HYDRAULIC EXCAVATOR

MAINTENANCE SPECIFICATIONS
SK130-8
SHOP SK130L-8
MANUAL model SK140LC-8

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.S5YP0001E02

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

2) WARNING- Indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury and is represented as
follows:

0-2
SAFETY PRECAUTIONS stands, capable of supporting the machine, before
performing any disassembly.

The proper and safe lubrication and maintenance

for this machine, recommended by Manufacturer, Do not operate this machine unless you have
are outlined in the OPERATOR’S MANUAL for the read and understand the instructions in the OP-
machine. ERATOR’S MANUAL. Improper machine opera-
Improper performance of lubrication or mainte- tion is dangerous and could result in injury or
nance procedures are dangerous and could result death.
in injury or death. Read and understand the MAN-
(6) Relieve all pressure in air, oil or water systems be-
UAL before performing any lubrication or mainte-
fore any lines, fittings or related items are discon-
nance.
nected or removed. Always make sure all raised
The serviceman or mechanic may be unfamiliar with components are blocked correctly and be alert for
many of the systems on this machine. This makes it possible pressure when disconnecting any device
important to use caution when performing service work. from a system that utilizes pressure.
A knowledge of the system and or components is im- (7) Lower the bucket, dozer, or other attachments to
portant before the removal or disassembly of any com- the ground before performing any work on the ma-
ponent. chine. If this cannot be done, make sure the bucket,
Because of the size of some of the machine compo- dozer, ripper or other attachment is blocked correct-
nents, the serviceman or mechanic should check the ly to prevent it from dropping unexpectedly.
weights noted in this manual. Use proper lifting proce- (8) Use steps and grab handles when mounting or dis-
dures when removing any components. Weight of com- mounting a machine. Clean any mud or debris from
ponents table is shown in the section ; steps, walkways or work platforms before using.
SPECIFICATIONS. Always face to the machine when using steps, lad-
The following is a list of basic precautions that must al- ders and walkways. When it is not possible to use
ways be observed. the designed access system, provide ladders, scaf-
folds, or work platforms to perform safe repair oper-
(1) Read and understand all Warning plates and decal
ations.
on the machine before Operating, Maintaining or
Repairing this machine. (9) To avoid back injury, use a hoist when lifting com-
ponents which weigh 20kg (45lbs) or more. Make
(2) Always wear protective glasses and protective
sure all chains, hooks, slings, etc., are in good con-
shoes when working around machines. In particu-
dition and are the correct capacity. Be sure hooks
lar, wear protective glasses when using hammers,
are positioned correctly. Lifting eyes are not to be
punches or drifts on any part of the machine or at-
side loaded during a lifting operation.
tachments. Use welders gloves, hood/goggles,
apron and the protective clothing appropriate to the (10)To avoid burns, be alert for hot parts on machines
welding job being performed. Do not wear loose fit- which have just been stopped and hot fluids in
ting or torn clothing. Remove all rings from fingers, lines, tubes and compartments.
loose jewelry, confine long hair and loose clothing (11)Be careful when removing cover plates. Gradually
before working on this machinery. back off the last two capscrews or nuts located at
(3) Disconnect the battery and hang a "Do Not Oper- opposite ends of the cover or device and carefully
ate" tag in the Operators Compartment. Remove ig- pry cover loose to relieve any spring or other pres-
nition keys. sure, before removing the last two capscrews or
nuts completely.
(4) If possible, make all repairs with the machine
parked on a firm level surface. Block the machine (12)Be careful when removing filler caps, breathers and
so it does not roll while working on or under the ma- plugs on the machine. Hold a rag over the cap or
chine. Hang a "Do Not Operate" tag in the Opera- plug to prevent being sprayed or splashed by liq-
tors Compartment. uids under pressure. The danger is even greater if
the machine has just been stopped because fluids
(5) Do not work on any machine that is supported only
can be hot.
by lift, jacks or a hoist. Always use blocks or jack

0-3
(13)Always use the proper tools that are in good condi- (21)Do not operate a machine if any rotating part is
tion and that are suited for the job at hand. Be sure damaged or contacts any other part during opera-
you understand how to use them before performing tion. Any high speed rotating component that has
any service work. been damaged or altered should be checked for
(14)Reinstall all fasteners with the same part number. balance before reusing.
Do not use a lesser quality fastener if replacements (22)Be careful when servicing or separating the tracks
are necessary. (crawlers). Chips can fly when removing or install-
(15)Repairs which require welding should be per- ing a track (crawlers) pin. Wear safety glasses and
formed only with the benefit of the appropriate ref- long sleeve protective clothing. Tracks (crawlers)
erence information and by personnel adequately can unroll very quickly when separated. Keep away
trained and knowledgeable in welding procedures. from front and rear of machine. The machine can
Determine type of metal being welded and select move unexpectedly when both tracks (crawlers)
correct welding procedure and electrodes, rods or are disengaged from the sprockets. Block the ma-
wire to provide a weld metal strength equivalent at chine to prevent it from moving.
least to that of the parent metal. Make sure to dis-
connect battery before any welding procedures are
attempted.
(16)Do not damage wiring during removal operations.
Reinstall the wiring so it is not damaged nor will be
damaged in operation of the machine by contacting
sharp corners, or by rubbing against some object or
hot surface. Do not connect wiring to a line contain-
ing fluid.
(17)Be sure all protective devices including guards and
shields are properly installed and functioning cor-
rectly before starting a repair. If a guard or shield
must be removed to perform the repair work, use
extra caution and replace the guard or shield after
repair is completed.
(18)The maintenance and repair work while holding the
bucket raised is dangerous due to the possibility of
a falling attachment. Don’t fail to lower the attach-
ment and place the bucket to the ground before
starting the work.
(19)Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not bend
or strike high pressure lines or install ones which
have been bent or damaged. Inspect lines, tubes
and hoses carefully. Do not check for leaks with
your hands. Very small (pinhole) leaks can result in
a high velocity oil stream that will be invisible close
to the hose. This oil can penetrate the skin and
cause personal injury. Use card-board or paper to
locate pinhole leaks.
(20)Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are in-
stalled correctly to avoid excessive heat, vibration
or rubbing against other parts during operation.
Shields that protect against oil spray onto hot ex-
haust components in event of a line, tube or seal
failure must be installed correctly.

0-4
 INDEX
SE Asia SK130-8
NZL SK130L-8
Thailand SK140LC-8
Book Code No. Index
Title 1
Distribution Year–Month No. 33 25

MAINTENANCE SPECIFICATIONS
S5YN0129E01
2009-07
OUTLINE 1
S5YP0201E02
2010-01
SPECIFICATIONS 2
S5YP0301E02
ATTACHMENT DIMENSIONS 3
2010-01 34 2
S5YP1101E01
TOOLS 11
2009-07
S5YP1201E01 STANDARD MAINTENANCE
2009-07
12
TIME SCHEDULE
S5YP1301E02 MAINTENANCE STANDARD
2010-01
13 3
AND TEST PROCEDURE
51 11
S5YP2101E01 MECHATRO CONTROL
2009-07
21
SYSTEM
S5YP2201E02
2010-01
HYDRAULIC SYSTEM 22
S5YP2301E02
SYSTEM

2010-01
ELECTRIC SYSTEM 23
12
S5YP2401E02
2010-01
COMPONENTS SYSTEM 24
S5YP2501E01
2009-07
AIR-CONDITIONER SYSTEM 25
_

S5YN3129E01 DISASSEMBLING 21 13
DISASSEMBLING

2009-07 & ASSEMBLING

31
S5YP3201E02
ATTACHMENT 32
2010-01
S5YP3301E01
2009-07
UPPER STRUCTURE 33
S5YP3401E02
TRAVEL SYSTEM 34 46 22
2010-01
E / G TROUBLESHOOTING

S5YY4618E01
2009-07
BY ERROR CODES 46
S5YY4718E01
2009-07
BY TROUBLE 47
S5YN4829E01 23
2009-07
TROUBLE DIAGNOSIS MODE 48 47 31
_

S5YY5118E01
ENGINE 51
2009-07
_
24
48 32
_

YP09-05001~ APPLICABLE MACHINES

0-5
NOTE:
This Manual is prepared as a technical material in This Manual may be properly revised due to the im-
which the information necessary for the maintenance provement of products, modification of specifications,
and repairing services of our hydraulic excavators are etc. And there are cases where the system on actual
collected, and is categorized into 7 Chapters, Specifica- machine and a part of the contents of this manual may
tion, Maintenance, System, Disassembly, Trouble- differ due to the variations of specification by countries.
shooting, Engine, and Installation Procedures for For the section in which the description is hardly under-
Optional Attachment. stood, contact our distributor.

• The Chapter "Specification" describes the specifi- The number is assigned to every part handled in this
cations for entire machine and material, which are Manual on account of the description, but the parts,
instructive for replacement and repairing of attach- which cannot be supplied as service parts are con-
ments. tained. Therefore, the order must be placed with re-
spective formal number with due confirmation on the
• The Chapter "Maintenance" describes the material,
Parts Manual for applicable machine.
which is helpful for maintenance service and adjust-
ments for entire machine.
• The Chapter "System" describes the operating sys-
tem like hydraulic system, electric system, compo-
nents, and so on.
• The Chapter "Disassembly" describes the removal
and installing of assembly mounted on the upper
structure and undercarriage, and the assembling
and disassembling of the associated hydraulic
equipment.
• The Chapter "Troubleshooting" describes how to
find the fault equipment.
• The Chapter "Engine" describes the engines mak-
ing use of the "Maintenance Manual" provided by
the suppliers.
• The Chapter "Installation Procedures for Optional
Attachment" describes the supplements added on
request as required.

0-6
 ［1. OUTLINE］

１
1. OUTLINE
TABLE OF CONTENTS

1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS ……………………………………………………1-3

1.1.1 PREPARATION BEFORE DISASSEMBLING …………………………………………………………1-3
1.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING ……………………………………………1-3
1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT ………………………………1-4
1.1.4 ELECTRICAL EQUIPMENT ………………………………………………………………………………1-6
1.1.5 HYDRAULIC PARTS ………………………………………………………………………………………1-7
1.1.6 WELD REPAIR ………………………………………………………………………………………………1-7
1.1.7 ENVIRONMENTAL ISSUES ………………………………………………………………………………1-7
1.2 INTERNATIONAL UNIT SYSTEM ……………………………………………………………………………1-8

Book Code No. S5YN0129E01

1-1
［1. OUTLINE］

Issue Date of Issue Applicable Machines Remarks

SK200-8 : YN12-56001~ S5YN0129E01
First Edition December, 2008
SK210LC-8 : YQ12-08001~ (SE Asia & Oceania)
SK200-8 : YN12-56001~
SK210LC-8 : YQ12-08001~ SE Asia (HS Engine)
SK330-8 : LC11-08501~
January, 2009
SK350LC-8 : YC11-04501~ (SE Asia & Oceania)

February, 2009 SK200-8 : YN12-T0301~

TKCM

SK200-8 : YN12-T0301~
TKCM (HS Engine)
E215B : YN12-56001~
E215BLC : YQ12-08001~ NHK-RUS (HS Engine)

E215B : YN12-56001~
NHK-Mid.East & Afr.
E215BLC : YQ12-08001~
(HS Engine)
E215B : YN12-56001~
E215BLC : YQ12-08001~ (NHK-TUR)

SK330-8 : LC11-08501~
SE Asia (HS Engine)
E265B : LQ13-07001~
E265BLC : LL13-06001~ NHK-RUS (HS Engine)

E265B : LQ13-07001~
NHK-Mid.East & Afr.
E265BLC : LL13-06001~
(HS Engine)
E265B : LQ13-07001~
E265BLC : LL13-06001~ (NHK-TUR)
SK460-8 : LS11-02501~
SK480LC-8 : YS11-02001~ (SE Asia & Oceania)
E385B : LC11-08501~
March, 2009
E385BLC : YC11-04501~ NHK-RUS (HS Engine)

E385B : LC11-08501~
NHK-Mid.East & Afr.
E385BLC : YC11-04501~
(HS Engine)

SK850LC : LY02-
(SE Asia)
SK460-8 : LS11-02501~
SK480LC-8 : YS11-02001~ SE Asia (HS Engine)
E235BSR : YF06-02501~
April, 2009
E235BSR(N)LC : YU06-03001~ (NHK-EUR)

SK235SRLC-2 : YU06-03001~
(NA)
SK235SR-2 : YF06-02501~
May, 2009
SK235SRLC-2 : YU06-03001~ (OCE)
SK125SR : YV06-05501~
SK125SRL : LD06-01801~
June, 2009
SK135SR-2 : YY06-15001~ (SE Asia & Oceania)
SK135SRLC-2 : YH06-08001~

July, 2009 SK140LC-8 : YP09-05001~

(SE Asia)

1-2
 ［1. OUTLINE］

1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS

１
1.1.1 PREPARATION BEFORE DISASSEMBLING

(1) Knowledge of operating procedure

Read Operator's Manual carefully to understand the operating procedure.

(2) Cleaning machines

Clean machines of soil, mud, and dust before carrying into the service shop. Carrying a soiled
machine into the service shop, causes making less efficient work and damage of parts.

(3) Inspecting machines

Confirm the disassembling section before starting work, determine the disassembly procedure taking the
conditions in work shop into account, and request to procure necessary parts in advance.

(4) Recording
Record the following items to keep contact and prevent malfunction from recurring.

1. Inspecting date, place

2. Model name, Serial number and Record on hour meter
3. Trouble condition, place, cause
4. Visible oil leak, water leak and damage
5. Clogging of filters, oil level, oil quality, oil contamination and looseness.
6. Examine the problems on the basis of monthly operation rate with the last inspection date and
records on hour meter.

(5) Arrangement and cleaning in service shop

1. Tools required for repair work.
2. Prepare the places to put the disassembled parts.
3. Prepare oil pans for leaking oil, etc.

1.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING

(1) Safety
1. Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves.
2. Attach "Don't operate" tag to control lever, and begin a meeting before starting the work.
3. Before starting inspection and maintenance stop the engine.
4. Confirm the position of first-aid kit and fire extinguisher, and also where to make contact for
emergency measure and ambulance to prepare for accidents and fire.
5. Choose a hard, lever and safe place, and put attachment on the ground without fail.
6. Use hoist, etc. to remove parts of heavy weight (23kg [50 lb] or more).
7. Use proper tools, and change or repair defective tools.
8. Machine and attachment required to work in the lifting condition should be supported with
supports or blocks securely.

1-3
［1. OUTLINE］

1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT

(1) Removing hydraulic equipment assy

1. Before removing pipes, release the pressure of hydraulic oil tank, or open the cover on the return
side to tank, and take out the filter.
2. Drain the oil in the removed pipes into pan to prevent the oil from spilling on the ground.
3. Pipes with plugs or caps to prevent oil leaking, entry of dust, etc.
4. Clean the outside surface of equipment, etc. before disassembling, and drain hydraulic oil and gear
oil before putting them on working bench.

(2) Disassembling hydraulic equipment

1. Since performance and function of hydraulic equipment after disassembly and assembly results in
immunity from responsibility on the manufacture's side, disassembly, assembly and modification
without permission are strictly prohibited.
2. If it is unavoidably necessary to disassemble and modify, it should be carried out by experts or
personnel qualified through service training.
3. Make match mark on parts for reassembling.
4. Before disassembling, read Disassembling Instruction in advance, and determine if the
disassembly and assembly are permitted or not.
5. For parts which are required to use jig and tools, don't fail to use the specified jig and tools.
6. For parts which can not be removed in the specified procedure, never force removal. First check
for the cause.
7. The removed parts should be put in order and tagged so as to install on proper places without
confusion.
8. For common parts, pay attention to the quantity and places.

(3) Inspecting parts

1. Check that the disassembled parts are free from adherence, interference and uneven working face.
2. Measure the wear of parts and clearance, and record the measured values.
3. If an abnormality is detected, repair or replace the parts.

(4) Reassembling hydraulic equipment

1. During the parts cleaning, ventilate the room.
2. Before assembly, clean parts roughly first, and then completely.
3. Remove adhering oil by compressed air, and apply hydraulic oil or gear oil, and then assemble
them.
4. Replace the removed O-ring, back-up rings and oil seal with new ones, and apply grease oil on
them before assembling.
5. Removes dirt and water on the surface on which liquid sealant are applied, decrease them, and
apply liquid sealant on them.
6. Before assembling, remove rust preventives on new parts.
7. Use special tools to fit bearings, bushing and oil seal.
8. Assemble parts matching to the marks.
9. After completion, check that there is no omission of parts.

1-4
 ［1. OUTLINE］

(5) Installing hydraulic equipment

1. Confirm hydraulic oil and lubrication oil.

１
2. Air release is required in the following cases ;
a. Change of hydraulic oil
b. Replacement of parts on suction pipe side
c. Removing and attaching hydraulic pump
d. Removing and attaching swing motor
e. Removing and attaching travel motor
f. Removing and attaching hydraulic cylinder
3. For air bleed of hydraulic pump and swing motor, loosen drain plug on the upper part, start
engine, and run in low idling, then bleed air until hydraulic oil is comes out. After completion of
comes, tighten plug securely.
4. For air bleed of travel motor and hydraulic cylinder, starts engine and operate it for 10 minutes
or more at no-load and low speed.
5. Air in pilot circuit can be bleed out by only operating digging, swing and traveling motions
thoroughly.
6. Check hydraulic oil level.
Move attachments to hydraulic oil check position, and check hydraulic oil level of tank. Refill oil if
the oil level is lower than the specified level.
How to check oil level of hydraulic oil tank

If hydraulic oil and lubricating oil are not filled and also air bleed is not performed, the hydraulic
equipment may be damaged.

For cylinder, don't move it to the stroke end at beginning.

1-5
［1. OUTLINE］

1.1.4 ELECTRICAL EQUIPMENT

(1) The disassembly of electrical equipment is not allowed.

(2) Handle equipment with care so as not to drop it or bump it.
(3) Connector should be removed by unlocking while holding the connector.
Never stress in tension to the caulked section by pulling wire.
(4) Check that connector is connected and locked completely.
(5) Engine key off before removing and connecting connector.
(6) Engine key off before touching terminals of starter and alternator.
(7) Remove battery grounding terminal before beginning work close to battery and battery relay with
tools.
(8) Wash machine with care so as not to splash water on electrical equipment and connector.
(9) When water has entered in the waterproofed connector, the removing of water is not easy. So
check the removed waterproofed connector with care to protect it from entry of water. If moisture
adheres on it, dry it completely before connecting.

Battery fluid is dangerous.

The battery fluid is dilute sulfuric acid, and causes scald and loss of eyesight by adhering on eyes,
skin and clothes. When the fluid has adhered on them, take an emergency measure immediately and
see a doctor for medical advice.
-When it has adhered on skin; Wash with soap and water.
-When it has got in eyes; Wash in water for 10 minutes or more immediately.
-When it has spilled out in large quantity; Use sodium bicarbonate to neutralize, or wash away with
water.
-When it was swallowed; Drink milk or water.
-When it has adhered on clothes; Wash it immediately.

1-6
 ［1. OUTLINE］

1.1.5 HYDRAULIC PARTS

１
(1) O-ring
・ Check that O-ring is free from flaw and has elasticity before fitting.
・ Even if the size of O-ring is equal, the usage differs, for example in dynamic and static sections,
the rubber hardness also differs according to the pressure force, and also the quality differs
depending on the materials to be seated. So, choose proper O-ring.
・ Fit O-ring so as to be free from distortion and bend.
・ Floating seal should be put in pairs.

(2) Flexible hose (F hose)

・ Even if the connector and length of hose are the same, the parts differ according to the
withstanding pressure. Use proper parts.
・ Tighten it to the specified torque, and check that it is free from twist, over tension, interference,
and oil leak.

1.1.6 WELD REPAIR

(1) The weld repair should be carried out by qualified personnel in the specified procedure after
disconnecting the grounding cable of battery. If the grounding cable is not disconnected, the
electrical equipment may be damaged.
(2) Remove parts which may cause fire due to the entry of spark beforehand.
(3) Repair attachments which are damaged, giving particular attention to the plated section of piston
rod to protect it from sparks, and don't fail to cover the section with flame-proof clothes.

