Sk70sr-1es Shop Manual

HYDRAULIC EXCAVATOR
MAINTENANCE SPECIFICATIONS
SHOP
MANUAL model SK70SR-1ES
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.S5YT0004E01

0-1
Copyright © 2018 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YT0004E01] [0207CsCsspWbYs]
SAFETY PRECAUTIONS
0-1
SAFETY PRECAUTIONS
GENERAL SAFETY INFORMATION nor or moderate injury. It may also be used to

alert against possible damage to the machine
and its components and is represented as fol-
lows:
Do not operate or perform any maintenance on this
machine until all instructions found in the OPERA-
TOR’S MANUAL and this MANUAL have been thor- (4) It is very difficult to forecast every danger that may
oughly read and understood. occur during operation. However, safety can be en-
Improper operation or maintenance of this machine sured by fully understanding proper operating pro-
may cause accidents and could result in serious in- cedures for this machine according to methods
jury or death. recommended by Manufacturer.
Always keep the manual in storage.
(5) While operating the machine, be sure to perform
If it is missing or damaged, place an order with an
work with great care, so as not to damage the ma-
authorized our Distributor for a replacement.
chine, or allow accidents to occur.
If you have any questions, please consult an autho-
(6) Continue studying the manual until all Safety, Oper-
rized our Distributor.
ation and Maintenance procedures are completely
(1) Most accidents, which occur during operation, are understood by all persons working with the ma-
due to neglect of precautionary measures and safe- chine.
ty rules. Sufficient care should be taken to avoid
these accidents. Erroneous operation, lubrication
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:
3) CAUTION- Indicates a potentially hazardous

situation which, if not avoided, may result in mi-
0-2
SAFETY PRECAUTIONS
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 level, hard 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
SAFETY PRECAUTIONS
(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
SAFETY PRECAUTIONS
INDEX SK70SR-1ES
Book Code No. Index
Title
Distribution Year–Month No.
MAINTENANCE SPECIFICATIONS
S5PW0108E01
2005-2
OUTLINE 1
S5YT0204E01
2005-2
SPECIFICATIONS 2
S5YT0304E01
ATTACHMENT DIMENSIONS 3
2005-2
S5YT1104E01
TOOLS 11
2005-2
S5YT1204E01 STANDARD MAINTENANCE
2005-2
12
TIME SCHEDULE
S5YT1304E01 MAINTENANCE STANDARDS
2005-2
13
AND TEST PROCEDURES
S5YT2103E01 MECHATRO CONTROL
2005-2
21
SYSTEM
S5YT2204E01
2005-2
HYDRAULIC SYSTEM 22
S5YT2304E01
SYSTEM
2005-2
ELECTRICAL SYSTEM 23
S5YT2404E01
2005-2
COMPONENTS SYSTEM 24
S5YT2503E01
2005-2
AIR-CONDITIONER SYSTEM 25
_
S5PW3108E01 DISASSEMBLING
DISASSEMBLING
2005-2 & ASSEMBLING

31
S5YT3203E01
ATTACHMENTS 32
2005-2
S5YT3304E01
2005-2
UPPER SWING BODY 33
S5YT3403E01
2005-2
TRAVEL FRAME 34
E / G TROUBLESHOOTING
S5YT4103E01
2005-2
MECHATRO CONTROL 41
S5YT4203E01
2005-2
HYDRAULIC SYSTEM 42
S5YT4303E01
2005-2
ELECTRICAL SYSTEM 43
S5YT4403E01
2005-2
ENGINE 44
S5YT5103E01
ENGINE 51
2005-2
S5YT6304E01 MOUNTING THE BREAKER
63
OPT.
2005-2 AND NIBBLER & BREAKER

_
YT04-07175~ APPLICABLE MACHINES
0-5
SAFETY PRECAUTIONS
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 REPAIRS ...................................................................... 1-3

1.1.1 PREPARATION BEFORE DISASSEMBLING ........................................................... 1-3
1.1.2 SAFETY IN 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 WELDING REPAIR ................................................................................................... 1-5
1.1.7 ENVIRONMENTAL MEASURE ................................................................................. 1-5
1.2 INTERNATIONAL UNIT CONVERSION SYSTEM(Based on MARKS’ STANDARD
HANDBOOK FOR MECHANICAL ENGINEERS) .............................................................. 1-6
Book Code No. S5PW0108E01
1-1
1. OUTLINE
Issue Date of Issue Applicable Machines Remarks

EH30.B : PW11–30001~ S5PW0108E01
First Edition June, 2004 KE
EH35.B : PX12–11001~ (NH Australia)
SK40SR–3 : PH05–03501~ S5PW0108E01
  KE
SK50SR-3 : PJ04–03001~ (KCM Australia)
S5PW0108E01
  EH50.B : PJ04–03001~ KE
(NH Australia)
  EH27.B : PV10–27001~  SZ
SK20SR–3 : PM07–07001~ S5PW0108E01
  SZ
SK27SR–3 : PV10–27001~ (KCM Australia)
SK30SR–3 : PW11–30001~ S5PW0108E01
  KE
SK35SR–3 : PX12–11001~ (KCM Australia)
S5PW0108E01
 August, 2004 SK50SR–3 : PJ04–03001~ KE
(KCM North America)
SK30SR–3 : PW11–30001~
   KE
SK35SR–3 : PX12–11001~
  SK27SR–3 : PV10–27001~  SZ
 September, 2004 SK70SR–1E(S) : YT04–07001~ S5PW0108E01 KE
  SK80MSR–1E(S) : LF04–02001~  KE
 October, 2004 SK80CS–1E : LF04–02001~  KE
S5PW0108E01
 February, 2005 SK70SR–1ES : YT04–07175~ KE
(NHK)
1-2
1. OUTLINE
1.1 GENERAL PRECAUTIONS FOR (2) Suspend warning tag "DO NOT OPERATE" from
REPAIRS the doorknob or the operating lever, and have a
preliminary meeting before starting work.
1.1.1 PREPARATION BEFORE DISASSEM- (3) Stop the engine before starting inspection and
BLING maintenance to prevent the operator being caught
in machine.
Read Operator’s Manual
before disassembling
(4) Identify the location of a first-aid kit and a fire extin-
guisher, and also where to make contact in a state
(1) Understanding operating procedure of emergency.
Read OPERATOR’S MANUAL and this MANUAL
(5) Choose a hard, level and safe place, and place the
carefully to understand the operating procedure.
attachment on the ground securely.
(2) Cleaning machines
(6) Use a lifter such as a crane to remove heavy parts
Remove soil, mud, and dust from the machine be-
(20 kg [45 lbs] or more) from the machine.
fore carrying it into the service shop to prevent loss
of work efficiency, damage of parts, and difficulty in (7) Use proper tools, and replace or repair defective
rust prevention and dust protection while reassem- tools.
bling. (8) Support the machine and attachment with supports
(3) Inspecting machines or blocks if the work is performed in the lifted condi-
Identify the parts to be disassembled before start- tion.
ing work, determine the disassembling procedure 1.1.3 DISASSEMBLING AND ASSEMBLING HY-
by yourself considering the workshop situations DRAULIC EQUIPMENT
etc., and request procurement of necessary parts in
advance.
(4) Recording
Record the following items for communication and (1) Removing hydraulic equipment
prevention of recurring malfunction.
1) Before disconnecting pipes, release the hy-
1) Inspection date and place draulic pressure of the system, or open the re-
2) Model name, applicable machine number, and turn side cover and take out the filter.
hour meter read 2) Carefully drain oil of the removed pipes into a
3) Trouble condition, place and cause. containers without spilling on the floor.
4) Visible oil leakage, water leakage and damage 3) Apply plugs or caps on the pipe ends to avoid
5) Clogging of filters, oil level, oil quality, oil con- oil spillage and dust intrusion.
tamination and loosening of connections 4) Clean off the external surface of the equipment
6) Result of consideration if any problem exists before disassembling, and drain hydraulic and
based on the operation rate per month calculat- gear oil before placing it on the workbench.
ed from hour meter indication after the last in- (2) Disassembling hydraulic equipment
spection date. 1) Do not disassemble, reassemble or modify the
(5) Arrangement and cleaning in service shop hydraulic equipment without the permission of
1) Tools required for repair work. the manufacturer, who is not responsible for the
performance and function of the product after
2) Prepare space to place the disassembled parts.
modification.
3) Prepare oil containers for draining oil etc.
2) When disassembling and reassembling for un-
1.1.2 SAFETY IN DISASSEMBLING AND AS- avoidable reason, refer the work to qualified
SEMBLING personnel who have the specific knowledge or
completed the parts service training.
3) Provide matching marks to facilitate reassem-
WARNING
bling work.
(1) Wear appropriate clothes with long sleeves, safety 4) Before starting the work, read the manual of
shoes, safety helmet and protective glasses. disassembling procedure, if it is provided, and
decide whether the work can be performed by
yourself.
1-3
1. OUTLINE
5) Use the special jig and tools without fail if they

are specified.
6) If it is hard to remove a part according to the
Operation of the hydraulic equipment with-
procedure, do not try it by force but investigate
out filling hydraulic oil or lubricant or with-
the cause.
out performing air bleeding will result in
7) Place the removed parts in order and attach damage to the equipment.
tags to facilitate the reassembling.
8) Note the location and quantity of parts com- 3) Perform air bleeding of the hydraulic pump and
monly applied to multiple locations. slewing motor after loosening the upper drain
plug, starting the engine and keep it in low idle
(3) Inspecting parts
condition.
1) Ensure that the disassembled parts are free Complete the air bleeding when seeping of hy-
from seizure, interference and uneven contact. draulic oil is recognized, and tightly plug.
2) Measure and record wear condition of parts 4) Perform air bleeding of the travel motor and the
and clearance. hydraulic cylinders by running the engine for
3) If the problem is found in a part, repair or re- more than 5 minutes at low speed without load.
place it with a new one.
(4) Reassembling hydraulic equipment
1) Turn ON the ventilation fan or open windows to
Do not allow the hydraulic cylinder to bot-
maintain good ventilation prior to starting the
tom on the stroke end just after the mainte-
cleaning of parts.
nance.
2) Perform rough and finish cleaning before as-
sembling. 5) Perform air bleeding of pilot line by performing
3) Remove washing oil by air and apply clean hy- a series of digging, slewing and travel.
draulic or gear oil for assembling. 6) Check hydraulic oil level after placing the at-
4) Always replace the removed O-rings, backup tachment to the oil check position, and replen-
rings and oil seals with new ones by applying ish oil if necessary.
grease in advance.
5) Remove dirt and moisture from and perform de-
Level gauge
greasing on the surface where liquid gasket to Oil level lines (Level
be applied. located between the
two lines shows
6) Remove rust preventive agent from the new appropriate amount
of oil)
parts before use.
7) Fit bearings, bushings and oil seals using spe- 1.1.4 ELECTRICAL EQUIPMENT
cial jigs.
8) Assemble the parts utilizing matching marks.
9) Ensure all the parts are completely assembled
after the work. (1) Do not disassemble electrical equipment.
(5) Installing hydraulic equipment (2) Handle it carefully not to drop and give a shock.
1) Ensure hydraulic oil and lubricant are properly (3) Turn the key OFF prior to connecting and discon-
supplied. necting work.
2) Perform air bleeding when: (4) Disconnect the connector by holding it and press-
ing the lock. Do not pull the wire to apply force to the
1. Hydraulic oil changed
caulking portion.
2. Parts of suction side piping replaced
(5) Connect the connector and ensure it is completely
3. Hydraulic pump installed
locked.
4. Slewing motor installed
(6) Turn the key OFF prior to touching the terminal of
5. Travel motor installed starter or generator.
6. Hydraulic cylinder installed (7) Remove the ground (earth) terminal of battery
when handling tools around the battery or its relay.
1-4
1. OUTLINE
(8) Do not splash water on the electrical equipment • Tighten the fitting at the specified torque.
and connectors during machine washing. Ensure no kink, tension, interference nor oil
(9) Check for moisture adhesion inside the waterproof leakage is recognized.
connector after pulling it out, since it is hard to re-
1.1.6 WELDING REPAIR
move moisture from the connector.
(1) Refer repair welding to qualified personnel accord-
If moisture adhesion is found, dry it completely be-
ing to the appropriate procedure.
fore the connection.
(2) Disconnect the ground (earth) cable of the battery
before starting the repair.
Failure to do so will cause damage to the electrical
Battery electrolyte is hazardous. equipment.
Battery electrolyte is dilute sulfuric acid. Exposure (3) Move away the articles in advance that may cause
of skin or eyes to this liquid will cause burning or fire if exposed to sparks.
loss of eyesight.
(4) Before starting the repair of the attachment, do not
If the exposure occurs, take the following emergen-
fail to cover the plated surface of the piston rod with
cy measures and seek the advice of a medical spe-
flameproof sheet to prevent it from being exposed
cialist.
to sparks.
• When skin exposed:
Wash with water and soap sufficiently. 1.1.7 ENVIRONMENTAL MEASURE
• When eyes exposed: (1) Run the engine at the place that is sufficiently ven-
Immediately wash away with city water continu- tilated.
ously for more than 10 minutes. (2) Industrial waste disposal
• When a large amount of the liquid flows out: Dispose of the following parts according to the rel-
Neutralize with sodium bicarbonate or wash evant regulations:
away with city water. Waste oil and waste container
• When swallowed: Battery
Drink a large amount of milk or water. (3) Precautions for handling hydraulic oil
• When clothes exposed: Exposure of eyes to hydraulic oil will cause inflam-
Immediately undress and wash. mation. Wear protective glasses before handling to
avoid an accident. If an eye is exposed to the oil,
take the following emergency measures:
1.1.5 HYDRAULIC PARTS
• When an eye exposed:
Immediately wash away with city water suffi-
ciently till stimulative feeling vanishes.
(1) O-ring • When swallowed:
Do not let vomit, and receive medical treatment
• Ensure O-rings have elasticity and are not dam-
immediately.
aged before use.
• When skin exposed:
• Use the appropriate O-rings. O-rings are made
Wash with water and soap sufficiently.
of various kinds of materials having different
hardness to apply to a variety of parts, such as (4) Others
the part for moving or fixed portion, subjected to Use replacement parts and lubricants authorized as
high pressure, and exposed to corrosive fluid, the manufacturer's genuine parts.
even if the size is same.
• Fit the O-rings without distortion and bend.
• Always handle floating seals as a pair.
(2) Flexible hose (F hose)
• Use the appropriate parts. Different parts are
used depending on the working pressure even
the size of fitting and the total length of the hose
is same.
1-5
1. OUTLINE
1.2 INTERNATIONAL UNIT CON- (3) Derived Units

VERSION SYSTEM Table 1-3
(Based on MARKS’ STANDARD QUANTITY UNIT SYMBOL
HANDBOOK FOR MECHANI- Area square meter m2
CAL ENGINEERS) Volume cubic meter m3
Velocity meter per second m/s
Introduction
Acceleration meter per second squared m/s2
Although this manual includes International System of
Density kilogram per cubic meter kg/m3
Unit and Foot-Pound System of Units, if you need SI
unit, refer to the following international system of units. (4) Derived Units bearing Peculiar Designations
Given hereinafter is an excerpt of the units that are re-
lated to this manual. Table 1-4
1. Etymology of SI Unites QUANTITY UNIT SYMBOL FORMULA

French : Le Systeme International d’ Unites Frequency hertz Hz 1/s
English : International System of Units Force newton N kg • m/s 2
2. Construction of SI Unit System Pressure and
pascal Pa N/m2
Stress
Base units Energy, Work
Table 1-1
and Quantity of joule J N•m
Derived units
Supplemen of base units heat
SI units tary units Table 1-3
SI unit Table 1-2
Power watt W J/s
system Derived units Quantity of
bearing peculiar coulomb C A•s
Derived electricity
units designations
Table 1-4 Electric poten-
tial difference,
Prefixes of SI
(n-th power of 10, where n is an integer) Voltage, and volt V W/A
Table 1- 5 Electromotive
force
(1) Base units Quantity of
Table 1-1 static electricity
farad F C/V
and Electric
QUANTITY UNIT SYMBOL
capacitance
Length meter m
Electric
Mass kilogram kg ohm V/A
resistance
Time second s
celcius
Electric current ampere A Celcius
degree or C (t+273.15)K
Thermodynamic temperature
kelvin K degree
temperature Illuminance lux lx l m/m2
Amount of sub-
mol mol
stance
Luminous
candela cd
intensity
(2) Supplementary units

Table 1-2
QUANTITY UNIT SYMBOL
Plane angle radian rad
Solid angle steradian sr
1-6
1. OUTLINE
(5) Prefixes of SI
Table 1-5
PREFIX SYMBOL MULTIPLICATION FACTORS
giga G 109
mega M 106
kilo k 103
hecto h 102
deca da 10
deci d 10–1
centi c 10–2
milli m 10–3
micro  10–6
nano n 10–9
pico p 10–12
(6) Unit Conversion

Table 1-6
QUANTITY Gravitational SI CONVERSION FACTOR
Mass kg kg
Force kgf N 1 kgf=9.807 N
Torque kgf•m N•m kgf•m=9.807 N•m
Pressure kgf/cm 2 MPa 1 kgf/cm2=0.09807 MPa
Motive
PS kW 1 PS=0.7355 kW
Power
Revolution rpm min–1 r/min *1
*1 Units that are allowed to use.
1-7
1. OUTLINE
[MEMO]
1-8
2
2. SPECIFICATIONS
TABLE OF CONTENTS
2.1 NAME OF COMPONENTS ................................................................................................. 2-3

2.2 MACHINE DIMENSIONS ................................................................................................... 2-4
2.2.1 2.07 M (6 ft-9 in) ARM ............................................................................................... 2-4
2.2.2 1.65 M (5 ft-5 in) ARM ............................................................................................... 2-4
2.3 WEIGHT OF COMPONENTS ............................................................................................. 2-5
2.4 TRANSPORTATION DIMENSION AND WEIGHT .............................................................. 2-7
2.5 SPECIFICATIONS AND PERFORMANCE ........................................................................ 2-10
2.5.1 SPEED AND CLIMBING CAPABILITY ..................................................................... 2-10
2.5.2 ENGINE ..................................................................................................................... 2-10
2.5.3 HYDRAULIC COMPONENTS ................................................................................... 2-10
2.5.4 WEIGHT .................................................................................................................... 2-10
2.6 TYPE OF CRAWLER ......................................................................................................... 2-11
2.7 TYPE OF BUCKET ............................................................................................................. 2-12
2.8 COMBINATIONS OF ATTACHMENT ................................................................................. 2-13
2.9 ENGINE SPECIFICATION ................................................................................................. 2-14
2.9.1 SPECIFICATIONS .................................................................................................... 2-14
2.9.2 ENGINE CHARACTERISTIC CURVE (ISUZU 4JG1NABGA) ................................... 2-15
Book Code No. S5YT0204E01
2-1
2. SPECIFICATIONS

S5YT0204E01
First edition February, 2005 SK70SR–1ES : YT04–07175~ KE
(NHK)
2-2
2. SPECIFICATIONS
2.1 NAME OF COMPONENTS
ARM ARM CYLINDER
BOOM
SWIVEL JOINT
BUCKET CYLINDER
SLEWING MOTOR
BATTERY
IDLER LINK FUEL TANK

BACK MIRROR
BUCKET LINK
BOOM CYLINDER HYDRAULIC TANK
CAB
CONTROL VALVE
BUCKET
OPERATOR CONTROLS ENGINE MUFFLER
PUMP ACCESS DOOR
HYDRAULIC PUMP
SHOE PLATE
FRONT IDLER
CRAWLER ADJUSTER
ENGINE
AIR CLEANER
UPPER ROLLER COUNTER WEIGHT
LOWER ROLLER RADIATOR
TRACK LINK TRAVEL MOTOR
2-3
2. SPECIFICATIONS
2.2 MACHINE DIMENSIONS

2.2.1 2.07 M (6 ft-9 in) ARM
Unit: mm (ft-in)
Reference : Arm cylinder pin A position (Working position)
Working height : 2920 mm (9 ft-7 in)
5,500 (18')
4,340 (14'3") R 1,160 (3'10")
Transport positioning pin (B position)
B
2,600 (8'6")
1,440 (4'9")
2,860 (9'5")
5,780 (18'12")
2.2.2 1.65 M (5 ft-5 in) ARM
R1,160
5,500 (18'0")
4,340 (14'3") R 1,160 (3'10")
2,600 (8'6")
2,600 (8'6")
(29.5")
*750
(15.0")
*380
1,440 (4'9") 450 (17.7")

2,860 (9'5") [600 (23.6")]
5,780 (18'12") 2,320 (7'7")
[2,470 (8'1")]
*Marked dimensions do not include height of shoe lug.
2-4
2. SPECIFICATIONS
2.3 WEIGHT OF COMPONENTS

Unit : kg (lbs)
Model 2.07 M (6 ft-9 in) Arm

Item +450 mm (17.7 in shoe)
Machine complete 7,190 (15,850)
1. Upper frame assy (including the following :) 3,196 (7,050)
1.1 Counterweight 820 (1,810)
Counterweight (Add-on) 400 (880)
1.2 Cab 191 (420)
1.3 Engine *250 (550)
1.4 Hydraulic oil tank *68 (150)
1.5 Fuel tank *53 (120)
1.6 Slewing motor (including reduction unit) 67 (150)
1.7 Control valve 48 (106)
1.8 Boom cylinder *92 (200)
1.9 Pin (2pcs. for mounting boom) 14 (31)
1.10 Pump 44 (97)
1.11 Radiator *39 (86)
2. Lower frame assy (including the following :) 2,854 (6,290)

2.1 Slewing bearing 115 (250)
2.2 Travel motor (including reduction unit) 90 (200)  2
2.3 Upper roller 4 (9)  2
2.4 Lower roller 15 (33)  10
2.5 Front idler 44 (97)  2
2.6 Track tension adjuster 29 (64)  2
2.7 Sprocket 27 (59)  2
2.8 Swivel joint 21 (46)
2.9 Dozer blade 305 (670)
2.10 Dozer blade cylinders *55 (120)
2.11 Track link with 450 mm (17.7 in) shoes assy 421 (928)  2
Track link with 600 mm (23.6 in) shoes assy 503 (1,110)  2
Track link with 600 mm (23.6 in) triangle shoes assy 470 (1,040)  2
2.11.1 Track link assy 155 (340)  2
3 Attachment
{3.72 m (12 ft-2 in) Boom+2.07 m (6 ft-9 in) Arm+0.22 m3 (0.28 cu•yd) Bucket} 982 (2,165)
3.1 Bucket assy 190 (420)
3.2 Arm assy (including the following :) 303 (670)
3.2.1 Arm 180 (400)
3.2.2 Bucket cylinder 48 (106)
3.2.3 Idler link 6 (13)  2
3.2.4 Bucket link 8 (17)  2
3.2.5 Pin (2 pcs. for mounting bucket cylinder / 2 pcs. for mounting bucket) *17 (37)
3.3 Boom assy (including the following :) 490 (1,080)
3.3.1 Boom 390 (860)
3.3.2 Arm cylinder 72 (160)
3.3.3 Pin (Mounting arm • Mounting arm cylinder) 16 (35)
2-5
2. SPECIFICATIONS
Model 2.07 M (6 ft-9 in) Arm

Item +450 mm (17.7 in shoe)
4. Lubricant and water (including the following :) 161 (355)
4.1 Hydraulic oil 68 (150)
4.2 Engine oil 9 (20)
4.3 Fuel 71 (157)
4.4 Water 10 (22)
Numerical values marked * indicate the dry weight.
2-6
2. SPECIFICATIONS
2.4 TRANSPORTATION DIMENSION AND WEIGHT

OVERALL DIMENSIONS OF MACHINE ON A TRAILER
OVERALL DIMENSIONS OF A COMPLETE MACHINE ON A TRAILER
Item Type 2.07 M (6 ft-9 in) Arm + 600 mm (23.6 in) shoes 2.07 M (6 ft-9 in) Arm + 450 mm (17.7 in) shoes
Width m (ft-in) 2,470 (8’1") 2,320 (7’7")
Weight kg (lb) 6,920 (15,260) 6,700 (14,770)
Specification :
• The parenthesis shows 2.07m arm model.

• Regarding 2.07m arm machine, put the arm cylinder rod in a transport position (B) by referring to the outside
dimensions in 2.2 MACHINE DIMENSIONS.
OVERALL DIMENSIONS OF WITHOUT ARM AND BUCKET
Type A : Shoe width L : Length H : Height W : Width Weight

Combination mm (ft-in) mm (ft-in) mm (ft-in) mm (ft-in) mm (ft-in)
600 (23.6") 5,670 (18’7") 2,600 (8’6") 2,470 (8’1") 6,440 (14,200)
Without arm and bucket
450 (17.7") 5,670 (18’7") 2,600 (8’6") 2,320 (7’7") 6,220 (13,715)
2-7
2. SPECIFICATIONS
OVERALL DIMENSIONS OF WITHOUT BOOM, ARM AND BUCKET
Type A : Shoe width L : Length H : Height W : Width Weight

Combination mm (ft-in) mm (ft-in) mm (ft-in) mm (ft-in) mm (ft-in)
Without boom, arm and 600 (23.6") 2,860 (9’5") 2,600 (8’6") 2,470 (8’1") 5,950 (13,120)
bucket 450 (17.7") 2,860 (9’5") 2,600 (8’6") 2,320 (7’7") 5,730 (12,630)
OVERALL DIMENSIONS OF BOOM
Item Type 3.72 m (12 ft-2 in) Boom

Length  Height  Width 3.86 1.43  0.36
m (ft-in)
LHW (12’8  4’8 1’2 )
Weight kg (lb) 490 (1,080)
OVERALL DIMENSIONS OF ARM + BUCKET
Type 1.65 m (5 ft-5 in) Arm+ 2.07 m (6 ft-9 in) Arm+

Item 0.28 m (0.37 cu•yd) Bucket
3 0.22 m3 (0.29 cu•yd) Bucket
Length  Height  Width 3.14 0.70  0.75 3.61  0.71  0.65
m (ft-in)
LHW (10’4"  2’4"  2’6" ) (11’10"  2’2.4" 2’2" )
Weight kg (lb) 450 (990) 480 (1,060)
H
2-8
2. SPECIFICATIONS
OVERALL DIMENSIONS OF ARM
Item Type 1.65 m (5 ft-5 in) Arm 2.07 m (6 ft-9 in) Arm
Length  Height  Width 2.17  0.53  0.36 2.64  0.53  0.36
m (ft-in)
LHW (7’1"  1’9"  1’2" ) (8’8"  1’9"  1’2" )
Weight kg (lb) 250 (550) 290 (640)
H
L
OVERALL DIMENSIONS OF BUCKET
Type Hoe bucket

Length  Height  Width 1.10  0.60  0.40 0.98  0.89  0.48 0.98  0.89  0.55 0.98 0.89  0.65
LHW m (ft-in) (3’7" 1’12"  1’4" ) (3’3"  2’11"  1’7" ) (3’3"  2’11"  1’10" ) (3’3"  2’11"  2’2")
Weight kg (lbs) 150 (330) 150 (330) 170 (380) 190 (420)
Bucket capacity m3 (cu•yd) 0.11 (0.14) 0.14 (0.18) 0.18 (0.23) 0.22 (0.29)
Type Hoe bucket Slope finishing

V-bucket
bucket
Length  Height  Width 0.98  0.89  0.75 0.98  0.89  0.85 1.08  0.47  1.41 0.79  0.62  1.50
LHW m (ft-in) (3’3" 2’11" 2’6" ) (3’3"  2’11"  2’9" ) (3’6"  1’6"  4’7" ) (2’7"  2’0"  4’11" )
Weight kg (lbs) 200 (440) 220 (490) 180 (340) 300 (660)
Bucket capacity m (cu•yd)
3
0.28 (0.37) STD 0.35 (0.45) 0.24 (0.31) 0.26 (0.34)
2-9
2. SPECIFICATIONS
2.5 SPECIFICATIONS AND PERFORMANCE

2.5.1 SPEED AND CLIMBING CAPABILITY
Model & Shoe spec. SK70SR-1ES

Item Iron shoe Rubber shoe
Swing speed rpm {min-1 } 11.5 {11.5}
Travel speed km/h 3.1 / 5.5 3.2 / 5.5
Gradeability % (degree) 70 (35)
2.5.2 ENGINE
Engine model ISUZU 4JG1NABGA

Type Water-cooled 4-cycle direct injection type engine
Number of cylinders-Bore  Stroke 4-95.4 mm  107 mm (3.76 in  4.21 in)
Total displacement 3,059 cc (187 cu•in)
Rated output / Rotation speed 40.5 kw / 2,000 rpm (55 PS / 2,100 rpm)
Maximum torque / Rotation speed 187 N•m (138 ft•lbs) / 1,800 rpm
Starter 24 V / 3.2 kW
Alternator 24 V / 30A
2.5.3 HYDRAULIC COMPONENTS
Hydraulic pump Variable displacement axial piston+gear pump

Hydraulic motor (Swing) Axial piston motor
Hydraulic motor (Travel) 2-speed axial piston motor
Control valve 6-spool control valve, 1–spool control valve (Dozer)
Cylinder
Double action cylinder
(Boom, arm, and Bucket)
Oil cooler Air-cooled type
2.5.4 WEIGHT
Unit : kg (lbs)
Fully equipped weight 6,940 (15,300) 7,180 (15,830)

Upper structure 3,250 (7,170) 
Lower machinery
(With 600 mm (23.6 in) grouser shoe) 2,370 (5,230) —
(With 450 mm (17.7 in) grouser shoe) — 2,590 (5,710)
Attachment
[ Boom+2.07 m (6 ft-9 in) Arm
1,080 (2,380) —
+0.22 m3 (0.29 cu•yd) bucket ]
[ Boom+1.65 m (5 ft-5 in) Arm
— 1,110 (2,450)
+0.28 m3 (0.37 cu•yd) bucket ]
2-10
2. SPECIFICATIONS
2.6 TYPE OF CRAWLER

Shoe width Overall width of crawler Ground pressure
Shape
mm (in) mm (in) kPa (psi)
Iron crawler
450 (17.7) 2,320 (7’7" ) 31.4 (4.5)
600 (23.6) 2,470 (8’1" ) 23.5 (3.4)

39 links
Flat shoe
450 (17.7) 2,320 (7’7" ) 32.3 (4.6)
39 links
Triangle shoe
600 (23.6) 2,470 (8’1" ) 22.5 (3.3)
700 (27.6) 2,570 (8’5" ) 19.6 (2.9)
39 links
Rubber crawler
450 (17.7) 2,320 (7’7" ) 31.4 (4.5)
Use grouser shoes 600 mm (23.6 in) or 450 mm (17.7 in) 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.) damage.
2-11
2. SPECIFICATIONS
2.7 TYPE OF BUCKET

Heaped Struck Outer width mm (ft-in) Number Availability
W or W/O Weight
capacity m3 With side Without side of of face
side cutter kg (lbs)
m3 (cu•yd) (cu•yd) cutter cutter tooth shovel
Hoe bucket 0.09 150
0.11 (0.14) — 400 (1’4" ) 3 No Yes
(0.12) (330)
0.12 Yes 160
0.14 (0.18) 480 (1’6" ) — 3 Yes
(0.16) (welded) (350)
0.14 170
0.18 (0.24) 550 (1’10" ) 480 (1’7" ) 3 Yes Yes
(0.18) (380)
0.18 190
0.22 (0.29) 650 (2’2" ) 580 (1’11" ) 4 Yes Yes
(0.24) (420)
STD 0.22 200
750 (2’6" ) 680 (2’3" ) 4 Yes Yes
0.28 (0.37) (0.29) (440)
0.26 220
0.35 (0.46) 850 (2’9" ) 780 (2’7" ) 4 Yes Yes
(0.34) (640)
V-shape bucket Slope finishing bucket

Capacity : 0.24 m3(0.31 cu•yd) Capacity : 0.26 m3(0.34 cu•yd)
Weight : 180 kg (400 lbs) Weight : 300 kg (660 lbs)
Face shovel unavailable Face shovel unavailable
")
( 4 ’7
10
1,4
1,2
70
(4’ ")
2" 11
) 4’
74 0 0(
0 (2’ 0 1,5
24 4") 5")
(9’
2-12
2. SPECIFICATIONS
2.8 COMBINATIONS OF ATTACHMENT

Bucket Applicable Arm
1.65 m (5 ft-5 in)
Heaped capacity Struck 1.65 m (5 ft-5 in) 2.07 m (6 ft-9 in)
Type Arm+
m3 (cu•yd) m3 (cu•yd) Arm Arm
Extension Arm
0.11 (0.14) 0.09 (0.12)
0.14 (0.18) 0.12 (0.16)
0.18 (0.24) 0.14 (0.18)
Hoe bucket
0.22 (0.29) 0.18 (0.24)
0.28 (0.37) 0.22 (0.29)
0.35 (0.46) 0.26 (0.34)
V-bucket 0.24 (0.31) 0.16 (0.21)
Slope finishing
0.26 (0.34) 0.14 (0.18)
bucket
Breaker — —
(Reinforced arm)
Nibbler — —
(Reinforced arm) (Reinforced arm)
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 KOBELCO. Reinforcement of arm allows to use it as nibbler and breaker.
The trouble due to the use in the condition "Use not allowed" described in the above table is not included in our
responsibility
• When bucket marked by has been attached or nibbler has been attached on long arm, the specified stability
may not be obtained. So add weight 400 kg (880 lbs) in add-on type as required.
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 SPECIFICATION

2.9.1 SPECIFICATIONS
Model SK70SR-1ES
Engine model ISUZU 4JG1NABGA
Type Diesel, 4-cycle water -cooled, in-line, Direct injection
Number of cylinder-Bore  Stroke 4-95.4mm (3.76 in) 107 mm (4.21 in)
Total displacement 3,059cc (187 cu•in)
Compression ratio 18.6
Rated out put 40.5 kW (55 PS) at 2,100 rpm
Maximum torque 187 N•m (138 lbf•ft) at 1,800 rpm
High idling 2,310±25rpm
Low idling 1,000±25rpm
Injection valve opening pressure 18.14 MPa (2,632 psi)
Thermostat action Start 82C°(180°F)/Full open 95C°(203°F)
Firing order 1-3-4-2
Compression pressure 2.94 MPa (427 psi) at 200 rpm
Lubrication oil pressure —
Fuel injection timing 10±1° before top dead point
Valve clearance Open Close
0.4 mm (0.016" ) 24.5° before top 55.5° after bottom
Intake valve
Valve clearance in cold condition dead point dead point
0.4 mm (0.016" ) 54° before top 26° after top
Exhaust valve
in cold condition dead point dead point
Starter capacity 3.2kW  24 V
Generator capacity (Alternator) 24 V30 A
Ø450 (17.7 in) suction type seven fans
Cooling fan drive method
V-belt drive, pulley ratio Crank / Fan=1.12
Full level 10.3 L (2.7 gal)
Engine oil quantity
Low level sensor actuation Oil filter, etc
Dry weight 250 kg (550 lbs)
Fuel consumption ratio 240 g / kw•h (176 g / PS•h)
Allowable inclination Front / Rear and Right / Left : 35°
Dimension (L  W  H) 760 mm  610 mm  710 mm (29.9 in  24.0 in  28.0 in)
Rotating direction Counterclockwise seeing from flywheel side
2-14
2. SPECIFICATIONS
2.9.2 ENGINE CHARACTERISTIC CURVE (ISUZU 4JG1NABGA)

Condition to be measured : With fan and generator
Without muffler and air cleaner
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 STANDARDS ........................................................................ 3-8
3.3 BUCKET ............................................................................................................................ 3-10
3.3.1 BUCKET DIMENSIONAL DRAWING ....................................................................... 3-10
3.3.2 BUCKET DIMENSIONAL TABLE ............................................................................. 3-12
3.3.3 DETAIL DIMENSIONAL DRAWING OF LUG SECTION ........................................... 3-13
3.3.4 DETAIL DIMENSIONAL DRAWING OF BOSS SECTION ........................................ 3-15
3.4 DOZER ............................................................................................................................... 3-16
3.4.1 DOZER DIMENSIONAL DRAWING .......................................................................... 3-16
3.4.2 DOZER MAINTENANCE STANDARD ...................................................................... 3-17
3-1

S5YT0304E01
(NHK)
3-2
3.1 BOOM
3.1.1 BOOM DIMENSIONAL DRAWING
VIEW Z
Fig. 3-1 Boom dimensional drawing
Unit : mm (ft-in)
3.7 m Boom YT02B00064P1
Code Item Dimension
A Boom length 3,715 (12'2")
B Boom foot width 360 (14.2")
C Boom end inner width 215 (8.46")
D Boom end outer width 315 (12.4")
E Height of boom cylinder rod pin 781 (30.7")
F Height of arm cylinder (head side) pin 1,085.5 (3'7")
G Distance between pins of boss R1,858.5 (6'1")
H Distance between of pins of bracket R1,706.5 (5'7")
I Arm cylinder (head side) inner width 100 (3.94")
J Inner width of bracket on the arm cylinder (rod side) mounting section 100 (3.94")
d1 Boom foot pin dia. Ø 60 (2.36")
d2 Boom cylinder (rod side) pin dia. Ø 70 (2.76")
d3 Pin dia. of arm end Ø 60 (2.36")
d4 Arm cylinder (head side) pin dia. Ø 60 (2.36")
3-3
3.1.2 BOOM MAINTENANCE STANDARD

(1) Clearance of pin and bushing on boom section
Fig. 3-2 Clearance of pin and bushing on boom section
Unit : mm (in)
Standard dimensions Clearance
Bushing Limit val- Service
Pos. Item Pin parts No. Pin dia. Standard Remedy
Pin dia. i.d. toler- ue for re- limit
tolerance value
ance pair value
–0.06 +0.10
0.09~0.19
Ø60 (-0.0024) (+0.0039)
A Boom foot YT02B01014P1 (0.0035
(2.3622) -0.09 +0.03
~0.0075)
(-0.0035) (+0.0012)
-0.06
0.11~0.34
Boom cylinder Ø75 (-0.0024)
B YT02B01027P1 (0.0043
(Head side) (2.9528) -0.09
~0.134) Replace
(-0.0035) 2.0 2.5
bushing
-0.06 +0.25 (0.08) (0.1)
0.11~0.34 or pin
Boom cylinder Ø70 (-0.0024) (+0.0098)
C YT02B01026P1 (0.0043
(Rod side) (2.7559) -0.09 +0.05
~0.0134)
(-0.0035) (+0.0020)
-0.06
0.11~0.34
Arm cylinder Ø60 (-0.0024)
D YT02B01025P1 (0.0043
(Head side) (2.3622) -0.09
~0.0134)
(-0.0035)
3-4
(2) Clearance in thrust direction on the boom and cylinder installation section
PL1
SECTION AA
PL2
PL3 PL4
SECTION CC SECTION DD SECTION BB

Fig. 3-3 Clearance in thrust direction on boom cylinder installation section
Unit : mm (in)
Clearance X adjusted by shim Length under
Basic size
(total of both sides) pin neck
Repair
Pos. Item Service Di- Remedy
Standard refer-
Code Size limit No. men-
value ence
valve sions
valve
Boom 360 (14.2) 0.6 (0.02) 1.0 1.5 *481
A-A Boom foot L1 PL 1
Upper frame 365 (14.4) or less (0.04) (0.06) (18.9)
Boom cylinder Head side 95 (3.74) 0.6~1.0 2.0 2.5 180
B-B L2 PL 2
(Head side) Upper frame 100 (3.94) (0.02~0.04) (0.08) (0.10) (7.09) Adjusted
Boom cylinder Boom cylinder 95 (3.74) 0.6~2.0 3.0 4.0 221 by shim
C-C L3 PL 3
(Rod side) Boom 100 (3.94) (0.02~0.08) (0.12) (0.16) (8.70)
Arm cylinder Arm cylinder 95 (3.74) 0.6~1.0 2.0 2.5 215
D-D L4 PL 4
(Head side) Boom 100 (3.94) (0.02~0.04) (0.08) (0.10) (8.46)
Provide * indicates a full length as it has no under neck.
3-5
3.2 ARM
3.2.1 ARM DIMENSIONAL DRAWING
1.65 m Standard arm

YT12B00056P1
A POINT
B POINT
2.07 m Long arm

YT12B00029P1
SECTION AA VIEW I SECTION BB
3-6
Unit : mm (ft-in)
Code Item Dimension Code Item Dimension
1,650 2,070 180
C Arm length L Arm top end 
(5'5") (6'9") (7.09")
R498 210
A point M Boss width 
Distance between pins R483 (19.6") (8.27")
D
of boss and bracket (19.0") R495 100
B point N Bracket inner width 
(19.5") (3.94")
Ø65 90
D1 I.D of boss  O Bracket inner width 
(2.56") (3.54")
Ø60 436.5
D2 I.D of boss  P Link dimension 
(2.36") (17.2")
380±0.5
Ø75
D3 I.D of boss  Q Link dimension (14.7" 
(2.95")
±0.0197")
Distance between pins of boss R1,504 Height between pins of boss and 15
E'  R 
and bracket (4'11") center (0.591")
Distance between of boss and R240 Ø50
F'  d1 Pin dia. 
boss (9.45") (1.97")
Height between pins of boss and 405.5 Ø50
G  d2 Pin dia. 
bracket (16.0") (1.97")
308.5 Ø60
A point d3 Pin dia. 
Height between pins 282.5 (12.1") (2.36")
H
of boss and bracket (11.1") 222.5 Ø60
B point d4 Pin dia. 
(8.76") (2.36")
180 Ø50
J Arm top end width (with bushing)  d5 Pin dia. 
(7.09") (1.97")
162
K Boss width 
(6.38")
3-7
3.2.2 ARM MAINTENANCE STANDARDS

(1) Clearance of pin and bushing
Fig. 3-4 Clearance of pin and bushing on arm section
Unit : mm (in)
Standard value Clearance
Bushing Limit Standard
Pos. Item Pin part No. Pin dia. Standard Remedy
Pin dia. i.d. value for limit
tolerance value
tolerance repair value
+0.12 +0.11
(+0.0047) (+0.0043)
A Arm point YR12B01019P1
-0.06 +0.05 +0.21
(-0.0024) (+0.0020) (+0.0083)
-0.09 +0.11
Bucket link (-0.0035) (+0.043)
B 
(Bucket side) +0.12 +0.21
(+0.0047) (+0.0083)
Idler link +0.05 +0.11
C YT12B01018P1
(Arm connection) Ø50 (+0.0020) (+0.0043)
Bucket link (1.9685) -0.06 +0.24
D
(Idler link) (-0.0024) (0.0094)
-0.12 +0.25 +0.11
YT12B01019P1 Replace
Bucket cylinder (-0.0047) (+0.0098) (+0.0043) 2.0 2.5
D' bushing
(Rod side) +0.05 +0.37 (0.08) (0.1)
or pin
(+0.0020) (+0.0146)
-0.06 +0.20 +0.06
Bucket cylinder (-0.0024) (+0.0079) (+0.0024)
E YT12B01054P1
(Bottom side) -0.09 +0.00 +0.29
(-0.0035) (+0.0000) (+0.0114)
-0.06 +0.25 +0.11
Arm cylinder (-0.0024) (+0.0098) (+0.0043)
G YT12B01055P1
(Rod side) -0.09 +0.05 +0.34
Ø60 (-0.0035) (+0.0020) (+0.0134)
(2.3622) -0.06 +0.20 +0.14
Connecting part of (-0.0024) (+0.0079) (+0.0055)
F YT12B01037P1
arm and boom -0.09 +0.08 +0.29
(-0.0035) (+0.0032) (+0.0114)
3-8
(2) Clearance of arm and cylinder installing section in thrust direction
PL1
PL3 PL5 PL6

SECTION AA SECTION CC SECTION EE SECTION FF
PL2 PL4 PL7
SECTION BB SECTION DD SECTION GG
Fig. 3-5 Clearance in thrust direction
Unit : mm (in)
Clearance X adjusted by shim
Basic size Pin length
(total of both sides)
Pos. Item Repair Di- Remedy
Standard Service
Code Size reference No. men-
value limit valve
valve sions
Arm 180 (7.09) 0.1 (0.04) 2.0 2.5 PL 335
A Arm point L1
Bucket 182 (7.17) or less (0.08) (0.10) 1 (13.2)
Link side — PL 335
B Bucket link L2
Bucket — 2 (13.2)
0.6 (0.02) 1.0 1.5
Idler link Arm 180 (7.09)
or less (0.04) (0.06) PL 263
C (Arm connec- L3 —
Link side 3 (10.4)
tion)
Bucket link —
Bucket link PL 263
Idler link L4 —
(Idler link side) 0.6~1.0 2.0 2.5 4 (10.4) Adjust-
D side ed by
(0.02~0.04) (0.08) (0.10)
Bucket link Rod side 85 (3.35) — — shim
L4
(Cylinder side) Link side —
Bucket cylin- Bottom side 85 (3.35)
0.6~2.0 3.0 4.0 PL 185
E der L5
Arm 90 (3.54) (0.02~0.08) (0.12) (0.16) 5 (7.28)
(Arm side)
Arm and boom Arm 210 (8.27) 0.6 (0.02) 1.0 1.5 PL 328
F L6
connection Boom 215 (8.46) or less (0.04) (0.06) 6 (12.9)
Arm cylinder Rod side 95 (3.74) 0.6~2.0 3.0 4.0 PL 204
G L7
(Arm side) Arm 100 (3.94) (0.02~0.08) (0.12) (0.16) 7 (8.03)
3-9
3.3 BUCKET
3.3.1 BUCKET DIMENSIONAL DRAWING
(1) Hoe bucket
Bushing out dia.
(2) Slope finishing bucket
(3) V-shape bucket
Fig. 3-6 Bucket dimensional drawing (1 / 2)
3-10
(4) Loader bucket
Fig. 3-7 Bucket dimensional drawing (2 / 2)
Code Name
A Distance between pin and bracket
B Distance between bucket pin and tooth end
C Inner width of bucket top end
D Inner width of lug
E Inner width of bracket
F Outer width of side cutter
G Outer width of bucket bottom
H Tooth outer width
I Pitch between teeth
Io Pitch between teeth
J finishing plate depth
d1 Pin dia.
d2 Pin dia.
3-11
3.3.2 BUCKET DIMENSIONAL TABLE
Unit : mm (ft-in)
Type Hoe Bucket
0.28 m 3 0.35 m 3 0.22 m3 0.18 m3 0.14 m3 0.11 m3
Capacity
(0.37 cu•yd) (0.46 cu•yd) (0.29 cu•yd) (0.24 cu•yd) (0.18 cu•yd) (0.14 cu•yd)
Part No. YT61B00015F1 YT61B00017F1 YT61B00019F1 YT61B00021F1 YT61B00023F1 YT61B00025F2
A 290 (11.4") 290 (11.4") 290 (11.4") 290 (11.4") 290 (11.4") 290 (11.4")
B R1,037 (3'5") R1,037 (3'5") R1,037 (3'5") R1,037 (3'5") R1,037 (3'5") R990 (39")
C 650 (25.6") 750 (29.5") 550 (21.7") 450 (17.7") 412 (16.2") 368 (14.5")
D 238 (9.37") 238 (9.37") 238 (9.37") 238 (9.37") 238 (9.37") 238 (9.37")
E 182 (7.17") 182 (7.17") 182 (7.17") 182 (7.17") 182 (7.17") 182 (7.17")
F 750 (29.5") 850 (33.5") 650 (25.6") 550 (21.7") 480 (18.9") 400 (15.7")
G 550 (21.7") 650 (25.6") 450 (17.7") 350 (13.8") 280 (11.0") 318 (12.5")
H 566 (22.3") 666 (26.2") 466 (18.3") 366 (14.4") 296 (11.7") 292 (11.5")
I 190 (7.48") 222 (8.74") 166 (6.54") 183 (7.20") 148 (5.83") 146 (5.75")
Io 188 (7.40") 222 (8.74") 150 (5.91") 183 (7.20") 148 (5.83") 146 (5.75")
d1 Ø65 (2.56") Ø65 (2.56") Ø65 (2.56") Ø65 (2.56") Ø65 (2.56") Ø65 (2.56")
d2 Ø50 (1.97") Ø50 (1.97") Ø50 (1.97") Ø50 (1.97") Ø50 (1.97") Ø50 (1.97")
Unit : mm (ft-in)
Slope finishing
Type V-shape bucket Loader bucket
bucket
0.26 m3 0.24 m3 0.34 m3 0.41 m3
Capacity
(0.34 cu•yd) (0.31 cu•yd) (0.44 cu•yd) (0.46 cu•yd)
Part No. LE61B00007F1 LE61B00023F1 LE63B00005F1 LE63B00005F2
A 290 (11.4") 290 (11.4") R330 (13.0") R330 (13.0")
B R731 (28.8") R1,016.9 (3'4") R1,016.9 (3'4")
C — 1,350 (53.1" ) 910 (35.8") 1,058 (41.7")
D 244 (9.60") 238 (9.37") 242 (9.53") 242 (9.53" )
d1 Ø65 (2.56") Ø65 (2.56") Ø65 (2.56") Ø65 (2.56")
d2 Ø50 (1.97") Ø50 (1.97") Ø50 (1.97") Ø50 (1.97")
E 182 (7.17") 182 (7.17") 204 (8.03") 204 (8.03")
F — — — —
G 1,500 (4'11") 240 (9.45") 962 (37.9") 1,110 (3'8")
H — — 834 (32.3") 982 (38.7")
I — 90 (32.8") 278 (10.9") 328 (12.9")
Io — — 278 (10.9") 327 (12.9")
J 740 (29.1") — — —
3-12
3.3.3 DETAIL DIMENSIONAL DRAWING OF LUG SECTION
3.3.3.1 FOR HOE BUCKET
SECTION BB
BOSS
2418P26830
SECTION AA
DETAIL OF PLATE
PLATE
BOSS
2418P27140
SHIM (t = 1.0)
DETAIL I
Fig. 3-8 Dimension of lug section
Unit : mm (ft-in)
Boss outer dia.
Boss outer dia.

Spring pin dia.
Pin hole dia.
Bush length
Screw hole
Boss width
Boss width
Screw dia.
thickness
Lug plate
Hole dia.
Capacity of
Type of
P.C.D
bucket Part No. of bucket

bucket
m3 (cu·yd)
A B C D E F G H J M N
0.28 (0.37) YT61B00015F1
0.35 (0.46) YT61B00017F1
0.22 (0.29) YT61B00019F1
Hoe bucket 50 19 53 65 8 110 M12 19 110 28 91
0.18 (0.24) YT61B00021F1
(1.97") (0.748") (2.09") (2.56") (0.315") (4.33") (0.748") (4.33") (1.10") (3.58")
0.14 (0.13) YT61B00023F1
0.11 (0.10) YT61B00025F2
3-13
3.3.3.2 FOR SPECIAL BUCKET
DETAIL II
DETAIL II DETAIL I
DETAIL I
Fig. 3-9 Dimension of lug section
Unit : mm (ft-in)
Hole dia./ Hole depth
Screw hole P.C.D

Boss outer dia.
Spring pin dia.
Boss outer dia

Pin hole dia.
Boss width
Boss width
Capacity of
Screw dia.
Bolt head
Type of Part No. of

thickness
Lug plate
Hole dia.
bucket
bucket bucket
m3 (cu·yd)
A B C1/C2 D E F G H J M N
Slope 1500 width
20/13
finishing (4'11") X 50 16 65 8 106 22 110 31 91
LE61B00007F1 (0.787" M10
bucket 740 length (1.97") (0.630") /0.512") (2.56") (0.315") (4.17") (0.866") (4.33") (1.22") (3.58")
(29")
V-shape 50 20/15 65
19 8 110 19 110 28 91
0.24 (0.31) LB61B00023P1 (0.787" M10
bucket (1.97") (0.748") /0.591") (2.56") (0.315") (4.33") (0.748") (4.33") (1.10") (3.58")
Loder 0.41 (0.46) LE63B00005F1 50 19 65 102 19 102 19
- - - -
bucket 0.34 (0.44) LE63B00005F2 (1.97") (0.748") (2.56") (4.02") (0.748") (4.02") (0.748")
3-14
3.3.4 DETAIL DIMENSIONAL DRAWING OF BOSS SECTION
II
SECTION II
Fig. 3-10 Dimension of boss section
Unit : mm (ft-in)
Capacity
Type of Part No. of Part No. of
of bucket ØA ØB ØC ØD E F ØG H I
bucket bucket boss
m3 (cu•yd)
0.28 (0.25) YT61B00015F1 75.5±0.2
82.6 54 80.5 23 38 13 10 2.5
0.35 (0.30) YT61B00017F1 2418P26830 (3.25") (2.13")
(2.972"
(3.17") (0.906") (1.50") (0.512") (0.394") (0.0984")
±0.0078")
Hoe 0.22 (0.20) YT61B00019F1
bucket 0.18 (0.16) YT61B00021F1 75.5±0.2
82.6 54 80.5 19 34 13 10 2.5
2418P27140 (2.972"
0.14 (0.13) YT61B00023F1 (3.25") (2.13") (3.17") (0.748") (1.33") (0.512") (0.394") (0.0984")
±0.0078")
0.11 (0.10) YT61B00025F2
1,500
Slope
width 75.5±0.2
finish- 82.6 54 80.5 23 38 13 10 2.5
(4'11")  LE61B00007F1 2418P26830 (2.972"
ing (3.25") (2.13") (3.17") (0.906") (1.50") (0.512") (0.394") (0.0984")
740 length ±0.0078")
bucket
(29")
V-shape
0.24 (0.20) LE61B00023F1 75.5±0.2
bucket 82.6 54 80.5 19 34 13 10 2.5
2418P27140 (2.972"
Loader 0.41 (0.35) LE63B00005F1 (3.25") (2.13") (3.17") (0.748") (1.33") (0.512") (0.394") (0.0984")
±0.0078")
bucket 0.34 (0.30) LE63B00005F2
3-15
3.4 DOZER
3.4.1 DOZER DIMENSIONAL DRAWING
E F
A G D B
d2 C
E
VIEW I
d1
Fig. 3-11 Dozer dimensional drawing
Unit : mm (ft-in)
DOZER DIMENSION
Code Name YT51B00046P1
A Blade width 2,320 (7'7")
B Blade height 478 (18.8")
C Distance from dozer attaching pin center to cutting edge end R1,374 (4'6")
D Inner width of dozer attaching bracket 653 (25.7)
E Width of dozer attaching bracket 60 (2.36")
Distance from dozer attaching pin center to attaching pin on dozer cylinder
F R933 (36.7")
head side
G Attaching bracket inner width on dozer cylinder head side 82 (3.23")
d1 Dozer attaching pin dia. Ø50 (1.97")
d2 Attaching pin dia. on dozer cylinder head side Ø70 (2.76")
3-16
3.4.2 DOZER MAINTENANCE STANDARD
M10 X 16
T=65.7 N·m (48 lbf·ft)
DETAIL I PL3
M12 X 125 M12 X 125
T=115 N·m (85 lbf·ft) T=115 N·m (85 lbf·ft)
PL2 PL1
M12 X 100
T=115 N·m
VIEW A VIEW A SECTION CC (85 lbf·ft)
Fig. 3-12 Dozer maintenance standard
(1) Clearance of pin and bushing
Unit : mm (in)
Standard value Clearance
Bushing Limit val- Standard
Pos. Item Pin part No. Pin dia. Clear- Remedy
Pin dia. i.d. toler- ue for limit
tolerance ance
ance repair value
Dozer cylinder -0.06 +0.10 +0.11
A YT51B01004P1
(Rod side) Ø70 (-0.0024) (+0.0098) (+0.0043)
Dozer cylinder (2.7519) -0.12 +0.03 +0.37
B  1.2 Replace
(Head side) (-0.0047) (+0.0020) (+0.0015) 2.0
(0.05) bushing
-0.06 +0.19 +0.12 (0.08)
or more or pin
Ø50 (-0.0024) (+0.0075) (+0.0015)
C Dozer foot YT51B01003P1
(1.9685) -0.09 +0.06 +0.28
(-0.0035) (+0.0024) (+0.0110)
(2) Clearance in thrust direction on the dozer cylinder installation section
Unit : mm (in)
Clearance X adjusted by shim (total of
Basic size Pin length
both sides)
Pos. Item Repair ref- Di- Remedy
Standard Service limit
Code Size erence No. men-
value valve
valve sions
Dozer cylinder Rod side 80 (3.15) PL
A L1 181
(Rod side) Lower frame 82 (3.23) 1
80
Dozer cylinder Head side PL
B L2 (3.15) 2.0 181
(Head side) 0.1~2.0 2 Adjusted
Dozer 82 (3.23) (0.08) 3.0
(0.04~0.08) by shim
60 or more
Dozer
(2.36) PL
C Dozer foot L3 132
63 3
Lower frame
(2.48)
3-17
[MEMO]
3-18
11. TOOLS
11
TABLE OF CONTENTS
11.1 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS .............................................. 11-3

11.1.1 Metric Coarse Thread Standard Tightening Torque Values.
Make Certainto tighten all Capscrews & Nuts to proper torque values ...................... 11-3
11.1.2 Metric Fine Thread Standard Tightening Torque values
Make certainto tighten all Capscrews & Nuts to proper torquevalues ....................... 11-4
11.2 SCREW AND TOOL SIZES ............................................................................................... 11-5
11.2.1 Capscrew .................................................................................................................. 11-5
11.2.2 Capscrew (Socket bolt) .............................................................................................. 11-5
11.2.3 Setscrew ................................................................................................................... 11-6
11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES ................................................. 11-6
11.3.1 JOINTS FOR PIPING (O-RING SEALING TYPE) ...................................................... 11-6
11.3.2 HYDRAULIC HOSE (30 FLARE TYPE) ................................................................... 11-6
11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS ................................ 11-7
11.4.1 SLEEVE TYPE TUBE FITTINGS ............................................................................... 11-7
11.4.2 PART NO. .................................................................................................................. 11-7
11.5 PLUGS ............................................................................................................................... 11-8
11.5.1 Plug for hydraulic pipe joint ........................................................................................ 11-8
11.5.2 Plug for hydraulic equipment ..................................................................................... 11-9
11.6 SPECIAL SPANNERS FOR TUBES .................................................................................. 11-10
11.7 SPECIAL TOOLS ............................................................................................................... 11-11
11.8 APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS ............................. 11-12
11.9 SUCTION STOPPER ......................................................................................................... 11-13
11.10 COUNTERWEIGHT LIFTING JIG ..................................................................................... 11-14
11.11 BOOM FOOT PIN PULLING TOOLS .................................................................................. 11-15
11.12 TRANION CYLINDER PIN PULLING TOOLS ..................................................................... 11-16
11.13 UPPER FRAME LIFTING JIG ............................................................................................. 11-17
11.14 ENGINE MOUNTING PEDESTAL ...................................................................................... 11-18
11.15 TRACK SPRING SET JIG ................................................................................................... 11-18
11-1
11. TOOLS

S5YT1104E01
(NHK)
11-2
11. TOOLS
11.1 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS

The following Torque Specifications are provided for use when actual torque value of a fastener is not known. Check
the capscrews and nuts for their looseness and dropping off before the start of daily work and at the periodical main-
tenance. Retighten the loosened ones, and install new ones for the dropped off. For the new machine, the check
and retightening of them must be carried out at first 50 hours operation. For the replacement of them, make sure to
use the same size of manufacturer's genuine parts.
Refer to the table below for the tightening and retightening of capscrews.
• The table below is not applicable for the capscrews to fix the cover, etc., made of plastic. For the tightening
torque for such capscrews, consult with an authorized our Distributor. Over-tightening may cause damages on
the parts to be fixed.
• In case that the tightening torque is specified in the manual, use such torque values regardless to the table be-
low.
• Numerical indication on the capscrew head shows the classification for strength (e.g., 7 = 7 T). No indication is
provided for smaller size of capscrews, M 5 or less.
11.1.1 Metric Coarse Thread Standard Tightening Torque Values. Make Certain to tighten all Capscrews
& Nuts to proper torque values.
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
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)
11-3
11. TOOLS

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)
11.1.2 Metric Fine Thread Standard Tightening Torque values. Make certain to tighten all Capscrews &
Nuts to proper torque values.

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 AND TOOL SIZES

11.2.1 Capscrew
Nominal B mm Nominal B mm
screw size screw size
Tool size Tool size
(d) (d)
M6 10 (M33) 50
M8 13 M36 55 d
M10 17 M42 65
M12 19 M45 70
(M14) 22 M48 75
M16 24 M56 85 B
(M18) 27 (M60) 90
M20 30 M64 95
(M22) 32 (M68) 100
M24 36 M72 105
(M27) 41 M76 110
M30 46 M80 115
screw size screw size
Tool Tool d
Unified Unified
size size
(screw threads) (screw threads)
1/4–20UNC 11 3/4–10UNC 29
5/16–18UNC 13 7/8–9UNC 33
B
3/8–16UNC 14 1–8UNC 38
7/16–14UNC 16 1 1/8–7UNC 43
1/2–13UNC 19 1 1/4–7UNC 48
5/8–11UNC 24 1 1/2–6UNC 57
11.2.2 Capscrew (Socket bolt)
screw size screw size d
Tool size Tool size
(d) (d)
M6 5 M20 17
M8 6 M24 19
M10 8 M30 22 B
M12 10 M36 27
M14 12 M42 32
M16 14 M48 36
(M18) 14
11-5
11. TOOLS
11.2.3 Setscrew
Nominal screw size B mm

(d) Tool size
M2.5 1.27
M3 1.5
M4 2
M5 2.5
M6 3
M8 4
M10 5
M12 6
M16 8
M20 10
11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES

11.3.1 JOINTS FOR PIPING (O-RING SEALING TYPE)
Nominal screw size Spanner size Tightening torque

(PF) (mm) N•m (lbf•ft)
1/8 14 17±2 (12±1)
1/4 19 36±2 (27±1)
3/8 22 74±5 (54±4)
1/2 27 108±9.8 (80±7)
3/4 36 162±9.8 (119±7)
1 41 255±9.8 (188±7)
11.3.2 HYDRAULIC HOSE (30° FLARE TYPE)
Nominal screw size Spanner size Tightening torque

1/8 17 15±2.0 (11±1)
1/4 19 29±4.9 (22±4)
3/8 22 49±4.9 (36±4)
1/2 27 78±4.9 (58±4)
3/4 36 118±9.8 (87±7)
1 41 137±15 (101±11)
NOTE : The application of the tightening torque is subject to a dry condition.
11-6
11. TOOLS
11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS

11.4.1 SLEEVE TYPE TUBE FITTINGS
Tube size Spanner size Tightening Torque

OD  Thickness (mm) (mm) N•m (lbf•ft)
10  1.5 19 44±4.9 (33±4)
15  2.0 27 147±20 (110±14)
18  2.5 32 177±20 (130±14)
22  3.0 36 216±20 (160±14)
28  4.0 41 275±29 (200±22)
35  5.0 55 441±44 (330±33)
11.4.2 PART NO.
SLEEVE NUT
B
d
d
Part NO. Opposing Part NO.

Tube size Tube size
flats(HEX)
ød Ihara Koatu Nippon A.M.C ød Ihara Koatu Nippon A.M.C
B
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 PLUGS
11.5.1 Plug for hydraulic pipe joint
(1) Cap nut (Joint plug)
Applicable Cap nut parts Opposing flats

A tube T screw
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
D Screw tube Nut parts No. D screw Opposing flats
A
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
11.6 SPECIAL SPANNERS FOR TUBES

Applicable tube diameter HEX Dimensions of a special spanner
Part No.
mm (in) mm 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 )
80(3.15) 109(4.29)
15.5(0.610)
28 (1.10) 2421T231 46 31 PA R T- N o . 35
(1.22) (1.38)
HEX46 19.05 (0.750 )
80(3.15) 109(4.29)
16.5(0.650)
33 PA R T- N o . 35
32 (1.26) 2421T232 50 (1.30) (1.38)
HEX50 19.05 (0.750 )
81(3.19) 90(3.54)
20.5(0.807)
41 PA R T- N o . 45
35 (1.38) 2421T314 55 (1.61) (1.77)
HEX55 20 (0.787)
11-10
11. TOOLS
11.7 SPECIAL TOOLS

No. Tools name Tools No. Shape Use
B
R
Allen wrench C
L1
(0.394")
1 Nominal ZT22A10000 Pump suction
10
B : 10
L
Commercial tool length (L1) - cut length = Required length
40 (1.57 ) - 10 (0.39 ) = 30 (1.18 )
B
R
Allen wrench
L1 C
(0.433")
2 Nominal ZT22A14000 Pump install
B : 14 11
L
Commercial tool length (L1) - cut length = Required length
56 (2.20 ) - 11 (0.43 ) = 45 (1.77 )
Cut
Spanner Nomi- 32 (1.25") Swing motor

3 ZT12A32000
nal B : 32 A, B port
S
D
Commercial tool outer width (D) - cut length = Required width

73 (2.87 ) - 13 (0.51 ) = 60 (2.36 )
M10 X 22 Additional
threading for For slinging the
4 Plug PF 3/4 ZE72X12000 M10 eye bolt
swing motor
PF 3/4 O-ring
Eye bolt For slinging the

ZS91C01000
[15] (0.59)
18 (0.71)
5 M10 X 18 swing & Flare

[ZS91C00800]
[M8 X 15) hose
M10
[M8]
M8 Eye bolt
Plug
ZF83P22000
(Nominal tube
6 dia. 22) Reference nut Flare hose
ZS91C00800
Reference Eye
ZF93N22000 M8 X 18
bolt Nut Additional threading
for M8 Eye bolt
Torx driver 4.4 (0.17")

(with tamper
For instrument
7 proof) — Nose shape
R.H cover
T25
(for M5)
11-11
11. TOOLS
11.8 APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS

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

(Manufacture : Loctite)
# 1901 Anti-seizure Cylinder
Three-bond # 1215 gray # 5699 Swing motor
Sealing compound & adhesive
# 1211 white # 5301J Swing motor

# 1303B # 211 Main pump
(Manufacture : Three-bond)
Loctite # 222 # 1344N Main pump
1
# 277 # 1307N Pilot valve
(Manufacture : Three-bond )
Loctite Parmatex 98D # 1121 Hydraulic oil tank : Hose
Sumitomo Chemi- Locktite # 515
Syano Bond P0-1 For swing bearing : Seal
cal Co.,Lad. Three-bond # 1215
Showa-shell petro-
Shell Albania EP2 New Molyknock Grease 2 Swing bearing grease bath
leum
11-12
11. TOOLS
11.9 SUCTION STOPPER

11.9.1 COMPONENTS
NO. NAME PARTS No. Q'ty

Suction Stopper Assy 24100P978F4
1 Rod 2420T4660D1 1
2 Nut ZN16C08007 1
3 Cover 2414T2123D4 1
4 O-Ring 45Z91D8 1
Fig. 11-1 Components of suction stopper
11.9.2 DIMENSION
ROD COVER
Fig. 11-2 Dimension of suction stopper
11.9.3 APPLICABLE MODEL
Applicable
model SK70SR-1ES SK80MSR-1ES
Part No.
24100P978F4
11-13
11. TOOLS
11.10 COUNTERWEIGHT LIFTING JIG

Bracket for left side Bracket for right side
Material : Mild steel
Fig. 11-3 Counterweight lifting bracket
11-14
11. TOOLS
11.11 BOOM FOOT PIN PULLING TOOLS
Fig. 11-4 Slide hammer for boom foot pin

Tools accessoroes assy YR01T00006F1

Rod YR02B01285P1
Boom foot pin

1
pulling
Boom foot pin

2 Hammer YR02B01286P1
pulling
11-15
11. TOOLS
11.12 TRANION CYLINDER PIN PULLING TOOLS
Fig. 11-5 Tranion cylinder pin pulling tools

Tools accessories assy YR01T00005F1
Q'ty : each 1pc.

Arm cylinder
1 Guide YR02B01283P1
for pin
Arm cylinder
2 Screw YR02B01284P1
for pin
Standard item Arm cylinder

3 Nut : M24 ZN18C24019
for pin
B=36
11-16
11. TOOLS
11.13 UPPER FRAME LIFTING JIG
Fig. 11-6 Upper frame lifting jig
11-17
11. TOOLS
11.14 ENGINE MOUNTING PEDESTAL
547 (21.54 )
(0.827 ) 21 505 (19.88 ) 21 (0.827 )
(5.12 )
130
(11.81 )
300
(0.827 )
240(9.45 ) 265 (10.43 )

21
(11.02 )
280
21 (11.02 )
280
8
R15 2 )
(5.51 )
(6.2
140
200 (7.87 )
(0.827 )
250 240 (9.45 ) 265 (10.43 )

(9.84 ) 325 (12.8 )
(11.81 )
300
(5.12 )
130
505 (19.88 )
(0.827 ) 21 21 (0.827 )
547 (21.54 )
Material : Plywood or wooden plate
Fig. 11-7 Engine stand
11.15 TRACK SPRING SET JIG
Retainer nut
Retainer plate
Stand
Hydraulic jack
Base
Fig. 11-8 Track spring set jig
11-18
12. STANDARD MAINTENANCE
TIME SCHEDULE
12
TABLE OF CONTENTS
12.1 STANDARD MAINTENANCE TIME SCHEDULE FOR EXCAVATOR ................................ 12-4

12.2 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF ENGINE ............... 12-15
12-1
12. STANDARD MAINTENANCE TIME SCHEDULE

S5YT1204E01
(NHK)
12-2
PREFACE
(1) Working condition
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 of wheeled construction machines).
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 neces-
sary 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 MAINTENANCE TIME SCHEDULE FOR EXCAVATOR

(1) Standard maintenance time schedule
1) Units of working time : 6 minutes = 0.1 hour
2) Calculating method of standard maintenance time :
Maintenance time = working time  the number of workers
(working time = Maintenance time / the number of workers)
3) When more than one operation is going on :
a. Add each standard service time.
b. A pure time (readily started) is given except covers easily removed by hand.
c. Assy works include the following works marked with black dot • .
4) O/H : Basically the installing and removing operation are included.
5) Abbreviation in the table.
A/C : Air conditioner F hose : Flexible hose

ASSY : Assembly O/H : Over haul
ATT : Attachment SOL : Solenoid
BRG : Bearing SW : Switch
C/V : Control valve V : Valve
Cyl : Cylinder
E/G : Engine
(2) Classification of working code
No. Group Remarks

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

1) Tools designated by E/G marker 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
GROUP WORK TO BE UNIT:

LOCATION UNIT REMARK
No. DONE HOUR
00 Bucket relation Refer to 32.1.2
01 Bucket ASSY Detach/attach 1 pc. Include adjustment 0.5
• Bucket attaching and detaching posi-
02 Preparation 1 pc. 0.1
tion
03 • Bucket attaching pin Detach/attach 1 Include omission of pin. 0.1
04 • Bucket drive pin Detach/attach 1 0.1
05 • Bucket sling and movement Preparation 1 pc. 0.1
06 Bucket (Single) O/H 1 pc. Not include attaching and 2.0
detaching.
07 • Tooth Replace 1 pc. 0.5
08 • Side cutter Replace 1 pc. 1.0
09 • Bushing Replace 1 pc. 0.5
10 Arm relation Refer to 32.1.3
11 Arm ASSY Detach/attach 1 pc. 1.0
• Bucket cylinder attaching and detach-
ing position and piping
13 • Bucket cylinder rod pin Detach/attach 1 pc. Include omission of pin. 0.1
14 • Bucket cylinder head pin Detach/attach 1 pc. Include omission of pin. 0.1
15 • Bucket cylinder assy Detach/attach 1 pc. 0.1
16 • Arm cylinder rod pin Detach/attach 1 pc. Include omission of pin. 0.1
17 • Boom top pin Detach/attach 1 pc. 0.1
18 • Arm sling and movement Detach/attach 1 pc. 0.1
01 Attachment
30 Boom relation Refer to 32.1.4

31 • Boom ASSY Detach/attach 1 pc. 1.0
• Boom attaching and detaching posi-
tion
33 • Boom cylinder temporary slinging Preparation 1 pc. 0.1
34 • Boom cylinder rod pin Detach/attach 1 Include omission of pin. 0.1
35 • Boom cylinder piping Detach/attach 1 pc. 0.1
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 omission of pin 0.2
39 • Boom assy slinging Detach/attach 1 pc. 0.1
40 Arm cylinder attaching and detaching Detach/attach 1 pc. 0.3
41 • Arm cylinder piping Detach/attach 1 pc. 0.1
42 • Arm cylinder head pin Detach/attach 1 Include omission of pin 0.1
43 • Arm cylinder slinging Detach/attach 1 pc. 0.1
50 Boom cylinder attaching and detaching Detach/attach 1 pc. 0.3
51 • Boom cylinder piping Detach/attach 1 0.1
52 • Boom cylinder head pin Detach/attach 1 pc. 0.1
53 • Boom cylinder slinging Detach/attach 1 0.1
60 Bucket cylinder O/H 1 3.0
61 • Pin bushing Preparation 1 Include seal 1.0
70 Arm cylinder O/H 1 3.0
71 • Pin bushing Preparation 1 set Include seal 1.0
75 Boom cylinder O/H 1 3.0
76 • Pin bushing Preparation 1 Include seal 1.0
12-5

No. DONE HOUR
10 Cab relation Refer to 33.1.1
11 Cab ASSY Detach/attach 1 pc. 1.5
1 pc.
12 • Front lower glass, floor mat Detach/attach 0.1
each
13 • Cab mounting bolts, nuts (front) Detach/attach 4 places 0.2
14 • Grille on seat rear side Detach/attach 1 pc. 0.2
15 • Grille on seat under side Detach/attach 1 pc. 0.1
16 • Air-con duct Detach/attach 2 0.2
17 • Coupler for cluster gauge (electric) Detach/attach 1 0.1
18 • Cab mounting bolts, nuts (rear side) Detach/attach 5 places 0.2
19 • Cab slinging Detach/attach 3 places 0.4
20 Guard relation Refer to 33.1.6
21 Cover (1) Detach/attach 1 pc. 0.2
22 • Cover (1) slinging Detach/attach 1 pc. 0.1
23 Panel assy (2) Detach/attach 1 pc. 0.1
24 Cover assy (6) Detach/attach 1 pc. 0.1
25 Guard assy (40) Detach/attach 1 pc. 0.1
02 Cab & Guard
27 Bonnet assy (65) Detach/attach 1 pc. 0.2

28 • Bonnet assy slinging Detach/attach 1 pc. 0.1
29 Cover (3) Detach/attach 1 pc. 0.1
30 Bracket (44) Detach/attach 1 pc. 0.1
32 Cover assy (60) Detach/attach 1 pc. 0.1
36 • Guard assy (8) slinging Detach/attach 1 pc. 0.1
40 Cover relation Refer to 33.1.7
41 Cover (1) Detach/attach 1pc. 0.1
50 Counter weight relation Refer to 33.1.5
51 Counter weight ASSY Detach/attach 1 pc. 0.4
52 • Counter weight lifting jig Detach/attach 1 set 0.1
53 • Counter weight temporary slinging Preparation 1 pc. 0.1
54 • Counter weight mounting bolt Detach/attach 1 pc. 0.1
55 • Counter weight slinging Detach/attach 1 pc. 0.1
03 Swing frame
00 Control relation
01 E/G control ASSY Detach/attach 1 pc. Include adjustment. 0.2

02 • Emergency stop knob (control) cable Replace 1 pc. 0.1
12-6

No. DONE HOUR
10 Intake relation Refer to 33.1.8
11 Air cleaner ASSY Detach/attach 1 pc. 0.4
12 • Hose (2) Detach/attach 1 0.1
13 • Hose (1) Detach/attach 1 0.1
14 • Element Replace 1 0.1
20 Exhaust relation Refer to 33.1.9
21 Muffler ASSY Detach/attach 1 pc. 0.4
22 • U bolt Detach/attach 1 pc. 0.1
23 • Clamp ASSY Detach/attach 1 pc. 0.1
24 • Gasket Replace 1 pc. 0.1
30 Radiator relation Refer to 33.1.13
31 Radiator ASSY Detach/attach 1 pc. 3.5
32 • Coolant (LLC) Replace 1 pc. 0.2
33 • • Concentration of coolant Measuring 1 pc. 0.2
34 • A/C condenser Detach/attach 1 pc. 0.2
35 • Stay Detach/attach 1 pc. 0.1
36 • Bracket Detach/attach 1 0.2
37 • Sub tank Detach/attach 1 pc. 0.1
38 • Fan guard Detach/attach 1 pc. 0.2
39 • Water hose (radiatorE/G) Detach/attach 1 0.2
40 • Radiator mounting bolts removing Detach/attach 1 pc. 0.2
03 Swing frame
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 coupling Detach/attach 1 pc. 0.8
44 • Hydraulic oil piping Detach/attach 1 pc. 0.2
45 • Water hose (E/Gradiator) Detach/attach 1 0.2
46 • Radiator lifting or hoisting Detach/attach 1 pc. 0.2
50 Fuel relation Refer to 33.1.10
51 Fuel tank ASSY Detach/attach 1 pc. 1.5
52 • Fuel Replace 1 pc. 0.2
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
56 • Connecting bracket between tanks Detach/attach 1 0.1
57 • Fuel tank installing bolts Detach/attach 1 pc. 0.2
58 • Tank slinging Detach/attach 1 pc. 0.2
Other necessary works Detach/attach 1 pc. Removing and installing 0.3
guard
Removing and installing bat- 0.2
tery
60 Hydraulic oil tank relation Refer to 33.1.11
61 Hydraulic oil tank ASSY Detach/attach 1 pc. After removing fuel tank ; 3.5
• Hydraulic oil tank attaching and de-
62 Detach/attach 1 pc. 0.1
taching position
63 • Return oil pipe on tank upper cover Detach/attach 1 pc. 0.4
64 • Hose on upper cover Detach/attach 1 pc. 0.2
65 • Cover Detach/attach 1 pc. 0.2
12-7

No. DONE HOUR
66 • Hydraulic oil Replace 1 pc. 0.4
67 • Other necessary works Detach/attach 1 pc. Multi C/V attaching bracket 0.2
movement
Multi pilot hose removing 0.4
and attaching
68 • Pilot drain hose Detach/attach 1 pc. 0.2
69 • Pump suction hose Detach/attach 1 0.4
70 • Mounting bolt Detach/attach 1 pc. 0.2
71 • Hydraulic oil tank slinging Detach/attach 1 pc. 0.2
72 • Return filter Replace 1 0.2
73 • Suction filter Cleaning 1 0.2
After removing counter
80 Pump relation
weight
81 Pump ASSY Detach/attach 1 pc. 2.3
82 • Hydraulic oil tank cover Detach/attach 1 pc. 0.3
83 • Strainer & stopper Detach/attach 1 pc. 0.3
84 • Piping Detach/attach 1 set 0.8
85 • Guard Detach/attach 2 pc. 0.4
86 • Pump slinging Detach/attach 1 pc. 0.4
87 • Cleaning Cleaning 1 pc. 0.1
88 • Vent air Adjust 1 pc.
03 Swing frame
89 Pump ASSY O/H 1 pc. 3.0

Other necessary works Detach/attach 1 set Counter weight 0.4
90 Swing motor unit relation After removing boom
91 Swing motor ASSY Detach/attach 1 pc. 1.8
93 • Drain hose clamp Detach/attach 1 0.2
95 • Unit slinging Detach/attach 1 pc. 0.3
96 • Cleaning and sealant Cleaning 1 set 0.2
97 • Swing motor O/H 1 pc. 3.0
98 • Swing reduction gear O/H 1 pc. 3.5
100 Swivel joint relation Refer to 33.1.19
101 Swivel joint ASSY Detach/attach 1 After removing boom 1.5
102 • Piping (Top part only) Detach/attach 1 set. 0.3
103 • Stop gap Detach/attach 1 0.1
104 • Cover Detach/attach 1 0.2
105 • Joint & elbow Detach/attach 1 set 0.2
106 • Mounting bolt Detach/attach 1 set 0.2
107 • Swivel joint slinging Detach/attach 1 0.2
108 • Cleaning Cleaning 1 set 0.1
109 Swivel joint O/H 1 set Removing and installing 3.0
guard
Other necessary works Detach/attach 1 set Front attach ASSY 1.5
Detach/attach 1 set Lower piping 0.5
12-8

No. DONE HOUR
120 Main control valve Refer to 33.1.15
121 Main control valve ASSY Detach/attach 1 pc. 1.5
122 • Attach tag to port name of pipe Preparation 1 pc. 0.5
124 • Bracket mounting bolt Detach/attach 1 pc. 0.1
125 • Valve slinging Detach/attach 1 pc. 0.1
126 Main control valve ASSY O/H 1 set 5.0
Other necessary works Detach/attach 1 set Guard 0.3
Detach/attach 1 set Battery 0.2
Detach/attach 1 set Fuel tank ASSY 1.5
Detach/attach 1 set Multi C/V movement 0.5
130 Dozer control valve (OPT)
131 Control V ASSY Detach/attach 1 0.5
• Write hose name on Control V con-
132 Detach/attach 1 set 0.1
necting hose
135 • Cleaning Cleaning 1 set 0.1
136 Control V ASSY O/H 1 set 1.0
140 Engine (E/G) mounting relation Refer to 33.1.14
Engine ASSY Detach/attach 1 pc. After removing pump & radi- 1.5
03 Swing frame
141
ator
• Harness connector & grounding & ca-
142 Detach/attach 1 pc. 0.2
ble connection
143 • Fuel hose Detach/attach 1 pc. 0.1
144 • Others Detach/attach 1 set 0.4
146 • Engine slinging Detach/attach 1 set 0.2
148 Engine O/H 1 set Reference for engine
Other necessary works Detach/attach 1 set Removing and installing 0.5
guard
Detach/attach 1 set Removing and installing 0.4
counter weight
pump
Detach/attach 1 set Removing and installing air 0.4
cleaner
Other necessary works
muffler
Detach/attach 1 set Removing and installing ra- 3.5
diator
150 Upper frame Refer to 33.1.20
151 Upper frame ASSY Detach/attach 1 pc. After removing swivel joint 1.0
153 • Upper frame slinging Detach/attach 1 pc. 0.3
12-9

No. DONE HOUR
155 • Sealant Apply 1 pc. 0.2
03 Swing frame
Other necessary works Detach/attach 1 set Cab 1.5

Detach/attach 1 set Guard 0.3
Detach/attach 1 set Counter weight 0.4
Detach/attach 1 set Boom 1.5
00 Travel relation Refer to 34.1.2
01 Track link ASSY Detach/attach One side Include adjustment of ten- 1.0
sion
02 • Track link attaching and detaching Preparation One side 0.1
position
03 • Master pin Detach/attach One side 0.4
04 • Track link extending and winding Detach/attach One side 0.4
05 Shoe plate Replace 1 pc. 0.4
10 Upper roller relation Refer to 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 Refer to 34.1.4
21 Lower roller ASSY Detach/attach 1 0.2
22 Lower roller O/H 1 1.0
30 Front idler relation Refer to 34.1.5
31 Front idler ASSY Detach/attach One side After removing track link 0.5
32 Front idler ASSY slinging Detach/attach One side 0.2
33 Front idler ASSY Disassemble One side 0.2
04 Travel system
34 Idler ASSY O/H One side 1.0

35 Idler adjuster ASSY O/H One side Replace spring 2.0
36 • Grease cylinder O/H One side 0.5
40 Sprocket Refer to 34.1.6
41 Sprocket Replace One side After removing track link 0.5
50 Travel motor relation Refer to 34.1.7
51 Travel motor ASSY Detach/attach One side After removing track link 1.4
52 • Motor cover Detach/attach One side 0.1
53 • Hydraulic piping Detach/attach One side 0.7
54 • Motor mounting bolt Detach/attach One side 0.4
55 • Motor slinging Detach/attach One side 0.1
56 • Motor cleaning Cleaning One side 0.1
57 Travel motor O/H One side 3.0
58 Travel reduction gear O/H One side 3.0
60 Swivel joint relation
61 Pipe on swivel joint travel side Detach/attach 1 pc. 0.5
62 Swivel joint O/H 1 pc. Refer to 33.2.6
70 Swing bearing Refer to 34.1.8
71 Swing bearing ASSY Detach/attach 1 pc. After removing upper flame 0.6
72 Swing bearing mounting bolt Detach/attach 1 pc. 0.4
73 Swing bearing slinging Detach/attach 1 pc. 0.2
12-10

No. DONE HOUR
80 Dozer relation OPT
04 Travel system
81 Dozer ASSY Detach/attach 1 pc. 0.6

81 • Dozer cylinder piping Detach/attach 1 pc. 0.2
82 • Dozer cylinder slinging Detach/attach 1 0.2
83 Dozer slinging Detach/attach 1 pc. 0.2
84 Dozer Cylinder O/H 1 2.0
Controller
C-1 Controller (KPSS) Replace 1 0.2
C-2 Gauge cluster Replace 1 0.2
C-4 Air conditioner Amplifier Replace 1 0.2
C-5 Power window controller (OPT) Replace 1 0.2
Diode
D-1 Diode Replace 1 0.2
Electric equipments
E-1 Fuse box Replace 1 Include C1 controller remov- 0.3
ing and installing.
06 Electric equipments
E-2 Alternator Include bonnet assy remov-

Replace 1 1.0
ing and installing.
Replace 1
E-3 Hour meter 0.2
E-5 Horn Replace 1 0.2

0.2
E-6 Cigar lighter Replace 1
E-7 Tuner AM & FM (OPT) Replace 1 0.2

E-7 Tuner AM Replace 1 0.2
E-8 Speaker left (OPT) Replace 1 0.2
E-9 Speaker right Replace 1 0.2
E-10 Receiver dryer Replace 1 Include gas sealing 0.3
E-11 Air compressor Replace 1 Include counter weight re- 0.5
moving and installing.
E-13 Travel alarm Replace 1 0.2
E-15 Socket Replace 1 0.2
E-17 Converter Replace 1 0.2
E-20 Buzzer Replace 1 0.2
E-21 Counter Replace 1 0.2
E-22 Sequence box assy Replace 1 0.2
Light
L-1 Boom work light left Replace 1 Bulb 0.2
12-11

No. DONE HOUR
L-2 Work light right Replace 1 0.2
L-3 Room light Replace 1 0.2
L-4 CAB work light (OPT) Replace 1 0.2
L-5 CAB work light (OPT) Replace 1 0.2
L-7 Engine room light Replace 1 0.2
L-10 Rotary light Replace 1 0.2
L-11 Starter alarm lamp Replace 1 0.2
Motor
M-1 Starter motor Replace 1 Include counter weight re- 1.0
M-2 Governor motor Replace 1 Include counter weight re- 0.5
M-3 Wiper motor (Non rise up) Replace 1 0.2
M-4 Washer motor Replace 1 0.2
M-5 Cable assy (P/W motor OPT) Replace 1 0.5
M-6 Power window lock motor (OPT) Replace 1 0.2
M-7 Power window lock motor (OPT) Replace 1 0.2
M-8 Skylight wiper motor (OPT) Replace 1 0.2
M-9 Fuel pump Replace 1 0.2
Proportionate valve
PSV-B P2 by-pass cut proportionate valve Replace 1 Include proportional valve 2.0
removing and installing.
PSV-C Travel straight proportionate valve Replace 1 Include proportional valve 2.0
PSV-D P1 by-pass cut proportionate valve Replace 1 Include proportional valve 2.0
Relay
R-1 Battery relay Replace 1 0.2
R-3 Glow relay Replace 1 0.2
R-4 Safety relay Replace 1 Include guard (9) removing 0.4
and installing.
R-5 Wiper motor relay Replace 1 Include C1 controller remov- 0.3
ing and installing.
R-6 Washer motor relay Replace 1 0.3
R-7 Horn relay Replace 1 0.3
R-8 Work light relay Replace 1 0.3
R-9 Wiper relay assy (OPT) Replace 1 0.3
R-10 Cab work light relay Replace 1 0.3
R-11 Travel alarm relay Replace 1 0.3
R-28 Auto idle stop relay 1 Replace 1 0.3
R-29 Auto idle stop relay 2 Replace 1 0.3
R-30 Timer unit Replace 1 0.3
R-31 Counter relay Replace 1 0.3
R-32 Travel two-speed relay Replace 1 0.3
12-12

No. DONE HOUR
Sensor
SE-1 Pressure sensor (low pressure ; bucket Replace 1 0.2
digging)
SE-2 Pressure sensor (low pressure ; bucket Replace 1 0.2
dump)
SE-3 Pressure sensor (low pressure ; boom Replace 1 0.2
up)
SE-4 Pressure sensor (low pressure ; boom 1 0.2
Replace
down)
SE-5 Pressure sensor (low pressure ; swing) Replace 1 0.2
SE-7 Pressure sensor (low pressure ; arm in) Replace 1 0.2
SE-8 Pressure sensor (low pressure ; arm Replace 1 0.2
out)
SE-9 Pressure sensor (low pressure ; travel Replace 1 Include removing installing 0.4
right) guard on cab lower side.
SE-10 Pressure sensor (low pressure ; travel Replace 1 Include removing installing 0.4
left) guard on cab lower side.
SE-13 Engine speed sensor Replace 1 Include guard removing and 0.5
installing.
SE-14 Engine water temperature sensor Replace 1 0.2
SE-15 Fuel sensor Replace 1 Include guard removing and 0.3
installing.
SE-16 Accel potentio Replace 1 0.2
SE-17 Pressure sensor (P3 pump) Replace 1 0.2
Solenoid
SV-1 Swing parking SOL Replace 1 Include proportional valve 2.0
SV-2 Conflux single flow switching SOL Replace 1 Include proportional valve 2.0
(OPT) removing and installing.
SV-3 2-speed travel SOL Replace 1 Include proportional valve 2.0
SV-4 Lever lock SOL Replace 1 Include proportional valve 2.0
SV-8 Travel boost-up SOL. Replace 1 Include proportional valve 2.0
Switch
SW-1 Key switch Replace 1 0.2
SW-2 Switch assy Replace 1 0.2
SW-3 2-speed travel switch Replace 1 0.2
SW-4 Swing parking release switch Replace 1 0.2
SW-6 Engine water temperature switch Replace 1 0.2
SW-7 Engine oil pressure switch Replace 1 0.2
SW-8 Clogged air filter switch Replace 1 0.1
SW-10 Horn switch Replace 1 0.2
SW-11 Lever lock switch Replace 1 0.3
SW-12 Heater switch (OPT) Replace 1 0.2
12-13

No. DONE HOUR
SW-13 Air conditioner switch Replace 1 0.2
SW-14 Power window switch (OPT) Replace 1 0.2
SW-15 Skylight wiper switch (OPT) Replace 1 0.2
SW-16 Work light switch (OPT) Replace 1 0.2
SW-17 Conflux-single flow select switch Replace 1 0.2

SW-18 OPT pedal pressure switch (1) Replace 1 Include removing installing 0.4
guard on cab lower side.
SW-19 OPT pedal pressure switch (2) Replace 1 Include removing installing 0.4
guard on cab lower side.
SW-20 Horn switch (R) (OPT) Replace 1 0.2
SW-26 Buzzer stop switch (travel alarm) Replace 1 0.2
SW-27 Engine room light switch Replace 1 0.2
SW-30 Auto accel release switch Replace 1 0.2
SW-40 Auto idle stop select switch Replace 1 0.2
12-14
12.2 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF ENGINE

Introduction
This standard working time table provides time required for maintenance (if the work is carefully carried out) under
the following condition :
• Tools designated by us are used.
• Genuine parts are prepared.
• Correct working procedures are observed.
• The engine is mounted correctly to the machine.
(1) The working hours given in this table can not be applied because of special machine construction.
(2) Special equipments not listed in this table may be used for operation.
If such operations are performed, fill out reasons in the Claim Application Sheet in detail and submit it to us.
• Unit of maintenance time :

The maintenance time is given in 6 minutes = 0.1 hour in the decimal system.
• Applicable models :
4JG1......SK70SR-1ES, SK80MSR-1ES
MAINTENANCE
LOCATION OF WORK WORK TO BE DONE
TIME (Hr)
Engine body
Flywheel assy Detach & attach 0.9
• Including replacing of ring gear, etc.
Engine cushion rubber (both sides) Replace 0.4
Drain plug Replace 0.1
Engine assy Detach & attach 21.6
• Incl. overhaul of engine and cylinder body
Sealing plug Replace 0.2
Cylinder block drain cock assy Replace 0.1
Piston & conn rod (2 cycle) Detach & attach 11.2
Incl. Replacing parts (4 cycle) 13.9
Crank shaft rear oil seal Replace 0.2
Crank shaft pulley Detach & attach 0.8
• Incl. replacement of front oil seal
Oil pan Retighten 0.3
Oil pan Detach & attach 0.9
• Incl. overhaul of oil pump
Crank casing & oil pan Detach & attach 2.3
Incl. overhaul of oil pump and replacement of other parts
Oil pan level gauge guide tube Replace 0.1
Cylinder head
Valve clearance Adjust 0.5
Cylinder head cover Detach & attach 0.5
• Incl. retightening cylinder head
Cylinder head assy Detach & attach 7.9
12-15
MAINTENANCE
TIME (Hr)
• Overhaul of cylinder head, replacement of valve guide, etc.
Valve timing mechanism

Locker arm & shaft assy Detach & attach 0.6
• Incl. overhauling rocker arm
Tappet Replace 5.4
Tappet chamber cover Detach & attach 0.4
Valve rocker stand Replace 0.4
Timing gear casing cover Detach & attach 1.2
• Incl. replacement of gear
Cam shaft Detach & attach 11.6
• Incl. replacement of bearing and tappet
Intake/exhaust system
Air intake hose Replace 0.3
Manifold fastening bolts Retighten 0.3
Inlet manifold Detach & attach 1.1
Exhaust manifold Detach & attach 0.7
Throttle valve assy Detach & attach 0.8
• Incl. overhaul of throttle valve
Intake shutter spring Replace 0.1
Intake shutter Detach & attach 0.5
• Incl. overhaul of intake shutter
Inlet pipe assy Detach & attach 0.2
Exhaust pipe adapt assy Detach & attach 0.2
Lubricating system
Oil filter element cover Detach & attach 0.5
• Incl. replacement of relief valve
Oil filter element (cartridge) Replace 0.2
Oil filter assy Detach & attach 0.6
• Incl. overhaul of oil filter
Oil filter oil pipe Detach & attach 0.1
Oil cooler assy (incl. replacement of one hose) Detach & attach 0.3
Oil cooler assy (2 hoses) Detach & attach 0.5
Oil cooler water hose Replace 0.1
Oil relief valve Replace 0.2
Fuel system
Injection time Adjust 0.3
Injection pump assy Detach & attach 2.8
• Incl. replacement of governor, feed pump, etc.
Injection pump overflow valve Replace 0.3
Fuel feed pump assy Detach & attach 1.0
• Incl. overhaul of pump and replacement of check valve
12-16
MAINTENANCE
TIME (Hr)
Feed pump strainer Detach & attach 0.3
• Incl. cleaning strainer
Injection pipe (2 pcs.) Detach & attach 0.1
Injection pipe (4 pcs.) 0.3
Injection pipe clip Replace 0.1
Nozzle leakoff pipe Replace 0.3
Priming pump Replace 0.4
Injection pump 0.1
Fuel cut solenoid Replace 0.1
Nozzle holder assy (1 pc.) Detach & attach 0.7
• Incl. replacement of nozzle (2 pcs.) Detach & attach 1.0
• Incl. replacement of nozzle (4 pcs.) Detach & attach 1.5
Fuel filter (cartridge) Replace 0.1
Fuel filter element Detach & attach 0.2
Fuel filter assy Detach & attach 0.6
Fuel filter overflow valve Detach & attach 0.4
Fuel pump (feed pump  filter) Replace 0.4
Fuel pipe (Filter  injection) Replace 0.4
Fuel return pipe Replace 0.4
Fuel hose Replace 0.2
Cooling water system

Fan belt Adjust 0.1
Fan belt Replace 0.1
Cooling fan Detach & attach 0.3
Water pump assy Detach & attach 1.2
• Incl. overhaul of pump
Water pipe and hose Detach & attach 1.0
• Incl. replacement of pipe and packings
Thermostat Detach & attach 0.6
• Incl. performance test
Electrical equipments of engine

Starter assy Detach & attach 0.6
Generator pulley Replace 0.6
Generator assy Detach & attach 0.7
Generator drive belt Replace 0.1
Voltage regulator Adjust 0.5
Voltage regulator Replace 0.1
Glow plug (2 pcs.) Replace 0.3
Glow plug (4 pcs.) Replace 0.4
Glow plug relay Replace 0.1
Switch unit relay

Ignition & starter switch Replace 0.2
Oil pressure unit Replace 0.1
12-17
MAINTENANCE
TIME (Hr)
Oil pressure switch Replace 0.1
Thermo unit Replace 0.2
Control resistor Replace 0.2
Auto stop motor assy Detach & attach 0.2
12-18
13. MAINTENANCE STANDARD AND
TEST PROCEDURE
TABLE OF CONTENTS 13
13.1 HOW TO USE MAINTENANCE STANDARD AND PRECAUTIONS ................................. 13-3
13.2 PERFORMANCE INSPECTION STANDARD TABLE ....................................................... 13-4
13.3 MEASUREMENT OF ENGINE SPEED............................................................................... 13-7
13.3.1 MEASUREMENT OF ENGINE SPEED ..................................................................... 13-7
13.4 MEASUREMENT OF HYDRAULIC PRESSURE ............................................................... 13-8
13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE .......................................... 13-8
13.4.2 PLACE TO INSTALL PRESSURE GAUGE .............................................................. 13-8
13.4.3 PRESSURE ADJUSTMENT POSITION ................................................................... 13-9
13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE .................................................... 13-11
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 TIGHTENESS OF CYLINDERS ........................................................................ 13-19
13.8 MEASURING PERFORMANCES OF SWING BEARING .................................................. 13-20
13.9 MECHATRO CONTROLLER "A" ADJUSTMENT ............................................................. 13-21
13.9.1 ENGINE CONTROL INPUT / OUT ........................................................................ 13-21
13.9.2 ENGINE CONTROL INSTALLATION ....................................................................... 13-21
13.9.3 E/G CONTROL EQUIPMENT ................................................................................... 13-22
13.9.4 ADJUSTMENT OF MECHATRO CONTORL ............................................................ 13-23
13-1
13. MAINTENANCE STANDARD AND TEST PROCEDURE

S5YT1304E01
(NHK)
13-2
13.1 HOW TO USE MAINTENANCE STANDARD AND PRECAUTIONS

(1) Application
1) When the machine is new ;
Confirm that the performances are in accordance with standard specifications as compared to the perfor-
mance standards.
2) At specific self inspection ; (Rule by country)
Use the date 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 date 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) Repairable level ;
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 ex-
pected to exceed the service limit before next inspection and correction are performed, replace the parts im-
mediately. 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 Judgement
1) Evaluation of measured date ;
Disagreement of measuring conditions, variations of date 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 re-
stored to new levels. Therefore, determine correction, adjustment or replacement, depending upon the op-
erating 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 reg-
ular 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 rec-
ommend 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 operator's manuals as
well.
13-3
13.2 PERFORMANCE INSPECTION STANDARD TABLE
The mode is already S mode when power is thrown. Unless otherwise specified, measure it on H mode.
Table 13-1
Measuring Ad-
Standard Tolerance Measuring
Inspection Item Position Unit justing
value condition
Position Size Port Hi Lo Point
Cleanliness of hydrau- Hydraulic oil in More than
— — Class — sampling
Standard measuring condition
lic oil tank NAS 9

Hydraulic oil tempera- Atmospheric temp
Tank surface 50 (122) +5 (41) -5 (23) —
ture °C 50°C~-10°C
Water temperature Radiator surface 75 (167) +15 (59) -15 (5) — (122°F~14°F)
Lo idle 1020 +30 -30 LOW throttle
Ad-
Engine speed
FULL throttle
Hi idle 2250 +30 -30 just-
(HI idle)
Injection pipe rpm ment
Decel 1050 [1200] +30 -30
not re-
S mode 2100 +30 -30
quired
FC mode 1800 +30 -30
Pilot primary pressure
G-pump a4 3.4 (500) +0.2 (30) -0.1 (10) PR1 HI idle
circuit
valve pressure
P1 a1
Main relief
ATT 29.4 (4270) +0.5 (70) 0 MR1 Boom up

P2 a2
Dozer P3 a3 19.6 (2840) +0.5 (70) 0 MR3 Dozer up
H 32.8 (4760) 0 -3.4 (493) OR3 Boom up

Boom a1
R 32.8 (4760) 0 -3.4 (493) OR4 Boom down
H 32.8 (4760) 0 -3.4 (493) OR1 Bucket digging
Bucket a1
High pressure circuit
R 32.8 (4760) 0 -3.4 (493) OR2 Bucket dump

PF1/4
R Forward — Simultaneous
Main pump
Port relief valve pressure
a1 — — —
H Reverse MPa — operation of travel
Travel
Forward (psi) — RH and LH

L
a2 — — — (Without port
H Reverse —
relief)
LH 24.5 (3560) +2.5 (360) +0.5 (70) OR5 Swing LH
Swing a2
RH 24.5 (3560) +2.5 (360) +0.5 (70) OR6 Swing RH
H 32.8 (4760) 0 -3.4 (493) OR7 Arm in
Arm a2
R 32.8 (4760) 0 -3.4 (493) OR8 Arm out
-7.8
H 27.5 (3980) 0 {+0} OR9 Dozer down
(1130)
Dozer a5
-7.8
R 27.5 (3980) 0 {+0} OR10 Dozer up
(1130)
13-4
Table 13-1
Measuring Ad-
Standard Tolerance Measuring
Inspection Item Position Unit justing
value condition
Position Size Port Hi Lo Point
P2 by- Performs propor-
AB
pass cut B tional calculation
2, 8
valve from actual current
Travel Indi- readings on
Straight C 3, 0 cated display No.
valve cur- Values which are
Secondary pilot pressure circuit
0.98 (140) +0.15 (20) -0.05 (7) rent calculated by con-

value verting pressure
Proportional valve block
C-1 Mechatro controller
P1 by- Hard check SW (mA) values in the left

pass cut D 2, 6 400 figure to current
valve MPa values are shown.
(psi) E/G Hi, Lever on
neutral position.
P2 by-
pass cut B 2, 8
valve
Travel
E/G Hi Lever on
Straight C 3, 0 1.57 (230) +0.2 (30) -0.15 (20) 700
full stroke
valve
P1by-
pass cut D 2, 6
valve
Table 13-2
Standard
Inspection item Unit
value
1-speed 32.5~29.3
H mode
2-speed 58.8~53.2
Sprocket revolution
S mode 2-speed 54.8~49.6 rpm
(RH, LH)
FC
2-speed 47.0~42.4
mode
Raise 2.4~3.0
Boom
Lower 3.3~3.9
Operating speed
In 2.4~3.0 When this machine is equipped

Operating time of Arm
Out 2.0~2.6 with the holding valve, the oper-
cyinder sec
Digging 3.2~3.8 ating times of Boom-down and
(At no load) Bucket
Dumpig 1.6~2.2 Arm-in have to add 0.3 second.
Lower 1.8~2.4
Dozer
Raise 1.1~1.7
RH
Swing speed 4.9~5.7 sec / 1rev
LH
Rubber 22.3~23.7
1-speed
Iron 23.0~24.4
Travel speed sec / 20m
Rubber 11.9~13.9
2-speed
Iron 12.6~14.6
13-5
Table 13-2
Standard
Inspection item Unit
value
Amount of travel devia-
2-speed 0~240 mm / 20m
tion
Parking brake drift 15º Gradient 0 mm / 5min
Neutral position
Performance of Swing
after 180° full — degree
brake
Performance
speed swing
Performance of Swing
15º Gradient 0 mm
parking brake
Tip of the bucket
85
tooth
ATT amount of drift Boom cylinder 5 mm / 5min (At no load)
Arm cylinder 5
Dozer cylinder 5
Amount horizontal play at the bucket tooth 30~45 mm
The port relifef valve No. PR1-PR8 on the control section are coincided with to the following operation numbers in
advance
(1) Bucket digging, (2) Bucket dumping, (3) Boom raise, (4) Boom lower
(5) Swing left, (6) Swing right, (7) Arm in, (8) Arm out
(8) (4)
(5) (6) (4) (2)
(7) (3)
LH RH
CONTROL LEVER
13-6
13.3 MEASUREMENT OF ENGINE SPEED

13.3.1 MEASUREMENT OF ENGINE SPEED
(1) Warming up of engine PICK UP
Start engine to raise the coolant temperature of en-
gine to 40° to 80°C (104° to 176°F).
The E/G coolant temperature gauge is used to
measure. The range in white color shows the tem-
SPEED METER
perature of approx. 40° to 100°C (104° to 212°F),
so confirm that the measured value indicates the
temperature within the range of white color.
Engine water
temperature gauge
Fig. 13-1 Measurement of E/G speed

SERVICE DIAGNOSTIC DISPLAY
(2) Measuring with diesel engine speed meter

1) Install diesel engine speed meter pickup on and
of injection pipes on which the pickup can be
easily installed. (See Fig. 13-1)
2) Check E/G speed shown in Table Table 13-1 in
idling speed.
(3) Engine speed measured value through service di-
agnosis
Insert precision driver (-) into convex place indicat-
ed by arrow of hard check SW A , B in C-1 control-
Remove grommet, and you can
ler., then direct the arrow to A = 0, B = 2, and 3 find the following switch
digits in unit of 10 rpm are displayed on service di-
agnostic display of controller, HARD CHECK SW
Example : 2100 rpm210 in display
INTERNAL ADJUSTMENT SW
HARD CHECK SW
Fig. 13-2 E/G speed measuring hard check SW
13-7
13.4 MEASUREMENT OF HYDRAULIC PRESSURE

13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE
(1) Hydraulic equipment a2 a1
6.9MPa (1000 psi) pressure gauge : 1 unit A2 A1
49MPa (7100 psi) pressure gauge : 2 unit
(3 pcs in dozer specification)
A3
Pressure measuring equipment and instrument for
analysis : 1 set
(2) Measuring cleanliness of hydraulic oil
A4
After releasing air in the hydraulic oil tank, open the Dr2 B1
cover and sample oil in the hydraulic tank, and measure
with the instrument for analysis. If the measured value
Fig. 13-3 Gauge port on main pump
is higher than the reference value, replace the return fil-
ter or change the hydraulic oil.
13.4.2 PLACE TO INSTALL PRESSURE GAUGE

(1) Main circuit
Replace plugs PF 1/4 of main pump gauge ports
a1, a2 with plugs for pressure measurement, and
attach pressure gauge 49MPa (7100 psi).
(2) Dozer circuit
Replace dozer pump gauge plug PF1/4 a3 with
plug for pressure measurement, and attach pres-
sure gauge 49MPa (7100 psi). PUMP
(3) Pilot circuit
Replace pilot gauge plug a4 with plug PF1/4 for
pressure measurement, and attach pressure gauge
6.9MPa (1000 psi).
Fig. 13-4 Gauge plug on dozer pump
PUMP PUMP
Standard specification Dozer specification

Fig. 13-5 Plug for pilot pressure measurement
13-8
13.4.3 PRESSURE ADJUSTMENT POSITION

(1) Main control valve
BUCKET DIGGING BOOM UP
ARM OUT
OR1-A3 OR3-A2
OR8-D3
PC3’ Pb2’
MAIN
DR3 DR5 RELIEF VALVE
MR1
D3 A2
A3
D1 D2 A1
P1
PS
DR2
P2
C1 B1
C2 C3 B3 B2
ARM IN BUCKET DUMPING BOOM DOWN

OR7-C3 OR2-B3 OR4-B2
From rear side From front side
Fig. 13-6 Outside view
(2) Control valve for dozer (dozer specification only)
DOZER DOWN
OR9-A1
B1 A1
P T
MAIN RELIEF VALVE

MR3
DOZER UP
OR10-B1 P T
Fig. 13-7 Control valve for dozer
13-9
(3) Pilot relief valve

Pilot relief valve PR1 is built in main pump.
a2 a1
A2 A1
PR1
A3 PILOT RELIEF
A4
Dr2 B1
Fig. 13-8 Pilot relief valve position

(4) Swing port relief
The swing motor is equipped with plugs for pressure measurement, but the measurement is carried out using
gauge ports a1 and a2 . (See Fig. 13-8)
Dr
RELIEF VALVE
OR5-B PORT PLUG 2-PT 1/4
for pressure
measurement
PF3/8 (PLUG)
AIR RELEASE PORT
PORT RELIEF VALVE

OR6-A
Fig. 13-9 Swing port relief position
13-10
13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE

(1) Pilot relief valve 660
Loosen nut (661) and adjust it with adjust screw
(660).
: 24 mm
: 6 mm
661
Pressure change T=2.94 N m
No. of turns of adjust screw MPa (psi) (22 lbf ft)
1/2 turn Approx.6.1 (880)
(2) Main relief valve Fig. 13-10 Pilot relief valve

(Travel section, ATT common section) 7 6
Loosen lock nut (7) and adjust it with adjust screw T=19.6 N m
(6). (14 lbf ft)
: 19 mm
: 4 mm
Pressure change
No. of turns of adjust screw MPa (psi) Fig. 13-11 Main relief valve
1/2 turn Approx.6.1 (880) (Travel section , ATT common section)
(3) Port relief valve (Boom, bucket, arm sections) 8

T=19.6 N m
Loosen lock nut (8) and adjust it with adjust screw (14 lbf ft)
(7).
: 19 mm
7
: 4 mm
Pressure change Fig. 13-12 Port relief valve

No. of turns of adjust screw MPa (psi) (Boom, bucket, arm, sections)
1/2 turn Approx.6.1 (880)
71
T=39.2 N m (29 lbf ft)
(4) Swing port relief valve
When the adjusted pressure is 10 kgf/cm2 (142 psi)
or less, loosen nut (71) and adjust it with cap (90).
: 24, 27 mm
: 5 mm
When the pressure adjusted value is over 0.98MPa 90
(142 psi), replace the relief valve assy. Fig. 13-13 Swing port 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
Operating oil temperature : 45~55°C (113~ 131°F)
Crawler on the right and left sides are tensioned
evenly.
(3) Preparation
Install the reflection panel with a magnet to the trav-
el motor cover. Fig. 13-14 One side lifted position
Swing the swing frame through 90° as shown in Fig.
13-14 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 and 2nd speed
Measuring points : Right and left
Method, example 1 :
Measure revolution with a stroboscope.
Method, example 2 :
Fig. 13-15 Adhering position of reflection panel
Measure the revolutions per minute visually.
Sprocket revolution Unit : rpm
Measurement Standard Repairable
item value level Service limit
H1 32.5~29.3 25.4~22.9 21.8~19.6
RH
H2 58.8~53.2 45.9~41.5 39.4~35.6
&
LH S2 54.8~49.6 42.7~38.7 36.7~33.2
FC2 47.0~42.4 36.7~33.1 31.5~28.4
13.5.2 DEVIATION OF TRAVEL

(1) Purpose
Measure the amount of deviation at 20 m (66 ft)
travel and confirm the horizontal balance between
the hydraulic pump and the travel motor of the trav-
el drive system.
(2) Condition
Hydraulic oil temperature : 45 ~ 55°C (113 ~ 131°F)
Approx.1 ft
RH and LH crawler are tensioned evenly. 30~40cm
Plain, level and solid ground
Engine revolution : Hi idle Fig. 13-16 Travel position
13-12
(3) Preparation
1) Straight course more than 30 m (33 yard)
2) Travel position in which the bottom of the bucket
is lifted by about 30 cm (1 ft).
(4) Measurement 20 m (66 ft)
1) Measure the max. deviation distance of the cir-

cular arc in the 20 m (22 yard) length, excluding
Fig. 13-17 Measuring method
the preliminary run of 3~5 m (10~16 ft).
2) Operate the travel lever at the same time. Travel deviation Unit : mm/20m
Measurement Standard Repairable
item value level Service limit
A 240 (9’45") or less 480 (18’9") 720 (28.3")
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 deg. gradient slope.
(2) Condition (1 ft)
30 cm
A slope with 15 deg. gradient and a stopped condi-
tion in a no-load travel position. 15 deg.
(3) Preparation GRADIENT
Place an angle meter on the shoe plate and confirm Fig. 13-18 Parking brake operating position
that it makes an angle more than 15 deg.
Hang a perpendicular in parallel with the guide
frame rib on the track frame and put a mark (match-
ing mark) on the shoe plate.
(4) Measurement
Five minutes after the engine stops, measure the
C ANGLE METER
movement distance of the matching mark. GUIDE FRAME
Fig. 13-19 Method of measurement
Parking brake Unit : mm/5min

Measuring Standard Repairable
position value level Service limit
C 0 1 (0.04 in) 2 (0.08 in)
13-13
13.5.4 DRAIN RATE OF TRAVEL MOTOR

(1) Purpose FORWARD
To measure the drain rate of the travel motor and to
confirm the performances of the travel motor. 22PIPE
(2) Conditions
Hydraulic oil temperature : 45~55°C (113~131°F) RIB "A"
STOPPER
Engine revolution : Hi idle "B"
(3) Preparation
1) Place a stopper under the RH and LH travel
ROTARY DIRECTION
sprockets.
2) Stop the engine and vent air from the hydraulic Fig. 13-20 Location of stopper applied to travel
oil tank. sprocket
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 cas-
es.
1) Start the engine and relieve pressure at the full

stroke of the travel lever.
2) Measure the drain rate for 30 seconds of reliev- Fig. 13-21 Method of measuring the drain rate of
ing. travel motor
Take three measurements in the forward motion
Drain rate of
on each side at one time and make the mean val- travel motor Unit : L/30sec
ue the measured value. Measuring Standard Repairable
Service limit
position value level
Drain rate 3.4 (0.9 gal) 6.8 (1.8 gal) 10 (2.6 gal)
13-14
13.6 MEASURING SWING PERFORMANCES

13.6.1 SWING SPEED
(1) Purpose
Measure the swing time and confirm the perfor-
mances between the hydraulic pump and the swing
motor of the swing drive system.
(2) Conditions
Hydraulic oil temperature : 45~55°C (113~131°F) 1.5m
(5 ft)
Hard and level ground
Engine : Hi idle Fig. 13-22 Swing speed measuring position
(3) Preparation Swing speed Unit : sec/rev
The height of 1.5 m (5 ft) at which the bottom of the Measuring Standard Repairable Service
bucket matches the tip of the tooth on condition that position value level limit
the bucket is empty, the arm cylinder is most re- Standard swing 4.9~5.7 6.3~7.3 8.0~
tracted and the bucket is used for digging.
(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.
1.5m
(5 ft)
Fig. 13-23 Swing brake performance measuring po-

sition
13.6.2 PERFORMANCE OF SWING BRAKE

(1) Purpose
Confirm the braking torque performances by the
swing relief valve.
(2) Conditions
Hydraulic oil temperature : 45~55°C (113~131°F)
Engine : Hi idle
13-15
(3) Preparation Measuring the length of the arc over the

1) A height of 1.5 m (5 ft) at which the bottom of the outer circumference of swing race
bucket matches the tip of the tooth on condition Matching marks
on swing race
that the bucket is empty, the arm cylinder is most B
retracted and the bucket is used for digging.
2) Put a mark (matching mark) on the outer circum-
ference of the swing bearing of the upper frame
side and of the track frame side.
Matching marks on track frame
Erect two poles (flags) at the front and back of
the extended line of the matching mark.
Fig. 13-24 Measuring position of swing brake per-
(4) Measurement formances
1) When operating in regular swing speed, by shift-
Swing brake
ing lever to neutral position at pole position the performance Unit : degree
swing operation stops. Repairable
Standard value level Service limit
2) Calculate the swing drift angle by the following 55 65 70
equation, after the upper swing body stops, us-
ing the amount of deflection (m) of the matching
marks on the swing race and the length (m) of
the circumference of the swing race :
Amount of deflection of
Swing drift matching marks [m (ft-in)]
angle ( ) = X 360
Circumferential length of
swing race [m (ft-in)]
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 with 15 deg. gradient stop the machine
at right angles with the slope at the height of 1.5 m
(5 ft) at which the bottom of the bucket matches the
tip of the tooth on condition that the bucket is empty,
Fig. 13-25 Swing parking brake performance mea-
the arm cylinder is most retracted and the bucket is
suring position
operated for digging.
13-16
(3) Preparation Measuring the length of the arc over the

Put the angle meter on the shoe plate and make outer circumference of swing race
sure that the angle is more than 15 deg. Matching marks
on swing race
Put a matching mark over the outer circumference C
of the swing bearing on the upper frame side and
on the track frame side.
(4) Measurement
When five minutes has passed after the engine
stops, measure the length of the movement of the Matching marks on track frame
matching marks.
Fig. 13-26 Measuring position of swing brake per-
formances
Performance of swing
Parking brake Unit : mm/5min
C 0 1 (0.4 in) 2 (0.08 in)
13.6.4 DRAIN RATE OF SWING MOTOR

(1) Purpose
Measure the drain rate of the swing motor and con-
firm the performances of the swing motor.
(2) Conditions
Hydraulic oil temperature : 45~55°C (113~ 131°F)
Engine revolution : Hi idle
(3) Preparation
1) Stop the engine.
2) Vent air from inside the hydraulic oil tank.
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
1) Start the engine and put the side faces against
the inside of the right or left shoe plate.
2) Relieve the swing motor at full stroke of the
Fig. 13-27
swing motion.
3) Receive in a container the amount of drain accu- Drain rate of
swing motor Unit : L/30sec
mulated in 30 seconds of relieving.
Drain rate 5.0 (1.3 gal) 7.5 (2.0 gal) 10 (2.6 gal)
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
(1 ft)
drive system.
30cm
(2) Conditions
Hydraulic oil temperature : 45~55°C (113~131°F) Fig. 13-28 Measuring position for bucket digging
Engine : Hi idle and dump
Operating time excluding the cushion stroke
(3) Preparation
Hard and level ground with the bucket empty
(4) Measurement 1 ; Boom up and down
With the boom operating lever at full stroke, mea-
sure the required operating time of the bucket be-
tween the ground surface and its highest position.
Fig. 13-29 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.
Measurement 2 ; Arm in and out, bucket digging and
dump
In a position in which the tooth of the bucket rises to a
Fig. 13-30 Measuring position for arm in and out
level of about 30 cm (1 ft) above ground, measure the
motions
full stroke operating time required with the arm and
bucket operating levers at full stroke. Cylinder Operating
time Unit : sec
1 3.2~3.8 4.1~4.9 5.3~
2 1.6~2.0 2.2~2.8 2.9~
3 2.4~3.0 3.1~3.8 4.1~
4 3.3~3.9 4.2~5.0 5.5~
7 2.4~3.0 3.1~3.8 4.1~
8 2.0~2.6 2.6~3.3 3.5~
Dozer down 1.8~2.4 2.3~3.1 3.2~
13-18
13.7.2 OIL TIGHTENESS OF CYLINDERS

(1) Purpose B
Confirm that the cylinder oil tight by checking the
C
moving length of the cylinder rods.
A
(2) Condition
Hydraulic oil temperature : 45~55°C (113~131°F) CONDITIONS D
1.5m (5 ft)
Immediately after cylinders are replaced, bleed off Fig. 13-31
air from the cylinders, before checking for oil tight-
ness. Oil tightness of
cylinder Unit : mm/5min
The arm cylinder has moved 30 mm (1.2 in) from
the stroke end. (Off the cushioning range) position value level Service limit
A 5 8 10
(3) Preparation
B 5 8 10
Keep the tip of the bucket at 1.5 m (5 ft) height, with
the bucket empty and the arm cylinder is most re- C - - -
tracted. [Provided the arm cylinder is extended by D 85 140 170
30 mm (1.2 in).] Dozer 5 8 10
(4) Measurement
Measure the items five minutes after the engine is
turned off.
13-19
13.8 MEASURING PERFORMANCES OF SWING BEARING

(1) Purpose
Measure the gap between the lower frame and the
bottom face of the swing bearing and estimate the
degree of wear of the swing bearing.
(2) Condition
The swing bearing mounting bolts are not loos-
ened.
The swing bearing is lubricated well, not making ab-
normal sound during turning.
Fig. 13-32 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.
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
the reading at zero. Fig. 13-33 Measuring position I
(4) Measurement 1 (Measuring position I and II)
1) Measure the travel of the outer race in the axial
direction in position I [The arm at 90°~110° and
the crawler front lifted about 30 cm (1 ft)] and in
position II, using a dial indicator.
Fig. 13-34 Measuring position II
Axial play of
swing bearing Unit : mm
A 0.5~1.5 1.9~2.9
(0.02~0.06 in) (0.07~0.11 in) 3.0 (0.12 in)~
(5) Measurement 2 (Measuring position III)

1) With the arm cylinder most retracted and the
bucket dump, lift the tip of the tooth of the bucket
about 10 mm (0.4 in) and swing the tip of the
bucket to the right and the left by man power.
But in this case, the gap of the attachment is in-
cluded.
Fig. 13-35 Measuring position III
Right and left

movement of
the tip of bucket Unit : mm
Bucket tiptoe 30~45 125 150
(1.2~1.8 in) (4.9 in) (5.9 in)
13-20
13.9 MECHATRO CONTROLLER "A" ADJUSTMENT

13.9.1 ENGINE CONTROL INPUT / OUT
Fig. 13-36
13.9.2 ENGINE CONTROL INSTALLATION
FINE CAPSCREW M10 X 35

TIGHTENING TORQUE
65 N m (48 lbf ft)
Apply Loctite #242 or equivalent.
2 places
FINE CAPSCREW M10 X 20
TIGHTENING TORQUE
65 N m (48 lbf ft)
SOCKET BOLT M6 X 25 SOCKET BOLT M10 X 35

TIGHTENING TORQUE TIGHTENING TORQUE
9.8 N m (7.2 lbf ft) 19.6 N m (14 lbf ft)
SECTION BB
Fig. 13-37
13-21
13.9.3 E/G CONTROL EQUIPMENT

(1) Governor motor and C-1 controller REDUCTION GEAR SECTION
1) By operating accel dial, the input voltage change OIL SEAL MOTOR SECTION
is sensed by 14-8 pins of C-1 controller. OUTPUT SHAFT
2) The C-1 controller computes the input voltage,
and outputs command to governor motor (M-2),
and incline governor lever of engine to the swing
CAM
angle corresponding to access dial set value.
3) The limit switch in governor motor is set to a an- LIMIT
gle from motor rotation OFF to ON position SWITCH
(Starting point).
(2) Rotation sensor
1) Installing place
Engine flywheel housing
Opposing flat 19
2) Sensor attaching procedure SIGNAL (Yellow)
M16 X 1.5 Opposing flat 17
a. Apply Loctite #262 on pick-up thread section.
b. Tighten thread until it contacts flywheel ring
gear, and turn it back one and half turns.
GND (Black)
c. After turning it back one and half, check that
the tightening torque of nut is 24.5~34.3 N•m SWITCH PANEL
(18 ~ 25 lbf•ft).
d. After installation, check that the engine
speed meter measured value corresponds to Wark mode
the engine speed in service diagnostics selector switch
while operating engine.
e. Output voltage at 850 rpm : 4V (AC) or more
Buzzer stop switch
Output voltage at 2250 rpm : 20V (AC) or
less
(3) Work mode selector switch
Press work mode selector switch, and the opera-
tion signal is sent to C-1 controller, and the work
mode is switched.
(4) Buzzer stop switch
When the error is detected by self-diagnosis, the C-
1 controller sends alarm by sounding buzzer, and
CPU lamp on gauge cluster flickers. And press
buzzer stop switch to stop buzzer sounding. Also,
when engine coolant temperature has risen or the
engine oil pressure has lowered, buzzer sounds.
But in this case the buzzer sounding does not stop.
13-22
13.9.4 ADJUSTMENT OF MECHATRO CONTROL

(1) When adjustment of mechatro control is required;
CONTROLLER DISPLAY
Case "A" adjustment

Replacement of C-1 mechatro controller
GROMMET
Replacement of governor motor
A
Disassemble governor rod
A
C-1 MECHATRO CONTROLLER
(2) Preparation
a. Warm up engine.
b. Turn starter switch OFF to stop engine, and turn A/C switch OFF .
c. Pull operator seat forward fully and incline seat-back forward.
d. Remove plastic cover on the rear side, then mechatro controller appears.
(Remove 5 attaching bolts form plastic cover with driver +).
Check to be sure that the engine emergency stop lever knob in fully pressed down. If mechatro controller in ad-
justed in the condition where the knob is pulled out, the engine speed can not be set rightly.
(3) Adjustment
Mode display on
Procedure Movement of governor motor
gauge cluster
1. Remove grommet on upper surface of mechatro controller, and switch internal adjustment switch from RUN
to TEST .
FULL
STOP
During
adjustment
LEVER
In normal
pisition GOVERNOR
MOTOR
SECTION AA
Internal adjustment jumper pin (JP) switch
2. Turn starter switch ON .

H S FC A
Stop at the position

set by accel dial
Display lamp lights
on in order
13-23
Mode display on
Procedure Movement of governor motor
gauge cluster
3. Keep pressing buzzer stop switch for approx 3 to
A
10 seconds and release. S
H S
Automatically run
Check that the display on this gauge cluster is as
to engine stop
the right. position (S)
4. After checking the right mode display, adjust the S

rod length so that the clearance A between gov- H S
ernor lever and engine stop set bolt in engine Stop at S position
side is 0.1 mm (0.0039 in). adjust rod (5) length
[TOOLS]
to 204 mm (8.03 in). Spanner 13 mm X 2
And, when the governor motor is replaced, con- Spanner 6 mm
Thickness gauge
firm that the right display is indicated, then insert
link rod.
e. Press buzzer stop switch once, and wait until the S A
mode is switched to the right display. S FC
Automatically run to the engine

available position A
f. After verification of the flowing mode, start en- A

gine. S FC
Then, any position of accel dial is allowable.
Stop at A position
g. Press buzzer stop switch once, and the mode is
Lo A
Hi
switched to the following, and governor lever H FC
moves from A position to low idling position, and
reading the engine speed to high idling automat-
ically.
(Required time : approx. 3 minutes.) Move from A position to Lo idling
position, and self-travels from Lo
position to high idling (Hi) position
Governor lever is set to the position of approx.

1700rpm~1900rpm. According to the command of
mechatro controller, the lever moves to the low
idling position after engine starts, then starts read-
ing out for self-travelling.
h. After completion of read out, wait until the mode Hi

display on gauge cluster switches to the follow- H S FC
ing.
After the display switches, the engine speed is (Approx.
A
returned automatically to the position set through 5 seconds) Hi
accel dial and adjustment is completed.
When mechatro controller is replaced, and start-
er key is turned on, CPU lamp starts flickering.
If CPU lamp is turned off after completion of "A"
adjustment, the adjustment is completd correctly.
But CPU lamp is flickering yet, the adjustment is
failed, readjust again.
13-24
(4) After completion of adjustment

a. Turn starter switch OFF to stop engine.
b. Switch internal adjustment JP switch from TEST to RUN position, and set hardware check B to 2.
(Note : When hardware check switch indicates "0-0", the mechatro controller displays error code.)
c. Press the blank side of auto accel switch to release auto accel, and after starting engine the speed increases
to high idling position, then check the engine speed at the status of H, S and FC position indicated on the
display of mechatro controller.
d. By switching work mode through switch panel, the mode display on gauge cluster is also switched. Then,
check that the engine speed changes.
e. After setting accel dial to low idling position, press the symbol side of auto accel switch to actuate auto accel
function.
f. Set accel dial to high idling, and check engine speed when running in auto accel position.
g. After verification of engine speed, set hardware check switch B on mechatro controller to "0", and attach
grommet.
h. Attach plastic cover as it was, and slide operator seat backward to move the seatback backward. Then,
check connector of speaker for disconnection.
(5) When adjustment of mechatro controller can not be performed.
1) After execution of procedure (g), HSFC is displayed, CPU lamp flickers, and adjustment can not be ex-
ecuted. ( "E01" is indicated on controller display.)
"A" (Display condition)
• While reading engine speed, the engine speed after stepping of governor motor is lower than that before
stepping in condition of engine speed 850rpm or high.
(Cause)
• The read-out of engine speed sensor is wrong.
(Corrective action)
• After measurement and adjustment of speed sensor voltage, carry out A adjustment.
High idling 3V or high (AC) (Voltage available for controller to read)
(When adjusting in factory, the voltage is set to 3V (AC) or high at high idling)
"B" (Display condition)
• When abnormal rotation (step-out) occurs on high idling side;
(Cause)
• Wrong connection of link rod of governor motor
(Corrective action)
• After verification of connection of link rod, perform "A" adjustment. [Rod length : 204 mm (0.031 in)] When
step-out occurs after adjustment, press buzzer stop switch once before stepping out as a temporary repair,
and it is switched to high idling temporarily.
2) The error code "E02" is indicated on the display of mechatro controller, but the adjustment cannot be exe-
cuted.
(Display condition)
• Engine speed is 300 rpm or lower, or 3000 rpm or higher.
(Cause)
• The read-out of engine speed sensor is wrong.
(Corrective action)
• After measurement and adjustment of speed sensor voltage, carry out "A" adjustment.
High idling 3V or high (AC)
13-25
3) When buzzer stop switch is pressed once to proceed from procedure (f) to (g), it does not proceed to proce-
dure (g), but procedure (h) directly, and CPU lamp flickers and error code E01 is indicated on the display on
mechatro controller.
(Display condition)
• Engine speed is 420 rpm or low.
(Cause)
• Buzzer stop switch is pressed once before starting engine.
• The read-out of engine speed sensor is wrong. (or disconnection)
(Corrective action)
• Adjust mechatro controller again as the procedure.
• After measurement and adjustment of speed sensor voltage, perform "A" adjustment.
High idling 4V or high (AC)
4) When buzzer stop switch is pressed once to proceed from procedure (d) to (e), but it does not proceed to
procedure (e).
(Display condition)
• Limit switch signal (grounding) is not input from governor motor to controller.
(Cause)
• Failure of limit switch in governor motor
• Disconnection of connector or harness on governor motor
(Corrective action)
• Check that limit switch of governor motor goes ON and OFF.
• Check connector and harness from possible damage, and adjust it.
5) Others
Error code "E02" is indicated on the display of controller, and engine stops.
Engine oil pressure switch and harness are short-circuited.
(6) CPU lamp on gauge cluster flickers, or error code "E01" is indicated on display of controller.
When mechatro controller is replaced, and the adjustment of controller has failed, this display appears.
When the adjustment is completed normally, CPU lamp goes off, and error code "E01" also disappears.
To perform the adjustment of mechatro controller again, press starter switch once to turn the power OFF, and
turn starter switch on and perform the adjustment again.
13-26
21. MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS
21.1 MECHATRO CONTROL SYSTEM ..................................................................................... 21-4

21.2 BOOM RAISE CONFLUX MECHATRO CONTROL SYSTEM ........................................... 21-7
21.3 SWING CUT VALVE CONTROL MECHATRO CONTROL SYSTEM ................................. 21-8 21
21.4 ARM IN / OUT CONFLUX MECHATRO CONTROL SYSTEM ........................................... 21-9
21.5 TRAVEL STRAIGHT MECHATRO CONTROL SYSTEM ................................................... 21-10
21.6 MECHATRO CONTROL .................................................................................................... 21-12
21.6.1 TROUBLESHOOTING .............................................................................................. 21-12
21.6.2 SERVICE DIAGNOSTICS ......................................................................................... 21-13
21.6.3 COMPONENT MECHATRO CONTROL ................................................................... 21-15
21-1

First edition September, 2004 SK70SR–1E(S) : YT04–07001~ S5YT2103E01 KE
S5YT2103E01
(NHK)
21-2
PREFACE
This manual describes the outline of electrical and hydraulic systems and equipment. For details, refer to electro
hydraulic diagrams.
21-3
21.1 MECHATRO CONTROL SYSTEM
Electric Controller
Input / Output signal
Oil pressure Proportional secondary

pressure
Proportional pressure
C/V Up side
LH RH LH RH 8 5 F
Pilot valve
Pilot valve
P2 by-pass
for travel
for ATT
Travel straight valve

conflux valve cut valve
Travel left
SE9
Swing
Arm
SE10
Boom raise
Rotary
multi
C/V To control
Gauge cluster valve
SE1 7 6 R
H/S/FC
display SE2 C/V Low side
SE3
SE4
Switch panel
SE5
H/S/FC
select SE7
SE8
Accel dial
Controller
Engine
Governor motor
Pump
: Low pressure sensor
: Accel dial
21-4
Boom cylinder raise conflux
F 3 1
P1 by-pass cut valve
Arm cylinder in conflux

Arm cylinder out conflux
Travel right
Bucket
Boom
R 4 2
Swing motor parking
Travel motor 2-speed select

P2 by-pass cut proportional valve

Travel straight proportional valve
Two speed travel SOL
Safety lock lever SOL
Travel boost-up SOL

Swing P/B SOL
PSV PSV PSV SV SV SV SV

-B -C -D -1 -3 -4 -8
Lever lock
SW-11
Proportional valve / Solenoid valve block
21-5
OPERATIONS & MECHATRO CONTROL EQUIPMENT FUNCTIONS
Mechatro control equipment Hydraulic

Hydraulic equipment pressure
Hydraulic Volt Solenoid valve
pressure (cut-off spool)
Mechatro control voltage Ampere (Current hydraulic pressure) voltage
equipment
Safety lock lever
Swing parking release

Travel 2-speed select
Governor motor
Travel boost-up
Low pressure sensor

Travel 2-speed
P2 by-pass cut
P1 by pass cut
Travel straight
Swing parking
Controller
Travel straight
Operation side
I O M
N U 1 3 4 8 B C D
T 2
Digging SE1
Bucket
Dump SE2
(Conflux) Raise SE3

Independent operation
Boom Lower SE4

Swing
(Cut valve Left, Right SE5
control)
(Conflux)
In (Dig) SE7
Arm
(Conflux) Out (Extend) SE8
Oil pressure
Operation side output signal
Right SE9
Travel
Left SE10
SE1
Digging SE9,10
Bucket /
Travel SE2
Dump SE9,10
SE3
Combined operation
Raising SE9,10
Boom /
Travel SE4
Lowering SE9,10
SE5
Left SE9,10
Swing /
Travel SE5
Right SE9,10
SE7
In (Dig) SE9,10
Arm /
Travel SE8
Out (Extend) SE9,10
Safety lock
SW-11 ON
lever
Electric
Travel 2-speed SW-3 ON

Swing parking
SW-4 ON
brake release
21-6
21.2 BOOM RAISE CONFLUX MECHATRO CONTROL SYSTEM
Pilot valve

for ATT
P2 by-pass

Travel right
cut valve
Travel left
Bucket
Swing
Boom
Arm
Boom raise operating
conflux valve
Pilot pressure
Boom raise
SE3
Low pressure sensor
Proportional voltage
Pilot signal process

Command PSV-B Proportional valve
proportional current P2by-pass cut secondary pressure
proportional
valve
Mechatro controller

secondary pressure
proportional valve
P2 by-pass cut
Pi
Operating pilot pressure
(1) Start boom raise operation, and the boom raise operation pilot pressure switches boom spool and boom conflux
spool, and inputs into low pressure sensor.
(2) The voltage output by low pressure sensor is input into mechatro controller, and the controller processes the
pilot signal and outputs the command corresponding to input voltage to P2 by-pass cut valve.
(3) P2 by-pass cut valve outputs pilot proportional valve secondary pressure corresponding to the command output
by mechatro controller, and switches P2 by-pass cut valve of control valve.
(4) Operation pilot pressure switches boom main spool and conflux valve. And the oil delivered by P1 and P2 pump
is conflixed in P2 by-pass cut valve switched by mechatro control.
21-7
21.3 SWING CUT VALVE CONTROL MECHATRO CONTROL SYSTEM
Pilot valve

for ATT
P2 by-pass

Travel right
cut valve
Travel left
Bucket
Swing
Boom
Arm
conflux valve
Boom raise
SE5
Low pressure sensor

Command PSV-B Proportional valve
proportional current P2by-pass cut secondary pressure
proportional
valve
Mechatro controller

secondary pressure
proportional valve
P2 by-pass cut
Pi
(1) Start swing operation, and the swing pilot pressure switches swing spool, and is input into low pressure sensor.
(2) The voltage output by low pressure sensor is input into mechatro controller, and the controller processes the
pilot signal and outputs the command corresponding to input voltage to P2 by-pass cut valve.
(3) P2 by-pass cut valve outputs pilot proportional valve secondary pressure corresponding to the command output
by mechatro controller, and switches P2 by-pass cut valve of control valve.
(4) By switching swing main spool with operation pilot pressure and switching P2 by-pass cut valve according to
mechatro control command, the swing operation control is performed more gently.
21-8
21.4 ARM IN / OUT CONFLUX MECHATRO CONTROL SYSTEM
Pilot valve

for ATT
P2 by-pass

Travel right
Travel left
cut valve
Bucket
Swing
Boom
Arm
Boom raise operating
conflux valve
Pilot pressure
Boom raise
SE7 or SE8
Low pressure sensor

Command PSV-D Proportional valve
proportional current secondary pressure
P1 by-pass
cut valve
Mechatro controller

secondary pressure
proportional valve
P1 by-pass cut
Pi
(1) Start arm in and out operation simultaneously, and operation pilot pressure switches arm spool, and is input into
low pressure sensor.
(2) The voltage output by low pressure sensor is input into mechatro controller, and the controller processe the pilot
signal and outputs the command corresponding to input voltage to P1 by-pass cut valve.
(3) P1 by-pass cut valve outputs pilot secondary pressure corresponding to the command output by mechatro con-
troller, and switches P1 by-pass cut valve of control valve.
(4) By switching arm main spool with operation spool pressure and switching P1 by-pass cut valve according to
mechatro control command, the oil delivered by P1 and P2 pumps is confluxed during arm operation.
21-9
21.5 TRAVEL STRAIGHT MECHATRO CONTROL SYSTEM
Pilot valve
for ATT

P2 by-pass

Travel right
Travel left
cut valve
Bucket
Swing
Boom
Arm
Pilot valve Boom raise operating
for travel
Travel straight operating
(Left) (Right)
Pilot pressure
conflux valve
Boom raise
Pilot pressure
SE10 SE9 SE5

Low pressure sensor
Travel straight signal

Proportional

Command PSV-C proportional
voltage
proportionate valve secondary

Travel straight current proportional pressure
proportional valve for travel
valve command straight valve
Command PSV-B proportional

P2 by-pass cut current P2 by-pass cut pressure
Pilot signal process proportional proportional
valve command valve
Command PSV-D proportional

P1 by-pass cut current P1 by-pass cut pressure
proportional proportional
valve command valve
Mechatro controller
Pilot signal process Pilot signal process

secondary pressure
secondary pressure
proportionate valve
proportional valve
P1 by-pass cut
P2 by-pass cut
Pi Pi
Operating pilot pressure Operating pilot pressure
21-10
TRAVEL STRAIGHT SYSTEM

(1) Start ATTs work operations (boom, arm, bucket, swing) in travel operation (right and left), and the pressure
switches respective spools, and is input into respective low pressure sensors.
Boom raise operation is explained here.
(2) If mechatro controller receives the input satisfying the following combination shown in Figure, the controller de-
termines it as travel straight, and the travel straight signal turns on.
(3) After the travel straight signal has turned on, the signal is input to respective proportional valve corresponding
to the following commands.
Travel straight proportional command
Outputs switching command corresponding to boom raise pilot pressure
(ATT pilot pressure in high priority in operation)
P1 by-pass cut valve command
Outputs switching command corresponding to boom raise pilot pressure (Att pilot pressure in high priority in
operation) and the pressure selected by travel left pilot pressure as high priority.
P2 by-pass cut vale command
Outputs switching command corresponding to boom raise pilot pressure (ATT pilot pressure in high priority in
operation )and the pressure selected by travel right pilot pressure as high priority.
(Reference) Operating condition where travel straight signal turns on
Boom Bucket Arm Swing

In travel right operation —
In travel left operation — —
21-11
21.6 MECHATRO CONTROL

21.6.1 TROUBLESHOOTING
"CPU lamp on gauge cluster flickers", and "buzzer sounds intermittently". In this case, error code is displayed on
LCD at the center of C-1 controller.
Determines the fault location and corrective action referring to Error diagnostics shown in the following page.
And in case "CPU lamp lights on", and "buzzer sounds continuously", the display indicates the trouble on C-1 con-
troller.
C-1 MECHATRO CONTROLLER GAUGE CLUSTER
CPU LAMP
OFF : Normal
Red lamp flickers :
System error
Display error code on
C-1 controller.
Red lamp lights on :
C-1 conroller error
Table 21-1 Error Diagnostics

Error code Error diagnostic items Corrective action
E01 EEPROM date error
Readjust engine speed, or replace controller.
E02 Mechatro controller maladjustment
E03 Boom raise pressure sensor error
E04 Boom lower pressure sensor error
E05 Arm in pressure sensor error
E06 Arm out pressure sensor error
E07 Bucket digging pressure sensor error
Replace sensor or check harness between sensor and
E08 Bucket dump pressure sensor error
controller for possible damage.
E09 Swing pressure sensor error
E10 P3 pump pressure sensor error
E11 Travel right pressure sensor error
E12 Travel left pressure sensor error
E13 Accel dial error
E14 Travel boost-up selector coil error Replace solenoid valve or check harness between so-
E15 Swing parking selector coil error lenoid valve and controller for possible damage.
Replace battery relay or check harness between bat-
E16 Battery relay error
tery relay and controller for possible damage.
E17 P1 by-pass cut valve coil error
Replace by-pass cut valve or check harness between
E18 P2 by-pass cut valve coil error
by-pass cut valve and controller for possible damage.
E19 Travel straight valve coil error
E20 Governor motor current error Replace governor motor or check harness between
E21 Governor motor start point error governor motor and controller for possible damage.
Replace engine oil pressure switch or check harness
E22 Engine reverse rotation between engine oil pressure switch and controller for
possible damage.
21-12
21.6.2 SERVICE DIAGNOSTICS

This service diagnostics is used to check equipment and harness when CPU lamp flickers, and errors are indicated
on C-1 controller LCD section, and also to determine normal / error according to the numeric values in "Service Di-
agnostics" displayed by switching hardware check switch (A) and (B). However, since the hardware check SWs (A)
and (B) are set to "0.0" in factory, the numeric value in C-1 controller LCD display indicated error code.
SERVICE DIAGNOSTICS DISPLAY ERROR CODE DISPLAY
Remove
grommet, and
you can find
the following
switches.
Hardware check SW (the left shows the "0.0" setting condition).

