolant drain plug 44.1±4.9 {450±50, 33±4}
Oil cooler case assembly mounting bolt 24.5±4.9 {250±50, 18±4}
Starting and Charging

Standard value (Alternator 50A)
JP31199020205012
Standard Service
Inspection item Repair limit Action
value limit
Resistance between stator coil terminals (for

0.22 - 0.26Ω — — Replacement
2 phases)
1MΩor
Resistance between stator coil core and coil — — Replacement
more
Resistance of feed coil 5.6 - 6.8Ω — — Replacement
1MΩor
Resistance between feed coil core and coil — — Replacement
more
25mm 24.98mm
Front —
Shaft outer diameter of {0.9843 in.} {0.9835 in.}
Replacement
rotor assembly 17mm 16.98mm
Rear —
{0.6693 in.} {0.6685 in.}
Forward Approx.
— —
Resistance between resistance value 10Ω
Replacement
diode and rectifier holder Reverse
Infinite — —
resistance value
Forward Approx.
Resistance between — —
resistance value 10Ω
regulator terminals F — Replacement
Reverse
E Infinite — —
resistance value
Tightening torque (Alternator 50A)

JP31199020205013

Bearing cover mounting bolt 1.9 - 2.5 {20 - 25, 1 - 2}
Pulley mounting nut 127 - 157 {1, 300 - 1, 600, 94 - 116}
Feed coil - Rear bracket 2.9 - 3.9 {30 - 39, 2 - 3}
Heat sink mounting bolt 1.9 - 2.5 {20 - 25, 1 - 2} Screw lock is
Regulator mounting bolt 1.9 - 2.5 {20 - 25, 1 - 2} used
Inside B terminal mounting nut 4.9 - 5.9 {50 - 60, 4 - 4}
Front side - Rear side mounting bolt 7.8 - 9.8 {80 - 99, 6 - 7}
Coupler holder mounting bolt 1.9 - 2.5 {20 - 25, 1 - 2}
Cover mounting bolt 3.3 - 4.4 {34 - 44, 2 - 3}
Standard value (starter)

JP31199020205014
Unit : mm {in.}
Standard
Inspection item Service limit Action
value
Resistance between coil lead Replace yoke

Yoke — 1kΩor less
wire and yoke assembly
assembly
Brush length 18 {0.7087} 13 {0.5118} or less Replace brush
Resistance between
1MΩor more 1kΩor less
commutator and core
Replace armature
Commutator outer diameter 36{1.4173} 34 {1.1458} or less
Armature assembly
Shaft outer diameter A 12 {0.4724} 11.98 {0.4717} or less
assembly
Shaft outer diameter B 9 {0.3643} 8.98 {0.3535} or less
0.5 - 0.8
Undercut depth 0.2{0.0079} or less Correction
{0.0197}
Resistance between holder Replace holder

Holder — 1kΩor less
and plate assembly
assembly
Brush length 18 {0.7087} 13 {0.5118} or less Replace brush
Shaft A 26 {1.0236} 25.90 {1.0197} or less

assembly Replace shaft
outer B 12.1 {0.4764} 12.04 {4.7401} or less assembly
diameter
Clutch assembly inner sleeve outer

25 {0.9843} 24.90 {0.9803} or more Replacement
diameter
Metal bushing inner diameter of pinion case 25 {0.9843} 25.2 {0.9921} or more Replace brush
Metal bushing inner diameter of center Replace center

26 {1.02362} 26.2 {1.0315}
bracket bracket
Standard
Inspection item Service limit Action
value
Metal bushing inner diameter of shaft Replace shaft

9 {0.3543} 9.2 {0.3622}
assembly assembly
Replace
Bearing housing inner diameter of rear
28 {1.1024} 28.1 {1.1063} or more commutator end
bracket
frame
Start Between C terminal and M

0.12 - 0.15Ω — Replace start
magnet terminal (P coil)
magnet switch
switch Between C terminal and body
1.13 - 1.25Ω — assembly
assembly (H coil)
Tightening torque (starter)

JP31199020205015
Unit : N⋅m{kgf⋅cm, lbf⋅tt}
C lead wire mounting bolt 2 - 3 {19 - 25, 1 - 2}

M lead wire mounting nut 12.3 - 15.2 {126 - 154, 9 - 11}
Commutator end frame mounting through bolt 15.7 - 17.6 {160 - 179, 12 - 13}
Brush holder set bolts of commutator end frame 3.6 - 4.9 {37 - 49, 3 - 4}
Start magnet switch assembly mounting bolt at

3.6 - 4.9 {37 - 49, 3 - 4}
pinion case
Pinion case switch set bolts 14 - 16 {140 - 160, 10 - 12}
Turbocharger
Standard value
JP31199020205016
Unit : mm {in.}
Standard
Inspection item Repair limit Service limit Action
value
Axial direction 0.1 {0.0039} — —

Turbine shaft play
Diameter direction 1.0 {0.0397} — —
Tightening torque
JP31199020205017
Unit : N⋅m{kgf⋅cm, lbf⋅tt}
Turbocharger mounting nut 56 {570, 41}

PARTS TO BE PREPARED 3–1
ENGINE
3 PARTS TO BE PREPARED
Special tool (SST)
3
Engine Body................................................................ 3-2
Special tool ............................................................. 3-2
Fuel System ................................................................ 3-2
Lubricant, etc. ........................................................ 3-2
Electrical...................................................................... 3-2
Special tool ............................................................. 3-2
Engine Mechanical ..................................................... 3-3
Special tool ............................................................. 3-3
Instruments ............................................................. 3-6
Lubricant, etc. ........................................................ 3-6
Lubrication .................................................................. 3-6
Special tool ............................................................. 3-6
Lubricant, etc. ........................................................ 3-6
Starting and Charging................................................ 3-7
Jig (reference dimensional drawing for manufacture)
................................................................................ 3-7
Instruments ............................................................. 3-8
Lubricant, etc. ........................................................ 3-8
Turbocharger............................................................... 3-8
Special tool ............................................................. 3-8
Engine Failure Diagnosis........................................... 3-9
Special tool ............................................................. 3-9
3–2 PARTS TO BE PREPARED
Engine Body
Special tool
JP31199030901001
Shape Part No. Description Remark
09491–1010 Wire rope For engine lifting
09552–1030 Compression gauge adapter
Fuel System
Lubricant, etc.
JP31199030901002
Name Remark
Guide bolt (9069-08180) For supply pump positioning
Electrical
Special tool
JP31199030901003
Shape Part No. Name Remark
For V–belt tension

09444–1210 Compression gauge
adjustment
95506–00090 For V–belt tension

Belt tension gauge
(Denso part No.) adjustment
Engine Mechanical
Special tool
JP31199030901004
For crankshaft front oil seal

09420–1731 Oil seal puller
removal
For crankshaft front oil seal

09407–1030 Oil seal press
press-fit
For assembly/disassembly
09433–1070 Eye bolt
of cylinder head
09470–1170 Valve spring press
of valve spring retainer
09471–1520 Guide For valve guide press-fit
09472–1210 Bar For nozzle seat clamping
For nozzle seat clamping

9800–06100 Steel ball
(together with 09472–1210)
09431–1020 Valve lapping tool For valve adjustment

For valve stem seal

09472–2100 Bar
mounting
For removal and inspection

09420–2100 Cylinder liner puller
of cylinder liner
09442–1011 Piston ring expander
of piston ring
For mounting of connecting

rod small end bushing
9191–08252 Bolt
(together with 09402–1480
or 09402–1540)
09402–1530 Press sub-assembly of connecting rod small end
bushing
of connecting rod small end
9233–10360 Wing nut
bushing (together with
09402–1530)
of connecting rod small end
09481–1130 Guide
bushing (together with
09402–1530)
09402–1540 Spindle of connecting rod small end
bushing
For mounting of connecting

09481–1540 Guide rod small end bushing
(together with 09402–1540)
09441–1370 Piston ring holder For piston mounting
09481–1340 Guide
of flywheel
For crankshaft rear oil seal

09420–1742 Oil seal puller
removal
09420–1100
For main/sub idle gear
Sliding hammer assembly and cam idle gear
09420–1442
shaft removal
09411–1300 Socket wrench
of Torx bolt
For crankshaft rear oil seal

09407–1040 Oil seal press
press-fit
09471–1490 Guide For insertion of cylinder liner
09472–1620 Tool For cooling jet repair
For cooling jet inspection

9001–24262 Check bolt
and adjustment
For cooling jet inspection

09470–1280 Tool assembly
and adjustment
Instruments
JP31199030901005
Name Remark
Micrometer For measurement of part outer diameter
Cylinder gauge For measurement of part inner diameter
Thickness gauge For measurement of each clearance

Dial gauge For measurement of parts
Lubricant, etc.
JP31199030901006
Name Remark
Liquid gasket (Threebond TB1207B or equivalent :

For sealing of parts
Black)
Liquid gasket (Threebond TB1207D or equivalent :

Silver)
Liquid gasket (Threebond TB1211 or equivalent : White) For sealing of parts

Red lead Valve adjustment
Dye penetrant For inspection of crack
Lubrication
Special tool
JP31199030901007
09503–1110 Oil filter wrench
Lubricant, etc.
JP31199030901008
Name Remark
Liquid gasket (Threebond TB1207D or equivalent :

Silver)
Liquid gasket (Threebond TB1211 or equivalent : White) For sealing of parts

Starting and Charging

Jig (reference dimensional drawing for manufacture)
JP31199030901009
This is used for assembly of bearing. Reference dimensions are shown in the figures below:
Jig A (Roller bearing insertion jig) Jig B (Support jig) Unit : mm{in.}
φ23{20.827} φ25{0.984}
1C{0.039}
35{1.378}
50{1.964}
70{2.756}
50{1.964}
1C{0.039}
10 - 20 φ50{1.969}
+0.5{0.0196} {0.394 - 0.787}
φ19{0.748}
0
φ30{1.181}
Jig C Jig D
φ34{1.339} φ41{1.614}
20{0.787} 20{0.787}
40{1.575} 40{1.575}
10{0.394} 10{0.394}
φ54{2.126} φ64{2.520}
φ60{2.362} φ70{2.756}
SAPH311990300034
Instruments
JP31199030901010
Alternator
Name Remark
Circuit tester For measurement of parts
Micrometer For measurement of parts
Regulator checker (G&M Machinery ICD-101D or

For inspection of regulator
equivalent)
Starter
Name Remark
Circuit tester For measurement of parts
Micrometer For measurement of part outer diameter
Growler tester For inspection of armature
Cylinder gauge For measurement of part inner diameter
Lubricant, etc.
JP31199030901011
Name Remark
Kyodo Yushi Multemp AC-N For lubrication of parts
Nisseki Mitsubishi Pyroknock #2 For lubrication of parts
Turbocharger
Special tool
JP31199030901012
09444-1800 Tool assembly

Engine Failure Diagnosis

Special tool
JP31199030901016
• Operating
system(OS):Windows95,
Windows98(IE5.0 or
later),
Windows2000(SP3,
IE5.0 or later),
WindowsXP(SP1a, IE6.0
– Personal computer (DOS-V) or later)
• CPU and memory:
Conditions that assure
operation of the above
operating system
• Display: 800 x 600, 256
colors or more
Failure diagnosis software

HinoDX
(CD-ROM)
Used together with the

cable between the vehicle
09121–1040 Hino-Bowie (Interface box)
and Hino-Bowie (09042-
1220)
This is installed as
interruption between vehicle
09049–1080 Signal check harness harness and the ECU.
Tester inspection is allowed
in energized status.
ENGINE ASSEMBLY/DISASSEMBLY 4–1
ENGINE
4 ENGINE ASSEMBLY/DISASSEMBLY
Service procedure
Overhaul item
Inspection Before Service ......................................... 4-2

Measurement of compression pressure ................. 4-2 4
Engine Body................................................................ 4-4
Removal .................................................................. 4-4
Installation............................................................... 4-6
Work after installation ............................................. 4-6
4–2 ENGINE ASSEMBLY/DISASSEMBLY
Inspection Before Service

Measurement of compression pressure
JP31199040702001
NOTICE • Measure the compression pressure before

disassembly of the engine and record the
result. Regular measurement of the
compression pressure can tell the engine
status.
1. Preparation before measurement

(1) Charge the battery completely.
(2) Check the valve clearance and adjust it when exceeding
the standard value.
(3) Warm the engine and set the water temperature to 80
°C{176°F}.
(4) Remove the air cleaner.
(5) Remove the head cover.
(6) Remove all injectors.
(7) To prevent spread of engine oil, attach a jig which cuts a head
cover in half. (Cut it so that the camshaft may be covered.
2. Measurement
(1) Attach a special tool to the nozzle sheet of the cylinder
where the compression pressure is measured with nozzle
clamp and clamp fixing bolts.
Special tool : Compression gauge adapter

Special
tool
Engine Part No. Parts tightened
Insert in the injector
09952-1110
SAPH311990400001
mounting area
09552-1030
Adjusting to screw size of
(3/4-16 UNF)
air gauge, the adapter
09552-1060
which it selects
(W16 ridges 18)
(2) Turn the starter and measure the compression pressure.
! CAUTION • Do not operate the starter for 15 seconds or

more.
• Since the air cleaner is removed, prevent
entry of dirt.
(3) Measure the compression pressure of each cylinder

continuously.
Engine revolution 150r/min {rpm}
Compression pressure:
Unit MPa {kgf/cm2,lbf/in.2}
Standard value 3.4 - 3.7 {35 - 38 ,493 - 537}

Service limit 2.7 {28, 392}
Difference between
0.3{3, 44} or less
cylinders
(4) If the compression pressure is the service limit or less or if

the difference between cylinders is over the standard
value, overhaul the engine.
(5) After measurement, reassemble the removed parts.
Engine Body
Removal
JP31199040702002
1. Preliminary work before removal of engine

(1) Place the vehicle on a level ground.
(2) Block tires with scotch.
(3) Remove the battery cable from the battery minus terminal.
2. Drain of coolant and engine oil

Right side of engine
(1) Drain coolant from the radiator drain cock and the oil
cooler drain plug.
NOTICE • Removal of the filler cap facilitates quick

drain.
• Connection of an appropriate hose to the oil
cooler drain pipe facilitates drain of coolant
Oil cooler drain plug
without spread.
SAPH311990400002
! CAUTION • To prevent burn, drain coolant after the

temperature is sufficiently low.
• To dispose coolant, observe the specified
method (waste disposal) or the method with
attention to environment.
(2) Drain engine oil from the oil pan drain plug as required.
! CAUTION • To prevent burn, drain coolant after the

temperature is sufficiently low.
• Dispose coolant according to the specified
method (waste treatment) or with a method
considering the environment.
3. Removal of intake hose, intercooler hose and exhaust

pipe
(1) Loosen the clamp and remove the intake hose.

Intake manifold
(2) Remove nuts and remove the exhaust pipe.
! CAUTION • Close the opening of the intake manifold with

a packing tape to prevent entry of dirt inside
Cylinder head
Cover
the engine.
SAPH311990400003
4. Disconnection of fuel hose
(1) Remove the fuel hoses (feed side and return side). Wrap
the removed hose with a plastic sheet with its end facing
upward to prevent spill of fuel.
! CAUTION • Wipe spilled fuel with a rag.
SAPH311990400004
5. Disconnection of water, engine oil pipes, etc.

Fan shroud Cooling
Fan (1) Disconnect the hose between the radiator and the engine.
(2) Disconnect the car heater pipe.
(3) Disconnect the oil filter hose.
Connector
(4) Disconnect the fuel filter hose.
Clip ! CAUTION • Wipe off spilled water and engine oil with
waste.
SAPH311990400005
6. Engine lifting (Lifting the engine single unit)

Within 30
Shackle (1) Place a commercially available shackle and a special tool
Shackle
wire rope with the engine hanger.
Special tool : 09491–1010 Wire rope
(2) Keep a little slack of the wire rope.
! CAUTION • Keep the wire inclination 30° from the vertical

line.
SAPH311990400006
(3) When the wire is completely tense, make sure that the
Image drawing wire is firmly engaged with the engine hanger. Then, lift
the engine slowly.
! CAUTION • Work carefully so that the engine may not

come in contact with the frame and others.
SAPH311990400007
Installation
JP31199040702003
1. Connection of fuel hose

(1) Insert a fuel hose and fix it with a hose band.
Work after installation

JP31199040702004
1. Inspection of engine oil
(1) Make sure that the drain cock is closed.

(2) Pour engine oil.
(3) Check the amount of oil with an oil level gauge.
Engine oil amount (L{us gal})
Oil pan Oil filter and etc
Approx. 18{4.76} Approx. 2.5{0.66}

Filler cap
SAPH311990400008
! CAUTION • Please use Hino genuine engine oil
Multi grade SAE #10W-30
Single grade SAE #30
2. Air bleeding of fuel system

Air bleeding bolt
Priming pump (1) Prepare a rag to receive fuel at the end of the drain valve.
(2) Loosen the air bleeding plug of the fuel filter.
(3) The priming pump is moved front and back.
(4) Move the pump until fuel without bubble comes out from
the drain valve.
Drain valve (5) Tighten the air bleeding bolt.
Tightening torque :
1.7 - 2.6 N⋅m {17.3 - 23 kgf⋅cm, 1.2 - 1.9 lbf⋅ft}
SAPH311990400009
(6) Move the priming pump again until it becomes heavy.
! CAUTION • After work, wipe off spilled fuel. After start of

the engine, make sure that there is no fuel
leak.
FUEL SYSTEM 5–1
ENGINE
5 FUEL SYSTEM
Setup layout
Layout
Fuel System ................................................................ 5-2

Fuel system diagram............................................... 5-2
Part layout .............................................................. 5-3
Fuel filter drain (on machine main unit)................... 5-5
Replacement of fuel filter element
5
(on machine main unit) ........................................... 5-6
Replacement of supply pump ................................ 5-7
Inspection of supply pump ...................................... 5-9
Replacement of injector ........................................ 5-10
Inspection of injector ............................................. 5-11
Replacement of common rail ................................ 5-12
Inspection of common rail ..................................... 5-12
5–2 FUEL SYSTEM
Fuel System
Fuel system diagram
JP31199050402001
Feed pipe Injection pipe

Flow damper
Injector
Common rail
Leakage pipe
Pressure limiter
Overflow pipe Through feed pipe
Supply pump
Fuel tank
Fuel filter
SAPH311990500001
FUEL SYSTEM 5–3
Part layout
JP31199050402003
SAPH311990500034
11195 Nozzle clamp holder 23670 Injector

11334 Bearing holder case 23810 Common rail assembly
11491A Common rail bracket 9645A O–ring*
22100 Supply pump 9851A O–ring*
Tightening torque
22825 63.7N⋅m {650 kgf⋅cm, 47lbf⋅ft} 9068-08320 28.5N⋅m {290kgf⋅cm, 21lbf⋅ft}
900124 108N⋅m {1,100 kgf⋅cm, 80lbf⋅ft} 9068-08400 28.5N⋅m {290kgf⋅cm, 21lbf⋅ft}
900124A 25N⋅m {250 kgf⋅cm, 18lbf⋅ft} 9068-08850 28.5N⋅m {290kgf⋅cm, 21lbf⋅ft}
9068-08250 28.5N⋅m {290kgf⋅cm, 21lbf⋅ft}
5–4 FUEL SYSTEM
SAPH311990500035
23081 Leakage pipe 23816A Through feed pipe

23711 Injection pipe 23816B Through feed pipe
23712 Injection pipe 9659B Gasket*
23713 Injection pipe 9659C Gasket*
23714 Injection pipe 9659D Gasket*
23783A Fuel pipe 9659E Gasket*
23816 Through feed pipe

Service procedure
Replacement procedure item
FUEL SYSTEM 5–5
Fuel filter drain (on machine main unit)

JP31199050704001
1. Prepare a water container under the drain pipe.

Air bleeding bolt
Priming pump
2. Loosen the fuel filter air bleeding bolt and the drain valve.
Discharge water at the bottom of the fuel filter case.
! CAUTION • Since discharged water contains fuel,

observe the local disposal procedure for
Drain valve disposal.
3. Close the drain valve.

SAPH311990500006
4. Start the priming pump and bleed air from the system.
! CAUTION • Make sure that the fuel filter air bleeding bolt
is loose.
5. Tighten the fuel filter air bleeding bolt.

Tightening torque :
1.7 - 2.6 N⋅m {17.3 - 23 kgf⋅cm, 1.2 - 1.9 lbf⋅ft}
! CAUTION • After work, wipe off spilled water or fuel.

After start of the engine, make sure that there
is no fuel leak.
5–6 FUEL SYSTEM
Replacement of fuel filter element (on

machine main unit)
JP31199050704002
1. Removal of water cup
(1) Refer to "Drain of the fuel filter" and discharge water from
Fuel filter head Fuel filter element the fuel filter.
(2) Remove the water cup of the fuel filter.
O-ring O-ring
2. Removal of fuel filter element
Water cup (1) Remove the fuel filter element.
! CAUTION • Since the filter contains diesel oil, prepare a
SAPH311990500007
tray.
3. Installation of fuel filter element

(1) The soiling and the foreign material of the clamp face are
removed.
! CAUTION • The fuel is applied to the O-ring surface of

fuel filter element.
(2) After the O-ring of the fuel filter element touches the fuel
filter head, turn by 3/4 to 1⋅1/2 and install the fuel filter
head.
! CAUTION • The fuel is applied to the O-ring surface of the

water cup.
(3) After the O-ring of the water cup touches the fuel filter
element, turn by 1/2 to 3/4 and install the fuel filter
element.
(4) Tighten the fuel filter drain valve.
! CAUTION • Element is not reused.
(5) Start the priming pump and bleed air from the system.
! CAUTION • Make sure that the fuel filter air bleeding bolt
is loose.
(6) Tighten the fuel filter air bleeding bolt.

Tightening torque :
1.7 - 2.6 N⋅m {17.3 - 23 kgf⋅cm, 1.2 - 1.9 lbf⋅ft}
! CAUTION • After work, wipe off spilled fuel. After start of

the engine, make sure that there is no fuel
leak.
FUEL SYSTEM 5–7
Replacement of supply pump

JP31199050704003
1. Compression upper dead center setting of No.1 cylinder

(1) Turn the crankshaft counterclockwise when viewed from
the flywheel. Set the timing mark in the flywheel housing
inspection window to "1".
Flywheel
(2) Remove the inspection window plug in the bearing holder
1 case of the supply pump. Tighten the guide bolt (9069-
Flywheel housing 08180) very gently and make sure that the bolt seating
comes in close contact with the bearing holder.
! CAUTION • If it is raised, there must be contact other than

SAPH311990500008 the stopper key for the coupling flange. Do
not tighten hard.
Close
contact
Raised
SAPH311990500009
2. Removal of supply pump

(1) Remove the fuel pipe connected to the supply pump.
Supply pump
! CAUTION • Do not remove pipes A.
(2) Remove the supply pump at the bearing holder case.