1.1.7 ENVIRONMENTAL ISSUES

(1) Engine should be started and operated in the place where air can be sufficiently ventilated.
(2) Waste disposal
The following parts follows the regulation.
Waste oil, waste container and battery
(3) Precautions for handling hydraulic oil
Hydraulic oil may cause inflammation of eyes.
Wear goggles to protect eyes on handling it.
-When it has got in eyes ;
Wash eyes with water until the stimulus is gone.
-When it was swallowed ;
Don't force him to vomit it, but immediately receive medical treatment.
-When it has adhered on skin ;
Wash with soap and water.
(4) Others
For spare parts, grease and oil, use KOBELCO genuine ones.

1-7
［1. OUTLINE］

1.2 INTERNATIONAL UNIT SYSTEM

Introduction
Although this manual uses the SI units system.
Outline of SI units system is described here.
Given hereinunder are an excerpt of the units
that are related to this manual :
1. Etymology of SI Units
English : International System of units
2. Construction of SI Unit System

1-8
 ［1. OUTLINE］

1-9
［1. OUTLINE］

1-10
 ［2. SPECIFICATIONS］

２
2. SPECIFICATIONS
TABLE OF CONTENTS

2.1 NAME OF COMPONENTS ……………………………………………………………………………………2-3

2.2 GENERAL DIMENSIONS ………………………………………………………………………………………2-4
2.2.1 SK140LC-8 [4.68m (15ft-4in) Boom+2.38m (7ft-10in) Standard Arm+0.5m3 (0.65cu-yd) Bucket]
…………………………………………………………………………………………………………………………2-4
2.2.2 SK130-8 [4.68m (15ft-4in) Boom+2.38m (7ft-10in) Standard Arm+0.5m3 (0.65cu-yd) Bucket] …2-5
2.2.3 SK130L-8 [4.68m (15ft-4in) Boom+2.38m (7ft-10in) Standard Arm+0.45m3 (0.59cu-yd) Bucket]
…………………………………………………………………………………………………………………………2-6
2.3 WEIGHT OF COMPONENTS …………………………………………………………………………………2-7
2.4 TRANSPOTATION ………………………………………………………………………………………………2-9
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER …………………………………………2-9
2.4.2 DIMENSIONS OF ATTACHMENT ………………………………………………………………………2-9
2.5 SPECIFICATIONS AND PERFORMANCE ……………………………………………………………………2-11
2.5.1 SPEED AND CLIMBING CAPABILITY …………………………………………………………………2-11
2.5.2 ENGINE ………………………………………………………………………………………………………2-11
2.5.3 HYDRAULIC COMPONENTS ……………………………………………………………………………2-11
2.5.4 WEIGHT ………………………………………………………………………………………………………2-12
2.6 TYPE OF CRAWLER ……………………………………………………………………………………………2-13
2.7 TYPE OF BUCKET ………………………………………………………………………………………………2-14
2.8 COMBINATIONS OF ATTACHMENT …………………………………………………………………………2-15
2.9 ENGINE SPECIFICATION ………………………………………………………………………………………2-16
2.9.1 SPECIFICATIONS …………………………………………………………………………………………2-16
2.9.2 ENGINE CHARACTERISTIC CURVE ……………………………………………………………………2-17

Book Code No. S5YP0201E02

2-1
［2. SPECIFICATIONS］

Issue Date of Issue Applicable Machines Remarks

S5YP0201E01
First Edition July, 2009 SK140LC-8 : YP09-05001~
(SE Asia)
S5YP0201E02
SK140LC-8 : YP09-05001~
(SE Asia)
Revision January, 2010 SK130-8 : LP09-20001~
(NZL)
SK130L-8 : LX07-11001~
(Thailand)

2-2
 ［2. SPECIFICATIONS］

2.1 NAME OF COMPONENTS

2-3
［2. SPECIFICATIONS］

2.2 GENERAL DIMENSIONS

2.2.1 SK140LC-8 [4.68m (15ft-4in) Boom+2.38m (7ft-10in) Standard Arm+0.5m3

(0.65cu-yd) Bucket]

Dimensions marked * do not include the height of the shoe lug.

2-4
 ［2. SPECIFICATIONS］

2.2.2 SK130-8 [4.68m (15ft-4in) Boom+2.38m (7ft-10in) Standard Arm+0.5m3

(0.65cu-yd) Bucket]

２
Dimensions marked * do not include the height of the shoe lug.

2-5
［2. SPECIFICATIONS］

2.2.3 SK130L-8 [4.68m (15ft-4in) Boom+2.38m (7ft-10in) Standard Arm+0.45m3

(0.59cu-yd) Bucket]

Dimensions marked * do not include the height of the shoe lug.

2-6
 ［2. SPECIFICATIONS］

2.3 WEIGHT OF COMPONENTS

Unit ; kg (lb)
Item / Model SK140LC-8 SK130-8 SK130L-8
Fully equipped weight 13,000 (28,600) 12,800 (28,220) 14,700 (32,410)
1. Upper frame assy (Assembly of following :) 6,550 (14,440) <-- 5,320 (11,730)
1.1 Upper frame 1,420 (3,130) <-- <--

２
1.2 Counter weight 2,400 (5,290) <-- 1,400 (3,090)
1.3 Cab 297 (655) <-- <--
1.4 Engine * 395 (871) <-- <--
1.5 Hydraulic oil tank * 107 (236) <-- <--
1.6 Fuel tank * 104 (229) <-- <--
1.7 Slewing motor (including reduction unit) * 106 (234) <-- <--
1.8 Control valve * 158 (348) <-- <--
1.9 Boom cylinder * 96 (212) X 2 <-- <--
1.10 Pin (for mounting boom) 61 (134) <-- <--
1.11 Pump * 85 (187) <-- <--
1.12 Radiator (including intercooler) * 77 (170) <-- <--
2. Lower frame assy (Assembly of following :) 4,275 (9,430) 4,445 (9,800) 7,070 (15,590)
2.1 Lower frame 1,520 (3,350) 1,460 (3,220) 2,100 (4,630)
2.2 Slewing bearing 150 (330) <-- <--
2.3 Travel motor (including reduction unit) * 145 (320) X 2 <-- 217 (478) X 2
2.4 Upper roller 9 (20) X 2 9 (20) X 2 16 (35) X 4
2.5 Lower roller 25 (55) X 14 25 (55) X 12 32 (70) X 14
2.6 Front idler 74 (163) X 2 <-- 106 (237)
2.7 Idler adjuster 58 (128) X 2 <-- 97 (214)
2.8 Sprocket 40 (88) X 2 <-- 65 (143) X 2
2.9 Swivel joint * 24 (53) <-- <--
2.10 Track link with 500mm (19.7in) shoes assy (LC) 760 (1,675) X 2 <-- -
Track link with 600mm (23.6in) shoes assy 912 (2,012) X 2 <-- -
Track link with 700mm (27.6in) shoes assy 1,013(2,234) X 2 <-- -
Track link with 900mm (35.4in) shoes assy - - 1,563(3,450) X 2
3. Attachment (Assembly of following :)
{4.68m (15ft-4in) Boom + 2.38m (7ft-10in) Arm + 2,347 (5,175) <-- <--
0.50m3 (0.65cu-yd) Bucket}
[{4.68m (15ft-4in) Boom + 2.38m (7ft-10in) Arm + [2,367 (5,220)] <-- <--
0.57m3 (0.75cu-yd) Bucket}]
[{4.68m (15ft-4in) Boom + 2.38m (7ft-10in) Arm + 2,322 (5,120) <-- <--
0.45m3 (0.59cu-yd) Bucket}]
3.1 Bucket assy (STD) 400 (882) <-- 355 (783)
3.2 STD Arm assy (Assembly of following :) 659 (1,453) <-- <--
3.2.1 STD Arm 435 (960) <-- <--
3.2.2 Bucket cylinder 82 (180) <-- <--
3.2.3 Idler link 30 (66) <-- <--
3.2.4 Bucket link 42 (93) <-- <--
3.2.5 Pin (2pcs. for mounting bucket cylinder / 2pcs. 46 (101) <-- <--
for mounting bucket)
3.3 Boom assy (Assembly of following :) 1,324 (2,920) <-- <--
3.3.1 Boom 893 (1,970) <-- <--
3.3.2 Arm cylinder 138 (304) <-- <--
3.3.3 Pin (Mounting arm - Mounting arm cylinder) 29 (64) <-- <--

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［2. SPECIFICATIONS］

Item / Model SK140LC-8 SK130-8 SK130L-8

4. Lubricant and water (Assembly of following :) 422 (930) <-- <--
4.1 Hydraulic oil 151 (333) <-- <--
4.2 Engine oil 16 (35) <-- <--
4.3 Fuel 241 (531) <-- <--
4.4 Water 14 (31) <-- <--

Marks * show dry weight.

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 ［2. SPECIFICATIONS］

2.4 TRANSPOTATION

2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER

(1) 4.68m (15ft-4in) Boom+2.38m (7ft-10in) Arm+0.5m3 (0.65cu-yd) Bucket
Item/Shoe type 700mm (27.6in) LC
Width : mm (ft-in) 2,690 (8'10")

２
Weight: kg (lbs) 13,500kg (29,770 lbs)

2.4.2 DIMENSIONS OF ATTACHMENT

(1) BOOM
Item / Type 4.68m (15ft-4in) Boom
Length X Height X Width 4.84 X 1.42 X 0.60
L X H X W: m (ft-in) (15'11" X 4'8" X 1'12")
Weight: kg (lbs) 1,350 (2,975)

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［2. SPECIFICATIONS］

(2) ARM AND BUCKET

2.38m (7ft-10in) Arm + 2.84m (9ft-4in) Arm +
Item / Type
0.50m3 (0.65cu-yd) Bucket 0.38m3 (0.50cu-yd) Bucket
Length X Height X Width 4.28 X 0.82 X 1.00 4.74 X 0.82 X 1.00
L X H X W: m (ft-in) (14'1" X 2'8" X 3'3") (15'7" X 2'8" X 3'3")
Weight: kg (lbs) 1,000 (2,205) 1,100 (2,426)

(3) Arm
Item / Type 2.38 m (7ft-10in) Arm 2.84 m (9ft-4in) Arm
Length X Height X Width 3.13 X 0.65 X 0.53 3.59 X 0.66 X 0.56
L X H X W: m (ft-in) (10'3" X 2'2" X 1'9") (11'9" X 2'2" X 1'10")
Weight: kg (lbs) 590 (1,300) 690 (1,521)

(4) Bucket
Type Hoe bucket
Length X Height X Width 1.19 X 1.07 X 0.70 1.19 X 1.07 X 0.70 1.19 X 1.07 X 0.80
L X H X W: m (ft-in) (3'11" X 3'6" X 2'4") (3'11" X 3'6" X 2'4") (3'11" X 3'6" X 2'7")
Weight: kg (lbs) 280 (620) 300 (660) 320 (706)
3
Bucket capacity: m (cu-yd) 0.24 (0.31) 0.31 (0.41) 0.38 (0.50)

Type Hoe bucket

Length X Height X Width 1.19 X 1.07 X 0.90 1.19 X 1.07 X 1.00 1.19 X 1.07 X 1.10
L X H X W: m (ft-in) (3'11" X 3'6" X 2'11") (3'11" X 3'6" X 3'3") (3'11" X 3'6" X 3'7")
Weight: kg (lbs) 350 (770) 390 (860) 400 (880)
STD
Bucket capacity: m3 (cu-yd) 0.45 (0.59) 0.57 (0.75)
0.50 (0.65)

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 ［2. SPECIFICATIONS］

2.5 SPECIFICATIONS AND PERFORMANCE

2.5.1 SPEED AND CLIMBING CAPABILITY

Item / Model SK140LC-8 SK130-8 SK130L-8

1
Swing speed : min- {rpm} 11 {11}
Travel speed (1-speed/2-speed) : km/h

２
3.4 / 5.6 (2.1 / 3.5) 3.0 / 5.3 (1.8 / 3.3)
(mile/h)
Gradeability : % (degree) 70 (35)

2.5.2 ENGINE

Engine model MITSUBISHI D04FR-74KW

Water-cooled, 4 cycle 4 cylinder direct injection type diesel
Type
engine with inter cooler turbo-charger
4 - 102 dia. mm X 130 mm
Number of cylinders-BoreXStroke
(4.02 in X 5.12 in)
Total displacement 4.249 L (259.27 cu-in)
Net 69.2 kW (94 PS) / 2,000 min-1 (ISO 9249)
Rated output / Engine speed
Net 74 kW (101 PS) / 2,000 min-1 (ISO 14396)
Net 359 N-m (265 lbf-ft)/ 1,600 min-1 (ISO 9249)
Maximum torque / Engine speed
Net 375 N-m (277 lbf-ft)/ 1,600 min-1 (ISO 14396)
Starter 24 V / 5.0kW
Alternator 24 V / 50A

2.5.3 HYDRAULIC COMPONENTS

Hydraulic pump Variable displacement axial piston pump X 2 + gear pump X 1

Hydraulic motor (swing) Axial piston motor X 1
Variable displacement axial piston motor X 2
Hydraulic motor (travel)
(with counterbalance valve)
Control valve 8-spool control valve X 1
Cylinder
Double action cylinder
(Boom, Arm, Bucket)
Oil cooler Air-cooled type

2-11
［2. SPECIFICATIONS］

2.5.4 WEIGHT

SK140LC-8 Unit : kg (lbs)

Fully equipped weight 13,000 (28,665)
Upper structure 6,550 (14,440)
Lower machinery
4,275 (9,430)
(500mm grouser shoe)
Attachment [STD]
4.68m (15 ft-4in) Boom+2.38m (7ft-10in) Arm 2,347 (5,175)
+0.50m3 (0.65cu-yd) Bucket
Attachment
4.68m (15 ft-4in) Boom+2.38m (7ft-10in) Arm 2,367 (5,220)
+0.57m3 (0.75cu-yd) Bucket

SK130-8 Unit : kg (lbs)

Fully equipped weight 12,800 (28,220)
Upper structure 6,550 (14,440)
Lower machinery
4,445 (9,800)
(500mm grouser shoe)
Attachment [STD]
4.68m (15 ft-4in) Boom+2.38m (7ft-10in) Arm 2,347 (5,175)
+0.50m3 (0.65cu-yd) Bucket
Attachment
4.68m (15 ft-4in) Boom+2.38m (7ft-10in) Arm 2,367 (5,220)
+0.57m3 (0.75cu-yd) Bucket

SK130L-8 Unit : kg (lbs)

Fully equipped weight 14,700 (32,410)
Upper structure 5,320 (11,730)
Lower machinery
7,070 (15,590)
(900mm grouser shoe)
Attachment [STD]
4.68m (15 ft-4in) Boom+2.38m (7ft-10in) Arm 2,322 (5,120)
+0.45m3 (0.59cu-yd) Bucket

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 ［2. SPECIFICATIONS］

2.6 TYPE OF CRAWLER

２
Use 500mm (19.7") grouser shoes on rough ground (areas covered with rocks and gravel). If you drive
or excavate with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly
(link, roller, etc.)

2-13
［2. SPECIFICATIONS］

2.7 TYPE OF BUCKET

2-14
 ［2. SPECIFICATIONS］

2.8 COMBINATIONS OF ATTACHMENT

２
When the only 2.38m (7ft-10in) arm is using, do not turn the bucket back to front to use as a shovel.

2-15
［2. SPECIFICATIONS］

2.9 ENGINE SPECIFICATION

2.9.1 SPECIFICATIONS

Applicable machine SK140LC-8 / SK130-8 / SK130L-8

Engine model MITSUBISHI D04FR-74KW
Water-cooled, 4 cycle 4 cylinder direct injection type diesel
Type
engine with inter cooler turbo-charger
Number of cylinderXBoreXStroke mm (in) 4 X 102 X 130 (4.02 X 5.12)
Total displacement cc (cu-in) 4,249 (259.27)
Compression ratio 17.8
Net 69.2 (94) at 2,000 (ISO 9249)
Rated output kW (PS) at min-1
Net 74 (101) at 2,000 (ISO 14396)
N-m (lb-ft) at Net 359 (265) at 1,600 (ISO 9249)
Maximum torque
min-1 Net 375 (277) at 1,600 (ISO 14396)
High idling min-1 2,220 ~ 2,260
Low idling min-1 995 ~ 1,035
Injection starting pressure MPa (psi) -
Start/Full open
Thermostat action 344 (160) / 358 (185)
K (degrees F)
Firing order 1 - 3 - 4 - 2
Starter capacity V X kW 24 X 5.0
Generator capacity (Alternator) V X A 24 X 50
600 dia (23.6") X suction type 6 fans, V-belt drive, pulley
Cooling fan drive method
ratio Crank / Fan= 0.9
Full level 17.5 (4.62)
Engine oil quantity L (gal) Low level 14.5 (3.83)
Total 18.5 (4.89)
Dry weight kg (lbs) 395 (871)
Fuel consumption ratio
g/kW-h (g/ps-h) 233 (171)
(At rated output)
Allowable inclination Front / Rear and Right / Left : 35 degrees
Dimension (LXWXH) mm (in) 911 X 719 X 940 (35.9in X 28.3in X 37.0in)
Rotating direction Counterclockwise seeing from flywheel side

2-16
 ［2. SPECIFICATIONS］

2.9.2 ENGINE CHARACTERISTIC CURVE

Condition to be measured: The net value is indicated, measuring without cooling fan.

2-17
［2. SPECIFICATIONS］

2-18
 ［3. ATTACHMENT DIMENSIONS］

3. ATTACHMENT DIMENSIONS
TABLE OF CONTENTS

３
3.1 BOOM ………………………………………………………………………………………………………………3-3
3.1.1 BOOM DIMENSIONAL DRAWING ………………………………………………………………………3-3
3.1.2 BOOM MAINTENANCE STANDARD ……………………………………………………………………3-4
3.2 ARM ………………………………………………………………………………………………………………3-7
3.2.1 ARM DIMENSIONAL DRAWING …………………………………………………………………………3-7
3.2.2 ARM MAINTENANCE STANDARD ………………………………………………………………………3-8
3.3 BUCKET……………………………………………………………………………………………………………3-12
3.3.1 BUCKET DIMENSIONAL DRAWING ……………………………………………………………………3-12
3.3.2 BUCKET DIMENSIONAL TABLE …………………………………………………………………………3-13
3.3.3 LUG SECTION DIMENSIONAL DRAWING ……………………………………………………………3-14
3.3.4 BOSS SECTION DIMENSIONAL DRAWING …………………………………………………………3-15

Book Code No. S5YP0301E02

3-1
［3. ATTACHMENT DIMENSIONS］

Issue Date of Issue Applicable Machines Remarks

S5YP0301E01
First Edition July, 2009 SK140LC-8 : YP09-05001~
(SE Asia)
S5YP0301E02
SK140LC-8 : YP09-05001~
(SE Asia)
Revision January, 2010 SK130-8 : LP09-20001~
(NZL)
SK130L-8 : LX07-11001~
(Thailand)

3-2
 ［3. ATTACHMENT DIMENSIONS］

3.1 BOOM

3.1.1 BOOM DIMENSIONAL DRAWING

３
Boom Dimensional Drawings

SK140LC-8
4.68M(15ft-4in) BOOM
LP02B00045F1
No. NAME DIMENSIONS: mm (ft-in)
A Boom length 4,680 (15'4")
B Boom foot width 575 (22.6")
C Boom end inner width 274 (10.8")
D Boom end outer width 386 (15.2")
E Height of boom cylinder rod pin 952 (37.5")
F Height of arm cylinder (head side) pin 1,079 (3.6")
G Distance between pins of boss R2,110 (6.11")
H Distance between pins of bracket R2,293 (7.6")
I Arm cylinder (head side) inner width 111 (4.4")
J Outer width of bracket on the boom cylinder (rod side) mounting 399 (15.7")
d1 Boom foot pin dia. 70 dia. (2.76")
d2 Boom cylinder (rod side) pin dia. 80 dia. (3.15")
d3 Pin dia. of boom end. 70 dia. (2.76")
d4 Arm cylinder (head side) pin dia. 70 dia. (2.76")

3-3
［3. ATTACHMENT DIMENSIONS］

3.1.2 BOOM MAINTENANCE STANDARD

(1) Clearance of pin and bushing on boom section

Clearance of pin and bushing on boom section

A. SE Asia spec, Thailand spec.

3-4
 ［3. ATTACHMENT DIMENSIONS］

B. NZL spec.

3-5
［3. ATTACHMENT DIMENSIONS］

(2) Clearance in thrust direction on the boom cylinder installation section

Clearance in thrust direction on the boom cylinder installation section

3-6
 ［3. ATTACHMENT DIMENSIONS］

3.2 ARM

3.2.1 ARM DIMENSIONAL DRAWING

３
ARM DIMENSIONAL DRAWING

3-7
［3. ATTACHMENT DIMENSIONS］

3.2.2 ARM MAINTENANCE STANDARD

(1) Clearance of pin and bushing

Clearance of pin and bushing on arm section

A. SE Asia spec, Thailand spec.

3-8
 ［3. ATTACHMENT DIMENSIONS］

B. NZL spec.

3-9
［3. ATTACHMENT DIMENSIONS］

(2) Clearance of arm and cylinder installing sections in thrust direction

Clearance of arm and cylinder installing sections in thrust direction

3-10
 ［3. ATTACHMENT DIMENSIONS］

3-11
［3. ATTACHMENT DIMENSIONS］

3.3 BUCKET

3.3.1 BUCKET DIMENSIONAL DRAWING

(1) Hoe bucket

Bucket dimensional drawing

No. NAME No. NAME

A Distance between pin and bracket G Inner width of bucket bottom
B Distance between bucket pin and tooth end H Bucket outer width of front side
C Inner width of bucket top end I Pitch between teeth
D Inner width of lug Io Pitch between teeth
E Inner width of bracket d1 Outer dia. of bushing
F Outer width of side cutter d2 Pin dia.