Turn the arrow at the center of switch and set it to numeric value.
Insert precision driver (-) in to convex indicated by arrow and turn
the arrow to set to numeric values.
Hardware
check SW Service diagnostics Contents of display Example
A B
Normal (without service
0 0 Error diagnostics (error code). —
diagnostics)
0 1 Engine speed set value Display 3 digits per 10 rpm 2.2.5 per 2250 rpm. 2.2.5
0 2 Engine speed measure value Display 3 digits per 10 rpm 2.2.5 per 2250 rpm. 2.2.5
Display key SW input condition in column 10. 24V  1
Key SW input / battery relay 0V  0
0 3
output Deexcite  0
Display battery relay output condition in column 1. Excite  1
H.S.FC
Mode SW input / auto accel SW Display mode SW input condition in column 10.
0 4 ON  0
input Display auto accel SW input condition column 1.
OFF  1
Display wiper SW in column 100 and washer SW in
Wiper SW washer SW / working ON  1
0 5 column 10.
light SW OFF  0
Display working light SW condition in column 1.
0 6 Accel dial voltage Accel dial input voltage (3 digits display). Eg. 2.34V 2.3.4
Governor motor position (%) calculated based on
0 7 Accel dial position accel dial voltage. 1.0.0
Example: for 4V or higher, the limit is 100%.
Display the present governor motor step number, Hi 1.0.0
0 8 Governor motor step number
integer 3 digits. Low 0.0.0
Hi 1.0.0
0 9 Governor motor position The present step number is displayed in %.
Low 0.0.0
Motor coil A output current
1 0 Governor motor A phase current 1.5.0
value
1.5A is required.
Motor coil B output current
1 1 Governor motor B phase current 1.5.0
value
21-13
Hardware
check SW Service diagnostics Contents of display Example
A B
Display governor motor limit SW input signal condi- Input  1
1 2 Governor motor limit SW
tion in column 1. Release  0
1 3 Boom raise pressure sensor
1 4 Boom lower pressure sensor
1 5 Arm out pressure sensor
1 6 Arm in pressure sensor
Value converted input from each pressure sensor
1 7 Bucket digging pressure sensor
to voltage 3.2.4
1 8 Bucket dump pressure sensor
EG.: 3.24V
1 9 Swing pressure sensor
2 0 P3 pump pressure sensor
2 1 Travel right pressure sensor
2 2 Travel left pressure sensor
Excite  1
Travel boost-up selector valve
Output command in column 10. Deexcite  0
2 3 output
Display feedback condition in column 1. Hi input  1
command / feedback
Lo input  0
Swing parking selector valve Excite  1
2 4 Output command in column 10.
output command / feedback Deexcite  0
Battery relay output command / Hi input  1
2 5 Display feedback condition in column 1.
feedback Lo input  0
P1 by-pass cut valve command
2 6
current (Prop. valve C)
P1 by-pass cut valve feedback
2 7
current
P2 by-pass cut valve command Values each command current value (mA) is con-
2 8
current (Prop. valve A) verted Eg: 600mA 6.0.0
P2 by-pass cut valve feedback Values each feed back current (mA) is converted 6.0.0
2 9
current Eg.: 600mA
Travel straight prop. valve com-
3 0
mand current (prop. valve B)
Travel straight prop. valve
3 1
feedback current
Wiper motor rise up LS in column 10.
Wiper motor rise-up LS / reverse ON  1
3 2 Display wiper motor rise-up LS condition in column
LS OFF  0
1.
Wiper motor arc protection relay Display wiper motor arc protection relay, positive
ON  1
3 3 / positive relay command and reverse relay command in col-
OFF  0
relay / reverse relay command umns 100, 10, and 1 respectively.
Washer motor relay / working Washer motor relay command, working light relay
ON  1
3 4 light relay / command. CPU lamp error command conditions in
OFF  0
CPU lamp error command columns 100, 10 and 1 respectively.
Display wiper operation command, power window
Wiper operation command / ON  1
3 5 operation input command condition in columns 10
wiper window operation input OFF  0
and 1 respectively.
Display internal adjustment JP SW condition in col- TEST  1
3 6 Internal adjustment JP SW
umn 1. RUN  0
21-14
21.6.3 COMPONENT MECHATRO CONTROL

(1) C-1 Mechatronic controller
In adjusting operation
In normal operation
SECTION AA
(Internal adjustment JP switch)
Table 21-2 CN-11

Input
No. NAME Wire color Remarks
Output
11–1 Battery relay (R-1) In WG
11–2 Swing parking select solenoid valve (SV-1) Out V
11–3 Work mode select switch (SW-2) Out G
11–4 Washer switch (SW-2) Out BrW
11–5 Buzzer stop switch (SW-2) Out LgR
11–6 Work light switch (SW-2) Out LG
11–7 Wiper switch (SW-2) Out VG
11–8 Buzzer (SW-2) In Br
11–9 Earth GND (SW-2) Out GW
11–10 engine oil pressure switch (SW-7) In O
11–11 P2 by-pass cut proportionate valve (PSV-B) Out BO
11–12 Travel straight proportionate valve (PSV-C) Out GB
11–13 P1 by-pass cut proportionate valve (PSV-D) Out BP
11–14 Travel boost-up select valve (SV-8) Out B
11–15 Starter switch (SW-1) In GrL
11–16 Wiper motor rise up (stop) (M-10) In L
11–17 Wiper motor (reverse) (M-10) In G
11–18 Wiper motor ark prevent relay (R-9) In LR
21-15
Table 21-2 CN-11

Input
Output
11–19 Wiper motor rotation relay (R-9) Out GB
11–20 Wiper motor reverse relay (R-9) Out Gr
11–21 Washer motor relay (R-6) Out GrL
11–22 Work light relay (R-8) Out BrY
11–23 CPU error lamp In PG
11–24 P2 by-pass cut proportionate valve (PSV-B) Out GrR
11–25 Travel straight valve (PSV-C) Out GrB
11–26 P1 by-pass cut proportionate valve (PSV-D) Out PW
Table 21-3 CN-12

Input
Output
12–1 Boom raise pressure sensor (GND) (SE-3) In BR
12–2 Boom raise pressure sensor (SE-3) In LgY
12–3 Boom raise pressure sensor (5V) (SE-3) In W
12–4 Boom lower pressure sensor (5V) (SE-4) In OB
12–5 Boom lower pressure sensor (SE-4) In LO
12–6 Boom lower pressure sensor (GND) (SE-4) In BrW
12–7 Arm in pressure sensor (GND) (SE-7) In BrY
12–8 Arm in pressure sensor (SE-7) In PG
12–9 Arm in pressure sensor (5V) (SE-7) In OL
12–10 Arm out pressure sensor (5V) (SE-8) In OW
12–11 Arm out pressure sensor (SE-8) In PL
12–12 Arm out pressure sensor (GND) (SE-8) In Gr
12–13 Bucket digging pressure sensor (GND) (SE-1) In BrR
12–14 Bucket digging pressure sensor (SE-1) In LgR
12–15 Bucket digging pressure sensor (5V) (SE-1) In RB
12–16 Opt. pedal pressure switch (SW-18, SW-19) In LO
21-16
Table 21-4 CN-13

Input
Output
13–1 Bucket extend pressure sensor (GND) (SE-2) In BL
13–2 Bucket extend pressure sensor (SE-2) In LgW
13–3 Bucket extend pressure sensor (5V) (SE-2) In RL
13–4 P3 pump pressure sensor (5V) (SE-17) In YL
13–5 P3 pump pressure sensor (SE-17) In PL
13–6 P3 pump pressure sensor (GND) (SE-17) In BrB
13–7 Swing pressure sensor (GND) (SE-5) In Br
13–8 Swing pressure sensor (SE-5) In VG
13–9 Swing pressure sensor (5V) (SE-5) In YG
13–10 Travel right pressure sensor (5V) (SE-9) In YL
13–11 Travel right pressure sensor (SE-9) In VY
13–12 Travel right pressure sensor (GND)) (SE-9) In BY
Table 21-5 CN-14

Input
Output
14–1 Governor motor A phase (M-2) Out G
14–2 Governor motor A phase (M-2) Out B
14–3 Governor motor A phase shield Out —
14–4 Travel left pressure sensor (GND) (SE-10) In BG
14–5 Travel left pressure sensor (SE-10) In Sb
14–6 Travel left pressure sensor (5V) (SE-10) In YR
14–7 Accel dial (5V) (SE-16) In WR
14–8 Accel dial (SE-16) In P
14–9 Accel dial (GND) (SE-16) In BW
14–10 Detects the P3 pump pressure sensor (SE-17) In O
14–11 Power supply 24V In RY
14–12 Governor motor B phase (M-2) Out R
14–13 Governor motor B phase (M-2) Out W
Dctccts the starting point of the governor
14–14 (M-2) Out V
motor
14–15 Power window operation signal (C-5) Out PB
14–16 Wiper operation signal (C-5) Out YB
14–17 Work mode display (C-2) Out LO
14–18 Work mode display (C-2) Out L
14–19 Engine speed sensor (SE-13) In B
14–20 Engine speed sensor (SE-13) In W
14–21 Shield earth In Gr
14–22 Power supply GND Out B
21-17
(2) Gauge cluster
Amp SCCS connector

(Nippon AMP 040)
Housing 174044-2
Terminal 173681-2
VIEW I
Table 21-6 Connector

No. NAME Wire color No. NAME Wire color
1 Fuel sensor BrR 11 CPU trouble PG
2 Engine coolant temp. sensor YR 12 Swing parking release switch Lg
3 Alternator (charge) WR 13 Over load GrB
4 Glow switch BrY 14 Spare 1
5 Engine oil pressure switch O 15 Spare 2
6 Engine coolant temp. switch GB 16 Mode display (Main controller) LO
7 Remaining fuel volume switch BrB 17 Mode display (Main controller) L
8 Air cleaner clogged switch BrL 18 Work light switch WB
9 Travel 1-2 speed switch LgB 19 Power supply (+24V) W
10 Buzzer signal Br 20 GND B
Table 21-7 Performances, lamp display and alarm

Display contents Input signal condition Buzzer
Input termi-
sounds or
No. Function nal No. Normal (OFF) Abnormal (ON)
not. *Note 1
1 Battery charge faulty CN21-3 1 0 No
2 Glow operation CN21-4 — 1 No
3 Engine oil pressure low CN21-5 — 0 Yes
4 Engine coolant temp. high temp. CN21-6 — 0 Yes
5 Fuel down CN21-7 800 or more 150 or less No
6 Air cleaner clogged CN21-8 — 0 No
7 Travel 2-speed operation CN21-9 — 1 No
8 Buzzer *Note 2 CN21-10 — 0 Yes
9 CPU trouble CN21-11 0 — No
10 Swing parking CN21-12 — 34 No
11 Over load alarm CN21-13 — 0 Yes
12 Spare 1 CN21-14 — 0 No
13 Spare 2 CN21-15 — 0 No
14 Work light (Back light) CN21-19 — 1 No
1. The buzzer sounds intermittently, 0.5 ± 0.2 sec : ON and 0.5 ± 0.2 sec : OFF when the battery charge is
short, or error Nos. 3, 4, 11 in the above Table occurred during normal operation.
2. The buzzer in error No.8 sounds only, and mechatro controls it.
21-18
(3) Switch assy
CN22 CN23
CN23 Wire
No. NAME color
1 Power supply+5V G
CN22 2 Address input Di1 LgR
3 Address input Di2 LG
4 Address input Di3 VG
CN22
5 Date output DO1 BrW
CN23 6 GND B
7 NC -
8 NC -
No. NAME Wire

color
1 Back light + WB
CN23
View from rear side 2 Back light - B
(4) Governor motor (M-2)
NAME PLATE
Connection diaqram
Brown Red
(A) (B)
Orange Yellow MOTOR CONNECTOR

(A) (B) LIMIT SWITCH CONNECTOR
Limit switch operation range
Limit switch connector wiring diagram Motor connector wiring diagram
No. Lead color Connection

line No. Lead color Connection
line
5 White COM 1 Brown A
_
6 Red NO 2 Orange A
7 Yellow NC 3 Red B
_
4 Yellow B
21-19
[MEMO]
21-20
22. HYDRAULIC SYSTEM
TABLE OF CONTENTS
22.1 SUMMARY ......................................................................................................................... 22-3

22.2 HYDRAULIC CIRCUITS AND COMPONENT MODELS ..................................................... 22-4
22.2.1 STANDARD SPECIFICATION ................................................................................... 22-5
22.2.2 DOZER SPECIFICATION (OPT.) ....................................................................... 22-6 22
22.2.3 DOZER SPECIFICATION (OPT.) ............................................................................... 22-7
22.2.4 BOOM & SAFETY SPECIFICATION (OPT.) .............................................................. 22-8
22.3 HYDRAULIC CIRCUIT OPERATION ................................................................................. 22-10
22.3.1 COLOR CODING STANDARD FOR HYDRAULIC .................................................... 22-10
22.3.2 NEUTRAL CIRCUIT .................................................................................................. 22-10
22.3.3 TRAVEL CIRCUIT ..................................................................................................... 22-12
22.3.4 BUCKET CIRCUIT .................................................................................................... 22-14
22.3.5 BOOM CIRCUIT ........................................................................................................ 22-16
22.3.6 SWING CIRCUIT ....................................................................................................... 22-20
22.3.7 ARM CIRCUIT ........................................................................................................... 22-22
22.3.8 COMBINED CIRCUIT (MULTIPLE CIRCUIT) ............................................................ 22-26
22.3.9 PILOT PIPING ........................................................................................................... 22-30
22.3.10 MAIN PIPING ............................................................................................................ 22-37
22.3.11 ADDITIONAL SPECIFICATIONS .............................................................................. 22-47
22-1

S5YT2204E01
(NHK)
22-2
22.1 SUMMARY bility, safety mass volume handling and low fuel con-
sumption.
22.1.1 FUNCTION AND FEATURES OF HYDRAU-
LIC CIRCUIT
The hydraulic circuits are built up with the following
functions and features in order to achieve easy opera-
Table 22-1
Perfor-
Device Function Features
mance
• Travel straight • Travel straight at composite operation

• 2-speed travel changeover. • 2-speed changeover of travel speed.
• Auto parking brake • Automatic braking when parking
• Motor overrun protection • Secure people from danger caused by overrun-
Travel
ning of motor on the slope.

• Travel pilot operation • Slow start and stop
• Travel boost-up • Travel speed up at traveling
• 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
Easy Operability and Safety
Swing
(simultaneous operation of arm digging and slanted leveeing, swing press digging.
swing motions) • Protect it from swing drift on the slope.
• Automatic swing parking brake.
• Hydraulic pilot control system. • Delicate operability.

• Lock valve (boom / arm)
Pilot lock system • Cut out of pilot circuit by safety lock lever.
Attachment
• • Protect boom and arm from natural drop when

parking.
• Closed pressure type hydraulic oil tank • To prevent hydraulic oil from being contami-
nated and to promote self suction ability of
pump.
Others
• Suction strainer • Remove dust on suction side.

• Line filter : pilot circuit • To prevent pilot operating circuit from malfunc-
tioning
• Return circuit • To prevent hydraulic oil from fouling.
• Cooling hydraulic oil by oil cooler. • To prevent hydraulic oil from being deteriorated.
• Total power shift control variable displacement • Use engine power effectively with 2 variable
Mass handling capability
pump displacement pumps (delivery side)

Pump
• Boom raise conflux circuit • Speed up for boom raise operation.

Attachment
• Arm conflux circuit • Speed up for arm operation.

Consumption
• Auto accel • Reduce fuel consumption and noise by lowering

computer
Low Fuel
Micro
engine speed when control lever is in neutral

position.
22-3
22.2 HYDRAULIC CIRCUITS AND

COMPONENT MODELS
STANDARD SPECIFICATION SK70SR-1ES
No. NAME PART No. MODEL No.
1 PUMP ASSY (WITH GEAR PUMP) YT10V00008F1 K3SP36B-101R-1002
2 CONTROL VALVE YT30V00010F1 BCV75-A2–2
3 SWING MOTOR UNIT YT15V00001F3 SG025E-096
4 TRAVEL MOTOR YT15V00008F1 GM09VN
5 BOOM CYLINDER YT01V00017F1 110–70–916
6 ARM CYLINDER YT01V00002F1 95–65–813
7 BUCKET CYLINDER YT01V00019F1 80–55–735
8 SWIVEL JOINT 24100J12125F2
9 PILOT VALVE (ATT) PX30V00043F2 PV48M1086
10 PILOT VALVE (TRAVEL) YN30V00070F1 PVD6PC4017A
11 SOLENOID VALVE YT35V00017F1 2KWE5G-30/G12WS-249A
12 RETURN FILTER YR52V01001F2
13 CHECK VALVE 2436R576F3 Y-2389
14 SUCTION STRAINER YT50V00001F1 Y-497500
15 INLINE FILTER YN50V00007F1 YTD9986
16 AIR BREATHER 2446U260F1 Y-382000
17 CONNECTOR HH25X04004G3
18 CONNECTOR 2444Z3541
19 CHECK VALVE (SLOW RETURN) YT21V00002P1
21 HYDRAULIC VALVE ASSY YT20V00002F1
22 CHECK VALVE (SLOW RETURN) PF21V00004P1
The part numbers and serial numbers of machine may

be changed due to modification, so use only the num-
bers for reference.
22-4
22.2.1 STANDARD SPECIFICATION
Applicable machines YT04-07175~
D2 D1
1 4 3 RED
Pf P3 A1 A2
B A PG
RED
RED
Dr
A B
a1
Pz a2
15
A3 D1 P TRAVEL RIGHT TRAVEL LEFT P D2
M
250kgf/cm2 250kgf/cm2
A4 F GA C H E D B 8 (3550psi) (3550psi)
Dr1 B1 a3 36kgf/cm2 B SWING Mu A

(508psi)
16 TRAVEL RIGHT REVERSE

TRAVEL RIGHT FORWARD
RH T P T P LH
TRAVEL LEFT FORWARD

P1 P2
T1' TRAVEL LEFT REVERSE
13 T1 TRAVEL
PRIORITY
T2 300kgf/cm2
12 T2' (4260psi)
P0
DR1
14 2 TRAVEL
21 2 1 3 4
9
6 5 7 8
TRAVEL
RIGHT LEFT
Pa1 Pd1
Pb1 Pc1 B A
A1 FORWARD FORWARD D1
B1 C1
REVERSE REVERSE Pd2' SWING LEFT
19 PS'
SWING RIGHT
Pa2
BOOM SWING
Pd2 SE5
21
Pb2 Pc2 P
11 Pb2'
DR5
335kgf/cm2
(4770psi)
LEFT D2
RIGHT C2 B A
A B C D
A2 UP
DR2 22 BUCKET IN
P
SE1
B2 DOWN Ps BUCKET DUMP SE2
TRAVEL P2 TRAVEL P1 BYPASS CUT 2
P
BOOSTER BY-PASS CUT PRIORITY & ARM CONFLUX
335kgf/cm
(4770psi) ARM
Pd3
17 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm2
(4770psi) OUT
DR3
D3
6 P SE3
B3 DUMP IN C3 RH P T LH
335kgf/cm2
SWING TRAVEL LEVER 335kgf/cm2 (4770psi)
PARKING 1-2SPEED LOCK P1 (4770psi) ARM
BY PASS CUT BOOM P2
BRAKE CHANGEOVER CONFLUX BY-PASS CUT
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
SINGLE FLOW
18
NIBBLER &
BREAKER
CONFLUX
CHANGEOVER Pd5
7 P SE9 P SE10
10
32.9MPa DR7
Pa5 {336kgf/cm2}
Pb5 HEAD
A5 ROD
B5
32.9MPa {336kgf/cm2}
BUCKET
22-5
22.2.2 DOZER SPECIFICATION (OPT.)
DOZER SPEC. YT01Z00053P1

50 SE5
P No. PART NAME PART NO. MODEL NO.
Pf P3 A1 A2 HYD.PUMP ASSY YT10V00003F5 K3SP36B-101R-2002
50
GEAR PUMP YT10V00005F1 (ASSY NO. YT10V00009F1)
51 CONTROL VALVE ASSY YR30V00014F1 KVS65-1
a1
a2
52 DOZER CYLINDER YT01V00020F1 120-70-150
A5 A3
NOTE:
M THIS HYDRAULIC CIRCUIT IS USED TO ADD TO
B2 STANDARD SPECIFICATION CIRCUIT.
A4 FG
Dr1 B1 a3 36kgf/cm2
(508psi)
P1 P2
52
T1 MAIN CONTROL VALVE
DOZER
T P
200kgf/cm2
(2840psi) 51
B1 DOZER UP
DOZER DOWN
2
280kgf/cm A1
(3990psi)
22-6
22.2.3 DOZER & EXTRA SPECIFICATION (OPT.)

50 SE5
P
Pf P3 A1 A2
a1
a2
A5 A3
M
B2
A4 FG
Dr1 B1 a3
2
36kgf/cm
(508psi)
52
P1 P2
T1 MAIN CONTROL VALVE
DOZER
T P
51
2
200kgf/cm
(2840psi)
A1 DOZER DOWN
DOZER UP
2
280kgf/cm B1
(3990psi)
Pa2 Pb2
A2
TO EXTRA HYD
220kgf/cm
2
B2
(3130psi)
53
DOZER & EXTRA SPEC. YT01Z00063P1

No. PART NAME PART NO. MODEL NO. T
T
HYD.PUMP ASSY YT10V00003F5 K3SP36B-101R-2002 P
P1
50
GEAR PUMP YT10V00005F1 (ASSY NO.YT10V00009F1) B A
51 CONTROL VALVE ASSY YT30V00021F1 KVS65-2 C1 C2
LEVER P SE11
LOCK 52 DOZER CYLINDER YT01V00020F1 120-70-150
4 53 PILOT VALVE YN30V00080F1 16030-00000
NOTE:
THIS HYDRAULIC CIRCUIT IS USED TO ADD TO
STANDARD SPECIFICATION CIRCUIT.
22-7
22.2.4 BOOM & SAFETY SPECIFICATION (OPT.)
A1 A2
DOZER & ARM SEAFTY SPEC. YT01Z00041P1
No. PART NAME PART NO. MODEL NO.
50 HOLDING VALVE YR28V00001F1 A-VB50-SECCAP90-EXC12-T-35
A3 NOTE:
THIS HYDRAULIC CIRCUIT IS USED TO ADD TO
M STANDARD SPECIFICATION CIRCUIT.
P1 P2
T1
BOOM
Pa2
Pb2
Pb2'
DR5 DR2
A2 UP ARM PS
B2 DOWN Pd3
Pc3 ARM IN
Pc3'
DR3
IN D3 C2 Pi1
OUT C3 335kgf/cm
2
(4770psi)
ARM
Pi1
V2 T
50
C2 Pi1
BOOM 335kgf/cm
2
(4770psi)
Pi1
V2 T
50
BOOM DOWN
22-8
This page is blank for editing convenience.
22-9
22.3 HYDRAULIC CIRCUIT OPERATION

22.3.1 COLOR CODING STANDARD FOR HYDRAU-
LIC
Blue : Feed, drain circuit, less than 0.34 MPa (50 psi)
Green : Return, make-up circuit, 0.34~ 0.59 MPa (50~85 psi)
Purple : Secondary pilot pressure, 0.59~3.5 MPa(85~508 psi)
Red : Primary pilot pressure, 3.5~4.9 MPa (508~ 710 psi)
Orange : Main pump drive pressure, 4.9~29.4 MPa (710~4270 psi)
Blue tone : At valve selection
Red valve : When proportional valve (reducing) is operating
Red solenoid : In active and exciting
Displaying the flow circuit and standby circuit when operating.
Regarding the electrical symbols in this manual, refer to the electric circuit diagram.
22.3.2 NEUTRAL CIRCUIT

This section describes the following.
22.3.2.1 SAFETY LOCK LEVER AND PILOT CIR-

CUIT
(1) Purpose
To protect attachment from unexpected operation for
safety, however, dozer is outside of adaptation.
(2) Principle
Cut pressure source of pilot valve for operation.
(3) Operation
After engine starts, push down the safety lock lever
(red), and the limit switch (SW-11) is turned on, the pi-
lot operation circuit is changed to standby condition.
22.3.2.2 PUMP CONTROL

(1) Type
Total power shift control variable displacement pump
(2) Operation
1) Since the pump delivery flow rate is unloaded
when in neutral position, the pump delivery pres-
sure (P1, P2) is low, and the average pressure
(P1+P2) / 2 on compensating piston (621) step-
ping section becomes small. Consequently the
force of spring (625, 626) becomes higher than
the average pressure, and the spool (652) is
moved rightward. And the passage to large bore
of servo piston (532) is connected with low pres-
sure side and moves leftward, then tilting angle
becomes larger, and pump delivery flow rate in-
creases.
2) Lever (611) rotates at a fulcrum of pin, and moves
with this operation, the feedback sleeve (651)
rightward, then keep moving until the openings of
spool (652) and sleeve (651) are closed.
22-10
COMPENSATING
PISTON(621)
D2 D1
1 4 3 RED
SPOOL
(652) Pf P3 A1 A2
B A PG
RED
SPRING
RED
(626) Dr
A B
a1
Pz a2
611
15
PISTON
(668)
M
SLEEVE 250kgf/cm2 250kgf/cm2
(651)
SPRING
SERVO
PISTON
(625) Dr1 B1 a3 36kgf/cm 2 B SWING Mu A

(532)
(508psi)

RH T P T P LH
TRAVEL LEFT FORWARD

P1 P2
13 T1 TRAVEL
PRIORITY
T2
12
2
300kgf/cm P0
T2' (4260psi)
DR1
14 2 TRAVEL
21 2 1 3 4
9
6 5 7 8
TRAVEL
RIGHT LEFT
Pa1 Pd1
Pb1 Pc1 B A
B1 C1
19 PS'
SWING RIGHT
Pa2
BOOM SWING
Pd2 SE5 21
Pb2 Pc2 P
2
11 Pb2'
DR5
335kgf/cm
(4770psi)
LEFT D2
RIGHT C2 B A
A B C D
A2 UP
DR2 22 BUCKET IN
P
SE1
B2 DOWN Ps BUCKET DUMP SE2
P
335kgf/cm
(4770psi) ARM
Pd3
17 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm
2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm
(4770psi)
2
OUT
DR3
D3
6 P SE3
335kgf/cm2
SWING TRAVEL LEVER 335kgf/cm
2 (4770psi)
BY PASS CUT BOOM P2
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
SINGLE FLOW
18
NIBBLER &
BREAKER
CONFLUX
CHANGEOVER Pd5
7 P SE9 P SE10
10
32.9MPa DR7
Pa5 {336kgf/cm2}
Pb5 HEAD
A5 ROD
B5
BUCKET
Neutral circuit safety lock lever ON 22-11

22.3.3 TRAVEL CIRCUIT 22.3.3.3 TRAVEL MAIN CIRCUIT

This section describes the following. (1) Operation
With travel pilot operation, the travel speed is
22.3.3.1 TRAVEL FORWARD PILOT SIMULTA-
switched, and the oil delivered through A1 port of
NEOUS OPERATION CIRCUIT
main pump passes through C/V P1-A1, flows into A
(1) Purpose port of travel motor (4) through C port of swivel joint
Soft operability (8) allowing travel motor to perform the operation
(2) Operation above mentioned. (Refer to "Travel Motor Func-
1) Start travel right and left at the same time with tion")
control lever, and the pilot proportional second-
22.3.3.4 TRAVEL MOTOR FUNCTION
ary pressure is delivered through P/V (10) 2, 4
(1) Function
ports, at the same time select higher pressure
and the higher pressure is delivered through 5, 1) Secure people from danger caused by overrun-
6 ports, then acts on low pressure sensors ning of motor on downhill slope.
(SE9) (SE10). 2) Hydraulic motor cavitation protective check
2) Pilot proportional secondary pressure flows into valve
Pd1, Pa1 ports of control valve, acts on travel 3) Shockless relief valve and anticavitation valve
spool, and switches main circuit. when stopping it with the force of inertia.
3) The signal output by low pressure sensor is in- 4) High and low speed 2 stage switching mecha-
put to mechatro controller, and executes signal nism
processing. 5) Travel parking brake
4) If the pressure of either low-pressure sensor
(SE-9) or low-pressure sensor (SE-10) ex-
ceeds the specified pressure, travel booster so-
lenoid is switched. Consequently, the pressure
is applied to pump PZ port; spring (625) is com-
pressed with piston (668), then the setting val-
ue of pump power control is increased.
22.3.3.2 TRAVEL 2 SPEED SOLENOID COM-

MAND CIRCUIT
(1) Purpose
Change travel motor speed with switch.
(2) Principle
Electric signal because of switching excites travel 2
speed solenoid and pilot primary pressure varies
swash plate angle of variable motor.
(3) Operation
Press switches with rabbit and turtle marks on trav-
el lever grips, and the solenoid (SV-3) of proportion-
al valve block (11) is excited and is switched, and
solenoid command is output by port 3 and sends to
P port of travel motor (4), opens oil passage to 2
speed piston, and switches it to 2 speed tilting an-
gle with self-pressure.
22-12
D2 D1
1 4 3 RED
Pf P3 A1 A2
B A PG
RED
RED
Dr
A B
a1
Pz a2
15
PISTON
(668)
M
SPRING A4 F GA C H E D B 8 (3550psi) (3550psi)
(625) Dr1 B1 a3 36kgf/cm2 B SWING Mu A

(508psi)

RH T P T P LH
TRAVEL LEFT FORWARD

P1 P2
13 T1 TRAVEL
PRIORITY
T2
12
2
300kgf/cm P0
T2' (4260psi)
DR1
14 2 TRAVEL
21 2 1 3 4
9
6 5 7 8
TRAVEL
RIGHT LEFT
Pa1 Pd1
Pb1 Pc1 B A
B1 C1
19 PS'
SWING RIGHT
Pa2
BOOM SWING
Pd2 SE5 21
Pb2 Pc2 P
2
11 Pb2'
DR5
335kgf/cm
(4770psi)
LEFT D2
RIGHT C2 B A
A B C D
A2 UP
B2 DOWN
DR2 22 BUCKET IN
P
SE1
Ps BUCKET DUMP SE2
P
335kgf/cm
(4770psi) ARM
Pd3
17 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm
2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm
(4770psi)
2
OUT
DR3
D3
6 P SE3
335kgf/cm2
2 (4770psi)
BY PASS CUT BOOM P2
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
SINGLE FLOW
18
NIBBLER &
BREAKER
CONFLUX
CHANGEOVER Pd5
7 P SE9 P SE10
10
32.9MPa DR7
Pa5 {336kgf/cm2}
Pb5 HEAD
A5 ROD
B5
BUCKET
Travel circuit : Travel 2nd speed operation 22-13

22.3.4 BUCKET CIRCUIT 22.3.4.4 BUCKET DIGGING MAIN CIRCUIT

This section describes the following. (1) Operation
With pilot operation, the pressure oil switches buck-
22.3.4.1 BUCKET DIGGING PILOT CIRCUIT
et spool, and is fed into bucket cylinder H side
(1) Operation through C/V A3 port. And the return oil from cylinder
Start bucket digging operation, and pilot proportion- R side flows into tank circuit while being restricted
al secondary pressure is output through port (1) of by bucket spool through C/V (2) B3 port.
right pilot V (9), and flows into C/V (2) Pa3 port, and
switches bucket spool.
22.3.4.2 AUTO ACCEL OPERATION

(1) Principle
Start operating with signal output by low pressure
sensor.
(2) Operation
[Lever in neutral position]
When the signal is not input to low pressure sensor
for 4 seconds or more after turning accel dial to
Max. position, set engine speed to 1050 rpm.
[Lever in operation position]
When the pressure of 0.59 MPa (86 psi) or more is
input to low pressure sensor in STD specification
(travel, bucket, boom, swing and arm), the propor-
tional voltage received from low pressure sensor is
output to C1 controller, and restores the E/G speed
to the speed set by accel dial with control lever op-
eration.
22.3.4.3 E/G OVERLOAD PROTECTION WITH

PUMP POWER CONTROL OPERATION
(1) Principle
Total power shift control with pump pressure
(P1+P2)/2
(2) Operation
1) With increase of pump delivery pressure P1 or
P2, (P1+P2)/2 pressure acts on compensating
piston (621) stepping section by the function of
restriction.
2) With bucket operation, the delivery pressure is
raised and pushes spool (652) leftward, and
moves it to the position where the force of
springs (625, 626) balances the hydraulic pres-
sure.
3) With movement of spool (652) leftward, the oil
passage to large bore of servo piston (532)
opens, and delivery pressure is led into it and
pushes the piston rightward.
4) Then, the tilting angle becomes smaller and re-
duces the delivery flow rate from the pump
used to protect engine from overloading.
22-14
COMPENSATING
PISTON(621)
D2 D1
1 4 3 RED
SPOOL
(652) Pf P3 A1 A2
B A PG
RED
RED
SPRING
(626) Dr
A B
a1
Pz a2
611
15
PISTON
(668)
M
SLEEVE 250kgf/cm2 250kgf/cm2
(651)
SPRING
SERVO
PISTON
(625) Dr1 B1 a3 36kgf/cm 2 B SWING Mu A

(532)
(508psi)

RH T P T P LH
TRAVEL LEFT FORWARD

P1 P2
13 T1 TRAVEL
PRIORITY
T2
12
2
300kgf/cm P0
T2' (4260psi)
DR1
14 2 TRAVEL
21 2 1 3 4
9
6 5 7 8
TRAVEL
RIGHT LEFT
Pa1 Pd1
Pb1 Pc1 B A
B1 C1
19 PS'
SWING RIGHT
Pa2
BOOM SWING
Pd2 SE5 21
Pb2 Pc2 P
2
11 Pb2'
DR5
335kgf/cm
(4770psi)
LEFT D2
RIGHT C2 B A
A B C D
A2 UP
B2 DOWN
DR2 22 BUCKET IN
P
SE1
Ps BUCKET DUMP SE2
P
335kgf/cm
(4770psi) ARM
Pd3
17 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm
2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm
(4770psi)
2
OUT
DR3
D3
6 P SE3
335kgf/cm2
2 (4770psi)
BY PASS CUT BOOM P2
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
SINGLE FLOW
18
NIBBLER &
BREAKER
CONFLUX
CHANGEOVER Pd5
7 P SE9 P SE10
10
32.9MPa DR7
Pa5 {336kgf/cm2}
Pb5 HEAD
A5 ROD
B5
BUCKET
Bucket circuit : Bucket digging operation 22-15

22.3.5 BOOM CIRCUIT

This section describes the boom raise conflux opera-
tion.
22.3.5.1 BOOM RAISE PILOT CIRCUIT

(1) Operation
1) Start boom raise operation, and pilot propor-
tional secondary pressure from right pilot valve
(9) is output through port (3), and acts on low
pressure sensor (SE3), and at the same time
the pressure is branched into 2 circuits and acts
on Pa2 and Pc4 port of C/V (2).
2) The voltage output by low pressure sensor is
processed by mechatro controller and outputs
command current to P2 by-pass cut valve
(PSV-B) and solenoid valve outputs proportion-
al secondary pressure and the pressure acts on
C/V (2) Pd4 port.
3) Then, the secondary pressure fed into C/V (2)
Pa2 port switches boom conflux spool. And the
solenoid proportional secondary pressure fed
into Pd4 port switches P2 by-pass cut valve.
22.3.5.2 BOOM RAISE 2 PUMPS CONFLUX

MAIN CIRCUIT IN C/V
(1) Purpose
Boom raise 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 by-
pass circuit and parallel circuit. However since
the boom spool is moved and by-pass circuit is
closed, the oil opens load check valve through
parallel circuit and flows into boom spool.
2) On the other hand, the oil delivered through A2
port of P2 pump passes through C/V (2) P2
port, flows into travel straight section, and
branches into by-pass circuit and parallel cir-
cuit. However, since P2 by-pass cut valve is
switched and closed, the oil passes through the
outside of boom conflux spool from parallel cir-
cuit, opens load check valve from boom conflux
circuit, confluxes with oil delivered by P1 pump
inside, and flows into boom spool.
3) Then the oil passes through boom spool, opens
lock valve of boom lock valve, and is led into H
side of boom cylinder through C/V (2) A2 port.
4) The return oil from boom cylinder R side flows
into tank circuit through boom spool from C/V
(2) B2 port.
22-16
D2 D1
1 4 3 RED
Pf P3 A1 A2
B A PG
RED
RED
Dr
A B
a1
Pz a2
15
M

(508psi)

RH T P T P LH
TRAVEL LEFT FORWARD

P1 P2
13 T1 TRAVEL
PRIORITY
T2
12
2
300kgf/cm P0
T2' (4260psi)
DR1
14 2 TRAVEL
21 2 1 3 4
9
6 5 7 8
TRAVEL
RIGHT LEFT
Pa1 Pd1
Pb1 Pc1 B A
B1 C1
19 PS'
SWING RIGHT
Pa2
BOOM SWING
Pd2 SE5 21
Pb2 Pc2 P
2
11 Pb2'
DR5
335kgf/cm
(4770psi)
LEFT D2
RIGHT C2 B A
A B C D
A2 UP
B2 DOWN
DR2 22 BUCKET IN
P
SE1
Ps BUCKET DUMP SE2
P
335kgf/cm
(4770psi) ARM
Pd3
17 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm
2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm
(4770psi)
2
OUT
DR3
D3
6 P SE3
335kgf/cm2
2 (4770psi)
BY PASS CUT BOOM P2
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
SINGLE FLOW
18
NIBBLER &
BREAKER
CONFLUX
CHANGEOVER Pd5
7 P SE9 P SE10
10
32.9MPa DR7
Pa5 {336kgf/cm2}
Pb5 HEAD
A5 ROD
B5
BUCKET
Boom circuit : Boom raise (up) operation, conflux function 22-17

This section describes the boom lower operation. valve is pushed back by the force of spring, and
the back pressure of lock valve becomes equal
22.3.5.3 BOOM LOWER PILOT CIRCUIT
to the return pressure.
(1) Operation
2) The area on back pressure side of lock valve is
1) Start boom lower operation, and the pilot pro- larger, the lock valve is completely seated, and
portional secondary pressure is output through the oil in boom cylinder H side is stopped from
port (4) of pilot valve, and acts on low pressure returning, protecting the boom from natural
sensor (SE4), at the same time branches into drop.
two circuits, then acts on C/V (2) Pb2 and Pb2'
port.
2) The voltage output by low pressure sensor
(SE4) is input into mechatro controller.
3) Then, the proportional secondary pressure fed
into C/V (2) Pb2 port switches boom spool. And
the proportional secondary pressure flown into
C/V (2) Pb2' port releases boom lock valve.
22.3.5.4 BOOM LOWER MAIN CIRCUIT

(1) Operation
1) The oil delivered through A1 port of P1 pump
passes through C/V (2) P1 port and flows into
travel straight section, and branches into by-
pass circuit and parallel circuit. However since
the boom spool is moved and by-pass circuit is
closed, the oil opens load check valve through
parallel circuit and flows into boom spool.
2) The oil passes through outside of boom spool,
and flows into boom cylinder R side through C/
V (2) B2 port.
3) On the other hand, the return oil boom cylinder
H side flows into C/V (2) A2 port, but since the
boom lock valve is open, it flows into boom
spool.
4) Then the oil passes through orifices on boom
spool and returns into tank while restricting.
22.3.5.5 NATURAL DROP PROTECTION WITH

BOOM LOCK VALVE
(1) Operation
[When boom lower secondary pressure is actuated]
1) The control secondary pressure flown into relief
port Pb2' of boom lock valve pushes needle
valve on the rear side of the lock valve seat,
and the back pressure of lock valve flows into
tank circuit through port DR5 making the open-
ing of valve easier.
2) The return oil from boom cylinder R side opens
lock valve, and flows into boom spool.
[When boom lower secondary pressure is not actu-
ated]
1) Where the pilot pressure in boom lock valve re-
lief port Pb2' is not actuated, the above needle
22-18
D2 D1
1 4 3 RED
Pf P3 A1 A2
B A PG
RED
RED
Dr
A B
a1
Pz a2
15
M

(508psi)

RH T P T P LH
TRAVEL LEFT FORWARD

P1 P2
13 T1 TRAVEL
PRIORITY
T2
12
2
300kgf/cm P0
T2' (4260psi)
DR1
14 2 TRAVEL
21 2 1 3 4
9
6 5 7 8
TRAVEL
RIGHT LEFT
Pa1 Pd1
Pb1 Pc1 B A
B1 C1
19 PS'
SWING RIGHT
Pa2
BOOM SWING
Pd2 SE5 21
Pb2 Pc2 P
2
11 Pb2'
DR5
335kgf/cm
(4770psi)
LEFT D2
RIGHT C2 B A
A B C D
A2 UP
B2 DOWN
DR2 22 BUCKET IN
P
SE1
Ps BUCKET DUMP SE2
P
335kgf/cm
(4770psi) ARM
Pd3
17 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm
2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm
(4770psi)
2
OUT
DR3
D3
6 P SE3
335kgf/cm2
2 (4770psi)
BY PASS CUT BOOM P2
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
SINGLE FLOW
18
NIBBLER &
BREAKER
CONFLUX
CHANGEOVER Pd5
7 P SE9 P SE10
10
32.9MPa DR7
Pa5 {336kgf/cm2}
Pb5 HEAD
A5 ROD
B5
BUCKET
Boom circuit : Boom lower (down) operation 22-19

22.3.6 SWING CIRCUIT 22.3.6.3 SWING MAIN CIRCUIT

This section describes the following operations. (1) Operation
The oil delivered through A2 port of P2 pump pass-
22.3.6.1 SWING LEFT PILOT CIRCUIT
es through C/V (2) P2 port and flows into travel
(1) Operation straight section, and branches into by-pass circuit
1) Start swing left operation, and pilot proportional and parallel circuit. However since the swing spool
secondary pressure through port (5) of left pilot is moved and by-pass circuit is closed, the oil opens
valve (9) is output, and acts on low pressure load check valve through parallel circuit and flows
sensor (SE5), and at the same time the pres- into B port of swing motor through C/V (2) D2 port,
sure is branched into 2 circuits and acts on Pd2 and has swing motor rotated in counterclockwise.
and Pd2’ ports of C/V (2).
2) The voltage output by low pressure sensor is
processed by mechatro controller and outputs
command current to P2 by-pass cut valve
(PSV-B) and solenoid valve outputs proportion-
C/V (2) Pd4 port.
Pd2 port switches swing spool. And the sec-
ondary pressure fed into Pd2' port flows into
PS' port through check ball, then into Ps port,
and acts on load check valve for arm operation.
In addition, the solenoid proportional secondary
pressure switches P2 by-pass cut valve.
22.3.6.2 SWING AUTO PARKING BRAKE

(1) Purpose
Swing lock and parking in neutral position
(2) Principle
Release only when required to operate mechanical
brake.
(3) Operation
1) Swing parking release SW-4 excites swing
parking SOL (SV-1) by-turning switch on.
2) Only when operation secondary pressure dur-
ing swing and arm digging operation acts on
any of low pressure sensor (SE5, 6, 7), it re-
lease the excitation to swing parking SOL.
3) After 5 seconds when the pressure of low pres-
sure sensor (SE5, 6) from swing operation has
exhausted, the swing parking SOL (SV-1) is ex-
cited. And in case of arm in operation, at the
same time when the pressure of pressure sen-
sor (SE7) for arm in operation has been ex-
hausted, the swing parking SOL (SV-1) is
excited.
22-20
D2 D1
1 4 3 RED
Pf P3 A1 A2
B A PG
RED
RED
Dr
A B
a1
Pz a2
15
M

(508psi)

RH T P T P LH
TRAVEL LEFT FORWARD

P1 P2
13 T1 TRAVEL
PRIORITY
T2
12
2
300kgf/cm P0
T2' (4260psi)
DR1
14 2 TRAVEL
21 2 1 3 4
9
6 5 7 8
TRAVEL
RIGHT LEFT
Pa1 Pd1
Pb1 Pc1 B A
B1 C1
19 PS'
SWING RIGHT
Pa2
BOOM SWING
Pd2 SE5 21
Pb2 Pc2 P
2
11 Pb2'
DR5
335kgf/cm
(4770psi)
LEFT D2
RIGHT C2 B A
A B C D
A2 UP
B2 DOWN
DR2 22 BUCKET IN
P
SE1
Ps BUCKET DUMP SE2
P
335kgf/cm
(4770psi) ARM
Pd3
17 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm
2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm
(4770psi)
2
OUT
DR3
D3
6 P SE3
335kgf/cm2
2 (4770psi)
BY PASS CUT BOOM P2
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
SINGLE FLOW
18
NIBBLER &
BREAKER
CONFLUX
CHANGEOVER Pd5
7 P SE9 P SE10
10
32.9MPa DR7
Pa5 {336kgf/cm2}
Pb5 HEAD
A5 ROD
B5
BUCKET
Swing circuit : Swing operation (Left) 22-21

22.3.7 ARM CIRCUIT but since the arm lock valve is open, it flows into
This section describes the following operations. arm spool.
5) Then, the oil passes through orifices on arm
22.3.7.1 ARM CONTROL PILOT CIRCUIT
spool and returns into tank while restricting.
(1) Operation
1) Start arm in operation, and pilot proportional
secondary pressure is output through port (7) of
left pilot valve (9), and acts on low pressure
sensor (SE7), and at the same time the pres-
sure branches into 2 circuits and acts on Pc3
and Pc3' ports of C/V (2).
(SE7) is input into mechatro controller and the
controller executes signal processing, and out-
puts command current to P1 by-pass cut valve
(PSV-D) and solenoid valve outputs proportion-
C/V (2) Pb4 port.
Pc3 port switches arm conflux spool. And the
solenoid proportional secondary pressure fed
into Pc3' port releases arm lock valve. In addi-
tion, solenoid proportional secondary pressure
switches P1 by-pass cut valve.
22.3.7.2 ARM IN 2 PUMPS CONFLUX MAIN CIR-

CUIT
(1) Purpose
Arm in speed up
(2) Principle
Confluxing oil from 2 pumps in C/V (2)
(3) Operation
1) The oil delivered by P2 pump flows into travel
straight section through C/V (2) P2 port, and
branches into by-pass circuit and parallel cir-
cuit.
However since the arm spool is moved and by-
pass circuit is closed, the oil opens load check
valve and flows into arm spool.
2) On the other hand, the oil delivered by P1 pump
passes through C/V (2) P1 port and flows into
travel straight section, and branches into by-
pass circuit and parallel circuit.
However, since P1 by-pass cut valve is
switched and low pressure circuit is closed, the
oil opens load check valve and confluxes with
oil delivered from load check valve on P2 paral-
lel circuit, and flows into arm spool.
3) Then, the confluxed oil is fed into arm cylinder
H side through C/V (2) C3 port from arm spool.
4) In addition, the return oil from arm cylinder R
side flows into arm lock valve through D3 port,
22-22
D2 D1
1 4 3 RED
Pf P3 A1 A2
B A PG
RED
RED
Dr
A B
a1
Pz a2
15
M

(508psi)

RH T P T P LH
TRAVEL LEFT FORWARD

P1 P2
13 T1 TRAVEL
PRIORITY
T2
12
2
300kgf/cm P0
T2' (4260psi)
DR1
14 2 TRAVEL
21 2 1 3 4
9
6 5 7 8
TRAVEL
RIGHT LEFT
Pa1 Pd1
Pb1 Pc1 B A
B1 C1
19 PS'
SWING RIGHT
Pa2
BOOM SWING
Pd2 SE5 21
Pb2 Pc2 P
2
11 Pb2'
DR5
335kgf/cm
(4770psi)
LEFT D2
RIGHT C2 B A
A B C D
A2 UP
B2 DOWN
DR2 22 BUCKET IN
P
SE1
Ps BUCKET DUMP SE2
P
335kgf/cm
(4770psi) ARM
Pd3
17 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm
2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm
(4770psi)
2
OUT
DR3
D3
6 P SE3
335kgf/cm2
2 (4770psi)
BY PASS CUT BOOM P2
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
SINGLE FLOW
18
NIBBLER &
BREAKER
CONFLUX
CHANGEOVER Pd5
7 P SE9 P SE10
10
32.9MPa DR7
Pa5 {336kgf/cm2}
Pb5 HEAD
A5 ROD
B5
BUCKET
Arm circuit : Arm in (digging) operation, conflux function 22-23

This section describes the following operations. 2) The area on back pressure side of lock valve is
larger, the lock valve is completely seated, and
22.3.7.3 ARM OUT PILOT CIRCUIT
the oil in arm cylinder R side is stopped from re-
(1) Operation turning to arm spool, protecting the arm from
1) Start arm out operation, and the pilot propor- natural drop.
tional secondary pressure is output through
port (8) of left pilot valve (9), and acts on low
pressure sensor (SE8), at the same time acts
on C/V (2) Pd3 port.
(SE8) is processed by mechatro controller, and
outputs command current to P1 cut valve (PSV-
D), and the solenoid valve outputs secondary
pressure and acts on C/V Pb4 port.
into C/V (2) Pd3 port switches arm spool. And
the proportional secondary pressure flown into
Pb4 port switches P1 by-pass cut valve.
22.3.7.4 ARM OUT 2 PUMPS CONFLUX MAIN

CIRCUIT
(1) Purpose
Arm out operation speed up
(2) Operation
1) The oil delivered by P1 and P2 pumps flows in
the same way until the oil reaches to arm spool.
2) Then, the oil passes through arm spool opens
arm lock valve with free flow and flows into arm
cylinder R side through C/V (2) D3 port.
3) And, the return oil from arm cylinder H side
flows into C3 port, passes through periphery on
arm spool, and returns into tank circuit.
22.3.7.5 NATURAL DROP PROTECTION WITH

ARM LOCK VALVE
(1) Operation
[When arm out operation pressure is actuated]
1) The control secondary pressure flown into relief
port Pc3' of arm lock valve pushes needle valve
on the rear side of lock valve seat, and the back
pressure of lock valve flows into tank circuit
through drain port DR3 making the opening of
valve easier.
2) The return oil from arm cylinder R side opens
lock valve, and flows into arm spool.
[When arm out operation pressure is not actuated]
1) Where the pilot pressure in arm lock valve relief
port Pc3' is not actuated, the above needle
valve is pushed back by the force of spring, and
the pressure of lock valve becomes equal to the
return pressure due to back pressure of lock
valve.
22-24
D2 D1
1 4 3 RED
Pf P3 A1 A2
B A PG
RED
RED
Dr
A B
a1
Pz a2
15
M

(508psi)

RH T P T P LH
TRAVEL LEFT FORWARD

P1 P2
13 T1 TRAVEL
PRIORITY
T2
12
2
300kgf/cm P0
T2' (4260psi)
DR1
14 2 TRAVEL
21 2 1 3 4
9
6 5 7 8
TRAVEL
RIGHT LEFT
Pa1 Pd1
Pb1 Pc1 B A
B1 C1
19 PS'
SWING RIGHT
Pa2
BOOM SWING
Pd2 SE5 21
Pb2 Pc2 P
2
11 Pb2'
DR5
335kgf/cm
(4770psi)
LEFT D2
RIGHT C2 B A
A B C D
A2 UP
B2 DOWN
DR2 22 BUCKET IN
P
SE1
Ps BUCKET DUMP SE2
P
335kgf/cm
(4770psi) ARM
Pd3
17 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm
2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm
(4770psi)
2
OUT
DR3
D3
6 P SE3
335kgf/cm2
2 (4770psi)
BY PASS CUT BOOM P2
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
SINGLE FLOW
18
NIBBLER &
BREAKER
CONFLUX
CHANGEOVER Pd5
7 P SE9 P SE10
10
32.9MPa DR7
Pa5 {336kgf/cm2}
Pb5 HEAD
A5 ROD
B5
BUCKET
Arm circuit : Arm out (extend) operation, conflux function 22-25

22.3.8 COMBINED CIRCUIT (MULTIPLE CIRCUIT)

This section describes only the difference in combined
operation.
22.3.8.1 BOOM RAISE/TRAVEL, PILOT CIRCUIT

(1) Operation
[ Points which are differed from the independent op-
eration ]
1) With signal processing of mechatro controller,
the controller outputs command current to trav-
el straight valve (PSV-C) and P2 by-pass cut
valve (PSV-B) and P1 by-pass cut valve (PSV-
D), and this solenoid valve outputs secondary
pressure, then acts on C/V (2) Po, Pd4 and Pb4
ports.
into C/V (2) PO port switches travel straight
valve. The Pd4 port pressure switches P2 by-
pass cut valve. And the Pb4 port pressure
switches P1 by-pass cut valve.
22.3.8.2 BOOM RAISE/TRAVEL, MAIN CIRCUIT

(1) Purpose
Travel straight operation is available even if the at-
tachment is operated during travel operation.
(2) Principle
The travel motion and attachment operations are
performed by respective pump.
(3) Operation
1) The oil delivered by P1 and P2 pumps flows into
travel straight section through C/V (2) P1, P2
ports. The travel straight spool is moved and
the oil delivered by P1 pump branches into P1
and P2 parallel circuits. In addition, the oil deliv-
ered by P2 pump branches into P1 and P2 by-
pass circuits.
2) And, both travel operations are performed by
by-pass circuit, that is performed by the oil de-
livered by P2 pump.
Since boom spool and other spool are operated
through parallel circuit, so oil delivered by P1
pump is available.
3) However, a part of flow is connected through or-
ifice of travel straight spool and the travel and
boom (ATT) speeds are regulated by connec-
tion to this orifice.
22-26
D2 D1
1 4 3 RED
Pf P3 A1 A2
B A PG
RED
RED
Dr
A B
a1
Pz a2
15
M

(508psi)

RH T P T P LH
TRAVEL LEFT FORWARD

P1 P2
13 T1 TRAVEL
PRIORITY
T2
12
2
300kgf/cm P0
T2' (4260psi)
DR1
14 2 TRAVEL
21 2 1 3 4
9
6 5 7 8
TRAVEL
RIGHT LEFT
Pa1 Pd1
Pb1 Pc1 B A
B1 C1
19 PS'
SWING RIGHT
Pa2
BOOM SWING
Pd2 SE5 21
Pb2 Pc2 P
2
11 Pb2'
DR5
335kgf/cm
(4770psi)
LEFT D2
RIGHT C2 B A
A B C D
A2 UP
B2 DOWN
DR2 22 BUCKET IN
P
SE1
Ps BUCKET DUMP SE2
P
335kgf/cm
(4770psi) ARM
Pd3
17 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm
2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm
(4770psi)
2
OUT
DR3
D3
6 P SE3
335kgf/cm2
2 (4770psi)
BY PASS CUT BOOM P2
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
SINGLE FLOW
18
NIBBLER &
BREAKER
CONFLUX
CHANGEOVER Pd5
7 P SE9 P SE10
10
32.9MPa DR7
Pa5 {336kgf/cm2}
Pb5 HEAD
A5 ROD
B5
BUCKET
Combined (conflux) operation : Boom raise (up) / Travel simultaneous operation in Travel straight function 22-27
This section describes difference in combined opera-

tion.
22.3.8.3 SWING/ARM IN, PILOT CIRCUIT

(1) Operation
1) Start swing left and arm in operation simulta-
neously, and with signal processing of mecha-
tro controller, the mechatro controller outputs
command to P2 by-pass cut valve (PSV-B) and
P1 by-pass cut valve (PSV-D), and this sole-
noid valve outputs secondary pressure and
acts on C/V (2) Pd4 and Pb4 ports. (These op-
erations are the same as that of the combined
respective independent operation.)
2) Then, the higher pilot proportional secondary
pressure selected in swing control side flows
into C/V (2) Ps port, acts on load check valve for
arm operation, and makes it less capable to the
oil flowing into arm spool.
22.3.8.4 SWING/ARM IN, SWING PRIORITY

MAIN CIRCUIT
(1) Purpose
Stable swing speed
(2) Principle
Control the oil flow rate to arm cylinder, and give a
priority of the delivery of P2 pump to swing opera-
tion.
(3) Operation
1) The swing main circuit functions with the deliv-
ery of P2 pump, but in P2 pump circuit the
swing and arm circuits are in parallel, therefore
the oil flows into swing and arm sides at the
same time.
However, in swing operation, the selected high-
er swing pilot proportional secondary pressure
limits the opening of load check valve on arm
side, allowing to stop confluxing with oil by P2
side. Therefore, the oil delivered by P2 pump
flows into swing side prior to arm side.
This is called "Swing Priority Circuit".
2) Arm in circuit functions with only P1 pump cir-
cuit, but only when the pressure rises higher
than the pressure specified for arm in load
check valve the oil delivered by P1 and P2
pumps are confluxed.
22-28
D2 D1
1 4 3 RED
Pf P3 A1 A2
B A PG
RED
RED
Dr
A B
a1
Pz a2
15
M

(508psi)

RH T P T P LH
TRAVEL LEFT FORWARD

P1 P2
13 T1 TRAVEL
PRIORITY
T2
12
2
300kgf/cm P0
T2' (4260psi)
DR1
14 2 TRAVEL
21 2 1 3 4
9
6 5 7 8
TRAVEL
RIGHT LEFT
Pa1 Pd1
Pb1 Pc1 B A
B1 C1
19 PS'
SWING RIGHT
Pa2
BOOM SWING
Pd2 SE5 21
Pb2 Pc2 P
2
11 Pb2'
DR5
335kgf/cm
(4770psi)
LEFT D2
RIGHT C2 B A
A B C D
A2 UP
B2 DOWN
DR2 22 BUCKET IN
P
SE1
Ps BUCKET DUMP SE2
P
335kgf/cm
(4770psi) ARM
Pd3
17 ARM OUT SE8
BUCKET P
Pc3 ARM IN SE7
Pa3 P
T 335kgf/cm
2 Pc3' BOOM DOWN
Pb3 P SE4
(4770psi) BOOM UP
P1
A3 DIGGING
335kgf/cm
(4770psi)
2
OUT
DR3
D3
6 P SE3
335kgf/cm2
2 (4770psi)
BY PASS CUT BOOM P2
1 3 4 DR6
& ARM CONFLUX
Pd4 5
Pc4
Pb4 DR4
BOOM
2 5 1 4 6 3
SINGLE FLOW
18
NIBBLER &
BREAKER
CONFLUX
CHANGEOVER Pd5
7 P SE9 P SE10
10
32.9MPa DR7
Pa5 {336kgf/cm2}
Pb5 HEAD
A5 ROD
B5
BUCKET
Conflux operation : Swing / Arm in (digging) operation, in swing priority function 22-29
22.3.9 PILOT PIPING
No. PARTS Q'ty PEMARKS No. PARTS Q'ty PEMARKS No. PARTS Q'ty PEMARKS No. PARTS Q'ty PEMARKS
(1) YT06H00015F1 PUMP CONTROL (STD) (5) YT68H00044F2 REMOTE CONTROL LINES 23 CHECK VALVE (SLOW RETURN) 1 1 YT21V00002P1 8 CAPSCREW 2 M10 X 25
(2) YT06H00015F2 PUMP CONTROL (DOZER) 1 HOSE : L=2050 1 PRIMARY PRESSURE OF LEFT P/V 24 PRESSURE SENSOR 4 4 LC52S00011P1 9 CAPSCREW 2 M8 X 25
1 INLINE FILTER 1 1 YN50V00007F1 2 HOSE : L=1900 1 DRAIN 26 CONNECTOR 1 1 PF 1/4 RESTRICTION Ø 0.8 10 WASHER 2 M10
2 CONNECTOR 1 1 PF 3/8 3 HOSE : L=1450 1 PRIMARY PRESSURE OF RIGHT P/V 27 CONNECTOR 1 1 RESTRICTION Ø 0.6 WITH FILTER 11 WASHER 2 M8
3 ELBOW 3 3 PF 3/8 4 HOSE : L=1400 1 DRAIN 28 TEE 1 2 PF 3/8 - PF 1/4 12 ELBOW 1 PF 1/4
4 PLUG 1 1 PF 1/4 5 HOSE : L=3450 (RED) 1 SECONDARY PRESSURE 29 HOSE : L=900 2 2 DRAIN 13 CONNECTOR 1 PF 1/4 L=25
FOR SWING RIGHT
5 ELBOW 1 1 PF 3/8 6 HOSE : L=3450 (BLUE) 1 SECONDARY PRESSURE 31 HOSE : L=1500 — 1 DRAIN 14 HYD.VALVE ASSY 1 YT20V00002F1
FOR ARM IN
6 TEE 1 1 PF 3/8 7 HOSE : L=3800 (GREEN) 1 SECONDARY PRESSURE 34 CONNECTOR 3 3 PF 1/4 WITH FILTER 15 ELBOW 1 PF1/4 WITH FILTER
FOR ARM OUT
7 TEE 1 1 2 - PF 3/8 - PF 1/4 8 HOSE : L=3600 (GRAY) 1 SECONDARY PRESSURE 35 CHECK VALVE 1 1 PF21V00004P1 16 CONNECTOR 1 PF1/4 WITH FILTER
FOR SWING LEFT
8 CAPSCREW 2 2 M10 X 20 9 HOSE : L=3200 (RED) 1 SECONDARY PRESSURE 36 CONNECTOR 1 1 PF 1/4 17 PLUG 1 PF 1/4
FOR BUCKET DIGGING
9 WASHER 2 2 M10 10 HOSE : L=2800 (BLUE) 1 SECONDARY PRESSURE 37 ELBOW 1 1 PF 1/4
FOR BUCKET DUMP
10 HOSE : L=550 1 1 DELIVERY RELIEF 11 HOSE : L=3200 (GREEN) 1 SECONDARY PRESSURE 38 TEE 1 1 PF 1/4
FOR BOOM UP
11 HOSE : L=400 1 1 PILOT DELIVERY 12 HOSE : L=2800 (GRAY) 1 SECONDARY PRESSURE 39 TEE 1 1 PF 1/4
FOR BOOM DOWN
12 CONNECTOR — 1 PF1 - Ø 25.4 13 CLIP 2 40 ELBOW 1 1 PF 1/4
13 HOSE — 1 SUCTION 14 BOOTS 2 41 TEE 5 6 PF 1/4
14 CLIP — 2 16 CAPSCREW 8 M6 X 25 42 TEE 1 1 PF 1/4
15 ELBOW — 1 PF 3/4 - Ø2 5.4 17 WASHER 8 M6
16 HOSE GUARD 2 2 18 CLIP 1 (8) YT62H00003F1 TRAVEL REMOTE CONT
17 CONNECTOR 1 1 PF 1/4 19 CAPSCREW 2 M10 X 20 1 HOSE : L=400 1 PRIMARY PRESSURE OF PILOT
18 ELBOW 1 1 PF 1/4 20 WASHER 2 M10 2 HOSE : L=450 1 DRAIN
19 TUBE 1 1 21 CONNECTOR 8 PF 1/4 3 HOSE : L=2300 2 1 : TRAVEL LEFT REVERSE 3 : TRAVEL RIGHT REVERSE
20 HOSE : L=650 1 1 DRAIN 22 CONNECTOR 2 PF 3/8 - PF 1/4 4 HOSE : L=3000 1 4 : TRAVEL RIGHT FORWARD
21 CONNECTOR 1 — PF 3/8 L=46 23 TUBE 1 5 ELBOW 4 PF 1/4
24 HOSE 1 DRAIN 7 CONNECTOR 1 PF 1/4 (WITH FILTER)
(3) YT64H00038F3 SOL.VALVE CONTROL (STD) 25 GROMMET 1 8 CONNECTOR 1 PF 3/8 - PF 1/4
(4) YT64H00038F4 SOL.VALVE CONTROL N&B (OPT.) 26 GROMMET 1 9 PRESSURE SENSOR 2 LC52S00011P1
1 ELBOW 1 1 PF 3/8 27 CLIP 1 10 CAPSCREW 4 M8 X 25
2 ELBOW 6 7 PF1/4 28 CONNECTOR 2 PF 1/4 WITH FILTER 11 WASHER 4 M8
3 CONNECTOR 1 1 PF 3/8 WITH FILTER 29 HOSE 2 12 PILOT VALVE 1 YN30V00070F1
4 ELBOW 1 1 PF 1/4 30 TUBE 1 13 HOSE : L=3200 1 2 : TRAVEL LEFT FORWARD
5 CAPSCREW 2 2 M10 X 70 31 PILOT VALVE 2 PX30V00043F2
6 WASHER 2 2 M10 (9) YT64H00036F1 (STD) BLOCK CONTROL
7 HOSE : L=450 1 1 SAFETY LOCK LEVER COMMAND (6) YT06H00022F6 CONTROL VALVE CONT. (10) YT64H00036F2 (OPT) BLOCK CONTROL
HOSE : L=3300 B : P2 CUT PROPORTIONAL SECONDARY PRESSURE
8 2 2 C : TRAVEL VALVE PROPORTIONAL SECONDARY PRESSURE (7) YT06H00022F9 CONTROL VALVE CONT. (with OPT./V) 1 BLOCK 1 1
9 HOSE : L=1350 1 1 TRAVEL 2-SPEED SELECT COMMAND 1 ELBOW 11 14 PF 1/4 2 CONNECTOR 1 1 PF 3/8
SWING PARKING BRAKE
10 HOSE : L=2000 1 1 RELEASE COMMAND 2 TEE 3 3 PF 1/4 3 ELBOW 3 3 PF 3/8
11 HOSE : L=2500 1 1 P1 CUT PROPORTIONAL SECONDARY PRESSURE 3 CONNECTOR 12 15 PF 1/4 4 ELBOW 3 3 PF 1/4
12 RUBBER 1 1 4 CONNECTOR 4 4 PF 1/4 L=38 5 CAPSCREW 2 2 M8 X 40
13 HOSE : L=3200 — 1 SINGLE/ CONFFLUX FLOW SELECT COMMAND 6 CONNECTOR 1 1 PF 1/4 - PF 3/8 6 WASHER 2 2 M8
14 HOSE : L=3200 1 1 DRAIN 7 HOSE : L=1000 1 1 DRAIN 8 CONNECTOR — 1 PF 1/4
15 HOSE : L=2600 1 1 PRIMARY PRESSURE OF PILOT PUMP 8 HOSE : L=1200 1 1 DRAIN 9 PLUG 1 — PF 3/8
17 RUBBER 1 1 9 HOSE : L=700 1 1 DRAIN 10 ELBOW 1 1 PF 3/8
18 RUBBER 1 1 10 HOSE : L=1600 1 1 DRAIN 11 ELBOW — 1 PF 3/8 - 1/4
PC3' : ARM LOCK VALVE RELEASE COMMAND
19 GROMMET 2 2 11 HOSE : L=750 2 2 PS : SWING PRIORITY HIGH PRESSURE SELECTION COMMAND 12 CONNECTOR 1 1 PF 1/4 L=23
BOOM CONFLUX VALVE
20 CLIP 9 9 12 HOSE : L=1050 1 1 SWITCHING COMMAND 13 PLUG 1 — PF 1/4
PF 3/8 Pb2' : BOOM LOCK RELEASE COMMAND
22 ELBOW 2 2 13 HOSE : L=900 2 2 Pd2' : SWING PRIORITY COMMAND AT SWING LEFT 16 CONNECTOR 1 1 PF 3/8
23 RUBBER 1 1 14 CONNECTOR 3 3 PF1/4 L=23
24 TUBE 1 1 15 CONNECTOR 1 1 PF 1/4 L=60 (11) YT64H00044F2 BLOCK CONTROL
25 GROMMET 1 1 16 HYD.VALVE ASSY 1 1 YT20V00002F1 1 HOSE : L=1000 1
26 HOSE : L=3700 1 1 17 CLIP 2 2 2 HOSE : L=500 1
27 ELBOW 1 1 PF1/4-PF3/8 18 ELBOW 2 2 PF 1/4 3 HOSE : L=900 2
28 TUBE 1 1 19 ELBOW 4 4 PF 1/4 4 ELBOW 7
29 SOLENOID VALVE 1 — YT35V00017F1 20 ELBOW 1 1 PF 3/8 5 PRESSURE SENSOR 3 LC52S00011P1
30 SOLENOID VALVE — 1 YT35V00018F1 21 ELBOW 3 2 PF 1/4 - PF 3/8 6 BLOCK 1
22 HOSE : L=450 — 1 DRAIN 7 BRACKET 1
22-30
(1) PUMP CONTROL (STD) : YT06H00015F1 (2) PUMP CONTROL (DOZER) : YT06H00015F2
VIEW I VIEW I
22-31
(3) SOL. VALVE CONTROL : YT64H00038F3 (STD)

(4) SOL. VALVE CONTROL : YT64H00038F4 N&B (OPT.)
ADHERE THIS RUBBER FROM

END OF WELDING BEAD.

POSITION SLIT
TO THIS SIDE.

TO BE CUT 10mm
O-RING TYPE JOINT HYD. HOSE (30 FLARED) IN ACTUAL LENGTH.
CAPSCREW ( 10T ) SCREW PF TOOL mm TORQUE N m{lbf ft}TORQUE N m{lbf ft}
SCREW TORQUE N m{lbf ft} 36.3 {26.8} 29.4 {21.7} TO BE CUT.

(ONLY NEAR SIDE)
M10 70.6 {52.1} 73.5 {54.2} 49.0 {36.1}
22-32
(5) REMOTE CONTROL LINE : YT68H00044F2
TIGHTENING
P PORT TORQUE
11.0 N·m
{8.1 lbf·ft}
4 PLACES
T PORT
VIEW
ASSEMBLE IN THE STATE OF

SLIDING THE CONTROL BOX
TO THE FOREMOST.
VIEW
DETAIL C
SWING (R) SECTION AA

ARM (R) BOOM (R)
CAPSCREW
SCREW TORQUE N·m {lbf·ft}
BUCKET (R) M8 35.3 {26.0}
M10 70.6 {52.1}

ARM (H)
BUCKET (H) BOOM (H) HYD.HOSE

SWING (L) FOR CONNECTOR ATTACHING TO P/V O-RING TYPE JOINT (30˚ FLARED)
LH RH
O-RING TYPE JOINT SCREW (PF) TOOL (mm) TORQUE N·m {lbf·ft} TORQUE N·m {lbf·ft}
DETAIL D SCREW (PF) TOOL (mm) TORQUE N·m {lbf·ft} 1/4 19 36.3 {26.8} 29.4 {21.7}
1/4 19 29.4 {21.7} 3/8 22 73.5 {54.2} 49.0 {36.1}

PILOT VALVE PORT POSITION
NOTE 1. DO NOT OVER TIGHTEN THE BOLT FOR CONTROL VALVE BECAUSE PILOT VALVE IS MADE OF ALUMINUM.
22-33
(6) CONTROL VALVE CONTROL : YT06H00022F6 (STD)

(7) CONTROL VALVE CONTROL : YT06H00022F9 (WITH OPTION VALVE)
D E TA I L G
D E TA I L H
22-34
(8) TRAVEL REMOTE CONTROL : YT62H00003F1 (9) BLOCK CONTROL : YT64H00036F1 (STD)
(10) BLOCK CONTROL : YT64H00036F2 (OPT)
22-35
(11) BLOCK CONTROL : YT64H00044F2
22-36
22.3.10 MAIN PIPING
(1) YT30H00003F1 PUMP DELIVERY (STD) 19 HOSE : L=2200 1 1 BOOM H 9 ELBOW — 1 PF 3/8 21 HOSE 1
1 CONNECTOR 2 PF 1/2 20 HOSE : L=2250 1 1 BOOM R 10 PLUG 2 — PF 3/8 22 HOSE 1
2 GROMMET 1 21 HOSE : L=2400 1 1 ARM H 23 HOSE 2
3 TUBE : Ø50.8 1 SUCTION 22 HOSE : L=2600 1 1 ARM R (9) YT02H00024F1 LOWER HYD. LINES (STD) 24 CLAMP 2
4 HOSE 1 SUCTION 23 HOSE : L=2450 1 1 BUCKET R 1 TUBE 1 Ø 18 25 HOSE 4 L=300
5 HOSE : L=850 1 DELIVERY P1 24 HOSE : L=1250 1 1 TRAVEL LEFT FORWARD 2 TUBE 1 Ø 18 26 CONNECTOR 2
6 HOSE : L=800 1 DELIVERY P2 25 HOSE : L=2500 1 1 BUCKET H 3 TUBE 1 Ø 18 27 CLIP 4
7 O-RING 1 1A G55 26 WASHER 1 — M12 4 TUBE 1 Ø 18
9 CLIP 4 27 ROD BOLT 1 — M12 L=160 5 TUBE 1 Ø 18 (14) YT42H00055F1 BOOM HYD. LINES
10 CAPSCREW 2 M12 X 35 28 NUT 4 — M12 6 TUBE 1 Ø 18 1 TUBE 1 Ø 22 X t3
11 LOCK WASHER 4 M12 29 ELBOW 3 3 PF1/2 7 TUBE 1 Ø 15 2 TUBE 1 Ø 22 X t3
12 CLIP 1 8 TUBE 1 Ø 15 3 TUBE 1 Ø 22 X t3
13 ELBOW 2 PF 3/4 (5) YT32H00009F1 RETURN HYD. LINES (STD) 9 TUBE 1 Ø 10 4 TUBE 1 Ø 22 X t3
14 O-RING 2 1B P24 (6) YT32H00009F3 RETURN HYD. LINES (DOZER EXTRA) 10 HOSE 2 5 CLUMP 4
15 CAPSCREW 1 M12 X 25 1 TUBE 1 1 11 CONNECTOR 2 6 CLUMP 6
16 CONNECTOR 1 Ø 12 - M12 2 TUBE 1 1 12 HOSE 4 L=300 7 CAPSCREW 8
17 CONNECTOR 1 PF 1/4 3 TUBE — 1 13 CLIP 4 8 CAPSCREW 1
18 O-RING 1 1B P11 4 HOSE : L=1700 1 1 DRAIN 14 CLAMP 2 9 NUT 1
19 HOSE : L=540 1 FOR SURGE CUT 5 HOSE : L=450 1 1 DRAIN 15 CLAMP 2 10 LOCK WASHER 11 M10
20 WASHER 1 M12 6 HOSE : L=1750 1 1 DRAIN 16 SPACER 2 11 WASHER 11 M10
21 PLUG 3 PF 1/4 7 HOSE : L=1300 1 1 RETURN 17 SPACER 2 12 CLAMP 2
22 CAPSCREW 2 M12 X 40 8 HOSE : L=2300 1 1 RETURN 18 CAPSCREW 4 13 CAPSCREW 2 M10 X 50
23 SUPPORT 1 9 CONNECTOR 1 2 PF 1/2 19 LOCK WASHER 4
10 ELBOW 1 1 PF 1/2 20 WASHER 4 (15) YT42H00069F1 BOOM CYL. HYD. LINES
(2) YT03H00043F1 PUMP DELEVERY (DOZER) 11 CONNECTOR 1 1 PF 3/4 L=60 1 TUBE
1 CONNECTOR 1 PF 1/2 L=32 13 TEE 1 1 PF 3/8 (10) YT12H00001F1 PROPEL HYD. LINES 2 TUBE 1
2 CONNECTOR 3 PF 1/2 14 TEE 1 1 PF 1/2 1 CONNECTOR 4 PF 1/2 - Ø 18 3 CONNECTOR 1
3 ELBOW 2 PF 3/8 - PF 1/2 15 TEE 1 1 PF 3/4 2 CONNECTOR 2 PF 3/8 - Ø 15 4 ELBOW 1
4 TEE 1 2 - PF 1/2 - PF 1/4 17 COUPLING 4 4 3 CONNECTOR 2 PF 1/4 5 O-RING 1 1B P18
5 PLUG 1 PF 1/4 18 COUPLING 1 1 4 O-RING 2 1B P14 6 CLAMP 2
6 HOSE : L=500 1 DOZER R 19 U-BOLT 4 4 7 CAPSCREW 2 M10 X 50
7 HOSE : L=580 1 DOZER H 20 NUT 16 16 M8 (11) YT19H00018F1 SWIVEL HYD. LINES (STD) 8 LOCK WASHER 2 M10
8 HOSE : L=1500 1 DOZER DELIVERY 21 WASHER 8 8 M8 (13) YT19H00016F1 SWIVEL HYD. LINES (DOZER) 9 GREASE NIPPLE 2
9 TUBE 1 22 WASHER 2 2 M10 1 CONNECTOR 4 4 PF 1/2 - Ø 18 10 GREASE NIPPLE 1
10 TEE 1 PF 1/4 23 CAPSCREW 1 1 M10 X 60 2 CONNECTOR 1 2 PF 3/8 - Ø 15 11 PLUG 1
11 HOSE : L=300 1 DOZER POWER SHIFT 24 CLAMP 1 1 3 TEE 1 — PF 3/8 - Ø 15
12 CONNECTOR 1 PF 1/4 L=23 25 CHECK VALVE 1 1 2436R576F3 3 CONNECTOR — 1 PF 1/4 - Ø 10 (16) YT43H00005F1 BUCKET CYL. HYD. LINES
13 CONNECTOR 1 PF 1/4 28 HOSE : L=1350 — 1 4 TEE — 1 PF 3/8 - Ø 15 1 TUBE 1
14 ELBOW 1 PF 1/2-PF3/8 30 RUBBER 1 1 4 PLUG 2 — PF 3/8 2 TUBE 1
15 ELBOW 1 PF 1/4 31 BRACKET 1 1 5 O-RING 4 4 1B P18 3 CONNECTOR 1
16 PRESSURE SENSOR 1 LC52S00012P1 32 CAPSCREW 1 1 M10 X 30 6 O-RING 1 3 1B P14 4 ELBOW 1
17 TEE 1 PF1/2 33 CLIP 1 1 7 O-RING 1 1 1B P11 5 CLAMP 2
34 CLIP 1 1 6 CAPSCREW 2 M10 X 50
(3) YT03H00027F1 UPPER HYD. LINES (STD) 36 TUBE : L=600 1 1 (12) YT02H00020F1 LOWER HYD. LINES (DOZER) 7 LOCK WASHER 2 M10
(4) YT03H00027F2 UPPER HYD. LINES (OPT) 37 TUBE : L=1100 — 1 1 TUBE 1 Ø 18 8 O-RING 2 1B P18
1 CONNECTOR 1 1 PF 1/2 L=32 38 TUBE : L=1400 1 1 3 TUBE 1 Ø 18 9 GREASE NIPPLE 1
2 CONNECTOR 3 3 PF 1/2 39 ELBOW 1 1 PF 1/2 - PF 3/8 5 TUBE 1 Ø 18 10 GREASE NIPPLE 1
3 CONNECTOR 2 2 PF 1/2 41 CONNECTOR 1 1 PF 3/4 6 TUBE 1 Ø 18
4 CONNECTOR 3 3 PF 1/2 42 TUBE 1 — 7 TUBE 1 Ø 18 (17) YT43H00036F1 ARM HYD. LINES (1.65 m)
5 CONNECTOR 3 3 PF 1/2 43 CAP 2 2 8 TUBE 1 Ø 18 (18) LF43H00005F1 ARM HYD. LINES (2.07 m)
7 CLAMP 2 2 44 PLUG 1 1 9 TUBE 1 Ø 15 1 HOSE : L=1000 BUCKET H & R
8 CLAMP 1 1 10 TUBE 1 Ø 15 2 HOSE : L=1450 — — BUCKET H & R
9 CLAMP 1 1 (7) YT19H00013F1 SWIVEL HYD. LINES (STD) 11 TUBE 1 Ø 10 2
10 BUSHING 6 6 (8) YT19H00013F2 SWIVEL HYD. LINES (DOZER) 12 CLAMP 2 (19) YT42H00003F1 ARM CYL. HYD. LINES
11 O-RING 6 6 1B P18 1 CONNECTOR 1 1 PF 1/4 13 CLAMP 2 1 TUBE 1 ARM H & R
12 CAPSCREW 4 4 M18 X 40 2 O-RING 4 4 1B P18 14 SPACER 2 2 HOSE : L=650 2
13 CLAMP 1 1 3 ELBOW 3 3 PF 1/2 15 SPACER 2 3 CONNECTOR 1
14 WASHER 4 4 M8 4 CONNECTOR 1 1 PF 1/2 16 CAPSCREW 6 4 CONNECTOR 1
15 GROMMET 2 2 5 CONNECTOR 2 2 PF 1/2 L=41 17 LOCK WASHER 6 5 O-RING 3
SWING RIGHT,
16 HOSE : L=1150 3 3 TRAVEL RIGHT · LEFT FORWARD 6 CONNECTOR 1 1 PF 3/8 18 WASHER 4 6 GREASE NIPPLE 1
17 HOSE : L=1200 1 1 TRAVEL RIGHT FORWARD 7 TUBE 1 1 19 TUBE 1
18 HOSE : L=1300 1 1 SWING LEFT 8 ELBOW — 1 PF 3/8 20 TUBE 1
22-37
(1) PUMP DELEVERY (STD) : YT30H00003F1 (2) PUMP DELEVERY (DOZER) : YT30H00043F1
22-38
(3) UPPER HYDRAULIC LINES : YT03HJ00027F1 (1 / 2) (STD)

(4) UPPER HYDRAULIC LINES : YT03HJ00027F2 (1 / 2) (OPT)
22-39
UPPER HYDRAULIC LINES : YT03HJ00027F1 (2 / 2) (STD)

UPPER HYDRAULIC LINES : YT03HJ00027F2 (2 / 2) (OPT)
22-40
(5) RETURN HYDRAULIC LINES : YT32H00009F1 (1 / 2) (STD)

(6) RETURN HYDRAULIC LINES : YT32H00009F3 (1 / 2) (DOZER)
22-41
RETURN HYDRAULIC LINES : YT32H00009F1 (2 / 2) (STD) (7) SWIVEL HYDRAULIC LINES : YT19H00013F1 (STD)
RETURN HYDRAULIC LINES : YT32H00009F3 (2 / 2) (DOZER, EXTRA) (8) SWIVEL HYDRAULIC LINES : YT19H00013F2 (DOZER)
22-42
(9) LOWER HYDRAULIC LINES : YT02H00024F1
NOTE
1. TIGHTENING TORQUES FOR NUTS AND SLEEVES
TUBE SIZE : Ø10 X 1.5 49.0 N·m (36.1 lbf·ft)
: Ø15 X 2.0 118 N·m (79.7 lbf·ft)
: Ø18 X 2.5 147 N·m (108 lbf·ft)
(MOTOR) (MOTOR)
2. REF DWG. NO
A (UPPER) REVERSE B (UPPER) REVERSE
HYD LINES, PROPEL : YT12H00001F1
(LEFT SIDE) (RIGHT SIDE)
B (LOWER) FORWAD A (LOWER) FORWAD HYD LINES, SWIVEL : YT19H00018F1
3. TIGHTENING TORQUES FOR HOSE MOUTH PIACE
MOUTH PIACE SIZE : PF1/4 29.4 N·m (21.7 lbf·ft)
(10) PROPEL HYDRAULIC LINES : YT12H00001F1
UPPER SIDE UPPER SIDE
LEFT SIDE RIGHT SIDE
(11) SWIVEL HYDRAULIC LINES : YT19H00018F1
VIEW I VIEW II
TIGHTENING TORQUE
29.4 N·m {21.7 lbf·ft}
TIGHTENING TORQUE
29.4 N·m {21.7 lbf·ft} SECTION AA SECTION DD
SECTION CC
22-43
(12) LOWER HYDRAULIC LINES (DOZER) : YT02H00020F1
NOTE
1. TIGHTENING TORQUES FOR NUTS AND SLEEVES
TUBE SIZE : Ø10 X 1.5 49.0 N·m (36.1 lbf·ft)
: Ø15 X 2.0 118 N·m (79.7 lbf·ft)
(MOTOR) (MOTOR)
: Ø18 X 2.5 147 N·m (108 lbf·ft)
A (UPPER) REVERSE B (UPPER) REVERSE
2. TIGHTENING TORQUES FOR PARALLEL PIPE THREADS
(LEFT SIDE) (RIGHT SIDE)
B (LOWER) FORWAD A (LOWER) FORWAD THREADS SIZE : PF1/4 36.3 N·m (26.8 lbf·ft)
: PF3/8 73.5 N·m (54.2 lbf·ft)
3. REF DWG. NO
HYD LINES, PROPEL : YT12H00001F1
TIGHTENING TORQUE HYD LINES, SWIVEL : YT19H00016F1
29.4 N·m {21.7 lbf·ft}
HYD LINES, CYLINDER : YJ13H00001F1
SECTION BB (2 PLACES) 4. TIGHTENING TORQUES FOR HOSE MOUTH PIACE

MOUTH PIACE SIZE : PF1/4 29.4 N·m (21.7 lbf·ft)
(13) SWIVEL HYDRAULIC LINES (DOZER) : YT19H00016F1
VIEW I VIEW II
TIGHTENING TORQUE TIGHTENING TORQUE

29.4 N·m {21.7 lbf·ft} 29.4 N·m {21.7 lbf·ft}
SECTION CC SECTION AA SECTION DD
22-44
(14) BOOM HYDRAULIC LINES : YT42H00055F1 (16) BUCKET CYL. HYDRAULIC LINES : YT43H00005F1
(15) BOOM CYLINDER HYDRAULIC LINES : YT42H00069F1
22-45
(17) ARM HYDRAULIC LINES : YT43H00036F1 (1.65 m)
(18) ARM HYDRAULIC LINES : LF43H00005F1 (2.07 m)
(19) ARM CYL. HYDRAULIC LINES : YT42H00003F1
22-46
22.3.11 ADDITIONAL SPECIFICATIONS
1 BOOM / ARM SAFETY SPECIFICATION 17 CAPSCREW 2 M10 X 35 (4) YT68H00037F3 EXTRA REMOTE CONTROL LINES 15 O-RING 2 1B P14
(1) YT64H00043F3 VALVE CONTROL LINES 18 LOCK WASHER 2 M8 2 HOSE : L=2000 1 PF 1/4 16 O-RING 3 1B P24
1 HOSE : L=3300 1 PF 3/8 19 LOCK WASHER 2 M10 3 HOSE : L=400 2 PF 1/4 17 PLUG 2 PF 3/4
2 HOSE : L=3100 1 PF 3/8 4 HOSE : L=500 1 PF 1/4 18 CLAMP 7
3 TUBE 2 2 EXTRA, N & B, DOZER SPECIFICATION 5 NUT 2 M8 19 CLAMP 1
4 TUBE 2 (1) YT03H00032F9 UPPER HYD. LINES FOR EXTRA & DOZER 6 PIN 2 20 CLAMP 3
6 CLIP 2 1 CONNECTOR 1 PF 1/4, L=23 7 WASHER 6 M8 21 CLAMP 10
7 CLIP 1 2 CONNECTOR 1 PF 1/4 8 CAPSCREW 4 M10 X 20 22 CLAMP 10
8 CAPSCREW 1 M12 X 20 3 CONNECTOR 2 PF 1/2 9 LOCK WASHER 4 M10 23 CAPSCREW 8 M8 X 20
9 WASHER 1 M12 4 ELBOW 1 PF 1/4 10 CAPSCREW 4 M10 X 25 24 CAPSCREW 2 M10 X 20
10 HOSE : L=2500 1 PF 3/8 5 ELBOW 3 PF 1/2 11 WASHER 8 M10 25 CAPSCREW 11 M10 X 35
11 HOSE : L=2400 1 PF 3/8 6 TEE 1 PF 1/4 12 CONNECTOR 2 PF 1/4, L=23 26 CAPSCREW 8 M10 X 45
12 BRACKET 1 7 TEE 1 2 - PF 1/2 - PF 1/4 13 ELBOW 7 PF 1/4 27 CAPSCREW 1
13 PLATE 1 8 PLUG 1 PF 1/4 14 ELBOW 2 PF 1/4 WITH FILTER 28 NUT 1 M10
14 BUSHING 1 9 HOSE : L=300 1 PF 1/4 15 PILOT VALVE 2 YN30V00080F1 29 LOCK WASHER 8 M8
15 CAPSCREW 3 M10 X 25 11 HOSE : L=1600 1 PF 1/2 17 CAPSCREW 4 M8 X 20 30 LOCK WASHER 22 M10
16 WASHER 3 M10 12 CAPSCREW 1 M12 X 70 18 LOCK ASSY 1 R/H 31 WASHER 1 M10
17 CLIP 3 13 BUSHING 2 19 PEDAL 2
18 TUBE 2 L=500 14 WASHER 2 20 RUBBER 2 (7) YT 43H00051F1 ARM HYD. LINES
15 TUBE 2 L=400 22 PRESSURE SWITCH 2 PT 1/8 GB50S00049F2 1 TUBE 2
(2) YT42H00075F2 BOOM CYL. HYD.LINES 16 TUBE 1 L=1200 23 CONNECTOR 1 PF 1/4 2 TUBE 1
1 TUBE 1 17 CLAMP 2 24 HOSE : L=2150 1 PF 1/4 3 TUBE 1
3 TUBE 1 18 HOSE : L=1800 1 PF 1/2 26 HOSE : L=2300 1 PF 1/4 4 TUBE 1
4 HOLDING VALVE 1 YR28V00001F1 19 TUBE 2 L=600 28 HOSE : L=420 1 PF 1/4 5 TUBE 1
6 BAND 1 20 HOSE : L=1550 1 PF 1/2 34 LOCK ASSY 1 L/H 6 HOSE : L=1050 2
7 CONNECTOR 2 M30 X 1.5 - PF 1/2 21 HOSE : L=500 1 PF 3/8 43 ELBOW 1 7 HOSE : L=900 2
8 CONNECTOR 1 22 HOSE : L=580 1 PF 3/8 44 CONNECTOR 1 PF 1/4, L=38 8 STOP VALVE 2 24100P1006F1
9 ELBOW 1 PF 1/4 - PF 3/8 23 CONNECTOR 2 PF 1/2, L=32 45 CONNECTOR 2 PF 1/4 - PT 1/8 9 CONNECTOR 2 Ø 22 - PF 3/4
10 ELBOW 1 M30 X 1.5 - PF1/2 24 ELBOW 2 PF 1/2 46 PLUG 2 PF 1/4 10 TEE 2 3 - Ø 15
11 ELBOW 1 PF 1/4 - PF 3/8 25 CONNECTOR 2 PF 1/2, L=55 47 HOSE : L=2800 1 PF 1/4 11 PULG 2 Ø 15
13 O-RING 4 1B P18 26 CONNECTOR 2 PF 1/2 - PF 3/8 12 PLUG 2 Ø 15
14 GREASE NIPPLE 1 PT 1/8 27 HOSE GUARD 2 L=1000 (5) YT64H00036F4 BLOCK CONTROL LINES 13 NUT 2
15 GREASE NIPPLE 1 PT 1/8 28 NUT 1 M12 1 BLOCK 1 14 O-RING 2 1B P24
16 CLAMP 2 34 TEE 1 PF1/2 2 CONNECTOR 1 PF 3/8 15 CLAMP 1
17 CAPSCREW 2 M8 X 50 35 ELBOW 1 PF1/2-PF3/8 3 ELBOW 3 PF 3/8 16 CLAMP 2
18 CAPSCREW 2 M10 X 35 36 PRESSURE SENSOR 1 LC52S00012P1 4 ELBOW 3 PF 1/4 17 CAPSCREW 8 M8 X 25
19 CAPSCREW 2 M10 X 50 5 CAPSCREW 2 M8 X 40 18 CAPSCREW 1 M8 X 40
20 LOCK WASHER 2 M8 (2) YT03H00025F1 UPPER HYD. LINES FOR N & B 6 WASHER 2 M8 19 CAPSCREW 2 M10 X 45
21 LOCK WASHER 4 M10 1 CONNECTOR 1 Ø 18 - PF 1/2 7 TEE 1 PF 3/8 20 LOCK WASHER 9 M8
28 TUBE 1 2 CONNECTOR 1 Ø 18 - PF 1/2 8 CONNECTOR 2 PF 1/4 21 LOCK WASHER 2 M10
29 BAND 1 3 O-RING 1 1B P18 10 ELBOW 1 PF 3/8
30 ELBOW 1 2-PF3/8 4 BUSHING 2 11 ELBOW 2 PF 3/8 - PF 1/4
31 PRESSURE SENSOR 1 LC52S00012P1 5 ROD BOLT 1 M12, L=240 12 CONNECTOR 1 PF 1/4, L=23
6 WASHER 1 M12 14 ELBOW 1 PF 3/8
(3) YT42H00058F1 ARM CYL. HYD. LINES 7 NUT 6 M12 15 TEE 1 PF 1/4
1 TUBE 1 Ø 22 X t3 8 HOSE : L=2500 1 Ø 18 16 CONNECTOR 1 PF 3/8
2 TUBE 1 Ø 22 X t3 9 CLAMP 2
3 TUBE 1 Ø 22 X t3 10 HOSE : L=2650 1 Ø 18 (6) YT42H00068F1 BOOM HYD. LINES
4 HOSE : L=650 2 1 TUBE 1 Ø 22 X t3
5 HOLDING VALVE 1 YR28V00001F1 (3) YT32H00009F8 RETURN HYD. LINES 2 TUBE 1 Ø 22 X t3
6 BAND 1 3 TUBE 1 Ø 31.8 3 TUBE 1 Ø 22 X t3
7 BAND 1 9 CONNECTOR 2 PF 1/2 4 TUBE 1 Ø 22 X t3
8 CONNECTOR 2 M30 X 1.5 - PF 1/2 12 ELBOW 1 PF 3/4 5 TUBE 1 Ø 15 X t2
9 CONNECTOR 1 M30 X 1.5 - M30 X 1.5 16 HOSE GUARD 1 L=1000 6 TUBE 1 Ø 15 X t2
10 CONNECTOR 1 PF 1/4 - PF 3/8 26 HOSE : L=3000 1 PF 3/4 7 SELECTOR VALVE 1 24100P1005F1
11 CONNECTOR 1 PT 1/4 - PF 1/4 27 BUSHING 1 8 SUPPORT 1
12 CONNECTOR 1 2 - PF 1/4 29 CLIP 1 9 BRACKET 1
13 ELBOW 1 PF 1/4 - PF 3/8 35 GROMMET 1 11 CONNECTOR 2 PF 1/2 - PF 3/8
14 O-RING 5 37 TUBE 1 L=1100 12 CONNECTOR 2 PF 3/8 - M22 X 1.5
15 GREASE NIPPLE 1 PT 1/8 40 BUSHING 1 13 CONNECTOR 1 PF 3/4 - M30 X 1.5
16 CAPSCREW 2 M8 X 50 45 HOSE : L=1450 1 PF 1/2 14 ELBOW 2 PF 3/4 - M30 X 1.5
22-47
1. BOOM/ ARM SAFETY SPECIFICATION

(1) VALVE CONTROL LINES : YT64H00043F3
TO BE FIXED TO UPPER FROM HIGH PRESSURE HOSE.
LENGTH FROM HOSE CLAMP.
22-48
(2) BOOM CYLINDER HYDRAULIC LINES : YT42H00075F2 (3) ARM CYLINDER HYDRAULIC LINES : YT42H00058F1
22-49
2. EXTRA, N & B, DOZER SPECIFICATION (2) UPPER HYDRAULIC LINES : YT03H00025F1

(1) UPPER HYDRAULIC LINES : YT03H00032F9 FOR N & B
FOR EXTRA & DOZER
22-50
(3) RETURN HYDRAULIC LINES : YT32H00009F8 (4) REMOTE CONTROL LINES :YT68H00037F3
22-51
(5) BLOCK CONTROL LINES : YT64H00036F4
22-52
(6) BOOM HYDRAULIC LINES : YT42H00068F1
22-53
(7) ARM HYDRAULIC LINES : YT43H00051F1
22-54
23. ELECTRICAL SYSTEM
TABLE OF CONTENTS
23.1 ELECTRICAL CIRCUIT DIAGRAM AND EQUIPMENT LIST .............................................. 23-3

23.1.1 ELECTRICAL CIRCUIT DIAGRAM........................................................................... 23-3
23.1.2 ELECTRICAL EQUIPMENT LIST ........................................................................... 23-6
23.2 HARNESS ........................................................................................................................ 23-7
23.2.1 HARNESS & CABLE LIST ......................................................................................... 23-7
23.2.2 HARNESS CONNECTION DRAWING ...................................................................... 23-8 23
23.2.3 CONTROLLER ASSY ............................................................................................... 23-9
23.2.4 INSTRUMENT PANEL ASSY .................................................................................... 23-13
23.2.5 UPPER ELECTRIC ASSY ..................................................................................... 23-15
23.2.6 UPPER HARNESS ASSY ......................................................................................... 23-16
23.2.7 ENGINE HARNESS ASSY ........................................................................................ 23-24
23.2.8 FLOOR PLATE HARNESS ASSY .............................................................................. 23-26
23.2.9 CAB HARNESS ASSY .............................................................................................. 23-28
23.2.10 BATTERY .................................................................................................................. 23-33
23.2.11 CAB ASSY ................................................................................................................. 23-34
23.2.12 MOUNTING CAB ...................................................................................................... 23-36
23.2.13 MOUNTING LIGHT ................................................................................................... 23-36
23.2.14 MOUNTING BOOM LIGHT ....................................................................................... 23-36
23.2.15 MOUNTING CAB WORK LIGHT ............................................................................... 23-37
23.2.16 AIR CONDITIONER .................................................................................................. 23-39
23.2.17 MOUNTING FUEL PUMP .......................................................................................... 23-40
23.2.18 NAME PLATE INSTAL (ELECTRIC COMPONENT FOR AUTO IDLE STOP) .......... 23-41
23-1

S5YT2304E01
First edition February, 2005 SK70SR-1ES : YT04–07175~ KE
(NHK)
23-2
23.1 ELECTRICAL CIRCUIT DIAGRAM AND EQUIPMENT LIST

23.1.1 ELECTRICAL CIRCUIT DIAGRAM
3 CIGARETTE LIGHTER
2 WASHER RELAY
1 CONTROLLER
9 CONVERTER
MECHATRO
8 FUEL PUMP
930 WR (5V) 14-7
530 P
10 KEY SW.
SE-16:ACCEL POTENTIO 14-8
4 TUNER
WIPER
5 HORN
970 BW (GND) 14-9
APPLICABLE : YT04-07175- PRESS.SENSOR(LOW)
900 RB (5V)
C-1:MECHATRO CONTROLLER
12-15
SE-1:BUCKET DIGGING 500 LgR 12-14 851 GREEN A PHASE
14-1
WG
950 BrR (GND) 12-13
WV
WV
WY
852 BLACK
RY
OL
YB
RL
1.25
1.25
14-2
901 RL (5V) 853 RED B PHASE
E-1:FUSE BOX 13-3 14-12 M M-2:GOVERNOR MOTOR
501 LgW 854 WHITE
10A
10A
10A
20A
20A
10A
10A
10A
SE-2:BUCKET DUMP 13-2 14-13
951 BL (GND) 13-1 14-3 SHIELD
51 1.25W 52 5R
50 1.25L 902 W (5V) 560 V B
53 5Y 12-3 14-14
502 LgY
10A
10A
20A
20A
10A
30A
20A
10A
20A
SE-3:BOOM RAISING 12-2
8 952 BR (GND) 12-1 N L E
TIO A AS
SI RM LE
TERMINAL
903 OB (5V) PO NO RE
WG
WORK LIGHT 16 1.25
CAB WORK LIGHT 17 1.25

RW
1.25
1.25
1.25
WR
WB
1.25B
WL
RB
12-4
RL
C-2:
W
SW-4:
O
503 LO
E
SE-4:BOOM LOWERING 12-5 GAUGE CLUSTER SWING PARKING BRAKE RELEASE SW.
TRAVEL ALARM 11
GAUGE CLUSTER 13
WIPER,WASHER 14
SOLENOID 15
AIR CON.HEATER 18
AIR CON. 19
RESERVE 20
953 BrW (GND) 12-6
561 0.5Lg
904 OL (5V) 5 3
12-9 701 PB B SV-1:
2
SE-7:ARM IN 504 PG 12-8 700 V SWING PARKING
11-2 1 BRAKE SOL.
954 BrY (GND)
12-7
60A 60A E-14: E-14: 905 OW (5V) 12-10
BATTERY BATTERY
SE-8:ARM OUT 505 PL 12-11
B A 60B 60B 60B
955 Gr (GND) 12-12
B
B 907 YG (5V) 13-9
60B
704 RL B
L SE-5:SWING 507 VG 13-8 11-14 SV-8:PQ SHIFT SOL.
SW-1: E-21: R-28: 957 Br (GND) 13-7
STARTER KEY SW. 60 GrL COUNTER AUTO IDLE STOP RELAY1
26 R-1:BATTERY RELAY 753 GB
D-3 908 YL (5V) 11-12
ION ATING 60 GrL 68 GY 13-10 PSV-C:
POSIT
PREHE 754 GrB
TERMINAL
508 VY 11-25 TRAVEL PRIORITY PROPOTIONAL SOL.

B SE-9:TRAVEL RIGHT 13-11
START
D-1 R-3:GLOW RELAY 958 BY (GND)

60 GrL 13-12 755 BP
ACC
OFF
11-13
ON
909 YR (5V) PSV-D:

10 1.25WV 71 RW
53 5Y 66 5W 14-6
11-26 756 PW
10 B C-2: GLOW SE-10:TRAVEL LEFT 509 Sb P1 BY-PASS CUT PROPOTIONAL SOL.
61 0.5BrY GAUGE B 14-5
ACC 3 959 BG (GND) 14-4
D-2 CLU STER 11-11 751 BO
M
61 BrY D-5 752 GrR PSV-B:
G1 550 O 11-10 11-24 P2 BY-PASS CUT PROPOTIONAL SOL.
62 GrB 62 GrB 60B B M E M-1: SW-7:ENG.OIL PRESS.SW. 2
G2 M
63 WY STARTER MOTOR SW-30: ENG.OIL PRESS.
ST
AUTO ACCEL RELEASE SW. B
R-29: S
R-4:SAFETY RELAY
65
AUTO IDLE STOP RELAY2
SV-2: 94 G
5L
63 WY 38 5BW C-2:
S C DOUBLE, SINGLE 6 CLUSTER GAUGE 4 702 0.5LgB
65 5L 5B SELECT SOL.
R-30: B B B E
71 RW
TIMER UNIT 23 R
R 110 Br SW-18:OPT.PEDAL PRESS. SWICH (1) SV-3:
R-31: E-2:ALTERNATOR B 702 LgB
E B D-4 TRAVEL TWO-SPEED
E-21:COUNTER COUNTER RELAY. L B 94 G 556 LO 12-16 SOL.
651 WR
SW-1: 60 GrL 1 5 72 L B
KEY SW. 26 64 GW
SW-19:OPT.PEDAL PRESS. SWICH (2) E-22:
B 63 WY SEQUENCE BOX ASSY.
73 RY B
3 4 WB B
15 1 6
L-11:STARTER 651 WR B
D-6 R-32:
B ALARM LAMP. 63 WY SW-21:OPT.PEDAL PRESS.SWICH (3) TRAVEL TWO-SPEED RELAY.
2 B SW-3:
E-3: TRAVEL TWO-SPEED SW.
C-2:GAUGE CLUSTER HOUR METER OPTION B 559 PL
2 4 760 LgR WB
ILLUMINATION 15
R-8:WORK LIGHT RELAY 1 85 0.5WB
13 0.5W P3 PUMP PRESS,SENSOR
13
CHARGE 651 0.5WR 705 O 14-10
C-1:MECHATRO CONTROLLER 2 B
550 0.5O ENG. OIL PRESS. R-30:TIMER UNIT 915 YL(5V) SW-2:SWITCH ASSY
SW-7:ENG. OIL PRESS. SW. 13-4
WY WR SW-6: 515 PL
R-30:TIMER UNIT. 24 2 5 7 651 ENG.WATER
13-5
5V MODE(H)
965 BrB(GND) 13-6 940 G
ENG. WATER TEMP. 558 LY 1 6 552 GB TEMP.SW. 11-3
552 0.5GB 24 603 LgR DI1 MODE(S)
SW-6:ENG. WATER TEMP. SW. LW 86 OW SW-11: 11-5
COOLANT THERMO INDICA TOR SW-40: 2 77 25 LEVER LOCK SW. OPT. SE-17:P3 PUMP 604 LG DI2 MODE(FC)
SE-14:COOLANT THERMO SENSOR 537 0.5YR AUTO IDLE STOP D-7 11-6
605 VG DI3
SELECT SW. Br B 11-7 BUZZER STOP
B 551 0.5BrL AIR CLEANER 10 120 BZ E-20:BUZZER KEY ON 857 WG 11-1 DI4
SW-8:AIR FILTER RESTRICTION SW. LIGHT
FUEL LEVEL 8 KEY ON 520 P 606 BrW DO1
553 0.5BrB 60 GrL 9 11-15 11-4
71 RW R-28,29: 607 GW GND WIPER
FUEL METER 23 AUTO IDLE 11-9
B 536 0.5BrR 3
SE-15:FUEL SENSOR B STOP RELAY. WASHER
12
61 0.5BrY GLOW
SW-1:STARTER KEY SW. 3 450 G WB 85 B
TRAVEL TWO-SPEED 7
702 0.5LgB
C-1:MECHATRO CONTROLLER 4 SHORT CIRCUIT IN CASE OF TIMER UNIT. SE-13: 534 0.5B 14-19 R-8:
ENG.SPEED WORK LIGHT RELAY BACK LIGHT
SWING PARKING 535 0.5W 14-20
SW-4:SWING PARKING BRAKE 561 0.5Lg SENSOR
5 SHIELD
RELEASE SW. 0.5B 14-21
CPU ALLERGY 859 0.5G 11-23
OPT.
WR 570 Sb 557 GrB OVERLOAD 860 0.5Br

20 5 4 11-8
931 RY(5V) (GND/OPEN) SW-28:
1 OVERLOAD INDICATE SW.
531 Lg 2 861 0.5LO
B 14-17
971 BY(GND) 3 6 MODE
H S FC 862 0.5L 14-18
SE-18:
PRESS,SENSOR E-23: 1 1.25RY
OVER LOAD PRESS ADJUST UNIT. 1 14-11
BOOM HEAD TO 2/3
CONTROLLER EARTH E 1.25B
8 14-22
YT03Z00023P1 01
Fig. 23-1 23-3

L-3:ROOM LIGHT
SW-15:ROOF WIPER SW.
9 YB
POSITION 9
TERMINAL
M-8:ROOF WIPER MOTOR
OFF
ON
98 LB
99 LW B
14 RB M
C-1:MECHATRO CONTOLLER 3 RL 1.25B
14 RB 3 E-6:CIGARETTE LIGHTER
OPTION
FROM 1/3 14 RB
R-5:
WIPER MOTOR RELAY 80 LY
14 1.25RB 81 BrB M
B M-3:WIPER MOTOR
14
2 WY R-10:CAB WORK LIGHT RELAY 1
2
17 17 1.25WL 179 1.25L 179 B
SW-23: 17 L-4:CAB WORKING LIGHT(FRONT 1)
WIPER INTERLOCK SW. 17 WL 185 LY B 179 B
L-5:CAB WORKING LIGHT (FRONT 2)
11-19 800 GB 800 GB 180 OL SW-16: B
WORK LIGHT SW.(OPT) 179
L-6:CAB WORKING LIGHT(FRONT 3)
R-6:
WINDOW WASHER MOTOR RELAY
14 RB 82 GO B M-4:WINDOW WASHER MOTOR 17 1.25WL 191 1.25LR 191 B
14 M L-8:CAB WORKING LIGHT(FRONT 4)
2 WY 17 WL 191 B
2 L-9:CAB WORKING LIGHT(REAR)
801 GrL R-13:CAB WORK LIGHT RELAY 2

11-21
802 BrY
11-22 10 R-8:WORK LIGHT RELAY
R-8:WORK LIGHT RELAY
R-30:TIMER UNIT 16 1.25RW 16 85 1.25WB 85 B

16 L-1:BOOM WORKING LIGHT LEFT
25 16 802 BrY 85 B
12 R-22,23: 10 L-2:WORKING LIGHT RIGHT
COUNTERCLOCKWISE/CLOCKWISE RELAY WORKING
LIGHT ON C-1: B
85
HAND CONTROL MECHATRO L-1:BOOM WORKING LIGHT RIGHT
CONTROLLER
R-20:TIMER 85
11 C-4:AIR CONDITIONER AMP.
15 WB 87 WL E D 86 OW B 85
15 1 C-2:GAUGE CLUSTER
SW-11:LEVER LOCK SW. 85
SV-4:OPERATING LEVER LOCK SOL. 7 SW-2:SWITCH ASSY
A B
TIMER
14-15
15 WB 100 LY 94 G SW-18:OPT. PEDAL PRESS.

15 6 SWITCH (1)
SW-17:DOUBLE, SINGLE
SELECT SW. SV-2:DOUBLE, SINGLE SELECT SOL.
R-7:HORN RELAY
5 WG 5 83 WL B E-5:HORN
5
5 84 WB B
SW-10:HORN SW.(LEFT)
M-9:FUEL PUMP
10A
84 WB B 8 1.25WV B
8 M
SW-20:HORN SW.(RIGHT)
OPT
SW-27: L-7:
ENGINE ROOM LIGHT SW. EMGINE ROOM LIGHT
9 YB R B
9
SW-29: L-10:
ROTARY LIGHT SW. ROTARY LIGHT
17 WL 189 YR B
17
23-4 Fig. 23-2

LEVER LOCK 12 120 YG

E-17:CONVERTER
SV-6:CLOCKWISE SOL.
ANT.
E-7:TUNER AM & FM
4 OL IGN 96 WG 121 O B
4 12V 101 LW
E-15:SOCKET 1(+) 122 LO B
DC-DC CONVERTER 102 Br E-8:SPEAKER LEFT
9 YB 24V MEM 97 YV 7(-)
9 B SW-46:CLOCKWISE SW.
FM/AM
B R-22:CLOCKWISE RELAY
GND 96 WG 2(+) 103 LR
4 E-9:SPEAKER RIGHT
8(-) 104 OB 123 GR SV-7:
97 YV (BACK UP) 11 COUNTERCLOCKWISE SOL.
B 124 GrL B
9
125 WG B
SW-47:COUNTERCLOCKWISE SW.
R-23:CONTERCLOCKWISE RELAY
E-10: E-11:
RECEIVER DRIER AIR COMMPRESSOR CLUTCH
R-8: C-4
WORK LIGHT 11 85 WB 92 BP 93 LW
RELAY HAND CONTROL FOR ROTATION
(OPTION)
AIR
CONDITIONER
18 1.25WG AMP.
18 B
19 RL
19
SW-13:AIR CONDITIONER SW. NOTES:
24V 181
R
24V 1. Wire used to be
TXD 182 G RXD
RXD 183 W TXD 1) "AVSS" or "AVX" for 0.75 mm2 and 1.25 mm2.
COOLING 184 B GND
2) "AVS" for 2 mm2, 5 mm2.
UNIT
3) "AV" for others.
2. Wires to be 0.75 mm2 unles otherwise specified.
3. Grounding for which wire color is not shown to
be performed with component case.
4. Number in square shows line No.
WIRE COLOR CODING TABLE

Sign Color Sign Color Sign Color Sign Color
B Black W White Br Brown V Violet
G Green Y Yellow Lg Light Green
L Blue P Pink Gr Gray
R Red O Orange Sb Sky Blue
Fig. 23-3 23-5

23.1.2 ELECTRIC EQUIPMENT LIST
Group Code Name Part No. Group Code Name Part No. Group Code Name Part No.
CONTROLLER
C-1 MECHATRO CONTROLLER YT22E00031F1 R-1 BATTERY RELAY YN24S00003F1 SW-1 KEY SWITCH YN50S00026F1
C-2 GAUGE CLUSTER YT59S00006F1 R-3 GLOW RELAY 894423-3140 SW-2 SWITCH ASSY YT50E00002F1
C-4 AIR CONDITIONER CONTROLLER YT20M00004S36 R-4 SAFETY RELAY 182553-0391 SW-3 TWO-SPEED SELECT SWITCH YN03M01286F1
R-5 WIPER MOTOR RELAY EN24S00008P1 SW-4 SWING PARKING RELEASE SWITCH YT50E00001F1
D-1 DIODE YN02D01001P1 R-6 WASHER MOTOR RELAY SW-6 ENG. WATER TEMPERATURE SWITCH 897125-6001
D-2 R-7 HONE RELAY SW-7 ENG. OIL PRESS SWITCH 582410-0122
D-3 R-8 WORK LIGHT RELAY SW-8 AIR FILTER ALARM SWITCH YR11P00008S005
DIODE
D-4 R-10 CAB WORK LIGHT RELAY EN24S00008P1 SW-10 HORN SWITCH (LEFT) YN50E01001P1
D-5 2475R132 R-13 CAB WORK LIGHT RELAY 2 SW-11 LEVER LOCK SWITCH YN50S01001P1
RELAY
D-6 YN02D01001P1 R-20 TIMER YN25S00001P1 SW-13 AIR CONDITIONER SWITCH YT20M01104F1
D-7 R-22 CLOCKWISE RELAY (OPT.) EN24S00008P1 SW-15 ROOF WIPER SWITCH (OPT.) 2479Z2334
R-23 COUNTERCLOCKWISE RELAY (OPT.) SW-16 WORK LIGHT SWITCH (OPT.) 2479U1190F1
E-1 FUSE BOX YT73E00003F2 R-28 AUTO IDLE STOP RELAY 1 SW-17 DOUBLE·SINGLE SELECT SWITCH 2479U1190F29
SWITCH
E-2 ALTERNATOR 897182-2892 R-29 AUTO IDLE STOP RELAY 2 LC24S00001P1 SW-18 OPT. PEDAL PRESSURE SWITCH ASSY (1) GB50S00049F2
E-3 HOUR METER YT58S00006P1 R-30 TIMER UNIT YT25S00001P1 SW-19 OPT. PEDAL PRESSURE SWITCH ASSY (2) GB50S00049F2
E-5 HORN CM53S00002F1 R-31 COUNTER RELAY EN24S00008P1 SW-20 HORN SWITCH (RIGHT) (OPT.) YN50E01001P1
E-6 CIGALETTE LIGHTER 2421R180F1 SW-21 OPT. PEDAL PRESSURE SWITCH ASSY (3) GB50S00049F2
ELECTRIC FITTINGS
E-7 TUNER AM & FM INSTALLED ON THE SPOT SW-23 WIPER INTERLOCK SWITCH YT50E00003P1
E-8 SPEAKER LEFT YN54S00006P1 SE-1 PRESSURE SENSOR (LOW) : BUCKET DIGGING YX52S00010P1 SW-24 OVER LOAD SWITCH INSTALLED ON THE SPOT
E-9 SPEAKER RIGHT SE-2 PRESSURE SENSOR (LOW) : BUCKET DUMP SW-27 ENGINE ROOM LIGHT SWITCH YT50S00005P1
E-10 RECEIVER DRIER YT54S00002P1 SE-3 PRESSURE SENSOR (LOW) : BOOM UP SW-28 OVERLDAD INDICATE SWITCH 2479U1190F33
E-11 AIR COMMPRESSOR CLUTCH YT91V00001F1 SE-4 PRESSURE SENSOR (LOW) : BOOM DOWN SW-29 ROTARY LIGHT SWITCH 2479U1190F20
E-14 BATTERY 2411U25 SE-5 PRESSURE SENSOR (LOW) : SWING SW-30 AUTO ACCEL RELEASE SWITCH 2479U1190F7
E-15 POWER SOCKET YN81S00001P1 SW-40 AUTO IDLE STOP SELECT SWITCH YN50S01004D5
E-17 CONVERTER YT77S00001P1 SE-7 PRESSURE SENSOR (LOW) : ARM IN YX52S00010P1 SW-46 CLOCKWISE SWITCH (OPT.) LF03M01005F3
E-20 BUZZER 2447Z156D1 SE-8 PRESSURE SENSOR (LOW) : ARM OUT SW-47 COUNTERCLOCKWISE SWITCH (OPT.)
SENSOR
E-21 COUNTER YT25S00003F1 SE-9 PRESSURE SENSOR (LOW) : TRAVEL RIGHT

SE-10 PRESSURE SENSOR (LOW) : TRAVEL LEFT
L-1 BOOM WORKING LIGHT LEFT YN80S00012F1 SE-13 E/G SPEED SENSOR 181510-5130
Note : The Part numbers may be changed due to modification, so use only the
L-1 BOOM WORKING LIGHT RIGHT SE-14 E/G WATER TEMPERATURE SENSOR YT52S00001P1 numbers for reference.
L-2 WORKING LIGHT RIGHT YT80S00002F1 SE-15 FUEL SENSOR YN52S00034F1
L-3 ROOM LIGHT 2456Z322F1 SE-16 ACCEL POTENTIO METER YN52S00032P1
L-4 CAB WORKING LIGHT FRONT (OPT.) INSTALLED ON THE SPOT
L-5 CAB WORKING LIGHT FRONT (OPT.)
LIGHT
L-6 CAB WORKING LIGHT (FRONT 3) SV-1 SWING PARKING BRAKE SOL. YT35V00017F1
L-7 ENGINE ROOM LIGHT 4056R4F1 SV-2 DOUBLE·SINGLE SELECT SOL. (OPT.) (VALVE ASSY)
SOLENOID VALVE
L-8 CAB WORKING LIGHT (FRONT 4) INSTALLED ON THE SPOT SV-3 TWO-SPEED SELECT SOL.
L-9 CAB WORKING LIGHT (REAR) SV-4 LEVER LOCK SOL.
L-10 ROTARY LIGHT SV-8 TRAVEL BOOST-UP SOL.
L-11 STARTER ALARM LAMP LS80E00001D1 SV-6 CLOCKWISE SOL. (OPT.) LC35V00004F2
SV-7 COUNTERCLOCKWISE SOL. (OPT.)
M-1 STARTER MOTOR 897137-4781
M-2 GOVERNOR MOTOR YN20S00002F1
PROPORTIONAL
MOTOR
M-3 WIPER MOTOR YT53C00011F1 PSV-B P2 BY-PASS CUT PROPOTIONAL SOL. YT35V00017F1
M-4 WASHER MOTOR 24100U157F1 PSV-C TRAVEL PRIORITY PROPOTIONAL SOL. (VALVE ASSY)
VALVE
M-8 ROOF WIPER MOTOR (OPT.) YT76S00001P1 PSV-D P1 BY-PASS CUT PROPOTIONAL SOL.
M-9 FUEL PUMP YR22P00001P1
23-6
23.2 HARNESS
23.2.1 HARNESS & CABLE LIST
Index No. DWG. No. HARNESS
Device Item Name Assy No. No. Name Part No.
2.3 Controller assy YT22E00032F5 18-6-1 Harness YT14E01069P1
2.4 Instrument panel assy YT17M00012F1

YT17M00013F1
YT17M00013F5
2.5 Upper electric assy YT03E00006F2 10 Harness YT13E01079P1
2.6 Upper harness assy (Dozer) YT13E00035F1 1 Starter cable YT13E01026D2

Upper frame
YT13E00035F2 2 Battery relay cable 2486R89D4

3 Battery cable YT13E01071D1
4 Battery ground cable 2486R87D1
5 Right guard harness YT13E01059P1
6 Main harness YT13E01106P1
8 Frame ground cable LE13E01006P1
13 P3 pump harness YT16E01017P1
2.7 E/G Harness YT16E00005F1 1 E/G Sub harness YT16E01018P1
2.8 Floor plate harness assy YT13E00034F1 1 Harness YT13E01108P1

3 Cable LE13E01005P1
2.9 Cab harness assy YT14E00019F1 1 Cab right front harness YT14E01062P1
2 Left instrument panel harness YT14E01065P1
7 Right instrument panel harness YT14E01061P1
2.10 Battery 2411U25

Cab
2.11 Cab YT02C00030F1 2-37 Wiper harness YT02C01106P1

61 Curl code harness YT02C01104P1
64 Cab harness YT02C01216P3
65 Antenna YT54S00018F1
189 Room lamp harness YT02C01513P1
2.12 Mounting cab YT02C00002F1
2.13 Mounting deck light YT80E00001F1

Light
2.14 Mounting boom work light LE80E00002F2 2 Boom light Harness YT15E01001D1
2.15 Mounting cab work light YT80E00006F3 18 Fore light harness YT80E01002P1
2.16 A/C Conditioner YT20M00008F3

A/C
2.17 Mounting fuel pump YT22P00003F1

Upper
frame
2.18 Name plate instal YT22T00081F2

(Electric component for AIS)
Notes : 1. The Part numbers may be changed due to modification,
so use only the numbers for reference.
2. AIS=AUTO IDLE STOP
23-7
23.2.2 HARNESS CONNECTION DRAWING
MECHATRO CONTROLLER
GOVERNOR MOTOR (INNER LS)
2.6-5
HORN SW. (L.H)
2.5
2.6-4
2.7-1
SWING PARKING SOL.
TRAVEL 1·2-SPEED SOL.
LEVER LOCK SOL.
PEDAL PRESSURE SW. (1)(OPT.)
TRAVEL 1·2-SPEED SW.
2.6-3
2.6-2
2.14-2
2.6-1
2.9-7
2.6-8 2.6-6
HORN
2.8-3 2.11-64
FUEL SENSOR
FUEL PUMP
KCME WASHER MOTOR

KCME 2MA-JMII+ AIR FILTER CLOGGING SW.
2.5-10
POWER SOCKET E/G ROOM HORN SW. (R.H) (OPT.)
LIGHT
WIPER MOTOR HARNESS WORK LIGHT (R.H) STARTER MOTOR
2.3-18-6-1
WIPER RELAY ASSY (OPT.) ALTERNATOR
BATTERY RELAY
WIPER MOTOR ON THE ROOF (OPT.) 2.9-1 ENGINE WATER TEMP. SENSOR
CN-231F GLOW RELAY
CAB WORK LIGHT (OPT.) E/G ROOM OVERLOAD INDICATE SW. ENGINE WATER TEMP. SW.
LIGHT ENGINE OIL TEMP. SW.
GAUGE CLUSTER TRAVEL ALARM
AUTO IDLE STOP RELAY 1 SAFETY RELAY
2.8-1 ENGINE ROOM LIGHT SW.
AUTO IDLE STOP RELAY 2 A/C CLUTCH
TIMER
TIMER UNIT GLOW PLUG
TUNER AM / FM
SW. ASSY (BACK LIGHT) ROTARY LIGHT (OPT.)
HOUR METER ROOM LIGHT
CIGAR LIGHTER DC/DC CONVERTER
AUTO ACCEL RELEASE SW.
COUNTER
STARTER ALARM LAMP 2.11-189
TUNER SW.
CN-67F
2.9-9
23-8 Fig. 23-4

23.2.3 CONTROLLER ASSY
CONTROLLER ASSY YT22E00032F5

No. Name Part No. Q'ty
7 SWITCH ASSY YT50E00001F1 1
8 RELAY EN24S00008P1 7
18 CAB HARNESS ASSY YT14E00023F1 1
18-6-1 INSTRUMENT PANEL HARNESS YT14E01069P1 1
18-6-2 FUSE YT73E00003F2 1
37 CONTROLLER YT22E00031F1 1
38 RELAY LC24S00001P1 3
40 COUNTER YT25S00003F1 1
Fig. 23-5 Controller assy 23-9

23.2.3-18-6-1 INSTRUMENT PANEL HARNESS : YT14E01069P1 (1/3)
23-10 Fig. 23-6 Instrument panel harness (1/3)

Fig. 23-7 Instrument panel harness (2/3) 23-11

23-12 Fig. 23-8 Instrument panel harness (3/3)

23.2.4 INSTRUMENT PANEL ASSY
YT17M00012F1
INSTRUMENT PANEL ASSY YT17M00013FE
YT17M00013FG
1 R/H PANEL ASSY YB17M00003F2 1
1-2 ACCEL POTENTIO DIAL YN52S00032P1 1
1-3 KYE SWITCH YN50S00026F2 1
1-4 MODE SELECT SWITCH YT50E00002F1 1
11 SPEAKER YT54S00006P1 2
15 COVER ASSY YT17M01031F1 1
15-4 CIGALETTE LIGHTER 2421R180F1 1
17 GAUGE CLUSTER YT59S00006F2 1
21 AUTO ACCEL RELEASE SWITCH 2479U1190F7 1
26 DC-DC CONVERTER YT77S00001P1 1
38 SOCKET YN81S00001P1 1
40 OVERLOAD INDICATE SWITCH 2479U1190F33 1
41 ROTARY LIGHT SWITCH 2479U1190F20 1
43 TUNER Local parts 1
44 ANTENNA Local parts 1
46 HOUR METER YT58S00006P1 1
Fig. 23-9 Instrument panel harness 23-13

23.2.5 UPPER ELECTRIC ASSY (1/2)
UPPER ELECTRIC ASSY YT03E00006F2

1 BATTERY RELAY YN24S00003F1 1
2 HORN CM53S00002F1 1
8 E/G ROOM LIGHT 4056R4F1 1
9 SWITCH YT50S00005P1 1
10 HARNESS YT13E01079P1 1
23-14 Fig. 23-10 Upper electric assy (1/2)

23.2.5 UPPER ELECTRIC ASSY (2/2) 23.2.5-10 E/G ROOM LIGHT HARNESS : YT13E01079P1
Fig. 23-12 E/G room light harness
Fig. 23-11 Upper electric assy (2/2) 23-15

23.2.6 UPPER HARNESS ASSY (1/4)
UPPER HARNESS ASSY YT13E00035F2

UPPER HARNESS ASSY YT13E00035F1
(Dozer spec.)
1 STARTER CABLE YT13E01026D2 1 1
2 BATTERY RELAY CABLE 2486R89D4 1 1
3 BATTERY CABLE YT13E01071D1 1 1
4 BATTERY GROUND CABLE 2486R87D1 1 1
5 RIGHT GUARD HARNESS YT13E01059P1 1 1
6 MAIN HARNESS YT13E01106P1 1 1
8 FRAME GROUND CABLE LE13E01006P1 1 1
13 HARNESS YT16E01017P1 1 —
23-16 Fig. 23-13 Upper harness assy (1/4)

Fig. 23-14 Upper harness assy (2/4) 23-17

23-18 Fig. 23-15 Upper harness assy (3/4)

Fig. 23-16 Upper harness assy (4/4) 23-19

23.2.6-1 STARTER CABLE : YT13E01026D2 23.2.6-4 BATTERY GROUND CABLE : 2486R87D1
Fig. 23-17 Fig. 23-20
23.2.6-2 BATTERY RELAY CABLE : 2486R89D4 23.2.6-5 RIGHT GUARD HARNESS : YT13E01059P1
Fig. 23-18
23.2.6-3 BATTERY CABLE : YT13E01071D1

Fig. 23-21
Fig. 23-19
23-20 Fig. 23-14 Instrument panel harness KCME (3/3)

23.2.6-6 MAIN HARNESS : YT13E01106P1 (1/2)
Fig. 23-22 Main harness (1/2) 23-21

23.2.6-6 MAIN HARNESS : YT13E01106P1 (2/2)
23-22 Fig. 23-23 Main harness (2/2)

23.2.6-8 FRAME GROUND CABLE : LE13E01006P1
Fig. 23-24
23.2.6-13 HARNESS : YT16E01017P1
Fig. 23-25
23-23
23.2.7 ENGINE HARNESS ASSY
E/G HAENESS ASSY YT16E00005F1

1 E/G SUB HARNESS YT16E01018P1 1
$%&' (

!" #

)&* &&
)&* &

$%&' % $%&' + %', %, )&* &&&

$%&' / $%&' + - & . .& .,- $
23-24 Fig. 23-26 Engine harness assy

23.2.7-1 ENGINE SUB HARNESS : YT16E01018P1
Fig. 23-27 Engine harness 23-25

23.2.8 FLOOR PLATE HARNESS ASSY 23.2.8-1 UNDER FLOOR HARNESS : YT13E01108P1 (1/2)
FLOOR PLATE HARNESS ASSY YT13E00034F1

1 UNDER FLOOR HARNESS YT13E01108P1 1
3 GROUND CABLE LE13E01005P1 1
23-26 Fig. 23-28 Floor plate harness assy Fig. 23-29 Under floor harness (1/2)
23.2.8-1 UNDER FLOOR HARNESS : YT13E01108P1 (2/2)
23.2.8-3 GROUND CABLE : LE13E01005P1

100 (3.94 )
LA308 5B E E 5B E
1PAM
YAZAKI 7122-3010
Fig. 23-31 Ground cable
Fig. 23-30 Under floor harness (2/2) 23-27

23.2.9 CAB HARNESS ASSY (1/2)
CAB HARNESS ASSY YT14E00019F1

1 CAB RIGHT FRONT HARNESS YT14E01062P1 1
2 LEFT INSTRUMENT HARNESS YT14E01065P1 1
7 RIGHT INSTRUMENT HARNESS YT14E01061P1 1
23-28 Fig. 23-31 Cab harness assy (1/2)

23.2.9 CAB HARNESS ASSY (2/2)
Fig. 23-32 Cab harness assy (2/2) 23-29

23.2.9-1 CAB INSTRUMENT HARNESS : YT14E01062P1
23-30 Fig. 23-33 Cab instrument harness

23.2.9-2 LEFT INSTRUMENT HARNESS : YT14E01065P1
Fig. 23-34 Left instrument harness 23-31

23.2.9-7 RIGHT INSTRUMENT HARNESS : YT14E01061P1
23-32 Fig. 23-35 Right instrument harness

23.2.10 BATTERY : 2411U25
Fig. 23-36 Battery
23-33
23.2.11 CAB ASSY
CAB ASSY YT02C00030F1

2 FRONT WINDOW ASSY YT50C00002F1 1
2-8 WIPER ASSY YT53C00011F1 1
2-37 WIPER HARNESS YT02C01106P1 1
25 DOOR SWITCH YT50S00004P1 1
61 CURL CODE HARNESS YT02C01104P1 1
64 CAB HARNESS YT02C01216P3 1
65 ANTENNA YT54S00018F1 1
68 ROOM LAMP YT80S00001P1 1
189 ROOM LAMP HARNESS YT02C01513P1 1
195-3 INTER LOCK SWITCH YT50E00003P1 1
23-34 Fig. 23-37 Cab assy

23.2.11-2-37 HARNESS : YT02C01106P1 23.2.11-61 CURL CODE HARNESS : YT02C01104P1 23.2.11-64 CAB HARNESS : YT02C01216P3
Fig. 23-38 Fig. 23-39 Fig. 23-40
23.2.11-65 ANTENNA : YT54S00018F1
Fig. 23-41
23.2.11-189 ROOM LAMP HARNESS : YT02C01513P1
Fig. 23-42
23-35
23.2.12 MOUNTING CAB 23.2.13 MOUNTING LIGHT 23.2.14 MOUNTING BOOM LIGHT
MOUNTING CAB YT02C00002F1 MOUNTING LIGHT YT80E00001F1 MOUNTING BOOM LIGHT LE80E00002F2
No. Name Part No. Q'ty No. Name Part No. Q'ty No. Name Part No. Q'ty
4 WASHER TANK YT54C00003F1 1 1 LIGHT YT80S00002F1 1 1 LIGHT YN80S00012F1 2
2 BOOM LIGHT HARNESS YT15E01001D1 1
Fig. 23-43 Mounting cab

Fig. 23-46 Mounting boom light
23.2.12-4 WINDOW WASHER TANK & PUMP 23.2.14-2 BOOM LIGHT HARNESS : YT15E01001D1
G CB104
CAP · 7120-1010
(1.2 )
30
870 (34.3 )
770 (30.3 ) 2970 (9´9 )
G
30 30 G
G
(1.2 ) (1.2 )
CB104
CAP · 7120-1010 1PAM
YAZAKI 7122-2810
TARMINAL 7114-2020
Fig. 23-45
Fig. 23-47
Fig. 23-44
23-36
23.2.15 MOUNTING CAB WORK LIGHT
MOUNTING WORK LIGHT YT80E00006F3

6 SWITCH 2479U1190F1 1
18 FOUR LIGHT HARNESS YT80E01002P1 1
Fig. 23-48 Mounting cab work light 23-37

23.2.15-18 FOUR LIGHT HARNESS : YT80E01002P1
Fig. 23-49
23-38
23.2.16 AIR CONDITIONER
AIR CONDITIONER (A/C) YT20M00008F3

1 A/C ASSY YT20M00009F1 1
1-3 SENSOR YT52S00003F1 1
1-11 A/C CONDITONER YT20M00004F2 1
2 AIR DRYER ASSY YT96V00001F3 1
2-1 RECEIVER TANK YT54S00002P1 1
3 AIR COMPRESSOR YT91V00001F1 1
4 PANEL YT20M01104F1 1
23.2.16-3 AIR COMPRESSOR : YT19V00001F1
Fig. 23-51 Detail of compressor wiring
Fig. 23-50 Air conditioner
23-39
Fig.Copyright
23-49 © 2018 Kobelco Construction Machinery Co.,Ltd. All rights reserved. [S5YT0004E01] [0207CsCsspWbYs]
23.2.17 MOUNTING FUEL PUMP 23.2.17-1 FUEL PUMP ASSY
MOUNTING FUEL PUMP YT22P00003F1 FUEL PUMP ASSY YF22P00003F3

No. Name Part No. Q'ty No. Name Part No. Q'ty
1 FUEL PUMP ASSY YF22P00003F3 1 1 FUEL PUMP YF22P00002F3 1
23-40 Fig. 23-52 Mounting fuel pump Fig. 23-53 Fuel pump assy
23.2.18 NAME PLATE INSTAL (ELECTRIC COMPONENT FOR AUTO IDLE STOP)
NAME PLATE INSTAL YT22T00081F2

1 SWITCH YN50S01004D5 1
2 LIGHT ASSY LS80E00001D1 1
Fig. 23-54 Cab switch instal
23-41
[MEMO]
23-42
24. COMPONENTS SYSTEM
TABLE OF CONTENTS
24.1 HYDRAULIC COMPONENTS ............................................................................................ 24-3

24.1.1 HYDRAULIC PUMP & REGULATOR ....................................................................... 24-3
24.1.2 PILOT VALVE (ATT) .................................................................................................. 24-13
24.1.3 PILOT VALVE (TRAVEL) .......................................................................................... 24-17
24.1.4 CONTROL VALVE .................................................................................................... 24-22
24.1.5 SWING MOTOR UNIT ............................................................................................... 24-53
24.1.6 TRAVEL MOTOR ...................................................................................................... 24-63
24
24.1.7 SWIVEL JOINT ......................................................................................................... 24-79
24.1.8 CYLINDER ............................................................................................................... 24-81
24.2 ELECTRIC EQUIPMENT ................................................................................................... 24-87
24.2.1 ELECTRIC EQUIPMENT LIST ................................................................................. 24-87
24.2.2 SPECIFICATION OF ELECTRIC EQUIPMENTS ...................................................... 24-90
24-1

S5YT2404E01
(NHK)
24-2
24.1 HYDRAULIC COMPONENTS

24.1.1 HYDRAULIC PUMP & REGULATOR
24.1.1.1 SUMMARY
(1) General view and hydraulic port
Code Port name Size

A1, A2 Delivery port PF 3/4
A3 Delivery port PF 3/8 Spec. 1
A4 Relief port PF 3/8
A5 Delivery port PF 1/2
a1, a2 Gauge port PF 1/4
a3 Air Bleed port PF1/4 Pz
B1 Suction port 48
B2 Suction port PF 1 Spec. 2
Dr1, Dr2 Drain port PF 1/2 C2
P3 Power shift port of the pilot pump PF 1/4
Pf Power shift port of the Pilot Pressure PF 1/4
C2 Pcl port PF 1/4
Pz Power shift port PF 3/8 Spec. 2 (side face)
Spec. 1
Spec. 2
Spec. 2 (bottom face)

Fig. 24-1 Hydraulic pump & regulator
(2) Specifications
Table 24-1

! 12 3 45 12 3 ;5
" 6 78& & 6 78& &
. +% 9 :
" % /#
"0 $ ;9
9<
$ % "

"0 % 77
4 :
% ,/
/
$ $ +$ $ . > $ +$
$
- $
-= $ $
-
- . +% ;= ;=
$ %"0 $% /#
9
= ;7
49 9
=
% "

"0 %
= 94=

=
% ,/
/
# $ %%

&
' %%
( 9
; 99
44
) *$+%% ,

7
$ $ $ $

$ & &
3( ! $
3(
24-3
24.1.1.2 CONSTRUCTION
Apply adhesive
(Three bond No.1303B)
Coat the circumference

of the oil seal with
adhesive
(Loctite No.222)
Fig. 24-2 Construction of hydraulic pump & regulator (1/2)
24-4
SECTION VV
GEAR PUMP
SECTION WW SECTION XX
SECTION YY
SECTION ZZ
Fig. 24-3 Construction of hydraulic pump & regulator (2/2)
24-5
Table 24-2
No. NAME Q’ty No. NAME Q’ty
111 SHAFT 1 624 SPRING SEAT 1
114 COUPLING 1 625 SPRING 1
115 COLLAR 1 626 SPRING 1
123 ROLLER BEARING 1 627 ADJUST STEM (E1) 1
124 NEEDLE BEARING 1 630 LOCK NUT : M30 1
127 SPACER 1 641 SPRING COVER 1
141 CYLINDER BLOCK 1 651 SLEEVE 1
151 PISTON 10 652 SPOOL 1
152 SHOE 10 653 PIN 1
153 PLATE 1 654 PIN 1
156 SPHERICAL BUSHING 1 655 PIN (Pf PISTON) 1
157 SPRING 10 656 PIN 1
212 SWASH PLATE 1 660 ADJUST SCREW (R) 1
214 BUSHING 1 661 LOCK NUT : M14  1.5 1
215 PIVOT BALL 1 662 SPRING SEAT 1
216 PIVOT BALL 1 663 SPRING 1
271 CASING 1 664 POPPET 1
273 COVER 1 665 SEAT (R) 1
312 VALVE COVER 1 666 ADJUST SCREW (E) 1
313 VALVE PLATE 1 667 ADJUST STEM (E2) 1
401 SOCKET BOLT : M16 40 4 668 PISTON (E) 1
402 FLANGE SOCKET BOLT ; M8  16 2 700 O-RING : 1B G35 1
403 SOCKET BOLT : M16  70 1 701 O-RING : 1B G55 1
404 SOCKET BOLT : M6  20 9 702 O-RING : 1B G135 1
467 DRAIN PLUG : PF 1/2 1 705 O-RING : 1B P16 2
468 PLUG : PF1/4 1 706 O-RING : 1B P11 7
490 PLUG : NPTF1/16, Meck coated 14 707 O-RING : 1B P18 1
492 PLUG : PT1/8, Meck coated 1 708 O-RING 1
493 PLUG : PT3/8 1 709 O-RING : 1B P26 1
710 O-RING 1
508 ORIFICE SCREW : NPTF1/16 4 751 GASKET 1
531 TILTING PIN : M16  1.5 1 774 OIL SEAL 1
532 SERVO PISTON : M16  1.5 1 787 BACKUP RING 1
534 SET SCREW : M27  1.5 1 789 BACKUP RING 2
535 STOPPER 1 801 LOCK NUT : M8 1
541 SEAT 2 803 LOCK NUT : M27  1.5 1
543 STOPPER 2 824 SNAP RING 1
545 BALL 2 825 SNAP RING 1
548 FEED BACK PIN 1 885 SPRING PIN 2
611 FEED BACK LEVER 1 901 EYE BOLT : M8 1
621 COMPENSATING PISTON 1
24-6
24.1.1.3 FUNCTION
(1) This pump is of split flow double-pump type capable of obtaining two independent delivery lines by branching off
the oil delivered from single cylinder block (141) to two delivery ports by the action of the valve plate (313). Fur-
ther, the pump has a common suction construction that integrates the suction of the gear pump at the rear end
and the suction of the main pump. The pump contains a relief valve for the gear pump for pilot pressure.
The pump consists mainly of :
The rotary group that makes rotary-movements, The swash plate group that changes the delivery rate, and the
regulator group that controls the tilting angle.
Fig. 24-4 Rotary group

(2) Rotary group (See Fig. 24-4)
The rotary group consists of shaft (111), cylinder block (141), piston (151), shoe (152), plate (153), spherical
bushing (156), and spring (157). The shaft is supported by bearings (123, 124) at its both ends. The shoe makes
a spherical joint caulked to the piston and relieves thrust load occurring by load pressure. Since the shoe slides
lightly on swash plate (212), it has a pocket that achieves hydraulic balance. The subgroup consisting of the pis-
ton and the shoe is pressed against swash plate (212) by spring (157) via the plate that slides smoothly on swash
plate (212). Likewise, the cylinder block is pressed against valve plate (313) by a spring.
Now, if the shaft is driven by the engine, the cylinder block (141) is driven (rotates) via a spline joint. If the swash
plate is tilted, the pistons arranged in the cylinder block make reciprocating motion relative to the cylinder while
rotating with the cylinder block. Now let us take a lock at a single piston : While the cylinder block makes one
turn, the piston moves away from valve plate (313) (the process of sucking oil) in 180° and moves close to valve
plate (313) (the process of deliverying oil) in the remaining 180°. The valve plate is provided with one suction
port and two delivery ports that are arranged in valve cover (312). The oil sucked into the cylinder block via the
suction port is branched off to two delivery ports of the valve plate and is connected to the external piping past
valve cover (312).
24-7
(3) Swash plate group (See Fig. 24-5)

The swash plate group consists of swash plate (212), pivot balls (215, 216), tilting bushing (214), tilting pin (531),
and servo piston (532). The swash plate (212) is supported by pivot balls (215, 216) on two spherical faces
formed on the opposite side of the shoe sliding surface. The regulator controls the supply and delivery of hy-
draulic oil to and from the large diameter chamber of the servo piston. The result is that the servo piston is moved
to the right and left. The swash plate swings pivot balls (215, 216) via the spherical part of tilting pin (531) and
changes the tilting angle ( ) or the delivery rate of the pump.
Fig. 24-5 Swash plate group
24-8
(4) Regulator group

1) Summary (See Fig. 24-6 and Fig. 24-7)
The regulator group consists of feedback lever (611), compensating piston (621), springs (625, 626), pilot
sleeve (651), and pilot spool (652).
Thus it makes up a hydraulic servo mechanism consisting of servo piston (532) and a positional feedback.
The delivery pressures P1, P2 of the pump are combined in the regulator and changes the delivery rate of
the pump according to the level of he pressure as shown in Fig. 24-6. For this reason, the input torque is
kept nearly constant which realizes a total horsepower control, in order to prevent the engine from being
overloaded.
This pump system is equipped with one or two gear pumps at its rear end. The load pressures P3 Pf of the
pump enables power shift control that shifts the horsepower set as illustrated in the figure on the right.
DELIVERY RATE Q
DELIVERY PRESSURE (P1+P2)/2

Fig. 24-6 Power shift control chart
COMPENSATING PISTON (621)
No.3 PUMP SHIFTED PIN (P3 PISTON)(655)
HORSEPOWER PORT CHECK VALVES
PILOT REDUCED (541),(543),(545)
HORSEPOWER PORT
ORIFICE
SPOOL (652) (508)
SPRING (626)
PISTON (668)
PZ GAUGE
SPRING (625) PORT
SLEEVE (651)
FIXED PIN (653)
FEEDBACK LEVER
(611)
SERVO PISTON (532)
TILTING PIN (531)
FEEDBACK PIN (548)
SWASH PLATE (212) DRAIN PORT SUCTION PORT
Fig. 24-7 Functional explanation of regulator

2) Function of added total horsepower control (See Fig. 24-7)
If pump delivery pressure P1 or delivery pressure P2 rises, the mean pressure (P1+P2)/2 acts upon the
stepped section of compensating piston (621) by the action of four orifices (508). In this case, spool (652) is
pushed to the right and moves till the action of spring (625) and spring (626) balances the hydraulic force.
As the spool moves to the right, the oil path to the larger diameter part of servo piston (532) consisting of the
sleeve and the spool opens. This admits the delivery pressure to push the spool to the left.
The delivery pressure enters the check valve [seat (541), stopper (543), and ball (545)] from which the higher
of the pressures P1, P2 is put out selectively to the smaller diameter side of the servo piston so that the de-
livery pressure is admitted at all times. In the meantime, swash plate (212) and servo piston (532) are linked
together by tilting pin (531). This decreases the tilting angle which in turn decreases the delivery rate of the
pump, in order to prevent the engine from being overloaded. The action of the servo piston is transmitted to
feedback lever (611) via the feedback pin (548). The feedback lever turns on pin (653) that is fixed to casing
(271) and moves sleeve (651) to the right. The sleeve moves till the opening of the path to the larger diameter
part of the servo piston closes and stops just when the opening is closed.
If the pump delivery pressures P1, P2 decrease, the spool is pushed back by the action of springs (625, 626).
24-9
This connects the oil path for the larger diameter of the servo piston to the tank.
This moves the servo piston to the right by the oil pressure from the smaller diameter side. The result is that
the tilting angle ( ) increases which in turn increases the delivery rate of the pump.
Then the feedback lever turns on the pin which moves the sleeve to the left till it closes the opening of the
spool-sleeve.
3) Horsepower shift control function
The function is capable of power shift control that changes a set horsepower of the pump with the load pres-
sure P3 of the gear pump installed to the rear end of the pump as a command pressure, as shown by doted
lines in Fig. 24-8.
The power shift pressure P3 is admitted to the left end of pin (655). The spool moves to the right as load
pressure P3 of the No.3 pump rises. This decreases the tilting angle of the pump as mentioned above which
in turn decreases the horsepower set. Inversely, the horsepower set rises as pressure P3 falls.
Likewise, power shift control is possible if the pump horsepower is changed with load pressure Pf of the gear
pump installed to the rear end of the pump as a command pressure. Power shift pressure Pf acts upon the
mount (smaller diameter) of the compensating piston. As the load pressure of the pilot pressure pump rises,
the tilting angle ( ) of the pump decreases which in turn reduces the horsepower set as mentioned above.
Inversely, the horsepower set rises as the pressure Pf falls.
DELIVERY RATE Q

Fig. 24-8 Power shift control
4) With regard to power up port (Pz port)
This system is used to shift up the main pump set power when the gear pump for slewing and dozer opera-
tions (hereafter called "4th pump") is unloaded.
• Explanation of the system
When the 4th pump is loaded, the pump set power is set to the power close to power B shown in Fig. 24-9 to
prevent engine stalling. Consequently, when the 4th pump is unloaded, the set power is set to the power close
to power A automatically, and it is anticipated that the delivery rate down in the range of high pressure area
may cause a large speed down of this machine.
To avoid this problem, the set power close to power A changes as shown in by a function of pressure signal
onto Pz port, preventing the delivery rate down in the range of high pressure area.
DELIVERY RATE Q
DELIVERY RATE Q
Power B Power A Power B Power A
DELIVERY PRESSURE (Pa+Pb) DELIVERY PRESSURE (Pa+Pb)
In power up operation
Fig. 24-9 Pump P-Q curve
24-10
24.1.1.4 ADJUSTING THE REGULATOR

The maximum flow and the horsepower control (630) (666)
characteristics may be adjusted by the adjust (HORSEPOWER CHARAC-
TER ADJUST SCREW E)
screws of the regulator. However, since they are set (801)
(667) (INPUT HORSEPOWER
to optimum at shipment, use care so as not to ADJUST SCREW) (E2)
tamper with these adjust screw in normal condition.
(803) (534) (MAX.FLOW ADJUST SCREW)
Fig. 24-10 Regulator adjust screws

(1) Adjusting the max. flow (See Fig. 24-10, Fig. 24-
11)
DELIVERY RATE Q
Loosen lock nut (803) and tighten (or loosen) set
screw (534) to adjust the flow. If the set screw (534)
is tightened 1/4 turn, the theoretical flow decreases
by approx. 0.7 cm3/rev. Only the max. flow changes
by it, leaving other control characteristics un-
changed.
Fig. 24-11 Max. flow adjustment
(2) Adjusting the horsepower control characteristics
(See Fig. 24-10, Fig. 24-12)
DELIVERY RATE Q
Adjust the spring by loosening lock nut (630) and

tightening (or loosening) adjust screw (E) (666). If
the adjust screw (E) is tightened 1/4 turn, the com-
pensating control start pressure rises by approx.
1.2 MPa (180 psi), as shown in Fig. 24-12 on the
right. If adjust screw (E) is rotated by N turns, a set
spring pressure changes also ; return the set screw DELIVERY PRESSURE (P1+P2)/2
(667) by N  1.2 turns. Fig. 24-12 Adjusting the horsepower control char-
acteristics
(3) Adjusting the input horsepower
(See Fig. 24-10 and Fig. 24-13.)
DELIVERY RATE Q
Adjust the spring pressure by loosening lock nut