Pipe A
(3) Remove the drive gear using the special tool designed for
that purpose.
Special tool : 09650-1101 Bearing puller
SAPH311990500010
3. Assembly of supply pump and bearing holder case

O-ring (1) Fit a new O-ring to the supply pump and install the
Supply pump
bearing holder case.
Tightening torque : 28.5 N⋅m {290 kgf⋅cm, 21 lbf⋅ft}
Bearing holder case
Bolt
SAPH311990500011
5–8 FUEL SYSTEM
(2) Secure the supply pump, install the injection pump drive
gear on the shaft, and use a vice or similar to prevent
turning while tightening the nut.
! CAUTION • Do not use the guide bolt for stopper key of

the shaft.
SAPH311990500012
4. Installation of supply pump

(1) Match the match mark of the bearing holder case with the
missing tooth of the injection pump drive gear.
SAPH311990500013
(2) Install a new O-ring and mount the air compressor and
Supply pump O-ring
supply pump assembly on the flywheel housing.
! CAUTION • Adjust the gear so that the compression top

dead center alignment of the No.1 cylinder
may not be changed.
• Be sure to remove the guide bolt in cranking
the engine.
SAPH311990500014
• After assembly, be sure to remove the guide
bolt and install the inspection window plug.
5. Update of supply pump learning value

(1) When the supply pump is replaced, update the learning
value memorized in the engine ECU with the failure
diagnosis tool (HinoDX) using PC. (Refer to "HinoDX
operation manual".)
! CAUTION • If learning value is not updated, correct

common rail pressure is not controlled,
resulting in engine stall or high common rail
pressure. Therefore, when the supply pump is
replaced, be sure to update the learning
value.
FUEL SYSTEM 5–9
Inspection of supply pump

JP31199050704004
1. Inspection of suction control valve and fuel temperature

sensor
(1) Measure the resistance of the suction control valve
terminals and the fuel temperature sensor terminals using
a circuit tester. If it is beyond the standard, remove the
Fuel temperature
sensor supply pump assembly and request for replacement at the
Denso service shop.
Suction control
valve
Between suction control valve terminals
SAPH311990500026
Standard
7.65 - 8.15Ω(at 20°C {68°F})
value
Terminals between fuel temperature

sensors
13.5 - 16.5kΩ(at -20°C{68°F})

Standard
2.2 - 2.7kΩ(at 20°C{68°F})
value
0.29 - 0.35kΩ(at 80°C{176°F})
5–10 FUEL SYSTEM
Replacement of injector
JP31199050704005
1. Removal of injector
(1) Remove the fixing bolt and remove the plate and the
injection pipe oil seal.
(2) Remove the nozzle clamp holder and remove the injector.
2. Installation of injector
(1) Attach a new O-ring to the groove of the cylinder head and
insert the injector.
Fixing bolt
Injector ! CAUTION • Apply engine oil to the O-ring and be careful
to prevent pinching of the O-ring.
Injection pipe (2) Install the nozzle clamp holder and tack weld the injector
temporarily.
Nozzle clamp ! CAUTION • Do not fix the nozzle holder until the injection
holder pipe is tack welded.
(3) Put a new injection pipe oil seal on the injector and install
the plate.
Injection pipe
oil seal
! CAUTION • Install the injection pipe oil seal to prevent
O-ring undue force to the injection nozzle. (Offset
position between the injection pipe oil seal
and the injection nozzle may cause oil leak or
poor assembly of the injection pipe.)
SAPH311990500027
(4) Assemble the injection pipe temporarily and tighten the
fixing bolt of the nozzle clamp holder.
Tightening torque : 25 N⋅m {250 kgf⋅cm, 1.8 lbf⋅ft}
3. Entry of injector correction value to the engine ECU (entry

using HinoDX and QR code reader)
QR code
! CAUTION • When the injector is replaced, it is necessary

to enter the injector correction value (QR
code) described on the new injector to the
engine ECU. Incorrect entry of the correction
Injector
value may result in faulty engine.
NOTICE • Available entry methods of the injector

SAPH311990500028
correction value are the PC tool and the QR
code reader.
• The flow of work is described in the following.
If you want details regarding any procedure,
however, refer to the PC Tools instruction
manual.
FUEL SYSTEM 5–11
(1) Read the injector QR code with the scanner of the QR

code reader and prepare the correction data file.
(2) Enter the injector correction value directly from the PC
tools to the engine ECU.
PC
QR Code reader
Hino-Bowie
Engine-use code
QR code
Connector
New injector
ECU
SAPH311990500029
Inspection of injector
JP31199050704006
1. Inspection of injector insulation

<Cross-section view of injector head>
(1) Remove the injector plastic terminal cap (upper).
(2) Measure the insulation resistance between the injector
upper body and one terminal (no polarity) of two terminals
for the injector harness.
Terminal
Terminal cap (upper)
(harness tightening area)
Standard value (normal
Terminal cap 1000MΩor more
temperature)
(lower)
(3) Measure the resistance value between two terminals

above.
Injector harness
and rubber seal
Standard value (at 20°C) 0.45Ω±0.1
(4) If the resistance value in (2) and (3) exceeds the standard
value, replace the injector assembly.
2. Cleaning of injector
Upper body
(1) Remove sludge at or around the terminal, if any.
! CAUTION • In removing sludge, do not use a cleaning

SAPH311990500030
agent. Wipe it off with a rag. Use of a cleaning
agent may result in electric failure due to
penetration of the agent.
5–12 FUEL SYSTEM
Replacement of common rail

JP31199050704007
1. Removal of common rail

(1) Remove the common rail together with the flow damper,
pressure sensor and pressure limiter from the intake
manifold.
! CAUTION • Remove dirt around parts before removing

Pressure limiter the common rail
Flow damper
Pressure sensor
SAPH311990500031
2. Installation of common rail

(1) Install the common rail on the intake manifold.
SAPH311990500032
Inspection of common rail

JP31199050704008
1. Inspection of common rail pressure sensor

(1) Measure the resistance value between terminals using a
circuit tester. If it exceeds the standard value, replace the
common rail assembly

Between 1 and 2 Between 2 and 3

SAPH311990500033 Standard value
(kΩ)
0.5 - 3.0 6.5 - 18.5
At stop of
engine
ELECTRICAL 7–1
ENGINE
7 ELECTRICAL
Setup layout
Layout
Electrical System........................................................ 7-2

Part layout ............................................................... 7-2
Part layout ............................................................... 7-5
Layout of components............................................. 7-5
Inspection of components ....................................... 7-8
Installation of component ...................................... 7-10
Installation of starter ............................................. 7-10
Installation of alternator ........................................ 7-11
7
7–2 ELECTRICAL
Electrical System
Part layout
JP31199070402001
SAPH311990700001
82051 Injector harness 89390 Boost pressure sensor

83420 Water temperature sender gauge 89410 Engine sub revolution sensor
83530 Oil pressure warning switch 89411 Engine main revolution sensor
Tightening torque
9190-06121 4N⋅m{40kgf⋅cm, 3lbf⋅ft}
ELECTRICAL 7–3
SAPH311990700002
12509 Alternator brace 9011-64410 Through bolt

12511 Alternator bracket 9241-10107 Fixing bolt at brace
27040 Alternator assembly 9189A Adjusting bolt
28100 Starter assembly
Tightening torque
9069A 154N⋅m{1,570kgf⋅cm, 114lbf⋅ft} 9241-10107 51N⋅m{520kgf⋅cm, 38lbf⋅ft}
9011-64401 83N⋅m{850kgf⋅cm, 61lbf⋅ft} 9241-14147 154N⋅m{1,570kgf⋅cm, 114lbf⋅ft}
9189A 5.9N⋅m{60kgf⋅cm, 4lbf⋅ft}
7–4 ELECTRICAL
SAPH311990700003
19110 Glow plug

ELECTRICAL 7–5
Layout of components
JP31199070402003
Boost pressure sensor
Engine sub revolution sensor
Engine main revolution sensor
Engine revolution sensor
Common rail pressure sensor Fuel temperature sensor

Suction control valve (SCV)
Left side view

SAPH311990700004
7–6 ELECTRICAL
Oil pressure warning switch

Coolamt temperature sender gauge
Engine sub revolution sensor
Engine main
revolution sensor
Boost pressure sensor Suction control valve (SCV) Fuel temperature sensor
Upper view
SAPH311990700005
ELECTRICAL 7–7
Coolamt temperature sender gauge
Front view
SAPH311990700006
Service procedure
Overhaul item
7–8 ELECTRICAL
Inspection of components
JP31199070702001
1. Inspection of oil pressure warning switch

(Laid out on the oil filter)
(1) Apply pressure with air or oil and check continuity

between terminals using a circuit tester. If it is faulty,
replace it.
At no load or less than 39kPa

With continuity
{0.4kgf/cm2 ,5.6565lbf/in.2}
At 39kPa
SAPH311990700007 Without continuity
{0.4kgf/cm2 ,5.6565lbf/in.2}
Oil pressure warning switch
39.2 - 58.8kPa
2 2
{0.4 - 0.6kgf/cm ,5.7 - 8.5 lbf/in } ON
2
2.9kPa{0.3kgf/cm ,
2
4.7lbf/in }
Within
OFF Toward pressure increase
SAPH311990700008
2. Inspection of coolant temperature sender gauge

Coolant temperature sender gauge
(Installation on thermostat case)
Connector color: Dark (1) Heat the coolant temperature sender gauge using hot
water.
A (2) Measure the resistance between terminals using a circuit
tester. If it is faulty, replace the gauge.
Between A and C
C
B Temperat
-20 20 80 110
SAPH311990700009
ure
{-68} {68} {176} {230}
(°C{°F})
Resistanc
13.84 - 2.32 - 0.31 - 0.1399 -
e value
16.33 2.59 0.326 0.1435
(Ω)
Between B and body
Temperat
75 100
ure
{167} {212}
(°C,°F)
Resistanc
35.5 -
e value 79 - 92
42.5
(Ω)
ELECTRICAL 7–9
3. Inspection of glow plug
(1) Measure continuity between the body and the terminal

using a circuit tester. If it is faulty, replace the glow plug.
Standard value
Resistance value :
Ω(Normal temperature 2.59 - 3.29
20°C{68°F})
SAPH311990700010
4. Inspection of suction control valve SCV and fuel

temperature sensor
(1) For inspection and replacement of the suction control

valve (SCV) and the fuel temperature sensor, refer to the
Fuel temperature
chapter of "J05E FUEL SYSTEM ".
sensor
Suction control valve

(SCV)
SAPH311990700011
5. Inspection of common rail pressure sensor
(1) For inspection and replacement of the common rail

pressure sensor, refer to the chapter of "J05E FUEL
SYSTEM".
SAPH311990700012
6. Inspection of injector
(1) For inspection and replacement of the injector, refer to
the chapter of "J05E FUEL SYSTEM".
7–10 ELECTRICAL
Installation of component
JP31199070702002
1. Installation of engine revolution sensor

(1) Confirm that there are O-rings on the sensors and then
mount one sensor on top of the flywheel housing and one
on the cam housing.
O-ring NOTICE • Since this sensor is a flange type, gap does

not have to be adjusted.
Engine sub-revolution sensor
O-ring
Engine main revolution sensor
SAPH311990700013
Installation of starter
JP31199070702003
1. Install the starter with bolts and nuts.
Tightening torque : 154 N⋅m {1,570 kgf⋅cm, 114 lbf⋅ft}
SAPH311990700014
ELECTRICAL 7–11
Installation of alternator
JP31199070702004
1. Installation of alternator
(1) Tighten the alternator temporarily using through bolts and
nuts.
(2) Tighten the adjusting bolts and fixing bolts temporarily.
2. V–belt tension adjustment

㧭 Coolant Pump Pulley
When installing a
Item At the time of inspection
new belt
8 - 10mm 10 - 12mm
Deflection
Alternator {0.3152 - 0.394in.} {0.394 - 0.472in.}
Pulley 490 - 570 N
320 - 400 N
Tension {50 - 58 kgf, 110 -
Crankshaft {33 - 41 kgf, 72 - 90 lbf}
128 lbf}
Pulley
SAPH311990700015
Special tool : 09444-1210 Compression gauge (used at
the time of measuring the deflection
amount) [ Reference push force 98N {10kgf,
22lbf} ]
95506-00090 (Denso part No.) Belt tension
gauge (used at the time of measuring the
tension force)
! CAUTION • If the V-belt is replaced with a new one, it

becomes loose due to initial fitting. Run the
engine for three to five minutes and adjust the
tension of the belt again.
NOTICE • At the time of inspection, the new V-belt has

reached the value after complete initial
stretching. A new V-belt completes initial
stretching after running the engine for
approximately two hours.
(1) Tighten the through bolt of the commutator end frame.

Tightening torque : Through bolt
83 N⋅m {850 kgf⋅cm, 61 lbf⋅ft}
(2) Tighten the lock nut on the brace side.
Tightening torque : Adjusting bolt
(3) Tighten the adjusting bolt and make sure the bolt is
locked.
5.9 N⋅m {60 kgf⋅cm, 4 lbf⋅ft}
(4) Securely connect the ground wire terminal for the
alternator.
INTAKE 8–1
ENGINE
8 INTAKE
Setup layout
Layout
Intake Manifold ........................................................... 8-2

Part layout ............................................................... 8-2
Replacement........................................................... 8-4
8
8–2 INTAKE
Intake Manifold
Part layout
JP31199080402001
SAPH311990800001
17103 Intake pipe 17113 Intake pipe

17111 Intake manifold 17171 Gasket*

Tightening torque
9068-08320 28.5 N⋅m {290 kgf⋅cm, 21lbf⋅ft} 9240-08087 28.5 N⋅m {290 kgf⋅cm, 21lbf⋅ft}
9068-08550 28.5 N⋅m {290 kgf⋅cm, 21lbf⋅ft}
INTAKE 8–3
SAPH311990800002
17104A Gasket* 17148 Plate

Service procedure
8–4 INTAKE
Replacement
JP31199080704001
1. Removal of intake manifold

(1) Remove bolts and nuts and remove the intake manifold.
2. Installation of intake manifold

(1) Clean inside of the intake manifold and the cylinder head.
(2) Assemble a new gasket.
! CAUTION • Install the gasket so that the protrusion may

come at the rear end stud bolt of the cylinder
head.
Protrusion
SAPH311990800003
(3) Install the intake manifold and tighten it with bolts and
nuts.
SAPH311990800004
3. Installation of intake pipe

(1) After removing contamination on the contact surface,
apply liquid gasket [Threebond TB1207B(black) or
equivalent] to the circumference of the contact surface.
! CAUTION • Apply it continuously.

• Apply the liquid gasket at the width of 1.5 to
2.5 mm {0.0591 to 0.09843 in.}
• Install the oil cooler within 20 minutes after
application of the liquid gasket.
(2) Install the intake pipe with bolts and nuts.

ENGINE MECHANICAL 9–1
ENGINE
9 ENGINE MECHANICAL
Setup layout
Layout
Cylinder Head ............................................................. 9-2

Part layout ............................................................... 9-2
Replacement of cylinder head ................................ 9-4
Liquid gasket application procedure for semicircular
plug (only when semicircular plug is removed) ....... 9-7
Replacement of head cover .................................... 9-7
Overhaul of cylinder head ....................................... 9-8
Cylinder Block .......................................................... 9-11
Part layout ............................................................. 9-11
Overhaul ............................................................... 9-12
Timing Gear Cover and Flywheel Housing............. 9-16
Part layout ............................................................. 9-16
Replacement of flywheel housing ......................... 9-17
Replacement of end plate ..................................... 9-17
9
Replacement of crankshaft front oil seal............... 9-18
Replacement of crankshaft rear oil seal................ 9-20
Main Moving Parts.................................................... 9-22
Part layout ............................................................. 9-22
Replacement of piston and connecting rod .......... 9-23
Inspection of piston and connecting rod ............... 9-27
Replacement of connecting rod bushing............... 9-29
Replacement of crankshaft ................................... 9-31
Inspection of crankshaft ........................................ 9-33
Replacement of crankshaft pulley ......................... 9-36
Replacement of flywheel ...................................... 9-36
Camshaft and Idle Gear ........................................... 9-39
Part layout ............................................................. 9-39
Removal of camshaft ............................................ 9-40
Disassembly of camshaft ...................................... 9-40
Inspection of camshaft and camshaft bearing ...... 9-41
Assembly of camshaft........................................... 9-42
Installation of camshaft ......................................... 9-43
Gear train layout ................................................... 9-45
Removal of timing gear ........................................ 9-45
Inspection of timing gear components .................. 9-46
Installation of timing gear ...................................... 9-47
Overhaul of sub-idle gear (bearing case side) ...... 9-49
Inspection of installation status for each gear ...... 9-51
Valve System............................................................. 9-55
Part layout ............................................................. 9-55
Overhaul of valve system...................................... 9-56
Adjustment of valve clearance .............................. 9-59
9–2 ENGINE MECHANICAL
Cylinder Head
Part layout
JP31199090402001
SAPH311990900001
11101 Cylinder head assembly 11135 Exhaust valve seat

11122 Valve guide 11176 Nozzle seat
11131 Intake valve seat 900115 O-ring*

SAPH311990900002
11115 Cylinder head gasket 12108 Oil filler cap

11188 Semicircular plug 12505 Silent block
11201 Cylinder head cover 23074 Injection pipe oil seal*
11213 Head cover gasket

Tightening torque
11185 59N⋅m{600kgf⋅cm, 44lbf⋅ft}+90°+90° 9069B 59N⋅m{600kgf⋅cm, 44lbf⋅ft}
11185A 59N⋅m{600kgf⋅cm, 44lbf⋅ft}+90°+135° 9349A 30N⋅m{300kgf⋅cm, 22lbf⋅ft}
11185B 59N⋅m{600kgf⋅cm, 44lbf⋅ft}+90°+180° SZ105 59N⋅m{600kgf⋅cm, 44lbf⋅ft}
9068-08400 28.5N⋅m{290kgf⋅cm, 21lbf⋅ft}
Service procedure
Replacement of cylinder head

JP31199090704001
1. Removal of cylinder head and head gasket

(1) Loosen the head bolts from outside to inside gradually (1/
4 turn for each) as shown in the order of the figure and
10 18 17 9 remove them.
6 14 21 13 5
7 15 20 12 4
11 19 16 8
No.4 - No.21 : M12 Bolts

SAPH311990900003
(2) Remove the cylinder head using a special tool and hoist.
Figure is an Special tool : 09433–1070 Eye bolt
example of work.
NOTICE • If it is difficult to remove the cylinder head,

insert a chisel between the cylinder head and
the cylinder block, and move the chisel
vertically so that the contact surface may not
be damaged. Then, separate the cylinder
head.
SAPH311990900004
2. Inspection of head bolt length

(1) Measure the underhead length of the head bolt (M12 only)
using vernier calipers. If it is beyond the service limit,
replace it with a new one.
Service limit (mm{in.}) 126.5{4.9803 in.}

Underhead length
SAPH311990900005
3. Installation of cylinder head gasket and liquid gasket

application procedure
(1) Cut the rear end plate gasket to be flush with the surface
Water hole seal ring
of the cylinder block upper surface using a scraper.
(2) Install the cylinder head gasket on the cylinder block and
the flywheel housing.
! CAUTION • Remove dirt, water or oil from the mounting

surfaces of the cylinder head and the cylinder
SAPH311990900006 block before work.
• Never reuse the gasket. Otherwise, it may
damage the engine.
• The water hole seal ring of the cylinder head
gasket is susceptible to damage. Avoid
contact with hand or object.
• Before installation of the cylinder head
gasket, make sure that there is no fall of or
damage to the seal ring.
(3) Apply appropriate amount of liquid gasket [Threebond

Application area of liquid gasket TB1211 (white) or equivalent] to the cylinder head gasket
hole at the joint surface between the cylinder block and
The arrow
shape the flywheel housing.
area is
different
from the ! CAUTION • Apply the liquid gasket so that the surface of
actual
shape. the liquid gasket may be raised on the
cylinder head gasket.
Application area of • Install the oil cooler within 20 minutes after

liquid gasket
Liquid gasket
Cylinder head
Cylinder Flywheel Small

block housing
Rear end plate

Clearance
Too small
Clearance Clearance
Raised from upper

Section A - A surface
SAPH311990900007
4. Installation of cylinder head

(1) Clean the head bolt seat at the cylinder head upper
surface and the cylinder head lower surface.
(2) Apply engine oil to the head bolt seat and the bolt thread.
(3) Align the dowel pins of the cylinder block using a special
Figure is an tool and hoist and mount the cylinder head.
example of work.
Special tool : 09433–1070 Eye bolt
! CAUTION • Before mounting the cylinder head, make

sure that there is no foreign matter in the
cylinder.
• When the cylinder head is mounted, be
SAPH311990900004
careful for engagement between the cam idle
gear and the sub-idle gear. (Contact of gear
teeth with undue force may cause impact
mark or chipping, resulting in abnormal noise
or missing tooth.)
NOTICE • Mounting of the cylinder head with guide bolt

can prevent displacement of the liquid gasket.
(4) Tighten the Nos. 21 - 4 head bolts (M12 only) in order,

starting at the center and working outward.
Tightening torque : 59 N⋅m {600 kgf⋅cm, 44 lbf⋅ft}
(5) Re-tighten the Nos. 21 - 4 head bolts in order, starting at

the center and working outward.

(6) Mark the heads of the head bolts (M12 only) using paint.
(7) Tighten the head bolts (M12 only) 90° more, following the
tightening sequence. (1st time)
SAPH311990900008
(8) Using the same procedure, tighten the head bolts (M12
only) to the angles shown in the table. (2nd time)
Tightening angle Head bolts No.
90° 1,2,7,8,9,10,15,16,17
135° 4,5,12,13
180° 3,6,11,14,18
SAPH311990900009
(9) Make sure the head bolts that have the same tightening
Paint mark angle markings have the same orientation.
! CAUTION • If a bolt is turned excessively in retightening,

do not loosen it.
SAPH311990900010
(10) Tighten remaining head bolts (M10) in the order in the

figure.
This just 3 tighten Tightening torque : 59 N⋅m {600 kgf⋅cm, 44 lbf⋅ft}
3
2
1
SAPH311990900012
Liquid gasket application procedure for

semicircular plug (only when semicircular
plug is removed)
JP31199090704002
1. Remove liquid gasket from the cylinder plug and the

Semicircular plug camshaft housing.
2. Coat the semicircular plugs at the front and rear of the

cylinder head with liquid gasket (Three Bond TB 1207B-
Black or equivalent), and install the semicircular plugs.
Liquid gasket 3. Temporarily install the cylinder head cover with the gasket
application region attached, and execute a parallel adjustment of the
SAPH311990900013 semicircular plugs.
! CAUTION • Be sure to wipe protruding liquid gasket.
Replacement of head cover

JP31199090704003
1. Installation of head cover

(1) Wipe off the liquid gasket stuck to the sides of the
semicircular plugs on the front and rear ends of the
cylinder head.
(2) Wipe dirt (including liquid gasket) and oil on the joint
Cylinder surfaces of the cylinder head cover and the camshaft
Head Cover housing. Install a new head cover gasket on the cylinder
head cover.
bolt
Silent Cylinder Head

Block Cover Gasket
SAPH311990900014
(3) Coat the semicircular plugs with liquid gasket (Three Bond
TB 1207B-Black or equivalent) just before you install the
cylinder head cover.
! CAUTION • Install the oil cooler within 20 minutes after

SAPH311990900015
(4) Put the cylinder head cover on the cylinder head and
Cylinder
Head cover Bolt tighten bolts.
Silent block
NOTICE • Silent block the rubber is attached to the

Cylinder
Head cover spacer
gasket Cylinder Head
cover lower
surface
Cylinder head
SAPH311990900016
Overhaul item
Overhaul of cylinder head

JP31199090702001
1. Cleaning of cylinder head
(1) Remove carbon or other deposit using a scraper.

(2) Clean the cylinder head.
! CAUTION • To remove carbon or other deposit, do not

damage the lower surface of the cylinder
head.
SAPH311990900017
2. Replacement of valve guide

Intake Exhaust
(1) Remove the valve stem seal.
(2) Remove the valve guide using a brass bar or press.
(3) When a new valve guide is assembled, do not pry the end
in assembly and press fit using a special tool.
Special tool : 09471–1520 Guide
! CAUTION • In press fit, be careful not to damage the

Lower surface of cylinder head
valve stem at the upper/lower ends of the
SAPH311990900018
guide.
• In press fit, be sure to apply engine oil to the
circumference of the valve guide.
3. Replacement of valve seat
Backing Valve seat ! CAUTION • The valve seat replacement procedure below
metal
may damage the cylinder head depending on
the case. It is recommended that a request for
replacement be made to a machining vendor.
Electric welding
Valve
(1) If the valve seat is replaced, use an out-of-use valve.
Cut three areas
from here. After cutting three pieces from the valve circumference,
weld them to the valve seat.
SAPH311990900019
! CAUTION • Apply grease to protect the cylinder head

lower surface from welding spatter before
work.
(2) Put a backup metal (e.g. brass bar) at the valve stem
head and pull out the valve seat using a press.
(3) Remove welding spatter or dirt on the valve seat surface.
(4) Heat the cylinder head to approx. 80 to 100 °C and strike
the cooled valve seat into the mounting area of the
cylinder head.
SAPH311990900020
(5) Apply small amount of lapping compound to the contact

surface between the valve and the valve seat.
(6) Strike gently while turning the valve using a special tool
for adjustment.
Special tool : 09431–1020 Valve lapping tool
SAPH311990900021
4. Replacement of nozzle seat
(1) Tap the nozzle seat from the cylinder head lower part.
Then, put an appropriate bolt inside.
(2) Hit the bolt head using a hammer and pull out the nozzle
seat toward the the cylinder head upper part.
(3) Remove the O-ring from the cylinder head.
! CAUTION • After pulling out the nozzle seat, be sure to

remove deposit such as remaining liquid
SAPH311990900022 gasket or dirt.
(4) After attaching a new O-ring into the nozzle seat hole of
Cylinder head the cylinder head, apply the liquid gasket [Threebond
O-ring
TB1211 (white) or equivalent] at the lower part of a new
nozzle seat and assemble it on the cylinder head.
Nozzle sheet ! CAUTION • Be sure to replace the O-ring with a new part.
Reuse may cause water leak or gas leak,
resulting in overheat or crack of the cylinder
head.
SAPH311990900023
(5) Clamp the nozzle seat using a special tool.

Bar Nozzle seat
Special tool : 09472–1210 Bar
9800–06100 Steel ball
Cylinder
Head
Steel ball
Stamp out and clamp

SAPH311990900024
5. Inspection of cylinder head
(1) Inspection of cylinder head distortion

a. Measure distortion of the cylinder head lower surface
and the manifold mounting surface using a ruler.
Standard value (mm{in.}) Service limit (mm{in.})

Longitudinal direction
0.06{0.0024} 0.2{0.0079}
Square direction 0.03{0.0012}
b. If the measurement value is beyond the service limit,

replace it.
! CAUTION • Repair of the lower surface by grinding can

change backlash of the timing gear. Do not
grind it.
(2) Inspection of cylinder head crack

a. With dye penetrant test method (red check), make sure
that there is no crack or damage in the cylinder head.
Setup layout
Layout
SAPH311990900025
Cylinder Block
Part layout
JP31199090402002
SAPH311990900026
11401 Cylinder block assembly 11467 Cylinder liner

11408 Cooling jet
Tightening torque
11521 69N⋅m{700kgf⋅cm, 51lbf⋅ft}+90°+45° 15605 22N ⋅m{220kgf⋅cm, 16lbf⋅ft}
Service procedure
Overhaul item
Overhaul
JP31199090702002
1. Replacement of cylinder liner
(1) Put match marks on the flange surfaces of the cylinder

block and the cylinder liner using a oil based marker.
! CAUTION • Store removed cylinder liners for each

Match mark cylinder number.
• Never provide match marks with a punch.
SAPH311990900027
(2) Pull out the cylinder liner toward the cylinder block upper
part using a special tool.
Special tool : 09420-2100 Cylinder liner puller
! CAUTION • Be careful for handling of the cylinder liner.

Do not reuse the cylinder liner which has
been dropped.
• Do not touch the cooling jet during work.
SAPH311990900028
(3) Apply engine oil to the inner bore of the cylinder block.
(4) Align the match mark of the cylinder liner with that of the
cylinder block. Install the cylinder liner using a special tool.
SAPH311990900029
! CAUTION • When a new cylinder liner is installed, install

Liner identification mark Engine type
the cylinder liner with the same identification
mark (A, B, C) stamped on the cylinder block.
Block front
Front of engine
SAPH311990900030
Cylinder liner
A, B and C marking
position
SAPH311990900031
2. Inspection of protrusion at cylinder liner flange
(1) Fix the cylinder liner using a special tool.