3-12
 ［3. ATTACHMENT DIMENSIONS］

3.3.2 BUCKET DIMENSIONAL TABLE

Unit : mm (ft-in)
Type Normal digging
[STD]
0.24 0.31 0.38 0.45 0.57 0.70
Capacity 0.50
(0.20) m3 (0.23) m3 (0.28) m3 (0.35) m3 (0.43) m3 (0.50) m3
(0.38) m3
Part No. YY61B00079F1 YY61B00080F1 YY61B00081F1 YY61B00075F1 YY61B00072F1 YY61B00082F1 YY61B00083F1

A R376 (14.8") <-- <-- <-- <-- <-- <--

R1,225
B <-- <-- <-- <-- <-- <--
(4'0.23")

C 462 (18.2") 562 (22.1") 662 (26.1") 772 (30.4") 863 (34.0") 962 (37.9") 1,112 (3'7.8")

D 324 (12.8") <-- <-- <-- <-- <-- <--

３
E 252 (9.9") <-- <-- <-- <-- <-- <--

F 593 (23.3") 700 (27.6") 800 (31.5") 910 (35.8") 1,000 (3'3.37") 1,100 (3'3.7") -

G 383 (15.1") 439 (17.3") 539 (21.2") 649 (25.6") 739 (29.1") 839 (33.0") 989 (39.0")

H 500 (19.7") 600 (23.6") 700 (27.6") 772 (30.4") 903 (35.6") 1,000 (3'3.37") 1,150 (3'9.3")

I 187 (7.4") 237 (9.3") 191 (7.5") 228 (9.0") 192.5 (7.6") 218.5 (8.6") 256 (10.1")

IO 187 (7.4") 237 (9.3") 191 (7.5") 228 (9.0") 192.5 (7.6") 218.5 (8.6") 256 (10.1")

d1 80dia. (3.2") <-- <-- <-- <-- <-- <--

d2 65dia. (2.6") <-- <-- <-- <-- <-- <--

Bucket capacity : SAE heaped (Stuck)

3-13
［3. ATTACHMENT DIMENSIONS］

3.3.3 LUG SECTION DIMENSIONAL DRAWING

Dimension of lug section

3-14
 ［3. ATTACHMENT DIMENSIONS］

3.3.4 BOSS SECTION DIMENSIONAL DRAWING

３
Dimension of boss section

3-15
［3. ATTACHMENT DIMENSIONS］

3-16
 ［11. TOOLS］

11. TOOLS
TABLE OF CONTENTS
11
11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS ………………………………………………11-3
11.2 SCREW SIZE ……………………………………………………………………………………………………11-5
11.2.1 CAPSCREW (BOLT) ………………………………………………………………………………………11-5
11.2.2 CAPSCREW (SOCKET BOLT) …………………………………………………………………………11-5
11.2.3 SOCKET SET SCREW …………………………………………………………………………………11-5
11.3 TIGHTENING TORQUE FOR HOSE AND FITTING ………………………………………………………11-6
11.3.1 JOINT (O-RING TYPE) …………………………………………………………………………………11-6
11.3.2 HYDRAULIC HOSE (30 DEG. FLARE TYPE) ………………………………………………………11-6
11.3.3 JOINT (ORS TYPE) ………………………………………………………………………………………11-6
11.3.4 SPLIT FLANGE ……………………………………………………………………………………………11-6
11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES……………………………………………………11-7
11.5 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 SPANNER FOR TUBE ……………………………………………………………………………11-11
11.7 SPECIAL TOOLS ………………………………………………………………………………………………11-12
11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND…………………11-14
11.9 SUCTION STOPPER……………………………………………………………………………………………11-15
11.9.1 COMPONENTS ……………………………………………………………………………………………11-15
11.9.2 DIMENSION…………………………………………………………………………………………………11-15
11.9.3 APPLICABLE MODEL ……………………………………………………………………………………11-15
11.10 COUNTER WEIGHT LIFTING JIG …………………………………………………………………………11-16
11.11 UPPER FRAME LIFTING JIG ………………………………………………………………………………11-17
11.12 ENGINE MOUNTING PEDESTAL …………………………………………………………………………11-19
11.13 TRACK SPRING SET JIG …………………………………………………………………………………11-20

Book Code No. S5YP1101E01

11-1
［11. TOOLS］

Issue Date of Issue Applicable Machines Remarks

S5YP1101E01
First Edition July, 2009 SK140LC-8 : YP09-05001~
(SE Asia)

11-2
 ［11. TOOLS］

11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS

Tables Table "Metric coarse thread (Not plated)" and Table "Metric fine thread (Not plated)" indicate
tightening torques applicable to cases where no special note is given.
Overtightening of bolts may result in a twist-off and a fracture under load.
Insufficient tightening may lead to a loosening or loss of bolts. Always tighten bolts to proper torques.

11

Tightening torque for metric coarse threads (not plated)

11-3
［11. TOOLS］

Tightening torques for metric fine threads (not plated)

11-4
 ［11. TOOLS］

11.2 SCREW SIZE

11.2.1 CAPSCREW (BOLT)

11

11.2.2 CAPSCREW (SOCKET BOLT)

11.2.3 SOCKET SET SCREW

11-5
［11. TOOLS］

11.3 TIGHTENING TORQUE FOR HOSE AND FITTING

11.3.1 JOINT (O-RING TYPE)

11.3.2 HYDRAULIC HOSE (30 DEG. FLARE TYPE)

11.3.3 JOINT (ORS TYPE)

11.3.4 SPLIT FLANGE

11-6
 ［11. TOOLS］

11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES

Table below indicates standard tightening torques applicable to cases where no particular note is given.
Overtightening or undertightening of nuts and sleeves in FLARELESS JOINT may develop oil leaks
through pipe connections.
Always tighten nuts and sleeves to proper torques.

11

11-7
［11. TOOLS］

11.5 PLUGS

11.5.1 PLUG FOR HYDRAULIC PIPE JOINT

(1) Cap nut (Joint plug)

(2) Plug (Tube plug)

(3) Nut

11-8
 ［11. TOOLS］

11.5.2 PLUG FOR HYDRAULIC EQUIPMENT

(1) PF screw

(2) PT screw

11

(3) Plug for(F)flare hose

11-9
［11. TOOLS］

(4) Plug for ORS joints

Male

Female

(5) Plug for half clamp

11-10
 ［11. TOOLS］

11.6 SPECIAL SPANNER FOR TUBE

11

11-11
［11. TOOLS］

11.7 SPECIAL TOOLS

11-12
 ［11. TOOLS］

11

11-13
［11. TOOLS］

11.8 APPLICATION OF SCREW LOCKING COMPOUND AND

SEALING COMPOUND
(1) For general use
Manufacturer
Service Features
Loctite Three-Bond
#242 1360K Low strength
Screw locking
#262 1374 Middle strength
compound
#271 1305 High strength
Sealing compound #515 1215 Sealing

(2) For specific location

No. Use Manufacturer Name Equivalent Applicable
(Manufacturer ; Loctite)
# 1901 Anti-seizure Cylinder
Three-Bond # 1215 gray # 5699 Swing motor
# 1211 white # 5301J Swing motor
# 1303B # 211 Main pump
(Manufacturer ; Three-Bond)
Sealing
Loctite # 222 # 1344N Main pump
compound
1 # 277 # 1307N Pilot valve
&
adhesive (Manufacturer ; Three-Bond)
Loctite Parmatex 98D # 1121 Hydraulic oil tank : Hose
Sumitomo
Chemical Co., Cyano Bond PO-1 Swing bearing : seal
Ltd.
Shell
petroleum Shell Alvania EP2 New Molyknock Grease 2 Swing bearing grease bath

11-14
 ［11. TOOLS］

11.9 SUCTION STOPPER

11.9.1 COMPONENTS

11

Components of suction stopper

11.9.2 DIMENSION

Dimension of suction stopper

11.9.3 APPLICABLE MODEL

11-15
［11. TOOLS］

11.10 COUNTER WEIGHT LIFTING JIG

(1) Standard eye bolt

Eye bolt

11-16
 ［11. TOOLS］

11.11 UPPER FRAME LIFTING JIG

11

11-17
［11. TOOLS］

1. EYE NUT (JIS B 1169-1994)

2. PIN (STUD BOLT)

11-18
 ［11. TOOLS］

11.12 ENGINE MOUNTING PEDESTAL

11

Engine stand

11-19
［11. TOOLS］

11.13 TRACK SPRING SET JIG

Track spring set jig

11-20
 ［12. STANDARD MAINTENANCE TIME TABLE］

12. STANDARD MAINTENANCE

TIME TABLE
TABLE OF CONTENTS

2.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ………………12-4
12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST……………………………………………12-15

12

Book Code No. S5YP1201E01

12-1
［12. STANDARD MAINTENANCE TIME TABLE］

Issue Date of Issue Applicable Machines Remarks

S5YP1201E01
First Edition July, 2009 SK140LC-8 : YP09-05001~
(SE Asia)

12-2
 ［12. STANDARD MAINTENANCE TIME TABLE］

PREFACE
(1) Working Conditions
1. Workers:
More than one worker shall be 1st class service technician (having five years or more of field
experience and having received training in the operation).
2. Equipment:
Jigs, tools, apparatuses and testers used in field service work shall be available commercially.
The maintenance plant shall be equipped with a service shop, a crane and inspection
apparatuses necessary for specific self inspection activities.
3. Place:
A flat land where work may be performed and to which a service car or a truck crane is
accessible.

(2) Range of standard maintenance time

1. Standard maintenance time=Direct maintenance time X 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.

12
(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. tems 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. STANDARD MAINTENANCE TIME TABLE］

12.1 STANDARD WORKING TIME TABLE FOR THE

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

A/C : Air conditioner C/V : Control valve O/H : Over haul

ASSY : Assembly Cyl : Cylinder SOL : Solenoid
ATT : Attachment E/G : Engine SW : Switch
BRG : Bearing F hose : Flexible hose V : Valve

(2) Classification of work code

No. GROUP REMARKS
01 Attachment Indicates installing, removing, replacement and overhaul.
02 Cab & Guard
03 Swing frame
04 Travel system
Electric Indicates the installing, removing and replacement of single items.
06
equipments
09 E/G relation Indicates overhaul of the single engine.
(Materials prepared by manufacturer)

(3) Conditions for standard service time of the engine

1. Tools designated by E/G maker are used
2. Genuine parts are changed
3. Correct working procedures are observed.

・ The time required for works specified in this Chapter shows the total time for maintenance.

12-4
 ［12. STANDARD MAINTENANCE TIME TABLE］

01 Attachment
Work to be Unit:
Group Location Unit Remarks
done Hour
00 Bucket relation See 32.1.2
01 Bucket ASSY Detach/attach 1 pc. Include adjustment 0.5
02 -Bucket attaching and detaching Preparation 1 pc. 0.1
position
03 -Bucket attaching pin Detach/attach 1 Include stopper pin. 0.1
04 -Bucket drive pin Detach/attach 1 0.1
05 -Bucket sling and movement Preparation 1 pc. 0.1
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 See 32.1.3
11 Arm ASSY Detach/attach 1 pc. 1.0
12 -Bucket cylinder attaching and Preparation 1 pc. 0.3
detaching position and piping Include stopper pin.
13 -Bucket cylinder rod pin Detach/attach 1 pc. Include stopper pin. 0.1
14 -Bucket cylinder head pin Detach/attach 1 pc. 0.1 12
15 -Bucket cylinder assy Detach/attach 1 pc. Include stopper pin. 0.1
16 -Arm cylinder rod pin Detach/attach 1 pc. 0.1
17 -Boom top pin Detach/attach 1 pc. 0.1
18 -Arm sling and movement Detach/attach 1 pc. 0.1
30 Boom portion See 32.1.4
31 Boom ASSY Detach/attach 1 pc. 1.0
32 -Boom attaching and detaching position Preparation 1 pc. 0.1
33 -Boom cylinder temporary slinging Preparation 2 pcs. 0.2
34 -Boom cylinder rod pin Detach/attach 2 Include two stopper pins. 0.2
35 -Boom cylinder piping Detach/attach 2 pc. 0.2
36 -Arm & bucket piping Detach/attach 1 pc. 0.2
37 -Boom assy temporary slinging Detach/attach 1 pc. 0.1
38 -Boom foot pin Detach/attach 1 Include stopper pin. 0.2
39 -Boom assy slinging Detach/attach 1 pc. 0.1
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 pc. Include stopper pin. 0.1
43 -Arm cylinder slinging Detach/attach 1 pc. 0.1
50 Boom cylinder attaching and detaching Detach/attach 2 pcs. 0.6
51 -Boom cylinder piping Detach/attach 2 0.2
52 -Boom cylinder head pin Detach/attach 2 pcs. 0.2
53 -Boom cylinder slinging Detach/attach 2 0.2
60 Bucket cylinder O/H 1 3.0
61 -Pin bushing Replace 1 Include seal. 1.0
70 Arm cylinder O/H 1 3.0
71 -Pin bushing Replace 1 set Include seal. 1.0
80 Boom cylinder O/H 2 6.0
81 -Pin bushing Replace 1 set Include seal. 1.0

12-5
［12. STANDARD MAINTENANCE TIME TABLE］

02 Cab & Guard (1/2)

Work to be Unit:
Group Location Unit Remarks
done Hour
10 Cab relation See 33.1.2
11 Cab ASSY Detach/attach 1 pc. 1.4
12 -Front lower glass, floor mat Detach/attach 1 pc. each 0.1
13 -Seat rear cover top, bottom Detach/attach 4 places 0.2
14 -Seat rear cover top, bottom Detach/attach 1 pc. each 0.2
15 -Right side panel (include A/C duct) Detach/attach 3 0.3
16 -Cable and harness (electric) Detach/attach 6 0.2
17 -Cab mounting bolt Detach/attach 8 pcs. 0.2
18 -Cab slinging Detach/attach 3 places 0.2
20 Guard relation See 33.1.4
21 Bonnet (B1) Detach/attach 1 pc. 0.2
22 Guard (C8) Detach/attach 1 pc. 0.2
23 Guard (A4) Detach/attach 1 pc. 0.2
24 Guard (A2) Detach/attach 1 pc. 0.2
25 Stay (G1) Detach/attach 1 pc. 0.2
26 Guard (A1) Detach/attach 1 pc. 0.2
27 Panel assy (C1) Detach/attach 1 pc. 0.2
28 Panel assy (C2) Detach/attach 1 pc. 0.2
29 Guard assy (A8,A12) Detach/attach 1 pc. 0.3
30 Guard assy (A9,10,11) Detach/attach 1 pc. 0.3
31 Pillar (A6,A7) Detach/attach 1 pc. 0.2
32 Pillar (A17,A18) Detach/attach 1 pc. 0.3
33 Bracket (A36) Detach/attach 1 pc. 0.2
34 Guard assy (D2) Detach/attach 1 pc. 0.2
35 Guard assy (D1) Detach/attach 1 pc. 0.2
36 Guard assy (D3) Detach/attach 1 pc. 0.2
37 Guard assy (F1) Detach/attach 1 pc. 0.2
38 Guard (H1) Detach/attach 1 pc. 0.2
39 Cover assy (E1) Detach/attach 1 pc. 0.2

Note: The numbers in the parenthesis like guard (14) match the guard numbers on the upper structure.

12-6
 ［12. STANDARD MAINTENANCE TIME TABLE］

02 Cab & Guard (2/2)

Work to be Unit:
Group Location Unit Remarks
done Hour
50 Under cover relation See 33.1.5
51 Cover (1) Detach/attach 1 pc. 0.1
52 Cover (2) Detach/attach 1 pc. 0.1
53 Cover (3) Detach/attach 1 pc. 0.1
54 Cover (4) Detach/attach 1 pc. 0.1
55 Cover (5) Detach/attach 1 pc. 0.1
56 Cover (6) Detach/attach 1 pc. 0.1
57 Cover (7) Detach/attach 1 pc. 0.1
60 Counterweight relation See 33.1.11
61 Counterweight ASSY Detach/attach 1 pc. 0.4
62 -Counterweight lifting eye bolt Detach/attach 1 set 0.1
63 -Counterweight temporary slinging Preparation 1 pc. 0.1
64 -Counterweight mounting bolt Detach/attach 1 pc. 0.1
65 -Counterweight slinging Detach/attach 1 pc. 0.1

Note: The numbers in the parenthesis like cover (2) match the guard numbers on the upper structure.