(801) and tightening (or loosening) set screw (667).
The flow increases as in the figure on the right if the
adjust screw is tightened. (The input horsepower
increases also.) If the set screw is tightened by 1/4
turn, the theoretical flow increases by approx.
2.5cm3/rev. DELIVERY PRESSURE (P1+P2)/2
Fig. 24-13 Adjusting the input horsepower
24-11
Control chart of pump Models SK70SR-1ES

2.0 MPa 280psi
66±1L 17.4±0.3G
Standard specification (Spec.1)
H mode A/C power cut pressure Pf=0K (0 psi)
70 11.3±0.5MPa
(18) S mode 64.6L
1640±71psi
17.0G
60
(16) FC mode
Pf
=0
MP
Delivery flow rate L/min (gal/min)
a
50 2470psi
(0
(13)
ps
9.0G
i)
17.1MPa
34.2L
40
(11)
Pz = 3.4MPa (500psi)
30
(8) 4270psi
5.2G
29.4MPa
20 19.5L
(5) 18.9MPa
25.1L 29.4MPa
2740psi 12.5L
6.6G 4270psi
10 3.3G
(3)
0
4.9 (710) 9.8 (1420)14.7 (2130) 19.6 (2840) 24.5 (3550) 29.4 (4270)
Pd1+Pd2
Delivery pressure MPa (psi)
280psi 710±210psi
2
17.4±0.3G 17.1G
2.0MPa 4.9±1.5MPa Control chart of pump SK70SR-1ES Dozer spec. (Spec.2)
H mode 66±1L 65.6L 1640±71psi
17.0G A/C power cut pressure Dozer pump pressure
70 11.3±0.5MPa
(18) a Pf = 0MPa P3 = 1.96MPa
64.6L
S mode 9.3MPa b Pf = 3.4MPa P3 = 1.96MPa
2.9MPa
Pf 500 Pa
66.9L 64.9L c Pf = 0MPa P3 = 19.6MPa

Pf
Pf
Pf 0ps a P
= 0 psi P
60
(0 Pa
(5 .4M
=3
=3
= 0 i)
( .4M
430psi 1350P
(0 Pa
M
d Pf = 3.4MPa P3 = 19.6MPa
ps P (28419.6
0 P
(16)
ps
M
17.7G 17.1G
i) 3
i) P3 280 MPa
FC mode
)
Delivery flow rate L/min (gal/min)
= 1 0psi MPa
(2 .6M
50
3=
3=
= 1 psi
84 P
2470psi 2460psi
(2 6M
9
(13)
( 96
80 Pa
0p
.9
9.0G 6.9G
1.
ps
si)
17.1MPa 17.0MPa
a
i)
)
34.2L 25.4L
)
40
(11) 2740psi
6.9G
12.5MPa 18.9MPa 4270psi
26.1L 25.1L 3.3G
30 29.4MPa
1540psi 1820psi
(8) 12.5L
7.0G 6.9G
10.6MPa
26.4L
20
(5) 4270psi
2.7G
29.4MPa
10 10.2L
(3) 29.4MPa
3970psi 27.3MPa 5.4L
4270psi
1.5G 5.7L
0 1.4G
4.9 (710) 9.8 (1420) 14.7 (2130) 19.6 (2840) 24.5 (3550) 29.4 (4270)
Pd1+Pd2
Delivery pressure MPa (psi)
2
24-12
24.1.2 PILOT VALVE (ATT)
24.1.2.1 SUMMARY
(1) General view
SINGLE SINGLE
PORT 2
OPERATION OPERATION
ANGLE ANGLE
(PORT 2,4) (PORT 1,3) PORT 3
T PORT
P PORT
PORT 1
PORT 4
VIEW A
Parts number PX30V00043F2

Max. primary pressure 6.9MPa (1,000 psi)
Rated flow 15 L/min (4.0 gal / min)
Weight 1.6 kg (3.5 lb)
A
PORT 1,3
50.0 4.9 4.9 50.0
Secondary pressure (MPa)
Secondary pressure psi
40.8 4.0 4.0 40.8

SINGLE OPERATION
3.43 TORQUE
35 3.09 +0.59
Operation torque
2.27{23.2}
31.5+60 0
Operation torque
30.6 3.0 SECONDARY 3.0 30.6

PRESSURE
2.29 23.3
2.16 22.0
20.4 2.0 2.0 20.4
19 1 1.86 0.1 1.73 17.6
10.2 1.0 1.0 10.2

+0.049
-0.074
1.16{11.8} 0.94 9.6
5.5-0.75
+0.50
0.54 0.98{10.0}
0 0 0
0 1.1 2 4 5.5 6 6.5 7
Push rod stroke mm
0 5 10 15 19
Operation angle (deg.)
PORT 2,4
50.0 4.9 4.9 50.0
SINGLE
OPERATION
Secondary pressure psi
TORQUE
40.8 4.0 4.0 40.8

SECONDARY
3.43 PRESSURE
Operation torque
Operation torque
35 3.09+0.59
0
31.5+60 3.0 3.0 30.6
30.6
2.37 24.1
2.34{23.8} 2.22 22.7
20.4 2.0 2.0 20.4
19 1 1.73 18.3
1.86 0.1
10.2 1.0 1.0 10.2

+0.049 0.94
-0.074
1.16{11.8}
9.6
5.5+0.50
-0.75
0.54 0.98{10.0}
0 0 0 0
0 1.1 2 4 6 7.5 8 8.5 9.4
Push rod stroke mm
0 5 10 15 20 25
Operation angle (deg.)
24-13
APPLY GREASE 312

ON ROTATIONAL
PART OF THE
UNIVERSAL JOINT
302 301
501
APPLY GREASE 1 3 2 4
213 ON TOP
511 HYDRAULIC SYMBOLS
507 151
RIGHT PILOT VALVE
PORT
OPERATION
510 NO.
211 1 BUCKET DIGGING
506 2 BOOM DOWN
3 BUCKET DUMP
214
216 4 BOOM UP
LEFT PILOT VALVE

503 508
PORT
OPERATION
NO.
221
509 1 SLEWING LEFT
2 ARM OUT
201 3 SLEWING RIGHT
4 ARM IN
217
SECONDARY 101
PRESSURE PORT 2,4 PORT 1,3
ADJUSTING SHIMS
Fig. 24-14 Pilot valve-Sectional view

Table 24-3
No. NAME Q’TY No. NAME Q’TY No. NAME Q’TY
101 CASING 1 217 WASHER 2 4 506 SPRING SEAT 2
151 PLATE 1 221 SPRING 4 507 SPRING SEAT 2
201 SPOOL 4 301 JOINT; M14 1 508 SPRING 2
211 PLUG 4 302 DISK 1 509 SPRING 2
213 SEAL 4 312 ADJUSTING NUT; M14 1 510 SPRING 4
214 O-RING; 1B P20 4 501 BELLOWS 1 511 PUSH ROD 4
216 SPRING SEAT 2 503 SPRING SEAT 2
24-14
24.1.2.3 OPERATION
(1) Lever in neutral position (See Fig. 24-15)
In this case, the force of the secondary pressure
setting spring (509) that determines the output
pressure of the pilot valve is not transmitted to the
spool (201). Accordingly, the spool (201) is pushed
up by the return spring (221) and spring seat (216)
permitting the output port 2, 4 to connect with the
tank port T. This makes the output pressure equal
to the tank pressure.
Fig. 24-15 Lever in neutral position

(2) When the Lever is tilted (See Fig. 24-16)
When the lever is tilted, the push rod (511) strokes.
The spool (201) and 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 flow out to the port 2, 4, to produce a pres-
sure.
Fig. 24-16 When Lever is tilted

(3) The Lever being held (See Fig. 24-17)
When the lever is tilted till the pressure of the port
2, 4 rises to an oil pressure corresponding to the
set spring force, the hydraulic pressure is balanced
with the spring (509) force. And when the pressure
of the port 2, 4 rises above a set pressure, the port
P are closed and the port T are opened. When the
pressure of the port 2, 4 falls below a set pressure,
the port P are caused to open and the port T are
caused to close, thus holding the second pressure
constant.
Fig. 24-17 Lever being held
24-15
(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 pres-
sure 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.
24-16
24.1.3 PILOT VALVE (TRAVEL)
24.1.3.1 OUTLINE
(1) General view
4-M8 X P1.25
T=16.7 N·m
(21.3 lbf·ft)
Back side
2-PF1/4
2-PF1/4 T=29.4 N·m
T=29.4 N·m (21.7 lbf·ft)
(21.7 lbf·ft)
4-PF1/4
T=29.4 N·m
(21.7 lbf·ft)
Hydraulic diagram
Fig. 24-18
(2) Specifications
Parts No. YN30V00070F1

Type PVD6PC4017A
Max.primary pressure 6.9MPa (1000 psi)
Rated flow 10 L/min (2.64 gal/min)
Weight 3.9 kg (8.6 lbs)
(3) Performance characteristics

Operation torque kgf·m (lbf·ft)
40.8 1.224
Operation torque
Secondary pressure kgf/cm2
Operation torque (N·m)
30.6 0.918
0.916
24.0 0.600
20.4 0.612
0.570
0.524
10.2 0.306
5.5 Secondary pressure
Torque required (Damper)
0 0 18.9~2.8 N·m (13.9~2.07 lbf·ft)
Push rod stroke (mm) Push rod speed 0.0275 m/s
Actual required torque is the valve
operation torque shown in left diagram
Operation angle (deg)
adding to damper operation torque.
Fig. 24-19
24-17
Fig. 24-20 Assembly view of pilot valve (travel)
Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
101 CASING 1 6.9 (5.1) 252 PLUG 6
102 CASING (Damper) 1 11.8 (8.7) 253 RO PLUG 2
191 SEAT 1 2 261 O-RING 3
192 SEAT 2 2 263 O-RING 2
193 BUSHING 2 2 8.8 (6.5)} 271 CAPSCREW 4
194 BALL 2 301 SPOOL 4
201 COVER 2 311 SPRING SEAT 4
202 PLUG 4 313 WASHER 4
203 GREASE CUP 4 324 SPRING 4
210 SEAL 4 335 SPRING 4
211 O-RING 4 336 SPRING 4
212 O-RING 4 413 CAM SHAFT 2
213 O-RING 2 414 BUSHING 4
214 PUSH ROD 4 420 CAM 2
217 SHIM 4 471 BALL 4
218 SPRING SEAT 4 6.9 (5.1) 472 LOCK NUT 2
224 PISTON 4 501 BOOTS 2
225 BALL 12
29.4 (21.7) 251 RO PLUG 3
24-18
24.1.3.2 FUNCTION
1. Reducing valve
(1) Neutral (Fig. 24-21)
Spool (301) is pushed up by spring (335) (for return)
via spring seat (311) and washer (215) and is locat-
ed in the neutral position as shown in the cross-sec-
tional view. Therefore, since the output port
connects only with port T by the spool select func-
tion, the pressures at output ports 1, 2 are equal to
that of port T.
311
335
301
PORT 2 (4) PORT 1 (3)

Fig. 24-21
(2) The control of the remote control valve is tilted from NEUTRAL
its neutral (Fig. 24-22) At the full stroke
If cam (420) is rotated clockwise in the cross–sec-
tional view, push rod (214) on port 1 is pushed
420
down. This moves the spool down via washer 1,
spring seat (for secondary pressure setting), spring
214
(324), washer 2 (217), and washer 3 (313) and con-
nects port P with port 1. The oil supplied by the pilot
pump runs to port 1 and generates pressure.
If the control lever (or pedal) is inclined and when
the pressure at port 1 rises to a level equivalent to
the action of the spring that sets the secondary
311
pressure, the hydraulic pressure acting on the
spool balances the spring action, thereby keeping 324
the output pressure at port 1 constant. The spool at
port 2 is held neutral ; the oil returning from the con- 217
313
trol valve is discharged via port T.
On some specifications, the push rod comes in di-
rect contact with the top of the spool in the neigh-
borhood of the maximum angle of the control. This
pushes in the spool forcibly which connects port P
with the output port and makes the pressures at PORT 2 (4) PORT 1 (3)
both ports equal. Fig. 24-22
24-19
2. Damping mechanism of the control

(1) Neutral
The push rod is pushed up by springs (336) via piston (224) (damping) and is located as shown in the cross-
sectional view.
(2) The control is inclined from its neutral position :
[Refer to the functional explanation (1) of damping]
If the cam is turned clockwise in the cross-sectional view, the push rod on the port 1 side is pushed down which
brings the piston down.
On that occasion, the oil in the damping piston chamber is discharged through the orifice. The pressure then
generated creates a damping force.
In the meantime, the push rod on the port 2 side moves up by the damping spring via the piston.
On that occasion, the oil in the tank chamber is sucked into the damping piston chamber through the ball checks
(3 places) that consists of bushing (223) and ball (225). The oil outside of the piston chamber gets out of the path
to port T, from the top end of the casing.
CAM
PUSH ROD
ORIFICE
PISTON
PISTON CHAMBER
If the lever is stroked in

the arrow direction from
its neutral, the oil in the
right-hand (left-hand)
piston chamber is
discharged from the
orifice. Damping force
occurs by the pressure
then generated.
BALL
PORT 2 (4) PORT 1 (3)
24-20
(3) The control lever (or pedal) is inclined from its maximum angle to its opposite side :
[Refer to the functional explanation (2) of damping.]
On the cross-sectional drawing, if the cam is tilted in its full clockwise direction and then turned counterclockwise,
the push rod on the port 2 side is pushed down. This moves the piston down.
On that occasion, the oil in the damping piston chamber is discharged from the orifice of the piston. The pressure
then generated creates a damping force.
In the meantime, the push rod on the port 1 side moves spring (335) (for return) and damping spring (336) up-
wards.
The oil in the tank chamber is sucked into the damping piston chamber through the ball checks (3 places) con-
sisting of a bushing and a ball. The oil outside of the piston chamber gets out from the top end of the casing to
the path that leads to the tank port.
That is to say, the mechanism is so constructed that damping force acts on any tilting operations i.e. from neutral
to full tilting or from full tilting to neutral.
NEUTRAL
At the full stroke
CAM
PUSH ROD The oil outside of the piston

flows out of the path to the
T port, from the top end of
the casing
( at operation)
PISTON
Oil
When the lever is neutral DAMPING
to reverse direction, the SPRING
push rod is pushed up by
the damping spring.
( operation) The oil in the piston
chamber is discharged
The oil in the T line through the orifice.
is sucked into the The oil then created
damper generates a damping
chamber through the ball force.
check (3 places).
( at operation) ( at operation)
When the lever is operated RETURN
in the reverse direction SPRING
(from to state), the
left-hand piston serves as a
damper piston this time.
Damping force is
generated on both
at all times.
PORT 2 (4) PORT 1 (3)
24-21
24.1.4 CONTROL VALVE
24.1.4.1 SPECIFICATIONS
(1) General view and hydraulic ports
6-PF1/2
ACTUATOR PORT 3-M12
(A1~A3, B1~B3) DEPTH OF TAPPED HOLE 19
ORV-A2
ORV-B2
PF1/4 (Pb2)
LOCK
VALVE
RELEASE
ORV-A3
ORV-B3
PF1/4(DR5) 2-M12
DRAIN PORT ROD SIDE
DEPTH OF TAPPED HOLE 5
HEAD SIDE VIEW A
6-PF1/2
3-M12 2-PF1/2 (P1,P2)
ACTUATOR PORT
DEPTH OF TAPPED FP TANK PUMP PORT
(C1~C3, D1~D3)
HOLE 19
M12, DEPTH 19
ORV-D3
PF1/4 (Pd2')
ORV-C3
HEAD SIDE
10-PF1/4 PF1/4 (DR2) PF1/4 (Pc3')
PILOT PORT DRAIN PORT ROD SIDE LOCK VALVE
PF1/4 (PS)
RELEASE
PS,DR1,Pb1~Pb4 PF1/4 (DR3)
Pc1~Pc4 DRAIN PORT
2-M12
DEPTH OF TAPPED HOLE 15
Fig. 24-23 General view and hydraulic ports (1/2)
24-22
Item Spec. Tightening

Port torque Port
N·m name Description
Part No. YT30V00001F4 size
(lbf·ft)
Model BCV75-A1 78~88
PF3/4 T1 Tank port
Main relief valve set pressure 29.4 MPa (4270 psi) (58~65)
(attach, travel) at 28 L/min (7.4 gal/min) P1 Pump A1 port
P2 Pump A2 port
Over load relief valve
32.9 MPa (4760 psi) A1 Travel right port (forward)
set pressure
at 20 L/min (5.3 gal/min) B1 Travel right port (reverse)
(OR-A2, A3, B2, B3, C3, D3) C1 Travel left port (reverse)
Pilot pressure (MAX) 3.9 MPa (569 psi) D1 Travel left port (forward)
59~69
PF1/2 A2 Boom up port
(43~51)
B2 Boom down port
C2 Swing port (right)
D2 Swing port (left)
A3 Bucket digging port
B3 Bucket dump port
C3 Arm in port
D3 Arm out port
39~49
PF3/8 DR4 Drain port
(29~36)
PS Load check valve for swing priority
PF3/8 (DR2) pilot port
TANK PORT
PS' Higher pilot pressure select port for swing
P0 Travel straight spool select pilot port
TRAVEL STRAIGHT Pa1 Travel right pilot port (forward)
Pb1 Travel right pilot port (reverse)
TRAVEL (L) TRAVEL (R)
Pc1 Travel left pilot port (reverse)
SWING
Pd1 Travel left pilot port (forward)
BOOM
Pa2 Boom up pilot port
BUCKET Pb2 Boom down pilot port
ARM Pb2' Boom lock valve release pilot port
BYPASS
CUT Pc2 Swing right pilot port
BYPASS VALVE 1 Pd2 Swing left pilot port
CUT 25~29
VALVE 2 PF1/4 (18~22) Pd2' Higher pilot pressure select port for swing left
Pa3 Bucket digging pilot port
9-PF1/4
PILOT PORT Pb3 Bucket dump pilot port
PF3/8 (DR4) Pc3 Arm in pilot port
DRAIN PORT PO,Pd1~,Pd4
Pa1~Pa3,DR6 Pc3' Arm lock valve release pilot port
Pd3 Arm out pilot port
Pb4 P1 bypass cut pilot port
Pc4 Boom conflux spool pilot port
Pd4 P2 bypass cut pilot port
DR1 Drain port
DR2 Drain port
DR3 Drain port
DR5 Drain port
DR6 Drain port
Fig. 24-24 General view and hydraulic ports (2/2)
24-23
Fig. 24-25 Construction of control valve (1/6)
24-24
24-25
24-26
24-27
24-28
24-29
24.1.4.3 HYDRAULIC CIRCUIT

(1) Hydraulic circuit and designation of main parts
Fig. 24-31 Hydraulic circuit and designation of main parts
24-30
Table 24-4
24-31
24.1.4.4 FUNCTIONAL EXPLANATION

(1) Neutral
The oil discharged from port A1 of the hydraulic pump enters port P1. It then flows into the control valve (C/V),
passes through the land of travel straight spool (7) and flows into the P1 parallel path (53) and the travel spool.
In the neutral position, the bypass path (52) on the P1 side is not shut off by travel straight spool (7). Therefore,
the oil passes through the travel (right)  boom  bucket  the bypass path (52) of the P1 side of the P1 bypass
cut spool, in that order, and flows out of the T1 port past the tank passage (60). (Fig. 24-32)
Fig. 24-32 Operation (1) at neutral
24-32
The oil which entered the P2 port from the A2 port of the hydraulic pump flows into the C/V, passes through the
land of travel straight spool (7), and flows into the P2 parallel path (56) and the travel spool. In the neutral posi-
tion, the P2 bypass path (55) is not shut off by the travel straight spool (7). Therefore, the oil passes through the
travel (left)  swing  arm  the P2 bypass path (55) of the P2 bypass cut spool, and flows out of the T1 port
past tank path (60). (Fig. 24-33)
Fig. 24-33 Operation (2) at neutral
24-33
(2) Travel operation

1) Travel forward operation
If the travel straight operation is performed the secondary pilot pressure enters the spring chamber of the
Pal and Pd1 ports of the C/V from the travel pilot valve, and shifts the travel spool (8). The oil which flows
in from the pump port passes through the land of travel straight spool (7) and flows into the main paths (51),
(54) of travel spool (8). The oil which flows into the main paths (51, 54) is then supplied to the travel motor
from the A1 and D1 ports which are now open because the bypass paths (52, 55) are shut off by the spool
(8) which is shifted.
In the meantime, the oil returning from the travel motor flows into the C/V from the B1 and C1 ports and flows
into the tank path (60) which is now open as the travel spool (8) has been shifted.
Fig. 24-34 Functions at travel straight operation
24-34
2) Travel reverse operation

If the travel reverse operation is carried out, the secondary pilot pressure enters the opposite side of the
chamber of the Pb1 and Pc1 ports from the travel pilot valve, and shifts the travel spool (8). The oil which
has flowed in from the pump port passes through the land of the travel spool (7) and flows to the main paths
(51), (54) of travel spool (8).
The oil which flows from the main paths (51), (54) is supplied to the travel motor from the B1 and C1 ports
which are now open, because the bypass paths (52), (55) are shut off by the spool (8) now shifted.
In the meantime, the oil returning from the travel motor flows into the C/V from the A1 and D1 ports and flows
to the tank path (60) which is now open as the travel spool (8) has been shifted.
Fig. 24-35 Functions at travel reverse operation
24-35
(3) Bucket operation

1) Bucket digging operation
If the bucket digging operation is performed, the secondary pilot pressure enters the spring chamber of the
Pa3 port of the C/V from the pilot valve and moves the bucket spool (12). When the bucket spool has been
shifted, the P1 bypass path (52) is shut off by the bucket spool (12). Therefore, the oil which has flowed in
from the P1 port flows into the P1 parallel path (53) arranged in the travel straight part. Now the passage
between the A3 port and the bridge path is opened as the bucket spool (12) has been shifted. Therefore, the
oil which has flowed into the P1 parallel path (53) passes through the load check valve (21) in the bucket
select section, and is fed to the head of the bucket cylinder by way of the bridge path and the A3 port.
Meanwhile, the oil which has returned from the cylinder rod flows into the B3 port, passes through the spool
notch which is opened as the bucket spool (12) is shifted, and flows out to the tank passage (60). As the
result, the bucket cylinder operates in the extending direction whereby the bucket performs digging opera-
tion.
Fig. 24-36 Functions at bucket digging operation
24-36
2) Bucket dump operation

If the bucket dump operation is performed, the secondary pilot pressure enters the opposite side of the
spring chamber of the Pb3 port of the C/V from the pilot valve and shifts the bucket spool (12).
If the spool is shifted, the P1 bypass path (52) is shut off by the bucket spool (12). Therefore, the oil which
has flowed in from the P1 port flows into the P1 parallel path (53) provided in the travel straight spool.
When the bucket spool (12) is shifted, the line between the B3 port and the bridge path is opened. Therefore,
the oil which flows into the P1 parallel path (53) passes through the load check valve (21) of the bucket select
part, and is fed to the rod of the bucket cylinder by way of the bridge path and the B3 port.
In the meantime, the oil returning from the cylinder head flows into the A3 port and flows out to the tank pas-
sage (60) which is now open as the bucket spool (12) has been shifted. Therefore, the bucket cylinder op-
erates in the contracting direction in order to dump the bucket.
Fig. 24-37 Function at bucket dump operation
24-37
(4) Boom operation

1) Boom up operation
If the boom up operation is performed, the secondary pilot pressure enters the spring chamber of the Pa2
port of the C/V from the pilot valve and shifts the boom spool (10).
The P1 bypass path (52) is shut off by the boom spool (10) as the spool has been shifted. Therefore, the oil
which has flowed in from the P1 port flows into the P1 parallel path (53) provided in the travel straight spool.
The line between the A2 port and the bridge path is opened as the boom spool is shifted. Therefore, the oil
which has flowed into the P1 parallel path (53) passes through the load check valve (21) of the boom select
part and is fed to the head of the boom cylinder from the A2 port via the bridge path and the lock valve (28)
(free flowing condition). (Fig. 24-38)
Fig. 24-38 Boom up opperation
24-38
The secondary pilot pressure for boom up operation is branched off. At the same time, secondary pilot pres-
sure enters the spring chambers of the boom conflux spool (13) and the P2 bypass cut spool and shifts the
boom conflux spool (13) and the P2 bypass cut spool (14).(Fig. 24-39)
If the P2 bypass cut spool (14) is shifted the P2 bypass path (55) is cut off by the P2 bypass cut spool (14).
Therefore, the oil which has flowed in from the P2 port flows into the P2 parallel path (56) provided upstream
of the P2 bypass path (55).
The oil which has flowed into the P2 parallel path (56) flows into the boom conflux path (58) which is now
opened as the boom conflux spool (13) is shifted.
The oil which has flowed into the boom conflux path (58) passes through the load check valve (21) of the
boom select part and is fed to the boom cylinder head from the A2 port. (Fig. 24-38)
As the result, the oil flow at the P1 port is combined with that at the P2 port and is fed to the boom cylinder
head.
In the meantime, the oil which has returned from the cylinder rod flows into the B2 port and flows to the tank
path (60) which is now open as the boom spool (10) is shifted.
Consequently, the boom cylinder operates in the extending direction and raises the boom.
Fig. 24-39 Functions of the boom conflux spool and the P2 bypass cut spool
24-39
(5) Boom down operation

1) If the boom down operation is performed, the secondary pilot pressure enters the opposite side of the spring
chamber of the Pb2 port of the C/V from the pilot valve and shifts the boom spool (10).
If the boom spool is shifted, the P1 bypass path (52) is cut off by the boom spool (10). The oil which has
flowed in from the P1 port flows into the P1 parallel path (53) provided in the travel straight spool.
Part of the oil passes through the P1 bypass path (52) past the notch of the boom spool (10) and flows out
to the tank path (60).
Transfer of the boom spool opens the line between the B2 port and the bridge path. The oil which has flowed
into the P1 parallel path (53) passes through the load check valve (21) in the boom select part and is fed to
the boom cylinder rod by way of the bridge path and the B2 port.
In the meantime, the oil which has returned from the cylinder head flows into the A2 port and flows out to the
tank path (60) from the spool notch which is now open as the boom spool (10) is shifted. (Refer to Fig. 24-
41 for the functions of the lock valve.)
As the result, the boom cylinder operates in the contracting direction to lower the boom. (The boom cylinder
rod is not subject to the combined flow of the flow from the P1 port and that from the P2 port.)
Fig. 24-40 Functions at boom down operation
24-40
(6) Function of lock valves (boom and arm)

1) When the boom spool (10) is in neutral position, the pilot piston chamber C is connected with the drain path
via the pilot port Pb2 (for releasing the lock valve). The piston C (36) is therefore held by the spring.
2) The oil which has returned from the boom cylinder passes through the lock valve (28) and fills up the lock
valve chamber. Therefore, the needle valve [poppet valve (29)] is positively seated against the poppet seat,
while the lock valve is also firmly seated against the body seat.
Fig. 24-41 The hold condition of lock valve

3) The moment the boom spool (10) is shifted to the spring chamber side, the Pb2 port of the lock valve releas-
ing pilot line is pressurized. The piston A (34) is pressed by the piston C (36) and opens the needle valve
[poppet (29)]. On the occasion, the oil passes through the lock valve  lock valve chamber  pilot piston
chamber B  drilled hole A, in that order, and flows to the drain port DR5.
4) If the needle valve [poppet (29)] opens, the pressure of the lock valve chamber falls. The result is that the
oil returning from the cylinder opens the lock valve (28) and then runs directly into the tank path via the boom
spool (10).
5) If the boom spool (10) is brought back to neutral, the lock valve returns to a state whereby the lock valve is
positively seated against the body seat.
Fig. 24-42 Lock valve in open condition
24-41
(7) Swing operation

1) Swing left operation
If the swing left operation is performed, the secondary pilot pressure from the pilot valve enters the spring
chamber of the Pd2 port of the C/V and shifts the swing spool (9).
At the same time, the secondary pressure from the pilot valve enters the Pd2 port through the external piping
and flows into the swing preference section via the shuttle valve. (Refer to Fig. 24-50 for the swing priority
section.)
When the swing spool (9) is shifted, the P2 bypass path (55) is shut off by the swing spool (9). The oil which
has flowed in from the P2 port flows into the P2 parallel path (56) provided in the travel straight spool.
Part of the oil passes through the notch in the swing spool (9) and the P2 bypass path (55), and flows out
to the tank passage.
Then, the proportional secondary pressure of the P2 bypass cut solenoid valve shifts the P2 bypass cut spool
(14) in the lower stream and cuts off the oil path. This causes all the oil flowing out to the P2 bypass path to
be fed to the swing motor, in order to soften the swing speed. If the swing spool (9) is shifted, the line between
the D2 port and the bridge path is opened by the spool notch. As the result, the oil which has flowed into the
P2 parallel path (56) passes through the load check valve (21) in the swing select part, and is fed to the swing
motor via the bridge path and the D2 port.
In the meantime, the oil which has returned from the swing motor flows into the C2 port and flows into the
tank path (60) from the spool notch which is now open as the swing spool (9) is shifted. Consequently, the
swing motor rotates counterclockwise.
Fig. 24-43 Function at swing left operation
24-42
2) Swing right operation

If the swing right operation is performed, the secondary pilot pressure from the pilot valve enters the opposite
side of the spring chamber of the Pc2 port of the C/V and shifts the swing spool (9). At the same time, the
secondary pressure from the pilot valve flows into the swing priority section via the shuttle valve. (Refer to
Fig. 24-50 for the function of the swing priority section.)
Shift of the swing spool (9) causes the P2 bypass path (55) to be cut off. Therefore, the oil which has flowed
in from the P2 port flows into the P2 parallel path (56) provided in the travel straight spool.
Part of the oil passes through the notch of the swing spool (9) and the P2 bypass path (55) and flows out to
the tank path (60).
Next, the secondary proportional pressure of the P2 bypass cut solenoid valve shifts the P2 bypass cut spool
(14) in the lower stream and cuts off the oil flowing out to the P2 bypass path. The result is that all the oil is
fed to the swing motor to soften the swing speed.
Shift of the swing spool (9) causes the line between the C2 port and the bridge path to be opened by the
spool notch. The oil which has flowed into the P2 parallel path (56) passes through the load check valve (21)
in the swing select section and is fed to the swing motor by way of the bridge path and the C2 port.
In the meantime, the oil returning from the swing motor flows into the D2 port and flows out to the tank path
(60) from the spool notch which is now open by the shift of the swing spool (9).
Fig. 24-44 Functions at swing right operation
24-43
(8) Arm operation

1) Arm in operation
If the arm in operation is performed, the secondary pilot pressure from the pilot valve enters the opposite
side of the spring chamber of the Pc3 port of the C/V and shifts the arm spool (11).
Shift of the arm spool (11) causes the P2 bypass path (55) to be cut off. Therefore, the oil pass path (55) to
be cut off. Therefore, the oil which has flowed in from the P2 port flows into the P2 parallel path (56) provided
in the travel straight spool.
Since the shift of the arm spool (11) causes the line between the C3 port and the bridge path to be open, the
oil which has flowed into the P2 parallel path (56) passes through the load check valve (21) in the arm select
part and is fed to the arm cylinder head by way of the bridge path and the C3 port. (Fig. 24-45)
Fig. 24-45 Function at arm in operation
24-44
In the meantime, the mechatro control system causes the secondary pilot pressure (electromagnetic propor-
tional) to enter the spring chamber of the P1 bypass cut spool (15) and shifts the spool (15). (Fig. 24-46)
Shift of the P1 bypass cut spool (15) causes the P1 bypass path to be shut off. The oil which has flowed in
from the P1 port flows into the P1 parallel path (53) provided in the check valve built in the P1 bypass cut
spool (15) and upstream of the P1 bypass path (52).
The oil which has flowed into the check valve and the P1 parallel path (53) flows into the arm conflux path
(59) which is now open by the shift of the P1 bypass cut spool (15). (Fig. 24-46)
Thus the arm cylinder head is subject to the oil stream at P1 port and that at port P2 combined.
The oil which has flowed into the arm conflux path passes through the load check valve (21) in the arm select
section and is fed to the arm cylinder head from the C3 port. (Fig. 24-45)
In the meantime, the oil which has returned from the cylinder rod flows into the D3 port and flows out to the
tank path (60) from the spool notch which is now open by the shift of the arm spool via the lock valve (28).
(Refer to Fig. 24-41 for the functions of the lock valve.)
Consequently, the arm cylinder operates in the extending direction to cause the arm to dig.
Fig. 24-46 Functions of P1 bypass cut spool
24-45
2) Arm out operation

If the arm out operation is performed, the secondary pilot pressure from the pilot valve enters the spring
chamber of the Pd3 port of the C/V and shifts the arm spool (11). If the arm spool (11) is shifted, the P2 by-
pass path (55) is cut off by the arm spool (11). The oil which has flowed in from the P2 port flows into the P2
parallel path (56) provided in the travel straight spool.
If the arm spool (11) is shifted, the line between the D3 port and the bridge path is opened. The oil which has
flowed into the P2 parallel path (56) passes through the load check valve (21) in the arm select section and
is fed to the arm cylinder rod by way of the bridge path, the lock valve (28) and the D3 port (free flow state).
(Fig. 24-47)
Fig. 24-47 Functions at arm out operation
24-46
In the meantime, the electromagnetic proportional secondary pilot pressure created by the mechatro control
system enters the spring chamber of the P1 bypass cut spool (15). (Fig. 24-48)
Since the P1 bypass path (52) is cut off by the shifted P1 bypass cut spool (15), the oil which has flowed in
from the P1 port flows into the check valve built in the P1 bypass cut spool (15) and into the P1 parallel path
(53) provided upstream of the P1 bypass path (52).
The oil which has flowed into the check valve and the P1 parallel path (53) flows into the arm conflux path
(59) which is now opened by the shifted P1 bypass cut spool (15). (Fig. 24-48)
The oil which has flowed into the arm conflux path (59) passes through the load check valve (21) in the arm
select section and is fed to the arm cylinder rod from the D3 port. (Fig. 24-47)
As the result, the arm cylinder rod is subject to the combination of the stream of the P1 port and the stream
of the P2 port. In the meantime, the oil returning from the cylinder head flows into the C3 port and flows out
to the tank path (60) which is now open by the shifted arm spool (11).
Consequently, the arm cylinder operates in the retracting direction to cause the arm to out.
Fig. 24-48 Functions of P1 bypass cut spool
24-47
(9) Combined operation

1) Simultaneous operation of travel and attachment(travel straight function)
The pilot line for a change signal of the travel straight spool (7) is normally (at neutral) connected with the
drain path by means of the travel straight solenoid valve. Therefore, the travel straight spool (7) is not
changed over.
If a combined operation of travel and attachment is performed, the travel straight solenoid valve is excited
by the mechatro control system. Therefore, the electromagnetic secondary pilot pressure enters the P0 port
of the C/V and shifts the travel straight spool (7).
If the travel straight spool (7) is shifted, the hydraulic oil supplied from the P1 port flows into the P1 and P2
parallel paths (53), (56) leading to the attachment select section. At the same time, the hydraulic oil flows
into both travel select sections via the orifice of the travel straight spool (7)
The hydraulic oil supplied from the P2 port flows into both travel select sections and at the same time flows
into the P1 and P2 parallel paths (53), (56) leading to the attachment select part, by way of the orifice of the
travel straight spool (7).
As the result, if the attachment select section is changed over when both travel select sections changed, the
hydraulic oil supplied to the P2 port acts mainly on both travel select sections, whereas the hydraulic oil sup-
plied to the P1 port acts mainly on the attachment select section. Consequently, the pressure variation of the
P2 port is small with limited branching of oil to both travel select sections. Consequently, the machine runs
straight without deviation and provides proper attachment action.
Fig. 24-49 Functions of travel straight spool
24-48
2) Simultaneous operation of arm and swing actions (swing priority function)

If the arm and the swing actions are performed at the same time, the secondary pilot pressure from the swing
pilot valve flows out again from the Ps' port of the C/V and flows into the Ps port by way of the external piping.
The oil which has flowed into the Ps port pushes in the piston D (67) that is held by the spring (70) and press-
es the load check valve (21) provided in the P2 parallel path (56) of the arm select section, via the stopper
pin (65). As the result, the hydraulic oil from port P2 flows preferentially into the swing system at all times,
free from the size of the load to the arm cylinder.
If the swing operation is stopped, the secondary pilot pressure from the swing pilot valve does not flow into
the Ps port. Therefore, the piston (67) is pushed up by spring (70). This releases the force pressing the load
check valve (21) located in the P2 parallel path (56) of the arm select section.
Fig. 24-50 Closing the load check valve (49) by secondary swing pilot pressure
24-49
(10)Function of main relief valve

1) The hydraulic oil P is filled up in the inner chamber A past the inside of the piston built in the plunger G and
the orifice B. The poppet F is securely seated against the socket which is also positively sealed against the
regulator body.
Fig. 24-51
2) When the hydraulic pressure at port P reaches a set pressure of the spring C, it acts upon the poppet F via
the piston and opens the poppet F. On that occasion, the hydraulic oil flows out to the tank passage past the
piston inside  the orifice B  the chamber A  the annular orifice D, and the passage E, in that order.
Fig. 24-52
3) If the poppet F opens, the pressure of chamber A falls. Then the plunger G opens and the pressure of port
P flows directly to the tank T passage through drilled hole H.
Fig. 24-53
4) If the pressure at port P falls below a set value of spring C, the poppet F is pressed against the seat by the
action of spring C. As the result, the pressure of chamber A equals that of port P. This presses the plunger
G against the socket seat and brings it back where it was. (Fig. 24-51)
24-50
(11)Function of over road relief valve

1) Pressurized oil P is filled up in chamber A through the inside of the piston built in the plunger G and choke B.
The plunger G and the socket are sealed securely. The socket is sealed securely against the poppet as well.
Fig. 24-54
2) When the hydraulic pressure at port P arrives at a set value of spring C, it pushes the piston which in turn
opens the poppet F.
On that occasion, the hydraulic pressure goes through the inside of the piston  choke B  chamber A 
annular orifice D and drilled hole E goes around the outer circumference of the socket and flows out to the
tank passage.
Fig. 24-55
3) If the poppet F opens, the pressure of chamber A falls. Then the plunger G opens and the pressure of port
P flows directly to the tank T passage through drilled hole H.
Fig. 24-56
4) If the pressure at port P falls below a set value of spring C, the poppet F is pressed against the seat by the
action of spring C. As the result, the pressure of chamber A equals that of port P. This presses the plunger
G against the socket seat and brings it back where it was. (Fig. 24-54)
Fig. 24-57
5) Function of anti-cavitation
This function supplies oil from the T (tank) path in case negative pressure occurs at port P. When the tank
path pressure gets higher than that of port P, the socket is subject to a force that pushes it up. This creates
a space between the body seat and the socket. The oil from the T path (tank) flows into port P, and fills up
the space.
24-51
24-52
24.1.5 SWING MOTOR UNIT
24.1.5.1 SPECIFICATION
(1) General view
Fig. 24-58 General view of swing motor unit
24-53
(2) Specifications
Table 24-5
Item Specifications
Swing unit YT15V00001F3 SG025E-126
Type & Part No. Motor YT15V00005F2 MFB40-330
Reduction unit YT32W00002F2 RG025S-155-52
Working pressure MPa (psi) 24.5 (3360)
Reduction ratio 1:15.54
Output torque kN•m (lbf•ft) 2.32 (3360) at 24.5 MPa (3360 psi)
Braking torque N•m (lbf•ft) 185 (1.4)
Brake release pressure MPa (psi) 2.0 (280), Allowable 3.9 (570)
The rotating direction (as seen from the shaft end) A port in : Clockwise, B port in : Counterclockwise
Weight (Including reduction unit) kg (lbs) 67 (148)
Reduction unit lubricate oil Nisseki gearlube SP90 : 1.5L (0.40 gal)
Grease Shell alvania EP2 : 150cc (9.15 cu•in)
24.1.5.2 EXPLANATION OF CONSTRUCTION

(1) The rotary group of the swing motor consists of
a cylinder (M-19) which is integral with the drive Swing unit
shaft and seven piston assy (M-21) arranged in
the cylinder bores. The cylinder (M-19) is sup-
ported by bearings (M-1) (M-6) on both ends.
Each piston assy (M-21) is guided by a return Swash plate type Two-stage planetary
axial piston motor gear reduction unit
plate (M-22) and retaining spring (M-20) so as to
slide smoothly on the cam plate (M-23).
The balance plate (M-10) is forced against the Mechanical brake
end of the cylinder by the force of the disc spring
(M-15) and the hydraulic force acting on the Relife valve
bushing (M-14).
A mechanical brake is installed between the cyl-
Make-up valve
inder exterior and the housing (M-26).
A relief valve to cushion hydraulic shock and a
backup valve to prevent cavitation are built in to By-pass valve
the cover (M-39).
Fig. 24-59
(2) The reduction gear system consists of two stage
planetary gears. The system decelerates high-
speed rotary motion of the swing motor and co-
verts it to low-speed large-torque motion in
order to rotate the pinion shaft.
24-54
(1) Swing motor
Fig. 24-60 Swing motor
24-55
torque No. Parts Q'ty torque No. Parts Q'ty
M-1 TAPER ROLLER BEARING 1 M-22 RETURN PLATE 1
M-3 FRICTION PLATE 2 M-23 CAM PLATE 1
M-4 SEPARATOR PLATE 2 M-24 LEVEL GAUGE 1
M-5 SNAP RING 1 M-25 O-RING 1
M-6 NEEDLE BEARING 1 M-26 HOUSING 1
M-7 O-RING 1 M-27 COLLAR 1
M-8 O-RING 1 M-28 OIL SEAL 1
M-9 O-RING 1 M-30 BACKUP RING 2
M-10 BALANCE PLATE 1 M-31 O-RING : 1B P21 2
M-11 PISTON 2 M-33 BACKUP RING 2
M-12 TEFLON RING 2 M-34 O-RING : 1B P26 2
M-13 PLUG : PT 1/4 2 M-35 PARALLEL PIN 2
M-14 BUSHING 4 M-36 PLUG : PF 3/8 1
M-15 SCROWAVE 4 M-37 O-RING : 1B P14 1
M-16 TEFLON RING 4 M-38 SOCKET BOLT : M12  30 4
M-17 SPRING 13 M-39 COVER 1
M-18 PISTON 1 M-40 PLUG 1
M-19 CYLINDER 1 70 RELIEF VALVE ASSY 2
M-20 SUPPORT SPRING 1 100 BY-PASS VALVE ASSY 2
M-21 PISTON ASSY 7
24-56
1) Relief & check valve assy (70)
Fig. 24-61 Detail of Relief & check valve assy
No. Parts Q'ty No. Parts Q'ty

70 RELIEF& CHECK VALVE ASSY 2 82 SEAT 2
71 LOCK NUT 2 83 POPPET 2
72 CAP 2 84 SPRING 2
76 BACKUP RING 2 85 O-RING 2
77 O-RING : 1B P26 2 86 SHIM 2
78 SPRING 2 87 PISTON 2
79 BUSHING 2 88 SLEEVE 2
80 CHECK 2 89 O-RING 2
81 SLEEVE 2 90 CAP 2
2) By-pass valve assy (100)
Fig. 24-62 Detail of by-pass valve assy (swing shockless valve)

100 BY-PASS VALVE ASSY 2 106 O-RING : 1B P21 2
101 SEAT 2 107 BACKUP RING 2
103 POPPET 2 109 SPRING 2
104 BACKUP RING 2 110 POPPET 2
105 O-RING : 1B P14 2 111 SPRING 2
24-57
(2) Swing reduction unit
Fig. 24-63 Swing reduction unit
torque No. Parts Q'ty torque No. Parts Q'ty
R-1 PINION SHAFT 1 R-15 HOLDER 2 ASSY 1
R-2 COLLAR 1 R-16 NEEDLE BEARING 6
R-3 PLATE 1 R-17 SHAFT 2 3
R-4 TAPER ROLLER BEARING 1 R-18 SPUR GEAR 5 3
R-5 GEAR CASE 1 R-19 THRUST PLATE 2 6
R-6 PLUG : PT1/8 1 R-20 SPRING PIN : 8  15 3
R-7 OIL SEAL 1 R-21 HOLDER 2 1
R-8 TAPER ROLLER BEARING 1 R-22 COLLAR 2
R-9 PIN 2 R-23 RELIEF NIPPLE 1
R-10 RING GEAR 1 R-24 CONNECTOR 1
R-11 SPUR GEAR 4 1 R-25 ELBOW 1
R-12 SUN GEAR 1 R-26 HOSE 1
R-13 HOLDER 1 ASSY 1 R-27 PLUG 1
R-14 SOCKET BOLT : M12  95 6
24-58
24.1.5.4 OPERATION
(1) Swing motor
The pressure oil fed by the pump via the control valve, etc. enters the motor through port A (or port B) installed
on cover (M-39), and is discharged from port B (or port A).
Also the oil leaking through the sliding section or clearance returns to the tank through drain port Dr installed on
cover (M-39).
The pressure oil fed to port A goes through passage (b) inside of cover (M-39) and to the passage on bushing
(M-11) section installed cover, then is fed to piston bore (f) on the cylinder through balance plate (M-10) passage
(b) which contains crescent shaped port switching supply and discharge by 180 degrees of core rotation of mo-
tor, and cylinder (M-19) passage (e).
The pressure oil exerts on piston assy (M-21), then the piston assy is pushed against cam plate (M-23) through
a part of the shoe. Since the shoe sliding surface of cam plate (M-23) is inclined at a uniform angle, the pushing
force of piston assy (M-21) on which pressure oil is exerted is converted into sliding power for the shoe on the
swash plate.
In addition, the shoe bulb is similarly joined to universal joint. As a result, the shoe sliding power on the swash
plate is converted into rotating power through piston assy (M-21) and cylinder assy (M-19) and transmitted to
the motor output shaft section.
In this way, every piston assy (M-21) receives the pressure oil within the stroke from top dead point to bottom
dead point on a grade, the oil pressure is converted to rotating power to rotate cylinder assy (M-19), resulting in
discharging oil in the stroke from bottom dead end and top dead point.
The discharge line function in reverse of the supply line, and the oil is discharged from port B.
As described above, the hydraulic motor is operated, and the output torque of hydraulic motor is determined by
oil pressure, and speed of revolution by supply flow rate.
(2) Parking brake
Separator plate (M-4) is fitted to the external section of cylinder assy (M-19) with spline.
Friction plate (M-3) is fitted to housing (M-26).
When the primary pilot pressure of brake release port is Zero, brake piston (M-18) locks the cylinder (M-19) (out-
put shaft) which is rotated by the force of the spring (M-17) pushing separator plate and friction plate.
Conversely, when pressure of 1.96 to 3.92MPa (280 to 570psi) exerted on the brake relief port, brake piston
power exceeds the force of spring and strokes to the contact with cover end. Then space is generated between
mating parts, and the mechanical brake released.
Fig. 24-64
24-59
(3) Relief valve

1) Starting
With operation of the lever, the oil fed to port A at first escapes and is discharged to port B without obtaining
regular revolution because the force of inertia of the upper structure is larger. The hydraulic oil from port A
to passage (i) of relief valve, opens poppet (83), and is discharged to port B.
2) Braking (Cushion)
By returning the lever to neutral position, the return circuit of motor discharge oil close, and immediately after
this operation, the motor is rotated by the force of inertia resulting in pumping function, and the oil is sucked
from port A and discharged to port B side. Then, since the return circuit of the control valve is closed, the
pressure of port B is raised.
The raised pressure of port B opposes the spring (84-B) force and opens poppet (83-B), and check valve
(80-B) through passage (g) (h), and flows into passage (c). The movement stops while absorbing the force
of inertia in this process.
In the above-mentioned process of pressure increase, the oil at port B enters the piston (L) chamber past
the small orifice of poppet (83-A), and causes the piston (87) to move till it hits the cap (90). In this period,
the poppet (83-A) is already open, so that the cushion relief action operates first at a little lower pressure.
3) 2-step relief at braking
(shockless relief action)
The increased pressure at port B enters the piston chamber (L) past the path (t) of the poppet (83-B). The
poppet begins to move to the right slowly by the throttling effect of the inlet path and stops when it hits the
shoulder J of piston (87) and the stopper K of sleeve (88). It pushes the spring (84-B), acting as 2-step relief
that rises to a specified pressure. This absorbs impacts at starts and stops.
SHOULDER STOPPER K i PORT A SIDE

J OF PISTON OF SLEEVE g PORT B SIDE
B (A PORT)
PASSAGE t
A
(B PORT)
PISTON
CHAMBER
L At starting port A side 80-A 84-A 83-A
At braking (port Bside 80-B 84-B 83-B)
Fig. 24-65 Detail of relief valve (70)

(4) Make-up valve
1) Operation in half lever position
(When cushion relief valve does not function.)
After accelerating slewing of the upper structure, when the speed is being reduced by half-lever with the
function of control valve, the supply flow rate from pump to port A is lowered. But if the upper structure is
slewed at a comparatively high speed, the pressure in the (C) section is lowered to negative pressure making
lubrication necessary. However, when the pressure of port B is equal to or lower than the working pressure
of cushion relief valve the all oil of (C) section led through port B is discharged to the control valve.
As a result, the flow rate from the control valve (Since the valve is in the half-lever position, the flow rate from
pump is limited.) does not satisfy the specified oil quantity. To prevent this, the make-up check valve is in-
stalled to supply necessary oil into the (C) section.
2) Braking
(When cushion relief valve is functioned)
When the lever is moved to neutral position rapidly as described in item 1), the pump does not supply oil to
port A, but the upper structure is slewed by the force of inertia. In this case, the cushion relief valve on port
B side functions, and the oil from relief valve goes through the passage (g) (h) and opens make-up check
(80) valve on the port A side to flow into passage (b) (c). But the oil quantity is insufficient due to the leakage.
Therefore oil opens make-up check valve (80) through the make-up port, and flows into passage (b) (c) to
prevent cavitation.
24-60
(5) By-pass valve (Swing shockless valve)

1) Accelerating
At the moment of swing operation, the high pressure oil in the "A" side flows instantly into the "B" side in-
stantly, but the high pressure oil enters the chamber on the back side of poppet A simultaneously. Then pop-
pet A moves rightward, resulting in the poppet A "Close" condition shown in Fig. 24-67
2) Braking
When braking, the pressure oil of B side is raised to high pressure, and the high pressure oil is bypassed
from B side to A side, but the high pressure oil enters the chamber on the back side of poppet B simulta-
neously.
The poppet B moves leftward, resulting in the poppet B "Close" condition.
3) Reverse rotation
After stopping the swing of the upper structure, the motor is reverse-rotated by high pressure on the B side.
But while the motor is rotated inversely, the high pressure oil is by-pass from A side to B side to hold the
reverse rotation to one rotation or less, protecting the generation of reverse-rotation pressure.
Fig. 24-66 Poppet A "Open"
Fig. 24-67 Detail of poppet
24-61
(6) Swing reduction gear

The power of the swing motor output shaft is transmitted to spur gear 4 (R-11) on the 2nd stage through sun
gear (R-12) on the 1st stage and holder assy (R-13).
Similarly, the power is transmitted to pinion shaft (R-1) through spur gear 4 (R-11) on the 2nd stage and holder
assy 2 (R-15). The pinion shaft is supported by two bearing (R-4) (R-8) in gear case (R-5).
In addition, oil seal is installed at the center of gear case (R-5) to protect the bearing on the pinion shaft side of
which the load condition is difficult from the gear friction power, and the A chamber side is lubricated by oil in the
gear case, and the B chamber is lubricated by the grease sealed inside.
Fig. 24-68 Function of reduction unit
24-62
24.1.6 TRAVEL MOTOR
(1) General view
D1
D2
FILLING PORT PF3/8

OIL LEVEL CHECK PORT PF3/8
DRAIN PORT PF3/8

VIEW Z
24.1.6.2 HYDRAULIC CIRCUIT
PORT NAME, SIZE

No. Ports Size
A Hydraulic oil filling / drain port
PF 1/2
B Hydraulic oil filling / drain port
D1 Drain port
PF 3/8
D2 Drain port
P 1st / 2nd speed select port PF 1/4
ROTATIONAL DIRECTION (Viewed from Z side)

INLET B PORT, OUTLET A PORT, CW
INLET A PORT, OUTLET B PORT, CCW
24-63
Table 24-6
Type GM09VN-B-19/34-1
Reduction ratio 61.6
Reduction unit Output torque 1st / 2nd N•m (lbf•ft) 8530 (6,300) / 4630 (3,410)
Revolution speed 1st / 2nd rpm 30.5 / 53.8
Displacement 1st /2nd cc / rev (cu-in/rev) 34.4 (2.1) / 19.1 (1.17)
Operation press. MPa (psi) 29.4 (4,270)
Revolution speed 1st / 2nd rpm 1877 / 3312
Hydraulic motor
1, 2 speed select press. MPa (psi) 3.5 (500)
Auto 1, 2 speed select press. MPa (psi) 22.6 (3,200)
Drain press. MPa (psi) STD 0.2 (28), MAX. 0.69 (100)
Breaking torque N•m (lbf•ft) 97.1 (72)
Parking brake
Release press. MPa (psi) 0.47 (68)
Lube oil SAE #90 GL-4 L (gal) Approx.1.3 (0.34)
Weight kg (lb) 81 (179)
24-64
(1) Basic construction of motor
Fig. 24-71
• Reduction gear
The reduction gear consists of a spur gear device (hereunder called 1st reduction gear) and a differential
gear device (hereunder called 2nd reduction gear) that employs a peri-cycloid tooth profile. The reduction
gear system reduces the high speed of the hydraulic motor and converts it to low-speed high torque rotation.
• Hydraulic motor
The hydraulic motor is of swash-plate axial piston type and converts the hydraulic pressure delivered by the
pump to rotary motion.
• Brake valve
The brake valve is composed of different valves. It stops the hydraulic motor smoothly, prevents the hydraulic
motor from over-running and prevents abnormally high pressure surges from occurring as the hydraulic mo-
tor is stopped jerkily.
• High-low 2-step speed select mechanism
The mechanism consists of a selector valve and a piston and changes the displacement capacity of the hy-
draulic motor in two steps.
• Parking brake
This is a friction plate type braking mechanism that is made integral with the hydraulic motor.
24-65
(2) Construction
Fig. 24-72
24-66
(3) Parts list

Table 24-7
1 HUB 1
PISTON KIT 1
SPINDLE KIT •PISTON ASSEMBLING PARTS 9
•SPINDLE ASSY 1 105 ••PISTON 1
2 ••SPINDLE 1 106 ••SHOE 1
3 ••HOLD FLANGE 1
19 •REAMER BOLT 3 •PISTON ASSEMBLING PARTS 1
161 ••PISTON 1
RV GEAR ASSEMBLING PARTS 1 162 ••SHOE 1
•RV GEAR KIT 1
4 ••RV GEAR A 1 102 SHAFT 1
5 ••RV GEAR B 1 103 SWASH PLATE 1
9 •CRANK SHAFT 3 104 CYLINDER BLOCK 1
12 •SPACER 6 107 RETAINER PLATE 1
22 •BEARING 6 108 THRUST BALL 1
23 •BEARING 6 109 TIMING PLATE 1
110 WASHER 2
6 INPUT GEAR 1 112 PISTON 1
113 SPRING 8
SPUR GEAR KIT 1 114 SPRING 1
7 •SPUR GEAR 3 115 FRICTION PLATE 2
116 SEPARATOR PLATE 2
FLOATING SEAL KIT 1 132 OIL SEAL 1
31 •FLOATING SEAL 2 135 O-RING 1
141 O-RING 1
8 COVER 1 146 SNAP RING 1
15 SHAFT 1 149 BEARING 1
17 PIN 28 150 BEARING 1
18 RING 1 151 BEARING (ROLLER) 3
20 SNAP RING 3 176 PIVOT 2
21 BEARING 2 177 PARALLEL PIN 2
24 SNAP RING 1 185 SPRING 1
25 SNAP RING 6
28 O-RING 2 REAR FLANGE ASSEMBLING PARTS 1
29 O-RING 1 •REAR FLANGE KIT 1
30 O-RING 1 201 ••REAR FLANGE 1
33 PLUG (WITH FLANGE) 1 223 ••SPOOL 1
34 PLUG 2 252 ••SOCKET PLUG 2
35 O RING 3 268 ••STEEL BALL 1
36 STEEL BALL 1 275 ••SOCKET PLUG 10
43 PARALLEL PIN 2 279 ••FILTER 1
24-67
Table 24-7
280 ••ORIFICE 4 282 •PLUG 4
283 • • PLUG (WITH FLANGE) 1 284 •PLUG 2
286 ••PISTON 2 285 •O-RING 2
299 ••NAME PLATE 1 287 •VALVE 2
288 •SLEEVE 2
•SPOOL KIT 1 289 •PLUG 2
271 ••SPOOL 1 290 •SPRING 2
272 ••OIL STOPPER 1 291 •O-RING 2
221 •PLUG 2 292 •O-RING 4
224 •PLUG 2 293 •PISTON SEAL 2
225 •SPRING RETAINER 2 294 •BACKUP RING 4
227 •VALVE 2 295 •BACKUP RING 4
228 •SPRING 2 296 •STEEL BALL 2
230 •SPRING 2 297 •ORIFICE 2
236 •O-RING 2
238 •O-RING 6 242 PARALLEL PIN 2
281 •SPRING 1 245 SOCKET BOLT 6
24-68
24.1.6.5 FUNCTIONAL EXPLANATION

(1) Reduction gear CRANK SHAFT (9)
SPUR GEAR (7)
1) Function
The reduction gear consists of a spur gear de-
vice (hereunder called 1st reduction gear) and a
differential gear device (hereunder called 2nd re-
duction gear) that employs a peri-cycloid gear
tooth profile. The reduction gear reduces the SHAFT (15)
high speed rotation of the hydraulic motor and
converts it to low-speed high torque rotation.
2) Functional explanation
2-1: 1st reduction gear
1. The rotary motion of the hydraulic motor is put
out of shaft (102). This rotation is transmitted
to input gear (6) that is linked to shaft (G) (15).
The input gear (6) meshes with three spur INPUT GEAR (6)
gears (7). Fig. 24-73
The speed of spur gears (7) is reduced and ro-
tate in the opposite direction. The reduction
gear composed of input gear (6) and spur gear
(7) is called 1st reduction gear. The reduction
ratio [i1] is as below :
i1 = Reduction ratio of 1st reduction gear

Zi = No. of teeth of input gear
Zs = No. of teeth of spur gear
2-2: 2nd reduction gear SPUR GEAR (7)

NEEDLE BEARING (23)
1. Spur gears (7) (3 pieces) are connected to re-
spective crankshafts (9). If spur gear (7) ro- ECCENTRIC BODIES ROTATION
tates, crankshaft (9) rotates in the same
direction and at the same revolution. This CRANK SHAFT (9)
causes the eccentric bodies A and B of crank- ROTATION

shaft (9) to make eccentric motion. (revolu-
tion). This eccentric motion (revolution) is
transmitted to RV gears A (4) and B [5] via
needle roller bearing (23).
RV gears A (4) and B (5) make eccentric mo-
tion in the same direction and at the same rev-
olution as the spur gears and the crankshafts.
ECCENTRIC MOTION
RV GEAR B (5)
RV GEAR A (4)
Fig. 24-74
24-69
2. The tooth face of RV gear A (4) and RV gear

B (5) meshes constantly with pins (17)(pin
number Zp). If RV gears A and B make eccen- HUB (1)
tric motion, the meshing point moves in se-
PIN (17)
quence as the gears turn. In a single eccentric
motion, pins (17) rotate with hub (1) by the dif-
ference between the number of teeth Zr of RV
RV GEAR A (4)
gears A, B and the number of pins Zp i.e. the OR RV GEAR B (5)
number of pins. The rotating direction of hub
(1) is the same as that of the eccentric motion CRANKSHAFT REVOLVING
of the RV gears. BODY SECTION
The hub (1) makes output rotation. The sec-
tion that is decelerated by the crankshafts, RV
gears, pins and hubs is called 2nd reduction
gear. The reduction gear (i2) of the 2nd reduc-
tion gear is as below :
i2 = Reduction ratio of 2nd reduction gear

Zr = No. of teeth of RV gear A, B
Zp = No. of pin
At half rotation (180 ) At one rotation

Fig. 24-75
2-3: Entire reduction gear
The motion of the entire reduction gear equals
the product that is made by multiplying the 1st
reduction gear with the 2nd reduction gear.
Therefore, if the hydraulic motor shaft makes
one turn, the total revolution (reduction ratio)
of the reduction gear is as follows:
i1 = Speed ratio of 1st reduction gear section.

i2= Speed ratio of 2nd reduction gear section.
24-70
(2) Hydraulic drive

This article describes the hydraulic motor, the brake
valve and parking brake driven by hydraulic pres-
sure and the high-low 2-step select mechanism of
the hydraulic motor.
1) Functions
1. Hydraulic motor
The hydraulic motor is of swash-plate axial pis-
ton type and converts the force of the pressur-
ized oil to rotary motion.
2. Brake valve CYLINDER BLOCK (104)
1. The brake valve controls inertia force to stop
the hydraulic motor smoothly. PISTON (105)
2. The brake valve prevents the hydraulic motor SWASH PLATE (103)
from over running by external force acting on
the hydraulic motor i.e. prevents hydraulic SHAFT (102)
cavitation.
3. The brake valve prevents abnormally high
pressure surges that are generated as the hy-
draulic motor is stopped jerkily.
3. High-low 2-step speed select mechanism
The mechanism changes the hydraulic motor
output in two steps; high-speed low-torque and
low-speed high-torque. TIMING PLATE (109)
4. Parking brake
The parking brake prevents the hydraulic motor
at rest from being turned by external force. The
brake is of friction plate type that is assembled
integral with the hydraulic motor.
2) Functional Explanation
1. Hydraulic motor
The pressurized oil supplied by the hydraulic Fig. 24-76
pumps enters the rear flange (201) of the hy-
draulic motor. The pressurized oil passes
through the brake valve and the timing plate
(109) and is admitted into the cylinder block
(104). The pressurized oil is admitted only to the
one side of the line (Y1-Y2) that connects the top
dead point with the bottom dead point of the pis-
ton (105) stroke. The pressurized oil pushes
each piston (105) and generates force F (= PA).
This force acts upon the tilted surface of swash
plate (103). The force F is split into components
F2, F3, depending upon the angle of the titled
surface. Out of them the radial component F3
generates torque = (F3  ri). The total force of
torque of the pistons (105) T= (F3  ri) equals
the rotary force of the hydraulic motor. This rotary
force causes the cylinder block (104) and the
shaft (102) to rotate via the pistons (105).
24-71
2. Brake valve
Ports A and B are the oil inlet and the outlet. The
following is an explanation in which hydraulic oil
(pressurized oil) is supplied to port A.
When hydraulic oil is supplied to port B, the di-
rection of flow and motion are reversed. The ro-
tating direction of the hydraulic motor is reversed
as well.
1. Normal action
If pressurized oil is supplied to port A by the
pumps, the hydraulic motor turns. Below is a
detailed explanation.
If the pressurized oil is supplied by the pumps, PARKING
the oil enters port A and opens the valve BRAKE
SPOOL (223)
(227). The oil then passes through valve
(227), enters the hydraulic motor via port C
and gives rotating force to the hydraulic motor. SPRING a b
In the meantime, the oil enters port A, passes
through the orifice of spool (223) and the pipe-
line (a) and enters chamber (b). Spool (223)
moves to the left from its neutral position by
the hydraulic force of chamber (b). In that
case, a hydraulic oil passage is formed be-
tween ports D and B by the groove provided
on the spool (223).
The hydraulic oil discharged by the hydraulic
motor flows from port D to port B. Thus the hy-
draulic motor rotates, and the hydraulic oil re-
VALVE (227)
turns to the oil tank.
In the meantime, if spool (223) moves to the Fig. 24-77
left, the pressurized oil enters port E and the
oil flows into the parking brake and the 2-
speed select valve.
24-72
2. Stop action (braking action)

If the oil supply is suspended, the hydraulic mo-
tor stops. More detailed functions are explained
below:
If the oil being supplied to port A is suspended,
the pressure at port A and chamber (b) falls. As
the pressure falls, spool (223) begins to shift
from left to right (toward the neutral position) by
the action of spring (228).
The passage between ports D and B is narrowed
as the spool (223) moves and shut off when the PISTON (286)
spool arrives at neutral.
In the meantime, the hydraulic motor keeps ro-
tating by inertia force even though the oil supply g
from port A is suspended. The hydraulic oil dis-
charged by the hydraulic motor is exhausted as VALVE
there is no passage for oil flowing out of port D. (287)
Thus, the hydraulic pressure from port D rises.
The hydraulic pressure thus boosted goes
f
through the orifice of the right hand valve (287)
and enters chamber (g) from chamber (f). The
piston (286) on the right moves to the left in the
b
illustration so the pressure does not rise. While SPOOL
(223)
the piston is moving, the pressure of chamber (f)
and (g) is lower than that of port D by the orifice
effect of valve (287).
SPRING (228)
In the meantime, the pressure difference causes
the valve (287) on the right to open.
The hydraulic oil runs from port D to port C.
When the piston (286) reaches the stroke end,
the pressure in chamber (g) and (f) rises to be
equal to the pressure of port D. The valve (287)
on the right is closed again. Since the passage Fig. 24-78
that allows the oil to flow from port D is shut off,
the pressure rises further.
Then, the valve (287) on the left opens. The hy-
draulic oil of port D flows to port C. The pressure
of port D falls as the inertia force decreases.
The valve (287) on the left is closed again. The
hydraulic motor stops rotating.
In this way, controlling the pressure at port D in
two steps allows the hydraulic motor to stop by
smooth braking action.
24-73
3. Self (over) run prevention function

If the hydraulic motor is forced to turn by exter-
nal force during normal running, self run (over
run) occurs. For instance, it occurs while the
excavator is going down on a slope. PARKING BRAKE
Now let us explain about the mechanism that (112)
SPOOL (223)
prevents such phenomenon from occurring.
If the hydraulic motor is forced to rotate by ex-
SPRING a b
ternal force during normal run, the pressure of
(228)
the hydraulic oil being supplied (port A or B)
falls. If the pressure rises close to a level at
which the machine begins to run by itself, the
spool (223) begins to move to its neutral in the
middle.
As the spool (223) moves, the area of the pas-
sage that lets the hydraulic oil run from outlet
port D to port B of the hydraulic motor is made
smaller, with the result that the flow of the hy-
draulic oil from port D to port B is restricted. At
the same time, the pressure at port D (back
VALVE (227)
pressure) rises as well.
In this way, self run of the motor is prevented Fig. 24-79
by controlling the flow and the pressure of the
outlet port of the hydraulic motor.
24-74
(3) High-low 2-step speed select mechanism (auto 2-

step speed select mode)
1) Low-speed step
The low-speed step is the status in which pilot
pressure is not being supplied from port P. In this
case, the spool (271) is pressed to the left by the
force of spring (281) and by the pressure from
port A or B. The pressure of port F is shut off.
The hydraulic oil of chamber S is released to
drain (motor casing) via spool (271). The thrust
of piston (161) is small. The swash plate (103) is
located along the Y face.
At that time, the swash plate (103) takes the
maximum tilting angle 1. That is to say, the hy-
draulic motor takes the maximum displacement
capacity and rotates at low speed.
Fig. 24-80
2) High-speed step
The high-speed step is the status in which a pilot
pressure of 3.43 MPa (500 psi) is supplied from
port P. In that case, the spool (271) is pressed to
the right, overcoming the force of spring (281)
and the pressure from port A or B. The pressure
of port F is led to chamber S via spool (271).
The thrust of piston (161) increases by the pres-
sure of chamber S. The piston (161) is pushed
up and held till swash plate (103) comes in con-
tact with face X.
On that occasion, the swash plate (103) takes
the minimum tilting angle 2. That is to say, the
hydraulic motor takes the minimum displace-
ment capacity and rotates at high speed.
Fig. 24-81
24-75
3) Functional explanation of automatic selection of

low-speed step while operating at high-speed
step
The pressure of A or B increases as load in-
creases at high speed step. When the pressure
reaches 22 MPa (3200 psi), the spool (271) is
pressed to the left, overcoming the pilot pressure
3.43 MPa (500 psi) of port P. The pressure of
chamber S is released to drain (motor casing) via
spool (271). In that case, the swash plate (103)
comes in contact with the Y face and takes the
maximum tilting angle 1. The angle is held,
with the result that the hydraulic motor rotates at
low speed.
Fig. 24-82
24-76
(4) Parking Brake

1) Machine is running:
If the pressure from the pumps is supplied to port
A or B, the spool (223) of the brake valve moves
to the right or the left. Port E opens, and the pres-
sure is led from port E to cylinder chamber C.
When the pressure reaches 0.47 MPa (68psi) or
over, the thrust of piston (112) overcomes the
force of spring (113). The piston (112) moves to-
ward rear flange (201). If the piston (112) loses
its pressing force against separator plate (116)
and friction plate (115), the friction plate (115) is
let free.
The friction plate (115) is engaged with cylinder
block (104) of the hydraulic motor. The result is
that the cylinder block (104) is freed from the
braking force. The hydraulic motor is freed to
run.
Fig. 24-83
2) Machine is not running:
If the pressure to port A or B is suspended, the
spool (223) of the brake valve moves to neutral.
Port E is shut off, and the pressure in cylinder
chamber C falls. When the pressure falls below
0.47 MPa (68psi), the hydraulic force of piston
(112) decreases below the force of spring (113).
Then the action of spring (113) causes the piston
(112) to be pressed against the separator plate
(116) and the friction plate (115). This pressing
force creates frictional force that makes braking
power. The friction plate (115) meshes with the
cylinder block (104) of the hydraulic motor. The
cylinder block (104) meshes with shaft (102) of
the hydraulic motor.
In this way, the hydraulic motor undergoes brak-
ing torque while the machine is at rest.
Fig. 24-84
24-77
24-78
24.1.7 SWIVEL JOINT
24.1.7.1 GENERAL VIEW
Fig. 24-85 General view of swivel joint
Table 24-8
Parts No. 24100J12125F2
Travel main port Working pressure 28.4 MPa (4120 psi)
A, B, C, D Max. impact pressure 38.2 MPa (5550 psi)
Dozer port Working pressure 20.6 MPa (2990 psi)
F, G Max. impact pressure 38.2 MPa (5550 psi)
Drain port
Max. working pressure 490 kPa (71 psi)
E
Pilot port
Working pressure 4.9 MPa (711 psi)
H
Revolution 15rpm
Weight 21kg (46 lbs)
24-79
T=Tightening torque : N·m (lbf·ft)
Note)
Fix seal (5) in the
perfectly degreased
seal groove without
applying grease.
SECTION K-K
T =30.4 (22) (Loctite #290) T =30.4 (22) (Loctite #290) VIEW M
SECTION J-J
Fig. 24-86 Construction
Table 24-9
1 BODY 1 8 SOCKET BOLT : M8  20 2
2 STEM 1 9 SOCKET BOLT : M8  30 3
3 THRUST PLATE 1 12 PLUG : PT1/8 1
4 COVER 1 13 PLUG : PT3/8 2
5 SEAL ASSY 7 15 SEAL 2
7 O-RING : 1A G95 1
24.1.7.4 OPERATION
The swivel joint consists mainly of mutually rotating body (1) and stem (2), thrust plate (3) that prevents them from
coming off, cover (4) that plugs up one part of body (1), seals (5) that partitioning circuits, and O rings (6, 7) that
prevents oil from leaking out.
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 binding with the stem (2). Such construction of the swivel joint makes it possible to connect circuits
between the swing body and the lower travel body at all times.
24-80
24.1.8 CYLINDER
(1) General view
B
gth
l en h A
ed gt
t e nd len
e x t e d
Fu
lly rac
l y ret
l
Fu
Part No. and Manufacturing No.

Stamp position
Fig. 24-87 General view of cylincer

(2) Specifications
Unit : mm (ft-in)
Table 24-10
Part No. of Cylinder bore/ Center distance of mounting pins Dry weight
Use Stroke Cushion
cylinder assy Rod Dia. Full extend B / Full retract A Kg (lbs)
110 / 70 916 2,291 / 1,375 With cushion on 94
Boom YT01V00017F1
(4.33"/2.76") (30.1") (7’6" / 4’6") rod side (200)
95 / 65 813 2,113 / 1,300 With cushion on 72
Arm YT01V00002F1
(3.74"/2.56) (32.0") (6’11" / 4’3") both sides (160)
80 / 55 735 1,855 / 1,120 48
Bucket YT01V00019F1 Without
(3.15"/2.16") (28.9") (6’1" / 3’8") (100)
120 / 70 150 840 / 690 55
Dozer YT01V00020F1 Without
(4.72"/2.76") (5.91") (33.1" / 27.2") (120)
24-81
24.1.8.2 CONSTRUCION AND OPERATION
24.1.8.2.1 CONSTRUCTION
(1) Boom cylinder
T=Tightening torque : N·m (lbf·ft) [screw size]
Press it in from both ends Press it in from both ends

of the boss so R2.5 (0.10") 27 of the boss so R2.5 (0.10")
holes face with each other holes face with each other
in the grease hole position. in the grease hole position.
24 23
25 26 28, 29
T=3.2 ± 0.6 (23 ± 4.3) [M10 X 1.5]
VIEW A-A
475
T=56.9 (42) [M12 X 1.75]

After tightening,fit it with punch
caulking on two portions.
T=830 (615) [M117 X 2]
Apply Three-bond #1901 on the thread 12 14 9,15 13
T=3000 (2210) [M52 X 2,HEX80]
8 3 7 11 6 4 9,10 5 2 1 16 17 19 18 20 21,22
With Detail of S
one hole
S
Fig. 24-88 Construction of boom cylinder
No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty

1 CYLINDER TUBE ASSY 1 11 O-RING 1 21 SET SCREW 1
2 PISTON ROD ASSY 1 12 O-RING 1 22 STEEL BALL 1
3 ROD COVER 1 13 CUSHION SEAL 2 23 PIN BUSHING 2
4 BUSHING 1 14 COLLAR 1 24 WIPER RING 2
5 SNAP RING 1 15 BACKUP RING 1 25 PIN BUSHING 2
6 BUFFER RING 1 16 CUSHION BEARING 1 26 WIPER RING 2
7 U-RING 1 17 PISTON 1 27 BAND ASSY 2
8 WIPER RING 1 18 SEAL RING ASSY 1 28 BOLT 2
9 O-RING 2 19 SLIDE RING 2 29 WASHER 2
10 BACKUP RING 1 20 NUT 1
24-82
(2) Arm cylinder

of the boss so R2.5 (0.10") of the boss so R2.5 (0.10")
33 34 32 29 31 holes face with each other
holes face with each other
T=39.8 (30)
30
[M12 X 1.75]
29
26 27 T=31.5 (23) [M10 X 1.5] 27

26
VIEW A-A
T=56.9 (42) [M12 X 1.75]

T=569 (420) [M100 X 2] caulking on two portions.
Apply Three-bond #1901 on the thread
T=2780 (2000) [M45 X 2, HEX70]
9 3 12 7,8 6 10,11 4 5 11,13 2 1 14 15 19 17 18 16 20 21 25 23 22 24
With
one hole
Face the slit to the piston side.
Fig. 24-89 Construction of arm cylinder

1 CYLINDER TUBE ASSY 1 13 O-RING 1 25 SNAP RING 1
2 PISTON ROD ASSY 1 14 CUSHION BEARING 1 26 PIN BUSHING 4
3 ROD COVER 1 15 CUSHION SEAL 1 27 WIPER RING 4
4 BUSHING 1 16 PISTON 1 28 BAND ASSY 1
5 SNAP RING 1 17 SEAL RING ASSY 1 29 BAND 1
6 BUFFER RING 1 18 SLIDE RING 2 30 BOLT 2
7 U-RING 1 19 SHIM 1 31 WASHER 2
8 BACKUP RING 1 20 SET SCREW 1 32 PIPE HOLDER 1
9 WIPER RING 1 21 STEEL BALL 1 33 BOLT 1
10 O-RING 1 22 CUSHION BEARING 1 34 WASHER 1
11 BACKUP RING 3 23 CHSHION SEAL 1
12 O-RING 1 24 STOPPER 2
24-83
(3) Bucket cylinder
T=31.5 (23) [M10 X 1.5]
45 45
VIEW B-B VIEW A-A
T=16.2 (12) [M8 X 1.25]

T=450 (330) [M82 X 2]
T=1420 (1000) [M39 X 3,HEX60)
8 3 7 11 6 4 9,10 5 2 1 12 14 13 15,16
With
one hole
Fig. 24-90 Construction of bucket cylinder

1 CYLINDER TUBE ASSY 1 9 O-RING 1 17 PIN BUSHING 1
2 PISTON ROD ASSY 1 10 BACKUP RING 1 18 WIPER RING 4
3 ROD COVER 1 11 O-RING 1 19 PIN BUSHING 1
7 U-RING 1 15 SET SCREW 1 23 WASHER 4
8 WIPER RING 1 16 STEEL BALL 1
24-84
(4) Dozer cylinder
T=56.2 (42) [M12 X 1.75]

T=1060 (780) [M125 X 2]
Apply Three-bond #1901 on the thread T=2900 (2100) [M52 X 2,HEX80]
8 3 7 11 6 4 9,10 5 2 1 12 13 14 15 16,17
With
one hole
Fig. 24-91 Construction of dozer cylinder

1 CYLINDER TUBE ASSY 1 8 WIPER RING 1 15 NUT 1
2 PISTON ROD ASSY 1 9 O-RING 1 16 SET SCREW 1
3 ROD COVER 1 10 BACKUP RING 1 17 STEEL BALL 1
4 BUSHING 1 11 O-RING 1 18 PIN BUSHING 2
5 SNAP RING 1 12 PISTON 1 19 WIPER RING 4
6 BUFFER RING 1 13 SEAL RING ASSY 1 20 GREASE NIPPLE 2
7 U-RING 1 14 SLIDE RING 2
24-85
Hydraulic cylinder construction (See Fig. 24-89)

The hydraulic cylinder is composed of three sections, cylinder tube assy (1), piston rod assy to transmit the motion
of piston (16) stroke in the tube, a rod cover (3) which serves as the cover and guide. Also, the cylinder tube assy
and piston rod assy (2) have piston mounting section (clevis) which are used to connect the other device. And, in
addition to these principal parts, seal ring assy (17), slide ring (18) and piston rod assy (2), buffer ring (6), U ring (7),
backup ring (8), and wiper ring (9) between piston rod assy (2) and rod cover (3), and O ring and backup ring be-
tween cylinder tube assy (1) and rod cover (3).
24.1.8.2.2 OPERATION
By feeding pressure oil through oil inlet and outlet on
cylinder alternately, the oil pressure exerts on the pis-
ton, and piston rod assy (2) starts moving the telescopic
motion (stroke).
Fig. 24-92 Cushion on the rod side

(1) Operation of cylinder with cushion
The hydraulic cylinder contains a shock absorber to
shock generated when the moving piston rod assy (2)
strikes rod cover (3) without speed reduction.
(Cushion on rod side) Fig. 24-93 Cushion on the rod side

When pressurizing the rod cover side, the oil in (A)
chamber returns to the tank in constant speed through
passage (B) in the midway of stroke. (Fig. 24-92)
As the end of the stroke approaches, the cylinder bear-
ing enters into passage (B), and the passage (B) is
throttle reducing oil quantity. As a result, the speed of
piston rod is also lowered. (Fig. 24-93) Fig. 24-94 Cushion on the head side
(Cushion on head side)

Like the cushion on the rod side, the piston end of the
piston rod enters into the cushion bearing, and passage
(B) is throttled. As a result, as the return oil level for (A)
chamber lowers, the speed of piston rod lowers, obtain- Fig. 24-95 Cushion on the head side
ing the effect of cushion. (Fig. 24-94 and Fig. 24-95)
24-86
24.2 ELECTRIC EQUIPMENT

24.2.1 ELECTRIC EQUIPMENT LIST
Group Code Name Part No.

CONTROLLER
C-1 MECHATRO CONTROLLER YT22E00031F1

C-2 GAUGE CLUSTER YT59S00006F1
C-4 AIR CONDITIONER CONTROLLER YT20M00004S36
D-1 DIODE YN02D01001P1

D-2  
D-3  
DIODE
D-4  
D-5  2475R132
D-6  YN02D01001P1
D-7  
E-1 FUSE BOX YT73E00003F2
E-2 ALTERNATOR 897182-2892
E-3 HOUR METER YT58S00006P1
E-5 HORN CM53S00002F1
E-6 CIGALETTE LIGHTER 2421R180F1
ELECTRIC FITTINGS
E-7 TUNER AM & FM INSTALLED ON THE SPOT

E-8 SPEAKER LEFT YN54S00006P1
E-9 SPEAKER RIGHT 
E-10 RECEIVER DRIER YT54S00002P1
E-11 AIR COMMPRESSOR CLUTCH YT91V00001F1
E-14 BATTERY (OPT.2) 2411U25
E-15 POWER SOCKET YN81S00001P1
E-17 CONVERTER YT77S00001P1
E-20 BUZZER 2447Z156D1
E-21 COUNTER YT25S00003F1
L-1 BOOM WORKING LIGHT LEFT YN80S00012F1
L-1 BOOM WORKING LIGHT RIGHT YN80S00012F1
L-2 WORKING LIGHT RIGHT YT80S00002F1
L-3 ROOM LIGHT 2456Z322F1
L-4 CAB WORKING LIGHT FRONT (OPT.) INSTALLED ON THE SPOT

LIGHT
L-5 CAB WORKING LIGHT FRONT (OPT.)

L-6 CAB WORKING LIGHT (FRONT 3) 
L-7 ENGINE ROOM LIGHT 4056R4F1
L-8 CAB WORKING LIGHT (FRONT 4) INSTALLED ON THE SPOT
L-9 CAB WORKING LIGHT (REAR) 
L-10 ROTARY LIGHT 
L-11 STARTER ALARM LAMP LS80E00001D1
24-87

M-1 STARTER MOTOR 897137-4781
M-2 GOVERNOR MOTOR YN20S00002F1
MOTOR
M-3 WIPER MOTOR YT53C00011F1

M-4 WASHER MOTOR 24100U157F1
M-8 ROOF WIPER MOTOR (OPT.) YT76S00001P1
M-9 FUEL PUMP YR22P00001P1
R-1 BATTERY RELAY YN24S00003F1
R-3 GLOW RELAY 894423-3140
R-4 SAFETY RELAY 182553-0391
R-5 WIPER MOTOR RELAY EN24S00008P1
R-6 WASHER MOTOR RELAY 
R-7 HONE RELAY 
R-8 WORK LIGHT RELAY 
RELAY
R-13 CAB WORK LIGHT RELAY 2 

R-20 TIMER YN25S00001P1
R-22 CLOCKWISE RELAY (OPT.) EN24S00008P1
R-23 COUNTERCLOCKWISE RELAY (OPT.) 
R-28 AUTO IDLE STOP RELAY 1 EN24S00008P1
R-29 AUTO IDLE STOP RELAY 2 LC24S00001P1
R-30 TIMER UNIT YT25S00001P1
R-31 COUNTER RELAY EN24S00008P1
SE-1 PRESSURE SENSOR (LOW) : BUCKET DIGGING YX52S00010P1
SE-2 PRESSURE SENSOR (LOW) : BUCKET DUMP 
SE-3 PRESSURE SENSOR (LOW) : BOOM UP 
SE-4 PRESSURE SENSOR (LOW) : BOOM DOWN 
SE-5 PRESSURE SENSOR (LOW) : SWING 
SENSOR
SE-7 PRESSURE SENSOR (LOW) : ARM IN 

SE-8 PRESSURE SENSOR (LOW) : ARM OUT 
SE-9 PRESSURE SENSOR (LOW) : TRAVEL RIGHT 
SE-10 PRESSURE SENSOR (LOW) : TRAVEL LEFT 
SE-13 E/G SPEED SENSOR 181510-5130
SE-14 E/G WATER TEMPERATURE SENSOR YT52S00001P1
SE-15 FUEL SENSOR YN52S00034F1
SE-16 ACCEL POTENTIO METER YN52S00032P1
SV-1 SWING PARKING BRAKE SOL. YT35V00017F1
SV-2 DOUBLE•SINGLE SELECT SOL. (OPT.) (VALVE ASSY)
SOLENOID
SV-3 TWO-SPEED SELECT SOL.

VALVE
SV-4 LEVER LOCK SOL.

SV-8 TRAVEL BOOST-UP SOL.
SV-6 CLOCKWISE SOL. (OPT.) LC35V00004F2
SV-7 COUNTERCLOCKWISE SOL. (OPT.) 
PSV-B P2 BY-PASS CUT PROPOTIONAL SOL. YT35V00017F1
PROPORTIONAL
PSV-C TRAVEL PRIORITY PROPOTIONAL SOL. (VALVE ASSY)

VALVE
PSV-D P1 BY-PASS CUT PROPOTIONAL SOL.
24-88

SW-1 KEY SWITCH YN50S00026F1
SW-2 SWITCH ASSY YT50E00002F1
SW-3 TWO-SPEED SELECT SWITCH YN03M01286F1
SW-4 SWING PARKING RELEASE SWITCH YT50E00001F1
SW-6 ENG. WATER TEMPERATURE SWITCH 897125-6001
SW-7 ENG. OIL PRESSURE SWITCH 582410-0122
SW-8 AIR FILTER ALARM SWITCH YR11P00008S005
SW-10 HORN SWITCH (LEFT) YN50E01001P1
SW-11 LEVER LOCK SWITCH YN50S01001P1
SW-13 AIR CONDITIONER SWITCH YT20M01104F1
SW-15 ROOF WIPER SWITCH (OPT.) 2479Z2334
SW-16 WORK LIGHT SWITCH (OPT.) 2479U1190F1
SWITCH
SW-17 DOUBLE•SINGLE SELECT SWITCH 2479U1190F29

SW-18 OPT. PEDAL PRESSURE SWITCH ASSY 1 GB50S00049F2
SW-20 HORN SWITCH (RIGHT) (OPT.) YN50E01001P1
SW-23 WIPER INTERLOCK SWITCH YT50E00003P1
SW-24 OVER LOAD SWITCH INSTALLED ON THE SPOT
SW-27 ENGINE ROOM LIGHT SWITCH YT50S00005P1
SW-28 OVERLOAD INDICATE SWITCH (OPT.) 2479U1190F33
SW-29 ROTARY LIGHT SWITCH 2479U1190F20
SW-30 AUTO ACCEL RELEASE SWITCH 2479U1190F7
SW-40 AUTO IDLE STOP SELECT SWITCH YN50S01004D5
SW-46 CLOCKWISE SWITCH (OPT.) 
SW-47 COUNTERCLOCKWISE SWITCH (OPT.) 
1. The Part numbers and serial numbers of machine may be changed due to modification, so use only the numbers
for reference.
24-89
24.2.2 SPECIFICATION OF ELECTRIC EQUIPMENTS
Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine
C-1
Controller
YT22E00031F1
Mechatro conntroller
YT04-07001~
C-2
Controller
YT59S00006F1
Gauge cluster
YT02-04001~
YT03-05432~
YT04-07001~
C-4
Controller
YT20M00004S036
Air conditioner
controller
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
24-90
Code No.
Parts Name
Use
Applicable Machine
D-1~4, 6, 7
Diode
YN02D01001P1
Key switch relay
Battery relay
Gauge cluster
Pedal pressure switch
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
D-5
Diode
2475R132
Glow relay
YT02-04001~
YT03-05432~
YT04-07001~
E-1
Fuse box
YT73E00003F2
Fuse
YT03-05432~
YT04-07001~
24-91
Code No.
Parts Name
Use
Applicable Machine
E-2
Alternator
897182-2892
Generator
YT02-04001~
YT03-05432~
YT04-07001~
E-3
Hour meter
YT58S00006P1
Service meter
YT02-04001~
YT03-05432~
YT04-07001~
E-5
Horn
CM53S00002F1
Warning sound
YT02-04001~
YT03-05432~
YT04-07001~
E-6
Cigar lighter
2421R180F1
Cigar lighter
YT03-05432~
YT04-07001~
24-92
Code No.
Parts Name
Use
Applicable Machine
E-8, 9
Speaker
YN54S00006P1
Radio
YT02-04001~
YT03-05432~
YT04-07001~
E-10
Receiver drier
YT54S00002P1
Air conditioner
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
E-11
Air compressor
YT91V00001F1
Air conditioner
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
24-93
Code No.
Parts Name
Use
Applicable Machine
E-14
Battery
2411U25
POWER
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
E-20
Buzzer
2447Z156D1
AUTO IDLE STOP
YT03-05432~
YT04-07001~
24-94
Code No.
Parts Name
Use
Applicable Machine
E-21
Counter
YT25S00003F1
AUTO IDLE STOP
YT03-05432~
YT04-07001~
L-1
Light (halogen)
YN80S00012F1
Boom work light
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
24-95
Code No.
Parts Name
Use
Applicable Machine
L-2
Light (halogen)
YT80S00002F1
Work light (R)
YT02-04001~
YT03-05432~
YT04-07001~
L-3
Light
2456Z322F1
Room light
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
L-7
Maker's part No. 3509-KB
Light
Bulb 12V, 10W
4056R4F1
E/G room light
YT04-07001~
L-11
Light
LS80E00001D1
Starter alarm lamp
YT03-05432~
YT04-07001~
24-96
Code No.
Parts Name
Use
Applicable Machine
M-1
Motor
897137-4781
Starter motor
YT02-04001~
YT03-05432~
YT04-07001~
M-2
Motor
YN20S00002F1
Governor motor
YT02-04001~
YT03-05432~
YT04-07001~
M-3
Motor
YT53C00011F1
For wiper (STD)
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
24-97
Code No.
Parts Name
Use
Applicable Machine
M-4
Motor (tank)
24100U157F1
Window washer
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
M-8
Motor
YT76S00001P1
For roof wiper (OPT)
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
24-98
Code No.
Parts Name
Use
Applicable Machine
M-9
Motor (pump)
YR22P00001P1
Fuel pump
YR02801~
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
R-1
Relay
YN24S00003F1
Battery relay
YT02-04001~
YT03-05432~
YT04-07001~
24-99
Code No.
Parts Name
Use
Applicable Machine
R-3
Relay
894423-3140
Glow relay
LE17701~
YR00101~
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
R-4
Relay
182553-0391
Safety relay
YT04-07001~
24-100
Code No.
Parts Name
Use
Applicable Machine
R-5, 6, 7, 8, 10, 13
21, 22, 23, 28, 31
Relay
EN24S00008P1
Wiper motor, Washer
motor, Horn relay,
Work light relay,
Cab work light relay (OPT),
Breaker relay (OPT)
Hand control rotating relay
(OPT)
YT02-04001~
YT03-05432~
YT04-07001~
R-20
Relay
YN25S00001P1
Timer
LQ08-04501~,
LL08-03001~
LC06-05501~,
YC06-02501~
YT02-04001~
YT03-05432~
YT04-07001~
R-30
Timer unit
YT25S00001P1
Auto idle stop
YT03-05432~
YT04-07001~
24-101
Code No.
Parts Name
Use
Applicable Machine
R-29
Relay
LC24S00001P1
Auto idle stop relay 2
YT03-05432~
YT04-07001~
SE-1~5, 7~10
Pressure sensor
(Iow pressure)
YX52S00010P1
Bucket digging, Dump,
Boom up, down, Swing
R,L
Arm in, out, Travel R,L
YT02-04001~
YT03-05432~
YT04-07001~
SE-13
Speed sensor
181510-5130
E/G Speed sensor
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
SE-14
Water temperature
YT52S00001P1
E/G Water temperature
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
24-102
Code No.
Parts Name
Use
Applicable Machine
SE-15
Fuel sensor
YN52S00034F1
Fuel sending
YT02-04001~
YT03-05432~
YT04-07001~
SE-16
Potentio meter
YN52S00032P1
Accel dial
YT02-04001~
YT03-05432~
YT04-07001~
24-103
Code No.
Parts Name
Use
Applicable Machine
SV-1~4, 8
Solenoid valve assy
YT35V00017F1
(7-spool)
YT35V00018F1
(8-spool)
Refer to hydraulic
symbol
YT04-07001~
PSV-B, C, D
Solenoid valve assy
YT35V00017F1
(7-spool)
YT35V00018F1
(8-spool)
Refer to hydraulic
symbol
YT04-07001~
24-104
Code No.
Parts Name
Use
Applicable Machine
SW-1
Switch
YN50S00026F1
Starter switch
YT02-04001~
YT03-05432~
YT04-07001~
SW-2
Switch
YT50E00002F1
Mode select
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
SW-3
Switch
YN03M01286F1
(Right travel lever)
Travel 1,2-speed
YT02-04001~
YT03-05432~
YT04-07001~
24-105
Code No.
Parts Name
Use
Applicable Machine
SW-4
Switch
YT50E00001F1
Swing parking release
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
SW-6
Switch
897125-6001
E/G Water
temperature switch
[105°C(221°F)]
YT02-04001~
YT03-05432~
YT04-07001~
SW-7
Switch
582410-0122
E/G Oil pressure
Switch
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
SW-8
Switch
YR11P00008S005
Air filter
alarm switch
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
24-106
Code No.
Parts Name
Use
Applicable Machine
SW-10, 20
Switch
YN03M01246P1
( Grip)
Horn
YN23301~
YQ02801~
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
SW-11
Switch
YN50S01001P1
Lock lever
YT02-04001~
YT03-05432~
YT04-07001~
SW-13
Switch
YT20M01104F1
Air conditioner
operation
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
SW-15
Switch
2479Z2334
Roof wiper switch
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
24-107
Code No.
Parts Name
Use
Applicable Machine
SW-16
Switch
2479U1190F1
Work light (OPT.)
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
SW-17
Switch
2479U1190F29
Operation select
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
SW-18, 19, 21
Switch
GB50S00049F2
Option pedal press
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
SW-23
Switch
YT50E00003P1
Wiper inter lock
YT00101~
YT02-04001~
YT03-05432~
YT04-07001~
24-108
Code No.
Parts Name
Use
Applicable Machine
SW-27
Switch
YT50S00005P1
Engine room
light switch
YT04-07001~
SW-29
Switch
2479U1190F20
Rotary light
YT02-04001~
YT03-05432~
YT04-07001~
SW-30
Auto accel release
switch
2479U1190F7
Auto accel release
YT02-04001~
YT03-05432~
YT04-07001~
SW-40
Switch
YN50S01004D5
Auto idle stop
YT03-05432~
YT04-07001~
24-109
[MEMO]
24-110
25. AIR-CONDITIONER SYSTEM
TABLE OF CONTENTS
25.1 CONSTRUCTION AND PIPING ......................................................................................... 25-3

25.1.1 CONSTRUCTION ..................................................................................................... 25-3
25.1.2 PIPING ...................................................................................................................... 25-4
25.2 CONSTRUCTION OF MAIN COMPONENTS .................................................................... 25-6
25.2.1 INTAKE UNIT ............................................................................................................ 25-6
25.2.2 AIR-CONDITIONER UNIT ......................................................................................... 25-7
25.2.3 RECEIVER DRYER ................................................................................................... 25-8
25.3 FUNCTION ......................................................................................................................... 25-9
25.3.1 MECHANISM OF COOLING CIRCUIT ..................................................................... 25-9 25
25.3.2 COOLING CIRCUIT .................................................................................................. 25-11
25.3.3 COMPONENT PARTS .............................................................................................. 25-12
25.4 DISASSEMBLY AND ASSEMBLY ..................................................................................... 25-16
25.4.1 PRECAUTIONS TO BE EXERCISED IN OPERATION ............................................. 25-16
25.4.2 REMOVAL AND INSTALLATION OF THE UNIT ....................................................... 25-17
25.5 CHARGING REFRIGERANT ............................................................................................ 25-21
25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION ............................................. 25-21
25.5.2 OPERATING PROCEDURE ..................................................................................... 25-22
25.5.3 CHARGING PROCEDURE ....................................................................................... 25-23
25.6 ELECTRIC CIRCUIT .......................................................................................................... 25-28
25.6.1 WIRING DIAGRAM AND CONNECTORS ................................................................ 25-28
25.6.2 INSPECTING FUNCTIONAL PARTS ........................................................................ 25-30
25.7 TROUBLESHOOTING ....................................................................................................... 25-32
25-1

  SK80MSR–1E(S) : LF04–02001~  KE
S5YT2503E01
(NHK)
PREFACE
We have developed an air conditioner for excavating machine which uses new refrigerant (R134a) instead of the
R12 traditionally used for the air conditioner installed on excavating machines. The advantage of this new refrigerant
(R134a) is that the detrimental effect of the refrigerant on the global environment is far lower, and the destruction of
ozone layer does not occur. This new refrigerant R134a could not use on the traditionally used air conditioner be-
cause the characteristics of new R134a are different from that of R12. This manual provides basic knowledge and
precautions required to furnish services for the air conditioner using the new refrigerant R134a which is installed on
excavating machine.
25-2
25.1 CONSTRUCTION AND PIPING

25.1.1 CONSTRUCTION
3
1
5
9 8
Fig. 25-1 Air-conditioner group
No. Part name Q'ty No. Part name Q'ty No. Part name Q'ty
1 AIR-CONDITIONER ASSY 1 5 FILTER ASSY 1 8–8 S TUBE: Ø16 1
1–1 AIR-CONDITIONER UNIT 1 8 AIR DRYER ASSY 1 9 CONDENSER 1
1–2 HARNESS 1 8–1 RECEIVER DRYER 1
1–3 SENSOR 1 8–2 BRACKET 1
1–4 PLATE 1 8–3 L HOSE 1
1–5 MACHINE SCREW 1 8–4 D HOSE 1
1–7 CAP 1 8–5 S HOSE: Ø24.5 1
3 COMPRESSOR 1 8–6 L HOSE: Ø15.5 1
4 PANEL 1 8–7 D TUBE: Ø12 1
25-3
25.1.2 PIPING
19
2 COMPRESSOR ASSY
T= Tightening torque 3
N m {lbf ft}
19
22 22
15 13
A
AIR-CONDITIONER UNIT
20 1
23
16
COMPRESSOR
CONDENSER
20
CONDENSER
23
11 17
14 32
26
9 21 RECEIVER TANK
33
8 36
OUT 35
4
27
28
B 7 25
37
10 IN
6 34
27
5
6
Bolt for tension pulley
31 T=45 {33.2}
OUT
27
IN
5
4
26
19 29
15
30
B A 11
12
9 21
10 24
38
8 20 21 7
24 9
18
Fig. 25-2 Installing air conditioner and heater
25-4
torque N•m No. Part name Q'ty torque N•m No. Part name Q'ty
(lbf•ft) (lbf•ft)
1 SUPPORT 1 20 WASHER 8
2 BRACKET 1 21 WASHER 3
3 PULLEY 1 22 LOCK WASHER 6
4 HOSE : L=2500 1 23 LOCK WASHER 6
5 HOSE : L=1950 1 46 (34) 24 NUT 2
6 TUBE : L=1400 1 24.5 (18) 25 CONNECTOR 1
7 TUBE : L=1500 1 26 TUBE : L=2100 1
8 TUBE : L=400 1 27 CLIP 4
9 TUBE : L=1900 1 28 GROMMET 1
10 TUBE : L=1250 1 29 GROMMET 1
11 CLIP 3 30 V-BELT 1
12 CLIP 1 31 CLIP 1
10.7 (8.0) 13 CAPSCREW : M8 X 100 4 46 (34) 32 CAPSCREW : M10 X 16 1
39 (29) 14 SEMS BOLT : M8 X 25 2 9.8 (7.2) 33 CLIP 1
10.7 (8.0) 15 CAPSCREW : M8 X 16 4 34 PIPE 1
4.4 (3.3) 16 CAPSCREW : M6 X 50 3 35 HOSE : L=150 1
4.4 (3.3) 17 NUT : M6 3 36 TUBE : L=100 1
18 CAPSCREW : M6 X 20 2 37 CLIP 2
19 WASHER 7 38 CLIP 1
25-5
25.2 CONSTRUCTION OF MAIN COMPONENTS

25.2.1 INTAKE UNIT
Fig. 25-3 Intake unit
25-6
25.2.2 AIR-CONDITIONER UNIT
Fig. 25-4 Air-conditioner unit
25-7
No. Part name Q'ty No. Part name Q'ty No. Part name Q'ty
1 ACTUATOR 3 22 LEVER 1 45 BRACKET 2
2 VALVE 1 23 LEVER 3 46 HOSE 1
3 THERMISTOR 1 24 LEVER 3 47 BLOWER MOTOR 1
4 CLAMP 2 25 CAM 1 48 CASING 1
5 ROD HOLDER 2 26 ROD 1 49 CASING 1
6 SENSOR HOLDER 2 27 ROD 1 50 FILTER 1
7 CLAMP 1 28 ROD 1 51 LEVER 1
8 EVAPORATOR 1 29 DAMPER 1 52 LEVER 1
9 CASING 1 30 DAMPER 1 53 DAMPER 1
10 CASING 1 31 DAMPER 1 54 FLANGE PLATE 1
11 CASING 1 32 DAMPER 1 55 SENSOR 1
12 THERMAL INSULATION 1 33 DAMPER 1 56 SEMS BOLT 1
MATERIAL 34 DAMPER 1 57 GASKET 1
13 THERMAL INSULATION 1 35 HEATER CORE 1 58 O-RING 1
MATERIAL 36 CONTROLLER 1 59 O-RING 1
14 PACKING 1 37 RELAY 1 60 TAPPING SCREW 6
15 PACKING 1 38 CLAMP 1 61 TAPPING SCREW 13
16 PACKING 1 39 BAND 1 62 SCREW 30
17 BRACKET 1 40 DUCT CAP 1 63 SEMS BOLT 3
18 CLAMP 1 41 HARNESS 1 64 TAPPING SCREW 9
19 PLATE 1 42 RESISTER 1 65 SCREW 1
20 LEVER 2 43 CASING 1 66 CAPSCREW 2
21 LEVER 1 44 CASING 1 67 TAPPING SCREW 4
25.2.3 RECEIVER DRYER
REFRIGERANT
INLET 2
REFRIGERANT
OUTLET
2-M6
1
No. Part name Q'ty

1 PRESSURE SWITCH 1
2 SIGHT GLASS 1
3 DESICCANT 1
4 SUCTION PIPE 1
5 FILTER 1
6 RECEIVER TANK 1
Fig. 25-5 Receiver dryer
25-8
25.3 FUNCTION
25.3.1 MECHANISM OF COOLING CIRCUIT
(1) Mechanism of Cooling
In the cooling process, the refrigerant that flows Item HFC-134a (R134a)
through the cooling circuit changes its phases from Chemical formula CH2FCF3
liquid to gas and vice versa during which process Molecular weight 102.03
heat is transferred from the low temperature part Boiling point -26.19 C (-15.14 F)
(compartment) to the high temperature part (out- Critical temperature 101.14 C (214.05 F)
side of the vehicle). Critical pressure 4.065 MPa (41.45 kgf/cm2)*1
1) Kind of Refrigerant Critical density 511 kg/m3 (31.9 lb/ft3)
Many kinds of refrigerants that change in that Density of saturated
1206 kg/m3 (75.3 lb/ft3)
way are available, but the following requirements liquid [25 C (77 F)]
are needed for use in such applications: Specific volume of
saturated vapor 0.0310 m3/kg (0.496 ft3/lb)
• Latent heat of vaporization (heat of vaporiza-
[25 C (77 F)]
tion) is large.
Latent heat of
• It is easy to liquefy (condense). (It dose not vaporization 197.5 KJ/kg {47.19 kcal/kg}
require very high pressure for condensation.) [0 C (32 F)]
• It is easy to gasify (evaporate). (It evaporates Flammabillty Nonflammable
sufficiently at not too low pressure, i.e. cools Ozone destruction coefficient 0
down an object.) *1 : 1 MPa (mega pascal) equals 10.1972 kgf/cm2
• It has small specific heat. (Since the refriger- (145 psi)
ant 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.
Out of refrigerants meeting the above-men-
tioned requirements, ones having character-
istics that suit the intended cooling unit are
chosen and used. If a refrigerant other that
those designated is used, sufficient refriger-
ation will not be performed or the equipment
in which the refrigerant is used may be bro-
ken. Therefore, always use a designated re-
frigerant for the cooling unit.
Table 1 shows the principal characteristics of
the R134a refrigerant that is used in this ma-
chine.
25-9
(2) Characteristics of Refrigerant (See Fig. 25-6.) PRESSURE

In general, the fluid (general term of gas and liquid) MPa (psi)
has the following qualities:

1) As a gas under certain pressure is cooled down,
it begins to condensate at a certain temperature LIQUID
to take a liquid state. The temperature at which
condensation begins is unique to each sub-
stance (fluid) at a given pressure. The tempera- GAS
ture determined by a given pressure is called
TEMPERA-
saturation temperature. TURE
[ C ( F)]
2) Inversely to 1) above, the pressure at which a
gas condenses for a temperature is determined. Fig. 25-6 Pressure-temperature characteristics of
This pressure is called saturation pressure. R134a
Fig. 25-6 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. 25-6, 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 refriger-
ant evaporates, it absorbs evaporation heat from
the air of the compartment. In order to cool the in-
side 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. 25-6 that R134a under a
pressure above the atmospheric pressure is ca-
pable of cooling the inside of the compartment
sufficiently. (If a refrigerant that requires a pres-
sure below the atmospheric pressure to cool it to
a required temperature is used, air is mixed into
the circuits, thereby deteriorating the perfor-
mance of the cooling unit.) In the process in
which gaseous refrigerant is brought back to a
liquid state, the refrigerant is cooled and con-
densed by the outer air exceeding 35°C (95°F).
Accordingly the refrigerant is capable of con-
densing at a pressure exceeding 1 MPa (145
psi), as seen from Fig. 25-6.
25-10
25.3.2 COOLING CIRCUIT

Fig. 25-7 illustrates the cooling circuit of the car aircon-
ditioner.
In this circuit diagram, the portion that cools the air of INSIDE OF COMPARTMENT
the compartment is the evaporator. The object air is
cooled off by utilizing the fact the refrigerant takes heat
off the surrounding area as evaporation heat as it evap-
EVAPORATOR EXPANSION
orates in the cooling circuit. Since the part at which va- VALVE
porization of the refrigerant takes place is the BLOWER
evaporator, cooled air is constantly delivered to the cir-

cumference of the evaporator by the blower fan. In the INSIDE OF ENGINE
ROOM
meantime, liquid refrigerant (slightly wet vaporized re- S D
frigerant) is fed into the evaporator, when "cooling" ef- COMPRESSOR COOLING FAN
fect 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 unless it evaporates at a temperature RECEIVER DRYER
lower that 15°C (59°F). For that purpose, it can be seen
CONDENSER
from Fig. 25-6 that the pressure of the refrigerant in the
evaporator must be less than 0.51 MPa (74psi).
Fig. 25-7 Construction of cooling curcuit
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 ex-
pansion 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 com-
pressor acts as a pump that allows the refrigerant to cir-
culate. The compressive action of the compressor and
the heat exchange (heat radiation) action of the con-
denser transform the refrigerant in a dry vapor state
back to a liquid state.
25-11
25.3.3 COMPONENT PARTS

(1) Evaporator (See Fig. 25-8.)
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 refriger-
O-RING
ant. Therefore, it is necessary that satisfactory heat EXPANSION
transfer between the object and the refrigerant take VALVE
place in the evaporator.

To that end, the evaporator is equipped with fins on SOCKET BOLT
M5 X 40 (2 pcs.)
the air side in order to increase the heat transfer
area of the air side and thereby perform excellent EVAPORATION
thermal transfer between the refrigerant and the air. SENSOR
The humidity in the air condenses as the air cools Fig. 25-8 evaporator
down and adheres to the outside of the evaporator
as water drops. The cooling effect deteriorates if
the water drops freeze. Therefore, how to dis-
charge water is an important point.
The amount of refrigerant supplied to the evapora-
tor is controlled by the expansion valve which is de-
scribed in the following. In order to attain proper
control, it is necessary to reduce the pressure drop
of the refrigerant of the evaporator. Accordingly, re-
ducing 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 refrigerant completes va-
porization 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 deterio-
rates the cooling effect, but also damages the com-
pressor valves.
The expansion valve feeds the flowing high-pres-
sure high-temperature liquid refrigerant to the
evaporator as low-pressure low-temperature liquid
refrigerant (damp vapor of low dryness). The ex-
pansion valve controls the feed rate of the refriger-
ant at the same time.
25-12
Fig. 25-9 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 tempera-
ture at the outlet of the evaporator.
The diaphragm contains R134a in saturated REFRIGERANT
EVAPORATOR OUTLET
state. The pressure in the diaphragm changes
SIDE
according to the temperature detected by the
sensor. The change in the pressure causes the SHAFT
force acting upon the diaphragm to vary accord-

ingly.
The high-pressure high-temperature liquid refig-
REFRIGERANT
erant that is fed from the receiver side reduces INLET
the pressure abruptly as it passes through the
valve (throttling action). On that occasion, part of BALL
the refrigerant evaporates by the heat of the re- BALVE
SPRING
frigerant and cooled off. The result is that low-
pressure low-temperature damp refrigerant va- Fig. 25-9 Block type expansion valve
por is fed to the evaporator.
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 un-
der the pressure in the evaporator, the refriger-
ant is properly overheated (3~8°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 re-
frigerant. For this reason, the smaller the pres-
sure 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. 25-10 Expansion valve outside view
securely. The air-conditioner of this machine
adopts a block type expansion valve.
25-13
(3) Compressor (See Fig. 25-11)

D HOSE
The compressor performs the following three func-
tions in the cooling circuit:
1) Suction action
S HOSE
2) Pumping action
3) Compressive action
1) The suction action, as combined with the throt-
tling action, works to decrease the refrigerant
pressure in the evaporator. This permits the re-
frigerant to vaporize at low temperature in order
to perform cooling effect.
2) The pumping action serves to cause all the re-
frigerant to circulate in the cooling circuit. This
enables continuous cooling.
3) The compressive action, as combined with the Fig. 25-11 Compressor
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. 25-12)
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 refriger-
ant. 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 com-
partment can not be cooled sufficiently by the evap-
orator. For that purpose, it is necessary to secure
ventilation required for cooling of the refrigerant.
Fig. 25-12 Condenser
25-14
(5) Receiver Dryer (See Fig. 25-13) REFRIGERANT SIGHT GLASS

1) Receiver Tank INLET
On the air-conditioner, the revolution of the com- REFRIGERANT
pressor varies greatly which cause the proper OUTLET
flow of refrigerant in the cooling circuit to vary. It
is the receiver tank that receives the variations.
When the cooling circuit the variations. When the
cooling circuit does not need much refrigerant,
the receiver tank stores extra refrigerant tempo-
rarily and supplies it when the cooling circuit
PRESSURE SWITCH
needs much refrigerant. The 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 deterio-
rates the compressor valves and oil, corrodes DESICCANT
the metallic parts of the circuit or clogs the circuit
as the water freezes in the expansion valve. It is SUCTION PIPE
desirable that the amount of water mixed in the
refrigerant should be held below a concentration
of 30 ppm. The air-conditioner uses a molecular
sieve as desiccant suited for the circuit, in order FILTER
to absorb water content that intrudes into the cir-
cuit when the dryer is installed or when refriger-
ant is charged.
3) Sight Glass
This is a window with which the refrigerant level
in the circuit is determined, the only means of RECEIVER TANK
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 cut-
ting off the power supply to the compressor when Fig. 25-13 Receiver dryer
high pressure increases abnormally high [more
than 3.1 MPa (460 psi)].
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 0.2 MPa (28 psi).
25-15
25.4 DISASSEMBLY AND ASSEMBLY

25.4.1 PRECAUTIONS TO BE EXERCISED IN OPERATION
(1) Special Refrigerator Oil
Pipe Joints 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, D hose and condenser 19.6~24.5 (14~18)
the following points must be noted: L hose and condenser 11.8~14.7 (8.7~11)
1) Keep open all pipe connections on a new com- L hose and receiver dryer
7.8~11.8 (5.8~8.7)
pressor and the component parts of the installed (M6 bolt)
refrigeration circuit. L hose and air-conditioner unit 11.8~14.7 (8.7~11)
(Remove valves and caps at the pipe openings S hose and air-conditioner unit 29.4~34.3 (22~25)
of the compressor, just before connecting popes. Inlet of expansion valve 11.8~14.7 (8.7~11)
If you have removed a pipe joint for repair, put a Outlet of expansion valve 19.6~24.5 (14~18)
Pressure sensing part of
cap to both ports immediately). 6.9~8.8 (5.0~6.5)
expansion valve
2) Use care so SP20 does not adhere to the paint-
ed surface and resin parts. In case SP20 has ad-
hered to such surfaces, wipe it off immediately.
Screws and Bolts Unit : N·m (lbf·ft)
(2) The receiver dryer is filled with desiccant to absorb
moisture in the circuit. Therefore, remove the valve Screw Size Tightening Torque
at the pipe port immediately before connecting N4, T4, machine screw, M4 0.78~1.18 (0.58~0.87)
pipes. N5, T5, machine screw, M5 1.96~2.45 (1.4~1.8)
(3) Tightening Torque M6 (mounting part of
7.85~11.8 (5.8~8.7)
L hose joint)
1) Pipe Joints (See the table "Pipe Joints" to the
M6 (except mounting part of
right.) 9.8~11.8 (7.2~8.7)
L hose joint)
When connecting pipe joints, coat the O ring with
M8 (mounting parts of
special oil (SP20) and fasten to the tightening 19.6~24.5 (14~18)
S,D hose joints)
torque indicated in the table, using a double M8 (mounting part of A/C unit) 9.8~11.8 (7.8~8.7)
spanner. M8 (other than those
1.18~15.7 (8.7~12)
2) Screws and Bolts (See the table "Screws and mentioned above)
Bolts" to the right.) N10 39.2~53.9 (29~40)
(4) Amount of Oil for Compressor (See the table
"Amount of Oil for Compressor" to the right.)
The compressor SD7H (HD type) is filled with Amount of Oil for Compressor
135cc (8.2 cu-in) of oil. If the oil volume is small,
Part to be Replaced Amount to be filled in
seizure at high revolution and shortening of service
Evaporator 40 cc (2.4 cu•in)
life will occur. If the oil volume is large, the cooling
Condenser 40 cc (2.4 cu•in)
ability will be deteriorated.
Drain out the volume of oil left in
Once the air-conditioner is operated, part of the oil
Compressor compressor to be replaced, from
is dispersed in the refrigeration circuit. Therefore,
the new cpmpressor.
when replacing the parts in Table 4, adjust the oil
level to that of table.
(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.
25-16
25.4.2 REMOVAL AND INSTALLATION OF THE UNIT

(1) Removing the blower unit
1) Remove the connectors connected to the inner/
INNER / OUTER
outer air select motor actuator, the blower motor AIR MOTOR
and the blower controller. Also remove the har- ACTUATOR
CONNECTOR
ness from the blower casing.
HARNESS
EVAPORATOR
SENSOR BLOWER
CONTROLLER BLOWER MOTOR
CONNECTOR
CONNECTOR CONNECTOR
Fig. 25-14
2) Draw out the inner air filter from the intake cas- INTAKE
ing. Remove four cross-recessed screws T5 X INNER AIR FILTER CASING
MOUNTING
14 (T1) from the top of the intake casing, using a SCREWS
screwdriver. Then remove the intake casing. (4 pcs.)
3) Remove three cross-recessed screws T5 X 14 INTAKE

(T1) fastening the blower casing with the unit CASING
casing. Then separate the blower unit from the BLOWER
air-conditioner unit. CASING
MOUNTING
SCREWS
(3 pcs.)
UNIT BLOWER
CASING
Fig. 25-15
(2) Replacing the blower motor
BLOWER CASING
1) Disconnect the cooling hose that is connected
between the blower motor and the blower cas-
ing.
2) Remove three cross-recessed screws N5 X 16
(W) fixed from the bottom of the blower unit cas-
BLOWER MOTOR
ing. Then draw out the blower motor.
BLOWER
• Do not separate the fan from the blower mo- CONTROLLER
tor.
COOLING HOSE
3) Assembly is the reverse order of disassembly.
(3) Replacing the blower controller BLOWER MOTOR
1) Remove two cross-recessed screws T4 X 14 BLOWER MOTOR
BLOWER MOUNTING
(T1) fixed from the bottom of the blower unit cas-
CONTROLLER SCREWS (3 pcs.)
ing and draw out the blower controller. MOUNTING
2) Install a new blower controller in the reverse or- SCREWS (2 pcs.)
der of removal. Fig. 25-16

• Do not disassemble the blower controller in
any circumstances.
25-17
(4) Removing the heater core

1) After discharging the cooling water, disconnect
the heater hose from heater core.
HEATER CORE
2) Remove one cross-recessed screw N5 X 16 (T2)
each for the AHC bracket fixing the heater core PIPE CLAMP
to the unit and for the pipe clamp. Then remove
the AHC bracket and the pipe clamp and draw
PIPE CLAMP
out the heater core from the unit casing. MOUNTING
SCREW (1 pc.)
3) Assembly is the reverse order of disassembly.
AHC BRACKET AHC MOUNTING
SCREW (1 pc.)
Fig. 25-17
(5) Removing the upper and lower parts of the air-con-
ditioner unit casing.
1) Draw out the connectors for the mode motor ac-
tuator and the evaporation sensor.
ROD 120
2) Separate the rod 120 from the rod holder that is REAR OF
UNIT CASING
fixed to the lever MAL1 on the mode motor actu- ROD HOLDER
ator. MOUNTING SCREW
LEVER MAL1
3) Remove three cross-recessed screws N4 X 22
BOTTOM OF
(T2) fastening the mode motor actuator that in- MOUNTING UNIT CASING
SCREW
stall the bottom of the unit casing to the back of
MOUNTING MODE MOTOR
the unit casing. Then separate the mode motor SCREW ACTUATOR
actuator.
4) Remove eleven cross-recessed screws N5 X 16 Fig. 25-18
(T2) that install the bottom of the unit casing to
the top of the unit casing. TOP OF
Draw out the top of the unit casing upwards, us- UNIT CASING
ing care so the evaporator sensor cord is not ar-
rested by the casing.
• On that occasion, do the work with the heater
core off the unit casing. EVAPORATOR ASSY
EXPANSION
VALVE
EVAPORATION
SENSOR
BOTTOM OF
UNIT CASING
TOP / BOTTOM
UNIT CASING
MOUNTING
SCREWS (11 pcs.)
Fig. 25-19
25-18
(6) Replacing the evaporator and the expansion valve

1) Remove the evaporator assy from the bottom of EVAPORATOR
the casing, together with the casing insulator and
the expansion valve.
2) Remove the upper and lower casing insulators
O-RING EXPANSION
from the evaporator assy and draw out the evap- VALVE
orator sensor with the sensor holder.
SOCKET HEAD
3) Remove the socket head cap screws M5 X 40 (2
CAPSCREW
pcs.) from the evaporator. Then separate the ex- M5 X 40 (2 pcs.)
pansion valve from the evaporator.
: 4 mm
EVAPORATION SENSOR
4) Attach O-rings (NFO-ring 5/8 and 1/2, one piece
each) to a new evaporator. Then install the ex- Fig. 25-20
pansion valve to it.
: 4 mm
Tightening torque 6.8 N•m (5.1 lb•ft)
• When attaching O-rings, use care so the O-
rings are not caught. 3rd row
(7) Installing the evaporator sensor

Install the evaporation sensor as shown in Fig. 5th and
6th rows
25-21.
• When installing the casing, exercise care so 13th and 14th rows
the sensor cord is not caught by the casing.
EVAPORATION SENSOR
Fig. 25-21
(8) Replacing the motor actuator
1) Replacing the mode motor actuator
Remove the connector fixed to the motor actua-
tor.
ROD 120
Remove the rod 120 linking the motor actuator REAR OF
UNIT CASING
with the mode cam, from the rod holder. ROD HOLDER
Remove three cross-recessed screws T4 X 14 MOUNTING
SCREW
(T1) fixing the motor actuator. Separate the mo- LEVER MAL1
tor actuator from the unit, together with the rod BOTTOM OF
MOUNTING UNIT CASING
holder and the lever MAL1. Remove the rod SCREW
holder and the lever MAL1 from the motor actu- MOUNTING MODE MOTOR
ator and install them to a new motor actuator. As- SCREW ACTUATOR
sembly is the reverse order of disassembly.
Fig. 25-22
25-19
2) Replacing the air mix motor actuator LEVER AM ROD 67

Disconnect the connector connected with the ROD HOLDER
motor actuator. LEVER MAL1
Separate the rod 67 linking the motor actuator AIR MIX MOTOR
ACTUATOR
with the lever AM, from the rod holder.
Remove three cross-recessed screws T4 X 14
(T1) fastening the motor actuator. Then remove
the motor actuator with the rod holder and the le-
ver MAL1, from the unit. Remove the rod holder
and the lever MAL1 from the motor actuator and
install them to a new motor actuator. Assembly is Fig. 25-23
the reverse order of disassembly.
3) Replacing the inner/outer air select motor actua-
tor
Disconnect the connector connected with the
motor actuator. LEVER MAL2
Separate the motor actuator with lever MAL2
from the unit.
Remove the lever MAL2 from the motor actuator
and install it to a new motor actuator, in the re-
INNER / OUTER AIR
verse order of disassembly. MOTOR ACTUATOR
Fig. 25-24
25-20
25.5 CHARGING REFRIGERANT

25.5.1 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.
• Always 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) Hold 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. Therefore, never 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 compart-
ment. The areas of the compartment which are exposed to direct sunlight may rise to a dangerous temper-
ature level. Therefore, 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, marks 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
Re-use 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.
25-21
25.5.2 OPERATING PROCEDURE

(1) Refrigerant charge into the air-conditioner consists mainly of "vacuum making operation" and "gas charge oper-
ation".
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 cir-
cuit, make vacuum and allow the water in the circuit to boil and vaporize. Water in the circuit is thus elimi-
nated.
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 lubricat-
ing 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 mim. for five minutes
Begin vacuum Stop vacuum Check Fill in Check for Fillin
making making air-tightness refrigerant gas leak refrigerant
Less than
-750mmHg
Gauge reading
wrong
Charge liquid gas to a gauge
Check and correct joints
pressure of 0.1 MPa (14 psi)
(3) Tools
Table 25-1
No. Part name Q'ty Sketch Service No. Part name Q'ty Sketch Service
Low pressure
4 Quick joint 1
Gauge man- side
1 1
ifold For service
5 T joint 1
can valve
Red: high
pressure side
Charging Blue: low pres- Service can For service
2 3 6 2
hose sure side valve can
Yellow: vacu-
um pump side
Vacuum
For vacuum
3 Quick joint 1 7 pump adapt- 1
pump
er
25-22
25.5.3 CHARGING PROCEDURE
25.5.3.1 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
GAUGE GAUGE MANIFOLD
pressure valve (LO) of the gauge manifold.
(CLOSED)LOW
2) Connect the charging hoses (red and blue) with HIGH PRESSURE
PRESSURE VALVE
VALVE (CLOSED)
the service valves of the compressor.
BLUE RED
Red hose:
High pressure side (HI) of the gauge manifold  HIGH
PRESSURE YELLOW
high pressure side (DIS) of compressor SIDE
DIC
Blue hose:
LOW
Low pressure side (LO) of gauge manifold  low PRESSURE
pressure side (SUC) of compressor SIDE
COMPRESSOR VACUUM PUMP (STOP)
• Take care so as not to mistake the high pres- Fig. 25-25 Connecting gauge manifold
sure side for low pressure side and push it in till
BLUE
a click is heard.
RED
• Connect the end bent like "L" of the charging
hose with the service valve of the compressor.
CHARGING HOSE
If the charging hose is connected the opposite
way, the mini core valve of the compressor (MINI CORE VALVE)
does not open. (See Fig. 25-26)
Fig. 25-26 Connecting piping with compressor
3) Connect the middle valve of the gauge manifold
with the charging hose of the vacuum pump.
Some kinds of gauge manifolds are not equipped

with an open/close valve in the center.
25-23
(2) Vacuum Making (See Fig. 25-27.)

1) Open the high pressure valve (HI) and the low
pressure valve (LO) of the gauge manifold.
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 pres-
sure valve of the gauge manifold.
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
than five minutes and make sure that the gauge in-
dication does not return toward zero.
Fig. 25-27 Vacuum making operation
If the gauge indication swings toward zero, there is

somewhere that is leaking. Retighten pipe joints,
make vacuum again and make sure of no leakage.
25-24
25.5.3.2 GAS CHARGING OPERATION

(1) Charging from High Pressure Side (See Fig. 25-
28.)
AIR PURGE
1) After making vacuum repeatedly, change the
CLOSE
charging hose (yellow) of the gauge manifold
RED
from the vacuum pump to the service can.
Open the service can valve. (However, close the OPEN SERVICE CAN VALVE
SCREWDRIVER
high and low pressure valves of the gauge man- OR SOMETHING
ifold.) Then push the mini core valve of the side BLUE YELLOW
service port on the low pressure side of the
gauge manifold, using a screwdriver or some-
thing, in order to let out the air in the charging
Fig. 25-28 Gas charging operation
hose by the pressure of the refrigerant. (See Fig.
25-28.) (The operation ends when a hissing
sound is heard.)
2) Open the high pressure valve of the gauge man- LOW PRESSURE
VALVE (CLOSE) HIGH PRESSURE VALVE
ifold and charge in refrigerant. [Charge in gas- (OPEN) (CLOSE)
eous refrigerant to a gauge pressure of 0.1 MPa RED
FILL IN 1~1.5 CANS
BLUE
(14 psi).] OF REFRIGERANT
After charging, close the high pressure valve of YELLOW
the gauge manifold and the service can valve.
(See Fig. 25-29.) SERVICE CAN
VALVE
(OPEN) (CLOSE)
CHARGE
• Do not run the compressor in any case, (Other-

wise the refrigerant flow in reverse direction Fig. 25-29 Gas charging operation (High pressure
which causes the service can and the hoses to side)
rupture. This is very dangerous.)
(2) Checking for Gas Leakage

Check for gas leakage in the cycle, using a gas leak
detector (electric type). Retighten and correct leak-
ing points.
• Always use R134a for the leak tester. (The pres-

ently used from gas affects the sensitivity ad-
versely.)
25-25
(3) Charging from Low Pressure Side (See Fig. 25-30.)

1) Make sure that the high-pressure and low-pres-
HIGH PRESSURE
sure valve of the gauge manifold and the service LOW PRESSURE VALVE (CLOSE)
can valve are closed. VALVE (MUST BE CLOSED
(OPEN) (CLOSE) POSITIVELY)
2) Start the engine and run the revolution to 1500 RED
WHEN AIR BUBBLES
±100 rpm and fully close the cab door and the IN THE SIGHT GLASS
windows. DISAPPEAR YELLOW
3) Turn on the air-conditioner switch to Max and the BLUE
temperature control switch to cool Max. SERVICE CAN
VALVE (OPEN)
4) When charging gas, set the discharge pressure
of the compressor to 1.37~1.57 MPa (200~230
psi).
COMPRESSOR
5) Open the low pressure valve of the gauge mani- OPERATION SERVICE CAN
fold and the service can valve and fill in refriger- (DO NOT TURN IT OVER)
ant till air bubbles of the sight glass of the Fig. 25-30 Gas charging operation
receiver go away. (See Fig. 25-7.) (Low pressure side)
[Total amount of gas to be charged : 900~950 g
SIGHT GLASS
(1.8~1.9 lbs)]
6) When refrigerant charge is over, close the low
pressure valve of the gauge manifold and the
service can valve.
• Do not open the high pressure valve of the

gauge manifold in any circumstances.
• Never place the service can upside down. (The
compressor valve may be scored because the
refrigerant is sucked in a liquid state.)
Fig. 25-31 Receiver dryer
25-26
(4) Criterion for Checking the Amount of Refrigerant Judgment of refrigerant level through the sight glass
Filled in of receiver dryer
Refrigerant volume Description
(A) Proper
• If the air-conditioner is run with scant refriger- After the air conditioner is turned ON, little
ant R134a, it has adverse effect on the compres- bubbles appear. The refrigerant becomes
transparent, then turns a light milky white.
sor.
(B) Overcharged
• If the refrigerant is charged too much (over-
charged), the cooling performance is deterio-
After the air conditioner is turned ON, no
rated. Moreover, the circuit pressure gets bubbles appear.
abnormally high : Always keep a proper level. (C) Insufficient
(5) Detaching Gauge Manifold

When the refrigerant level has been checked, dis- After the air conditioner is turned ON,
bubbles appear continuously.
connect the charging hoses from the compressor in
the following manner : Bubbles : Refrigerant gas is mixed with
refrigerant fluid.
1) Press the "L" shape metal fitting of the charging
hose (blue) on the low pressure side against the No Bubbles : Whole refrigerant becomes fluid
service valve of the compressor so the refriger- and transparent.
ant does not leak out and loosen the nut. As soon
as the nut has been removed, disconnect the Cloudy : Refrigerant is separated from oil.
The fluid becomes a light milky
charging hose from the service valve.
white.
2) Leave the high pressure side as it is till the high
pressure gauge reading falls. [below 0.98 MPa
(140 psi)].
3) Disconnect the charge hose (red) on the high
pressure side the same way as on the low pres-
sure side.
25-27
25.6 ELECTRIC CIRCUIT

25.6.1 WIRING DIAGRAM AND CONNECTORS
Fig. 25-32 Electric diagram (1/2)
25-28
Fig. 25-33 Electric diagram (2/2)
25-29
25.6.2 INSPECTING FUNCTIONAL PARTS

(1) Relay (24-4PE)
1) Coil resistance : 320 (across 1 and 2)
2) Operating voltage : DC20-30V
3) The coil of the relay has polarity : Care is need- As viewed from A
ed.
4) Turn on and off the power to the blower motor by
controlling the controller.
5) Check : Check conductance across 3 and 4 in
the following condition :
Apply 20-30V across terminals 1 and 2 : continue
No voltage applied across terminals 1 and 2 : dis-
continue
Fig. 25-34 Relay
(2) Inner air sensor (C44)
Resistance across terminals :
at 0°C (32°F) : 7.2 K 1/2
at 25°C (77°F) : 2.2 K 1/2
The inner air sensor is installed to the sensor brack-
et under the operator's seat. The temperature in the
cab is sensed by the thermistor. Changes in the re-
sistance according to temperature variations are
transmitted to the controller.
Fig. 25-35 Inner air temperature sensor
(3) Blower controller
The blower controller changes output voltages for
the motor according to signals emitted by the con-
troller.
Fig. 25-36 Blower controller

(4) Motor actuator
1) Operating voltage : DC20-30V
2) Operating temperature range : -30°C (-22°F) to
+75°C (167°F)
The motor is controlled by signals (pulses) put
out by the controller.
Fig. 25-37 Motor actuator
25-30
(5) Pressure Switch (Attached to Receiver Dryer) PRESSURE SWITCH

1) Contents of checking (specification)
Low pressure side OFF pressure :
0.2 ± 0.02 MPa (28 ± 3 psi)
Low pressure side return pressure :
OFF pressure + 0.03 MPa (4.3 psi) or below
High pressure side OFF pressure :
3.1 ± 0.2 MPa (455 ± 28 psi)
High pressure side return pressure :
OFF pressure -0.59 ± 0.02 MPa (-85 ± 2.8psi)
Fig. 25-38 Pressure switch
LOW PRESSURE RETURN HIGH PRESSURE RETURN MPa (psi)

(26) (30) (31) (36) (310) (430) (480)
0.18 0.21 0.22 0.25 2.16 2.94 3.33
LOW PRESSURE OFF HIGH PRESSURE OFF
2) Performance
Low pressure side :
To prevent actuation of the compressor clutch
where refrigerant is deficient
High pressure side :
To prevent actuation of the compressor clutch
where pressure rises abnormally because of the
clogging of the refrigeration circuit, etc.
(6) Thermistor (C19)
1) Contents of checking (specification)
Resistance across terminals
at 0°C (32°F) : 7.2 K1/2
at 25°C (77°F) : 2.2 K1/2
Normally check that there is no shortcircuit or discon-

Fig. 25-39 Thermistor
nection.
2) Performance
In order to prevent freezing of the evaporator, the
blowoff air temperature of the evaporator is con-
trolled by turning the compressor clutch ON and
OFF. The thermistor operates as the sensor of
the control.
25-31
25.7 TROUBLESHOOTING
[ Temperature does not fall. ] Note) M/A : Motor actuator
If A/C switch is pushed, "HL.E" is indicated on the set temp. display of the panel.
NO YES
Connector for air mix M/A is

*
"HL. " is shown on the set temp. display of the panel.
disconnected or in poor contact.
Note) is any of the
NO YES *numbers 0 ~ 9. M/A is broken.
Main harness shows poor conductance.
** E on display.
A snow mark on the A snow mark on panel is flickering.
panel is flickering. Inspect and correct or replace parts.
NO YES NO YES
Inner air sensor or harness Both inner air sensor and

is disconnected or shorted. evaporation sensor are
Inner air sensor connector is disconnected or sohrted.
disconnected or in poor contact. Controller failed.
Inspect and correct or replace parts.
Blowout temp. falls if temp. is set

Evaporation sensor connector
at 18.0 (64.4 F) (COOLMAX) and the
is disconnected or in poor contact.
blowout mode is changed to vent mode.
Evaporation sensor is
NO YES disconnected or sohrted.
*1 Air mix damper is

in COOLMAX.
Chilly air flowing
into inner air sensor
NO YES NO YES
If M/A is at stop Turn compressor clutch Controller is faulty Inspect duct or

halfway, eliminate on and off. Inspect and or inner air eliminate cause for
cause, correct and correct electric circuits. sensor is faulty. chilly air intrusion.
measure operating
force. (less than Refer to Troubleshooting Inspect and replace.
1.5 kgf : OK) for refrigeration cycle.
*1 COOL-MAX
acting condition
NO YES
Inspect, correct or replace M/A is faulty or controller

M/A lever link. is out of order.
After cleaning lever link,
apply grease.
Replace.
25-32
[ Temperature does not rise. ]
HL.E is shown on the set temp. display of panel.
NO YES
*
"HL. " is shown on the set temp. display of the panel. Note)
* is any of the numbers 0 ~ 9
NO YES
*2Blowout temp. rises at blowout Inner air sensor or harness

mode if temp. is set at is disconnected or shorted. Air mix M/A connector is off.
HOTMAX 32.0 C (89.6 F). Inner air sensor connector M/A is broken.
is off or in poor contact. Main harness shows
poor continuity.

Inspect and correct
NO YES
or replace parts.
*2 Air mix damper is Warm air is flowing into

at HOT MAX. inner sensor.
NO YES
NO YES
If M/A action is at Inspect warm water piping.
stop, eliminate cause, Controller or Inspect duct or
correct and measure inner air sensor eliminate causes
operating force. is out of order. for warm air entry.
(less than 1.5kgf : OK)
Inspect and replace.
NO YES
Inspect, correct or M/A failed or controller *2 : HOT-MAX

replace M/A lever link. is out of order. operating condition.
Clean lever link and apply grease.
Replace.
25-33
[ Blower motor does not run. ]
At air flow HI, battery voltage acts across Note) Measure with
both terminals (+) and (-) of blower motor. connector set.
NO YES
Battery voltage acts across red Blower motor fails.

(+) and body of blower motor.
Replace.
Note 1) Always turn off air- NO YES
conditioner, starter
key switch and light
switch before work.
Inspect blower motor relay. Approx. 10V acts across

Note 1 Blower motor rotates if white / blue / black (0.85) and
green (2.0) and red of blower earth of blower amplifier.
motor relay are direct connected.
NO YES
NO YES
Controller is out of order.
Wire harness is Battery voltage acts across Remove blower amplifier and check for
faulty. Inspect white / green (0.85) and continuity across blue / black (0.85)
and correct or replace. body of blower motor relay. and black wires ; you get continuity.
NO YES NO YES
Inspect and repair Blower turns if Eliminate cause Inspect and

harness or replace. brown / red of and replace repair
blower motor blower amplifier. harness.
relay is connected
with earth.
NO YES
Replace relay. Inspect and correct harness

or replace controller.
[ Blower motor speed does not change. ]
HL. Note) is any of the

* is shown on the set temp. display of panel. *
numbers 0 ~ 9.
NO YES
Air flow rate is constant regardless of readings. Inner air sensor and harness
are disconnected or shorted.
Inner sensor connector is
disconnected or in poor contact.
Replace blower
amplifier or controller. Inspect and correct or replace parts.
25-34
[ 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 B Terminal voltage present across Clutch faulty.

pressure switch harness.
NO YES Replace compressor.
Voltage acts across red and Pressure switch is faulty or gas

blue terminals of connector is under charged or overcharged.
connected to excavator.
NO YES
Inspect air-conditioner Inspect air-conditioner

and vehicle connector. harness. No fault.
Also clutch fuses.
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 Connector of inner/outer air M/A is

foreign matter disconnected or in poor contact.
or is broken. Or M/A failed or main harness failed.
NO YES
Inspect or replace.
M/A failed Remove foreign matter

and replace parts.
Replace
25-35
[ Modes do not change. ]
Mode display on operating

panel is flickering.
NO YES
M/A rod is linked. Mode M/A connector is not linked or

in poor contact or M/A failed or main
harness is faulty.
NO YES
Inspect or replace.
Repair. Each damper lever is linked.
NO YES
When rod is removed and cam is operated

Repair. by hand, it is heavy. (more than 2kgf.)
NO YES
M/A or controller is out of order. Cam or damper shaft includes

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

Clean cam and apply new grease.
25-36
[ Trouble with refrigeration cycle. ]
Both high and low pressures are lower. Low pressure is lower.
Air bubbles are seen in sight glass. Air bubbles are High pressure
seen in sight glass. is lower.
NO YES
Cooling does not work Oil oozes out from Compressor Hot air Compressor
if run at high speed. piping and parts. cylinder does comes out of cylinder gets
not get hot. heater unit. very hot.
NO YES NO YES
Expansion Expansion Natural Gas leaks Expansion Water cock Compressor

valve is valve is leak from from pipe valve is mal- is mal- does not
clogged frozen or hose. joints and adjusted. adjusted discharge
or mal- intruded parts. (too much or faulty. well.
adjusted. by water. open)
Adjust or After making Charge gas. Retighten Replace Adjust or Replace

replace vacuum, refill or replace expansion replace compressor.
expansion refrigerant parts. valve. water cock.
valve. and replace
receiver.
High pressure is lower. If system is run continuously in HI idle,

it does not cool down or air flow decreases.
Air bubbles are seen in sight glass. Frost deposits.
NO YES
High pressure gets Condenser is Thermistor does

lower gradually. fouled or clogged. not cool off.
YES NO YES
NO
High pressure
circuit before Air bubbles are hard to Thermostat is Thermistor position
receiver is go out even if water not turned off. is normal.
clogged up. is poured on condenser.
NO YES NO YES
Remove Clean Air is mixed. Functions and Thermistor Thermistor Air

clogging condenser. Make vacuum performances is faulty or position is leaks
or replace and refill are normal. cord is faulty. out of
parts. refrigerant. Familiarize disconnected. Correct casing.
the user with position.
how to use it.
25-37
[MEMO]
25-38
31. GENERAL DISASSEMBLY AND
ASSEMBLY
TABLE OF CONTENTS
31.1 GENERAL DISASSEMBLY AND ASSEMBLY .................................................................... 31-3

31.1.1 CONTENTS OF GENERAL DISASSEMBLY AND ASSEMBLY ................................. 31-3
31.1.2 SPECIFICATION OF TIGHTENING TORQUE .......................................................... 31-3
31
Book Code No. S5PW3108E01
31-1
31. GENERAL DISASSEMBLY AND ASSEMBLY
Issue Data of Issue Applicable Machines Remarks

EH30.B : PW11–30001~ S5PW3108E01
First Edition June, 2004 KE
EH35.B : PX12–11001~ (NH Australia)
SK40SR–3 : PH05–03501~ S5PW3108E01
  KE
SK50SR–3 : PJ04–03001~ (KCM Australia)
S5PW3108E01
  EH50.B : PJ04–03001~ KE
(NH Australia)
SK30SR–3 : PW11–30001~ S5PW3108E01
  KE
SK35SR–3 : PX12–11001~ (KCM Australia)
S5PW3108E01
 August, 2004 SK50SR-3 : PJ04-03001~ KE
(KCM North America)
SK30SR–3 : PW11–30001~
   KE
SK35SR–3 : PX12–11001~
 September, 2004 SK70SR–1E(S) : YT04–07001~ S5PW3108E01 KE
  SK80MSR–1E(S) : LF04–02001~  KE
  SK80CS–1E : LF04–02001~  KE
S5PW3108E01
(NHK)
31-2
31.1 GENERAL DISASSEMBLY AND ASSEMBLY

31.1.1 CONTENTS OF GENERAL DISASSEMBLY AND ASSEMBLY
This chapter is consist of three sections as follows.
(1) ATTACHMENT ............................................................................................................Index No. : 32
Part I : Removing and Installing Assembly
Part II: Disassembling and Assembling Components
1) Hydraulic cylinder
(2) UPPER SLEWING STRUCTURE.................................................................................Index No. : 33
1) Hydraulic pump
2) Control Valve
3) Pilot Valve (ATT)
4) Pilot Valve (Travel)
5) Slewing Motor
6) Swivel Joint
(3) TRAVEL SYSTEM .........................................................................................................Index No. : 34
1) Travel Motor
31.1.2 SPECIFICATION OF TIGHTENING TORQUE

Tightening torque is indicated as follows, for example;
T=100N•m (73.8 lbf•ft)
Tolerance is ± 10% unless otherwise specified.
• Refer Index No. 11 TOOLS for standard tightening torque.
31-3
[MEMO]
31-4
32. ATTACHMENTS
TABLE OF CONTENTS
32.1 REMOVING AND INSTALLING ......................................................................................... 32-3

32.1.1 ATTACHMENT AND COMPONENT ......................................................................... 32-3
32.1.2 BUCKET ................................................................................................................... 32-3
32.1.3 ARM .......................................................................................................................... 32-6
32.1.4 BOOM ....................................................................................................................... 32-8
32.2 DISASSEMBLING AND ASSEMBLING ............................................................................ 32-13
32.2.1 CYLINDER ................................................................................................................ 32-13
32
32-1
32. ATTACHMENTS

S5YT3203E01
(NHK)
PREFACE
(1) This Manual covers all the procedures from removing to attaching, arranging them by item.
(2) This manual consists of first part; 32.1 REMOVING AND INSTALLING, and second part; 32.2 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 start working.
32-2
32. ATTACHMENTS
32.1 REMOVING AND INSTALLING

32.1.1 ATTACHMENT AND COMPONENT
BOOM CYLINDER ROD PIN (C)
ARM CYLINDER HEAD PIN (D)
4. BOOM BOOM INSTALL (FOOT) PIN (A)

ARM CYLINDER
BOOM TOP PIN (F)
ARM CYLINDER
ROD PIN (E)
BOOM CYLINDER
2. BUCKET
BUCKET CYLINDER
HEAD PIN (G)
BUCKET CYLINDER
3. ARM
IDLER LINK PIN (I) BUCKET DRIVE PIN (J)
BOOM CYLINDER HEAD PIN (B)
IDLER LINK
BUCKET LINK
BUCKET CYLINDER ROD PIN (H) BUCKET ATTACHING PIN (K)
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)
Expand slit of ring (1) with driver, and remove it.
Push out the pin (2) with driver (–).
SECTION AA
Fig. 32-3 Removing pin (2)
32-3
32. ATTACHMENTS
(3) Removing bucket attaching pin (K).