Special tool : 09420–2100 Cylinder liner puller
(2) Measure protrusion of the flange using a dial gauge.
0.01 - 0.08
Standard value (mm{in.})
{0.0004 - 0.0031}
SAPH311990900032
3. Inspection and adjustment of cooling jet
(1) Remove the standard oil check valve and install the
cooling jet on the cylinder block using a special tool.
Special tool : 9001–24262 Check bolt
Check bolt
SAPH311990900033
(2) Connect the injection test oil hose from the lower part of
the cylinder block to the special tool check bolt.
! CAUTION • Use new engine oil for injection of oil.
Check bolt
Oil hose
SAPH311990900034
(3) Set a special tool on the cylinder block.

Special tool : 09470–1280 Tool assembly
Special tool
Tool assembly
Cylinder liner
Cooling jet
SAPH311990900035
(4) Inject oil from the nozzle of the cooling jet at the hydraulic
Oil injection unit (example)
Pressure pressure of 196kPa{2kgf/cm2, 28lbf/in.2}.
Regulator
Oil
Hose NOTICE • Refer to the drawing for the oil injection unit.
Air tank
(Oil tank) Compressed
Air gauge air
Air hose
To cooling jet Valve
SAPH311990900036
(5) When the injection center hits within the specified line of
the gauge, it is considered normal.
Injection Gauge target circle
! CAUTION • Oil is susceptible to combustion due to
spread. Do not use fire near around.
• Work at well ventilated place.
Faulty Faulty Normal Normal

(6) Make sure that the jet position check gauge hole at the
tool assembly end may not interfere with the cooling jet
pipe.
SAPH311990900037
(7) If injection does not hit the target circle, correct it with a
special tool.
Special tool : 09472–1620 Tool
(8) If it cannot be corrected, install a new cooling jet for

reinspection.
(9) Remove the check bolt and install the cooling jet on the
cylinder block using the genuine oil check valve.
SAPH311990900038
(10) After assembly of the piston, make sure that the cooling
jet does not interfere with the piston at the piston bottom
dead center.
4. Inspection of cylinder block
(1) Inspection of cylinder block distortion

a. Measure distortion on the cylinder block using a ruler.

Longitudinal direction
0.06{0.0024}
0.2{0.0079}
Square direction
0.03{0.0012}
b. If the measurement value is beyond the service limit,

replace it.
! CAUTION • Repair of the upper surface by grinding can

change backlash of the timing gear. Do not
grind it.
(2) Inspection of cylinder block crack

a. With dye penetrant test method (red check), make sure
that there is no crack or damage in the cylinder block.
Setup layout
Layout
SAPH311990900039
Timing Gear Cover and Flywheel Housing

Part layout
JP31199090402003
SAPH311990900040
11309 Front oil seal retainer 11390 End plate

11351 Flywheel housing 9828A Front oil seal*
11357 Gasket* 9828B Rear oil seal*
11357A Gasket*

Tightening torque
9068-08000 36N⋅m{370kgf⋅cm, 27lbf⋅ft} 90124A 196N⋅m{2,000kgf⋅cm, 145lbf⋅ft}
9068-10750 55N⋅m{560kgf⋅cm, 41lbf⋅ft} 9241-10107 55N⋅m{560kgf⋅cm, 41lbf⋅ft}
9068-60850 55N⋅m{560kgf⋅cm, 41lbf⋅ft} 9339A 55N⋅m{560kgf⋅cm, 41lbf⋅ft}
90124 196N⋅m{2,000kgf⋅cm, 145lbf⋅ft} 9419A 196N⋅m{2,000kgf⋅cm, 145lbf⋅ft}
Service procedure
Overhaul item
Replacement of flywheel housing

JP31199090702003
1. Removal of flywheel housing
(1) Remove bolts and remove the flywheel housing.
! CAUTION • Remove bolts fixing the flywheel housing

from the cylinder block.
SAPH311990900041
2. Installation of flywheel housing

Liquid gasket
(1) Remove contamination from the joint surfaces of the
flywheel housing and the end plate using a scraper.
(2) Apply the liquid gasket [Threebond TB1207D (silver) or
equivalent] to the flywheel housing as shown in the figure.

2.5 mm{0.0591 to 0.0984 in.}.
SAPH311990900042
(3) Install the flywheel housing on the cylinder block with

B
A A bolts.
B C Tightening torque :
196 N⋅m {2,000 kgf⋅cm, 145 lbf⋅ft} (Area A)
C
C 36 N⋅m {370 kgf⋅cm, 27 lbf⋅ft} (Area B)
C
A A 55 N⋅m {560 kgf⋅cm, 41 lbf⋅ft} (Area C)
A
A ! CAUTION • Tighten bolts fixing the flywheel housing from
the cylinder block.
SAPH311990900043
Replacement of end plate

JP31199090702004
1. Removal of end plate
(1) Remove bolts.

(2) Remove the Torx bolt and remove the end plate using a
special tool.
Special tool : 09411–1300 Socket wrench
SAPH311990900044
2. Installation of end plate

(1) Install the end plate and a new gasket with bolts.
! CAUTION • Make sure that there is no dirt or foreign

matter on the installation surface of the
cylinder block and the screw holes.
(2) Apply sealant (Super 5M or equivalent) to the thread of

the Torx bolt.
(3) Install the Torx bolt using a special tool.
Special tool : 09411–1300 Socket wrench
SAPH311990900044

(4) Cut the gasket with a scraper to be flush to the upper/
Gasket lower surfaces of the cylinder block.
Cylinder block End plate
Flywheel housing
SAPH311990900045
Replacement of crankshaft front oil seal

JP31199090704004
1. Removal of front oil seal

(1) Install the plate of the special tool oil seal puller on the
crankshaft using two crankshaft damper mounting bolts.
Special tool : 09420–1731 Oil seal puller
SAPH311990900046
(2) Hook the special tool oil seal puller with the tab of the front
oil seal and install the hook on the plate of the special tool
oil seal puller with accompanying bolts.
SAPH311990900047
(3) Remove two bolts which installed the plate of the special
tool oil seal puller on the crankshaft.
(4) Attach the accompanying center bolt to the special tool oil
seal puller and tighten it. Pull out the front oil seal.
SAPH311990900048
2. Installation of front oil seal

Guide
(1) Insert a new oil seal into the guide of the oil seal press.
Special tool : 09407–1030 Oil seal press
! CAUTION • Be careful for front/rear directions of the front

oil seal. (The felt surface is at the crankshaft
damper side.)
Oil seal
SAPH311990900049
(2) Remove contamination from the joint surface of the front

oil seal and the cylinder block.
(3) Apply small amount of engine oil to the seal area of the
front oil seal.
(4) Install the oil seal press guide inserting a new front oil seal
with accompanying guide bolts on the crankshaft.
SAPH311990900050
(5) Align the oil seal press hole to the guide bolt and insert
the oil seal press.
(6) Attach the accompanying center bolt to the oil seal press
and tighten it until stop. Press fit the front oil seal.
SAPH311990900051
Replacement of crankshaft rear oil seal

JP31199090704005
1. Removal of rear oil seal
(1) Install the plate of the special tool oil seal puller on the
crankshaft using two flywheel assembly mounting bolts.
Special tool : 09420–1742 Oil seal puller
! CAUTION • Align the large hole of the plate with the collar
dowel of the crankshaft.
SAPH311990900052
(2) Hook the oil seal puller with the tab of the rear oil seal and
install the hook on the plate of the oil seal puller with
accompanying bolts.
(3) Remove two bolts which installed the plate of the oil seal
puller on the crankshaft.
SAPH311990900053
(4) Attach the accompanying center bolt to the oil seal puller
and tighten it. Pull out the rear oil seal.
SAPH311990900054
2. Installation of rear oil seal
Guide of oil seal press (1) Insert a new rear oil seal into the guide of the oil seal
press.
Special tool : 09407–1040 Oil seal press
! CAUTION • Be careful for front/rear directions of the rear

oil seal. (The felt surface is at the flywheel
Rear oil seal side.)
SAPH311990900055
(2) Remove contamination from the joint surface of the rear

oil seal and the flywheel housing
(3) Apply small amount of engine oil to the seal area of the
rear oil seal.
(4) Install the oil seal press guide inserting a new rear oil seal
with accompanying guide bolts on the crankshaft.
! CAUTION • Align the large hole of the guide with the

collar dowel of the crankshaft.
SAPH311990900056
(5) Align the oil seal press hole to the guide bolt and insert
the oil seal press.
SAPH311990900057
(6) Attach the accompanying center bolt to the oil seal press
and tighten it until stop. Press fit the rear oil seal.
Setup layout
Layout
SAPH311990900058
Main Moving Parts

Part layout
JP31199090402004
SAPH311990900059
11011 Thrust bearing 13260 Connecting rod assembly

11701 Main bearing 13271 Connecting rod bush
11703 Main bearing US 0.25 13411 Crankshaft
11704 Main bearing US 0.50 13450 Flywheel assembly
13005 Piston, Piston ring set 13453 Ring gear
13041 Connecting rod bearing 13470 Crankshaft pulley
13041A Connecting rod bearing 13521 Crankshaft gear
13041B Connecting rod bearing 9819A Retainer ring*

Tightening torque
13265 69N⋅m{700kgf⋅cm, 51lbf⋅ft}+90°+45° 900125 118N⋅m {1, 200 kgf⋅cm, 87lbf⋅ft}
13455 186N⋅m {1, 900 kgf⋅cm, 137lbf⋅ft}
Service procedure
Overhaul item
Replacement of piston and connecting rod

JP31199090702005
1. Removal of piston
Figure is an
example of work. (1) Remove bolts and remove the connecting rod cap.
! CAUTION • Insert a large flat tip screwdriver into the

flywheel gear from the flywheel housing
inspection hole to prevent turning of the
crankshaft.
• Store removed connecting rod cap for each
cylinder number so that combinations of the
SAPH311990900060 connecting rod and the connecting rod cap
may not be changed.
(2) Remove carbon on the cylinder liner inner surface with a

scraper or a sand paper (No. 150 or so) in the
circumferential direction.
! CAUTION • Do not damage parts lower than the carbon

deposit area.
(3) Fix the cylinder liner with bolts and a plate.
SAPH311990900061
(4) Hit the connecting rod from underneath the engine using
a handle of a hammer. Remove the piston together with
the connecting rod.
SAPH311990900062
NOTICE • In removing the piston, rotate the connecting

Cooling jet
rod as shown in the figure. Do not bend the
cooling jet.
! CAUTION • Store removed pistons and connecting rods

for each cylinder number.
• Be careful not to touch the cooling jet.
0
SAPH311990900063
2. Disassembly of piston and connecting rod
(1) Remove the retainer ring using snap ring pliers.

(2) Remove the piston pin using the brass bar and disconnect
the piston from the connecting rod.
SAPH311990900064
(3) Remove the piston ring using a special tool.
Special tool : 09442–1011 Piston ring expander
! CAUTION • Since the piston ring is susceptible to

damage, be careful for handling.
• Store piston rings for each cylinder number.
• Store the piston rings so that the upper and
lower surfaces may be identified.
SAPH311990900065
3. Assembly of piston and connecting rod

"0" mark position Piston
(1) Install the piston on the connecting rod so that the "0"
mark on the piston may be opposite to the match mark
Exhaust side Intake side
stamp on the connecting rod
(2) Install a new retainer ring using a snap ring pliers.
Oil hole
! CAUTION • Make sure that there is no backlash in the
Match mark retainer ring.
stamp
SAPH311990900066
(3) Face the side with the piston ring identification print
upward and install in the order of the oil ring, second ring
and top ring using a special tool.
NOTICE • The identification print is present only on the

secondary ring and the top and bottom of the
top ring and the oil ring are not identified.
Top ring Second ring Oil ring
Upper surface
Special tool : 09442–1011 Piston ring expander
(4) Connect the joint of the coil expander and fit the oil ring
Lower surface
inside the ring. Offset the coil expander joint with the ring
Oil ring joint Clearance
joint by 180 deg for installation.
(5) Allocate the joints of the piston ring with uniform intervals
as shown in the figure.
Coil expander Ring
Second ring
Oil ring Top ring
SAPH311990900067
4. Installation of piston and connecting rod

Oil hole
Concave shape (1) Allocate the joints of the piston ring with uniform intervals
as shown in the figure.
Oil hole
(2) Install the connecting rod bearing to suit concave shape of
Bearing
the connecting rod.
! CAUTION • Make sure that the oil hole of the connecting

rod bearing is aligned with the oil hole of the
Connecting rod
connecting rod.
SAPH311990900068
(3) Apply engine oil to the piston, cylinder liner and

connecting rod bearing and compress the piston ring
using a special tool.
Special tool : 09441–1370 Piston ring holder
! CAUTION • Make sure that there is no deformation or

damage to the special tool piston ring holder.
SAPH311990900069
(4) Insert the piston carefully so that the connecting rod may
not come in contact with the cooling jet.
! CAUTION • Face the "0" mark on the piston toward the

exhaust side for insertion.
• Set the crankshaft of the cylinder as the top
dead center for assembly.
• Do not damage the cylinder liner, crankshaft
and cooling jet during work.
SAPH311990900070
(5) Install the connecting rod bearing to suit concave shape of

the connecting rod cap.
Cap
Bearing
SAPH311990900071
(6) Align the match mark of the connecting rod cap with that
of the connecting rod and fix it with a dowel pin.
Match mark
Stamp ! CAUTION • Do not change the combination between the
connecting rod and the connecting rod cap.
1234 1234
SAPH311990900072
(7) Measure the underhead length of the connecting rod bolt

using a vernier calipers. If it is out of the service limit,
Service limit (mm{in.}) 68.0{2.6772} or less

Underhead length
(8) Apply engine oil to the connecting rod bolt thread and the
seat and install it on the connecting rod.
SAPH311990900073
(9) Tighten the connecting rod bolt and mark the bolt head in
Paint mark the same direction with paint.
Connecting rod cap Tightening torque : 69 N⋅m {700 kgf⋅cm, 51 lbf⋅ft}

(10) Retighten the connecting rod bolt 90 °.
(11) Retighten the connecting rod bolt further 45 °.
45°
90° (12) Make sure that all marks are in the same direction.
! CAUTION • If a bolt is turned excessively in retightening,

do not loosen it.
SAPH311990900074
Inspection procedure item
Inspection of piston and connecting rod

JP31199090703001
1. Inspection of piston clearance
(1) Measure the inner diameter of the cylinder liner sliding

surface using a cylinder gauge.
112{4.4095} 112.15{4.4153}
SAPH311990900075
(2) Measure the piston outer diameter using a micrometer.
! CAUTION • The measuring position is 23 mm{0.9055 in.} above

the piston lower end and square to the pin hole.
Standard value
111.9±0.006{4.4055±0.0002}
(mm{in.})
(3) Calculate the difference between the inner diameter of the
SAPH311990900076
cylinder liner and the outer diameter of the piston. If it is beyond
the standard value, replace the cylinder liner and the piston.
Standard value
0.088 - 0.112{0.0035 - 0.0044}}
(mm{in.})
2. Inspection of clearance between piston ring and ring

groove
(1) Measure the piston ring width using a micrometer. If it is

beyond the service limit, replace the piston ring.
Standard value Service limit

(mm{in.}) (mm{in.})
Top ring 2.5{0.0984} 2.40{0.0945}
SAPH311990900077 Second ring 2{0.0787} 1.90{0.0748}
Oil ring 4{0.1575} 3.90{0.1535}

(2) Measure the piston ring groove using a thickness gauge.

If it is out of the service limit, replace the piston.

(mm{in.}) (mm{in.})
Top ring groove 2.5{0.0984} 2.70{0.1063}
Second ring groove 2{0.0787} 2.20{0.0866}
Oil ring groove 4{0.1575} 4.10{0.1614}

SAPH311990900078
3. Inspection of piston ring joint clearance

Cylinder liner
(1) Insert the piston ring into the cylinder liner by 80 mm
horizontally using piston.
(2) Measure the piston ring joint clearance using a thickness
gauge. If it is out of the service limit, replace the piston ring.
Piston Ring
Service limit
(mm{in.})
Top ring 0.3 - 0.40 {0.0118 - 0.0157} 1.5{0.0591}

SAPH311990900079
Second
0.75 - 0.9 {0.0295 - 0.0354} 1.2{0.0472}
ring
Oil ring 0.15 - 0.3 {0.0059 - 0.1181} 1.2{0.0472}
4. Inspection of piston pin
(1) Measure the outer diameter of the contact area of the

piston pin with the piston boss using a micrometer.
37 {1.4567} 36.96{1.4551}
SAPH311990900080
(2) Measure the piston boss inner diameter using a cylinder gauge.
37 {1.4567} 37.05{1.4587}
(3) Calculate the difference between the outer diameter of the

piston pin contact area with the piston boss and the inner
diameter of the piston boss. If it is out of the service limit,
replace the piston pin or piston.
SAPH311990900081
Standard value (mm) Service limit (mm{in.})
–0.002T-0.025L 0.05{0.0020}
T : Tightening allowance, L : Clearance

Replacement of connecting rod bushing

JP31199090704006
1. Removal of connecting rod bushing

Press (1) Put the special tool press sub-assembly together with the
Sub-assembly
Wing nut special tool guide nut and fix them using the special tool
wing nut.
Guide
09402–1530 Press sub-assembly
9233–10360 Wing nut
! CAUTION • Face "H" mark of the guide upward for

SAPH311990900082
assembly.
• Assemble it on a level table and make sure
that the lower end of the guide and the press
sub-assembly is flat.
(2) With the large end bearing removed, assemble the

connecting rod and put it on the assembled special tool.
SAPH311990900083
(3) Install the special tool spindle on the bushing of the

connecting rod.
Groove
Spindle
Special tool : 09402–1540 Spindle
Connecting rod ! CAUTION • Align the press sub-assembly groove with the
special tool spindle groove for installation.
Press
Sub-assembly
SAPH311990900084
(4) Remove the bushing of the connecting rod using a press.
! CAUTION • Move the press slowly.
SAPH311990900085
(5) Chamfer one side of the connecting rod small end

uniformly according to the figure.
Chamfer
! CAUTION • Remove burr completely.
• After chamfering, remove dirt from the inner
surface at the small end and from the oil hole.
SAPH311990900086
2. Installation of connecting rod bushing

(1) Install a new bushing on the special tool spindle and
Groove install the special tool guide and the special tool bolt.
Spindle
Special tool : 09402–1540 Spindle
09481–1540 Guide
Bushing
9191–08252 Bolt
Guide
Tightening torque :
Bolt
5 - 6 N⋅m {50 - 70 kgf⋅cm, 3.5 - 4 lbf⋅ft}
SAPH311990900087
! CAUTION • Align grooves of the special tool guide and
the special tool spindle for installation.
• Make sure that the edge of the special tool
spindle and the special tool guide is in close
contact.
(2) Align the connecting rod oil hole with the bushing oil hole
assembled on the special tool. Make sure that the groove
of the special tool spindle is in alignment with the groove
of the special tool press sub-assembly.
Groove
Oil hole ! CAUTION • Place the connecting rod so that the chamfer
side of the connecting rod small end inner
diameter may be the bushing side
• Apply engine oil to the inner diameter surface
SAPH311990900088 of the connecting rod.
(3) Install the bushing on the connecting rod using a press.

(4) Insert a rod with the diameter of 6 mm from the oil hole at
the connecting rod large end and make sure that it goes
through the oil hole at the small end.
NOTICE • Displacement of oil holes may cause

insufficient lubrication, resulting in seizure.
(5) Insert a new piston pin and check if there is no drag or

backlash.
SAPH311990900089
Replacement of crankshaft
JP31199090704007
1. Removal of crankshaft
(1) Remove the main bearing cap and the main shaft bearing.
Remove the crankshaft using a hoist.
! CAUTION • Since the part is heavy, be careful for

handling.
• Store removed main bearing caps and main
bearings for each cylinder number.
SAPH311990900090
2. Installation of crankshaft
(1) Face the groove side (front) of the thrust bearing toward
the crankarm and the part number side (back) toward the
main bearing cap or the cylinder block. Install it on the
cylinder block and the main bearing cap.
! CAUTION • To prevent falling in assembly, apply engine

oil or grease to the back of the thrust bearing.
(2) Install the main bearing on the cylinder block and each
bearing cap.
! CAUTION • Assemble the bearing with oil hole on the

cylinder block and assemble the bearing
without oil hole on the cap.
• Apply new engine oil to the sliding surfaces of
each bearing.
(3) Align the crankshaft with the cylinder block.
SAPH311990900091
(4) Align the main bearing cap which has the thrust bearing
Stamp number and the main bearing with the cylinder block.
Front of engine
! CAUTION • The pentagon mark on the main bearing cap

should face the front of the vehicle. Align in
1 2 3 4 5 6 7 the order of 1, 2, 3, 4, 5, 6 and 7 from the
front.
• Check the stamp number of each main
Stamp number bearing cap with the stamp number of the
SAPH311990900092 cylinder block.
(5) Measure the underhead length of the bearing cap bolt

using a vernier calipers. If it is out of the service limit,
Service limit (mm{in.}) 108{4.252}

Underhead length
SAPH311990900073
(6) Apply engine oil to the bolt seat and the bolt thread of the
bearing cap bolt.
(7) Tighten the bearing cap bolt according to the sequence in

2 4 6 8 10 12 14 the figure.
1 3 5 7 9 11 13
(8) Loosen the bearing cap fixing the thrust bearing and hit
the crankshaft gently at the front/rear end using a plastic
Front of engine hammer.
(9) Loosen all bearing cap bolts.
SAPH311990900093
(10) Tighten the bearing cap bolt as in (7).
(11) Mark bearing cap bolt heads in the same direction with
paint.
(12) Tighten 90 deg (1/4 turn) with the same order as in (7).
(13) Retighten 45 deg (1/8 turn) as in (7).
Paint mark (14) Make sure that all paint marks are in the same direction.
! CAUTION • If it is excessively retightened, do not loosen

it.
45ࠑ (15) After tightening, hit the front/rear ends of the crankshaft
90ࠑ
gently with a plastic hammer for initial fit.
! CAUTION • Make sure that the crankshaft turns smoothly.

SAPH311990900094 • Measure the end play of the crankshaft and
make sure that it is within the standard value.
Standard value Repair limit Service limit

(mm{in.}) (mm{in.}) (mm{in.})
0.050 - 0.219
{0.0020 - 0.50{0.0197} 1.219{0.0480}
0.0086}}

Inspection of crankshaft
JP31199090703002
1. Inspection of end play

(1) Measure the end play of the crankshaft using a dial
gauge. If it is beyond the repair limit, replace the thrust
bearing. If it is beyond the service limit, replace the
crankshaft.
Standard value Repair limit Service limit

SAPH311990900095
(mm{in.}) (mm{in.}) (mm{in.})
0.050 - 0.219
0.50{0.0197} 1.219{0.0480}
{0.020 - 0.0086}
NOTICE • Standard width of thrust

bearing2.5mm{0.0984in.}
2. Inspection of rotation runout

Figure is an
example of work. (1) Measure the crankshaft rotation runout using a dial
gauge. If it is beyond the repair limit, grind the crankshaft
and use the undersize bearing.
Repair limit (mm{in.}) 0.15{0.0060}
SAPH311990900096
3. Inspection of journal wear
Measure two (1) Measure the outer diameter of the crankshaft journal
places. using a micrometer. If it is faulty, grind or replace the
90ࠑ
crankshaft. When the crankshaft is ground, use the
undersize bearing.
Journal standard value

80{3.1496}
(mm{in.})
SAPH311990900097
Wear value (mm{in.}) Action

Eccentric wear
Regrind for correction.
0.10{0.0039}
Wear of 0.20{0.0079} or
Regrind
more
Wear of 1.20{0.0472} Replace the crankshaft.

(2) Measure the crankshaft center journal width using a

Figure is an vernier calipers. If it is out of the service limit, replace the
example of work.
crankshaft.
36{1.4173} 37.0{1.4567}
SAPH311990900098
4. Inspection of crankshaft oil clearance
(1) Measure the outer diameter of the crankshaft journal

using a micrometer.
90
80{3.1496} 78.8{3.1024}
SAPH311990900099
(2) Do not install the crankshaft. Install the crankshaft bearing

and the main bearing cap on the cylinder block.
(3) Measure the crankshaft bearing inner diameter using a

cylinder gauge.
crankshaft journal and the inner diameter of the
crankshaft bearing. If it is beyond the repair limit, grind
the crankshaft and use the undersize bearing.
SAPH311990900100
Standard value (mm{in.}) Repair limit (mm{in.})
0.051 - 0.102
0.2{0.0079}
{0.0020 - 0.0040}
NOTICE • Standard bearing thickness : 2.5mm

• Undersize bearing value : 0.25, 0.50, 0.75,
1.00
Bearing size Journal outer diameter (mm{in.})

Standard 79.940 - 79.960 {3.1472 - 3.1480}
0.25.00US 79.690 - 79.710 {3.1374 - 3.1382}
0.50US 79.440 - 79.460 {3.1276 - 3.1283}

0.75US 79.190 - 79.210 {3.1177 - 3.1185}
1.00US 78.940 - 78.960 {3.1079 - 3.1087}

(5) Dimension of fillet "R"
Crank pin
Radius is
incomplete. Radius is 2.5 to 3.0mm {0.0984 to 0.1181 in.}
small. Step Step
R
Journal
2.5 to 3.0mm {0.0984 to 0.1181 in.}
Good Poor
SAPH311990900101
5. Inspection of crack and damage on crankshaft and of oil

Figure is an hole
example of work.
(1) Check for crack or damage using dye penetrant. If a faulty
condition is found, replace the crankshaft.
SAPH311990900102
(2) Check for clogging of the crankshaft oil hole. If faulty

Figure is an condition is found, replace the crankshaft.
example of work.
SAPH311990900103
6. Inspection of pin wear
(1) Measure the outer diameter of the crankshaft crank pin

90°Measurement
at 2 places using a micrometer. If it is faulty, grind or replace the
crankshaft.
When the crankshaft is ground, use the undersize
bearing.
Crank pin standard value 65
SAPH311990900104
Wear value (mm{in.}) Action
Eccentric wear
Regrind for correction.
0.10{0.0039}
Wear of 0.20{0.0079} or
Regrind
more
Wear of 1.20{0.0472} Replace the crankshaft.