12

12-7
［12. STANDARD MAINTENANCE TIME TABLE］

03 Swing frame (1/3)

Work to be Unit:
Group Location Unit Remarks
done Hour
10 Intake relation See 33.1.9
11 Air cleaner ASSY Detach/attach 1 pc. 0.5
12 -Hose (2) Detach/attach 1 0.1
13 -Hose (4) Detach/attach 1 0.1
14 -Air cleaner mounting bolt Detach/attach 1 set 0.1
15 -Element Replace 1 0.1
20 Exhaust relation See 33.1.10
21 Muffler ASSY Detach/attach 1 pc. 0.4
22 -U bolt Detach/attach 1 pc. 0.2
23 -Clamp ASSY Detach/attach 1 pc. 0.2
30 Radiator relation See 33.1.12
31 Radiator ASSY Detach/attach 1 pc. 5.0
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 hose Detach/attach 1 pc. 0.1
38 -Fan guard Detach/attach 1 pc. 0.2
39 -Water hose (radiator ~ E/G) Detach/attach 2 0.4
40 -Radiator mounting bolts removing Detach/attach 1 set 0.2
41 -Under cover Detach/attach 1 pc. 0.1
42 -Hydraulic oil tank suction stopper Detach/attach 1 pc. 0.2
43 -Hydraulic oil piping Detach/attach 1 pc. 0.6
44 -Inter cooler hose & tube Detach/attach 2 pcs. 0.4
(E/G to inter cooler)
45 -Radiator lifting or hoisting Detach/attach 1 pc. 0.2
46 -Radiator inter cooler core & oil cooler Cleaning 1 pc. 0.8
Other necessary works Detach/attach 1 pc. 1.0
50 Fuel relation See 33.1.6
51 Fuel tank ASSY Detach/attach 1 pc. 1.0
52 -Fuel Replace 1 pc. 0.2
53 -Hose (tank side) Detach/attach 2 0.1
54 -Fuel filter Detach/attach 1 pc. 0.1
55 -Fuel tank installing bolts Detach/attach 1 set. 0.2
56 -Tank slinging Detach/attach 1 pc. Guard 0.2
Other necessary works Detach/attach 1 pc. 0.6
60 Hydraulic oil tank relation See 33.1.7
61 Hydraulic oil tank ASSY Detach/attach 1 pc. 2.5
62 -Cover Detach/attach 1 pc. 0.2
63 -Hydraulic oil Replace 1 pc. 0.4
64 -Main line return hose Detach/attach 2 pc. 0.4
65 -Pilot drain hose Detach/attach 1 pc. 0.2
66 -Pump suction hose Detach/attach 1 pc. 0.4
67 -Mounting bolt Detach/attach 1 pc. 0.2
68 -Hydraulic oil tank slinging Detach/attach 1 pc. 0.2
69 -Return filter Replace 1 0.2
70 -Suction filter Cleaning 1 Guard 0.2
Other necessary works Detach/attach 1 pc. 1.0

12-8
 ［12. STANDARD MAINTENANCE TIME TABLE］

03 Swing frame (2/3)

Work to be Unit:
Group Location Unit Remarks
done Hour
80 Pump relation See 33.1.8
81 Pump ASSY Detach/attach 1 pc. 2.0
82 -Hydraulic oil tank cover Detach/attach 1 pc. 0.2
83 -Strainer & stopper Detach/attach 1 pc. 0.3
84 -Piping Detach/attach 1 set 0.8
85 -Pump slinging Detach/attach 1 pc. 0.4
86 -Cleaning Cleaning 1 pc. 0.1
87 -Vent air Adjust 1 pc. 0.1
88 Pump ASSY O/H 1 pc. 3.0
Other necessary works Detach/attach 1 pc. Guard, Counterweight 1.0
90 Swing motor unit relation See 33.1.18
91 Swing motor ASSY Detach/attach 1 pc. 2.2
92 -Piping Detach/attach 1 set 0.8
93 -Mounting bolt Detach/attach 1 set 0.6
94 -Unit slinging Detach/attach 1 pc. 0.4
95 -Cleaning and sealant Cleaning 1 set 0.2
96 Swing motor O/H 1 pc. 3.0
97 Swing reduction gear O/H 1 pc. 3.5 12
100 Swivel joint relation See 33.1.19
101 Swivel joint ASSY Detach/attach 1 2.2
102 -Piping (Top part only) Detach/attach 1 set 0.4
103 -Whirl stop bolt Detach/attach 1 0.2
104 -Cover Detach/attach 1 0.3
105 -Joint & elbow Detach/attach 1 set 0.3
106 -Mounting bolt Detach/attach 1 set 0.3
107 -Swivel joint slinging Detach/attach 1 0.3
108 -Cleaning Cleaning 1 set 0.2
109 Swivel joint O/H 1 set Lower piping 3.0

Other necessary works Detach/attach 1 set 0.5

120 Main control valve See 33.1.15
121 Main control valve ASSY Detach/attach 1 pc. 2.0
122 -Attach tag to port name of pipe Preparation 1 pc. 0.5
123 -Piping Detach/attach 1 set 1.2
124 -Bracket mounting bolts Detach/attach 1 set 0.1
125 -Valve slinging Detach/attach 1 pc. 0.1
126 Main control valve ASSY Detach/attach 1 set 5.0
Other necessary works Detach/attach 1 set Guard 1.0

12-9
［12. STANDARD MAINTENANCE TIME TABLE］

03 Swing frame (3/3)

Work to be Unit:
Group Location Unit Remarks
done Hour
130 Valve relation
131 Solenoid valve ASSY (7-section) Detach/attach 1 1.0
132 -Attach tag to port name of pipe Preparation 1 0.2
133 -Piping Detach/attach 1 set 0.5
134 -Mounting bolts Detach/attach 1 set 0.3
Other necessary works Detach/attach 1 set Guard 0.6
135 Hydro valve assy (Swing pilot line) Detach/attach 1 set 0.3
140 Engine (E/G) mounting relation See 33.1.13
141 Engine ASSY Detach/attach 1 pc. After removing pump & 1.5
radiator
142 -Harness connector & grounding & Detach/attach 1 set 0.2
cable connection
143 -Fuel hose Detach/attach 1 set 0.1
144 -Others Detach/attach 1 set 0.4
145 -Mounting bolt Detach/attach 1 pc. 0.4
146 -Engine slinging Detach/attach 1 set 0.2
147 -Cleaning Cleaning 1 pc. 0.2
148 Engine O/H 1 set Reference for engine
(Chapter 51)
Other necessary works Detach/attach 1 set Removing and installing 0.6
guard
Detach/attach 1 set Removing and installing 0.4
Counterweight
Detach/attach 1 set Removing and installing 2.0
pump
Detach/attach 1 set Removing and installing air 0.4
cleaner
Detach/attach 1 set Removing and installing 0.4
muffler
Detach/attach 1 set Removing and installing 2.5
radiator
150 Upper frame See 33.1.20
151 Upper frame ASSY Detach/attach 1 pc. After removing swivel joint 1.0
152 -Mounting bolts Detach/attach 1 set 0.3
153 -Upper frame slinging Detach/attach 1 pc. 0.3
154 -Cleaning Cleaning 1 set 0.2
155 -Sealant Apply 1 set 0.2
Other necessary works Detach/attach 1 set Cab 1.4
Detach/attach 1 set Guard 0.3
Detach/attach 1 set Counterweight 0.4
Detach/attach 1 set Boom 1.4

12-10
 ［12. STANDARD MAINTENANCE TIME TABLE］

04 Travel system
Work to be Unit:
Group Location Unit Remarks
done Hour
00 Travel relation See 34.1.2 OPT
01 Track link ASSY Detach/attach One side Include adjustment of 1.0
tension
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 See 34.1.3
11 Upper roller ASSY Detach/attach 1 After removing track link 0.2
12 Upper roller O/H 1 1.0
20 Lower roller relation See 34.1.4
21 Lower roller ASSY Detach/attach 1 0.2
22 Lower roller O/H 1 1.0
30 Front idler relation See 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 12
33 Front idler ASSY Detaching One side 0.2
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 See 34.1.6
41 Sprocket Replace One side After removing track link 0.5
50 Travel motor relation See 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 bolts 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. See 33.1.19 0.5
62 Swivel joint O/H 1 pc. See 33.2.6 3.0
70 Swing bearing See 34.1.8
71 Swing bearing ASSY Detach/attach 1 pc. After removing upper frame 0.6
72 Swing bearing mounting bolts Detach/attach 1 set 0.4
73 Swing bearing slinging Detach/attach 1 pc. 0.2

12-11
［12. STANDARD MAINTENANCE TIME TABLE］

06 Electric equipments (1/3)

Work to be Unit:
Group Location Unit Remarks
done Hour
Controller
C-1 Controller (KPSS) Replace 1 0.5
C-2 Gauge cluster Replace 1 1.0
C-4 Air conditioner Amplifier Replace 1 2.0
C-8 Engine controller Replace 1 0.5
Diode
D-4 Diode Replace 1 0.3
D-5 Diode Replace 1 0.3
D-6 Diode Replace 1 0.3
D-9 Diode Replace 1 0.3
D-10 Diode Replace 1 0.3
D-12 Diode Replace 1 0.3
D-13 Diode Replace 1 0.3
D-14 Diode Replace 1 0.3
D-15 Diode Replace 1 0.3
D-16 Diode Replace 1 0.3
D-17 Diode Replace 1 0.3
D-18 Diode Replace 1 0.3
D-19 Diode Replace 1 0.3
D-20 Diode Replace 1 0.3
D-21 Diode Replace 1 0.3
D-32 Diode Replace 1 0.3
Electric equipments
E-1 Fuse & relay box Replace 1 0.3
E-2 Alternator Replace 1 1.0
E-3 Hour meter Replace 1 0.3
E-5 Horn (High) Replace 1 0.3
E-6 Horn (Low) Replace 1 0.3
E-10 Receiver dryer Replace 1 Include gas sealing. 1.0
E-11 Air compressor Replace 1 0.4
E-12 Battery Replace 2 0.4
E-14 Cigarette lighter Replace 1 0.3
E-15 Fusible link Replace 1 0.2
E-27 Accei redundant volume Replace 1 0.3
E-38 Resister Replace 1 0.3
Light
L-1 Boom work light left Replace 1 Bulb 0.2
L-2 Frame Work light right Replace 1 0.2
L-3 Swing flusher left Replace 1 0.2
L-4 Swing flusher right Replace 1 0.2
L-5 Room light Replace 1 0.2

12-12
 ［12. STANDARD MAINTENANCE TIME TABLE］

06 Electric equipments (2/3)

Work to be Unit:
Group Location Unit Remarks
done Hour
Motor
M-1 Starter motor Replace 1 Include Counterweight 1.0
removing and installing.
M-3 Wiper motor Replace 1 0.5
M-4 Washer motor Replace 1 0.5
M-8 Grease motor Replace 1 0.5
M-9 Roof wiper motor Replace 1 0.5
Proportional valve
PSV-A Arm variable recirculation proportional Replace 1 0.3
valve
PSV-B P2 unload proportional valve Replace 1 0.3
PSV-C Travel straight proportional valve Replace 1 0.3
PSV-D P1 unload proportional valve Replace 1 0.3
PSV-P1 P1 pump proportional valve Replace 1 0.3
PSV-P2 P2 pump proportional valve Replace 1 0.3
Relay
R-1
R-2
Battery relay
Starter relay
Replace
Replace
1
1
0.3
0.3
12
R-3 Glow relay Replace 1 0.3
R-4 Safety relay Replace 1 0.1
R-5 Horn relay Replace 1 0.1
R-6 Work light relay Replace 1 0.1
R-19 Flashre relay Replace 1 0.1
R-23 Auto idle stop relay 1 Replace 1 0.1
R-24 Auto idle stop relay 2 Replace 1 0.1
R-25 E/G emergency stop relay Replace 1 0.1
R-26 Safety lock lever relay Replace 1 0.1
R-28 Alternator relay Replace 1 0.1
R-29 Wiper motor relay (Normal rotation) Replace 1 0.1
R-30 Wiper motor relay (Reverse rotation) Replace 1 0.1
R-31 Wiper motor relay arc prevention relay Replace 1 0.1
R-32 Washer motor relay Replace 1 0.1
R-53 Glow relay (ECU) Replace 1 0.1

12-13
［12. STANDARD MAINTENANCE TIME TABLE］

06 Electric equipments (3/3)

Work to be Unit:
Group Location Unit Remarks
done Hour
Sensor OPT
SE-1 Pressure sensor : Bucket digging Replace 1 0.3
SE-2 Pressure sensor : Bucket dump Replace 1 0.3
SE-3 Pressure sensor : Boom up Replace 1 0.3
SE-4 Pressure sensor : Boom down Replace 1 0.3
SE-5 Pressure sensor : Swing Replace 1 0.3
SE-7 Pressure sensor : Arm in Replace 1 0.3
SE-8 Pressure sensor : Arm out Replace 1 0.3
SE-9 Pressure sensor : Travel right Replace 1 Include under cover 0.5
removing and installing
SE-10 Pressure sensor : Travel left Replace 1 Include under cover 0.5
removing and installing
SE-11 Pressure sensor : P2 side OPT. Replace 1 Include under cover 0.3
removing and installing
SE-13 E/G speed sensor Replace 1 0.3
SE-15 Fuel level sensor Replace 1 Include guard removing 0.5
and installing
SE-16 Accel potentio Replace 1 0.5
SE-20 Pressure sensor : P1 side (OPT.) Replace 1 Include under cover 0.5
removing and installing
SE-22 Pressure sensor : P1 pump Replace 1 0.3
SE-23 Pressure sensor : P2 pump Replace 1 0.3
SE-29 Opt. selector detect sensor Replace 1 0.3
Solenoid
SV-1 Swing parking SOL Replace 1 0.3
SV-3 2-speed travel SOL Replace 1 0.3
SV-4 Safety lever lock SOL Replace 1 0.3
Switch
SW-1 Key switch Replace 1 0.3
SW-4 Swing parking release switch Replace 1 0.3
SW-5 Horn switch (RH) Replace 1 0.3
SW-8 Clogged air filter switch Replace 1 0.3
SW-10 Horn switch (left) Replace 1 0.3
SW-11 Safety lock lever switch Replace 1 0.3
SW-15 Conflux/single select switch Replace 1 0.3
SW-17 Skylight wiper switch Replace 1 0.3
SW-19 Wiper interlock switch Replace 1 0.3
SW-22 KPSS release switch Replace 1 0.3
SW-36 Water separator restrlction switch Replace 1 0.3
SW-55 Boom work light switch Replace 1 0.3
SW-111 Attachment mode select switch Replace 1 0.3

12-14
 ［12. STANDARD MAINTENANCE TIME TABLE］

12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST

12

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12-15
［12. STANDARD MAINTENANCE TIME TABLE］

12-16
 ［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

13. MAINTENANCE STANDARD AND

TEST PROCEDURE
TABLE OF CONTENTS

13.1 HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS …………………………………13-3

13.2 PERFORMANCE INSPECTION STANDARD TABLE ……………………………………………………13-5
13.2.1 STANDARD VALUE TABLE ……………………………………………………………………………13-5
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 …………………………………………………………………13-13 13
13.5.1 TRAVEL SPEED …………………………………………………………………………………………13-13
13.5.2 DEVIATION OF TRAVEL…………………………………………………………………………………13-13
13.5.3 PERFORMANCES OF PARKING BRAKE ……………………………………………………………13-14
13.5.4 DRAIN RATE OF TRAVEL MOTOR …………………………………………………………………13-15
13.6 MEASURING SWING PERFORMANCES……………………………………………………………………13-16
13.6.1 MEASURING SWING PERFORMANCES ……………………………………………………………13-16
13.6.2 PERFORMANCE OF SWING BRAKE …………………………………………………………………13-16
13.6.3 PERFORMANCE OF SWING PARKING BRAKE ……………………………………………………13-17
13.6.4 DRAIN RATE OF SWING MOTOR ……………………………………………………………………13-18
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES …………………………………………13-19
13.7.1 OPERATING TIME OF CYLINDERS …………………………………………………………………13-19
13.7.2 OIL TIGHTNESS OF CYLINDERS ……………………………………………………………………13-20
13.8 MEASURING PERFORMANCES OF SWING BEARING …………………………………………………13-21
13.9 MECHATRO CONTROLLER …………………………………………………………………………………13-23
13.9.1 ENGINE CONTROL INPUT / OUTPUT ………………………………………………………………13-23
13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT) …………13-23

Book Code No. S5YP1301E02

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［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

Issue Date of Issue Applicable Machines Remarks

S5YP1301E01
First Edition July, 2009 SK140LC-8 : YP09-05001~
(SE Asia)
S5YP1301E02
SK140LC-8 : YP09-05001~
(SE Asia)
Revision January, 2010 SK130-8 : LP09-20001~
(NZL)
SK130L-8 : LX07-11001~
(Thailand)

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13.1 HOW TO USE MAINTENANCE STANDARDS AND

PRECAUTIONS
(1) Application
1. When the machine is new;
Confirm that the performances are in accordance with standard specifications as compared to the
performance standards.
2. At specific self inspection; (Rule by country)
Use the data for the criterion, for the purpose of correction, adjustment and replacement.
3. When performances are deteriorated;
Determine whether it is caused by a fault or end of service life after long hours of operation, to
be used for safety and economical considerations.
4. When main components are replaced;
For example, use data to restore performances of pumps and others.

(2) Terminology
1. Standard values;
Values to be used to condition or assemble a new machine. Where special notes are not given,
these values represent standard specifications (machine with standard attachments and standard
shoes).
2. Reference values for remedy;
Values at which readjustment is required. In order to ensure performance and safety it is strictly
prohibited to use the machine over the specified values.
3. Service limit;
This is the limit value at which reconditioning is impossible without replacement of parts. If the
value is expected to exceed the service limit before next inspection and correction are performed, 13
replace the parts immediately. The operation over the specified values causes increase of
damage and requires the down time of machine, and also causes safety problems.

(3) Cautions to be Exercised at Judgment

1. Evaluation of measured data;
Disagreement of measuring conditions, variations of data peculiar to a new machine, and
measuring errors are to be evaluated. Determine generally at what levels measured values are
located, instead of determining whether or not values fall within or run out of the reference values.
2. Determining correction, adjustment or replacement;
Machine performances deteriorate with time as parts wear and some deteriorated performances
may be restored to new levels. Therefore, determine correction, adjustment or replacement,
depending upon the operating hours, kind of work and circumstances in which the machine is
placed, and condition the machine performances to its most desirable levels.

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［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

(4) Other Cautions to be Exercised

1. Parts liable to degrade;
Rubber products, such as, hydraulic hoses,
O rings, and oil seals deteriorate with time ; replace them at regular intervals or at overhauls.
2. Parts requiring regular replacement;
Out of critical hoses that are necessary to secure safety, we designate Very Important Parts
(V.I.P) and recommend that they should be replaced regularly.
3. Inspection and replacement of oils and greases;
In performing maintenance, it is necessary for the user to familiarize himself with how to handle
the machine safely, cautions to be exercised and inspection/lubrication procedures. Refer to the
operators manuals as well.

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 ［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

13.2 PERFORMANCE INSPECTION STANDARD TABLE

Unless otherwise specified, measure it on "H" mode.

13.2.1 STANDARD VALUE TABLE

13

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 ［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

13.3 MEASUREMENT OF ENGINE SPEED

13.3.1 MEASUREMENT OF ENGINE SPEED

(1) Warming up of engine
Start engine to raise the coolant temperature of engine to 60 to 90C degrees (140 to 194F degrees)
at surface of radiator upper tank.
The E/G coolant tem-perature gauge is used to measure. The range in white color shows the
temperature of approx. 65 to 105 C degrees (149 to 221F degrees), so confirm that the pointer
indicates the temperature within the white range.

(2) Engine speed measured value through service diagnosis (See below Fig.)
1. Turn "ON" the starter switch with the buzzer stop switch pressed.
2. A program No. and an actual engine revolution are displayed as the No.2 Item.
3. The screen advances like No.2, No.3....each time the "Wiper switch" on the gauge cluster is
pushed.
4. The screen returns like No.45, No.44....each time the "Washer switch" is pushed. 13
5. The display does not disappear unless the starter switch is turned to"OFF".

Service diagnosis for E/G speed measuring

(Example)

Switch for E/G speed indication

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［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

13.4 MEASUREMENT OF HYDRAULIC PRESSURE

13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE

(1) Hydraulic equipment
6.9 MPa (1000psi) pressure gauge: 1unit
49 MPa (7100psi) pressure gauge: 2 units
Pressure measuring equipment and instrument for analysis: 1 set
(2) Measuring cleanliness of hydraulic oil

After releasing air in the hydraulic oil tank, open the cover and sample oil in the hydraulic tank, and
measure with the instrument for analysis. If the measured value is higher than the standard value,
replace the return filter or change the hydraulic oil.

13.4.2 PLACE TO INSTALL PRESSURE GAUGE

(1) Main circuit
After releasing the pressure in hydraulic oil
tank and system, replace plugs PF1/4 of
main pump gauge ports (a1) (a2) with plugs
for pressure measurement, and attach
pressure gauge 49 MPa (7100 psi).
(2) Pilot circuit
Replace pilot gauge plug (a3) with plug
PF1/4 for pressure measurement, and
attach pressure gauge 6.9 MPa (1000 psi).

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 ［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

13.4.3 PRESSURE ADJUSTMENT POSITION

(1) Main control valve

13

Relief valve position on main control valve

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［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

(2) Pilot relief valve

The pilot relief valve PR1 is located on the gear pump that is attached to the main pump.

Pilot relief valve position

(3) Swing over load relief

The swing motor is equipped with plugs PA,PB for pressure measurement, but the measurement is
carried out using gauge ports (a1) and (a2). (See "Gauge port on main pump" Fig.)