Lift up bucket, position it so that bucket attaching
pin (K) is not adjust bucket link, and pull out 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,
and pull out pin (J).
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 the pulling out.
• When aligning the pin holes, do not put your fin-

ger in the pin holes in any circumstances, but
align them visually.
• Check that the seals are not scored and replace
a faulty one if necessary.
• When inserting the pin, coat the shaft with
grease.
Fig. 32-6 Attaching bucket
32-4
32. ATTACHMENTS
32.1.2.3 PROCEDURE FOR ADJUSTING CLEARANCE

Adjustment of clearance between bucket and arm
1) Shift O-ring (3) toward the bucket boss, using a
spatula. (ab)
2) When adjusting clearance (B), bring the non-ad-
justing side of the bucket in contact with the arm.
3) Measure clearance (B) and check that it is within
1.0 mm (0.04 in).
4) Adjust clearance (B) where it is more that 1.0
mm (0.04 in).
5) An average of 5 shims (8) of 1mm (0.04 in) thick-
ness are set in each of the three M12  45 bolts
(10). The clearance can be adjusted by 1mm
(0.04 in) if one shim is removed.
: 19 mm
6) After adjustment, tighten the bolts evenly.
The gap exceeding the specified dimension
causes a rapid progress of wear.
7) Operate the bucket and confirm that the total
sum of both clearances are within 1.0 mm (0.04 Fig. 32-7 Adjusting clearance between bucket and
in) arm
8) Refit O-ring (3) to its original position.
• When shifting O-ring (3) by means of a spatula, use

care so as not to score O-ring (3).
• Remove shims (8), push out bushing (7) rightwards
by means of three bolts (10) and adjust clearance
(B) so it falls within the standard value evenly all
round.
• Check the clearance at 120 hours' intervals in nor-
mal operation. Shorten these intervals in special
hard operation. Adjust the intervals as necessary.
32-5
32. ATTACHMENTS
32.1.3 ARM
32.1.3.1 REMOVING ARM

(1) Put the machine in position to remove arm. Fold
arm, and the bucket cylinder is retracted and the
arm is put on the ground.
Fig. 32-8 Position to remove arm

(2) Separating piping of bucket cylinder
Release pressure of hydraulic tank, place oil pan to
prepare for oil leaking, and separate pipes.
Plug both section of separated pipes.

Plug : M30
When the removal of bucket cylinder is not required

skip to procedure (6).
Fig. 32-9 Separating piping of bucket cylinder

(3) Removing bucket cylinder rod pin (H) Insert resin shim into bucket link side.
1) Loosen nut (9), remove capscrew M12  100 (8), SHIM RESIN SHIM
and push out pin (H). After adjustment of shim, the total gap
should be within 0.6~1.0 mm (0.02~0.04 in).
: 19 mm SHIM
2) Retract cylinder rod.
DUST SEAL
SECTION DD
SHIM RESIN SHIM

Insert resin shim into bucket link side.
Fig. 32-10 Detail of bucket cylinder rod pin (H)
32-6
32. ATTACHMENTS
(4) Removing cylinder head pin (G) Insert resin shim into bucket link side.
Loosen nut (3), remove capscrew M12  100 (2), SHIM
RESIN SHIM
and push out pin (G). After adjustment of shim, the total gap
: 19 mm SHIM
SECTION AA
Fig. 32-11 Detail of bucket cylinder rod pin (H)
(5) Removing bucket cylinder
Sling tube of bucket cylinder with nylon sling, and
remove it.
Bucket cylinder weight : 44 kg (97 lbs)
Fig. 32-12 Slinging bucket cylinder

(6) Removing arm cylinder rod pin (E)
Insert resin shim into cylinder side.
Loosen nut (4), remove capscrew (3), and push out SHIM RESIN SHIM
arm cylinder rod pin (E). After adjustment of shim, the total gap
: 22 mm SHIM
Retract arm cylinder rod, and return pin (E) to the
original position (hole).
SECTION BB
Fig. 32-13 Detail of arm cylinder rod pin (E)
(7) Removing boom top pin (F) Insert resin shim into cylinder side.
Loosen remove capscrew (12), and pull out boom, SHIM RESIN SHIM
top pin (F).
Put block between arm cylinder and boom. After adjustment of shim, the total gap
should be within 0.5 mm (0.02 in).
: 19 mm
SHIM
Insert pin (F) into the original hole.
(8) Slinging arm assy
Sling arm with nylon sling and remove it.
Arm weight : 200 kg (440 lbs) (with bucket cylinder)
:150 kg (330 lbs) (without bucket cylinder)
SECTION AA
Fig. 32-14 Detail of boom top pin (F)
32-7
32. ATTACHMENTS
32.1.3.2 ATTACHING ARM

(1) Attaching boom top pin (F)
Attach boom top pin (F) first, and continue in the re-
verse procedure of the removing.
• When aligning the pin holes, do not put your fin-

ger in the pin holes in any circumstances, but
align them visually.
Fig. 32-15 Slinging arm assy
• Check that the dust seals is not scored and re-
place a faulty one if necessary.
• When inserting the pin, coat the shaft with
grease.
32.1.4 BOOM
32.1.4.1 PREPARATION FOR REMOVING AND ATTACHING BOOM

When removing and attaching boom in the position
A
shown in Fig. 32-16, to remove and attach boom
foot pin (A), removing and attaching of cab and
guard are required.
Wood blocks
Fig. 32-16 Position to remove boom
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 atten-
tion for arm cylinder rod not to be extracted.
(2) Lifting up boom cylinder temporarily
Lift up boom cylinder temporarily to prevent it from
dropping.
Fig. 32-17 Lifting up boom cylinder temporarily
32-8
32. ATTACHMENTS
(3) Removing boom cylinder rod pin (C) Insert resin shim into bucket link side.
Loosen nut (7), remove capscrew (3), and push out RESIN SHIM
IRON SHIM
pin (C).
After adjustment of shim, the total
(4) Preparing for separating cylinder pipes gap should be within 0.6~2.0 mm
(0.02~0.08 in).
Retract boom cylinder rod side, and place one side SHIM
of cylinder on block (See Fig. 32-17)
SECTION AA
Fig. 32-18 Detail of boom cylinder rod pin (C)
(5) Separating piping of arm cylinder and bucket cylin-
der
Release pressure in hydraulic tank, and separate
pipe at section E-E.
: 36 mm
After separation of pipe, plug every pipe.
Plug : M30
SECTION EE
Boom piping separation
32-9
32. ATTACHMENTS
(6) Lifting up boom assy temporarily

Lift up boom cylinder with nylon sling so that boom
foot pin (A) is not loaded.
Weight of boom assy : 400 kg (880 lbs)
(7) Removing boom foot pin (A)

1) Remove snap ring (3) and washer (4) and pull Insert resin shim into
boom side.
out pin (2). RESIN SHIM t = 2 (0.08 in)
2) Tools to Thread M16 X 54 for pin (1) : Screw slide
hammer in
Refer to Tool 10. Tools for boom attaching pin.
3) Force slide hammer in until the pin is out.
SECTION AA
Fig. 32-19 Details of boom foot pin (A)section
Fig. 32-20 Removing pin (A) using slide hammer
32-10
32. ATTACHMENTS
(8) Slinging boom assy

Sling and remove boom assy.
Weight of boom assy : 400 kg (880 lbs)
(9) Completion of removal of front attachments

When the removing and attaching of cylinder are
not required, the work is finished. Opposing flats 27
A
(10)Removing arm cylinder
Opposing flats 27
Disconnect hose at A section, and plug both ends.
Plug 4-1 Opposing flats 36
Opposing flats 36
: 36 mm
Tightening torque : 216 N•m (160 lbf•ft) Insert resin shim
into cylinder side.
RESIN SHIM
: 27 mm IRON SHIM
Tightening torque : 108 N•m (80 lbf•ft)

(11)Removing arm cylinder head pin (D)
Loosen nut (3), remove capscrew (2)and pull out
pin (D)
SHIM
After adjustment of shim, the
total gap should be within
0.6~1.0 mm (0.02~0.04 in)
Fig. 32-21 Removing arm cylinder
32-11
32. ATTACHMENTS
(12)Removing boom cylinder

Disconnect hose at B section. Plug both ends. Opposing flats 36
plug 4-1
: 36 mm
(13)Removing boom cylinder foot pin (B)
Loosen capscrew (4) and pull out pin (B).
Opposing flats 36
Fig. 32-22 Removing boom cylinder
32.1.4.3 ATTACHING BOOM

(1) Attaching boom foot pin (A)
Screw tool 10. slide hammer M16 into boom foot
pin (A) first, and fit boom assy.
Attach it in the reverse procedure of removing pay-
ing attention to the following points.
• When aligning the pin holes, do not put your finger

in the pin holes in any circumstances, but align
them visually.
Fig. 32-23 Boom cylinder head pin (B)
• Check that the dust seals is not scored and replace
a faulty one if necessary. Insert resin shim into
cylinder side.
• When inserting the pin, coat the shaft with grease. RESIN SHIM t = 2 (0.08 in)
SHIM
• M12 Tightening torque : 115 N•m (85 lbf•ft) After adjustment of shim, the total gap should
be within 0.6~1.0 mm (0.02~0.04 in)
• Pin lock nut handling procedure IRON SHIM
(0~0.02)
0~0.5
• To attach shim, fit resin shim on operating side and

iron shim on the outside, and reduce the space.
SECTION BB
Fig. 32-24 Attaching boom cylinder head pin
32-12
32. ATTACHMENTS
32.2 DISASSEMBLING AND ASSEMBLING

32.2.1 CYLINDER
32.2.1.1 PREPARATION BEFORE DISASSEMBLE

Before disassembly, it is necessary to keep a dustfree workshop and facilities.
32.2.1.1.1 WORK AREA

The following working area is required for disassembly :
(1) Ample space
For disassembly of the hydraulic cylinder, the cylinder tube and the piston rod must be extracted. Therefore, the
first prerequisite is that the working area must have sufficient space for such work. It is also necessary that the
space have amply space widthwise to accommodate disassembly, cleaning and measuring facilities.
(2) Suitable working environment
The hydraulic cylinder is a precision-machined product incorporating seals and packings made of rubber and
plastic materials. For this reason, care should be used so that the hydraulic cylinder is free from dust, dirt, sand,
metal chips weld slag and other hard substance. If the hydraulic cylinder is assembled without being aware of
hard particles stuck on the cylinder tube and the piston rod, the tube inner surface and the rod surface may be
scratched as the cylinder operates, thereby 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 be avoided near 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 marking level and liner movement under load for inserting and extracting the piston rod and the tube.
(2) Work bench
The work bench must have strength and rigidity 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 clevis part of 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 such.
(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 skids, rag and sawdust in which oil soaked are also necessary.
32-13
32. ATTACHMENTS
32.2.1.1.3 TOOLS NEEDED

Tools and jigs vary with types of cylinder, but it is necessary to prepare the tools in Table 32-1 as a guideline.
Table 32-1
Tool/Jig Remarks Tool/Jig Remarks
1.Steel hammer A sharp-point tool may be used in place
Hammer Gimlet
2.Wooden or plastic mallet of a gimlet.
Screwdriver A few types of large and small sizes 1. For fitting seal ring
2. For pushing seal ring
Jig
Chisel Flat chisel 3. For inserting bushing
4. For press-fitting wiper ring
One having an operation wide enough to
1. Slide calipers
Vise hold cylinder head O.D. and tube mount-
Measuring in- 2. Micrometer
ing pins (clevis)
struments 3. Cylinder gauge (Fig. 32-1)
1.Hook wrench
Wrench 4. V-block
2.Extension pipe for wrenches
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
Fig. 32-25 Cylinder gauge
steam before bringing it into the workshop.
• The following describes the construction of arm
cylinder (with cushions on both sides). When
disassembling and servicing the cylinder, con-
firm the construction of cylinder referring to
Parts Manual.
Fig. 32-26 Discharging oil
32.2.1.1.5 DISCHARGING OIL

Place a wooden-block on the work bench and mount the cylinder on it to prevent it from rotating. Charge air into
ports A and B alternately to actuate the piston rod till the hydraulic oil in the cylinder is drained out. At this time,
connect a suitable hose to each port so that the hydraulic oil may not gush out.
32-14
32. ATTACHMENTS
32.2.1.2 CONSTRUCTION OF CYLINDER (AN EXAMPLE OF ARM CYLINDER)

T = Torque : N•m (lbf•ft) (Thread)

of the boss so R2.5 (0.10") of the boss so R2.5 (0.10")
33 34 32 29 31 holes face with each other
holes face with each other
T=39.8 (30)
30
[M12 X 1.75]
29
26 27 T=31.5 (23) [M10 X 1.5] 27 26
VIEW A-A
T=56.9 (42) [M12 X 1.75]

T=569 (58) [M100 X 2] caulking on two portions.
T=2780 (2000) [M45 X 2, HEX70]
9 3 12 7,8 6 10,11 4 5 11,13 2 1 14 15 19 17 18 16 20 21 25 23 22 24
With
one hole
Face the slit to the piston side.
Fig. 32-27 Construction of cylinder (An example of arm cylinder)
No. NAME Q'ty No. NAME Q'ty No. NAME Q'ty

1 CYLINDER TUBE ASSY 1 13 O-RING 1 25 SNAP RING 1
2 PISTON ROD ASSY 1 14 CUSHION BEARING 1 26 PIN BUSHING 4
3 ROD COVER 1 15 CUSHION SEAL 1 27 WIPER RING 4
7 U-RING 1 19 SHIM 1 31 WASHER 2
8 BACKUP RING 1 20 SET SCREW 1 32 PIPE HOLDER 1
9 WIPER RING 1 21 STEEL BALL 1 33 BOLT 1
10 O-RING 1 22 CUSHION BEARING 1 34 WASHER 1
11 BACKUP RING 3 23 CHSHION SEAL 1
12 O-RING 1 24 STOPPER 2
32-15
32. ATTACHMENTS
32.2.1.3 DISASSEMBLING
• Before starting disassembling and servicing,
m m
confirm the construction and supply parts refer- 200
p r ox, ")
ring to Parts Manual in the separate volume, and Ap (8
also required tools and jig.
• Figures noted just after the "Part name" corre-
spond to the number stated in Fig. 32-27 Arm
cylinder. Other cylinders may have some differ-
ent parts. Fig. 32-28 Removing piston rod
32.2.1.3.1 REMOVING ROD COVER AND PISTON ROD

(1) Fix the tube installing pin side using a vise. (Fig. 32- CHISEL
26) (Meet the width of chisel with
the groove width, flatten the
lock washer)
Take care not to damage the cylinder tube and ma-

chined surface.
Never use external pipe to stop turning.
Fig. 32-29 Flatten the slit lock

(2) Pull piston rod (2) out about 200 mm (8 in).
If pipe does not
Use air to push piston rod (2) out after draining the found, strike this
oil because of the weight of piston rod (2). portion with hammer.
Turn counter
(3) Flatten the lock on slit section installed between rod clockwise
cover (3) and cylinder tube (1) with chisel and ham-
mer.
Cover this portion
(4) Lift up cylinder rod section with nylon sling tempo- with cloth.
rarily.
(5) Then, Hook a hook wrench to rod cover (3), turn it
counterclockwise and remove it.
Special tool : Refer to Table 32-11. Fig. 32-30 Removing rod cover
(6) After putting threads out of mesh, remove the end
of rod cover (3) using plastic hammer.
Sling
In this case, apply the hoisting force equivalent to the

weight of piston rod, because the weight of piston rod Pull it straight out
horizontally
weights upon the rod cover.
OIL PAN
Fig. 32-31 Pulling piston rod out
32-16
32. ATTACHMENTS
(7) Place pulled out piston rod assy (2) on the wooden
V-block horizontally.
WOODEN V-BLOCK
(cover with cloth.)
Fig. 32-32 Placing piston rod assy

(8) Remove slide ring (18)
Expand the slit portion in 45
degrees and remove.
Fig. 32-33 Removing slide ring
32.2.1.3.2 REMOVING PISTON ASSY

(1) Fix piston rod (2) grasping the installing pin portions
WOODEN BLOCK
with vise. Then fix it in strength so that it can with-
stand the tightening torque for piston rod 2) be-
cause the piston rod (2) is secured with large
tightening torque.
WOODEN V-BLOCK
Cover with cloth.
Fig. 32-34 Fixing piston rod assy

(2) Shave off the caulked section on set screw (20) DRILL
with hand drill, loosen set screw and take out steel
ball (21).
STEEL BALL
Fig. 32-35 Removing setscrew
32-17
32. ATTACHMENTS
(3) Remove nut section of piston with a closed wrench. EYE WRENCH
Special tool : See Table 32-12 1.0
(3’ ~1.5
3"~ m
• Since the piston section (16) is tightened by high 4’1
1")
torque, use the closed wrench closely fitted to
the width across flat.
Turn counter
• Approx. 1.5 times or higher of torque is required clockwise
to loosen piston nut. So prepare power wrench
equipped with hydraulic jack or hydraulic cylin-
der, if possible.
PLATE
PISTON ROD WIPER RING
PIN BUSHING
Fig. 32-36 Removing piston nut

(4) Removing cushion bearing on the retraction side. THREADED CUSHION BEARING (22)
PART
1) Remove snap ring (25). Strike it lightly being
STOPPER (24)
careful not to damage cushion bearing and pis- (DIVIDE INTO
ton rod. 2 PORTIONS)
2) Move cushion bearing (22) to threaded side, and

remove stopper (24) (two pieces type).
CUSHION SEAL (23)
3) Pull out cushion bearing (22).
4) Expand slit (1 place) of cushion seal (23) and re- SNAP RING (25)
move it. PISTON ROD (2)
SLITTING
(1 PLACE)
Fig. 32-37 Disassembling cushioning bearing

(5) Removing cushion bearing on extension side.
1) Pull out cushion bearing (14).
2) Expand slit (1 place) on cushion seal (15) and re-
CUSHION SEAL (15) CUSHION BEARING (14)
move it.
SLITTING (1 PLACE)
Fig. 32-38 Disassembling cushioning bearing
32-18
32. ATTACHMENTS
32.2.1.3.3 DISASSEMBLING PISTON ASSY

Removing piston seal
SEAL RING (17)
1) Remove slide ring (18) by hand.
SLIDE RING (18)
2) Cut seal ring (17) with driver (-) and hammer as
WOODEN PIECE
shown in the right figure.
3) Pull out O-ring with spatula. VISE
4) Strictly prohibited to use pulled out seal parts.
O-RING
Fig. 32-39 Disassembling piston assy
32.2.1.3.4 REMOVING ROD COVER ASSY

Remove rod cover assy from piston rod (2). If it is Strike with a
too difficult to remove, strike flange section of rod plastic mallet Lift here
cover (3) with plastic hammer.
Hang the rod cover assy with crane and remove it
straight horizontally.
Pull straight
Care should be taken not to damage the bushing (4) lip
section of link and seal with screw of piston rod (2)
when pulling out rod cover (3).
Fig. 32-40 Removing rod cover assy
32.2.1.3.5 DISASSEMBLING ROD COVER ASSY

(1) Removing buffer ring
BUFFER RING (6)
1) Buffer ring (6) (Teflon made seal) is fitted on the O-RING AND
BACK-UP RING
inside of rod cover (3). Pierce with pointed tool (10, 11) (11, 13)
on the seal, raise it, insert spatula and take it out. WIPER
RING (9)
• Strictly prohibited to use the removed seal.
BUSHING (4)
SNAP RING (5)
U RING (7) AND BACK-UP RING (8)
Fig. 32-41 Construction of rod cover assy
32-19
32. ATTACHMENTS
(2) Removing U-ring (7), backup ring (8) and wiper ring
BUFFER RING ASSY
(9)
(SQUARE RING + SLIDE RING)
1) Remove U-ring (7) and backup ring (8) with driv-
er, etc. SQUARE RING
(PROJECTION)
2) The wiper ring (9) is press-fitted.
Pierce with driver, etc. on rubber and strike and
remove it with driver.
SLIDE RING
• Strictly prohibited to use removed seal. (SLITTING)
SNAP RING
Fig. 32-42 Direction of buffer ring

(3) Removing bushing (4)
Push with a press
Raise snap ring (5) with hooked bar and take it out
from cylinder rod cover. And press out bushing (4) JIG
with jig. If it is too difficult to take it out with jig, use
lathe to remove it.
ROD COVER (3)
BUSHING (4)
JIG
Fig. 32-43 Removing bushing
32-20
32. ATTACHMENTS
(4) Removing pin bushing WIPER RING (27)

1) Remove wiper ring (27).
2) The pin bushing (26) of piston rod (2) is pressfit- Push with a press
ted, so press it out with a press applying a plate PLATE
to the section.
Where it is impossible to press it out, cut it with gas BASE

burner.
(5) Cleaning
1) After completion of cylinder disassembly, clean
all the parts with detergent.
Fig. 32-44 Drawing out pin bushing (rod & tube)
Apply hydraulic oil on them and cover them to
store.
Leaving them in the as-disassembled condition
causes rust, adherence of dust, etc., which may
cause malfunction after assembling.
Do not use volatile agents (gasoline and thinner) as

they deteriorate rubber.
2) Replace all of U-ring, wiper ring, O-ring and

backup ring as a general rule.
32-21
32. ATTACHMENTS
32.2.1.4 INSTALL
Start install with the sub assy listed below :
• Cylinder tube assy
• Piston rod assy
• Rod cover assy
• Piston assy
32.2.1.4.1 ASSEMBLING CYLINDER TUBE ASSY, PISTON ROD ASSY

(1) Apply hydraulic oil on the head in which pin bushing Push with a press
is inserted and on the pin bushing hole of rod.
(2) Press pin bushing (26) into cylinder tube (1) and
piston rod (2), using a press.
(3) Insert wiper ring (27) in both sides.
OIL HOLE LOCATION
PLATE
PISTON ROD
WIPER RING
PIN BUSHING
Fig. 32-45 Pressing in pin bushing (rod & tube)
32-22
32. ATTACHMENTS
32.2.1.4.2 ASSEMBLING ROD COVER ASSY

(1) Press fit bushing (4) in rod cover (3) applying plate Push with a press straight down
on the section. After press-fitting, check that the
bushing is not projected from the end surface (A).
(See Fig. 32-46)
(2) Fit snap ring (5). PLATE
(3) Fit backup ring (8) on U-ring groove.

(4) Apply hydraulic oil on U-ring (7) and fit it on the U-
ring groove.
• The U-ring is harder than other seals, so fit it in the

groove by hand first, then press in with pushing bar
Fig. 32-46 Pressing in bushing
until it is fitted with a click.
• Fitting U-ring paying attention to the direction.
PUSH BAR
• After fitting backup ring (8) and U-ring (7), check
that they are free from the permanent set.
Fig. 32-47 Fitting U-ring

(5) Installing buffer ring assy
SLIDE RING SQUARE RING
Buffer ring assy (6) is equipped with square ring
Depress slide ring
and slide ring. in U shape to fit.
1) Fit square ring on the groove.
2) Depress slide ring in U shape by hand to house
it in groove, and fit it pushing out to periphery.
BUFFER RING ASSY (6)

(SQUARE RING + SLIDE RING)
• Depress it R 6 mm (0.24 in) or more, because if the
depressed R is too small, it may remain wrinkled. SQUARE RING (PROJECTION)
• After fitting, check that it is free from wrinkles.

• Fit it giving attention to the seal fitting direction. Re-
SLIDE RING
verse fitting produces high pressure between U-
(SLITTING)
ring and seal and may cause the deformation of rod SNAP RING (5)
cover. Fig. 32-48 Installing buffer ring assy (6)

• Fit slide ring so that the groove matches to the root
section of square ring.
32-23
32. ATTACHMENTS
(6) Press fit wiper ring (9) by means of Jig Table 32-8. Push with a press
JIG
RUBBER
METAL RING CLIP
Fig. 32-49 Pressing in wiper ring

(7) Fit backup ring (11) and O-rings (10), (13). (Atten- O-RING AND
tion should be paid to the fitting order.) BACK-UP RING
(10, 11) (11, 13)
Fig. 32-50 Fixing back-up ring and O-ring
32.2.1.4.3 ASSEMBLING PISTON ASSY

(1) Installing seal ring assy SEAL RING PRESSING JIG SEAL RING (17)
1) Fit O-ring so as not to be distorted. PISTON (16)
2) Press in seal ring (17) referring to Jig Table 32-8,
Table 32-6.
PUSH
O-RING
Fig. 32-51 Installing the seal ring (17)

3) Since the seal ring (17) is extended when fitting, CORRECTION JIG
press it referring to Correction jig Table 32-9.
PUSH
Fig. 32-52 Correcting the seal ring (17)
32-24
32. ATTACHMENTS
4) Fitting slide ring (18) Expand 45 deg. slit

Fit it from rod side expanding slit by both hands. section in direction
specified by arrow and
• Expand slit in minimum. fit the ring.
If expansion is exceeded, the ring cannot be
fitted.
• Slit is mutually shifted 90 degree.
Fig. 32-53 Installing the slide ring (18)
32.2.1.4.4 INSTALLING ROD COVER ASSY ON ROD

(1) Fix piston rod assy on work bench.
(2) Apply grease (or hydraulic oil) on outside of piston
rod (2), inner surface of buffer ring (6), U-ring (7),
backup ring (8), wiper ring (9) and bushing (4), and
slide rod cover assy on piston rod (2) taking care
not to damage the lip of wiper ring (9).
It may not slide smoothly due to frictional resistance
of U-ring. In this case, sling rod cover assy horizon- Fig. 32-54 Installing rod cover assy
tally with crane, and push it striking flange of rod ROD COVER PRESSING JIG
cover with mallet.
PISTON ROD ROD COVER
While pushing, be careful that the rod cover assy is not PUSH
rotated to piston rod (2).
Fig. 32-55 Pressing rod cover
32.2.1.4.5 INSTALLING PISTON ASSY ON ROD

(1) Fitting cushion bearing (14) on the extension side.
Before attaching piston (nut ) (16), fit cushion bearing CUSHIONING CUSHIONING BEARING (14)
SEAL (15)
(14). If the piston nut is attached, the bearing can not be
fitted. CUT OUT
FLAT SECTION
1) Expand slit of cushion seal (15) and insert it into
groove piston rod (2). SLITTING (1 PLACE)
Fig. 32-56 Fitting cushion bearing (14)

on the extension side
Insert cushion seal (15) directing the cut out toward the
thread side of rod as shown in Figure.
2) Fit cushion bearing (14) .
Fit cushion bearing (14) directing the flat section toward

as shown in Figure.
32-25
32. ATTACHMENTS
(2) Fitting cushion bearing (22) on retraction side CUSHION BEARING (22)
THREADED
1) Fit cushion seal (23) in groove directing the cut- PART STOPPER (24)
(DIVIDE INTO
out toward the thread side. 2 PORTIONS)
2) Assemble cushion bearing (22) directing the flat FLAT
SECTION
section toward as shown in Figure.
PISTON CUSHION SEAL (23)
3) Fit stopper (24) in groove.
ROD (2)
4) Push cushion bearing (22) to stopper (24) fully, CUT
SNAP
OUT
and strike and fit snap ring (25). RING (25) SLITTING
(1 PLACE)
Fig. 32-57 Fitting cushion bearing (22) on retraction

side
Strike snap ring with plastic hammer being careful not
to damage rod (2) and cushion bearing (22).
(3) Tightening piston nut EYE WRENCH

1) Insert shim (19) and piston (nut) (16) into rod,
and tighten piston (nut) (16) to the specified
torque.
Special tool : See Table 32-12
Tightening torque : See Fig. 32-64.
Fig. 32-58 Tightening piston nut (16)

2) Put steel ball (21) in and tighten setscrew (20). CAULK
: Tightening torque : See Fig. 32-65.
3) Caulk 2 places on outer surface with punch. PUNCH
SETSCREW (20)
STEEL BALL
Fig. 32-59 Caulking set screw of piston nut
32-26
32. ATTACHMENTS
32.2.1.4.6 OVERALL INSTALL

(1) Place a V-block on a rigid work bench (A wooden V Bar used to prevent rotation
block is preferable.) Mount the cylinder tube assy (Wood is preferable) or fix with vise
(1) on it and fix the assy by barring a bar through the
attaching pin hole to lock the assy. (Fig. 32-60)
(2) Insert piston rod (2) into cylinder tube (1 while Lift it lever
hanging and moving it with crane. Then, apply hy-
draulic oil on tube lip inner side and piston outer
surface and insert horizontally aligning the center of
piston rod and center of cylinder tube.
• Also, the use of fork lift makes inserting easier.
• Insert piston into tube being careful that seal ring PISTON
and slide ring are not caught in the stepped sec- Apply Three-Bond #1901
tion of tube.
Fig. 32-60 Installing piston rod
SLIT
ROD COVER (3)
CHISEL
Fig. 32-61 Bending lock of slit

(3) Apply Three Bond #1901 on thread section of rod SET SPACE
cover and hydraulic oil on O-ring (12), rotate rod
cover assy (3) by hand. Screw in 2 or 3 threads first,
then tighten it to the specified torque with hook
spanner wrench.
(4) Bend slit of cylinder tube toward cutout of rod cover
(3) to lock.
(5) Tighten band for piping on both sides equally to the PIPE HOLDER
specified torque in order not to have a set space.
Tightening torque : SET SPACE BAND BOLT
See 32.2.1.7 "TIGHTENING TORQUE".
• Fix port section of cylinder pipe with wrench, etc.
on main body and install pipe for cylinder, and
rubber hose, nipple, etc. Installation without fixa-
tion may cause bending of port plate, conse-
quently oil leakage, and interference with body.
SET SPACE SET SPACE
Fig. 32-62 Installing band for piping
32-27
32. ATTACHMENTS
32.2.1.5 MAINTENANCE STANDARDS

(1) Inspection after disassembly
1) Inspection
Table 32-2
Part Name Inspecting Section Inspection Item Remedy
1. Neck of rod pin Presence of crack Replace.
2. Stepped part to which pis-
Presence of crack Replace.
ton is attached
3. Threads Presence of seizure Recondition or replace
4. Bend Measure degree of bend Refer to rod bend
5. Plated surface Check that :
Piston rod
1) Plating is not worn off to base 1) Replace.
metal
2) Rust is not present on plating. 2) Replace.
3) Scratches are not present. 3) Recondition or replace
6. Rod Wear of O. D. Recondition or replace
7. Bushing at mounting part Wear of I. D. Replace.
1. Weld on bottom Presence of crack Replace.
2. Tube at mounting part Presence of crack Replace.
Cylinder tube
3. Tube interior Scratches are not present. Replace if oil leak is seen.
4.Bushing at mounting part Wear of I. D. Replace.
1) Wear of I. D.
Rod cover 1.Bushing Replace.
2) Flaw on inner surface
(2) Maintenance standards

Replace sliding parts and seal parts according to the following.
1 Bushing ....................................... Where 1/4 of circumference is worn in red copper color.
2 Seals and slide ring ..................... Replace them when cylinder is disassembled.
3 Pin bushing ................................. Where severe scuffing is produced
4 Piston rod .................................... Where the bent 0.5 mm/m or more is produced
(3) Inspection after assembling
Table 32-3
No-load perfor- When operating 5 time or more in full stroke at no-load, it operates smoothly with no
mance inspection abnormality.
Dimensional
Check the fully retracted length and stroke specified in drawing.
inspection
After applying test pressure specified in drawing to each stroke end for 3 minutes or
Pressure inspection
more, it is free from loosening, permanent set and oil leaking.
No-load perfor- Check rod section for oil leaking.
mance inspection (Refer to Criterion of oil leak quantity on rod section in proceeding page.)
Oil leak quantity unit mL (cc) / 10min
Oil leak Oil leak Oil leak
I. D. mm (in) I. D. mm (in) I. D. mm (in)
quantity quantity quantity
Internal leakage 32 (1.26) 0.4 100 (3.94) 4.0 160 (6.30) 10.0
inspection 40 (1.57) 0.6 125 (4.92) 5.6 180 (7.09) 12.6
50 (1.97) 1.0 140 (5.51) 6.0 200 (7.87) 15.6
63 (2.48) 1.6 220 (8.66) 20.0
80 (3.15) 2.3 250 (9.84) 22.0
32-28
32. ATTACHMENTS
(4) CRITERION OF OIL LEAK QUANTITY ON ROD SECTION

Determine according to the oil ring condition produced on rod after 20 strokes in oil temperature 20°C (68°F) to
40°C (104°F). When oil ring is changed to A condition, it is in abnormality. Refer to 32.2.1.9 "Troubleshooting",
and take a measure.
OIL RING
Reject Accept
Fig. 32-63 Oil ring condition on rod section
32.2.1.6 GENERAL TOOL

Table 32-4
No. Tools name Q'TY
1 Flat-bladed screw driver 1
2 Allen key wrench 1 set
3 Vise 1
Spanner (see page II-1-18)

4 1 set
(for piston nut)
5 Punch 1
6 Torque wrench 1 set
7 Hammer (Plastic mallet) 1
8 Adjustable wrench 1
9 Spatula 1 pair
32-29
32. ATTACHMENTS
32.2.1.7 TIGHTENING TORQUE

(1) Piston nut

! "# $%%& '#(
% "# $%) '#(*
&+% "# $&) '#(
%, "# $%&+ '#(
Fig. 32-64
(2) Setscrew

!"

' )'*+ , -(. /,0

"#$ ( 1'*. , -1. /,0

%& ' )'*+ , -(. /,0

Fig. 32-65
(3) Rod cover
Cylinder name Tightening torque HOOK WRENCH PIPE
Boom 834 N·m (615 lbf·ft)
Arm 569 N·m (420 lbf·ft)
Bucket 450 N·m (330 lbf·ft)
Dozer 1060 N·m (780 lbf·ft)
Fig. 32-66
(4) For piping
+ "

" "
#$ #$

! % &' ( 0 %0&1 (
$-. )*% +(, )*0 +(,

/
Fig. 32-67
32-30
32. ATTACHMENTS
32.2.1.8 TOOL AND JIGS LIST

(1) Seal ring fitting jig ( I )
Fig. 32-68
Table 32-5
Unit : mm (in)
Applicable cylinder D0 D1 (D2) D3 L0 (L1) L2
Boom 111 (4.3701) 110 (4.3307) 86 (3.39) 96 (3.78) 100 (3.94) 72 (2.83) 24 (0.9449)
Arm 96 (3.7795) 95 (3.7401) 71 (2.80) 81 (3.19) 100 (3.94) 72 (2.83) 23(0.9055)
Bucket 81 (3.1890) 80 (3.1496) 56 (2.20) 66 (2.60) 100 (3.94) 72 (2.83) 20 (0.7874)
Dozer 121 (4.7638) 120 (4.7244) 96 (3.78) 106 (4.17) 100 (3.94) 72 (2.83) 24 (0.9449)
(2) Seal ring fitting jig ( II )

Material : Nylon or acrylic resin
Fig. 32-69
Table 32-6
Unit : mm (in)
Applicable cylinder D0 D1 L
Boom 112 (4.41) 104 (4.09) 100 (3.9370)
Arm 97 (3.82) 89 (3.51) 100 (3.9370)
Bucket 82 (3.23) 74 (2.91) 100 (3.9370)
Dozer 122 (4.80) 114 (4.49) 100 (3.9370)
32-31
32. ATTACHMENTS
(3) Bushing press-fit jig

Fig. 32-70
Table 32-7
Unit : mm (in)
Applicable cylinder D0 D1 (D2) D3 L0 (L1)
Boom 75 (2.9528) 69.5 (2.74) 68 (2.68) 95 (3.74) 65.5 (2.58) 59.5 (2.3425)
Arm 70 (2.7559) 64.5 (2.54) 63 (2.48) 90 (3.54) 65.3 (2.57) 53.3 (2.0984)
Bucket 60 (2.3622) 54.5 (2.15) 53 (2.09) 80 (3.15) 20.5 (0.807) 8.5 (0.3346)
Dozer 75 (2.9528) 69.5 (2.74) 68 (2.68) 95 (3.74) 25.5 (1.00) 13.5 (0.5315)
(4) Wiper ring (rod cover) press-fit jig

finishing unless otherwise specified.
Fig. 32-71
Table 32-8
Unit : mm (in)
Applicable cylinder D0 D1 D3
Boom, Dozer 70 (2.7559) 78.5 (3.0905) 95 (3.74)
Bucket 55 (2.1654) 63.5 (2.5000) 80 (3.15)
Arm 65 (2.5591) 73.5 (2.8937) 90 (3.54)
32-32
32. ATTACHMENTS
(5) Seal ring straightening jig

finishing unless
otherwise specified.
Fig. 32-72
Table 32-9
Unit : mm (in)
Applicable cylinder D0 (D1) L0 (L1)
Boom 110 (4.3307) 130 (5.12) 120 (4.72) 40 (1.57)
Arm 95 (3.7401) 115 (4.53) 120 (4.72) 40 (1.57)
Bucket 80 (3.1496) 100 (3.94) 120 (4.72) 40 (1.57)
Dozer 120 (4.72) 140 (5.51) 120 (4.72) 40 (1.57)
(6) Piston insert jig

Split into 2 portions with

2 to 3 mm (0.08~0.12 ) cutter.
finishing unless otherwise specified.
Fig. 32-73
Table 32-10
Unit : mm (in)
Applicable cylinder ØA ØB ØC D E
Boom 122 (4.80) 110 (4.3307) 113 (4.4488) 67 (2.64) 42 (1.65)
Arm 107 (4.21) 95 (3.7401) 98 (3.8583) 67 (2.64) 42 (1.65)
Bucket 92 (3.62) 80 (3.1496) 83 (3.2677) 62 (2.44) 37 (1.46)
Dozer 132 (5.20) 120 (4.7244) 123 (4.8425) 62 (2.44) 37 (1.46)
32-33
32. ATTACHMENTS
(7) Hook wrench
Material : Chromium-vanadium steel, hardness HRc 36 – 4
Fig. 32-74
Table 32-11
Unit : mm (in)
Applicable
A B C t D r f L
cylinder
Boom 130 (5.1181) 12 (0.4724) 5 (0.1969) 15 (0.591) 2 (0.0787) 86 (3.39) 12 (0.472) 380 (15.0)
Arm 120 (4.7244) 12 (0.4724) 4.5 (0.1772) 15 (0.591) 2 (0.0787) 80 (3.15) 12 (0.472) 380 (15.0)
Bucket 100 (3.9370) 10 (0.3937) 4.5 (0.1772) 15 (0.591) 2 (0.0787) 68 (2.68) 9 (0.354) 320 (12.6)
Dozer 140 (5.5118) 12 (0.4724) 5 (0.1969) 15 (0.591) 2 (0.0787) 93 (3.66) 12 (0.472) 460 (18.1)
(8) Eye wrench
Tolerance of A : 0.3 mm~0.8 mm

(0.0118"~0.0315") Straight in Material : Mild steel
this area FInish by grinding after gas cutting
Fig. 32-75
Table 32-12
Unit : mm (in)
Applicable L=300 (11.8) L=500 (19.7)
Size A
cylinder B1 B2 t B1 B2 B3 t
Boom 80 (3.1496) 110 (4.33) 78 (3.07) 28 (1.10) 122 (4.80) 107 (4.21) 87 (3.43) 28 (1.10)
Arm 70 (2.7559) 95 (3.74) 67 (2.64) 25 (0.984) 104 (4.09) 90 (3.54) 78 (3.07) 25 (0.984)
Bucket 60 (2.3622) 95 (3.74) 67 (2.64) 16 (0.630) 104 (4.09) 90 (3.54) 78 (3.07) 16 (0.630)
Dozer 80 (3.1496) 110 (4.33) 78 (3.07) 28 (1.10) 122 (4.80) 107 (4.21) 87 (3.43) 28 (1.10)
32-34
32. ATTACHMENTS
32.2.1.9 TROUBLESHOOTING
Failure on hydraulic cylinder and corrective action
It is very difficult to find defective section. The following table explains general phenomenon, estimated causes
and corrective actions.
For repair, refer to the 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 Table is often required. Please contact us to pursue
the problems and causes further and to take appropriate corrective action.
Items Phenomenon
Oil leakage from piston rod sliding section
1
(For criterion, refer to Table 32-3.)
2 Oil leakage from rod cover set section
3 Oil leakage from pipe and cylinder tube weld zone
4 Malfunction
Items Phenomenon Related parts Abnormalities Measures and corrective actions

1) Remove flaws with oil stone to make the surface
smooth. If oil is leaking after making rod surface
smooth (1.5S or less), disassemble it and check
Flaw and rust on slid-
seals of U ring, etc. that it is free from flaw.
ing surface.
2) In case the flaw is too wide to repair with oilstone,
Piston rod replace seals of U ring and wiper ring, etc. and
bearing parts of piston rod.
1) Plate it again, or replace piston rod.
2) At the same time, check seals and bearing parts
Plating is peeled.
of piston rod for possible damage, if damaged,
replace it.
Foreign matter is 1) Remove foreign matter.
caught in inner bore
2) Replace defective packing.
and outer surface.
Flaw on inner bore
1) Replace it.
and outer surface.
Oil leakage from
1) May be a burning caused by adiabatic compres-
1 piston rod slid-
A part of lip and sion due to the remained air.
ing section
groove is carbonized 2) After replacement of packing, release air com-
(burned). pletely through operation in low pressure and low
speed and start cylinder operating.
Rod packing 1) Replace it.
(Buffer ring, 2) May be service life expired, deterioration of hy-
U ring) Rubber packing is de- draulic oil and high temperature.
teriorated. Or lip sec- a) Change hydraulic oil with new one.
tion is damaged. b) Check hydraulic oil temperature. (Temperature
80°C or less is preferable.)
c) Be certain that temperature is not locally raised.
1) Replace it.
2) Extraordinary high pressure may be applied to
The protrusion of
packing.
packing heel section is
a) Check pressure at operating.
too large.
b) Where buffer ring is fitted, it may be damaged.
Check buffer ring for possible damage.
32-35
32. ATTACHMENTS

1) Replace rod packing at the same time as a rule.
(Where buffer ring is fitted, it is preferable to re-
place it at the same time.)
Backup ring Large deformation
2) It may be caused by extraordinary high pressure.
In this case, check it using the same procedure
as the above packing heel.
Foreign matter is
1) Remove foreign matter.
caught on lip section
Wiper ring Lip is damaged.
Or there is another 1) Replace it.
Oil leakage from abnormal damage.
1 piston rod slid- Worn, and the space
ing section between bearing and
piston rod exceeds the
maximum clearance. 1) Replace it.
Bearing (Refer Item 32.2.1.5
(Bushing) (2) "Maintenance
Standard".)
1) Replace it.
Large flaw on sliding
2) Check piston rod for possible damage at the
surface
same time.
Flaw and rust on seal 1) Remove flaw and rust with oilstone.
Rod cover
fitting surface 2) In case it is too large to repair, replace rod cover.
2) Replace damaged O-ring.
3) Inspect inner surface of tube.
If flaw and rust are detected, make it smooth with
Foreign matter is oil stone.
O-ring caught in inner bore 4) Inspect groove of rod cover.
and outer surface. - do -
5) Inspect backup ring.
Replace deformed or incompletely fit O-
ring.Check O-ring for above failure. If failed, re-
place it.
Deformed and
Backup ring 1) Replace it with O-ring
Oil leakage from incomplete fitting
2 rod cover set 1) Disassemble rod cover, check O-ring and back-
section up ring for possible damage.
If damaged, replace it.
Rod cover Loosen 2) Check thread ridges of tube and rod cover for
possible damage.
3) After inspection, tighten it to the specified torque.
(See Item 32.2.1.4 "Install".)
Loosen, elongation 1) Replace all bolts, and tighten them to the speci-
Bolt
and damage fied torque.
1) Replace it with new one.
The oil leakage from set section may be caused
Cylinder tube Abnormal expansion by the production of extraordinary high pressure.
Check tube for expansion and deformation, and
also circuit pressure for possible error.
32-36
32. ATTACHMENTS

1) Replace it.
Oil leakage from • Crack is progressed and ruptured mechani-

Cylinder tube, cally.
pipe and cylin-
3 pipe (hollow Crack on weld zone
der tube weld • The rupture is very dangerous. So when
piston rod)
zone crack has been detected, stop operating im-
mediately and replace the parts with new
one.
• The weld on crack for repair is ineffective.
Bending exceed the

specified deformation.
Piston rod Seal and sliding parts may be damaged.
(See Item 32.2.1.5 (2)
Cylinder tube Check for possible damage. If damaged, replace
"Maintenance Stan-
it.
dard".)
Malfunction 1) Replace it with new one.
Cylinder tube Dent Check seal and sliding parts for possible dam-
Unsmooth age same as the above.
operation 1) Replace it with new one.
Wear or damage on
Check seal and sliding parts for possible dam-
Piston rod sliding parts Foreign
age same as the above.
Cylinder tube matter is caught in pis-
sliding parts ton and cylinder head
Check seal and sliding parts for possible dam-
sliding section.
age same as the above.
Piston seal Flaw, wear, etc. Check inner surface of cylinder tube for possible
4 damage.
1) Remove flaw and rust with horning and oilstone
Internal to make it flat.
leakage Flaw and rust on inner
Cylinder tube If it is too large to repair, replace cylinder tube
Piston rod is surface
with new one.
extended and 2) Replace piston seal with new one.
retracted of itself 1) Tighten it to the specified torque.
or abnormally Piston nut Insufficient tightening (See Item 32.2.1.4.5 "Installing piston assy on
drops in rod".)
operation.
Valves Leakage from valve 1) Inspect the leaking quantity and repair it.
And the speed
does not rise to
the specified
speed. Hydraulic oil is expanded and contracted with change of temperature and pressure.
Consequently the cylinder is also extended and retracted, so care must be taken in
order not to mistake this for internal leakage. Check it for internal oil leakage in the
constant temperature and pressure conditions.
32-37
32. ATTACHMENTS

1) Remove air.
a) If cylinder is not equipped with air bleed port ;
Release air by extending and retracting it at low
speed several times.
b) If cylinder is equipped with air bleed port ;
Unload so that the internal pressure is not raised,
The operation is Air is remained in
Air loosen air breather and release air completely.
unstable. cylinder.
(Reference)
When cylinder has stopped in an emergency,
cylinder may be extended and contracted slight-
ly. This phenomenon is caused by the pressure
of hydraulic oil, and easily occurs on the cylinder
of which the stroke is longer.
Great shock
4 when changed The space between fit- 1) Measure dimension of pin and pin bushing, if it
Pin bushing
from / to exten- ting section and pin exceeds the specified dimension, replace it with
Pin
sion to / from re- bushing is too large. new one.
traction.
Insufficient
Noise Lubrication 1) Lubricate.
lubrication
when cylinder is
Pin bushing Scuffing on engaged
worked. 1) Replace it with new one, and lubricate.
Pin section
Hydraulic oil is expanded and contracted with change of temperature and pressure.
Consequently the cylinder is also extended and retracted, so care must be taken in
order not to mistake this for internal leakage. Check it for internal oil leakage in the
constant temperature and pressure conditions.
32-38
33. UPPER SLEWING BODY
TABLE OF CONTENTS

33.1.1 CAB ........................................................................................................................... 33-3
33.1.2 OPERATOR SEAT .................................................................................................... 33-5
33.1.3 BATTERY .................................................................................................................. 33-6
33.1.4 INSTRUMENT PANEL .............................................................................................. 33-7
33.1.5 COUNTERWEIGHT .................................................................................................. 33-9
33.1.6 GUARD ..................................................................................................................... 33-10
33.1.7 UNDER COVER ........................................................................................................ 33-14
33.1.8 AIR CLEANER .......................................................................................................... 33-15
33.1.9 MUFFLER ................................................................................................................. 33-17
33.1.10 FUEL TANK .............................................................................................................. 33-18
33.1.11 HYDRAULIC TANK ................................................................................................... 33-20
33.1.12 PUMP ........................................................................................................................ 33-23
33.1.13 RADIATOR & OIL COOLER ..................................................................................... 33-27
33.1.14 ENGINE ..................................................................................................................... 33-31
33
33.1.15 CONTROL VALVE .................................................................................................... 33-35
33.1.16 PILOT VALVE (FOR ATT) ......................................................................................... 33-37
33.1.17 PILOT VALVE (FOR TRAVEL) .................................................................................. 33-38
33.1.18 SWING UNIT ............................................................................................................. 33-39
33.1.19 SWIVEL JOINT ......................................................................................................... 33-41
33.1.20 UPPER FRAME ......................................................................................................... 33-44
33.2.1 HYDRAULIC PUMP • REGULATOR ......................................................................... 33-46
33.2.2 CONTROL VALVE .................................................................................................... 33-59
33.2.3 PILOT VALVE (ATT) ................................................................................................. 33-73
33.2.4 PILOT VALVE (TRAVEL) .......................................................................................... 33-83
33.2.5 SWING MOTOR UNIT ............................................................................................... 33-89
33.2.6 SWIVEL ..................................................................................................................... 33-103
33-1

S5YT3304E01
(NHK)
PREFACE
(1) This manual describes all the procedures from removing to installing, arranging them by item.
(2) This Manual consists of first part; 33.1 Removing and installing, and second part; 33.2 Disassembling and as-
sembling.
(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) Please be aware that procedure to be followed must be determined according to the above conditions.
good understanding, then starts working.
33-2

33.1.1 CAB
33.1.1.1 REMOVAL
(1) Remove floor mat Rotate 90 degrees
(2) Remove the following parts for air-con cover. to remove.
GROMMET BOLT(24)
1) 5 bolts for catch (24) COVER
24
2) Cover (1)
3) Grille under front seat CATCH BRACKET
4) Duct from duct (14) to under right duct on cab in- 14

side.
1
: Cross recessed screw driver GRILLE
: 13 mm
FLOOR MAT
Fig. 33-1 Detaching and attaching air conditioner

cover
(3) Remove the following parts for harness and con-
FOR ROOM LAMP CURL CODE
nector. FOR WINDOW
1) Antenna cable from back side of tuner GROMMET WASHER
2) Harness for room lamp

DOOR SW
3) Harness on cab front right side
ANTENNA
4) Harness for gauge cluster
5) Harness on front right side of cab for power win-
dow. (OPT) GROMMET
(4) Remove window washer tube To instrument panel
(5) Remove the following parts for cab mounting bolt TO TUNER
GROMMET
1) 5 capscrews (A1) M10
A1
M10 X 5 pcs. TUBE Remove
2) 4 nuts M16 washer tube
3) Sems-bolt (B2) M10, 2 pcs on lower section of at floor
TUBE
hand rail
NUT
M16 X 4 pcs.
30 (1.18")
HOLE FOR HAND RAIL
Fig. 33-2 Removing and attaching harness connec-
tor and cab mounting bolts
33-3
(6) Slinging cab

1) Remove 2 plastic plugs on front side of cab ceil-
ing, and attach eye bolts M10, and hook wire 3 M10
places, 2 bolts and lifting eye, on rear left side. EYE BOLT LIFTING EYE
2) Then lift up slowly avoiding interference with sur-

roundings.
Wire with hook :
Length 1.5 m (4ft 11 in)  Dia. 8 mm (0.315 in)
3 pcs.
Weight of cab : Approx 200 kg (440 lbs)
Fig. 33-3 Slinging cab
33.1.1.2 INSTALLATION
Mount it in reverse procedure of Dismouting according to the Tightening Torque Table.
Tightening
Tool torque
Tightening position Hex. mm N·m (lbf·ft)
Lower section of hand rail
Sems-bolt (B2) 17 46 (34)
Nut M16 24 191 (140)
Capscrew (A1) 17 46 (34)
33-4
33.1.2 OPERATOR SEAT
33.1.2.1 REMOVAL
(1) Remove seat. (Include upper rail.)
1) Remove four M8 capscrews (15) in the upper
rail. SEAT
2) Remove seat. M8X16
15
[Approx.15kg (33 lbs) with upper rail]
: 6 mm
(2) Remove slide on lower rail of seat. UPPER RAIL

1) Remove four capscrews (15) M8. 4
2) Remove support (4).
3) Remove four capscrews (8) M8.
4) Remove lower rail (3).
: 6 mm LOWER RAIL
3 15
M8X16
(3) Remove seat stand (1).
M8X30
1) Remove four capscrews (9) M10. 18
2) Remove seat stand (1).
M8X16 13
: 8 mm 15 M8X25
Weight of seat stand : 17 kg (37 lbs) PLATE (STOPPER)
1
M10X25
9
Floor plate
Fig. 33-4 Dismounting and mounting seat
Install it in reverse procedure of removing according to the tightening torque table.
Tool Tightening
Tightening position wrench torque
mm N·m (lbf·ft)
Capscrew (9) 8 46 (34)
Capscrew (15) 6 24 (17)
Reference : Movement on rail

Upper rail ... Fixed on lower surface of seat
(Forward 80, backward 80)
Lower rail ... Fixed on seat stand.
Height adjustment lever (L.H)
Seat raise 23mm (0.91 inch)
Seat lower 37mm (1.5 inch)
33-5
33.1.3 BATTERY
33.1.3.1 REMOVE
(1) Open right front cover.
RIGHT FRONT COVER
1) Open it with engine key.
2) Open cover.
3) Fix it with stay
Fig. 33-5
(2) Remove 3 battery cables
1) Cable (between ground and battery (-)) (Always
STAY
remove (-) terminal first and install it at last.)
2) Cable (between battery (+) and (-))
3) Cable (between battery and (+) battery relay) BATTERY
RELAY
: 13 mm
Follow the battery removal order.

Start removing battery from grounding side, and finish
1) 2) 3)
attaching to grounding side. If this order is missed,
short-circuits may occur. Fig. 33-6 Grounding cable for main body
(3) Remove battery (B1)

1) Remove 2 attaching bolts (A2) M10.
: 17 mm
2) Remove cover (A1)
3) Remove battery (B1)
33.1.3.2 INSTALL
(1) Install counterweight in the reverse procedure of
A2
removing.
Battery attaching bolt
A1
: 17 mm
Tightening torque : 11 N•m (8.0 lbf•ft)
(2) Installing grounding cable B1
Install grounding cable last. Especially care must

be taken that the grounding face is free from paint-
ing, rust, etc.
: 13 mm
Fig. 33-7 Removing battery
33-6
33.1.4 INSTRUMENT PANEL
33.1.4.1 PREPARATION FOR REMOVAL

Remove terminal (-) from battery.
33.1.4.2 REMOVAL
(1) Remove RH, LH instrument panel
1) Remove 8 sems-bolts (12) M5.
: Cross recessed screw driver
2) Lift instrument panel 12 12
3) Remove two connectors and antenna cable on

rear side of left instrument panel
1. 8P connector for air-con panel 12
12
2. 9P connector for tuner.
Fig. 33-8 Around of instrument panel

4) Remove four connectors on rear side of right 12
12 M5 X 16
panel
12
1. 6P connector for key switch 12
2. 3P connector for accel dial
3. 2P & 8P connectors for switch panel
28
12
28
28 M5 X 10
TUNER ANTENNA CABLE
Fig. 33-9 Removing instrument panel

(2) Remove control box
A13 PILOT VALVE
1) Remove four (4) sems-bolts (19) M8 on right M8 X 25
and left sides. SUPPORT
PILOT
ASSY
2) Separate control box from support. VALVE
A19 M8 X 25
A20
: 13 mm M6 X 16
Weight : Left control box 8.5 kg (19 lbs) and right
control box 7 kg (15 lbs) including pilot valve. SUPPORT
SEAT STAND
Remove hose referring to Item 33.1.15.2. Fig. 33-10 Removing control box
33-7
Install it in reverse procedure of removing according to the tightening torque table.
Tightening
Tightening position Tool torque
N·m (lbf·ft)
Sems-bolt (19) 13 24 (17)
Sems-bolt (12) cross recessed 2.6 (2.0)
screw driver
Capscrew (46) Torx driver 2.6 (2.0)
(T25)
33-8
33.1.5 COUNTERWEIGHT
33.1.5.1 PREPATATION FOR REMOVAL

(1) Removing bonnet assy.
Remove bonnet on engine. (See Fig. 33-20 )
(2) Remove cover (3) (See GUARD Fig. 33-21)
(3) Preparing slinging jig
Remove C7 plug, and attach weight slinging jig
(See Chapter Tools.) to counterweight.
: 36 mm
Fig. 33-11 Lifting up counterweight
33.1.5.2 REMOVAL
(1) Lifting up counterweight temporarily
Hook wire rope to slinging jig, and lift it and stretch A1
wire rope to the degree where it is providing no LIFTING HOLE
slack temporarily. C7
Weight of counterweight : Approx. 850 kg (1870
lbs)
C3 C3
Wire more than ø10 (0.394") : 1.5 m (4 ft 11 in)  2 SHIM
C2
pcs.
(2) Removing counterweight
1) Remove 1 capscrew (C1) M20  75. SHIM
2) Remove 2 capscrews (C3) M20  135.
: 30 mm
C2
3) Remove shim.
C3
Fig. 33-12 Removin counterweight
(1) Install counterweight in the reverse procedure of re-
moving.
(2) Install shim as it was
(3) Slinging counterweight
Check that 3 attaching bolts can be screwed in by
hand.
(4) Apply Loctite #262 on capscrews (C1, C3), and
tighten them with washers (C2).
: 30 mm
(5) Remove slinging tools, and attach plugs (C7). Fig. 33-13 Attaching bolts counterweight
33-9
33.1.6 GUARD

(1) Remove guard in the following procedure. 1
For removing equipment Items (1) to (8). 7 2
5
For dismounting engine, Items (9) to (13). 41
(2) All the locked equipment, open them using starter
key. 40 1A
8,9
Fig. 33-14 Guard assy
33.1.6.2 REMOVE GUARD

(1) Remove cover assy (1) 1 COVER ASSY
1) Open cover assy (1) and lift it up.
2) Pull out snap pin (23) and remove gas cylinder
(87).
3) Remove two nuts (26) M12.
4) Remove cover assy (1).
26 23
: 19 mm 23
Weight : 11 kg (24 lbs) 87
Fig. 33-15 Removing cover assy (1)

(2) Remove panel assy (2) 24
1) Remove two sems-bolts (24) M12  25.
2) Remove two nuts (26).
3) Remove panel assy (2). 2
PANEL
: 19 mm 24 ASSY
Weight : 11 kg (24 lbs)
26
SHIM
Fig. 33-16 Removing panel assy (2)
33-10
(3) Remove cover assy (6) 25

COVER ASSY
1) Remove two capscrews (38) M12  45. 6
SEMS-BOLT 24
2) Remove a sems-bolts (24) M12  25. M20 X 30 SEMS-
25 BOLT
3) Remove three sems-bolts (25) M12  30. M12 X 25
4) Remove cover assy (6).
: 19 mm 38
Fig. 33-17 Removing cover assy (6)

(4) Remove guard assy (40) 40
1) Remove three capscrews (64) M8  20.
2) Remove guard assy (40). 64
: 13 mm
Fig. 33-18 Removing guard assy (40)

(5) Remove guard assy (41) 41
24
1) Remove four sems-bolts (24) M12  25.
2) Remove guard assy (41).
: 19 mm
24

(6) Remove bonnet assy (5)
1) Open bonnet assy (5) and lift it up with nylon 5
slings.
2) Pull out snap pin (23) and remove gas cylinder
(21).
3) Remove four sems-bolts (24) M12  25.
4) Remove bonnet assy (5).
23
24
: 19 mm
23
21
Fig. 33-20 Removing bonnet assy (5)
33-11
(7) Remove cover (1A)

COUNTERWEIGHT
1) Remove four capscrws (3) M10  25. 1A COVER 3
2) Remove cover (1A).
: 17 mm
• Then remove counterweigtht (A1).
• (See 33.1.5 COUNTERWEIGHT.) The re-
moving procedures (1) through (7) for guards
and counterweight is available for removing
hydraulic equipment, but to remove engine
and all guards together, the performance of
procedures (8) through (13) are required.
(A1)
Fig. 33-21 Removing cover (1A)

(8) Remove bracket (44) 24
1) Remove a sems-bolt (25) M12  30.
3) Remove bracket (44). 44
BRACKET
: 19 mm
25
24
Fig. 33-22 Removing bracket (44)

(9) Remove guard assy (7) 7 GUARD ASSY
25
1) Remove a sems-bolt (25) M12  30. 73
2) Remove a capscrew (73) M12  25.
3) Remove guard assy (7).
: 19 mm
(10)Remove cover assy (60)
24
Remove two capscrews (64) M8 X 20, then cover
assy (60).
: 13 mm 60
COVER ASSY
(11)Remove guard assy (11)
Remove a sems-bolts (25) M12  30 and a sems-
bolt (24) M12  25. 64
: 19 mm 11
GUARD ASSY
25
Fig. 33-24 Removing guard and cover assy (11), (60)
33-12

GUARD ASSY
Remove four sems-bolts (24) M12  25 and guard 41 24
assy (9).
: 19 mm
(13)Remove guard assy (41) GUARD ASSY
Remove four sems-bolts (24) M12  25 and guard 9
assy (41). 24
24
Fig. 33-25 Removing guard assy (9), (41)

1) Remove 3 sems-bolts (25) M12  30
2) Lift up guard assy (8) with nylon sling.
8
: 17 mm 25 25
SEMS-BOLT
Weight : 45 kg (100 lbs) M20 X 30
(1) Installing is done in the reverse order of removing.
(2) Tightening torque
: 19 mm M12, 79 N•m (59 lbf•ft)
: 17 mm M10, 66 N•m (48 lbf•ft)
: 17 mm M10 Capscrew (3)

20~24N•m (15~18 lbf•ft)
: 13 mm M8, 24 N•m (18 lbf•ft)
33-13
33.1.7 UNDER COVER
33.1.7.1 REMOVAL
(1) Remove under cover (1, 2, 3, 4, 5, 6)
1) Remove sems-bolts (7) M12 X 25.
2) Remove covers
: 19 mm
COVER 1
6 COVER
COVER 2 7
7
3 COVER
7
7
4 COVER
7
COVER 5
Fig. 33-27 Removing under cover assy
(1) Install under cover (1, 2, 3, 4, 5, 6)
: 19 mm
33-14
33.1.8 AIR CLEANER

(1) Opening bonnet assy (5) 5
1) Unlock it with starter key.
2) Open bonnet (5) and support it with stay (15).
15
Fig. 33-28 Opening bonnet assy (5)

(2) Opening cover assy (4) STAY 15
(3) Unplug terminals on indicator lines (5-5)
(See Fig. 33-31)
4
COVER ASSY
Fig. 33-29 Opening cover assy (4)
33.1.8.2 REMOVAL
(1) Pulling out hose (2)
1) Loosen clip (8) on air cleaner side. 8 CLIP
2) Pulling out hose (2)
: Flat-blade screw driver
2 HOSE
Fig. 33-30 Pulling out hose (2)
33-15
(2) Pulling out hose (1)

1) Loosen clip (8) on air cleaner side.
2) Pulling out hose (1) 1 HOSE
5-5 8 CLIP
: Flat-blade screw driver
5
(3) Remove air cleaner assy (5)
TERMINAL AIR CLEANER ASSY
1) Remove 2 capscrews (14) M8  20
2) Remove air cleaner assy (5) together with brack- 4 BRACKET
et (4).
: 13mm 14 M8 X 20
Fig. 33-31 Pulling out hose (1)
FILTER ELEMENT
(2) Spare parts for deteriorated elements LE11P00002S002
O-RING
YT11P00002S006
Fig. 33-32
33-16
33.1.9 MUFFLER

(1) Open bonnet assy (5). (See Fig. 33-20)
68
(2) Remove cover (3). (See Fig. 33-21)
(3) Remove sems-bolt (68), then cover (42).
42 COVER
Fig. 33-33 U-bolt a nut (As seen from pump)
33.1.9.2 REMOVAL
(1) Remove U-bolt (5).
1) Remove four nuts (9) M8.
5 U-BOLT
2) Remove two U- bolts (5).
A 2 MUFFLER
: 13 mm E/G parts
9 CAPSCREW
LOCK NUT M8
Fasten in with
T=10.8 N·m
pump bracket tog
(8.0 lbf·ft)
9
NUT M8
T=8.8 N·m
( ff) 9
Fig. 33-34 Removing U-bolt (5)
(2) Remove clamp assy (6) CAPSCREW M10 X 35
T=83 N·m (61 lbf·ft)
1) Remove two capscrews (7) M10  35 7
2) Separate clamp assy (6) from muffler (2). CLAMP
NUT M8 9 ASSY 6
A
: 17 mm
WASHER
EX TUBE 3 NUT
GASKET 4
Fig. 33-35 Removing clamp assy (6)
(1) Done in the reverse order of removing
M8 lock nut Tightening torque : 10.8 N•m (8.0 lbf•ft)
M8 nut Tightening torque : 8.8 N•m (6.5 lbf•ft)
M10 capscrew Tightening torque : 83 N•m (61 lbf•ft)
(2) Deteriorated parts
2. Muffler assy: YT12P00010P1
33-17
33.1.10 FUEL TANK

(1) Draining fuel. A3
1) Open cap (A3).
2) Loosen plug assy (A4) under the tank. 12
Installing position (See Fig. 33-38) 11
3) Draining fuel 15
Capacity of tank : 85 L(22 gal) 7
(2) Remove hose (6, 7)
1) Loosen band and pull out hoses (6, 7)
2) Plug hoses.
6
Water separator Injection pump
Fig. 33-36 Removing fuel hose (6, 7)
(3) Remove water separator (2)
1 WATER SEPARATOR
1) Remove two capscrews (15) M8  25 YX02P00001S002
2) Remove water separator (1). ISUZU NO.
697218-6470
: 13 mm
(4) Remove tube (11)
Loosen clip (12) and pull out tube (11).
Fig. 33-37 Removing water separator (1)
33.1.10.2 REMOVAL
(1) Removing bracket (B3) used to secure two tanks. M12 X 25
1) Remove two sems bolts (B4) M12  25. T=66.7 N·m (49 lbf·ft)
B4 SEMS-BOLT
2) Remove bracket (B3) and shim (If used).
B3
: 17 mm
(2) Remove fuel tank assy (A1)
Shim
1) Remove four capscrews (B1) M16  30. t=1.2
t=2.0
2) Sling and remove fuel tank assy.
B1
: 24 mm T=216 N·m
(160 lbf·ft) B1
CAPSCREW
M16 X 30
Capacity of tank :
A1 85 L (22 gal)
Weight :
PLUG ASSY A4 54 kg (119 lbs)
Fig. 33-38 Removing fuel tank
33-18
Tank attaching bolt M16  30
: 24 mm
Apply Loctite #262
Special attention must be paid not to drop tightening tools in far side when tightening bolts.
33-19
33.1.11 HYDRAULIC TANK

(1) Swinging upper structure 45 degrees.
Swing upper structure to make the removal of suc-
tion hose for pump installed under tank easier.
Fig. 33-39 Swinging upper structure 45 degrees

(2) Bleeding internal air of tank Push
Press cap by finger to bleed internal air.
(ELEMENT NO.
YN57V000025S010)
Keep pressing until the hissing sound stops.

Fig. 33-40 Bleeding internal air of tank
(3) Removing hydraulic pipe on the upper cover of
tank.
1) Remove two nuts M8 for coupling (17).
2) Open the gap and remove the coupling.
(4) Remove hose (4)
: 22 mm
(5) Remove hose (6)
: 27 mm
4
17
6
Fig. 33-41 Removing hydraulic pipe on the upper

cover of tank
(6) Remove cover (8) 8
1) Remove six cpscrews (14) M1020
2) Remove cover (8). 14
WASHER
: 17 mm
Fig. 33-42 Removing cover (8)
33-20
(7) Emptying hydraulic oil

Place pump in tank and drain hydraulic oil.
Capacity of tank : Approx. 78 L (21 gal)
Care should be taken that pump does not damage suc-

tion strainer.
Fig. 33-43 Emptying hydraulic oil
33.1.11.2 REMOVAL
(1) Draw out the suction hose (4)
1) Remove two (2) clips (9) on tank side through
under side of swing frame.
2) Pulling out hose (4).
: Flat-blade screwdriver HYDRAULIC OIL TANK
9 4
Fig. 33-44 Draw out the suction hose (4)
(2) Disconnecting pilot return hose (DR)
Disconnect 7 pilot drain hoses on rear side of tank.
Fig. 33-45 Disconnecting pilot return hose (DR)
33-21
(3) Remove hydraulic tank attaching bolt

Tightening torque :
Remove four capscrews (1) M16  40. 216 N·m (160 lbf·ft)
Apply Loctite #262
equivalent
: 24 mm
1 1
(4) Slinging hydraulic oil tank Tightening torque :
Hook wire to neck of tank upper cover. 216 N·m (160 lbf·ft)
Apply Loctite #262
Tank weight : Approx. 65 kg (143 lbs) equivalent
BOOM FOOT PIN HOLE

Fig. 33-46 Removing hydraulic tank attaching bolt
(1) Cleaning hydraulic oil tank
(2) Cleaning suction hose
(3) Cleaning mount of tank
Installing is done in the reverse order of removing.
(4) Attaching bolt
Apply Loctite #262
: 24 mm
Fig. 33-47 Slinging hydraulic oil tank

(5) Connection of suction hose O-RING
Apply PERMATEX on pipe side of hose connection
and insert it.
(6) Clip (9)
Tightening torque : 5.4 N•m (4.0 lbf•ft)
(7) Tank cover attaching bolt
M10 Tightening torque : 46.1 N•m (34 lbf•ft)
SUCTION
RETURN FILTER STRAINER
REPAIR KIT YT50V00001F1
YR52V01001R200
O-RING
ZD11G15500
Fig. 33-48 Element & Filter
33-22
33.1.12 PUMP

(1) Remove counterweight. BREATHER
(2) Release pressure in hydraulic oil tank. (See item A8 14 CAPSCREW
T=46.1 N·m (34 lbf·ft)
"Hydraulic oil tank")
(3) Remove six capscrews (A14) M10.
(4) Remove cover (A8)
SUCTION SUCTION
SIRAINER STOPPER
: 17 mm
(5) Take out suction strainer.
(6) Install suction stopper.
For suction stopper, see Chapter "Tools".
Pump can be removed even when counterweight is not HYDRAULIC

removed. But removal of counterweight facilitates OIL TANK
working, and the working time is also reduced.
Fig. 33-49 Hydraulic oil tank
(7) Remove two capscrews (64) M8.
(8) Remove cover (60).
(9) Remove a sems bolt (25) M12 and two sems bolts
COVER
(24) M12. 24 SEMS-BOLT
(10)Remove guard (11) assy.
60
: 13 mm, 19 mm
64
(11)Disconnect drain down pipe installed under engine 11
muffler.
25
Fig. 33-50 Removing guard
33.1.12.2 REMOVAL
(1) Loosen cap nuts (5), (6) and remove 2 hoses from
delivery sides (A1), (A2). 6
: 36 mm
(2) Remove suction flange
1) Remove four socket bolts (10) M12. 5
HYDRAULIC
2) Remove flange (3) of suction hose (4) from pump OIL TANK
(B1).
PUMP B1
40 mm
(1.57 in) : Special service tool No.6-1 of opposing 3
frats 10 mm
10
CLIP CLIP
4
Fig. 33-51
33-23
(3) Removing other hoses

1) Disconnect hoses of the following ports. (See
A3
Fig. 33-52) A1 *A5
A2 A5
Dr1
Port Size Tool Connected Remarks
to
Dr1 PF1/2 27 Tank Drain
HOSE
Dr2 PF1/2 27 Plug
Pf PF1/4 19 Tank Air-con power P3 A4 Pz

shift port
B2
P3 PF1/4 19 A5 Do not have
Pf
to remove it.
A3 PF3/8 22 Inlet of Delivery port
in-line filter
B1
A4 PF3/8 22 Outlet of Relief port
in-line filter Dr2
(PLUG)
Dozer Delivery port
*A5 PF1/2 27
C/V-P for dozer Fig. 33-52 Pump port (with dozer)
Suction port
B2 PF1 41 Tank for dozer
Pz PF3/8 19 SOL. Block Power shift port
2) Attach tags to hoses to identify.

(4) Remove main pump
Clockwise
1) Attach eye bolt (M8) on upper surface of pump.
2) Lift it with wire lightly.
3) Remove 2 socket bolts (7) M16.
4) Pull pump horizontally and remove it.
EYE BOLT
45 mm
(1.77 in): Special service tool No.6-2 of 14 mm
(For bolts on upper side)
Weight of pump : Approx. 45 kg (99 lbs)
I
Tightening torque :
7 191 N·m (140 lbf·ft)
Apply Loctite #262
Fig. 33-53 Removing pump
33-24
Installing pump in the reverse procedure of removal fol-
lowing the specification for tightening torque and seal-
ant.
(1) Apply grease on spline of input shaft.
Grease ; Shell Retinax AM (General-purpose ex-
treme-pressure molybdenum disulfide grease) Apply
grease
(2) Hook wire to eye bolts (M8) on upper surface of
pump and lift it.
(3) Insert pump spline section.
Fig. 33-54 Installing pump

(4) Apply sealant on suction port (B2) for dozer and fix
it with hose connecting clip. 6
Sealant : Permatex B2 port is omitted
in this Drawing
Socket screw driver 7 mm
(5) Apply sealant on socket bolt (7) and mount pump
with it.
Sealant : Loctite #262 5
HYDRAULIC
: 14 mm
OIL TANK
(* Special service tool No.6-2)
Tightening torque =191 N•m (140 lbf•ft)
(6) Install the suction flange mounting socket bolts (10)
PUMP
M12 (4 pcs.)
: 10 mm
(* Special service tool No.6-1)
Tightening torque =98 N•m (72 lbf•ft) 3
(7) Installation
Tightening
Tool torque
Tightening position
Hex. mm N·m (lbf·ft) 10
Cap nut A1, A2 36 118 (87)
Cap nut Dr1 27 78 (58) CLIP CLIP
Cap nut Pf, Pz 19 29 (22) 4

Cap nut A3 22 49 (36) Fig. 33-55 Hose installing
Cap nut A4 22 49 (36)
Cap nut A5 27 78 (58)
*
(8) Install a water drain pipe under the engine muffler.
33-25
(9) Remove suction stopper

a2 a1
(10)Mounting suction strainer
(11)To bleed air in pump, loosen plugs on pressure
measuring ports a1, a2 and a3.
: 19 mm
(12)Check hydraulic oil level.
(13)Start engine and check it for oil leakage and noise. a3
Fig. 33-56 Release air in pump

(14)Install guards
Tightening
Tightening position Tool torque
N·m (lbf·ft)
Capscrew (64) 17 66 (48)
COVER
Sems-bolt (24), (25) 19 79 (59) 64
24
60
64
11
After replacing pump, be sure to fill hydraulic oil of 1L 25

(0.26 gal) or more.
Fig. 33-57 Guard installing
33-26
33.1.13 RADIATOR & OIL COOLER
Connection of hoses for air-con should not be loosened and removed. Refrigerant may be leaked.
B9 SUB TANK
HOSE
B6 RADIATOR HOSE (UPPER)
B5
SHROUD · BRACKET
RADIATOR
HOSE
(LOWER) CAP M8 X 20
T=28 N·m
(21 lbf·ft)
4 GUARD
4-M12 X 30
Loctite #262
T=120 N·m DRAIN COCK
(88 lbf·ft) STAY
M10 X 25
T=57 N·m
(42 lbf·ft)
Fig. 33-58 Relative drawing of radiator

(1) Remove counterweight 3 HOSE
(2) Bleeding internal air of hydraulic oil tank
(3) Remove cover of suction strainer, and adjust oil
quantity so that oil level becomes lower than the re- 2 HOSE
turn tube level.
7
(4) Remove air cleaner hose
Refer to 33.1.8 AIR CLEANER 7
1) Loosen two bands (7).
Fig. 33-59 Removing hose
: Flat-blade screwdriver
(5) Removing under cover installed on lower side of ra-
diator.
1) Remove four sems bolts (A7) M12  25.
2) Remove cover (A5).
: 19 mm
COVER A5
A7
Fig. 33-60 Removing under cover
33-27
(6) Drain down of radiator D HOSE 9

Put container 18 L (4.8 gal) under drain cock hose (AIR-CON) A6
Tightening torque :
for draining water. Tightening torque : 4.4 N·m (3.3 lbf·ft)
4.4 N·m 17, 20, 23
(7) Remove washer tank (3.3 lbf·ft)
16, 20, 23 Tightening torque :
1) Pulling out hose. 39 N·m (29 lbf·ft)
CAPSCREW CONDENSER 14
2) Move washer tank. M6 X 60 3 pcs. SEMS-BOLT
RECEIVER M8 X 25 2 pcs.
(8) Move air-con condenser (A6) TANK
1
1) Remove three capscrews (16) M6  50. WASHER TANK
11
S HOSE
3) Move A/C condenser (A6) (AIR-CON)
8
: 10 mm, 13 mm L HOSE (AIR-CON)

10
(9) Move receiver tank
1) Remove two capscrews M8  16 which are used Fig. 33-61 Removing air condenser
to install regulator tank with bracket.
2) Move receiver tank
: 13 mm
33.1.13.2 REMOVAL
(1) Remove radiator stay CAP
1) Remove two capscrews (2) M10  25.
2) Remove stay (A1). STAY
: 17 mm
A1 CAPSCREW
(2) Remove bracket (B2) T=120 N·m
(88 lbf·ft) M10 X 25
1) Remove four capscrews (B17) M8  20. B17 T=57 N·m
A2 (42 lbf·ft)
2) Remove bracket (B2).
DRAIN COCK
4-M8
: 13 mm B2 COOLER MOUNTING BOLT
Fig. 33-62 Removing radiator stay (A1) & brackt
(3) Remove sub tank (B9) B9 SUB TANK
1) Loosen clip on one side of hose (B11) and pull
out hose.
BRACKET
2) Lift sub tank (B9) directing upward, and remove
B11 HOSE
it from bracket (B3).
TO RADIATOR
Fig. 33-63 Removing sub tank
33-28
(4) Remove guard (B4) B19 CAPSCREW

1) Remove three capscrews (B19) M8. B4
2) Remove guard (B4).

B6
: 13 mm B12
(5) Remove water hose (B6)

1) Loosen the hose band (B12).
2) Remove hose (B6).
C1
: Flat-blade screwdriver
(6) Remove main radiator (C1)
Remove four capscrews (A3) M12  30.
: 19 mm
CAPSCREW
: 19 mm M12 X 30
Loctite #262
T=120 N·m
(88 lbf·ft)
A3
Fig. 33-64 Removing radiator

(7) Removing connection coupling for hydraulic oil (Oil 17
cooler) M8
1) Remove 4 bolts M8 of coupling (17) just below
the radiator.
2) Put oil pan under the coupling (17), remove cou-
pling and let oil out.
(8) Disconnecting hydraulic oil pipe Fig. 33-65 Removing coupling
1) Shift radiator outward.
2) Plug up pipe ends with rag, etc.
(9) Disconnecting water lower hose (B5)
1) Loosen the hose band (B13).
2) Pulling out hose (B5).
RADIATOR
OIL COOLER
B5
Remove the hose while sliding the radiator little by little.
B13
(10)Removing radiator
Remove radiator assy by power of men or with
crane.
Fig. 33-66 Removing water lower hose (B5)
33-29
(2) Install radiator assy
Lift up radiator by power of men or with crane,
match the holes for water hose and hydraulic oil
pipe and also the position respectively, and assem-
RADIATOR
ble them temporarily. CENTER
However, water hose insert standard 30 ± 2 mm
(1.18 ± 0.08 in)
Hydraulic oil pipe insert standard 30 ± 2 mm
7.5
(1.18 ±0.08 in)
8
(3) Radiator attaching bolt
Apply Loctite #262 on 4 capscrews (A3) M12, and
tighten it with washer respectively.
: 19 mm
Tightening Torque : 120 N•m (88 lbf•ft)
FAN CENTER
Adjust chip-clearance to be
20mm for all around.
(4) Making up hydraulic oil and LLC

After completion of other installation, make up hy-
draulic oil and water. See pages 4-7 in Operator's
Manual.
Tighten it with
attaching bolts
of radiator
3 shroud.
T=8.1 N·m
(6.0 lbf·ft)
Fig. 33-67 Installing radiator
33-30
33.1.14 ENGINE
33.1.14.1 PREPARATION FOR REMOVING

(1) Remove guard (See Fig. 33-14~Fig. 33-26.)
(2) Remove counterweight (See Fig. 33-11~Fig. 33-13.)
(3) Remove battery ground (See Fig. 33-7)
(4) Remove air cleaner hose (See Fig. 33-30)
(5) Remove radiator hose (See Fig. 33-64~Fig. 33-66.)
(6) Remove fuel hose and heater hose, and if necessary air-con hose.
(7) If necessary, remove pump, air cleaner, muffler and radiator.
(8) Remove harness and connector
1) Starter cable Starter B terminal
E/G sub harness terminal
CN357M
M-2
CN-351F E/G sub
2) Main harness
CN-352M harness
CN-363F
3) Engine grounding cable
Prepare a stand which withstands the weight of the engine assy and should be able to place the removed engine
firmly.
33-31
E/G LIFTING FITTING
GROUND
E/G OIL PRESSURE SW
E/G OIL FILTER
E/G SPEED SENSOR E/G GROUND CABLE T=79 N·m
8 PIN CONNECTOR (59 lbf·ft)
CN-352M
BRACKET 2 E/G SUB HARNESS
TO ALTERNATOR
1 PIN CONNECTOR
TO E/G SPEED CN-351F
SENSOR
TIGHTEN CABLE TOGETHER WITH
CAPSCREW OF GROUND
Torque : 40 N·m (30 lbf·ft)
E/G OIL PRESSURE SW

Torque : 40 N·m (30 lbf·ft)
Apply Loctite #262
8 PIN CONNECTOR
CN-363F
SEMS-BOLT
Torque : 9.6 N·m (7.1 lbf·ft)
SAFETY RELAY
CLIP
TO MAIN HARNESS
DETAIL I
PT3/8 (PLUG)
FOR HEATER
HOSE
Clamp the white 4-M10 X 1.25
E/G WATER
tape portion
TEMPERTURE
SW [105 C (221 F)]
33-32
WATER
TEMPERTURE
FUEL FILTER FUEL RETURN (OUT)
SENSOR
M16 X 1.5
E/G LIFTING
FITTING
Clamp the white

tape portion
M-1
STARTER
MOTOR
A/C
COMPRESSOR
FUEL FEED (IN) STARTER CABLE

M-2
STEPPING (GOVERNOR) MOTOR
Connect with
the starter motor RUBBER CAP S
CN-357M
1PAM-58Y STARTER CABLE
B
TO E/G SUB
HARNESS M
DETAIL OF STARTER MOTOR TERMINAL
33-33
33.1.14.2 REMOVAL
6 6 CAPSCREW
M18 X 90
T=225 N·m (170 lbf·ft)
1 Apply Loctite #271
2 BRACKET
10 CAPSCREW
M10 X 35
T=43 N·m (32 lbf·ft)
Apply Loctite #271
8
3 4
4 RUBBER MOUNT
3
12
5
5
12 SHIM
7 5
5 RUBBER
7
7 7 NUT
(1) Removing attaching bolt to frame

1) Remove four nuts (7) M18.
2) Remove rubber mount (5) and shim (12).
3) Remove four capscrews (6) M18  90.
: 27 mm
(2) Slinging engine body
1) Sling engine hooking wire to lifting lugs on the front and rear sides.
Weight : Approx. 250 kg (550 lbs)
Wire : ø6 (0.236")  1 m (3 ft 3 in)-2 pcs.
(3) Position engine on the mount stable.
(1) Installing is done in the reverse order of removing. For tightening torque and Loctite, refer to above figure.
33-34

(1) Remove cover assy (1) (See Fig. 33-15)
(2) Remove panel assy (2) (See Fig. 33-16)
(3) Remove cover assy (6) (See Fig. 33-17)
(4) Release air in hydraulic oil tank, open cover of suction element of hydraulic oil, and lower the level.
(See Fig. 33-49)
(5) Move bracket for multi control valve (11) (See .)
33.1.15.2 REMOVAL
(1) Removing hoses for each piping
Attach tag on hose, and write port name on it, then
remove hoses.
Ports Functions Ports on upper sides (on machine) Ports Functions
P0 Travel straight FAR SIDE
T1 Tank TRAVEL
STRAIGHT
TRAVEL
Pd1 Travel left forward (LEFT) Pa1 Travel right forward
Pd2 Swing left SWING Pa2 Boom up

REAR FRONT
ARM
Pd3 Arm extending Pa3 Bucket digging
Pd4 P2 by-pass cut CUT DR6 Drain

VALVE-2
DR4 Drain
NEAR SIDE
Ports Functions Ports on rear sides (on machine) Ports Functions
BOTTOM FAR SIDE TOP
P2 P2 pump P1 P1 pump
C1 Travel left backward D1 Travel left forward
C2 Swing right D2 Swing left
C3 Arm in D3 Arm out
PS Swing priority PC3· Lock valve
DR2 Drain NEAR SIDE DR3 Drain
33-35
Ports Functions Ports on front sides (on machine) Ports Functions

TOP BOTTOM
A1 Travel right forward
A2 Boom up B1 Travel right reverse
A3 Bucket digging B2 Boom down
Pb2· Boom lock release B3 Bucket dump
DR5 Drain
Ports Functions Ports on bottom sides (on machine) Ports Functions

FAR SIDE
DR1 Drain
PC1 Travel left reverse
Pb1 Travel right reverse PC2 Swing right
Pb2 Boom down PC3 Arm in

FRONT REAR
Pb3 Bucket dump PC4 Boom conflux
Pb4 P1 by-pass cut PS· Swing priority output

(Arm conflux) Pd2· Swing priority input
NEAR SIDE
(2) Remove control valve

1) Remove 4 capscrews (2) M12  30 from upper
frame.
2) Remove bracket (1) together with control valve.
3) Three capscrews (2) M12  30 from bracket.
: 19 mm
4) Weight : 42 kg (93 lbs)
2
2
Fig. 33-68 Removing main control valve
(1) Installing is done in the reverse order of remove.
: 19 mm
Weight of seat stand : 121 N•m (89 lbf•ft)
(2) Make certain that attachment moves normally in operation.
(3) Check oil level and that it is free from oil leakage.
33-36
33.1.16 PILOT VALVE (FOR ATT)

The removing procedure for right and left is the same,
PANEL ASSY
so the preparation for left side is described here.
(1) Put attachment on ground, stop engine and release
26
pressure in tank. 25
(2) Remove panel assy referring to Section 4. Instru-

ment Panel.
(3) Remove one sems-bolt (12) M5 from lower side of
control box.
(4) Remove cover on outer surface.
12
(5) Remove sems-bolt (25) and rubber sheet (26) se-
curing cover and control box on inner surface. Fig. 33-69 Removing instrument panel
: Cross recessed screw driver BOOTS
(6) Remove cover on inner surface.
16
(7) Remove harness connector for horn.
PILOT VALVE
(8) Attach tag to hoses for identification.
T=29 N·m
(22lbf·ft)
T=29 N·m PF1/4
(22lbf·ft)
PF1/4 Opposing
VALVE SIDE
Opposing flats 19
flats 22
MARK “ F ”
PF3/8
PF1/4
1-4, 5-8 PORT AND
HOSE SIDE P PORT (WITH FILTER)
T PORT CONNECTOR CONNECTOR
Fig. 33-70 Pilot valve connector
33.1.16.2 REMOVAL
(1) Remove hoses from your side to far side in order.
FRONT OF THE MACHINE
: 19 mm, 22 mm
BOOM (R)
(2) Shift boots. ARM (R)
BUCKET (R)
(3) Remove four socket bolts (A1) M6.
: 5 mm SWING (R)
(4) Remove pilot valve.
(5) Plug hose ends. Plug PF1/4 BUCKET (H)
SWING (L) BOOM (H)
ARM (H)
LEFT SIDE RIGHT SIDE
Fig. 33-71 Pilot valve port position (for upper side)
Install it in the reverse order of removal and tighten it to the below tightening torque.
: 5 mm T=11 N•m (8.0 lbf•ft)
: 19 mm T=29 N•m (22 lbf•ft)

: 22 mm T=49 N•m (36 lbf•ft)
33-37
33.1.17 PILOT VALVE (FOR TRAVEL)

(1) Release pressure in hydraulic oil tank
(2) Remove under cover (See 33.1.7 UNDER COVER)
(3) Remove floor mat
33.1.17.2 REMOVAL
(1) Disconnect pre pressure sensors connectors at two
places from under floor harness.
(2) Remove two pressure sensors.
: 19 mm
7
(3) Disconnect lead cable CA103 for travel 1,2 speed
at two places from under floor harness.
(4) Attach tag, and disconnect connectors and hoses. Lead cable for
travel 1,2 speed
10
: 19 mm (P port) Connect to under
floor harness
: 19 mm (T port, 1~4 port) PF1/4
with CA103 plug
(5) Plug hose ends PRESSURE PRESSURE SENSOR
Plug PF1/4 SENSOR
(6) Remove four capscrews (7) M10

T
(7) Remove right and left levers. CONNECTORS
P
(8) Remove four socket bolts (10) M10. 4
: 8 mm 3
2
(9) Remove four sems-bolts (9) M10 and remove two
plate (18) 1 GROMMET
25 24
: 17 mm
(10)Remove pilot valve lifting it upward.
(11)Stop up holes with blank plugs PF1/4, 3/8.
Install it in the reverse order of removal and tighten it to Opposing
the below tightening torque. PF3/8 flats 22
PF1/4
: 19 mm, 22 mm T=29 N•m (22 lbf•ft)
: 8 mm T=46 N•m (34 lbf•ft)

VALVE SIDE HOSE SIDE
: 17mm T=46 N•m (34 lbf•ft) VALVE SIDE T port connector
Pressure sensor PF3/8 Opposing

Opposing flats 22 MARK F
flats 22 PF1/4 PF1/4
: 19 mm T=29 N•m (22 lbf•ft)
PF1/4
HOSE SIDE
1-4 port connector P port connector
Fig. 33-72 Installing and Removing pilot V
33-38
33.1.18 SWING UNIT

(1) Park machine on flat and solid ground and put at-
tachment and dozer on ground.
CONTROL VALVE
(2) Stop engine and release pressure in circuit operat- FOR DOZER
ing dozer lever.
(3) Release internal pressure through bleeder of hy-
draulic oil tank.
(4) Remove boom as necessary to make work easier.
(Refer to chapter of Attachment.) T
(5) Remove cab if necessary to make work easier. (Re- P

fer to Chapter of Upper structure.)
MU
(6) Remove cover under engine.
Dr P
(7) Attach tag to hose.
B
A
Fig. 33-73 Swing unit piping
33.1.18.2 REMOVAL
(1) Remove hose.
1) Two hoses from connectors of T, P ports on con- B1
trol valve for dozer SPECIAL EYE BOLT
: 27 mm
2) One hose from tee of MU port.
M10
: 36 mm B9

B10
3) One hose from tee of Dr port. B11
: 22 mm B8
4) One hose from elbow of P port (for swing parking
brake).
: 19 mm
5) One hose from tee of A, B ports.
: 32 mm
(* Special service tool No. 6-3)
6) Install PF1/2 plug
Plug No.4-2-1 Fig. 33-74 Removing swing unit
33-39
(2) Loosen one nut (B9) M10 from under side of upper
frame and remove drain hose clip for reduction unit.
: 17 mm
(3) Remove eight the swing unit mounting socket bolt
(B1) M16
Allen key socket wrench : 14 mm
Loctite #262 (Three Bond #1350)
(4) Remove Tee of swing motor MU port and plug up
holes with plug used as eye bolt.
: 36 mm
Plug No. 6-4, Eye bolt No. 6-5
(5) Hook sling to eye bolts attached on MU port. Weight
of swing unit : Approx. 70 kg (150 lbs)
33.1.18.3 PREPARATION FOR INSTALL

(1) Clean mating surfaces of swing unit and upper frame.
Tools : spatula, cleaning fluid
(2) Apply sealant on entire mounting surface of swing unit.
Sealant : Loctite # 515 (Three Bond #1215)
Installing is done in the reverse order of removing
Fill inside from motor drain port to casing with hydraulic oil before piping for drain
33.1.18.5 PREPARATION FOR DRIVE

(1) Before starting operation, check that gear oil (#90 grade GL-4) level of swing reduction is sufficient.
Amount of charge : 1.5 L (0.40 gal)
(2) When starting operation, operate motor in low idling and at low speed for several minutes, and check it for pos-
sible oil leakage and noise.
(3) Confirm proper functions.
33-40
33.1.19 SWIVEL JOINT
33.1.19.1 PREPARATION FOR REMOVE

(1) Remove attachment assy 17 24 16-1
(Refer to 3. ATTACHMENT DIMENSIONS)
(2) Remove cab (See 33.1.1 CAB)
(3) Remove guard (See 33.1.6 GUARD)
(4) Removing hoses on undercarriage SWIVEL
JOINT A
(See Chapter : Undercarriage) C
(5) Remove swing reduction unit if necessary. D
B
(See 33.2.5 SWING MOTOR UNIT) A
B
16-2
SWING MOTOR
Fig. 33-75 Removing piping
33.1.19.2 REMOVAL
(1) Remove travel motor hose C3
1) Remove hose (24). (D port) CAPSCREW
2) Remove hose (16-1). (A port) C5 M16

3) Remove hose (17). (C port) T=157 N·m
(120 lbf·ft)
4) Remove hose (16-2). (B port)
(2) Disconnect drain hose from pipe (6).
(3) Disconnect 2-speed travel hose from joint 1. Fig. 33-76 Removing whirl-stop nut & the capscrew
(4) Remove dozer hose. (OPT) (Port F, G)
CAPSCREW B4
(5) Remove whirl-stop of swivel joint. M8 X 25
T=9 N·m
1) Loosen the nut (C5) M16. B7 (6.5 lbf·ft)
2) Remove a capscrew (C3) M16  90. PLATE B2
: 24 mm
(6) Remove joint for piping DUST COVER B1
1) Remove three elbows (3).

2) Remove tube (7). Fig. 33-77 Removing dust cover (B1)
3) Remove connector for travel 2-speed change 6 T=105 N·m (80 lbf·ft)
over (1).
7 3 H
: 27 mm, 19 mm
˚
60
A
15˚
4) Remove plug (10) if attached. (Machine not

20˚
C
equipped with dozer) D
D B
H G F
: 22 mm
10˚
F
G
(7) Remove dust cover (1) 1
T=36 N·m 10
T=74 N·m B
1) Remove four capscrews (4) M8  25. (27 lbf·ft)
(54 lbf·ft)
2) Remove plate (B2). VIEW I
3) Remove dust cover (B1). Fig. 33-78 Removing joint for piping
: 13 mm
33-41
(8) Remove socket bolt for installation

Attach eye bolt on pipe (6), lift it up temporarily, and
remove three (3) socket bolts (2) M8  20.
BALL POINT
ALLEN KEY
WRENCH
2
SOCKET BOLT
M8 x 20
Loctite #262
T=35 N·m
(26 lbf·ft) 1
SWIVEL JOINT
Fig. 33-79 Removing socket bolt for installation

(9) Slinging the swivel joint
Weight : Approx. 21kg (46 lbs)
Fig. 33-80 Slinging swivel joint
33-42
Piping tightening torque
Thread dia. Tool Tightening torque

PF HEX O-ring type Hydraulic hose
36 N·m 29 N·m
1/4 19
(27 lbf·ft) (22 lbf·ft)
74 N·m 49 N·m
3/8 22
108 N·m 79 N·m
1/2 27
(2) Check for oil leakage and the hydraulic oil level.
(3) Check for operating.
33-43
33.1.20 UPPER FRAME

(1) Remove attachment
(Refer to 3. ATTACHMENT DIMENSIONS)
(2) Remove cab (See 33.1.1 CAB) WIRE ROPE
(3) Remove guard (See 33.1.6 GUARD) 16 X2.5 m
(0.630")
(4) Remove counterweight (8 ft 2 in)
(See 33.1.5 COUNTERWEIGHT) CHAIN BLOCK
(5) Remove swivel joint.

(Perform the steps (1) thru (7) of 33.1.19 SWIVEL
JOINT)
LIFTING JIG No.12 FOR UPPER SWING BODY

Fig. 33-81 Temporarily lift upper frame
33.1.20.2 REMOVAL
(1) Lifting up upper frame temporarily
MATCH
Hook upper structure sling tools to boom foot rear MARK
hole and position two chain blocks on boom foot
side, and raise it up temporarily at three points.
Wire rope : ø16 (0.630")  2.5 m (8 ft 2 in),1 pcs.
ø16 (0.630")  1.5 m (4 ft 11 in),2 pcs.
Chain block : 750 kg (1650 lbs) 2 pcs.
(2) Marking match marks on swing bearing Mark
match marks on upper frame and swing bearing.
Fig. 33-82 Matching mark on swing bearing and up-
per frame
(3) Removing upper frame mounting bolts
Remove twenty capscrews M16  90 and three
reamer bolts used to install swing bearing and up-
per frame.
: 24 mm
(4) Slinging upper frame
Sling according to Fig. 33-81, and remove upper
frame and put it on a stand resistant to the weight.
Weight : Approx. 1,500 kg (3310 lbs)
Fig. 33-83 Removing upper frame mounting bolts
33-44
(1) Installing is done in the reverse order of removing. Apply Loctite #515 or equivalent torace
(2) Cleaning mating surfaces of upper frame and swing surface of the inside of capscrew to only
perimeter specified by slanting line.
bearing.
(3) Applying Loctite #515 on mating surface.
(4) Slinging upper frame
Match marks and install it with three reamer bolts
temporarily.
Fig. 33-84 Bearing mount

Confirm the reamer bolt positions referring to Fig. 33- OUTER S ZONE POSITION
85.
12
: 24 mm Apply Loctite #262

(5) Install swing bearing
Install twenty capscrews (5) M16 X 90.
: 24 mm Apply Loctite #262

Fig. 33-85 Reamer bolt position (*)

Apply Loctite on section specified by slanting lines
33-45

33.2.1 HYDRAULIC PUMP • REGULATOR
33.2.1.1 STRUCTURAL EXPLODED VIEW
33-46
Table 33-1
* : Apply loctite #222
torque No. Name Q’ty torque No. Name Q’ty
111 SHAFT 1 624 SPRING SEAT 1
114 COUPLING 1 625 SPRING 1
115 COLLAR 1 626 SPRING 1
123 ROLLER BEARING 1 627 ADJUST STEM (E1) 1
124 NEEDLE BEARING 1 157 (120) 630 LOCK NUT : M30 1
127 SPACER 1 641 SPRING COVER 1
141 CYLINDER BLOCK 1 651 SLEEVE 1
151 PISTON 10 652 SPOOL 1
152 SHOE 10 653 PIN 1
153 PLATE 1 654 PIN 1
156 SPHERICAL BUSHING 1 655 PIN (Pf PISTON) 1
157 SPRING 10 656 PIN 1
212 SWASH PLATE 1 660 ADJUST SCRW (R) 1
214 BUSHING 1 29.4 (22) 661 LOCK NUT : M14  1.5 1
215 PIVOT BALL 1 662 SPRING SEAT 1
216 PIVOT BALL 1 663 SPRING 1
271 CASING 1 664 POPPET 1
273 COVER 1 665 SEAT (R) 1
312 VALVE COVER 1 666 ADJUST SCREW (E) 1
313 VALVE PLATE 1 667 ADJUST STEM (E2) 1
235 (170) 401 SOCKET BOLT : M16  40 4 668 PISTON (E) 1
29.4 (22) 402 FLANGE SOCKET BOLT ; M8  16 2 700 O-RING : 1B G35 1
235 (170) 403 SOCKET BOLT : M16  70 1 701 O-RING : 1B G55 1
11.8 (8.7) 404 SOCKET BOLT : M6  20 9 702 O-RING : 1B G135 1
108 (80) 467 DRAIN PLUG : PF 1/2 1 705 O-RING : 1B P16 2
36.3 (27) 468 PLUG : PF1/4 1 706 O-RING : 1B P11 7
8.8 (6.5) 490 PLUG : NPTF1/16, Meck coated 14 707 O-RING : 1B P18 1
98.1 (72) 492 PLUG : PT1/8, Meck coated 1 708 O-RING 1
44 (33) 493 PLUG : PT3/8 1 709 O-RING : 1B P26 1
710 O-RING 1
8.8 (6.5) 508 ORIFICE THREAD : NPTF1/16 4 751 GASKET 1
98.1 (72) 531 TILTING PIN : M16  1.5 1 774 OIL SEAL* 1
98.1 (72) 532 SERVO PISTON : M16  1.5 1 787 BACKUP RING 1
534 SET SCREW : M27  1.5 1 789 BACKUP RING 2
535 STOPPER 1 15.7 (12) 801 LOCK NUT : M8 1
541 SEAT 2 127 (94) 803 LOCK NUT : M27  1.5 1
543 STOPPER 2 824 SNAP RING 1
545 BALL 2 825 SNAP RING 1
548 FEED BACK PIN 1 885 SPRING PIN 2
611 FEED BACK LEVER 1 901 EYE BOLT : M8 1
621 COMPENSATION PISTON 1
Bold No. shows adjusting screw and nut. Don’t touch these parts. Turning these parts causes losing of proper ad-
justment.
33-47
33.2.1.2 REMOVAL AND INSTALLATION

(1) Tools
Tool name Dimension
The following list shows the tools required for re-
Allen wrench Opposing flats 4, 5, 6, 8, 10, 14 mm
move and install.
Eye wrench
(2) General precautions for remove Socket wrench Opposing flats 27 mm
Wrench with double
1) Work in clean area. heads (single head)
2) Spread rubber sheet or cloth on work bench to Adjust wrench Medium size 1 pc.
protect parts from damaging. Screw driver Flat-bladed screw driver 1 pc.
3) Remove dust and rust, etc. on pump surface with Hammer Plastic mallet 1 pc.
wash oil. Plier For snap ring TSR-160
Steel bar for key
Steel bar Approx. 10 X 8 x 200
• Following explanations and illustrations describe
(0.40" X 0.31 X 0.79")
the Hydraulic pump, which doesn't equip the
One that may be fastened to
power up port. Assembly and disassembly of Torque wrench
specified torque
power up port is described later.
(3) Removal GEAR PUMP

1) Letting oil out
Remove drain plug (467) and let oil out of casing 402
(271).
312
: 27 mm
2) Remove coupling (114)
Remove socket bolts (402) used to fasten valve
cover (312) and gear pump, remove gear pump,
and remove coupling (114) from inside of valve
cover (312).
: 6 mm
3) Remove valve cover (312) Fig. 33-86 Remove coupling (114)
Remove socket bolt (401) used to fasten valve
cover (312) and casing (271). 401
: 14 mm 271
312
Fig. 33-87 Remove socket bolt (401)
33-48
2. Remove valve cover (312) from casing (271).

271
312
Fig. 33-88 Remove valve cover (312)

4) Remove valve plate (313)
Remove valve plate (313) from inside of casing
(271). 271
313
Fig. 33-89 Remove valve plate (313)

5) Remove cylinder assy and swash plate (212)
Remove cylinder block (141), piston (151), plate 271
(153), spherical bushing (157) and swash plate
(212) from casing (271). 212 151
• Also, special attention must be paid not to
damage sliding surface of cylinder block
(141), spherical bushing (156), shoe (152),
swash plate (212), etc.
153 141 (156, 157)

Fig. 33-90 Remove cylinder assy and swash plate
(212)
6) Remove pivot ball (215), (216)
Remove pivot ball (215), (216) from casing 271
(271).
215
216
Fig. 33-91 Remove pivot ball (215), (216)
33-49
7) Remove shaft (111)

Remove snap ring (825) from casing (271) and
remove shaft (111) striking shaft end with plastic 271
hammer.
• Then, special attention must be paid not to
damage oil seal (774) fitted on casing (271). 111
(825)
Fig. 33-92 Remove shaft (111)

8) Remove spring (625), (626) and spring seat
(624)
641 (624, 625, 626)
Remove socket bolt (404), then remove spring
cover (641), spring (625) spring (626) and spring
seat (624).
: 5 mm
• Never loosen lock nuts (630), (801) of spring cover

(641). If loosened, the set value of regulator may be
changed.
Fig. 33-93 Remove spring (625),(626) and spring
• The regulator is made up of small precision parts,
seat (624)
so care should be taken not to lose and damage
any of them when remove and install.
9) Remove feed back lever (611)

Remove socket bolt (404) and cover (273). Then 611
remove feed back lever (611) from casing (271).
: 5 mm
271
Fig. 33-94 Remove feed back lever (611)
33-50
10) Remove spool sub assy and compensation pis-

ton (621)
651 (621),(652)
Remove sleeve (651), spool (652), and compen-
sation piston (621).
Fig. 33-95 Remove spool sub assy and compensa-

tion piston (621)
11) Remove pin (655)
Remove plug (468), then remove pin (655).
468 (655)
: 6 mm
12) Remove servo piston sub assy
Since the set screw (534) installed on servo pis-
ton sub-assy is screw used to regulate flow rate
of regulator, it should not be removal if not re-
quired.
If required to removal, remove set screw (534)
with lock nut (803), stopper (535), servo piston
(532) and tilt pin (531).
: 19 mm, : 41 mm
Fig. 33-96 Remove pin (655)

• Lock nut (803) and set screw (534) are not allowed
to be removal unnecessarily. A set flow rate chang- 271 531 532 535 803
es.
534
• Since servo piston (532) and tilt pin (531) are ap-
plied Three Bond, it is not allowed to removal them.
• Care must be taken not to damage servo piston fix-
ing tilt pin when remove.
Fig. 33-97 Remove servo piston sub assy
33-51
13) Remove valve cover (312) 661

660
If necessary, remove relief valve lock nut (661), 705
adjusting screw (660), spring seat (662), spring 662
663
(663), poppet (664), seat (665) and needle bear- 664
CHECK VALVE SUB 665
ing (124). RELIEF VALVE
541
: 22 mm 545 706
543
508
• Relief valve are not allowed to be removal 706
508
unnecessarily. A set pressure relief rate 508
706
changes. 508
706
• Strictly prohibited to pull out needle bearing 541
545
other than when the life time is exceeded. 543
14) Remove check valve sub and orifice thread 271 124
(508)
Remove check valve sub (541), (543), (545) and 312
orifice thread (508) from casing (271)
: 4 mm
• Use wrench taking care not to damage orifice
thread (508) when remove.
Fig. 33-98 Remove valve cover (312), and remove

check valve sub-assy and orifice thread (508).
15) Power up port (Pz port)
a. Pull pistion of power up using M4 thread. Put a
match mark on set position of lock nut etc. for
convenience of reassembly.
b. Lossen hexagon nut (803). This nut is tightened

by torque 98N•m (72lbf•ft).
33-52
c. Loosen adjusting stem E2 (667).
d. This completes the disassembly of power up

port. And after pump assembling, assemble
power up port in the reverse order of disassem-
bling.
(4) General precautions to be exercised in installation

Installation is basically the reverse order of remov-
al, but exercise care of the following.
1) Repair scored parts at disassembly, Get replace-
ment ready beforehand.
2) Clean every parts with wash oil, and dry them
before attaching.
3) Do not forget to coat the sliding areas and bear-
ings with clean hydraulic oil.
4) In principle, replace sealing parts such as O-
rings, oil seals, and gasket.
5) Tighten bolt and plugs to specified torques in
Service Standard, using a torque wrench.
(5) Install 271 531 532 535 803
1) Installing servo piston sub assy 534
When lock nut (803), set screw (534), stopper
(535), servo piston (532) and tilt pin (531) have
been removed, attach those parts on casing
(271) first.
Fig. 33-99 Installing servo piston sub assy
• Fasten servo piston (532) and tilt pin (531) stopping

tilt pin. And apply Three Bond #1303B on threaded
section.
: 14 mm
• After tightening, check that servo piston (532)
moves smoothly.
33-53
2) Installing drain plug (467)

Attach drain plug (467) and O-ring (707) first on
casing (271).
: 27 mm 707
Tightening torque : 108 N•m (80 lbf•ft) 467
Fig. 33-100 Installing drain plug (467)

3) Installing shaft (111)
Set shaft (111) on which bearing (123), spacer
(127) and snap ring (824) are fitted on casing
111
(271), and fit snap ring (825) on it.
123(127,824)
271
• Insert shaft (111) completely striking outer race of
bearing (123) with plastic hammer using steel bar.
Be careful not to strike shaft (111) with plastic ham-
mer.
• Fit shaft taking care not to damage oil seal (774).
Fig. 33-101 Installing shaft (111)

4) Assembling pivot ball (215), (216)
Fit pivot ball (215) on right side and pivot ball
215
(216) on left side directing top cover installing
216
surface of casing (271) upward.
• Diameter of pivot ball (215) is smaller, and
271
equipped with O-ring (710) and backup ring
(787).
Fig. 33-102 Assembling pivot ball (215), (216)

5) Installing swash plate (212)
Fit tilt bushing (214) to tilt pin (531) top end and
install the swash plate (212) on casing (271).
• Before installing swash plate (212), apply 212
214
grease on the surface where pivot balls
(215), (216) side.
271
Fig. 33-103 Installing swash plate (212)
33-54
6) Installing pin (655) 655

Fit pin (655) on casing (271) and attach plug 271
(468) with O-ring (706).
: 6 mm
Fig. 33-104 Installing pin (655)

7) Assembling compensation piston (621)
Install compensation piston (621) on casing 621
(271).
271
Fig. 33-105 Assembling compensation piston (621)

8) Assembling sleeve (651) and spool (652)
Install sleeve (651) and spool (652) on casing
(271). 271
651
(652)
Fig. 33-106 Assembling sleeve (651) and spool

(652)
9) Installing feed back lever (611) and cover (273)
Install feed back lever (611) to tilt pin (531), in-
611
stall cover (273) aligning with pin and tighten
socket bolt (404).
: 5 mm
271
Fig. 33-107 Installing feed back lever (611) and cov-

er (273)
33-55
10) Installing spring cover (641)

Install spring (625), spring (626) and spring seat
(624), and install spring cover (641) on casing
271
(271) with socket bolt (404). 641
(624,625,626)
: 5 mm
Fig. 33-108 Installing spring cover (641)

11) Installing piston cylinder sub assy
Assemble cylinder assy [cylinder block (141), 271
piston (151), shoe (152) plate (153), spherical
151,152
bushing (156) and spring (157),] and install it on
casing (271) meeting the spline phases of spher-
ical bushing (156) and cylinder block (141).
12) Installing needle bearing (124) and relief valve
When needle bearing (124) and relief valve have
been removed, attach those parts on valve cover
(312) first. 153 141
(156,157)
13) Installing check valve sub and orifice thread
Fig. 33-109 Installing piston cylinder sub assy
(508)
When check valve sub assy [seat (541), stopper
(543), ball (545)] and two orifice threads (508)
have removed, attach those parts on casing
(271) and valve cover (312) first.
14) Installing valve cover (312)
Install valve equipped with valve plate (313) on
casing (271) and tighten socket bolt (401). 401
271
: 14 mm
• Then, apply grease on installing surface of
valve cover (312) and valve plate (313) to
protect it from slipping out.
312
(313)
Fig. 33-110 Installing valve cover (312)

15) Installing gear pump
Set coupling (114) from rear side of pump to the
inside, install gear pump, and tighten flange
socket bolt (402).
: 6 mm
Tightening torque : 29.4 N•m (22 lbf•ft)
402
Fig. 33-111 Installing gear pump
33-56
33.2.1.3 MAINTENANCE STANDARD

(1) Replacement standards for parts
Recommended
Standard
Part name and inspection item value for Remedy
dimension
replacement
Clearance between piston

0.036 0.056
(151) and cylinder (141) d D Replace piston or cylinder.
(0.0014") (0.0022")
bore (D-d)
Gap between piston (151)

0~0.1 0.3
and caulked part of shoe Replace piston shoe assy.
(0.004") (0.012")
(152) ( )
3.9 3.7
Thickness of shoe (152) (t) Replace piston shoe assy.
t (0.154") (0.146")
Free height of spring (157) 31.0 29.9

Replace spring.
(L) (1.22") (1.14")
L
Combined height of plate

19.0 18.3 Replace or spherical
(153) and spherical bush-
h H (0.748") (0.720") bushing and plate.
ing (156) (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
Cylincer (sliding section) Standard surface roughness
Less than 0.4Z (lapping)
Roughness of each surface (correction value)
33-57
33-58

For part names and marks used in this explanation, refer to Section "Construction of Control valve" explained in
Chapter "Equipment System" in attached sheet.
33.2.2.1 PREPARATION FOR CONSTRUCTION

(1) General precautions
The disassembling and assembling should be performed in shop as a rule. If it is unavoidably necessary to dis-
assemble, it must be carried out by authorized personnel following the precautions described below.
1) Place
The hydraulic equipment is machined in precision, and space in each section is very narrow. So select clean
place and be careful so that dust, sand, etc. are not entered inside when disassembling and assembling.
2) Preliminary investigation
Before disassembling, understand the construction and operation of control valve thoroughly.
3) Cleaning
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 control valve assy.
Use an appropriate workbench. Lay a clean sheet of paper, rubber mat, or the like over the workbench.
4) Rust prevention and sealing
After disassembling, apply rust preventives on all parts or seal to protect them from rusting.
5) Transportation
In case control valve is required to carry or transport, it is prohibited to support control valve by applying sup-
port to pilot cover section, relief valve and overload relief valve.
6) Handling
Even if movement of control valve parts is not smooth, never strike it or handle forcibly.
7) Hydraulic testing device
After completion of assembly, various tests (relief characteristic, leak test, overload pressure setting, perfor-
mance test, etc.) are required. Hydraulic testing device is therefore required. But it is not allowed to disas-
semble equipment which can be disassembled mechanically, but can not be adjusted through test.
(2) Tools (Excluding general tools.)
Prepare the following tools before disassembling the control valve.
Table 33-2
No. Tool name Q’ty Remarks
a Vise 1
b Mouth plate 2 For vise (Copper plate)
c 1 of each size 4, 5, 8, 10, 12 mm
d 1 of each 19, 21, 22, 30 mm
e 1 of each 13,19, 21, 22, 30 mm
f Tweezers 1
g Magnet 1
h Torque wrench 1 For 0~69 N•m (0~51 lbf•ft)
i Others Proper Q’ty Wash oil, hydraulic oil,grease, tag, oil marking ink, etc.
33-59
(3) Placing on work bench

Place it on work bench directing swing priority section upward.
Swing priority section
X X
Z
Y Y
Work bench
TRAVEL Top of machine

STRAIGHT
A A
SPOOL
TRAVEL(L) B B
SPOOL
SWING C C
SPOOL
ARM D D
SPOOL
E E
BOOM CONFLUX P2 BY-PASS

SPOOL CUT SPOOL
SECTION XX (Back of machine)
Top of machine
TRAVEL(R)
B B
SPOOL
BOOM
C C
SPOOL
BUCKET D D
SPOOL
P1 BY-PASS E E
CUT SPOOL
SECTION YY (Front of machine)
Fig. 33-112 Placing on work bench and cross-section
33-60
33.2.2.2 DISASSEMBLY
(1) Pulling out travel straight spool (7), travel right and SWING PRIORITY SECTION PILOT COVER D (16) FOR ARM
left spool (8), swing spool (9) and bucket spool (12). BOOM TRAVEL (L)
CONFLUX SPOOL (8)
(Spool without lock valve) SPOOL(13) SWING TRAVEL
(REVERSE SIDE) SPOOL (9) STRAIGHT
(See Fig. 33-113, Fig. 33-114.) SPOOL (7)
1) Remove two socket bolts (47) of each spool,

then washer (49) and pilot cover C (18).
(See Fig. 33-114)
: 5 mm
• Then, special care must be taken that O-ring (52) of P1 BY-PASS PILOT COVER TRAVEL (R)
pilot cover C (18) does not slip out. CUT SPOOL (15) D (16) FOR BOOM SPOOL (8)
BUCKET SPOOL (12)
VIEW Z of Fig.2-1
2) Hold each spool with spring (26) section, pull it
out slowly in parallel to spool hole, and remove Fig. 33-113 Position of spool without lock valve
spool assy from body (1).
• Don't disassemble spool assy. If it is damaged, re-

place it.
• When two types of spool have been removed, at-
tach tag and record the position before disassem-
bling.
(2) Pulling out P2 by-pass cut spool (14), P1 by-pass SOCKET

TRAVEL SPOOL RIGHT (8) O-RING (52) BOLT (47)
cut spool (15) and boom conflux spool (13).
TRAVEL SPOOL LEFT (8) SPRING (26)
(Spool without lock valve.)
(See Fig. 33-113, Fig. 33-115.)
1) Remove two socket bolts (47) of each spool,
then washer (49) and pilot cover C (18).
(See Fig. 33-115) PILOT
COVER C (18)
: 5 mm
Fig. 33-114 Pulling out travel right and left spool
(section BB)
• Then, special care must be taken that O-ring (52) of
pilot cover C (18) does not slip out.
33-61
2) Hold each spool with spring (26) section, pull it P2 BY-PASS

out slowly in parallel to spool hole, and remove CUT SPOOL (14)
BOOM CONFIUX O-RING (52)
spool assy from body (1). SPOOL (13) SOCKET
BOLT (47)
3) Pull out boom conflux spool (13) in the reverse PILOT
COVER C (18)
direction.
• Don't disassemble spool assy. If it is damaged, re-

place it.
• When two types of spool have been removed, at- P1 BY-PASS CUT SPOOL (15)
tach tag and record the position before disassem-
Fig. 33-115 Pulling out P2 by-pass cut spool, P1 by-
bling.
pass cut spool and boom conflux spool (section
EE)
(3) Pulling out boom spool (10). BOOM SPOOL (10) SPRING (26)
(Spool with lock valve.) (See Fig. 33-116.) PILOT COVER D (16)
1) Remove three (3) socket bolts (48). PISTON A (34)
: 5 mm
2) Remove pilot cover D (16). Since pilot cover D is SOCKET BOLT (48)
equipped with piston guide (33), piston A (34), pi- O-RING
ton C (36), and lock valve spring A (35), remove (52)
as equipped-pilot cover D. O-RING PISTON C (36)

(59)
POPPET (29) PISTON LOCK VALVE
O-RING (53) GUIDE (33) SPRING A (35)
Fig. 33-116 Example of pulling out boom spool
• Special care must be taken that O-rings (52), (53), (section CC)
(59) on bottom of pilot cover D (16) and poppet (29)
do not slip out.
• Take care not to damage piston guide (33) protrud-
ed from the bottom of pilot cover D (16).
3) Spring section (26) of each spool is disposed, so

hold spool with the spring (26) section, pull it out
slowly in parallel to spool hole, and remove spool
assy from body (1).
• Don't fail to pull spool assy out from spring side.

• If spool assy is damaged, don't disassemble it.
Replace it.
33-62
(4) Pulling out arm spool (11) (See Fig. 33-117.)

ARM SPOOL (11)
Same procedure as boom spool (10).
PILOT COVER D (16)
1) Remove three (3) socket bolts (48).
: 5 mm
2) Remove pilot cover D (16). Since pilot cover D is
equipped with piston guide (33), piston A (34),
piston C (36), and lock valve spring A (35), re-
move as equipped-pilot cover D.
Fig. 33-117 Pulling out arm spool

(5) Disassembling lock valve pilot cover D (16) PILOT COVER D (16)
(SeeFig. 33-118.) PISTON C (36)
O-RING (58)
1) Remove pilot cover D (16).
LOCK VALVE (28) PISTON A (34) PLUG (20)

RESTRICTOR (30),
Keep poppet (29) carefully because it is slipped out
easily.
( SPRING B (31),
SPRING HOLDER (32),
RETAINER RING (51)
)PISTON GUIDE (33)
POPPEET (29) SPRING A (35)
Fig. 33-118 Disassembling lock valve pilot cover D

2) Hold pilot cover D (16) with vise, and remove (16)
plug (20).
: 8 mm
• Don't hold on port surface with vise.

• Take care not to damage piston guide (33) project-
ed from the bottom of pilot cover D (16).
3) Take out piston C (36), spring A (35) and piston

A (34) with pin set or magnet through the plug
hole where it has been removed.
• Record the direction Piston C (36) has been in-

stalled.
• Don't disassemble piston guide C (33). If it is dam-
aged, replace a set of pilot cover D (16).
4) Take out a set of lock valve (28), restrictor (30),

spring B (31) spring holder (32) and retainer ring
(51) from control valve body with magnet.
Don't disassemble lock valve (28). If it is damaged, re-

place a set of lock valve body.
33-63
(6) Disassembling shuttle valve (See Fig. 33-119) SHUTTLE

VALVE STEEL SHUTTLE VALVE
1) Remove two places socket bolts (47). SOCKET (37) BALL (46) SEAL (38) O-RING (52)
: 5 mm
2) Remove pilot cover E (17).
Then, special care must be taken that O-ring (52) of pi-

lot cover E (17) does not slip out. SOCKET BOLT (47)
PILOT COVER E (17)

3) Fix pilot cover E (17) in a vise and remove shuttle
valve socket (37).
: 21 mm
Fig. 33-119 Disassembling shuttle valve
• When pilot cover E (17) is required to be held, don't

hold on port surface with vise.
• Don't disassemble shuttle valve socket (37). If it is
damaged, replace a set of shuttle valve socket (37),
shuttle valve seat (38) and steel ball (46).
(7) Disassembling swing priority section

(See Fig. 33-120.) SOCKET BOLT (74)
1) Remove two places socket bolts (74). PILOT

O-RING (71) COVER (66)
: 5 mm PILOT BODY (68)
2) Remove pilot cover F (66), spring (70), piston D PISTON GUIDE (69)
(67) and pilot body (68).

STOPPER PIN (65)
PISTON
SPRING (22) D (67)
LOAD
Then, special care must be taken that O-ring (71) and CHECK
VALVE (49)
piston D (67) of pilot caver F (66) does not slip out.
3) Take out stopper pin (65) with tweezers or mag-

net. SPRING (70)
4) Removing pin guide (69). O-RING (72)
: 13 mm O-RING (58)
5) Take out load check valve (49) and spring (22)

with tweezers or magnet.
Fig. 33-120 Disassembling swing priority section
33-64
(8) Disassembling load check valve (21)

O-RING (58)
(See Fig. 33-121.)
1) Hold control valve body and remove 10 plugs PLUG (20)
(20). LOAD CHECK VALVE (21)
SPRING (22)
: 8 mm
2) Take out load check valve (21) and spring (22)
with tweezers or magnet.
For load check valve (21) of arm switching section, dis-

assemble swing priority section first. [Refer to (7) Dis-
assembling swing priority section.]
LOAD CHECK VALVE (21) SPRING (22)

PLUG (20)
Fig. 33-121 Removing load check valve

(Example of section BB)
(9) Remove main relief valve (60) and over load relief
valve (61)
1) Hold control valve body and remove a main relief
valve (60). (See Fig. 33-122.)
Opposing flats 30
: 30 mm
2) Remove six places over load relief valves (61).
(See Fig. 33-123.)
MAIN RELIEF
: 22 mm VALVE (60)
Fig. 33-122 Removing main relief valve (section AA)
Opposing flats 22
• Remove main relief valve (60) and overload relief
valve (61) taking care not to apply tools on hexago-
nal section in opposing flats 19 mm. OVER LOAD
RELIEF
• Attach tag on removed overload relief valve (61), VALVE (61)
and record the position before disassembling.

• Handle the removed main relief valve and overload
relief valve taking care not to damage on the seat. OVER LOAD
RELIEF VALVE (61)
• Main relief valve and overload relief valve are very
Fig. 33-123 Removing over load relief valve (Exam-
essential for safety operation, and also readjust-
ple of section CC)
ment of pressure is very difficult, so don't disassem-
ble them. If damaged, replace the assy.
33-65
(10)Remove end cover. (See Fig. 33-124.)

1) Hold control valve body (1) directing the end cov-
Mark on the O-RING (3) SOCKET BOLT (6)
er (5) upward, and mark between end cover (5)
surface.
and body (1) with marking ink. END COVER (5)
2) Remove four socket bolts (6). O-RING (2)

O-RING (3)
: 10 mm
3) Remove end cover (5).
• Remove end cover taking care so that O-rings (2),

(3) on mating surface are not slipped out.
• Handle it taking care not to cause damage, such as
flaws and dents, on mating surface.
(11)Removing other parts BODY (1)

In addition, remove pilot cover B1 (19), plugs (41),
(43), (45), (50), (62), (64) and (73), backup ring
(75), etc. as required. Fig. 33-124 Removing end cover
33.2.2.3 ASSEMBLY
Here, only the assembly procedures are described.
Regarding drawings, refer to the disassembly procedures.
(1) Precautions on installing
1) Cleaning the parts
Before using parts for assembly, clean all of them with clean cleaning oil.
2) O-ring, seals
a. Confirm that O-ring and seals are free of forming defects or defects caused by poor handling.
b. Lubricate O-ring, seals and sealing surfaces with sufficient grease or hydraulic oil.
c. Fit O-ring taking care not to make a distortion. If it is distorted, it may cause oil leakage.
3) Handling
Even if sliding parts and engaging parts are not operated smoothly, never strike them and handle forcibly.
4) Preliminary preparation
Before assembling, prepare structural drawing and check number of parts to avoid mistakes and missing of
parts.
5) Tightening torque
Tighten socket bolts and screws in each section to the specified torque with torque wrench.
(2) Assembling end cover (See Fig. 33-124.)
1) Hold body (1) directing mating surface upward, and fit O-rings (2), (3).
• Check that mating surface is free from dust and O-ring is securely fitted on the groove.
• Don't apply hydraulic oil or grease on O-rings (2), (3) fitted on mating surface.
2) Install end cover (5) meeting positions marked when disassembling.

3) Tighten four socket bolts (6) to the specified torque.
: 10 mm
Tightening torque : 66.7~68.6 N•m (49~51 lbf•ft)
33-66
• Don't tighten four socket bolts (6) at a time, but tighten them evenly in order by separating in several
times.
• Check that body (1) and end cover (5) are fitted rightly.
(3) Assembling Main relief valve and over load relief valve (See Fig. 33-122, Fig. 33-123.)
1) Hold body (1), and tighten main relief valve (60) to the specified torque.
: 30 mm
2) Tighten six over load relief valve (61) to the specified torque.
: 22 mm
• Install over load relief valve (61) to the original position with reference to the tag attached when disas-
sembling.
• Install main relief valve (60) and overload relief valve (61) taking care not to apply tools on hexagonal
section in opposing flats 19 mm.
(4) Assembling ten load check valves

(See Fig. 33-121.)
1) Hold body (1) to the position where every load check valve (21) can be inserted, and install load check valve
(21) and spring (22).
2) Fit O-ring (58) on plug (20) and tighten it to the specified torque.
: 8 mm
(5) Assembling swing priority section (See Fig. 33-120.)
1) Hold body (1) directing swing priority section upward, an install load check valve (49) and spring (22).
2) Tighten pin guide (69) on which O-rings (58), (72) are installed to the specified torque.
: 13 mm
3) Insert stopper pin (65) into piston guide (69).
4) Insert pilot body (68) on piston guide (69) and fit O- ring (71) to the groove.
Insert pilot body (68) into piston guide (69) taking care not to damage O-ring (72).
5) Install piston (67) and spring (70) on pilot cover F (66), and tighten two socket bolts (74) together with wash-
ers (49) to the specified torque.
: 5 mm
Tightening torque : 9.8~10.8 N•m (7.2~8.0 lbf•ft)
Check that the O-ring is securely fitted on the groove.
33-67
(6) Assembling shuttle valve (See Fig. 33-119.)

1) Hold pilot cover E (17) on the side face other than the port surface with vise, tighten shuttle valve socket (37)
on which O-rings (55), (57) are fitted to the specified torque.
: 21 mm
Then, Tighten it slowly taking care not to damage O-rings (55), (57) of shuttle valve socket (37).
2) Fit O-ring (52) on faucet joint, install pilot cover E (17) on which shuttle valve socket (37) is installed on the
faucet joint of body (1).
Check that the O-ring is securely fitted on the faucet joint.
3) Tighten two socket bolts (47) together with washer (49) to the specified torque.
: 5 mm
(7) Assembling lock valve pilot caver D (See Fig. 33-118.)
1) Hold pilot cover D (16) on the side face other than the port surface with vise, insert piston A (34), spring A
(35) and piston C (36).
• Place the groove side face of piston C (36) into the piston A (34).
• Care should be taken not to damage piston guide (33) protruded from pilot cover D (16).
2) Tighten plug (20) on which O-ring (58) are installed to the specified torque.
: 8 mm
3) Hold body (1) on side face other than port surface with vise directing lock valve (28) upward, and insert a set
of lock valve (28) and needle valve [poppet (29)] into body (1).
(8) Assembling boom spool and arm spool (Spool with lock valve) (See Fig. 33-116,Fig. 33-117.)
1) Hold body (1) on side face other than port surface with vise in the condition where spool assy can be installed
through upper side, and insert boom spool assy and arm spool assy into body (1) paying attention to the
directions.
When it is hard to insert spools into body, insert it getting in and out slowly.
2) Install pilot cover D (16) on body (1) slowly meeting piston guide (33) protruded from the bottom with needle
valve [poppet (29)].
Then, check that O-rings (52), (53), (59) are securely fitted on the groove.
33-68
3) Tighten three socket bolts (48) together with washer (49) to the specified torque.
: 5 mm
(9) Assembling P2 by-pass cut spool, P1 by-pass cut spool and boom conflux spool (Spool without lock valve)
(See Fig. 33-115.)
1) Insert every spool assy into body (1) taking care the directions.
2) Fit pilot cover C (18) on faucet joint of body (1).
Then, check that O-ring (52) is securely fitted to the faucet joint.
3) Tighten two socket bolts (47) together with washer (49) to the specified torque.
: 5 mm
(10)Assembling travel straight spool, travel R/L spool, swing spool, and bucket spool
(Spool without lock valve) (See Fig. 33-114.)
1) Insert every spool assy into body (1) taking care the directions.
2) Fit pilot cover C (18) on faucet joint of body (1).
Then, check that O-ring (52) is securely fitted to the faucet joint.
3) Tighten two places socket bolts (47) together with washer (49) to the specified torque.
: 5 mm
(11)Installation of other parts
In addition, install all the removed parts such as pilot cover B1 (19), plugs (41), (43), (45), (50), (62), (64) and
(73), backup ring (75), etc.
33-69

INSPECTION OF COMPONENTS
Part name Inspection item Criterion and remedy

Body 1) Check scratches, rusting, corrosion. 1) If any of the following parts are damaged,
replace the component as a unit.
• Sliding part of spool, particularly the land,
to which holding pressure is applied.
• Part of seal pocket or flange through
which spool is inserted.
• Area of sealing part that is in contact with
O-ring.
• Seat of main relief valve, overload relief
valve and lock valve.
• Defects of other parts that seem to harm
normal function.
Spool 1) Check scratches, galling rusting, corro- 1) Replace if there are scratches (which can
sion. be caught by your nail) on the outer sur-
face.
2) Insert the spool in the body, and move it 2) If the spool does not move smoothly, re-
while turning it. pair or replace the spool.
Load check valve 1) Damage to the load check valve or the 1) Correct or replace if the seat is incom-
load check valve spring plete.
Spring and related parts 1) Check rust, corrosion, deformation, and 1) If damaged severely, replace.
breakage of the spring, spring seat, plug
and cover.
Spool seal and related 1) Check external oil leakage. 1) Replace.
parts
Main relief valve Over 1) Check rust and damage on outer surface. 1) Replace.
load relief valve 2) Inspect the contact face of the valve seat. 2) If damaged, replace.
33-70
(1) When you find a malfunction or a fault, inspect whether or not it comes from the control valve, pump, motor or
hydraulic circuits. For this purpose it is necessary to measure pilot pressure, pump discharge pressure and load
pressure. If any part of the control valve is removed and inspected, do it according to the above mentioned re-
moving and installing procedures.
(2) Dust is extremely harmful to hydraulic components.
Use care so as not to allow dust from intruding inside. Take dustproofing measures in case any part of the control
valve is to be removed.
(3) Handle the moving part prudently. If a flaw is detected, even a small flaw, remove it with oilstone, or replace it
with new one. After repair, clean it.
(4) Handle surfaces of O-rings so as not to score them as scoring will result in oil leakage.
Trouble Cause Remedy

1. ATT does not move. 1) Malfunctioning relief valve 1) Measure relief valve pressure
Slow to start up (or • Foreign matter between plunger and • Replace assy. *
poor power). seat. * • Replace assy. *
Slow response.
• Foreign matter between poppet and • Replace assy. *
seat. *
• Replace assy. *
• Sticking plunger. *
• Replace assy. *
• Broken or deformed spring. *
• Replace it and tighten lock nut to the spec-
• Clogged piston orifice. * ified torque.
• Loosened adjusting screw. • Disassemble and clean. If the flaw is se-
2) Foreign matter caught between body and vere, replace body and spool with new
spool or sticking. ones.
2. Excessive natural fall 1) Excessive clearance between control 1) Replace spool.
of cylinder under its body and spool. 2) Measure secondary pilot pressure.
own weight when 2) Spool is not completely in neutral position. • Remove and clean. If it is stuck, replace
spool is in neutral.
• Foreign matter between body and both the control body and the spool as
spool, or sticking spool. a pair.
• Broken or deformed spring. • Replace spring.
3) Malfunctioning over load relief valve. Re- 3) Measure over load relief valve pressure.
fer to item * above. Refer to item * above.
3. When extending 1) Malfunctioning load check valve. 1)
boom cylinder, at first • Foreign matter caught between load • Disassemble and clean. If the flaw is
it retracts. check valve and body. severe, replace body and load check
• Sticking load check valve. valve with new ones.
• Broken or deformed spring. • Disassemble and clean. If the flaw is
severe, replace body and load check
valve with new ones.
• Replace spring.
If such faults as those marked * should occur, always replace the relief valve assy.
33-71
33-72
33.2.3 PILOT VALVE (ATT)
APPLY GREASE 312

ON ROTATIONAL
PART OF THE
UNIVERSAL JOINT
302 301
501
APPLY GREASE
213 ON TOP
511
507 151
510
211
506
214
216
503 508
221
509
201
217
SECONDARY 101
PRESSURE PORT 2,4 PORT 1,3
ADJUSTING SHIMS
Fig. 33-125 Pilot valve (ATT)

Table 33-3
Item Thread size Tightening Torque Table
N•m (lbf•ft)
301 M14 47.1 (34.7)
302, 312 M14 68.6 (50.6)
Table 33-4
No. NAME Q’TY No. NAME Q’TY No. NAME Q’TY
101 CASING 1 217 WASHER 2 4 506 SPRING SEAT 2
151 PLATE 1 221 SPRING 4 507 SPRING SEAT 2
201 SPOOL 4 301 JOINT; M14 1 508 SPRING 2
211 PLUG 4 302 DISK 1 509 SPRING 2
213 SEAL 4 312 ADJUSTING NUT; M14 1 510 SPRING 4
214 O-RING; 1B P20 4 501 BELLOWS 1 511 PUSH ROD 4
216 SPRING SEAT 2 503 SPRING SEAT 2
33-73
33.2.3.2 DISASSEMBLY & ASSEMBLY

(1) Tools
No. Tool Name Remarks

15~100N m class
a Torque wrench
(10~75 )
b Screw driver ( ) W= 2 ~ 3, 4 ~ 5
c Screw driver ( )
d Wrench 22mm and 32mm
(2) Jig
Special jig : for disassembling and assembling the joint (301)
(See Fig. 33-126).
BUSHING
1. Material :
Ø29 (1.14 ) SCM415 N SECTION AA
Carburizing and Quenching
Ø26.5 (1.04 )
23.5 (0.925 )
(Opposing flats) 2. Material : S45C
A A
(0.512 )
13
Ø19 (0.748 )
69 (2.72 )
54 (2.13 )
50 (1.97 )
46 (1.81 )
25 (0.984 )
(0.669 )
Installing condition on joint

17
12 )
(0.5 3
R1
Ø23 (0.906 )
Ø27 (1.06 )
0.5 X 15˚
(0.0197 )
Ø31 (1.22 )
R
5.
8
15.5 6.5
(0
*1 and 2 are tight fitted. (0.256 )

.2
(0.61 ) R
12.5 (0.492 )
28
(0. 4.5 C0.5

17
)
7) (0.0197 )
(0.374 )
9.5
C0.5
11.6 (0.457 ) (0.0197 )
Ø16 Material :
(0.63 ) Detail of bushing SCM415 N
Sectional drawing of jig A Carburizing Hardening
Q'ty : 2
Fig. 33-126 Special jig
33.2.3.3 Disassembling procedure
33.2.3.3.1 General cautions for disassembly

(1) Since all the parts are very precisely manufactured, carefully handle them without causing collision with each
other or dropping.
(2) Perform the work carefully without hammering or using excessive force even if the part is sticking. Otherwise
burrs may be produced or the part is damaged, leading to oil leakage or performance deterioration.
(3) When leaving the parts in the disassembled condition, always take rust preventive and dust protective mea-
sures. Otherwise rust may be produced on the parts due to humidity or dust.
33-74
33.2.3.3.2 Disassembly
(1) Plug each port of pilot valve, and clean it with kero-
501
sine.
P port : PF1/4
1~4 and T port : PF3/8
(2) Fix pilot valve with vise via a protective plate (Almi-
num plate etc.), and remove boots (501).
Fig. 33-127 Removing boot (501)

(3) Remove adjusting nut (312) applying spanners to
adjusting nut (312) and circular plate (302).
: 22 mm, 32mm 312

302
Fig. 33-128 Adjusting nut (312) removal

(4) Remove circular plate (302).
: 32 mm 302
Fig. 33-129 Removing circular plate (302)
Fig. 33-130 Circular plate is removed
33-75
Fig. 33-131 Installing Jig A

(5) Turn joint (301) in counterclockwise with Jig A to re-
move. JIG A
Jig A : Refer to Fig. 33-126 Special jig on page, 33-
74.
301
: 24 mm
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 Fig. 33-132 Removing joint (301)
two fingers.
(6) Remove plate (151).

• When the force of return springs (221) are
strong, press plate to let it come up slowly.
151
Fig. 33-133 Removing plate (151)

• When the force of return springs (221) are weak,
plug is left in casing (101) due to sliding resis-
tance of O-ring (214).
Pull plug (211) out with a driver (–).
To prevent personel injury, plug (211) must be removed

slowly and evenly until the return spring (221) force is
211
completely released.
Fig. 33-134 Removing plug (211)
33-76
(7) Remove push rod (511), plug (211), pressure re-

ducing valve assy (spool), return springs (221) from
511
casing (101).
211
221
Record combination of port holes on casing and the

pulled out parts. The stroke differs according to direc- 101
tion.
Fig. 33-135 Removing push rod, plug, pressure re-

ducing valve and spring
(8) Push springs (508) in the range of that the move-
ment of spring seats (216), (503) and shift the seats
(216) in a side direction, and remove spools (201)
through the larger hole of seat.
201
Never push down spring seat (216) in 6 mm (0.236 in)

or more.
Fig. 33-136 Removing spool (201)

(9) Remove spool (201), spring seats (216), (503),
spring (508), (509) and washer (217). 201 217
Fig. 33-137 Disassembling pressure reducing valve

(10)Remove spring (*510), spring seat (*506), (*507)
from push rod (511). 214
510
The parts marked * may not be equipped depending on

valve type.
511
211
Fig. 33-138 Disassembling push rod
33-77
(11)Pull out push rod (511) from plug (211).

(12)Remove O-ring (214) from plug (211).
511
Fig. 33-139 Removing push rod (511)

(13)Remove inside seal (213) from plug (211) with
small driver.
213
Fig. 33-140 Removing seal (213)
33.2.3.4 Assembling procedures
33.2.3.4.1 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. 201
217
Fig. 33-141 Assembling pressure reducing valve
33-78
33.2.3.4.2 Assembly
(1) Fit washer 2 (217), springs (508), (509), spring
seats (216), (503) to spool (201).
(2) Push spring (508), (509) in the range of that the
movement of spring seats (216), (503) in a side di-
rection, and install spools (201) through the larger
hole of spring seat. (See Installing spools (201).)
Never push down spring seats (216) in 6 mm (0.236 in) 201

or more.
Fig. 33-142 Installing spools (201)

(3) Place spring (221) into ports 1,3 of casing (101),
221
and then install pressure reducing valve assy in it. 101
Place springs (221) into ports 2,4 and install it.
Install the removed respective assy into respective

holes.
PRESSURE REDUCING
VALVE ASSY
Fig. 33-143 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
PLUG (211) 213
SEAL (213)
O-RING (214)
PUSH ROD (511)

Apply hydrailic oil
For the assembling

direction of seal (213). Fig. 33-144 Installing O-ring (214) and seal (213)
33-79
(5) Insert push rod (511) in plug (211) and install spring
(*510) and spring seat (*506) to push rod (511) on *510
port 1,3 side.
And install spring seat (*507) to push rod on port
2,4 side.
The parts marked * may not be equipped depending on

valve type.
511
*506
211
Fig. 33-145 Assembling push rod, spring (510) and

seat (506)
(6) Fit plug (211) assy to casing (101).
1) When the force of spring (211) is weak, it stops 101
at the position where it is pushed in by the sliding
resistance of O-ring (214).
211
Fig. 33-146 Installing plug assy

2) When the force of spring (221) is strong, attach
plate (151) and press 4 push rods by hand at the
same time, and tighten joint (301) temporarily.
301
• 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. 33-147 Installing plug assy and plate (151)

(7) Install joint (301) on casing (101) with jig A securely.
Jig A : Refer to Fig. 33-126 Special jig on page, 33-
74.
Tightening torque : 47±3 N•m (35±2.2 lbf•ft)
101
JIG A
Fig. 33-148 Installing joint (301)
33-80
(8) Install circular plate (302) to joint (301)
• Screw it in until it comes in contact with 4 push 312

rods (511) equally.
• The exceeding of screw in may cause malfunc- 302
tion of machine.
(9) Screw adjusting nut (312) in until it touches circular

plate (302), and tighten it applying spanner to stop
circular plate returning.
Fig. 33-149 Installing circular plate (302)
: 32 mm
: 22 mm
• Apply Loctite #277 to threads of joint.
Tightening torque : 69±5 N•m (51±3.6 lbf•ft)
GREASE
(10)Apply heat-resisting grease to joint (301) rotating
section and the top of push rod (511).
(11)Cover it with boots.
(12)Spray rust preventives through each port and at- 301
tach plug respectively.
511
Fig. 33-150 Applying grease to joint section and
push rod
33-81
33.2.3.5 Maintenance standard
Maintenance item Standard Remarks

Amount of leakage Replace with a complete set of pilot valve when Condition :
the amount of leakage reaches more than 1000 Primary pressure : 2.94MPa (427 psi)
cc/min (61 cu•in/min) or 2000 cc/min (122 cu•in/ Oil viscosity : 23 mm2/s
min) at the neutral position of the handle or dur-
ing operation, respectively.
Spool Replace with a complete set of pilot valve when The wear condition to the left is con-
an amount of wear at the sliding section is more sidered to correspond to the above
than 10 m (0.0004") in comparison with the amount of leakage.
non-sliding section.
Push rod Replace when a wear amount of the tip is more than 1 mm (0.04").
Unnecessary play in Replace when a play more than 2 mm(0.079") A play generated by loosening of tight-
operation section due to wear and so on is found on the disk (302) ening portion should be adjusted.
or joint section (301) of the operation section.
Action stability Replace with a complete set of pilot valve when
abnormal noise, hunting or primary pressure
drop is generated during operation and the trou-
ble cannot be remedied according to Section
33.2.3.6 TROUBLESHOOTING.
Replace seal such as O-ring with new ones after every disassembly.
Phenomenon Possible Cause Corrective action

Secondary pressure 1) Primary pressure is insufficient. 1) Secure primary pressure.
does not rise. 2) Springs (241-1, 241-2) are broken or 2) Replace with new ones.
fatigued.
3) Clearance between spool (201-1, 201- 3) Replace assembly.
2) and valve body (101) is abnormally
large.
4) Play of handle portion is too much. 4) Disassembly and reassembly or re-
place handle portion.
Secondary pressure is 1) Sliding parts are caught. 1) Correct.
unstable. 2) Tank line pressure varies. 2) Return directly to oil tank.
3) Air has contained into pipeline. 3) Release air.
Secondary pressure is 1) Tank line pressure is high. 1) Return directly to oil tank.
high. 2) Sliding parts are caught. 2) Correct.
33-82
33.2.4 PILOT VALVE (TRAVEL)
Fig. 33-151 Pilot valve (Travel)
Torque Torque
No. Name Q’ty No. Name Q’ty
101 CASING 1 29.4 (22) 251 RO PLUG 3
102 CASING (DAMPER) 1 6.9 (5.1) 252 PLUG 6
191 SEAT 1 2 253 RO PLUG 2
192 SEAT 2 2 261 O-RING 3
193 BUSHING 2 2 263 O-RING 2
194 STEEL BALL 2 8.8 (6.5) 271 SOCKET BOLT 4
201 COVER 2 301 SPOOL 4
202 PLUG 4 311 SPRING SEAT 4
203 GREASE CUP 4 313 WASHER 4
210 PACKING 4 324 SPRING 4
213 O-RING 2 413 CAM SHAFT 2
214 PUSH ROD 4 414 BUSHING 4
217 SHIM 4 420 CAM 2
218 SPRING SEAT 4 471 STEEL BALL 4
224 PISTON 4 6.9 (5.1) 472 SET SCREW 2
225 STEEL BALL 12 501 BELLOWS (BOOTS) 2
33-83
33.2.4.2 DISASSEMBLY AND ASSEMBLY

(1) Special jig for disassembly and assembly
Special jig 1(for removal of bushing)
(2) Precautions for disassembly and assembly
1) Disassemble and assemble the pilot valve paying attention to the rust protection fordust, dirt, etc. in order
not to allow them to enter in.
2) Handle parts carefully not to damage
3) Write down the installing positions of respective part during disassembly, and assemble respective part to
the position as they were before.
(3) Disassembly
1) Stop respective port (P, T, 1, 2, 3, 4, 5 and 6) of the valve with plugs and clean the outer surface.
2) Fix the cleaned valve with vise.
3) Remove bellows (501) from cover (201).
4) Remove set screw (472).
: 6 mm
5) Contact pry bar (ø7 or less) to one end of cam shaft (413), and strike it slightly with a hammer.
6) Remove cam (420).
7) Remove socket bolt (271).
: 6 mm
8) Remove cover (201).
9) Remove the casing upper assy, and fix the assy with vise, again.
10) Draw push rod (214) out of plug (202).
11) Remove plug (202) with grease cup (203), packing (210) and O-ring (212).
12) Remove piston (224).
13) Remove damping spring (336) from the casing.
14) Take out spring seat (218) from casing (102) with pincette.
15) Take out steel ball (225) using magnet.
16) Fix the lower casing assy with vise, and take out O-rings (211,213) from casing (101).
17) Remove reduction unit valve assy and return spring (335) from casing (101).
18) Place cover (201) on the flat bench transverse, apply bushing (414) to special jig 1, strike it lightly with ham-
mer, and draw the bushing out.
CENTERING HOLE IS ALLOWABLE

(SMALLER THAN Ø2 mm)
-0.0157")
(Ø0.3937" -0.0118"
-0.0118")
(Ø0.315" -0.008"
Ø10 -0.3
-0.4
Ø8 -0.2
-0.3
30˚
(0.787")
20 2 (0.008")
30
(1.181")
Fig. 33-152 Special jig 1
33-84
19) For disassembly of the reduction unit valve assy first push spring seat (311) in and shift the spring seat cross-
wise making secondary pressure spring (324), remove it from spool (301) passing through the large hole.
• Handle the assembled unit as a assy.
Fig. 33-153
20) Separate spool (301), spring (324) for secondary pressure setting, shim (217) and washer.
• Handle the assembled unit as a assy. And there may be unit on which washer is not installed.
21) Remove grease cup (203) from plug (202).
22) Remove O-ring (212) from plug (202).
(4) assembly
1) Clean all parts before assembly, and dry them by means of compressed air. Do not use rag.
• Repair the parts damaged when being disassembled, clean them, apply oil to the moving section, and
install the same parts on the positions where they are before.
• Replace every O-ring and packing with new ones.
2) Install washer (313), shim (217), spring (324) for resetting the secondary pressure, and spring seat on spool
(301) in order.
3) Pass spool (301) through the larger hole of spring seat (311), push the spring seat in , and install it making
the spring for the secondary pressure flex and shifting the spring seat crosswise.
4) Fix casing (101) with vise, and place spring (335) for return in casing (101).
5) Place the reduction unit subassy described in Articles 2) and 3) in casing (101).
• Install them on the positions as they were before.
• When placing the reduction unit subassy in, pay attention to the spool lower end so as not to bring into
contact with the corner of the casing.
Pay attention to the

corner of the casing
Fig. 33-154
6) Place O-rings (211,213) in casing (101).
7) Fix upper casing (102) with vise and place the steel ball in it.
33-85
8) Place spring seat (218) in casing (102) with tweezers.