Replacement of crankshaft pulley

JP31199090704008
1. Removal of crankshaft pulley

(1) Remove bolts and remove the crankshaft pulley.
NOTICE • Insert a large flat tip screwdriver into the

crankshaft.
SAPH311990900105
2. Installation of crankshaft pulley
1 crankshaft pulley mounting bolt.
6 3 (2) Install the crankshaft pulley on the crankshaft and tighten
it according to the figure.
4 5 Tightening torque : 118 N⋅m {1,200 kgf⋅cm, 87 lbf⋅ft}
2
SAPH311990900106 inspection hole to prevent turning of the
crankshaft.
Replacement of flywheel
JP31199090704009
1. Removal of flywheel
Flywheel
(1) Remove the engine revolution sensor.
Mounting bolt (2) Remove bolts fixing the flywheel.

crankshaft.
SAPH311990900107
(3) Install a special tool into the bolt hole of the crankshaft to
remove the flywheel.
! CAUTION • Since the flywheel is heavy, be careful for

handling.
• Do not give impact to the special tool during
work.
SAPH311990900108
2. Removal of ring gear
(1) Heat the entire ring gear circumference with a burner until
it is about 200 °C(392°F).
! CAUTION • Do not touch the ring gear and the flywheel

with bare hand while they are hot.
SAPH311990900109
(2) Hit the circumference of the ring gear gently using a

backing rod to remove the ring gear from the flywheel.

SAPH311990900110
3. Installation of ring gear
(1) Heat the entire ring gear circumference with a burner until
it is about 200 °C(392°F).

SAPH311990900111
(2) Face the chamfered side toward the flywheel and install it
on the flywheel quickly.

SAPH311990900112
4. Installation of flywheel
(1) Make sure that there is no burr or dirt on the joint surface
of the crankshaft and the flywheel and the screw hole.
(2) Install the special tool into the bolt hole of the crankshaft.
NOTICE • Install one special tool on the collar dowel

and the other at the opposite side of the collar
dowel.
SAPH311990900113
(3) Insert the flywheel until it comes in contact with the collar
dowel of the crankshaft and adjust the position.
! CAUTION • Since the flywheel is heavy, be careful for

handling.
• Do not give impact to the special tool during
work.
(4) Insert the flywheel until it comes in contact with the

crankshaft.
flywheel mounting bolt.
SAPH311990900114
(6) Tighten 6 bolts by 2 to 3 threads temporarily with hand in

the bolt holes without installation of the special tool.
(7) Tighten 6 bolts gradually and tighten temporarily.

(8) Remove the special tool and tighten remaining two bolts
temporarily as in (6) and (7).
SAPH311990900115
(9) Tighten the flywheel according to the order in the figure.

1 NOTICE • Insert a large flat tip screwdriver into the
5 8
3 4
7 6 crankshaft.
2
(10) Loosen all bolts.

(11) Tighten the bolts again.
SAPH311990900116
(12) Install the engine revolution sensor.
Setup layout
Layout
Camshaft and Idle Gear

Part layout
JP31199090402005
SAPH311990900117
13501 Camshaft assembly 13572B Idle gear thrust plate

13505 Cam idle gear 13581 Idle gear shaft
13505A Sub-idle gear 13581A Idle gear shaft
13505B Main idle gear 13581B Idle gear shaft
13520 Camshaft gear 9867A Idle gear bush
13572 Idle gear thrust plate 9867B Idle gear bush
13572A Idle gear thrust plate
Tightening torque
900124 59N⋅m{600kgf⋅cm, 44lbf⋅ft}+90° 900125 172N⋅m {1, 750 kgf⋅cm, 127lbf⋅ft}
900124A 108N⋅m {1, 100 kgf⋅cm, 80lbf⋅ft}
Service procedure
Overhaul item
Removal of camshaft
JP31199090702006
1. Removal of rocker arm and camshaft assembly
(1) Loosen the lock nut and turn the adjusting screw
completely.
Rock nut
! CAUTION • Removal without turning the adjusting screw

may bend the rocker shaft.
SAPH311990900118
(2) Loosen the rocker arm support bolts gradually from the
center and remove the rocker arm and the rocker arm
shaft.
SAPH311990900119
Disassembly of camshaft
JP31199090702007
1. Disassembly of camshaft
(1) Fix the camshaft gear using a vice to disassemble the
camshaft.
! CAUTION • Prevent faulty conditions on the gear such as

deformation, impact, scratch, etc.
SAPH311990900120
Inspection of camshaft and camshaft

bearing
JP31199090702008
1. Inspection of cam height on camshaft

(1) Measure the cam height using a micrometer. If it is
beyond the service limit, replace the camshaft.

(mm{in.}) (mm{in.})
Cam IN 50.067{1.9711} 49.987{1.9680}

height EX 52.104{2.0513} 52.024{2.0482}
SAPH311990900121 IN 8.067{0.3176} (7.987{0.3144})

Cam lift
EX 10.104{0.3978} (10.024{0.3946})
2. Inspection of camshaft runout
(1) Put the journal at both ends of the camshaft on the V

Camshaft contact measuring area
block.
(2) Put a dial gauge to each journal of the camshaft and
measure runout of the camshaft. If it is beyond the service
limit, replace the camshaft.
0.04{0.0016} 0.1{0.0039}
SAPH311990900122
3. Inspection of camshaft bearing oil clearance

(1) Measure the outer diameter of the camshaft journal using
a micrometer.
40{1.5748} 39.85{1.5689}
(2) Measure the camshaft bearing inner diameter using a

cylinder gauge.
SAPH311990900123
40{1.5748} 40.15{1.5807}
(3) Calculate the difference of the camshaft journal bearing

inner diameter. If it is beyond the standard value, replace
the camshaft or the camshaft bearing.
0.020 - 0.063
{0.0008 - 0.0025}
Assembly of camshaft
JP31199090702009
1. Measure the camshaft mounting bolt using a vernier

calipers. If it is out of the service limit, replace it with a
new one.
Service limit (mm{in.}) 31{1.2205}
Underhead length
SAPH311990900124
2. Fix the camshaft gear using a vice. Apply engine oil to the
seat and the bolt thread of the camshaft gear mounting
bolt.
3. Set the dowel pin to the camshaft and the camshaft gear
and tighten the camshaft gear mounting bolt.
4. Retighten 90 deg (1/4 turn).

SAPH311990900125
! CAUTION • If it is excessively retightened, do not loosen
it.
• Prevent faulty conditions on the gear such as
deformation, impact, scratch, etc.
Installation of camshaft
JP31199090702010
1. Align the No. 1 cylinder to the compression top dead

center.
2. Installation of camshaft and rocker arm.

(1) Place the camshaft so that two holes at 180 degrees from
Timing decision the three drilled holes of the camshaft gear may be
drill hole
horizontal to the upper surface of the camshaft housing.
! CAUTION • Place a transparent plastic ruler or an edged

ruler on the upper surface of the camshaft
housing and the side of the camshaft gear.
Make sure that the position of the foolproof
Ruler or etc drilled hole is below the ruler.
Misconnection prevention drill hole
SAPH311990900126
(2) Coat the bearing parts with engine oil and then install the
camshaft bearing caps in numerical order 1-2-3-4-5 from
the front of the engine, making sure the five-sided mark on

the cap points forward.
Engine Foreword
SAPH311990900127
(3) Make sure the crosshead is correctly laid across each

valve.
Crosshead
! CAUTION • To make sure the crosshead is correctly in
place, move it to the left and right by hand and
make sure it clicks against the valves.
• If the crosshead is not sitting properly on the
valves, it will push the upper seat and cause
the valve to drop out.
SAPH311990900128
(4) Make sure the rocker arm is correctly assembled on the
rocker arm shaft.
(5) Fully unscrew the adjust screw on the end of the rocker
arm.
NOTICE • Securing the rocker arm and nozzle clamp

together with a string will facilitate installation
work.
(6) Apply engine oil to the cam threads and set the rocker
arm in position, making sure it is correctly laid on the
crosshead. Then, tighten the bolts in the sequence
shown in the figure, making several passes and gradually
tightening them each time.
! CAUTION • After the bolts are tightened, make sure the

rocker arm moves smoothly.
Setup layout
Layout
SAPH311990900129
Gear train layout

JP31199090402006
SAPH311990900130
Service procedure
Overhaul item
Removal of timing gear

JP31199090702011
1. Removal of main idle gear

(1) Remove the idle gear shaft mounting bolt and pull out the
main idle gear assembly using a special tool.
Special tool : 09420–1100 Sliding hammer

09420–1442 Sliding hammer
(2) Remove the idle gear thrust plate.

(3) Remove the idle gear shaft from the main idle gear.
SAPH311990900131
2. Removal of sub-idle gear

(1) Remove the idle gear shaft mounting bolt and the idle
gear thrust plate and pull out the sub-idle gear assembly
using a special tool.
Special tool : 09420–1100 Sliding hammer

09420–1442 Sliding hammer

(3) Remove the idle gear shaft from the sub-idle gear.
SAPH311990900132
Inspection of timing gear components

JP31199090702012
1. Inspection of clearance between idle gear shaft and idle

gear bushing
(1) Measure the idle gear shaft outer diameter using a
micrometer and the idle gear bushing inner diameter
using a cylinder gauge.
Standard value
(mm{in.})
Main idle Shaft outer diameter 57{2.2441}

gear shaft Bushing inner diameter 57{2.2441}
Sub-idle Shaft outer diameter 50{1.9685}

gear shaft Bushing inner diameter 50{1.9685}
(2) Calculate the difference between the idle gear bushing

inner diameter and the idle gear shaft outer diameter. If it
is beyond the service limit, replace the idle gear shaft and
the idle gear bushing.
SAPH311990900133 Standard value Service limit

(mm{in.}) (mm{in.})
Main idle gear 0.030 - 0.090

0.20{0.0079}
shaft {0.0012 - 0.0035}
Sub-idle gear 0.025 - 0.075

0.20{0.0079}
shaft {0.0010 - 0.030}
Installation of timing gear

JP31199090702013
1. Installation of sub-idle gear

(1) Install the idle gear shaft on the sub-idle gear.
Thrust plate
(2) Install the idle gear thrust plate.
(3) Provide the lubricating hole of the idle gear shaft in the
Idle gear thrust vertical direction.
plate (4) Install the idle gear thrust plate on the idle gear shaft.
Lubricating
hole idle gear shaft mounting bolt.
Cylinder block
SAPH311990900134
(6) Install the idle gear shaft mounting bolt.

SAPH311990900135
2. Installation of main idle gear

Idle gear thrust plate (1) Install the idle gear shaft on the main idle gear.
Lubricating
hole
Cylinder
Block
SAPH311990900136
(3) Face the lubricating hole of the idle gear shaft toward the
oil pan (downward). Install A in the figure by adjusting the
Sub-idle gear timing of the crankshaft gear and the main idle gear as in
the detailed drawing.
Oil pump
gear
A
Main idle gear
Crankshaft gear
Arrange drilled holes in line.

Detail
SAPH311990900137
idle gear shaft mounting bolt.
(5) Install the idle gear shaft mounting bolt.

(6) Measure backlash and end play of each idle gear. Make
sure that it is within the standard value.
SAPH311990900138
Overhaul of sub-idle gear (bearing case side)

JP31199090702014
1. Removal of bearing case assembly

(1) Remove the supply pump.
"Reference : Replacement, Supply pump".
(2) Disconnect the bearing case assembly.
! CAUTION • One bolt is tightened from the timing gear

case.
(3) Fix the bearing case with a vice.
SAPH311990900139
(4) Remove the sub-idle gear shaft mounting bolt and pull out
the idle gear shaft using a sliding hammer.
SAPH311990900140
(5) Remove the sub-idle gear.
SAPH311990900141
2. Inspection of clearance between sub-idle gear shaft and

sub-idle gear bushing
(1) Measure the outer diameter of the idle gear shaft.
SAPH311990900142
(2) Measure the inner diameter of the sub-idle gear.
(3) Calculate the clearance. If it is beyond the standard value,

replace the shaft and the bushing.
0.025 - 0.075
{0.0010 - 0.030}
SAPH311990900143
3. Installation of bearing case assembly

(2) Install the gear shaft on the sub-idle gear.
(3) Face the lubricating hole of the gear shaft downward and
install it on the bearing case.
(4) Install the sub-idle gear shaft mounting bolt.
SAPH311990900144
(5) Assemble the supply pump and bearing case.
! CAUTION • Be careful for fall of the O-ring

SAPH311990900145
Inspection of installation status for each

gear
JP31199090703003
1. Inspection of backlash between camshaft gear and cam

idle gear
(1) Insert a large flat tip screwdriver into the cam idle gear
from the side of the camshaft gear of the camshaft
housing to prevent turning of the cam idle gear.
SAPH311990900146
(2) Measure backlash between the camshaft gear and the

cam idle gear using a dial gauge. If it is beyond the
service limit, replace each gear.
0.030 - 0.253
0.30{0.0118}
{0.0012 - 0.0100}
SAPH311990900147
2. Inspection of camshaft end play
(1) Measure the end play of the camshaft using a thickness

gauge. If it is beyond the standard value, replace the
camshaft.
0.100 - 0.178
Standard value (mm)
{0.0039 - 0.0070}
SAPH311990900148
3. Inspection of backlash between main idle gear and air

compressor idle gear
(1) Remove the supply pump drive at the bearing case.

"Reference : Replacement, Supply pump".
(2) Insert a large flat tip screwdriver into the main idle gear
from the timing gear dust cover of the flywheel housing to
prevent turning of the main idle gear.
SAPH311990900149
(3) Measure backlash between the main idle gear and the air
compressor idle gear using a dial gauge and a magnet
stand. If it is beyond the service limit, replace each gear.
NOTICE • If the magnet stand is not stable, provide a

steel plate for measurement using bolt holes
of the cylinder block.

SAPH311990900150
0.032 - 0.096
0.10{0.0039}
{0.0013 - 0.0038}
4. Inspection of backlash between idle gear at bearing case

and supply pump drive gear
(1) Remove the supply pump drive.
"Reference : Replacement, Supply pump"
(2) Remove the bearing case assembly.
(3) Fix the supply pump drive with a vice and install the
Work example bearing case assembly.
(4) Measure backlash between the idle gear and the supply
pump drive gear using a dial gauge and a magnet stand. If
it is beyond the service limit, replace each gear.
0.020 - 0.083
0.10{0.0039}
{0.0008 - 0.0033}
SAPH311990900151
5. Inspection of backlash between main idle gear and sub-

idle gear
(1) Insert a large flat tip screwdriver into the main idle gear
from the timing gear dust cover of the flywheel housing to
prevent turning of the main idle gear.
SAPH311990900152
(2) Measure backlash between the main idle gear and the
sub-idle gear using a dial gauge and a magnet stand. If it
is beyond the service limit, replace each gear.
0.030 - 0.113
0.30{0.0118}
{0.0012 - 0.0044}
SAPH311990900153
6. Inspection of backlash between sub-idle gear at cam idle

gear and oil pump gear
(1) Insert a large flat tip screwdriver into the sub-idle gear to
prevent turning of the sub-idle gear.
SAPH311990900154
(2) Measure backlash between the sub-idle gear and the oil
pump gear using a dial gauge and a magnet stand. If it is
beyond the service limit, replace each gear.
0.030 - 0.131
0.30{0.0118}
{0.0012 - 0.0005}
SAPH311990900155
7. Inspection of idle gear end play
(1) Measure the end play of each gear using a thickness

gauge. If it is beyond the service limit, replace each gear
or shaft.

(mm{in.}) (mm{in.})
0.114 - 0.160
Main idle gear {0.0045 - 0.30{0.0118}
SAPH311990900156
0.0063}
0.040 - 0.095
Sub-idle gear {0.0016 - 0.30{0.0118}
0.0037}
8. Inspection of backlash between cam idle gear and sub-idle

gear
(1) Insert a large flat tip screwdriver into the sub-idle gear
from the side of the cam idle gear of the cylinder head to
prevent turning of the sub-idle gear.
SAPH311990900157
(2) Measure backlash between the cam idle gear and the
sub-idle gear using a dial gauge. If it is beyond the service
limit, replace each gear.
0.050 - 0.218
0.30{0.0118}
{0.0020 - 0.0086}
Setup layout
Layout
SAPH311990900158
Valve System
Part layout
JP31199090402007
SAPH311990900159
13706 Crosshead assembly 13735 Valve spring upper seat

13709 Adjusting screw (rocker arm) 13787 Adjusting screw (cross head)
13711 Intake valve 13830 Rocker arm intake
13715 Exhaust valve 13840 Rocker arm (exhaust)
13719 Valve stem seal* 13901 Rocker shaft
13731 Outer valve spring 13951 Rocker arm support
13732 Inner valve spring 900126 Valve spring retainer
13734 Valve spring lower seat
Tightening torque
13788 25N⋅m {250 kgf⋅cm, 18lbf⋅ft} 9069B 28.5N⋅m{290kgf⋅cm, 21lbf⋅ft}
9069A 28.5N⋅m{290kgf⋅cm, 21lbf⋅ft} 9069C 28.5N⋅m{290kgf⋅cm, 21lbf⋅ft}
Service procedure
Overhaul item
Overhaul of valve system

JP31199090702015
1. Inspection of rocker arm oil clearance
(1) Measure the outer diameter of the rocker shaft using a

micrometer.
22{0.8661} 21.92{0.8630}
(2) Measure the rocker arm bushing inner diameter using a

cylinder gauge.
SAPH311990900160
22{0.8661} 20.08{0.7905}

rocker shaft and the inner diameter of the rocker arm
bushing. If it is beyond the standard value, replace the
rocker shaft or the rocker arm bushing.
0.03 - 0.101
0.15{0.0059}
{0.0012 - 0.0039}
2. Removal of valve spring

Example
(1) Compress the valve spring using a special tool and
remove the valve spring retainer.
Special tool : 09470–1170 Valve spring press
SAPH311990900161
(2) Remove the intake and exhaust valves.
! CAUTION • Attach a tag with the applicable cylinder

number to the valve so that combinations of
the valve and the cylinder head may not be
mixed.
SAPH311990900162
3. Replacement of valve stem seal

Valve stem seal
Special tool (1) After removing the valve stem seal, assemble the valve
Valve spring spring lower seat. Apply engine oil to the lip and the inner
lower seat surface of the valve stem seal. Strike the valve guide
using a special tool until the special tool comes in contact
with the valve spring lower sea
Special tool : 09472–2100 Bar
! CAUTION • After assembly of the valve stem seal, make

sure that there is no deformation, crack or
inclination of the rubber.
Oil application
Rubber
SAPH311990900163
(2) After striking, check the height.
22.5 - 23.0
+0.1{0.0039in.}
{0.8858 - 0.9055}
22.9mm{0.9022in.}
-0.4{0.0157in.}
SAPH311990900164
4. Installation of valve spring
(1) Install the valve spring upper seat on the valve spring.
(2) Compress the valve spring using a special tool and install
the valve spring retainer.
Special tool : 09470–1170 Valve spring press
! CAUTION • Apply engine oil to the contact surface of

each part before assembly.
SAPH311990900165
• Be sure to assemble each valve at the original
cylinder position.
• When the valve spring is compressed, avoid
contact of the valve spring upper seat with the
valve stem seal.
• Since the valve spring has equal spacing,
vertical direction is not specified for assembly.
• Check for scratch on the valve stem seal
when the valve is reused.
5. Inspection of valve spring

Clearance A
(1) Measure squareness of the valve spring using a square or
a thickness gauge. If it is beyond the service limit
(clearance A), replace the valve spring.
Clearance A (mm{in.}) 2.0{0.0787}
SAPH311990900166
(2) Measure the free length of the valve spring using a vernier
calipers. If it is out of the service limit, replace the valve spring.

Measuring item
(mm{in.}) (mm{in.})
Inner valve spring (64.6[2.5433]) 61.6[2.4252]

Outer valve spring (75.7[2.9803]) 72.7[2.8622]
The value in [ ] is the reference value.

SAPH311990900167
6. Inspection of oil clearance between valve guide and valve stem
(1) Measure the outer diameter of the valve stem using a

micrometer.
Measuring item Standard value (mm{in.})
Intake valve stem 7{0.2756}
Exhaust valve stem 7{0.2756}
SAPH311990900168
(2) Measure the valve guide inner diameter using a cylinder

gauge.

Intake valve guide 7{0.2756}
Exhaust valve guide 7{0.2756}
(3) Calculate the difference between the valve stem outer

diameter and the valve guide inner diameter. If it is beyond
SAPH311990900169
the standard value, replace the valve or the valve guide.

Intake valve oil 0.023 - 0.058
clearance {0.0009 - 0.0023}
Exhaust valve oil 0.050 - 0.083

clearance {0.0020 - 0.0033}
Attachment procedure item
Adjustment of valve clearance

JP31199090706001
1. Precautions before adjustment
! CAUTION • Before adjustment, make sure that bolts of

the cylinder head, rocker arm support,
nozzle clamp, camshaft housing and
camshaft bearing cap are tightened to the
specified torque.
2. Adjustment of valve clearance

(1) Make sure that there is no dirt between the crosshead and
the valve stem
(2) Turn the crankshaft in the forward direction and adjust the
cylinder to the compression top dead center.
! CAUTION • Make sure that there is a roller on the cam

base circle.
(3) Loosen the adjusting screw and the lock nut of the
Adjusting screw of rocker arm
Roller crosshead completely.
Cam base
circle Lock nut
Adjusting screw of
crosshead ! CAUTION • Provide the adjusting screw protrusion of 10
10 mm or more
mm or more from the top surface of the
crosshead. If the adjusting screw is not
completely separated from the valve stem,
Clearance correct adjustment is not allowed.
Close contact
Lock Nut
SAPH311990900170
(4) Insert a thickness gauge between the rocker arm and the
Rocker arm Thickness gauge crosshead and adjust the clearance with the adjusting
screw of the rocker arm. Tighten the lock nut.
Standard value IN 0.30mm{0.0118 in.}

(cold engine) EX 0.45mm{0.0177 in.}
Close contact Tightening torque : 25 N⋅m {250 kgf⋅cm, 18 lbf⋅ft}

Crosshead
SAPH311990900171
(5) Loosen the adjusting screw of the crosshead with the

Start thickness gauge inserted. Make sure that feel on the
Feel of thickness gauge
thickness gauge is not lighter.

(No move) Nut fixing position
! CAUTION • If it becomes lighter, make adjustments again

(Appropriate from the beginning.
contact)
Feel remains the same.

Loosening of adjusting screw Large
SAPH311990900172
(6) Tighten the adjusting screw of the crosshead until the

thickness gauge does not move.
Close contact
Close contact
SAPH311990900173
(7) While loosening the adjusting screw of the crosshead

Start gradually, tighten the lock nut of the crosshead at the
Feel of thickness gauge
position where feel on the thickness gauge is appropriate.

(No move) Nut fixing position
(Appropriate ! CAUTION • Do not over-loosen the adjusting screw. Over-

contact)
loosening of the adjusting screw reproduces
Feel remains the same. the original status. Although feel on the
Loosening of adjusting screw Large thickness gauge is appropriate, there is
SAPH311990900174 clearance between the adjusting screw and
the valve of the crosshead. Correct
adjustment is not allowed.
EXHAUST 10–1
ENGINE
10 EXHAUST
Setup layout
Layout
Exhaust Manifold...................................................... 10-2

Part layout ............................................................. 10-2
Replacement......................................................... 10-4
10
10–2 EXHAUST
Exhaust Manifold
Part layout
JP31199100402001
SAPH311991000001
17104 Gasket* 17141 Exhaust manifold

Tightening torque
9209A 53 N⋅m {540 kgf⋅cm, 40lbf⋅ft}
EXHAUST 10–3
SAPH311991000002
17104A Gasket* 17148 Plate

Service procedure
10–4 EXHAUST
Replacement
JP31199100704001
1. Removal of exhaust manifold

(1) Remove nuts and remove the exhaust manifold.
2. Replacement of stud bolt

(1) Remove dirt (e.g. sealant) at the female thread of the
cylinder head and clean the thread again with tap (M10 x
1.5).
(2) Use the Torx wrench to tighten a new stud bolt.
! CAUTION • Excessive tightening with over torque may

cause crack in the cylinder head.
3. Installation of exhaust manifold

(1) Assemble a new gasket.
! CAUTION • Since a gasket has front and back, install the

black side on the exhaust manifold.
Black side
SAPH311991000003
(2) Tighten the mounting nut of the exhaust manifold

according to the order in the figure.
When a new exhaust manifold is used Tightening torque : 53 N⋅m {540 kgf⋅cm, 40 lbf⋅ft}
12 11 10 9 8 7 6 5
! CAUTION • When nuts are tightened, prevent each
spacer from riding on the counterbore area of
4
the manifold flange.
1 2 3
• The tightening sequence of the exhaust
When exhaust manifold is reused
manifold varies between use of a new part
8 9 2 3 5 6 11 12 and reuse.
(3) Tighten the same nuts again according to the order in the
7 1 4 10 figure.
Spacer
! CAUTION • Be sure to retighten it.
SAPH311991000004
COOLING 11–1
ENGINE
11 COOLING
System drawing
Cooling System ........................................................ 11-2

Cooling system drawing........................................ 11-2
Part layout ............................................................. 11-3
Replacement of thermostat case .......................... 11-4
Inspection of thermostat ....................................... 11-5
Replacement of coolant pump .............................. 11-6
11
11–2 COOLING
Cooling System
Cooling system drawing
JP31199110803001
Reservoir
Water temperature
Thermostat case
Cylinder head
Thermostat
Radiator
Cylinder block
Turbo charger
Car
heater
Coolant pump Oil cooler
Drain cock
Drain cock
SAPH311991100001
Setup layout
Layout
COOLING 11–3
Part layout
JP31199110402002
SAPH311991100002
16100 Coolant pump assembly 16325 Gasket*

16173 Coolant pump pulley 16331 Thermostat case cover
16303 Thermostat case 16377 Fan spacer
16306 Cooling fan 9851A O–ring*
16323 Thermostat case cover

Service procedure
11–4 COOLING
Replacement of thermostat case

JP31199110704001
1. Removal of thermostat case

(1) Remove bolts and remove the thermostat case.
(2) Remove the O-ring from the groove on the coolant pump.
SAPH311991100003
2. Installation of thermostat case

(1) Remove contamination on the joint between the
Liquid gasket
thermostat case and the cylinder head using a scraper.
Cylinder head
Opening
(2) Apply liquid gasket [Threebond TB1207B(black) or
equivalent] to the thermostat case as shown in the figure.