Swing over load relief position

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 ［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE

(1) Pilot relief valve
Adjust it with adjust screw (311).
Tools: Spanner: 24 mm,
Tightening torque : 29.4 N-m (22 lbf-ft)
Tools: Allen wrench: 6 mm

Pilot relief valve

(2)Main relief valve

(Common for travel and ATT sections)
Loosen lock nut (7) and adjust the pressure with adjust screw (6).
Tightening torque : 27~31 N-m (20~23 lbf-ft)
Tools: Spanner: 19 mm, Adjust screw
Tools: Allen wrench: 4 mm
13

Main relief valve (Travel section, ATT

common section)

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［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

(3) Over load relief valve

(Boom, bucket, arm sections)
Loosen lock nut (1) and adjust it with adjust screw (2).
Tools: Spanner: 22 mm,
Tightening torque : 27.4~31.4 N-m (20~23 lbf-ft)
Tools: Allen wrench: 6 mm

Over load relief valve (Boom, bucket, arm

sections)

(4) Over load relief valve (Swing)

When the pressure adjustment is required, loosen lock nut (1) and adjust the pressure with cap (2).
Tools: Spanner: 30, 38 mm,
Tightening torque: 118 N-m (87 lbf-ft)
Tools: Allen wrench: 12 mm

Swing over load relief valve

(5) Travel over load relief valve

This valve was adjusted by manufacturer and
shipped. Do not replace the parts except O-ring.
Loosen cap (205) and adjust the pressure with
shim (213).
Tools: Allen wrench: 10 mm Travel over load relief valve

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 ［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

13.5 MEASURING TRAVEL PERFORMANCES

13.5.1 TRAVEL SPEED

(1) Purposes
Measure the travel sprocket revolution and
confirm the performances between the
hydraulic pump and the travel motor of the
travel drive system.

(2) Conditions
Hydraulic oil temperature;
45 to 55C degrees (113 to 131F degrees)
Crawler on the right and left sides are One side lifted position
tensioned evenly.

(3) Preparation
Attach the reflection panel with a magnet to the
travel motor cover.
Swing the swing frame through 90C degrees as
shown in upper right Fig. and make the
crawler on one side take off the ground, using
the attachment.

Adhering position of reflection panel 13

(4) Measurement
Engine revolution; Hi idle
2-speed travel switch; 1st speed and 2nd speed
Measuring points; Right and left
Method, example 1;
Measure revolution with a stroboscope
Method, example 2;
Measure the revolutions per minute visually.

13.5.2 DEVIATION OF TRAVEL

(1) Purpose
Measure the amount of deviation at 20 (66 t)
travel and confirm the horizontal balance
between the hydraulic pump and the travel
motor of the travel drive system.

(2) Condition
Hydraulic oil temperature;
Travel position
45 to 55C degrees (113 to 131F degrees)
RH and LH crawler are tensioned evenly.
Firm, level ground
Engine revolution; Hi idle

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［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

(3) Preparation
1.
Straight course more than 30 m (108 ft)
2.
Travel position in which the bottom of the
bucket is lifted by about 30 cm (1 ft).
Measuring method

(4) Measurement
1.
Measure the max. deviation distance of the
circular arc in the 20 m (66 ft) length, excluding
the preliminary run of 3 to 5 m (10 to 16 ft).
2.
Operate the travel lever at the same time.

13.5.3 PERFORMANCES OF PARKING BRAKE

(1) Purpose
Confirm that the parking brake holds a
stopped condition of the machine in a no-load
travel position and on a 15 degree slope.

(2) Condition
A slope with (Approx. 15 deg) gradient and a
stopped condition in a no-load travel position

(3) Preparation
Place an angle meter on the shoe plate and Parking brake operating position
confirm that it makes an angle more than 15
degree.
Hang a perpendicular in parallel with the guide
frame rib on the track frame and put a mark
(matching mark) on the shoe plate.

(4) Measurement
Five minutes after the engine stops, measure
the movement distance of the matching mark.

Method of measurement

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 ［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

13.5.4 DRAIN RATE OF TRAVEL MOTOR

(1) Purpose
To measure the drain rate of the travel motor
and to confirm the performances of the travel
motor.

(2) Conditions
Hydraulic oil temperature;
45 to 55C degrees (113 to 131F degrees)
Engine revolution; Hi idle Location of stopper applied to travel sprocket

(3) Preparation
1.
Place a stopper under the RH and LH travel
sprockets.
2.
Stop the engine and release pressure from the
hydraulic circuit.
3.
Connect a hose with the drain port of the travel
motor and take drain in a container.

Method of measuring the drain rate of travel

motor
13
(4) Measurement ; at Travel Lock
1.
Start the engine and relieve pressure at the
full stroke of the travel lever.
2.
Measure the drain rate for 30 seconds of
relieving.

Unless you observe the rotary force direction at travel lock, rib "A" may be broken by stopper "B" in
some cases. (See Upper right Fig.)

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［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

13.6 MEASURING SWING PERFORMANCES

13.6.1 SWING SPEED

(1) Purpose
Measure the swing time and confirm the
performances between the hydraulic pump
and the swing motor of the swing drive
system.
(2) Conditions
Hydraulic oil temperature;
45 to 55C degrees (113 to 131F degrees)
Firm, level ground
Engine revolution; Hi idle
(3) Preparation
Swing speed measuring position (at the min.
Put the bucket empty and extend the
reach)
boom, arm and bucket cylinder fully.
And the machine becomes a position of
minimum reach.
(4) Measurement
Swing the machine by bringing the swing
lever to its full stroke. Measure the time
required to make two turns after one turn
of preliminary run and calculate the time
required for one turn.

13.6.2 PERFORMANCE OF SWING BRAKE

(1) Purpose
Confirm the braking torque performances by the swing relief valve.

(2) Conditions
Hydraulic oil temperature;
45 to 55C degrees (113 to 131F degrees)
Firm, level ground
Engine revolution; Hi idle

(3) Preparation
1.
Put the bucket empty, retract the arm cylinder
fully and extend the bucket cylinders fully. And
move the boom so that the arm top pin is
positioned at same height with boom foot pin.
Swing brake performance measuring position
2.
Put a matching mark on the outer
circumference of the swing bearing of the upper
frame side and of the track frame side. Place
two poles (flags) on the front and back of the
extended line of the matching mark.

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 ［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

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

13.6.3 PERFORMANCE OF SWING PARKING BRAKE

(1) Purpose
To confirm the mechanical performances of the
swing parking brake that is fitted to the inside
of the swing motor.

(2) Conditions
On a slope of 15 degree incline. 13
Stop the machine at right angles with the slope.
Put the bucket empty, retract the arm cylinder Swing parking brake performance measuring
fully and extend the bucket cylinder fully. And position
move the boom so that the arm top pin is
positioned at same height with boom foot pin.

(3) Preparation
Put the angle meter on the shoe plate and
make sure that the angle is more than 15
degree.
Put a matching mark on the outer race side
and on the inner race side.

Measuring position of swing parking brake

performances

(4) Measurement
When five minutes has passed after the
engine stops, measure the length of the
movement of the matching marks.

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［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

13.6.4 DRAIN RATE OF SWING MOTOR

(1) Purpose
Measure the drain rate of the swing motor and
confirm the performances of the swing motor.

(2) Conditions
Hydraulic oil temperature; 45 to 55C degrees
(113 to 131F degrees)
Firm, level ground
Engine revolution; Hi idle

(3) Preparation
1.
Stop the engine.
2.
Release pressure from inside the hydraulic
circuit.
3.
Disconnect the swing motor drain hose from
its end returning to the hydraulic oil tank and
take oil in a container.
4.
Put a plug to the tank side.

(4) Measurement; at Swing Lock

1.
Start the engine and put the side faces of
bucket against the inside of the right or left
shoe plates.
2.
Relieve the swing motor at full stroke of the
swing motion.
3.
Collect the amount of drained oil in a
container for 30 seconds.

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 ［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES

13.7.1 OPERATING TIME OF CYLINDERS

(1) Purpose
Measure the operating time of the boom, arm
and bucket and confirm the performances
between the hydraulic pump and the cylinder
of the attachment drive system.

Measuring position for bucket digging and

dump

(2) Condition
Hydraulic oil temperature; 45 to 55C degrees
(113 to 131F degrees)
Engine revolution; Hi idle
Operating time excluding the cushion stroke

Measuring position for boom up and down

motions

(3) Preparation
Firm level ground with the bucket empty 13
(4) Measurement1; Boom up and down
With the boom operating lever at full stroke,
measure the required operating time of the
bucket between the ground surface and its Measuring position for arm in and out
highest position. motions

Measurement 2; Arm in and out, bucket

digging and dump
In a position in which the tooth of the bucket
rises to a level of about 30 cm (1ft) above
ground, measure the full stroke operating time
required with the arm and bucket operating
levers at full stroke.

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.

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［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

13.7.2 OIL TIGHTNESS OF CYLINDERS

(1) Purpose
Confirm that the cylinder oil tight by checking the moving length of the cylinder rods.
(2) Condition
Hydraulic oil temperature; 45 to 55C degrees (113 to 131F degrees)
Firm, level ground
After cylinders are replaced, bleed off air from the cylinders, before checking for oil tightness.
Retract the arm cylinder rod 50 mm (2 in) from stroke end so that the piston does not match a
same range of the cushioning mechanism.
(3) Preparation
Put the bucket empty. Extend the arm cylinder rod 50mm (2in) from the most retracted position.
And extend the bucket cylinders fully. Then hold the boom so that the arm top pin is positioned at
same height with boom foot pin.
(4) Measurement
Measure the items five minutes after the engine is turned off.

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 ［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

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
Firm, level ground
The swing bearing mounting bolts are not
loosened. How to measure the axial play of swing
The swing bearing is lubricated well, not making bearing
abnormal sound during turning.

(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
Measuring position 1
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. 13
(4) Measurement 1 (Measuring position 1 and 2)
1.
Measure the displacement of the outer race in
the axial direction in position 1 [The arm at 90
degrees to 110 degrees and the crawler front is
lifted by attachment about 30cm (1ft)] and in
Measuring position 2
position 2, using a dial indicator.

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［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

(5) Measurement 2 (Measuring position 3)

1.
Retract the arm cylinder fully and extend the
bucket cylinder fully. And move the boom so
that the arm top pin is positioned at same
height with boom foot pin. Then swing the
Measuring position 2
bucket right and left by man power. But in this
case, the gap of the attachment is included.

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 ［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

13.9 MECHATRO CONTROLLER

13.9.1 ENGINE CONTROL INPUT / OUTPUT

INPUT / OUTPUT

13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C

ADJUSTMENT)
13.9.2.1 PURPOSE OF THE ADJUSTMENT 13
There are 2 kinds of adjustment of mechatro controller as shown below; every adjustment is an
essential function to ensure performance of machine.

(1) Adjustment of pump ("B" adjustment)

This adjustment is performed to correct the output variation by coordinating the output hydraulic
pressure with engine rated output.
(2) Adjustment of unloading valve ("C" adjustment)
This adjustment is performed to correct the open variation of unloading valve to improve the
operability further.

13.9.2.2 IN CASES WHERE THE ADJUSTMENT OF MECHATRO CONTROLLER IS REQUIRED;

When the following parts are replaced or repaired, carry out the adjustment without fail.

(1) Mechatro controller

(2) Engine or engine controller
(3) Hydraulic pump or hydraulic pump proportional valve
(4) Unloading proportional valve, spool of unloading valve

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［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

13.9.2.3 PREPARATION
(1) Raise the oil temperature to about 50C degrees (122F degrees) to warm up the engine.
(2) Turn the air-con OFF.
(3) Turn the starter key switch OFF to stop the engine.
When the mechatro controller was replaced, the following error code is displayed because the
adjustment data is not entered.
A215, A225, A015, A025, A035
As the error codes other than those shown above may suggest failures of machine, repair the
machine into the ordinary operating condition according to Error Code List.

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 ［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

13.9.2.4 ADJUSTING PROCEDURE

Gauge cluster

(1) Adjustment of engine ("B" adjustment)

Procedure
1.
Turn starter key switch ON keeping the work
mode selector switch on the gauge cluster
pressed, and hold it for 5 to 10 seconds, and
then release it. (If the engine is started, the 13
following indication is not displayed. Therefore
do not start the engine.)

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

3.
Press selector switch on gauge cluster to
display "START ENG".
"Engine SPEED", P1, P2 "PUMP PRESSURE"
and "STEP" (acceleration command voltage) are
indicated.

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［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

4.
The adjustment automatically shifts from engine
to pump, the speed shifts from LOW idling to
HIGH idling. And "MEMORY PUMP" is
displayed. And the unloading proportional valve
and pump proportional valve actuate,
accordingly the loading of pump is increased.
The "ENGINE SPEED", P1, P2 "PUMP
PRESSURE" and P1, P2 pump
"PROPO-VALVE" current (command value) are
indicated.

5.
After detection of the engine rated speed, the
adjustment of pump is automatically completed.
And "FINISH PUMP" is displayed.
(Press the buzzer stop switch on gauge cluster
while this display is appeared and the
adjustment is completed. The unloading
adjustment required later is not performed, and
default value is written.)

(2) Adjustment of unloading valve ("C" adjustment)

Procedure
1.
The adjustment shifts from pump to unloading,
and the unloading valve actuates, accordingly
the pump pressure is detected. And "MEMORY
UNLOAD" is displayed.
The "ENGINE SPEED", P1, P2 "PUMP
PRESSURE" and P1, P2 "PROPO-VALVE"
voltage (command value) are indicated.

2.
When the unloading valve operates to the
specified value, the adjustment of unloading
proportional valve is automatically terminated.
And "FINISH UNLOAD" is displayed.
The speed is shifted to the speed
corresponding to acceleration potentiometer.
The adjusting current value is indicated on the
display of current of P1, P2 unloading
proportional valves. The adjusting range is
usually 520 to 635 mA.

Stop the engine. (The adjusted data is

automatically stored.)

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 ［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

(3) Corrective actions taken when the adjustment can not be performed;

1.
In cases where the adjustment of pump can not
be performed; And "ERROR PUMP" is
displayed.
Judging condition 1:
P1 and P2 average pump pressure at the time
when the adjustment is completed is 25MPa or
less.
Judging condition 2:
The adjustment does not complete although
the pump proportional valve current reaches to
the specified value.

The P1 and P2 pump pressures usually

increase to 33~38MPa.
When the pressure does not increase;

a. Identify the reason why the pressure does not increase,

-Check that the relief valve operates normally.
-Check that the hydraulic circuit is free from leak of pressure.
-Check that the pressure sensor functions normally.
And so on.
b. Identify the reason why the actual flow rate does not increase,
-Check that the pump proportional valve operates normally. 13
-Check that the pump regulator operates normally.
And so on.

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［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

2.
In cases where unloading valve can not be
performed; And "ERROR UNLOAD" is displayed.
Judging condition 1:
The pump pressure does not increase up to the
pressure in the range of the specified
adjustment. Or the increased pressure is held
as it is.
Judging condition 2:
Pressure sensor of either P1 pump or P2 pump
is failed.

Normally the pump pressures of P1 and p2

pumps gradually increase to 10 to 25 MPa.
(It may be affected by operating oil
temperature.)

When the pump pressure does not increase;

a. Identify the reason why the pressure does not increase,

-Check that the relief valve operates normally.
-Check that the hydraulic circuit is free from leak of pressure.
-Check that the pressure sensor functions normally.
And so on.

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 ［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

(4) Other precautions:

1.
In the event of a failure, there is case where the adjustment may not be performed normally.
First serve the machine, and perform the adjustment work.
2.
In the condition where large load is constantly applied to engine, the adjustment could not be
performed normally.

(5) When the adjustment of unloading valve only is performed; ("C" adjustment)

In the event where only unloading valve and unloading proportional valve are replaced, perform the
adjustment of unloading valve only.

Procedure
1.
Turn starter switch ON keeping the work mode
selector switch on the gauge cluster pressed,
and hold it for 5 to 10 seconds, and then
release it.
(If the engine is started, the following indication
is not displayed. Therefore do not start the
engine.)

2.
Keep buzzer stop switch on gauge cluster 13
pressed for 5 seconds and release it and the
screen for selection of adjustment type is
displayed. And "ADJUST" is displayed.
When adjustment data is not entered in
mechatro controller, "READY" is indicated. If the
adjustment operation is once performed, "FIN" is
indicated.
And the lever lock solenoid is automatically
released, disabling all operations.

3.
Change the adjusting items with washer switch
(▲) and wiper switch (▼), and select
"ADJUST UNLOAD". (See Fig. "Gauge cluster")
Like the output adjustment, when adjustment
data is not entered in mechatro controller,
"READY" is indicated. If the adjustment
operation is once performed, "FIN" is indicated.

4.
Press selector switch on gauge cluster to
display "START ENG".
"ENGINE SPEED", P1, P2 "PUMP PRESSURE"
and "STEP" (acceleration command voltage) are
indicated.

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［13. MAINTENANCE STANDARD AND TEST PROCEDURE］

5.
After starting engine, press selector switch on
gauge cluster and "MEMORY UNLOAD" is
indicated, the engine speed is automatically
increased and the adjustment of unloading valve
is performed.
"ENGINE SPEED", P1, P2 "PUMP PRESSURE"
and "PROPO-VALVE" (acceleration command
current) are indicated.

6.
When the unloading proportional valve operates
to the specified value, the adjustment of
unloading proportional valve automatically
completes. "FINISH UNLOAD" is indicated.
The speed is shifted to the speed
corresponding to acceleration potentiometer.
The value of adjusting current is indicated on
the display of current of P1 and P2 unloading
proportional valves. The adjusting range is
usually 520 to 635 mA.

Stop the engine. (The adjusted data is

automatically stored.)

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 ［21. MECHATRO CONTROLLER］

21. MECHATRO CONTROLLER

TABLE OF CONTENTS

21.1 SUMMARY OF MECHATRO CONTROL SYSTEM ………………………………………………………21-4

21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL ……………………………………………………21-4
21.1.2 UNLOAD VALVE CONTROL ……………………………………………………………………………21-6
21.1.3 POSITIVE CONTROL & P-Q CONTROL ……………………………………………………………21-7
21.1.4 BOOM UP CONFLUX CONTROL ………………………………………………………………………21-9
21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL ………………………………………………21-11
21.1.6 ARM-IN ANTI-CAVITATION CONTROL ………………………………………………………………21-13
21.1.7 ARM-OUT CONFLUX CONTROL ………………………………………………………………………21-14
21.1.8 BUCKET DIGGING (DUMP) CONTROL ………………………………………………………………21-16
21.1.9 SWING PRIORITY CONTROL …………………………………………………………………………21-17
21.1.10 TRAVEL STRAIGHT CONTROL ………………………………………………………………………21-19 21
21.1.11 PRESSURE RELEASE CONTROL ……………………………………………………………………21-21
21.1.12 N&B SWITCH CONTROL (OPTION) …………………………………………………………………21-23
21.1.13 OPTION CONFLUX CONTROL (OPTION) …………………………………………………………21-25
21.2 MECHATRO CONTROLLER …………………………………………………………………………………21-27
21.2.1 SUMMARY OF MULTI DISPLAY ………………………………………………………………………21-27
21.2.2 SELF DIAGNOSIS DISPLAY ……………………………………………………………………………21-35
21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION ………………………………………………………21-38
21.2.4 TROUBLE HISTORY DIAGNOSIS………………………………………………………………………21-48
21.2.5 TROUBLE DIAGNOSIS MODE …………………………………………………………………………21-49
21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE ………………………………………………21-50
21.2.7 ADJUSTING PROCEDURE OF DISPLAY ……………………………………………………………21-51
21.2.8 MECHATRO CONTROL EQUIPMENT …………………………………………………………………21-54

Book Code No. S5YP2101E01

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［21. MECHATRO CONTROLLER］

Issue Date of Issue Applicable Machines Remarks

S5YP2101E01
First Edition July, 2009 SK140LC-8 : YP09-05001~
(SE Asia)

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 ［21. MECHATRO CONTROLLER］

PREFACE
This manual explains only those related to the electro hydraulic conversion as mechatro control. This
manual summarizes the mechatro system and the function of the mechatro controller related
apparatuses. Regarding the conditions before and after each conversion, refer to the hydraulic system
and the electric system.