9) Place damping spring (336) in casing (102).
10) Install piston (224).
11) Place O-ring (212) in plug (202).
12) Place packing (210) in plug (202).
• Pay attention to the direction when placing the packing in.
• Apply grease slightly before placing packing in.
Packing
Fig. 33-155
13) Place grease cup (203) in plug (202).
14) Install push rod (214) on plug (202).
15) Place the push rod subassy which is sub-assembled by the procedures in Articles 11) to 14) in casing (102).
16) Put cover (201) on the flat work bench, press bushing (414) with special jig 1, and press fit the bushing strik-
ing lightly.
17) Fix the lower cover assy which is assembled by the procedures in Articles 2) to 6) with vise, and install the
upper cover assy which is assembled by the procedures in Articles 7 to 15) on it.
18) Install cover (201) on casing (102).
19) Tighten socket bolt (271) to the specified torque.
20) Install cam (420) on cover (201).
21) Insert cam shaft (413) from the outside pressing cam (420).
22) Apply Loctite #241 or equivalent to the thread of socket bolt.
23) Tighten socket set bolt (472) to the specified torque.
24) Incline cam (420), apply grease to the top end of push rod (214), and fill grease cup (203) of plug (202) with
grease.
25) After fitting the top end of bellows (501) in cam (402), fit the lower side in the groove of cover (201).
33-86
33.2.4.3 CAUSE OF FAILURES AND CORRECTIVE ACTION
Phenomenon Causes Corrective action

Secondary pressure 1) Insufficient primary pressure 1) Secure primary pressure.
does not rise. 2) Permanent set of spring (324) for setting 2) Replace it with new one.
of secondary pressure
3) The gap between spool and casing is too 3) Replace it with complete remote control
large. valve.
4) The control section is loosened. 4) Replace parts of control section.
Secondary pressure is 1) Sliding part is not smooth. 1) Repair unsmooth section.
unstable. 2) Variation of pressure of tank line 2) Return oil to oil tank directly.
3) Air contamination in piping 3) Bleed air by operating several times.
Secondary pressure is 1) Pressure of tank line is high. 1) Return oil to oil tank directly.
high. 2) Sliding part is not smooth. 2) Repair unsmooth section.
Damping does not work. 1) Air is accumulated in piston chamber. 1) Bleed air by operating several times.
2) Sliding part is not smooth. 2) Repair unsmooth section.
3) Permanent set of damping spring (336) 3) Replace it with new one.
4) Gap between damping piston (224) and 4) Replace it with complete remote control
casing (damper) (102) is too large. valve.
5) Malfunction of check valve 5) Disassemble and check on check valve
section.
6) Orifice of damping piston (224) is too 6) Replace damping piston.
large.
Damping torque is 1) Sliding part is not smooth. 1) Repair unsmooth section.
heavy. 2) Orifice of damping piston (224) is 2) Repair or replace damping piston.
clogged.
33-87
33-88
33.2.5 SWING MOTOR UNIT
(1) Swing motor Composition
Slewing motor assy

34 36,37
33 35 38
Swash plate type Two-stage planetary
axial piston gear reduction unit
motor
Mechanical brake
Relief valve
Makeup valve
31
Bypass valve
30
39
100
13 70 14 16
15 17
11,12
10
18
9
8
7 19
6
20
5
21
4
22
3
23
40
24,25
26
1 28 27
Fig. 33-156 Swing motor
33-89
Torque Torque
No. Parts Q’ty No. Parts Q’ty
1 TAPERED ROLLER BEARING 1 22 RETURN PLATE 1
3 FRICTION PLATE 1 23 CAM PLATE 1
4 SEPARATOR PALATE 2 24 LEVEL GAUGE 1
5 SNAP SING 2 25 O-RING 1
6 NEEDLE BEARING 1 26 HOUSING 1
7 O-RING 1 27 COLLAR 1
8 O-RING 1 28 OIL SEAL 1
9 O-RING 1 30 BACK UP RING 2
10 BALANCE PLATE 1 31 O-RING : 1B P21 2
11 PISTON 1 33 BACK UP RING 2
12 TEFLON RING 2 34 O-RING : 1B P26 2
13 PLUG ; PT 1/4 2 35 PARALLEL PIN 2
14 BUSHING 2 36 PLUG : PF3/8 1
15 SCROLL WAVE 4 37 O-RING : 1B P14 1
16 TEFLON RING 4 38 SOCKET BOLT : M12  30 4
17 SPRING 4 39 COVER 1
18 PISTON 13 40 PLUG 1
19 CYLINDER 1 70 RELIEF VALVE ASSY 2
20 RETAINING SPRING 1 100 BY-BASS VALVE ASSY 2
21 PISTON ASSY 7
1) Relief & check valve assy (70)
71 72 76 77 78 79 80 81 82 No. Parts Q’ty No. Parts Q’ty

70 RELIEF & 2 82 SEAT 2
CHECK VALVE ASSY 83 POPPET 2
71 LOCK NUT 2 84 SPRING 2
72 CAP 2 85 O-RING 2
76 BACK UP RING 2 86 SHIM 2
77 O-RING ; 1B P26 2 87 PISTON 2
78 SPRING 2 88 SLEEVE 2
79 BUSHING 2 89 O-RING 2
90 89 88 87 85 86 84 83
80 CHECK SEAT 2 90 CAP 2
Detail view of relief & check valve assy 81 SLEEVE 2
2) By-pass valve assy (100)
101 102 103 104 105 106 107
No. PartsQ’ty No. Parts Q’ty

100 BY-PASS VALVE ASSY 2 106 O-RING : 1B P21 2
101 SEAT 2 107 BACK UP RING 2
103 POPPET 2 109 SPRING 2
104 BACK UP RING 2 110 POPPET 2
105 O-RING : 1B P14 2 111 SPRING 2
111 110 109 108

Detail view of by-pass valve assy (swing shockless valve)
33-90
(2) Swing reduction unit
12 13 14
11
10
16
9
17
18
8
15
19
7
20
6
1 21
22
27
23
4
26
3
2
1
25
24
Fig. 33-157 Swing reduction unit
Torque Torque
1 PINION SHAFT 1 15 HOLDER 2 ASSY 1
2 COLLAR 1 16 NEEDLE BEARING 6
3 PLATE 1 17 SHAFT 2 3
4 TAPER ROLLER BEARING 1 18 SPUR GEAR 5 3
5 GEAR CASE 1 19 THRUST PLATE 2 6
6 GREASE NIPPLE 1 20 SPRING PIN : 8  5 3
7 OIL SEAL 1 21 HOLDER 2 1
8 TAPER ROLLER BEARING 1 22 COLLAR 2
9 PIN 2 23 RELIEF NIPPLE 1
10 RING GEAR 1 24 CONNECTOR 1
11 SPUR GEAR 4 1 25 ELBOW 1
12 SUN GEAR 1 26 HOSE 1
13 HOLDER 1 ASSY 1 27 PLUG 1
14 SOCKET BOLT : M12  95 6
33-91
33.2.5.2 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR

(1) Disassembly 70
1) Remove the relief assy (70).
: 27 mm
2) Remove the by-pass valve (100).
: 8 mm
100
Install it in the original position.
Fig. 33-158 Removing relief valve assy and by-pass

valve
3) Apply match mark on cover (39) and housing
39
(26).
26
MATCHING
MARK
Fig. 33-159 Maching marks on cover and housing

4) Remove socket bolt (38). 39
: 10 mm
26
38
Fig. 33-160 Removing cover mounting bolts

5) Lift up and remove cover (39).
39
Fig. 33-161 Removing cover
33-92
6) Remove snap ring (5) with plier.

7) Remove inner race of needle bearing (6).
Fig. 33-162 Removing bearing (6) inner race

8) Remove the O-ring (9).
Fig. 33-163 Removing O-ring (9)

9) Remove the balance plate (10).
10
Fig. 33-164 Removing balance plate

10) Remove the bushing (14) with a teflon ring (16)
on it, and the scroll wave (15).
14
Fig. 33-165 Removing bushing (14) and scrollwave

(15)
33-93
11) Remove spring (17) from brake piston (18).
Fit spring in the original position.

17
18
Fig. 33-166 Removing spring (17)

12) Remove brake piston (18). 18
The O-ring (7) (8) make it difficult to slide the piston (18)
easily from the housing (26). For this reason, use
tapped hole (M6) provided in the piston (18) to remove
it, as shown in the Fig. 33-167.
Fig. 33-167 Removing brake piston (18)
13) Remove the separator plate (4) and friction
plate (3).
Fig. 33-168 Removing separator plate (4) and fric-

tion plate (3)
14) Remove cylinder assy (19) from housing (26).
19
• Oil seal (28) and outer race of taper roller bearing
(1) are left in housing.
• Take care not to damage the sliding surface on up-
per section of cylinder housing.
26
• Assemble piston bore of cylinder (19) and piston
assy (21) in the same original combination.
Fig. 33-169 Removing cylinder assy (19)
33-94
15) Remove the outer race of tapered roller bearing 1

(1) from the housing.
Fig. 33-170 Removing outer race of tapered roller

bearing (1)
16) Remove oil seal (28) from housing (26) with
driver and hammer.
• The reuse of the removed oil seal is not al-
lowed.
28
26
Fig. 33-171 Removing oil seal (28)

17) Removing the cylinder assy.
1. Attach an gear puller to two positions of the
inner race of the tapered roller bearing (1)
and to the splined end of the cylinder (19),
and pull out the inner race along with the col-
lar (27). 27
Fig. 33-172 Pulling inner race of tapered roller bear-

ing (1)
2. Remove the cam plate (23), piston assy (21)
and return plate (22) together from the cylin-
der (19).
23
22
21
Fig. 33-173 Removing cam plate (23), piston assy
(21) and return plate (22)
33-95
3. Remove cam plate (23) from the piston assy

(21) as is by sliding it on sliding surface of
piston assy (21).
21
23
• Handle cam plate with care so as not to damage its

sliding surface.
Fig. 33-174 Removing cam plate (23)

4. Remove retaining spring (20) from cylinder
(19).
19 20
Fig. 33-175 Removing retaining spring (20)

(2) Installation
Install swing motor unit in the reverse procedure of
disassembling.
1) Jigs
Jig used for installing is not provided with part
number.
Jigs Dimensions Jigs Dimensions

(1.1909"±0.0039")
C1
(1.0039±0.0039)
35 (1.38")
(0.04")
30.25±0.1
25.5±0.1
(1.9488"±0.0039")
(2.4350" -0.00591")
Press-fitting jig
(1.1417"±0.0039")
-0.15"
49.5±0.1
29±0.2
+0
61.85 +0
for inner race Press-fitting jig

of tapered 3 for oil seal (28)
(0.008") (0.08") 2
roller bearing (1) 60 (2.36") 10.5 (0.413")
75 (2.95") (0.5315" +0.0039
-0 ) 155 (6.10")
13.5 +0.1
-0
)
R3 18"
.1
)
(0
30.3 (1.19")
(0.9921"+0.0039"
(0.8720")
)
(0.689")
22.15
(+0.0059"
(1.06")
+0.1
17.5
27
+0.15"
-0
25.2-0
-0
-0
Press-fitting jig
Seal protector
for collar (27) 7
(0.276") 50 (1.97") 25 (0.984")
60 (2.36") 45 (1.77")
33-96
2) Assembling relief assy 70

Fit relief assy (70) to cover (39).
39
: 27 mm
Fig. 33-176 Assembling relief assy (70)

3) Confirming correct assembly A,B release
Open the brake release port, apply a pilot pres- (inlet / outlet ports)
Rotate spline by
sure of 1.96 MPa (280 psi) to the P port and con- 19.6 to 29.4 N·m
(14 to 22 lbf ·ft)
firm that the output shaft rotates more than 1 turn with torque
smoothly by 19.6~29.4 N•m (14~22 lbf•ft) torque. wrench.
In case the output shaft does not rotate, disas-
semble it again and readjust.
Apply pressure 1.96 MPa

(280 psi) to brake release
port (PF 1/4)
Fig. 33-177 Confirming correct assembly
33-97
33.2.5.3 DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT

(1) Removal
1) Remove the sun gear (12) and then remove the
15
holder 1 assy (13).
• Because the shafts in the holder 1 assy (13)
are press-fit in the holder (1), and caulked at
the end, further removal of the assy is impos-
sible.
20
Fig. 33-178 Removing spring pin (20)

2) Remove spur gear 4 (11) and then remove the
holder 2 assy (15).
3) Removing the holder 2 assy (15).
1. Drive the spring pin (20) through the holder 2
assy (15).
• The spring pin (20) cannot be reused.
2. Holding spur gear 5 (18) with your hand, re- 18
move the shaft 2 (17) from holder 2 (15).
17
Fig. 33-179 Removing shaft (17)
4) Remove the ring gear (10).
• The mating surface between the ring gear (10)
and the gear case (5) is coated with liquid 10
packing (Three Bond #1215, gray) to prevent
oil leakage. Use the notch in the gear case (5)
5
to remove the ring gear (10).
5) Removing the collar (16).
Remove the collar (16) from the shaft (1) by tap-
ping the collar with a screwdriver and hammer.
Fig. 33-180 Removing ring gear (10)

6) Removing the shaft (1) assy.
Place blocks about 300 mm high under the PRESS
flange of the gear case (5) to allow removal of the
shaft (1) and push the end of the shaft with a hy-
draulic press to remove the shaft (1), collar (2),
plate (3) and taper roller bearing (4) as an assy.
5
Do not remove any further, unless the bearings etc. are

abnormal. Fig. 33-181 Removing shaft (1) assy
7) Remove the oil seals (7) from the gear case (5).
• Do not reuse the oil seals.
33-98
(2) Installation
• The jigs to be used for installation are shown be-
low.
Unit : mm (in)
Oil seal (7) press-fitting jig Seal protector Remarks
Ø50 15˚
(1.97")
• Heat vinyl chloride tube in hot
(0.591") (0.272") (0.591") (1.18")

15 6.9 15 30
water and inset it onto the pinion
±0.1 (0.00394")
shaft to from a seal protector.49
150 (5.91")
C2
(0.08")
85 (3.34")
(0.118") 3
0"
(2.5512" -0.0079" )
0
Ø64.8-0.2 15˚
Ø89 -0.2 -0.0079"

-0.5 (3.5039" -0.0197" )
Ø119 (4.69") Ø65

(2.56")
1) Apply grease to the rollers of the taper roller

bearing (4).
• Grade : SHELL ALVANA EP2 or equivalent
(grease for extreme pressure duty) GREASE
• Quantity : About 150cc (9.15 cu•in)
Fig. 33-182 Applying grease to taper roller bearing

(4)
2) Press-fitting the oil seal (7) 5
Degrease the oil seal position on the gear case SEAL
(5) and the oil seal (7). Apply liquid packing PRESS-
7 FITTINGH
(Three Bond #1211, white) to the outside of the JIG
oil seal. Using the seal press-fitting jig and a
hand press, install the oil seal (7) on the gear
case (5).
• After press-fitting, apply grease to the oil seal
lips. Fig. 33-183 Press-fitting oil seal (7)
33-99
3) Place the gear case (5) with the output shaft side 1
facing upward, and install the pinion shaft (1)
assy into the gear case (5). 4
• Use the seal protector to prevent the spline of
the pinion shaft (1) from damaging the lips of SEAL
PROTECTOR
the oil seal (7).
5
Fig. 33-184 Installing pinion shaft (1) assy

4) Installing the taper roller bearing (8)
Place gear case (5) directing pinion shaft down-
ward, warm collar (22) of taper roller bearing to
temperature adding +50°C (122°F) to the room
temperature and fit it.
22
Fig. 33-185 Installing taper roller bearing (8)

5) Installing the collar (22) Adjust the clearance
The nominal thickness of the collar (22) is 7.0 0.06 mm (0.0024 in)
mm (0.2756 in). Adjust this thickness so that the
clearance between the collar (22) and the groove
COLLAR (22)
in the shaft (1) is 0.06 mm (0.0024 in).
TAPER ROLLER
BEARING (8)
SHAFT (1)
Fig. 33-186 Adjusting clearance between collar (22)

and shaft (1)
33-100
6) Installing the ring gear (10).

• Degrease the mating surface between the
gear case (5) and the ring gear (10) and the
pin (9).
• Apply liquid packing (Three Bond #1215, gray)
to the area of the gear case (5) inside the bolt
circle, and install the ring gear (10) on the gear
case (5).
• Apply sealant equally so that the thickness
projecting from nozzle is about 1.5 mm (0.06 Fig. 33-187 Applying liquid packing to gear case (5)
in) in diameter.
10
Fig. 33-188 Installing ring gear (10)

7) Installing the holder 2 assy (15)
1. Install the needle bearing (16) in spur gear 5
(18). Install this assy together with the thrust
plate 2 (19) into holder 2 (21), and insert the
shaft 2 (17) into the spur gear.
• Apply hydraulic oil to the inside diameter of 15
spur gear 5 (18), needle bearing (16) and the
outside diameter of the shaft 2 (17).
17
Fig. 33-189 Installing holder assy 2 (15)
2. Drive the spring pin (20)
Drive spring pin facing the split to gear side.
Beware of the direction

of spring pin.
20
GEAR SIDE
15
Caulk two point with a punch.
Fig. 33-190 Driving spring pin (20)
33-101
8) Carefully mesh the holder 2 assy (15) in the in-

ternal teeth of the ring gear (10), and the spline
of the pinion shaft (1) with its mating part. In this
15
condition, insert the holder 2 assy (15) while
turning it.
9) Carefully mesh spur gear 4 (11) in the spur gear
5 (18).
11
Fig. 33-191 Inserting holder 2 assy (15)
10) Installing the holder 1 assy (13)
1. Carefully mesh the holder 1 assy (13) in the
internal teeth of the ring gear (10), and holder
1 (13) in the teeth of sun gear (12). In this
condition, insert the holder 1 assy (13) while
turning it slowly.
2. Place sun gear (12) in while engaging with 13
planet gear of holder 1 assy (13) slowly.
11) Turn the holder 1 assy (13) with your hand to
confirm that the pinion shaft rotates smoothly.
Fig. 33-192 Inserting holder 1 assy (13)
Parts Maintenance
Replace if harmful wear, pitting, peeling, scratch, etc. are found on the tooth
Gear, Pinion
face.
Replace if harmful wear, indentation, etc. are found on the spline portion,
there is a backlash on the pin portion (For holder 1 assy, loosening of caulk-
Holder 1, 2 assy
ing, for holder 2 assy, wear of pin bore), or the needle bearing is worn mak-
ing a backlash.
Even if the bearing works normally, when the "Hour meter" arrives to the
time in 3000 hours, replace them with new ones.
Even through the "Hour meter" is within 3000 hours, when the rolling contact
Taper roller bearing,
surface of needle bearing is flawed while removing, replace them with new
Needle bearing
ones.
And if possible we will recommend that you replace bearings with new ones
because they will often be damaged during removing.
When the lip is damaged, replace it with a new one.
Oil seal And even if there is no leak, replace seal every 3000 hours.
Also, replace it with new ones without fail while installation.
Other parts Replace parts worn or damaged with new ones.
33-102
33.2.6 SWIVEL
12 T=Tightening torque : N·m (lbf·ft)

M
C D
G
2
15
Note)
Fit completely-degreased
seal saay (5) and seal (15)
in seal groove without
H application of oil and
grease.
D
SECTION K-K
C
J
G F
B 5
A
C
B F A
G
1 A E B
F
D G C
H D
7 K K
E
H
9 13 4 3 8 J
T = 30.4 (22) T = 30.4 (22) VIEW M
(Loctite #290) (Loctite #290)
SECTION J-J
Fig. 33-193 Construction

Table 33-5
1 BODY 1 5 SEAL ASSY 7 12 PLUG : PT1/8 1
2 STEM 1 7 O-RING ; 1A G95 1 13 PLUG : PT3/8 2
3 THRUST PLATE 1 8 SOCKET BOLT : M8  20 2 15 SEAL 2
4 COVER 1 9 SOCKET BOLT : M8  30 3
33-103
33.2.6.2 DISASSEMBLY AND ASSMBLY
33.2.6.2.1 TOOLS
Table 33-6
Code Tool Name Used for Remarks
1. Steel hammer
a Hammer
2. Wooden or plastic hammer
b Rubber mat Disassembly 500 mm (20 in) square or more
Assembly 1. Allen wrench
c Wrench 2. Double-ended and single-ended wrench
3. Extension pipe
d Torque wrench Assembly 98 N•m (72 lbf•ft)
Grind the tip of "a nail"
to shape as a screwdriver.
e Pin Disassembly
Made from a hack-saw blade
Disassembly Approx. 120 mm (5 in)

f Spatula
Assembly
Remove the edge completely

Vinyl tape and make corner round smooth.
Disassembly
g V block or vise Vises movable over 150 mm (6 in)
Assembly
Thrust plate,
h Loctite #290
Cover
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 assembly.
(2) Work bench
The work bench should have an area of 1.2 m  1.5 m (4ft  5ft)
(3) Others
Also prepare rag, wooden block and oil container.
33.2.6.2.3 CLEANING
Clean the swivel joint to remove dirt, dust, etc. using steam, wash oil, etc.
• Never fail to plug up every port before starting cleaning
33-104
33.2.6.2.4 DISASSEMBLY
The part numbers used in this disassembly procedure 1
correspond to those of a construction drawing in Fig. MATCHING MARK
33-193. 9
(1) Removing cover
4
1) Place a V-block on a work bench, mount a swivel
joint set on the side, fix it and loosen capscrew
(9) by means of allen wrench.
: 6 mm
• Apply match mark on cover (4) and body (1).
ALLEN
• Alternately the swivel joint may be fixed by hold- WRENCH
V-BLOCK
ing stem (2) in a vise. PIPE
2) Remove cover (4) from body (1) and draw out O-
ring (7) from cover (4).
Fig. 33-194 Removing cover (4)
(2) Removing thrust plate 7 O-RING
Loosen socket bolts (8) fastening thrust plate (3), in
the same manner as the removing of the above-
mentioned cover.
: 6 mm
4 COVER
Fig. 33-195 Removing O-ring (7)
When removing thrust plate (3) by fixing body (1), sup- 1 BODY
port stem (2) so it may not fall dawn.
3 THRUST PLATE
8 CAPSCREW
PIPE
2
STEM
Fig. 33-196 Removing thrust plate (3)

(3) Extraction of stem 1 BODY
Place body (1) on a V-block. Put a wooden block
against stem (2), then knock it out using a hammer.
By hitting out the stem over about 1/2 from the
body, it can be easily pulled out by hand. Weight of
stem ; About 11kg (24 lbs)
WOODEN V-BLOCK
BLOCK 2 STEM
Work bench
Fig. 33-197 Drawing out stem (2)
33-105
(4) Removing seals

1) Stick pin (e) to seal (15) and remove seal (15).
Fig. 33-198 shows the use of one pin, but by us-
ing two pins, this can be extracted with more
sureness.
15
(SEAL RING)
PIN (e)
Fig. 33-198 Taking out seal (15)

2) Pull out back-up ring from the O ring groove with SPATULA (f)
the aid of a spatula.
1 BODY (BACK-UP RING)
Use the tip of the spatula taking not to harm the body
(1).
3) Stick pin (e) to slipper ring and remove seal assy

(5) in the same procedure as seal (15). Then re- Fig. 33-199 TAKING OUT SEAL (15)
move back-up ring by means of spatula (f).
SLIPPER RING
BACK-UP RING
GROOVES
Detail of seal assy (5) FOR SEAL ASSY
PIN (e) GROOVES FOR

SEAL
HYDRAULIC OIL
ASSY
5 GROOVES
FOR SEAL ASSY
Fig. 33-200 Taking out seal assy (5)
33-106
33.2.6.2.5 ASSEMBLY
Prior to assembly, clean each parts (excluding the O-
ring and seal), and arrange in the sequence of assem-
bly.
(1) Assembling seals to body
1) Install seal (15) (back-up ring and seal ring in or-
der) into the seal groove. In this time, deform and
fit the seal ring as shown in Fig. 33-201. And af-
ter inserting entire seal section, fit it in seal
groove completely with spatula.
2) After deform slipper ring of seal assy (5) as
shown in Fig. 33-201, install back-up ring. And
after inserting entire seal section, fit it in seal Fig. 33-201 Inserting seal ring (15)
groove completely with spatula.
Before fitting seal (15) and seal assy (5), check that
seal groove is free from hydraulic oil, vaseline, grease,
etc.
(2) Assembling stem

Press in by applying your weight
Lightly coat the outer circumference of stem (2) and by your both hands.
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. SEAL 15
• The clearance between body (1) and stem (2) is 1 BODY
about 0.1 mm (0.004 in). Push stem straight along
the shaft center. SEAL ASSY 5
WORK BENCH
Fig. 33-202 Inserting stem (2)

(3) Assembling thrust plate 8 3 2
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 bolts (8), coat it with Loctite #290 and
tighten to stem (2).
: 6 mm
Fig. 33-203 Tightening socket bolts (8)
33-107
(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),
9
and tighten socket bolts (9) which will then com-
plete assembly. 4
: 6 mm
ALLEN WRENCH
V-BLOCK
PIPE
Fig. 33-204 Tightening socket bolts (9)
33-108
33.2.6.3.1 USABLE LIMIT OF PARTS

Table 33-7
Parts Maintenance Standards Remedy
Sliding surface with sealing Plating worn or peeled due to seizure or contamina-
Replace
sections tion.
1) Worn abnormality or damaged more than 0.1 mm
Sliding surface between Replace
(0.004 in) in depth due to seizure or contamination.
body and stem other than
Smooth with oil
Body, Stem sealing sections 2) Damaged more than 0.1 mm (0.004 in) in depth.
stone.
1) Worn more than 0.5 mm (0.02 in) or abnormality. Replace
Sliding surface with thrust 2) Worn less than 0.5 mm (0.02 in). Smooth
plate 3) Damage due to seizure or contamination remedia-
Smooth
ble within wear limit 0.5 mm (0.02 in).
1) Worn more than 0.5 mm (0.02 in) or abnormality. Replace
Sliding surface with thrust 2) Worn less than 0.5 mm (0.02 in). Smooth
Cover
plate 3) Damage due to seizure or contamination remedia-
Smooth
ble within wear limit 0.5 mm (0.02 in).
1) Extruded excessively from seal groove square
ring.
EXTRUSION Replace
(With back-up
ring)
BACK-UP RING
2) Slipper ring 1.5 mm (0.06 in) narrower than seal

groove, or narrower than back-up ring.
Slipper ring Replace

Seal ring (With back-up
1.5 mm (max.) ring)
(0.06 in)
BACK-UP RING
3) Worn more than 0.5 mm (0.02 in).
0.5 mm (max.) Replace

(0.02 in) (With back-up
ring)
33-109
33.2.6.3.2 INSPECTION AFTER ASSEMBLY

After completion of assembly, inspection for oil leakage, 1
pressure resistance, etc., using a device as shown in
the figure right.
(1) High pressure port 9 Connect to
Install a changeover valve and pressure gauge to body side
the stem side port and body side port respectively,

and while watching the pressure gauge (for high
2
pressure) installed on the body side and also by
Connect to
regulating high pressure relief valve (7), gradually stem side
increase the pressure and when the pressure has
reached 1.5 times the maximum working pressure, 3
close stop valve (3) and lock in the hydraulic oil in
8
the swivel. Keep stop valve (6) on the low pressure
relief valve side closed at this time.
Apply high pressure for 3 minutes, and check the
7
looseness, deformation and breakage on every
parts.
Pressure down should be within 10% of closing
pressure.
These inspections are performed on every circuit.
6 5
Fig. 33-205 Hydraulic circuit for inspection equip-
ment
(2) Low pressure port (Drain port, return port, etc.)
Item Description Remarks
Similar to the high pressure port, install a
1 Pressure Gauge High and Low Pressures
changeover valve and pressure gauge on each port are required.
of the stem side and body side. 2 Swivel Joint
Open stop valve (6) on the side of low pressure re- 3 Stop Valve
lief valve (5) and while watching the pressure 5 Relief Valve for Setting Pressure :
low pressure 0.49 MPa (71 psi)
gauge (for low pressure) connected to the body
6 Stop Valve
side and also by regulating low pressure relief valve
Setting Pressure :
(5), gradually increase the pressure and check for Relief Valve for [Max. operating pressure
7 high pressure 25.5 MPa
outside leakage with a color check at a pressure of
(3700 psi) X 1.5 times]
0.49 MPa (71 psi).
8 Directional Valve
• The maximum working pressure stands for pres-
9 Piping, etc.
sure of hydraulic excavator equipped with swivel
joint.
33-110
33.2.6.3.3 TROUBLESHOOTING
Table 33-8
Trouble Cause Remedy
1. External leakage of hydraulic oil Defective O-ring 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 joint seized 1) Stem and body seized 1) Grind and hone.
Replace assy, if stem and body are too loose
and causing oil leakage.
2) Setting failure of swivel stopper 2) Reinstall
bracket Secure 2~3 mm (0.08~0.12 in) allowance for
bolt stopper.
4. Loose swivel stem and cover Socket bolt tightened insufficiently. Retighten to specified torque.
33-111
[MEMO]
33-112
34. TRAVEL SYSTEM
TABLE OF CONTENTS

34.1.1 COMPONENTS OF TRAVEL SYSTEM .................................................................... 34-3
34.1.2 CRAWLER ................................................................................................................ 34-3
34.1.3 UPPER ROLLER ...................................................................................................... 34-7
34.1.4 LOWER ROLLER (TRACK ROLLER) ...................................................................... 34-12
34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) .............................................................. 34-19
34.1.6 SPROCKET .............................................................................................................. 34-28
34.1.7 TRAVEL MOTOR ...................................................................................................... 34-30
34.1.8 SWING BEARING ..................................................................................................... 34-32
34.2.1 TRAVEL MOTOR ...................................................................................................... 34-37
34
34-1
34. TRAVEL SYSTEM

S5YT3403E01
(NHK)
PREFACE
(1) This Manual describes all the procedures from removing to attaching, them by item.
(2) This Manual consists of first part; 34.1 Removing and Installing assy, and second part; 34.2 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 difference
(5) Please be aware that the procedure to be followed must be determined according to the above conditions.
good understanding, then starts working.
34-2
34. TRAVEL SYSTEM

34.1.1 COMPONENTS OF TRAVEL SYSTEM
<Part I : Removing and Installing>
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) Set master pin to positions shown in the figure.
2) 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 Projection
Master pin
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.
Master pin
drawing jig
• If you use a big hammer, wear a long-sleeved gar- Fig. 34-3 Pushing out master pin
ment and protective goggles to protect yourself
from flying objects.
34-3
34. TRAVEL SYSTEM
(3) Removing crawler

Put attachment on ground so that weight is not Removing
master pin
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 con- Front
idler side
verge, facing the front idler, as shown in the figure
on the right.
Fig. 34-5 Installing direction of crawler

(2) Installing crawler
1) Preparation for installation
Treat paint flaking protection with care not to
damage lower flame.
2) Winding crawler
Insert bar into master pin hole, lift lower frame up
1 or 2 cm (0.4 in~0.8 in) using attachment and
hold it, then turn sprocket in rearward positioning
the machine so that the weight is not loaded to
shoe.
Fig. 34-6 Winding crawler

(3) Preparation for press fitting master pin
1) Preparing for installation
Put wood block under the shoe plate.
2) Aligning master pin holes
Aligning master pin holes through fine adjust-
ment turning sprocket.
Connecting
position of master pin
Fig. 34-7 Preparation for press fitting master pin
34-4
34. TRAVEL SYSTEM
(4) Press fitting of master pin

Apply press fitting jig on master pin, and strike it
with a mallet to press fit.
• If you use a big hammer, wear a long-sleeved gar-

ment and protective goggles to protect yourself
from flying objects.
• Coat the master pin with molybdenum disulfide
grease, before pressing it in. Master pin fixing jig
Fig. 34-8 Press fitting of master pin

(5) Adjusting crawler tension (See Fig. 34-9)
After installing, adjust tension of crawler.
: 19 mm
MODEL A DIMENSION
Proper tensioning SK70SR-1E(S) 200~230 mm
of the iron crawler (8 in~9 in)
Proper tensioning 140~150 mm
of the rubber crewler SK70SR-1E(S) (5 in~6 in)
)
Fig. 34-9 Adjusting crawler tension
PART YT60D00012F1 [Width of shoe 450 mm(17.7 in)]

No. YT60D00012F2 [Width of shoe 600 mm(23.6 in)] 7
No. Name Q'ty 4
3
SHOE ASSY 2
7
• TRACK LINK ASSY 1X2 8
1 • • TRACK LINK (R.H) 39 X 2
2 • • TRACK LINK (L.H) 39 X 2
11 1
3 • • BUSHING 38 X 2 5
4 • • PIN 38 X 2
8
5 • • MASTER BUSHING 1X2 2
6
6 • • MASTER PIN 1X2
7 • • SEAL 76 X 2 9
8 • • MASTER COLLAR 2X2

9 • SHOE 39 X 2
10 • SHOE BOLT 156 X 2
11 • SHOE NUT 156 X 2
10
Fig. 34-10 Shoe assy
34-5
34. TRAVEL SYSTEM

"
#
!
Fig. 34-11
Unit : mm (in)
REPAIR-
SERVICE
No. ITEM STANDARD VALUE ABLE REMEDY
LIMIT
LEVEL
A Link pitch 155.6±0.1(6.126±0.0039) 160 (6.30) 164 (6.46)
Replace the link
B O.D. of bushing Ø41 (1.6142 ) Ø37 (1.46) Ø36 (1.42) assy if the service
C Height of link 75±0.15 (2.9528±0.0059) 69 (2.72) 67 (2.64) limit is exceeded.
Basic di-
Tolerance Fit Fit
mension
Interference between +0.214
D Interfer-
bushing and link Ø41 (+0.0084 ) Interfer-
Shaft ence 0.05
(1.6142) +0.174 ence 0
(0.0020) Replace
(+0.0069)
+0.15
Interfer-
Interference between Ø24 (+0.008) Interfer-
E Shaft ence 0.05
track pin and link (0.9449) 0 ence 0
(0.0020)
(0)
-0.05
Interfer-
Interference between Ø24 (-0.0020) Interfer-
F Shaft ence 0.05 Replace Link
master pin and link (0.9449) -0.08 ence 0
(0.0020)
(-0.0032)
Clearance between
G 1.6 (0.06) 8 (0.32) 10 (0.39) Replace
links (both sides)
H STD shoe plate 26 (1.02) 15 (0.59) 13 (0.51) Replace
Tightening torque of
I 294 N•m (220 lbt•ft) Retighten
shoe bolt
34.1.2.5 TOOLS AND JIGS
No. JIGS SHAPE
a Master pin fixing jig
34-6
34. TRAVEL SYSTEM
34.1.3 UPPER ROLLER
34.1.3.1 UPPER ROLLER ASSY
ASSY PART No. YT64D00002F1 4 4

No. Parts Q’ty Remarks
IDLER SIDE
1 CAPSCREW 2 M16 X 90
2 NUT 2 M16
3 ROLLER ASSY 2 YT64D01001F1 2 1
4 WASHER 4
3
Fig. 34-12 Upper roller assy
34.1.3.2 REMOVING
(1) Preparation for removal
Remove crawler (2).
(2) Removing upper roller (3)
1) Remove nuts on support tightening section, and
also remove cap screw M16 X 90.
(1)
: 24 mm M16 X 80
Fig. 34-13 Removing upper roller
34.1.3.3 INSTALLING
IDLER SIDE
(1) Inspection
Before reassembling, check it that it rotates smooth 3
Countersinking
manually and for leakage. 2
Up
SUPPORT 1 Apply Loctite #262

COLLAR T=279 N·m (210lbf·ft)
Fig. 34-14 Installing upper roller
(2) Installing upper roller (3)
1) Fit it directing nut toward idler side.
2) Insert it until collar comes in contact with support.
3) Fit it directing the countersinking mark of shaft
end upward.
4) Apply Loctite #262 on capscrew M16 X 90, and
tighten it to the specified torque.
: 24 mm
Fig. 34-15 Installing upper roller (3)
34-7
34. TRAVEL SYSTEM
ASSY PART No. YT64D01001F1 10 7 8 1 5 6 11

2
1 ROLLER 1 7 O-RING ; G45 1A 1
2 SHAFT 1 8 SOCKET BOLT
3 PLATE 1 ; M8 X M22 2
4 COVER 1 9 SNAP RING 1
5 BUSHING 1 10 PLUG 1
6 FLOATING SEAL 1 11 COLLAR 1
9 4 3
Fig. 34-16 Construction of upper roller

(1) Disassembly 8 9
1) Draining out oil 3
Remove plug (10) and drain out oil. 10
7
: 5 mm 4
2) Removing snap ring (9)
Mount the end face inside upper roller (1) on 1
stand jig (f) and separate snap ring (9), using
snap ring pliers.
3) Removing cover (4)
Take off cover (4) upwards, utilizing the screwed f
hole for the plug.
4) Removing O-ring (7)
Separate O-ring (7) from cover (4).
5) Removing plate (3)
Loosen two socket bolts (8) and draw out plate
(3) from upper roller (1). Fig. 34-17 Removing snap ring (9), cover (4), O-ring
(7), plate (3)
: 6 mm
6) Removing shaft (2) Push with press
Put the extrusion jig (g) against the end face of
shaft (2) and lightly extrude shaft (2) with retainer
g
for floating seal (6), using a press or hammer.
Press machine capacity : 10 ton class.
2
Fig. 34-18 Extruding shaft (2)
34-8
34. TRAVEL SYSTEM
7) Removing floating seal (6).

6
Take out floating seal (6) from upper roller (1).
Fig. 34-19 Taking out floating seal (6)

8) Removing floating seal (6).
2
Take out, from retainer, floating seal (6) that is lo-
cated on the side from which shaft (2) was dis-
parted. 6
RETAINER
Retainer is press fitted into shaft (2). Therefore do not

disassemble it.
9) Removing bushing (5).
Since the thickness of bushing is thin, remove it
Push-out bar
through lathe or strip it. When the wear of bush-
ing is too small, place upper roller (1) on jig (f) for
repair stand and apply push-out bar on the end
face of busing (5), and push it out by striking it 5
with mallet.
1
Fig. 34-21 Extruding bushing (5)

(2) Assembly Push with press
Assembly of the upper roller is done in the reverse
order of disassembly. h
1) Pressing the bushing (5).

Align inner hole of roller (1) and bushing (5) and 5
press fit it vertically with press so that jig (h) for
bushing push-in jig (h) is inserted into bushing 1
(5). f
Fig. 34-22 Pushing in bushing (5)
If you fail in this operation by pressing the bushing un-

evenly, the bushing is distorted and gets unserviceable.
In that case, do not re-use the bushing as it may devel-
op malfunctioning after assembly.
34-9
34. TRAVEL SYSTEM
2) Installing floating seals (6).

6
Two floating seals (6) make a pair. Attach one 2
floating seal to retainer fixed in shaft (2), and an-
6 1
other to the inside of upper roller (1).
• Prior to placing floating seal (6) in, apply en-
gine oil lightly to seal surface.
COLLAR

3) Inserting shaft (2).
Coat shaft (2) with a thin film of oil and insert it
into upper roller (1). 2
4) Installing plate (3).
Mount upper roller (1) on the stand jig (f) and at-
tach plate (3) to the end face of the shaft with
socket bolt (8). In that case, coat the screwed
1
part of socket bolt (8) with Loctite #242 before-
hand.
: 6 mm
Fig. 34-24 Pressing the shaft (2)
5) Installing O-ring (7). 9
8
Fit O-ring (7) to the groove of cover (4). 7
4
•Apply grease to O-ring.
3
6) Installing cover (4). 1
Attach cover (4) to upper roller (1). Use a press
in this operation as a press fit is used.
7) Installing snap ring (9).
Fix snap ring (9) into upper roller (1), using snap
ring pliers. f
Fig. 34-25 Installing plate (3), O-ring (7), cover (4),

snap ring (9)
8) Filling oil
Fill in 20 cc (1.22 cu•in) of engine oil API grade
CD#30 through the plug hole in cover (4). 10
9) Installing plug (10). 4
Place seal tape around plug (10) and screw it
1
into the plug hole of cover (4).
: 5 mm
• After assembling the upper roller, confirm that
oil is not leaking from it and that it rotates f
smoothly by hand.
Fig. 34-26 Filling oil
34-10
34. TRAVEL SYSTEM
(1.34")
34
A D C
E
Fig. 34-27 Upper roller
Unit : mm (in)
REPAIR-
SERVICE
No. ITEM STANDARD VALUE ABLE REMEDY
LIMIT
LEVEL
A Tread dia. Ø82 (3.23) Ø73 (2.87) Ø70 (2.76)
B Tread width 102 (4.02) 95 (3.74) 92 (3.62)
Replace
Basic di-
Tolerance Fit Fit
mension
Clearance between -0.025
C
shaft and bushing Ø32 (-0.00098 ) Clearance Clearance
Shaft
(1.2598) -0.050 0.7 (0.028) 1.0 (0.04)
(-0.00197) Replace bushing
0 Clearance
Interference between Ø36 Interfer-
D Hole -0.03 0.01
roller and bushing (1.4173) ence 0
(-0.0012) (0.0004)
Tightening torque of
E 33 N•m (25 lbt•ft) Apply Loctite #242
socket bolt
Oil Engine oil API grade CD #30, 20 cc (1.22 cu•in) Replenish.
Roller rotation Roller rotates smoothly by hand. Reassembly.
34.1.3.7 TOOL AND JIGS
Unit : mm (in)
No. JIGS SHAPE No. JIGS SHAPE
For extruding
g
shaft
f Stand jig
Bushing fixing
h
jig
34-11
34. TRAVEL SYSTEM
34.1.4 LOWER ROLLER (TRACK ROLLER)
34.1.4.1 LOWER ROLLER ASSY
ASSY PART No. YT64D00005F1

No. Parts Q'ty Remarks
1 LOWER ROLLER 10 YT64D00004F1
2 1
Apply Loctite #262
T=181 N·m (130 lbf·ft)
Fig. 34-28 Lower roller assy
34.1.4.2 REMOVAL
(1) Where crawler is removed
1) Preparation for removal
Loosen grease nipple to slacken the link. Put
wood blocks on the front and rear sides of under
section of lower frame, and stabilize the ma-
chine.
2) Removing lower roller
Remove capscrew (2) M14 X 55.
: 22 mm
Fig. 34-29 Holding up the lower frame
Weight of lower roller : Approx.15 kg (33 lbs)
(2) Where crawler is installed.
1) Preparation for removal
Slacken crawler, and stop engine keeping lower
frame lifted up with front attachment.
2) Put safe blocks under the front and rear sides of
lower frame.
3) Remove lower roller
Remove capscrews (2) in the same procedure
as that shown in Fig. 34-28.
Fig. 34-30 Removing lower roller
(1) Securing lower roller temporarily
Apply Loctite #262 on 4 capscrews (2) and tighten GREASE NIPPLE
them temporarily.
: 22 mm
(2) Securing lower roller regularly.
Tighten capscrews (2) to the specified torque.
(3) Adjusting tension of crawler.
Tighten grease nipple and fill it with grease.
Fig. 34-31 Adjusting tension of crawler
34-12
34. TRAVEL SYSTEM
ASSY PART No. YT64D00004F1 T=23 N·m (17 lbf·ft)

8
No. Parts Q'ty
1 ROLLER 1
2 SHAFT 1
3 BUSHING 2
4 PIN 2
5 SEAL 2
6 O-RING 2
7 COLLAR 2
8 PLUG 2 1 2 3 5 6 4 7
Fig. 34-32 Construction of lower roller

(1) Disassembly
1) Drain oil
14
Remove plug (8) and drain out oil. (0.551")
J
: 6 mm
2) Removing pin (4) 4
Put both ends of lower roller assy on the V-
shaped blocks (K), apply push-out bar (j) on up-
per end face of pin (4), and push pin out striking
K
with mallet.
Fig. 34-33 Drawing out collar fixing pin (4)

3) Removing collar (7), O-ring (6) Push with press Push with press
Put lower roller on jig (m) for repair stand so that
the shaft is perpendicularly located, apply push-
P P
out jig (P) on shaft end on upper side, and push
shaft (2) until the O-ring separate from collar (7) 7 7
with press or mallet, and take out collar (7) and
O-ring (6). 6 6
4) Removing shaft (2)
In addition, push out and remove shaft (2) to-
gether with the lower collar (7) and O-ring (6). 2 2
m m
The shaft (2) extrusion operation may cause the re-

maining lube oil to flow out and contaminate the floor.
Prepare an oil container beforehand.
Fig. 34-34 Removing shaft (2), collar (7), O-ring (6)
34-13
34. TRAVEL SYSTEM
5) Removing collar (7), O-ring (6) 5

Insert shaft (2) with collar (7) and O-ring (6) re-
moved in the said procedure into roller (1) direct-
ing the collar (7) side upward, and take out collar
(7) and O-ring (6) from shaft (2) in the same pro-
cedure as that described in Item 3). 7
6) Removing floating seal (5)

Take out floating seal (5) from collar (7). Fig. 34-35 Taking out floating seal (5)
7) Removing floating seal (5)
Take out floating seal (5) from roller (1).
5

8) Removing bushing (3)
Since thickness of bushing (3) is thin, remove it
a
through lathe or strip it with care not damage in-
n
ner hole of roller. When the wear of bushing is 16 (0.63")
200 (8")
not large, place upper roller (1) on jig (m) for re-
pair stand and apply the end of push-out jig on
the end face of bushing (3) end, and push it out
striking it with mallet.
3
Hammer the inside surface of roller lightly so as not to m

damage the surface. Put the extrusion jig (n) uniformly
over the circumference of bushing (3) and extrude it lit- Fig. 34-37 Extruding bushing (3)
tle by little.
(2) Installing
6 2
1) Attach O-ring (6) to one side
Install O-ring (6) to shaft groove.
•Replace O-ring with new one.
Fig. 34-38 Attach O-ring (6) to one side
34-14
34. TRAVEL SYSTEM
2) Press fitting bushing (3)

Push with press
Align inner hole of roller (1) and bushing (3) and q
press fit it vertically in capacity of press fit load,
3600kg (7940 lbs), in the condition that bushing
push-in jig (g) is inserted into bushing (3). 3
• Apply molybdenum disulfide grease on press-
fit section of bushing, and press-fit it in ordi-
1
nary temperature.
• Bushing which fails to press-fit because of the
one-side pressing should not be fitted.
Fig. 34-39 Press fitting bushing (3)
3) Press fitting collar (7)
5
Fit O-ring to the one side of shaft (2) mating pin
hole of collar (7) on which floating seal (5) is fit 4
with pin hole of shaft (2) in advance.
• Care should be taken not to damage O-ring
(6) while press-fitting collar (7) to shaft. 2
4) Inserting pin (4)
Press-fit pin (4) to pin hole on aligning pin holes
of shaft (2) and collar (7).
6 7
Fig. 34-40 Inserting pin (4)
5) Attach floating seal (5) to roller side
Fit floating seal (5) to inner holes on both ends of
roller (1).
• Check that the seal surface is free from flaws,
rusts, etc. before reusing the floating seal.
1
6) Inserting roller (1)
Insert roller (1) from the side where collar (7), O-
ring (6) is not press-fitted to the shaft (2).
Fig. 34-41 Inserting roller (1)
34-15
34. TRAVEL SYSTEM
7) Installing O-ring (6) Press

Install O-ring (6) to shaft groove.
•Replace O-ring with new one. Pin
7
8) Press fitting collar (7)
Press-fit collar (7) to shaft (2).
6
•Press-fit collar (7) on aligning pin (4) hole.
9) Inserting pin (4)
Press-fit pin (4) described in to the pin hole mat-
ing pin hole of collar (7) with pin hole on the end 2
side of shaft (2).
Fig. 34-42 Installing O-ring (6), collar (7)

10) Filling oil 8
Remove plug (8) and fill in 90 cc (5.49 cu•in) of Tightening torque :
engine oil API grade CD#30. 23 N·m (17 lbf·ft)
11) Check it for leakage

Before tightening plug (8), check it for leakage in
the condition of air pressure 0.2 MPa (28 psi).
12) Installing plug (8)
Apply oil resistant sealant on plug (8), and tight-
en it in the plug hole on the collar (7) end face. 7
: 6 mm
Tightening torque : 23 N•m (17 lbf•ft) Fig. 34-43 Installing filling oil plug (8)
After assembling the lower roller, confirm that oil is not

leaking and that the roller rotates smoothly by hand.
34-16
34. TRAVEL SYSTEM
C 95 (3.74)
G
(0.945")
24
ØD
ØB
ØA
199 (7.83")
Before tightening plug,
apply oil resistant sealant on it.
Tightening torque 23 N·m (17 lbf·ft)
Fig. 34-44 Lower roller (Track roller)
Unit : mm (in)
REPAIRABLE
No. ITEM STANDARD VALUE SERVICE LIMIT REMEDY
LEVEL
A O.D. of flange Ø147 (5.79) — — Reinforce-
ment weld.
B Tread dia. Ø120 (4.72) Ø110 (4.33) Ø106 (4.17) repair or re-
place
C Flange width 17.5 (0.689) 12 (0.472) 10 (0.394)
Basic di-
Tolerance Fit Fit
mension
Clearance between
-0.060
D shaft and bushing
Ø40 (-0.00236) Clearance Clearance
(Coiled bushing) Shaft Replace
(1.57480) -0.090 0.7 (0.028) 1.0 (0.39)
bushing
(-0.00354)
+0.025
Interference between Ø44 (+0.00098) Interference Clearance
E Hole
roller and bushing (1.73228) -0.020 0 0.01 (0.0004)
(-0.00079)
Oil Engine oil API grade CD #30, 90 cc (5.49 cu•in) Replenish.
Reassem-
Roller rotation Rotates smoothly by hand.
bly.
Clearance between
G Keep 2.5±0.5 (0.09843±0.01969) space.
roller and collar
34-17
34. TRAVEL SYSTEM
34.1.4.7 TOOL AND JIGS
Unit : mm (in)
No. JIGS SHAPE
k V-block
Pin (4)
l
extrusion rod
Bushing
n
extrusion rod
m Stand jig
Shaft
p
extrusion jig
Bushing
q
fixing jig
34-18
34. TRAVEL SYSTEM
34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY)
34.1.5.1 FRONT IDLER ASSY
700 IRON SHOE (27.6")
205 495 IRON SHOE (19.5")

(8.07")
ASSY PART No. YT52D00006F1
1 116 270+STROKE 31.8
No. Parts Q'ty Remarks (4.57") (10.6") (1.25")
1 IDLER ASSY 2 YT52D00002F1 ")

7.6
(1
2 IDLER ADJUSTER 2 YT54D00002F1
3 GREASE NIPPLE 2 2444P803
4 2 3
Apply Loctite #262 Grease nipple is
or equivalent positioned on the outside
T=115 N·m (85 lbf·ft) T=58.8 N·m (43 lbf·ft)
Fig. 34-45 Front idler assy
34.1.5.2 REMOVING
Remove crawler. (Above mentioned)
(2) Removing front idler assy
Sling idler assy, and push it forward with pry-bar.
Weight of front idler assy : 146 kg (320 lbs)
PRY-BAR
Keep away from the front side of front idler.
(3) Installing
(4) Where idling assy (1) has to be separated
Loosen capscrew (4), and separate idler assy (1)
from idler adjuster assy (2).
: 19 mm
Weight of idler assy : 45 kg (99 lbs) Fig. 34-46 Removing and installation the front idler
Weight of idler adjuster assy : 49 kg (110 lbs) assy
• The separated idler assy should be placed on 1
wood blocks.
4
3
Fig. 34-47 Separating idler assy (1) from idler ad-

juster assembly
34-19
34. TRAVEL SYSTEM
34.1.5.3 IDLER ASSY
IDLER ASSY PART No. YT52D00002F1

No. Parts Q’ty Remarks
1 8
1 IDLER 1 YT52D00003P1
4
2 SHAFT 1
3
3 COLLAR 2 YT52D01002P1
4 BUSHING 2 2
5 PIN 2 16 X 78
5
6 SEAL 2
7
7 O-RING 2 1A G45
6
8 PLUG 2 PT1/8 Storage procedure
Fig. 34-48 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
idler assy of oil.
: 5 mm
2) Removing pin (5)
Apply pin push bar (jig R) to the top of pin, and
take out striking bar (jig R) lightly by hammer.
Fig. 34-49 Removing pin (5)
3) Removing collar (3) Push with press
Put idler (1) on repair stand (U), apply push-out
jig (S) on shaft (2), push out shaft (2) with collar S
2
(3), then remove collar (3).
3
1
U
3
Fig. 34-50 Removing collar (3)

4) Removing collar (3) from shaft (2) Push with press
If removal of collar (3) on the opposite side is re-
quired, turn over front idler and proceed with the S
2
procedure described in Item 3).
3
Fig. 34-51 Removing collar (3)
34-20
34. TRAVEL SYSTEM
5) Removing bushing (4)

With idler (1) mounted on the stand, tap bushing 4
T
(4) lightly by hammer, while placing the bushing 1
drawing rod (T) against the end face of bushing
(2) evenly all round, till it comes out.
6) Removing floating seals (6)
Take out floating seals (6) from idler (1), collar
(3). If you intend to re-use floating seals (6), con-
firm that there is no scoring and rusting on the U
contact surface and store the floating seals in
Fig. 34-52 Removing bushing
pairs by placing thick paper between the sealing
faces.
7) Removing O-ring (7)
Separate O-ring (7) from shaft (2).
(2) Assembly Push with press
1) Pressing in bushing (4) 4 V 1
Align inner hole of idler (1) and bushing (4) and
press-fit it vertically with press so that jig (V) for
bushing press-fitting jig (V) is inserted into bush-
ing (4).
2) Installing O-ring (7)
Fit O-ring (7) to O-ring groove on shaft (2).
Fig. 34-53 Pressing in bushing (4)
• Apply grease to O-ring.
3) Installing collar (3) (See Fig. 34-54) Pressing
Press-fit the O-ring installed side of shaft into col-
2
lar (3), and drive pin (5).
3
5
Fig. 34-54 Installing collar (3), shaft (2)

4) Installing floating seal (6) 2
Fit one piece of two (2) pieces type floating seal 6
(6) on each side of collar (3).
1
5) Inserting idler (1)
Insert floating seal (6) fitted side of idler (1) into
shaft (2).
6) Installing floating seal (6)
Fit floating seal (6) on the other side of idler (1).
Fig. 34-55 Inserting idler (1) and installing floating
seal (6)
34-21
34. TRAVEL SYSTEM
7) Installing collar (3) 2

8 3
Fit floating seal (6) on the other collar (3), press-
5
fit it in shaft, and drive pin (5) in with mallet.
8) Filling oil • Inspection
1
Fill in 150~160 cc (9.15~9.76 cu•in) of engine oil
API grade CD#30 through the plug hole of collar,
place the screwed part of plug (8) with seal tape
and put in plug (8).
: 5 mm Fig. 34-56 Installing collar (3) and filling oil

• After mounting the idler assy to the idler ad-
juster 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
104 (4.09")
C
F
C
E D
A B
A B
DETAIL TREAD PORTION
Fig. 34-57 Front idler

Table 34-1
Unit : mm (in)
REPAIRABLE
No. ITEM STANDARD VALUE SERVICE LIMIT REMEDY
LEVEL
A Dia. of idler projection Ø446 (17.6) Ø440 (17.3) Ø438 (17.2)
B Tread dia. Ø400 (15.8) Ø394 (15.5) Ø392 (15.4) Replace.
C Flange width 43 (1.69) 38 (1.50) 36 (1.42)
Basic di-
Tolerance Fit Fit
mension
Clearance between -0.050
D
shaft and bushing Ø50 (-0.00197) Clearance Clearance
Shaft
(1.96850) -0.075 1.5 (0.059) 2.0 (0.079) Replace
(-0.00295) bushing
-0.03
Interference between Ø57 (-0.0012) Interference Clearance
E Hole
roller and bushing (2.2441) -0.02 0 0.01 (0.0004)
(-0.0008)
Oil Engine oil API grade CD #30, 150~160 cc (9.15~9.76 cu•in) Replenish.
Reassem-
Roller rotation Rotates smoothly by hand.
ble
34-22
34. TRAVEL SYSTEM
34.1.5.3.4 TOOLS AND JIGS
Unit : mm (in)
No. JIGS SHAPE
Pin
R
striking jig
Shaft
S
push out jig
Bushing
T
drawing rod
About 80 (3.15")
About 400
(15.7")
U Repair stand
About
250
(9.84")
2 pcs
Bushing
V
Press fitting jig
34-23
34. TRAVEL SYSTEM
34.1.5.4 IDLER ADJUSTER ASSY
ASSY PART No. YT54D00002F1 4

3
1 GREASE CYLINDER 1 2
2 BRACKET 1 10
3 NUT 1 SPECIAL M36 X P3
4 SPRING PIN 1
5 SPRING 1 1B G50 5
6 PISTON 1
7 O-RING 1
8 OIL SEAL 1
9 PIN 2 1
10 COVER 1
8 9
11 GREASE NIPPLE 1
7
6
9
11
Fig. 34-58 Idler adjuster assy
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 10 tons

V
(22000 lbs)
: 46 mm Hydraulic jack
BASE
Large power is needed to set the spring.
Prepare a special jig before disassembly and assembly. Fig. 34-59 Spring set special jig (V)
2) Preparation for working

Place a hydraulic jack between the jig base and
the stand.
Loosen the holding-down nuts of the jig and draw
out the retainer plate upward.
: 46 mm
3) Draw out grease cylinder (See Fig. 34-58)
5
Draw out piston (6) from grease cylinder (1) of
the idler adjuster assy.
4) Removing oil seal (8), O-ring (7) (See Fig. 34-58)
Taken out oil seal (8) and O-ring (7) from grease
cylinder (1). V
5) Slinging work idler adjuster Fig. 34-60 Slinging work idler adjuster
Set the idler adjuster assy on the stand of the jig,
with its bracket side (2) facing up.
34-24
34. TRAVEL SYSTEM
6) Fixing idler adjuster assy

Fit retainer plate to bracket (2), tighten holding-
down nuts alternately, and secure idler adjuster
assy.
: 46 mm

Fig. 34-61 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).
: 46 mm
Fig. 34-62 Compression of spring (5)

8) Removing bracket (2)
Allow the hydraulic jack to shrink slowly till the
spring is extended to its free length. Remove the
retainer plate, and take off bracket (2) and cover
(10).
The free length of the spring : about 320 mm
(12.6 in)
: 46 mm
Fig. 34-63 Removing retainer plate, bracket (2)

9) Removing spring (5), grease cylinder (1)
Hook lifting eye nut (W) to screw M36 X P3 on 9
grease cylinder (1) top end and hoist it. Then, re-
move the set of grease cylinder (1) and spring (5)
using crane from the jig.
Remove spring (5), grease cylinder (1), in that
#
order.
Fig. 34-64 Removing spring (5), grease cylinder (1)
34-25
34. TRAVEL SYSTEM
(2) Assembly
Assembly is done in the reverse order of disassem- W
bly. 1
1) Installing spring (5), grease cylinder (1)
Insert grease cylinder (1) into spring (5) and at-
5
tach lifting eye nut (W) to screw M36 X 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.
2) Fixing idler adjuster assy
Fig. 34-65 Mounting spring (5) and grease cylinder
Install bracket (2) on top of spring (5). Center the
(1) to the jig
rod of grease cylinder (1) and the holes in brack-
et (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.
: 46 mm
3) Compressing spring (5) and removing nut (3)

Extend the hydraulic jack, compress spring (5) to
a set length and screw in nut (3) to the screwed
part at the tip of grease cylinder (1).
Set length of the spring : 270 mm (10.63 in)

4) Installing spring pin (4)
Tighten nut (3) till the holes for locking spring
pins (4) are aligned. Then fit spring pin (4).

: 46 mm
: 55 mm Fig. 34-66 Compression of spring (5), and attaching

nut (3) and spring pin (4)
5) Removing idler adjuster assy
Remove idler adjuster assembly from jig.
Fig. 34-67 Removing idler adjuster assy
34-26
34. TRAVEL SYSTEM
6) Installing oil seal (8), O-ring (7)

Fit oil seal (8) and O-ring (7) to grease cylinder
(1). &
• Apply grease to oil seal (8) and O-ring (7). %
7) Filling grease cylinder (1) with grease. $
Fill grease cylinder (1) with grease, remove
grease nipple from piston (6), and press piston
by hand to discharge air through grease nipple
hole.
• Direct grease nipple hole downward to make
air discharge easier. Fig. 34-68 Grease cylinder (1)
8) Installing grease nipple (11)
Tighten grease nipple (11) to piston (6).
: 19 mm
34.1.5.4.3 MAINTENANCE STANDARD
No. ITEM STANDARD VALUE H
A Installed length of mm 270 (10.63 in)

spring
B Free length of spring mm About 320 (12.6 in)
C Stroke mm 31.8 (1.25 in)
D Set length mm 495 (19.49 in)
Outer circumference No scoring and rusting
E of piston
Tightening torque of A, B, (C)
F grease nipple 58.8 N.m (43 lbt.ft)
Close contact length of spring 235 (9.25 in) H
Fig. 34-69
34-27
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 wood
blocks to float and stabilize.
(2) Removing sprocket
Loosen twelve capscrews (2) (M14) for the mount-
ing of the sprocket by means of a socket and re-
move the sprocket.
Weight of sprocket : 28 kg (62 lbs)
Fig. 34-70 Preparation for removal
: 22 mm

Fig. 34-71 Removing sprocket
34.1.6.2 INSTALLING
(1) Check before installing
Check the mating portion of the travel reduction
gear and the sprocket, eliminate burrs and contam-
ination thoroughly and install the sprocket.
(2) Securing sprocket temporarily.
Coat the sprocket mounting capscrews with Loctite
#262 and fasten the sprocket temporarily.
(3) Securing sprocket completely
Take out wood blocks placed under track frame,
and tighten capscrews to the specified torque.
: 22 mm
Fig. 34-72 Securing sprocket completely
34-28
34. TRAVEL SYSTEM
34.1.6.3 MAINTENANCE STANDARD (2404N267)

Table 34-2
PRINCIPAL PAR- PITCH 78.7 mm (3.10 in) NUMBER OF TEETH 21

TICULARS ROLLER DIA. Ø41 (1.61 in) PITCH DIA. 527.9 (20.78 in)
4 (0.157")
)
94"
4 (0.157")
10
(0.3
(0
.3
10 ")
9 4
20.64
64
(0.813")
20.813")
(0.
7.9
4")
P.C.D 52
(20.783
Fig. 34-73 Sprocket

Table 34-3
Unit : mm (in)
No. ITEM STANDARD VALUE REPAIRABLE LEVEL SERVICE LIMIT REMEDY
Reinforcement weld,
A O.D. of sprocket Ø540 (21.260 ) 534 (21.0) 532 (20.9)
repair or replace
B Width of sprocket teeth 38 (1.4961 ) 32 (1.26) 30 (1.18) Replace.
Reinforcement weld,
C I.D. of sprocket Ø487 (19.2) 481 (18.9) 479 (18.9)
repair or replace
34.1.6.4 SPROCKET TOOTH PROFILE GAUGE
Fig. 34-74 Tooth profile gauge
34-29
34. TRAVEL SYSTEM
34.1.7 TRAVEL MOTOR
34.1.7.1 TRAVEL MOTOR
Apply Loctite #262

2 T=181 N·m (130 lbf·ft)
3
D2 (PF 3/8) Apply Loctite #262
or equivalent
T=279 N·m (210 lbf·ft)
B (PF 1/2)
P (PF 1/4)
A (PF 1/2)
VIEW I D1 (PF 3/8)
Fig. 34-75 Installing travel motor
TRAVEL MOTOR INSTALL LE53D00001F1

1 SPROCKET 2 2404N267
4 TRAVEL MOTOR ASSY 2 YT15V00008F1
34.1.7.2 REMOVING
(1) Preparation for removal 1
Remove crawler, lift up crawler frame using attach-
ment, and put it on wood blocks to float and stabi-
lize.
(2) Removing cover (1) 7
Remove capscrew (7) and also remove covers (1).
: 19 mm
Fig. 34-76 Removing and installing capscrew (7)
34-30
34. TRAVEL SYSTEM
(3) Preparation of oil pan

(4) Removing hydraulic pipe
Bleed air in hydraulic oil tank, remove all pipes con-
necting to travel motor. Then plug up all pipes and
joint section to protect them from entry of dust.
: 19 mm, 22 mm, 24 mm, 27 mm, 32 mm

Plug 4-1
Fig. 34-77 Removing and installing hydraulic pipe

(5) Removing sprocket
Removing twenty four capscrews (2) M14 X 35.
: 22 mm
Fig. 34-78 Removing and installing sprocket

(6) Loosening travel motor mounting bolts Remove pipes (Disconnect)
Apply match marks on travel motor and lower
frame, and remove twenty four capscrews (3) M16
X 40.
: 24 mm
3
Fig. 34-79 Removing and installing travel motor

mounting bolts
(7) Slinging travel motor assy
Sling travel motor with nylon sling applied on the
the side close to sprocket installing section and re-
move the motor.
Weight of motor Approx.90 kg (198 lbs)
Fig. 34-80 Slinging travel motor
34-31
34. TRAVEL SYSTEM
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 track frame is free from burr and stain.
2) Tightening torque
Tighten capscrew and hydraulic pipes to the specified torque.
3) Fill inside from motor drain port to cashing 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.
Parts Size Tools No. Tightening Torque N•m(lbf•ft) Remarks

M14 22 2 181 (134)
Capscrew
M16 24 3 279 (210) Apply loctite #262
Flareless nut Ø10 X 1.5 19 — 49 (36)
for pipes, Ø15 X 2.0 27 — 118 (87)
sleeve Ø18 X 2.5 32 — 147 (110)
PF1/4 19 P 36.3 (27)
Connector PF3/8 22 D1,D2 73.6 (54)
PF1/2 27 A,B 108 (80)
34.1.8 SWING BEARING
34.1.8.1 SWING BEARING ASSY
2
FRONT A A
SECTION A-A
Inner S mark position
of swing bearing
Fig. 34-81 Swing bearing assy
ASSY PART No. LE40F00001F1

1 SWING BEARING 1 2425U261F1
34-32
34. TRAVEL SYSTEM
34.1.8.2 REMOVING
(1) Matchmarks

Remove upper structure, apply matchmarks on in-
ner race of swing bearing and lower frame.

(2) Remove thirty capscrews (2) M16 X 90 for installa-

tion inner race.

: 24 mm
(3) Drawing out grease
Remove grease in grease bath.
Fig. 34-82 Matchmarks
(4) Removing swing bearing
Attach eyebolt on swing bearing (1) and sling it.
Weight of swing bearing : 110 kg (240 lbs)

Fig. 34-83 Removing and installing swing bearing
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 stain.
(2) Installing
Install swing bearing on lower frame meeting the

matchmarks and positioning the S mark on inner
race as shown in the figure.
(3) Temporary fastening of inner race
Coat the threads of the capscrews (2) with Loctite
#262 and tighten all the capscrews (2) (24 pcs) to
an extent that they are fastened temporarily.

: 24 mm

(4) Regular tightening of inner race

Fasten the capscrews (2) (24 pcs) at 180 degrees Fig. 34-84 Location of S mark on swing bearing
intervals alternately and tighten them up to a spec-
2
ified torque. Apply Lpctite #262 or equiva-
lent to be applied
: 24 mm T=279 N·m (210 lbf·ft)
1
(5) Filling grease
Fill grease bath with 5 kg (11 lbs) of grease NLGI-
2 (molybdenum disulfide grease) or equivalent.
SECTION A-A
Fig. 34-85 Removing and installing capscrew (2)
34-33
34. TRAVEL SYSTEM

Fig. 34-86 Cross-section
ASSY PART No. 2425U261F1

1 OUTER RACE 1 6 SEAL 1
2 INNER RACE 1 7 GREASE NIPPLE
3 BALL 84 (PT1/8) 1
4 RETAINER 84 8 TAPER PIN 1
5 SEAL 1 9 PLUG 1

(1) Disassembly

1) Take out seal (5) fitted in the groove in the outer
circumference under inner race (2) and seal (6)
fitted in the groove in the inner circumference on
top of outer race (1) and place them level on a

wood blocks or something.
2) Draw out taper pin (8), using a hammer and an
extrusion rod.
3) Draw out plug (9), inserting a pull bolt in the
screwed hole of the plug and using a puller.
Fig. 34-87 Removing swing bearing
4) While rotating outer race (1) little by little, take out
ball (3) and retainer (4) through plug hole, in that
order.
"
!
Fig. 34-88 Removing balls (3) and retainers (4)
34-34
34. TRAVEL SYSTEM
(2) Installing
1) After cleaning grooves for seal (6) on inner sur-
face on the upper side of outer race (1), and for
seal (5) on the outer surface of inner race (2), ap-
ply adhesive agent Cyano-bond PO-1, fit seal 1
(5), and place them on a surface plate.
Push rod 6
2) Lower outer race (1) to the position where upper
surface of inner race (2) and lower portion of seal 2
groove are mated, put adjusting washer under
outer race (1) so that raceway surface of ball (3) Wood rod 53
agrees, and support it. Fig. 34-89 Fitting balls (3)
3) Insert ball (3) and retainer (4), on which grease
Eye blte
is applied, through plug (9) 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
plug hole. 4
4) Fit plug (9) to outer race (1) while checking it for Wood blocks
direction and position of taper pin hole. Fig. 34-90 Fitting retainer (4)
5) Apply adhesive agent Cyano-bond PO-1 to seal
(7), and fit it to groove of outer race (1).
6) Check that grease nipple (7) is properly fitted,
and fill it with grease. Then, check bearing for
smooth rotation and flaws on seal lip portion.

Maintenance standard concerning wear of swing bearing is described in the item 13.6"Measuring Swing Perfor-
mance" in the section 13. "Maintenance Standard and Test Procedure" in the separate volume.
34-35
34. TRAVEL SYSTEM
34-36
34. TRAVEL SYSTEM

34.2.1 TRAVEL MOTOR
(1) General view
D1
B
D2
OIL LEVEL CHECK PORT PF3/8 FILLING PORT PF3/8
DRAIN PORT PF3/8

VIEW Z
Fig. 34-91
HYDRAULIC CIRCUIT
PORT NAME AND SIZE

No. Ports Size
A Hydraulic oil filling / drain port
PF 1/2
B Hydraulic oil filling / drain port
D1 Drain port
PF 3/8
D2 Drain port
P 1st / 2nd speed select port PF 1/4
ROTATIONAL DIRECTION (Viewed from Z side)

INLET B PORT, OUTLET A PORT, CW
INLET A PORT, OUTLET B PORT, CCW
Fig. 34-92
34-37
34. TRAVEL SYSTEM
(2) Exploded view

1) Exploded view of reduction unit
21
31
19
3
2
17
21
30 5
43
12
23
9
23 18
12 34
4
8 35
22 29
28
6
7
25 15
25
20
22
35 33
36
24
2) Exploded view of hydraulic motor

"#
" !#
&
!& %#
! !
% ' '
!
& # #
$
" $ #
%
&
!& &$
& # " #
%# "
%'
'% !$ '' %
'! ! "
& !&
' '$
$& & "$ &
&' &#
!& ' &" & %#
' '$ &$ !
&% &! !& $ "'
# & $
'# &#
&& '" &"
' &#
& !
% '
% & '! #
%%
' %# '% & %$

'" !$
&& "
'#
&%
'
!&
&'
34-38
34. TRAVEL SYSTEM
(3) Parts list

1 HUB 1 PISTON KIT 1
• PISTON ASSEMBLING PARTS 9
SPINDLE KIT 105 • • PISTON 1
• SPINDLE ASSY 1 106 • • SHOE 1
2 • • SPINDLE 1
3 • • HOLD FLANGE 1 • PISTON ASSEMBLING PARTS 1
19 • REAMER BOLT 3 161 • • PISTON 1
162 • • SHOE 1
RV GEAR ASSEMBLING PARTS 1
• RV GEAR KIT 1 102 SHAFT 1
4 • • RV GEAR A 1 103 SWASH PLATE 1
5 • • RV GEAR B 1 104 CYLINDER BLOCK 1
9 • CRANK SHAFT 3 107 RETAINER PLATE 1
12 • SPACER 6 108 THRUST BALL 1
22 • BEARING 6 109 TIMING PLATE 1
23 • BEARING 6 110 WASHER 2
112 PISTON 1
6 INPUT GEAR 1 113 SPRING 8
114 SPRING 1
SPUR GEAR KIT 1 115 FRICTION PLATE 2
7 • SPUR GEAR 3 116 SEPARATOR PLATE 2
132 OIL SEAL 1
FLOATING SEAL KIT 1 135 O-RING 1
31 • FLOATING SEAL 2 141 O-RING 1
146 SNAP RING 1
8 COVER 1 149 BEARING 1
15 SHAFT 1 150 BEARING 1
17 PIN 28 151 BEARING (ROLLER) 3
18 RING 1 176 PIVOT 2
20 SNAP RING 3 177 PARALLEL PIN 2
21 BEARING 2 185 SPRING 1
24 SNAP RING 1
25 SNAP RING 6 REAR FLANGE ASSEMBLING PARTS 1
28 O-RING 2 • REAR FLANGE KIT 1
29 O-RING 1 201 • • REAR FLANGE 1
30 O-RING 1 223 • • SPOOL 1
33 PLUG (WITH FLANGE) 1 252 • • SOCKET PLUG 2
34 PLUG 2 268 • • STEEL BALL 1
35 O-RING 3 275 • • SOCKET PLUG 10
36 STEEL BALL 1 279 • • FILTER 1
43 PARALLEL PIN 2 280 • • ORIFICE 4
34-39
34. TRAVEL SYSTEM

283 • • PLUG (WITH FLANGE) 1 284 • PLUG 2
286 • • PISTON 2 285 • O-RING 2
299 • • NAME PLATE 1 287 • VALVE 2
288 • SLEEVE 2
• SPOOL KIT 1 289 • PLUG 2
271 • • SPOOL 1 290 • SPRING 2
272 • • OIL STOPPER 1 291 • O-RING 2
221 • PLUG 2 292 • O-RING 4
224 • PLUG 2 293 • PISTON SEAL 2
225 • SPRING RETAINER 2 294 • BACKUP RING 4
227 • VALVE 2 295 • BACKUP RING 4
228 • SPRING 2 296 • STEEL BALL 2
230 • SPRING 2 297 • ORIFICE 2
236 • O-RING 2
238 • O-RING 6 242 PARALLEL PIN 2
281 • SPRING 1 245 SOCKET BOLT 6
282 • PLUG 4
34-40
34. TRAVEL SYSTEM
34.2.1.2 TOOLS AND JIGS

(1) Standard tools
Tools Size Q'ty Application item (No.)

Torque wrench Nominal 450 Dial type 1 284
Torque wrench Nominal 1800 Dial type 1 33, 34, 221, 245, 282, 289
Torque wrench Nominal 5500 Dial type 1 19, 224
Allen wrench Nominal 5 1 284
Allen wrench Nominal 6 1 34
Allen wrench Nominal 8 1 33, 34, 221
Allen wrench Nominal 10 1 245, 282
Socket Nominal 5 Inset square 12.7 1 284
Socket Nominal 8 Inset square 12.7 1 33, 34, 221
Socket Nominal 10 Inset square 12.7 1 245, 282
Socket Nominal 22 Inset square 12.7 1 289
Socket Nominal 36 Inset square 12.7 1 19, 224
Extention bar Inset square 12.7 1 19
Spanner Round shaped powerful spanner 36 1 224
Hammer Nominal 12 1 1, 21
Plastic hammer L=300 (12") or so 1 8, 102
Snap ring pliers For shaft 1 24, 25
Snap ring pliers For bore 1 20, 145
Center punch Ø9.5 X 100 (0.374" X 4" ) 1 1
Pin punch Ø3 X 150 (0.127" X 6" ) 1 21
Lifting tool Hook, wire rope 1 Set 1,2 for lifting
Car washing brush 1 Cleaning the parts
Wire brush 1 Cleaning the parts
Vat for general use
Lubricant, draining hydraulic oil
Container W450 X D300 X H120 3
ball (36, 268, 296) retainer
(W18" X D12" X H5" )
Paint marker Oil base white 1 For matching mark
Metal screen basket 1 17
Rubber mat 1
Leather gloves 1 Pair 149
Jug For hydraulic oil, For lubricant. 2 Oil filling
34-41
34. TRAVEL SYSTEM
(2) Tools
Tools Size Application item (No.) Q'ty

General work bench Disassembly and assembly 1 set
Cleaning bath For rough cleaning and finish cleaning Cleaning the parts 1 set
Work bench for press Pressing capacity 200 kg (441 lb) or over 104, 149 1 set
Heating capacity 100°C (212°F) or over
Heating bath 149 1 set
Size 500 X 500 X 500 (20" X 20" X 20")
Portable electric drill
Electric drill 1 1
[Max. drill depth Ø10 (0.394")]
Drill Ø2 (0.0787") 1 1
Disassembly 161,162,163, 112
Compressed air Pressure 0.29~0.49 MPa (43~71 psi)
Drying after cleaning
Lathe 3 1 set
(3) Measuring instrument
Tools Size Application item (No.) Q'ty

Measurement range : 0.04~0.3 mm For snap ring (20)
Thickness gauge 2
(0.0016~0.012 in) thickness adjustment
Measured range : 0~25 mm (0~0.98 in) For snap ring (20)
Outside micrometer 1
Minimum graduation : 0.01 mm (0.0004 in) thickness adjustment
Measured range : 0~25 mm (0~0.98 in) For bearing (21)
Single depth micrometer 1
Minimum graduation : 0.01 mm (0.0004 in) pre-load adjustment
34-42
34. TRAVEL SYSTEM
1) Working bench for travel motor

This is used to carry out the work for assembly
and disassembly of travel motor easy and safe.
2) Fixing metal
This is used to connect spindle (2) and hub (1).
3) Retainer metal (I)

This is used to insert spring (114), washer (110),
snap ring (145) into cylinder block (104).
4) Retainer metal (II)

This is used to pull out bearing (149) from shaft
(102).
34-43
34. TRAVEL SYSTEM
5) Retainer metal (III)

This is used to press-fit oil seal (132) into oil seal
fitting hole of spindle (2).
6) Retainer metal (IV)

Apply it on outer race of bearing (22) fitted on
crankshaft (9) of RV gear assy, then strike it to in-
sert RV gear assy securely.
7) Jig for adjusting the preload to the bearing

This is used to press-fit bearing (21) in hub (1),
and also used to measure clearance of bearing
(21) in shaft direction.
8) Steel rod (I)

This is used to remove ring (18) from hub (1).
34-44
34. TRAVEL SYSTEM
9) Eye bolt for PF

This eye bolt is used to remove cover (8) from
hub (1) with wire and crane.
Screw size : PF3/8
PF3/8
10) Long eye bolt

This eye bolt is used to sling up travel motor,
spindle (2) and hub (1).
Application "A"
Hub M14
Spindle M16
"A"
Travel motor M16
11) Spatula
This is used to remove timing plate (109) from
rear flange (201).
12) Pin punch

This is used to remove outer race of bearing
(21).
34-45
34. TRAVEL SYSTEM
13) Jig for removing cover

This is used to remove cover (8) from hub (1).
14) Floating seal fitting tool (I)

This is the tool that is used to assemble floating
seal (31) to hub (1).
15) Floating seal fitting tool (II)

seal (31) to spindle (2) and hub (1).
16) Floating seal fitting tool (III)

seal (31) to spindle (2).
34-46
34. TRAVEL SYSTEM
34.2.1.3 TIGHTENING TORQUE
Application Bolt • Nut Opposing flats Tightening torque

Item (No.) Parts Size (mm) N•m (lbf•ft)
19 Reamer bolt M24 P2.0 36 794 ± 49(586 ± 36)
33 Plug (with flange) PF3/8 8 59 (43)
34 Plug PF3/8 8 59 (43)
221 Plug PF3/8 8 59 (43)
224 Plug M30 P1.5 36 353 (26)
245 Socket bolt M12 P1.75 10 102 (75)
282 Plug PF1/2 10 98 (72)
284 Plug PF1/8 5 12.3 (9.0)
289 Plug PF1/2 22 98. (72)
34.2.1.4 WEIGHT
Parts Weight [kg (lb)]

Travel motor assy Approx. 81 (179)
Hub 19 (41)
Spindle 27 (60)
Rear flange assy 9.7 (21)
34-47
34. TRAVEL SYSTEM
34.2.1.5 DISASSEMBLY
(1) Preparation
Prepare as below before disassembly :
1) Preparation of work bench
Prepare a work bench for the travel motor.
The work bench must be sufficiently solid to disassemble and assemble the internal components of the travel
motor and sufficiently spacious to place components so components do not fall or move during operation.
Place a rubber or plastic sheet on the work bench.
2) Preparation of tools and materials
Prepare those tools and materials listed under Article. 34.2.1.2.
(2) General precautions to be exercised at work
• The internal components are wet with hydraulic oil and slippery during disassembly :
Handle them with care because you may be injured by the fall of components may or components may be
damaged.
• Such flammables as clear kerosene are used to clean components. Handle flammables as they are easy to
be caught a fire.
1) Before disassembly, decide inspection points and check the nature of the trouble.
2) Handle the components with care as they are finished to high precision. Take care so as not to hit and drop
the components.
3) If the components are struck or twisted by force during disassembly, they develop burrs or broken in some
cases. This makes the components unable to be reassembled or deteriorates the performances. Therefore,
handle them with care and patience.
4) If components are left separated or in the midst of disassembly, they develop rusting by humidity and dust.
Take rust and dust prevention treatment in case work is suspended halfway.
5) During disassembly, leave a matching mark on the mating face of each component.
6) Arrange disassembled components in order as the work proceeds so they are not damaged or lost during
work.
7) It is a rule to replace seals once disassembled. (even though they are not scored on an appearance) Get new
seals ready before disassembly.
8) Photos and illustrations shown are typical models. Although they may differ from those in use, they do not
affect the disassembly procedure.
34-48
34. TRAVEL SYSTEM
(3) Removing
1) Cleaning travel motor
1. Tighten the eye bolts into the tapped holes of the
spindle (2).
• Fasten two eye bolts into the tapped holes for the
spindle so they are located diagonally opposite to
one another.
2. Place a wire sling in the eye bolts, lift the travel

motor by hoist, and carry in to the cleaning bath.
3. Clean the travel motor with a car brush.
• Since soil and sand are entered in the clearance

(where the floating seal is fixed) between hub (1)
and spindle (2), clean it with particular care.
1 2
2) Installing travel motor

1. Fix travel motor with two socket bolts on working
bench.
• Align threaded holes of hub (1) and working bench

and place travel motor in fixing hole of working
bench slowly.
Tighten up the socket bolts rigidly. Unless tightened rig-

idly, the components drop as the travel motor is turned
over and cause bodily injuries.
34-49
34. TRAVEL SYSTEM
3) Draining oil.
1. Turn over the travel motor.
2. Loosen one plug (33) and two plugs (34).
• If the plug (33), (34) is removed and the travel mo-

tor is reversed, oil spills. Stop loosening the plug
when it can be turned by hand.
33, 34
• When draining out the oil, place a container under

the work bench.
4. Remove one plug (33) and two plugs (34) from 34

the cover (8) and drain out the oil. OIL FILL PORT
(PF3/8)
5. Remove O-ring (35), one plug (33) and two plugs
(34).
6. Remove O-ring (35) from two plugs (34).
• Do not reuse removed O-ring (35).
33 DRAIN PORT (PF3/8)
4) Removing cover.
2. Mark on the mating surface between hub (1) and
cover (8), using marker paint.
8 1
34-50
34. TRAVEL SYSTEM
3. Find the mating part of ring (18), and punch at a 18

point of the outside of the hub, approximately 20
mm (0.8 in) inward from the tip of ring (18) for
drilling purpose.
(Mating part) (0.

8") COVER (8) RING (18)
2
(0.08")
HUB
4. Drill through a 2mm (0.08 in) hole from the out- 18

side of hub (1) toward ring (18) using electric drill.
• Put a drill against the punched hole and drill it

through so the ring takes off the cover as it is
pushed by the drill.
• Wipe off the metal chips produced by drilling so
they do not score the parts to be removed.
5. Put a steel bar into the hole and push ring (18). 18
• In that case, the tip of the ring (18) stands out above
the cover (8) as pressed by a steel bar.
6. Hold the tip of ring (18) sticking out of the cover 8

(8) and draw the ring (18) out of the ring groove
of the hub (1).
18 1
34-51
34. TRAVEL SYSTEM
7. Fix two bolts inside of jig to the plug holes of drain

(33)(34).
• In case the cover (8) is hard to remove because of

the resistance of the O-ring (29), lift it up while light-
ly tapping the outer rim of the cover by means of a
plastic mallet.
8 COVER REMOVING JIG
8. Tighten two bolts outside of jig then two bolts (in-

stalled in plug holes) inside of jig float with cover
(8).
9. Remove O-ring (29) from cover (8).
8 (29)
5) Removing input gear. 15

1. Remove snap ring (24) from shaft (15).
• When the snap ring is removed, the tip of the pliers

slips from the snap ring hole and the snap ring
jumps up in some cases. Be careful not to slip the
pliers.
24
34-52
34. TRAVEL SYSTEM
2. Remove input gear (6) from shaft (15). 36 6
15
6) Removing spur gear 9, 25

1. Remove two snap rings (25) from crank-shaft (9).

pliers.
2. Remove three spur gears (7) from crank-shaft 7

(9).
3. Remove three snap rings (25) from crank-shaft 9

(9).

pliers.
25
34-53
34. TRAVEL SYSTEM
7) Removing shaft 15
1. Remove shaft (15) from shaft (102).
8) Removing rear flange 289

1. Turn over the travel motor
• This work is intended to remove the plug easily

when removing the inside of the rear flange.
• On that occasion, loosen the plug so it can be re-
moved by hand.
• Do not loosen the plug if you do not remove the in-
side of the rear flange.
2. Loosen two plugs (282)

5. Loosen six socket bolts (245) from rear flange
(201).
245
34-54
34. TRAVEL SYSTEM
6. Remove rear flange (201) from spindle (2). 201
• Hold the rear flange by both hands, hold it up gently

upright and remove it.
Forced prying or striking it may cause timing plate
(109) to fall and damage it.
7. Remove parallel pins (43) from spindle (2).
43
8. Remove O-ring (28),(30) from spindle (2).
• Do not reuse removed O-ring (28), (30).
30 28
34-55
34. TRAVEL SYSTEM
9) Removing the rear flange fittings

1. Place rear flange (201) on a work bench, with the
mating surface for spindle (2) facing up.
2. Remove timing plate (109) from rear flange
(201).
• If it is hard to remove the rear flange in some cases

as the mating surface of it is stuck with oil. Insert a
spatula into the draft groove of the mating surface
on the rear flange side and hold the timing plate up.
201 109
Then the rear flange comes off. If a sharp tool like
screwdriver is put into the mating surface, the mat-
ing surface is scored, causing an oil leakage ; do
not use sharp tools.
3. Remove parallel pins (242) from rear flange

(201).
242 201
4. Remove bearing (150) from rear flange (201).
150
201
34-56
34. TRAVEL SYSTEM
10) Removing the shockless relief valve (SRV) from

the rear flange.
1. Remove two plugs (282) of rear flange (201).
2. Remove O-ring (238) from plug (282).
282 201
3. Remove piston (286) from rear flange (201).
286 201
4. Remove two plugs (289) from rear flange (201).

289 238
6. Remove spring (290), valve (287) and sleeve

(288) from rear flange (201) in that order.
287, 288, 290 201
34-57
34. TRAVEL SYSTEM
7. Remove O-ring (292), backup ring (294) from

sleeve (288).
• Do not reuse removed O-ring (292) and backup ring

(294).
294 288
8. Remove piston seal (293) from valve (287).
PISTON SEAL (293)

• Do not reuse removed piston seal (293).
VALVE (287)
9. Remove plug (285) and steel ball (296) from rear

flange (201).
• Do not disassemble plug (285) except in case nec-

essary.
• Be careful to fall the steel ball (296).
285, 296 201
11) Removing the brake valve parts from the rear

flange.
1. Remove two plugs (224) of rear flange (201).
236, 224 201
34-58
34. TRAVEL SYSTEM
3. Remove two spring retainer (225) and two

springs (228) from rear flange (201).
4. Remove spool (223) from rear flange (201).
• To remove spool (223), place your hand on one part

of the plug port of rear flange (201) and tilt it down.
Then spool (223) falls down. Hold the tip and re-
move it.
223, 225, 228 201
5. Remove two plugs (282) from rear flange (201).

238 282
7. Remove two springs (230) and two valve (227)

from rear flange (201).
227, 230 201
12) Removing the pilot valve parts from the rear

flange.
1. Remove plug (221), spool (271) and spring (281)
from the rear flange (201).
221
271
281
34-59
34. TRAVEL SYSTEM
13) Removing the parking brake 112
The sudden blowing of compressed air may cause pis-

ton (112) to jump out of the spindle (2) incurring the
danger of injury. Cover piston (112) for protection.
1. Blow jet air into the passage hole for the paring
brake of the spindle (2) and take out the piston
(112) from the spindle (2).
2. Remove O-ring (135), (141) from piston (112). 112
• Do not reuse removed O-ring (135), (141).
135, 141
14) Removing the hydraulic motor section
• When placing the travel motor on its side, oil spills ;

place a container under the travel motor. 115
115
116
116
1. Incline travel motor 90 degrees. (Lay it down.)
2. Drain out the oil of the travel motor.
3. Remove two friction plate (115) and two separa-
tor plate (116).
34-60
34. TRAVEL SYSTEM
4. Hold cylinder block (104) by hand, remove shoe 106

(106) adhered on swash plate (103) turning 2 or
3 times alternately.
• If the cylinder block is pulled out without separating

shoe, the shoe (106) remained on swash plate
(103) (piston, shoe) may drop in spindle (2).
5. Remove cylinder block (104) from shaft (102).

6. Remove piston assy [piston (105) and shoe
(106)] and retainer plate (107) from cylinder
block (104). 104 102 2
• When removing the cylinder block, hold the retainer

plate (107) by both hands and remove it with the
piston assy.
106
• The piston (105) and the shoe (106) are made in 107
one piece as they are caulked by the spherical sur-
105
face of the piston. It is not possible to remove the
piston from the shoe without damaging the shoe. 104
When replacement is required, replace 9 sets of
piston (105) and shoe (106). (Hereafter called pis-
ton assy.)
7. Remove the piston assy (105), (106) from retain-

er plate (107). [Nine pistons]
107 105, 106
34-61
34. TRAVEL SYSTEM
8. Remove thrust ball (108) from cylinder block 108

(104).
104
9. Remove three rollers (151) from cylinder block 151

(104).
104
15) Remove spring (114) from inside of cylinder

block.
1. Place cylinder block (104) on the press bench.
PRESS
• Do not remove the spring except when replaced.

• When removing the spring, align the Jig (I) with the Plastic sheet
washer in order to prevent the cylinder block from
being damaged by contact.
• Put a plastic sheet over the cylinder block so as not
to score the surface of the cylinder block. JIG 104
34-62
34. TRAVEL SYSTEM
2. Apply Jig (I) on washer (110), remove snap ring

JIG (I)
(146) from the groove with snap ring plier press- PRESS
ing the metal with a press. 146
114
110 104
Release press slowly. Sudden releasing may cause
spring to fly out incurring the danger of injury.
3. Remove the snap ring (146), washer (110),

110
spring (114), and washer (110) from inside the
cylinder block (104).
110
114
114
104
16) Removing out swash plate (103).

1. Removing swash plate (103) from shaft (102).
• When removing it, check that pivot (176) is not ad-

hered on swash plate (103).
102 103
2. Pull shaft (102) out of spindle (2). Then bearing

(149) is removed together.
• The shaft comes off easily if the tip of the shaft on

the reduction gear side is tapped lightly, using a
plastic mallet. If it is struck forcibly, shaft may be
projected. Strike it with care.
3. Remove two pivots (176) and two parallel pins

(177) from the spindle (2).
149 102 176, 177 2
34-63
34. TRAVEL SYSTEM
161, 162
The blowing of compressed air may cause two speed

piston assy projecting incurring the danger of injury.
Cover projection section for protection.
4. Blow compressed air through passage of spin-

dle, and remove two speed switching piston assy
(piston, shoe) and spring (185) from spindle (2).
Piston assy
• Piston (161)
• Shoe (162)
• Compressed air
Pressure : 0.29~0.49 MPa (43~71 psi)
17) Removing bearing. PRESS
149
1. Place the retainer metal (II) on a press bench.
RETAINER METAL (II)
• Remove it only when replacing the ball bearing.

102
2. Put the shaft (102) in it. Hold down the tip of the
shaft by press and remove the bearing (149)
from the shaft.
• Do not reuse the bearing.
18) Remove hold flange (3) FIXING METAL
2. Fix hub (1) and spindle (2) with fixed metal. Then,
the fixed metals should be tightened on symmet-
rical positions each other.
• If the hold flange (3) is removed without at-
taching the fixing metal, the hub (1) sepa-
rates from the spindle (2), causing the
spindle (2) to fall from the work bench.
1 2
When the snap ring is removed, the tip of the pliers slips
from the snap ring hole and the snap ring jumps up in
some cases. Be careful not to slip the pliers.
4. Remove three snap rings (20) from the hold

flange (3).
20 1 3
34-64
34. TRAVEL SYSTEM
5. Put matching mark on snap ring (20) and hold

flange (3) with an oil paint marker.
• This is to place them in the same positions as at in-

stallation.
3 20
6. Incline travel motor 90 degrees.

7. Loosen three reamer bolts (19).
• The threaded portion of reamer bolt (19) is provided

with adhesive agent and may cause the seizure on
the reamer portion where the adhesive agent is ap-
plied, leading to the difficulty of disassembling.
Therefore loosen reamer bolt 19) slowly. If it turns
tightly in the middle way, tighten it one more time,
then loosen it again.
19
• The tightening torque is 794 ± 49 N•m (590 ± 36
lbf•ft). A torque more than it is needed to loosen the
bolt because of adhesive.
8. Tilt the travel motor to 90 degrees once again to

bring it back where it was.
9. Remove holding flange (3) from spindle (2).
10. Put match marks on hold flange (3) and spindle

(2) with paint marker.
• This is intended to install the hold flange (3) in the

same position as the spindle (2).
• The three mounting holes for reamer bolts (19) in
the spindle (2) are machined together. In case they
must be replaced, replace the spindle 2) and the
hold flange (3) together as a set assy). [Hereafter
called spindle assy]
3
34-65
34. TRAVEL SYSTEM
19) Removing fixing metal. FIXING METAL

2. Remove three fixing metal.
20) Removing spindle.

1. Place a clean container under the travel motor.
2. Tighten two eye bolts into the tapped holes of
spindle (2) so they are located in diagonally op-
posite positions.
3. Hook sling to eye bolt, lift spindle (2) up and re-
move it from hub (1). Then, floating seal (31),
outer race of bearing (22), and oil seal (132) are
also removed together.
1 2, 31, 22, 132
21) Removing bearing, RV gear assy and pin

1. Remove floating seal (31) from hub (1).
2. Remove bearing (21) from hub (1) striking
pin(17) end face with punch and mallet. Then,
RV gear assy [RV gear A (4), RV gear B (5),
crankshaft (9), bearing (22) bearing (23), spacer
(12)] and pin (17) are also removed together.
• Remove bearing (21) striking 3 or 4 points of perim-

eter evenly taking care for bearing not to be in-
31
clined.
• When the fit section of outer race of bearing (21) is MALLET 1
separated, bearing (21), RV gear assy and pin (17) ALUMINUM ROD 21
drop from hub (1). So spread rubber mat under the
working bench to protect them from damage.
22 4
17
23
5
12
21
9
34-66
34. TRAVEL SYSTEM
3. Separate RV gear A (4) and RV gear B (5) from

crankshaft (9).
21
• Never remove bearing (22), bearing (23) and spac-
er (12) from crankshaft (9) except for replacement.

5. Remove bearing (21)
21
• Remove bearing (21) striking 3 or 4 points of perim-

eter evenly taking care for bearing not to be in-
clined.
22) Removing the spindle fittings.

OIL SEAL (132)
1. Remove oil seal (132) from spindle (2).
SPINDLE (2)
• Never reuse removed oil seal (132).
2. Remove floating seal (31) from spindle (2).
31
34-67
34. TRAVEL SYSTEM
3. Remove the outer races (3 pcs.) of bearing (22)

from spindle (2).
• It is sometimes hard to remove the outer race of the

bearing (22) as the outer race of the taper roller
bearing comes in close contact with the mating sur-
face of the spindle by oil films of lubricating oil. In
that case, tap the center of the spindle (2) with alu-
minum rod. Then the outer race is removed easily.
2 22
23) Disassembling holding flange

1. Remove outer race of bearing (22) from hold
flange (3).
3 22
24) Rough washing of parts.

1. Classify the parts as four groups ; hub (1), spin-
dle (2), cover (8), and rear flange (201) and other
parts (hereafter called built-in parts).
2. Put the hub, spindle, cover and rear flange in a
cleaning bath and clean them.
• Soil and sand are adhered to the outer surface of

parts in some cases ; clean them and remove soil
and sand from the parts.
1
Wash oil is flammable. Be careful not to catch fire.
3. Put the built-in parts in a rough cleaning bath and

clean the parts.
• Before cleaning stained parts, immerse them in

wash oil until dust and stain become soft and are
floated to protect them from damaging when clean-
ing.
34-68
34. TRAVEL SYSTEM
25) Finish cleaning

1. Put parts in a finish cleaning container and clean
them well, turning them slowly.
2. Wipe off the light oil adhered to the parts, using a
clean rag.
• Blow compressed air in the inner surface of hub (1),

spindle (2) and hold flange (3) to dry in the dust free
and dry conditions. After drying, apply hydraulic oil
to every part.
3
• Inner surface of rear flange (1), hydraulic motor
parts, and RV gear assy are to be dried naturally in
the dust free and dry conditions. After drying every
part, apply hydraulic oil to every part.
• Use care not to damage the surface of twenty eight
pins (17) or lose them while handling.
34-69
34. TRAVEL SYSTEM
34.2.1.6 ASSEMBLY
(1) Assemble it by reversing the procedure of disassembly.
(2) General precautions for assembly
1) Assemble it in clean air condition.
2) Do not use cloth gloves during assembly.
3) Replace or repair the damaged parts during disassembly according to the instructions in the "Maintenance
standard". Replace O-ring, oil seal, etc. with new one.
4) Clean every part sufficiently, and blow them with compressed air do not use rag.
5) Prior to assembling, apply clean hydraulic oil to moving and sliding portions of hydraulic motor valve.
6) Tighten bolt and plug to the specified torque using torque wrench.
7) Replace reamer bolt with new ones. If it is unavoidably reused, remove completely the adhesive agent on
reamer bolt, repair flaws on bolt seat surface with oilstone, and degrease it.
8) Prior to assembling, apply grease to lip portions of O-ring, oil seal, and floating seal to protect it from being
damaged, and to moving section and sliding section.
9) After assembly, plug every port to prevent the entry of dust, etc.
(3) Preparatory arrangement for assembly
After replacing parts with new ones, adjust the pre-load of bearing and thickness of snap ring without fail.
1. When the following parts are replaced, the preload adjustment of bearing is required.
Hub (1)
Spindle (2)
Hold flange (3)
Bearing (21)
2. When the following parts are replaced, the snap ring thickness adjustment is required.
Spindle kit (2)
Hold flange (3)
Crankshaft (9)
Spacer (12)
Bearing (22)
The assembling procedure varies according to the procedure of the above described parts.
• Where replacing the above parts, the previously adjusted parts should be used. If unadjusted parts are used,
the travel motor moves abnormally, causing early breakage.
34-70
34. TRAVEL SYSTEM
1) Installing hub (1).

1. Install two eye bolts into the tapped holes of hub
(1) so they are located in diagonally opposite po-
sitions.
2. Hook eye bolt of hub (1), and lift up and place it
on working bench.
• Align hub (1) to the mounting holes of the work
bench, while matching the holes in hub (1) with
those in the work bench.
3. Install hub (1) to the work bench and fasten sock-

et bolts so they are located in diagonal positions.
Fasten the socket bolts securely. If the bolts are not

tightened sufficiently, the travel motor may fall when
turned over, which is dangerous.
4. Insert bearing (21) in hub (1).
• Place a pin punch against the outer race of bearing

(21), hammer it lightly all around and press in the
bearing little by little.
21
5. Assemble floating seal (31) to hub (1), using the

assembling jigs (I), (II).
31 FLOATING SEAL INSERT JIG (I) (II)
34-71
34. TRAVEL SYSTEM
2) Assembling spindle section.

1. Coat the O-ring of floating seal (31) with hydrau-
lic oil and install the floating seal into the groove
of the floating seal groove in spindle (2), using
assembling jigs (II), (III).
• Remove O-ring from floating seal and apply
grease on its outside lightly.
• Fit floating seal so that spindle groove is in
parallel with floating seal surface after fitting
O-ring in spindle groove rightly.
FLOATING SEAL
31 2 INSERT JIG (II) (III)
2. Insert three outer races of bearing (22) in holes

of spindle (2) respectively.
22 2
3. Tighten two eye bots in the threaded holes on

spindle (2) in symmetric situations.
4. Tighten eye bolt, and lift up spindle (2) and place
it in hub (1).
1 2
5. Fix hub (1) and spindle (2) with fixing metal in

symmetrical position.
• If the motor is turned over without attaching the fix-

ing metal, the hub (1) separates from the spindle
(2), causing the spindle (2) to fall from the work
bench.
FIXING METAL 1 2
34-72
34. TRAVEL SYSTEM
3) Install RV gear assy.

1. Insert RV gear A (4) to hub (1).
1 4
2. Fit three crankshafts (9) in holes for bearing (22)

inside of spindle (2).
• Then, bearing (22), bearing (23) and spacer
(12) are already fitted in crankshaft.
9, 12, 22, 23
3. Insert RV gear B (5) to hub (1)

• Since teeth of RV gear A (4) and RV gear B
(5) are engaged in phase, match punched
point on the end, and fit it.
1 5
4. Insert twenty eight pins (17) between pin groove

of hub (1) and tooth groove of gear.
• Prior to inserting, apply lube oil to pin (17).
17
34-73
34. TRAVEL SYSTEM
5. Insert bearing (21) to hub (1) 21

• Apply pin punch on outer race of bearing
(21), and strike it in all around with mallet to
press fit.
4) Installing hold flange
1. Check that hub (1), spindle (2), hold flange (3),
two bearings (21) are not replaced with new
ones.
• If they are not replaced, proceed the next
process.
• Even if one of them is replaced, adjust hold
flange (3) referring to Item " procedure of the
1
Pre-load to bearing (20)" in this section, and
proceed to next process.
2. Fit hold flange (3) to inner race of bearing (21) in
hub (1).
• Install hold flange (3) to bearing (21) on the
same position as it was, put matchmarks on
spindle (2) and crankshaft (9).
• If it is difficult to insert hold flange (3) in inner
race of bearing (21), strike hold flange (3)
lightly and equally with plastic mallet to insert
in bearing (21).
21 1 9 3
5) Tightening reamer bolt (19).

1. Coat the reamer part of reamer bolt (19) with an-
tiseize lubricant and coat the threaded part of the
reamer bolt with adhesive.
• In case oily matter is stuck to the reamer bolt,
degrease it and after cleaning, dry them in
natural condition. Coat the reamer bolts with
adhesive.
• Fasten three reamer bolts (19) equally little
by little. If you fasten one or two bolts first,
hold flange (3) tilts, making bearing (21) un-
able to be pressed into hold flange (3). This 19 3
causes reamer bolts (19) to seize them-
selves. Therefore, tighten them evenly all
round.
2. Tighten three reamer bolts (19) until hold flange
(3) is fitted into bearing (21) evenly.
3. Tighten three reamer bolts (19) to the specified
torque.
34-74
34. TRAVEL SYSTEM
4. Turn over the travel motor. 22

5. Remove (two) fixing metal.
7. Fit the outer race of bearing (22) to hold flange
(3).
6) Fixing snap ring.

1. Check that spindle (2), hold flange (3), crankshaft
(9), bearing (22) and spacer (12) are not re-
placed.
• Go to next process if nothing is replaced.

• Even if one of them is replaced, adjust clearance in
shaft direction of bearing (22) and proceed to next
process.
(Refer to Item 21) "Procedure of axial clearance ad-
3 20
justment of bearing (22)" in this section.)
• When replacement of snap ring (20) only is re-
quired, use the same snap ring as the removed
snap ring (20) or select one equivalent to the re-
moved one from 15 types.
2. Fix snap ring (20) to the snap ring groove in hold

flange (3).
• Install three snap rings (20) meeting to match mark

on hold flange (3).
When required to use new snap ring (20), use snap
ring selected according to the specified thickness in
the previous process.
34-75
34. TRAVEL SYSTEM
3. Put three snap rings (25) to crankshaft (9).
9 25
7) Installing spur gear (7).

1. Install three spur gears (7) to crankshaft (9).
• Put the matching marks (punched) of three
spur gears (7) as shown below and fix them
to crankshaft (9).
Position the matching marks

(punched) on the spur gears and
install them.
HOLD FLANGE
7
2. Fix three snap rings (25) into the snap ring

grooves of crankshaft (9).
25
8) Install oil seal (132).

1. Turn over travel motor.
2. Coat the lip of the oil seal with lithium grease and
fix oil seal (132) into the oil seal hole in spindle
(2), using retainer metal and a hammer.
RETAINER METAL (III) 2 132
34-76
34. TRAVEL SYSTEM
9) Fixing shaft (102).

1. Put bearing (149) in a heating bath and heat it at
100 ±10°C (212 ±18°F) for ten minutes and in-
sert it into shaft (102).
Carry out the insertion work with leather gloves. Use

care so as not to get burns.
102 149
• Insert bearing (149) into shaft (102) so it comes in
close contact with the flange of the shaft.
2. Fix two parallel pins (177) into the pin holes of

spindle (2).
3. Coat two pivots (176) with lithium grease and fix
it into parallel pins (177) of spindle (2).
4. Install spring (185) and piston assy [piston shoe
(161), shoe (162)] on spindle (2).
5. Incline travel motor 90 degrees. (Lay it down)
2 176, 177
6. Install shaft (102) into spindle (2).

• Install shaft (102) to spindle (2) taking care
so as not to score the lip of oil seal (132)
placed in spindle (2). Scoring of the lip caus-
es oil leakage which leads to early damage
of the travel motor.
2 102
34-77
34. TRAVEL SYSTEM
7. Coat the spline of shaft (102) with lithium grease. 103

8. Install swash plate (103) to spindle (2).
• Apply grease on contact surface of swash
plate (103) with spindle (2).
• Meet two pivots (176) with pivot attaching
holes of swash plate and install swash plate
(103) in spindle (2).
10) Installing cylinder block

1. Place washer (110), spring (114), washer (110) 110
110
and snap ring (146), in that order into cylinder
block (104).
2. Place cylinder block (104) on the press bench. 114
114
104
3. Put retainer metal (I) on washer (110) and fit snap

ring (146) in the groove of cylinder block (104).
• Put a plastic sheet over cylinder block (104)
so the contact surface of cylinder block is not
PRESS
scored in contact with timing plate (109).
Plastic sheet
RETAINER METAL (I) 104
34-78
34. TRAVEL SYSTEM
11) Installing hydraulic motor parts.

1. Put three rollers (151) into the holes cylinder
151
block (104).
2. Put thrust ball (108) on cylinder block (104).
3. Fit nine piston assy to retainer plate (107). 108
• After fixing it, immerse the whole unit in hy-
draulic oil.
104
4. Fit nine piston assy to cylinder block (104).
• Match retainer plate (107) with the spherical
part of thrust ball (108) and install them.
107 Piston assy
5. Install cylinder block (104) into shaft (102). 104

• Insert cylinder block (104) into the spline of
shaft (102) by aligning the spline hole with
the spline of the shaft.
• After installing the cylinder block, turn it by
hand and make sure that it does not loosen.
34-79
34. TRAVEL SYSTEM
12) Installing parking brake.

• Immerse friction plate (115) in hydraulic oil
before fitting it.
1. Incline work bench 90 degrees. (Lay it down.)
2. Install friction plate (115) and separator plate
(116) on groove outside of cylinder block alter-
nately. Then install friction plate first, and then
separator plate.
3. Fit O-rings (135),(141) to the O-ring grooves of
piston (112). In that case, coat O-rings (135),
(141) with a thin film of grease.
4. Incline the travel motor 90 degrees. (Lay it down) 116
5. Install piston (112) into spindle (2).

• If it is hard to fit the piston (112) into the spin-
dle (2) due to the resistance of O-rings
(135),(141), lightly tap the end face of the
piston (112), using a plastic mallet.
• Take care so as not to score the O-rings
when installing the piston (112).
141 112
34-80
34. TRAVEL SYSTEM
13) Installing the brake valve parts into rear flange 238
1. Fit two O-rings (238) to two plugs (282).
• Coat O-ring (238) with grease.
2. Install valve (227) and spring (230) on rear flange

(201). Apply grease on valve and spring in order
to adhere them to rear flange (201).
3. Install the plug (282) in rear flange (201).
282
• Place on the work bench by directing rear flange

(201) with its plug attaching face up. Align the cen-
ter of threaded hole with the plug 282) center.
• Prevent spring (230) from falling from valve 227).
Note that if spring (230) falls from valve 227), the
valve does not contact with the seat surface of rear
flange (201) properly, causing oil leaks.
4. After installing two plugs (282), temporarily fas-

ten rear flange (201) by means of allen wrench.
5. Install spool (223) into rear flange (201).
227 201
• Coat the spool with hydraulic oil and insert the

spool into the rear flange.
• Attach the spool by aligning the hole of the rear
flange with the spool and prevent the inner surface
of the rear flange and the outer surface of the spool
from being damaged by mutual interference.
• In case damage resulting from inter-ference should
occur to the holes in the rear flange and the outer
surface of the spool, internal leaks will occur after
assembly, ultimately deteriorating the performanc-
es of the travel motor.
282
6. Fit O-ring (236) to plug (224). 236
7. Fit spring retainer (225) and spring (228) to plug

(224).
224
34-81
34. TRAVEL SYSTEM
8. Tighten two plugs (224) into rear flange (201). 224
• When tighten the plugs into the rear flange, use

care so as not to deform the spring.
9. Temporarily tighten two plugs (224) to rear flange

(201) by means of a spanner.
201
14) Into rear flange assembling shockless relief

valve (SRV).
1. Fit O-ring (291), O-ring (292) and backup ring
(294),(295) to sleeve (288).
2. Fit O-rings (238) to plug (289).
• Coat O-ring (291),(292),(238) with grease.
294, 295 288
3. Install piston seal (293) to valve (287).
PISTON SEAL (293)

• Piston seal (293) is made up of O-ring and teflon
ring, and apply grease on both rings and fit O-ring
first, then teflon ring.
VALVE (287)
4. Insert sleeve (288), valve (287) and spring (290) 288

to rear flange (201).
• Apply hydraulic oil on valve (287) and insert it in

sleeve (288).
• Parts inside of sleeve are fitted in the factory as a
sleeve kit, so take care not to make a wrong combi-
nation.
201
34-82
34. TRAVEL SYSTEM
5. Temporarily tighten two plugs (289) to rear flange 289


201
6. Fit O-ring (238) to plug (282). 282
7. Insert piston (286) to rear flange (201).
• Piston (286) and rear flange (201) are factory fitted

for assembly. Do not mistake the combination.
8. Temporarily tighten two plugs (282) to rear flange

9. Install steel ball (296) to rear flange (201).
• Assemble the steel balls into the rear flange by

caulking.
10. Tighten plug (284) to rear flange (201) and tight-

en it to specified torque.
296 201
34-83
34. TRAVEL SYSTEM
15) Installing fittings to rear flange. 271

1. Installing pilot valve into rear flange.
1) Place rear flange directing the contact surface
with spindle (2) upward.
2) Insert spring (281), spool (271) into rear flange
(201).

3) Fit O-ring (292) to plug (221). 201
221
4) Tighten plug (221) to rear flange (201) and tight-

en it to specified torque.
2. Apply hydraulic oil to bearing (150), and install it

in rear flange (201).
150
201
3. Drive two parallel pins (242) in pin holes of rear

flange (201).
242 201
34-84
34. TRAVEL SYSTEM
4. Apply grease to the surface of timing plate (109)

in contact with rear flange (201).
5. Install timing plate (109) on rear flange (201) tak-
ing parallel pin (242) as a guide.
• Install timing plate (109) until it is completely con-

tacted with rear flange (201). Grease film is used to
protect them from dropping.
109 201
16) Connecting rear flange with spindle.

1. Fix O-ring (28),(30) into the O-ring groove of
spindle (2).
• Fit O-ring (30) without application of grease. Appli-

cation of grease may cause taking the oozed
grease out of contact face of rear flange and spin-
dle for the leaking oil. So never apply grease on O-
ring (30).
2 30
2. Fix two parallel pins (43) to spindle (2). 43

3. Fill hydraulic oil 0.5 (0.13 gal) into spindle (2).
4. Align two parallel pins (43) set in spindle (2) with 201
the pin holes of the rear flange and install rear
flange (201) to spindle (2).
• At the time when rear flange (201) is installed
on spindle (2), fit eight springs (113) on the
rear flange side. Apply grease on spring
(113) to prevent them from dropping.
34-85
34. TRAVEL SYSTEM
5. Install six socket bolts (245) to spindle (2) and

tighten them up.
245 2
6. Tighten plug (282). 282



34-86
34. TRAVEL SYSTEM

17) Installing input gear.

1. Turn over travel motor.
2. Fit shaft (15) to shaft (102).
3. Fit input gear (6) to shaft (15).
• Fix input gear (6) to shaft (15) by matching the teeth

of three spur gears (7). When gear is not engaged,
check it for possible error.
15
4. Fix snap ring (24) into the snap ring groove of the 36 6
shaft (15).
5. Coat steel ball (36) with grease and put it on the
concave part of input gear (6).
15 24
18) Installing cover

1. Fill lubricating oil in hub (1).
Oil volume : 1.3 (0.34 gal)
2. Fit O-ring (29) into the O-ring groove of cover (8).
• Apply grease to O-ing (29).
34-87
34. TRAVEL SYSTEM
3. Install hub (1) to cover (8).
• Align the matching marks on cover (8) and hub (1)

and install them.
• Install cover (8) in hub (1), tapping the outer circum-
ference of cover (8) lightly by means of a plastic
mallet. Use care that if the cover is fixed jerkily by
striking it hard, the O-ring is scored and brings
about an oil leakage.
4. Fix ring (18) into the ring groove of hub (1).
18 1
5. Fit the O-ring (35) to flange plug (33). 33

Tighten with flange plug (33) into the cover (8).
6. Fit the O-ring (35) to flange plug (34).
Tighten with flange plug (34) into the cover (8).
8 34
19) Removing travel motor

1. Remove the travel motor attaching bolts from the
work bench.
34-88
34. TRAVEL SYSTEM
20) The specified pre-load must be applied to bear-

ing (21) to ensure the proper life.
• Therefore, when the parts exerting influences on

the pre-load are replaced, assemble it temporarily
in the following procedure and check the pre-load.
If it is assembled without checking the pre-load, the
malfunction of hydraulic motor may be caused and
the life may be shortened.
• Parts exerting influences on the pre-load. Hub (1),
spindle (2), hold flange (3), bearing (21). BEARING PRELOAD ADJUSTING JIG
• When the above parts are not replaced, omit this

procedure, and proceed to the procedure shown in
Item 4) " 1 " in this section.
• Pre-load checking and pre-load adjusting proce-
dure are described below.
1. Procedure of the pre-load to bearing.

1) Attach the bearing pre-load adjusting jig to spin-
dle (2) tighten the special nut, and press bearing
(21) into hub (1).
A specified tightening
Torque of special nut : 39.2 N•m (29 lbf•ft)
2) Determine the depth "A" through the measuring
hole of the bearing pre-load adjusting jig, using a
Depth micrometer
depth micrometer. BEARING (21) Bearing pre-load
3) Since the dimension "B" of the bearing pre-load B adjusting JIG
adjusting jig is known, determine the clearance A
"C" by the following formula : C
"C"="A"-"B" HUB (1)
SPINDLE (2)
A : Actual value
B : Dimensions of jig body
C : Specified dimension
34-89
34. TRAVEL SYSTEM
4) Then determine dimension "D" of hold flange (3).

D
E
E
5) After measurement steps 2)~4), adjust hold
flange (3) as follows :
Dimension "C" is the specified dimension of the
hold flange.
I. When actual dimension "D" of hold flange (3) is 3
0.02 mm (0.0008 in) smaller than a specified val-
ue "C";
Remove surface E of hold flange (3) to a speci-
fied value by lathe.
II. Where the actual dimension of the hold flange
falls within ± 0.02 mm (0.0008 in) of the specified
clearance "D" ;
Use the hold flange (3) as it is.
III. When actual dimension "D" of the hold flange (3)
is 0.02 mm (0.0008 in) larger than a specified
value "C" ;
Replace the flange with a new spindle assy.
The adjustment allowance for new hold flange
(3) is specified without fail.
• Since hold flange and spindle are drilled at the

same time, they are integrated in an assembly unit. BEARING PRELOAD ADJUSTING JIG
Therefore they can not be replaced separately. Re-
place them as an assembly unit, that is, together
with spindle.
This assy is called as spindle assy.
• To replace the spindle assy, disassembling and as-
sembling works should be performed again.
6) Remove bearing pre-load adjustment jig from

spindle (2).
7) After completion of hold flange adjustment in the
procedure shown in Sections I, II, and III, pro-
ceed to the procedure shown in Item 4) " 2 " in
this section.
34-90
34. TRAVEL SYSTEM
21) Procedure of axial clearance adjustment of

bearing (22)
• When the following parts have been replaced, it is

necessary to adjust the axial clearance of taper roll-
er bearing (22) to a specified value by adjusting the
thickness of snap ring (20). If it is installed without
adjustment, malfunction of hydraulic motor may be
caused and the life may be shortened.
Spindle (2), hold flange (3),

crankshaft (9), spacer (12),
bearing (22).
• When the above parts are not replaced, the adjust-

ment of thickness of snap ring is unnecessary. Pro-
ceed to the regular assembly shown in Item 6) " 1 "
in this section.
• The clearance adjustment is described below.
1. Lightly tap the outer race with mallet and jig (IV)
of bearing (22) attached to crankshaft (9).
• Put the RV gear assy in spindle (2) securely.
RETAINER METAL (IV)
2. Fix the thinnest snap ring (20) into the snap ring
groove in hold flange (3).
20 3
34-91
34. TRAVEL SYSTEM
3. Lightly tap the outer periphery of snap ring (20)

via jig (IV).
• Confirm that the RV gear assy is securely set in

spindle (2).
RETAINER METAL (IV)
4. Insert a thickness gauge between snap ring (20)

and bearing (22) and measure the clearance.
5. Thickness measurement of snap rings
• Set thickness of snap ring (max.)
MAX. = Thickness of thickness gauge + Thick-
ness of presently set snap ring
• Set thickness of snap ring (min.)
THICKNESS
MIN. = Thickness of thickness gauge + Thick-
GAUGE
ness of presently set snap ring - 0.05 mm
(0.002 in)
6. When the thickness of the snap ring has been
determined, select one out of fifteen kinds A
through Z (refer to 34.2.1.7) and fit it to the hold
flange.
7. Install snap ring satisfying the set thickness, and
proceed to the procedure Item 6) "2" in this sec-
tion.
31
34-92
34. TRAVEL SYSTEM
34.2.1.7 DIMENSIONS OF SNAP RING
Item Dimension
Snap ring (20) Class Dimension t mm (in)
A over 1.90 to 1.95 (0.075 to 0.077) incl.
B over 1.95 to 2.00 (0.077 to 0.078) incl.
C over 2.00 to 2.05 (0.078 to 0.081) incl.
D over 2.05 to 2.10 (0.081 to 0.083) incl.
E over 2.10 to 2.15 (0.083 to 0.085) incl.
F over 2.15 to 2.20 (0.085 to 0.087) incl.
G over 2.20 to 2.25 (0.087 to 0.089) incl.
H over 2.25 to 2.30 (0.089 to 0.091) incl.
I over 2.30 to 2.35 (0.091 to 0.093) incl.
J over 2.35 to 2.40 (0.093 to 0.094) incl.
K over 2.40 to 2.45 (0.094 to 0.096) incl.
L over 2.45 to 2.50 (0.096 to 0.098) incl.
X over 1.75 to 1.80 (0.069 to 0.071) incl.
Y over 1.80 to 1.85 (0.071 to 0.073) incl.
t MARKING STAMP
(CLASS) Z over 1.85 to 1.90 (0.073 to 0.075) incl.
34-93
34. TRAVEL SYSTEM
34.2.1.8 PERFORMANCE INSPECTION

• After completing the maintenance, carry out the performance inspection in the following procedure
34-94
34. TRAVEL SYSTEM
34.2.1.9 SERVICE STANDARDS

Disassemble and inspect the motors according to this standard. Handle each component carefully, exercising par-
ticular care so the moving parts and the sliding parts are not scored.
(1) Seals
Replace all seals (O-ring, oil seal, floating seal) once used even if no damage is seen.
(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.
Item
Parts Trouble Reference value Allowable value
No.
Spindle kit
(2) Spindle • Severe damage to appearance
(3) Hold flange • Abnormal wear such as scoring is
(19) Reamer bolt present.
RV gear assy
(4) RV gear (A) • The RV gear tooth surface shows
(5) RV gear (B) uneven wear.
(9) Crankshaft • Crankshaft-related parts do not
(22) Conical roller bearing move smoothly when crankshaft
(23) Needle roller bearing (9) is turned.
• The end face of the circumference

20 Snap ring
is abnormally worn.
• Dent is present.
21 Bearing • Flaking is seen.
• Uneven wear is present.
Rear flange kit
• Part in contact with spool (223) is
scratched.
• Clearance with spool is large.
(201) Rear flange • Surface in contact with valve (227) Clearance on
Clearance on diameter
is scratched. diameter
35 
• Depth to the contact surface with 9~15 
(0.0014 in)
valve (227) is large. (0.0003~0.0006 in)
• Outer circumference is scored.
(223) Spool • Outer circumference is worn un-
evenly.
Clearance on
• Outer circumference is scored. Clearance on diameter
diameter
(286) Piston • Outer circumference is worn un- 40 
12~20 
evenly. (0.0016 in)
(0.0005~0.0008 in)
• Contact surface with oil seal (132)
(102) Shaft is worn.
• Spline is worn.
• Spline is worn.
• Bore surface is worn badly.
(104) Cylinder block
• Sliding surface with timing plate
(109) is scored or worn unevenly.
34-95
34. TRAVEL SYSTEM
Item
Parts Trouble Reference value Allowable value
No.
Piston Assy
(105) Piston • Clearance is present in the axial
direction between piston (105) and Clearance Clearance
shoe (106). 0.04 mm 0.14 mm
(106) Shoe
• Shoe is worn abnormally. (0.0016 in) (0.0055 in)
• Shoe is worn unevenly.
• The end face of the circumference
(107) Retainer plate
is worn unevenly.
• Spherical sliding part with retainer
(108) Thrust ball
plate (107) is worn unevenly.
• Sliding surface is seized or worn
(109) Timing plate
unevenly.
(115) Friction plate • Both end faces are worn unevenly. Braking torque
Braking torque
• Specified torque can not be 97 N•m
97 N•m
(116) Separator plate reached. (72 lbf•ft)
(72 lbf•ft)
• Seizure is seen. or over
(227) Valve • Seat surface is scored.
(149) Bearing • Dent is present.
• Flaking is seen.
(150) Bearing
• Uneven wear is present.
(287) Valve • Outer circumference is scored.
(288) Sleeve • Outer circumference is scored.
34-96
41. TROUBLESHOOTING
(MECHATRO CONTROL)
TABLE OF CONTENTS
41.1 OUTLINE ............................................................................................................................ 41-3

41.1.1 JUDGMENT OF ACTUAL THING AT SITE ............................................................... 41-3
41.2 TABLE OF ACTUATOR FOR TROUBLESHOOTING : MECHATRO CONTROL .............. 41-5
41.3 TROUBLESHOOTING SUMMARIZED : MECHATRO CONTROL .................................... 41-8
41.4 CHECK POINT FOR MECHATRO SYSTEM ...................................................................... 41-10
41
41-1
41. TROUBLESHOOTING (MECHATRO CONTROL)

S5YT4103E01
(NHK)
41-2
41.1 OUTLINE
Troubleshooting provides process locating for the
cause of trouble in the order that trouble occurred.
This manual describes how to solve the specific phe-
nomenon systematically as possible. For troubleshoot-
ing concerning the inside of equipment, refer to
troubleshooting for each manual of equipment.
41.1.1 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 unrea-
sonable.
3) Operating time on the hour-meter.
4) History of trouble occurred and additional works.
5) Recurrence of past trouble, or problems on the
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 part can not be verified, surmise
causes systematically.
4) Verify reasons for surmise.
5) Report methods, procedure, and period for re-
pairing to user.
(4) Explanation of the cause of trouble
1) Explain the cause of trouble to clients. For exam-
ple, oil leak through piston is caused by flaws on Confirm the symptoms of the trouble.
the piston rod. And the method of using the ma-
chines should be explained so that the same
kind of trouble 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, soil, etc.
into port of hydraulic unit, etc. and return them.
And also use care not to flaw and damage those Diagnosing fail by means of troubleshooting
surfaces.
41-3
41-4
41.2 TABLE OF ACTUATOR FOR TROUBLESHOOTING : MECHATRO CONTROL
Electric Hydraulic
Low pressure sensor

Actuator
proportional valve
proportional valve
proportional valve
Safety lock lever

Travel 1-2speed
Travel boost-up
solenoid valve
solenoid valve
solenoid valve
solenoid valve
P2 bypass cut
P1 bypass cut
Travel straight
Swing P / B
P2 Pump
S P P P S S S S
P1 pump
E S S S V V V V
-
Opeating condition
~1 V V V 1 3 4 8
-
-
10 B C D
Boom up inching operation
Boom up full lever operation
Boom down operation
Arm out inching operation

Indenpendent operation
Arm out full lever operation
Arm in inching operation
Arm in full lever operation
Bucket digging
Bucket dump
Swing operation
Travel LH / RH operation
(1st. speed)
(2nd. speed)
Travel right operation
+ Boom operation
+ Bucket operation
Combined operation
+ Arm operation
+ Swing operation
Travel left operation
+ Boom operation
+ Bucket operation
+ Arm operation
+ Swing operation
+ Boom up operation
41-5
Hydraulic
Control valve Motor
Actuator
P1 bypass cut valve
P2 bypass cut valve
Boom conflux valve
Travel right motor
Travel left motor
Swing motor
Travel right
Travel left
Bucket
Swing
Boom
Opeating condition Arm
Boom down operation

Bucket digging
Bucket dump
Swing operation
(1st. speed)
(2nd. speed)
+ Boom operation
+ Bucket operation
Combined operation
+ Arm operation
+ Swing operation
+ Boom operation
+ Bucket operation
+ Arm operation
+ Swing operation
+ Boom up operation
41-6
Hydraulic
Cylinder Other
Actuator
Boom lock valve
Arm lock valve

Bucket
Boom
Arm
Opeating condition
Boom down operation

Bucket digging
Bucket dump
Swing operation
(1st. speed)
(2nd. speed)
+ Boom operation
+ Bucket operation
Combined operation
+ Arm operation
+ Swing operation
+ Boom operation
+ Bucket operation
+ Arm operation
+ Swing operation
+ Boom up operation
41-7
41.3 TABLE OF ACTUATOR FOR TROUBLESHOOTING : MECHATRO CONTROL
Electric or hydraulic cause Hydrau- Normal criterion

Operating
No. Trouble lic or
condition
Cause Check point electric 1 2 3
1-1 No Safety lock Safety lock lever SOL (SV-4) 24V at SV-4 connector. 24V at SW-11. 24V at fuse box
operation lever down solenoid (SV-4) does connector connector
works at full not change over and (CN-14M)
Electric
stroke there is no hydraulic white & black
source for pilot valve.
Lever at P1 bypass cut P1 bypass cut Current for P1 bypass cut Arm in sensor and arm
neutral proportional valve proportional Electric proportional valve : 315mA. out sensor values :
moves freely and valve (PSV-D) less than 1.3V.
the P1 circuit connector Secondary pilot pressure for Secondary pilot
pressure rises. Hydrau-
P1 bypass cut valve : pressure :
lic
0.54MPa (78psi). 0.59MPa (85psi).
1-2 Moves freely
Lever at P2 bypass cut P2 bypass cut Current for P2 bypass cut Boom raise sensor and
neutral proportional valve proportional Electric proportional valve : 315mA. swing sensor values :
moves freely and P2 valve (PSV-B) less than 1.3V.
circuit pressure rises. connector Secondary pilot pressure for Secondary pilot
Hydrau-
P2 bypass cut proportional pressure :
lic
valve : 0.54MPa (78psi). 0.59MPa (85psi).
2-2 Only bucket Bucket P2 bypass cut P2 bypass cut Current for P2 bypass cut Boom raise sensor and
is slow lever and proportional valve proportional Electric proportional valve : 315mA. swing sensor values :
other levers moves freely, valve (PSV-B) less than 1.3V.
at full P2 circuit pressure connector Secondary pilot pressure for Lever at neutral Secondary pilot
stroke rises, and P1 circuit Hydrau-
P2 bypass cut valve : Secondary pilot pressure with pressure for bucket :
flow decreases. lic
0.54MPa (78psi). lever neutral : 0.59MPa (85psi). 3.43MPa (500psi)
2-3 Only boom Boom lever P2 bypass cut P2 bypass cut Feedback current for P2 Command current for P2 Boom raise sensor
raise speed at full proportional valve proportional Electric bypass cut proportional bypass cut proportional : more than 4.0V
is low stroke does not move and valve (PSV-B) valve : 700mA. valve : 700mA.
the boom conflux feedback current Secondary pilot pressure for Secondary pilot
flow is not created. Hydrau-
P2 bypass cut valve : pressure for travel :
lic
2.55MPa (370psi) 2.35MPa (340psi)
Travel lever Travel straight valve Travel straight Command current for P2 Travel right and left
at neutral moves freely and proportional Electric bypass cut proportional sensors: less than
is actuated by P1 valve (PSV-C) valve : 315mA. 1.3V.
pump flow. command current Secondary pilot pressure for Secondary pilot
Hydrau-
P2 bypass cut valve : pressure for travel :
lic
0.54MPa (78psi). 0.59MPa (85psi).
Only speeds Travel lever Travel straight valve Travel straight Command current for travel Travel right and left
other than at neutral moves freely and proportional Electric straight proportional valve : sensor value : less
boom raise, P2 pump flow to tank. valve (PSV-C) 315mA. than 1.3V.
arm in and command current Secondary pilot pressure for Secondary pilot
out are low Hydrau-
PO port travel straight valve : pressure for travel :
lic
0.54MPa (78psi). 0.59MPa (85psi).
2-4 Only arm in Arm lever Arm conflux flow is P1 bypass cut Command current for P1 Arm in sensor :
speed is at full not created. proportional Electric bypass cut proportional valve : more than 4.0V
low stroke valve (PSV-D) 700mA.
command current Secondary pilot pressure for Secondary pilot
Hydrau-
P1 bypass cut valve : pressure for arm in :
lic
2.55MPa (370psi). 3.43MPa (500psi)
2-5 Only arm Arm lever Arm conflux flow is P1 bypass cut Command current for P1 Arm out sensor :
out speed is at full not created. proportional Electric bypass cut proportional valve : more than 4.0V.
low stroke valve (PSV-D) 315mA
command current Secondary pilot pressure for Secondary pilot
Hydrau-
P1 bypass cut valve : pressure for arm out :
lic
0.54MPa (78psi). 3.43MPa (500psi)
4-1 Fine bucket Fine bucket P1 bypass cut P1 bypass cut Command current for P1 Arm in and arm out
close and operation proportional valve proportional Electric bypass cut proportional valve : sensor values :
open moves freely and valve (PSV-D) 315mA less than 1.3V.
operations the P1 circuit connector Secondary pilot pressure for Secondary pilot Unload pressure for
can not be pressure rises Hydrau-
P1 bypass cut valve : pressure for arm in and P1 pump : approx.
done lic
0.54MPa (78psi). out : 0.59MPa (85psi) 1.96MPa (280psi)
4-2 Fine boom Fine boom P1 bypass cut P1 bypass cut Command current for P2 Arm in and arm out
raise and raise and proportional valve proportional Electric bypass cut proportional valve : sensor values :
lower lower moves freely and valve (PSV-D) 315mA. more than 1.3V.
operations operations the P1 circuit connector Secondary pilot pressure for Secondary pilot Unload pressure for
can not be pressure rises. Hydrau-
P2 bypass cut valve : pressure for arm in and P1 pump : approx.
done lic
0.54MPa (78psi). out : 0.59MPa (85psi). 1.96MPa (280psi)
4-3 Fine swing Fine swing P2 bypass cut P2 bypass cut Command current for P2 Swing sensor and
right and right and proportional valve proportional Electric bypass cut proportional valve : boom raise sensor
left left moves freely and valve (PSV-D) 315mA. values : less than 1.3V.
operations operations the P2 circuit connector Secondary pilot pressure for Unload pressure for P2 Secondary pressure for
can not be pressure rises. Hydrau-
P2 bypass cut valve : pump : approx. 1.96MPa swing and boom raise :
done lic
0.54MPa (78psi). (280psi) or less. 0.59MPa (85psi)
41-8
Note : The below tabel shows items to be highlighted in the electrical and hydraulic troubleshooting.
"Normal criterion" is a list of figures which come up in the electrical and hydraulic troubleshooting.
Regarding the inspecting procedures, refer to each troubleshooting.
Electric or hydraulic cause Hydrau- Normal criterion
Operating
No. Trouble lic or
condition
Cause Check point electric 1 2 3
4-3 Fine swing Swing left or Swing parking Swing parking Command voltage for swing Swing sensor
right and left right lever to solenoid is not solenoid (SV-1) Electric parking solenoid : 0V values :
operations full stroke deenergized. connector more than 4.0V
impossible. Secondary pilot pressure for Secondary pilot pressure
Hydrau-
swing parking solenoid : for swing :
lic
3.43MPa (500psi) 3.43MPa (500psi)
4-4 Fine arm in Fine arm in or P2 bypass cut Connector of P2 Command current for P2 bypass Swing sensor and
and out out operation proportional valve bypass cut Electric cut proportional valve : 315mA boom raise sensor
motions moves freely and the proportional valve values : less than 1.3V
impossible. P2 circuit pressure (PSV-B) Secondary pilot pressure for Secondary pressure for Unload pressure for
rises. Hydrau-
P2 bypass cut valve : swing and boom P2 pump : approx.
lic
0.54MPa (78psi) raise actions : 0.59MPa (85psi) 1.96MPa (280psi)
5 Travel 1-2 Travel 1-2 Travel 1-2 speed Connector for travel 24V across power supply for 100th is indicated as
speed change speed select solenoid (SV-3) does 1-2 speed solenoid Electric travel 1-2 speed solenoid and 1 in controller service
impossible. switch is on. not change over. earth. diagnosis 23.
Secondary pilot pressure
Hydrau-
for command travel 1-2 speed
lic
select : 3.43MPa (500psi)
6 Travel speed Travel lever at Travel straight valve Command current of Command current of travel 8 sensor values for
is low. full stroke. moves freely and the travel straight Electric straight proportional valve : bucket, boom, swing
(single (Other levers machine travels only proportional valve 315mA and arm : less than 1.3V
operation) in neutral) by the delivery rate of (PSV-C) Secondary pilot pressure of PO 8 sensor values for Secondary pilot
P1 pump. Hydrau-
port travel straight valve : bucket, boom, swing pressure for travel :
lic
0.54MPa (78psi) and arm : 0.59MPa (85psi) 2.35MPa (340psi)
8 Machine can Levers at full Travel straight valve Command current of Command current for travel Swing sensor and
not travel stroke in does not change over travel straight Electric straight proportional valve : arm in/out sensor :
straight. composite and the travel action proportional valve 315mA more than 4.0V
swing/travel or is affected by the (PSV-C) Secondary pilot pressure for PO Secondary pilot pressure
arm/travel delivery rate of P1 Hydrau-
port travel straight valve : for swing and arm
actions. pump. lic
2.55MPa (370psi) in/out : 3.43MPa (500psi)
Levers at full Travel straight valve Command current of Command current for travel Boom raise/lower sensor
stroke in does not change over travel straight Electric straight proportional valve : and bucket close/open
composite and the travel action proportional valve 315mA sensor : more than 4.0V
operations of is affected by the (PSV-C) Secondary pilot pressure for PO Secondary pilot pressure for
boom/travel or delivery rate of P1 Hydrau-
port travel straight valve : boom raise/lower and bucket
bucket/travel. pump. lic
2.55MPa (370psi) close/open : 3.43MPa (500psi)
10 Swing power Swing lever at Swing parking Connector for swing 0V across power supply of swing Swing sensor :
is not available. full stroke. solenoid does not parking solenoid Electric parking solenoid and ground more than 4.0V
demagnetize. (SV-1)
Secondary pilot pressure for Secondary pilot pressure
Hydrau-
swing parking solenoid for swing :
lic
: 3.43MPa (500psi) 3.43MPa (500psi)
11 Swing speed Swing lever at P2 bypass cut Feedback current of Feedback current for P2 bypass Command current for P2 Swing sensor :
is low. full stroke. proportional valve P2 bypass cut Electric cut proportional valve : 700mA bypass cut proportional more than 4.0V
does not change over proportional valve valve : 700mA
and part of the (PSV-B) Secondary pilot pressure for P2 Secondary pilot pressure
delivery of P2 pump Hydrau-
bypass cut valve : 2.55MPa for swing :
flows to tank. lic
(370psi) 3.43MPa (500psi)
12 Swing power Swing lever at P2 bypass cut Feedback current of Command current for P2 bypass Command current for P2 Swing sensor :
is poor. full stroke. proportional valve P2 bypass cut Electric cut proportional valve : 700mA bypass cut proportional more than 4.0V
does not change over proportional valve valve : 700mA
and the P2 circuit (PSV-B) Secondary pilot pressure for P2 Secondary pilot pressure
pressure does not Hydrau-
bypass cut valve : 2.55MPa for swing :
rise. lic
(370psi) 3.43MPa (500psi)
13 Swing motion Swing lever at Swing parking brake Connector for swing 24V across power supply of Swing sensor and
can not be neutral. is released. parking solenoid Electric swing parking solenoid and arm in sensor
held on a ground. values : more than 1.3V
slope. Secondary pilot pressure of Secondary pressure for
Hydrau-
swing parking solenoid : swing and arm
lic
3.43MPa (500psi) in : 0.59MPa (85psi)
14 Travel boost Travel lever at Travel pilot pressure Check value of Value of travel
doesn't work at full stroke. sensors (SE9) and pressure sensor. Electric pressure sensor
travel single (SE10) are failure. is 4V or more.
operation Travel boost-up Check movement of If apply 24V to travel boost-up When solenoid is
solenoid (SV8) is solenoid or replace Hydrau-
solenoid, the solenoid is disassembled, does
failure. solenoid. lic
switched. spool move smoothly?
41-9
41.4 CHECK POINT FOR MECHATRO SYSTEM

(1) Mounting position of connectors for solenoids (solenoid valves) : SV-1, SV-3, SV-4 (SV-2 OPT), SV-8
(2) Mounting position of connectors for solenoid proportional valves : PSV-B, PSV-C, PSV-D
(3) Detail sensor connector : SE-1~SE-10
TRAVEL BOOST-UP SOL (SV-8)

CONFLUX-SINGLE SELECT SOL (SV-2) SWING PARLING P2 BYPASS CUT PROPORTIONAL VALVE (PSV-B)
Normal spec. does not need connection. SOL (SV-1)
UNDER FLOOR HARNESS
TRAVEL 1,2-SPEED SOL (SV-3)
SAFETY LOCK LEVER SOL (SV-4) TO INSTRUMENT PANEL HARNESS
TRAVEL STRAIGHT PROPORTIONAL

PRESSURE SENSOR (TRAVEL LEFT) (SE-10) VALVE (PSV-C)
P1 BYPASS CUT PROPORTIONAL
PRESSURE SENSOR (TRAVEL RIGHT) (SE-9) VALVE (PSV-D)
OPT PEDAL PRESSURE SWITCH HYD. FLUID TEMP. SW
(KCMA OPT.)
TRAVEL 1,2-SPEED SWITCH

4, P, T PORT : PF 3/8 GROUND
1, 2, 3, 8, B, C, D PORT : PF1/4 GROUND CABLE CONNECTOR
4, P, T PORT : PF 3/8
1, 2, 3, A, B, C, D PORT : PF1/4
Fig. 41-1 Solenoid valve, solenoid proportional valve connector / Detail sensor connector
41-10
42. TROUBLESHOOTING
(HYDRAULIC SYSTEM)
TABLE OF CONTENTS
42.1 TROUBLE DIAGNOSIS : HYDRAULIC ............................................................................. 42-3

42
42-1
42. TROUBLESHOOTING (HYDRAULIC SYSTEM)

S5YT4203E01
(NHK)
42-2
42.1 TROUBLE DIAGNOSIS : HYDRAULIC
Hydraulic
Pump Control valve
Component
Check valve for relief

P2 bypass cut valve
P1 bypass cut valve
Travel straight spool
Load check valve

Pilot relief valve
Pump regulator
E/G revolution
Conflux spool
Bucket spool
Shuttle valve
Swing spool
Boom spool
Travel spool
Classification
Lock valve
Arm spool
Group No.
P1 pump
P2 pump
P3 pump
Device
No.
Trouble 1 2
No operation is possible.
1
Machine operates freely even
though lever is in neutral.
All actions
Bucket digging and dump
Speed is low.
Lower
2 Boom
Raise
Arm in conflux
Attachment operation
Arm out conflux

All motions
Power lacks.

3 Lower
Boom
Raise
Arm in and out
Hydraulic systems
Bucket digging
impossible.
Lower
Fine operation
Boom
4 Raise
Swing left, right
Arm in and out
5 Travel 1,2 speed change impossible
Travel operation
6 Travel speed is low.