2.5 mm{0.0591 to 0.0984 in.}.
SAPH311991100004
(3) Install the new O-ring on the groove of the coolant pump.
(4) Put the thermostat case mounting bolt through the

bolt2 thermostat case in advance.
(5) Align the thermostat case at the mounting position and
tighten mounting bolt 1 temporarily to the cylinder head.
(6) Tighten mounting bolt 2 temporarily to the coolant pump.
(7) Tighten bolts in the order mounting bolt 1 to the cylinder
bolt1
head and mounting bolt 2 to the coolant pump.
SAPH311991100005
COOLING 11–5
Inspection of thermostat
JP31199110703001
1. Individual inspection of thermostat

Wire Thermometer (1) Put the thermostat in water as shown in the figure and
heat it.
! CAUTION • Support the thermostat in the center to

prevent approach to the heat source.
Thermostat • Stir the water well so that water temperature
in the container may be uniform.
Heat source Valve lift
SAPH311991100006
(2) Measure the temperature (valve opening temperature)

T1 : Valve opening temperature (start of valve opening)
T2: Full open lift inspection temperature
that opens the thermostat valve.
13mm
Thermostat valve opening
{0.5122in.} 74.5 - 78.5
temperature standard value :
{166.1 - 173.3}
Valve lift
T1(°C{°F})
0°C{32°F} 10°C Temperature NOTICE • The thermostat valve opening temperature

T1°C{°F} T2°C{°F}
{50°F}
(T1) is stamped on the thermostat seat.
SAPH311991100007
(3) Increase the water temperature to 95 °C{203°F} and

measure the lift of the thermostat valve.
Thermostat valve full

open lift inspection Valve lift : L (mm{in.})
L1 At cold open temperature : T2 (°C{°F})
L2 :Temperature at (T2)°C{°F}
L : Valve lift
L 95{203} 10{0.3937} or more
L 1
L 2
(4) Put the full open thermostat valve in water at normal
SAPH311991100008
temperature. Make sure that the thermostat valve closes
completely within 5 minutes.
(5) If faulty item is found with the inspection above, replace
the thermostat.
11–6 COOLING
Replacement of coolant pump

JP31199110704002
1. Removal of coolant pump

(1) Remove bolts and remove the coolant pump.
SAPH311991100009
2. Installation of coolant pump

Liquid gasket (1) Remove contamination on the joint surface between the
coolant pump and the cylinder block using a scraper and
degrease the surface.
(2) Apply the liquid gasket [Threebond TB1207B (black) or
equivalent] to the coolant pump as shown in the figure.

• Apply the liquid gasket at the width of 2 to
SAPH311991100010 3mm{0.0787 to 0.1181in.}.
• Fill the groove on the water pump flange with
the liquid gasket.
(3) Install the coolant pump to the dowel pin of the cylinder
block.
NOTICE • When the coolant pump is installed using a

guide bolt, displacement of the liquid gasket
does not occur.
SAPH311991100009
LUBRICATION 12–1
ENGINE
12 LUBRICATION
System drawing
Oil Cooler, Oil Filter and Oil Pump.......................... 12-2

System drawing .................................................... 12-2
Part layout ............................................................. 12-3
Replacement of oil cooler ..................................... 12-5
Overhaul of oil cooler ............................................ 12-6
Replacement of oil pump ...................................... 12-9
Overhaul of oil pump........................................... 12-10
Replacement of oil strainer ................................. 12-13
Oil Pan ..................................................................... 12-14
Part layout ........................................................... 12-14
Replacement....................................................... 12-15
Inspection of lubrication status ........................... 12-16
12
12–2 LUBRICATION
Oil Cooler, Oil Filter and Oil Pump

System drawing
JP31199120805001
Roller pin
Cam Roller
Adjusting Rocker
Valve Crosshead Rocker arm arm
screw shaft
Camshaft
Oil pan
Cam idle
gear shaft
Sub-idle
gear shaft
Turbocharger
Strainer
Oil pump Main

Oil cooler Oil filter oil hole
Piston pin Connecting Crankshaft

rod
Supply
pump
drive
Sub-idle gear shaft

(supply pump drive)
Piston cooling jet Sub-oil

(check valve) hole
Main idle
gear shaft
: Lubrication
: Return
SAPH311991200001
Setup layout
Layout
LUBRICATION 12–3
Part layout
JP31199120402001
SAPH311991200002
15012 Oil pump cover assembly 15710 Oil cooler

15104 Oil strainer 9500-40400 Cotter pin*
15107 Driven gear 9851A O–ring*
15110 Oil pump assembly 9851B D–ring*
15119 Gasket* 15139 Seat2
15132 Relief valve spring 15139A Seat1
15135 Safety valve

Tightening torque
9068-08160 28.5N⋅m {290kgf⋅cm, 21lbf⋅ft} 9068-08750 24.5±4.9N⋅m {250±50kgf⋅cm, 18±4llbf⋅ft}
9068-08250 31N⋅m {320kgf⋅cm, 23lbf⋅ft} 9068-08900 24.5±4.9N⋅m {250±50kgf⋅cm, 18±4lbf⋅ft}
9068-08320 24.5±4.9N⋅m {250±50kgf⋅cm, 18±4lbf⋅ft} 9068-58100 24.5±4.9N⋅m {250±50kgf⋅cm, 18±4llbf⋅ft}
9068-08550 28.5N⋅m {290kgf⋅cm, 21lbf⋅ft}
12–4 LUBRICATION
SAPH311991200003
15662 Drain plug 9644A O–ring*

15675 Safety valve 9739A Elbow
15701 Oil cooler case 9851A O–ring*
15710 Oil cooler assembly 9851B O–ring*
15712 Oil cooler element 9851C O–ring*
15717 Gasket* 9851D O–ring*
15720 Oil cooler case assembly 9851E O–ring*

Tightening torque
15662 44.1±4.9 N⋅m {450±50 kgf⋅cm, 33±4llbf⋅ft} 9201-10080 24.5±4.9 N⋅m {250±50 kgf⋅cm, 18±4llbf⋅ft}
Service procedure
LUBRICATION 12–5
Replacement of oil cooler

JP31199120704001
1. Removal of oil cooler
(1) Remove bolts and hose joint, and remove the oil cooler.
SAPH311991200004
(2) If it is difficult to remove the oil cooler due to liquid gasket

Figure is an sticking to the cylinder block, put a flat tip screwdriver at
example of work.
the protrusion in the figure for removal.
SAPH311991200005
2. Installation of oil cooler

D-Ring (1) Assemble the new D-ring into the D-ring groove of the oil
Block
Oil cooler cooler.
! CAUTION • Face the D-ring flat area toward the oil cooler.
Flat area
SAPH311991200006
(2) Remove contamination on the joint surface between the

oil cooler and the cylinder block using a scraper. Apply the
Liquid gasket
liquid gasket [Threebond TB1207 (silver) or equivalent] to
the oil cooler as shown in the figure.

2.5 mm{0.0590 to 0.0984 in.}.
SAPH311991200007 application of the liquid gasket.
12–6 LUBRICATION
(3) Insert the positioning stud into the screw hole of the
cylinder block and install the oil cooler.
(4) After temporary tightening with bolts, remove the

positioning stud and tighten bolts.
Tightening torque :
24.5±4.9 N⋅m {250±50 kgf⋅cm, 18±4 lbf⋅ft}
! CAUTION • Tighten together with the alternator ground.

• Be sure to connect the turbocharger
SAPH311991200008 lubricating oil hose.
(5) Install the drain plug.
Tightening torque :
44.1±4.9 N⋅m {450±50 kgf⋅cm, 33±4 lbf⋅ft}
! CAUTION • If a new part is used, tighten it to 58.8±4.9N·m

{600±50kgf·cm, 43±4lbf·ft} and loosen it.
Then, tighten it again to the torque above.
SAPH311991200009
Overhaul item
Overhaul of oil cooler

JP31199120702001
1. Removal of oil cooler element

(1) Remove nuts and remove the oil cooler element.
2. Inspection of oil cooler element

(1) Wash water and oil channels with kerosene oil or washing
fluid.
(2) Check for crack or deformation on the stud bolt mounting
area and element visually.
(3) Blow air of approx. 0.5kgf/cm2 into the oil channel to
SAPH311991200010 check for leak from parts. If crack, leak or deformation is
found, replace it with a new part.
3. Disassembly of oil cooler case
! CAUTION • Disassembly immediately after stop of the

engine may cause blowout of engine oil.
(1) Remove valve spring plugs and safety valves using a

hexagonal wrench.
SAPH311991200011
LUBRICATION 12–7
(2) Remove the oil pressure warning switch.
SAPH311991200012
4. Inspection of safety valve wear and damage

(1) If wear or damage is found, replace it.
SAPH311991200013
5. Inspection of oil pressure warning switch

(1) For inspection of oil pressure warning switch, refer to
"Inspection of components"- "Electrical".
6. Assembly of oil cooler case

(1) Install a new O-ring and install valve spring plugs and
safety valves using a hexagonal wrench.
Tightening torque :
24.5±4.9 N⋅m {250±50 kgf⋅cm, 18±4 lbf⋅ft} (M14, M20)
29.4±4.9 N⋅m {300±50 kgf⋅cm, 22±4 lbf⋅ft} (M22)
34.3±4.9 N⋅m {350±50 kgf⋅cm, 25±4 lbf⋅ft} (M24)
SAPH311991200011
(2) Apply the liquid gasket [Threebond TB1211 (white) or

equivalent] to the sealing surface of a new soft washer.
(3) Install the soft washer in (2) and the oil pressure warning
switch.
SAPH311991200012
12–8 LUBRICATION
7. Installation of oil cooler element

(1) Assemble new gasket and new O-ring and assemble the
oil cooler element with nuts.
Tightening torque :
24.5±4.9 N⋅m {250±50 kgf⋅cm, 18±4 lbf⋅ft}
! CAUTION • In handling the oil cooler element, be careful

not to give damage to it.
SAPH311991200010 Replacement procedure item

LUBRICATION 12–9
Replacement of oil pump

JP31199120704002
1. Removal of oil pump

(1) Dismount the engine from the machine.
(2) Remove the flywheel.
(3) Remove the flywheel housing.
(4) Remove the timing gear.
(5) Remove the oil pump.
2. Installation of oil pump

(1) Apply engine oil to the pump case and the bearing
(shaded area) of the cylinder block.
! CAUTION • Without application of engine oil, poor oil

suction may occur at the initial start,
Application of engine oil resulting in seizure or abnormal wear.
(Shaded area)
SAPH311991200014
(2) To prevent bolt hole offset of the new gasket, apply

engine oil to the cylinder block in advance and place and
fix the gasket.
! CAUTION • Assembly with offset gasket may cause faulty

sealing. Oil in the oil pump may be completely
discharged when the engine stops. Faulty
sealing may cause insufficient suction of oil
at initial revolution of engine restart,
resulting in seizure or abnormal wear.
(3) Tighten the oil pump according to the order in the figure.
! CAUTION • If the tightening order is not observed, the oil

Gasket
pump may be damaged.
Oil pump • After tightening, make sure that the gear can
be turned with hand.
Overhaul item
SAPH311991200015
12–10 LUBRICATION
Overhaul of oil pump

JP31199120702002
1. Remove the driven gear.
SAPH311991200016
2. Remove the cotter pin and remove seat 2, seat 1, relief

valve spring and safety valve.
! CAUTION • When the cotter pin is removed, seat 2 and

the relief valve spring may eject out.
SAPH311991200017
3. Inspection of clearance between drive gear and cylinder

block
(1) Measure the outer diameter of the drive gear and the
inner diameter of the pump chamber at cylinder block.
Standard value
Measuring area
(mm{in.})
Outer diameter of drive gear 54{2.1260}
SAPH311991200018 Inner diameter of pump chamber

54{2.1260}
at cylinder block

drive gear and the inner diameter of the pump chamber at
the cylinder block. If it is beyond the service limit, replace
the oil pump assembly.

0.100 - 0.202{0.0039 -
0.30{0.0118}
0.0080} (reference)
SAPH311991200019
LUBRICATION 12–11
4. End play inspection between drive gear and cylinder block
(1) Measure the drive gear width and the pump chamber
depth at the cylinder block using a depth gauge.
Standard value
Measuring area
(mm{in.})
Width of drive gear 28.5{1.1220}
Depth of pump chamber at

28.5{1.1220}
SAPH311991200020 cylinder block
(2) Calculate the difference between the depth of the drive

gear and the pump chamber depth at the cylinder block. If
it is beyond the service limit, replace the oil pump
assembly.
0.049 - 0.113{0.0020 -
0.15{0.0060}
0.0044} (reference)
SAPH311991200021
5. Inspection of clearance between outer diameter of driven

gear shaft and cylinder block hole diameter
(1) Measure the outer diameter of the driven gear shaft using
a micrometer and measure the cylinder block hole
diameter using a cylinder gauge.
Standard value
Measuring area
(mm{in.})
Outer diameter of driven gear

SAPH311991200022 18{0.7087}
shaft
Cylinder block hole diameter 18{0.7087}

driven gear and the cylinder block hole diameter. If it is
beyond the service limit, replace the oil pump assembly.
0.040 - 0.099
{0.0016 - 0.0039}
SAPH311991200023
12–12 LUBRICATION
6. Inspection of clearance betweeen outer diameter of driven

gear shaft and inner diameter of driven gear bushing
a micrometer and measure the inner diameter of the
driven gear bushing using a cylinder gauge.
Standard value
Measuring area
(mm{in.})

SAPH311991200024 18{0.7087}
shaft
Cylinder block hole diameter 18{0.7087}

driven gear and the cylinder block hole diameter. If it is
beyond the service limit, replace the oil pump assembly.
0.030 - 0.075
{0.0012 - 0.0030}
SAPH311991200025
7. Inspection of clearance betweeen outer diameter of driven

gear shaft and inner diameter of driven gear bushing
a micrometer and measure the inner diameter of the
driven gear bushing using a cylinder gauge.
Standard value
Measuring area
(mm{in.})

SAPH311991200024 18{0.7087}
shaft
Inner diameter of driven gear

18{0.7087}
bushing

driven gear shaft and the inner diameter of the driven gear
bushing. If it is beyond the service limit, replace the oil
pump assembly or the driven gear bushing.
0.040 - 0.083
0.15{0.00059}
{0.0016 - 0.0033}
SAPH311991200026
LUBRICATION 12–13
8. Inspection of drive gear backlash
(1) Fix the oil pump assembly with a vice.

(2) Measure backlash between the drive gear and the driven
gear using a dial gauge. If it is beyond the service limit,
replace the oil pump assembly.
0.072 - 0.277
0.30{0.0118}
{0.0028 - 0.0109}
SAPH311991200027
9. Assembly of oil pump

(1) Install the safety valve, relief valve, seat 1 and seat 2 on
the oil pump cover assembly with new cotter pins.
SAPH311991200017
(2) Install the driven gear.
SAPH311991200016
Replacement of oil strainer

JP31199120704003
1. Removal of oil strainer

(1) Remove bolts and remove the oil strainer.
2. Installation of oil strainer

(1) Replace the O-ring with new ones and install the oil
strainer.
Setup layout
Layout
SAPH311991200028
12–14 LUBRICATION
Oil Pan
Part layout
JP31199120402003
SAPH311991200029
12111 Oil pan assembly 12149 Drain plug

12151 Oil pan gasket* 9659A Gasket*

Tightening torque
12149 30 N⋅m {300 kgf⋅cm, 22lbf⋅ft} 9068-08800 30 N⋅m {300 kgf⋅cm, 22lbf⋅ft}
Service procedure
LUBRICATION 12–15
Replacement
JP31199120704004
1. Installation of oil pan
(1) Cut the gasket of the rear end plate to be flush to the
cylinder block lower surface using a scraper.
(2) Make sure that there is no deformation, dirt or oil on the
joint surface between the cylinder block and the oil pan.
Protrusion
Apply liquid gasket [Threebond TB1207D (silver) or
equivalent] to the front rear end of the cylinder block lower
surface.
(3) Insert several stud bolts (70 mm{2.7559 in.} or larger) for
Bolt tightening
attaching direction
positioning into the cylinder block screw hole.
(4) Position the oil pan gasket protrusion at the intake side
and the flywheel housing (printed seal surface at cylinder
block). Align the new oil pan gasket and oil pan to the
cylinder block lower surface and tighten bolts in the arrow
order of the figure.
Tightening torque :
Liquied gasket application position 19.6 - 24.5 N⋅m {200 - 250 kgf⋅cm, 14 - 18 lbf⋅ft}
(5) Remove positioning stud bolts and install the correct bolts.
Engine front side (6) Tighten bolts in the arrow order of the figure.
SAPH311991200030
! CAUTION • Check if the washer is not riding on the

flange.
• Make sure that the printed seal is not peeled
or damaged before installation of the oil pan
gasket.
12–16 LUBRICATION
Inspection of lubrication status

JP31199120703001
1. Inspection of valve system
! CAUTION • Perform inspection with the water

temperature at 60 °C{140°F}.
(1) Remove the head cover.
! CAUTION • To prevent spread of engine oil, attach a jig

which cuts a head cover in half. Cut it to the
degree that the camshaft is covered.
(2) Adjust the engine revolution to the standard idling

revolution [1,000/min{rpm}].
(3) After start of the engine, make sure that oil is supplied to
the areas below of all rocker arms within about 10
seconds.
• Roller and cam surface
• Cross head and spring upper seat surface through
adjusting screw
! CAUTION • If time until lubrication is long or if lubrication

is not performed, the oil pressure may be low
SAPH311991200031
or the oil channel may be clogged. Seizure,
abnormal wear or abnormal noise may occur
due to insufficient lubrication.
STARTING AND CHARGING 13–1
ENGINE
13 STARTING AND CHARGING

Setup layout
Layout
Starter ........................................................................ 13-2

Part layout (typical example)................................. 13-2
Disassembly.......................................................... 13-3
Inspection of components ..................................... 13-9
Assembly ............................................................ 13-14
Alternator (50A) ...................................................... 13-21
Part layout (typical example of 50A) ................... 13-21
Circuit drawing (50A) .......................................... 13-22
Disassembly........................................................ 13-23
Inspection of components ................................... 13-26
Assembly ............................................................ 13-29
Inspection after assembly ................................... 13-33
13
13–2 STARTING AND CHARGING
Starter
Part layout (typical example)
JP31199130402001
SAPH311991300001
28011 Clutch assembly 28138 Packing*

28100 Starter 28140 Brush holder assembly
28111 Bushing 28142 Brush
28111A Bushing 28142A Brush
28113 Lever assembly 28143 Spring
28115 Start drive housing 28150 Center bracket
28117 Packing* 28160 Armature assembly
28117A Packing* 28168 Retainer clip*
28118 Plate 28199 Dust protector
28118A Brake plate 28240 Start magnet switch
28118B Plate 28251 Pinion
28118C Sim 28252 Rear side bearing*
28118D Cover 28255 Shaft assembly
28120 Yoke assembly 28253 Planetary gear
28133 Commutator end frame 28253A Internal gear

Tightening torque
28112 14-16 N⋅m{140-160kgf⋅cm, 10-12lbf⋅ft} 28112E 15.7-17.6 N⋅m{160-179kgf⋅cm, 12-13lbf⋅ft}
28112A 3.6-4.9 N⋅m{37-49kgf⋅cm, 3-4lbf⋅ft}
Service procedure
Overhaul item
Disassembly
JP31199130702001
NOTICE • Fix the starter on the working table to ease

M lead wire
accessibility.
M terminal
1. MRemoval of lead wire

(1) Remove the cap of the M terminal.
(2) Remove nuts and remove the M lead wire.
SAPH311991300002
2. Removal of commutator end frame

Through bolt (1) Loosen and remove two through bolts.
Commutator end
frame
SAPH311991300003
(2) Remove two set bolts and remove the commutator end
frame.
Set bolt
! CAUTION • Hold the M lead wire and remove the
commutator end frame by lifting.
SAPH311991300004
3. Removal of brush holder assembly

Brush holder
Assembly (1) Lift the spring using a flat tip screwdriver or pliers.
Remove four brushes from the brush holder assembly.
! CAUTION • Do not cut the brush lead fixing clamp.
(2) Remove the brush holder assembly from the armature

assembly.
Spring
Brush
Brush lead
Clamp
SAPH311991300005
4. Removal of yoke assembly

M lead wire (1) Remove the yoke assembly from the center bracket
Yoke assembly
assembly.
! CAUTION • Do not hold the M lead wire and hold the yoke
assembly outer diameter for removal.
Center bracket
assembly
SAPH311991300006
5. Removal of packing
Yoke assembly (1) Remove the packing from the centering parts at both ends
of the yoke assembly.
! CAUTION • Damaged packing must not be resued.

Replace it with a new part.
Packing Packing
SAPH311991300007
6. Removal of armature assembly

(1) Remove the armature assembly by lifting.
Armature
assembly
! CAUTION • When the armature assembly is removed, the
washer at the end of the gear may be dropped
and lost. Be careful for handling.
Center bracket
assembly
SAPH311991300008
7. Removal of rear bearing

(1) Pull out the bearing of the armature assembly using a
Rear bearing puller or press.
! CAUTION • Removed bearing must not be reused.

Replace it with a new one.
Puller
SAPH311991300009
8. Removal of cover
Packing Cover (1) Remove the cover from the center bracket assembly.
(2) Remove the packing.

SAPH311991300010
9. Removal of planetary gear

(1) Remove the planetary gear from the carrier pin.
Planetary gear ! CAUTION • Make sure that the gear is not damaged or
chipped.
Carrier pin
SAPH311991300011
10. Removal of internal gear

(1) Remove the internal gear from the center bracket.
! CAUTION • Make sure that the gear is not damaged or

chipped.
Internal gear
Center bracket
SAPH311991300012
11. Removal of shim washer

(1) Remove the shim washer from the center bracket.
Shim
SAPH311991300013
12. Removal of pinion

(1) Remove the retainer clip using a tool such as snap ring
pliers.
Retainer clip ! CAUTION • Retainer clip must not be reused. Replace it

Pinion stopper
with a new one.
NOTICE • Push upward or pull out the chipped part of

the clip mouth.
Pinion
SAPH311991300014
(2) Remove the pinion stopper.

(3) Remove the pinion.
Pinion stopper
! CAUTION • Make sure that the gear is not damaged or
Pinion chipped.
SAPH311991300015
13. Removal of center bracket

Center bracket
(1) Remove two set bolts at the switch using a box
screwdriver or offset wrench.
(2) Lift and remove the center bracket.
Clutch
assembly
SAPH311991300016
14. Removal of lever

(1) Hold the lever holder and press the entire lever to the
Plunger clutch. Remove the link with the plunger.
Holder
Lever assembly
SAPH311991300017
(2) Turn and pull out the lever assembly using the clutch as
the axis.
Lever assembly
SAPH311991300018
15. Removal of brake plate

(1) Hold the clutch case outer diameter and slide the clutch
assembly upward. Pinch the clip end fixing the brake plate
and remove it by bending.
SAPH311991300019
(2) Remove the brake plate.
Brake plate
SAPH311991300020
16. Removal of clutch assembly

(1) While pressing the clutch assembly to the center bracket
Clutch assembly
assembly, offset the helical spline by one tooth.
Pull out the clutch assembly upward from the offset
Center bracket position and remove it.
assembly
SAPH311991300021
17. Removal of shaft assembly

Washer
(1) Turn the center bracket assembly upside down. Hold the
carrier plate and pull out the shaft assembly.
! CAUTION • Washers are available at the upper and lower

parts of the carrier plate. Be careful for loss of
the washers.
Shaft assembly
SAPH311991300022
18. Removal of packing

(1) Turn the center bracket upside down again and remove
the packing.
! CAUTION • Packing must not be reused.
Packing
SAPH311991300023
JP31199130703001
1. Inspection of yoke assembly

(1) Make sure that the coil lead wire has electric continuity
using a circuit tester.
(2) Make sure that there is no discoloration at the coil.
SAPH311991300024
(3) Measure the resistance between the coil lead wire and the
Tester rod yoke with a circuit tester and check insulation.
When the value is below the service limit, replace it.
Feed coil
Service limit 1kΩor less
! CAUTION • After cleaning and drying, take

Yoke assembly measurements.
SAPH311991300025
(4) Measure the brush length using vernier calipers.

18{0.7087} 13{0.5118} or less
SAPH311991300026
2. Inspection of armature assembly

Piece of steel
(1) Turn the armature assembly using a commercially
available growler tester and put a piece of steel on the
armature assembly. Make sure that the steel piece is not
vibrating on the core circumference.
Growler tester
SAPH311991300027
(2) Make sure that adjacent segments of the commutator

have electric continuity using a circuit tester.
(3) Make sure that there is no discoloration at the coil.
SAPH311991300028
(4) Measure the resistance between the commutator and the

core using a circuit tester and check insulation.
Core
Commutator
1MΩor more 1kΩor less

measurements.
SAPH311991300029
(5) Measure the commutator outer diameter using vernier

calipers.
! CAUTION • After removing roughness on the surface

(after polishing), take measurements.
Commutator outer diameter

Commutator
SAPH311991300030 36{1.4173} 34{1.3386} or less
(6) Measure the undercut depth between segments. If the

undercut depth is beyond the service limit, repair it.