21

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［21. MECHATRO CONTROLLER］

21.1 SUMMARY OF MECHATRO CONTROL SYSTEM

21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL

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 ［21. MECHATRO CONTROLLER］

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［21. MECHATRO CONTROLLER］

21.1.2 UNLOAD VALVE CONTROL

(1) On starting any one of operations, the control pilot secondary pressure switches spools and
enters in respective low pressure sensors.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to each
unload pressure proportional valve.
(3) Each unload pressure proportional valves output pilot secondary pressure according to the
command output by mechatro controller and switches each unload spools.
(4) With this operation, the bleed opening according to lever manipulated movement is obtained,
consequently the pump pressure which is used to actuate each actuators are delivered and
makes each actuator start operating.

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 ［21. MECHATRO CONTROLLER］

21.1.3 POSITIVE CONTROL & P-Q CONTROL

21

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［21. MECHATRO CONTROLLER］

(1) Positive control

1. On starting any one of operations, pilot secondary pressure switches each spool and is input to
each low pressure sensor.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to each
unload pressure proportional valve.
3. Each pump proportional valve outputs pilot secondary pressure according to the command output
by mechatro controller and changes the tilting angle of each pump and controls the delivery rate.
4. With this operation, the delivery rate according to lever manipulated movement is fed to the
actuator, and consequently the working speed according to the lever manipulated movement will be
obtained.

(2) P-Q control

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

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 ［21. MECHATRO CONTROLLER］

21.1.4 BOOM UP CONFLUX CONTROL

21

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［21. MECHATRO CONTROLLER］

(1) On starting boom up operation, boom up operating pilot pressure switches boom spool and boom
up conflux spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to P1 and P2
proportional valves and P1 and P2 unload proportional valves.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the
command output by mechatro controller and changes P1 and P2 pump delivery rate and switches
P1 and P2 unload pressure control valve.
(4) With original hydraulic pressure command, boom main spool and boom up conflux spool are
switched, and also with the command by mechatro controller, P1 and P2 pumps and P1 and P2
unload valves are switched and consequently the delivery oil on P1 pump side confluxes delivery
oil on P2 pump side during boom up operation.

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 ［21. MECHATRO CONTROLLER］

21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL

21

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［21. MECHATRO CONTROLLER］

(1) Recirculation and conflux (Low loading)

1. On starting arm-in operation, arm-in operating pilot secondary pressure is input to arm 1 spool,
arm and low pressure sensor.
2. The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to P1 and P2
proportional valves, P1 and P2 unload proportional valves and reverse proportional valve for arm-in
2 spool.
In case of combined operation, the pilot pressure other than arm-in operation is input to low
pressure sensor and the output voltage is input to mechatro controller. And the mechatro
controller processes pilot signal according to the combined operation and outputs command, which
is different from the arm-in independent operation, to P1 pump proportional valve, P1 unload
proportional valve and reverse proportional valve for arm-in 2 spool.
3. Primary pressure of reverse proportional valve for arm-in 2 spool is arm-in pilot secondary pressure
and it switches arm 2 spool by proportional secondary pressure according to command. (Arm 2
spool controls recirculation rate and conflux rate.)
The other proportional valves output proportional secondary pressure according to command from
mechatro controller. These proportional valves change the delivery rate of P1, P2 pump, and
switch P1, P2 unload valve.
4. The arm 1 spool is switched according to original oil pressure command, and P1, P2 pumps, P1,
P2 unload spools and arm 2 spool are switched according to the command output by mechatro
controller, and consequently the return oil from the arm cylinder rod side is recirculated in P1 and
P2 pumps delivery oil during arm operation.

(2) Recirculation cut

The voltage output by high pressure sensor on P2 side is input to mechatro controller, and when the
load is raised during arm-in operation the mechatro controller processes a pilot signal according to the
detected pressure by high pressure sensor, in this time the command value outputs to the reverse
proportional valve for arm 2 spool so that the arm-in 2 speed spool is shifted to the recirculation cut
position.
The reverse proportional valve for arm-in 2 spool outputs pilot secondary pressure according to the
command output by mechatro controller and switches arm 2 spool to recirculation cut position, and
consequently recirculation passage is blocked.

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 ［21. MECHATRO CONTROLLER］

21.1.6 ARM-IN ANTI-CAVITATION CONTROL

21

(1) On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and
is input to low pressure sensor.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
(3) Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller
processes pilot signal processing and outputs command according to the input voltage to P2 pump
proportional valve and P2 unload proportional valve.
(4) And also outputs command according to input pressure output by potentiometer to reverse
proportional valve for arm 2 spool.
(5) Each proportional valves output pilot secondary pressure according to each command output by
mechatro controller, and consequently since the reverse proportional valve for arm 2 spool is
controlled to spool stroke according to engine speed and changes recirculation rate to prevent the
cavitation from occurring even if pump delivery rate is low due to low engine speed.

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［21. MECHATRO CONTROLLER］

21.1.7 ARM-OUT CONFLUX CONTROL

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 ［21. MECHATRO CONTROLLER］

(1) On starting arm-out operation, arm-out operating pilot pressure switches arm 1 spool and arm 2
spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to P1 and P2
proportional valves and P1 and P2 unload proportional valves.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the
command output by mechatro controller and changes P1 and P2 pump delivery rate and switches
P1 and P2 unload pressure control valves.
(4) With original hydraulic pressure command, arm 1 spool and arm 2 spool are switched and also
with the command output by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves
are switched, and consequently the delivery oil on P2 pump side confluxes delivery oil on P1
pump side during arm-out operation.

21

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［21. MECHATRO CONTROLLER］

21.1.8 BUCKET DIGGING (DUMP) CONTROL

(1) On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure
switches bucket spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to P1 pump
proportional valve, and P1 unload proportional valve.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the
command output by mechatro controller and changes P1 pump delivery rate and switches P1
unload valve.

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 ［21. MECHATRO CONTROLLER］

21.1.9 SWING PRIORITY CONTROL

21

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［21. MECHATRO CONTROLLER］

(1) During arm-in operation, arm operating pilot secondary pressure switches arm 1 spool and is
input to low pressure sensor on starting swing operation (or arm-in operation during swing
operation), and swing operation pilot secondary pressure switches swing spool and is input to low
pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to P1 and P2
proportional valves, P1 and P2 unload pressure proportional valves, travel straight valve and
reverse proportional valve for arm 2 spool.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the
command output by mechatro controller and changes P1 and P2 pump delivery rate and switches
P1 and P2 unload spool, travel straight spool, arm 2 spool.
(4) With original hydraulic pressure command, arm 1 spool and swing spool are switched and also
with the command by mechatro controller, P1 and P2 unload spools, travel straight spool and
arm 2 spool are switched enabling for two pump flow rates to be supplied to the arm cylinder
head side, and consequently the return oil on arm cylinder rod side is recirculated into arm
cylinder head side.
(5) Because the return oil on the arm rod side is recirculated, the working pressure is raised and
pump delivery rate is used for swing operation by priority, and operated by the recirculated oil,
making the operation with minimum speed drop possible.

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 ［21. MECHATRO CONTROLLER］

21.1.10 TRAVEL STRAIGHT CONTROL

21

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［21. MECHATRO CONTROLLER］

(1) Judgment travel straight

1. During travel operation (right and left), pilot pressure switches each spool and is input to low
pressure sensor on carrying out attachment system operation.
2. Mechatro controller decides as travel straight on receiving the input according to the combination
shown in the table from the low pressure sensor and turns travel straight signal on.
3. On turning travel straight signal on, the following commands are output to each proportional valve.

(2) Operation of each proportional valve

(Basically attachment operation is actuated by P1 pump and travel operation is actuated by P2 pump
in travel straight condition.)

1. Travel straight proportional valve

Outputs switching pressure according to the high priority select pressure in the attachment system
operating (Boom, arm, bucket, swing, option) pilot pressure during operation.
2. P1 unload proportional valve
Outputs switching pressure according to the high priority select pressure in the attachment system
operating pilot pressure during operation.
3. P2 unload proportional valve
Outputs switching pressure according to the high priority select in the travel operating pilot
pressure during operation.
4. P1 pump proportional valve
Outputs switching pressure according to the high priority select pressure in the attachment system
operating pilot pressure during operation.
5. P2 pump proportional valve
Outputs switching pressure according to the high priority select in the travel operating pilot
pressure during operation.

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 ［21. MECHATRO CONTROLLER］

21.1.11 PRESSURE RELEASE CONTROL

21

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［21. MECHATRO CONTROLLER］

(1) Change mechatro controller to "PRESSURE DRAINING MODE" by operating switch on gauge
cluster.
For detail of changing mode method, refer to "How to switch to "Pressure release mode"" on item
22.11.1.
(2) Once mechatro controller decides it as pressure release control, regardless of each input signal
(operating pilot, accel potentiometer, etc.) the mechatro controller;
1.Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump
to minimum tilt angle.
2.Outputs command of pressure release and outputs command of pressure release control to
ECU and fixes engine speed to pressure release control speed.
3.Outputs maximum command to P1 and P2 unload valves and each pilot secondary pressure
fixes P1 and P2 unload valves to the maximum opening.
(3) Mechatro controller senses output voltage from the main pump high pressure sensor, decides the
pump pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on gauge
cluster.
(4) Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped
pressure) to be released by operating each control lever and switching spool with the unload valve
opened.

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 ［21. MECHATRO CONTROLLER］

21.1.12 N&B SWITCH CONTROL (OPTION)

21

21-23
［21. MECHATRO CONTROLLER］

(1) Nibbler circuit

1. Select nibbler mode through select switch.
2. Nibbler display appears on gauge cluster.
3. The return oil from the nibbler passes through selector valve and option spool and led to tank
line of main control valve.
4. When selecting nibbler mode through select switch, the breaker pressure sensor has not function
to output.
It is in normal when there is no output from sensor in nibbler mode, and in cases of other than
above, error display is output to gauge cluster.

(2) Breaker circuit

1. Select breaker mode through select switch.
2. Breaker display appears on gauge cluster.
3. The return oil from the breaker passes through selector valve and directly returns into hydraulic oil
tank.
4. When selecting breaker mode through select switch, the breaker pressure sensor outputs signal.
It is in normal when there is an output from sensor in breaker mode, and in cases of other than
above, error display is output to gauge cluster.

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 ［21. MECHATRO CONTROLLER］

21.1.13 OPTION CONFLUX CONTROL (OPTION)

21

21-25
［21. MECHATRO CONTROLLER］

(1) Select the Conflux with the aid of Conflux/Single switch.

(2) On starting option operation, option operating pilot pressure switches option spool and is input to
low pressure sensor.
(3) The output voltage of low pressure sensor is input to mechatro controller and the mechatro
controller processes pilot signal and outputs command according to the input voltage to P1 and P2
pump proportional valves, P1 and P2 unload pressure proportional valves and travel straight
proportional valve.
(4) Each proportional valves output pilot proportional valve secondary pressure according to the
command output by mechatro controller and changes P1 and P2 pump delivery rate and switches
P1 and P2 unload valves and travel straight valve of the control valve.
(5) The parallel passage on P2 side is connected to P1 port because of the travel straight valve
switched and P1 pump delivery oil confluxes P2 pump delivery oil because of the P2 unload valve
switched.

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 ［21. MECHATRO CONTROLLER］

21.2 MECHATRO CONTROLLER

21.2.1 SUMMARY OF MULTI DISPLAY

Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.

(1) Controls

21

(2) Gauge cluster

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［21. MECHATRO CONTROLLER］

(3) Screen selection by work mode select switch

The mode after the engine starting is always the start from "S" mode.
The work mode is switched in order of "S" -> "H" each time the work mode select switch is pressed.
Select proper work mode shown below according to the work condition and the purpose.
For the selected work mode, refer to the table shown below.

・ S mode: For standard excavating work

・ H mode: For heavy duty excavating work

S mode
"S mode" is suitable for standard digging and
loading works and is in saving fuel consumption
and is in good balance to the workload.

H mode
"H mode" is suitable for heavy duty digging
work which gives priority to the workload at
the high speed.

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 ［21. MECHATRO CONTROLLER］

(4) Screen selection by attachment mode select switch (SE Asia : Option)
This switch is used for switching the attachment
mode.
The screen is changed from "Digging" to
"Nibbler" to "Breaker" each time the attachment
mode switch (3) is turned to respective position.
Depending on the attachment employed, select
the applicable mode from "Digging", Nibbler",
and "Breaker".
Before the working, confirm whether
appropriate attachment had been selected.

21

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［21. MECHATRO CONTROLLER］

(5) Pump flow rate adjustment (Nibbler mode / Breaker mode)

According to some kind of attachment, it is required to change the flow rate for service circuit. Change
the flow rate in accordance with the procedure mentioned below.
In this machine, last set flow rate has been stored and the initial flow rate is 130L/min. The
adjustment (increase or decrease) of flow rate is changeable by 10L/min step.

1: Screen Change Switch

2: Buzzer Stop Switch
3: Work Mode Select Switch
4: Washer Switch
5: Wiper Switch
6: Travel Speed Select Switch
7: Auto Accel Switch
8: Select Switch
9: Attachment Mode Select Switch
(SE Asia : Option)

1. Turn starter key switch on and display main screen (a).

2. The screen is changed from "Digging" to "Nibbler" to "Breaker" each time the attachment mode
select switch (9) is turned when the main screen (a) is displayed.
3. Turn the switch (9) to "B", and "Nibbler mode" screen is displayed. Or turn the switch (9) to "A",
and "Breaker mode” screen is displayed.
4. When the nibbler/breaker select screen (b) or (c) is displayed, press the select switch (8) and the
value of flow rate reverses to black, and the screen is changed to (d). To increase flow, press the
up arrow (4) (washer switch), or to decrease flow, press the down arrow (5) (washer switch).
5. Select the desired setting value and then press select switch (8) and the flow rate is set to the
desired value.

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(6) MAINTENANCE SCREEN DISPLAYS

This screen displays the remaining time to the
end of recommended replacement/change
interval specified for filter/oil.

After turning starter key switch ON or starting

engine, the screen is changed in order of "Time
for engine oil change" --> "Time for fuel filter
replacement" --> "Time for hydraulic oil filter
change" --> "Time for hydraulic oil change" -->
"Main screen" each time the screen change
switch (2) is pressed.
With this menu, the time range to the
recommended change time for the filter and oil
in use can be identified.
21

For the initial set value of recommenced replacement/change time, see the following table.

Replacement interval
Item Default
Engine oil 500 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
Hydraulic oil 2,000 Hr

This menu is available for confirmation of the following items.

The maintenance screen changes each time the screen change switch is pressed.

1.
Remaining time display to the engine oil change
This display shows the remaining time to the
coming engine oil change.

2.
Remaining time display to the coming fuel filter
replacement
This display shows the remaining time to the

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［21. MECHATRO CONTROLLER］

coming engine fuel filter replacement.

3.
Remaining time display to the coming hydraulic
oil filter replacement
This display shows the remaining time to the
coming hydraulic oil filter replacement.

4.
Remaining time display to the coming hydraulic
oil change
This display shows the remaining time to the
coming hydraulic oil change.

-The display automatically changes to the main screen, if switch is not operated for 30 seconds.
-For the setting procedure of maintenance time to be performed to the coming oil change in each
type and filter replacement, see the 21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE.

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(7) Gauge cluster display

After key is switched on and logo mark display disappears, screen for operator is displayed on multi
screen. The display functions of multi display are explained below.

1. Display function for operator:

Screen usually displayed during operation
1.1 Clock display function:
Current time is displayed.
1.2 Self-diagnosis display :
When abnormality is detected on mechatro system like sensor, proportional valve, etc., this displays
error code.
1.3 Warning display:
When machine was thrown into dangerous state, or was failed, displays warning contents with the
symbol and statement.

21

Error codes were stored as trouble history, and displayed on the monitor by the trouble history display
function.

1.4 Machine condition display :

Displays machine operating condition.

2. Display function for maintenance:

Displays remaining time up to replacement/change of following items.
(1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil

3. Failure history display function:

Stores abnormality occurred on mechatro system in the past and displays in order of recent occurrence.

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［21. MECHATRO CONTROLLER］

4. Mechatro adjustment display:

Displays procedure for adjustment of mechatro system like output adjustment and unload adjustment,
etc.

5. Service diagnosis display :

Displays information like pressure sensor sensed value, proportional valve command, etc. output by
mechatro controller

6. Failure diagnosis mode display function:

Specifies failed section automatically for failures which are not detected by self diagnosis and displays
the results.

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 ［21. MECHATRO CONTROLLER］

21.2.2 SELF DIAGNOSIS DISPLAY

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

(2) I/O configuration

(3) Self diagnosis display items

As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure
type with the aid of error code.

21

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［21. MECHATRO CONTROLLER］

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 ［21. MECHATRO CONTROLLER］

21

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［21. MECHATRO CONTROLLER］

21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION

The current service diagnosis is displayed on multi display based on the data received from mechatro
controller. This section explains the operating procedure and examples of each screen. The values in
display changes according to the conditions like engine speed, attachment position, etc.

(1) Service diagnosis display screen operating procedure

1. Turn starter switch ON keeping buzzer stop switch pressed.

Buzzer stop switch

2. After logo mark is displayed, the screen changes in service diagnosis mode.
The service diagnosis screen "Mode No.1", "Screen No.1" is displayed first.
The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in
"Screen No.1".
The screen number each mode can display differs. The screen number displayed by each mode is as
follows.

・ Mode No.1 : Screen No.1 to No.30

・ Mode No.2 : Screen No.1, Screen No.31 to No.40
・ Mode No.3 : Screen No.1, Screen No.41 to No.50

3. The screen changes each time each switch is pressed from now on.

Washer switch
Screen gains by 1 in order.
(No.2-->No.3-->No.4-->...)

Wiper switch
Screen loses by 1 in order.
(No.24-->No.23-->No.22-->...)

Auto idling switch

Service diagnosis number advances from No.1
to No.3, and then returns to No.1.
(No.1 No.2 No.3 No.1 ...)

Travel 1, 2 speed switch

Service diagnosis number advances from No.3
to No.1, and then returns to No.3.
(No.3-->No.2-->No.1-->No.3-->...)

4. Turn key switch OFF and the display of service diagnosis mode is closed.

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(2) Service diagnosis display screen (Example)

The service diagnosis display screen list is shown below. The conditions for display are H mode,
engine low speed and lever to neutral position.)

1) Service diagnosis mode No.1

21

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 ［21. MECHATRO CONTROLLER］

2) Service diagnosis mode No.2

21

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［21. MECHATRO CONTROLLER］

3) Service diagnosis mode No.3

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 ［21. MECHATRO CONTROLLER］

(3) Service diagnosis data list

Preface and precaution
The following is the data decided as normal status after service diagnosis for every operation. Use
these data to decide normal/abnormal status.

・ The values in following display are reference values with standard attachment attached machine.
・ The value of pressure sensor is calculated taking variation into accounts. When compared to
performance check reference criteria, measure it with the aid of calibrated measuring instrument.
・ The current of proportional valve is not the measured value, but command value. The measured
value should be confirmed by the value in the displayed value for each proportional valve.
・ The current value of pump proportional valve is reference value because it varies according to
pump pressure and adjusted torque value.
・ The value in display during operation shows the value in steady state, rather than, at start of
operation.
・ Check on machine after sufficiently warming up machine.
・ The value in display may differ according to software version. Contact our dealer/distributor.