7 Travel power is low.
8 Machine cannot travel straight or
deviates in one direction or zigzags.
9 Machine drifts on a downhill and
does not stop still on a slope.
10 Swing motion does not work.
Swing operation
11 Swing speed is low.

Swing power is poor.
12
Swing motion drifts very large.
Machine is not held still on a slope.
13
An unusual sound is heard during
swing motion.
42-3
Hydraulic
Swing motor Travel motor Cylinder Other valve
Counter balance check valve

Pilot valve (1-2speed select)
Component
Counter balance valve
Multi control valve

Pilot valve (travel)
Pilot valve (ATT)
Reduction parts
Bukcet cylinder
Boom cylinder
Parking brake
Parking brake
Bypass valve
Arm cylinder
Swivel joint
Classification
Group No.
Motor
Device
No.
Trouble 3 4 5 6 7 8 9 10 12
1
All actions
Speed is low.
Lower
2 Boom
Raise
Arm in conflux
Arm out conflux

All motions
Power lacks.

3 Lower
Boom
Raise
Arm in and out
Hydraulic systems
Bucket digging
impossible.
Lower
Fine operation
Boom
4 Raise
Swing left, right
Arm in and out
Travel operation

Swing operation

12
13
swing motion.
42-4
Hydraulic
Proportional valve block Filter
P2 bypass cut proportional valve
P1 bypass cut proportional valve

Component
Safety lock lever sol. valve

Travel 1-2speed sol. valve
Swing parking sol. valve
Travel booster sol. valve
Suction strainer
Bypass check
Return filter
Classification
Inline filter
Group No.
Breather
Device
Trouble No. 11 13 14 15 16 17
1
All actions
Speed is low.
Lower
2 Boom
Raise
Arm in conflux
Arm out conflux

All motions
Power lacks.

3 Lower
Boom
Raise
Arm in and out
Hydraulic systems
Bucket digging
impossible.
Lower
Fine operation
Boom
4 Raise
Swing left, right
Arm in and out
Travel operation

Swing operation

12
13
swing motion.
42-5
Hydraulic
Relief valve
Main control valve Travel Swing
Component
Main relief valve
Right shockless
Right shockless
Boom lowering
Bucket digging
Left shockless
Left shockless
Boom raising
Bucket dump
Classification
Group No.
Arm out
Arm in
Device
No.
Trouble
1
All actions
Speed is low.
Lower
2 Boom
Raise
Arm in conflux
Arm out conflux

All motions
Power lacks.

3 Lower
Boom
Raise
Arm in and out
Hydraulic systems
Bucket digging
impossible.
Lower
Fine operation
Boom
4 Raise
Swing left, right
Arm in and out
Travel operation

Swing operation

12
13
swing motion.
42-6
(1)-1
24V is alive across white/blue and black terminals of connector NO To electric

(CN-256F) of lever lock solenoid (SV-4). troubleshooting
YES Is the main relief valve
Only the hydraulic pilot system NO pressure within a standard NO Pilot relief valve NO
(ATT and travel motion) not value? pressure is about Replace relief valve.
operative? [P1,P2 : 29.4MPa (4270psi)] 3.43MPa (500psi).
[P3 : 19.6MPa (2840psi)] Inspect or replace pump.
YES YES
YES Also inspect pump
coupling.
Inspect if there is any other cause.

NO
The primary pressure of pilot pump is about 3.43MPa (500psi). Inspect or replace pilot pump and pilot relief valve.
YES
NO
The pilot valve P port inlet pressure is approx. 3.43MPa (500psi). Inspect or replace safety lock lever solenoid valve.
YES
NO
The secondary pressure of pilot valve is approx. 3.43MPa (500psi). Inspect or replace pilot valve.
(1)-2
Machine moves freely with levers in neutral.
Machine stops moving freely if the connector (CN-253F) for YES To electrical
proportional valve P1 bypass cut is disconnected. troubleshooting
NO
Pump NO The secondary pilot pressure of the system that is YES Inspect or replace pilot
delivery moving freely is generated when the lever is in
valve.
pressure in neutral.
unloaded NO
condition is YES
approx. The spool returning spring of the circuit that is Inspect or replace spool
1.96MPa moving freely is broken. assy and pilot cover.
(280psi). NO
NO The outer YES
The spool of the system that is operating freely
YES moves smoothly by hand. (Remove pilot cover.)
circumference of Replace spool assy.
spool is scratched.
NG
NO
YES Replace control valve
Pilot pressure at ports Pb4, Pb4 (P1, P2 bypass YES Inspect or replace the proportional valve for bypass
cut valve) is approx. 0.54MPa (78psi). cut valve that is defective.
NO NG
Inspect or replace proportional valve block.
YES Inspect or replace bypass cut valve spool assy and

Return spring of bypass cut valve spool is broken.
pilot cover.
NO
Bypass cut valve spool moves smoothly by hand. NO Spool is scored YES Replace bypass cut valve
(together with P1 and P2 bypass cut valves) on inspection. spool assy.
YES NO NG
Replace control valve.
Boom or YES Inspect or replace overload relief valve. Inspect lock

arm? valve parts and replace if faulty.
NO
YES
Spool of the circuit that operates freely is scored on. Replace spool assy.
NO Inspect or replace Inspect the cylinder of the circuit that Inspect or replace control
overload relief valve. operates freely and replace if faulty. valve.
(Inside leak)
42-7
(2)-1
All attachment motions are slow.
Do motions get normal if the coupler for YES

tralve straight proportional valve is To electric troubleshooting.
disconnected?
NO
NO Inspect or replace pilot
Primary pilot pressure is 3.43MPa (500psi).
pump and pilot relief valve.
YES
Secondary pilot pressure at PO port (travel YES Inspect or replace travel
straight) is approx. 0.54MPa (78psi). straight proportional valve.
NO NG
Inspect or replace
proportional valve block.
NO Inspect or replace travel

Return spring of travel straight spool is
straight spool assy and pilot
broken.
cover.
YES
NO Outer circumference of YES
Travel straight spool moves smoothly by Replace travel straight spool
travel straight spool is
hand. (Remove the pilot cover.) assy.
scored.
YES NG
NO
Main relief pressure is approx. 29.4MPa NO Inspect or replace main NG Replace control valve or
(4270psi) relief valve. pump.
(2)-2
Only the bucket motion is slow.
Is the motion normal if connector (CN-254F) YES

To electrical troubleshooting.
for proportional P2 bypass cut is disconnected?
NO
Secondary pilot pressure at Pa3, Pb3 ports (bucket NO Inspect or replace pilot
close and open ports) is 3.43MPa (500psi). valve.
YES
Inspect overload relief valve
Relief pressure that selects bucket is approx. NO Relief pressures for both YES on the faulty pressure side
29.4MPa (4270psi). Check the pressure for bucket close and open are
and replace valve if
bucket close and open as well. not at 29.4MPa (4270psi).
defective.
YES NO Confirm the check valve
before relief valve for NG
control valve. Check the
seat of it as well.
YES
Return spring for bucket spool is broken. Replace bucket spool assy.
NO
Bucket spool moves smoothly by hand. NO Outer circumference of YES
Replace bucket spool assy.
(Remove pilot cover.) bucket spool is scored.
NO NG
YES
Is the motion slow if coupler for travel NO To electric troubleshooting.

straight proportional valve is disconnected? (to "All motions are slow.")
YES
Pilot pressure at port PO (travel straight) is NO Inspect or replace travel
approx. 0.54MPa (78psi). straight proportional valve.
YES NG
Inspect or replace
Return spring for travel straight spool is
broken.
NO YES
Inspect travel straight spool
assy and pilot cover and
Continued on next page.
replace them if faulty.
42-8
Continued from previous page.
NO
hand. assy.
scored.
YES NG
NO
Is the motion slow if pump delivery ports P1 NO

Inspect or replace pump.
and P2 are exchanged.
YES
Inspect bucket cylinder for

oil tightness and replace if
defective.
(2)-3 Diagnosis 29 ; mechatronic (C-1) controller service diagnosis 29

Only the boom raise motion is slow.
(Diagnosis 29)
Control current of P2 bypass cut proportional NO
valve is approx. 700mA when full lever To electric troubleshooting.
operation is performed for boom raise motion.
YES
Secondary pilot pressure at port Pc4 (P2 NO Inspect or replace P2 bypass NG Inspect or replace
bypass cut valve) is approx. 2.55MPa (370psi). cut proportionate valve. proportional valve block.
YES
Pilot pressure at Pa2, Pd4 ports (boom raise NO Inspect or replace ATT pilot
and boom conflux) is approx. 3.43MPa
valve.
(500psi).
YES
Relief pressure is approx. 29.4MPa (4270psi) NO NG
Adjust boom port relief Replace overload relief valve
when full lever operation is performed for
pressure. at port A2 (boom head side).
boom raise motion.
YES
YES Inspect or replace P2 bypass
Return spring for P2 bypass cut valve spool is
cut spool assy and pilot
broken.
cover.
NO
NO Outer circumference of P2 YES
P2 bypass cut valve spool moves smoothly by Replace P2 bypass cut spool
bypass cut valve spool is
hand. (Remove pilot cover.) assy.
scored.
YES NG
NO
Return spring of boom spool is broken. YES Inspect or replace boom

(Remove pilot cover.) spool assy and pilot cover.
NO
Boom spool moves smoothly by hand. NO Outer circumference of YES
Replace boom spool assy.
(Remove pilot cover.) boom spool is scored.
YES NO NG
Return spring for boom conflux spool is YES Inspect or replace boom
broken. spool assy and Pilot cover.
NO
NO Outer circumference of YES Replace boom conflux spool
Boom conflux spool moves smoothly by hand.
boom conflux spool is scored. assy.
YES NG
NO
42-9
(2)-4
Motions other than boom raise, arm in and out are slow.
(Diagnosis 30)
Control current for travel straight
proportional valve is approx. 315mA. NO
To electric troubleshooting
(Are the motions slow if coupler for travel
straight proportional valve is disconnected?)
YES
Pilot pressure at port PO (travel straight) is YES Inspect or replace travel NG Inspect or replace
approx. 0.54MPa (78psi). straight proportional valve. proportional valve block.
NO
Inspect or replace travel
Return spring for travel straight spool is broken. YES
cover.
NO
NO Outer circumference of YES Replace travel straight spool
Travel straight spool moves smoothly by
travel straight spool is assy.
hand. (Remove pilot cover.)
scored.
YES
NO Replace control vlave.
(2)-5
Only arm digging action is slow.
(Diagnosis 26)
Command current for P1 bypass cut NO
proportional valve is approx. 700mA when To electric troubleshooting.
boom raise lever is shifted to the full.
YES
Secondary pressure of P1 bypass cut
proportional valve at port Pb4 (P1 bypass
NO Inspect or replace P1 bypass NG IInspect or replace
cut proportional valve. proportional valve block.
cut) is approx. 2.55MPa (370psi).
YES
Secondary pilot pressure at Pc3, Pc3 ports NO Inspect or replace pilot
(arm in, lock valve release) is approx.
valve.
3.43MPa (500psi).
YES
NO Inspect or replace overload
Relief pressure is approx. 29.4MPa (4270psi)
relief valve at port C3 (arm
when arm in lever is shifted to the full.
head side).
YES
YES Inspect or replace arm spool
Arm spool return spring is broken.
assy and pilot cover.
NO
Arm spool moves smoothly by hand. NO Outer circumference of arm YES
Replace arm spool assy.
(Remove pilot cover.) spool is scored.
NO NG
YES
42-10
(2)-6
Only arm out operation is slow.
(Diagnosis 26)
Command current for P1 bypass cut NO
proportional valve is approx. 700mA when To electrical troubleshooting
arm out lever is shifted to the full.
YES
Secondary pilot pressure at port Pb4 NO Inspect or replace P1 bypass NG Inspect or replace
(P1 bypass cut valve) is approx. 2.55MPa
(370psi).
YES
Secondary pilot pressure at port Pd3 (arm out) NO Inspect or replace pilot
is approx. 3.43MPa (500psi) or over. valve.
YES
Inspect or replace overload
Relief pressure is approx. 29.4MPa (4270psi) NO relief valve at port D3 (arm
when arm out lever is shifted to the full. rod side).
YES
NO
(Remove pilot cover.) spool is scored.
YES NO NG
(3)-1
All ATT operating power is poor.
Each independent operating speed is within a NO Refer to "All motions are

standard value. slow.".
YES
Relief pressures of P1, P2 pumps are approx. NO Adjust main relief pressure NG Replace the relief valve of
29.4MPa (4270psi). of control valve. main control valve.
YES
Primary pilot pressure is approx. 3.43MPa NO Replace pilot pump and
Adjust pilot relief pressure.
(500psi). relief valve.
YES
Inspect or replace travel
Travel straight spool return spring is broken. YES straight spool assy and pilot
cover.
NO
hand. (Remove pilot cover.) assy.
scored.
YES NG
NO
Inspect or replace control

valve or pump.
42-11
(3)-2
Bucket close power is poor.
No-load independent operating speed is within NO Refer to "Only bucket

a standard value. motion is slow."
YES
NO NG Replace overload relief valve
Relief pressure is approx. 29.4MPa (4270psi) Adjust overload relief valve
at port A3 (bucket head
when bucket close lever is shifted to the full. on bucket close side.
side).
YES
Secondary pilot pressureat port Pa3 (bucket NO Inspect or replace pilot
close) is approx. 3.43MPa (500psi). valve.
YES
YES Inspect or replace bucket
Bucket spool return spring is broken. spool assy and pilot cover.
NO
Bucket spool moves smoothly by hand. NO Outer circumference of YES
(Remove pilot cover.) bucket spool is scored.
YES NO NG
Replace control valve or

pump.
(3)-3
Boom up operating power is poor.
No-load independent operating speed is within NO Refer to "Only boom raise

a standard value. motion is slow."
YES
Relief pressure of both P1 and P2 pumps is NO Inspect or replace overload
approx. 29.4MPa (4270psi) when boom raise relief valve at port A2
lever is shifted to the full. (boom head side).
YES
Secondary pilot pressure at port Pa2 (boom NO Inspect or replace pilot
raise) is approx. 3.43MPa (500psi). valve.
YES
YES Inspect or replace boom
Boom spool return spring is broken. spool assy and pilot cover.
NO
Boom spool moves smoothly by hand. Replace boom spool assy.
boom spool is scored.
YES NO NG
Inspect or replace control

valve or pump.
42-12
(3)-4
Arm in power is poor.
No-load independent operating speed is within NO Refer to "Only arm in is

a standard value. slow.".
YES
Relief pressure of both P1 and P2 pumps is NO NG Replace overload relief valve
Adjust overload relief
approx. 29.4MPa (4270psi) when arm in at port C2 (on arm head
pressure on arm head side.
lever is shifted to the full. side).
YES
Secondary pilot pressure at ports Pc3 and
PC3' (arm in and lock valve release) is
NO Inspect or replace pilot
approx. 3.43MPa (500psi). valve.
YES
NO
(Remove pilot cover.) Replace arm spool assy.
spool is scored.
YES NO NG
Replace control valve or

pump.
(4)-1
Machine can not perform fine operation of bucket close and open.
Machine returns normal if connector of P1 bypass cut YES

To electric troubleshooting.
proportional valve (PSV-D) is disconnected.
NO
Unload pressure of P1 NO No-load independent operating NO Refer to "Only bucket
pump is less than speed is within a standard
motion is slow.".
1.96MPa (280psi) when value.
bucket close lever is at
neutral. YES
Secondary pilot pressure at
YES Inspect or replace P1 NG
port Pb4 (P1 bypass cut valve) YES Inspect or replace
bypass cut
is approx. 0.54MPa (78psi) proportional valve block.
proportional valve.
when lever is at neutral.
NO
P1 bypass cut spool return cut spool assy and pilot
spring is broken. cover.
NO
P1 bypass cut spool moves NO Outer circumference of YES Replace P1 bypass cut spool
smoothly by hand. (remove P1 bypass cut spool is
assy.
pilot cover.) scored.
NG
YES NO
Secondary pressure of pilot
valve is approx. 0.54MPa Replace control valve.
(78psi) when bucket close
lever is just shifted a YES Inspect or replace pilot
little. valve.
NO
Pilot spool return spring is YES Inspect or replace bucket
broken. spool assy or pilot cover.
NO
Bucket spool moves NO Outer circumference of bucket YES
smoothly by hand. spool is scored.
(Remove pilot cover.) NG
NO
YES Replace control valve.
42-13
(4)-2
Machine can not perform fine operation of boom raise and lower motions.
Machine gets normal if connector of P1 bypass cut proportional YES To electrical

valve (PSV-D) is disconnected. troubleshooting.
NO
Unload pressure of P1
pump is less than NO Secondary pilot pressure at YES Inspect or replace NG Inspect or replace
port Pb4 (P1 bypass cut valve) proportional valve for
1.96MPa (280psi) when proportional valve block.
is approx. 0.54MPa (78psi). P1 bypass cut valve.
boom lever is at neutral.
YES NO
Return spring or P1 bypass
cut spool is broken.
cover.
NO Outer circumference of Replace P1 bypass cut spool
P1 bypass cut spool moves NO P1 bypass cut spool is YES assy.
smoothly by hand. scored.
NG
YES NO
Secondary boom pilot pressure is approx. YES To electrical

0.54MPa (78psi) when lever is just shifted. troubleshooting.
NO
YES To electrical
Return spring of boom spool is broken.
troubleshooting.
NO
Boom spool moves NO Outer circumference of boom YES
Replace boom spool assy.
YES NO NG
Does boom lock valve NO Inspect or replace lock

move smoothly by hand? valve.
YES Replace control valve.
(4)-3
Machine can not perform fine swing operation.
Machine gets normal if connector of P2 bypass cut proportional YES To electrical

valve (PSV-B) is disconnected. troubleshooting.
NO
Machine gets normal if connector for swing parking brake YES
To electrical troubleshooting.
solenoid (SV-1) is disconnected.
NO
Secondary pressure of swing pilot valve is approx. 0.59MPa YES Inspect or replace NG Inspect or replace
(85psi), while pilot pressure of parking brake soleonid valve is swing parking solenoid
0kgf/cm2 (0psi). valve.
NO
Unload pressure of P2 Pilot pressure of port Pd4 (P2
pump is approx. 1.96MPa NO bypass cut valve) is approx. YES Inspect or replace NG Inspect or replace
proportional valve for
(280psi) or less when 0.54MPa (78psi) when swing proportional valve block.
P2 bypass cut valve.
swing lever is at neutral. lever is at neutral.
YES NO
Return spring for P2 bypass YES Inspect or replace P2 bypass
cut spool is broken. cut spool and pilot cover.
NO
P2 bypass cut spool moves NO Outer circumference of YES
Replace P2 bypass cut spool
smoothly by hand. (Remove P2 bypass cut spool is
assy.
pilot cover.) scored.
NG
YES NO
Continued on next page. Replace control valve.
42-14
Continued previous page.
Secondary pilot pressure of parking brake solenoid valve is NO Inspect or replace swing
0MPa (0psi) when secondary pressure of pilot valve is
parking solenoid valve.
approx. 0.59MPa (85psi).
NG
YES
Inspect or replace pilot
pump and pilot relief valve.
Secondary pressure of pilot
valve at start up is approx. NO Inspect or replace pilot
0.54MPa (78psi). valve.
YES
NO Inspect or replace swing
Fine operation is possible
pilot shuttle valve of control
if Pd2 port is pluged.
valve.
YES
Return spring for swing YES
Replace swing spool assy.
spool is broken.
NO
Swing spool moves NO Outer circumference of swing YES
YES NO NG

(4)-4
Machine can not perform fine operation of arm in and out.
Machine gets normal if connector of P2 bypass cut proportional YES

To electrical troubleshooting
valve (PSV-B) is disconnected.
NO
P2 pump unload pressure NO Secondary pilot pressure at YES Inspect or replace NG Inspect or replace
is less than 1.96MPa port Pd4 (P2 bypass cut valve) proportional valve for
(280psi) when arm lever is is approx. 0.54MPa (78psi). P2 bypass cut valve.
at neutral.
NO
YES YES Inspect or replace P2 bypass
Return spring of P2 bypass
cut spool is broken.
cover.
NO
P2 bypass cut spool moves NO Outer circumference of YES
Replace P2 bypass cut spool
smoothly by hand. P2 bypass cut spool is
assy.
(Remove pilot cover.) scored.
NG
YES NO
Secondary pressure is Replace control valve.

approx. 0.54MPa (78psi)
when arm lever is shifted YES Inspect or replace pilot
a little. valve.
NO
Return spring of arm spool YES
is broken.
NO
Arm spool moves smoothly NO Outer circumference of swing YES
by hand. spool is scored.
YES NO NG
Arm lock valve moves NO Inspect or replace lock

smoothly by hand. valve.
YES
Piston in swing Confirm piston movement by disconnecting NO Inspect or replace swing
priority block connector at port Pc3' and pushing piston
priority block parts.
moves smoothly. through the port hole, using a rod.
YES
42-15
(5)
Travel 1 and 2 speeds can not be changed over.
24V is alive across light green/black and NO

black of connector for travel 1-2 speed To electrical troubleshooting
soleonid (SV-3).
YES
Pilot pressure of travel 1-2 speed select NO Inspect or replace travel 1-2 NG Inspect or replace
solenoid (SV-3) is approx. 3.43MPa (500psi). speed select solenoid valve. proportional valve block.
YES
Travel 1-2 speed select can not be done in NO Inspect travel motor (ristrict in passage to 1-2 select valve, inclusion
heavy duty condition on a slope or on a muddy
of foreign matter in shuttle valve, etc.) or replace it.
land.
Since the delivery rate of pump is small at heavy duty, the difference
YES between 1 and 2 speeds gets smaller. This makes you feel sometimes
that speed is not changed. But this is normal.
(6)
Travel independent speed is low.
Are both travel speeds low? NO Refer to "Machine

(H-mode, Hi idle, 1-speed, sprocket
deviates."
revolution ; 31rpm)
YES
Command current of proportional
valve is approx. 315mA. (Is the speed NO To electrical
low if coupler of travel straight troubleshooting.
proportional valve is disconnected?)
YES
Secondary pressure for NO Inspect or replace travel
travel remote control is
remote control valve.
approx. 2.35MPa (340psi).
YES
NO Secondary pilot pressure at YES Inspect or replace NG Inspect or replace
Is the pivot turn possible?
port PO (travel straight valve) travel straight
(in both directions) proportional valve block.
is approx. 2.55MPa (370psi). proportional valve.
YES
NO
YES Inspect or replace travel
Return spring of travel
straight spool is broken.
cover.
NO
Travel straight spool moves NO Outer circumference of YES Replace travel straight spool
smoothly by hand. assy.
scored.
YES NG
NO
Return spring of travel YES Inspect or replace travel

spool is broken. spool assy and pilot cover.
NO
Travel spool moves NO Outer circumference of travel YES
Replace travel spool assy.
smoothly. spool is scored.
YES NO NG
Relief pressure in all NO
travel motions is approx. Inspect or replace travel
29.4MPa (4270psi). motor relief valve.

motor.
42-16
(7)
Travel power is poor.
(Diagnosis 30)
Command current for travel straight NO To electrical
proportional valve is approx. 315mA. troubleshooting.
YES
Power lack is felt on a slope YES Inspect or replace travel
or in muddy fields. power boost SOL.
NO NG
NG Since the delivery rate of pump is small and travel
Replace pump power boost
speed is low in heavy duty condition, power lack
regulator inspect or replace it.
is felt in some cases, but it is normal.
The value of travle RH/LH NO Abnormality removed after YES Travel RH/LH pressure
pressure sensor (SE9 or replacing travel RH/LH pressure
sensor error.
SE10) is 4.0V or more at sensor (SE9 or SE10).
full lever condition. NO
YES The value of travle RH/LH pilot YES Inspect harness between
pressure is 2.35MPa (340psi) or travel RH/LH pressure
more at full lever condition. sensor and C1 controller.
NO
Inspect travel pilot valve.
Is the secondary pilot NO Inspect or replace travel

pressure for travel approx.
pilot valve.
2.35MPa (340psi)?
YES
Is a pivot turn possible? NO Pilot pressure at port PO NO Inspect or replace NG Inspect or replace travel
(travel straight valve) is travel straight
(in both directions) pilot valve.
approx. 0.54MPa (78psi). proportional valve.
YES
YES
cover.
NO
Travel straight spool moves NO Outer circumference of YES Inspect or replace travel
smoothly by hand. pilot valve.
scored.
YES NG
NO
Return spring of travel YES Inspect or replace travel

spool is broken. straight spool and pilot
cover.
NO
Travel spool moves NO Outer circumference of travel YES
Replace travel spool assy.
YES NO NG
Relief pressure is approx. Replace control valve.
29.4MPa (4270psi) when
travel lever is turned to NO IInspect or replace travel
the full. motor relief valve.
motor.
42-17
(8)-1
Machine does not travel straight.
Feed current for travel NO

straight proportional To electrical troubleshooting
valve (PSV-C) is 700mA.
YES
Secondary pilot pressure
at port PO (travel straight NO Secondary pressure of travel NO Inspect or replace travel
pilot valve is approx.
valve) is approx. 2.55MPa pilot valve.
2.35MPa (340psi).
(370psi).
YES Inspect or replace NG Inspect or replace
YES travel straight
proportional valve.
cover.
NO
Travel straight spool NO Outer circumference of travel YES Replace travel straight spool
moves smoothly by hand. straight spool is scored. assy.
YES NO NG
(8)-2
Machine deviates in travel independent motion.
Does the machine deviates

In idle run, machine runs to the right and the NO in opposite direction if NO Inspect or replace control
left at different speeds. (H-mode, Hi idle, delivery ports are
valve.
1-speed, and sprocket rotation : 31rpm) exchanged?
YES YES
Inspect or replace pump.
Is the secondary pilot pressure for travel NO Inspect or replace travel
motions normal in both the right and the left
remote control valve.
directions? It is approx. 2.35MPa (340psi).
YES
Does the machine deviates if the right and NO Relief pressure in right and NO Inspect or replace travel
left pipes between control valve and motor are left travel motions is
motor rilief valve.
exchanged? approx. 29.4MPa (4270psi).
YES YES Inspect or replace travel
motor.
Return spring of travel spool is broken.
spool assy and pilot cover.
NO
NO Outer circumference of NO
Travel spool moves smoothly by hand. Replace travel spool assy.
travel spool is scored.
YES YES Replace control valve.
Confirm check valve and seat located before NO

the relief valve of control valve.
YES
42-18
(9)
Machine drifts on a slope. (Machine can not be held on a slope.)
Machine can not be held on a slope when YES Inspect or replace travel
engine is off. motor.
NO
Secondary pilot pressure for travel is 0MPa NO Inspect or replace remote
(0psi). control valve.
YES
Return spring of travel spool is broken.
NO
NO Outer circumference of NO
Travel spool moves smoothly by hand. Replace travel spool.
travel spool is scored.
YES YES NG
42-19
(10)
On disconnecting connector YES
Swing motion To troubleshooting for
(CN-259F) on swing parking
does not work. electric failures.
SOL (SV-1), it swings.
NO
Does the pilot pressure of
parking SOL rise to 0Mpa NO NG
Check or replace swing Check or replace
(0kgf/cm2) at the time when
parking solenoid valve. proportional valve block.
pilot valve secondary pressure
is 0.59MPa(85psi)?
In case of a machine with a
YES multi control valve, check if the
condition returns normal by
changing swing lever back &
forth operation.
Swing pilot valve secondary NO

pressure on both right and left Check or replace pilot valve.
sides is 3.43MPa(500psi).
YES
The return spring of swing YES Check or replace swing
spool is damaged. spool Assy and pilot cover.
NO
The swing spool moves
smoothly. (Remove pilot cover, NO The outer surface of swing YES
Replace swing spool Assy.
and check it for possible spool is damaged.
damage.) NG
NO
YES
Check or replace P2 by-pass

The return spring of P2 by-pass YES
cut valve spool Assy and
cut valve spool is damaged.
pilot cover.
NO
P2 by-pass cut valve spool
moves smoothly. (Remove NO The outer surface of P2 cut YES
Replace P2 by-pass cut Assy.
pilot cover, and check it for valve spool is damaged.
possible damage.) NG
NO
YES
The swing relief pressure is in

the range of reference value. NO Check or replace swing
(With P2 pump) 25.5~28.3MPa motor relief.
(3700 ~ 4120psi)
NG
YES
The swing motion can be held NO Check and replace swing

on a slope. reduction unit or swing motor.
YES
Machine drifts largely when the YES Check or replace swing

swing parking is released (arm
motor.
in fine operation) on a slope.
NO Check or replace swing

reduction unit or swing motor.
42-20
(11)
Swing speed is low.
Feedback current of P2 bypass cut NO

proportional valve (PSV-B) is 700mA when To electrical troubleshooting
swing lever is turned to the full.
YES
Secondary pilot pressure at Pd4 port (P2 NO Inspect or replace P2 bypass NG Inspect or replace
bypass cut valve) is approx. 2.55MPa (370psi)
when swing lever is shifted to the full.
YES
Return spring of P2 bypass cut spool is
broken.
cover.
NO
NO Outer circumference of P2 YES Replace P2 bypass cut spool
P2 bypass cut spool moves smoothly by hand.
bypass cut spool is scored. assy.
YES NO NG

multi control valve, check if the
forth operation.
Secondary pilot pressure for swing motion is NO Inspect or replace pilot

approx. 3.43MPa (500psi) when lever is
valve.
turned to the full in either direction.
YES Inspect or replace swing
pilot shuttle valve of control
valve.
Swing relief pressure is 25.5 to 28.3MPa NO Inspect or replace swing

(3700~4120psi). motor relief.
YES NG
Machine drifts very much when swing YES Inspect or replace swing
parking is released (arm in action) on a slope. motor.
NO
Swing motor port pressure is 34.3MPa NO NG
Inspect or replace swing Inspect or replace
(500psi) when swing lever is shifted to the full
parking solenoid valve. proportional valve block.
or arm in operation.
NO
YES Inspect or replace swing
Return spring of swing spool is broken.
NO
Swing spool moves smoothly. (Confirm the NO Outer circumference of YES
action of spool by removing pilot cover) Replace swing spool assy.
swing spool is scored.
YES NO NG
42-21
(12)-1 The swing speed is in the

Swing range of reference value. NO Refer to Article "Swing
power is poor. (12.5rpm {11.5 rpm : EU spec.} speed is slow."
or more at Hi idling in H mode.)
YES
The return spring of P2 YES Check or replace P2 by-pass
by-pass cut spool is damaged. cut spool Assy and pilot cover.
NO
P2 by-pass cut spool move NO The outer surface of P2 YES Replace P2 by-pass cut
smoothly by hand. by-pass cut spool is damaged. spool Assy.
YES NO NG
multi control valve, check if the
forth operation.
Swing pilot valve secondary

pressure is 3.43MPa NO
(500psi) when the levers Check or replace pilot valve.
on both right and left sides are
to full position.
YES
The swing relief pressure is in
the range of reference value. NO Check or replace swing
(With P2 pump) 25.5~28.3MPa
motor relief.
(3700~4120psi)
YES NG
Machine drifts largely when the YES Check or replace swing

swing parking is released
motor.
(arm-in operation) on a slope.
NO
Swing motor (PG) port pressure
is 3.43MPa(500psi) when NO Check or replace swing NG Check or replace
the swing lever is to full position parking SOL valve. proportional valve block.
or to arm-in position.
YES
NO
The swing spool moves NO YES
The outer surface of swing
smoothly. (Remove pilot cover Replace swing spool Assy.
spool is damaged.
and check the operation.)
NO NG
YES
42-22
(12)-2
Swing relief pressure is in the
Swing motion range of reference value. NO Check or replace swing
drifts very large. (With P2 pump) 25.5~28.3MPa motor relief valve.
(3700~4120psi)
YES
The swing motion can be held NO Replace swing motor
on a slope. parking brake lining.
YES
Machine drifts largely when the YES
swing parking is released Check and replace swing
(arm-in operation) on a slope. motor.

NO multi control valve, check if the
forth operation.
The swing pilot secondary

pressure lowers in 0.2 seconds NO
Check or replace pilot valve.
or less after the swing lever
returns to the neutral position.
YES
NO
The swing spool moves NO YES
Outer surface of swing spool
smoothly. (Remove pilot cover Replace swing spool Assy.
is damaged.
and check the operation.)
NO NG
YES
42-23
(13)-1
The swing The command voltage for YES
To troubleshooting for
motion swing parking SOL. is
electric failures.
cannot be output.
held on a
slope. NO
Check or replace swing
motor reduction unit.
(13)-2
Noise when Make noise when swing YES Check or replace swing
swinging motion is released. motor relief valve.
NO
Make noise when swing YES Check swing shockless
motion stops. valve.
NO
Swing relief pressure is in The control current of
the range of reference value. NO proportional valve for P2 NO To troubleshooting for
(With P2 pump) 25.5~28.3 by-pass cut valve is electric failures.
Mpa (3700~4120psi) approx.585mA.
YES YES
P2 by-pass cut port Pb4
pressure is approx. 2MPa NO Check or replace NG Check or replace
proportional valve
(290psi) in swing proportional valve block.
for P2 by-pass cut.
operation.
YES
The main relief valve
pressure is in the range YES Check or replace NG Check or replace swing
swing motor
of reference value. motor.
relief valve.
(With P2 pump) 29.4MPa
(4270psi)
NO
The return spring of P2 YES Check or replace P2
cut valve spool is by-pass cut valve spool
damaged. Assy and pilot cover.
NO
spool moves smoothly. YES Check or replace main
(Remove pilot cover and
relief valve.
check it for possible
damage)
NO
Outer surface of P2 YES Replace P2 by-pass cut
by-pass cut valve spool
valve spool Assy.
is damaged.
NO NG

NO
The swing spool moves
smoothly by hand. NO Outer surface of P2 YES Replace swing spool
by-pass cut valve spool
(Remove pilot cover and Assy.
is damaged.
check it.)
NO NG
YES
The swing motion is held NO Check or replace swing

on a slope. motor or reduction unit.
YES
Check or replace swing
motor pinion gear,
swing race, bearing.
42-24
43. TROUBLESHOOTING
(ELECTRIC)
TABLE OF CONTENTS
43.1 TROUBLE DIAGNOSIS TABLE : ELECTRIC .................................................................... 43-3

43.2 CONTROLLER ERROR CODE DISPLAY .......................................................................... 43-6
43.3 SERVICE DIAGNOSIS ....................................................................................................... 43-7
43
43-1
43. TROUBLESHOOTING (ELECTRIC)

S5YT4303E01
(NHK)
43-2
43.1 TROUBLE DIAGNOSIS TABLE : ELECTRIC
C1 mechatro controller
Proportional valve Sensor
Boom raising pressure sensor
Bucket digging pressure sensor

Boom lowering pressure sensor


Components
Arm out pressure sensor

Arm in pressure sensor
Swing P/B selector valve
Travel boost-up SOL

Group No.
G(A1)5V 5V(A2)G G(A3)5V 5V(A4)G G(A5)5V

System
Pin 11 11 11 11 11 11 11 11 12 12 12 12 12 12 12 12 12 12 12 12 12 12 12
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Trouble No 2 11 12 13 14 24 25 26 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
No motions operate
1
Machine moves freely
when lever is at neutral
All operation
Only bucket speed is
slow.
Speed is slow
Only boom raise

speed is slow.
2 Motions are slow
except boom raise
and arm digging.

Only arm motion is slow.
Only arm out motion
is slow.
All operation
Power is poor
Bucket digging
3
Boom raising
Arm in
Electric systems
Bucket digging
Fine operation
Boom raising, lowering

impossible
4
Swing left, right
Arm in, out
5 not be 1-2
Travel speed can
changed
6 Travel independent
speed is low.
Travel operation
7 Travel power is poor

ATT travel combined and
8 travel straight are
impossible.
Machine drifts on a
9 downhill and does not
stop still on a slope
10 Swing
work
motion does not
Swing operation
11 Swing speed is slow

Swing power is poor
12
Swing drifts too much
Swing can not be held
on a slope
13
An unusual sound is
heard during swing
Others
14 Auto Idle stop is not

actuated
43-3
C1 mechatro controller Electrical fittings

Sensor Other Proportionate valve
Bucket dump pressure sensor


Components
Travel right pressure sensor
Travel left pressure sensor

P3 pump pressure sensor
Travel 1-2speed select SW

Swing pressure sensor
Fuse blown, shortcircuit,
Gauge cluster
disconnection
Group No.
G(A6)5V 5V(A7)G G(A8)5V 5V(A9)G G(A10)5V

System
P P P
Pin 13 13 13 13 13 13 13 13 13 13 13 13 14 14 14 14 E C S S S
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Trouble No 1 2 3 4 5 6 7 8 9 10 11 12 4 5 6 10 1 V V V
2
-
-
-
B C D
No motions operate
1
All operation
slow.
Speed is slow
Only boom raise

speed is slow.
2 Motions are slow
except boom raise
and arm digging.

Only arm out motion
is slow.
All operation
Power is poor
Bucket digging
3
Boom raising
Arm in
Electric systems
Bucket digging
Fine operation

impossible
4
Swing left, right
Arm in, out
5 not be 1-2
Travel speed can
changed
speed is low.
Travel operation

impossible.
Machine drifts on a
10 Swing
work
motion does not
Swing operation

Swing power is poor
12
on a slope
13
An unusual sound is
heard during swing
Others

actuated
43-4
Electrical fittings
Sensor Solenoid Switch Others
Components
Auto idle stop select SW

Swing P/B release SW
Safaty lock lever SOL
Travel 1-2speed SOL
Safety lock lever SW

Travel boost-up SOL
Travel 1-2speed SW
Swing parking SOL
Bucket digging
Bucket dump
Boom lower
Boom raise
Travel right
Timer unit
Travel left
Arm out
Arm in
Swing
Group No.
System
S S S S S S S S S S S S S S S S SW R
Pin E
-
-
Trouble E E E E E E E E V V V V W W W 20 20
No or or
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
1 2 3 4 5 7 8 9 10 1 3 4 8 3 4 11 30 30
No motions operate
1
All operation
slow.
Speed is slow
Only boom raise

speed is slow.
2 Motions are slow
except boom raise
and arm digging.

Only arm out motion
is slow.
All operation
Power is poor
Bucket digging
3
Boom raising
Arm in
Electric systems
Bucket digging
Fine operation

impossible
4
Swing left, right
Arm in, out
5 not be 1-2
Travel speed can
changed
speed is low.
Travel operation

impossible.
Machine drifts on a
10 Swing
work
motion does not
Swing operation

Swing power is poor
12
on a slope
13
An unusual sound is
heard during swing
Others

actuated
43-5
43.2 CONTROLLER ERROR CODE DISPLAY

When the hard check switch of the controller is set to "00" (The machine is tuned to "00" at shipment.), faults of de-
vices and harnesses connected to them are listed as below. When an error code is displayed, the CPU lamp on the
gauge cluster flickers and the buzzer blows intermittently. In some cases, the CPU lamp on the gauge cluster lights
continuously and the buzzer sounds continuously. This is to indicate a fault on the controller itself.
1. Trouble diagnosis
Error Error
Trouble diagnosis item Corrective action Trouble diagnosis item Corrective action
code code
E01 EEPROM data faulty Readjust engine speed or E16 Battery relay faulty Replace battery relay or
E02 Mechatronic adjustment faulty replace controller inspect harness between
E03 Fault on boom raise pressure sensor battery relay and controller.
E04 Fault on boom lower pressure sensor E17 Fault on P1 by-pass cut proportional valve Replace proportional valve
E05 Fault on arm in pressure sensor E18 Fault on P2 by-pass cut proportional valve or inspect harness between
E06 Fault on arm out pressure sensor E19 Fault on travel straight proportional valve proportional valve and controller.
E07 Fault on bucket digging pressure sensor Replace sensor or inspect E20 Fault on governor motor current Replace governor motor or
E08 Fault on bucket dump pressure sensor harness between sensor E21 Fault on governor motor inspect harness between
E09 Fault on swing pressure sensor and controller. starting point governor motor and controller.
E10 Fault on P3 pump pressure sensor E22 Reverse rotation of engine Replace engine hydraulic
switch or inspect harness
E11 Fault on travel right pressure sensor
between engine oil switch
E12 Fault on travel left pressure sensor and controller.
E13 Accel dial faulty pressure sensor
E14 Fault on travel boost-up solenoid valve Replace selector valve or
inspect harness between
E15 Fault on swing parking selector valve selector valve and
controller.
SERVICE DIAGNOSIS DISPLAY
HARDWARE CHECK SW A
Remove grommet,
and the right Hardware check SW (The left shows the
switches are "0.0" setting condition.)
appear. Turn the arrow at the center of switch
and set it to numeric value.
Insert precision driver (-) in to convex
indicated by arrow and turn the arrow to
set to numeric values.
INTERNAL ADJUSTMENT JP SW
HARDWARE CHECK SW B
43-6
43.3 SERVICE DIAGNOSIS

The following items are displayed if the hard ware check switch located in the controller is changed over. Since the
hard ware check switch is tuned to "00" at shipment, error codes are displayed.
Hardware
check SW Service diagnosis item Contents of display Normal value
A B
0 0 Normal (no service diagnosis) Trouble diagnosis (error code)
0 1 A set value of engine rpm Displayed in 3 digits by 10 rpm. [230] at 2300 rpm. 1020~2250
0 2 An actual engine rpm Displayed in 3 digits by 10 rpm. [230] at 2300 rpm. Approx. 1020 to
approx. 2250
0 3 Key switch input / option switch input Statuses of key switch on 10th digit (ON [1] / OFF [0] ), and
battery relay on the 1st digit (ON [1] / OFF [0] ) are displayed.
0 4 Mode switch / washer switch / work light Mode switch on the 10th digit ( [H] [S] [F] ) Status of option switch on
switch the 1st digit (ON [1] / OFF [0] ) is displayed.
0 5 Wiper switch / washer switch / work light The following statuses are displayed ; wiper SW on the 100th digit
swich (push [1] / [OFF] [0] ), washer SW on the 10th digit (push [1] /
[OFF] [0] ), work lamp SW on the 1st digit (push [1] / OFF [0] ).
0 6 Voltage of accel dial Displayed in whole numbers to the 2nd decimal points. 0.4~4.6
0 7 Accel dial position Governor motor position converted from accel dial voltage is displayed in per cents. 0~100
0 8 Step number of governor motor Present step number of governor motor is displayed in three whole numbers. 0~630
0 9 Governor motor position What percent in position the present step number is between low 0~100
idle and high idle is displayed.
1 0 Phase current of governor motor A Displayed in whole numbers to the 2nd decimal points. 2.34A is Approx. 150
1 1 Phase current of governor motor B displayed in [234] .
1 2 Governor motor limit switch Status of governor motor limit switch on the 1st digit (ON [1] /
OFF [0] ) is displayed.
1 3 Boom raise pressure sensor Displayed in whole numbers to the 2nd decimal points. 2.34V is 0.4~5.0
1 4 Boom down pressure sensor displayed in [234] .
1 5 Arm out pressure sensor
1 6 Arm in pressure sensor
1 7 Bucket digging pressure sensor
1 8 Bucket dump pressure sensor
1 9 Swing pressure sensor
2 0 P3 pump pressure sensor
2 1 Travel right pressure sensor
2 2 Travel left pressure sensor
2 3 Travel boost-up selector valve Statuses of output command on the 10th digit (ON [1] / OFF [0] ),
output command and feedback on the 1st digit (ON [1] / OFF [0] ) are displayed.
2 4 Output command of swing parking Statuses of output command on the 10th digit (ON [1] / OFF [0] ),
selector valve / feedback and feedback on the 1st digit (ON [1] / OFF [0] ) are displayed.
2 5 Battery relay output command / feedback
2 6 Command current for P1 bypass cut proportionate valve Current is displayed in mA. 280~760
2 7 Feedback current of P1 bypass cut proportionate valve
2 8 Command current of P2 bypass cut proportionate valve
2 9 Feedback current of P2 bypass cut proportionate valve
3 0 Command current of travel straight proportionate valve
3 1 Feedback current of tralve straight valve
3 2 Wiper motor rise-up LS / reverse LS Statuses of LS on the 10th digit (ON [1] / OFF [0] ), wiper motor
rise-up LS on the 1st digit (ON [1] / OFF [0] ) are displayed.
Wiper motor arc preventive relay / forward Statuses of wiper motor arc preventive relay command on the 100th
3 digit (ON [1] / OFF [0] ), forward relay command on the 10th digit
3 relay / reverse relay command
(ON [1] / OFF [0] ), and reverse relay command on the 1st digit
(ON [1] / OFF [0] ) are displayed.
Washer motor relay / work light relay / Statuses of washer motor relay command on the 100th digit (ON [1]
4 / OFF [0] ), work light relay command on the 10th digit (ON [1] /
3 CPU trouble lamp command
OFF [0] ), CPU trouble lamp command on the 1st digit (ON [1] /
OFF [0] ) are displayed.
3 5 Wiper operating command / power window Statuses of wiper operating command on the 10th digit (ON [1] /
operating input OFF [0] ), and wiper window operating input command on the 1st
digit (ON [1] / OFF [0] ) are displayed
Status of internal adjust switch on the 1st digit (TEST [1] / RUN
3 6 Internal adjust switch
[0] ) is displayed.
43-7
(1)-1
No motions operate.
Lever stand down

24V is alive across
white/blue and black of YES To hydraulic
connector (CN-256F) for troubleshooting
lever lock solenoid (SV-4).
NO
24V is alive across white Harness between lever

and blue of connector YES lock switch (SW-11) and YES
Inspect harness.
(CN-66F) for lever lock lever lock solenoid
switch (SW-11). (SV-4) is disconnected.
NO
Lever lock switch (SW-11) YES

Replace switch (SW-11).
is faulty.
24V is alive across white

and black of connector YES
(CN-66F) for lever lock
switch (SW-11).
NO Lever lock switch (SW-11) YES
Adjust and mount.
is mounted improperly.
YES YES Inspect the shorted point

Fuse No.15 is blown. Harness shorted to frame.
of harness.
NO
Inspect if there is no
disconnection in fuse box.
43-8
(1)-2
Machine moves freely when lever is at neutral.
(Hard check SW00) ; error code E17 is indicated at this time.

Machine moves not freely when NO To hydraulic
connector (CN-253F) for P1 bypass cut
troubleshooting
proportional valve is disconnected.
YES
(Hard check SW15)
Arm out sensor (SE-8) shows more than YES Trouble disappears if arm out operation YES Arm out operation sensor
1.3V even when lever is at neutral. sensor (SE-8) is replaced. (SE-8) is faulty.
NO NO
Arm out pilot pressure is 0.59MPa NO
Replace C-1 controller.
(85psi) when lever is at neutral.
YES
Inspect ATT pilot valve.
(Hard check SW16)
Arm in sensor (SE-7) shows more than NO
ReplaceC-1 controller.
1.3V when lever is at neutral.
YES
Trouble disappears if arm in sensor (SE-7) YES Arm in sensor (SE-7) is
is replaced. faulty.
NO
Arm in pilot pressure is more than NO
0.59MPa (85psi) when lever is at neutral.
YES
(Hard check SW00) ; error code E18 comes out at this time.
Machine stops moving freely when NO To hydraulic
connector (CN-254F) for P2 bypass cut
troubleshooting
proportional valve is disconnected.
YES
(Hard check SW13)
Boom raise sensor (SE-3) shows more YES Trouble disappears when boom raise YES Boom raise sensor (SE-3)
than 1.3V when lever is at neutral. sensor (SE-3) is replaced. is faulty.
NO NO
Boom raise pilot pressure is more than NO
YES
(Hard check SW19)

Swing sensor (SE-5) shows more 1.3V YES Trouble disappears when swing sensor YES Swing sensor (SE-5)
when lever is at neutral. (SE-5) is replaced. is faulty.
NO NO
Swing pilot pressure is more than NO
YES
43-9
(2)-1
Only bucket motion is slow
(Hard check SW00) ; Error code E18 comes out on that occasion.
Is the motion normal after
connector (CN-254F) of P2 NO To hydraulic
bypass cut proportional troubleshooting
valve is disconnected.
YES (Hard check SW13)
Boom raise sensor (SE-3) YES Trouble disappears if boom YES Boom raise sensor (SE-3)
shows 1.3V when lever is raise sensor (SE-3) is
is faulty.
at neutral. replaced.
Boom raise pilot pressure
NO NO is more than 0.59MPa NO
(85psi) when lever is at
neutral.
YES
(Hard check SW19)
Swing sensor (SE-5) YES Trouble disappears if swing YES Swing sensor (SE-5)
shows 1.3V when lever is
sensor (SE-5) is replaced. is faulty.
at neutral.
NO NO Swing pilot pressure is NO
more than 0.59MPa (85psi) Replace C-1 controller.
YES
(2)-2
Only boom raise speed motion is slow.
(Hard check SW29)

Feedback current for P2 bypass
cut proportional valve (PSV-B) YES To hydraulic
is approx. 700mA when boom troubleshooting
raise lever is shifted to the full.
NO (Hard check SW28) (Hard check SW13)

Command current for P2 bypass Boom raise sensor (SE-3)
cut proportionl valve (PSV-B) NO shows more than approx. 4.0V YES
is approx. 700mA when boom when boom raise lever is
raise lever is shifted to the full. shifted to the full.
YES NO
Trouble disappears when boom YES Boom raise operating
raise sensor (SE-3) is replaced. sensor (SE-3) is faulty.
NO
Boom raise pilot pressure is
more than approx. 3.43MPa NO
(500psi) when boom raise lever Inspect ATT pilot valve.
is shifted to the full.
YES Harness between
Error code E03 is displayed on YES C-1 controller and YES
Inspect harness.
C-1 controller. boom raise sensor
(SE-3) is shorted.
NO
Contact between C-1 controller YES
Continued on P6. and boom raise sensor (SE-3) Inspect harness.
is poor.
43-10
Continued from P5
YES Harness between C-1 controller Inspect harness between

Error code E18 is shown on C-1 YES and P2 bypass cut proportional YES C-1 controller and P2
controller. valve (PSV-B) is disconnected or bypass cut proportional
(Hard check SW30) shorted. valve (PSV-B).
NO
Command current for travel
straight proportional valve NO To hydraulic
(PSV-C) is more than approx.
troubleshooting
350mA only when boom raise
lever is shifted to the full.
YES
Travel right sensor (SE-9) shows NO
approx. 1.3V when travel right Replace C-1 controller.
lever is at neutral.
YES
Trouble disappears if travel right YES Travel right sensor (SE-9)
NO
Travel right pilot pressure is NO Inspect harness between
more than 0.59MPa (85psi) when travel right sensor (SE-9)
lever is at neutral. and C-1 controller.
YES
(2)-3
Only boom raise and arm in motions are slow.
YES (Hard check SW30) ; controller service diagnosis 30
Command current for
travel straight
proportional valve is NO To hydraulic
approx. 350mA or over at troubleshooting
boom raise or arm in
motions.
YES (Hard check SW21) (Hard check SW22)
Travel right sensor (SE-9) Travel left sensor (SE-10)
shows more than 1.3V NO shows approx. 1.3V or over NO
when travel right lever is when travel left lever is at
at neutral. neutral.
YES YES
Trouble disappears if travel NO Travel left pilot pressure is NO Inspect harness between
left sensor (SE-10) is more than 0.59MPa (85psi) travel left sensor (SE-10)
replaced. when lever is at neutral. and C-1 controller.
YES YES
Replace travel left sensor

(SE-10).
Travel right pilot pressure

Trouble disappears when NO NO Inspect harness between
is more than 0.59MPa
travel right sensor (SE-9) travel right sensor (SE-9)
is replaced. and controller.
neutral.
YES
YES
Replace travel right

sensor (SE-9).
43-11
(2)-4
Only arm in motion is slow.
(Hard check SW26)
Command current for
bypass cut proportional YES To hydraulic
valve (PSV-D) is approx.
troubleshooting
700mA when arm in lever
NO (Diagnosis 16)
Arm in sensor (SE-7) shows (Hard check SW00)
approx. 4.0V or over when YES NO
Error code E17 is displayed. Replace C-1 controller.
arm in lever is shifted to
the full.
YES
NO Inspect harness between
P1 bypass cut
proportional valve (PSV-
D) and C-1 controller.
Trouble disappears if arm YES Arm in sensor (SE-7) is

in sensor (SE-7) is replaced. faulty.
NO
Arm in pilot pressure is
YES Inspect harness between
arm in sensor (SE-7) and
or over when arm in lever
C-1 controller.
NO
(2)-5
Only arm out motion is slow.
(Hard check SW26)
Command current for P1
bypass cut proportional YES To hydraulic
valve (PSV-D) is approx.
troubleshooting
700mA when arm out lever
NO (Hard check SW15)
Arm out sensor (SE-8) (Hard check SW00)
shows approx. 4.0V or over YES NO
Error code E17 is displayed. Replace C-1 controller.
when arm out lever is
shifted to the full.
YES
P1 bypass cut
proportional valve (PSV-
D) and C-1 controller.
Trouble disappears if arm YES Arm out sensor (SE-8) is

out sensor (SE-8) is
faulty.
replaced.
NO
Arm out pilot pressure is
or over when arm out lever
C-1 controller.
NO
43-12
(4)-1
Fine operation of bucket digging and dump motions can not be performed.
YES
Trouble gets normal if
connector on P1 bypass cut NO To hydraulic
proportional valve (PSV-D) troubleshooting.
is disconnected.
Arm in sensor (SE-7) shows NO Arm out sensor (SE-8) NO
approx. 1.3V or over when shows approx. 1.3V or over Replace C-1 controller.
lever is at neutral. when lever is at neutral.
YES YES
Trouble gets normal if arm YES Arm out sensor (SE-8) is
faulty.
replaced.
NO
Arm out pilot pressure is NO Inspect harness between
more than 0.59MPa (85psi) arm out sensor (SE-8) and
when lever is at neutral. C-1 controller.
YES
Trouble is corrected if arm YES Arm in sensor (SE-7) is

NO
Arm in pilot pressure is NO Inspect harness between
more than 0.59MPa (85psi) arm in sensor (SE-7) and
YES
(4)-2
Fine operation of boom raise and lower motions can not be performed.
YES (Hard check SW00) ; Error code E17 is displayed at this time.
connector of P1 bypass cut NO To hydraulic
proportional valve (PSV-D) troubleshooting
is disconnected.
Arm in sensor (SE-7) shows YES Trouble disappears if arm YES Arm in sensor (SE-7) is
approx. 1.3V or over when
NO NO
0.59MPa (85psi) or over arm in sensor (SE-7) and
YES

(Hard check SW15)
Arm out sensor (SE-8) NO
shows approx. 1.3V or over Replace C-1 controller.
YES
Trouble disappears if arm YES Arm out sensor (SE-8) is
faulty.
replaced.
NO
Arm out pilot pressure is NO Inspect harness between
more than 0.59MPa (85psi) arm out sensor (SE-8) and
YES
43-13
(4)-3
Fine operation of swing motion can not be performed.
(Hard check SW00) ;
error code E18 is
indicated at this time.
(Hard check SW19)
connector of P2 bypass cut YES Swing sensor (SE-5) YES Trouble is corrected if YES Swing sensor (SE-5)
shows approx. 1.5V or over swing sensor (SE-5) is
proportional valve (PSV-B) if faulty.
when lever is at neutral. replaced.
is disconnected.
NO NO
NO
Swing pilot pressure is NO Inspect harness between
more than 0.59MPa (85psi) swing sensor (SE-5)
when lever is at neutral. and C-1 controller.
YES
Boom raise sensor (SE-3) YES Trouble disappears if boom YES Boom raise sensor (SE-3)
shows approx. 1.3V or over raise sensor (SE-3) is
is faulty.
when lever is neutral. replaced.
NO NO
is more than 0.59MPa NO Inspect harness between
boom raise sensor (SE-3)
and C-1 controller.
neutral.
YES

connector of swing parking NO To hydraulic
solenoid (SV-1) is troubleshooting
disconnected.
Swing sensor (SE-5)
NO Trouble gets normal if YES
shows approx. 4.0V or over Swing sensor (SE-5)
swing sensor (SE-5) is
when lever is shifted to the is faulty.
replaced.
full.
NO
YES
Swing pilot pressure is
swing sensor (SE-5)
or over when lever is
and C-1 controller.
NO
43-14
(4)-4
Fine operation of arm in and out motions is not possible.
(Hard check SW00) ; error code E18 is displayed at this time.
connector of P2 bypass cut NO To hydraulic
proportional valve (PSV-B) troubleshooting.
is disconnected.
YES
(Hard check SW19)
Swing sensor (SE-5)
indicates approx. 1.3V or YES Trouble gets normal if YES Swing sensor (SE-5)
swing sensor (SE-5) is
over when lever is at is faulty.
replaced.
neutral.
NO
NO
Swing pilot pressure is NO Inspect harness between
more than 0.59MPa (85psi) swing sensor (SE-5)
YES
(Hard check SW13)

Boom raise sensor (SE-3)
indicates approx. 1.3V or NO
over when lever is at
neutral.
YES
Trouble disappears if boom YES Boom raise sensor (SE-3)
raise sensor (SE-3) is
is faulty.
replaced.
NO
Boom raise pilot pressure is NO Inspect harness between
more than 0.59MPa (85psi) boom raise sensor (SE-3)
YES
43-15
(5)
Travel 1-2 speed can not be changed.
24V is alive across light green /

black harness and black harness of YES To hydraulic
connector for travel 1-2 speed troubleshooting
selecting solenoid (SV-3).
NO
YES
Fuse No. 15 is blown out. Replace fuse.
NO
There is continuity between pink / There is disconnection of harness (pink)
blue harness and ground in holding YES between travel 1-2 speed switch (SW-3) YES
Replace harness.
circuit, when travel 1-2 speed select and holding circuit unit (E-23), or
switch (SW-3) is pressed. disconnection of ground harness (black).
NO Replace travel 1-2 speed
NO switch.
There is 24V between light green /
blue harness of holding circuit unit NO Replace travel 1-2 speed
(E-23) and ground, when travel 1-2 relay.
spped switch (SW-3) is pressed.
YES
Replace holding circuit unit.
(6)
Travel independent speed is low.
(Hard check SW30)
Command current of travel
straight proportional (PSV-C) is NO To hydraulic
more than 350mA during troubleshooting
traveling.
Bucket digging sensor (SE-1) YES Trouble disappears if bucket digging YES Bucket digging sensor
indicates 1.3V when lever is at
sensor (SE-1) is replaced. (SE-1) is faulty.
neutral.
NO
NO
Bucket digging pilot pressure is NO
more than 0.59MPa (85psi) when Replace C-1 controller.
YES
(Hard check SW18)
Bucket dump (SE-2) indicates more YES Trouble disappears if bucket dump YES Bucket dump sensor
than 1.3V when lever is at neutral. sensor (SE-2) is replaced. (SE-2) is faulty.
NO NO
Bucket dump pilot pressure is NO
more than 0.59MPa (85psi) when Replace C-1 controller.
YES
(Hard check SW13)
Boom raise sensor (SE-3) indicates YES YES
Trouble disappears if boom raise Boom raise sensor (SE-3)
more than 1.3V when lever is at
neutral.
NO NO
Boom raise pilot pressure is more NO
than 0.59MPa (85psi) when lever is Replace C-1 controller.
at neutral.
YES
Continued on P12. Inspect ATT pilot valve.
43-16
Continued from P11.
NO (Hard check SW14)

Boom lower sensor (SE-4) indicates YES YES
Trouble disappears if boom lower Boom lower sensor (SE-4)
neutral.
NO NO
Boom lower pilot pressure is more NO
at neutral.
YES
(Hard check SW19)
Swing sensor (SE-5) reads YES Trouble disappears if swing YES Swing sensor (SE-5)
neutral.
NO
NO
Swing pilot pressure is more NO
at neutral.
YES
(Hard check SW16)
Arm in sensor (SE-7) reads more YES Trouble disappears when arm in YES Arm in sensor (SE-7) is
than 1.3V when lever is at neutral. sensor (SE-7) is replaced. faulty.
NO NO
Arm in pilot pressure is more than NO
0.59MPa (85psi) when lever is at Replace C-1 controller.
neutral.
YES
(Hard check SW15)
Arm out sensor (SE-8) reads more YES Trouble disappears if arm out YES Arm out sensor (SE-8) is
than 1.3V when lever is at neutral. sensor (SE-8) is replaced. faulty.
NO NO
Arm out pilot pressure is more NO
at neutral.
YES
Replace C-1 controller
43-17
(8)
Machine does not travel straight.
(Hard check SW31)

Feedback current of travel YES To hydraulic
straight proportional
troubleshooting
valve (PSV-C) is 700mA.
NO
Check harness (green/
(Hard check SW00) black and gray/black)
Error code E19 is YES between travel straight
indicated. proportional valve
(PSV-C) and C-1
NO controller.
(Hard check SW19)
Swing sensor (SE-5)
Machine deviates to the YES reads more than 4.0V NO Trouble disappears if swing YES Swing sensor (SE-5)
sensor (SE-5) is
left. when lever is shifted to the is faulty.
replaced.
full.
NO
NO
YES
more than approx. YES Check harness between
swing sensor (SE-5)
3.43MPa (500psi) when
and C-1 controller.
NO
(Hard check SW15) Check ATT pilot valve.
Arm out sensor (SE-8)

indicates more than 4.0V NO Trouble disappears if arm YES Arm out sensor (SE-8) is
when lever is shifted to the faulty.
replaced.
full.
NO
YES
Arm out pilot pressure is
approx. 3.43MPa (500psi) YES Inspect harness between
arm out sensor (SE-8) and
C-1 controller.
NO
(Hard check SW16)
Arm in sensor (SE-7) reads NO Trouble disappears if arm YES Arm in sensor (SE-7) is
more than 4.0V when lever in sensor (SE-7) is
faulty.
is shifted to the full. replaced.
YES NO
Replace controller. Arm in pilot pressure is
C-1 controller.
NO
(Hard check SW13) Inspect ATT pilot valve.
Boom raise sensor (SE-3)
Trouble disappears if boom YES Boom raise sensor (SE-3)
reads more than 4.0V
raise sensor (SE-3) is
replaced.
full.
NO
YES
is approx. 3.43MPa YES Inspect harness between
boom raise sensor (SE-3)
(500psi) or over when lever
and C-1 controller.
NO
Continued on P14 Inspect ATT pilot valve.
43-18
Continued from P13

Boom lower sensor (SE-4)
NO Trouble disappears if boom YES
reads approx. 4.0V or over Boom lower sensor (SE-4)
lower sensor (SE-4) is
replaced.
full.
NO
YES
Boom lower pilot pressure
is approx. 3.43MPa
boom lower sensor (SE-4)
and C-1 controller.
NO
Bucket digging sensor (SE-
NO Trouble disappears if YES
1) reads approx. 4.0V or Bucket digging sensor
bucket digging sensor (SE-
over when lever is shifted (SE-1) is faulty.
1) is replaced.
to the full.
NO
YES
Bucket digging pilot
pressure is approx. 3.43MPa
bucket digging sensor
(SE-1) and C-1 controller.
NO
Bucket dump sensor (SE-2)
NO Trouble disappears if YES
reads approx. 4.0V or over Bucket dump sensor (SE-
bucket dump sensor (SE-2)
when lever is shifted to the 2) is faulty.
is replaced.
full.
NO
YES
Bucket dump pilot pressure
is approx. 3.43MPa
bucket dump sensor (SE-
2) and C-1 controller.
NO
(10)
Swing motion does not work.
Swing motion works if NO To hydraulic

connector of swing parking
troubleshooting
solenoid (SV-1) is disconnected.
Swing sensor (SE-5) reads NO YES
Trouble disappears if swing Swing sensor (SE-5)
approx. 1.3V or over when
YES NO
approx. 3.43MPa (500psi) or
swing sensor (SE-5)
over when lever is shifted to
and C-1 controller.
the full.
NO
43-19
(11)
Swing speed is low.
(Hard check SW29)

Feedback current of P2 bypass
is approx. 700mA when swing troubleshooting
Command current of P2 bypass Swing sensor (SE-5)
cut proportional valve (PSV-B) NO reads approx. 4.0V NO Trouble disappears if swing YES Swing sensor (SE-5)
sensor (SE-5) is
is approx. 700mA when swing when lever is shifted is faulty.
replaced.
lever is shifted to the full. to the full.
YES NO
YES
swing sensor (SE-5)
and C-1 controller.
NO
Error code E18 is YES Inspect harness between P2 bypass cut

indicated. proportional valve (PSV-B) and C-1 controller.
NO
(12)
(Hard check SW29)

Feedback current of P2 bypass
is approx. 700mA when swing troubleshooting
Command current of P2 bypass Swing sensor (SE-5)
cut proportional valve (PSV-B) NO reads approx. 4.0V NO Trouble disappears if swing YES Swing sensor (SE-5)
sensor (SE-5) is
is approx. 700mA when swing when lever is shifted is faulty.
replaced.
lever is shifted to the full. to the full.
YES NO
YES
swing sensor (SE-5)
and C-1 controller.
NO
YES
Continued on P16.
43-20
Continued from P15
YES
Error code E18 is NO
indicated.
YES Inspect harness between P2 bypass cut
proportional valve (PSV-B) and C-1 controller.
(13)-1
Swing motion can not be held on a slope.
YES
24V is alive across
pink/black and black wires YES To hydraulic
of connector for swing troubleshooting
parking solenoid (SV-1).
NO
Swing parking release NO
switch (SW-4) is at Turn to NORMAL.
NORMAL.
Swing sensor (SE-5) YES Trouble gets normal if YES Swing sensor (SE-5)
reads more than 1.3V swing sensor (SE-5)
is faulty.
when lever is at neutral. is replaced.
NO NO
Swing pilot pressure
is more than 0.59MPa
swing sensor (SE-5)
and C-1 controller.
neutral.
YES
Arm in sensor (SE-7) reads YES Trouble gets normal if arm YES Arm in sensor (SE-7) is
more than 1.3V when lever in sensor (SE-7) is
faulty.
is at neutral. replaced.
NO NO
more than 0.59MPa (85psi) arm in sensor (SE-7) and
YES
Inspect that harness (pink

If swing right (or swing
YES and black) between swing
left, or arm in) lever is
parking brake solenoid
operated, error E15 is
(SV-1) and C-1 controller
indicated.
is not disconnected.
NO
43-21
(14)
Auto idling stop (AIS) does not When overheating is
function. E/G does not stop after an NO Is E/G water temperature warning YES detected, AIS does not work
elapse of 30 seconds after the lock to protect E/G.
indicated?
lever was moved upward to locked Check on it in normal opera-
position.) NO tion condition.
YES When AIS selector SW is

Is AIS selector SW off? off, it does not work. Switch
AIS SW on and check on it.
NO
Check the line between AIS

24V is impressed on timer unit No.1 NO
selector SW and timer unit,
pin terminal.
and check fuse No.2
YES
Check the line between timer

24V is impressed on timer unit No.7 NO unit and alternator. The AIS
pin terminal during engine running. is not actuated if alternator
is not actuated.
YES
Is ATT operation possible even if the YES

Replace a limit switch of
lock lever is moved upward to locked
lock lever.
position?
NO
24 V is impressed on timer unit No.2 YES (24V) Check the line between
pin terminal during lock lever is moved locklever limit switch and
upward to locked position. controller.
NG
Replace a timer unit.
43-22
44. TROUBLESHOOTING
(ENGINE)
TABLE OF CONTENTS
44.1 TROUBLE DIAGNOSIS : ENGINE ..................................................................................... 44-3

44
44-1
44. TROUBLESHOOTING (ENGINE)

  SK80MSR–1E(S) : LF04–02001~  KE
S5YT4403E01
(NHK)
44-2
44.1 TROUBLE DIAGNOSIS : ENGINE
Service man
Inspection Visual check
Filters Fluid Gas / Fluid
Poor quality fuel is used or heavy oil is used.

Fuel system trouble (Air or water entered.)
Viscosity of engine oil is not suited, engine oil is
Gas leaks from valve and gasket.

leaking, or the engine oil level not proper.
Fuel is of poor quality or leaking.
Specific gravity of battery fluid
Component
Fuel not filled up or leaking.

Oil cooler element clogged.
Engine oil is too much.

Gauze filter clogged.
Blowby gas is much.

Air cleaner clogged.
Breather hose bent.

Cooling water level
Fuel filter clogged.
Battery fluid level

Oil filter clogged.
Group No.
V-belt slips.
System
Trouble
Starting trouble
1 Starter does not run.
2 Starter runs but does ont start.
Idling unsmooth
Medium speed hunting

Rotation trouble
3 High speed unsmooth
Does not reach max revolution.
Max. revolution is too high.
Revolution does ont change if

4
work modes are changed.
Accel potentiometer does
5
Engine
not work properly.
E/G deficiency in output

Drop in output
6
Over heat
Knocking occurs after

7
warming-up E/G
Exhaust gas is black

8
Exhaust gas is white
(In cold state, white smoke does
not disappear after idling.)
Other trouble
9 Excessive oil consumption.
10 Excessive fuel consumption.
Engine does not stop when

11
key is turned off.
Power is off the moment the key
12 is turned to OFF, but engine does
not stop.
44-3
Service man Engine dealer

Shovel side Engine side
Fuel system
Electrical fittings Electrical fittings
Component
Connector and electric wiring

Mechatoronic controller
Check injection timing

Mechatoro "A" adjust.
Auto idle stop relay 2

Accel potentiometer
Feed pump function

Stepping motor
Inspect nozzle.
Injection pump
Starter motor
Battery relay
Starter relay
Group No.
Safety relay
Starter key
Glow relay
Timer unit
Alternator
System
Glow
Fuse
Trouble
Starting trouble
Idling unsmooth

Rotation trouble

4
5
Engine
not work properly.

Drop in output
6
Over heat

7
warming-up E/G

8
Other trouble

11
key is turned off.
Stop
Power is off the moment the key position
not stop.
44-4
Engine dealer
Suction/ Lubrication
exhaust Cooling Main structure
system system
chamber through piston or through valve guide.
Control rack movement unsmooth.

Component
Check if engine oil goes into combustion
Oil cooler element damaged.
Crank shaft oil seal no good.

Compression pressure low.
Governor spring fatigued.
Flywheel gear damaged.

Valve spring is fatigued.
Valve spring fatigued.

Air cleaner & muffler
Oil strainer clogged.
Internal parts stuck.
Head gasket faulty.

Check thermostat.
Check relief valve.
Piston liner worn.

Piston ring worn.
Check fuel feed.

Valve clearance
Fuel is mixed.
Group No.
System
Trouble
Starting trouble
Idling unsmooth

Rotation trouble

4
5
Engine
not work properly.

Drop in output
6
Over heat

7
warming-up E/G

8
Other trouble

11
key is turned off.
Power is off the moment the key
not stop.
44-5
44-6
(1)
Starter does not run.
NO Check a battery fluid level and NO

Check a battery voltage. Charge or replace battery.
specific gravity.
OK
NO Battery relay’s B terminal of coil side YES Check a grounding of battery
Battery relay is turned on if starter
relay, and if necessary re-
key is turned on. is impressed 24V.
place battery relay.
YES NO
24V is impressed on output side NC YES Check the line between AIS
terminal of AIS relay No.1. relay No.1 and battery relay.
NO
24V is impressed on common terminal NO Check a key switch, fuse
of AIS relay No.1. and fusible link.
YES
If disconnect a connector of timer unit YES
Replace a timer unit.
for AIS, battery relay turns on.
NO
Replace an AIS relay No.1.
If 24V is impressed on ST terminal

of key switch, check this 24V at S NO 24V is impressed on NC terminal YES Check the line between AIS
terminal side of safety relay in engine output side of AIS relay No.2. relay No.2 and safety relay.
sub-harness assy.
NO
YES NO Check key switch, and check
24V is impressed on common
the line between ST terminal
terminal of AIS relay No.2.
and AIS relay No.2
YES
Replace an AIS relay No.2.
NO Check the cable between

24V is impressed on starter motor
battery relay and starter
B terminal.
motor.
YES
24V is impressed on starter motor YES
Replace a starter motor.
S terminal.
NO
YES Check the line between
24V is impressed on safety relay
safety relay C terminal and
C terminal.
starter motor S terminal.
NO
Replace a safety relay.
NOTES:
AIS means Auto Idling Stop.
Check key switch in START position.
Emergency stop knob (Engine stop) is returned to running position.
44-7
(2)
Starter turns but engine is hard to start.
Check starter power is strong WEAK Check battery fluid level and
Charge or replace battery.
or weak. specific gravity.
OK
Check engine itself. Check compression
pressure and valve
clearance. Check that
Check that air filter clogged valve spring is not
Check air suction system. fatigued, that piston liner
lamp lights.
is not worn, that piston
OK OK ring is not worn, that
head gasket is not faulty
Check that air cleaner clogged
and that flywheel gear is
lamp and sensor.
not damaged. Also check
radiator and thermostat.
E/G side Check gauze filter.

Check feed pump
OK performance, injection
Check fuel feed system.
pump, injection nozzle
Check fuel gauge and water and injection timing.
Machine
separator. Check that poor
side
quality fuel is not used.
YES
Check electric system. E/G side 24V is alive on glow plug. Glow plug is faulty.
NO
24V is alive on wire No.66 YES Harness between glow
(5W) of CN-153F on glow relay relay and glow plug is
(R-3). faulty.
NO
NO Harness between glow
24V is alive on wire No.55 (5Y)
relay and battery relay is
of CN--154F on glow relay (R-3).
faulty.
OK
24V is alive across wire No.62 YES
of CN-155F on glow relay (R-3) Replace glow relay.
and earth.
NO
NO Harness between glow
Ground connection is poor. relay and battery relay is
faulty.
Check E/G oil of viscosity if it NO

Check viscosity of E/G oil. is suited to atmospheric Replace engine oil.
temperature.
Checking condition : E/G starter key is in ON position.
Internal connection
44-8
(3)
E/G revolution is faulty.
Check high pressure pipe

and injection nozzle.
Check that compression
Idling not smooth.
pressures in cylinder are
equal. Check injection
pump and thermostat.
Idling is faulty.
1
Idling revolution is too *Adjust mechatro "A"
high.
Check control rack.

Medium revolution is Hunting occurs at
Change over governor
faulty. medium revolution.
spring.
Check that air is not YES

Bleed air.
mixed in fuel.
OK
Check that air cleaner is
Check air suction system.
not clogged.
OK
Check fuel gauge, water
separator and gauze filter.
Check fuel system.
Check also that poor
quality fuel is not used.
High idling is faulty. OK
Check injection nozzle,

injection pump and
injection timing.
E/G does ont reach max.

1
revolution.
*Adjust mechatro "A"
Max revolution is too
high.
Checking condition ; E/G water temperature is more than 50 C (122 F).

1 ; Refer to Electric Troubleshooting.
*
44-9
Note ; (6) matches the group No. on page 1. The same is true on the following pages.
(6)
E/G output is insufficient.
Check that E/G water OK Check the contents of
Overheat temperature lamp is on and
excavating.
that buzzer sounds.
NO Check E/G water
temperature switch,
Inspect electric system.
gauge cluster, electric
wiring and connectores.
OK
Check coolant level.
Inspect cooling system. Check that fan belt does
not slip.
OK Check thermostat.
Also check that radiator.
Oil cooler is not clogged.
Check that poor quality

Check fuel system.
fuel is not used.
OK
Check E/G oil system. Check E/G oil filter.
Check air suction Check that air filter clogged OK Check that air cleaner is
system. lamp lights. not clogged.
OK
Check that air is not mixed
Check fuel system. Bleed air.
in fuel.
OK OK
Check feed pump, injection
Check water separator and
pump, injection nozzle and
gauze filter. Check also that
injection timing.
poor quality fuel is not used.
Check viscosity of E/G oil if

Check E/G oil. it is suited to atmospheric Replace engine oil.
temperature.
OK
Check that blowby gas is not Check compression
much, that gas does not leak pressure and valve
from gasket, and that engine clearance. Check that
Check engine body oil goes into combustion valve spring is not
chamber through piston or fatigued. Check that
through valve guide control rack moves
smoothly. Check that
piston ring is not worn.
Checking condition ; High idling Check also that head
gasket is net faulty.
(7)
Knocking occurs after warming-up E/G.
OK
Check that poor quality fuel
Check fuel system. Replace fuel.
is not used.
Check that engine oil goes into Judge it if oil is there on

Check E/G itself. combustion chamber through exhaust port.
piston.
OK
Check that blowby gas is not Check compression
much and that gas does not pressure, injection timing
leak from gasket. and injection nozzle.
Checking condition ; E/G water temperature is more than 50 C (122 F).
44-10
(8)
Exhaust is abnormal.
OK
Check that air cleaner is not
Exhaust gas is black. Replace air element.
clogged.
OK
Check engine oil viscosity.
Check that engine oil is not
too much.
Check injection nozzle,
OK injection timing, injection
Check that gas is not leaking pump and valve clearance.
from head gasket. Check that valve spring is
not fatigued and that piston
ring is not faulty.
Check that water is not

Exhaust gas is white. Check water separator.
mixed in fuel.
OK
Check that engine oil goes
into combustion chamber
through piston or through valve Check compression pressure
guide. Blowby gas is much. and injection timing.
A lot of gas leaks from gasket.
Checking condition ; Engine water temperature is more than 50 C (122 F).
(9)
Excessive oil consumption.
Check leakage by checking

Check that engine oil is not Retighten.
the ground under E/G or by
leaking. Replace packing and seal.
placing an oil pan under E/G.
(Check that engine oil is not
filled up too much.) OK
Check that breather hose is
Replace breather hose.
not bent or clogged.
OK
Advise to replace fuel.
is not used.
OK
Check viscosity of engine oil. Advise to replace engine oil.
OK Check that ; CR shaft oil seal

Check that engine oil does is not faulty, piston liner is
not into combustion chamber not worn, or piston ring is
Checking condition ; No engine oil leaks. through piston or through valve not worn.
guide.
(10)
Excessive fuel consumption.

Check fuel leakage. Advise to replace fuel.
is not used.
OK
Blowby gas is much.
Check that gas does not leak Check nozzle function.
from gasket.
OK
Check injection timing.
Check compression pressure.

Checking condition ; Use proper fuel.
44-11
(11)
Check that
E/G does not stop Confirm governor Check if governor
governor motor link
when starter key is lever stop bolt motor is not faulty
connecting bolts are
turned off. position. mechanically.
not loose.
OK
Check that Wire number 60 Check resistance
NG Replace starter key
terminal M of of instrument panel across terminals M
if resistance across
starter key switch harness CN-43F and B on starter
M and B is 0‰.
shows 0V. shows 0V. key.
See Fig.3.
OK
Check that battery Does resistance
relay terminal L Wire No.857 of NG across C1 controller
Check C1
measures 0V four main harness CN- terminals 11-1 and
controller.
seconds after key is 150F measures 0V. 14-22 measure
turned off. 72‰?
(12) OK
When starter key is Replace C1
Does battery NG
turned off, power is Check that battery Replace battery controller if
terminals A and B
cut off but engine relay operates. relay. resistance measures
measure 0‰?
does not stop. 0‰.
See Fig.2.
Checking condition ; Starter key is off.
CN-152F
TERMINAL A1 LOCK
Flowing direction of main current
TERMINAL A1, A B, B1 TERMINAL TERMINAL B1

FLW FLW
TERMINAL A
VIEW I
2.0 sq 2.0 sq
FLW 2.0 sq
TERMINAL B
FLW 2.0 sq
G B2
W L P COIL
H COIL
BRACKET EARTH
Circuit diagram TERMINAL L

TERMINAL L
TERMINAL B2
AVS 1.25L TERMINAL B2

AVS 1.25G GROUND
GROUND CABLE TERMINAL
AVS 1.25B
CN-150M
Fig. 44-1 Battery relay
Fig. 44-2 Key SW. terminal
44-12
51. ENGINE
TABLE OF CONTENTS
See the attached Engine manufacturer's SERVICE MANUAL
51
51-1
51. ENGINE

  SK80MSR–1E(S) : LF04–02001~  KE
S5YT5103E01
(NHK)
PREFACE
This manual explains the engine proper and is a faithful reproduction of Engine manufacturer's service manuals.
51-2
匡悶DuS耳R昏A虹
D臆S匡虹臣悶G畳悶臣
A-轟JG確
聞OD監L
[S5YT0004E01] [20180207CsCsspWbYs]
FOREWORD
This Workshop Manual is desJ'gned to heJp you perform necessary

maJ'ntenance, Service, and Procedures on appJicabJe Jsuzu
･repaJr
l'ndustria] engJneS.
JnformatJ'on contal'ned in this Workshop ManuaI J's the latest
avaJ'JabJe at the tJ'me of publication.
Isuzu reserves the n'ght to make changes at any tJ-me without prror
notice.
This Workshop Manual is applicabFe to 1999 and Later models.
NOTICE
Before using this Workshop Manua一 you to in assJ.St
performing engJne Service and maintenance operatI'ons,
J'tis recommended that you carefuHy read and throughJy
understand the I'nformatJlon contained in Section 1 -
under the headings ''GeneraI Repalr Jnstruction” and

JLNotes on The Format ofThJ's ManuaJ”
TABLE OF CONTENTS
SECTION 1. GENERALINFORMAT10N..‥=.‥‖‖..………‥.‥...‥ 1
SECT[ON2. MAJNTENANCE ”.......”...”.”....”.”””.”....... 17
SECTION3. ENGINEASSEMBLY川 29
(DISASSEMBLYI
SECTJON 4. ENG]NEASSEMBLY (2) 47
(JNSPECTION AND REPAIR)
SECT[ON5. ENGfNEASSEMBLY(3) ”””..””..””..”..””. 81

(REASSEMBu｢I
SECT10N 6. LUBFIJCATINGSYSTEM…‥‥…‥‥‥‥…....‥‥‥=.” 109
SECT10N 7. COOuNGSYSTEM ”””.””..”,,”...”””.”. 121
SECTION 8. FUELSYSTEM.....H‥‥….……‥…………‥…‥…‥ 127
SECTJON 9. ENGrNEELECTRJCALS...””””.”...,””..””.”... 141
SECTJON 10. TROUBLESHOOT[NG.”....”...””.””””.”.”.. 169
SECTIONll. SPECJALTOOLuST.......=…‥‥..……‥∴‥‥‥…‥. 195
SECTION 12. REPAIRSTANDARDS......……...”‥..‥…‥.……..” 199
SECT10N 13. CONVERS[ONTABLE.......”””.”........”......... 213
GENERAL INFORMAT]ON
SECTION 1
GENERAL fNFORMATJON
TABLE OF CONTENTS
ITEM PAGE
Generalrepairinstructions .......,............................,.......”.......” 2
Notesontheformatofthismanua[‥‥‥.‥‥‥‥‥‥‥‥‥‥‥‥‥...‥‥‥‥‥‥. 2
Maindataandspec;ficatjons.........”.................................”..””... 6
TlghtenjngtorquespecJ'ficatJ'ons ‥･.----･.‥..‥‥‥‥..‥‥‥‥.‥..‥‥‥.‥. 7
GENERAL JNFORMAT10N
GENERAL REPATFHNSTRUCT10NS
l･ Before performlng any Service with the engJne mounted, disconnect the
operation grounding cab一e
from the battery.
This vvilF reduce the chance ofcable damage and burnlng dueto short circuiting･
2. AJways usethe propertooJ athand.
ortoo[sforthejob
Where specified, use the speciaHy designed tool ortooJs.
3. Usegenuine ISUZU parts.
41 Never reuse cotter p)ns, gaskets, 0-rings･ lock vvashers･ and self 一ocking nuts･ Discard them as you
｢emove them. Rep一ace them with new ones.
5･ A一ways keep disassembled parts neatly in groups･ This win ensure a

smooth reassemb.y operatJ'on.
1t is especiaHy Important tO keep fastening parts separate･ These parts vary jn hardness design,
and
depending on their insta(lat壬on position.
6･ AI[ parts shouJd be carefuJJy cleaned before inspection or
reassembfy.
Oil ports and other open[ngs should be cJeaned with compressed air to make sure that they are
completely free of obstructions.
7･ Rotating and sliding part surfaces shou(d be (ubricated with oI'1or grease before reassembly.
8. 1f necessary, use a sealer on gaskets to prevent feakage.
9. Nut and bo[ttorque specifications should be carefuJly fo=owed.

10･ AJways re一ease the air pressure from any machine-mounted before dismounting the
airtank(s) engine
or disconnecting pIPeS and hoses･ To not do so is extreme[ydangerous.
11･ A一ways check and recheckyourwork. No service operation is complete until you have donethis.
NOTES ON THE FORMAT OF T川S MANUAL
This Workshop Manua[ is appJicab】e to ISUZU industrial eng)ne or engrnes which is or are in the
stated
title.
When more than two englne models are dealt in the manual, such engmes have common
parts and
components as we‖ as data and unless otherwise specified,
specifications,
1･ Find the appI7cab[e section by referr-ng to theTable of Contents beginnlng Ofthe ManuaL
atthe
2･ Common technl'cal data such as genera一 maintenance items, service specifications′ and tighten(ng
torques are included J'n the ”GeneraHnformation” section.
The section ENGINE ASSEMBLY is an
exception. This parts are divided in three sections to facilitates
indexing.
3･ Each section is divided into sub-sections dealing with disassembJy, inspection and repair, and
reassembJy.
GENERAL INFORMATION
4. When the same serv[ctng operation is applicable to several different units, the manual w‖ direct you
to the appropriate page.
5, Forthe sake of brevity, se(f-explanatory remova( and insta一lation procedures are omitted.
More procedures are in detaiI･

complex covered
6. Each service operation sectJ.On in this Workshop Manua[ begms with an
exploded view of the
area. A brief exp[anation of the notation used foIIows.
appricable
Parts marked with an asterisk (*) are
included in the repair kit.

/
/
甘ド
/`呈 Parts within a square frame are to be
I ････････-･
○
話; ㍗ removed and instaJ[ed as a smgJe unit,
J+ and their disassemb[y steps or reas-
1 2
し≡ sembly steps are shown in the
什8
埠
” irlustrations respectively.
/ r)
フ′/
＋OJ The number tells you the service oper-
3--T& ,f ♂
ation sequence.
.し寸㊨
QL譜
12
Removal of unnumbered parts is unne-
修髪
し
ll
cessary unFess rep[acement is.required.
㌔
♂
''*
The Repa)r Kit” indicates that a
repair kit is avaiJabJe.
di去
14サ席
de The parts J舌sted under ”DisassembJy
Steps′′ o｢ ”Reassemb-y Steps′′ 8re in
the service operation sequence.
Di9J与一●rrtbly St叩& ∼
2
1. Wz)t8r by･pJSS hose 10. CylJ'ndor h餌d g8宇ket

The or instaHation of parts
2. Thermostz)I hou5Jng ▲11, Crankshz)ft daTnpO( PUlrey wlth removal
A
3.
4.
W&ter pump
lnLt}ction nozz一e hoJdcr
dust s881
Timhg q8ar C8叩COVer
marked with'a triangle (▲=s an
Tlnling gear COVOr
5.
6.
Glow plug and glow plug ⊂onn8CtOr
CyJind即head亡OYOr Tlm7叩g帥r Important OPeratJ-on. Detai一ed infor-
Oi一pipo
Ftock8r arm Shaft and rockt)r Aml Jdler 9EI8( 'E)'8nd
▲ 7.
8. Push rod ldJBr g朗r ∼A'
shaft
mation is gIVen in the text.
▲ 9. CyrindEIr h8ad ld(8r ge8T 5hJ)托
lnyert8d 【ng事ne
GENERAL [NFORJV]ATJON
7. BeJow is a Manual･
sampleofthetextoftheWorkshop
This is the item shown in the iI[us-

tratT'on. ft is marked with a triangle
I. CJrTIfh■ft Tlrni叩G4＋r (▲)on the Major Components p89e.
1=nsta”.th｡thrust pI8tB ①
2) Apply th8 bolt thr88ds ㊨
臼
engLnB O･=o
3J JnstaJI the cBm5haft tin7lng gea( With the (lming Letters and numbers contained in a
mark stamp8d sido faclng out
回
as磯
Camshaft TImlng Gear Bolt Torque kgf･rnfTb f(JN･m)
circle refer to the刑ustration.
ll.0土10 (79,5土7.2/107.8士9.a)
T?.
国
Special too一s are identified by the
13. Crz[nbhJlft Re8r Oif So●I
too一 name and/or number.
LJ卓 l】 Apply OII to the
日
■■ ' engJne oJ'rsea=p clrCUmfer.
JI
i. J
ence and the oll s8al E)uler clrCurnf8renCC
21 Use The oll seahnstalre( to
The川ustr∂tion shows how the spe-
)nst8‖ the 0川sea7 to
医I
∼
th8 Cyhnder body
cial toot is to be used.
i
も卜
O†lSeal lnstz)LIwe･ 5･8840･0141.0
i..戸!
Jr
+ Symbols indicate the type of service

operation o｢ step to be
′
I
14･ FIywbee) HoLJSiq per-
l) Apply IJ-qua gasket to the 5h8dcld ar8a Shown l'n formed. A detai一ed explanatJ'on of
盟 the illus(ratiorl.
2)丁]ghten the flywheel housing bolts I(】 the SPeCl･ these symbo一s follows.
＼ミ ■′･
良 fled torque
shown Fn tho
a littJB8t a time
ll)LJStratrOrl.
ln the
sequence
I.1..1
も′ FJywhBeI HDU幻ng 8olt Torque kgトrn=b.∼./∼ ml
MIOX1 25 10.40×0.05) BE)I( 56土1 0 (40.5士7.2/ 549士981 Service data and specifications are
¶･ M12Xl.25 fO47×8 D5) 8olt 10 5土=〕け6 0土7 2/103.0士9.8I
in this table.
M12X1 75 (047×0.07J BoJt 9.8±1 O f71.0士7.2/ 960±9.a)
given
8, The foJ[ow盲ng symbols appear throughout this Workshop Manual･ They teI[ you the type of service
or to perform.
operation step
■■
Ej Removal Adjustment
-
+l
■■l
･･-
-
巨] -･ JnstaHation
田-･･ Cleanlng
匡卜 Disassemb[y
∇- Important operation requJrLng extra Care
匡卜 Reassemb】y
国=+ Specified torque (tighten)
匡卦- 園--
Specia( toof use
required or
Ali9nment (marks)
recommended(lsuzu tool or too一s)
CommerciaHy
回･-
too一 use
回･･.I Directional indication available
required or
recommended
団･- [nspection
日･- Lubrication (oil)
囲-. Measurement
E] ････
Lubrication (grease)
団-･ Sealant app一ication
GENERAL [NFORMATION
9. Measurement criteria are defined bythe terms川standard.rand J'(亨mjt''.

A measurement fa川ng within the ▲`standard■- range indicates that the appLicabfe part or parts are
serviceabJe.
''Limit'lshould be thoughtofas an
absoJute vaJue･
A measurement which is outside the ''(imitl■

J'ndjcates that the appticabJe part or parts must be eJ'ther
repaired or replaced.
10. Components and parts are IJ'stedin the s[ngularform throughoutthe Manuaf,
ll, Directions used inthis Manual are asfoflows:

Front
The cooling fan side of the engJne Viewed from the flywheel.
RJ'ght
The right hand side viewed from the same position.
Left
The left hand side vJ'ewed from the same position.
Rear
The fJywheef side of the engJne.

Cylinde｢ numbers are
counted from the front of the en91ne.
The front mostcy[inder is Nor 1 and rear mostcylinder is thefinal cyJindernumber of the engJne･
The engJne's dJ'rection of rotation J-s counterclockwise viewed from the f[ywheeL
GENERAL JNFORMATfON
MAIN DAm AND SPECl円CAT10NS
EngineModeJ
A･4JGl
Item
Enginetype Watercooled′fouトCyCle.in-line.overheadvaTve
Combustionchambertype Directinjection
Cylinder=nertype Dry
No,ofcy[inders-BorexStrokemm(in､) 4-95.4xlO7
Totalpistondisplacement‖t(cJ'd) 3.059(186.7)
Compressionratio(Tol) 18.6
☆EngTnedimensionsmm(in.) 739x625x746
LengthxWidthxHeight (29.1x24.6x29.4)
*Engineweight(Dry)kg(]b.) 248(547)
Fuelinjectionorder 1-3-4-2
*FuelinjectiontJ.ming(B.T.D.C.)degrees 16
Specified fuel DieseJfueT
fnjectionpump ln-1inepZunger,BoschAtype
Governor VariabJespeedmechanicaltype
★Lowidlespeedmin-i B50-1′000
lnjectionnozzle Multi-ho(etype
fnjectionstartingpressureMPa(kgf/cm2/psi) 18.1(185/2630)
Fuelfiltertype Cartridgepapaerelement
Watersedimentor(ifsoequipped) Sediment/water]evelindicatingtype
CompressionpressureMPa(kgf/cm2/psi) 3.04(31/441)
Va]veclearance(atcold)[ntakemm(in.) 0.40(0.0157)
Exhau占tmm(in.) 0.40(0.0157)
Lubricationmethod Pressurizedcirculation
Oilpump Trochoidtype
Maino‖filtertype Cartridgepaperelement,fu‖flow
Partialoi[fi[ter NotequIPPed
*Lubricatingoilvolumerit.(qts) 7.6-9.6(Oilpan)
Oilcoo[er(ifsoequipped) Watercooledbuiltinoilfi[ter
Coo‖ngmethod Pressurizedforcedcirculation
Coo[antvolumelit.(qts) 5.0(5.3)
Waterpump Bertdriven,impel[ertype
Thermostattype WaxpeHettype
廿A[ternatorV-A 12-50
*StarterV-kVV 12-2.2
Spec汀ications marked with an asterisk (貴)w= vary according to engine application.
GENERAL INFORMATJON
TJGHTENING TORQUE SPECIFICATJONS
The tightening torque va[ues glVen in the table below are appJicabfe to the bolts unless otherwise
specified.
STANDARD BOLJ N･m (kgf.m)
Bolt
㊨ @@ ㊨
ldentifJ-cation
◎ ◎◎ 珍
Bolt
Diameterx
pitch(mm)
M6×1.0 3.9-7.8fO.4-0.8) 4.9-9.8(0.5-1.01
M8×1.25 7.8-17.7(0.8-1.8) ll.8-22.6(1.2-2.3) 16.7-30.4(1.7-3.1)
MIOxl.25 20.6-34.3(2.1-3.5‡ 27.5-46,l(2.8-4.7) 37.3-62.8(3.8-6.4)
＋MIOxl.5 19.6-33.4(2.0-3.4) 27.5-45.1(2.8-4.6) 36.3-59.a(3.7-6.1)
M12)く1.25 ヰ9.l-73.6(5.0-7.5) 60.a-91.2(6.2-9.3) 75.5-114.0(7.7-ll.6)
*M12×1.75 45.1-68,7(4.6-7.0〉 56.9-84,4(5.8-8.6) 7l.6-107.0(7.3-10.9)
M14×1.5 76.5-115.0(7.8-ll.7〉 93.2-139.0(9.5一-14.2) 114.0-171.a(ll.6-17.4I
書M14×2.0 71.6-107.0(7.3-10,9) 88.3-131.0(9.0-13.4) 107.0-160.0(10.9-16.3)
M16×1.5 104.0-157.0(10.6-16.0) 135.0-204.0(13.8-20.8) 160.0-240.0(16.3-24.5)
★M16×2.0 100.0-149.0(10.2-15.2) 129.O-194.0(13.2-19.8) 153.0-230.0(15.6-23.4)
M18×1.5 15l.0-226.0(15.4-23,0) 195.0-293,0(19,9-29.9) 230.0-345.0(23.4-35.2)
≠M18×2.5 151.0-226.0(15.4-23.0‡ 196.0-294.0(20.0-30.0) 231.0-346.0(23.6-35.3)
M20×1.5 206.0-310.0(21.0-31.6) 270.0-405.0(27.5-41.3) 317.0-476.0(32.3…48.5)
*M20×2.5 190.0-286.0(19.4-29.2) 249,0-375.0(25.4-38.2) 293.0-440.0(29.9-44.9)
M22×1.5 251.0-414.0(25.6-42.21 363.0-544.0(37.0-55.5〉 425.0-637.0(43,3-64.9)
*M22x2.5 218.0-328.0(22.2-33.41 338.0-507.0(34.5-5l.7) 394.0-592.0(40.2-60.4〉
M24x2.0 359.0-540.0(36.6-55.0) 431.0-711.0(43.9-72.5) 554.0-831.0(56.5-84.7)
★M24×3.0 338.0-507,0(34.5-51.7) 406.0-608.0(41.4-62.0) 521.O-782.0(53.1-79.7)
asterisk (i) indicates

An that the bolts are used for female threaded parts that are made of soft materiats
such as
casting.
GENERAL INFORMATION
T[GHTENJNG TORQUE SPECIF]CATJONS
The tightening torque vaJues glVen in the tab一e be[ow are

appJicable to the bolts un一ess otherwise
specified.
FLANGED HEAD 801J N･m (kgf･m)
Bolt
Identification
Bolt 4 ら 9
Diameterx
pitch(mm)
M6×1.0 4.6-8.5(0.5-0.9) 6.6-12.2(0.6-1.2)
MBxl.25 10.5-196(1.1-2.0) 15.3-28.4(1.6-2.9) 18.1-33.6(2.1-3.4)
MIOxl.25 23,1-38.5(2.4-3.9) 35,4-58.9(3.6-6.ll 42.3-70.5(4.3-7.2)
★MIOxl.5 22.3-37,2(2.3-3,8) 34.5-57.5(3.5-5.8) 40.1…66.9(4.1-6.8)
M12×1.25 54.9-82.3(5.6-8.4) 77.7-117.0(7.9-ll.9) 85.0-128.0(8.7-13.0)
書M12xl.75 51.0-76.5(5.2-7.8) 71.4-107.0(7.3-10.9) 79.5-119.0(8.1-12.2)
M14×1.5 83.0-125.0(a.5-12.7〉 115.0-172.0(ll.7-17.6) ■123.0-185.0(12,6-18.9)
★M14×2.0 77.2-116.0(7.9-ll.8) 108,0-162.0(1l.1-16.6) 116.0-173.0(ll.8-17.7)
M16×1.5 116.0-173.0(ll.8-17.7) 171.0-257.0(17.4-26.2) 177.0-265.0(18.0-27.1)
廿M16x2.0 109.0-164.0(ll.2-16.7) 163.0-244.0(16.6-24.9) 169.0-253.0(17.2-25.8)
A bolt with an asterisk (*) is used forfema[e screws as iron.

of soft materia一 such cast
GENERAL JNFORMATJON
国 SPECIAL PARTS FIXING NUTS AND BOu`s
cylinder Head Cover, Cylinder Head, and Rocker Arm Shaft Bracket
N･m (k9f･m/lb.柑
8-18
感
(0.8- 1.8/5.8- 13)
!
(# 49-59
こ-
I/B#
(5.0 -
6.0/36- 43)
0
⑮
l
10-20
∩.0-2.0/7 -
141
冒
＼
(≡)
匂噂蹄
冒
U
i
l
Q鮮宗些
⊂)
7T
￠
くJ
磨 Q U
7T
e2
/
く⊃
U
訟
敬
＼こ)
勺
勺
G)
♂
F
勺
1st Step 2nd Step 3rd Step
44-54
60-75o 60-75o
(4.5 -
5.5/30 -
40I
Apply englne Oil to thread portion
GENERAL INFORMAT10N
国
■
Crankshaft Bearlng Cap, Connecting Rod BearJng Cap,

Crankshaft Damper Puf[ey, F[ywheel, and Oil Pan
N･m (kgf･m/fb.ft)
or ーて丁て一士
e5 盲
(3 症;弓
亡〉 ′
琶∈主友≦
;夢
m =t
2s5
辺 ”
幣
a に
113-123
∼
I ヽ
a (ll.5- 12.5/83-90)
27-31ぅ45o-Boo
関
(2.8 -3.2/20- 23I
Appfy OiJ to thread
%?
engTne portion
157-177
看ち
(16- 18/116- 130)
Apply engine oil to thread portion ＼
d a
＼
197-240
(20.1 -24.5/145 -
177) 〆ク
⑳
,VS
i:
ンら
壬哲
字空
宅才＼
”
鋼 Q
14-24
A (1.4- 2.4/4.4- 7.2)

a
10
GENERAL rNFORMATJON
国
■
Inning Gear Case･ FJywheeJ Houslng, Camshaft, 'Tlming Gear

and
N･m (kgf･m/1b,ft)
MIOxl.25 35-45 (3.6- 4.6/26-33)
M12xl.5 74191 (7.5-9.3/54-671
a
9
消
1
ウ ♂
/′
⊂) 勺
m6)Q)
○ a
14-24
∩.4-2.4/10 -
17)
⊂⊃
＼.
⊂⊃
＼ト
kS ♂
@
＼
t
♂
&
礼 /
r3
&
馳 SS
※
N
Q勺Q
恵〕
派
14-24
(1.4-2.I/10-17I
14-24
(1.4-2.4/10-17I
98-118
㊨
14-24
=0- 12/72-87)
(1.4-2.4/10- 17)
⑤ @
% @@◎
潤
♂
a
10-15
(1.0-1.5/7-ll) @@@ 98-118
(10- 12/72-87)
ll
GENERAL INFORMATJON
国 Cooling and Lubricating System
N･m (kgf･m/Ib.印
冒冒
14-24
句b
什4-2.4/10-17)
I
l
ー研一･愈
◎
L3
I
宏:
&@i&
L〉
lLt;
くJ
7T
･@& ○
q 蛋 Z2
L)
{qQi
14-24
∩.ヰー2.4/10-17)
(3
/二
＼ミ g#
リu
巳ゝ巳ノ基≠汚友≦
メ
ク房
r
ヽ a
SS
14-24
(1.4-2,4/10- 17) :b3
･愈
も､
_dク
ウ､､1
/
a 14-24
(10-17/10-17)
ン′
♂ 敏一/
14-24
∩.4-2.4/10-17I
12
GENERAL INFORMAT10N
国 Intake and Exhaust ManJ'fo[d
N[m (kgf･m/[b.ft)
14-24
(1.4-2.4/10- 171
@@%
a
Ct
∠〇
” 9
a
C2 ど
習E2
C!
5 rl
EB
a
C!
0
0
0
モ〕o
0
0 C2
pく
0
♂
￠ ○
＼ ♂
♂ □ 巨≡去 T7
♂ □ 毛:I
七)
% Q
@@
14-24
=.4-2.4/10･- 17I
13
Gt;NERAL ]NFORMATION
国
■
EngTne ElectrJ-cal
N･m (kgf･m/Ib.叫
14-24 15-20
(1^-2.4[10-17) ∩.5-2.0/ll
-14)
i
<%
14-24
(1.4-2.4/10- 17)
S しi3
@@
96
S #
@
ヽ
@%@>
66-86
(6.7 -8.7/49 63I

-
14
GENERAL INFORMAT10N
国 FueHnjection System
N･m (kgf･m/lb.柑
√､ _
∼
♂
@
√￣￣-････････-.
-
-
J
i
#
20-39
(2.0 -
4.0/14-29)
｢ー￣--- --
J
轡
@
@
♂ 象､
臥@
31-43
(3.2 4.4/23 32)

-
-
14-24
ll.4-2.4/10- 17)
㊤
14-24
什4-2.4/10- 17)
㊧
確執ク′
A /
?
/
ら F
+
”
14-2ヰ
(1.4-2.4/10- 17)
14-24
∩.4-2.4/10- 17)
14-24
∩.4-2.4/10- 17)
15
MEMO
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16
MAINTENANCE
SECT10N 2
MAINTENANCE
TABLE OF CONTENTS
ITEM PAGE
Modelidentjfication ‥…‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥”.‥‥‥‥‥.‥‖‖
18
JnJ'ectionpumpidentification.”....”..”....”...”....”.....”.,”...”.”.”.. 18
Lubricatingsystem ‥.‥‥‥‥‥…..‥.....‥‥‥‥‥‥=‥.‥‥.‥‥‥‥.‥‥..
18
Fuelsystem .......”.....”........,...............,..,...................,....
19
CooJingsystem ‥‥‥.‥.‥‥‥‥‥,.‥‥‥‥..‥‥‥‥‥‥.‥‥‥‥‥‥‥‥‥‥
22
Va[vecfearanceadjustment,.........”....,.....”.....,,.....”....”....,....” 23
■
JnjectionthJng･･...............”,”......”......,........”....”.....”..... 24
Compressionpressuremeasurement ”.......................”......”.”.”...”.
26
RecommendedJubricants.‥‥‥‥‥.,.‥….‥‥..‥..‥.‥‥‥‥‥‥‥,‥‥.‥.. 27
Enginerepajrkit -‥･‥‥‥‥‥‥･･‥‥･‥‥･‥‥‥‥‥‥‥‥‥‥‥..‥.‥‥‥”
28
17
MAINTENANCE
MAINTENANCE
Servicing refers to generar maintenance procedures to be performed by qualified service personnel･
Maintenance intervaf such as fuel or oil filter changes shou一d be refered to 'LINSTRUCTJON MANUAL”,
MODEL JDENT[FJCAT]ON
Engine Serial Number
The engfne number isstamped on the rear Left hand side

of the cy[inder body.
恒
○ k=
)NJECTLON PUMP ]DENT[FICATION
lnjection vo一ume be to
shourd adjusted after referring
the data app[icabre to the J-n)eCtion
adjustment pump
installed.
Pump No.
NP-P∈
The injection pump identification number (A) is stamped
(LICENCE BOSCH) on the injection pump identifications pJate.
Note:
④･･･ldentification
number
Always check the identificatJ'on number before beg(nn-

h-‖ne type
ing a
service operation.
App]icabJe servI-ce data will vary according to the ident-

ifJ'cation Use of the wrong service data w川
number,
resuJt in reduced engine performance and englne
dama9e.
MAKERyp ① ZEXEL (Manufacturer of the injectionpump) identifト

ASS'Y NO. ①
cation number
1NJ.PUMP
ASS'Y NO. ② ① lSUZU P∂什sNumbe｢
Distributor type
LUBRICATING SYSTEM
く=⊃
Main Oil F‖ter
Replacement Procedure
0
1. Loosenthedrain p)ugto drainthe englne OiL

＼.
2. Wait a few minutes and then retighten the drain
plし唱.
3. Loosen the used oi一fi[ter by turnlng it counterclock-
国 wise with
Filter VVrench
a f‖terwrench.
18
MAJNTENANCE
4. C一ean the oi( coolerfitting face.
四 This w川aIJowthe new oi川[terto seat properly1
5･ App一y a lightcoatofenglneOir tothe OィJ'ng.
冒 6･ Turn in the
fitted against
new oil fi[ter until
the sea‖ng face.
the filter 0-ring rs
7. Use a fi一ter wrench to turn in the filter
団
an
51(I
addJ'tionaf
l and 1/4ofaturn.
(ラ F‖ter Wrench
___ノ
ココL 8･ Checkthe englne Oi[ (eveJ and repJenish to the spec-
-2
ified (evef if required.
漂野丁､ 9･ Start the for oil (eakage from
囲
eng(ne and check the
main oil fi-ter.
FUEL SYSTEM
ヽ==⊃
Fuel F‖ter
Rep(acement Procedure
○
1. Loosen the fuef fi[ter by it counter-
回
used turning
cJockwise with the fitter wrench.
＼.
Filter VVrench
2. Clean the uppercoverfitting face.
田 This will afrowthe newfuef filterto seat properry.
SS
@ _.∠こ￣
3･ Apprya [ightcoatofengJne Oil tothe 0-ring.
Ej 4. Supply
ing.
fuel to the new fuel fjJter to facilitate bleed-
5･ Turn in the newfuel fi一teruntiJ thef‖ter 0-ring is fit-

ted against the searing face.
Po Be very carefu( to avoid fuel spil[age.

6. Use filterwrench to turn in the fuel fi[ter an
団
a addi-
tiona1 1/3to 2/3 ofaturn.
19
MAINTENANCE
Water Separator (Water Sedimentor)

申
磨 (Optiona] Equipment)
Check the water separator float ① 1eveI.

Jfthef[oat① has reached leve一 ②. Joosen the drain plug
@ (at the bottom side of the water separator) to drain
the water.
Drain PJug Torque N･m (kgf･m/Ib.ft)

固 9-15(0.9-1.5〝-ll)
Air B)eeding
1. For the eng(ne equlPPed with in-fine type

′￣
Injection
ヽ
PumP
1) Loosen the priming pump cap ① on the injection

A 9
PumP･
2) Loosen the fueいeturn eye bolt① on the fue=iJter.

-
1HFO
闇iB
3) Operate the priming pump un川the｢e are no more
bubb[es visib[e in the fueJ being

discharged from the
fue) return eye bolt on the fue( filter.
4) Retighten the fueJ return eye boTt on the fuel filter.
5) Loosen the bleeder bo一t ③ while operating the

pump prlming pump to check that the
lnjection air
has been bled completely.
6) Operate the priming pump several timesto check for

fue] leakage around the in)'ection pump and the fueJ
f‖ter.
2. For the englne equ[PPed with distributor type ]n)ec-

亡:頚F￣l川 tion pump
Air SCreW
○
○ 1) Loosen the bJeeder screw on the injection pump

overf)ow valve.
2) Operate the priming pump unti一 fue[ mixed with
0
foam f(ows from the bleeder screw.
3) Ti9hten the b一eeder screw.

○
(⊃
j匂
o)
D 盟｢ち○ 4) Operate the primin9
for fue一 leaka9e.
Pump SeVe｢a=imes and check
I
l I
i I
I
†
(㌔
′′
I
llfL.4･･.･ -∫
l`
ヽ_一
20
MAJNTENANCE
Injection NozzJe
Jnjection NozzJe Inspection
Use a nozzle tester to check the injection nozzle openJng

pressure and the spray condition.
復 1fthe openJng is above or below
Pressure the specified
value, the nozzle must be
J'njection repfaced or
recondi-
t'10ned.
cctq rfthe spray

or
condition is bad, the injectionnozzle must be
replaced reconditioned.
JnjectionNozzJe OpenJng Pressure MPa (kgf/cm2/psi)
18.1 (185/2′630)
Spray Condition
① ④ ④
1 Co rrect
2 (ncorrect (Restrictions jn orifice)
3 ∫ncorrect (Dripping)
■l■
■■ lnJ'ection Nozzle Adjustment
イl
-
■■ 1. CJampthe hjection nozzle in a

vise.
21 Use a wrench to remove the injection nozzJe retain_
lng null
3･.nstaJJ the in)'ection nozz(e ① the push rod ①. the

㌔ ∫
sp｢in9 ③′and adjusting shin ④.

Retaining Nut Torque N･m (kgf･m/[b.ft)
39-49 (4.0-5.0/29-36)
国 4･ Attach the inJ'ection nozz(e holder to the injection

nozzle tester.
5･ AppTy pressure to the nozzfe tester to check that the

injectJ'onnozzle opens at the specified pressure,
(D
(喜妻∃ Jf the injection nozzle does not open at the specifJ'ed
pressure, instaJ( or remove the appropriate
I
number
of adjusting shims to it.
adjust
④ ④④ AdjustJ'ng shim Avaifabifity mm(in.)
Range 0･1 -
0.59 (0.0039-0.023)
WARNING:
TEST FLUID FROM THE JNJECTION NOZZLE TESTER
WILL SPRAY OUT UNDER GREAT PRESSURE.汀CAN
EASILY PUNCTURE A PERSON'S SKJN. KEEP YOUF!
HANDS AWAY FROM THE INJECTION NOZZLE TESTER
ATALL TIMES.
21
MAINTENANCE
COOLING SYSTEM
ち
Cooling Fan Dr;ve BeTt
C
Fan beJttension is adjusted by movlng the arternator.
A Crankshaft damper pulley

B Alternator puJIey
C Coolingfan drive pu‖ey
D Depress the drive belt mid-portion with a 98.N (10

kgf/22 [b.ft)force.
Drive Be一t DefJection
mm(in.)
10.0 (0.39)
Thermostat
Operat'Lng Test
1. CompleteFy submerge the thermostat in water.
2. Heatthe water.
Stir the water constantly to avoid direct heat being

to the thermostat.
applied
IA
3. Checkthe thermostat init7a] openlng temperature.

① 固 Thermostat lnitia[ Openlng Temperature oC(oF)
@ 82く180)
4. Checkthe thermostatfuH temperature.
囲
opemng
Thermostat Fu‖ Opening Temperature QC(oF)
SS ③
95 (203)
育 Valve Lift at Fu‖y Open Position
圃
mm(in.)
8.0 (0.315)
① Thermostat
② Agitatin白Rod
a Wooden Piece
22
MAINTENANCE
■■ VALVE CLEARANCE ADJUSTMENT

イl
JI
■■■
■l■
1. Retighten the arm shaft bracket bolts in

rocker
国 sequence as shown in the川ustration.
RockerArm Shaft Bracket Bo叶

Torque N･m (k9f･m/胤印
49-59 (5-6/36-43)
2, Bring the piston in eitherthe No. 1 cylinder or the

No. 4 cylinderto TDC on the compression stroke by
◎
1∴ TDC
turning
puJleyTDC
the crankshaft
一ine is a=gned
until
with
･the crankshaft
the timing pointer.
damper
A
諏
@
3. Check for play in the No. 1 intake and exhaustvalve
push rods.
If the No. 1 cylinder J'ntake and exhaust va)ve push

rods have pJay, the No. 1 piston is atTDC on the
compression stroke.
1fthe No. 1 cylinder intake and exhaust vafve push

rods are depressed, the No. 4 piston is atTDC on the
compression stroke.
JI<
l■■
Ad)lust the No. i or the No. 4 cy(inder vafve clearances
■■l
Jl
∼
■■ while their respective cvlinders are at TDC on the com-
pression stroke.
ヽ
/
＼モ
Valve Clearance mm(in.)
ヽ
ヽ
､､･コ
J%
′■■￣￣
0.40 (0.016)
ヽ
Loosen each valve clearance screw as shown
adjusti.ng
等 in the i‖ustration. (At TDC on the compression stroke of
the No. 1 cy‖nder)
Jnsert a fee一er gau.ge of the appropriate thickness
圃 between
4. Turn
the
the
rockerarm
va一ve cJearance
and the valve stem end.
adjusting screw
until a
slightd｢a9 Can be fe一ton thefeelergauge.
5. Tighten the rock nutsecurefy･
23
MAINTENANCE
Rotate the crankshaft 360o.
Rea‖gn the crankshaft damper pulJey TDC line w托h the

timlng POinter.
/ ヽ
ヽ
＼∋
for the remainJng

Adjust the cJearances VaJves as shown
;A in the i=ustration. (At TDC on the compression stroke of
the No. 4 stroke)
感熱
INJECTJON TJMfNG
0
Injection Timing Confirmation Procedure
0
□
1. ]n-‖netypeJnjection pump
◎
㊨
囲 1) Rotate
shaft gear
the crankshaft
timing mark
clockwise
”0” with
to align
the
the
timing
cam-
gear
⑥ case cover pointer.
The No. 1 cy=nderw川now be atthe poht where

nearly lnjectiontiming.
2) Removethe No. 1 fuel injection pipe.
3) Remove the de一ivery valve holder ① ∫ the deJivery
③.
(モミⅠ)
q=も valve spring ①′and the delive｢yvalve
CE:ち)
4) Tighten the delivery valve holder to the specified
qb
to｢que･
Delivery Valve Ho(der Torque N･m (kgf･m/1b.ft)
39-44 (4.0-4.5/29-33)
5) Operate the injection pump priming pump whi[e

(つ
l巨===-
哩
ヒ= f[ow-
sLowly rotating the crankshaft until fuel stops
@ C
[ng from the delivery valve hoJder･
17
6) Conform that the crankshaft damper pu[Jey notched
◎
囲 =ne is a[igned
pointer,
vvith the timing gear case cover
Injection TimJ'ng (Static BTDC)
65
鷲 16o
7) Remove the delivery valve ho(der.

くヒこ王)
(ヒ:a 8) Instal一 the delivery valve ① ′ the de一ivery valve
q=こb
spring @ , and the deliveryva(ve ho]der@.
屯::ち
9) Tighten the delivery va一ve ho[der to the specified

to｢que-
10) lnstaJI the fue[ injection pipes and tighten them to

the specified torque.
･
Fuel hiection Pipe Torque N･m (kgf･m/Ib.ft)
国 20-39(2-4/15-29)
ll) Operation to airbreeding.
24
MAINTENANC∈
2. Distributortype injection pump

1) Rotate the crankshaft clockvvise to afign the cam-
○
shaft geartiming mark ''･0” with the timing gear
0
□
case cover pointer.
㊨
◎ The No. 1 cyJjnder w川now be atthe point vvhere
nearly injection tJlmJng･
㊨ 2) Remove
3) Fita d7aJgaugeand
inJ'ector pump
Top
set(iftto
distributor
1 mm
head plug.
(0･039 in).
Center
4) Set crankshaft damper pu=ey Dead mark
about 45o before Top Dead Center from the pointer.
5) Setdial gauge in the ``0” position.
MeasurJng device: 5-8840-0145-0
園
lO
6) Turn the a rittre rightwise and Jeftwise

⑳￠c?e crankshaft
and see if the pointeris stab一e in the ''0” position.
-v('Qfq5Sr- 7) Turn the crankshaft J-n the normaJ direction and read
the measunng device′s indication at TDC.
S'
監) Starting TimJng mm(in.)

)ーOo￣
0.5 (0.02)
jもfnl___ー∩._,(2]o≡○ CE)OESOO2
8) (fthe injection timing I-s outside the specified range,
continue with the foHowJng StePS･
9) Loosen the hjectlon pump fix-fng nuts and bracket
bolts.
珍
⑳ 8
10) Adjustthe injection pump setting angJe.
8 ⑳
｢･
ff injection timing vvI'H be advanced, move the
(つ
from
表露 tnjection pump away the eng[ne.

m ･ lfinjection timing wJ'lJ be retarded′ move the
ず/
injection pump toward the englne･
L-
○
Tighten the pump fixing nut, bolt and pump
○
adjust
○
distribution head pJug to the specified torque.
08O ∈S008
Pump Fixing Bo[t N･m(kgf･m/[b.ft)
19 (1.9/14)
Injection Pump
Distributor Head Plug N･m(kgf･m/Ib.ft)
17 (1.7/12)
25
MAINTENANCE
COMPRESS10N PRESSURE MEASUREMENT

野｢
1. Startthe it to for
/ engLne and a=ow run
severaJ
a minutesto warm it up,
2. Stopthe en∈‖ne and supp一y.

∼ cutthefuel
: ド7;
3. Remove alJ of the glowp]ugsfromthe engJne-
Compression Gauge :5-8840-2008-0
% 甲 /”
園 Adapter :518531-7001-0
4. Seta compression gauge tothe No1 1 cy=nderg)ow
p山9 hole.
5. Turn the eng)ne overwith the starter motor and take

the compression 9aし唱e reading,
Compression Pressure MPa (kgf/cm2/psりat 200 rpm
Standard Limit
3.04(31/441) 2.2(22/313)
26
MAINTENANCE
RECOMMENDED LUBRICANTS
ENGFNETYPE TYPESOFLUBRJCANTS
Dieseleng]neoiJ
W'rthoutturbocharger
CCorCDgrade
DJ'eselenglneOil
Withturbocharger
CDgrade
ENGINE O比VISCO$lTY CHART
ENGINE O比VISCOSITY GRADE -
AMB陀NT TEMPERATURE
【Single grade]
SA臣 20. 20W E.I

S.'Å40
1.pW. SAE 30
(TAemmbiee?三tu
〕
15oC 25oC 30oC
-30oC -15oC -OoC
,e ト22oF卜 (5oF) (32oF) (59oF) (77oF) (86oF)
[MuJti grade]
SA臣 IOⅥト30
SA臣 1 5W-40,
27
MAINTENANCE
ENG]NE REPAIR K[T
Alf of the numbered parts listed be(ow are included in the EngLne Repair Kit.
The gaskets marked with an asterisk (i) are
also inc[uded in theTop Overhau] Kit.
3 20
e2
℃㍑
D
e(
(つ
e-c(ll
87
♂哲紺
?
ヽJ
15 14
A
/
.A
13 0 lO
U
班 ” L3
E2
&
/I_F∠･プ
11
0 E2
&
…喪 0
J
t2 0
e
tin
U 19 格
0
Q
/レ
0
u e
ら I
○
･:,i
9
○
s)i 之≠
おプ
で
i/
く重〉一ー8
@
*
l
2
Cy=nde｢
Cy=nde｢
head
head
ョasket
cover gasket
.6}で 11
12
Water
Water
pump
outlet
gasket
pipe gasket
≠ *
3 Head cove｢cap nut gasket 13 Thermostat hou引ng gasket
*
4 Drain cock gasket 14 Intake manifold gasket
*
5 Crankshaft rear
oi一 sea一 15 Exhaust manifo[d gasket
6 Gear case gasket 16 Crankshafrfront oil sear
∼
7 Gear case cover
gasket 17 Nozz一e holder O-ri｢唱
求
8 Oil pan drain plug gasket ･18 Nozzle holder gasket
9 OiL pan gasket 19 Joint bolt gasket
10 Oil fitter gasket 20 Vacuum pump pIPe gasket
28
ENGINE ASSEMBLY ” )
SECT10N 3
ENGINE ASSEMBLY ” I
TABLE OF CONTENTS
ITEM PAGE
Generaldescr;ption‥.....,..‥.‥‥‥‥‥-･･---‥‥..･-･---.･‥‥‥‥‥. 30
Disass￠mbly.....-----------.--.--....---.-----.---... 31
29
ENGINE ASSEMBLY ‖ I
ENGINE ASSEMBLY
GENERAL DESCRIPT10N
This川ustration is based on the A-4JAl englne in 4J series.
i 4r
a
∩ L%
○ 皿
l ｢
千 iJ 抑 I
1
I
チド
E] ∼
+
▲=d･:･屯
ム
l 鼓し
訂
a
堤
○
㊨ □
0
◎ LJ
Fr.･･;
l
ド
J
【
J
Li
㍑
The 4J Series of industriaJ englneS features the umque lSUZU troidal square combustion chamber･ This
design provides superiorfue] economy for a wide ranged
Auto-thermatic pistons cast stee[ struts are

used to reduce thermal expansion and resulting engJne
with
noise when the englne is co一d.
chrome plated drytype cy(inder liners provide the highest durab=ty.
The laminated steef sheet cyJinder head gasket is very durabreL
This type of gasket eliminates cyIJ'nder head bolt retightening･
The tufftrided crankshaft has a long service life. Because it is tufftrided, it cannot be reground･
plated･ These bearings

The crankshaft beanngs
main and the connecting rod bearlngS are a(uminum are
especially sensitive to foreign materiaE such as metal scraps･ lt is very important that the oil ports and
parts be kept c(ean and free offore(gn materiaF･
other related
30
ENGINEASSEMBLY (1 )
回 DJSASSEMBLY
These disassembly steps are based on the A-4JGl engine.
18 17 16 78 5 12 ll 13 10
≡=よ
』+u
=払上==
皮 I
∩ l
ら.
1 t
ト
I
1 I ○
C! こ∋
l
十 I 1
ト
I
I ｢l 1 1
1
○ -”
CrしJ8
†二2
15 19 4 14 19
Disassenbly Steps I
1 Coo=ng fan and spacer 10 FueHeak off p'[pe

2 Cooling fan
drive be[t ▲ ll Fue) injection pJPe With clip
3 Coo=ng fan drive pu‖ey ▲ 12 )njection pump
4 Alternator and adjusting plate 13 lntake manifold
5 Fuel pJ'pe (Fuel filter to 14 Sta什er
injectionpump) 15 Oil fi)ter
6 Fuel pJ'pe (Fuel fiJterto feed pump) 16 Cooling water rubber hose
7 Fue一 pipe (Fue[ fi(ter Leak off) 17 Coo一ing water intake pfPe
8 Fuel fitter ▲ 18 Exhaust manifoJd
9 Oi一pipe (Injectionpump to cy‖nder 19 Stiffner (RH 良 LH)
body)
31
ENG(NEASSEMBLY (1 )
∇ ∫mportant OperatJlons (Disassembly Steps ･
1)
a
ご喝
〔)
E9
碍 0
ll, FueHnjection Pipe with CJip
1) Loosen the injection pipe sJeeve nuts atthe defivery

CI O O
vaJveside,
I
岩
Do not app[y excessive force to the injection
L p[pes.
2) Loosenthe in)'ection pipe c(ips.
3) Removethe injection pipes.
12. hJ'ection Pump
/ 1) Remove the six injection pump bracket bolts from

the cylinder bodytimlng gear Case.
2) Remove the injection pump rear bracket bolts from

the rear bracket.
過 3) Pu一l the injection pump wl'th the injection pump

timlng gear free from the rear.
Note:
P(ug the de=very hoJder the

J'njectionpump ports with
shipping caps (or the equivalent) to prevent the entry of
foreJgn material.
｡,愈
ノ′
＼
/
覇
酌￠ダ
L.dS
￠
18. Exhaust Manifold
Loosen the exhaust manifold bolts a litt!e at a time

in the numerica[ ordershown in the illustration.
① ① ㊨
32
ENGINE ASSEMBLY (1 I
/一1
9
/
申
/
｢
㍗
曾 6
★
-■■-O
I
1/ト｢
一l
猷
駅
/
冒
＼､ミ一′
1 2
㍗/
討
仁表
鴨
∩
男コ
㍗
め
0 フくこ>
ゝ 13
＼＼＼こ
10-★
⑳ d
♂ 翫 i.
4
52 ■▲
■l
♂
L上
∈主
/二
LJ
フ=≦
闘
＼ふ
I句
･≠二
SS
i
rlJt
♂/
★ Repair kit
Djsassembfy Steps I
1 Water by-pass hose 10. Cy=nde｢head gasket

2 Thermostat houslng ▲ ll. Crankshaftdamperpu=eywith
3 Water pump dust seal
▲ 4 lnjection nozzle ho(der 12 Timing 9ea｢ Case cover (Option)
5 G一ow p山9 and 9low p一ug connecto｢ 13 Timing gear cover
6 Cylinder head cover 14 Timlng gearOil pIPe

▲ 7 Rocker arm shaft and rocker arm 15 暮dJergear ”B''and shaft
8 Push rod ▲ 16 tdle｢ gear `′A′'
▲ 9 Cylinder head 17 ldler 9ear Shaft
Inverted Englne
ENGJNEASSEMBLY (1 )
15 4
A
捕 YQ
p随†-*-1
節
＼ヽ.
1i3
5
6 i
/
/ 10
12
/ ♂ 亡戸
節
ヾ㍗/ ke
i:
｢
I
∈∋ ll
＼＼
2a
''.I:
笹し＼
u 当紹
,
関醐
_工忘
7
負
___鷲且
1駈- 4
1a
メ
⊥
A
★ Repair kit
Disassembry Steps -
1, Oi(pan 8. Piston and connecting rod with

^ 2, Flywheel upper bearl咽
2a. ▲ 9. Crankshaft beari｢唱CaP With

RearfJywhee川fso equipped)
3. FlywheeJ houslng Lower beanng
4. OilpumpwithoiJpipe 10. Crankshaft thrust bean-ng
▲ 5. Camshaftwithcamshafttimlng 11. Crankshaft with crankshaft timJng gear
▲ 12. Crankshaft upper bearlng
宙ear and thrust p一ate
6 Timing case ▲ 13. Tappet
gear
▲ 7 Connecting rod cap with 14. Crankshaft rear
oil sea一
lower beanng 15. Cy一inder body
34
ENGINE ASSEMBLY = )
∇ [mportant Operations (Djsassembly Steps ∼
2)
4, JnJ'ection Nozzle Holder
l) Remove the nozz一e holder bracket nuts.
〟
百中
C2
㊨
A
2) Use the nozzle ho[der remover the s)iding
園
and
hammer to remove the nozzle holder together
with the ho(der bracket.
Nozzle Ho一der Remover: 5-8840-2034-0

SlidJ'ng Humme: 5-8840-0019-0
ヴ＼!6＼L か､
7. Rocker Arm Shaft and Rocker Arm
Loosen the rocker arm shaft bracket boJts -fn numer-
icaJ order a )ittJeat a time.
Note:
Fai[ure to loosen the rocker arm shaft bracket bolts in

numericaf order a IittEeat a time w川adversely effectthe
rocker arm shaft.
9. Cylinder Head
Loosen the cy‖nder head bolts in numerica一 order a
JittJeat a time.
腐空,dot4Qe5...7矧
0000
Note:
Fai[ure to loosen the head bo[ts in numerica一

1 cylinder
1 Jittle at time
order a a
w川adverseLy effect the cylinder
o占毛913′1612o,4 head暮ower surface.
u＼8
35
ENGINE-ASSEMBLY ” )
ll. Crankshaft Damper Pu[ley with Dust Seat
@ O
(揺ノb
C⑳
1) B(ockthe flywheel with a piece of wood to pre-
0 vent it from turnlng.
b
¶
Cn 2) Use the damper to the
回
pu‖ey remover remove
i亡7 ヽ damper pulley.

Dampe｢ Pu一ley Remover
16. 1dler Gear ``A′′
Measure the timing backlash′ the
園
camshaft gear
crankshaft tim∫ng gear backlash, and the idler gear
”A” before the idler gear ''A”
end play removing
and shaft.
TjmJ-ng Gear Backlash Measurement

0
o⊂⊃
0
1) Seta diaJ indicatorto thetiming gearto be mea-
sured.
HoTd both the gear to be checked and the

○
0
adjoin[ng
oトJO stationary.
0 gear
○
○ ㊨ 2) Move the bechecked
圃
gearto asfaras possibreto
A ○ both
Take
the right and
diaJ indicator
the 一eft.
O the
0
0
reading.
S)竺
S3 1f the the fimit,
○
measured value exceeds specified
thetim]ng gear must be rep一aced.
Tim[ng Gear Backlash
mm(in.)
GEAR Standard
CAM-[DLE(A) 0.032-0,060
CRANK-IDLE(A) 0.032-0.066
IDLE(A)-lDLE(B) 0-0.035
IDLE(B)-lNJ,PUMP 0-0.029
Jd(er Gear ''A” End P(ay Measurement
tさ
囲 Insert a
thrust co‖arto
feeler gauge
measure
between
the gap
the
and
idJer gear
determine
and the
the idler
宙ear end p一ay.
■
○
If the the limit,
# ○ measured value exceeds specified the
○
ヽヽ
○ thrust colla｢ must be replaced.

㌔ :/
勺l Idler Gear End play mm(in.)

Q 0
Standard Limit
こL 0.08-0.18(0.003-0.007) 0.30(0.012)
36
ENGINE ASSEMBLY ‖ I
∇ Jmportant Operations (Disassembly Steps -
3)
2. FJywheeJ
l) BJockthe flywheel with a piece of wood to pre-

疹;`≠ vent itf｢om turnlng.
2) Loosenthef(ywheel bolts a fittJe ata time jnthe

,<j order shown in the =ustratjon,
エ
numericaJ
診
臥
5. Camshaft with Camshaft Timzng Gear and Thrust

P)ate
l) Removethethrustpfate bolts.
a
2) Pu‖ the camshaft free along with the camshaft
timing gear and the thrust prate･
Note:
Be careful not to damage the camshaft )'ournaI, the cam,
and the camshaft during the disassembJy procedure.
7. Connecthg Rod Cap with Lower BearJng
Jfthe connecting rod Lower bearLngS are tO be rein-

staHed, mark their fitting positJ-ons by tag9Ing each
♂ bearJng VVith the cylinder number from whJ'ch it was
removed.
”
8. Piston and Connecting Rod with Upper BearJng
0 1) Remove carbon deposits from the upper portion

a ofthe cyljnder warr with a scraper before remov-
bQ@
Q
Q〟ト.＼ (ng the piston and connecting rod･

D 2) Move the piston to
the top of the cy[inder and
∩ tap it with a hammergr(p or simi(ar object from
rod lowersideto drive it out,
/
the connecting
Q
q
)9
0 El
l
A:/pi91
ヽヽ
ら
rD
lfthe connecthg rod upper bearings are to be rein-

sta=ed′ mark their fitting positions by tagglng each
∈∋ bearing vvith the cylinder number from which it was
removed.
/cl
37
ENGJNEASSEMBLY (1 )
9. Crankshaft Bearlng Cap with Lower BearJng
l) Measure the crankshaft end play at the center
JOu｢nal of the crankshaft.
)
ll ∫
小 Do this before removing the crankshaft bear∫ng

∫
1
( ) CaPS.
rf the the
measured vaJue exceeds specifJ-ed
【 a
E limit, the thrust bearing must be

crankshaft
/ ｢￣
節 Crankshaft
repJaced.
End P一ay mm(in.)
Standard Lim)-t
0.10(0,0039) 0.30(0.0118)
2) Loosen the crankshaft bearing cap bo一ts in

a (ittle at a time.
10 numericaT order
ff the crankshaft bearings are to be reinstaJ[ed,
mark their fitting positions by tagglng
8 9 each
4 5 beanng the from it
○ with cyEinder number which
○
was removed.
12･ Crankshaft Upper Beartng
A lfthe crankshaft upper beanngs are to be reinstalled,

mark their fitting positions by tagglng each bearing
臥 with
removed.
the cylinder number from which it was
｢r)o
ooOo
13. Tappet
]f the tappets are to･be reinstaJled, mark their fitting
positions by tagglng each tappet with the cylinder

numberfrom vvhich itwas removed.
_A 1
巾｡.
14. Crankshaft Rear Oil Seal (Axial Type)

Remove the ftywheel houslr唱.
0 /､､
/､
With the oil seal pushed in deep, instal[ the special
tooL as shown in the ilJustration and remove the oiL
嶺｡
seaI.
eア Oi】 Sea一 Remover: 5-8840-2360-0
38
∈NGIN∈ ASSEMBLY ” )
国 DISASSEM8LY
SJNGLE UrWT
ROCKER ARM SHAFT AND ROCKER ARM
冒
◎
I 工 a;
丁モ己ゝ
さく
㊨
管!】
冒
U
C)
払
P)ド ;iLRIL”S
5
Disassembry Steps
▲ 1 Rocker arm shaft snap rLng 5. Rockerarm shaftsprlng

▲ 2 Rocker arm 6. Rockerarm sh8ftsnap ｢ln9
3 7. Rockerarm
▲ Rocker arm
shaft bracket shaft
4 Rocker arm
39
ENGINE ASSEMBLY I1 )
∇ Jmportant Operations
1. RockerArm ShaftSnap Ring
2. Ro￠kerArm
3. Rocker Arm Shaft Bracket
l) Use a pair of snap ring pliers to remove the

SnaP r]ngS･
2) Removethe rockerarms.
Removethe
3) rocker arm
shaft bracket,
]fthe rocker arms and rocker arm shaft brackets
are to be reinsta]led, mark their instaIJation
positions by taggFng each rocker arm

and rocker
arm shaft bracket with the cy=nder number from
which it was removed.
40
ENGJNE ASSEMBLY (1 )
CYLINDER HEAD
ec'
∈∋
日
U
⊂)
U
C1
玩
く⊃
O
岳5
/■ O
ヽ U
′＼く⊃
P
O
盟♂P E] e2
e
◎
I
( 0 e3
I
DisassembJy Steps
▲ 1 Sp.it collar 5. Valvestem oiJseaJ

2 Valve sprlng upper Seat 6. Valve sp｢Ing lowerwashe｢
3 Valve 7. Cy=nde｢head
sprJng
▲ 4 Intake and exhaust va一ves
41
ENGINE ASSEMBLY (1 )
∇ Important Operations
1. Split CoJJar
l) Place the cyJinder head on a flat wooden

surface.
2) Use the to the
園
spring compressor remove spJit
coHar.
宿 ○ 【)
○
0 ○
Do not to faJ[ from
allow the varve the cylinder
head.
⊂) -･-････
【⊂) O
⊂) ○
A Sp｢in9 Comp｢esso｢: 9-8523-1423-0
｢＼｢1 ∩
4. Intake and Exhaust Valve
lfthe intake and exhaust valves are to be reinsta=ed,

mark their insta‖ation positions by tagg[ng each
valve with the cylinder number from which it was
∼/a.ノ〟o1 removed.
1fthere is excessive va一ve wear or damage, the va(ve
fィFl ＼叫
must be replaced.
Referto Page 50 of ”Jnspection and Repair” for the

valve and va[ve seat insert procedure.
Note:
(f there is excessive va一ve guide wear or damage. the

valve guide must be rep(aced.
Refer to Page 49 of ”lnspection and Repair” for the va一ve
guide replacement procedure.
The va一ve and the valve guides must be replaced as a
⊂)
′
set. Never replace only one orthe other.
C〉し⊃ Cl
亡
2i
42
円STON AND CONNECTING ROD
∈∋
ノ
&6
C5
O
㌶､､ U
聖＼ ∼
D]'sassembFy Steps
▲ 1 Connecting rod beanng 5 Connectin9 rod

▲ 2 Piston nng ▲ 6 Piston pm snap rJng
▲ 3 Piston pln Snap nng ▲ 7 Piston
▲ 4 Piston pln
43
ENGINE ‖ )
･ASSEMBLY
∇ lmportant Operations
1. Connecting Rod Bearng

Tf the
connecting rod bearings are to be reinstalled,
∈∋
mark their fitting positions by tagg[ng each bear]ng
with the cylinder number from which it vvas
removed.
∼El1
2. Piston Ring
l) Clamptheconnecting rod inavise.

∈≡≡〉 damage
Take care notto the connecting rod.
2) Use
団
a piston pin replacer to remove the
i≧±言== piston
rings.
ゝ､ー
Piston Ring Rep[acer
Do not attempt to use some other tool to

remove the piston nngs･ Piston ring stretching
will result in reduced piston rlng tension.
3, Piston Pin Snap Ring
4. P;ston Pin Snap R盲n9
＼ー
隠 Use
Pln
a
Snap
palr
rlngS.
Of snap nng p[iers to remove the piston
5. Piston Pin
7. Piston
Tap the piston pLn OutWith a hammer and a brass

bar.
pistons are to be reinsta[Ied, mark

1f the their instaト
Iationposit'[ons by tagg(ng each piston with the
from it
虹 cy[inder which was
number removed.
/
44
CAMSHAF:T, CAMSHAF:T TJM(NG GEAR, AND THRUST PLATE
@1.
浴
港
;i;
RS
ES b
Disassemb)y Steps
▲ 1. CanlShafttiml｢唱9ea｢ 3 Feather key

▲ 2. Th｢ustplate 4 Camshaft
45
1. Camshaft Timing Gear
2. Thrust PIate
l) avise.
rCIampthecamshaftin
Take care notto damage the camshaft.
2) Usethe
園
uni.versa[ pu([ outthe
pu[JerOto
camshafttimln9
③ gear②.
Universal Pu[Ler: 5-8840-0086-0
,1､.
] 3) Removethethrustpfate@.
6T'1.E.J
①
46
SECT10N 4
TABLE OF CONTENTS
ITEM PAGE
rnspectionandrepaJr .‥‥‥.‥‥‥‥‥---L‥-‥...,.”..‥‥‥‥‥‥‥‥.‥.
48
47
囲 lNSPECT10N AND REPAIR
Make the necessary adjustments, repa[rs, and part replacements if excessive wear or damage is
dL'scovered during ]nspectllon.
CYLINDER HEAD
Cy[inder Head Lower Face Warpage

l･ Use a st｢ai9ht
圃 edge and a feeler gaし唱e tO measure
the four sides and the two diagonals of the cy一inder

head lowerface.
くJ
2. Re9｢ind
ら
head lowerface if the

随 the
cJ
⊂+
<⊥
cy=nder mea-
9
く.1
亡I
国
つ a L
sured values are greater than the specified 一imit but

敬
勺
@ less than the maximum grinding a‖owance,
i [f the measured vafues exceed the maximum grind･

⑪ lng al]owance, the cylinder head must be rep一aced.
Cylinder Head Lovver Face Warpage
mm(in)
1 MaximumGrinding
Standard Limit
A(1wance
E
A-/1 F
0.05
0.2(0.008) 0.3(0.012)
CD (0.002)orless
I-㌔-
ら
Ll Cyhrnder Head Height (Reference) mm(jn)
Standard
Limit￣1
91.95(3.620)-92.05(3.624) 91.65(3.60)
Note:
(fthe cylinder head lower face is reground, valve

depression must be checked.
Exhaust Manifold Fitting F:ace Warpage

Use
and a feeler gauge
囲
a straight edge to measure the
manifold cylinder head fitting face warpage･
Regn'nd the manifold cy(盲nder head fitting faces if the
0
- than
0 measured values are greater the specified Jimjt but
鞄 co& tess than the maximum grinding

0 a[]owance.
ooo
0 1f the measured vafues exceed the maximum
tQOO.6d
grinding
(
0
0
0 0
the cylinder head must
0
oooo aHowance, be replaced.
48
Manifofd FittJ'ng Face Warpage mm (in)

MaximumGrinding
Standard Limit
Allwance
0.05
0.2(0.008) 0.4(0.016)
(0.002)orless
VALVE GUIDE
Va[ve Stem Va一ve Guide Clearance
園
and
■
MeasurJng Method I
I
e)
l･ With the
va一ve stem inserted in the valve guide,
ア set
L
the dial indicator J'oW,
a
needJeto
2. MovethevaJve head from sideto side.
a
Read the dJ'a( indicator.
Note the highest dial indication.
Jf the measured values exceed the Hmit,

specified
the valve and the va一ve 9uide must be rep一aced as a
set.
Valve Stem clearance

mm(in)
Standard Limit
0.039-0.071 0.20
JntakeVa[ve
(0.0015-0.0028) (0.008)
0.064-0.096 0.25
ExhaustVa[ve
(0.0025-0.0037) (0.0098)
Measur]ng Method -
JI
塾 ◎ 固
1. Measurethe
Referto the
valve
Item
stem
hValve
outside
Stem
diameter.
Outside Diameter”.
2･ Use a caliper ca]ibrator or a telescoprng to
gauge
measure the valve guide inside diameter.
Valve Guide Replacement
Valve Guide Removal
回 Use a
the vaLve
hammer
and the va一ve guide replacerto drive
from the cy[inder head lower face.
out
guide
∈う
O
園 Valve Guide Repracer: 9-8523-1212-0
亡フ a
…雇夢
u
U
dJ
u
∩ ∈)
0
OIO
_彪
｢1 ∈)∩
49
Valve Guide JnstaJ[at盲on
回 1. App[y
enCe.
engJne Oi一 to the va一ve gu-1de outer circumfer-
___-･--一一ニー-′
田 2.
3.
Attach
Use a
the
hammerto
valve guide
drive
replacerto
the valve
the
guide
vafve
into
guide.
position
園 from
VaJve
the
Guide
cylinder
Replacer:
head upper
9-8523-1212-0
face.
密琶園
4. Measure the height of the va[ve g山de upper
圃
end
from the upper face of the cy[inder head.
Valve Guide Upper[nd Hei9ht (H)

I
(Reference) mm(in)
13.0 (0.512)
J
⑪
Note:
●●.-.I.....J
････.･･･.!/･･ ]fthe has been both the

●●▲ ●-●
valve guide removed, va一ve and

the va[ve guide must be replaced as a set.
VALVE AND VALVE SEAT INSERT

＋ /
一■一-
Va一ve Stem Outside Diameter
1J/ diameter
Measure the at three
圃
valve stem points.
Jfthe measured value is (ess than the specified JJ'mit, the
va[ve and the valve guide must be repJaced
ち
/
as a set.
Valve Stem Outside Diameter mm(in)

ら,こ
Standard Limit
7.946-7.961 7.88
lntakeValve (0.3128-0.3134) (0.3102)
7.921-7.936 7.88
ExhaustVaJve
(0.3118-0.3124) (0,3102)
Valve Thickness
Measure the va[ve thickness.
圃 1fthe
va[ve
measured
and the
value王s
valve guide
less
must
than the specified
be replaced as a
Iimit′the
set.
Intake and Exhaust Va一ve Thickness mm(in)

Standard Limit
lntakeVa]ve 1.79(0.070) 1.1(0.043)

ExhaustVa[ve 1.39(0.0547) 1.1(0.043)
50
Va)ve Depression
1. lnstalrthevaFve①tothecyrinderhead②.
2
+ Use depth
圃2.
gauge or a
孤
a straight edge wJ'th steel ru[e
from the cylinder
] )
_JIJ
to measure the valve depression
1II
I head lower surface.
①
i
t
If the
the vaJve
measured
seat insert
value
must
exceeds the specified
be replaced.
Jimit′
I Valve Depression mm(in)

Standard Limit
Jntake 0.65(0.026) 1.28(0.050)

Exhaust 1.10(0.043) 1.60(0.063)
VaJve Contact Width

1. Check the vaレve contact faces for rou9hness and
UneVenneSS.
JJl Jm
●●●
Make smooth the va一ve contact surfaces.
拙･:･･
｡I■
6:.A:軒
I
2. MeasurLe the valve conlactwidth.
i
l
圃 Jf the
the vafve
measured
seat insert
value
must
exceeds the
be repJaced.
specified limit′
I Valve Contact Width mm(in)

Standard Limit
lntake 1.7(0.067) 2.2(0,087)
Exhaust 2.0(0.079) 2.5(0.078)
Va[ve Seat Insert Replacement
④ Valve Seat Jnsert Removal

③＼
0 0
Ei) 1. Arc weld the
insert
entire inside circumference ① of the
@.
o
0 varve seat
財
○
insertto fora
④! 0
2. AHowthe va一ve seat cool few minutes.
This w‖ invite contraction and make removal of the

/ さ･､ ○
valve seat insert easier.
(か
51
3. Use a
screwdriver ③ to prythe valve seat insert
free.
Take care notto damagethe cy一inder head ①.
4. CarefuJ[y forelgn
E5]
remove carbon and other material
f｢om the cylinder head insert bore.
Va[ve Seat Insert Jnsta[Jation
___ゝ′
① Ej 1. Carefuf[y
outside
p[ace
diameter
the attachment
than the valve
0 (having
seat
a smaHer
insert) on the
① valve seat insert①.
1;1 Note:
㊨ The smooth side of the attachment must contact the

l valve seat insert.
I
ヽ
2. Use a bench press @ to gradual[y apply pressure to
the attachment and press the va一ve seat insert hto

ヽ
place.
Note:
Do not apply an excessive amount of pressure with the

bench press. Damage to the va[ve seat insert wi[l
result.
Valve Seat hsert Correction

/'' /[50' ∼--㌔
/ 固 1. Remove the carbon from the va一ve seat insert suト

/ face.
/
1 2. Use (15o, blades)
圃
a vafve cutter 45o, and 75o to
minimize scratches and other rough areas. This w=
bring the contactwidth backto the standard va[ue.
Remove onJy the scratches and rough areas. Do not
cut awaytoo much･ Take care ロotto cut away
unbJemished areas of the va一ve seat surface.
Valve Seat Ang一e 45o
Note:
Use
団
an cutter
adjustable va一ve pi一ot.
Do not allovv the valve cutter pi一otto vvobble inside the
valve guide.
52
3. App一y abrasive compound to the valve seat insert
＼ surface.
1L 4, lnsertthe valve into the vaJve guide.