Undercut length:
0.5 to 0.8 mm 0.5 - 0.8{0.0197 - 0.0315} 0.2{0.0079} or less
Segment {0.0197 - 0.0315}
! CAUTION • In repair, do not leave insulation material at

the end of the segment.
Insulating material
SAPH311991300031
(7) Measure the shaft outer diameter using a micrometer. If it

is beyond the service limit, replace the shaft.
A Standard value Service limit

Measuring area
(mm{in.}) (mm{in.})
B 11.98{0.4717} or
Area 12{0.4724}
less
8.98{0.3535} or
Area 9{0.3543}
SAPH311991300032 less
3. Inspection of brush holder assembly

(1) Measure the resistance between the holder (plus) and the
plate using a circuit tester and check insulation.
Service limit 1kΩor less

measurements.
SAPH311991300033
(2) Measure the brush length using vernier calipers.

Brush Spring When the value is below the service limit, replace it.
18{0.7087} 13{0.5118} or less
(3) Make sure that the spring has pressure.
Brush
SAPH311991300034
4. Inspection of shaft assembly

(1) Measure the outer diameter of the shaft using a
micrometer
If it is beyond the service limit, replace the shaft.
B A
Measuring area
(mm{in.}) (mm{in.})
25.90{1.0197} or
Area 26{1.0236}
less
SAPH311991300035
12.04{0.4740} or
Area 12.1{0.4764}
less
5. Inspection of clutch assembly

(1) Measure the outer diameter of the inner sleeve using a
micrometer.
If it is beyond the service limit, replace the clutch
assembly.
25{0.9843} 24.90{0.9803} or less
SAPH311991300036
6. Inspection of bearing
(1) Measure the bearing metal inner diameter (1 in the figure)
of the pinion case using a cylinder gauge. If it is beyond
the service limit, replace the bushing.
1
25{0.9843} 25.2{0.9921} or more
SAPH311991300037

of the center bracket using a cylinder gauge. If it is beyond
the service limit, replace the center bracket.
2 26{1.0236} 26.2{1.0315}
SAPH311991300038

3 4 of the shaft assembly using a cylinder gauge. If it is
beyond the service limit, replace the shaft assembly.
9{0.3543} 9.2{3.6220}
(4) Measure the bearing housing inner diameter (4 in the

figure) of the commutator end frame using a cylinder
SAPH311991300039
gauge. If it is beyond the service limit, replace the
commutator end frame.
28{1.1024} 28.1{1.1063} or more
7. Inspection of start magnet switch assembly (resistance of

C terminal
P coil)
M terminal (1) Measure the P coil resistance between the C terminal and
the M terminal using a circuit tester.
If it is beyond the service limit, replace the start magnet
switch.
Standard value (Ω) 0.12 - 0.14
SAPH311991300040
8. Inspection of start magnet switch assembly (resistance of

H coil)
(1) Measure the H coil resistance between the C terminal and
C terminal the body using a circuit tester.
If it is beyond the service limit, replace the start magnet
switch.
Body
Standard value(Ω) 1.13 - 1.25
SAPH311991300041
9. Inspection of start magnet switch assembly (electric

continuity inspection)
M terminal (1) Check electric continuity between the B terminal and the
M terminal using a circuit tester, and make sure that there
is no electric continuity.
B terminal
SAPH311991300042
(2) Push the end of the start magnet switch assembly (close
the internal contact) and make sure that there is electric
continuity between the B terminal and the M terminal
using a circuit tester.
SAPH311991300043
Overhaul item
Assembly
JP31199130702002
1. Installation of packing
(1) Install a new packing on the center bracket assembly.
Packing
SAPH311991300023
2. Installation of shaft assembly

Washer
(1) Turn the center bracket assembly upside down and hold
the carrier plate. Lubricate parts (refer to the lubrication
point drawing and the lubrication list) and install the shaft
assembly.
! CAUTION • Washers are available at the upper and lower

Shaft assembly parts of the carrier plate. Be careful for loss of
the washers.
SAPH311991300022
3. Installation of clutch assembly

(1) Lubricate parts (refer to the lubrication point drawing and
Clutch assembly
the lubrication list) and insert the clutch assembly into the
center bracket assembly.
Center bracket
assembly
SAPH311991300044
4. Installation of brake plate

the lubrication list) and install the brake plate.
Brake plate
SAPH311991300045
5. Installation of lever
the lubrication list). Turn and install the lever assembly
using the clutch as the axis.
Lever assembly
SAPH311991300018
6. Installation of pinion case

Center bracket
(1) Install two set bolts at the switch using a box screwdriver
or offset wrench.
Tightening torque :
Clutch 14 - 16 N⋅m {140 - 160 kgf⋅cm, 10 - 12 lbf⋅ft}
assembly
SAPH311991300016
7. Installation of pinion
Pinion stopper the lubrication list) and install the pinion and the pinion
stopper.
Pinion
SAPH311991300015
(2) Install the retainer clip using a tool such as snap ring
pliers.
Retainer clip
Pinion stopper
Pinion
SAPH311991300014
8. Installation of shim washer

the lubrication list) and install the shim washer on the
center bracket.
Shim
SAPH311991300013
9. Removal of internal gear

the lubrication list) and install the internal gear on the
center bracket.
Internal gear
Center bracket
SAPH311991300012
10. Installation of planetary gear

the lubrication list) and install the planetary gear on the
Planetary gear carrier pin.
Carrier pin
SAPH311991300011
11. Installation of cover

Packing Cover (1) Install a new packing.
(2) Install the cover on the center bracket assembly.
SAPH311991300010
12. Installation of rear bearing

(1) Install the bearing on the armature assembly using a
press.
! CAUTION • When the bearing is removed, replace it with

a new one.
13. Installation of armature assembly

(1) Install the armature assembly.
Armature
assembly
! CAUTION • When the armature assembly is installed, the
washer at the end of the gear may be dropped
and lost. Be careful for handling.
Center bracket
assembly
SAPH311991300008
14. Installation of packing

Yoke assembly (1) Install a new packing on the centering location at both
ends of the yoke assembly.

Packing Packing
SAPH311991300007
15. Installation of yoke assembly

M lead wire (1) Install the yoke assembly on the center bracket assembly.
Yoke assembly
Center bracket
assembly
SAPH311991300006
16. Installation of brush holder assembly

Brush holder
Assembly (1) Lift the spring using a flat tip screwdriver, long-nose pliers
or pliers. Install four brushes on the brush holder
assembly.
Spring
Brush
Brush lead
Clamp
SAPH311991300005
17. Installation of commutator end frame

Through bolt (1) Tighten the through bolt of the commutator end frame.
Tightening torque :
15.7 - 17.6 N⋅m {160 - 179 kgf⋅cm, 12 - 13 lbf⋅ft}
Commutator end
frame
SAPH311991300003
(2) Tighten two set bolts.

Tightening torque :
Set bolt
3.6 - 4.9 N⋅m {37 - 49 kgf⋅cm, 3 - 4 lbf⋅ft}
! CAUTION • Hold the M lead wire and remove the

commutator end frame by lifting.
SAPH311991300004
18. Installation of lead wire

M lead wire
(1) Install the M lead wire.
M terminal
SAPH311991300002
19. Lubrication
Refer to the following figure and table for lubricant to be applied.
! CAUTION • There shall be no lubricant on the commutator surface, brush and contact.
SAPH311991300046
Table of lubricant
Amount Lubricant
Code Lubricating point Lubricant used Remark
(g{oz}) manufacturer
Pinion case metal 0.8 - 1.5

1 Multemp AC-N Kyodo Yushi
and grease reservoir {0.03 - 0.05}
Bracket center metal 0.5 - 1.5

and grease reservoir {0.03 - 0.05}
0.2 - 0.5 Applied to both sides

3 Shim washer Multemp AC-N Kyodo Yushi
{0.01 - 0.02} of washer.
0.5 - 1
4 Armature front metal Multemp AC-N Kyodo Yushi
{0.02 - 0.04}
0.2 - 0.5 Applied to both sides

5 Shim washer Multemp AC-N Kyodo Yushi
{0.01 - 0.02} of washer.
Internal gear
7 -11
6 Armature gear Multemp AC-N Kyodo Yushi
{0.25 - 0.39}
Planetary gear
Pinion straight 0.5 - 1

Spline {0.02 - 0.04}
0.3 - 0.6
8 Inner sleeve metal Multemp AC-N Kyodo Yushi
{0.01 - 0.02}
0.5 - 1
9 Helical spline Multemp AC-N Kyodo Yushi
{0.02 - 0.04}
Clutch case lever 1-2 Nippon Oil

10 Pyroknock No.2
shifter {0.04 - 0.07} Corporation
Bracket rear bearing 0.2 - 0.5 Nippon Oil

11 Pyroknock No.2
housing {0.01 - 0.02} Corporation
1-2
12 Planetary gear metal Multemp AC-N Kyodo Yushi
{0.04 - 0.07}
0.4 - 0.8
13 Lever holder Multemp AC-N Kyodo Yushi
{0.01 - 0.03}
Assemble the roller

after application of
0.2 - 0.5 Nippon Oil
14 Lever roller rod Pyroknock No.2 grease to prevent fall
{0.01 - 0.02} Corporation
of the roller in
assembly.
Setup layout
Layout
Alternator (50A)
Part layout (typical example of 60A)
JP31199130402002
SAPH311991300047
27017 Feed coil 27383A Insulator

27040 Alternator 27389 Insulator
27310 Drive end frame assembly 27392 Cover
27311 Drive end frame 27410 Stator coil
27312 Bearing cover 27412 Collar
27330 Rotor assembly 27431 Pulley
27350 End frame assembly 27441 Fan
27353 Rectifier minus 27445A Coupler holder
27356 Rectifier plus 27700 Regulator
27359 End frame 28252 Front bearing
27383 Insulator 28252A Rear bearing
Tightening torque
27317 7.8-9.8 N m{80-99 kgf cm, 6-7lbf⋅ft} 27317C 1.9-2.5 N⋅m{20-25 kgf⋅cm, 1-2lbf⋅ft}
27317A 1.9-2.5 N⋅m{20-25 kgf⋅cm, 1-2lbf⋅ft} 27391 127 - 157 N⋅m{1, 300 - 1, 600 kgf⋅cm, 94-
116lbf⋅ft}
27317B 2.9 - 3.9 N⋅m{30 - 39 kgf⋅cm, 2-3lbf⋅ft} 27391A Internal nut : 4.9-5.9 N m{50-60 kgf cm,
3.6-4.3lbf⋅ft}
System drawing
Circuit drawing (50A)

JP31199130803001
Capacitor
Diode
Fuse Load
L Lamp 1.4 to 3W
R
Starter switch
P
Feed coil
N
Regulator
Battery 24V
Stator coil
Alternator
SAPH311991300048
Service procedure
Overhaul item
Disassembly
JP31199130702003
! CAUTION • Place a rubber mat and perform work on the

mat.
1. Disconnection of front from rear
(1) Remove fixing bolts and remove the cover.
! CAUTION • Press the tabs of the cover for removal. Be

careful not to break the tab with excessive
force.
SAPH311991300049
(2) Remove bolts with a screwdriver and remove the coupler

holder.
SAPH311991300050
(3) Remove three through bolts and disconnect the front from
the rear.
SAPH311991300051
2. Disassembly of front
(1) Remove nuts and remove the pulley, fan and collar.
! CAUTION • Tie around a general V –belt in the pulley

groove and fix the pulley with a vice.
SAPH311991300052
(2) Remove the rotor assembly using a press.
! CAUTION • Do not damage the end of the thread.

• Support the rotor assembly to prevent fall of
the rotor assembly.
SAPH311991300053
(3) Remove three bolts with a screwdriver and remove the

bearing cover.
SAPH311991300054
(4) Remove the ball bearing from the front bracket using a
press or jig C.
Jig C
! CAUTION • Place jig C at the inner race of the front
bearing.
• Removed bearing must not be reused.
SAPH311991300055
3. Disassembly of rear
(1) Remove solder of the lead wire connecting the stator coil
and the diode using a soldering bit and suction line or a
solder suction device
! CAUTION • At solder of the stator coil and the diode, the

end of the diode is clamped. Do not damage
the diode by prying. Deformed diode must not
be reused.
SAPH311991300056 • Perform soldering in a short time (within 5
seconds).
(2) Remove the stator coil from the rear bracket.
! CAUTION • Do not damage the stator coil.
SAPH311991300057
(3) Remove solder of the lead wire connecting the regulator

and the field coil using a soldering bit.
! CAUTION • Remove the lead wire of the field coil by

raising the terminal of the regulator.
• Perform soldering in a short time (within 5
seconds).
SAPH311991300058
Terminal
Lead wire
Regulator assembly
SAPH311991300059
(4) Loosen the nut at the B terminal.
! CAUTION • Loosen the nut to some extent and do not

remove it from the B terminal.
SAPH311991300060
(5) Remove five bolts using a screwdriver and remove the

heat sink assembly (plus), heat sink assembly (minus)
and regulator all together.
! CAUTION • Screw lock is used. Since torque is high until

bolt is removed, be careful not to damage the
groove of the bolt head.
• When the rear bracket is reused, clean the
screw hole.
SAPH311991300061
(6) Remove the capacitor.

(7) Remove three bolts with a screwdriver and remove the
field coil from the rear bracket.
SAPH311991300062
(8) Remove the roller bearing from the rear bracket using a
press, jig A and jig B.
! CAUTION • Removed bearing must not be reused.
SAPH311991300063
JP31199130703002

mat.
1. Inspection of stator coil and field coil
(1) Measure the resistance between U-V, V-W and W-U

terminals of the stator coil using a circuit tester.
SAPH311991300064
(2) Measure the resistance between the stator coil core and
each terminal using a megger tester.
Standard value (MΩ) 1 or more
SAPH311991300065
(3) Measure the resistance of the field coil using a circuit

tester.
! CAUTION • Do not damage the circumferential surface of

the coil.
• Damaged coil circumference must not be
reused.
SAPH311991300066
(4) Measure the resistance between the core and the coil
using a megger tester.
Standard value (MΩ) 1 or more
SAPH311991300067
2. Inspection of rotor assembly
(1) Measure the outer diameter of the shaft at the ball bearing
insertion area of the rotor assembly using a micrometer.
Standard value (mm{in.}) 25{0.9843}
Service limit (mm{in.}) 24.98{0.9835}
SAPH311991300068
(2) Measure the outer diameter of the shaft at the roller

bearing insertion area of the rotor assembly using a
micrometer.
Standard value (mm{in.}) 17{0.6693}
Service limit (mm{in.}) 16.98{0.6685}
SAPH311991300069
3. Inspection of diode, capacitor and regulator
(1) Measure the resistance of the holder between the minus

diode and the heat sink holder using a circuit tester.
Standard value
Forward resistance value Approx. 10 Ω
Reverse resistance value Infinite
SAPH311991300070
(2) Measure the resistance between the capacitor terminal

and the body using a circuit tester. Make sure that it
indicates 800 kΩ and then immediately indicates infinite
value.
SAPH311991300071
(3) Inspection of regulator

Measure the resistance between regulator terminals F
and E using a circuit tester.
Standard value
Forward resistance value Approx. 10 Ω
Reverse resistance value Infinite
Overhaul item
SAPH311991300072
Assembly
JP31199130702004

Jig C
mat.
1. Assembly of front
(1) Press fit a new ball bearing into the front bracket using a
press and jig C.
! CAUTION • Place jig C at the outer race of the ball

bearing.
SAPH311991300073 • Removed bearing must not be reused.
(2) Install the bearing cover with bolts.

Tightening torque :
1.9 - 2.5 N⋅m {20 - 25 kgf⋅cm, 1 - 2 lbf⋅ft}
SAPH311991300074
(3) Install the rotor assembly using a press.
! CAUTION • Be sure to support the inner race of the

bearing for press fit of the rotor.
• Do not damage the shaft.
SAPH311991300075
(4) Install the space collar, fan and pulley on the shaft of the
rotor assembly.
Tightening torque :
127 - 157 N⋅m {1,300 - 1,600 kgf⋅cm, 94 - 116 lbf⋅ft}
! CAUTION • Tie around a general V –belt in the pulley

groove and fix the pulley with a vice.
SAPH311991300076
2. Assembly of rear
(1) Press fit a new roller bearing into the rear bracket using a
Jig A
press, jig A and jig B.
! CAUTION • Press fit until jig A comes in contact with the

Roller bearing rear bracket.
Jig B
SAPH311991300077
(2) Install the field coil on the rear bracket.
Tightening torque :
2.9 - 3.9 N⋅m {30 - 39 kgf⋅cm, 2 - 3 lbf⋅ft}
! CAUTION • Tighten bolts finally after temporary

tightening. Tighten them evenly.
SAPH311991300078
(3) Assemble the stator coil on the rear bracket temporarily.
! CAUTION • Do not damage the stator coil.
SAPH311991300079
(4) Install parts referring to the part layout.
Tightening torque :
1.9 - 2.5 N⋅m {20 - 25 kgf⋅cm, 1 - 2 lbf⋅ft}
! CAUTION • Apply screw lock to the ends of the heat sink

mounting bolt and the regulator mounting
bolt.
SAPH311991300080
(5) Solder the lead wire connecting the regulator and the field
coil, and connecting the stator coil and the diode using a
soldering bit.
! CAUTION • Perform soldering after tightening of bolts.

• Bend and fix the regulator terminal before
soldering the lead wire of the field coil.
• Clamp the end of the diode of the stator coil
before soldering.
SAPH311991300081 • Perform soldering in a short time (within 5
seconds).
Terminal
Lead wire
Regulator assembly
SAPH311991300082
(6) Tighten the nut inside the B terminal.
Tightening torque :
4.9 - 5.9 N⋅m {50 - 60 kgf⋅cm, 3.6 - 4.3 lbf⋅ft}
NOTICE • After installation of the alternator, connect

the wire and tighten the outside nut
SAPH311991300083
3. Joint of front and rear

(1) Joint the front with the rear with bolts.
Tightening torque :
7.8 - 9.8 N⋅m {80 - 99 kgf⋅cm, 6 - 7 lbf⋅ft}
! CAUTION • Tighten bolts evenly.
SAPH311991300084
(2) Install the coupler holder and tighten bolts.
Tightening torque :
1.9 - 2.5 N⋅m {20 - 25 kgf⋅cm, 1 - 2 lbf⋅ft}
SAPH311991300085
(3) Align the tab and install the cover. Fix it with bolts.
Tightening torque :
3.3 - 4.4 N⋅m {34 - 44 kgf⋅cm, 2 - 3 lbf⋅ft}
! CAUTION • Do not hit the cover because the tab may be

broken.
SAPH311991300086
Inspection after assembly

JP31199130703003

mat.
1. Inspection of rotation
(1) Turn the pulley with hand to check if there is no
interference with internal parts and if rotation is smooth.
SAPH311991300087
(2) Measure the resistance between B and E terminals and

between P and E terminals using a circuit tester. If it is
beyond the standard value (e.g. 0 Ω), disassemble it
again and reassemble the unit correctly.
Circuit tester lead

Standard value
(+) (–)
B E Approx. 20 Ω
SAPH311991300088
E B Infinite
P E Approx.7 Ω
E P Infinite
R L
N P
E
Connector details
SAPH311991300089
TURBOCHARGER 14–1
ENGINE
14 TURBOCHARGER
Setup layout
Layout
Turbocharger Assembly........................................... 14-2

Part layout ............................................................ 14-2
Inspection ............................................................. 14-3
Replacement......................................................... 14-6
14
14–2 TURBOCHARGER
Turbocharger Assembly
Part layout
JP31199140402001
SAPH311991400010
15407 Oil inlet pipe 24109 Gasket*

16691 Coolant pipe 24109A Gasket*
16691A Coolant pipe 24135 Gasket*
17291 Exhaust manifold connector 24135A Gasket*
24100 Turbocharger assembly 9654-12100 Gasket*
24107 Oil outlet pipe 9659A Gasket*

Tightening torque
9209A 56 N⋅m {570 kgf⋅cm, 41lbf⋅ft}
Maintenance
List of maintenance
inspection
inspection
(preventive service)
TURBOCHARGER 14–3
Inspection
JP31199140501001
1. Inspection of turbine shaft axial play

(1) Inspect play of the turbine shaft at the exhaust side using
a special tool.
Special tool : 09444-1800 Tool assembly
(2) If the measurement value is beyond the standard value,

ask the manufacturer to overhaul the unit.
Standard value Axial direction 0.1 {0.0039}

SAPH311991400002
(mm{in.}) Radial direction 1.0 {0.0393}
NOTICE • Since the assembly is replaced, disassembly

and inspection are not allowed.
2. Inspection procedure with special tool

(1) Remove dial gauge (key No. 1), loosen the bolt (key No.
13) of the guide (key No. 13) and turn the guide (key No.
2) 90°. Put the dial gauge into the plate (key No. 8) which
is inspected for axial play, and tighten the bolt (key No.
19) for fixing.
SAPH311991400003
Bolt
SAPH311991400004
(2) Insert the guide (key No. 9) to preventment horizontal

Guide movement of the measuring instrument.
SAPH311991400005
14–4 TURBOCHARGER
(3) When the guide (key No. 9) is fixed, move the bar (key
No. 4) vertically and fix the guide (key No. 9) with the
stopper (key No. 10) so that the needle of the dial gauge
may come at the center.
SAPH311991400006
(4) Hold the puller (key No. 5) and press it toward the turbine
in the axial direction. Set the dial gauge reading to 0.
0 point adjustment
SAPH311991400007
(5) Pull it to the opposite side and measure movement in the

axial direction.
(6) Take three measurements and use the average value as
the measurement value.
SAPH311991400008
TURBOCHARGER 14–5
Special Tool Details
Key No. Part name Key No. Part name

Assembly Tool assembly 10 Stopper
1 Gauge (dial gauge) 11 Bolt
2 Guide 12 Sleeve
3 Stopper 13 Bolt
4 Bar 14 Bolt
5 Puller 15 Bolt
6 Sleeve 16 Hook
7 Plate 17 Snap ring (cotter pin)
8 Plate 18 Bar (spring)
9 Guide 19 Bolt
SAPH311991400009
Service procedure
14–6 TURBOCHARGER
Replacement
JP31199140704001
1. Removal
(1) Remove the boost pipe and U-turn pipe.
(2) Disconnect all pipes connected to the turbocharger.
! CAUTION • Loosen union bolt of the coolant pipe, drain

coolant and remove the pipe. Disconnect the
lower pipe similarly and remove the oil pipe.
• After removing pipes, be sure to seal oil
holes, water holes and cylinder block holes
to prevent entry of dirt.
(3) Remove the bolts fixing the exhaust pipe and the
turbocharger and remove the turbocharger.
! CAUTION • After removal, seal holes both at the exhaust

manifold and the exhaust pipe to prevent
entry of foreign matter.
• If a stud bolt is sticking, remove and replace
the stud bolt using a commercially available
stud remover.
2. Installation
(1) Install the turbocharger in the reverse order of
disassembly. When the turbocharger is installed on the
engine or after installation, observe the following
precautions for work. Pay special attention to entry of
foreign matter inside the turbocharger.
Tightening torque :
(Turbocharger to exhaust manifold)
(2) Lubrication and cooling system
a. Before installation on the engine, pour new engine oil
from the oil inlet and turn the turbocharger with hand to
lubricate the journal bearing and the thrust bearing.
b. Clean the oil pipe, oil hose, coolant pipe and hose.
Check for pipe deformation, hose crack or dirt or
foreign matter in the pipe or hose.
c. Do not use sealant at the installation surface of the oil
pipe and the coolant pipe or joint between the coolant
hose and the coolant pipe to prevent failures such as
damage due to clogging or loosening of tightened
areas.
d. Be sure to use new soft washers, O-rings and gaskets.
e. Be sure to install the oil pipe, oil hose, coolant pipe and
coolant hose correctly to prevent leak of oil or water
from connections.
TURBOCHARGER 14–7
(3) Air intake system

a. Make sure that there is no dirt or foreign matter in the
air intake system.
b. Do not use sealant at the inlet/outlet of air to prevent
failures such as damage due to clogging or loosening of
tightened areas.
c. Be sure to install the air feed pipe and the air hose
correctly to prevent air leak from connections.
(4) Exhaust system
a. Make sure that there is no dirt or foreign matter in the
exhaust piping system.
b. Since heat resistant steel is used for bolts and nuts, do
not mix them with normal bolts for installation.
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS 16–1
ENGINE
16 FAILURE DIAGNOSIS FOR EACH ENGINE

STATUS
Failure diagnosis list
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

.................................................................................... 16-2
Engine mechanical ............................................... 16-2
Alternator .............................................................. 16-5
Starter ................................................................... 16-6
Turbocharger......................................................... 16-7
16
16–2 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