Operation No.1: No operation Operation No.2: No operation

H mode Hi idle S mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 350 mA E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 750 mA D-2 P2-UL(BPC) 750 mA 21
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1870~1930
POWER SHIFT 0 mA POWER SHIFT 0 mA

Operation No.3: Operation No.4:

Boom up in full lever operation & relief Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.31 BOOM No.31 BOOM
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 11.0~16.0 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 11.0~16.0 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 560~750 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 450~550 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
B-1 BOOM RAISE 3.0 M B-1 BOOM RAISE 3.0 M
B-2 BOOM LOWER 0.0 M B-2 BOOM LOWER 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

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［21. MECHATRO CONTROLLER］

Operation No.5:
Boom down in full lever operation & in operation
H mode Hi idle
No.31 BOOM
C-1 P1-PRES 12.5~16.0 M
C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 549 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 750 mA
B-1 BOOM RAISE 0.0 M
B-2 BOOM LOWER 3.0 M
G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA

Operation No.6: Operation No.7:

Arm-in in full lever operation & relief Arm-in in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 12.0~16.5 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 12.0~16.5 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 550~700 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 550~750 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 200 mA D-6 ARM-IN-2 370 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 3.0 M B-4 ARM IN 3.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

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 ［21. MECHATRO CONTROLLER］

Operation No.8: Operation No.9:

Arm-out in full lever operation & relief Arm-out in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 12.0~18.0 M
C-2 P2-PRES 32.0~35.8 M C-2 P2-PRES 12.0~18.0 M
E-1 P1-PSV 385~495 mA E-1 P1-PSV 606~750 mA
E-2 P2-PSV 385~495 mA E-2 P2-PSV 606~750 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 3.0 M B-3 ARM OUT 3.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

* Measure the values after a lapse of 5 * Measure the values after a lapse of 5
minutes or after release of low temperature minutes or after release of low temperature
mode mode

Operation No.10: Operation No.11:

Swing in full lever operation & relief Swing in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING 21
C-1 P1-PRES 0.2~1.5 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 28.0~35.8 M C-2 P2-PRES 8.0~13.0 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 500~610 mA E-2 P2-PSV 642 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 3.0 M B-7 SWING 3.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

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［21. MECHATRO CONTROLLER］

Operation No.12: Operation No.13:

Bucket digging in full lever operation & relief Bucket digging in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 4.0~8.0 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 500~610 mA E-1 P1-PSV 750 mA
E-2 P2-PSV 350 mA E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
B-5 BUCKET DIG 3.0 M B-5 BUCKET DIG 3.0 M
B-6 BUCKET DUMP 0.0 M B-6 BUCKET DUMP 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

Operation No.14: Operation No.15:

Bucket dump in full lever operation & relief Bucket dump in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 32.0~35.8 M C-1 P1-PRES 6.0~15.0 M
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 0.2~1.5 M
E-1 P1-PSV 500~610 mA E-1 P1-PSV 650 mA
E-2 P2-PSV 350 mA E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
B-5 BUCKET DIG 0.0 M B-5 BUCKET DIG 0.0 M
B-6 BUCKET DUMP 3.0 M B-6 BUCKET DUMP 3.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

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 ［21. MECHATRO CONTROLLER］

Operation No.16: Operation No.17:

P2 side option in full lever operation & relief P2 side option in full lever operation & relief
Nibbler mode Hi idle Breaker mode Hi idle
No.35 OPT No.35 OPT
C-1 P1-PRES 22.5~26.0 M C-1 P1-PRES 0.2~1.5 M
C-2 P2-PRES 22.5~26.0 M C-2 P2-PRES 22.5~26.0 M
E-1 P1-PSV 480~590 mA E-1 P1-PSV 500 mA
E-2 P2-PSV 480~590 mA E-2 P2-PSV 665~750 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 720 mA D-3 S-TRAVEL 350 mA
E-3 OPT RELIEF 0 mA E-3 OPT RELIEF 0 mA
B-16 P1 OPT 0.0 M B-16 P1 OPT 0.0 M
B-17 P2 OPT 2.0~2.6 M B-17 P2 OPT 2.0~2.6 M
F-4 OPT SELECT NIB F-4 OPT SELECT BRK
DOUBLE FLOW SW. ON DOUBLE FLOW SW. OFF
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

* Conflux switch is ON. Relief set pressure is * Conflux switch is OFF. Relief set pressure is
value of shipping. value of shipping.

Operation No.18: Operation No.19 :

Travel right in full lever operation & travel idling Travel left in full lever operation & travel idling
H mode Hi idle H mode Hi idle
No.34 TRAVEL No.34 TRAVLE
C-1 P1-PRES 5.0~12.0 M C-1 P1-PRES 0.2~1.5 M 21
C-2 P2-PRES 0.2~1.5 M C-2 P2-PRES 5.0~12.0 M
E-1 P1-PSV 750 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 350 mA E-2 P2-PSV 750 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 750 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
B-9 TRAVEL(R) 2.0~2.5 M B-9 TRAVEL(R) 0.0 M
B-10 TRAVEL(L) 0.0 M B-10 TRAVEL(L) 2.0~2.5 M
Pi-P1 0.0 M Pi-P1 0.0 M
Pi-P2 0.0 M Pi-P2 0.0 M
G-3 ENG SPEED 1970~2030 G-3 ENG SPEED 1970~2030
POWER SHIFT 0 mA POWER SHIFT 0 mA

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［21. MECHATRO CONTROLLER］

21.2.4 TROUBLE HISTORY DIAGNOSIS

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

(1) How to display

1. Turn starter switch on.

2. Press buzzer stop switch for 10 seconds continuously 5 times and the trouble history screen is
displayed.

3. Transmit trouble history data (One or many) and hour meter to gauge cluster.
-Hour meter and 4 failure data are displayed on screen.
-In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
4. Paging (Up and down)
-Press washer switch (UP), and the item moves upward.
-Press wiper switch (DOWN), and the item moves downward.
5. Turn starter switch off, and the display is disappeared.

(2) How to delete contents of trouble history

1. Display trouble history screen.
2. Press work mode change switch and buzzer stop switch simultaneously for 10 seconds or more.
3. When "NO ERROR" is displayed, the deletion is completed.
4. Turn starter switch off.

All the stored items are erased. It is impossible to erase data partially.

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 ［21. MECHATRO CONTROLLER］

21.2.5 TROUBLE DIAGNOSIS MODE

The recent control system includes many electrical systems and it makes troubleshooting very difficult.
The failure diagnosis mode is used to automatically specify the failed sections for the failures which
can not be detected through the use of self diagnosis function (the failure can be specified through the
use of error code) like disconnection and abnormal output. This is useful to save the time for
troubleshooting.

(1) Function
There are two types of trouble diagnosis mode.

1. Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system
and engine system.
2. Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not moved, both directional valve and proportional valve are
automatically actuated, the sensor detects the machine status and the mechatro controller
identifies the normal condition or failed condition of the system.

For details of how to use, refer to "Chapter 48 TROUBLESHOOTING TROUBLE DIAGNOSIS MODE".

21

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［21. MECHATRO CONTROLLER］

21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE

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

Interval of replacement of parts is mentioned below.

-Engine oil: 250 Hr
-Fuel filter: 500 Hr
-Hydraulic filter: 1,000 Hr
-Hydraulic oil: 2,000 Hr

1. After displaying the display for setting by pressing the display change switch, set the respective
maintenance time for fuel filter, hydraulic oil filter and hydraulic oil while repeating the procedure 2 to 5.
2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the
buzzer does not sound.

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 ［21. MECHATRO CONTROLLER］

21.2.7 ADJUSTING PROCEDURE OF DISPLAY

(1) For operator
2) Clock Adjustment Switches

21

1. Turn starter key switch on and display main screen (a) for operator, and then press select switch
(8) and display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).
2. In operations of FEED UP (4) and FEED DOWN (5), move cursor to "CLOCK/CONTRAST"
screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen
(d) is displayed.
3. In operations of FEED UP (4) and FEED DOWN (5), move cursor to "ADJUST CLOCK" and then
press select switch (8) and the "ADJUST CLOCK" screen (e) is displayed.
4. Select any of "Y-M-D-H-M" in operation of FEED UP (4) and FEED DOWN (5) and vary the
values in operations of FEED UP (4) and FEED DOWN (5).
5. After adjustment, press select switch (8) and the adjusted values are stored as memory and time
setting is completed, and then the screen returns to main screen (a).

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［21. MECHATRO CONTROLLER］

2) Contrast Adjustment Switches

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

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 ［21. MECHATRO CONTROLLER］

(2) Function for service

Following items are provided for adjustment of service function.

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

21

21-53
［21. MECHATRO CONTROLLER］

21.2.8 MECHATRO CONTROL EQUIPMENT

(1) C-1 Mechatro controller
1) Outside view

2) List of connectors

21-54
 ［21. MECHATRO CONTROLLER］

21

21-55
［21. MECHATRO CONTROLLER］

21-56
 ［21. MECHATRO CONTROLLER］

21

21-57
［21. MECHATRO CONTROLLER］

21-58
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(2) Gauge cluster (symbol C-2)

1) General view

2) Connector CN-600 (Harness side)

No. Item name Wire color No. Item name Wire color
Gauge cluster --> Mechatro
GND source (+24V Battery direct
1 controller (RS232C White 5 Yellow / Black
connection)
communication)
Mechatro controller --> Gauge
2
cluster (RS232C communication)
Red 6 GND Black 21
3 Reserved - 7 Source (+24V starter switch ON) White
4 Reserved - 8 GND (RS232C communication) Black

3) Function
a. It processes signals by communication between the gauge cluster and the mechatro controller,
displays them in lamps, displays them in LCDs and actuates the buzzer.
b. It outputs coolant temperature signals, fuel level signals and panel switch signals to the mechatro
controller through the communication port.

4) Summary of display and drive item

No. Item Remarks
1 Monitar display LCD dot 120X168
2 Gauge display (Coolant temp., Fuel level) Stepping motor
3 -
4 Buzzer Piezo-electricity type
5 Screen change switch
6 Buzzer stop switch
7 Work mode select switch
8 Back light LED

21-59
［21. MECHATRO CONTROLLER］

(3) Relay & fuse box (symbol E-1)

1) General view

21-60
 ［21. MECHATRO CONTROLLER］

2) Circuit diagram

21

21-61
［21. MECHATRO CONTROLLER］

21-62
 ［21. MECHATRO CONTROLLER］

21

21-63
［21. MECHATRO CONTROLLER］

(4) High pressure sensor : LS52S00015P1

(5) Low pressure sensor : LC52S00019P1

21-64
 ［22. HYDRAULIC SYSTEM］

22. HYDRAULIC SYSTEM

TABLE OF CONTENTS

22.1 SUMMARY ………………………………………………………………………………………………………22-3

22.2 HYDRAULIC CIRCUITS AND COMPONENTS ……………………………………………………………22-4
22.3 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS …………………………………………22-8
22.4 NEUTRAL CIRCUIT ……………………………………………………………………………………………22-8
22.5 TRAVEL CIRCUIT ………………………………………………………………………………………………22-10
22.6 BUCKET CIRCUIT ………………………………………………………………………………………………22-12
22.7 BOOM CIRCUIT …………………………………………………………………………………………………22-14
22.8 SWING CIRCUIT ………………………………………………………………………………………………22-18
22.9 ARM CIRCUIT …………………………………………………………………………………………………22-20
22.10 COMBINED CIRCUIT …………………………………………………………………………………………22-26
22.11 PRESSURE DRAINING ………………………………………………………………………………………22-30

22

Book Code No. S5YP2201E02

22-1
［22. HYDRAULIC SYSTEM］

Issue Date of Issue Applicable Machines Remarks

S5YP2201E01
First Edition July, 2009 SK140LC-8 : YP09-05001~
(SE Asia)
S5YP2201E02
SK140LC-8 : YP09-05001~
(SE Asia)
Revision January, 2010 SK130-8 : LP09-20001~
(NZL)
SK130L-8 : LX07-11001~
(Thailand)

22-2
 ［22. HYDRAULIC SYSTEM］

22.1 SUMMARY

22.1.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT

The hydraulic circuits are built up with the following functions and features in order to achieve easy
operability, safety, mass volume handling and low fuel consumption.

22

22-3
［22. HYDRAULIC SYSTEM］

22.2 HYDRAULIC CIRCUITS AND COMPONENTS

STD. SCHEMATIC HYD. LINES LP01Z00044P1 (02)

Item Component name Part No. Model No.
1 Hyd. pump assy YY10V00009F1 K7V63DTP179R-0E13-VC
2 Control valve (main) YY30V00058F1 KMX13YD/B44904
3 Swing motor unit YY15V00016F1 M2X63CHB
4 Travel motor unit YY15V00015F1 GM21VX-A-45/75-2
5 Boom cylinder (RH & LH) YY01V00053F2 100 dia. X 70 dia. X 1092
6 Arm cylinder YY01V00054F3 115 dia. X 80 dia. X 1120
7 Bucket cylinder YY01V00055F3 95 dia. X 65 dia. X 903
8 Swivel joint YN55V00053F1
9 Pilot valve (ATT) YN30V00111F1 PV48K2017
10 Pilot valve (travel) YN30V00105F1 6TH6 NRZ
11 Inline filter YN50V00020F1 Y-457400
12 Suction strainer YN50V00025F1 SB281J0A021A
13 Solenoid valve assy YY35V00013F1 8KWE5A-30/G24WRX-827
14 Filter element YN52V01016F1 FZ1F180A001C
15 Air breather YN57V00004F1 AB0210GA008A
16 Restrictor YN21V00005F3 07580-00000
17 Restrictor YN21V00005F2 07579-00000

The part numbers may be changed due to modification, so use only the numbers for references.

22-4
 ［22. HYDRAULIC SYSTEM］

22.2.1 STANDARD
A. SK140LC-8, SK130-8

22

22-5
［22. HYDRAULIC SYSTEM］

B. SK130L-8

22-6
 ［22. HYDRAULIC SYSTEM］

22.2.2 N&B SPECIFICATION (OPTION)

22

22-7
［22. HYDRAULIC SYSTEM］

22.3 COLOR CODING STANDARD 22.4 NEUTRAL CIRCUIT (2) Principle: spool sleeve is closed.
The current command I to the pump's solenoid
FOR HYDRAULIC CIRCUITS
This section describes the following. proportional valve controls the delivery rate of the 22.4.4 PUMP P-Q CURVE CONTROL
Blue pump. OPERATION
(1) Bypass cut valve and unload valve control (3) Operation: (1) Type:
Feed, drain circuit
(2) Safety lock lever and pilot circuit Electrical flow control type variable pump
less than 0.44 MPa (64 psi)
(3) Pump positive flow control 1. Flow rate rise operation (Eg. P1 pump) (2) Principle:
Green
(4) Pump P-Q (Pressure-Quantity) curve control By operating any of control levers, the operating Perform an operation of the value from pump high
Return, make up circuit, secondary pressure of pilot valve rises, and the pressure sensor to P-Q curve control value, and
0.44~0.59 MPa (64~86 psi) 22.4.1 OPERATION OF BY-PASS CUT rising pressure is transformed to the rise of output send a command to the pump solenoid
Purple VALVE AND UNLOADING VALVE voltage corresponding to the pressure input by the proportional valve.
Secondary pilot pressure, HOUSED IN CONTROL VALVE low pressure sensor. Mechatro controller (3) Operation:
(including proportional vlave) (1) By-pass cut valve signal-processes this change of voltage, resulting The pump high pressure sensor converts the
On starting engine, P1 and P2 unloading in rise of command current value I to the pump pressure to the output voltage corresponding to
0.59~5 MPa (86~725 psi)
proportional valves (PSV-D, PSV-B) output proportional solenoid valve and consequently the the pump delivery pressure.
Red
secondary pressure according to the command pump flow rate rises. This is called "Positive The mechatro controller converts the voltage
Primary pilot pressure,
output by mechatro controller, and this pressure Control System". output by the high pressure sensor to the P-Q
(including proportional vlave) exerts on PBp1 and PBp2 ports, and As the pump command current value rises, the curve control value. On the other hand, select the
5 MPa (725 psi) consequently the by-pass cut spool is switched secondary pressure of proportional solenoid valve pump positive control command current value from
Orange to CLOSE side. also rises. On the regulator attached on the the low pressure sensor in lower order, and the
Main pump drive pressure, The by-pass cut spool is usually held on CLOSE pump, the spool (652) through piston (643) is values are output to respective pump proportional
side after the engine started. And it is switched to pushed leftward, and stops at the position where valve as a command current.
5~34.3 MPa (725~4970 psi)
OPEN side only when failure occurred on pump being in proportion to the force of pilot spring With this operation, the pump power is controlled
Blue tone
proportional valve and mechatro controller. (646). so as not to be exceed the engine power,
At valve operation
(2) Unloading valve The tank port connected to the large bore of therefore engine dose not stall.
Red valve On starting engine, like by-pass cut valve, the servo piston (532) opens, and the piston moves
When solenoid proportional valve (reducing) is secondary pressures output by P1 and P2 leftward by delivery pressure P1 of the small bore
operating unloading proportional valves (PSV-D, PSV-B) resulting in the increase of tilt angle (α).
Red solenoid exert on PCb and PCa ports, consequently the The servo piston and spool (652) are connected
In active and exciting P1 and P2 unloading valves are switched to to feedback lever (611). Therefore when servo
Displaying the flow circuit and standby circuit when OPEN side. piston moves leftward, the spool (652) also moves
operating. rightward by means of feedback lever. With this
Regarding the electrical symbols in this manual, refer to 22.4.2 SAFETY LOCK LEVER AND PILOT movement, the opening of spool sleeve closes
the electric circuit diagram. CIRCUIT gradually, and the servo piston stops at the
(1) Purpose: position the opening closed completely.
To protect attachment from unexpected 2. Flow rate reduction operation
movement for safety. As the current value I of mechtro controller
(2) Principle: reduces, the secondary pressure of solenoid
Cut pressure source of pilot valve for operation. proportional valve reduces, and spool (652) is
(3) Operation: moved rightward by the force of pilot spring (646).
If the safety lock lever (red) is pushed forward With the movement of spool, the delivery pressure
after the engine starts, the limit switch (SW-11) P1 usually flows into the large bore of piston
is turned on. The timer relay is actuated one through the spool.
second later which causes the solenoid (SV-4) of The delivery pressure P1 flows in the small bore
the solenoid valve block (13) to be energized of servo piston, but the servo piston moves
and makes the pilot operating circuit to stand by. rightward due to the difference of area, resulting
in the reduction of tilt angle. Similarly, when the
22.4.3 PUMP POSITIVE FLOW CONTROL servo piston moves rightward, the spool (652) is
(1) Type: moved leftward by the feedback lever.
Electric flow controlled variable displacement pump. The operation is maintained until the opening of

22-8
 ［22. HYDRAULIC SYSTEM］

22

NEUTRAL CIRCUIT : Positive control function at safety lock lever down (unlocked position)

22-9
［22. HYDRAULIC SYSTEM］

22.5 TRAVEL CIRCUIT switches the unloading spool in CLOSE side.

This section describes the following. 22.5.2 2-SPEED TRAVEL SOLENOID

COMMAND CIRCUIT AND AUTO 1st
(1) Travel forward pilot simultaneous operation circuit SPEED RETURN FUNCTION
(2) 2 speed travel solenoid command circuit and (1) Purpose:
auto 1-speed return function Change travel motor speed with switch.
(3) Travel main circuit (2) Principle:
(4) Travel motor function If the switch is turned, an electric signal is
issued. It excites the 2-speed travel solenoid
22.5.1 TRAVEL FORWARD PILOT which in turn converts the primary pilot pressure
SIMULTANEOUS OPERATION and the self pressure to a tilting angle of the
CIRCUIT variable displacement motor.
(1) Purpose: (3) Operation:
Light operating force and shockless operation If the rabbit marked switch on the gauge cluster
(2) Mechatronics: is pressed, the solenoid (SV-3) of the
proportional valve block (13) is excited and
1. If the travel lever with damping mechanism is changes the proportional valve. Then the
operated for travel right, left and forward solenoid command pressure is issued from port
motions, the secondary pilot proportional pressure A3, enters the P port of the travel motor (4),
comes out of the 3, 1 ports of P/V (10). The opens the oil passage to the 2nd speed select
higher of the pressures is selected, comes out of piston, and causes the motor to run in the 2nd
the 6, 5 ports and acts upon the low pressure speed tilting mode by its self pressure. However,
sensors (SE-9) (SE-10). when the main circuit pressure rises above 27.3
2. The pilot secondary pressure flows to PBr and MPa (3960 psi), the motor's self pressure pushes
PBL ports of the control valve (2), moves the the 2nd speed select piston back to the 1st
travel spool, and switches the main circuit. speed.
3. The low pressure sensor output voltage is input
into mechatro controller. The mechatro controller 22.5.3 TRAVEL MAIN CIRCUIT
performs signal processing and outputs current (1) Operation:
corresponding to the increase of flow rate to P1 The delivery oil from Pump A1 and A2 ports by
pump proportional valve (PSV-P1) and P2 pump changing the travel spool with the operation of
proportional valve (PSV-P2), and at the same time travel pilot flows in each A,B port on the left
the command current is output to P1 unloading side of travel motor (4) through C,D ports of
valve (PSV-D) and P2 unloading valve (PSV-B). swivel joint (8) from AL, AR ports of C/V, and
4. The secondary pressures output by P1 pump rotates the travel motor.
proportional valve (PSV-P1) and P2 pump
proportional valve (PSV-P2) exert on pump 22.5.4 TRAVEL MOTOR FUNCTION
regulator, actuating the pump on the delivery (1) Function:
flow rate increase side.
5. The secondary pressure delivered in P1 unloading 1. Prevents the motor from over running on a slope.
valve (PSV-D) and P2 unloading valve (PSV-B) 2. Check valve that prevents cavitation of the
is fed to PBp1, Pcb, PBp2 and PCa ports hydraulic motor.
provided in control valve (2). 3. Shockless relief valve and anti cavitation valve
The secondary pressure from proportional valve when inertia force stops.
which has exerted on PBp1 and PBp2 ports holds 4. High/Low 2 step speed change mechanism and
the by-pass cut spool on CLOSE side, like the auto 1st speed return at high load.
operation in the lever neutral position. 5. Travel parking brake.
The secondary pressure from proportional valve
which has exerted on PCb and PCa ports

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22

TRAVEL CIRCUIT : Travel 2nd speed, RH & LH simultaneous operation.