⊂ノ 5･ Turn the valve whi一e tappJng Zt to fit the valve seat
C)
堰
insert.
⊂ノ /, ,
⊂ノ :ち 6. Checkthatthe valve contact width is correct.

C) C.) C
7. Check that the insert is
臼鮎
va.ve seat surface J'n contact
∩
with the entire circumference of the valve.
VALVE SPRING
Valve Spring Free Height
Use to the free
囲
a vern盲er caliper measure
valve spnng
height.
[fthe measured value is Jess than the Limit, the
specified
valve spring must be replaced.
Vafve Spring Free Height
mm(in)
Standard Limit
49.7(1.96) 48.2(1.90)
VaJve Spring Inclination

Use
囲
a surface p(ate and a to measure the
square valve
spnng lnC[ination.
(f the measured value exceeds the specified Hmit, the

valve sprlng must be rep[aced.
Valve Spring Jnc‖nation
mm(jn)
Standard Limit
1.5(0.06)orJess 2.5(0.098)
Square
Valve Spring Tension
Use teStertO the
囲
a sprlng measure tension.
valve sprJng
【fthe measured va[ue is 一ess than the limit′ the
specified
valve sprlng must be rep一ace.
Valve Spring Tension N(kgf/fb)

CompressedHeight Standard Limit
254 225
38.9mm(1.53in)
′ (25.9/57) (23/51〉
53
ENGINE ASSEMBLY (2 1
Rocker Arm Shaft Run･Out
1. Pf ace the rockerarm shaft on a V-b[ock.

Use dia一 indicator to the
囲2.
a measure rocker arm shaft
central portion run-out.
1f the run-out is very sTight, correct the rocker arm
帽 shaft run-out wL[th a bench press. The rocker arm
must be at cofd condition.
[f the measured rocker arm shaft run-out exceeds

the specified limit, the rocker arm shaft must be
rep)aced.
Rocker Arm Shaft Run-Out mm(J'n)
Standard Limit
0.2(0.008) 0.6(0.024)
Rocker Arm Shaft Outside Diameter
to the fi吋ng
固
a measure rocker arm
･Use micrometer
portion outside diameter.
If the measured value is less than the specified limit, the
rocker arm shaft must be ｢eplaced.
Rocker Arm Shaft Outside Diameter mm(in)

Standard Limit
18.98-19.00(0.747-0.748) 18.85(0.742)
Rocker Arm Shaft and Rocker Arm C一earance
1. Use d舌af indicatorto
園
either a vernier ca‖per or a
measure the rocker arm bushing LnSide diameter.

Rocker Arm Bushing Inside Diameter mm(in)
Standard Limit
19.01-19.03(0.748-0.749) 19.05(0.750)
2. Measure diameter.
園
the rocker arm sha托outside
1f the measured value exceeds the specified limit,
repface eitherthe rocker arm or the rocker arm shaft.
RockerArm and Rocker Arm Shaft Clearance mm(in)
Standard L'rmit
0.01-0.05(0.0004-0.002) 0.2(0.008)
54
3. Check thatthe rocker arm

oi( port is free of obstruc-
tions.
1f necessary, use compress'ed air to clean the rocker

arm oil port.
′
Rocker Arm Correction
⇒
Jnspect the rocker arm valve stem contact surfaces for
一/一･③
step wear① and scorin∈I ②.
1f the contact surfaces have (ight step wear or sconng,
①
they may be honed with an oil stone.
1fthe step wearorsconng JS Severe, the rocker arm must
be ｢eplaced.
CYLINDER BODY
Cy)hder Liner Bore Measurement

Use a cylinder indicator to measure the cylinder bore
園
at
measuring in thethrust X-X and axiaJ Y-Y
y￠y
point①
directions of the crankshaft.
Measuring Point① : Maximum wear portion
ノ
【11-15mm(0.43-0.59in)】
①
lf the measured value exceeds the specified limit, the
表芸≧ニ cyrinder (iner
Cy一inder Liner
must be replaced.
Bore
mm(in)
Standard Limit
95.421-95.460(3.7567-3.7583) 95.5(3.7598)
Note:
The inside of the dry type cylinder Liner is chrome
prated. Jtcannot be rebored or honed.
Jf the inside of the cy[inder =ner is scored or

scorched,
the cylinder [iner must be replaced.
Cyrlnder Liner ProJ'ection lnspection
杏
① l･ Hold a
st｢ai9hted9e ① along the top edョe Ofthe
llmer to be measured.
ゝ､ cy=nder
2. Use fee[er ①to ‖ner
圃
a gauge measure each cylinder
projection.
弓J
⊂J
Cylinder Liner Proj'ection

mm(in)
冒
r Standard
②
那 0-0.10(0-0.0039)
The difference in the cylinder liner projection height

between any two cy一inders must not
adjacent
exceed 0.03 mm (0.0012 in).
55
CylJLnder Liner RepJacement
CyJinder Liner Removal
)＼＼＼回 1. Removethe cylinder

nner
body dowel.
2. Setthe cylinder removerto the cy=nder finer.
3. Check thatthe remover shaft ankle is firmly grJPPlng

the cylinde=iner bottom edョe.
4. SJowJy turn the remover shaft handle counterc[ock-

I-”
wise to pu一lthe cylinder liner free.

●l Lr
CyTinder Liner Remover Ankle: 5-8840-2304-0
園 Cyfinder Liner Remover: 9-8523-1 169-0
NOTE:
Take care not to damage the cylinder body upper during
the cylinder Liner removal procedure.
CyJinder Body Upper Face Warpage
圃 1.
2.
Remove
Removethe
the cylinder bodydovver.
rlrner.
cylinder
3. Use a
straightedge① and a
feeJergauge①to
冒 measure the four and the two diagonals
sides of the
cylinder body upper face.
@ rI*j=
/′■
Cylinder Body Upper Face Warpage

mm(in)
Standard Lim叶
0.05(0.002)orless 0.2(0.008)
lfthe measured value is more than the (古mit, the

A
cylinder body must be replaced.
F
E
CD
I-㌔_
B
ll
Cy=nder Body Height (Reference) mm(in)

Standard
272.945-273.105 (10.746- 10.752)
4. Reinsta‖ the cy=nder =ner.
Referto 'JCylinder Body Bore Measurement”.
5. ReinstaJl the cy一inder body dovvel.
56
Cylinder Liner Grade Selection

Measure the body inside diameter
@
cy‖nder and seJect
the proper cy=nder =ner grade'number corresponding to
the body inside diameter.
cyIJ'nder
Standard Fitting Interference (Reference) mm(in)
/1
0.001 -0.019 (0.00004-0.00075)
ー一--=ゴr
(f the =ner fitting interference is too smaFf,

､ヽ
cy=nder
ゝてアご eng(ne cooling efficiency wiJJ be adversely affected.
%. 1fthe cylinder [iner fitting interference盲s too large. it w川
be diffJ-cuJtto insert the cylinder liner into the cylinder
body.
The cylinder block deck has been marked during

イー production to indicate the correct liner sizes･ The =ner
grade (J'.e.1, 2, 3′ 4) is indicated in permanent ink.
rn the case of a questionab一e Jiner marking measure the

0
o&o. too oiEfo o&oi cyJinder body hside diameter･
e/mqSoo
0
10
0
0 ○ 0 0
Cylinder Body 8o柑Measurement
1. Take measurements at measuring point 0 across
圃 positions
Measun'ng Point①
(”W-W”),
: 98 mm
(”X-X”),
(3.86 in)
(Y-Y) and (Z-Z).
2.CalcuJate the average value of the four

measurements to determine the correct cylinder
9rade.
Cylhder Liner Grade
Nominal CyrinderBody
LinerGrade
I- Dimension BoreDiameter
” Z
97.001-97.010 l
Y
-∠y
_一＼
mO. 97.001-97.020 2
≠97
97.021-97.030 3
3 ”
x
C> 97.031-97.040 4
57
Cy)盲nder Liner Jnstallation
Ei] 1. Cy[inder Liner JnstalJation

kerosene
Using
diese一
The Specia[ TooT･
1) Use new or oil to thoroughfy
田 clean
2) Use compressed
the cy=nde=iners
air to
and bores.
b一ow-dry the cy=nde｢

Jiner and bore surfaces.
Note:
A= foreign material must be carefu][y removed from the

cylinder liner and the cy=nder bore before installation.
3) Jnsertthe cylinder [iner ① into the cy=nder body

③ ① from the top of the cylinder body.
①
②
謂
y,
r/
4) Setthe Liner I-nstaHer③ to thetop of the
園
cy[inder
cylinder liner.
③ 5-8840-2313-0
Cy=nder Line‖nsta‖er:
5) Position the cylinder body so that the instatler

r center @ is directly beneath the bench press
二=之ニ
shaft center ④.
0 D
i r)
ーIl r) r3
㍗ Note:
Check that the cylinder =ner is set perpendicular to the

Q ㊨ bench press and thatthere is no wobble.
force
6) Use the bench pressto app一y a seating of
500 kgf(1,102.5 [b/4,900 N) tothe cy[inder =ner.
7) Apply a force of 2′500 kgf (5,512.5 1b/24,500 N)
to fully seatthe cylinder liner.
8) After instaHing the cylinder finer, measure the
cylinder finer projection.

Refer to一`Cylinder Liner Projection lnspection′′.
2. Cylinder Liner lnstallation Using Dry [ce
回 lfthe
advisable
cylinder
to
=ner
use
is a chrome
dry Ice
p一ated drytype,
during the
it is
instaltation
procedure･
Cooling the cy一inder =ner with dry ice w‖ cause the
cyJinder Liner to contact, thus making insta‖at盲on
eaSler.
Note:
lt is important that the cy[inder liner be inserted to the
cy‖nder body immediately after it has been coo(ed.
･
58
WARNING:
DRY ICE MUST BE USED WITH GREAT CARE. CARE-

LESS HAND”NG OF DRY JCE CAN RESULT fN SEVERE
FROSTBITE.
Piston Selection
Se一ect the same

9rade number as the one for the
cylinder =ner I-ns亨dediameter.
Gradeofcyfinder
Gradeofpiston Combination
ins手dediameter
AX AX OK
CX CX OK
AX CX NG
CX AX NG
59
Piston Grade Selection
Measure finer bore. Then
画
the cyHnder select the
appropriate piston grade for the instaHed liner.
y!%fy
cylinder
1. Measure the cy[inder =ner bore.
ノ There ( ① and
aretwo measuring points ②).
l①
Liner
′
Measure the cyfinder bore in four different

_･一一戸丁二
′ ヽヽ i,@ direction (W-W. X-X, and Z-Z) at both mea-
噌ニー午 surlng POints.
% Ca[cufate the average va(ue of the eight measure-
ments to determ-[ne the correct cy=nder liner bore.
MeasurJ'ng pointsO : 20 mm (0,79 in)

①:160mm(6.30in)
Cy一inder Liner Bore mm(in)
Standard Limit
95.421-95.460(3.7567-3.7583〉 95.5(37598)
Relat7on between Lher Bore and Piston Grade mm(in)

LinerBoreDiameter PistonGrade
95.421-95.440
AX
(3.7567-3.7575)
95.441-95.460
CX
(3.7575-3.7583)
Note:
暮tis most important that the correct piston grade be
used. Fa‖ure to select the correct piston grade w川result

in engJne fai[ure.
2. Measure the pJ-ston outside diameter.
画 Piston Measuring Point① : 71 mm (2.79 in)

Piston Outside Diameter mm(J'n)
OutsideDiameter PistonGradeforService
95.365-95.384
a (3.7545-3.7553)
AX
95.385-95.404
CX
(3.7553-3.7561)
Cy=nder Liner and Piston Clearance mm(I'n)

0.037 (0.0015 -
0.0030)
-0.075
Note:
:Cy一inder (iner kit clearances are preset. However, the

cy一inder liner instaHation procedure may resu一t in s[ight
decreases in cylinder )iner clearances. A[ways measure
the cylinder finer c一earance after instaHation to be sure

that itis correct.
60
TAPPET AND PUSH ROD
○◎
.-.:.一･
■ t l1 VisuaT[y [nspect the tappet camshaft contact surfaces for
A.
I:･1.1'/ The
pitting, cracking, and other abnormal conditions.
● ● ■
tappet must be repJaced if any of these conditions are
Pr(∋Sent･
Referto the iHustration [eft.
￠
atthe
1 Pitting
2 Cracking
3 Norma一 contact
4 lrregular contact
5 lrreg山8r COntaCt
Note:
The tappet surfaces are spherJ'ca[. Do not attempt to
grindthem with an oil stone orsim‖artool in an
effortto
repair the tappet. Jf the tappet is damaged, it must be
rep一aced.
Tappet Outside Diameter
Measure the tappet diameter
囲
outside vvith a micrometer.
Ifthe measured value is Jess than the specified limit, the
tappet must be rep)aced.
∼ Tappet Outside Diameter
mm(in)
′
Standard Limit
12.97-12.99(0.510-0.511) 12.95(0.509)
61
Tappet and Cylinder Body Clearance
囲
mm(in)
W2i Standard Limit
0.03(0.0012) 0.1(0.0039)
⊂
こ⊃
#
こ⊃
く.⊃
茅妻芳
㍗I_⊥-⊂⊃
￣⊂⊃
Push Ftod Curvature
1. Laythe push rod on a

suげace plate.
2. RoJl the the
囲
push rod along surface plate and mea-
sure the push rod curvature with a thickness gauge,
If the measured the 一imit.
vaJue exceeds specified
the push rod must be rep一aced.
Push Rod Curvature mm(in)

LimJ't
0.3 (0.012)
3. Visua][y inspect both ends of the push rod for

excessive wear and damage. The push rod must be
repJaced if these conditions are discovered during
inspection.
CAMSHAFr
Visua‖y ins･pect the journa一s, the cams, the oi一 pump

drive gear, and the camshaft bearings for
excessive
wear and damage. The camshaft and the camshaft
bearings must be replaced if these conditions are
discovered dur'Ing mSPeCtion.
Camshaft Journal Diameter
Use a micrometer to journaF

圃
measure each camshaft
diameter in two directions ((X- X) and (Y-Y)). If the
measured value is 一ess than the limit, the
specified
yby
camshaft must be ｢eplaced.
Camshaft Journa( Diameter

mm(in)
Standard Limit
49.945-49.975 49.60
(1.9663-1.9675) (1.953)
62
ENGINEASSEMBLY (2 )
Cam Height
Measure the cam height (H) with a 1f the
囲
micrometer.
measured vafue is 一ess than the limit, the
specified
camshaft must be rep一aced.
I
H cam Height ⑪ mm(in)
Standard Limit
42.02(1.65) 41.65(1.64)
Camshaft Run･Out
i. Mountthe camshafton V-b.ocks.

○
2. Measurethe dial indicator.
圃
run10utWith a
Ff the measured value exceeds the specified limI't′

the camshaft must be ｢eplaced.
Camshaft Run-Out mm(in)

Standard Limit
0.02(0.0008) 0.10(0.004)
Camshaft and Camshaft Bear]ng
Use inside dial indicator
圃
an to measure the camshaft
bearJng diameter.
鉦+ ｡
_.o Camshaft
Inside
Bear[ng Inside Diameter
q C) mm(in)
&@yljo3
Standard Limit
50,0-50.03 50.08
(1.9685-1.9696) ∩.9716)
Jf the clearance between the camshaft bearlng Inside

diameter and the journal exceeds the Jimit′ the
specified
camshaft bearlng must be rep一aced.
Camshaft Bearlng Cle∂r∂nce mm(in)

Standard Limit
0.025-0.085
0.12(0.005)
(0,0010-0.033)
Camshaft Bear暮ng Rep一acement
Camshaft Bearlng Removal
町 Ei) 1. Remove the cylinder body pJug plate.

￠
2･ Use bearing
園
the camshaft repl∂cer to remove the
o
o旬
camshaft bea｢lng.
ノノ
屯
Beanng RepJacer: 5-884012038-0
(]?
＼㌔
a 一1∋
63
Camshaft Bear[ng lnsta[1at盲on
節r). /
少
日 l･ A=gn
ho】es.
the bearlng O‖ holes with the cylinder body oi一
∫
a
刀
一句 2. Use bearJng instalJer
周
I the camshaft reP[acer to instaH
;il
J
the camshaft bearing,
Beanng Repfacer: 5-8840-2038-0
Db･
∂
･Q
'^ ∂ 1
Camshaft End P一ay
l･ Before removin9 the camshaft gear ①′ push the

th｢ust prate ① as far as it w川go toward the
① 〟 cam-
shaft gear ①.
2. Use feeler
圃
a 9aUge tO measure the clearance
between the thrust plate and the camshaftjournal.
Jf the measured va[ue exceeds the specified (imit′
thethrust p一ate must be replaced.
④ Camshaft End P(ay
② mm(in)
Standard Limit
0.050-0.114(0.002-0.0044) 0.2(0.008)
Thrust Pfate Rep(acement

②
③ Thrust Plate Removal
⊥､回 1. Use
timing
the universa一 p山Ier ①to remove the camshaft
gear@.
園 2･
Universal
Removethethrust
Pu=er: 5-8840-0086-0
∫
① p(ate@.
冒 Lj
Thrust Plate lnstaIIat;on
Ej 1. Install thethrust p一ate.

2- Apply
E]
♂1 en9lne Oil to the bo一t setting face and the bolt
〈ク
threads.
3･ [nstal] the
響
camshaft gear.
国 Camshaft Gear Torque N･m(kgf･m/[b.ft)

98-118(10-12/72-87)
♂鷹
64
ENGINEASSEMBLY (2 )
CRANKSHAFT AND BEARING
Inspect the of the crankshaft journals

surface and
crankpins for excessive wear
and damage.
1nspect the oil seal fitting surfaces for excessive wear
and damage.
Inspect the oil ports for obstructJ'ons.
Note:
To increase crankshaft strength, tufftriding (Nitrizing

Treatment) has been appI盲ed. Because of this, it is not
possibJe to regrind the crankshaft surfaces.
Crankshaft Tufftriding Inspection
1. Use to
田
The portion to be tested an
organic c(eaner thorough一y clean, the
Jha‖ be he一d horizontal]y
Te卓t liq山d shou一d crankshaft. There must be no traces of oi一 on the
iOaS not tOlet the test
not be applied to
IOJution flovv. surfaces to be inspected.
th8 a(ea around the
oil port. 2･ Prepare a 5 10% solution of ammonium cuprous

-
The IIiding
打7
of the pin
cMorJ'de (dissolved in distJ'Hed
or
water).
J'ourn8L
3, Use a syrlnge tO aPPJythe solution to the surface to
ApproxILmateZy
Omm be inspected.
Hold the surface to be inspected perfect一y horizontaJ

to prevent the solution from runmng.
Note:
Do not alJowthe to come in contact

so[ut了on vvith the oil
ports and theJ-r surrounding area.
Judgment
1. Wait forth-IrtytO forty seconds.

ff there is
discoJoration
no after thirty or forty see-
onds′ the crankshaft is usable.
1f discoloration appears (the surface being tested

wiII become the color of copper), the crankshaft
must be ｢eplaced.
2･ Steam the immediately
E5]
clean crankshaft surface
afte｢ completing the test.
Note:
The ammonium cuprous chloride solution is highly cor-
rosive, Because of this, it is imperative that the surfaces

being tested be cleaned immediately after completing
the test.
65
Crankshaft Thrust CJearance
Setthe dia[盲ndicator as shown in the =ustration and

measure the crankshaft thrust c一earance.
[f the thrust clearance exceeds the specified Jimit′ re-
pracethethrust bearing as a set.
やや mm(in)
Standard Limit
ド
¶■ 0 J
○ 3V: 0.10(0.0039) 0.30(0.0118)
Crankshaft Run･Out
1. Set a dial indicator to the center of the crankshaft
/
/ ､′ ヽ
/ )ournaJ.
/
I(
ノ
ク
) ≠ 園
2. GentJyturn
rotation.
the crankshaft in the normal direction
of
Read the dial indicator as you turn the crankshaft.

1f the measured value exceeds the specified Limit,
+ the crankshaft must be repJaced.

Crankshaft Run-Out mm(in)
Standard Limit
0.05(0.002)orfess 0.08(0.0031)
Bearlng Tension
Checkto see ifthe bearJng has enough tension, so that a
good finger pressure is needed to fit the bearJng into
position.
∫-ノ
§;⊇=三≧≠
Crankshaft JournaL and Crankpin Diameter

③④
l･ Use to journa一
圃
a micrometer measure the crankshaft
や白
diameter across
po'[nts (”1 -
1”) and ('12-2'').

＼ 2. Use the micrometer to measure the crankshaft
＼'
＼
圃 3･
journaE diameteratthetwo
RepeatSteps 1 and 2to
points
measure
(@ and a
thecrankpin
).
diameter.
乙′
】fthe measured va(ues are less than the )imit, the
crankshaft must be replaced.
66
Crankshaft Journ∂l Diameter mm(in)

Standard Limit
69.917-69.932 69.910
(2.7526-2.7531) (2.7524)
Crankpin Diameter mm(in)

Standard Limit
52.915-52.930(2.0833-2.0839) 52.906(2.0829)
Crankshaft Journa[ and Crankpin

Uneven Wear mm(in)
Standard Limit
0.05(0.002)orJess 0,08(0.003)
Crankshaft Journal and Bearmg clearance
⑳冒圃
/
tf the c一earance between the measured bearing Inside
diameter and the crankshaft journal diameter
こ /
exceeds
the specified limit, the bearing and/or the crankshaft
t/
must be replaced.
⑳ Crankshaft Beanng Cap Bolt

＼
･＼ Torque N･m(k9f･m/lb.柑
∠ゝ ′
157-177(16-18/116-130)
♂
さ､. -iilttt
Crankshaft brg′ cap Bo什Torque
国 Crankshaft
Beamg
JournaJ
Clearance
and
mm(in)
Standard Limit
0.031-0.063(0.0012-0.0025) 0.ll(0.0043)
Connecting Rod BearJng lnside Diameter

1･ lnsta[l the bear[ngtothe connecting rod big end.
21 Tighten the bearfng the
国
CaPtO specified torque･
Connecting Rod Bearlng Cap Bolt

Torque N･m(kgf･m/)b.ft)
27-31 (2.8-3.2/20-23)一45o-60o
3. Use inside dial indicator to measure
圃
a
the connect-
]ng rod bearing Inside diameter.
67
Crankpin and Bearing Clearance
圃 Jf the
diameter
clearance
and the
between
crankpin
the measured
exceeds the
bearlng
specified
Inside
Limit,
the bearhg and/or the crankshaft must be replaced.
Crankp盲n and Beanng clearance mm(in)

Standard Limit
0.029-0.066(0.0011-0.0026) 0.10(0.0039)
clearance Measurements (With PJastigage)

0 9 o
Crankshaft Journal and Bearlng Cfearance
＼田
1. C一ean the cy(盲nder body,
surface, the bearlng Caps,

the
and
journal bearlng
the bearJngS.
fitting
2. Jnsta[1the bear]ngs to the cyl].nder body.

3. Carefu‖y place the crankshaft on the bea｢in9S.
◎
⊂〉 4. Rotate the crankshaft approximately 30o to seat the

○ bearln9.
5. place the PFastigage (arrow) over the crankshaft
)ournal acrossthe fun width of the beanng.
6. lnstaJlthe beanng caps with the bearJng.
7. Tighten the bea｢ln9 Caps tOthe specified torque.
国 Crankshaft
Torque
Beanng Cap Bo[t
N･m(kgf･m/[b,ft)
157-177(16-18/116-130)
n Do the crankshaft to turn during beanng

not arfow
cap insta[Jation and tightening.
一￣
0
⑨ー 0 ○/の〔
8. Removethe bearJng Cap.
68
9. Compare the width of the Plastigage attached to
圃 either the
prJ'nted on
crankshaft orthe
the P[astJ'gage
bearing
container.
agaJnSt the scale
E2
でげthe measured
fo]lowlng
va山e exceeds
additional steps.
the limit, perform the
1) Use to the
回
a micrometer measure crankshaft
outside diameter.
0
2) Use an inside dia一 indicator to measure the

○
国 bea｢Ing
If the
JnSide diameter,
crankshaft journa( and bearJng clearance
exceeds the limit, the crankshaft and/or the

bearmg must be replaced.
Crankshaft Journal and BearJng clearance mm(in)

Standard Limit
0.ll
0.031-0.063
(0.0043)
Crankpin and Bearmg Clearance
1. Clean the
crankshaft′ the connecting rod, the bear-
1n9 Cap. and the bearln9S.
2. hsta‖ the bearing to the connecting rod and the

be∂｢lng Cap.
Do not aflow the crankshaftto move when instaHing

the beanng cap.
3. Prevent the connecting rod from movln9.
4. Attach the P[astigage to thre crankpin.
AppJy englne OH to the PJastigage to keep it from

fa[Jing.
5. Jnstarl the bearJng Cap and tighten itto the specJ-fJ-ed
国 torque･
Do not a‖owthe connecting rod to move when

insta川ng and tightening the bearrng cap.
Connecting Rod Bearing Cap Bo一t

Torque N.m(kgf･m/1b.ft)
27-31 (2.8-3.2/20-23卜◆45o-60o
6. Removethe bea｢lng Cap.
7, Compare the width of the Plastigage attached to
圃 eitherthe
printed on
crankshaft
the PlastJ'gage
or the beanng
container.
against the sca一e
1f the measured vaJue exceeds the specified limit′

perform the fo‖owlng additional steps.
1) Use to the
圃
a micrometer measure out-
c｢ankpin
side diameter,
2) Use inside dial indicator to the

圃
an measure
bearLng [nSide diameter.

1f the and bearing ctearance exceeds
crankpin
the lim7t, the crankshaft the
specified and/or
bearlng must be rep一aced.
Crankpin and Bearlng Clearance mm=n)

Standard Limit
0.029-0.066 0.10
(0,001l-0.0026) (0.0039)
69
CRANKSHAFT BEARING SELECTION

No.3
No2 Nod When insta=｢唱neW Crankshaft bearings or replacing
1 ｢
No.5
No''1 ｢ old bearings, referto the s(ection table below.

Se[ect and install the new crankshaft bearings, pay[ng
c一ose attention to the cy)盲nder body journal hole
0 0 ○
diameter size mark and the crankshaft journal diameter

a EEZ=
size mark.
ロE] E]E] E]
No.1 No.2 No.5
I ●
No.3 No.4
MainBearlng Crankshaft Cranksha冊

OifCfearance
BoreDiametermm(in.) MainJournalDiametermm(in.) Beanng
SizeMark InsideDiameter SizeMark OutsideDiameter SizeMark
mm(in.)
69.927-69.932 0.035∼0.061
1or- (2.7530-2.7532) Black (0.0014-0.0024)
73.987-.74.000 69.922∼69,927 O.O32∼.0.058
1 2or--
(2.9129-2.9134) (2,7528-2.7530) (0.0013-0.0023)
BJue
69.917∼69.922 0.037ー0.063
3or--
(2.7526-2,7528) (0.0015-0.0025)
69.927∼69.932 0.031-0.056
1or- (2.7530-2.7532) (0.0012←0.0022)
Green
73.975-73.987 69.922∼69.927 0.036∼0.048
2 2or--
(2.9124-2.9129) (2,7528-2.7530) (0.0014-0.0019)
69,917∼69.922 0.033-0.058
3or-- Black
(2.7526-2.7528) (0.0013-0.0023)
Crankshaft Timing Gear Rep(acement
① ｢ノ Crankshaft Timing Gear Remova]
Ej 1. Use the crankshaft ∈Iear remover ① to remove the

O
U
crankshaft gear②.
⊂)
2. Remove the crankshaft feather key.
r
ー､｢′ ∫/
園 Crankshaft Timlng Gear Remover: 9-8840-2057-0
7/ ㊨
し
Crankshaft Timing Gear ]nstaHation
) Ei] 1. (nstafT the crankshaft gear.
2･ Use the crankshaft gear instal(er ① to instaH the

園 crankshaft
The crankshaft
gea｢①.
gear timing (LLX X”) must be
mark
-
♂ 任)
㊨
画 faci｢唱OutWard.
Crankshaft Gear lnstaller: 9-8522-0020-0

つDつ
70
CRANKSHAFT PILOT BEARING
Check the crankshaft piJot bearing for excessive wear
and damage and rep face jt if necessary.
Crankshaft Pilot BearJng Rep(acement
Crankshaft Pilot BearJng Removaf
￠
珍
匡l Use
ing.
the pilot bearJng remover tO remove the pilot bear-
匝I P‖ot Beanng
Sliding Hammer:
Remover: 5-8840-2000-0
518840-0019-O
Crankshaft Pnot BearJng lnstarration
巨] l･ P(ace
the
the
crankshaft
crankshaft
beanng
pilot beanng
jnstallation
horizontaJ[y
ho一e.
across
2･ Tap around the edges of the crankshaft pilot bearJng
園 outer
1ng into
races
the
with
crankshaft
aLbrass hammer
bearmg
to drive the bear-
instaJIation hole.
YS Note:
Pifot Beanng lnstaJJer: 5-8522-0024-0
Strike onry the crankshaft pi一ot bearlng outer races

VVith
the hammer･ Do not strike the bearing Inner races.
Bearlng damage and reduced beanng service Fife w=

result.
71
FLYWHEEL AND RING GEAR
① F)ywhee1
1. ∫nspect the fJywheeT friction surface for excessive

wear and heat cracks.
2. Measure the flywhee一 friction surface wear amount
(depth)
The fJywheeJ friction surface area actuar暮y making
contact with the crutch driven prate (the shaded area
in the川ustration) w川be smaFler than the originar

surface area.
mach盲ned
There will be a ridge on the fJywhee( surface area.
Be sure to measure the surface wear in the area
inside the ridge.

げthe measured va一ue is between the standard and
the specified (舌mit, the flywhee一 may be reground.
1f the measured value exceeds the specified ‖mljt,
the flywheel must be replaced.
Flywhee( Friction Surface Depth ① mm(in)

Limit
1.0 (0.04) o｢more
Note:
Because a
ridge is produced at the f[ywheef frictJ'on sur-
face as iHustrated, do not measure the friction surface
wea｢amount at
nonィidge the
area but be sure to
measure it at the rear-friction surface which is shown in
the iIJustration by shaded area.
Ring Gear
Jnspectthe nng gear.

(fthe rmg gearteeth are broken or excessively worn, the
｢ln9 gear must be rep一aced.
RJ'ng Gear Rep(acement
Ei] Ring Gear Removal
Strike around the edges of the nng gear with a hammer

/
it.
_
and diese( to remove
･二=石:::こ二コト-
衰㌍
{#
;ぎミき⊆ -･･ーマI
72
ENG[NE ASSEMBLY (2 )
Ring Gear lnsta=ation
顔 1. Heatthe
thermal
ring
expansion.
gearevenly with a gas burnerto invite
Do not the tempe｢atu｢e of the gas burner to

allow
♂ 2.
exceed
JnstaJJ the
200oC (390oF).
it js sufficiently heated.
ring gearwhen
The ring gear must be insta=ed with the chamfer
facing the cJutch.
Note:
to
Another method of heating the nng gear ]'nvite ther-
mal expansion is to soak a rag in diesel fuel, wrap the
diesel fue[ soaked rag around the rim of the rJng gear,
and then fightthe rag.
PISTON
Piston Grade Selection and CyHnder Liner Bore
Measurement
Refer to the Sect.ion ”CYLINDER BODY”, Item ”CyJinder
園 Liner
selection
Bore Measurement”
and cylinder
for
or liner bore
detaJ'1s on
measurement.
piston grade
PISTON RING
I Piston R;ng Gap
1. Jnsert the piston r[ng horizontaHy JLnTo the cyrinder

liner.
l
2. Use a piston 'lnSerted upside down to push the
/
piston ring into
cy[inder the liner untiHt reaches
either measuring point ① or measuring point ①,

Cy=nder liner diameter is the smallest at these two
y/
points.
Do allow the piston
not rJng tO Slantto one side or
the other. It must be perfectly horizontal.
変電 0
0
圃
3. Use afeelergaugeto
Measurl!ngPoint①‥
measurethe
10 mm (0･39 in)
piston
Or
rJng gap.
痩
MeasurJng Point@.- 120 mm (4.72 in)
Ifthe piston rlng gap exceeds the specified fimit′the

0
piston rmg must be rep(aced･
0
′
●一一-メ
♂ 0
73
Piston Ring Gap mm(in)

Standard L.[mit
0.2-0.35
1stCompressionRing
(O.008-0.014)
0.37-0.52 1.5
2ndCompressionRing
(0.015-0.020) (0.059)
0.2-0.4
OilRing
(0.008-0.016)
Piston Ring and Piston Ring Groove C一earance
Use feeler to the between
圃
a gauge measure clearance
6) the
points
piston
around
ring
the
and the
piston.
piston ring groove at severa[
If the clearance between the piston rlng and the piston

nng groove exceeds the specified ['(m舌t,the pEStOn rJng
must be replaced.
Piston Ring and PJ'ston Ring Groove
Clearance mm(in)
Standard Limit
0.09-0.130
1stCompressionRing
(0.003510.0051)
0.05-0.090 0.15
2ndCompressionRing (0.002-0.0035) (0.006)
0.03-0.07
OJ-[Ring
(0.0012-0.0028)
Visua一ly the piston. (f is
囲
Inspect a piston ring groove
damaged or distorted, the piston must be rep[aced.
74
PrSTON PJN
＼ ′
Piston
Use a
PJ'n Diameter
to measure the
micrometer
画
p】ston pJn OutSt'de
-一一{■ diameter at several points,
Jfthe measured value J's Less than the specified Jimit′the
piston p[n must be replaced.
Piston Pin Diameter mm(in)
誕± Standard
33.995-34.000(1.3384-1.3386)
Limit
33.97(l.3374)
Piston Pin and Piston CJearance

∈∋ Use inside diaI･indicator to the
圃
an measure
piston pln
hole (in the piston).
Piston Pin Ho一e
mm(in)
Standard
34.004-34.012 (1.3387- 1.3391)
Piston Pin and Piston Pin Hole

CJearance mm(in)
0.004 -
0.O17 (0.0002 -0.0006)

Piston Pin and Connecting Rod SmaIT End Bushing
Clearance
Use a caJiper ca=brator and a dial indicator to
㌔ measure
圃 the piston pln and connecting rod smaH end bushing
T 虻ゴ( clearance.
1fthe clearance between the piston pln and the connect-
mg smaH end bushing exceeds the specified h'mit,
rod
replace the piston pin and/or the connecting rod
a bushing.
Piston Pin and Connecting Rod Sma=

End Bushing Cfearance
mm(in)
Standard Limit
0.008-0.020 0.05
(0.0003-0.0008) (0.OO2)
Connecting Rod Bushing Replacement
Connecthg Rod Bushing Removal
E] 1. CJampthe
2. Use
connecting rod J'n dvise.
the connecting rod bushing to
団
remover remove
the connecti｢唱rOd bushin9.

Connectin9 Rod Bushing Replacer
75
Connecting Rod Bushing lnstaHation
巨) 1, CFamptheconnecting rod in av盲ce.
2. Use the rod bushing暮nSta‖er insta,I
団
connecting to
∼ the connecting rod bushhg.
Connecting Rod 巨ushing Repl∂cer:
3, Use a piston pin hole with

grinder①fitted a reamer
⊂= ①to ream the piston pin hole.

モ＼
墜
Inner Diameter ofSmaJJ End Bushing
mm(in)
＼
Standard
F= 34.008-34.015 (1.3389- 1.3392)
迄』
き謬
､･ー.==
_
､
-￣･●
I ′--･
'＼.ゝ-＼_
CONNECTING ROD
Connecting Rod A)ignment

iTq
Use a connecting rod a[jgner to measure the distortion
E7 ∩
圃 and
hole
the
and
paraHelism
theconnecting
between
rod
the connecting
small end hole.
rod big end
過
F:” a
Ll[ 1f either
the
the
specified
measured
limit, the
distortion
connecting rod
or para[FeJism
must
exceed
be rep(aced.
i Connecting Rod Alignment
J｢l
PerLength oflOO mm (3.94in) mm(in)

Standard Limit
0.20
Distortion
0.05orLess (0.008)
(0.002) 0.15
ParalleJJ'sm
(0.006)
76
ENGfNE ASSEMBLY (2 )
ConnectJrng Rod Side Face Clearance

1. hsta‖ the connecting rod tothe crankpin.
Use a fee(er gauge to measure the
園2`
clearance
betvveen the connecting rod big end side face and
the crankpJ'n side face.
Jf the measured value exceeds the specified Limit,

つ the connecting rod must be ｢eplaced.
Connecting Rod and Crankpin SJ'de Face

Clearance mm(in)
Standard Limit
0.175-0.290(0.0069-0.0114) 0,35(0.014)
JDLER GEAR SHAFT AND IDLER GEAR
ldrer Gear Shaft Outside Diameter
Use to the idler gear
圃
a measure
micrometer shaft out-
こ⊃
side diameter.
Jfthe measured vaJue is Less than the specified limit, the
idle｢ gear must be replaced.
rdfer Gear Shaft Outside Diameter

mm(in)
Standard Limit
44.95-44.98 44.90
(1.769-1,770) (1.767)
77
Jdler Gear ''A” ]nside Diameter
1. Use inside dia一 indic ator to measure the idJer
囲
an
gear
Jd]er Gear Inside Diameter mm(in)

Standard Lim)'t
45.0-45.03 45.10
(1.7717-1.7718) (1.7756)
If the between
clearance the id一er gear shaft outside
diameter and the id(er gear inside diameter exceeds the
limit, the id一ergear must be replaced･
[drer Gear Shaft and JdJer Gear

C一earance mm(in)
Standard Limit
0.025-0.085 0.2
(0.0010-0.0033) (0.008)
[d]er Gear ''B”
Bearing replacement
I
圃 Usea
Bearlng
suitable barand a
amount
bench press
be
orhammer.
within the
Pro)'ection shou[d spec-
⑦
] I
腔 ① ified height.
+_ mm(in)
Projection① 0.4-0.6(0.016-0,024)
Height② 23.7-24.0(0.933-0.945)
TIMING GEAR CASE COVER
Replace the crankshaft front oil sea一 if it is excessively

worn or damaged.
Crankshaft Front Oil Seat Rep一acement
OjJ Sea暮RemovaI
回 Use p一astic hammer

a and
the oi[ sear to free itfromthe
a
screwdriver
gearcase･
to tap around
∈‡∋
Take care not to damage the oi一 sea暮fitting surfaces.
潤
監萱薗
■■■ー...I
､ヾ苛
琶萄
78
OiI Seat InstaHation
回 l･ AppJyacoatofengfne
ference.
Oi一 to the oil sea川p circum-
○
I-ヽヾ
仏､
目 21 Use the
insertthe
oil searinstalfer and
oi一sea一 1 mm (0･039
the insta(Jer
in) intothe
gn'p to
front poト
園 tion of the timln9 gearCaSe.
敬S
OiJ Seal lnstafJer: 5-8840-2061-O
79
MEMO
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80
SECT10N 5
TABLE OF CONTENTS
JTEM PAGE
ReassembJy....-‥‥..---,....---------...------‥‥‥‥‥‥. 82
81
国 REASSEMBLY
SINGLE UNIT
3 2
冒 A
? 1
ni
トミ皇⊂i
kJ
冒
♂
㊨
@
”
匂払
P)ド
7
ReassembTy Steps
▲ 1 Rocker arm shaft 5. Rockerarm

2 Rocker arm shaft snap ring 6. Rockerarm shaftspnng
3 Rocker arm 7. Rockerarm shaftsnap ring
4 Rocker arm
shaft bracket
82
1. RockerArm Shaft
l) Position the rocker arm shaft with the large oil

hole (Dial 4 (0･136 in)) facingthefrontofthe
脚m㈹?
mm
en9Ine･
2) Jnsta[r the rocker-arm shaft together the

with
rocke｢ arm′ the ｢ocke｢ arm
shaft bracket′ and
the sp｢1ng.
｢￣￣ヽ
l￠q
83
CYLINDER HEAD
7
---------8
6一･J暫
3
---一･8
2
--一･･(亘)
f
冒
廼 U
C1
玩
O
く⊃
U
鮎
′
ヽ O
撫
′＼
P
莞轡
a;
e]
節
O
◎
I
t G) e3
I
Reass￠mbly Steps
1 Cylinder head 5. Va(vesprJng

2 Valve 6. Valvesprln9 uPPe｢Seat
sprl咽】owerwasher
▲ 3 VaJve stem oil seal 7. Splitcollar
▲ 4 Intake and exhaust valve
84
3. VaJveStem Oil Seal
l) AppJya coatengine oilto theoi[ seat inner face.
し_ J
′ 巨I 2) Use an oil sear
the va[ve guide.
instaHerto instaH the oil seal to
ノー--一一
園 Oil Seal lnstaI[er: 5-8840-2033-0
I一一-￣￣￣￣■ー一･･･一･一:I
零軍奈軍
コ≡守一
(A ｢[ ｢¶ 三野-
A. Intake and Exhaust Valve
l) App]yacoatofengine oil tovalvestem.
日 2) JnstaJI the intake and exhaustva]ves.
3) Turn the cylinder head up to盲nstaIJ the valve

SPrlngS.
Take care motto allow the installed va(ves to fa[(

free.
5. Valve Spring
l) Turn the cyrinder head up to install the va一ve
回 SPrJngS･
2) JnstaI‡ the va)ve springs with the fine

pitched
end (painted pink) facing down.
Take care notto the instafJed va)ves to faJ[
allow
free.
7. SpfitCo[Lar
l) Use the spring compressor to push the vaFve
園 sprng into position.
SprlJng Compressor: 9-852311423-0
2) 1nstallthe sp榊coIIa｢tothe va一ve stem.
3) Set the spfit col[ar by tapping around the bead
請
ク･■￣￣
ofthe collarwith a rubber hammer,
LS Ft C
qh
蔓豊ミ
85
PISTON AND CONNECTING ROD
∈∋
_ノ
C5
㌶､､
くっ
u
星＼ ∼
ReassembJy Steps
▲ 1 Piston 5 Piston pln Snap rmg

▲ 2 Piston pln Snap r[ng ▲ 6 Piston r[ng
▲ 3 Connectinョ rod ▲ 7 Connecting rod bea｢lng
▲ 4 Piston pJn
86
1. P;stoれ
∈≡∋ ■ t
2. P盲ston p]n snap rJng
3. Connecting rod
l) CJampthe connecting rod in a vise.
Take care ロotto dama9e the con=ectir唱rOd.
) 2) Use a pairofsnap instaffthe
団
ring p[iersto piston
pln Snap ring to the piston.
3) ]nstal] the piston to the connecting
回
rod.
①
The piston head front mark ① and the con-
necting rod I'fSUZU” casting mark @ must be

facing the same direction.
㊤
②
4. Piston pln
l) Apply a coatofengine
o‖ tothe piston pin and
the piston pin hoFe.
(S
2) Use your fingers to force the into the
日
piston pin
piston untit it makes contactwith the snap nng.
3) Use your fingers to force the piston pin snap

nng 'TntO the piston snap ring groove,
4) Check that the connecting rod moves

smoothly
onthe piston pm.
C]
87
6. P盲ston Ring
⑦ Use ring replacer to instal( the three
回1'
a piston
∈遜 piston rJngS.
/
/
Piston RJ'ng RepJacer:
さ､紛 [nstall the

piston nngs in the order shown in the
＼蒜
‖ustration.
① OJ-fring (Coil expandertype)
① 2nd compression ring (Taper undercut type)
③ 1st compression ring (Barrel face type)
Note:
Install the compression rings with the stamped side
回 facinョ
fnsert
uP.
the expander coif into the oiJ rlng groove SO that

there is no gap on eitherside of the expandercoir before
instal[ing the o盲I rLng.
2) Apply engine o‖ tothe piston ring surfaces.

日 3) Check
the piston
that the piston
r]ng grooves.
rings rotate smoothly in
7. Connecting Rod Bearlng
Carefully w(pe any oil or other forelgn material from

the connecting rod bearing back face and the
connecting rod bearlng fitting surface.
88
CAMSHAFT, CAMSHAFT TJMJNG GEAR. AND THRUST PLATE
@1.
刀
港
RS
ES A
Reassembry Steps
l. Camshaft 3. Thrust p一ate

2. Feathe｢key 4. Camshafttiming gear
89
4. Camshaft TJ'm盲ng Gear
l) JnstaJJthethrust p]ateO.
2) App]yengineo‖tothe boltthreads①.
E] 3) lnsta‖ the camshaft
mark stamped side
timing
facing
gear
out.
with the timing
回
@&願
Camshaft Timing Gear Bo一t Torque N･m(kgf･m/Jb.ft)
98-118(10-12/72-87〉
90
MEMO
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91
国 REASSEMBnr
2
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tQ
p電汁*-1
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F=
冒/
8 13
A
14
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l Iヰa
笹
リ担i
10
醐
且
6頂
1垂虹 ll
16a
/
1
A
★ Repair kit
Reassembry Steps -
▲ 1. Cy=nde｢ body ▲ 10. Connecting rod capwith lower beanng
▲ 2. Tappet ▲ ll. OHpumpwithoi】 prpe

^ 3. Crankshaft upper bearln9 ▲ 12. Crankshaft rear oil seal
▲ 4. Crankshaft with crankshaft timlng gear ▲ 13, Flywhee=10uSln9
▲ 5. Crankshaft thrust bearlng ▲ 14. F】ywheel
▲ 6. Crankshaft bearing cap with 】owe｢ 14a Rear flywhee=げso equipped)
bea｢in;I ▲ 15. Oilpan
▲ 7. Timing gearcase
▲ 8. Camshaft with camshafttiming gear Inverted Engine
and thrust plate

▲ 9. Piston and connecting rod with upper
bearing
92
ENGtNE ASSEMBLY (3 )
/′1
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/ 冒
ド
㍗
曾 17
★ I
短ミ
------令
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冒
ll
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討
L-I;
10
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( 遠野戸丁
チ+
L#3フ/二
琴モ O
亡)
O
o
8-★
★
a
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♂
読 ♂
琶∋
(J /
フ芸≦
ゝ､､
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rl
S
★ Repair kit
Reassembly Steps -
2
▲ 1. [dJer gear 10 Push rod

shaft
▲ 2. [d]er gear ''A” ▲ ll Rocker arm shaft and rocker arm
▲ 3. Idle｢ gear `甘′ ▲ 12 Water pump

4. Timlng gearOi) pJPe ▲ 13 Thermostat hou引咽
▲ 5. Timlng Case cover 14 Water by-pass hose
6. Timing gear case cover ▲ 15 Glow plug and g一ow p山g connector
▲ 7. Crankshaft damper pu[(ey with dust sea一
seal ▲ lnjection nozzle holder

▲ 8. Cylinder head gasket Cylinder head cover
^ 9. Cy一inder head
∇ Jmportant OperatJ'ons (ReassembJy Steps-1)
1, Cylinder Body
Use compressed air to thorougMy clean the inside

∈慧田
∼
∫
and outside surfaces of the cy一inder body, the oil

呈⊂二三
∈∋
こ∋
holes. and the water jackets.
ヽ. ∼
.Je
屯
∋クノ
一旬 L. d2
,Q
2. Tappet
l) Apply a coat of engine oi) to the tappet① and
日 bodytappet insert holes ①.
㌔
the cylinder
2) Locate the position mark applied at disassemb(y
(ifthe tappet is to be reused).
Note:
The tappet must be installed before the camshaft,
3. Crankshaft Upper Bear[ng
The crankshaft upper bearJngS have an

oi=10le and
U
an oil groove. The lower bear[ngs do not.
?
t) ∼ l■
亡 1) CarefuHy foreign from the
E5]
wJ'pe any materia[
し.
bearing
I
JJ すしべ . i/- c｢ankshaft upper and the crankshaft

beanng fitting surfaces.
# upper
a 令也 2) Locate the position mark applied at disassembry
U ifthe removed crankshaft upper bearJngS are tO
U
be reused.
4. Crankshaft with Crankshaft Tim;ng Gear
AppJy an ample coat of engine Oil to the crankshaft
E] )ournaFs
insta[Fing
and the crankshaft
the crankshaft.
bearfng Surfaces before
Note:
Do not apply eng∫ne Oil to the bear[ng back faces the
and
cylinder body bearJng fitting surfaces.
94
ENGINE ASSEMBLY ( 3､)
5. Crankshaft Thrust BearJ'ng
l) App一y anample coat of engine oiJ to the
日
/ crank-
shaft thrust beanngs.
て
./I-
2) Ensta= the crankshaft thrust bearhgs to the
回
一￣￣￣￣- -■･._.■-_
crankshaft center )ournal.

/
The crankshaft thrust bearing oil groove must
be facJ'ng the s=ding face.
ヽ.
!?I/ J
亡1
6. Crankshaft Bear∫ng Cap with Lower Bearlng

ヽヽ.__′
○ l) Apply searant TB 1207B or

equivaJant to the
-
body No･ 5 bearing fitting

6) ○
cy=nder cap surface
atthe points in the ilJustration.
shovvn
○ Note:
∈ Be sure that the beanng cap fittJ'ng surface is completeJy

也 ♂ free of oil before app[ying the silicon adhesive.
l■==■
三■ _一一
Do not allowthe to obstruct the cy[inder

siJicon､adhesive
thread holes and bearl咽S.
2) Jnsta(I the bearing caps.
0 O t〕
○ 回 The bea｢l｢唱CaP
f｢ont of the en91ne.
a｢｢OW marks must be facin9 the
The arrow mark J'ournaf number must corre-
spond to thejournaJ to which the beanng cap IS
installed.
ぐコ ⊂〉
＼ Note:
o O 0 0
2 3 Nile 5 The No. beanng does have

4journar cap not a number
stamped on it.
3) App一y a coat ofengjne oi一 to the bearJ-ng cap
メ. E] bolts.
4) Tighten the
crankshaft bearing cap bo[ts to the
国 specified torque
shown
a =ttle
in the illustration.
at a tJ'me in the sequence
㊨ ① ①
① ① Crankshaft Beanng Cap Torque N･m(kgf･m/Jb.ft)
157-177(16-18/116-132)
①①
① ⑩
○ 5) Check to see that the crankshaft turns
smoo仙y
by rotating it manua[[y.
7. Timing Gear Case

0
l) Tighten the timing gear case with timhg gear
国
○
璽窮璽ョasket to the specified

case torque.
0 o
0
Timlng Gear Case Bolt Torque N･m(kgf.m/Ib.ft)
き窃
○
軒
14-24(1.4-2.4/10-17)
り
0
軒
○
2) Cut away any excessive flash from the timing
0
0
0
● 0
gear gasket.
0
95
8. Camshaft wI'th Camshaft Timing Gear and Thrust

PJate
l) App一y a coat of engine oil to the camshaft and
巨I
○
the camshaft bearlngS.
㊨ OOO 2) 1nstal( the camshaftto the cyfinder body.
Take care not to damage the camshaft bearJngS.
3) Tighten the thrust to the torque.
国
⊂) plate specified
ql Cl
q 0
Thrust PJate Bo[t Torque N･m(kgf･m/fb.ft)
14-24(1.4-2.4/10-17〉
4) Check to see that the camshaft turns smoothly

by rotating it manual一y.
9. Piston and Connecting Rod with Upper Beanng
⑦ 10. Connecting Rod Bearing Cap with Lower Bearmg

■
1) Apply oi一 to the
占
a coat of engine circumference
日 ofeach piston rmg and piston.
2) Position the piston ring gaps as

shown in the
ll②
匡I ‖ustration.
① 1st
compressi?n riTg
@ 2nd compressJOn rlng
③Oi川咽
3) App(y a coat of molybdenum disulfide grease to
the two piston skirts.
This wilJ fac=tate smooth break-in when the

engine is first started after reassembJy･
③'yヽーJクも①
4) Apply a to the bearing
冒
coat of engine oH upper
surfaces.
Note:
E] Do
connecting
notappryengJne
rod
Oiltothe
bear[ng fitting
beanng
surfaces.
back faces
andthe
5) App[yacoatofengine oiJtothecy[inderwaJ[.
96
6) Position the piston head front mark so that it is

facing the front of the cylinder body.
I-i T
7) Use to
団
a piston compressor
3 a
ring compress the
pjston rings.
13
哲
刀 Tr一
l
PJ'ston Ring Compressor
8) Use a hammer grip to push the piston J'n until
⑦
00
〇 the connectin9 rod makes contact with the

}
O 戸モ crankpin.
At the same time, rotate th岳cran七s11aft until the
cr8nkpin is at BDC.
9) Instalr the connecting rod bearing

囲
I I ∼ caps.
′
∼＼ I The bearlng Cap front marks must be facJ'ng the

front of the englne.
磨
∫
The bearing cap (at the sJ'de
number of the
bearing cap) and the connecting rod number
β must bethe same.
l
∼
I
l Note:
o⊂ノO ノ [t is absolutely bearing
0
essential that the caps be
installed in the correct direction･ ReversJng the beanng
cap direction w‖ result in serious englne damage.
10) App一y oil to the threads
回
a coat of engine and
-一----I-I-
setting faces of each connecting rod cap bolt.
11) Tighten the connecting rod caps to the岳pecified
国 torque.
周刀I
Connecting Rod Cap Bolt Torque N･m(kgf･m/Ib.ft)
三J
= =
○
27-31 (2.8-3.2/20-23) -45c-Goo
■■
0 く】 0 ○
Q
壱
Cjj
○
′_ヽ
97
ll. OiJPumpwithOit Pipe

Jnsta‖ the oir pumpwith the oil pJPe and tighten the
bolts to the specified torque.
lI Oil Pump Bolt Torque N･m(kgf･m/Ib.ft)

14-24(1.4-2.4/10-17)
I
l
[ Note:
J i
-
O
J宮- L> ○
Take care not to damage the 0-rings when tightenFng

=JLt4Pnq the oil pfPe bo一ts.
12. Crankshaft Rear Oil Sea一 (AxiaT Type)
ド 12.5士0.3
1) Tighten the adapter
2 bolts.
to the crankshaft rear
and
section with
2) Jnsert the oil seal into the peripheraJ section of
adapter.
3) Insertthe s一eeve into the adapter section, and 1)
tighten itwith a bolt(M12x 1.75L=70) until the
adapter section hits the sleeve,
4) Remove the adapter and the s一eeve.
5) Withthesea[ pressed in, checkthe dimension of

the oil sear section.
Standard Dimension = 12.5 ± 0.3 mm
(0.492 ± 0.012 in)
OiJ SeaHnstaHer: 518840-2359-1
13. FIywhee=1ousJng
L5
6 勺
8 10 l) Apply to the area in the
sealant shaded shown
3
9
5
固 2)
i]Iustration.
Tighten the frywheer housing bolts to the speci-
国
匂
fied torque a Jitt】e at a time in the sequence
削
鰐
2
in the ilEustration.
7 〇 shown
Flywhee] Hous[ng Bo[t Torque N･m(kgf･m/1b.ft)
MIOxl,25 35-45(3.6-4.6/26-33〉
E) こ滋
4 M12xl,5 74-91(7.5-9.3/54-67)
98
14. FJywhee]
1) Blockthe flywhee( with a

piece of wood to pre-
vent it from turn'rng.
2) App(y a coat of eng'fne OI.Jto the threads of the

●ヽ
●
●一
8
E] 3)
ffywheeJ
Tighten
bolts.
the f[ywheel bo一ts in the numericaf
5@ 国 F(ywhee[
order shown
Bolt Torque
in the ‖ustration.
N･m(kgf･m/Jb.ft)
113-123 (ll.5-12.5/83-90)
15. OiJPan
l) App一y sealant TB 1207B the

a
-
or equJ'va[antto
つ
a No. 5 beanng cap arches, the bear[ng grooves,
0
and the timlng gear Case arches atthe positions
○ ○ shovvn in the i[lustration.
･11
D
昏
○ ⊂ 也
らノ
()o()
2) Fitthe gasket rear =pped portion into the No. 5

bearJng Cap groove.
Be absoruteJy sure that the ripped portion is

∩ fitted snug一y in the groove.
01)00 t)dOocI
｢￣￣■￣￣￣￣丁･ヽ
_D oO
○
＼ C
○
I
4
l
D D D
､?
I
0
○
0
㌫ ○
0
3) TI'ghten the oil pan boJts to the specified torque
@
也
重要
軒＼ ○
①
a little at
=ustration.
a time in the sequence shown in the
Oj] Pan Bolt Torque N.m(kgf･m/fb.ft)

き孝＼
① il!
/ ”
14-24(1.4-2.4/10-17)
&＋ id
99
∇ Jmportant Operations (Reassembfy Steps-2)
1. [d)er Gear Shaft

J
/ ;3b(i
O :三=1
J
回 The idrergearshaftoil hole must be facing up.
〕
○
Ⅶ 3 つ
ノ
つ -
2. Id)erGear ”A'r
l) Apply engine oi一 to the idlergear① the
巨】
and
① ⑦
id[ergearshaft(致.
2) Position the idJer gear setthg marks ``X” and
回 ``Y′′so that they are facing the front

of the
⑳唱
englne.
3) A[ign the idler gear 'JX” setting the
国
mark with
一一Yl′
crankshafttiming ”X-X” setting mark.
gear③
珍 4) AIign idler gear
the ''Y” setting mark with the
㊨ 0
0
0 国 camshafttiming
5) Tighten the
gear④ 'JY Y” setting
id[er gear boJt
-
to the
mark.
specified
○ torque.
○ ヰ･
1dler Gear ”Ar'Bolt Torque N･m(kgf･m/7b.ft)

0
0
一■X'' 21-30(2.1 -3.1/15-22)
3
3. 1dlerGear ''Bw
l) Apply engine oil to the idler gear and the idler

gear shaft.
2) ATign the idler ”Z” setting
0 o (】
囲 gear⑤ markwith the

○ ○
idlergear① ''Z” setthg mark.
○
㊨
ldJer Gear ''B”BortTorque N.m(kgf･m/Jb.ft)
○顎
国
HZ'′
○
93-113(9.5-11】5/69-83)
○
100
5, Thing Case Cover
l) Before insta=ng the timing gearcase′ appJy a 3

mmx5mm (0･12 in xO.20 in) strip ofsealantto
馳､>､J ∼
Si
the
arrow
portion
in the
of the feather
iHustration.
key indJ-cared by the
2) Checkthatthe timing case cover O-ring is fJ'mlly
o?-63ゥ inserted into the gear

Tighten
case groove.
bolts
3) the timing to the
国
case cover speci-
fJ'ed torque.
TimJng Case Cover Bolt Torque N.m(kgf･m/Fb.ft)
M8xl.25 14-24(1.4-2.4/10-17)
○■
￣#&/(
Q.Q..---○
M12xl.25 65-85(6.7-8.7/48-63)
7. Crankshaft Damper Pu[rey with Dust Seal
1) BlockthefJywheel ring gearwith a piece of

wood to prevent it from turninョ.
2) Tighten the crankshaft damper puFley to the
国 Crankshaft
specified
Damper
torque.
Puf[ey Bo(t
Torque N･m(kgf･m/1b.ft)
197-240(20.1 -
177)
-24.5/145
Take care not to damage the crankshaft damper
pu=ey boss.
8. Cylinder Head Gasket
l･ Carefully deposits
圃
remove carbon and gasket
residue from the piston top face the
く=∋ and
t^/y
cylinder body upper surface.
∈∋
101
2. Use a dial indicatorto measure the piston head
○ projection at measuring.points ① and ③ on the

Ooo
也 0 0 piston head and measurLng POints ① and店) on
○
0 the cy=nde｢ body.
0
Do this for each cy=nder.
○
③ ●-- ① Notethe
3. highest measured value.
○
This w= determine the cylinder head gasket
○ ○
Oo thickness.
○ Piston Head Projection mm(in)
0.758-0,913 (0.0298-0.0359)
Piston head must be within the range

projection
shown in the abovetabJe.
4. Select a cy=nder head gasket of the appropriate

ぐコFront thickness.
TOP
The difference between the highest measured
head the Lowest
@
㊨ 'LtV<3工二:芳
珍 piston projection and measured
piston head must not exceed mm(in).
○ projection
Ej E3 mm(in〉
Grade Averagepiston Gasket
g5= mark projection

thickness
(Reference)
o;FIB
0 0 ○
A ZZZZZZ 0.758-0.812(0.0298-0.0319) 1.60
Grade mark
B Za 0,813-0.858(0.0320-0.0337) 1.65
C ZZa2ZZ 0.859-0.914(0.0338-0.0359) 1.70
5. The cylinder gasket ”TOP” mark must be facing
UP･
9. Cy一inder Head
l) A=gn the cylinder body dowels and the cy一inder
囲 head
CarefuETy
doweJ
set
ho)es.
the cyI'fnder head to the cylinder

head gasket.
2) App[y engine oil to the cylinder head fixing bolt
日 threads and setting faces.
3) Tighten the cy=nder head bolts to the specifJ'ed
国 torque
order shown
lLn
three steps
in the川ustration.
foHowJng the numerical
暦1o3｡9o5｡.o4 Cy=nder Head Bolt Torque N.m(kgf.m/1b.ft)
000
8き2恩
○ 1ststop
44-54
2ndstop
60-75o
3rdstop
60-75o
7Or15
苧o14Tlo｡′2o (4.5-5.5/64-78)
ll
u､63 Ll
102
ll. RockerArm Shaftand Rocker Arm
Tighten the rocker arm shaft bracket bolts in the
国 numericaJ
RockerArm Shaft
order shown
Bracket
in the ‖ustration.
Bo什Torque N･m(k9f･m/lb.印
49-59 (5.0-6.0/36-43)
eSi
B5;
Q)
12. Water Pump
l) Temporarily tighten the water pump bolt
marked with an arrow in the川ustration.

〇 This
0 boJt w川be tightened to the specified to
岱ヂ torque
instal[ed.
when the a[ternator adjusting plate is
@ ＼留
Cl
国 Water
2) Tiョhten the
fied torque.
Pump Bolt Torque
othe｢water pump bo一ts to the specト
N.m(kgf･m/1b.ft)
14-24(1.4-2.〟10-17〉
13. Thermostat Hous∫ng
l) lnstarl the thermostat housing.
2) Tighten the thermostat housing bolts to the
国 Thermostat
specified
Housrng
torque.
8o[t Torque Jリ･m(kgf･m/fb.ft)
14-24(1.4-2.4/10-17)
15. GJowP[ug and G[owPJug Connector
l〉 Tighten the gJovv pfugs to the specified torque.
国 G(ow Plug Torque N･m(kgf･m/Jb.ft)
15-20‖.5-2.0/ll-14)
2) 】nstall the ;‖ow plし唱COnneCtOrS.
16. lnjectionNozzle Holder
l) (nstall the hjection nozzle gasket ① and the O-

ring @to the injectionnozzle hofder@.
2) 1nsta[1 the nozzle holder ③ together with the
nozzle holder bracket①to the cylinder head.
3) Tighten the hoJder nuts with washer ⑤ to the
国 specified
Injection Nozzle
torque.
Holder Nut Torque N･m(kgf･m/[b.ft)

31 (3.2-4t4/23-32)
-43
103
㌍(磨
R
『意鮎C2
し覇気蘇議
i#
ミ一覧愈
104
ll 13 17 7 6
∩∩
⊂】
I
畠 I
I
l
し+
○
l I ○
.L･1
■￣○
C3 ○ 十I l
√･
+ l
:L･1
l
i
○ (
Oo( l
L
Lt
I
e :諺
ooEjo夢㌢
●
＼ゝ
15 16 20 12 14 18 19 102120
Reassembly Steps -
▲ 1 lntake manifo一d ▲ 10- Starter

▲ 2 fnjection pump ▲ ll. Exhaust manifo7d
▲ 3 Fue[ injectionpIPe With c(ip 12. Cooling water intake pJPe
4 Fuel Leak off pipe 13. CooHng water rubber hose
5 Oil pipe (Jn)'ectioりPumPtO Cylinder ▲ 14. Alternator and adjusting plate
body) ▲ 15. Oil fiJter
6 Fue一 filter 16. Oi一p｢essu｢e switch
7 Fuel pipe (Fuel filterto leakoff) 17. Cooling fan drive pu)rey
8 Fuel pipe (Fue[ filtertofeed 18. Cooling fan drive belt
pump)
9 Fue[ pipe (Fuel fi(terto injection 19. Cooli｢唱fan and space｢
pump) 20. Stiffner (RH a LH)
21. Air breather hose
105
ENGINE ASSEMBLY( 3 I
∇ Important Operations (ReassembTy Steps-3)
1. Intake Manifold
lnstall the intake manifo一d the end hav-
回
gasket with
ln9 the the front
sharp co｢nersfacin9 of the en91ne.
'1j. ⊃oouruo
Li)c,oーノO ooニ′OQQQ
oooぜ) -o-@9-teo碇eo雪害
乙::⊃
2. [nject;on PLJmP
l) Turn the crankshaftsfowlyclockw盲seto the
囲
a=gn
0
camshaft timing check ho[e pointer ① with the

0
□ camshafttiming gear ”ou

珍 mark@.
◎
㊨
2
0
2) JnstaTl the injection pump to the timing gear
#. CaSe.
A‖gn the injection timing hole
圃
○ pump check
モこ＼
O pointer③with thetiming 9ea｢”○′'mark④.
3) Temporari一y tighten the injection pump bracket
U
○ bolt⑤.
This bolt w川be final一y tightened injec-
after the
㊦ tion pump rear bracketbolts⑥.
4) Tighten the injectionpump rear bracket boJts to
固 the
InjectionPump
specified
Rear
torque
Bracket
@.
Bolt
Torque N.m(kgf･m/Lb.ft)
4
㌔
/
/
14-24(1.4-2.〟10-17)
5) Tighten the injection pump bracket boft⑤to the
specified torque. ､
#iLa
㌔
Injection Pump Bracket Bo一t Torque N･m(kgf･m/Zb.ft)
㊨
14-24(1.4-2.〟10-17)
106
6&
ン′二
＼
/
覇
酌￠ダ
`曲
3, Fuel JnJ.eCtion Pipe Clip

with
l) Temporarily tJ'ghten the injection pipe s[eeve
nut.
2) Setthe clip in the prescribed position.
Note:
Make absoZute】ysure thatthe clip JS COrreCtfy positioned.

An improperly pos'ltioned c一ip w川result in pJPe
Injection
breakage and fue一 pulsing noise.
3) Tighten the injection pIPe

国
Sleeve nutto the
specified torque.
Injection Pipe S[eeve NutTorque N･m(kgf･m/Ib.ft)

20-39 (2.0-4.0/14-29)
d@dF
I,./
g..･1.1t･配c.･:'/
10. Starter
Tighten the starter bolts to the torque.

specified
Starter Bo[t Torque N･m(kgf･m/Ib.ft)
65-85 (6.7-8.7/48- 63)
ll. Exhaust Manifo[d
Tighten the exhaust manifo一d bolts to the specified

国 torque
in the
a ljttleat a time in the numerica一 ordershown
iHustration.
Exhaust Manifold BoltTorque N,m(kgf.m/[b.ft)

⑦ ⑨ ㊨
14-24(1.4-2.〟10-17)
3
107
14, Alternator and AdJruSting plate
Tighten the bolts and the plate

alternator adjusting
国 bolts
Alternator
to the
Bolt Torque
specified to｢que･
N･m(kgf.m/lb･ft)
14-24(1.4-2.〟10-17)
Tighten the plate bolts to the specified

adjusting
国 torque
Adjusting
after cooling
Plate BoTt Torque

drive belt J'nsta[Jation.
N･m(kgf･m/Jb.ft)
14-24(1.4-2,4/10117)
15. Oil Filter
Tighten the oi=ilter bolts to the specified torque･
国 Oi==i[ter Bolt Torque N･m(kgf･m/]b.ft)
14-24(1.4-2.4/10-17)
Sofenoid
巨∃ l) lnstafl the so[enoid, connectthe fink rod vvith the
什 stop lever on the in)ection pump, and semi-
帖
-1.2mm tighten the fixing bo[t.
○
2) Adjust the soJenoid instarJation so that the gap

between the stop leve｢ and stopper on the
0
pump is broughttowithin 0.7- 1,2 mm
○
0 @ lnjection
○ when the soJenoid valve is energized on.
3) Tighten the solenoid fix'(ng bolts to the specified

torque.
l
4) With the engine running on trial, be sure that
solenoid 6) the englne is stopped, when the starter svvitch is
⊂1 turned to off position.
O ⊃
TVA
Fixing bo7t
108
LUBRICATING SYSTEM
SECT!ON 6
LUBRICATING SYSTEM
TABLE OF CONTENTS
ITEM PAGE
Maindataandspecjfications ‥..‥‥‥‥‥‥...‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥.. 110
Genera】description...‥‥‥･=‥‥...,.I.-----I---=‥-‥‥‥,.‥‥‥. 111
0iTpump-------.,--------･･･L･･･---.･‥-.-I,‥‥‥‥‥=.. 114
0ilfi[terwJ'thbu=t-inoi[coo)er...‥...‥‥‥‥‥‥,...‥.‥.‥‥‥‥‥‥.‥‥‥.,. 117
109
LUBRICATJNG SYSTEM
MAIN DATA AND SPECJFICAT10NS
Item 4JGl
Oi[pumptype Trochoid
DeLiveryvoJumeLjt(qts)/min･ 17.5(18.4)
Pumpspeed 1000
DeliverypressurekPa(kgf/cm2/psi) 392(4.0/57)
OiltemperatureoC(oF) 47-53･(116,6-127.4)
EnglneOi[ SAE30
Oirfi(tertype FuIZfJowwithcartridgepaperelement
ReguJatingvalvekPa(kgf/cm2/psi) 420-460(4.3-4.7/6l-67)
OPenlngPreSSure
RefiefvalveopenlngkPa(kgf/cm2/psi) 79-118(0.8-1.2/ll-17)
Pressure
OilcooJertype(ifsoequipped) VVater-cooled
safetyvalveopemngkPa(kgf/cm2/psi) 225-265(2.3-2.7/33-38)
Pressure
110
LUBRrCATJNG SYSTEM
GENERAL DESCRIPTJON
LUBR[CATING 0)L FLOVV

This iJlustration is based on 4J Series engine with oi. coo一er (option).
Lubricathg oil flow may vary according to the engJne specification.
L-Ba-”-er-y
Wa｢nlng
1
I
-
Light
Oil pressure switch
Cy=nder b一ock oil ga(Iery
ldFe gear
Oil fjJter shaft
∩
Filter cartridge
Vacuum
｢ [
Crank shaft Camshaft
be即m9 bearin9 Pump
Main flow
+ oi一fi一ter Oil pipe
] Rocker arm
shaft
Re[ief vaJve
Connecting
卜
(98±20kPa)
rod bea｢ln9
1lming Rocker arm
ge8｢S
OiI ≡烹1 (at;n g

vRaelgvUe
(441±20kPa)
Oi一 strainer
Oil pan
The 4J Series engJne lubricating system is a fu‖ forced circulation type.
Lubricatl-ng oiE is pumped from the oif pumpto the cylinder bodyoil gal]erythrough the oi一cooler and the
is
oiJ flfJter. It then delivered to the vital parts of the englnefrom thecy[inder body oil gaFlery.
111
LUBRICATING SYSTEM
0比PUMP
ク:
4J Series engine are

equ)pped with a trochoid type o盲Ipump･
112
LUBRICATING SYSTEM
MAIN O比円LTER
√て
ヾ
∫
OIL FllJER WITH BUILトIN OIL COOLER
疏
I
l 1l
I
一{
113
LUBRICATING SYSTEM
OIL PUMP
団 DISASSEMBnr
∈∋ 1
+//
5
＼丘
4＼垂 (⊃
⊂)
a ⊂)
lこ=ノ
a
Disassembly Steps
4. Vane
l.Oil pIPe
A 5･ Pump bodywith rotorand pinion
2. Strainer case
3. Pump cover
114
LUBRJCAT)NG SYSTEM
磨 lNSPECT10N AND REPAIR
Make the necessary ｢epal｢S′ and part replacements if excessive damage is dis-
adjustments. vvear or
covered duri｢唱lnSPeCtion.
Vane, Rotor, Cover CJearance
囲
and
Use a feele｢ gauge to measure the c一earance between
the vane′ the rotor, and the cover.
1f the clearance between the vane, the rotor, and the

the Limit. the (pin,
⊥ cover exceeds specified rotor set
shaft, rotor, and vane) must be replaced.
■■
Vane′ Rotor, and Cover Clea｢ance

mm=n)
Standard
Limit1
0.02-O.07(0.0008-0.0026) 0.15(0.006)
Rotor and Vane CJearance
圃 Use
the
a
rotor
fee一er gauge
and the vane.
to measure the c一earance between
Zf the clearance between the rotor and the exceeds the

specified limit, the rotor kit (shaft, rotor, and vane) must
be replaced.
Rotor and Vane CJearance

mm(in)
Standard Limit
0.14(0.006)orless 0.20(0.008)
Vane and Pump Body CJearaTLCe
圃 Use a fee一er gauョe tO measure the c一earance between
/ゝべ
thevaneandthe pump body.
Jfthe clearance between the vane and the pump body
exceeds the specified Jimit, the ent-Ere Pump assembly
must be ｢eplaced.
Vane and Pump Body C(earance
⊂〕 mm(in)
●
Standard Limit
■l
0.20-0.27(0.008-0.011) 0.40(0.016)
115
LUBRICATING SYSTEM
盟 REASSEMBⅣ
∈∋ 5
+//
1
----応
＼＼垂 ⊂)
⊂>
Q>
く⊃
ヾ=ン
a
Reassembly Steps
4. St柑iner case
l. Pump bodywith rotorand pinion
5.OiFpIPe
2. Vane
3. Pump cover
116
LUBRICATJNG SYSTEM
OIL FILTER WJTH BUILJ･[N OIL COOLER
団 DISASSEMBnl
⊂⊃
JF5
ノ⑳
Disassemb]y Steps
l. Drain p[ug 5. Safety va一ve

2. Cartridge filter 6. Re[iefvalve
oir
3. Oi一cooler 7. Oil filter body
4. 0-ring
117
LUBRICATING SYSTEM
囲 JNSPECTJON AND REPAIR
Make the necessary repalrS, and part replacements if excessive wear or damage is
adjustments,
discovered during JnSPeCtion,
Reguratjng Va[ve
l･ Attach an oil pressure gauge to the oil gallery near
the oiJ filter.

2. Start the engrne to check the regulating va(ve
0 openin9 Pressure.
Relief Valve Open[ng Pressure kPa(kgf/cm2/psi)

421 (4.3-4.7/61
-462 -67)
Oil Cooler
/
Water Leakage At Water Pass;唱e
l･ Plug one side of the oiJ coo[erwater passage.

芦三戸￣￣￣￣￣=￣
2. Submerge the oil cooEer in water.
3･ App[y compressed air (196 kPa (2 kgf/cm2/28 to

psi￣))
the other side of the oi) coolerwater passage.
[f air bubb[es rise to the surface, there is water (ea-
kage.
∨
118
LUBRICATING SYSTEM
国 REASSEMBLY
⊂⊃
JF3
′⑳
Reassemb[y Steps
l. Oi川Iter body ▲ 5.Oi]cooler

▲ 2. Reliefvalve ▲ 6･ 0'r[ fJ'rter cartridge
▲ 3. Safetyvalve A 7.Drainp[ug
4. 0-ring
119
LUBR[CATJNG SYSTEM
∇ Jmportant Operations
2. Regu[ating Vale
A. 園
Tighten the reJiefva(ve to the specified torque.
* a Regu(ating Valve Torque

25-34 (2.5-3.5/18-25)
N･m(kgf.mnb.ft)
t@S 5. 0;[ Coofer
l)Align the oil fi)ter ho一es with the body knock
pJnS at instaHation.
∼/壁 2) Tighten the oi一cooJerto the specified torque.
%Ql 一⑳ 国 Oi] Coo一er Torque
25-34 (2.5-3.5/18-25)
N･m(kgf.m/Ib.ft)
6. Oi[ Filter Carl:ridge
l)AppJyengine o‖tothe 0-ring.

⊂⊃ 1●■ 巨I 2)Turn
1ng face
in the cartridge oi( filter untiJ the filter sea[-
makes contact with the 0-ring.
%Ql 3)Turn in the cartridge

l/4 ofa turn.
oi】filteran additionaf 1 and
7. Dra;nP山9
Tighten the drain plug to the specified
国
torque.
⊂⊃
Drain PIug Torque N.m(kgf.m/Jb.ft)
20-30 (2.0-3.0/14-22)
%Q≠
120
COOLING SYSTEM
SECT!ON 7
COOLING SYSTEM
TABLE OF CONTENTS
IJTEM PAGE
MaindataandspecificatJLons............””･･･L･････,.”･････.･.･”......”..”. 122
GeneraldescrJ-ption‥‥‥‥‥..‥‥‥....‥‥‥----‥.‥--‥‥‥‥‥‥..‥ 123
Thermostat.‥‥‥‥‥‥‥‥‥‥‥‥‥.‥...‥‥‥‥‥‥‥‥‥=‥‥‥...‥‥‥ 125
121
COOLING SYSTEM
MAIN DAm AND SPECIFICATIONS
[tem
Waterpumptype CentrifugalimpeHer
Pumptocrankshaftspeedratio(Tol) 1.1
De=veryvo[umeLit(qts)/m舌n. 100(105.5)
Tola[headkPa 60
Pumpspeedat3000rpm
Watertemperatureat30oC(86oF)
Pumpbearingtype Doub!erowshaft
Thermostattype Waxpefletwithjigglevarve
Valveinitia[openJngtemPeratureoC(oF) 82(180)
Valvefu‖open[ngtemperatureoC(oF) 95(203)
Valveliftatfu=yopenpositionmm(in.) 8.0(0.31)
122
COOLING SYSTEM
GENERAL DESCRIPTION
COOLANT FLOW
●
●
●
- ー
+ + + J
The englne COOh'ng system consists of the radiator, the water pump, the cooling fan, and the thermostat.
To hcrease co)d englne COOJanttemperature for smooth engine operation, the coolant is
quickly circu(ated
by the water pump and thermostat through the by-pass hose and back to the cy】inde｢ body･ The coolant
does not circulate through the radiator.
When the coolant temperature reaches 82oC (180oF), the thermostat wiJ[ begin to open and a graduaHy
increasJng amount Of coolant w川circu(ate through the radiator･
The thermostat win be fuJJy open when the coolant temperature reaches 95oC (203oF). A(I of the coolant is
now circulating through the radiator for effective engJne COOIant･
123
COOLING SYSTEM
VVATER PUMP
J
T†
lF
I( O
ヽノ
0
A
A centrifugal type water pump forcefuT[y circulates the coolant through the coo=ng system･
124
COOLING SYSTEM
THERMOSTAT
囲 INSPECT10N AND REPAIR
Make the necessary repaJrS, and part rep[acements if excessive wear or damage is
adjustments,
discovered du｢ing JnSPeCtion.
Operating Test
1. Completely submerge the thermostat in water.
2. Heatthewater.
Stir the water constantly to avoid direct heat being
appried to the thermostat.
LZ
3. Checkthethermostat initial open[ng temperature.
/① 固 Thermostat lnitia1 0penlng Temperature oC(oF)

@ 82 (180)
4. CheckthethermostatfuFE opening temperature.
SS
囲 Thermostat Full 0penrng Temperature
95 (203)
oC(oF)
帯 Va一ve Lift at Ful[y Open Position mm(in.)
圃 8.0 (0.315)
① The｢mostat
① Agitathg Rod
@ WoodenPiece
125
MEMO
126
FUEL SYSTEM
SECT!ON 8
FUEL SYSTEM
TABLE OF CONTENTS
ITEM PAGE
Maindataandspecifications ･･--------･･----.---･･---･L--･･ 128
Genera[description‥,‥‥----･=-----･･--∴------=----･ 129
lnJ'ectionnozzJe ‥‥=･･--I-----･･･-=-I--------･･･----. 132
137
Jnjectionpumpcaribrationdata---･--･･-I-･････--･･.I---=････---
127
FUEL SYSTEM
MAIN DAm AND SPECIFICAT10NS
Item
lnjectionpumptype BoschAtype
P[ungeroutsidediametermm(in.) 9.0(0.35)
Governortype RSVvariabJespeedmechanicaFtype
FueJfeedpumptype Singfeaction
fnjectionnozzJetype HoJetype
Numberofinj'ectionnozzleorifjces 5
lnjectionnozzleorificeinsidediametermm(”.) 1.0(0.039)
lnjectionnozzleopeningpressureMPa(kg/cm2/psi) 18.1(185/2,630)
MaJ'nfueZfirtertype Cartr'Idgepaperelement
128
FUEL SYSTEM
GENERAL DESCRIPTION
FUEL FLOW
Fue.
filter
Noz2Ie
Water seperator
廿巨 lnJ'ection punlP
Fue[ tank
The fuel system of the fue一 tank′ the water separator (if so equipped). the fuel filter, the injection
consists
pump, and the injection nozzle･
The fuel from the fuel tank passes through the water separator and the fuel fi[terwhere water particles and
other forelgn materia一 are removed from the fuel.
Fuel, fed bythe injection pump plunger, is del'Nered to the injection nozzle in the measured volume atthe
optimum timlng for efficient engine operation･
129
FUEL SYSTEM
JNJECTJON NOZZLE
I
∫
i
J [
I_J
”OZZ [e holder
Ad■Ju sting shirn
I
Spring
Spring seat
リ
fq'ection nozzle R eta lng nut
A hole (with 5 orifices) type injection nozzle is used. 1t consists of the nozz[e body and the need[e valve
assembly.
The in)'ection nozz[e sprays pressurized fueJ from the injection pump into the combustion chamber
through the nozzle body in)'ection orifjce･
130
FUEL SYSTEM
FUEL FILJER AND WATER SEPARATOR
圭
l
Drain Lever
# -`●(44
●
I-r.
■● ●●●●●■一
I
●●●一●
●●●●●･
Acartridge type fue[ fi(ter and a water separator are used･
As inside of the injectionpump

the lubricated bythe IS fue一 which it is pumptng, the fuel must be perfectly
fuel fitter and the water separator remove water partic[es and other forelgn material from the
clean二The
fueE before it reaches the hjection pump.
The water separator has an hterna) float･ When the float reaches the drain level, remind you to drain the
water from the water separator.
131
FUEL SYSTEM
INJECT10N NOZZLE
団 DISASSEMBLY
C)
Disassemb]y Steps
1 Retaining nut 5 Spring

▲ 2 Injection nozzfe 6 Adjusting shim
3 Space｢ 7 Nozzle ho一der
4 Spring seat
132
FUEL SYSTEM
Performance this test before disassembJing the injection

1｢ nozz一e.
㌧ノ 1) Insta‡1the injection nozzle to the nozzletester.
2) Use the nozzle tester to apply compressed fuel at
18LI MPa (185 kgf/cm2/2,630 psi) to the injectT'on
托
nozzle.
固 3) Check
teakage.
the area around the nozzle seat for fueJ
cot: 1f there is fue一一eakage, the injection nozzle and the
Jnject盲onbody must be replaced as a set.
2. lnjection Nozzle
1) Remove the inJ'ection nozzles from the nozz(e
holders,
The nozzfe needle valve and nozzle body
combinations must be interchange.
2) Fmmerse the injection nozzfes in a tool tray fiJled
with clean diesel fuel to protectthem from dust.
133
FUEL SYSTEM
囲 lNSPECT10N AND REPAIR
Make the necessary adjustments, repa(rs, and part replacements if excessive wear or damage is
discovered during [nspection.
InjectionNozz一e Needle lnspection

l･ Removethe nozzle needlefromthe nozzle body.
2. Carefu[1y wash the nozz-e and the nozzle

need[e
body in clean diese一 fuel.
3. Checkthatthe nozzle need一e moves smoothty暮nSide
□ the injection nozzle body.
Jfthe nozzle needle does not moves

smooth[y, it
must be repaired (See ''Nozzre Lapping Procedure”
below.)
Nozzle LappJng Procedure

1. Lapthe nozzle nozzle body@by
needleOandthe
app[y(ng a compound chrome
of oxidized and
animaJ oil ③.
Note:
Do not app[y an excessive amount of the oxidized

to the
chrome and animal oi一 compound injection needle
valve seat area.
① 2･ CarefulJywash the needfevalve and the nozzle body
E5] Nozz)e
in c[ean
Body
diesel fuel after Fapp]ng.
Inspect‡on
and Need一e Valve
Checkthe nozzle body and the need(eva[ve fordamage

and deformation.
The nozz一e and body must be replaced ifeitherofthese

two conditions are discovered during Inspection.
134
FUEL SYSTEM
国 REASSEMBn｢
汁 ⊂)
Reassemb[y Steps
1 Nozz一e holder 5. Spacer

▲ 2 Adjustng sh盲m 6. 1njection nozzle
3 Spring ▲ 7. Retainin9nut
4 Spring seat
135
FUEL SYSTEM
Important Opera胡ons
31 AdjustShim
Adjust Shim Ava‖abiFity mm(in.I
Ran9e 0.10-0.59 (0.0039-0.0232)
7. RetainingNut
Tighten
国
to the retaining the torque.
nutto specified
Retaけ‖ng Nut Torque N･m(k9f･m/lb.印
29-39 (3-4/22-29)
-
InJ'ect;on Nozzle Adjustment
-
J∼
∼
-
l･ Attach the injection nozzle ho一der to the injection
nozzle tester.
2. Apply pressure to the testerto that the

nozzle check
現 injection nozz一e opens at the specified pressure.
[fthe injection nozz[e does not open at the specified

pressure, instal[ or remove the appropriate number
of adjusting shims to
adjust it.
cctt WARNING:
TEST FLUID FROM THE ]NJECT[ON NOZZLE TESTER

WILL SPRAY OUT UNDER GREAT PRESSURE. ]T CAN
EAS)LY PUNCTURE A PERSON'S SKIN. KEEP YOUR
HANDS AWAY FROM THE mJECT10N NOZZLE TESTER
AT ALL TIMES.
136
FUEL SYSTEM
lNJECTrON PUMP CALIBRATrON DATA
lDENT肝1CAT10N PLATE AND PRODUCT

SERIAL NUMBER
I 1 Injection pump and reparr should be
MADE TN adjustment
･ZEXEL
.
JAPA N
made by the nearest ZEXEL CORPORATION or
ROBERT BOSCH Authorized Service Out[et.

○ ○
Pump No. 2. When you ask such authorllzed service outlet the
NP-PE the identification Prate
･--･-････--=
or repair, and
ad)'ustment
(UCENCE BOSCH)
Product Seria一 Number w= gNe them a necessary
to get technicaJ data distributed by the
㊨･･･Jdentif7cation number c[ue
manufacturers prev壬ous[y.
Without this data, the Service Outret w川be unab[e

to effectively service your lnJeCtJ-on pump.
Jf you are unab)e to locate the data appricabre to
your pump, please contact [SUZU MO一

Injection
丁ORS LTD throu9h your machine supp=e｢.
3. Do not remove the [dentification Pfate and Product
Serial Number from the injection pump.
Keep the Identification Plate and Product Seria一

Numberc(ean atalltimes. Do notallow itto rust or
become illegible.
Examples data are as foIJows･

Note: of test conditions and calibration
TEST CONDmONS REQUJRED FOR THE FUEL JNJECT)ON AMOUNT ADJUSTMENT
Nozzle *ZEXEL No.: 105780-0000

Injection
Bosch Type No.: DN12SD12T
ZEXEL No.: 105780-2080

Injection Nozzle Ho一der
Bosch Type No∴ EF8511/9
Pressure 17.2 (175)
Jnjection Starting MPa(k9〃cm2)
injection Line Dimensions mm(in.)
lnside Diameter 2.0 (0.079)
Outside Diameter 6.0 (0.236)
Len9th 600.0 (23.6)
Transfer Pump Pressure 1.6 (22.75)
Testing Diesel Fuel ISO4113 or SAE Standard Test Oil (SAEJ967D)
Operating Tempe｢atu｢e oC(oF) 40-45(104-113)

Pump Rotation Direction CIockwise (Vievved from the drive side)
137
FUEL SYSTEM
rNJ. PUMP CAuBRATION DATA Ass'y No. 000000-0000

Date : 2
ENGINE MODEL 4JBIPAVV-01 Company : JSUZU
N o. 0-00000-000-0
Injection pump : PES4A Governor : EP/RSV Tim]ng device :
OOOOOO-0000 000000-0000
1. Test Conditions :
Pump rotation :
ctockwJ'se (Viewed from drive side)
Nozzle : 000000-0000 N･∼- 1rder : 00OOOO-0000

(BOSCH Type No. DN12SD12T) (BOSCH Type No. EF8511/9A)
Nozzle openhg pressure : 175 kgf/cm2 Pump Pressure : 1.6 kgf/cm2
メ.tjr
hjectionpipe:
Test Oil : lSO4113
lnnerDia.
orSAE
2
Standard
mrrl
銀牌漣ゝr'ヽl''
J967d)
mJ
mm-Length 600
Oi( Temp∴
mm
40'5oc
.JAE
OverfJow valve opening pressure : 1.b kgf/cm2
2. lnJ'ection llming :
Pre-stroke: No. 1 P[unger 3.3±0.05mm Note : Adjustwith control rod position of mm
[njectionorder: 1 3′1 4.1 2

90o±30′ 1 80o±30` 270o±30′
Q±
(interva一 : 30')
PJungersarenumberedfromthe Driver
side.
Tappetclearance: Boltadjustmenttype ,-
Morethan 0.3 mmforaII cylinders.
Shim ; Manua‖y rotate the camshaft 2-3 times confirm that
adjustmenttype and
it rotates smoothly.
4. lnjection Quantity :
Rod Pump Max.var

Adjust- In).ectionQ'ty
Position Speed bet.cy[ Fixed Remarks
ingpoint (cc/1000strokes)
(mm) くr.p.m) (%)
A 8.3 1,5Oo 64-65 ±2.5 Lever Basic
Approx.
C 500 9.5-13.5 ±15 Rack
6.6
D Above14.0 100 (70-85) Lever
鉢弼 pl丘
5. Timing advance specification :
PumpSpeed
(｢.p.m)
Advance
Angle(deg.)
I
= EX EL zEXsEeLN.?eODRePp?nRmAello”享-eTl(.K
Japan
138
FUEL SYSTEM
GOVERNOR ADJUSTMENT
Full Adjustment
Above 14.0
ldJe･sub sprJng Setting
13.0
Governor sprJng Setting
9.3
9.1±0.1
■■■■■
8.3
≡
7.8±0. 1
呈
⊂
0
500
's
'a
＼
O
6.3 ＼
a.
&
O 4.3±0.4
l■
丘:
l
I
l
I
L_
160±30 250 500 (610I ‖535)1545 1610
Pump speed (rpm)
Speed L.ever Angle
35o±3o 1 2o士5凸
Stop
25 o士58
139
MEMO
140
ENGINE ELECTRICALS
SECTION 9
ENGINE ELECTRICALS
TABLE OF CONTENTS
ITEM PAGE
Starter.‥‥‥..‥‥‥‥‥.”..=.‥‖‖..”‥‥‥‥‥‥.‥‥‥‥.‥‥=‥‥‥. 142
Afternator‥‥‥‥‥‥‥‥‥..‥‥‥.....‥‥‥‥....‥.‥‥‥‥‥‥‥‥”.=.. 157
141
ENGINE ELECTRICALS
STARTER
STARTER rDENT(FICAT[ON
MJTSUB)SHJ
A EL[CTRIC COR戸, +APAN 24V MfTSUE31SHI
to
starter
the
motor is identified by name
pJate
attached yoke.川山stration)
TYPE ①
NO. ① Manufacturer`stype
② @ Jsuzupartnumber
③ ③ Barcode
Note:
A一ways check the identification before beg[n-

number
nlng a Service operat]1on.
App]icabJe service data will vary to the ident･

according
ification number･ Use of the data
wrong service w川
result in starter damage.
142
ENGINE ELECTRICALS
MAJN DATA AND SPECJFICAT(ON
lsuzuPartNo.
89720471301897137-478.
Mitsubl'shicodeNo.
L
RatedvortageV 1224
RatedoutputkVV 2.23.2
RatJ'ngsec 30
Directionofrotation
(VJ'ewedfromthepinionside) C一ockwise
CJutchtype RoIJer
TerminaJvoltage(No.Load)V 1123
Minimumcurrent(No.Load)A 14080
Startermotorminimumoperatingspeed
(No･Load)rpm 38003750
Piniongear
Modu)es 2.75
Numberofteeth ll
Outsidediametermm(”.) 38.5(15.2)
Yokeoutsidediametermm(in.) 81.6(3.21)
Brushlength
Standardmm(in.) 18(0.71)
Limitmm(in.) ll(0.43)
Brushspnngstandardfitting)oadN(kgf) 26.7-36.1(2.7-3.7〉
Commutator
Outsidediameter
Standardmm(in.) 32(1.26)
Limitmm(in.) 31.4(1.23)
Depthofundercutmica
Standardmm(in.) 0.5(0.02)
Limitmm(in.) 0.2(0.008)
143
ENGJNE ELECTR]CALS
･GENERAL DESCRIPTION
Magnetic switch Lever sp｢】ng
Lever
Rear bracket
OverrunnJng C(utch
Brush C(utch shaft
Front bracket
Beanng
a /
Oi[ seal
+
Pinion
Bal[ Gear Bearing

shaft
Armature Yoke ASM

Jnternal gear
円anetary gear
144
ENGINE ELECTRICALS
団 DISASSEMBLY
Disassembly Diagram: Disassembre in numer了cal orders.
3 13 15
㌔廷〕
○
rT17
4) (4)∩) 19
ll
9
蛋 / ㊨
罪 ○
⊂:=7
12
『 20
14 16 17 21 18
Disassembly Steps
1 Nut : MTermina( 14. Prate&packing

2 Screw 15. LeverASM
3 Magnetic switch (1) Lever
4 Pinion (2) Packing (notdescribed)
5 Bo一t (3) Plate (not described)
6 Screw (4) Leversprin9
7 Rear bracket 16. P[anetarygear
8 Yoke ASM 17. Gearshaft
9 Brush sprlr唱 18. C山tch
10 Brush 19. Bracket
ll Brush holderASM 20. hternalgea｢
12 Armature ASM 21. Washer
13 Bal)
Assemb一y: Assemble in reverse

procedure to the disassembly.
145
ENGINE ELECTRICALS
∇ DisassembJy
When disassembJing the starter motor, to
make
easier, to match the magnet
reassembfing mark switch
and the yoke.
Magnetic 1. Nut (MtermhaI)

switch
Nut Remove JIM” terminal
the nut of the magnet switch
and then the cab一e.
Yoke
2. Screw
Remove the screw.
sc
rev/AA& 3. Magnet
Remove
Switch
the magnet switch and the plunger.
4. Phion
Removlng the p)nion requires simp[e too一s. A set

consists of3 parts (1 bolt, 1 nut and 1 smaH tJLn
pJate).
These too一s are not used during assemb一y. The
pln10n is assemb一ed uslng the pu=er.
･
Pul[thelever with the boltinstead
of the
plunger and push out where to
the plnion can
be moved forward. Jn orderto fixthe (ever and

the pln暮On,fixthe bolttothe smaII p一ate.
146
ENGINE ELECTRICALS
Soket Hold the adjustable socket on the stop ring. Hit

Snap rlr唱 the socket with a hammer and remove the stop
Stop ring, expose the snap ring, then remove the

nng
Pinion snap ring, the stop ring, the pinion′ and the
plnion snap rJng.
円∩'ron spnng
The snap rlng lS not ｢euSable.
5. Bo一t
Screw
6. Screwand Brush holder
＼滋 Remove the bolt and the screw.
5 7. Rear bracket
Remove the rear bracket.
Rear bracket
8. YokeASM
HoJd the socket (maJ'or diameter 32mm) on the

a｢mature commutator and remove the yoke ASM
⊂) 8S
you slide the brush onto the socket.
Removlng this
･
way makes reassembring easier

and inspection of the brush rotation can be
brush from
貞迎 conducted with the removed the
socket.
＼
Yoke ASM
9. Brush sprJng
lO. Brush
Pu= upthe brush sprJng and remove the brush.
ll. Brush holder
After removlng the brush, remove the brush holder.
Brush holder
Brush
12. Armature ASM
:g&
P=ll out the a｢m8ture from
the planetary ヨear and
remove the bearlng With the puJler.
Armature
147
ENGINE ELECTRICALS
13. Bal∫
Be careful motto (osethe balL
14. P[ate
Lever packinョ -､
Remove the plate and the packin9.
逮
ヽ Leve｢sprln9 plate
15. LeverASM
Remove the
lever spnngs.
lever packing. the p(ate and the two
Lever
16. Planetary gear

Remove the four packing, the pLate the two
and
a @珍
lever sprlngS.
Gear shaft g
腎
17. Gearshaft
Q
Planet8ry 9ear
18. C[utch; Overrun
19. Bracket; Front
Put the gear shaft′ the overrunnlr唱C山tch and the

lever together, then from
remove them the front
bracket.
Overrun clutch
20. lnternal gear

21. Washer
When the two E type washers are removed, it

divides into the overrunning clutch, the internal
@
9ear′ the washer and the gear shafts.
rnterna( gear
148
ENGINE ELECTRICALS
囲肌ISPECT10N AND REPAIR
Make the necessary repaJrS, and part replacements if excessive wear damage is dis-
adjustments, or
covered during Inspection.
ARMATURE
Armature Short Circuit Test

6) l･ place the armature on a
growJertesterO.
2, Hold a hack saw blade ① againstthe armature core
wh‖e slowly rotating the armature.

h
Jfthe armature is short circuited, the hack savv blade
w‖ vibrate and wiH be attracted to the armature
COre.
A short circuited armature must be replaced.
Armature Winding Ground Test
Check for
囲
continuity across the commutator segments
and the core.
rfthere is continuity′ the armature is interna[Iy grounded

due to insulation failure and must be repZaced.
Armature Winding Continuity Test
Check for conthuity the
E2] 圃
across commutator segment.
)f there is
continuity′ the coif is open
no armature and
must be replaced.
⊃○｡
+ 二___
149
ENGINE ELECTRICALS
Commutator Run･Out Test
闘 Use dJ'a! indicator V-bJockto the
圃
a a measure com-
and
mutator ｢unout.
Jf the measure
va[ue exceeds the limit, the commutator
must be replaced.
Commutator Run-Out mm(in.)
Standard Limit
0.02(0.0008) 0.O5(0.002)
Commutator Outs)'de Diameter Measurement
Use to the
圃
a vernier caliper measure commutator out-
一`､勺 side diameter.
Jf the measured value exceeds the limit′ the armature

L? C
c
must be repfaced.
Commutator Outside Diameter mm(in.)
Standard Limit
32(1.26) 31.4(1.24)
Segment Mica Depth Measurement
Use depth depth.
圃
a gaugeto measurethe segment mica
1f the va(ue exceeds the limit, the segment
measured
mica must be undercut.
Segment Mica Depth mm(in.)

Standard Limit
0.5
0.2(0.008)
(0.02)
Bearing Inspection
Visuafly bear]ng.
匝
JnSPeCtthe
Ifthe beanng ISWOrn Or damaged, it must be repJaced.
150
ENGINE ELECTRICAL.S
YOKE
Field Winding Ground Test
Use a circuittesterto checkthe field winding ground.

1. Touch one probeto the brush field winding end.
2. Touch the other probe to the bare surface of the

yoke body.
There should be no
continuity.
Zfthere is continuity, the field windings are grounded.
RepaJr Or
replace the fiefd windings,
Fie[d Winding Continuity Test
〟
Use a circuittesterto checkthe fJLe[dwinding continuity.
1. Touch one
probetothefield winding leadwire.
2. Touch the other probetothe brush.
There should be continuity.
1fthere is no
continuity, the field windings are open.
Repa[r or replace the field windings.
BRUSH AND BRUSH HOLDER
Brush Length Measurement
囲 Use a verniercafiperto measure the brush length.
l千the measured value exceeds the 一imit. the brush

and/
orthe yoke must be replaced.
Brush Len9th mm(in.)

Standard Limit
18(0.71) ll(0.43)
151
ENGINE ELECTRtCALS
Brush Spring Inspection
l VJ'suaHy
ing.
check the brush sprJng for weakness and rust-
Replacethe brush sprlng if it is weakor rusted.
Use a spnng ba[ancerto measurethe sprlng tension.
1fthe measured valve exceeds the limit,the brush spnng

must be rep一aced.
Brush Holder [nsuJat]1on Test
Use a circuittesterto checkthe brush hofder insulation.
1. Touch one
probetothefieJd winding read vvire.
2. Touch the other probetothe brush.
There should be no
continuity.
Ifthere is continuity, the brush ho[der must be
or replaced.
repaired
MAGNETJC SWITCH
圃 Check for continuity across the magnetic ''S”

switch
産室 termina(
coil is open
and
and
coi) case.
shou[d
ff no
be
continuity
replaced,
exists, the shunt
Check for continuity across magnetic svvitch 'LS” termト
==二二==
囲 nat
are
and
open
`′M”terminaJ.
and shou一d be
[f no
replaced.
continuity exists, series coir
152
ENGLNE ELECTRJCALS
OVERRUNrVJNG CLUTCH AND PJNJON GEAR
Hold the overrunn(ng clutch housing and turn the

pJnion
by hand. Jf it turns one
resist声nCe but
way with s=ght
not the other, the condition is normal. [f not, reprace the
overrunning crutch. 1f abrasions or damage is found

during JnSPeCtion of the pJnion, rep face it.
･ The inside of the overrunning clutch isf=ed
w汁h grease, There may be a danger ofsp‖ing
the grease when washed with detergent used
for cJeanlng Off oil and kerosene.
FRONT BRACKET
lf any oil sp川age or damage is found during JnSPeCt盲on

of the bearJng and the oil seat, rep一ace with front bracket
assembJy (including bearing and oil seaり.
lNT∈RNAL GEAR AND PLANETARY GEAR
lfany abrasions or damage is found durJ'ng lnSPeCtion of

the gear tooth. replace the internal gear or the pZanetary
gear･
LEVER
Lightlypushthehead of the
overrunnlngCIutchsh aft
fnspect both ends (where it touches the overrunning
backbyhand
of the lever for abrasion. Jncomplete
clutch)
蘇
engagement may result if the 一ever is worn, making the
pJnion ineffective･
When the projection position of the plmOn is outside the
reference value, adjustment cannot be made, so

replace
the fever.
Rangeofshaftrnov ement
ProJ'ection Position of the Pinion mm(in.)
0.5-2.0
153
ENGINE ELECTRICALS
国 ASSEMBn｢
AIthough is done盲n the reverse procedureto disassemb[y, some

points need to be expJained･
assembly
l. Oiljng section and t言ghtening torque
Referto the specifications attached. (P.155)

･
Recommended 9reaSe is MUL TEMP#6129
(Kyodo Yushi), Mo[ykote RAG-650 (Dow
Corning) or equivalent.
2. Tightening torque
Referto the specif.[cations attached. (P.155)
●
●
3. lnspectjon of the proJreCtion position of the pln10n
A什er reassemblir唱the cranking motor. inspect the

Sw;tch projection position of the pJnLOn.
守 Position Pinion
Projection of the mm(in.)
0.5-2.0
Battery
Sta rter
motor
Measurlng method
Lightlypushtheh ead of the
overrunnmgc[utc h shaft As shown in the diagram, connect the starter motor to
backbyhand
the battery.
When the switch isturned
蘇
･
on′the plnion w=
move forward to the cranking position. At this
time, the armatures･may aLso turn, so care is
needed.
･
Light[y push the head of the overrunnTng Clutch
Rangeofshaft movement by hand
shaft and measure the movement
(return) of the c[utch shaft.
Lfthe value is within 0.5-2.0, it is in the normal

position. Jf it is outside the Limit, replace the
Jever.
154
ENGINE ELECTRICALS
OJL[NG SECTION AND TJGHTENJNG TORQUE
4.9-8.8N･m
(0.5-0.9k9f･ml
8.8一-13N･m (0.9-1.3kgf･ml
㌔
顎ヽ
e[
2.4-4.4N･m
b a
(1.25-0,45k9f･m)
7･8-13N･m (0.8-1.3k9f･m〉
OiFingSection Brandname
a S】eaveBearJngandBaJ[ MolycoatRAG-650
b SIeaveBeanng Mo[ycoatRAG-650
C OverrunnlngClutchandBear[ng MolycoatRAG-650
d GearShaftSp[ine MoJycoatRAG-650
e SJidingpartbetweenleverandoverrunnlngCIutch MULTEMP#6129
f Armatureshaftgear,Jnterna[gear,PJanetarygear Mo[ycoatRAG1650
g PIungersurface MULTEMP#6129
h lnternaJandexternaJsidesurfaceofarmaturebearlng MULTEMP#6129
I Oi(seal MULTEMP#6129
155
ENGJNE ELECTRICALS
PERFORMANCE TEST
Performance Test
The starter motor characteristics are

sJgnificantry
inf[uenced by the capac-rty of the battery. Therefore, test
by using a battery of the designated capacity.
Since a large amount of current w川fJow. conduct the

test quickly.
No Load Test
A Turn Load
under no and measure the rotationaF speed
Ammeter Switch
and vo托age orcurrent.
No-road characteristics (Standard vafue)

V Vo[tmeter Voltage 23V
Battery
Current 80Amax
Starte r
motor Numberofrotations 3′750rpmmin
156
ENGINE ELECTRICALS
AIJERNATOR
ALTERNATOR IDENTJFJCATJON
HJTACH[
Hitachi MfTSUBJSHI identified
=*=
or alternators are by
name
p一ate attached to the rear
cover.川山stration)
=*= ① lsuzu part number
I ② Manufacturer′s code number
田 HITACH[ _@= ③ Rated voltage
01
0 Isuzupartnumber
MITSUBISHL Manufacturer`s
② name
⊂=二 ① 二二=] ③ RatedvoZtage
=二 ① 二=コ @ Barcode
□ =③:=] ⊂コ Note:
｢｢ A一ways
I
④ I check the J'dentificatjon number before begJn-
+ a
nJ'ng service operation.
_+
AppJJ'cabJe service data w川vary according to the ident-
ificat'fOn number･ Use of the wrong data
service vv川
resu[t alternator damaged.
157
ENGINE ELECTRICALS
MAIN DATA AND SPECJF[CATJON
EnglneModehobeEqulPPed 4JSeries
ManufacturerLsname HITACHJ MITSUB)SHr
897201-2810
】suzuPartNo. 897228-3180 897023-2631 897182-2892
Manufacturer'sCodeNo. LR150 LR240-388 AOO2TA8383
12
RatedvoJtageV 字4 24
RatedoutputA 50 40 30
Operat盲ngspeedrpm 1200-18000 1000-13500 1200-18000
RatedoutputatrpmAN/rpm 47/13.5/5000 38/27/5000 -/-/5000

No-loadoutputatOamperesV/rpm 13.5/1200or[ess 27/1000orJess 27/1000orJess
Directionofrotation(viewedfromthe C一ockwise Clockwise･
pu‖eyside)
Po(aritygrounded Negative Negative
Pulleydiameter(P.C.D.)mm(in･) 82(3.23) 80(3.15)
Coilresistanceat20oC
Rotorcoilf2 2.6 12.5 6.5-7.8
Statorcoiln 0.101 0.14
Brushlength
Standardmm(in.) 22(0.86) 25(0.98) 18.5
Limitmm(in.) 6(0.24) 6(0.24) 5.0
SliprJngdiameter:
Standardmm(in.) 27(1.06) 31.6(1.24) 22.7(0.89)

Limitmm(in.) 26(1.02) 30.6(1.20) 22.1(0.87)
Shaftdiameter
Frontmm(in.) 17(0.67) 17.0(0.67) 17(0.67)
Rearmm(in.) 10(0.39) 12.0(0.47) 8(0.31)
Regu[ator(s)appI7cabJe Bu主(t-J'n
JsuzuPartNo. 897184-6290 897184-6280
Manufacturer(s)codeNo. TR2Z-47 A866X42272
158
ENG[NE ELECTRICALS
GENERAL DESCRIPT10N
(
1_
Based on LR240
The alternator consists of the front cover, the rotor, the stator, the built-in (C regulator (some engines use a
TirreTl alternator with separate regulator), and the rear cover.
This smaH size and 一ightweight aJternator provides excelfent re‖ability. Jts simp一e construction makes it
very easyto service. The bui一t-in lC regulator mJ'nimizes circuit wiring.
159
ENGINE ELECTRICALS
団 DISASSEMBn｢
These disassembfy steps are based on the bui一t-in [C regulator type･
J事
Q
a O
I
Jb
○
?
ヽヽ
C)
@ @ 4
＼､､
/一一㍍′′ ♂宣惑
1
Disassemb[y Steps
1 Through bolt 7 Ball bearln9

2 Rear cover
and stator 8 Front cover
▲ 3 Pulley and fan ▲ 9 Stator

▲ 4 Spacer collar ▲10 Rectifier with brush holder
5 Rotor with bearJng 11 IC regulator
6 BearJng retainer 12 Rear cover
160
ENG[NE ELECTR[CALS
3. Puueyand Fan
凸==コ Clampthe
(1) rotorshaftin a
softjawvise.
(2) Loosenthe pu‖eyJocknut①.
(カ (3) Removethe pu‖ey ① alon9 With帥e spacer
collar.
5Q
③ チ
r/r ヽ
4. Rotor and Bearlng
凸 (1) Use a p一astic hamme｢or a

press①to remove
the roto｢from the front cover ①.

ーー/
①
(2) Remove the space｢co‖ar.
＼ .ノづクー
ヽ
｢や
②
bd
[i
8. Front Cover
Use to the front from

screwdrivers pry cover
① the
stator @.
戯 Note:
Do not attempt to prythe coil wires from the stator.
9. Stator
10. Rectifier with Brush Holder
Use a soldering iron ①and a long

-
pairof nose
pliers
①to remove the rectifiers.
@
Note:
㊨ ③
㊨ Hold the
G) rectifier leads between the rectifier and the
ニーく soldering Iron With the 一ong nose p‖ers. This w川

protect the rectifier from the heat,
161
ENGINE ELECTR]CALS
囲 lNSPECT10N AND REPAtR
Make the necessary repalrS, and part replacements if excessive wear or damage is dis-
adjustments,
covered during lnSPeCtion･
ROTOR AND BEARING
Check the face of the slip nngs for contamination and

rouョhness. 1ffound to be ｢ou9hened′ dress with a fine
sand paper (#500 -
600). [f found to be contaminated,

clean with a cfoth saturated with alcohol.
BaJf Bearng
Check thatthe ball bearmgs rotate smooth[y.
1fthe ball beanngs are noisy, they must be replaced.
〟
/
Use a vernier ca]iper to measure the slip ring outside
園 diameter.
1f the measured va[ue exceeds the Omit, the rotor must
G be ｢eplaced.
/遡 S=p Fung Outside Diameter
Limit
mm(in.)
Standard
31.6(1.24) 30.6(1.20)
162
ENG[NE ELECTRJCALS
Rotor CoJ'[ Continuity Test
:I-辛圃
Use an
1･ Touch
circuittesterto
both
testthe
circuittester
rotor
probes
coiJ continuity.
to the rotor coir s=p
恩￣ 2.
rings.
Note the circuittester reading.
The circuit tester should register approximately 9

ohms.
3, 1fthe circuit tester does not show continuity, check

the connections between the lead wire and the slip
rings.
[f breaks are founded, repaJr and repeat the rotor

coil continuity test.
Ifthere is st川no rotor coil continuity, the rotor must

be replaced.
Rotor Coi[ Ground Test
Use an circuittesterto testthe rotor co‖ for grounding.

G喜ヨ / 1･ Touch of the circuit tester to the
圃
one
作 probes rotor
○
shaft.
㊨ 2･ Touch
rir唱S.
the other circuit tester probe to one of sfip
3. Note the circuittester reading.

4･ Touchthe circuittester probe to the other s一ip nng.
5. Notethe circuittester readhg.
The circuit tester should show infinity (no need(e
movement) at both measurin9 Points.
Jfthe tester does not show infinity (the need(e
circuit
at both measuring points, the rotor is
moves)
grounded and must be rep[aced.
STATOR CO]L
Stator CojJ Continu;ty Test
Use an
circuit tester to testthe stator coil conthuity.
1L]
1. Touch the circuit tester to two of the bare
圃
probes
stator wires.
鵡貫 2. Note the circuittester reading.

3. Move one of the circuittester a third wire.
probesto
163
ENGJNE ELECTRJCALS
4･ Note the circuittester reading.

1fthe two readings (Steps 2 and 4) are identical, the
stator coif has continuity.
If the two circuit tester readings are different, there

is no st8tOr COntinuity.
5. Checkthe neutral junction (arrow mark) forbreaks.
Jf breaks are found, repalr repeat the stator
and coif
continuity test.
1f there is stilt no stator coir continuity, the stator
must be repl8Ced.
Stator CoiJ Ground Test

7:
Use for grounding･
囲
an circuittesterto testthe statorcoiF
I_Q
1･ Touch one bear

circuit tester probe to the metal
sur†ace of the stator.
2･ Touch the other circuit tester probe to a bare stator
･
74
′ ＼
lead vvire.
3･ Note the circuittester reading.
The circuit tester shou一d show infinity (no need一e

movement).
1fthe circuit tester shows a value other than infinity
(the needle moves)∫ the stator is grounded and must
be rep[aGed.
RECTIF旺R
0 Rectifier (Positive DiodeI Cont;nuity Test

I｢｢ l ◎
BAD GOOD
○
rum
○
Use circuit tester to test
囲
○ an rectifier continuity･
Oo
oO
空＼ 1･ Touch the circuit tester positive probe to the rectjf7er

○ A
holder,
⑮
○
玩 i@
2･ Touch the cjrcuittester negative to each
書ヨ
probe of the
diodeterminats 'rn
turns.
164
ENGINE ELECTRrCALS
3. Note the meter reading foreach diode terminaL

AJl of the diode shou[d showcontinuity.
Jfa diode shows no continuity, it is open circuit. The

｢ectifier assembly must be replaced.
4. Touch the circuit tester negative probe to the recti-

fier holder.
GOOD BAD
∈) 5. Touch the circuittester positive probe to each of the
憾
0
od 0 a diodeterminals in turn.
oO
n 6. Note the meter foreach diode termina一.
○ a reading
㊨
0
None of the diodes should showcontinuity.
@
(f a diode shows continuity, it is shorted. The recti-
fie｢ assemb一y must be replaced.
Rectifier (Negative Diode) ContJ'nuity Test
￣￣
｢ l Use a circuit testerto test the rectifier continuity.
圃
f ｢
BAD GOOD ◎ 0
○ 0
1. Touch the circuit tester negative probe to the rectト
fier holder.
-0.
Oo
oO
@;
2. Touch the circuJ't tester positive probe to each of the
diode terminals in turn.
⑳i
3. Note the meter reading foreach diode terminal.
AJJ of the diode should shovvcontinuity.

1fa diode shows no
continuity, it is open. The rec-
tifier assembly must be rep faced.

4. Touch the circuit tester positive probe to the rectifier
GOOD
hoJder.
BAD ◎ (∋
5. Touch to
0 0 the circuittester negative probe each of the
a diodeterminals盲n
wm.旦＼ ○
Oo
0 ○
6, Notethe
turn.
foreach diodeterminal.
meter reading
㊨ & None of the
1f a diode shows
fi即aSSemb】y must
diode should
continuity, it is shorted.
be rep一aced.
show continuけy.
The rect]'-
RectifJ'er Assembly Replacement Procedure

①
Use the Rectifier Service Kit to rep[ace the rectifier
壷L 圃 assembly in the foHow]ng

1. Connectthethree inside
steps.
(Cad wires to the ''N” termト
na)s①.
2. Connect the three outside Lead wires ② to the out-
side terrninals.
/ 3. lead
Wind the stator wires around the rectifier read
@ w7res (inc一uded in the RectJ-fier Service Kit) and soI-
derthem.
165
ENGINE EL.E:CTRJCALS
Note:
1･ The be
圃
stato=ead wires must cut to the proper
(ength before they are connected to the rectifier
Jead wZres･ lf the stator lead wires are too long or
[￣二 Stator
too short,
Lead
troub(e
Wire Length
may occur.
mm(in.)
33.5 (1.32)
2･ Take care not to damage the rectifier paint surfaces.
BRUSH
囲 Use a verniercaliperto measurethe brush.

(fthe measured va)ue exceeds the limit, the brush must
be replaced.
Brush Length mm(in.)

Standard Limit
897201-2810 22(0.86) 6(0.24)

897023-2631 25(0.98) 6(0.24)
Brushes are provided with a line whJ.Ch indicates the

[imJ't of usage.
166
ENGINE ELECTRICALS
国 REASSEMBLY
ll
メl
○
∼
i 4G
○
?
＼ ■
@ 噂タ
10
■′-
/
//
ーー/一一∴ #
rt-:g十表しン-
Steps
-
/
_′
一■
)一一一1
Reassemb[y
1 Rear cover ▲ 7 Bal=)ea｢lng

2 (C regulator 8 Beanng retainer
▲ 3 Rectifl'er with brush holder 9 Rotor with bearJng
▲ 4 Stator 10 Spacer co‖ar
5 Rear cover and stator ▲11 P山1ey and fan
6 Front cover 12 Through bo一t
167
ENGINE ELECTRICALS
3. RectifJ'er with Brush HoJder

/ 4. Stator
When connecting stator and diode Jeads

coiHeads
using soJder, use [ong-nose pfiers and finish the
work as
quickJy as possib[e to prevent the heat from
being transferred to the diodes.
ll. Pu‖eyandFan
Tighten.the fan to the specified torque.
国
Fつ
pu=ey and
Pu一ley and Fan NutTo｢que N･m(k9f･m/Ib.柑
⊂⊃
49-64 (5.0-6.5/36- 48)
⊂⊃
⊂>
歩行
/′=
168
TROUBLESHOOTING
SECT10N IO
TROUBLESHOOTJNG
TABLE OF CONTENTS
JTEM PAGE
Hardstartt'ng -...----.,..--------------･･-･--.-....--. 171
UnstableidJJ'ng..‥‥-----.･.---I--L･-‥-..I..‥..‥‥‥‥=‥,.=‥ 175
[nsufFicientpower ‥‥.‥‥‥‥‥‥‥‥.‥..-.‥”･-･･=･”‥‥.･”.‥‥‥..‥ 178
ExcessivefueJconsumptJ'on‥‥.‥‥‥‥‥..‥･･･.‥-‥‥..‥‥.-‥‥.,‥‥‥‥ 182
ExcessiveojJconsumption...........･1...”.････.･･-””,.1･.....･･･..”,.”... 184
Overheating-------.,･-----･･----･･･-----.I.-･.----.. 185
Whiteexhaustsmoke ‥.‥.‥..‥‥‥‥‥‥‥‥‥‥.‥‥‥..‥‥‥‥...‥‥.‥‥ 187
Darkexhaustsmoke ...”..”.......”..............,......”.......,,....””.. 188
Oi[pressuredoesnotrise.,..‥‥..,.‥‥-I--‥･...‥･=‥‥‥..,....‥...‥‥ 189
■
AbnormalengJnenOise,.....,....･”....････････････.･･･････”.I.”...A..,...... 191
169
TROU8LESHOOTING
TROUBLESHOOTING
Referto this Section to diagnose repa(r eng(ne

quickly and problems.
Each troubleshooting chart has three headings arranged from leftto right.
(1) Checkpoint (2) TroubleCause (3) Countermeasure
This Section is divided into ten sub-sections:

1. HardSta｢ting
l) Starter inoperative
2) Starteroperates but engine does notturn over
3) Engineturnsoverbutdoes notstart
2. Unstableld=ng
3. Insufficient Power
4･ Excessive Fuel ConヲumPtion
5. Excessive Oil Consumption
6. Overheating
7. VVhiteExhaustSmoke
8. DarkExhaustSmoke
9. OiJPressure DoesNotRise
10. Abnorma)Eng盲neNoise
170
TROUBLESHOOTING
1. HARDSTARTING
1. STARTER JNOPERATJVE
Checkpoht l†ouble Cause Countermeasure
NG NG
Neutral switch (Jf so Defective neutral switch RepI8Ce the
equipped) neutra一 switch
NG Loose battery cable termina一s NG CJean the bat-

and/or retighten
B∂tte｢y
Poor connections due to rusting tery cable termina(s
NG NG
Battery discharged or weak Recharge or rep(ace the battery
NG NG
Fan be一t loose or broken AdJ'ust or rep)ace the fan belt
OK
NG NG
Fusible 一ink Fusible Fink shorted Replace the fusJ'b[e ”nk
OK
NG Defective starter swJ'tch or NG Replace the starter or

Starter switch
switch
starter relay the starter re)ay
OK
NG Defective magnetic or NG RepaJr the

Starter sw['tch Or replace magnetJ'c
starter re一ay switch
OK
NG NG
Starter Defective starter Repair or repFacethe starter motor
171
TROUBLESHOOTING
1. HARDSmRTING
2. STARTER OPERATES BUT ENGINE DOES NOTTURN OVER
Checkpoint Trouble Cause Countermeasure
NG Loose battery cab)e terminals NG clean the bat-

Battery and/or retighten
Poor connections due to rusting tery cab一e terminaLs
NG NG
Battery discharged or weak Recha｢9e Or ｢ePl8Ce the battery
NG NG
Fan be(t Loose or broken Adjust or replace the fan belt
OK
NG NG
Starter Defective pinion 9ea｢ Replace the pln10n gear
NG NG Repa汀0｢ rep一ace the magnetic

Defective magnetI'c switch
switch
NG Brush we∂｢ NG Rep一ace the brush and/orthe

Weak brush sprJng brush sprJng
OK
NG Piston, crank bearJng Seizure, NG RepalrOr replace the re一ated

Engine
o｢ other damaョe Parts
172
TROUBLESHOOTING
1. HARD STARTlrUG
3. ENGJNE TURNS OVER BUTDOES NOTSTART
Checkpoht TroubJe Cause Countermeasure
DefectiveengJneStOPmeChanism Replacetheeng[nestop
NG NG
Enginestopmechanism mechanism
controlwireimproper[yadjusted
(JnJJ'nepump) Ad)'ustthecontrorwJ're
NG DefectJ'vefuefcutsoJenoJ-dvaJve NG ReplacethefuelcutsoJenoid
(VEpump) valve
FUEL TS NOT BEING DEuVERED TO THE (NJECT10N PUrV]P
NG NG
Fuel FueJ tank is empty F川thefueZ tank
OK
Repa[r or rep[ace the fueHl'nes

NG CIog9ed or damaged fue川nes NG
Fue一 pIPlng Retighten the fuel h'ne
Loose fuel line connections
connections
OK
NG Fuel fi(ter overfJow valve does NG RepaJr Or replace the fuel fJ'(te[
Fuef filter
not close overfJovv valve
NG RepTace the fue( fi一terelement or

NG fuel fitter element
C(ogged
the fuel fi一ter carl｢id9e
OK
NG NG
Fuel Ai( in the fuel system 別ee° the air from the fue一 system
system
Continued on the next page
173
TROUBLESHOOTJNG
1. HARDSTARTJNG
3. ENG.NE TURNS OVER BUT DOES NOTSTART
FUEL IS BEING DELIVERED TO THE INJECT10N PUMP
Checkpojnt ■什ouble Cause Countermeasure
Continued from the previous page
OK
hjectl'on nozzle injection startfng

NG NG Adjust or repJace the
l'njection
”)'ect]'on nozz[e pressure too row
nozzle
Improper spray condJ'tion
OK
Defective fuel injection nozzle

NG NG
fuel drippage Replace the deJivery
Jnjection pump resultJ'ng I'n after valve
fuel injection
NG Defective inJ'ection pump controf NG Repair or replace the injection

rack ope｢8tion pump control rack
NG NG Replace the injection pump

Jnjection pump plunger worn or
stuck plunger assembly
OK
NG lnjectionpump drive NG RepJace the drive

(VE pump)
shaft J'njectionpump
InjectI'onpump or damage
seizure other shaft
NG Injection pump governor spnng NG Replace the in).ection pump

SelZU｢e governor SPrJng
174
TROUBLESHOOTING
2. UNSTABLE JDLJNG
Checkpoht Trouble Cause Countermeasure
NG NG
Idring system [d=ng the id=ng
JmPrOPerly adjusted Adjust
OK
NG Defective fast id=ng speed NG RepaJr Or replace the fast idling

Fast J'd‖ng speed control device
control device speed control device
OK
NG Accelerator contro一 system NG Adjust the accelerator control

Acce[erator control system
imp｢oper【y System
adjusted
OK
NG NG
Fuel system Fue( system leakage or blockage Repa[r or replace the fuel system
NG NG
AJ-r in the fuel system B!eed the air from the fue( system
NG NG
Water particles J'n the fuel system Changeth白fuel
OK
NG NG Repf ace the fuer fJlter eJement or

Fuel付te｢ Crogged fue( filter e一ement
the fue一 fi一terca｢trid9e
Continued on the next paョe
175
TROUBLESHOOTING
2. UNSTABLE IDLING
Checkpoint Troub一e Cause Countermeasure
Contl'nued from the prevL'ous page
oKi
NG NG Repa[rorrepfacethegovernor
[njectJ-onpump DefectivegovernorJeveroperatron
lever
NG Regu[atorvalveimproper[y NG AdJ'ustorrep)acetheregulator
adjusted(VEpumponJy) valve
NG NG
Brokenplungersprlng RepJacethep[ungerspr-ng
NG NG
WornpFunger ReplacethepJungerassembry
NG NG
Worncamshaft(ln-nlePumPOnly) Replacethecamshaft
NG Wornro[Jertappet(ln-=nepump NG
Replacetherollertappet
on一y)
NG NG
Worncamdisc(VEpumponly) Rep[acethecamdisc
176
TROUBLESHOOT-NG
2. UNSTABLE IDLING
ContJ'nued from the prevf'ous page
OK
NG Va[ve clearance improperly NG

Valve cJearance Ad)Lust the valve clearance
adjusted
OK
BJown out cyIFnder head gasket

Worn cylinder ‖ner
NG NG
Compression pressure PI'ston nng sticking or broken Replace the reTated parts
lmproper seating between the
va)ve and the va[ve seat
177
TROUBLESHOOTJNG
3. 1NSUFFICIENT POWER
CheckpoJ'nt Troub(e Cause Countermeasure
NG NG Clean or rep一ace the air cleane｢

Air c一eaner Clogged air c一eaner e一ement
e一ement
OK
NG NG
Fue一 Water particles in the fue一 Replace the fue(
OK
NG NG Replace thefuef fJ'rter element or

Fuel fnter C[ogged fuel filter element
the fuel futer cartridge
OK
NG NG Repair or replace the fuef feed

Fue一 feed pump Defective fuel feed pump
Pump
OK
NG NG
InJ'ection Replace the injection nozzJe
Jnjection nozzle nozzle sticking
Injectionnozz一e in)'ection startJ'ng

NG NG Adjust or repTace the injection
pressure too low
nozz一e
Improper spray condition
OK
NG Fuel in)'ection pLPeS damaged or NG

Fuel injectionp]pes Rep[ace the fueh'n)'ection pIPeS
obstructed
178
TROUBLESHOOTJNG
3. JNSUFFJCJENT POWER
OK
NG Defectiveregu7atJlngvaZve NG Repa]rorrepracetheregufatJ-ng
Injectionpump (VEpumponfy) vaFve
NG NG
DefectivedeJiveryvaJve Repracethede‖veryvalve
NG NG
Defectl.Vetimer Repairorrep[acethetJ'mer
NG NG
Worncamdisc(VEpumponry) Rep[acethecarndisc
NG NG Adjustorreplacethecontrol
lmpropercontrorleveroperation
Jever
AdjusttheinjectJ'ontiming
NG NG
DefectiveinjectiontI-ming RepalrOrrePlacetheFnjection
pumptimer
NG NG
Weakgovernorspnng Replacethegovernorsprlng
ContJLnued on the next page
179
TROUBLESHOOTING
3. 1NSUF円CIENT POWER
oKf
NG NG
lnJ'ectionpump Wornplunger Replacetheplungerassembly
NG NG
Worncamshaft(ln-=nepumpon[y) Replacethecamshaft
NG Wornronertappet(I什Iinepump NG
RepracetheroIIertappet
only)
NG NG
Worncamdisc(VEpumponry) RepLacethecamdisc
OK
NG BoostercompensatorpIPe NG Replacetheboostercompen-
brokenorcracked SatOrPIPe
Exhaustgasleakagefromthe
NG NG RepaJrOrrePJacethereJated
exhaustsystem
Parts
AJ'rleakagefromtheintakesystem
NG NG Repa(rorreplacethepovverecho
Defectjvepowerechogate
gate
180
TROUBLESHOOTING
3. 肌ISUF円C陀NT POWER
Checkpoint TroubTe Cause Countermeasure
OK
NG NG
Turbocharger Defective turbocharger assembly Replace the turbocharger assembly
OK
B一own out cy=nde｢ head !IaSket

Worn cylinder h'ner
NG NG
Compression pressure Piston or broken Replace
ring sticking the related parts
Jmproper seatJ'ng between the
va一ve and the v∂lve seat
OK
NG Valve c一earance improper一y NG

V8lve c一earance Adjust the vafve clearance
adjusted
OK
NG NG
Va一ve spnng Va[ve sprrng vveak or broken Rep face the valve sprlng
OK
NG NG
Exhaust system Exhaust pipe clogged Cfean the exhaust pipe
OK
NG Open and improper(y set NG Adjust and reseal the

Fun load screw seal adjusthg
adjusting screw sea.
adjusting SCreW
181
TROUBLESHOOTING
4. EXCESSIVE FUEL CONSUMPTION
Checkpoint TroubJe Cause Countermeasure
NG NG Repalr Or ｢ePlace the fue一 system

Fuel system Fuel leakage
｢elated parts
OK
NG NG Clean or replace the air c(eaner

AJ'r c)eaner clogged air cleaner element
elemenl:
OK
NG NG
ld=ng Poorly idring speed Adjustthe id口ng speed
speed adjusted
OK
1njection nozzre hjection starting

NG in)'ection
NG Adjust or replace the
Injection nozzle pressure too row
nozzle
Improper spray condition
OK
NG Fuel injectiontiming LmPrOPer]Y NG

Fuel Adjust the fue( injectl'ontiming
injectiontiming
adjusted
OK
Defective de[ivery va一ve resuJting

NG NG
is fuel drippage fuel Replace the deJive,ry
Injection pump after valve
l'njection
OK
NG Ai‖eakage from the turbocharger NG Repai｢ the turbocharger intake

Tu｢bocha｢ger
intake side side
Continued on the next p89e
182
TROUBLESHOOTJNG
4. EXCESS(VE FUELCONSUMPTION
Checkpoint 1†ouble Cause Countermeasure
ContJ'nued from the previous page
OK
NG NG
Turbocha｢9e｢ Defective turbocharger assembly Replace the turbocharger assemb)y
OK
NG Valve clearance improperly NG

Valve clearance Ad)Lust the valve clearance
adjusted
OK
B[own out cylinder head gasket

Worn Finer
NG
cyh'nder NG
Compression pressure Piston nng sticking or broken Replace the related parts
Jmproper seating between the
valve and the vaJve seat
OK
NG NG
VaTve spnng Va[ve spnng weak or broken F!ep(ace the vaJve spnng
183
TROU8LESHOOTING
5. EXCESSIVE O比CONSUMPT10N
CheckpoI'nt TroubJe Cause Countermeasure
NG Engine ol-1unsu7table NG Rep一ace the engine oH

Engine oil Too much englne OI.I Correctthe engJne Oil vo[ume
OK
NG Oil leakage from the ol'(seat NG Replace the oJ'lsea一 and/or the
Oil sea一 and gasket
the gasket gasket
and/or
OK
NG NG
AT'r breather Clogged af'r breather CJean the air breather
OK
Defective valve seals

Fnlet and exhaust va一ves NG NG Rep(ace the va(ve seals, the
Worn v8lves stems and valve
Valve sea一s varves, and the valve guides
guides
OK
NG Piston nngs worn, broken or NG Replace the piston nngs or

Piston r(ngs
J-mproperly JlnstaJled properJy insta(J
OK
NG Cylinder Lines scored or NG

Cy臼nder [J'ners Replace the cyHnder =ners
WOrn
184
TROUBLESHOOTmG
6. OVERHEATING
NG NG
CooHn9 Water Insufficient coo=ng water Replenish the water
cooJJ'ng
OK
NG NG
Fan coupIJ'ng (ifso ○‖eakage from the fan coup=∩9 Rep face the fan
equJ'pped) coupJing
OK
NG Fan be(I (oose or cracked causing NG

Fan be一t Rep一ace the fan be一t
s‖pp;唱e
OK
NG DefectJ've radiator cap or clogged NG RepJace the or

Radiator radJ'ator cap c(ean
radial:or core the radiator core
OK
NG NG
Water pump Defective water pump RepaJr Or the
rep(ace water pump
OK
Cylinder head
and cylinder body NG Defective sea(ing cap resulting ln NG
RepJace the seaJjng cap
se∂‖n9 Cap water leaka9e
OK
NG NG
Thermostat Defective thermostat Rep一ace the thermostat
185
TROUBLESHOOTJNG
6. OVERHEATING
ContJ'nued from the prevJ'ous page
OK
NG Coo=∩9 System C】099ed by NG Clean the forelgn maten'ar from

Cooling system
fore唱n materia一 the coo(ing system
OK
NG Fue一 J'n)'ection timing JmPrOPerly NG

Fue( Ad)lust the fuel injection tl'ming
J'nJeCtI'on timing
adjusted
186
TROUBLESHOOTING
7. WHITE EXHAUSTSMOKE
NG NG
Fue一 Water partic[es l'n the fuel RepJace the fue(
OK
NG NG
Fue( injectiontiml-ng Delayed fu白( in)'ectJ'on tFmlng AdJ'ust the fueJ injection tJlming
OK
BJown out cylinder head gasket

Worn cylinder liner
NG NG
Compressl'on pressure Piston ring sticking or broken Replace the related parts
Improper seating between the
valve and the va)ve seat
OK
NG NG
Turbocha｢9er Defective turbocharger Replace the turbocharger
OK
Defective vafve seals

Inlet and exhaustvalves NG NG Rep[ace the va(ve seaJs, the
Worn valves stems and vaJve
Valve seats valves, and the valve guides
guides
OK
NG Piston rln9S WOrn′ broken or NG RepJacethe piston nn9S Or

Piston rl咽S improperly insta[led properJy J'nstalJ
OK
NG Cylinder nnes scored or NG

Cylinder Liners Replace the cyhlnder ”-ners
WOrn
187
TROU8LESHOOTING
8. DARKEXHAUSTSMOKE
NG NG CleanorrepJacetheal'rcreaner
AJ'rcleaner Cloggedaircreanerelement
element
OK
fnjectionnozz]einjectionstarting NG
NG Adjustorreplacetheinjection
1njectionnozzle pressuretoolow
nozz[e
lmproperspraycondition
OK
NG NG
FuelinjectiontimingJmPrOPerJy
Fue[injectiontimhlg AdjustthefuelinjectJLontiming
adjusted
OK
Defectivedeliveryvalveresufting
NG NG
infueldrippageafterfuel Replacetheddiveryvafve
)njectjonpump
Jnjection
NG NG
Excessivehjectionvolume Adjusttheinjectionvolume
188
TROUBLESHOOTING
9. 0[LPRESSURE DOES NOTRISE
NG Lmproper viscosity englne Oil NG Replace the en91ne Oi一

En9ine oi一
Too much eng[ne oi一 Correct the engJne Oil vo(ume
OK
Defective oil pressure gauge or Repa[r or rep一ace the

OJ'J pressure or NG NG oi[ pres-
gauge unJ't
unit sure 9aU;】e Or Unit
Oil pressure indicator Light
Defective indl'cator =ght Rep一ace the indic8tO川ght
OK
NG NG Replace the o‖ filter eJement or

Oil fi[ter Clogged oJ'JfL'[tereFement
the ou filter cartridge
OK
NG ReJiefvalve sticking weak NG Rep(ace the

Re[ief by-pass and/or relief valve and/or
valve and valve
by-pass valve sprln9 the by-pass va(ve sprlng
OK
NG NG
Oi一 pump C一ogged oil pump strainer Clean the oil pump strainer
NG NG Rep[ace the
Worn oil pump related
oi[ pump reJated parts
Pa ｢tS
OK
NG NG
Rocker arm shaft Worn rocker arm bushing F!eplace the bushhlg
rocker arm
Continued on the next paョe
189
TROUBLESHOOTtNG
9. OILPRESSURE DOES NOTRISE
Checkpoint Troubfe Cause Countermeasure
OK
NG Worn and NG Rep(ace the camshaft and the

camshaft camshaft
Camshaft
bean'ng camshaft be8rhgs
OK
NG NG Rep(ace the crankshaft

beanngs Worn bea｢ln9S and/or
Crankshaft and c柑nkshaft and
the bearings
190
TROUBLESHOOTING
10. ABNORMALENGINE NOISE
l･ EngJneKnocking
Checkpo]'nt 一打ouble Cause Countermeasure
Checkto see thatthe engine has been thoroughly warmed before beginnJ'ng the troubJeshooting
up procedure.
NG NG
Fuef Fuel unsuI'tab[e RepLace the fuel
OK
NG Fue一 hjection timJ'ng improperly NG

Fuef
(InjectiontimJng Adjust the fuel
J'njectiontllmJng
adjusted
OK
NG ∫mproper injectJ'onnozzle NG
starting Adjust or replace the
l'njection
Injection nozzle
pressure and spray condition nozz一e
OK
NG B一own out head 9aSket NG Repl8Ce the head 9aSket orthe

Compression pressure
Broken piston rln9 pJtStOn ring
2･ GasLeaka9￠Noise
Tightentheexhaustpipe
NG LooseFyconnectedexhaustpipes NG
Exhaustpipes connections
BrokenexhaustpJ'pes
Replacetheexhaustpipes
OK
Rep[acethewashers
lnjectionnozzlesand/orgJow NG Looseinjectionnozz[esand/or NG
TightentheinjectJ'onnozzJes
pfugs g[owp(ugs
and/ortheglowpJugs
Continued on the next pa9e
191
TROUBLESHOOTfNG
10. ABNORMAL ENGINE NOISE
2. GasLeakageNoise
Checkpoint Troub[e Cause Countermeasure
Continued from the prevJ'ous page
OK
NG Loose一y connected exhaust mani- NG TJ'ghten the exhaust

Exhaust maniford
manifoJd fold gfow plugs connections
and/or
OK
NG NG
Cy一inder head 9aSket Damaged cylinder head gasket Rep一ace the cyfhder head gasket
3. ContinuousNoise
NG NG
Fanbert Loosefanbe(t
ReadjustthefanbeLttension
OK
NG NG
Coo[J-ngfan Loosecoo=ngfan Retightenthecoo=ngfan
OK
NG Wornordamagedwaterpump NG
VVaterpumpbearLng Repracethevvaterpumpbeanng
beanng
OK
NG DefectiveaJternatororvacuum NG RepaJrOrrePJacethealternator
AIternatororvacuumpump
Pump orthevacuumpump
OK
NG VarvecJearancel'mproperly NG
Va[vecJearance Adjustthevalvec(earance
adjusted
192
TROUBLESHOOTING
10. ABNORMAL ENGINE NOISE

■
4. SZapplngNoise
Checkpoint TroubTe Cause Countermeasure
NG Valve cJearance improperly NG

VaJve clearance Adjust the valve c一earance
adjusted
OK
NG NG
Rocker arm D∂ma9ed rocker arm Rep一ace the rocker arm
OK
NG NG
FJywheel Loose fZywheeJ bolts Reti9hten the fJywhee=)olts
OK
NG Worn or damaged crankshaft NG Rep一ace the crankshaft the

Crankshaft and thrust bearJngS and/or
and/or thrust bearings thrust bearmgs
OK
Crankshaft and connecting rod NG Worn or d8ma9ed c｢8nkshaft NG Rep一ace the crankshaft and/or the
bearln9S and/or connecting rod bearings connecting rod bearJlngs
OK
Connecting rod bushing and NG Worn or damaged connectJ.ng NG Rep(ace the connectJ'ng rod
piston pJn rod bushing and piston pln hushing piston
and/orthe pf-n
OK
Worn or damaged piston and

NG NG Replace the piston and the
Piston =ner ‖ner cy(in-
and cylinde｢ cy=nder
der Hner
Fo｢elgn materia一 in the cy一inder
193
MEMO
194
SPECIAL TOOL LIST
SECT10N ll
SPECIAL TOOL UST
195
SPECIAL TOOL LIST
SPECIAL TOOL LIST
JTEMNO. JLLUSTRATJON PARTNO. PARTSNAME PAGE
l /ul･ 5-8840-0145-0 MeasurlngDevice 25
2 5-8840-2008-0 CompressionGauge 26
3 5-8531-7001-0 CompressionGaugeAdapter 26
35
4 5-8840-0019-0 S=di.ngHammer
71
/
/A NozzleHotder
5 5-8840-2034-0 35
Remover
匂'i
42
6 9-8523-1423-0 VaZveSpringCompressor
85
旺〆〆
Q
CamshaftTim[ngGear 46
7 5-8840-0086-0
C
Un]'versa[PuJler 64
49
#
8 9-8523-1212-0 ValveGuideRe-placer
50
節
9 5-8840-2313-0 Cy[inderLiner[nstalrer 58
63
10 C3 5-8840-2038-0 CamshaftBear)ngReplacer
64
196
SPECIAL TOOL LJST
rTEMNO. 1LLUSTRATJON PARTNO. PARTSNAME PAGE
I
CrankshaftT盲mingGear
ll 9-8840-2057-0 70
Remover
I-(
CrankshaftTimingGear
12
電霜謎 9-8522-0020-0
(nstaller
70
鶴
CrankshaftPilotBeanng
13 5-8840-2000-0 71
Remover
CrankshaftPiFotBeanng
14 5-8522-0024-0 71
:I lnstaller
15
0 5-8840-2061-0 .CrankshaftFrontOilSea[
JnstaHer
79
J土l ValveStemOi[Seaf
16 5-8840-2033-0 85
lnstaller
■■■
17
匡∋ 5-8840-2304-0 CylinderLinerRemoverAnk[e 56
18
管 9-8523-1169-0 CylinderLinerRemover 56
19 5-8840-2360-0 RearOilSeaIRemover 38
OHSea[lnsta‡ler
20 5-8840-2359-1 98
e9② (AxiaJType)
197
MEMO
198
REPAZR STANDARDS
SECT10N 12
REPAIR STANDARDS
TABLE OF CONTEJqTS
汀EM PAGE
Generalrdes......”.”””..””...”..”...”.””..”””.”..,.........””....”....”.”....”199
Repairstandardschart
‥…‥‥‥‥…=…...”…‥………‥‥…‥‥….=……‥‥‥‥……‥‥….200
Genera一 Ru∫卓s
1･ Thesetab[es provide diese一 engine,･

standards relating the repaJr Ofthefol[owing
ModeJ A-4JG1
2･ These RepairStandards are based on inspection items, togetherwith dimensions,

assembly standards,
limit values, and repalr Procedures.
(1) Nominal dimensions arethe standard production values.
(2) Assembly standards considered to be the values used as during the
objectives assemb)y
procedures which foHow repafrS･･ aS a result, they may be somewhat at van'ance with the assembly
dimensions ofa new eng[ne.
(3) Limitvalues referto the measured vaJues resulting from wear, etc., beyond a must
which part not
be Jf a measured value fans beyond the ‥mit value, the part involved be repaired
used･ must or
｢eplaced.
(4) 'IRepair Procedures” indicates repair methods.
normaf
(5) Unless otherwise the unit of numerical in tables be taken to to
stated, values should refer
m=imeters′ mm (in).
3. Explanation of Terms Used inTables