Engine mechanical
JP31199160601001
Status Cause Action

Engine overheat (coolant) Insufficient coolant Replenish coolant
Faulty thermostat Replace thermostat
Water leak from cooling system Correction
Faulty coolant pump Repair or replace
Faulty head gasket Replace head gasket
Engine overheat Clogging of radiator Cleaning of radiator
(radiator) Corrosion of cooling system Clean and repair cooling system
Clogging of radiator core front part Clean radiator
Faulty radiator cap Replace radiator cap
Engine overheat (compression Non-synchronous injection timing Injection timing inspection
pressure) Faulty fuel injection pressure Injection pressure inspection
Faulty injector Replace injector
Engine overheat (lubrication Deterioration of engine oil Replace engine oil
unit) Faulty oil pump Replace oil pump
Insufficient engine oil Replenish engine oil
Large engine oil consumption Wear of piston ring and cylinder Replace piston ring and cylinder
(piston, cylinder liner and piston liner liner
ring) Damage to piston ring Replace piston ring and cylinder
liner
Faulty fixing of piston ring Replace piston ring and cylinder
liner
Faulty assembly of piston ring Replace piston ring and cylinder
liner
Faulty engine oil Replace engine oil
Faulty piston ring joint Reassemble piston ring
Large engine oil consumption Wear of valve stem Replace valve and valve guide
(valve and valve guide) Wear of valve guide Replace valve guide
Faulty assembly of valve stem seal Replace stem seal
Excessive oil lubrication to rocker Inspection of clearance between
arm rocker arm and rocker arm shaft
Large engine oil consumption Faulty oil level gauge Replace with correct level gauge
(others) Excessive filling of engine oil Fill with appropriate amount of oil.
Leak of engine oil Repair or replace the part of oil
leak.
Piston seizure (in operation) Sudden stop of engine Perform warm-up before stop of
engine
Piston seizure (lubrication unit) Insufficient engine oil Replenish engine oil
Deterioration of engine oil Replace engine oil
Incorrect engine oil Replace with correct engine oil.
Low oil pressure Inspection of lubrication unit
Faulty oil pump Replace oil pump
Status Cause Action

Piston seizure Abnormal combustion Refer to overheat section.
Piston seizure Cooling unit Refer to overheat section.
Insufficient engine power (air Clogging of air cleaner element Clean or replace air cleaner
cleaner) element
Insufficient engine power Overheat Refer to overheat section.
Insufficient engine power (fuel Faulty injection of injector Replace injector
unit) Faulty injector due to deposit of Replace injector
carbon
Entry of air into fuel system Air bleeding of fuel system
Faulty fuel filter Replace element
Insufficient engine power Abnormal compression pressure Refer to overheat section.
Insufficient engine power Piston, cylinder liner and piston Refer to overheat section.
ring
Faulty engine start (electric unit) Faulty battery Check battery
Faulty wiring of starter Replace starter wiring
Loose battery cable Tighten battery terminal connection
or replace cable
Faulty operation of starter Replace starter assembly
Faulty start assist unit Replace start assist unit

Faulty engine start (air cleaner) Clogging of air cleaner element Clean or replace air cleaner
element
Faulty engine start (fuel unit) Insufficient fuel Replenish fuel and bleed air from
fuel system
Clogging of fuel system Clean fuel system.
Air intake from connection of fuel Tighten connections
system
Clogging of fuel filter Replace fuel filter
Loose connection of injection pipe Tighten connecting nut of injection
pump
Faulty engine start (injector) Injector seizure Replace injector
Faulty engine start (lubrication Excessive viscosity of engine oil Replace with engine oil with correct
unit) viscosity
Faulty engine start (others) Piston seizure Replace piston, piston ring and
cylinder liner
Bearing seizure Replace bearing and crankshaft
Low compression pressure Overhaul engine
Damage to ring gear Replace ring gear and replace
starter pinion gear.
Faulty idling (injector) Faulty injection pressure Injection pressure inspection
Faulty injection status Adjust or replace injector.
Status Cause Action

Faulty idling (nozzle) Faulty injection pressure Injection pressure inspection
Faulty spray status Adjust or replace nozzle
Carbon deposit at nozzle end Remove carbon
Seizure of needle valve Replace nozzle
Faulty idling (engine) Faulty valve clearance Adjustment of valve clearance
Faulty contact of valve seat Adjust or replace valve and valve
seat.
Low coolant temperature Perform warm-up.
Large variation of compression Overhaul engine
pressure between cylinders Training of engine difference not
performed after exchange of the
engine ECU
Training of engine difference not Perform training of engine
performed after exchange of the difference after exchange of the
engine ECU engine ECU
Gas leak (head gasket) Reuse Replace gasket.
Damage Replace gasket.
Replace gasket. Replace gasket.
Gas leak (head bolt) Loose head bolt Tighten bolt.
Incorrect tightening sequence or Tighten bolt to correct torque
incorrect tightening torque according to the correct tightening
sequence.
Extension of head bolt Replace bolt.
Gas leak (cylinder block) Crack Replace cylinder block.
Distortion of cylinder block upper Repair or replace cylinder block.
surface
Depression of cylinder liner Replace cylinder liner or block.
insertion (insufficient protrusion of
cylinder liner)
Gas leak (cylinder head) Crack of cylinder head Replace cylinder head.
Distortion of cylinder head lower Repair or replace cylinder head.
surface
Gas leak (cylinder liner) Crack of cylinder liner Replace cylinder liner.
Corrosion of cylinder liner Replace cylinder liner.
Insufficient protrusion of cylinder Replace cylinder liner or block.
liner
Gas leak (others) Incorrect injection timing Injection timing inspection
Alternator
JP31199160601002
Status Cause Action

Lamp is ON.→Charge current Faulty regulator (open PTr) Replace regulator.
does not run (alternator). Faulty stator coil (disconnection, Replace stator coil.
rare shorting)
Fault feed coil (disconnection, rare Replace feed coil.
shorting)
Faulty diode (open, shorting) Replace rectifier.
Disconnection or poor contact of Repair or replace lead wire.
lead wire (plate, support, etc.)
Lamp is ON.→Charge current Disconnection of wire (fuse) Replace wire (fuse).
does not run (wiring).
Lamp is ON.→Voltmeter Faulty regulator (shorting of PTr) Replace regulator.
indicates 29V or more Faulty tightening of voltage Repair, replace voltage detection
(alternator). detection circuit (e.g. support) circuit or replace regulator.
Lamp is ON.→Charge current is Faulty regulator (open Tr) Replace regulator.
correctly running (alternator).
Lamp is OFF.→Charge current is Faulty stator coil (disconnection of 1 Replace stator coil.
always limited.→Battery goes flat phase, rare shorting)
(alternator). Faulty diode (open, shorting) Replace rectifier.
Disconnection or poor contact of Repair or replace lead wire.
lead wire (plate, support, etc.)
Lamp is OFF.→Charge current is Operation load is large (Load Reduce load
always limited.→Battery goes flat balance is poor).
(operation load).
Lamp is OFF.→Charge current is Faulty regulator (shorting of PTr) Replace regulator.
always large.→Battery fluid runs Faulty tightening of voltage Repair or replace voltage detection
short in a short period of time detection circuit (e.g. support) circuit.
(alternator).
Lamp is OFF.→Charge current is Battery is close to the service life. Replace battery.
always large.→Battery fluid runs
short in a short period of time
(battery).
Others→Abnormal noise Faulty stator coil (rare shorting, Replace stator coil.
(alternator) grounding)
Contact of inner surface (faulty Repair or replace bearing.
bearing, wear of bracket)
Others→Abnormal noise (V belt) Faulty tension of V belt (belt slip) Correction
Starter
JP31199160601003
Status Cause Action

Starter does not turn. Turning is Faulty connection of starter key Repair connecting area.
low. Flat battery Charge or replace.
Disconnection, loosening or After cleaning, tighten.
corrosion of battery terminal
Grounding wire is disconnected. Be sure to connect it.
Use of incorrect engine oil Replace with correct oil.
Faulty contact of start magnet Replace start magnet switch
switch assembly. assembly
Faulty contact or failure of starter Replace starter relay.
relay
Wear of starter brush Replace brush
Seizure of commutator Repair commutator.
Wear of commutator Undercut
Shorting of armature Replace armature assembly
Insufficient tension of brush spring Replace brush spring.
Faulty operation of clutch Clean or replace.
Turbocharger
JP31199160601004
Status Cause Action

Exhaust smoke is black Clogging of air cleaner element Clean or replace air cleaner
(insufficient intake air). element.
Air intake inlet is closed. Recover normal status.
Leak from connection of air intake Check and repair.
system
Revolution of blower impeller and Disassembly and repair.
turbine shaft is heavy
Exhaust smoke is black Oil impurities are deposited at the Replace engine oil and
(Turbocharger is not operating). sealing part of the turbine and disassemble the turbocharger for
revolution of the turbine shaft is heavy. cleaning.
Seizure of bearing Replace turbocharger.
Seizure of bearing (insufficient Check the oil system of the engine
lubrication or clogging of oil pipe) and repair faulty areas. Also,
replace engine oil.
Seizure of bearing (Oil temperature Check the oil system of the engine
is too high.) and repair faulty areas. Also,
replace engine oil.
Seizure of bearing (Balance of Replace or clean revolving part.
revolving body is poor.)
Seizure of bearing (insufficient Observe the precautions strictly in
warm-up or sudden stop from the operation manual.
loaded operation: Unloaded
operation)
Contact of or damage to turbine Check and repair engine parts.
shaft and blower impeller
(excessive operation)
Contact of or damage to turbine Check and repair engine parts.
shaft and blower impeller
(excessive increase of exhaust gas
temperature)
Contact of or damage to turbine Disassemble the engine to remove
shaft and blower impeller (entry of foreign matter completely. Check
foreign matter) and repair the air cleaner and
engine parts.
Contact of or damage to turbine shaft Replace turbocharger.
and blower impeller (wear of bearing)
Contact of or damage to turbine shaft Reassemble or replace.
and blower impeller (faulty assembly)
Exhaust smoke is black (due to Exhaust gas is leaking before the Check and repair mounting area.
exhaust gas resistance). turbocharger. Revolution is not
increased.
Since pipe of the exhaust system is Recover normal status.
deformed or clogged, revolution of
the turbocharger is not increased.
Status Cause Action

Exhaust smoke is white. Engine oil runs out to the blower or Repair or replace pipe.
the turbine due to clogging or
deformation of the oil return pipe.
Negative pressure at the back of Check and replace the pipe.
the blower impeller is increased and Replace or clean the air cleaner
engine oil runs out to the blower. element.
Seal ring is excessively worn or Disassemble and repair
damaged due to excessive wear of turbocharger.
the bearing.
Entry of water into the cylinder Exchange or repair of the parts
where water has entered
Oil is quickly reduced. Seal ring is excessively worn or Disassemble and repair
damaged due to excessive wear of turbocharger.
the bearing.
Engine oil enters into exhaust gas Check and service engine parts.
before the turbocharger.
Low engine output Gas leak from exhaust system Check and repair faulty areas.
parts
Air leak from blower outlet Check and repair faulty areas.
Clogging of air cleaner element Clean or replace air cleaner
element
Contamination of or damage to Replace turbocharger.
turbocharger
Acceleration (follow-up of Carbon deposit at the turbine (disc Replace engine oil and clean
turbocharger) is poor (slow). sealing area) makes revolution of turbocharger.
the turbine heavy.
Air and gas leak from intake/ Check and repair faulty areas.
exhaust system parts
Combustion is faulty. Check the engine fuel system and
recover correct combustion status.
Abnormal noise If the gas passage is extremely Replace turbocharger.
narrowed due to clogging at the
turbine case nozzle or if
acceleration is performed, reverse
flow (usually called surging) occurs
due to clogging of blower discharge
air.
Revolving part is in contact. Replace turbocharger.
Air and gas leak from intake/ Check and repair faulty areas.
exhaust system parts
Status Cause Action

Vibration Loosening between turbocharger Check the turbocharger mounting
and intake/exhaust pipe and status and repair faulty areas.
between oil pipe and mounting area
Failure of metal, contact between Replace turbocharger. Remove
revolving part and peripheral parts, foreign matter completely, if any.
or damage to the blower impeller of
the turbine rotor due to entry of
foreign matter is found.
Balance of revolving body is poor. Replace revolving body.
ENGINE DIAGNOSIS CODE 17–1
ENGINE
17 ENGINE DIAGNOSIS CODE

General information
Engine ECU ............................................................... 17-2 Injector common 1 ground short

Precautions ........................................................... 17-2 (DTC code P1211),
System block diagram........................................... 17-3 Injector common 2 ground short
Inspection ............................................................. 17-4 (DTC code P1214) .............................................. 17-34
Table of failure code .............................................. 17-5 Injector common 1 power source line short
Signal check harness............................................ 17-8 (DTC code P1212),
Computer pin arrangement ................................. 17-10 Injector common 2 power source line short
Check the ECU power supply voltage................. 17-11 (DTC code P1215) .............................................. 17-36
Check the ground................................................ 17-11 Injector circuit malfunction
Engine speed main sensor circuit malfunction (DTC code P0201 to P0204)............................... 17-38
(DTC code P0335) .............................................. 17-12 Cylinder contribution/balance fault
Engine speed sub sensor circuit malfunction (DTC codes P0263, P0266, P0269, P0272) ....... 17-41
(DTC code P0340) .............................................. 17-14 Supply pump SCV malfunction
Engine speed main and sub sensor circuit malfunction (DTC code P0628, P0629).................................. 17-43
(DTC code P0335) .............................................. 17-15 Supply pump SCV sticking
Coolant temperature sensor malfunction (DTC code P2635),
(DTC code P0117, P0118) ................................. 17-16 Supply pump malfunction
Engine overheat (DTC code P2635),
(DTC code P0217) .............................................. 17-17 Supply pump abnormal pressure record
Engine overrun (DTC code P2635) .............................................. 17-45
(DTC code P0219) .............................................. 17-17 Preheat circuit malfunction
Fuel temperature sensor malfunction (DTC code P0540) .............................................. 17-46
(DTC code P0182, P0183) ................................. 17-18 Injector correction data conformity error
Boost pressure sensor malfunction (DTC code P1601) ............................................. 17-47
(DTC code P0108, P0237) ................................. 17-19 ECU internal error
Turbocharger over boost (DTC code P0605, P0606, P0607) ..................... 17-47
(DTC code P0234) .............................................. 17-21 ECU charge circuit malfunction
Excessive common rail pressure (DTC code P0200, P0611).................................. 17-48
(DTC code P0088) .............................................. 17-21 Main relay malfunction
Excessive common rail pressure, supply pump excess (DTC code P0686) .............................................. 17-49
forced feed (DTC code P0088) ........................... 17-22 Starter signal malfunction
Common rail pressure sensor malfunction (DTC code P0617) .............................................. 17-49
(DTC code P0191) .............................................. 17-23 17
Common rail pressure sensor malfunction
(DTC code P0192, P0193) ................................. 17-24
Accelerator sensor 1 malfunction
(DTC code P2122, P2123) ................................. 17-26
Accelerator sensor 2 malfunction
(DTC code P2127, P2128) ................................. 17-28
Accelerator sensor 1 and 2 malfunction
(DTC code P2120) .............................................. 17-30
Emergency accelerator sensor malfunction
(DTC code P1133) .............................................. 17-31
Atmospheric pressure sensor malfunction
(DTC code P2228, P2229) ................................. 17-33
17–2 ENGINE DIAGNOSIS CODE
Engine ECU
Precautions
JP31199170102001
! CAUTION • Make sure that each connector is connected

before inspection.
• Do not place a tester rod on the connecting
surface of the connector. Otherwise,
terminals are damaged or short-circuited.
• Delete the past failure memory after
recording. Perform failure diagnosis again to
check current failure.
• After failure analysis, delete the past failure
memory. If the past failure memory is not
deleted, the failure indicator lamp remains
ON.
• All connector drawings are viewed from the
connecting surface. Place the tester rod from
SAPH311991700001
the back.
System drawing
System block diagram

JP31199170803001
ACT Relay
Fuse
Each Sensor Power
Main relay
Key switch signal Fuse
Starter signal
- + Battery
Accelerator signal 1,2

Diagnosis tool
Diagnosis switch
Accelerator sensor for operation

I/F
Engine speed main sensor
Engine speed sub sensor
PC Diagnosis tool
OUTPUT
Glow relay
INPUT
Injector drive signal

Supply pump
Supply pump control valve drive signal

Supply pump drive signal S/P
Others
Fuel temperature sensor (Supply pump)

Common rail pressure sensor1
Water temperature sensor
Common rail pressure sensor2 Engine ECU
Common rail T
Engine
P
SAPH311991700002
Service procedure
Inspection
JP31199170703001
1. Pre-inspection
(1) If an error occurs on the system, The DTC code is
indicated in the console panel.
(2) Reading of failure code
a. Connection of HinoDX
1. Remove the left side cover at the rear of the driver's

seat and connect the failure diagnosis connector
with a PC which installed HinoDX through the
interface box.
Engine ECU
Failure diagnosis
connector
SAPH311991700003
Special tool : 09121-1040 Hino-Bowie (Interface

Failure diagnosis connector
box)
09042-1220 Connecting cable
CD-ROM HinoDX
Hino-Bowie
Connect to the failure diagnosis Connecting cable

connector at the unit side.
SAPH311991700004
2. Deletion method of past failure

(1) To delete past failures of the engine ECU, use HinoDX on
the PC. (Refer to "HinoDX operation manual".)
Failure
List of failure
diagnosis
diagnosis
SAPH311991700005
Table of failure code

JP31199170601001
NOTICE • For the system status by indication of DTC code in the table, refer to "1. Pre-inspection,
Inspection, Engine ECU".
"Reference : Inspection, Engine ECU, Engine diagnosis code"
[a] Failure diagnosis and

DTC code Estimated failure cause Page
[b] Alarm display (alarm status)
a. Engine does not start P0335 Engine speed main sensor circuit
17-12
Engine stopped. malfunction
P0606 CPU malfunction (Hard detection) 17-47

b. DTC code indication. P0629 Supply pump SCV malfunction
17-43
(Power source line short)
a. Low output P0200 ECU charge circuit high input 17-48
P0611 ECU charge circuit low input

17-48
b. DTC code indication.
a. Low output (LOW idle 800rpm P2120 Accelerator sensor 1 and 2 malfunction
fixing)
17-30
a. Low output P0217 Engine overheat

17-17
a. Difficult to start engine. P0540 Preheat circuit malfunction

17-46
a. Low output P0234 Turbocharger over boost 17-21
P0088 Excessive common rail pressure 17-21

b. DTC code indication. P0088 Excessive common rail pressure, supply
17-22
pump excess forced feed
P0108 Boost pressure sensor circuit high input 17-19
P0117 Coolant temperature sensor circuit low

17-16
input
P0118 Coolant temperature sensor circuit high

17-16
input
P0191 Common rail pressure sensor malfunction 17-23
P0192 Common rail pressure sensor circuit low

17-24
input
P0193 Common rail pressure sensor circuit high

17-24
input
P0201 Injector circuit malfunction -cylinder 1 17-38


a. Low output P0203 Injector circuit malfunction -cylinder 3 17-38

b. DTC code indication. P0237 Boost pressure sensor circuit low input 17-19
P0605 Flash ROM error 17-47

P0607 Monitoring IC malfunction in CPU 17-47
P0628 Supply pump SCV malfunction

17-43
(Full discharge mode)
P1211 Injector common 1 ground short 17-34
P1212 Injector common 1 power source line short 17-36
P1212 Injector common 1 open circuit 17-36
P1214 Injector common 2 ground short 17-34
P1215 Injector common 2 power source line short 17-36
P1215 Injector common 2 open circuit 17-36
P1601 Injector correction data conformity error 17-47
P2228 Atmospheric pressure sensor circuit low

17-33
input
P2229 Atmospheric pressure sensor circuit high

17-33
input
P2635 Supply pump SCV sticking 17-45
P2635 Supply pump malfunction 17-45
a. Other problems P0182 Fuel temperature sensor circuit low input 17-18
P0183 Fuel temperature sensor circuit high input 17-18

b. DTC code indication. P0340 Engine speed sub sensor circuit
17-14
malfunction
P0686 Main relay malfunction 17-49
P2122 Accelerator sensor circuit 1 low voltage 17-26
P2123 Accelerator sensor circuit 1 high voltage 17-26
P2127 Accelerator sensor circuit 2 low voltage 17-28
P2128 Accelerator sensor circuit 2 high voltage 17-28
P1133 Emergency accelerator sensor malfunction

17-31
high input

a. Other problems P0219 Engine overrun 17-17
P0263 Cylinder 1 contribution/balance fault 17-41

b. No indication P0266 Cylinder 2 contribution/balance fault 17-41
P0617 Starter signal malfunction 17-49
P2635 Supply pump abnormal pressure record 17-45
U1001 Interruption of CAN communication (unit) -
Function, movement
Description of function
and operation

JP31199170301001
1. Signal check harness
! CAUTION • When measuring terminal of the engine ECU,

connect the signal check harness to prevent
damage to the connector. Place the tester rod
on the contact box of the signal check
harness for measurement.
NOTICE • Terminal numbers in the text and the

illustrations correspond as shown below in
the "Computer pin arrangement".
ECU terminal name
[Example] For A8 terminal ECU terminal number

(contact box)
SAPH311991700006
2. Connection of signal check harness

(1) Set the starter key to "OFF" and disconnect the connector
from the engine ECU.
(2) Connect the signal check harness to the engine ECU and
the unit harness.
Special tool : Signal check harness (09049-1080)
Specification
Wiring diagram(performance)
Unit harness
Test lead
Signal check connector
SAPH311991700007
Computer pin arrangement

JP31199170201001
SAPH311991700008
Failure diagnosis list
Check the ECU power supply voltage

JP31199170601002
1 Measurement of voltage between terminals
1. Set the starter key to "OFF" and connect the signal check
# 㧭 # & 㧰 ' 㧱 ' harness.
#
2. Turn the starter key "ON" and measure voltage between
terminals A5, A6, A7 and terminals D1, E4, E5.
Standard value : 20 V or more
NG • 0 V : Blown fuse, harness failure, ground failure,

etc.
SAPH311991700009 • 20 V or less : Battery deterioration, ground
failure, etc.
OK
Normal
Check the ground

JP31199170601003
1 Measurement of resistance between terminals
D1 D E4 E E5 harness.
2. Disconnect the ECU side connector of the signal check

Frame harness and measure the resistance between terminals D1,
E4, E5 and the terminal (-) of the battery.
Standard value : 1 Ω or less
NG Disconnection of ground harness, contact failure,

SAPH311991700010 etc.
OK
Normal
Engine speed main sensor circuit malfunction (DTC code P0335)

JP31199170601004
B6 B B7 harness.

harness and measure the resistance between terminal B6 and
terminal B7.
Standard value : Approx. 125.5 ± 17 Ω (20 °C{68 °F})
NG [3] Go to measurement of resistance between sensor

terminals.
SAPH311991700011
OK
2 Check of diagnosis code
1. Connect the ECU side connector of the signal check harness.

After deleting the past failure, Start the engine and confirm that
no diagnostic code is put out.
Standard : No diagnostic code
NG Contact failure of ECU connector, ECU failure,

short-circuit of harness
SAPH311991700012
OK
Normal
1. Disconnect the connector of the main engine speed sensor and

measure the resistance between No. 1 and No. 2 terminals at
the sensor.
Standard value : Approx. 125.5 ± 17 Ω (20 °C{68 °F})
NG Failure of main engine speed sensor
SAPH311991700013
OK
Harness disconnection or connector failure

Engine speed sub sensor circuit malfunction (DTC code P0340)

JP31199170601005
1 Measurement of voltage between sensor terminals
harness.
GND +5V
2. Disconnect the connector of the sub-speed sensor.
3. Set the starter key to "ON" and measure voltage between the
+5V terminal and the GND terminal of the sub-speed sensor
connector (at unit harness side).
Standard value : 5.0 ± 0.5 V

SAPH311991700014
NG [2] Go to measurement of voltage between terminals.
OK
[3] Go to measurement of voltage between terminals.
1. Measure voltage between terminal D32 and terminal D30 of

D the signal check harness.
D32 D30
Standard value : 5.0 ± 0.5V
NG Engine ECU failure, connector failure
SAPH311991700015
OK
Harness failure
1. Set the starter key to "OFF" and connect the connector of the
D D19
sub-speed sensor.
D30
2. Start the engine and keep idling status.
3. Measure voltage between terminal D19 and terminal D30 of

the signal check harness.
4. After measurement, stop the engine.
SAPH311991700016 Standard : Pulse waveform of 0 ↔ 5 V
NG [4] Go to measurement of resistance between

terminals.
OK
Engine ECU failure, ECU connector failure
1. Leave the connector of the sub-speed sensor connected.

SIG
D19 2. Measure resistance between the No. 1 terminal at the unit
harness of the sub-speed sensor connector and terminal D19
of the signal check harness.
! CAUTION • The connector of the sub-speed sensor in the

figure is viewed from the fitting surface.
SAPH311991700017
NG Harness failure
OK
Failure of sub-speed sensor
Engine speed main and sub sensor circuit malfunction (DTC code P0335)
JP31199170601006
1. Inspection item
(1) Take actions of (DTC code P0335) and (DTC code P0340).
"Reference : Engine speed main sensor circuit malfunction (DTC code P0335), Engine ECU, Engine
diagnosis code"
"Reference : Engine speed sub sensor circuit malfunction (DTC code P0340), Engine ECU, Engine
diagnosis code"
Coolant temperature sensor malfunction (DTC code P0117, P0118)

JP31199170601007
DTC P0117 Coolant temperature sensor circuit low input
DTC P0118 Coolant temperature sensor circuit high input
D E harness.
E19
D34 2. Disconnect the ECU side connector of the signal check
harness and measure the resistance between terminal E19
and terminal D34.
Standard value (Measure either one point of the

following.)
: 2.45 kΩ (Coolant temperature at 20 °C{68 °F})
SAPH311991700018
: 584 Ω (Coolant temperature at 60 °C{140 °F})
NG [2] Go to measurement of resistance between sensor

terminals.
OK
Engine ECU failure, ECU connector failure, harness short-circuit
1. Disconnect the connector of the coolant temperature sensor

and measure the resistance between No. 1 and No. 2 terminals
at the sensor.

following.)
SAPH311991700019
NG Failure of coolant temperature sensor
OK
Harness disconnection, connector failure

Engine overheat (DTC code P0217)

JP31199170601008
1. Set the starter key to "OFF", disconnect the connector of the

coolant temperature sensor and measure the resistance
between No. 1 and No. 2 terminals at the sensor.

following.)
: 2.45kΩ (Coolant temperature at 20 °C{68 °F})
: 1.15kΩ (Coolant temperature at 40 °C{104 °F})
: 584Ω (Coolant temperature at 60 °C{140 °F})
: 318Ω (Coolant temperature at 80 °C{176 °F})
SAPH311991700019
NOTICE • This code is displayed when the coolant

temperature sensor is normal and the coolant
temperature is 115 °C{221 °F} or more.
• While this failure code is detected, the
maximum injection volume is restricted.
When the coolant temperature is 80 °C{176°F}
or less, normal control is resumed.
NG Failure of coolant temperature sensor

Take actions of (DTC code P0117,P0118)
OK
Failure of engine cooling system
Engine overrun (DTC code P0219)

JP31199170601009
1. This failure code is displayed when the engine speed of 2,600 r/min or more is detected. While this
failure code is detected, fuel injection is stopped. When the engine speed is lower than 2,500 r/min.,
fuel injection is resumed.
NOTICE • The objective of this failure code is not to detect overrun due to failure of this system, but
to memorize high revolution of the engine.
• Engine speed may be incorrectly recognized with noise on the speed sensor signal due to
harness failure or modification, resulting in detection of overrun.
Fuel temperature sensor malfunction (DTC code P0182, P0183)

JP31199170601010
DTC P0182 Fuel temperature sensor circuit low input
DTC P0183 Fuel temperature sensor circuit high input
D34 E27 harness.

harness and measure the resistance between terminal E27
and terminal D34.

following.)
: 2.45 kΩ (Fuel temperature at 20 °C{68 °F})
SAPH311991700020
: 584 Ω (Fuel temperature at 60 °C{140 °F})

terminals.
OK
Engine ECU failure, ECU connector failure, harness short-circuit
2 Measurement of sensor resistance
1. Disconnect the connector of the fuel temperature sensor and

measure the resistance between No. 1 and No. 2 terminals at
the sensor.

following.)
SAPH311991700021
NG Failure of fuel temperature sensor
OK
Harness disconnection, connector failure

Boost pressure sensor malfunction (DTC code P0108, P0237)

JP31199170601011
DTC P0108 Boost pressure sensor circuit high input
DTC P0237 Boost pressure sensor circuit low input
harness.
GND +5V
2. Disconnect the connector of the boost pressure sensor.
+5V terminal and the GND terminal of the boost pressure
sensor connector (at unit harness side).
Standard value : 5 ± 0.5 V

SAPH311991700022
OK
1. Measure the voltage between terminal D25 and terminal D33

D D25
of the signal check harness.
D33 NG Engine ECU failure, ECU connector failure
SAPH311991700023
OK
Harness failure
1. Set the starter key to "OFF" and connect the connector of the
D D27
boost pressure sensor.
2. Set the starter key to "ON" and measure the voltage between
terminal D27 and terminal D33 of the signal check harness.
D33
Standard value : 0.2 to 4.8 V
SAPH311991700024
OK
1. Leave the connector of the boost pressure sensor connected.

GND SIG
2. Measure the voltage between the SIG terminal and the GND
terminal of the boost pressure sensor connector (at unit
harness side).
NG Boost pressure sensor failure
SAPH311991700025
OK
Harness failure
Turbocharger over boost (DTC code P0234)

JP31199170601012
1 Inspection with failure diagnosis tool
1. After failure, perform failure diagnosis with a failure diagnosis

tool (HinoDX) using PC.
2. Connect the failure diagnosis tool (HinoDX) using PC and set

the starter key to "ON".
SAPH311991700026
OK
Perform diagnosis of the boost pressure sensor (DTC code P0108, P0237).
Excessive common rail pressure (DTC code P0088)

JP31199170601013
D D20 harness.
D31 2. Set the starter key to "ON" and measure the voltage between
D33 terminals D20/D31 and terminal D33 of the signal check
harness.
NG Engine ECU failure or harness/connector contact

SAPH311991700027 failure
OK
Failure of common rail pressure sensor

Excessive common rail pressure, supply pump excess forced feed (DTC
code P0088)
JP31199170601014
㧰 D20 harness.
D31 2. Start and warm-up the engine until the coolant temperature
D33 gauge moves.
3. Set the engine speed to idling. PFIN = Approx. 30 MPa

(approx. 1.5V)
4. Measure the voltage between terminal D20/D31 and terminal

SAPH311991700028
D33 of the signal check harness.
Standard value : 1.56 V or less
NG Failure of common rail pressure sensor
OK
2 Check of failure code
1. Make sure that other failure code is not output.

If other failure code is output, repair the failure code and make
sure again that DTC code P0088 is output. In particular, if a
failure code of the main and sub-engine speed sensor systems
is output, make necessary repairs to prevent output of the
code.
2. Check the fuel injection timing of the supply pump. If the timing
is not set 0° for the top dead center, set it correctly.
3. When there is no error after the check above, delete the past
failure using the PC diagnosis tool and start the engine.
If the same code is output again, possible failures are the
supply pump, common rail pressure sensor system and engine
ECU. Perform more detailed diagnosis with failure diagnosis
Common rail pressure sensor malfunction (DTC code P0191)

JP31199170601015
D D20 harness.
D33 terminals D20/D31 and terminal D33.
NG Engine ECU failure or harness/connector contact

failure
SAPH311991700029
OK
1. Start the engine.

㧰 D20
2. While measuring the voltage between terminals D20/D31 and
D31 terminal D33 of the signal check harness, repeat full opening/
D33 closing of the accelerator.
Standard : Voltage must change. (1.0 to 3.2 V)
NG Common rail pressure sensor failure or harness/

connector contact failure
SAPH311991700030
OK
Engine ECU failure, connector contact failure

Common rail pressure sensor malfunction (DTC code P0192, P0193)

JP31199170601016
DTC P0192 Common rail pressure sensor circuit low input
DTC P0193 Common rail pressure sensor circuit high input
D33 D D20
harness.
terminals D20/D31 and terminal D33 of the signal check
harness.

SAPH311991700031
OK
1. Set the starter key to "OFF" and disconnect the connector of

the common rail pressure sensor.
GND +5V
+5V terminal and the GND terminal of the common rail
pressure sensor connector (at unit harness side).

SAPH311991700032 terminals.
OK
1. Set the starter key to "OFF" and disconnect the ECU side
connector of the signal check harness.
D
D20
D31 2. Measure the resistance between terminals D20/D31 of the
signal check harness and the SIG terminal of the common rail
SIG
NG Harness failure
SAPH311991700033
OK
Connector contact failure
1. Set the starter key to "OFF" and disconnect the ECU side
2. Measure the resistance between terminals D24 of the signal

D24 D +5V
check harness and the +5 V terminal of the common rail
SAPH311991700034
3. Measure the resistance between terminal D33 of the signal

check harness and the GND terminal of the common rail
D GND
NG Harness failure
D33
SAPH311991700035
OK

Accelerator sensor 1 malfunction (DTC code P2122, P2123)

JP31199170601017
DTC P2122 Accelerator sensor circuit 1 low voltage
DTC P2123 Accelerator sensor circuit 1 high voltage
harness.
terminal A21 and terminal B20 of the signal check harness.
B20
A21 Standard value : 0.7 - 1.5V (idle status)
NG [3] Voltage measuring at the output port of the

mechatronic controller
SAPH311991700036
OK
1. While increasing the throttle, measure the voltage between

Standard value
B20 Engine revolution

A21 Measuring item Voltage(V)
(r/min)
Low idle 1,000 Approx.1.4
High idle 2,000 Approx.3.3
SAPH311991700036
NG Defective mechatronic controller
OK
Harness failure
3 Voltage measuring at the output port of the mechatronic controller
1. With the starter key set to "ON", do not open the slot and
measure the voltage between pin 25 of the pin connector 28 of
the mechatronics controller and B21 of the signal check
harness.
When an abnormal value is detected, the mechatronics
controller becomes defective.
Abnormal value
: 0.3 V or less
: 4.85 V or more
NG Engine ECU failure, ECU connector failure or

disconnection of harness, short-circuit of harness
OK
Defective mechatronic controller

Accelerator sensor 1 malfunction (DTC code P2127, P2128)

JP31199170601018
DTC P2127 Accelerator sensor circuit 2 low voltage
DTC P2128 Accelerator sensor circuit 2 high voltage
㧭㧮 harness.
A22
B21
Standard value : 0.7 - 1.5V (idle status)
NG [3] Voltage measuring at the output port of the

mechatronic controller
SAPH311991700037
OK
1. While increasing the throttle, measure the voltage between

㧭㧮 terminal A22 and terminal B21 of the signal check harness.
A22
B21
Standard value
Engine revolution
Measuring item Voltage(V)
(r/min)
Low idle 1,000 Approx.1.4
High idle 2,000 Approx.3.3
SAPH311991700037
NG Defective mechatronic controller
OK
Harness failure
3 Voltage measuring at the output port of the mechatronic controller
1. With the starter key set to "ON", do not open the slot and
measure the voltage between pin 25 of the pin connector 28 of
the mechatronics controller and B21 of the signal check
harness.
When an abnormal value is detected, the mechatronics
controller becomes defective.
Abnormal value
: 0.3 V or less
: 4.85 V or more
NG Engine ECU failure, ECU connector failure or

disconnection of harness, short-circuit of harness
OK
Defective mechatronic controller

Accelerator sensor 1 and 2 malfunction (DTC code P2120)

JP31199170601019
1 Inspection item
1. Take action of DTC code P2120.

"Reference : Accelerator sensor 1 malfunction (DTC code P2122,
P2123), Engine ECU, Engine diagnosis code"
"Reference : Accelerator sensor 2 malfunction (DTC code P2126),
Engine ECU, Engine diagnosis code"
Emergency accelerator sensor malfunction (DTC code P1133)

JP03Z01030703026
1 Power supply voltage measuring
1. With the ECU connector connected, disconnect the sensor

connector and measure the voltage between the power
+5V terminal (+5 V) and the GND terminal.
! CAUTION • The connector in the figure is seen from the

fitting surface.
GND Standard value : 5.0 ± 0.5 V

SAPH311991700038
OK
1. Measure the voltage between terminals B20 and B23 of the

㧮 signal check harness.
B23 B20
Standard value : 5.0 ± 0.5 V
NG Engine ECU, engine ECU connector failure
SAPH311991700039
OK
Harness failure
1. Connect the sensor connector and measure the voltage

between terminals A23 and B20 of the signal check harness.
Standard value : Approx. 0.0 to 3.2 V (idle to full

throttle)
B20
A23 NG [4] Go to measurement of voltage between terminals.
SAPH311991700040
OK
Engine ECU failure, engine ECU connector failure
1. Leave the emergency accelerator sensor connected.
2. Connect the sensor connector and measure the voltage

GND between the terminals SIG and GND of the sensor.
! CAUTION • The connector in the figure is seen from the

SIG
fitting surface.
Standard value : Approx. 0.0 to 3.2 V (idle to full

throttle)
SAPH311991700041
NG Emergency accelerator sensor failure
OK
Harness failure
Atmospheric pressure sensor malfunction (DTC code P2228, P2229)

JP31199170601020
DTC P2228 Atmospheric pressure sensor circuit low input
DTC P2229 Atmospheric pressure sensor circuit high input
1. After deleting the past failures with the failure diagnosis tool
(HinoDX) using PC, check again if the same code (DTC code
P2228, P2229) is output.
Standard : Normal
NG Engine ECU failure
SAPH311991700026
OK
Since it may be a temporary malfunction due to radio interference, it is acceptable when the system recovers
normal operation.
Injector common 1 ground short (DTC code P1211), Injector common 2

ground short (DTC code P1214)
JP31199170601021
harness.

harness.
3. Measure the resistance between each terminal of the signal
D5 D D6 check harness and the ECU case ground.
ECU case ground
(ECU mounting bolt)
DTC code Terminal to measure resistance
ECU case
E6 E E7 P1211 D5, D6
ground
ECU case
P1214 E6, E7
ground
SAPH311991700042 Standard value : ∞ Ω

injector terminals.
OK
1. Set the starter key to "OFF" and connect the ECU side
2. Start the engine and delete the past failures with the failure
diagnosis tool (HinoDX) using PC.
3. If the same failure code is output again, replace the engine

ECU. If the normal code is output, it is considered that a
temporary error has occurred.
SAPH311991700026
3 Measurement of resistance between injector terminals
1. Set the starter key to "OFF".
2. The injector clustered connector at the front side of the engine

shall be disconnected.
1 2 12 11
7 8 6 5 3. Measure the resistance between terminals of the injector
3 4 10 9 clustered connector (at unit harness side).
Terminal to measure resistance

DTC code
SAPH311991700043
+ side – side
ECU case
P1211 5, 6, 10, 12
ground
ECU case
P1214 2, 4, 7, 8
ground
Standard value : ∞ Ω
NG Harness failure (failure including pinching of harness

which has not satisfied the standard value)
OK
Inspection of harness inside head cover (Short-circuit of the harness inside the head cover to the ground line may
have occurred.)
Injector common 1 power source line short (DTC code P1212), Injector
common 2 power source line short (DTC code P1215)
JP31199170601022
D5 D D6 harness.
ECU case ground
(ECU mounting bolt)
harness and set the starter key to "ON".
E6 E E7
3. Measure the voltage between each terminal of the signal check
harness and the ECU case ground.
! CAUTION • Never start the engine because it may cause

SAPH311991700044 failure of the unit or electric shock.
Terminal to measure voltage

DTC code
+ side – side
ECU case
P1212 D5, D6
ground
ECU case
P1215 E6, E7
ground
Standard value : 14 V or less
NG [3] Go to measurement of voltage between injector

terminals.
OK
3. If the same failure code is output again, replace the common

rail ECU. If the normal code is output, it is considered that a
SAPH311991700026
3 Measurement of voltage between injector terminals
1. Set the starter key to "OFF".

shall be disconnected and set the starter key to "ON".
1 2 12 11
7 8 6 5 3. Measure the voltage between terminals of the injector
3 4 10 9 clustered connector (at unit harness side).
! CAUTION • Never start the engine because it may cause

failure of the unit or electric shock.
SAPH311991700043
Terminal to measure voltage

DTC code
+ side – side
ECU case
1212 5, 6
ground
ECU case
1215 7, 8
ground
Standard value : 14 V or less
NG Harness failure (harness failure of terminal that has

not satisfied the standard value)
OK
Inspection of harness inside head cover (Short-circuit of the harness inside the head cover to the power line may
have occurred.)
Injector circuit malfunction (DTC code P0201 to P0204)

JP31199170601023
DTC P0201 Injector circuit malfunction -cylinder 1
harness.

D2 D5
D3 harness and measure the resistance between terminals.
Terminal to
E1 Failure area
E2
DTC code measure
(injector)
E6 resistance
SAPH311991700045
P0201 #1 D2 ↔ D5
P0202 #2 E2 ↔ E6
P0203 #3 E1 ↔ E7
P0204 #4 D3 ↔ D6

injector terminals.
OK
3. If the same failure code is output again, replace the common

rail ECU. If the normal code is output, it is considered that a
SAPH311991700026

shall be disconnected.
2. Measure the resistance between terminals of the injector

1 2 3 4
clustered connector (male) at the cam housing.
5 6 7 8
9 10 11 12
Terminal to measure
DTC code
resistance
P0201 5 ↔ 10
SAPH311991700046 P0202 7 ↔ 11
P0203 3↔8
P0204 2↔6

injector terminals.
OK
unit harness disconnection (Check the harness between the ECU and the injector clustered connector.)
1. Remove the head cover and disconnect the injector connector

(injector side) of the cylinder indicated by the failure code.
Measure the resistance between the No. 1 terminal and the No.
2 terminal.
Standard value : 0.45 ± 0.05 Ω

injector terminals.
SAPH311991700047
OK
Contact failure of harness or connector inside the head cover

1. Remove the terminal cap of the injector of the cylinder

indicated by the failure code and measure the insulation
resistance between the terminal and the upper body.
Standard value : 1, 000 MΩ or more
NG Injector TWV coil disconnection (Replace the injector

assembly.)
SAPH311991700048
OK
Injector harness disconnection (Replace the injector harness.)

Cylinder contribution/balance fault (DTC codes P0263, P0266, P0269,

P0272) JP31199170601024
DTC P0263 Cylinder 1 contribution/balance fault
1 Inspection of flow damper 1
1. Set the starter key to "OFF" and stop the engine.
2. Wait for approx. 30 seconds and start the engine.
3. Warm-up the engine until coolant temperature is 60 °C{140 °F}

or more, delete the past failure with a failure diagnosis tool
(HinoDX) using PC.
SAPH311991700026
4. If the same failure code is displayed as the current failure after

deleting the past failure, check the flow damper of the cylinder
indicated by the failure code.
Failure area
DTC code
(Flow damper)
P0263 #1
P0266 #2
P0269 #3
P0272 #4
SAPH311991700049
2 Inspection of flow damper 2
1. Remove the flow damper from the common rail and run air from
one side of the flow damper. Check if the damper is not blocked
by release of air to the opposite side.
! CAUTION • When air is run, be careful so that dirt, water,

etc. may not enter the flow damper.
Standard value : Air must flow. (Flow damper is
normal.)
NG Replace the flow damper (if air is not run)
SAPH311991700050
OK

If other failure code is output, repair the failure first and delete
the past failure with the failure diagnosis tool (HinoDX) using
PC.
Then, if this failure code is output again, the following failures
may be estimated.
• Excessive fuel flow due to leak from broken pipe, crack in

pipe or pipe connection between the flow damper and the
injector pipe
SAPH311991700026
→ Check for leak
• Too large or too small fuel flow due to increase of leak inside
inside the injector
→ Check for leak on the individual injector with a nozzle
tester
• Excessive fuel flow due to failure of injection nozzle and seat
→ Check for seat failure on the individual injector with a
nozzle tester
• Too large or too small fuel flow due to malfunction of the
injector
→ Check with replacement of injector
• Too small fuel flow due to clogging in the fuel supply system
→ Inspection of fuel filter
2. To specify a failure location above, check the compensation

between cylinders with the failure diagnosis tool (HinoDX)
using PC and stop an injector. Then, perform diagnosis while
viewing the engine data.
Supply pump SCV malfunction (DTC code P0628, P0629)

JP31199170601025
DTC P0628 Supply pump SCV malfunction (Full discharge mode)
DTC P0629 Supply pump SCV malfunction (Power source line short)
1 Measurement of resistance between solenoid terminals
1. Set the starter key to "OFF", disconnect the connector of the

supply pump solenoid valve and measure the resistance
between No. 1 and No. 2 terminals at the supply pump solenoid
valve.
Standard value : 7.9 ± 0.5 Ω (20 °C{68 °F})
NG Failure of supply pump solenoid valve
SAPH311991700051
OK
1. Set the starter key to "OFF", connect the signal check harness
and disconnect the ECU side connector.
2. Measure the resistance between terminals E10/E11 of the

E E8 signal check harness and the No. 1 terminal of the supply
E9 E10
E11 pump solenoid valve (at unit harness side).
In a similar manner, measure the resistance of terminals E8/E9
of the signal check harness and the No. 2 terminal of the
supply pump solenoid valve connector (at unit harness side).
SAPH311991700052
NG Harness disconnection, connector failure
OK
1. Turn "ON" the starter key.
E4
E E8
E9
2. Measure voltage between terminal E4 and terminals E8/E9 of
the signal check harness.
Standard value : Pulse waveform at 24V ↔ 0V
NG Failure of ECU connector
SAPH311991700053
OK
Engine ECU failure
! CAUTION • After turning "ON" the starter key, take measurements within 40 seconds.
Supply pump SCV sticking (DTC code P2635), Supply pump malfunction
(DTC code P2635), Supply pump abnormal pressure record (DTC code
P2635)
JP31199170601026
1 Inspection of supply pump
1. Set the starter key to "OFF" and stop the engine.
2. Wait for approx. 30 seconds and start the engine.
3. Warm-up the engine until coolant temperature is 60 °C{140 °F}

or more, and delete the past failure with the failure diagnosis
4. Run the engine at no load up to HI idle. Or repeat no-load

operation from LOW idle to HI idle two or three times and
SAPH311991700026
confirm that the same fault code is displayed again.
NG Replace supply pump.
OK

If other failure code is output, repair the failure code and make
sure again that DTC code P2635 is output.
2. When there is no error after the check above, delete the past
failure and operate the engine.
If the same code is output again, possible failures are the
supply pump and engine ECU. Perform more detailed
diagnosis with failure diagnosis tool (HinoDX) - HinoDX
SAPH311991700054 [Inspection Menu], using PC.
Preheat circuit malfunction (DTC code P0540)

JP31199170601030
C2
C1 C D1 D E4 E E5
harness.

harness and measure the resistance between terminals C1, C2
and terminals D1, E4, E5.
Standard value : 25 ± 2.5 Ω

SAPH311991700055 terminals.
OK
2 Measurement of relay resistance
1. Remove the heater relay and measure the resistance between

terminals.
Standard value : 24.8 ± 0.5 Ω
NG Heater relay failure
SAPH311991700056
OK
Harness failure, connector failure

Injector correction data conformity error (DTC code P1601)

JP31199170601031
1 Inspection of QR code
1. Read the QR code data with the failure diagnosis tool (HinoDX)
using PC.
Reference value: This shall coincide with the QR code

managed by the unit manufacturer.
NG Write the QR code again.
SAPH311991700026
OK
Replace engine ECU.
ECU internal error (DTC code P0605, P0606, P0607)

JP31199170601032
DTC P0605 Flash ROM error
DTC P0606 CPU malfunction (Hard detection)
DTC P0607 Monitoring IC malfunction in CPU
1. Set the starter key to "OFF" and set it to "ON" again.
2. After deleting the past failure, check if the same code (DTC
code P0605, P0606, P0607) is output again.
Standard : Normal
SAPH311991700026
OK
normal operation.
ECU charge circuit malfunction (DTC code P0200, P0611)

JP31199170601033
DTC P0200 ECU charge circuit high input
DTC P0611 ECU charge circuit malfunction
1 Check of ECU
1. Set the starter key to "OFF" and set it to "ON" again.
2. After deleting the past failure, check if the same code (DTC
code P0611, P0200) is output again.
Standard : Normal
SAPH311991700026
OK
normal operation.
Main relay malfunction (DTC code P0686)

JP31199170601034
A6
A5 A A7 harness.

harness and set the starter key to "ON". Measure the voltage
Frame
between terminals A5, A6, A7 and the chassis GND.
Standard value : 0 V
NG Defective harness
SAPH311991700057
OK
Engine ECU failure, engine ECU connector failure
Starter signal malfunction (DTC code P0617)

JP31199170601035
B B14 C C4
harness.
C3 2. Disconnect the ECU side connector of the signal check

harness and set the starter key to "ON".
3. Measure voltage between terminal B14 and terminals C3/C4.
! CAUTION • Measuring shall be done in an environment

SAPH311991700058 where the engine may be started.
Standard value
: 0 V (when starter key is at "OFF")
: 24 V (when starter key is at "START")
NG Harness failure
OK

SM - E215b Japan Hs Afme - en

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SM - E215b Japan Hs Afme - en

Uploaded by

Copyright:

Available Formats

HYDRAULIC EXCAVATOR

Book Code No. 87731204

2) WARNING- Indicates a potentially hazardous

The proper and safe lubrication and maintenance

2007-7 & ASSEMBLING

1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS ......................................................1-3

Book Code No. S5YN0118E01

Issue Date of Issue Applicable Machines Remarks

prepare for accidents and fire.

5) For parts which are required to use jig and

(6) Unit Conversion Table

QUANTITIES JIS SI REMARKS

2.1 NAME OF COMPONENTS................................................................................................2-3

Book Code No. S5YN0225E01

Issue Date of Issue Applicable Machines Remarks

2.1 NAME OF COMPONENTS

SHOE AND TRACK LINK

AIR CLEANER TRACK GUIDE

LOWER ROLLER BATTERY

2.2 GENERAL DIMENSIONS

Dimensions marked * do not include the height of the shoe lug.

9530 (31'3") Unit : mm(ft-in)

4170 (13'8") [4450 (14'7")]

9520 (31'3") Unit : mm(ft-in)

4840 (15'11") [4980 (16'4")]

Dimensions marked * do not include the height of the shoe lug.

2.3 WEIGHT OF COMPONENTS

Marks * show dry weight.

* marks indicate LC specifications.

2.4.2 DIMENSIONS OF ATTACHMENT

(2) ARM AND BUCKET

Type Hoe bucket

Type Hoe bucket Slope finishing bucket

Hoe bucket Slope finishing bucket

2.5 SPECIFICATIONS AND PERFORMANCE

Area & Model

Engine model HINO J05E-TG

2.5.3 HYDRAULIC COMPONENTS

Hydraulic pump Variable displacement axial piston pump × 2 + gear pump × 1

2.6 TYPE OF CRAWLER

STD 2,900 (9'6") 40 (5.80)

STD 3,000 (9'10") 35 (5.08)

2.7 TYPE OF BUCKET

2.8 COMBINATIONS OF ATTACHMENT

0.51 (0.67) 0.39 (0.51)

• Use the attachments recommended by NEW HOLLAND KOBELCO.

2.9 ENGINE SPECIFICATIONS

Applicable machine E215B, E215BLC

2.9.2 ENGINE CHARACTERISTIC CURVE (HINO J05E-TG)

FUEL CONSUMPTION RATE

ENGINE SPEED (min-1)

Fuel consumption volume

3.1 BOOM ................................................................................................................................3-3

Book Code No. S5YN0322E01

Issue Date of Issue Applicable Machines Remarks

3.1.2 BOOM MAINTENANCE STANDARD

Fig. 3-2 Clearance of pin and bushing on boom section

(2) Clearance in thrust direction on the boom cylinder installation section

SECTION Y-Y SECTION Z-Z

Fig. 3-4 ARM DIMENSIONAL DRAWING

2.94m (9ft-8in) ARM YN12B00904F1 Unit : mm (ft-in)

3.2.2 ARM MAINTENANCE STANDARD

Fig. 3-5 Clearance of pin and bushing on arm section

%!