''wear”
(1) The dimension of refers to the dJ'fference between the dimensions of a part which is not
worn (orthe ``nomina[ dimension” of a
partwithout wear) and the dimension of the part suffering
from the most wear (the dimensl'on of the vvorn part).
(2) Uneven wear meansthe difference between the maximum and minimum wearvarues.
41 When repaJrS are requested on the overall engJne･ first perform bench tests to determine what parts
require repalrS･ then perform the minimum disassembry and repafrS to correct the
required problems.
When repalrS On a Part are tO be in reference
specific englne requested, repalrS made to the relevant
items in accordancewith the repair standards [isted in this manuaL
199
REPAIR STANDARDS
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REPAIR STANDARDS
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211
MEMO
212
CONVERSION TABLE
SECTION 13
CONVERSION TABLES
INDEX
CONTENTS PAGE
Length.･,･-･･･････････.･･････-････-･･.･-.････････.･･･-I..･･f-..-･･･････ 213
Area..‥‥‥.=..‥‥..‥‥.‥‥..‥‥‥‥‥.‥‥..‥‥...‥‥.‥‥‥‥‥‥... 215
VoJume ..”...”......................””..................”..”............ 215
Mass ‥‥‥‥‥‥‥..‥‥.‥‥‥‥‥‥‥‥‥‥.‥‥‥..‥...---..‥‥‥‥‥ 217
Pressure -----------------･.--------------- 218
Torque.....,.･･.”･･･..･･･.I-,･･･-･･･････････････････････...,････-･････-･.･ 219
Temperature‥･---I--･･---------I.---･･-I----･･･.-I-･･ 220
LENGTH
M]LLJMETERS TO [NCHES INCHES TO MILLIMETERS
mm in. mm in. mm in. mm in. in. mm in.mm
1 0.0394 26 1.D236 51 2.OO79 76 2.9921 1/64 0.3969 33/6413.0969

2 0.0787 27 1.0630 52 2.0472 77 3.0315 1/32 0.7938 17/32 13.4938
3 0.1181 28 1.1024 53 2.0866 78 3.0709 3/64 1.1906 35/64 13.8906
4 0.1575 29 1.1417 54 2.1260 79 3.1102 1/16 1.5875 9/16 14.2875
5 0.1969 30 1.1811 55 2.1654 80 3.1496 5/64 1,9844 37/64 14.6844
6 0.2362 31 l.2205 56 2.2047 81 3.189O 3/32 2.3813 19/32 15.0813
7 0.2756 1.2598 57 2.2441 82 3.2283 7/64 2.7781 39/64 15.4781

-32
8 0.3150 33 1.2992 58 2.2835 83 3.2677 1/8 3.1750 5/8 15.8750
9 0.3543 34 1.3386 59 2.3228 84 3.3071 9/64 3.5719 41/64 16.2719
10 0.3937 35 1.3780 60 2.3622 85 3.3465 5/32 3.9688 21/32 16.6688
ll 0.4331 36 1.4173 61 2.4016 86 3.3858 ll/64 4.3656 43/64 17.0656
12 0.4724 37 1.4567 62 2.4409 87 3.4252 3/16 4.7625 ll/16 17.4625
13 0.5118 38 1.4961 63 2.4803 88 3.4646 13/64 5.1594 45/64 17.8594
14 0.5512 39 1.5354 64 2.5197 89 3.5039 7/32 5.5563 23/32 18.2563
15 0.5906 40 1.5748 65 2.5591 90 3.5433 15/64 5.9531 47/64 18.6531
16 0.6299 41 1.6142 66 2.5984 91 3.5827 1/4 6.3500 3/4 19.O500
17 0.6693 42 1.6535 67 2.6378 92 3.6220 17/64 6.7469 49/64 19.4469
18 O.7087 43 1,6929 68 2.6772 93 3.6614 9/32 7.1438 25/32 19.8438
19 D.7480 44 1.7323 69 2.7165 94 3.7008 19/64 7.5406 51/64 20.2406
20 0.7874 45 1.7717 70 2.7559 95 3.7402 5/16 7.9375 13/16 20,6375
21 0.8268 46 1.8110 71 2.7953 96 3.7795 21/64 8.3344 53/64 21.0344
22 0.8661 47 1.850ヰ 72 2.8346 97 3.8189 ll/32 8.7313 27/32 21.4313
23 0.9055 48 1.8898 73 2.8740 g8 3.8583 23/64 9.1281 55/64 21.8281
24 0.9449 49 1.9291 74 2.9134 99 3.8976 3/8 9.5250 7/8 22.2250
25 0.9843 50 1.9685 75 2.9528 100 3.9370 25/64 9.9219 57/64 22.6219
13/32 10.3188 29/32 23.0188
01 3.9764 1 4.3701 21 4.7638 31 5.1575 27/64 10.7156 59/64 23.4156
02 4.0157 2 4.4094 22 4.8031 32 5.1968 7/16 ll.1125 15/16 23.8125
03 4.0551 3 4.4488 23 4.8425 33 5.2362 29/64 1l.5094 61/64 24.2094
04 4.0945 4 4.4882 24 4.8819 34 5.2756 15/32 ll.9063 31/32 24.6063
05 4.1339 5 4.5276 25 4.9213 35 5.3150 31/64 12.3031 63/64 25.0031
06 4.1732 6 4,5669 26 4.9606 36 5.3543 1/2 12.700D 1 25.4000
07 4.2126 7 4.6063 27 5.0000 37 5.3937
08 4.2520 8 4.6457 28 5.0394 38 5.4331
09 4.2913 9 4.6850 29 5.0787 39 5.4724
213
CONVERSJON TABLE
LENGTH
FEET TO METERS
ft. 0 1 2 3 4 5 6 7 8 9 ft.
rTl m m m m m m m m m
0.305 0,610 0.914 1,219 1.524 l.829 2.134 2.438 2.743
10 3.048 3.353 3.658 3,962 4.267 4.572 4.877 5.182 5.486 5.791 10
20 6.096 6.40l 6.706 7-010 7.315 7.62D 7.925 8.230 8.534 8.839 20
30 9.144 9.449 9.754 10.058 10.363 10.668 10.973 ll.278 ll.582 1l.887 30
40 12.192 12.497 12.802 13.106 13.411 13.716 14.D21 14.326 14.63O 14.935 40
50 15.240 15,545 15.85O 16.154 16.459 16.764 17.069 17.374 17.678 17.983 50
60 18.288 18.593 18.898 19.202 19.507 19.812 20.117 20.422 20,726 21.O31 60
70 2l.336 21.641 21.946 22.250 22.555 22.860 23.165 23.470 23.774 24.079 70
80 24.384 24.689 24,994 25.298 25.603 25.908 26.213 26.518 26,822 27.127 80
90 27.432 27.737 28.042 28.346 28.651 28.956 29.261 29.566 29.870 30.175 90
100 30.480 30.785 31.090 31.394 31.699 32.004 32.309 32.614 32.918 33.223 100
METERS TO FEET
rn 0 l 2 3 4 5 6 7 8 9
ft. f[. f[. ft. ft. ft. f(. ft. ft. ft.
3.28O8 6.5617 9.8425 13.1234 16.4042 19,6850 22.9659 26.2467 29.5276
1O 32,8084 36.0892 39.3701 42.6509 45.9318 49.2126 52.4934 55.7743 59.0551 62.3360 10
2O 65.6168 68.8976 72.1785 75.4593 78.7402 82.0210 85.3018 88.5827 91.8635 95,1444 2O
30 98.4252 101.7060 104.9869 108.2677 111.5486 114.8294 118.1102 121.3911 124.6719 127.9528 30
40 131.2336 134.5144 137.7953 141.0761 144,3570 147.6378 150.9186 154.1995 157.4803 160.7612 40
50 164.0420･ 167.3228 lワo.6037 173.8845 177.1654 180.4462 183.7270 187.0079 190.2887 193.5696 50
60 196.8504 200.1312 203.4121 206.6929 209.9738 213.2546 216.5354 219.8163 223.0971 226.3780 60
70 229.6588 232.9396 236.2205 239.5013 242.7822 246.0630 249.3438 252.6247 255.9O55 259.1864 70
80 262.4672 265.7480 269.0289 272.3097 275.5906 278.8714 282.1522 285.4331 288.7139 291,9948 80
90 295.2756 298.5564 301,8373 305.1181 308.3990 311.6798 314.9606 318.2415 321.5223 324.8032 90
100 328,0840 331.3648 334.6457 337.9265 341.2074 344.4882 347.7690 351.0499 354.3307 357.6116 100
MILES TO K比OMETERS
0 l 2 3 4 5 6 7 8 9
rniFes
km km km km km km km km km km
1.609 3.219 4.828 6.437 8.047 9.656 ll.265 12.875 14.484
1O 16.093 17.703 19.312 20.921 22.531 24.140 25.75O 27.359 28.968 30.578 10
20 32.187 33.796 35.406 37.015 38.624 40.234 41.843 43_452 45.062 46.671 20
30 48.280 49.890 5l.499 53.108 54.718 56.327 57.936 59.546 61.155 62.764 30
40 64.374 65.983 67.592 69.202 7O.811 72.420 74.030 75.639 77.249 78.858 40
50 80.467 82.077 83.686 85.295 86.905 88.514 90.123 91.733 93.342 94.951 50
60 96.561 98.170 99.779 101,389 102.998 104.607 106.217 107.826 109,435 lll.045 60
70 112.654 114.263 115.873 117.482 119.091 120.701 122.310 123.919 125.529 127.138 70
80 128.748 130.357 131.966 133.576 135.185 136.794 138.404 140.013 141.622 143.232 80
90 144.841 146.450 148.060 149.669 15l.278 152.888 154,497 156.106 157.716 159.325 90
100 160.934 162.544 164.153 165.762 167.372 168.981 170.590 172.200 173.809 175.418 100
K)LOMETERS TO JVTrLES
km 0 1 2 3 4 5 6 7 8 9
mJ'Jes m‖es mites miles mJ'1es miles mi一es miles miles mHes
0.62l 1.243 1.864 2.485 3.107 3.728 4.350 4.971 5.592
10 6.214 6.835 7.456 8.078 8.699 9.321 9.942 10.563 ll.185 ll.806 10
20 12.427 13.049 13.670 14.292 14.913 15,534 16.156 16.777 17.398 18.020 20
30 18.641 19.262 19.884 20.505 21.127 21.748 22.369 22.991 23.612 24.233 30
40 24.855 25.476 26.098 26.719 27.340 27.962 28.583 29.204 29.826 30,447 40
50 31.069 31.690 32.all 32.933 33.554 34,175 34.797 35.418 36.039 36,661 50
60 37.282 37.904 38.525 39.146 39.768 40.389 41.010 41.632 42.253 42.875 60
70 43.496 44.117 44,739 45.360 45.981 46.6(〕3 47.224 47.845 48.467 49.088 70
80 49.710 50.33l 50.952 51.574 52.195 52.816 53.438 54,059 54.681 55.302 80
90 55.923 56.545 57.166 57.787 58.409 59.030 59.652 60,273 60.894 61.516 90
100 62.137 62.758 63.380 64.001 64.622 65.244 65.865 66.487 67.108 67.729 100
214
CONVERSION TABLE
AREA
SQUARE JNCHES TO SQUARE CENTJMETERS
in2 0 1 2 3 4 5 6 7 8 9 in2
cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2 cm2
6.452 12.903 19.355 25.806 32.258 38.71O 45.161 51.613 58.064
10 64.516 70.968 77.419 83.871 90.322 96.774 103.226 109.677 116.129 122.58O 10
20 129.032 135.484 141.935 148.387 154,838 161.290 167.742 174.193 180.645 187.096 20
30 193.548 200,000 206.451 212.903 219.354 225.806 232.258 238.709 245.161 251.612 30
40 258.064 264.516 270.967 277.419 283.870 290.322 296.774 303.225 309.677 316.128 40
50 322.580 329.032 335.483 341.935 348.386 354.838 361.290 367.741 374.193 380.644 50
60 387.096 393.548 399.999 406.451 412.902 419.354 425,806 432.257 438.709 445.160 60
70 451.612 458,064 464.515 470.967 477.418 483.870 490.322 496.773 503.225 509.676 70
80 516.128 522.580 529.031 535.483 541.934 548.386 554.838 561.289 567.741 574.192 80
90 580.644 587.096 593.547 599.999 606.450 612.902 619,354 625.805 632.257 638.708 90
100 645.160 651.612 658.063 664.515 670.966 677.418 683.870 690.321 696.773 703.224 100
SQUARE CENTJMETERS TO SQUARE JNCHES
cm2 O' l 2 3 4 5 6 7 8 9 cm2
J'n2 ['n2 in2 in2 in2 7'n2 in2 in2 11n2 J'n2
0.155 0.310 0.465 0.620 0.775 0.930 1.085 1.240 1.395
10 1.550 1.705 l.860 2.015 2.17O 2.325 2.480 2.635 2.790 2.945 1O
20 3.100 3.255 3.410 3.565 3.720 3.875 4.030 4.185 4.340 4.495 20
3O 4.65O 4.805 4.960 5.115 5.270 5.425 5.580 5,735 5.890 6.045 3O
4O 6.200 6.355 6.510 6.665 6.820 6.975 7.130 7.285 7.440 7.595 40
5O 7.750 7.905 8.060 8.215 8.370 8.525 8.680 8.835 8,990 9.145 5O
60 9.300 9.455 9.610 9.765 9.920 l().075 10.23O 10.385 10.540 10.695 60
70 10.850 ll.005 ll.160 ll.315 ll.470 ll.625 ll,780 ll.935 12.090 12.245 70
80 12.400 12.555 12.710 12.865 13.020 13.175 13.330 13.485 13.640 13.795 80
90 13.950 14.105 14.260 14.415 14.570 14.725 14.880 15.035 15.190 15.345 90
loo 15.500 15.655 15.810 15.965 16.120 16.275 16.430 16.585 16.740 16.895 100
VOLUME
CUBtC INCHES TO CU別C CENTIMETERS
in3 0 1 2 3 4 5･ 6 7 8 9 Jln3
cm3(cc) cm3(cc) cn13(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) cm3(cc) crn3(cc)
16.387 32.774 49.161 65.548 81.935 98.322 114.709 131.097 147.484
1D 163,871 180.258 196.645 213.032 229.419 245.806 262,193 278.580 294.967 311.354 10
20 327.741 344.128 360.515 376.902 393.290 409.677 426.064 442.451 458.838 475.225 20
30 491.612 507.999 524.386 540.773 573.547 589.934 606.321 622.708 639.095 30

.557.160
40 655.483 671.87O 688.257 704.644 721.031 737.418 753.8O5 770.192 786.579 802.966 40
50 819.353 835.740 852.127 868.514 884.901 901.289 917.676 934,063 950.450 966,837 50
6O 983.224 999.611 1015.998 1032.385 1048.772 1065.159 1081.546 1097.933 1114.320 1130.707 60
70 1147.094 1163.482 1179.869 1196.256 1212.643 1229.030 1245.417 1261.804 1278.191 1294.578 70
80 1310.965 1327.352 1343.739 1360.126 1376.513 1392.900 1409.28B 1425.675 1442.062 1458.449 80
90 1474.836 1491.223 1507.610 1523.997 1540,384 1556.771 1573.158 1589.545 1605.932 1622.319 90
100 1638.706 1655.093 1671.481 1687.868 1704.255 1720.642 1737.029 1753.416 1769.8O3 1786.190 loo
CUBIC CENTrMETERS TO CUB]C rNCHES
0 1 2 3 4 5 6 7 8 9
cm3(cc) cm3(cc)
in3 in3 in3 l'n3 in3 in3 J'n3 jn3 in3 in3
0.0610 0.1220 0.1831 0.2441 0.3051 0.3661 0.4272 0.4882 0.5492
10 0.6102 0.6713 0.7323 0.7933 0.8543 0,9153. 0.9764 1.D374 1,0984 1.1594 10
20 1.2205 l.2815 1.3425 1.4035 1.4646 1.5256 1.5866 1.6476 1.7086 1.7697 20
30 1.8307 1.8917 1.9527 2.0138 2.O748 2.1358 2.1968 2.2579 2.3190 2.3799 30
40 2.4409 2.5020 2.5630 2.6240 2.6850 2.7460 2.8071 2.8681 2.9291 2.9901 40
50 3.0512 3.1122 3.1732 3.2342 3.2952- 3.3563 3.4173 3.4783 3.5393 3.6004 50
60 3.6614 3.7224 3.7834 3.8444 3.9055 3.9665 4.0275 4.0885 4.1496 4.2106 60
70 4.2716 4.3326 4.3937 4.4547 4.5157 4.5767 4.6377 4.6988 4.7598 4.8208 70
80 4.8818 4.9429 5.0039 5.0649 5.1259 5.1870 5.2480 5.3090 5.3700 5.4310 80
90 5.4921 5.5531 5.6141 5.6751 5.7362 5.7972 5.8582 5.9192 5.9803 6.0413 90
loo 6.1023 6.1633 6.2243 6.2854 6.3464 6.4074 6.4684 6.5295 6.5905 6.6515 100
215
CONVERSION TABLE
VOLUME
GALLONS (U.S.I TO LITERS
U.S.gal. 0 1 2 3 4 5 6 7 8 9 U.S.gal.
Jiters 一iters =ters )iters [J'ters liters 一iters I)'ters liters 一iters
3.7854 7,5709 ll.3563 15.1417 18.927l 22.7126 26.4980 30.2834 34.0688
10 37.8543 41.6397 45.425l 49.2105 52.9960 56.7814 6O.5668 64.3523 68.1377 7l.9231 10
20 75.7085 79.4940 83.2794 87.0648 90.8502 94.6357 98.4211 102.2065 105.9920 109.7774 20
30 113.5628 117.3482 121.1337 124.9191 128.7045 132.4899 136.2754 140.0608 143.8462 147.6316 30
40 151.4171 155.2025 158.9879 162.7734 166.5588 170.3442 174.1296 177.9151 181.7005 185.4859 40
50 189.2713 193.0568 196.8422 200.6276 204.4131 208.1985 211.9839 215.7693 219.5548 223.3402 50
60 227.1256 230.9110 234.6965 238.4819 242.2673 246.0527 249.8382 253.6236 257.4090 261.1945 6O
70 264.9799 268.7653 272.5507 276.3362 280.1216 283.9070 287.6924 291.4779 295.2633 299.0487 70
80 302.8342 306.6196 310.4050 314,1904 317.9759 321.7613 325.5467 329.3321 333.1176 336.9030 80
90 340.6884 344.4738 348.2593 352.0447 355.8301 359.6156 363.4010 367.1864 370.9718 374.7573 90
100 378.5427 382.3281 386.1135 389.8990 393.6844 397.4698 40l.2553 405.0407 408.8261 412.6115 100
LrrERS TO GALLONS (U.S.)
拙ers 0 1 2 3 4 5 6 7 8 9 ”-ters
gaJ. gaJ. ga一. gal. gaL gal, gal. gal. ga一. gal,
0.2642 0.5283 0.7925 1.0567 1.3209 1.5850 1.8492 2.1134 2.3775
10 2.6417 2.9059 3.1701 3.4342 3.6984 3.9626 4.2268 4.4909 4.7551 5.0193 10
20 5.2834 5.5476 5.8118 6.0760 6.3401 6.6043 6.8685 7.1326 7.3968 7.6610 20
30 7,9252 8.1893 8.4535 8.7177 8.9818 9.2460 9.5102 9.7744 10.0385 10.3027 30
40 10.5669 10.8311 ll.0952 ll.3594 ll.6236 ll.8877 12.1519 12.4161 12.6803 12.9444 40
50 13.2O86 13.4728 13.7369 14.0011 14.2653 14.5295 14.7936 15.0578 15.3220 15.5861 50
60 15.8503 16.1145 16.3787 16.6428 16.9070 17.1712 17,4354 17,6995 17.9637 18.2279 60
70 18.4920 18.7562 19.0204 19.2846 19.5487 19.8129 20.0771 20.3412 20.6054 20.8696 70
80 21.1338 21.3979 2l.6621 21,9263 22.1904 22.4546 22.7188 22.983O 23.2471 23.5113 80
90 23.7755 24.0397 24.3038 24.5680 24.8322 25.0963 25.3605 25.6247 25.8889 26.1530 90
100 26.4172 26.6814 26.9455 27.2097 27.4739 27.7381 28.0022 28.2664 28.5306 28.7947 100
GALLONS (IMP.) TO UTERS
fmpga(. 0 1 2 3 4 5 6 7 8 9 FmpgaJ.
lFters liters liters 一iters liters liters liters Liters (iters liters
4.5459 9.0918 13.6377 18.1836 22.7295 27.2754 31.8213 36.3672 40.9131
1O 45.4590 50.0049 54.5508 59.0967 63.6426 68.1885 72.7344 77.2803 8l.8262 86.3721 10
2D 90.9180 95.4639 100.0098 104.5557 109.1016 113.6475 118.1934 122.7393 127.2852 131.8311 20
30 136.3770 140.9229 145.4688 150.0147 154.5606 159.1065 163.6524 168.1983 172.7442 177.29Ol 30
40 181.8360 186.3819 190.9278 195.4737 200.O196 204.5655 209.1114 213.6573 218.2032 222.7491 40
50 227.2950 231.8409 236.3868 240.9327 245.4786 250.0245 254,5704 259.1163 263.6622 268,2081 50
60 272.7540 277.2999 281.8458 286.3917 290.9376 295.4835 300.0294 304.5753 309,1212 313.6671 60
70 318.213O 322.7589 327.3048 331.8507 336.3966 340.9425 345.4884 350.0343 354.5802 359.1261 70
80 363.6720 368.2179 372.7638 377.3097 381.8556 386.4015 390.9474 395.4933 400.0392 404.5851 80
90 409.1310 413.6769 418.2228 422,7687 427.3146 431.8605 436.4064 440.9523 445.4982 450.0441 90
100 454.5900 459.1359 463.6818 468.2277 472.7736 477.3195 481,8654 486,4113 490.9572 495.5031 loo
UTERS TO GALLONS ()MP.)
liters 0 1 2 3 4 5 6 7 8 9 Hters
9aL gaL ga一. gal. gaL gal. gal. 9aE. gal. ga[.
0.2200 0.4400 0.6599 0.8799 l.0999 1.3199 1.5399 i.7598 l.9798
10 2.1998 2.4198 2.6398 2.8597 3.0797 3.2997 3.5197 3.7397 3.9596 4.1796 10
20 4.3996 4.6196 4.8396 5.0595 5.2795 5.4995 5.7195 5.9395 6.1594 6.3794 20
30 6.5994 6,8194 7.0394 7.2593 7.4793 7,6993 7.9193 8.1393 8.3592 8.5792 30
40 8.7992 9.0192 9.2392 9.4591 9.6791 9.8991 10.1191 10.3391 10.5590 10.7790 40
50 10.9990 1l.2190 ll.4390 ll.6589 ll.8789 12.0989 12,3189 12.5389 12.7588 12.9788 50
60 13.1988 13.4188 13.6388 13.8587 14.0787 14.2987 14.5187 14.7387 14.9586 15.1786 60
70 15.3986 15.6186 15.8386 16.0585 16.2785 16.4985 16.7185 16.9385 17.1584 17.3784 70
80 17.5984 17.8184 18.0384 18.2583 18.4783 18.6g83 18.9183 19.1383 19.3582 19.5782 80
90 19.7982 20.O182 20.2382 20.4581 20.6781 20.8981 21.1181 21.3381 2l.5580 21.7780 90
100 21.9980 22.2180 22.4380 22-6579 22.8779 23,0979 23.3179 23.5379 23.7578 23.9778 loo
216
CONVERS10N TABLE
MASS
POUNDS TO KILOGRAMS
(bs. 0 l 2 3 4 5 6 7 8 9 lbs.
kg kg kg kg kg kg kg kg kg kg
0,454 0.907 1.361 i.814 2.268 2.722 3.175 3.629 4.082
1O 4.536 4,990 5.443 5.897 6.35O 6.804 7.257 7.711 8.165 8.618 10
20 9.072 9.525 9.979 10.433 10.886 ll.340 1l.793 12.247 12.701 13.154 20
30 13.6O8 14,061 14.515 14.970 15.422 15.876 16,329 16.783 17.237 17.690 30
40 18.144 18.597 19.051 19.504 19.958 20.412 20.865 21.319 2l.772 22.226 40
50 22.680 23.133 23.587 24,Oho 24.494 24.948 25.401 25.855 26.308 26.762 50
60 27.216 27.669 28.123 28.576 29,030 ■29.484 29.937 30.39l 30.844 31.298 6O
70 3l.751 32.205 32.659 33.112 33.566 34.019 34.473 34.927 35,38O 35.834 70
80 36.287 36.741 37.195 37.648 38,102 38.555 39.009 39.463 39.916 40.370 BO
90 40.823 41.277 41.731 42.184 42.638 43.091 43.545 43.998 44.452 44.905 90
100 45.359 45.813 46.267 46.720 47.174 47.627 48.O81 48.534 48.988 49.442 100
KILOGRAMS TO POUNDS
kg 0 1 2 3 4 5 6 7 8 9 kg
Jb5. lbs. lbs. Jbs. fbら. rbs. Ibs. Jbs. lbs. lbs.
2.205 4.409 6,614 8.818 ll.023 13.228 15.432 17.637 19.842
10 22.046 24.251 26.455 28.660 30,865 33.069 35.274 37.479 39.683 41.888 10
2O 44.092 46.297 48.502 50.706 52.911 55.116 57.320 59.525 61.729 63.934 20
3O 66.139 68.343･ 70.548 72.753 74.957 77.162 79.366 81.571 83.776 85.980 30
40 88.185 90.390 92.594 94.799 97,003 99.208 101.413 103.617 105.822 1O8.026 40
50 110.231 112.436 114.640 116,845 119.050 121.254 123.459 125.663 127.868 130.073 50
6O 132,277 134.482 136.687 138.891 141.096 1ヰ3.300 145,505 147.710 149.914 152.119 60
70 154.324 156.528 158.733 160.937 163.142 165.347 167.551 169.756 171.960 174.165 70
80 176.370 178.574 180.779 182.984 185.188 187.393 189.597 191.802 194.007 196.211 80
90 198.416 200.621 202,825 205.030 207.234 209.439 211.644 213.848 216.053 218.258 90
100 220.462 222.667 224,871 227.076 229.281 231.485 233.690 235.895 238.099 240.304 100
KILOGRAMS TO NEWTOrU
kgf 0 1 2 3 4 5 6 7 8 9 kgf
N N N N N N N N N N
9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26
10 98.07 107.87 117.68 127.49 137.29 147.10 156.gl 166.71 176.52 186.33 10
20 196.13 205.94 215.75 225.55 235.36 245.17 254.97 264.78 274.59 284.39 20
30 294.20 304.01 313.81 323.62 333,43 343.23 353.04 362.85 372.65 382.46 30
40 392.27 4O2_07 411.88 421.69 431.49 441.3O 45l.ll 460,91 470,72 480.53 40
50 490.33 500.14 509.95 519.75 529.56 539.37 549.17 558.98 568.79 578.59 50
60 588.40 598.21 608.Ol 617.82 627.63 637.43 647.24 657.05 666.85 676.66 60
70 686.47 696.27 706.08 715.89 725.69 735.50 745,31 755.ll 764.92 774,73 70
80 784.53 794.34 804.15 813.95 823,76 833.57 843.37 853.18 862.99 872.79 80
90 882.60 892.41 902.21 912.02 921.83 931.63 94l.44 951.25 961,05 970.86 90
100 980.67 99O.47 1000.2B 1010.08 1019.89 1029.70 1039.50 1049.31 1059.12 1068.92 loo
NEWTON TO K(I.OGRAMS
N O 10 20 30 40 50 60 70 80 gO N
kgf kgf kgf kgf kgf kgf kgf kgf kgf kgf
i.020 2.039 3.059 4.O79 5.099 6.118 7.138 8.158 9.177
100 10.197 ll.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 100
200 20.394 21.414 22.434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 200
300 30.592 31.611 32.631 33.651 34.670 35.690 36.710 37.730 38,749 39.769 300
4(】0 40.789 41.809 42.828 43.848 44.868 45.887 46.907 47.927 48.947 49.966 400
500 50.986 52.006 53.025 54.045 55.065 56.085 57.104 58.124 59.144 60.163 500
600 61.183 62.203 63.223 64.242 65.262 66.282 67.302 68.321 69.341 70.361 600
700 71.380 72.400 73.420 74.44D 75.459 76.479 77.499 78.518 79.538 80.558 700
800 81.578 82.597 83.617 84.637 85.656 86.676 87.696 88.716 89.735 90.755 800
900 91.775 92.795 93.814 94,834 95.854 96.873 97.893 98.913 99.933 100.952 900
1000 1Ol.972 102.992 104.011 105.031 106.051 107.071 108.090 log.110 110.130 111.149 1000
217
CONVERS10N TABLE
PRESSURE
POUNDS PER'SQUARE INCHES TO KILOGRAMS PER SQUARE CENTIMETERS
Jb/in2 0 1 2 3 4 5 6 7 8 9 lb/J'n2
(psi) kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/cm2 kgf/crn2 kgi/cm2 kgf/cm2 kgf/cm2 kgf/cm2 (psJ')
0.0703 0.1406 0.2109 0.2812 0.3515 0.4218 0.4921 0.5625 0.6328
10 0.7031 0.7734 0.8437 0.9140 0.9843 1.0546 1.1249 l.1952 1.2655 1.3358 10
20 1.4061 1.4764 1.5468 1.6171 1.6874 1.7577 1,8280 l.8983 1.9686 2.0389 20
30 2.1092 2.1795 2.2498 2.3201 2.3904 2,4607 2.5311 2.6014 2.6717 2.7420 30
40 2.8123 2.8826 2.9529 3.0232 3.0935 3.1638 3.2341 3.3044 3,3747 3.4450 40
50 3.5154 3.5857 3.6560 3.7263 3.7966 3.8669 3.9372 4.0075 4.0778 4.1481 50
60 4.2184 4.2887 4.3590 4.4293 4.4996 4.5700 4.6403 4.7106 4.7809 4.8512 60
70 4.9215 4.9918 5.0621 5.1324 5.2027 5.2730 5.3433 5.4136 5.4839 5.5543 70
80 5.6246 5.6949 5.7652 5.8355 5.9058 5.9761 6.0464 6.1167 6.1870 6.2573 80
90 6.3276 6.3979 6.4682 6.5386 6.6089 6.6792 6.7495 6.8198 6.8901 6.9604 90
100 7.0307 7.101O 7.1713 7.2416 7.3119 7.3822 7.4525 7.5228 7.5932 7.6635 100
KILOGRAMS PER SQUARE CENTIMETERS TO POUNDS PER SQUARE INCHES
kgf/cm2 0 1 2 3 4 5 6 7 8 9 kgf/cm2
Jb/l'n2(psi) Ib伽2(pst) Ib/in2(psi) Fb/in2(psi) Ib/in2(psり tb/in2(psり lb/in2(psi) lb/in2(psi) Ib/fn2(ps7) Jb/in2(psi)
14.22 28.45 42.67 56.89 71.12 85.34 99.56 113.78 128.Ol
10 142.23 156.45 170.68 184.90 199.12 213.35 227.57 241.79 256.01 270.24 10
20 284.46 298.68 312.91 327.13 341.35 355.58 369.80 384.02 398.24 412.47 20
3O 426.69 440.91 455.14 469.36 483.58 497.81 512.03 526.25 540.47 554.70 30
40 568.92 583.14 597.37 611.59 625.81 640.04 654.26 668.48 682.70 696.93 40
50 71l.15 725.37 739.60 753.82 768,04 782.27 796.49 810.71 824.93 839.16 50
60 853.38 867.60 881.83 896.05 910.27 924.50 938,72 952.94 967.16 98l.39 60
70 995,61 1009.83 1024.06 1038.28 1052.50 1066.73 1080.95 1095.17 1109.39 1123.62 70
80 1137.84 1152.06 1166.29 1180.51 1194.73 1208.96 1223.18 1237.40 1251.62 1265.85 80
90 1280.07 1294,29 1308.52 1322､74 1336.96 1351.19 1365.41 1379.63 1393.85 1408.08 90
100 1422.30 1436.52 1450.75 1464.97 1479.19 1493.42 1507.64 1521.86 1536.08 1550.31 100
KILOGRAMS PER SQUARE CENT)METERS TO K]L.0 PASCAL
kgf/cm2 0 1 2 3 4 5 6 7 8 9 kgf/cm2
KPa KPa KPa KPa KPa KPa KPa KPa KPa KPa
98.1 196.1_ 294.2 392.3 490.3 588,4 686.5 784.5 882.6
10 980.7 1078,7 1176.8 1274.9 1372.9 1471.0 1569,1 1667.1 1765.2 1863.3 10
20 1961.3 2059.4 2157.5 2255.5 2353,6 2451.7 2549.7 2647.8 2745.9 2843.9 20
30 2942.0 3040.1 3138.1 3236.2 3334.3 3432.3 3530.4 3628.5 3726.5 3824.6 30
40 3922.7 4020.7 ヰ118.8 4216.9 4314.9 4413.0 4511.l 46O9.1 4707.2 4805.3 40
50 4903.4 5001.4 5099.5 5197.5 5295.6 5393.7 5491.8 5589.8 5687.9 5785.9 50
60 5884.0 5982.1 6080.1 6178.2 6276.3 6374.4 6472.4 6570.5 6668.6 6766.6 60
70 6864.7 6962.7 7060.8 7158.9 7256.9 7355.0 7453.1 7551.1 7649,2 7747.3 70
80 7845.3 7943.4 8041,5 8139.5 8237.6 8335.7 8433.7 8531.8 8629.9 8727.9 80
90 8826.0 8924.1 9022.1 9120.2 9218.3 9316.3 9414.4 9512.5 9610.5 9708.6 90
100 9806.7 9904.7 lOOO2.8 10100.8 10198.9 10297.0 1O395.1 10493.1 10591.2 10689.2 100
K]LO PASCAL TO KLLOGRAMS PER SQUARE CENT)METERS
KPa 0 100 200 ョoo 400 500 600 700 800 900 KPa
kgf/cm2 kgf/crn2 kgt/cm2 kgt/cm2 kgf/cm2 kgf/cm2 kgt/cm2 kgf/cm2 kgf/cm2 kgf/cm2
1.020 2.O39 3.059 4.079 5.099 6.118 7.138 8.158 9.177
1000 10.197 ll.217 12.237 13.256 14.276 15.296 16.316 17.335 18.355 19.375 1000
2000 20.394 21.414 22,434 23.454 24.473 25.493 26.513 27.532 28.552 29.572 2000
30DO 30.592 31.611 32.631 33.651 34.670 35.690 36.710 37.730 38.749 39.769 3000
40OO 40,789 41.809 42.828 43,848 44.868 45.887 46.907 47.927 48.947 49.966 4000
5000 50.986 52.006 53.025 54.045 55.065 56.085 57.104 58.124 59.144 60,163 5000
6000 61.183 62.203 63.223 64.242 65.262 66.282 67,302 68,321 69.341 70.361 6000
7000 71.3白o 72.400 73.420 74.44O 75.459 76.479 77.499 78.518 79,538 80.558 7000
8000 81.578 82.597 83.617 84.637 85.656 86.676 87.696 88.716 89.735 90.755 8000
9000 9l.775 92.795 93.814 94.834 95.854 96.873 97.893 98.913 99.933 100.952 9000
10000 10l.972 102.992 104.011 105,031 106.O51 107.071 108.090 109.110 110.130 111.149 10000
218
CONVERSION TABLE
TORQUE
FOOT POUNDS TO KILOGRAMMETERS
ft.1bs. 0 l 2 3 4 5 6 7 8 9 ftJbs.
kgf-rn kgf-m kgf-m kgf･m kgf-m kgf･m kgf･m kgf-m kgf-m kgf-m
0.138 0.277 0.415 0.553 0.691 0.830 0.968 1.106 1.244
10 1.383 1.521 l.659 1.797 l.936 2.074 2.212 2.350 2.489 2.627 10
20 2.765 2.9O3 3.042 3.180 3.318 3.456 3.595 3.733 3.871 4.OO9 20
30 4.148 4.286 4.424 4.562 4.701 4.839 4.977 5.115 5.254 5.392 30
40 5.530 5.668 5.807 5.945 6.083 6.221 6.360 6.498 6.636 6.774 40
50￣ 6.913 7.051 7.189 7.328 7.466 7.604 7.742 7.881 8.019 8.157 50
60 8.295 8.434 8.572 8.710 8.848 8.987 9.125 9.263 9.401 9.540 60
70 9.678 9.816 9.954 10.093 10.231 10.369 10.507･ 10.646 10.784 10.922 70
80 ll.060 ll.199 ll.337 1l.475 ll.613 1l.752 ll.890 12.028 12.166 12.305 80
90 12.443 12.581 12.719 12.858 12.996 13.134 13.272 13,ヰ11 13.549 13.687 90
loo 13.826 13.964 14,102 14.240 14.379 14.517 14.655 14.793 14.932 15.070 100
KILOGRAMMETERS TO FOOT POUNDS
kgf-m 0 1 2 3 4 5 6 7 8 9 kgf-m
f[.Jbs. fLlbs. fLlbs. ft.1bs. ft.1bs. ft.Jbs. ft.1bs. ft.rbs, f[.1bs. ft.Jbs.
7.23 14.47 21.70 28.93 36.17 43.40 50.63 57.86 65.10
10 72.33 79.56 86.80 94.03 101.26 108.50 715.73 122.96 130.19 137.43 10
20 144.66 151.89 159.13 166.36 173.59 180.83 188.06 195,29 202,52 209.76 20
30 216.99 224.22 231.46 238,69 245.92 253.16 260.39 267.62 274.85 282.09 30
40 289.32 296.55 303-79 311.02 318.25 325.49 332.72 339.95 347.18 354.42 40
50 361.65 368.88 376,12 383.35 390.58 397.82 405.05 412.28 419.51 426.75 5O
60 433.98 441.21 448.45 455.68 462.91 470.15 477.38 484.61 49l.84 499.08 60
70 506.31 513.54 520.78 528.01 535.24 542.48 549.71 556.94 564.17 571.41 70
80 578.64 585.87 593.ll GOO.34 607.57 614.81 622.04 629.27 636.50 643▲74 80
90 650.97 658.20 665.44 672.67 679.90 687.14 694.37 701.60 7O8.83 716.07 90
loo 723.30 730.53 737.77 745.00 752.23 759.47 766.70 773.93 781.16 788.40 100
KILOGRAMMETERS TO NEWTONMETERS
kgf･m 0 1 2 3 4 5 6 7 8 9 kgfィn
N-m N-m N･m N-m N･m N-m N-m N-m N-rTl N-m
9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26
10 98.07 107.87 117,68 127,49 137.29 147.10 156.91 166.71 176.52 186.33 1O
20 196.13 205.94 215.75 225.55 235.36 245.17 254.97 264.78 274.59 284.39 20
30 294.20 304.Ol 313.81 323.62 333.43 343.23 353.04 362.85 372.65 382.46 3O
4O 392.27 402.07 411.88 421.69 431.4g 44l.30 451.ll 460.91 470.72 480.53 40
5O 490.33 50O.14 509.95 519.75 529.56 539.37 549.17 558.98 568.79 578.59 50
60 588.40 598.21 608.01 617.82 627.63 637.43 647.24 657.05 666.85 676.66 60
70 686.47 696.27 706.08 715.89 725.69 735.50 745.31 755.ll 764.92 774.73 70
80 784.53 794.34 804.15 813.95 823.76 833.57 843.37 853.18 862.99 872.79 80
90 882.60 892.41 902.21 912.02 921.83 931.63 941.44 951,25 961.O5 970.86 90
一oo 980.67 990.47 1OOO.28 1010.08 1019.89 1029.70 1039.51 1049.31 1059.12 1068.93 loo
NEWTONMETERS TO KILOGRAMMETERS
N･m 0 10 20 30 40 50 60 70 80 90 N-rn
kgf-m kgf-m kgf-r71 kgf-m kg†-m kgf-m kgf-m kgf-m kgf-m kgfィTl
1.020 2.039 3.059 4,879 5.099 6.118 7.138 8.158 9.177
100 10.197 ll.217 12.236 13.256 14.276 15.296 16.315 17.335 18.355 19.374 100
200 20.394 21.414 22.433 23.453 24.473 25.493 26,512 27.532 28.552 29.571 200
300 30.591 31.611 32.630 33.650 34.670 35.690 36.709 37.729 38.749 39.768 300
4OO 40.788 41.808 42.827 43.847 44.867 45.887 46.906 47.926 48.946 49.965 400
500 50.985 52.005 53.024 54.044 55.064 56.084 57,103 58.123 59.143 60.162 500
600 61.182 62.202 63.221 64.241 65.261 66.281 67.300 68,320 69.340 70.359 600
700 71.379 72.399 73.418 74.438 75.458 76.478 77.497 78.517 79.537 80.556 700
800 81.576 82.596 83.615 84.635 85.655 86.675 87.694 88.714 89.734 90,753 800
900 91.773 92.793 93.812 94.832 95.852 96.872 97.891 98.911 99.931 100.950 900
1000 101.970 102.990 104.009 105.029 106.049 107.069 108.088 log.108 110.128 lil.147 1000
219
CONVERSION TABLE
TEMPERATURE
FAHRENHEIT TO CENTIGRADE
oF ロC ロF oC oF oC oF c'C oF oC cF oC oF oC t)F oC
56 13.3 114 45.6 172 77.8 230 110.0 288 142.2 346 174,4
-60 151.1 -2 -18.9
0 58 14,4 116 46.7 174 78.9 232 lll.1 290 143.3 348 175.6
-58 -50.0 ,17.8
2 ･16.7 60 15,6 118 47.8 176 80.0 234 112.2 292 144.4 350 176.7
-56 -48.9
4 62 16.7 120 48.9 178 81.i 236 113.3 294 145.6 352 177.8
-54 -47.8 -15.6
6 ･14.4 64 17.8 122 50.0 180 82.2 238 114.4 296 146.7 354 178.9
-52 -46.7
8 66 18.9 124 51.1 182 83.3 24O 115.6 298 147.8 356 180.0
-50 -45.6 ･13.3
10 68 20.0 126 52.2 184 84.4 242 116.7 300 148.9 358 181.1
-48 144.4 -12.2
12 70 21.1 128 53.3 186 85.6 244 117.8 302 150.0 360 182.2
-46 -43.3 -ll.1
14 72 22.2 130 54.4 188 86.7 246 118.9 304 151.1 362 183.3
･44 -42.2 ･10.0
16 74 23.3 132 55.6 190 87.8 248 120.0 3O6 152.2 364 184.4
-42 -41.1 -8.9
18 76 24.4 134 56.7 192 88.9 250 121.i 308 153.3 366 185.6
-40 -40.0 -7.8
20 78 25.6 136 57.8 194 90.0 252 122.2 310 154.4 368 186.7
-38 ･38.9 -6.7
22 80 26.7 138 58.9 196 91.1 254 123.3 312 155,6 370 187.8
･36 ･37.8 -5.6
24 82 27,8 140 60.0 198 92.2 256 124.4 314 156.7 372 188.9
-34 -36.7 ･4.4
26 84 28.9 142 61.1 200 93.3 258 125.6 316 157.8 374 190,0
-32 -35.6 ･3,3
28 86 30.0 144 62.2 202 94.4 260 126.7 318 158.9 376 191.i
-30 -34.4 -2.2
30 88 3l.1 146 63.3 204 95.6 262 127.8 320 160.0 378 192.2
･28 -33.3 -1.1
32 0.0 90 32.2 148 64,4 206 96.7 264 128.9 322 161.1 380 193.3
-26 ･32.2
34 1.1 92 33.3 150 65.6 208 97.8 266 130.0 324 162.2 382 194.4
･24 -31.1
36 2.2 94 34.4 152 66.7 210 98.9 268 131.1 326 163.3 384 195.6
･22 -30.0
38 3.3 96 35.6 154 67,8 212 100.0 270 132.2 328 164.4 386 196.7
-20 -28.9
40 4.4 98 36.7 156 68.9 214 10l.1 272 133.3 330 165.6 388 197.8
-18 -27.8
42 5.6 100 37,8 158 70.0 216 102.2 274 134.4 332 166.7 390 198.9
･16 ･26.7
44 6.7 102 38.9 160 71.1 218 103.3 276 135.6 334 167.8 392 200.0
-14 -25.6
46 7.8 104 40.0 162 72.2 220 104.4 278 136.7 336 168.g 400 2O4.4
･12 ･24.4
48 8.9 106 41.1 164 73.3 222 105.6 280 137,8 338 170.0 410 210.0
-10 -23.3
50 10.0 108 42.2 166 74.4 224 106.7 282 138.9 340 171.1 420 215.6
-8 -22.2
52 ll.1 110 43.3 168 75.6 226 107.8 284 140.0 342 172.2 430 221.1
-6 ･21,1
54 12.2 112 44.4 170 76.7 228 108.9 286 14l.1 344 173.3 440 226.7
-4 -20.0
CENTIGRADE TO FAHRENHEIT
c'C oF oC oF oC oF cC oF oC E'F oC cF oC oF oC oF
14 57.2 46 114.8 78 172.I 110 230.0 142 287.6 174 345.2

･50 -58.0 -18 -0.4
1.4 15 59.0 47 116.6 79 174.2 111 231.8 143 289.4 175 347.0
-49 ･56.2 ･17
3.2 16 60.8 48 118.4 80 176.0 112 233.6 144 291.2 176 348,8
-48 -54.4 ･16
5.0 17 62.6 49 120.2 81 177,8 113 235.4 1ヰ5 293.0 177 350.6
-47 -52.6 -15
6.8 18 64.4 50 122.0 82 179.6 114 237.2 146 294.8 178 352.4
-46 -50.8 -14
8.6 19 66.2 51 123.8 83 18l.4 115 239.0 147 296.6 179 354.2
-45 -49.O ･13
10.4 20 68.0 52 125.6 84 183.2 116 240.8 148 298.4 180 356.0
･44 ･47.2 -12
12.2 21 69.8 53 127,4 85 185.O 117 242.6 149 300.2 181 357.8
-43 -45.4 -ll
14.O 22 71.6 54 129.2 86 186.8 118 244.4 150 302.0 182 359.6
-42 -43.6 ･10
15.8 23 73.4 55 131.0 87 188.6 119 246.2 151 303.8 183 361.4
-41 ･41.8 -9
17.6 24 75.2 56 132.8 88 190.4 120 248.0 152 305.6 184 363.2
-40 -40.0 -8
19.4 25 77.0 57 134.6 89 192.2 121 249.8 153 307.4 185 365.0
-39 ･38.2 -7
21.2 26 78.8 58 136.4 90 194.0 122 251.6 154 309.2 186 366.8
-38 ･36.4 -6
23.0 27 80.6 59 138.2 91 195.8 123･ 253.ヰ 155 311.0 187 368.6
-37 ･34.6 15
24.8 28 82.4 60 140.0 92 197.6 124 255.2 156 312.8 188 370.4
-36 ･32.8 -4
26.6 29 84.2 61 14l.8 93 199.4 125 257.0 157 314.6 189 372.2
-35 -31.O -3
28.4 30 86.0 62 143.6 94 201.2 126 258.8 158 316.4 190 374.0
134 -29.2 ･2
30.2 31 87.8 63 145.4 95 203.0 127 260,6 159 318,2 191 375.8
-33 -27.4 ･1
0 32.0 32 89.6 64 147.2 96 2O4,8 128 262.4 leo 320,0 192 377.6
-32 ･25.6
1 33.8 33 91,4 65 149.0 97 206,6 129 264.2 161 321.8 193 379.4
-31 ･23.8
2 35.6 34 93.2 66 150.8 98 208.4 130 266.0 162 323.6 194 38l.2
･30 ･22.0
3 37.4 35 95.0 67 152.6 99 21O.2 131 267.8 163 325.4 195 383.0
-29 -20.2
4 39.2 36 96.8 68 154.4 100 212.0 132 269.6 164 327.2 196 384.8
128 ･18.4
5 41.0 37 98.6 69 156.2 101 213.8 133 27l.4 165 329.0 197 386.6
-27 ･16.6
6 42.8 38 10(】.4 70 158.0 102 215.6 134 273.2 166 330.8 198 388.4
-26 ･14.8
7 44.6 39 102.2 71 159.8 103 217.4 135 275,0 167 332.6 199 390.2
-25 ･13.0
8 46.4 40 104.0 72 161.6 104 219.2 136 276.8 168 334.4 200 392.0
-24 -ll.2
9 48.2 41 105.8 73 163.4 105 221.0 137 278.6 169 336.2 210 410.0
･23 -9.4
10 50.0 42 107.6 74 165.2 106 222.8 138 280.4 170 338.0 220 428.0
-22 -7.6
ll 51.8 43 109.4 75 167.0 107 224.6 139 282.2 171 339.8 230 446.0
-21 -5.8
12 53.6 44 111.2 76 168.8 108 226.4 140 284.0 172 341.6 240 464.0
-20 -4.0
13 55.4 45 113.0 77 170.6 log 228.2 141 285.8 173 343.4 250 482.0
119 .-2.2
220
Copyright reserved for this manual may not be
reproduced or copied, in whore or in part,. without the

written consent of FSUZU MOTORS UMITED,
WORKSHOP MANUAL (lNDUSTRtALI
A-4JG I
(lDE-2320)
Jssued by
ISUZU MOTORS LIM汀ED

POVVERTRAJN SERV[CE a PARTS
POVVERTRA[N OPERATIONS
6-26･1. Minahli-of, Shinagawa･ku.Tokyo, 140-8722, Japan
TEL 03-547ト1111
First edition Aug., 1999 907-01K
63. MOUNTING THE BREAKER AND
NIBBLER & BREAKER
TABLE OF CONTENTS
63.1 LIST OF ADDITIONAL PARTS .......................................................................................... 63-4

63.1.1 ADDITIONAL PARTS FOR THE MODIFICATION OF THE BREAKER .................... 63-4
63.1.2 ADDITIONAL PARTS FOR THE MODIFICATION TO THE NIBBLER &
BREAKER ................................................................................................................. 63-10
63.2 SUMMARY ......................................................................................................................... 63-16
63.2.1 GENERAL PRECAUTIONS ...................................................................................... 63-16
63.2.2 BASIC METHOD TO BE TAKEN WHEN MOUNTING .............................................. 63-16
63.2.3 LAYING OF PIPING .................................................................................................. 63-17
63.3 HYDRAULIC CIRCUIT DIAGRAM ..................................................................................... 63-18
63.3.1 FUNCTION ................................................................................................................ 63-18
63.4 HYDRAULIC COMPONENTS ............................................................................................ 63-24
63.4.1 CONTROL VALVE ASSY (50) : YT30V00010F4
OPTION VALVE (BREAKER, NIBBLER & BREAKER) (50-1) : YT30V00007F1 ........ 63-24
63.4.2 SOLENOID VALVE : YT35V00010F2 ....................................................................... 63-24
63.4.3 PILOT VALVE : YN30V00080F1 ............................................................................... 63-25
63.4.4 PILOT VALVE : YT30V00004F1 ................................................................................ 63-25
63.5 MODIFICATION PROCEDURE FOR BREAKER ............................................................... 63-27
63.5.1 MODIFICATION ITEM ............................................................................................... 63-27
63.5.2 FLOOR MAT ............................................................................................................. 63-28
63.5.3 INSTALL OF THE CAB GUARD ............................................................................... 63-28
63.6 CONTROL PIPING [BREAKER] ........................................................................................ 63-30
63.6.1 MAIN CONTROL PIPING [OPTION VALVE] ............................................................ 63-30
63.6.2 CONTROL VALVE PIPING [BREAKER] .................................................................. 63-32
63.6.3 REMOTE CONTROL PIPING [BREAKER] &
BLOCK CONTROL PIPING [BREAKER, NIBBLER & BREAKER] ............................. 63-36
63.7 UPPER HYDRAULIC PIPING [BREAKER] ....................................................................... 63-40 63
63.7.1 MODIFICATION PROCEDURE ................................................................................ 63-40
63.8 RETURN HYDRAULIC PIPING [BREAKER] ..................................................................... 63-42
63.8.1 MODIFICATION PROCEDURE ................................................................................ 63-42
63.8.2 PARTS TO BE DISUSED .......................................................................................... 63-43
63-1
63. MOUNTING THE BREAKER AND NIBBLER & BREAKER
63.9 INSTALL OF THE GUARD [BREAKER] ............................................................................ 63-44

63.9.1 MODIFICATION PROCEDURE................................................................................. 63-44
63.9.2 PARTS TO BE DISUSED........................................................................................... 63-44
63.10 MODIFICATION PROCEDURE FOR NIBBLER & BREAKER ........................................... 63-45
63.10.2 FLOOR MAT ............................................................................................................. 63-46
63.10.3 CONTROL PIPING [NIBBLER & BREAKER] ........................................................... 63-46
63.10.4 UPPER HYDRAULIC PIPING [NIBBLER & BREAKER] .......................................... 63-56
63.10.5 RETURN HYDRAULIC PIPING [NIBBLER & BREAKER] ....................................... 63-58
63.10.6 INSTRUMENT PANEL ASSY [NIBBLER & BREAKER] .......................................... 63-61
63.10.7 INSTALL OF THE GUARD [NIBBLER & BREAKER] ............................................... 63-62
63.10.8 INSTALL OF THE NAME PLATE [NIBBLER & BREAKER] ..................................... 63-63
63.11 MODIFICATION PROCEDURE FOR ATTACHMENT ........................................................ 63-64
63.11.2 MODIFICATION OF THE 3.7M (12 ft-2 in) BOOM .................................................... 63-65
63.11.3 MODIFICATION OF THE STD. ARM [BREAKER, NIBBLER & BREAKER] ............ 63-70
63.11.4 MODIFICATION OF THE 2.07M (6 ft-9 in) LONG ARM [BREAKER, NIBBLER &
BREAKER] ............................................................................................................... 63-74
63.11.5 CONNECTOR ASSY [BREAKER] ............................................................................ 63-78
63.11.6 CONNECTOR ASSY [NIBBLER] .............................................................................. 63-79
63.11.7 REINFORCING THE IDLER LINK [NIBBLER & BREAKER] ................................... 63-80
63.12 REMINDERS ON THE USE OF NIBBLER & BREAKERS ................................................. 63-81
63.12.1 CHANGING OVER THE SELECTOR VALVE ........................................................... 63-81
63.12.2 FLUSHING METHOD ................................................................................................ 63-82
63.12.3 REPLACING HYDRAULIC OIL AND RETURN FILTER ........................................... 63-82
63.12.4 OPERATING PROCEDURE ..................................................................................... 63-83
63.13 PRECAUTIONS TO BE EXERCISED ON BREAKERS OF DIFFERENT
MANUFACTURERS ........................................................................................................... 63-85
63.14 REFERENCE ..................................................................................................................... 63-88
63-2

S5YT6304E01
(NHK)
63-3
PREFACE
This manual deals with items necessary for changing standard specification machine SK70SR-1ES to one with a
breaker specification or a nibbler & breaker specification. Follow the procedure given here in when changing the
machine specification in the field (service shop).
63.1 List of Additional Parts

How to utilize the list of additional parts
This manual is compiled to change the standard machine to this specification on the basis of "Parts Manual" for the
standard machine. This list consists of additional parts and disused parts.
The manual consists roughly of two sections : Breaker and Nibbler & Breaker. Each of the section is divided into four
parts, 1. Upper structure, 2. Boom, 3. Standard arm, and 4. Long arm, each being assigned a kit number. The cab
guard should be ordered optionally. In the case of the arm, select a connector suited for the attachment (Nibbler,
Breaker) for ordering.
63.1.1 ADDITIONAL PARTS FOR THE MODIFICATION OF THE BREAKER
63.1.1.1 CAB GUARD [SAME AS BREAKER, NIBBLER & BREAKER]
Applicable
No. Part No. Parts name Q’ty Remarks
Machines
Since the cab guard is an option, it is not as-
—
signed a kit number.
YT01C00004F1 1 GUARD ASSY *1 YT04–07175~
43 YT02C00023P1 CAB ASSY (1) *1
43-1 YT02C01175P1 • • PLATE ASSY 2 *1
43-2 YT02C01375P1 • • PLATE ASSY 1 *1
43-3 YT02C01452P1 • • PLATE ASSY 1 *1
1 YT02C01372P1 • GUARD 1 *1
39 ZM32C12025 • SEMS BOLT 4 *1
YT01C00004F2 2 GUARD ASSY *1 YT04–07175~

44 YT02C00024P1 CAB ASSY (1) *1
44-1 YT02C01175P1 • • PLATE ASSY 3 *1
44-2 YT02C01375P1 • • PLATE ASSY 1 *1
44-3 YT02C01452P1 • • PLATE ASSY 2 *1
1 YT02C01372P1 • GUARD 1 *1
2 YT02C01371P1 • GUARD 1 *1
6 YT02C01457P3 • • PLATE ASSY 1 *1
7 YT02C01456P2 • • PLATE ASSY 1 *1
36 ZS18C10030 •• CAPSCREW 4 *1
37 ZW26X10000 •• LOCK WASHER 4 *1
38 ZW16H10000 •• WASHER 4 *1
39 ZM32C12025 •• SEMS BOLT 8 *1
At your site select the parts, which were marked *1. And order those parts depending on your needs.
63-4
63.1.1.2 UPPER STRUCTURE [BREAKER]
Applicable
Machines
YT32T01069F1 Upper structure modification kit No. (BREKER) YT04-07175~
YT21C00010FA INSTALL OF THE GUARD

98 YT21C01191F3 •• GUARD ASSY 1
YT06H00022F9 MAIN CONTROL PIPING

1 ZH32X04000 •• ELBOW 3
3 ZH22X04000 •• CONNECTOR 2
28 HH55Q06004G3 •• TEE 1
31 2444R1120D150 •• HOSE 1
YT64H00038F4 VALVE CONTROL PIPING

performed in
2 ZH32X04000 •• ELBOW (1)
factory.
performed in
13 2420R349D320 •• HOSE (1)
factory.
performed in
30 YT35V00018F1 •• SOLENOID VALVE (1)
factory.
YT68H00043F1 REMOTE CONTROL PIPING

1 2444R1120D055 •• HOSE 1 *1
2 2420R349D052 •• HOSE 1 *1
5 HH35X04004G3 •• ELBOW 1 *1
6 ZH32X04000 •• ELBOW 1 *1
7 ZH22X04000 •• CONNECTOR 2 *1
8 YT64H01016P1 •• BRACKET 1 *1
9 YN35V00010F2 •• SOLENOID VALVE 1 *1
10 ZS18C06016 •• CAPSCREW 2 *1
11 ZS18C08016 •• CAPSCREW 2 *1
12 ZW16H06000 •• WASHER 2 *1
13 ZW16H08000 •• WASHER 2 *1
14 HH55Q04004G1 •• TEE 1 *1
15 HH55Q06006G1 •• TEE 1 *1
16 ZH22X04006 •• CONNECTOR 1 *1
24 2420R349D320 •• HOSE 1 *1

A1 2420R349D215 •• HOSE 1
A2 2420R349D040 •• HOSE 1
A3 2444R1120D050 •• HOSE 1
A4 ZN18C08007 •• NUT 1
63-5
Applicable
Machines
A5 PY03M01026P1 •• PIN 1
A6 ZW16X08000 •• WASHER 3
A7 ZS18C08045 •• CAPSCREW 2
A8 ZW16H08000 •• WASHER 2
A9 YN68H01038P1 •• BRACKET 1
A10 2419T3757D6 •• PIN 1
A11 2419R9D4 •• PIN 1
A12 HH25R04004G5 •• CONNECTOR 1
A13 2416Z566 •• CUSHION RUBBER 1
A14 ZH42X04000 •• ELBOW 2
A15 YT30V00004F1 •• PILOT VALVE 1
A16 2444Z3833 •• ELBOW 1
A18 YT30M01002F1 •• LOCK ASSY 1
A19 YN68H01039P2 •• PEDAL 1
A20 YR03M01134P1 •• COVER 1
A21 ZW16X12000 •• WASHER 1
A22 GB50S00049F2 •• PRESSURE SWITCH 1
A23 2418T18004 •• PLATE 2
YT64H00036F2 CONTROL BLOCK PIPING

B8 ZH22X04000 •• CONNECTOR 1
B11 ZH32X04006 •• ELBOW 1
YT03H00025F3 UPPER HYDRAULIC PIPING

1 ZA23F18008 •• CONNECTOR 1
3 ZD12P01800 •• O-RING 1
4 YT32H01030P1 •• BUSHING 2
5 YT03H01018P1 •• ROD BOLT 1
6 ZW16H12000 •• WASHER 1
7 ZN18C12010 •• NUT 6
8 YT03H01039D1 •• HOSE 1
9 YT03H01022P1 •• CLAMP 2
11 YT32H01016P1 •• BUSHING 2
12 ZE72X08000 •• PLUG 1
YT32H00009F5 RETURN HYDRAULIC PIPING

12 ZH42X12000 •• ELBOW 1
16 2414Z199D60 •• HOSE 1
26 YT32H01031D5 •• HOSE 1
29 PY01P01043D8 •• CLIP 1
35 YT32H01021P1 •• GROMMET 1
63-6
63.1.1.3 BOOM [BREAKER]
Applicable
Machines
YT32T01060F7 Boom modification kit No. (BREAKER) YT04-07175~
YT02B00063F4 BOOM ASSY

1 YT02B00063F3 •• BOOM ASSY (1)
2 HY35B10032G1 •• TAPPED BLOCK 6
3 YR02B01274P1 •• TAPPED BLOCK 1
4 YT02B01022P1 •• PLATE 1
YT42H00063F1 BOOM HYDRAULIC PIPING

1 YT42H01253P1 •• TUBE 1
2 YT42H01254P1 •• TUBE 1
3 ZE72X12000 •• PLUG 2
4 ZC26X22011 •• CLAMP 6
5 ZC36X22011 •• CLAMP 3
6 ZS18C10045 •• CAPSCREW 8
8 ZN18C10008 •• NUT 1
9 ZW26X10000 •• LOCK WASHER 9
10 ZW16X10000 •• WASHER 1
63.1.1.4 STD ARM [BREAKER]
Applicable
Machines
YT32T01060FA STD Arm modification kit No. YT04-07175~
(BREAKER)
YT12B00088F2 1.65 M (5'5") ARM ASSY

1 YT12B01056P1 •• ARM ASSY (1)
2 YT12B01108P1 •• PLATE 1
3 YT12B01109P1 •• PLATE 1
4 YT12B01110P1 •• PLATE 1
5 2416T24666 •• BRACKET 2
6 YT12B01095P1 •• TAPPED BLOCK 1
1.65 M (5'5") ARM HYDRAULIC PIP-

YT43H00052F1
ING
1 YT43H01056P1 •• TUBE 2
2 YT43H01013DD •• HOSE 2
3 24100P1006F1 •• STOP VALVE 2
4 ZC26X22011 •• CLAMP 2
63-7
Applicable
Machines
6 ZD12P02400 •• O-RING 2
63.1.1.5 LONG ARM [BREAKER]
Applicable
Machines
YT32T01060FD Long arm modification kit No. YT04-07175~
(BREAKER)
YT12B00080F2 2.07M (6'9") ARM ASSY KCME

1 YT12B00080F1 •• LONG ARM ASSY (1)
2 YT12B01114P1 •• PLATE 1
3 YT12B01115P1 •• PLATE 1
4 YT12B01110P1 •• PLATE 1
5 2416T24666 •• BRACKET 2
6 YT12B01095P1 •• BRACKET 1

YT43H00053F1
ING
1 YT43H01056P1 •• TUBE 2
2 YT43H01013DB •• HOSE 2
3 24100P1006F1 •• STOP VALVE 2
4 ZC26X22011 •• CLAMP 2
6 ZD12P02400 •• O-RING 2
63.1.1.6 CONNECTOR
Kit No. is not given because it is provided after selection.
Applicable
Machines
LE43H00006F1 CONNECTOR ASSY For NPK
1 2444P1744D1 •• CONNECTOR 1
63-8
Applicable
Machines
2 2420T4405 •• PLUG 1
3 ZD12P02400 •• O-RING 1
LP43H00005F1 CONNECTOR ASSY For TOKU

KRUPP
1 2444P1745D2 •• CONNECTOR 1
2 2420Z1228D4 •• PLUG 1
3 ZD12P02400 •• O-RING 1
63-9
63.1.2 ADDITIONAL PARTS FOR THE MODIFICATION TO THE NIBBLER & BREAKER
63.1.2.1 UPPER STRUCTURE [NIBBLER & BREAKER]
Applicable
Machines
Since the cab guard is an option, Common to the
— it is not assigned a kit number. breaker : See
Sec.63.1.1
YT32T01069F2 Upper structure modification kit No. YT04-07175~
(NIBBLER & BREAKER)
YT17M00012F2 MODIFICATION OF INST-PANEL

40 2479U1190F32 •• SWITCH 1
YT21C00010FA INSTALL OF THE GUARD

YT22T00055F4 INSTALL OF THE NAME PLATE

20 YB20T01013P1 •• LABEL 1
21 YY20T01039P1 •• LABEL 1
22 PY20T01062P1 •• LABEL 1
YT06H00022F7 MAIN CONTROL PIPING

1 ZH32X04000 •• ELBOW 2
3 ZH22X04000 •• CONNECTOR 1
YT64H00038F4 VALVE CONTROL PIPING performed in

factory.
2 ZH32X04000 •• ELBOW (1) performed in
factory.
13 2420R349D320 •• HOSE (1) performed in
factory.
30 YT35V00018F1 •• SOLENOID VALVE (1) performed in
factory.
YT68H00043F1 REMOTE CONTROL PIPING *1

1 2444R1120D055 •• HOSE 1 *1
2 2420R349D052 •• HOSE 1 *1
5 HH35X04004G3 •• ELBOW 1 *1
6 ZH32X04000 •• ELBOW 1 *1
7 ZH22X04000 •• CONNECTOR 2 *1
8 YT64H01016P1 •• BRACKET 1 *1
9 YN35V00010F2 •• SOLENOID VALVE 1 *1
10 ZS18C06016 •• CAPSCREW 2 *1
11 ZS18C08016 •• CAPSCREW 2 *1
63-10
Applicable
Machines
12 ZW16H06000 •• WASHER 2 *1
13 ZW16H08000 •• WASHER 2 *1
14 HH55Q04004G1 •• TEE 1 *1
15 HH55Q06006G1 •• TEE 1 *1
16 ZH22X04006 •• CONNECTOR 1 *1
24 2420R349D320 •• HOSE 1 *1
YT13E01092D1 HARNESS 1 For single /

conflux
switching
solenoid

A1 2420R349D280 •• HOSE 1
A2 2420R349D215 •• HOSE 1
A3 2420R349D040 •• HOSE 1
A4 2444R1120D050 •• HOSE 1
A5 ZN18C08007 •• NUT 1
A6 PY03M01026P1 •• PIN 1
A7 ZW16X08000 •• WASHER 3
A9 ZW26X10000 •• LOCK WASHER 2
A12 2444Z2525 •• CONNECTOR 1
A13 ZH32X04000 •• ELBOW 1
A14 HH35X04004G3 •• ELBOW 1
A15 YN30V00080F1 •• PILOT VALVE 1
A18 YT30M01002F1 •• LOCK ASSY 1
A19 YN03M01265P1 •• PEDAL 1
A20 YN03M01266P2 •• RUBBER 1
A21 GB50S00049F2 •• PRESSURE SWITCH 1
A23 2444Z3322D2 •• CONNECTOR 1
A24 ZW16X10000 •• WASHER 4
A25 ZE72X04000 •• PLUG 1
YT64H00036F2 BLOCK CONTROL PIPING

B8 ZH22X04000 •• CONNECTOR 1
B11 ZH32X04006 •• ELBOW 1
YT03H00025F1 UPPER HYDRAULIC PIPING

63-11
Applicable
Machines
2 YT03H01053P1 •• CONNECTOR 1
3 ZD12P01800 •• O-RING 1
4 YT32H01030P1 •• BUSHING 2
5 YT03H01018P1 •• ROD BOLT 1
6 ZW16H12000 •• WASHER 1
7 ZN18C12010 •• NUT 6
8 YT03H01039D1 •• HOSE 1
9 YT03H01022P1 •• CLAMP 2
10 YT03H01039D4 •• HOSE 1
YT32H00009F2 RETURN HYDRAULIC PIPING

12 ZH42X12000 •• ELBOW 1
16 2414Z199D60 •• HOSE GUARD 1
26 YT32H01031D5 •• HOSE 1
27 YT32H01030P1 •• BUSHING 1
29 PY01P01043D8 •• CLIP 1
35 YT32H01021P1 •• GROMMET 1
40 YT32H01016P1 •• BUSHING 1
63.1.2.2 BOOM [NIBBLER & BREAKER]
Applicable
Machines
YT32T01060FL Boom modification kit No. YT04-07175~
(NIBBLER & BREAKER)
YT02B00063F4 BOOM ASSY

1 YT02B00063F3 •• BOOM ASSY (1)
2 HY35B10032G1 •• TAPPED BLOCK 6
3 YR02B01274P1 •• TAPPED BLOCK 1
4 YT02B01022P1 •• PLATE 1
YT42H00061F1 BOOM HYDRAULIC PIPING

1 YT42H01234P1 •• TUBE 1
2 YT42H01235P1 •• TUBE 1
3 YT42H01015P1 •• TUBE 1
4 YT42H01074P1 •• TUBE 1
5 24100P1005F1 •• SELECTOR VALVE 1
6 YR42H01056P1 •• SUPPORT 1
8 ZA33F22012 •• ELBOW 2
9 ZE72X12000 •• PLUG 2
63-12
Applicable
Machines
10 ZD12P02400 •• O-RING 3
11 ZC26X22011 •• CLAMP 7
12 ZC36X22011 •• CLAMP 3
15 HS18C10105G2 •• CAPSCREW 1
16 ZN18C10008 •• NUT 1
19 ZW16X10000 •• WASHER 1
63.1.2.3 STD ARM [NIBBLER & BREAKER]
Applicable
Machines
YT32T01060FP STD arm modification kit No. YT04-07175~
(NIBBLER & BREAKER)
YT12B00088F2 1.65 M (5'5") ARM ASSY

1 YT12B00088F1 •• 1.65 M (5'5") ARM ASSY (1)
2 YT12B01108P1 •• PLATE 1
3 YT12B01109P1 •• PLATE 1
4 YT12B01110P1 •• PLATE 1
5 2416T24666 •• BRACKET 2

YT43H00052F1
ING
1 YT43H01056P1 •• TUBE 2
2 YT43H01013DD •• HOSE 2
3 24100P1006F1 •• STOP VALVE 2
4 ZC26X22011 •• CLAMP 2
6 ZD12P02400 •• O-RING 2
YT12B01025P1 IDLER LINK (L.H)

YT12B01024P1 IDLER LINK (R.H)
For STD
0 YT12B01017P1 •• IDLER LINK (L.H) (1)
machine
63-13
Applicable
Machines
For STD
0 YT12B01016P1 •• IDLER LINK (R.H) (1)
machine
1 YT12B01025P1002 •• PLATE 2
63.1.2.4 LONG ARM [NIBBLER & BREAKER]
Applicable
Machines
YT32T01060FT Long arm modification kit No. YT04-07175~
(NIBBLER & BREAKER)
YT12B00080F2 2.07 M (6'9") ARM ASSY

1 YT12B00080F1 •• LONG ARM ASSY (1)
2 YT12B01114P1 •• PLATE 1
3 YT12B01115P1 •• PLATE 1
4 YT12B1110P1 •• PLATE 1
5 2416T24666 •• BRACKET 2
2.07 M (6'9") ARM ASSY HYDRAULIC

YT43H00053F1
PIPING
1 YT43H01056P1 •• TUBE 2
2 YT43H01013DB •• HOSE 2
3 24100P1006F1 •• STOP VALVE 2
4 ZC26X22011 •• CLAMP 2
6 ZD12P02400 •• O-RING 2
8 ZS18C10045 ••CAPSCREW 2
YT12B01025P1 IDLER LINK (L.H)

YT12B01024P1 IDLER LINK (R.H)
0 YT12B01017P1 •• IDLER LINK (L.H) (1) For STD
machine
0 YT12B01016P1 •• IDLER LINK (R.H) (1) For STD
machine
1 YT12B01025P1002 •• PLATE 2
63-14
63.1.2.5 CONNECTOR
Kit No. is not given because it is provided after selection.
Applicable
Machines
LE43H00006F1 CONNECTOR ASSY For NPK
1 2444P1744D1 •• CONNECTOR 1
2 2420T4405 •• PLUG 1
3 ZD12P02400 •• O-RING 1
LP43H00005F1 CONNECTOR ASSY 1 For TOKU

KRUPP
1 2444P1745D2 •• CONNECTOR 1
2 2420Z1228D4 •• PLUG 1
3 ZD12P02400 •• O-RING 1
LE43H00007F1 CONNECTOR ASSY For N & B
1 ZA23H22012 •• CONNECTOR 1
2 ZA82P22000 •• PLUG 1
3 ZD12P02400 •• O-RING 1
63-15
63.2 SUMMARY
63.2.1 GENERAL PRECAUTIONS
(1) Application of Breaker or Nibbler & Breaker
Breaker piping ................ Applicable only when breaker is mounted.
Nibbler & Breaker ........... Applicable only when nibbler and breaker are mounted.
(2) Modifying Breaker and Nibbler & Breaker
There are specific procedures to be followed when modifying breaker and nibbler & breaker. Therefore, when
they are to be modofied at our service shop, contact the nearest breaker and nibbler manufacturer's office, and
obtain instructions, so that you install the pipes and handle the machinery correctly.
(3) Differences Between Breaker Piping and Nibbler & Breaker Piping
• Breaker Piping:
There is a single oil flow from pump P1 to the breaker. The oil returns to the hydraulic tank directly. The flow is
single flow.
If the return oil from the breaker is fed back to the control valve, the pulsation of the breaker is transmitted to the
oil cooler. This causes the machine to break down.
• Nibbler Piping:
The oil flows to the nibbler is conflux flow : the oil flow is changed to the rod and the head of the nibbler cylinder.
63.2.2 BASIC METHOD TO BE TAKEN WHEN MOUNTING

When mounting the breaker or nibbler, always execute the following seven items :
(1) Install an option valve to the main control valve, to use the pressure oil from pump P1 for the breaker and nibbler.
(Standard machine is equipped with option valve already.)
(2) Functions of the option valve :
The option valve transmits oil pressure to the nibbler or the breaker. It contains a spool that changes the flow of
the oil to the rod and the head of the nibbler cylinder. It also contains a single / conflux flow spool that selects a
single flow the A1 port of the main pump or conflux flow of the A1 and A2 ports of the main pump.
(3) Action of the single / conflux flow switch :
A solenoid valve is provided under the floor plate and the single / conflux select switch in the instrument panel,
in order to operate the single /conflux change spool.
(4) Installing the operation pedal :
A pedal and a pilot valve are mounted to the floor plate and a remote control piping is placed between the option
valve and pedal, in order to operate the breaker or the nibbler.
(5) Installing the selector valve :
On the nibbler & breaker attached machine, a selector valve is mounted to the boom in order to change the oil
flow for the breaker and for the nibbler.
(6) Reinforcement of the attachment : (If required)
Reinforcement plates are welded to the standard arm (civil engineering services : for general use) and to the
idler links of the nibbler & breaker attached machine.
(7) When the machine equipped with breaker or nibbler & breaker is modified, replace the return filter with new stan-
dard filter.
63-16
63.2.3 LAYING OF PIPING

(1) Breaker specification
ARM HYDRAULIC
PIPING
HYDRAULIC PIPING FOR BOOM
STOP
VALVE
BRACKET UPPER HYDRAULIC PIPING
RETURN HYDRAULIC PIPING
ARM
ARM TOP
HYDRAULIC OPTION VALVE
PIPING
BREAKER (ADD-ON VALVE)
MAIN CONROL PIPING
OPERATING PEDAL
SOLENOID VALVE
(UNDER FLOOR)
FLOOR MAT REMOTE CONTROL PIPING
Fig. 63-1 Outside view of Breaker-attached machine

(2) Nibbler & breaker specification
HYDRAULIC PIPING FOR BOOM
ARM HYDRAULIC
PIPING
STOP
VALVE SELECTOR VALVE
BRACKET
ARM UPPER HYDRAULIC PIPING
HYDRAULIC ARM TOP RETURN HYDRAULIC PIPING
BREAKER PIPING
Replacing the
breaker with the OPTION VALVE
nibbler is possible. (ADD-ON VALVE)
MAIN CONROL PIPING

OPERATING
PEDAL
SOLENOID VALVE
(UNDER FLOOR)
FLOOR MAT REMOTE CONTROL PIPING
SINGLE / CONFLUX FLOW SELECT SWITCH
Fig. 63-2 Outside view of Nibbler & Breaker-attached machine
63-17
63.3 HYDRAULIC CIRCUIT DIAGRAM

63.3.1 FUNCTION
63.3.1.1 HYDRAULIC CIRCUIT FOR BREAKER
A1 A2
BREAKER SPECIFICATION YT01Z00058P1

No. Parts Part No. Type
50 CONTROL VALVE ASSY YT30V00010F4 BCV75-A2-2
A3 50-1 CONTROL VALVE (OPT) YT30V00007F1 -
51 SOLENOID VALVE ASSY YT35V00018F1 To be performed in factory.
M 52 PILOT VALVE YT30V00004F1 16030-00000
61 SOLENOID VALVE SV-2 YN35V00010F2 To be performed in service shop.
Note : Add this hydraulic circuit to the standard circuit of SK70SR-1ES

for completion
P1 P2
T1
12
51
A B C D
TRAVEL P2 TRAVEL P1 NEUTRAL CUT
BOOSTER NEUTRAL CUT PRIORITY & ARM CONFLUX
T
SINGLE FLOW
NIBBLER & CONFLUX
P1 BREAKER CHANGEOVER
Pa5 32.9MPa
SINGLE TRAVEL Pb5 {336kgf/cm2}
SWING FLOW 1-2SPEED
CONFLUX A5 HEAD
PARKING CHANGE LEVER B5 ROD
CHANGE LOCK
BRAKE OVER OVER 32.9MPa
1 2 3 4 {336kgf/cm2}
SV-2
SINGLE FLOW
CONFLUX To be performed
CHANGEOVER in service shop.
To be performed A T
in factory. 61
SINGLE FLOW
CONFLUX P
CHANGEOVER
63-18
The pressurized oil which enters port (P1) of the control

valve (50) from port (A1) of the hydraulic pump flows
into the nibbler & breaker spool of the option valve (50-
1). Meanwhile, the pressurized oil which enters port
(P2) of the control valve (50) from port (A2) of the hy-
draulic pump flows into the single / conflux flow switch
spool of the option valve (50-1). If the pilot valve (52)
operates, the secondary pilot pressure from the port (A)
shifts the nibbler & breaker spool.
The spool transmits the pressurized oil from the pump
port to the breaker and actuates the breaker. The oil re-
turning from the breaker returns directly to the hydraulic
oil tank through the return filter (12).
50
BREAKER
DR2
SW18
52 P
Pd5
DR7
T
A
50-1
63-19
63.3.1.2 HYDRAULIC CIRCUIT FOR NIBBLER & BREAKER
NIBBLER & BREAKER SPECIFICATION YT01Z00054P1

A1 A2
50-1 CONTROL VALVE (OPT) YT30V00007F1 -
A3 52 PILOT VALVE YN30V00080F1 16030-00000
53 STOP VALVE 24100P1006F2 -
M
54 SELECTOR VALVE LE30V00004F1 -
61 SOLENOID VALVE YN35V00010F2 To be performed in service shop.

for completion
P1 P2
T1
12
51
A B C D
T
SINGLE FLOW
NIBBLER & CONFLUX
Pa5 32.9MPa
SWING FLOW 1-2SPEED
CONFLUX A5 HEAD
PARKING CHANGE LEVER
CHANGE LOCK B5 ROD
1 2 3 4 {336kgf/cm2}
SV-2
SINGLE FLOW
To be performed
in factory. 61
A T 50-1
SINGLE FLOW
CONFLUX P
CHANGEOVER
63-20
• Switch operating (Nibbler & Breaker)
Specification Switch position Circuit

Breaker OFF Single flow
Nibbler ON Conflux flow
• Nibbler operating
Foot pedal depressing section Operating condition

Depress toe section Nibbler close
Depress heel section Nibbler open
(1) When the nibbler used

When the nibbler is used, the selector valve (54)
and the stop valve (53) are shifted in the illustrated
position. The pressurized oil which centers port
(P1) of the control valve (50) from port (A1) of the
hydraulic pump flows into the nibbler & breaker
spool of the option valve (50-1). In the meantime,
50 the pressurized oil which center port (P2) of the
control valve (50) from port (A2) of the hydraulic
pump flows into the single / conflux flow switch
spool of the option valve (50-1). If the single / con-
flux selector switch on the rear panel is turned on,
DR2 the solenoid valve (SV-2) in the solenoid valve assy
(51) operates. This causes the pilot pressure to
BREAKER
change the single / conflux flow switch spool.
Then the hydraulic oil from port (P2) is combined
with the hydraulic oil from port (P1) and flows into
NIBBLER the nibbler & breaker spool. If the single / conflux
53 selector switch is turned off, the pressurized oil
Pd5
DR7 NIBBLER
from the pump port (A2) is shut off, with the result
BREAKER
52 that only the single flow from the pump port (A1)
flows into the nibbler & breaker spool.
54 Now if the toe of the pilot valve (52) is depressed,
T the secondary pilot pressure from port (B) shifts the
P nibbler & breaker spool, which in turn causes the
B A hydraulic pressure to be transmitted to the head (H)
C1 C2
P SE11 of the nibbler cylinder and actuates the nibbler. The
oil returning from the rod (R) of the nibbler cylinder
passes through the nibbler & breaker spool and re-
turns to the hydraulic oil tank through the port (T1)
of the control valve (50) and the return filter (12).
Action is reversed of you depress the heel of the pi-
lot valve (52).
63-21
NIBBLER & BREAKER SPECIFICATION YT01Z00054P1

A1 A2
50-1 CONTROL VALVE (OPT) YT30V00007F1 -
A3 52 PILOT VALVE YN30V00080F1 16030-00000
53 STOP VALVE 24100P1006F2 -
M
54 SELECTOR VALVE LE30V00004F1 -
61 SOLENOID VALVE YN35V00010F2 To be performed in service shop.

for completion
P1 P2
T1
12
51
A B C D
T
SINGLE FLOW
NIBBLER & CONFLUX
Pa5 32.9MPa
SWING FLOW 1-2SPEED
CONFLUX A5 HEAD
PARKING CHANGE LEVER
CHANGE LOCK B5 ROD
1 2 3 4 {336kgf/cm2}
SV-2
SINGLE FLOW
To be performed
in factory. 61
A T 50-1
SINGLE FLOW
CONFLUX P
CHANGEOVER
63-22
• Hydraulic breaker operating

Pedal in neutral position Breaker stops operating.
Depress heel section Breaker starts operating
(2) When the Breaker Used

When the breaker is used, the selector valve (54)
and the stop valve (53) are shifted to the illustrated
position. The pressurized oil which enter port (P1)
of the control valve (50) from the port (A1) of the hy-
draulic pump flows into the nibbler & breaker spool
of the option valve (50-1). In the meantime, the
pressurized oil which enters port (P2) of the control
valve (50) from port (A2) of the hydraulic pump
flows into the single / conflux switch spool of the op-
tion vlave (50-1). If the single / conflux selector
switch on the rear panel is turned on, the solenoid
valve (SV-2) in the solenoid valve assy (51) oper-
50 ates. This causes the pilot pressure to shift the sin-
gle / conflux switch spool. The result is that the
hydraulic oil from port (A2) combines with that from
port (A1) and flows into the nibbler & breaker spool.
If the single / conflux selector switch is turned off,
DR2
the oil pressure from the pump port (A2) is shut off,
with the result that only the single flow from the
BREAKER
pump port (A1) flows into the nibbler & breaker
spool. Now, if you depress the heel of the pilot valve
(52), the secondary pilot pressure from port (A)
NIBBLER
shifts the nibbler & breaker spool, cause the oil
53 pressure from the pump port to the breaker and ac-
Pd5
DR7 BREAKER tuates the breaker. The oil which returns from the
NIBBLER
52 breaker returns directly to the hydraulic oil tank
through the selector valve (54) and the return filter
54 (12).
T
P
B A
C1 C2
P SE11
63-23
63.4 HYDRAULIC COMPONENTS

63.4.1 CONTROL VALVE ASSY (50) : YT30V00010F4
OPTION VALVE [BREAKER, NIBBLER & BREAKER] (50-1) : YT30V00007F1
ORV-A2
ORV-B2
PF1/4 (Pd2’)
PF1/4 (Pd2’)
LOCK VALVE
RELEASE
ORV-A3 ORV-B3
PF1/4 (DR5) DRAIN PORT
ORV-A5 ORV-B5
HEAD SIDE 50-1
TRAVEL TRAVEL
STRAIGHT STRAIGHT
ORV-D3 TRAVEL (L.H)
TRAVEL (L.H) TRAVEL (L.H)
SWING
ORV-C3 SWING BOOM
ARM
BUCKET
BOOM ARM
CONFLUX CUT VALVE 1 &
SINGLE / CONFLUX ARM CONFULX
SWITCH CUT VALVE 2
NIBBLER &
SINGLE / CONFLUX
BREAKER
DR2 SWITCH
63.4.2 SOLENOID VALVE : YT35V00010F2
(-) Black (+) Red
AMP MARK 2 POLE

VIEW A
Houshing 174354-2
Plate 174355-7
Tab terminal 173706-1
Plug 172888-2
3-PF1/4
(JIS O-RING SEAL)
CIRCUIT DIAGRAM
63-24
63.4.3 PILOT VALVE : YN30V00080F1
CIRCUIT DIAGRAM
SECONDARY OPERATING TORQUE

PRESSURE
Secondary pressure
Operating torque
4-PF1/4
Operating angle
2- 11 CONTROL DIAGRAM
THROUGH
63.4.4 PILOT VALVE : YT30V00004F1
CIRCUIT DIAGRAM
SECONDARY OPERATING FORCE

PRESSURE
Secondary pressure
Operating torque
Stroke
CONTROL DIAGRAM
63-25
63-26
63.5 MODIFICATION PROCEDURE FOR BREAKER

63.5.1 MODIFICATION ITEM
The main items that are needed to modify the standard machine into a breaker-mounted machine are as follows :
Refer-
Main modifica- Main items to be added and
No. Item Assy No. ence
tion points change
pages
Cutout of floor
5.2 Modification of floor mat YT03M00027F3 63-28 Floor mat
mat
1 guard YT01C00004F1 Install of the
5.3 Install of the cab guard 63-28
2 guard YT01C00004F2 bracket & guard
Main control piping Control piping
YT06H00022F9 63-30 Hose
(Option valve) for option valve
Install of the [performed in factory.]
Control valve piping YT64H00038F4 63-32
solenoid valve Solenoid valve
The single / con-
[performed in service shop.]
Control Remote control piping YT68H00043F1 flux flow switch 63-36
6 Solenoid valve
piping solenoid added
Pilot valve Install
Remote control piping pilot Pilot valve
YT68H00031F1 of the pedal 63-34
valve Pedal
Control piping
Block control piping Install of the
YT64H00036F2 63-38 Block
(Pedal block) block and piping
Control valve 
Hose
7 Upper hydraulic piping YT03H00025F3 Hydraulic piping 63-40
Plug
for breaker
Breaker 
Hydraulic piping Tube
8 Return hydraulic piping YT32H00009F5 63-42
for hydraulic Hose
tank
Part of the guard
9 Install of the guard YT21C00010FA 63-44 Guard
changed
63-27
63.5.2 FLOOR MAT

Make slits (notch) to face of the standard floor mat ac-
CUT OUT
cording to Fig. 63-3 and cut out the hatching.
Floor mat for breaker : YT26M00024P1
Fig. 63-3 Modification of floor mat
63.5.3 INSTALL OF THE CAB GUARD
63.5.3.1 1 GUARD & 2 GUARD

Install the additional parts listed in Table 63-1 to the cab of the standard machine, as shown in Fig. 63-4.
Table 63-1
YT01C00004F1 1 GUARD
CAB ASSY
YT01C00004F2 2 GUARD
No. Part No. Name Q'ty Remarks
43 YT02C00023P1 CAB ASSY – (1)
43-1 YT02C01175P1 • PLATE ASSY – 2
43-2 YT02C01375P1 • PLATE ASSY – 1
43-3 YT02C01452P1 • PLATE ASSY – 1
44 YT02C00024P1 CAB ASSY (1) –
44-1 YT02C01175P1 • PLATE ASSY 3 –
44-2 YT02C01375P1 • PLATE ASSY 1 –
44-3 YT02C01452P1 • PLATE ASSY 2 –
1 YT02C01372P1 GUARD 1 1
2 YT02C01371P1 GUARD 1 –
6 YT02C01457P3 PLATE ASSY 1 –
7 YT02C01456P2 PLATE ASSY 1 –
36 ZS18C10030 CAPSCREW 4 –
37 ZW26X10000 LOCK WASHER 4 –
38 ZW16H10000 WASHER 4 –
39 ZM32C12025 SEMS BOLT 8 4
63-28
36, 37, 38
7
39
36, 37, 38
6
39
Fig. 63-4 Install of the guard (1 guard, 2 guard)
CAB ASSY
YT02C00030F1 (Manual window specification)
YT02C00030F2 (Power window specification)
Fig. 63-5 Installing procedure for cab guard
63-29
63.6 CONTROL PIPING [BREAKER]

63.6.1 MAIN CONTROL PIPING (OPTION VALVE)
(1) Modification procedure
Install the additional parts listed in Table 63-2 to the main control piping of the standard machine, as shown in
Fig. 63-7.
TIGHTENING TORQUE for installing parts on the control valve side

O-ring type coupling Hydraulic hose
Thread size Spanner Tightening torque Tightening torque
(PF) (mm) N•m (lbf•ft) N•m (lbf•ft)
1/4 19 29.4 (22) 29.4 (22)
3/8 22 49.0 (36)
TIGHTENING TORQUE for installing parts on the hydraulic tank side

1/4 19 36.3 (27) 29.4 (22)
3/8 22 73.5 (54)
• Before starting the modification work, check parts according to the Additional Parts List.
• When disconnecting and reconnecting pipes, take care, so as not to allow dirt and foreign matter to enter.
(2) Connector mounting direction
As seen from the top of the control valve of the machine. As seen from the bottom of the control valve of the
machine.
DR7 Pb5
3
BREAKER,
31
NIBBLER &
BREAKER
TO TANK
BREAKER,
NIBBLER & BREAKER
Pa5 Pd5
1 1
Fig. 63-6 Control valve piping
63-30
Table 63-2
MAIN CONTROL YT06H00022F9
PIPING
1 ZH32X04000 ELBOW 3 PF1/4
3 ZH22X04000 CONNECTOR 2 PF1/4
28 HH55Q06004G3 TEE 1 PF3/8-PF1/4
31 2444R1120D150 HOSE 1 PF1/4, L=1500
TO TANK SOL. V 2
1
31
28
3
C/V
DR2
3 C/V
Pa5
1 31
TANK
TO P/V
A
Fig. 63-7 Main control piping [Breaker]
63-31
(3) Part to be disused

When the main control piping, the part shown in Table 63-3 and Fig. 63-8 is disused from the standard machine.
Table 63-3
2 ZE72X04000 PLUG 3 PF1/4
C21 ZH32X04006 ELBOW 1 PF3/8
2
C21
2
C/V
DR2
TANK
Fig. 63-8 Part to be disused
63.6.2 CONTROL VALVE PIPING [BREAKER]

Install the additional parts listed in Table 63-4 to the control piping of the standard machine, as shown in Fig. 63-
9. On that occasion, some parts become unnecessary.
• When disconnecting and reconnecting pipes, take care so as not to allow dirt and foreign matter to enter.
Table 63-4
CONTROL VALVE PIPING YT64H00038F4 Performed in factory.
2 ZH32X04000 ELBOW 1 PF1/4
13 2420R349D320 HOSE 1 PF1/4, L=3200
30 YT35V00018F1 SOLENOID VALVE 1
TIGHTENING TORQUE for installing parts on the control valve side

1/4 19 36.3 (27) 29.4 (22)
3/8 22 73.5 (54) 49.0 (36)
63-32
F
CONTROL VALVE
13
SWING MOTOR
A SWIVEL JOINT
S/V
C S/V
Pd4 B
INLINE FILTER
TANK
2 Pd5
PT PO S/V
P 2
13 S/J P1 13
4
H
CONTROL VALVE
3
2
C/V
Pd5 T
D
1
S/M Pb4
C
PG
B
30 A
C/V
Pb4
C/V
Po
C/V
Pd4 S/V
D
PUMP
A F
Fig. 63-9 Control valve piping (Breaker, Nibbler & Breaker)
63-33
(2) The procedure of adding the single / conflux selector solenoid valve
Install the additional parts listed in Table 63-5 to take care so as not to allow dirt and foreign matter to enter. the
remote control piping of the standard machine, as shown in Fig. 63-10. In this time, install simultaneously the P
and T ports connector of pilot valve for breaker. (See Fig. 63-12, Fig. 63-13)
Remove plug
14 15
Use existing parts B11(Fig. 3-12)

P T
P T
A 7 B8 (Fig. 3-12) 16
/V T
/V P
Remove plug
TO OPT S/V P TO OPT S/V T
RP
R P
KE KE
DETAIL A
A A
B RE B RE
OPT S/V T 2 places

1 -PT T
24 11, 13
OPT S/V T 7
2 -PT P 6
A
P T 8
B
5 10, 12
9
DETAIL B VIEW I
Fig. 63-10 Addition 1-section solenoid valve

Table 63-5
(Add to solenoid valve)
REMOTE CONTROL Performed in service
YT68H00043F1
PIPING shop.
1 2444R1120D55 HOSE L=550 1 PF1/4
2 2420R349D052 HOSE L=520 1 PF1/4
5 HH35X04004G3 ELBOW 1 PF1/4
6 ZH32X04000 ELBOW 1 PF1/4
8 YT64H01016P1 BRACKET 1
9 YN35V00010F2 SOLENOID VALVE 1
10 ZS18C06016 CAPSCREW 2
12 ZW16H06000 WASHER 2
14 HH55Q04004G1 TEE 1 PF1/4
15 HH55Q06006G1 TEE 1 PF3/8
16 ZH22X04006 CONNECTOR 1 PF3/8-PF1/4
24 2420R349D320 HOSE 1 PF1/4 L=3200
63-34
63-35
63.6.3 REMOTE CONTROL PIPING [BREAKER] & BLOCK CONTROL PIPING [BREAKER, NIBBLER &
BREAKER]
Assemble the additional parts listed in Table 63-6 and Table 63-7 to the control valve of the standard machine,
as shown in Fig. Fig. 63-11 and Fig. 63-12. On that occasion, some of the existing parts must be used and some
of them become unnecessary.
Table 63-6
REMOTE CONTROL PIPING PILOT VALVE YT68H00031F1
No. Part No. Name Q'ty Remarks No. Part No. Name Q'ty Remarks
A1 2420R349D215 HOSE 1 PF1/4 A13 2416Z566 CUSHION 1
L=2150 RUBBER
A2 2420R349D040 HOSE 1 PF1/4 A14 ZH42X04000 ELBOW 2 PF1/4
L=400
A3 2444R1120D050 HOSE 1 PF1/4 A15 YT30V00004F1 PILOT VALVE 1
L=500
A4 ZN18C08007 NUT 1 A16 2444Z3833 ELBOW 1 PF1/4
PT1/8
A5 PY03M01026P1 PIN 1 A17 ZS18C08020 CAPSCREW 2
A6 ZW16X08000 WASHER 3 A18 YT30M01002F1 LOCK ASSY 1 R.H
A7 ZS18C08045 CAPSCREW 2 A19 YN68H01039P2 PEDAL 1
A8 ZW16H08000 WASHER 2 A20 YR03M01134P1 COVER 1
A9 YN68H01038P1 BRACKET 1 A21 ZW16X12000 WASHER 1
A10 2419T3757D6 PIN 1 A22 GB50S00049F2 PRESSURE 1
SWITCH
A11 2419R9D4 PIN 1 A23 2418T18004 PLATE 2
A12 HH25R04004G5 CONNECTOR 1 PF1/4
L=23
TIGHTENING TORQUE
Capscrew (10T)
Thread size Spanner Tightening torque N•m
(PF) (mm) (lbf•ft)
M8 13 35.3 (26)

1/4 19 36.3 (27) 29.4 (22)
63-36
A19
A20
A5
A18-2
A6
A4 A18-4 A7 A11
A21
A17 A8
A6
A18-3 A9
A18 A23
A18-1
A18-5 A10 A13
A18-6
A15
A14 T
A12
P
A14
A3 A
T Pb5
A2
P
A22 A16 A1 CONTROL VALVE
A A Pb5
A1
A2
A3 B
Fig. 63-11 Remote control piping [Breaker]
63-37
Table 63-7
BLOCK CONTROL PIPING YT64H00036F2
B8 ZH22X04000 CONNECTOR 1 PF1/4
B11 ZH32X04006 ELBOW 1 PF3/8-PF1/4
T
P
T
P
T T
T
P/V B8
P
P/V
T B11
B
Fig. 63-12 Remote control piping [Breaker, Nibbler & Breaker]
(2) Parts to be disused
Concerning the control block piping, the parts listed in Table 63-8 and Fig. 63-13 are disused from the standard
machine.
Table 63-8
C9 ZE72X06000 PLUG 1 PF3/8
C13 ZE72X04000 PLUG 1 PF1/4
P
P
P/V T
P
P
T
P
T
T
T
C13
C9
P/V
T
Fig. 63-13 Control block piping (STD)
63-38

Concerning the remote control piping, the parts listed in Table 63-9 and in Fig. 63-14 are disused from the stan-
dard machine.
Table 63-9
A2 YT03M01113P1 SUPPORT 1
A4 YN03M01200P1 COVER 1
A8 ZM22C10035 SEMS BOLT 2
A4
A8
A2
63-39
63.7 UPPER HYDRAULIC PIPING [BREAKER]

63.7.1 MODIFICATION PROCEDURE
Fit the additional parts in Table 63-10, according to Fig. 63-15.
On that occasion, some parts become unnecessary.
TIGHTENING TORQUE
O-ring type coupling
Thread size Spanner Tightening torque
1/2 27. 32 108 (80)
Nut sleeve joint

Tube size Spanner Tightening torque
(mm) N•m (lbf•ft)
Ø18  t2.5 27. 32 147 (110)

M 12 19 121 (89)
Table 63-10
UPPER HYDRAULIC PIPING YT03H00025F3
1 ZA23F18008 CONNECTOR 1 Ø18-PF1/2
3 ZD12P01800 O-RING 1
4 YT32H01030P1 BUSHING 2
5 YT03H01018P1 ROD BOLT 1 M12  200
7 ZN18C12010 NUT 6
8 YT03H01039D1 HOSE 1 Ø18,L=2500
9 YT03H01022P1 CLAMP 2
12 ZE72X08000 PLUG 1 PF1/2
• At assembly, use care of O-ring do not come off.
• Regarding the tightening torque of O-ring type joints, hydraulic hoses and Nut sleeve joints, refer to the Remarks
of Table 63-10 and the Tightening Torque Table.
63-40
TO BREAKER
A
CONTROL VALVE
7
6
8
5
7
11
9
7
12 4
12-1
9
A5
7
B5
1
8 3
CONTROL
BREAKER VALVE
7
A B
Fig. 63-15 Upper hydraulic piping [Breaker]
63.7.2 PART TO BE DISUSED

Concerning the upper hydraulic piping, the parts listed inTable 63-11 and Fig. 63-16 are disused from the standard
machine.
Table 63-11
1 ZE72X08000 PLUG 2 PF3/8
A5
1
B5
CONTROL
VALVE
Fig. 63-16
63-41
63.8 RETURN HYDRAULIC PIPING [BREAKER]

Install the additional parts listed in to the return hydraulic piping of the standard machine, as shown in Fig. 63-17.
TIGHTENING TORQUE
3/8 22 73.5 (54) 49.0 (36)
1/2 27 108 (80) 78.5 (36)
3/4 36 162 (120) 118 (87)

M8 13 35.3 (27)
M 10 17 70.6 (110)
B
HYDRAULIC TANK
26
TO BREAKER T 29
CONTROL VALVE
35
SWING MOTOR
16
HYDRAULIC PUMP
SWIVEL JOINT
UPPER HYDRAULIC RADIATOR

PIPING
A
Fig. 63-17 Upper hydraulic piping [Breaker]
63-42
Table 63-12
HYDRAULIC PIPING FOR
YT32H00009F5
RETURN
12 ZH42X12000 ELBOW 1 PF3/4
16 2414Z199D60 HOSE GUARD 1 L=1000
26 YT32H01031D5 HOSE 1 PF3/4
L=3000
29 PY01P01043D8 CLIP 1
35 YT32H01021P1 GROMMET 1
12 12-1
26
BREAKER
T
HYDRAULIC TANK
B
63.8.2 PARTS TO BE DISUSED
Concerning the return hydraulic piping the part listed in Table 63-13 and Fig. 63-18 disused from the standard ma-
chine.
Table 63-13
44 ZE72X12000 PLUG 1
44 44-1
HYDRAULIC TANK
Fig. 63-18 Parts to be disused
63-43
63.9 INSTALL OF THE GUARD [BREAKER]

Install the additional parts listed in Table 63-14 to the guard of the standard machine, as shown in Fig. 63-19. On
that occasion, some parts become unnecessary.
Table 63-14
INSTALL OF THE GUARD YT21C00010FA
A98 YT21C01191F3 GUARD ASSY 1
A109
A98
Fig. 63-19 Install of the guard
63.9.2 PARTS TO BE DISUSED

When the guard is installed, the parts shown in Table 63-15 and Fig. 63-20 are disused from the standard machine.
Table 63-15

A104
A97
63-44
63.10 MODIFICATION PROCEDURE FOR NIBBLER & BREAKER

The main items that are needed to modify the standard machine into a nibbler & breaker mounted machine are as
follows :
Refer- Main items to

Main modification
No. Item Assy No. ence be added and
points
pages change
10.2 Modification of floor mat YT03M00027F2 Cutout of floor mat 63-46 Floor mat
Refer to 1 guard YT01C00004F1 Install of the bracket &
Install of the cab guard 63-28
sec 5 2 guard YT01C00004F2 guard
Control piping for
Main control piping YT06H00022F7 63-46 Hose
option valve
[Performed in
Install of the solenoid
Control valve piping YT64H00038F4 63-48 factory.]
valve
Solenoid valve
The single / conflux [Performed in
Control Remote control piping YT68H00043F1 selector solenoid add- 63-50 service shop.]
10.3
piping ed Solenoid valve
For single / conflux
Harness — Harness
select solenoid
63-51
Pilot valve Install of the Pilot valve
Remote control piping YT68H00027F1
pedal Control piping Pedal
Change the Connector
Block control piping YT64H00036F2 63-52
connectors Tee
Control valve 
10.4 Upper hydraulic piping YT03H00025F1 Hydraulic piping for 63-56 Hose
breaker
Breaker  Hydraulic
Tube
10.5 Return hydraulic piping YT32H00009F2 piping for hydraulic 63-58
Hose
tank
Install the single /
10.6 Modification of instrument panel YT17M00012F2 63-61 Switch
conflux selector switch
Part of the guard
10.7 Install of the guard YT21C00010FA 63-62 Guard
changed
10.8 Install of the name plate YT22T00055F4 Add to label 63-63 Label
63-45
63.10.2 FLOOR MAT

Make slits (notch) to face the standard floor mat according to Fig. 63-21 and cut out the hatching.
Floor mat for Nibbler & breaker : YT26M00023P1
CUT OUT
Fig. 63-21 Modification of floor mat
63.10.3 CONTROL PIPING [NIBBLER & BREAKER]
63.10.3.1 MAIN CONTROL PIPING

Fig. 63-22, Fig. 63-23.
Table 63-16
MAIN CONTROL PIPING YT06H00022F7
1 ZH32X04000 ELBOW 2 PF1/4
Tightening torque for installing parts on the control valve side
— O-ring type coupling Hydraulic hose

Tightening torque Tightening torque
Thread size (PF) Spanner (mm)
1/4 19 29.4 (22) 29.4 (22)
3/8 22 49.0 (36) —
63-46
(2) Connector mounting direction
DR7 Pb5
3
BREAKER,
20
NIBBLER &
20 BREAKER
BREAKER,
NIBBLER &
BREAKER
1 Pa5 1 Pd5
As seen from the top of the control valve of the machine. As seen from the bottom of the control valve of the machine.
Fig. 63-22 Control valve piping [Nibbler & Breaker]
1
TO P/V SOL. V 2
B
3
TO P/V
A
Fig. 63-23 Main control piping [Nibbler & Breaker]
63-47

When the main control piping, the part shown in Table 63-17 and Fig. 63-24 is disused from the standard ma-
chine.
Table 63-17
2 ZE72X04000 PLUG 3 PF1/4
63.10.3.2 CONTROL VALVE PIPING [BREAKER, NIBBLER & BREAKER]

Fig. 63-25. On that occasion, some parts become unnecessary.
Table 63-18
CONTROL VALVE PIPING YT64H00038F4 Performed in factory.
2 ZH32X04000 ELBOW 1 PF1/4
13 2420R349D320 HOSE 1 PF1/4, L=3200
30 YT35V00018F1 SOLENOID VALVE 1
63-48
F
CONTROL VALVE
13
SWING MOTOR
A SWIVEL JOINT
S/V
C S/V
Pd4 B
INLINE FILTER
TANK
2 Pd5
PT PO S/V
P 2
13 S/J P1 13
4
H
CONTROL VALVE
3
2
C/V
Pd5 T
D
1
S/M Pb4
C
PG
B
30 A
C/V
Pb4
C/V
Po
C/V
Pd4 S/V
D
PUMP
A F
Fig. 63-25 Control valve piping [Breaker, Nibbler & Breaker]

Tightening torque for installing parts on the control valve side

1/4 19 36.3 (27) 29.4 (22)
3/8 12 73.5 (54) 49.0 (36)
63-49
(2) The procedure of adding the single / conflux selector solenoid valve
Install the additional parts listed in Table 63-19 to the remote control piping of the standard machine, as shown
in Fig. 63-26.
In this time, install simultaneously the P and T ports connector of pilot valve for N & B.
(See Fig. 63-27, Fig. 63-28)
Table 63-19
REMOTE CONTROL (Add to solenoid valve)
YT68H00043F1
PIPING Performed in service shop.
1 2444R1120D055 HOSE L=550 1 PF1/4
2 2420R349D052 HOSE L=520 1 PF1/4
5 HH35X04004G3 ELBOW 1 PF1/4
6 ZH32X04000 ELBOW 1 PF1/4
8 YT64H01016P1 BRACKET 1
9 YN35V00010F2 SOLENOID VALVE 1
14 HH55Q04004G1 TEE 1 PF1/4
15 HH55Q06006G1 TEE 1 PF3/8
16 ZH22X04006 CONNECTOR 1 PF3/8- PF1/4
24 2420R349D320 HOSE 1 PF1/4 L=3200
14 Remove plug
15
Use existing parts B11

P T
P T
A B8
7 16
Remove plug
VP
VT
TO OPT S/V P TO OPT S/V T

P/
P/
DETAIL A
&B
&B
N N
2 places
OPT S/V T 11, 13
1 -PT T 24
7
OPT S/V T 6
2 -PT P
A
8
P T 5 10,12
B 9
DETAIL B VIEW I
Fig. 63-26 Addition of 1–section solenoid valve
63-50
(3) Connect a harness to the single/conflux solenoid valve.

Connect this harness to the existing connector (CN-266F) of the under floor harness of standard machine. And
connect the other side of this harness to the single/conflux flow selector solenoid that was added by above-men-
tioned procedure (2).
HARNESS (FOR SINGLE / CONFLUX SOL)

1 YT13E01092D1 HARNESS 1
2FA-JM II+ 2MA-JM II+

Single / conflux flow To under floor
select solenoid harness
63.10.3.3 REMOTE CONTROL PIPING [NIBBLER & BREAKER] &

CONTROL BLOCK PIPING [BREAKER, NIBBLER & BREAKER]
(1) Assemble the additional parts listed in Table 63-20 to the remote control piping and the additional parts listed
Table 63-21 to the block control piping of the standard machine, as shown in Fig. 63-27.
TIGHTENING TORQUE
O-ring type
— Capscrew (10T) — Hydraulic hose
coupling
Tightening torque Tightening torque Tightening torque
Thread size (PF) Thread size (PF) Spanner (mm)
N•m (lbf•ft) N•m (lbf•ft) N•m (lbf•ft)
M8 35.3 (26) 1/4 19 36.3 (27) 29.4 (22)
M10 70.6 (52) 3/8 22 73.5 (54) 49.0 (36)
— Pilot valve attaching connector (O-ring type coupling)

Thread size (PF) Spanner (mm) Tightening torque N•m (lbf•ft)
1/4 19 29.4 (22)
63-51
Table 63-20
REMOTE CONTROL
YT68H00027F1
PIPING
No. Part No. Name Q'ty Remaks No. Part No. Name Q'ty Remaks
A1 2420R349D280 HOSE 1 PF1/4 A13 ZH32X04000 ELBOW 3 PF1/4
L=2800
A2 2420R349D215 HOSE 1 PF1/4 A14 HH35X04004G3 ELBOW 1 PF1/4
L=2150 WITH
FILTER
A3 2420R349D040 HOSE 1 PF1/4 A15 YN30V00080F1 PILOT VALVE 1
L=400
A4 2444R1120D050 HOSE 1 PF1/4 A17 ZS18C08020 CAPSCREW 2
L=500
A5 ZN18C08007 NUT 1 A18 YT30M01002F1 LOCK ASSY 1
A6 PY03M01026P1 PIN 1 A19 YN03M01265P1 PEDAL 1
A7 ZW16X08000 WASHER 3 A20 YN03M01266P2 RUBBER 1
A8 ZS28C10020 CAPSCREW 2 A21 GB50S00049F2 PRESSURE 1
SWITCH
A9 ZW26X10000 LOCKWASHER 2 A23 2444Z3322D2 CONNECTOR 1
A10 ZS18C10025 CAPSCREW 2 A24 ZW16X10000 WASHER 4
A12 2444Z2525 CONNECTOR 1 PF1/4 A25 ZE72X04000 PLUG 1 PF1/4
L=23
Table 63-21
BLOCK CONTROL
YT64H00036F2
PIPING
No. Part No. Name Q'ty Remaks
B8 ZH22X04000 CONNECTOR 1 PF1/4
B11 ZH32X04006 ELBOW 1 PF3/8- PF1/4
63-52
Pa5
A
CONTROL VALVE
Pb5
A1
A3 B
A4
A2
A8
A9
A6 A24 A20
A18-2
A7
A5 A18-4
A17
A7 A19
A10 P
A24
A18-3
A25 A12 P
A18 T A13
T
A18-5 A18-1 P
A18-6
A4 P
P T
A15 P/T P
A23 T
T T
A21
P/T
P A14
B
A3 P/V B8
T
C/V P
A P/V
Pa5 T B11
C/V
Pb5
A13 A1
A13 A2
A B
Fig. 63-27 Remote control piping [Nibbler & breaker]
63-53

Concerning the control block piping, the parts listed in Table 63-22 and Fig. 63-28 are disused from the standard
machine.
Table 63-22
C9 ZE72X06000 PLUG 1 PF3/8
C13 ZE72X04000 PLUG 1 PF1/4
P
P
P/V T
P
P
T
P
T
T
T
C13
C9
P/V
T
Fig. 63-28 Control block piping (STD)

Concerning the remote control piping, the parts listed in Table 63-23 and in Fig. 63-29 are disused from the stan-
dard machine.
Table 63-23
A2 YT03M01113P1 SUPPORT 1
A4 YN03M01200P1 COVER 1
A8 ZM22C10035 SEMS BOLT 2
63-54
63-55
63.10.4 UPPER HYDRAULIC PIPING [NIBBLER & BREAKER]
63.10.4.1 MODIFICATION PROCEDURE

Assemble the additional parts listed in Table 63-24 to the upper hydraulic piping of the standard machine, as shown
in Fig. 63-30. On that occasion, some parts become unnecessary.
TIGHTENING TORQUE
— O-ring type coupling

Thread size (PF) Spanner (mm) Tightening torque N•m (lbf•ft)
1/2 27. 32 108 (80)
— Nut sleeve joint

Tube size Spanner (mm) Tightening torque N•m (lbf•ft)
Ø18  t2.5 32 147 (108)
Thread size Spanner (mm) Tightening torque N•m (lbf•ft)

M 12 19 121 (89)
Table 63-24
UPPER HYDRAULIC
YT03H00025F1
PIPING
No. Part No. Parts Q'ty Remarks
1 ZA23F18008 CONNECTOR 1 Ø18-PF1/2
2 YT03H01053P1 CONNECTOR 1 Ø18-PF1/2
3 ZD12P01800 O-RING :1B P18 1
5 YT03H01018P1 ROD BOLT 1 M12  240
7 ZN18C12010 NUT 6
8 YT03H01039D1 HOSE 1 Ø18 L=2650
9 YT03H01022P1 CLAMP 2
10 YT03H01039D4 HOSE 1 Ø18 L=2500
63-56
A
B
TO N&B H
CONTROL VALVE
TO N&B R
A
A
10
7
8 6
5
9
10 7
2 4
2-1
9
A5 7
N&B B5
1
H 3
8
N&B CONTROL
R VALVE
7
A B
Fig. 63-30 Upper hydraulic piping [Nibbler & Breaker]
63.10.4.2 PART TO BE DISUSED

Concerning the upper hydraulic piping, the parts listed inTable 63-25 and Fig. 63-24 are disused from the standard
machine.
Table 63-25
1 ZE72X08000 PLUG 2 PF3/8
A5
1
B5
CONTROL
VALVE
Fig. 63-31
63-57
63.10.5 RETURN HYDRAULIC PIPING [NIBBLER & BREAKER]

Install the additional parts listed in Table 63-26 to the return hydraulic piping of the standard machine, as shown in
Fig. 63-32. On that occasion, some parts become unnecessary.
• Regarding the tightening torque of O-ring type joints, hydraulic hoses and flareless joints, refer to the Remarks
TIGHTENING TORQUE

3/8 22 73.5 (54) 49.0 (36)
1/2 27 108 (80) 78.5 (58)
3/4 36 162 (120) 118 (87)
Tightening torque
Thread size Spanner (mm)
N•m (lbf•ft)
M8 13 35.3 (27)
M 10 17 70.6 (52)
Table 63-26
RETURN HYDRAULIC
YT32H00009F2
PIPING
No. Part No. Parts Q'ty Remarks
12 ZH42X12000 ELBOW 1 PF3/4
16 2414Z199D60 HOSE GUARD 1 L=1000
26 YT32H01031D5 HOSE 1 PF3/4
L=3000
29 PY01P01043D8 CLIP 1
35 YT32H01021P1 GROMMET 1
63-58
12 12-1
26
TO N&B
T
HYDRAULIC TANK
B HYDRAULIC TANK
26
CONTROL VALVE
TO N&B T 29
35
TO N&B H
A
SWING MOTOR
16
HYDRAULIC PUMP
E
40
27 SWIVEL JOINT
RADIATOR
UPPER HYDRAULIC
PIPING
Fig. 63-32 Return hydraulic piping [Nibbler & Breaker]
63-59
63.10.5.2 PARTS TO BE DISUSED

Concerning the return hydraulic piping the part listed in Table 63-27 and Fig. 63-33 are disused from the standard
machine.
Table 63-27
44 ZE72X12000 PLUG 1
44 44-1
HYDRAULIC TANK
63-60
63.10.6 INSTRUMENT PANEL ASSY [NIBBLER & BREAKER]

Install the additional parts listed in Table 63-28 to the
instrument panel assy of the standard machine, as
shown in Fig. 63-34. On that occasion, some parts be-
come unnecessary.
40
Fig. 63-34 Modification of instrument panel
Table 63-28
INSTRUMENT PANEL
YT17M00012F2
ASSY
40 2479U1190F32 SWITCH 1 For single /conflux select

When the instrument panel is modificated the parts
shown in Table 63-29 and Fig. 63-35 are disused from
the standard machine.
13
Table 63-29
13 2414T4530 CAP 1
63-61
63.10.7 INSTALL OF THE GUARD [NIBBLER & BREAKER]

Install the additional parts listed in Table 63-30 to the
guard of the standard machine, as shown in Fig. 63-36.
A109
A98
Fig. 63-36 Install of the guard
Table 63-30
INSTALL OF THE GUARD YT21C00010FA KCMA, KCME

When the guard is installed, the parts shown in Table
63-31 and Fig. 63-37 are disused from the standard
machine.
A104
A97
Table 63-31
63-62
63.10.8 INSTALL OF THE NAME PLATE [NIBBLER & BREAKER]

Fit the labels shown in Table 63-32 to the cab of the standard machine, according to Fig. 63-38 and Fig. 63-39.
Table 63-32
INSTALL OF THE NAME
YT22T00055F4
PLATE
20 YB20T01013P1 LABEL 1
21 YY20T01039P1 LABEL 1
22 PY20T01062P1 LABEL 1
22
20 21
VIEW IV
INDICATES RIGHTHAND VIEW OF CAB INTERIOR
IMDICATES VIEW OF REAR PANEL
Fig. 63-38 Labeling position
(20) YB20T01013P1 (21) YY20T01039P1
Procedure to change MAINTENANCE

selector valve (When using nibbler, breaker or extra)
Mark SELECTION · Contamination and deterioration
N Nibbler of hydraulic oil may develop
B Breaker malfunctioning of control valves,
E EXTRA early wear and seizure of
YB20T01013P1
hydraulic pumps, and consequential
Please adjust suitable damage of entire hydraulic
notch to capscrew. circuit.
(22) PY20T01062P1 (some mark may not be Replace filters and hydraulic oil,
indicated) refering to the following table.
CAPSCREW
Notch (1) Hydraulic oil change
: Every 600 HRS.
Attachment operation by foot pedal. (2) Hydraulic line filter change
First : 50 HRS
Always check the foot pedal control pattern Regular : Every 250 HRS
Marks YY20T01039P1
before operation.
Always read operators manual before operating
machine.
YN20T01062P1
Fig. 63-39 Additional
63-63
63.11 MODIFICATION PROCEDURE FOR ATTACHMENT

Modification Reinforcement Standard assy

No. Item
piping assy assy (without bushing)
YT02B00063F3
Boom 3.71 M (12 ft-2 in) boom YT42H00063F1 YT02B00063F4
(YT02B00066P1)
YT12B00088F1
Breaker 1.65 M (5 ft-5 in) arm YT43H00052F1 YT12B00088F2
(YT12B01056P1)
Arm
YT12B00080F1
2.07 M (6 ft-9 in) arm YT43H00053F1 YT12B00080F2
(YT12B00029P1)
L•H — YT12B01025P1 YT12B01017P1
Idler link
R•H — YT12B01024P1 YT12B01016P1
YT02B00063F3
Boom 3.71 M (12 ft-2 in) boom YT42H00061F1 YT02B00063F4
(YT02B00066P1)
Nibbler &
YT12B00088F1
Breaker 1.65 M (5 ft-5 in) arm YT43H00052F1 YT12B00088F2
(YT12B01056P1)
Arm
YT12B00080F1
2.07M (6 ft-9 in) arm YT43H00053F1 YT12B00080F2
(YT12B00029P1)
Connector assy LE43H00007F1 — —
Breaker, NPK, LE43H00006F1 — —
Nibbler & Connector assy TOKU,
LP43H00005F1 — —
Breaker KRUPP
63-64
63.11.2 MODIFICATION OF THE 3.7M (12 ft-2 in) BOOM
63.11.2.1 MODIFICATION OF THE 3.7M (12ft-2in) BOOM [BREAKER, NIBBLER & BREAKER]
Weld the additional parts listed in Table 63-33 to the boom of the standard specification, according to Fig. 63-40.
• Use weld symbol B welding rod (mild steel 50kg grade).

• Seal the unwelded areas of the tapped block.
Table 63-33
BOOM ASSY (BREAKER) YT02B00063F4
(Without bushing)
1 YT02B00063F3 BOOM ASSY (1) With bushing
(YT02B00066P1) BOOM STD
(Without bushing)
2 HY35B10032G1 TAPPED BLOCK 6
3 YR02B01274P1 TAPPED BLOCK 1
4 YT02B01022P1 PLATE 1
Seal the unwelded areas

of the tapped block.
SECTION AA SECTION BB
Fig. 63-40 Modification of the 3.7 m (12 ft-2 in) boom (Breaker, Nibbler & Breaker)
63-65
63.11.2.2 HYDRAULIC PIPING FOR 3.7M (12 ft-2 in) BOOM [BREAKER]
Install the additional parts listed in Table 63-34 to the 3.7m (12 ft-2 in) boom modified under par.63.11.2.1 as shown
in Fig. 63-41.
Table 63-34
HYDRAULIC PIPING
YT42H00063F1 [BREAKER]
FOR BOOM
1 YT42H01253P1 TUBE 1
2 YT42H01254P1 TUBE 1
3 ZE72X12000 PLUG 2
4 ZC26X22011 CLAMP 6
8 ZN18C10008 NUT 1
9 ZW26X10000 LOCK WASHER 9
10 ZW16X10000 WASHER 1
• Apply Loctite #242 to the clamp mounting bolts.

• For M-threads Tightening torque
Thread size Tightening torque
M10 65.7 N m (48 lbf ft)
• For PF,PT-threads Tightening torque

1/2 108 N m (80 lbf ft)
3/4 162 N m (120 lbf ft)
• Tightening torque of Nut-sleeve joint

Piping size Tightening torque
22 X 3.0 216 N m (160 lbf ft)
• At assembly, use care of O-rings do not come off.

• Remove item 3 plug as necessary, and install an accumulator recommended by the breaker maker.
63-66
VIEW F
SECTION AA SECTION CC
SECTION EE
SECTION BB SECTION DD
Fig. 63-41 Hydraulic piping for 3.7M (12ft-2in) boom [Breaker]
63-67
63.11.2.3 HYDRAULIC PIPING FOR 3.7M (12ft-2in) BOOM [NIBBLER & BREAKER]
Install the additional parts listed in Table 63-35 to the 3.7m (12 ft-2 in) boom modified under par.63.11.2.1 as shown
in Fig. 63-42.
Table 63-35
HYDRAULIC PIPING FOR
YT42H00061F1 [NIBBLER & BREAKER]
BOOM
1 YT42H01234P1 TUBE 1
2 YT42H01235P1 TUBE 1
3 YT42H01015P1 TUBE 1
4 YT42H01074P1 TUBE 1
5 24100P1005F1 SELECTOR VALVE 1
6 YR42H01056P1 SUPPORT 1
7 ZA23F22012 CONNECTOR 1
8 ZA33F22012 ELBOW 2
9 ZE72X12000 PLUG 2
10 ZD12P02400 O-RING 3
11 ZC26X22011 CLAMP 7
12 ZC36X22011 CLAMP 3
15 HS18C10105G2 CAPSCREW 1
16 ZN18C10008 NUT 1
19 ZW16X10000 WASHER 1

M8 33.3 N m (25 lbf ft)
M10 65.7 N m (48 lbf ft)
• For PF,PT-threads Tightening torque

1/2 108 N m (80 lbf ft)
3/4 162 N m (120 lbf ft)

22 X 3.0 216 N m (160 lbf ft)

• Remove item 9 plug as necessary, and install an accumulator recommended by the breaker maker.
63-68
SECTION AA SECTION CC SECTION EE
SECTION BB SECTION DD
Fig. 63-42 Hydraulic piping for 3.7M (12ft-2in) boom [Nibbler & Breaker]
63-69
63.11.3 MODIFICATION OF THE STD. ARM [BREAKER, NIBBLER & BREAKER]
63.11.3.1 MODIFICATION OF THE 1.65M (5 ft-5 in) ARM [BREAKER, NIBBLER & BREAKER]
When the additional parts listed in Table 63-36 to the arm of the standard specification, according to and Fig. 63-43.
• Sectional shape of fillet welding should be concave but convex.

• Use weld symbol B welding rods (mild steel 50 kg grade).
Table 63-36
1.65M(5ft-5in) ARM ASSY YT12B00088F2 [BREAKER, N&B]
No. Part No. Name Remarks
1 YT12B00088F1 ARM ASSY (1) With bushing
(YT12B01056P1) ARM STD
(Without bushing)
5 2416T24666 BRACKET 2
6 YT12B01095P1 TAPPED BLOCK 1
7 LE16B01006P1 TAPPED BLOCK –
63-70
SECTION BB
SECTION AA
SECTION CC SECTION DD
Fig. 63-43 Modification of the 1.65 M (5 ft-5 in) arm [Breaker, Nibbler & Breaker]
63-71
63.11.3.2 HYDRAULIC PIPING FOR 1.65M (5 ft-5 in) ARM [BREAKER, NIBBLER & BREAKER]
This hydraulic piping applies to both the breaker machine and the nibbler & breaker machine. Install the additional
parts listed in Table 63-37 to the 1.65m (5 ft-5 in) arm modified under par. 63.11.3.1 as shown in Fig. 63-44.

• For M-threads
M8 33.3 N m (25 lbf ft)
M10 65.7 N m (48 lbf ft)
• For PF, PT-threads

3/4 162 N m (120 lbf ft)

22 X 3.0 216 N m (160 lbf ft)
Table 63-37
1.65M (5ft-5in) ARM
YT43H00052F1 [BREAKER, N&B]
HYDRAULIC PIPING
1 YT43H01056P1 TUBE 2
2 YT43H01013DD HOSE 2
3 24100P1006F1 STOP VALVE 2
6 ZD12P02400 O-RING 2 1B P24
7 ZS18C08025 CAPSCREW 8 M8  25
8 ZS18C10045 CAPSCREW 2 M10  45
63-72
Fig. 63-44 Hydraulic piping for 1.65 M (5 ft-5 in) arm [Breaker, Nibbler & Breaker]
63-73
63.11.4 MODIFICATION OF THE 2.07M (6 ft-9 in) LONG ARM [BREAKER, NIBBLER & BREAKER]
63.11.4.1 MODIFICATION OF THE 2.07M (6 ft-9 in) ARM

Install the additional parts listed in Table 63-38 to the long arm of the standard machine, as shown in Fig. 63-45.
• Use weld symbol B welding rods (mild steel 50 kg grade).

Table 63-38
2.07M(6ft-9in) LONG ARM
YT12B00080F2 [BREAKER, N&B]
ASSY
1 YT12B00080F1 LONG ARM ASSY (1) With bushing
(YT12B00029P1) LONG ARM STD
(Without bushing)
5 2416T24666 BRACKET 2
6 YT12B01095P1 TAPPED BLOCK 1
63-74
SECTION AA SECTION DD
SECTION CC
SECTION BB
Fig. 63-45 Modification of the 2.07 M (6 ft-9 in) long arm [Breaker, Nibbler & Breaker]
63-75
63.11.4.2 HYDRAULIC PIPING FOR 2.07M (6 ft-9 in) LONG ARM [BREAKER, N&B]
This hydraulic piping applies to both the breaker machine and the nibbler & breaker machine. Install the additional
parts listed in Table 63-39 to the 2.07m (6 ft-9 in) long arm under par. 63.11.4.1 as shown in Fig. 63-46.

M8 33.3 N m (25 lbf ft)
M10 65.7 N m (48 lbf ft)
• For PF, PT-threads Tightening torque

3/4 162 N m (120 lbf ft)

22 X 3.0 216 N m (160 lbf ft)
Table 63-39
HYDRAULIC PIPING
YT43H00053F1 [BREAKER, N&B]
FOR 2.07M (6ft-9in) ARM
1 YT43H01056P1 TUBE 2
2 YT43H01013DB HOSE 2 L=1450
3 24100P1006F1 STOP VALVE 2
6 ZD12P02400 O-RING 2 1B P24
7 ZS18C08025 CAPSCREW 8 M8  25
8 ZS18C10045 CAPSCREW 2 M10  45
63-76
Fig. 63-46 Hydraulic piping for 2.07 M (6 ft-9 in) long arm [Nibbler & Breaker]
63-77
63.11.5 CONNECTOR ASSY [BREAKER]

When using the machine with a breaker. Attach the below parts to the tip of the stop valve. for use with NPK, TOKU
and KRUPP breakers.
CONNECTOR ASSY FOR

LE43H00006F1
NPK
1 2444P1744D1 CONNECTOR 1 PF3/4-3/4 16UNF
2 2420T4405 PLUG 1
3 ZD12P02400 O-RING 1 1B P24
2 3 1
3/4-16UNF
PF3/4
B : FOR NPK
Fig. 63-47 Connector assy [NPK]
CONNECTOR ASSY FOR

LP43H00005F1
TOKU, KRUPP
1 2444P1745D2 CONNECTOR 1 PF3/4
2 2420Z1228D4 PLUG 1
3 ZD12P02400 O-RING 1 1B P24
2 PF3/4 1 3 PF3/4
A : FOR TOKU,KRUPP
Fig. 63-48 Connector assy [TOKU, KRUPP]
63-78
63.11.6 CONNECTOR ASSY [NIBBLER]

When using the machine with a nibbler. Attach the below parts to the tip of the stop valve.
CONNECTOR ASSY LE43H00007F1

1 ZA23H22012 CONNECTOR 1 PF3/4
2 ZA82P22000 PLUG 1
3 ZD12P02400 O-RING 1 1B P24
2 M30 X 1.5 1 3
PF3/4
Fig. 63-49 Connector assy [NIBBLER]
63-79
63.11.7 REINFORCING THE IDLER LINK [NIBBLER & BREAKER]

When using the machine as a nibbler & breaker machine, the right and left idler links need reinforcement. Reinforce
them according to Table 63-40 and Fig. 63-50.
Table 63-40
IDLER LINK (L.H) YT12B01025P1
IDLER LINK (R.H) YT12B01024P1
0 YT12B01017P1 IDLER LINK (1) (RH)
0 YT12B01016P1 IDLER LINK (1) (LH)
1 YT12B01025P1002 PLATE 2 RH and LH in
common
Fig. 63-50 Reinforcing the idler link
63-80
63.12 REMINDERS ON THE USE OF NIBBLER & BREAKERS

63.12.1 CHANGING OVER THE SELECTOR VALVE
A nibbler & breaker-attached machine is equipped with a selector valve in both the operation circuit and the main
circuit. When running the machine after completion of modification, always set the selector valves according to a
nibbler or a breaker used.
Incorrect setting of the selector valves not only deteriorates operating efficiency and decreases speed but also caus-
es failure of the machine. Therefore, confirm completion of the modification and give proper advice to the user.
• Tool used
For main circuit changeover
: 5 mm
: 24 mm
PLUG
ALLEN WRENCH (HEX 5 mm)
SPANNER (HEX 5 mm)
SELECTOR VALVE
BOOM
C/V C/V
BREAKER BREAKER
TANK TANK
WHEN USING WHEN USING

BREAKER NIBBLER
Fig. 63-51 Changing over procedure of the selector valve
Changing over procedure of the selector valve

(1) Remove socket bolt with allen wrench.
(2) Turn the nibbler or the breaker to its operating position, using a spanner.
(3) Stop it at a specified position and tighten the setscrew.
63-81
63.12.2 FLUSHING METHOD

After completion of piping work, connect the high pressure side and the low pressure side, as shown in Fig. 63-52,
open the stop valves on both sides and depress the operating pedal to perform flushing.
• Before beginning flushing, run the engine at low speed, depress the breaker operating pedal and then run the
engine at high speed.
• Perform flushing operation for at least 40 minutes, and during the operation, make sure of no oil leakage from
each of the connections of the newly attached breaker circuit and the nibbler & breaker circuits.
An example of flushing time (23 min) in a single process
Fig. 63-52 Flushing method
63.12.3 REPLACING HYDRAULIC OIL AND RETURN FILTER

Contamination and deterioration of hydraulic oil may develop malfunctioning of the control valve, early wear and sei-
zure of the hydraulic pumps and malfunctioning of the entire hydraulic circuits : always replace hydraulic oil at regular
intervalvs, based on Table 63-41.
Table 63-41
Replacement intervals
Inspection / mainte-
Item Regular replace-
nance points First replacement 2 nd replacement
ment
Hydraulic oil Hydraulic oil tank — — Every 600h
Return filter Hydraulic oil tank 25h 100h Every 200h
63-82
63.12.4 OPERATING PROCEDURE

This machine is provided with breaker single circuit and nibbler and breaker combined (conflux) circuit. To use break-
er or nibbler, select circuit appropriate to the specification through switch on the left rear side of driver’s seat.
63.12.4.1 SWITCH OPERATING [NIBBLER & BREAKER SPECIFICATION]
Specification Switch position Circuit

Breaker OFF Single flow
Nibbler ON Conflux flow
Never turn switch on (conflux) to operate breaker. It may cause trouble of machine.
NIBBLER & BREAKER SPECIFICATION
63-83
63.12.4.2 CONTROL PEDAL

(1) Hydraulic breaker single circuit
Release pedal lock on the right front side of driver's seat to operate pedal.
Precaution for pedal operation

The operation varies in the specification, so before operating, read the Operator Manual carefully.

Depress toe section Breaker starts operation
Pedal in neutral position Breaker stops operating
RELEASE
LOCK
PUSH LOCK PULL LOCK ROD
ROD FORWARD BACKWARD
TO RELEASE TO LOCK PEDAL
BREAKER ONLY
(2) Nibbler and breaker combined (conflux) circuit.

Release pedal lock on the right front side of driver's seat to operate pedal.
• Hydraulic breaker

Pedal in neutral position Breaker stops operating
Depress heel section Breaker starts operation
• Nibbler

Depress toe section Nibbler close
Depress heel section Nibbler Open
Fig. 63-53 Operate pedal
63-84
63.13 PRECAUTIONS TO BE EXERCISED ON BREAKERS OF DIFFERENT MANU-

FACTURERS
There are some differences between manufactures as to the piping to breakers and the handling of breakers. For
this reason, consult with the manufacturer when mounting a breaker in the field. The following is a summary of how
breakers should be handled that is extracted from manufacturers’ catalog use and operation manuals
This is a general outline of how breakers should be used and may differ with excavator models. Always contact the
breaker manufacturer before field mounting.
(1) Placing high and low pressure accumulators
N P K They must be placed basically (depending upon models).
T O K U
K R U P P Check the oscillation of the pulsation of the breaker pressure and if pulsation is
O K A D A large, always install accumulators.
FURUKAWA
Standard of judgement on the installation of accumulators
High pressure side :

Measure the pulse oscillation by pressure on the high pressure side of the breaker at the inspection port for the
pump’s delivery pressure by actuating the breaker at the full revolution of the engine in mode H and set the max-
imum pressure difference to within 20% of he excavator's system pressure 29.4MPa (4270 psi). In case it ex-
ceeds 20%, install a high pressure accumulator.
The pulse oscillation is 300 X 20% = 5.9MPa (850 psi). Therefore, if it is more than this level, an accumulator
must be installed.
Install the accumulator by referring to Table 63-42 result of verfication test.
max
min
Max. press-Min press <system press X 20%>
Low pressure side :

Measure the inlet pressure of the line filter on the breaker side by actuating the breaker at full engine revolution
in the H mode, and in case the maximum pressure exceeds 5.4MPa (780 psi), install a low pressure accumula-
tor. max. < 5.4MPa (780 psi)
Regarding the capacity and the charge pressure of accumulators, contact the breaker manufacturer before in-
stallation.
63-85
(2) Installation of a relief valve
Installation is not necessary. (Contact the breaker manufacturer as it is necessary

N P K
depending upon models.)
T O K U Installation is necessary.
K R U P P A relief valve is specified by each breaker manufacturer.
O K A D A Since the method of pressure setting of the relief valve differs with breaker
T A I S E I manufacturers, install a relief valve according to the manufacturer’s instructions.
FURUKAWA
Only the B series of TOKU machine requires a relief valve to be installed.
HIGH PRESSURE SIDE PLUG
LOW PRESSURE SIDE PLUG
SELECTOR VALVE
Fig. 63-54 Relief valve mounting
6
4
2 1. HIGH PRESSURE
2. NIPPLE
3
TO TANK
3. ADAPTER
4. PLUG
RETURN SIDE 5. ELBOW
5 1 6. RELIEF VALVE
TO BREAKER OIL SUPPLY SIDE
63-86
(3) Restriction of engine revolution
N P K Full engine revolution may be used.
T O K U There are restriction on the engine revolution.

K R U P P Since a specified revolution differs with breakers, follow the breaker manufacturer’s
O K A D A instructions.
T A I S E I
FURUKAWA
In the case of a breaker for which the engine revolution is limited, the breaker does not increase impact power
and cycles even at full engine revolution.
Since extra hydraulic oil returns to the hydraulic oil via the relief valve, it causes the hydraulic oil temperature to
rise and the fuel consumption to increase.
Plaster the label (furnished by the breaker maker) indicating the revolution (Check the engine revolution.), to the
throttle potentiometer position. Always observe the indicated revolution.
(4) Changing over the breaker to high and low speeds
N P K
T O K U
These breakers are not so constructed as to be switched over to high and low speed.
T A I S E I
FURUKAWA
MKB1200 or larger breakers are constructed with a switching function.
K R U P P
It can be operated from inside the cab by the installation of a solenoid valve.
For piping work, consult with the breaker manufacturer.
Piping work is not required in some cases if a high-low cangeover function is not necessary at user's request.
On that occasion, it is necessary to fix the changeover valve contained in the breaker to the low speed side before-
hand. Consult with the breaker manufacturer in that case.
It is prohibited to use the high-low speed changeover valve without laying high-low speed piping and without fixing
the high-low speed changeover valve.
HIGHT-LOW SPEED
CHANGEOVER VALVE
RELIEF VALVE HYDRAULIC

BREAKER
TO CONTROL VALVE
TO TANK
CHECK VALVE
63-87
63.14 REFERENCE
Typical combinations are quoted from breaker manufacturers’ catalog use as below, but concerning applicable
breaker models, decide it after consultation with the breaker manufacturer.
When fitting a breaker, read through reminders on the use of breakers and cautions instructed by breaker manufac-
turers.
Applicable Working press Oil volume used Total weight Total length Bucket capacity
Manufacturer
breaker MPa (psi) L/min (gal/min) kg (lbs) mm (in) m3 (cuyd)
11.8~13.7 160~200 1,450 2,156
H-10XB
(1,710~1,990) (42.2~52.8) (3,200) (84.9)
NPK
12.7~14.7 35~60 410 1,644
H-4XB
(1,850~2,130) (9.24~15.8) (900) (64.7)
9.8~13.7 110~140 1,000 0.55~0.70
TNB-10B
(1,420~1,990) (29.0~37.0) (2,210) (0.72~0.92)
11.8~13.7 140~160 1,400 0.70~.090
TNB-14B
(1,710~1,990) (37.0~42.2) (3,100) (0.92~1.18)
9.8~15.7 45~80 391 1,476 0.25~0.35
TOKU TNB-6B
(1,420~2,280) (11.9~21.1) (860) (58.1) (0.33~0.46)
11.8~16.7 100~140 997 1,850 0.55~0.70
TNB-10E
(1,710~2,420) (26.4~37.0) (2,200) (72.8) (0.72~0.92)
12.7~16.7 130~170 1,500 2,190 0.70~0.90
TNB-14E
(1,850~2,420) (34.3~44.9) (3,300) (86.2) (0.92~1.18)
14.7~15.7 80~110 1,100~1,250 2,278 0.50~0.90
MKB1100
(2,130~2,280) (21.1~29.0) (2,430~2,760) (89.7) (0.65~1.18)
KRUPP
14.7~17.6 90~130 1,120~1,200 0.55~1.00
NKB1200
(2,130~2,560) (23.8~34.3) (2,470~2,650) (0.72~1.31)
14.7~17.6 110~ 1,450 2,240 0.70~
UB 11
(2,130~2,560) (29.0~ ) (3,200) (88.2) (0.92~ )
OKADA
12.7~15.7 110~155 1,070 2,040 0.55~0.70
OUB 310
(1,850~2,280) (29.0~40.9) (2,360) (80.3) (0.72~0.92)
14.7~16.7 100~120 1,330 [1,596] 0.60~0.90
TAISEI TF-150
(2,130~2,420) (26.4~31.7) (2,930) (62.8) (0.78~1.18)
15.7~17.6 125~150 1,400 2,119
FURUKAWA HB20G
(2,280~2,560) (33.0~39.6) (3,100) (83.4)
[ ] Excludes chisels.
63-88
Table 63-42 General precautions to be exercised on the installation of breakers

by different manufacturers
Restriction of
Installation of Installation of High-low speed
Manufacturer engine
accumulators a relief valve changeover
revolution
changeover type not
Manufacturer
available.
changeover type not
TOKU Series B
available.
changeover type not
TOKU Series E
available.
changeover type available
— KRUPP
for large machines.
changeover type available
— OKADA
for special request.
changeover type not
— HURUKAWA
available.
changeover type not
— TAISEI
available.
One that must be installed.
One that does not need to be installed.
Adaptation test completed.
One that must be adjusted at installation.
Capacity 1 liter, pressure is 6.9MPa (1,000psi)
63-89
[MEMO]
63-90

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HYDRAULIC EXCAVATOR

Book Code No.S5YT0004E01

GENERAL SAFETY INFORMATION nor or moderate injury. It may also be used to

2) WARNING- Indicates a potentially hazardous

3) CAUTION- Indicates a potentially hazardous

SAFETY PRECAUTIONS stands, capable of supporting the machine, before

The proper and safe lubrication and maintenance

2005-2 & ASSEMBLING

2005-2 AND NIBBLER & BREAKER

YT04-07175~ APPLICABLE MACHINES

1.1 GENERAL PRECAUTIONS FOR REPAIRS ...................................................................... 1-3

Book Code No. S5PW0108E01

Issue Date of Issue Applicable Machines Remarks

5) Use the special jig and tools without fail if they

1.2 INTERNATIONAL UNIT CON- (3) Derived Units

1. Etymology of SI Unites QUANTITY UNIT SYMBOL FORMULA

(2) Supplementary units

(6) Unit Conversion

*1 Units that are allowed to use.

2.1 NAME OF COMPONENTS ................................................................................................. 2-3

Book Code No. S5YT0204E01

Issue Date of Issue Applicable Machines Remarks

2.1 NAME OF COMPONENTS

ARM ARM CYLINDER

IDLER LINK FUEL TANK

OPERATOR CONTROLS ENGINE MUFFLER

PUMP ACCESS DOOR

LOWER ROLLER RADIATOR

TRACK LINK TRAVEL MOTOR

2.2 MACHINE DIMENSIONS

2.2.2 1.65 M (5 ft-5 in) ARM

1,440 (4'9") 450 (17.7")

*Marked dimensions do not include height of shoe lug.

2.3 WEIGHT OF COMPONENTS

Model 2.07 M (6 ft-9 in) Arm

2. Lower frame assy (including the following :) 2,854 (6,290)

Model 2.07 M (6 ft-9 in) Arm

Numerical values marked * indicate the dry weight.

2.4 TRANSPORTATION DIMENSION AND WEIGHT

OVERALL DIMENSIONS OF A COMPLETE MACHINE ON A TRAILER

• The parenthesis shows 2.07m arm model.

OVERALL DIMENSIONS OF WITHOUT ARM AND BUCKET

Type A : Shoe width L : Length H : Height W : Width Weight

OVERALL DIMENSIONS OF WITHOUT BOOM, ARM AND BUCKET

Type A : Shoe width L : Length H : Height W : Width Weight

OVERALL DIMENSIONS OF BOOM

Item Type 3.72 m (12 ft-2 in) Boom

OVERALL DIMENSIONS OF ARM + BUCKET

Type 1.65 m (5 ft-5 in) Arm+ 2.07 m (6 ft-9 in) Arm+

OVERALL DIMENSIONS OF ARM

OVERALL DIMENSIONS OF BUCKET

Type Hoe bucket

Type Hoe bucket Slope finishing

2.5 SPECIFICATIONS AND PERFORMANCE

Model & Shoe spec. SK70SR-1ES

Engine model ISUZU 4JG1NABGA

2.5.3 HYDRAULIC COMPONENTS

Hydraulic pump Variable displacement axial piston+gear pump

Fully equipped weight 6,940 (15,300) 7,180 (15,830)

2.6 TYPE OF CRAWLER

600 (23.6) 2,470 (8’1" ) 23.5 (3.4)

450 (17.7) 2,320 (7’7" ) 32.3 (4.6)

600 (23.6) 2,470 (8’1" ) 22.5 (3.3)

700 (27.6) 2,570 (8’5" ) 19.6 (2.9)