22-11
［22. HYDRAULIC SYSTEM］

22.6 BUCKET CIRCUIT <When lever is set to neutral position>

In the event where the sensor does not receive
This section describes the following. signal for 4 seconds or more even though the
acceleration dial is set to MAX position, the
(1) Bucket digging pilot circuit engine speed should be raised to 1000 rpm.
(2) Auto accel operation <When lever is operated>
(3) Flow control in the work mode When the pressure 0.6 MPa (87 psi) is input to
low pressure sensor in STD specification (travel,
22.6.1 PILOT CIRCUIT FOR BUCKET bucket, swing, arm), proportional voltage from
DIGGING low pressure sensor inputs in mechatro
(1) Mechatronics: controller, and then the engine speed returns to
the dial set position corresponding to the lever
1. When the operation for bucket digging is operation.
performed, the pilot proportional secondary
pressure is delivered through port 1 of the right 22.6.3 STAND-BY CURRENT CONSTANT
pilot V (9), flows to PAc port, and acts on the CONTROL
low pressure sensor (SE-1), and at the same time (1) Principle:
the bucket spool is switched. When the engine speed is intermediate speed or
2. The voltage output by low pressure sensor lower, command current value to have the pump
inputs in mechatro controller. The mechatro delivery rate constant is output.
controller performs signal processing and outputs (2) Operation:
current corresponding to the increase of pump Even if the engine speed specified by acceleration
flow rate to pump proportional valves (PSV-P1) on potentiometer is low speed, as the delivery rate
the P1 pump sides, and at the same time the corresponds to the intermediate speed, the
command current is output to P1 unloading valve actuator moves earlier than the movement
(PSV-D). equivalent to the control lever angle rate in light
In the following pages, the relation of operation of load operation.
low pressure sensor to both the increase of pump
flow rate and unloading proportional valve is the
same. Therefore the explanation is omitted.
3. The secondary pressure output by P1 pump
proportional valve (PSV-P1) exerts on pump
regulator, actuating the pump onto the delivery
flow increase side.
4. The secondary pressure delivered in P1 unloading
valve (PSV-D) is led to PBp1 and PCb ports
provided in control valve (2).
The secondary pressure from proportional valve
which has exerted on PBp1 ports holds the
by-pass cut spool on CLOSE side, like the
operation in the lever neutral position.
The secondary pressure from proportional valve
which has exerted on PCb ports switches the
unloading spool in CLOSE side.

22.6.2 AUTO ACCELERATION OPERATION

(1) Principle:
Auto acceleration actuates according to signals
from low pressure sensor.
(2) Operation:

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 ［22. HYDRAULIC SYSTEM］

22

BUCKET CIRCUIT : Bucket digging, Auto-accelation and Standby flow rate constant control

22-13
［22. HYDRAULIC SYSTEM］

22.7 BOOM CIRCUIT into tank circuit through boom spool from C/V (2)
Bb port.
This section describes the boom raise conflux
operation.

(1) Boom up pilot circuit

(2) Boom up 2 pumps conflux main circuit in C/V

22.7.1 BOOM RAISE PILOT CIRCUIT

(1) Operation:

1. If boom up operation is performed, the

secondary pilot proportional pressure from the
right pilot valve (9) gets out of port 3 and acts
upon the low pressure sensor (SE-3). At the
same time, the pressure acts upon the PAb and
PB1 ports.
2. The secondary pressure which enters the PAb
port of C/V (2) shifts the boom spool. The
secondary pressure which enters the PB1 port
shifts the boom conflux spool.

22.7.2 BOOM UP 2 PUMPS CONFLUX

MAIN CIRCUIT IN C/V
(1) Purpose:
Boom up speed up
(2) Principle:
Confluxing oil from 2 pumps
(3) Operation:

1. The oil delivered through A1 port of P1 pump

flows into C/V (2) P1 port, and branches into
bypass circuit and parallel circuit. Since P1
unloading valve is closed, the boom spool is
moved and bypass circuit is closed, the oil
opens load check valve LCb through parallel
circuit and flows into boom spool.
2. Then the oil passes through boom spool, opens
lock valve of boom lock valve CRb, and is led
into H side of boom cylinder through C/V (2) Ab
port.
3. Meanwhile, the oil delivered from the A2 port of
the P2 pump enters the P2 port of C/V (2) and
due to shut off the P2 unloading valve, the oil
then passes through the parallel circuit and via
the restrictor on the circumference of the boom
conflux spool, pushes the load check valve CCb
open from the boom conflux circuit, and combines
the oil delivered by the P1 pump internally.
4. The return oil from boom cylinder R side flows

22-14
 ［22. HYDRAULIC SYSTEM］

22

BOOM CIRCUIT : Boom up operation, Confluence function.

22-15
［22. HYDRAULIC SYSTEM］

This section describes boom lower operation. 22.7.5 CONSTANT RECIRCULATION

(1) Boom down pilot circuit FUNCTION OF BOOM DOWN MAIN
(2) Prevention of natural fall by lock valve and CIRCUIT
actuation at lowering (1) Purpose:
(3) Constant recirculation function of boom down main Prevention of cavitation during boom lowering
circuit motion.
(2) Principle:
22.7.3 BOOM DOWN PILOT CIRCUIT The oil returning from the boom cylinder head (H)
(1) Operation: is recirculated to the rod (R).
(3) Operation:
1. If the boom down operation is performed, the When the oil is supplied to the boom cylinder
secondary pilot proportional pressure comes out of rod (R) side during boom down operation, the
porta4 of the right pilot valve (9) and acts upon boom moves faster than it should do in some
the low pressure sensor (SE-4). cases by the self weight of the attachment.
At the same time, the pressure acts upon the On that occasion, the circuit pressure on the rod
PBb port of C/V (2). (R) side is on the negative side.
2. The voltage output of the low pressure sensor The oil supplied to the boom cylinder rod (R)
(SE-4) enters the mechatro controller and flows into the A1 port of the P1 pump and the
processed in it. P1 port of C/V. The oil then passes through the
3. Then, the proportionl secondary pressure fed into boom spool and goes out of the Bb port.
C/V (2) PBb port and branches off in two lines On that occasion, the oil returning from the head
and switches boom spool and releases boom lock (H) goes through the recirculation path in the
valve. boom spool, pushes the check valve in the spool
open, is recirculated to the Bb port and is
22.7.4 PREVENTION OF NATURAL FALL supplied to the rod (R). When the (R) pressure
BY LOCK VALVE AND ACTUATION is larger than the head (H) pressure, the check
AT LOWERING valve in spool closes.
(1) Purpose: Thereupon, the recirculation is stopped.
Prevention of natural fall when the lever is neutral.
(2) Principle:
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
(3) Operation:
In the boom down action, the selector valve is
changed over by the secondary proportional
pressure of PBb port. Then the poppet spring
chamber of the lock valve CRb gets through the
drain line (Dr) and makes the lock valve poppet
open.
When the boom lever is at neutral, the drain line
on the lock valve CRb poppet spring chamber is
closed which causes the poppet closed.
The result is that the oil returning from the boom
cylinder head (H) to the boom spool is held and
makes the leak from the boom spool zero.
Thus the boom cylinder is prevented from
making a natural fall.

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 ［22. HYDRAULIC SYSTEM］

22

BOOM CIRCUIT : Boom down operation & Prevention of natural boom falling.

22-17
［22. HYDRAULIC SYSTEM］

22.8 SWING CIRCUIT 22.8.3 SWING MAIN CIRCUIT

(1) Operation:
This section describes the following operations. The oil delivered from the A2 port of the P2
(1) Swing left pilot circuit pump enters the P2 port of C/V (2) and is
(2) Swing auto parking brake branched off into the bypass line and the parallel
(3) Swing main circuit circuit. However, since the bypass line is closed
(4) Swing motor circuit as the swing spool is shifted, the oil pushes the
load check valve LCs open through the parallel
22.8.1 PILOT CIRCUIT FOR LEFT SWING circuit, enters the B port of the swing motor via
(1) Operation: the As port of C/V (2), and rotates the swing
motor counterclockwise.
1. When the left swing operation is performed, the
pilot proportional secondary pressure is delivered 22.8.4 SWING MOTOR CIRCUIT
through port (5) of left pilot V (9), and the (1) Anti cavitation circuit at swing deceleration
secondary pressure acts on PAs port of C/V (2), (2) Shockless relief valve that prevents the swing
and simultaneously flows out from Pss port of motor from being reversed.
C/V and acts on low pressure sensor (SE-5).
2. The voltage output by the low pressure sensor is
input in the mechatro controller, and is
signal-processed.
3. Then, the secondary pressure led into PAs port of
C/V (2) switches the swing spool.

22.8.2 SWING AUTO PARKING BRAKE

(1) Purpose:
Swing lock in neutral position and parking
(2) Principle:
Release mechanical brake only when required to
operate swing and arm in.
(3) Operation:

1. The swing parking system excites the swing

parking SOL (SV-1) usually if the key switch is
turned on and works by the action of the
mechanical brake.
2. The mechanical brake is released if the swing
parking solenoid is de-excited only when the
secondary operating pressure in the swing and
arm in actions acts upon any of the low
pressure sensors (SE-5, 7).
3. The swing parking solenoid (SV-1) is excited five
seconds after the pressure of the swing low
pressure sensors (SE-5) is reduced to zero. In
the case of arm in operation, the swing parking
solenoid (SV-1) is excited the moment the
pressure of the arm in low pressure sensor
(SE-7) is reduced to zero. This causes the
mechanical brake to operate.

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 ［22. HYDRAULIC SYSTEM］

22

SWING CIRCUIT : Swing operation (LH)

22-19
［22. HYDRAULIC SYSTEM］

22.9 ARM CIRCUIT section and travel right tandem path. Then
because arm 2 spool was switched, the delivery
This section describes the following operations. oil opens load check valve LCAT2, goes through
arm 2 spool, and confluences with P2 pump
(1) Arm in, light-load operating pilot circuit delivery oil in the valve section, and then is
(2) Arm in, light-load variable normal recirculation flowed into arm cylinder head (H) side through Aa
main circuit / internal conflux main circuit port of C/V (2).
3. The return oil from arm cylinder (R) side flows in
22.9.1 ARM IN, LIGHT-LOAD Ba port of C/V (2) and passes through the Ba
OPERATING PILOT CIRCUIT port because the arm lock valve CRa is open,
(1) Purpose: and is flowed into arm 2 spool through arm 1
Speed-up and Anticavitation when the arm is at spool.
light loaded. 4. Because arm 2 spool is switched to normal
(2) Principle: recirculation position, causing restriction of
The oil returning from the arm cylinder rod (R) is passage to tank, the return oil from arm cylinder
recirculated variably to the head (H) at arm 2 (R) side flows into arm cylinder (H) side.
spool in C/V. -Because, at light load, the pressure in cylinder
(3) Operation: rod (R) side is higher than that in the head (H)
side, it opens the check valve housed-in arm 2
1. When the arm in operation is performed, the spool and is recirculated in the head (H) side,
secondary pilot proportional pressure gets out of resulting in the speed up of arm-in operation at
port 7 of the left pilot valve (9) and acts upon the light load.
low pressure sensor (SE-7). 5. Cavitations prevention control in arm-in operation
At the same time, the pressure is branched off Command current is output to arm 2 solenoid
in two flows, acts upon the PAa1 port and the proportional valve by signal processing of E/G
PLc2 port, changes over the arm spool and the speed and arm-in pilot pressure, accordingly the
arm lock valve CRa. releases. arm 2 spool is switched to neutral (cavitations
2. The output voltage by the low pressure sensor is prevention) position, resulting in cavitations
input into mechatro controller, and is pilot prevention.
signal-processed, and is output to P1, P2 pump
proportional valve (PSV-P1), (PSV-P2) and arm 2 Position of arm 2 spool
inverse proportional valve (PSV-A).
3. The secondary pressure from pilot proportional
valve, which is reduced by arm 2 inverse
proportional valve (PSV-A) switches arm 2 spool.

22.9.2 ARM-IN, LIGHT-LOAD VARIABLE

NORMAL RECIRCULATION,
INTERNAL CONFLUX MAIN CIRCUIT
(1) Operation:
Reference:
1. The P2 pump delivery oil flows in travel left In light-load arm-in operation (normal recirculation,
section through P2 port of C/V (2) and is conflux), when the attachment to which the circuit in
branched off in by-pass circuit and parallel P1 pump side is applied is operated, the meter-in
circuit, but because arm 1 spool is switched, the path of arm 2 spool is closed, resulting in single flow
delivery oil which goes through parallel circuit operation.
opens load check valve LCa and is flowed into
arm 1 spool.
2. On the other hand, P1 pump delivery oil flows in
P1 port of C/V (2), and the flows in travel straight

22-20
 ［22. HYDRAULIC SYSTEM］

22

ARM CIRCUIT : Arm in (Light load) operation, Arm variable recirculation & Anti cavitation function

22-21
［22. HYDRAULIC SYSTEM］

This section describes the following operations. valve, but because the arm lock valve is open,
the return oil goes through arm lock valve CRa
(3) Arm in, heavy load operating pilot circuit and flows in arm 2 spool.
(recirculation cut) 4. The return oil returns directly into tank circuit
(4) Arm in, heavy load operating sequence confluxed because arm 2 spool is switched to recirculation
main circuit cut position.

22.9.3 ARM IN, HEAVY LOAD Position of arm 2 spool

OPERATING PILOT CIRCUIT
(1) Operation:

1. In arm-in operation, when the heavy loading is

applied to arm and the P2 pump pressure
increases to the set pressure, the voltage output
by P2 pump pressure sensor (SE-23) is converted
to signal (signal processing) by mechatro
controller, consequently the current of arm 2
solenoid proportional valve is controlled according
to the load pressure and the arm variable
recirculation is cut.
When the recirculation is cut, internal confluence
is held similarly to that in light load operation.
2. Left pilot valve actuation due to arm-in operation
is equivalent to that at light load operation.

22.9.4 ARM IN, HEAVY LOAD

OPERATING RECIRCULATION CUT
MAIN CIRCUIT
(1) Purpose:
Power up for arm in operation
(2) Principle:
Cut the recirculation and reduce rod pressure.
(3) Operation:

1. P2 pump delivery oil flows in the travel left

section through P2 port of C/V (2) and branched
off in by-pass circuit and parallel circuit.
Consequently the arm spool is switched and
pushes and opens load check valve LCa through
parallel circuit, and flows in the arm spool.
2. On the other hand, P1 pump delivery oil flows in
P1 port of C/V (2), and flow in travel right
tandem passage through travel straight section.
Then because arm 2 spool was switched, the
delivery oil opens load check valve LCAT2, and
confluences with P2 pump delivery oil in the valve
section, and is flowed into arm cylinder head (H)
side through Aa port of C/V(2).
3. The return oil from arm cylinder (R) side flows in
Ba port of C/V(2) and is flowed to arm lock

22-22
 ［22. HYDRAULIC SYSTEM］

22

ARM CIRCUIT : Arm in (Heavy load) operation, Arm confluence & recirculation cut function

22-23
［22. HYDRAULIC SYSTEM］

This section describes the following operations. weight of the arm and bucket.
(5) Arm out pilot circuit (2) Principle:
(6) Arm out 2 pumps conflux main circuit Complete seat of the return circuit against the
(7) Natural fall protection with arm lock valve arm spool of the arm cylinder (R) side circuit.
(3) Operation:
22.9.5 ARM OUT PILOT CIRCUIT
(1) Operation: 1. When the secondary pressure for arm operation
disappears and the arm cylinder stops, the
1. When the arm out operation is performed, the pressure on the rod (R) side passes through the
secondary pilot proportional pressure gets out of selector of the lock valve from the Ba port of C/V
port 8 of the left pilot valve (9), and acts upon (2), acts the back pressure on the lock valve CRa
the low pressure sensor (SE-8). At the same and seats the lock valve.
time, the oil is branched off in two flows and act 2. Since the oil flow into the arm spool from the
upon the PBa1 and PBa2 ports of C/V (2). lock valve is shut off completely, natural fall of
2. The operating proportional secondary pressure the arm due to oil leaks through the arm spool is
flowed in Pba1 port of C/V (2) switches the arm prevented.
1 spool.
3. Then, the operating secondary pressure flowed in
PBa2 port of C/V (2) switches the arm 2 spool
valve.

22.9.6 ARM OUT 2 PUMPS CONFLUX

MAIN CIRCUIT
(1) Purpose:
Arm out operation speed up.
(2) Principle:
The oil delivered by the P1 pump is confluxed
with that delivered by the P2 pump in C/V (2).
(3) Operation:

1. P1 pump delivery oil opens load check valve

(LCAT2) by switching arm 2 spool and confluxes
with P2 pump delivery oil just short of the arm
lock valve.
2. And, P2 pump delivery oil flows through arm 1
spool and confluences with P1 delivery oil,
opens lock valve of arm lock valve CRa with
free flow and is flowed into arm cylinder rod (R)
side through Ba port of C/V(2).
3. On the other hand, the return oil from arm
cylinder (H) side flows in Aa port, and returns into
tank circuit through arm 1 spool and arm 2 spool.
The return line which does not pass through
boost check valve is used for this return circuit
to reduce the pressure loss.

22.9.7 NATURAL FALL PROTECTION

WITH ARM LOCK VALVE
(1) Purpose:
To prevent the arm from falling naturally by the

22-24
 ［22. HYDRAULIC SYSTEM］

22

ARM CIRCUIT : Arm out operation, Confluence function

22-25
［22. HYDRAULIC SYSTEM］

22.10 COMBINED CIRCUIT P2 pump flows in left travel spool to travel

leftward.
This section describes only the difference in combined The delivery oil flowed into travel straight spool of
operation. P2 pump flows in right travel spool because the
travel straight spool is shifted and exerts on the
(1) Boom up / travel, pilot circuit right travel operation.
(2) Boom up / travel, main circit (In travel straight operation, P2 pump delivery oil
exerts on travel operation.)
22.10.1 BOOM UP / TRAVEL, PILOT 4. However, a portion of the flow is led to the
CIRCUIT travel straight spool notch restriction. The speed
(1) Operation: of attachments like travel, boom, etc. is adjusted
<Operation: Different point of pilot circuit from by the circuit of restriction.
independent operation >

1. The mechatro controller outputs command current

to travel straight solenoid proportional valve
(PSV-C) after signal processing, and the solenoid
valve outputs secondary pressure and acts on
PTb port of C/V (2).
2. Then the pressure of PTb port switches the travel
straight valve.

22.10.2 BOOM UP / TRAVEL, MAIN

CIRCUIT
(1) Purpose:
To insure straight travel movement during travel
operation even if the attachment is operated.
(2) Principle:
The travel action and the attachment action are
actuated by separate pumps.
(3) Operation:

1. P1 pump delivery oil flows through P1 port of

C/V(2) and branches off in P1 parallel circuit and
travel straight spool.
P2 pump delivery oil flows through P2 port of
C/V(2) and branches off in P2 tandem circuit
and travel straight spool.
2. The delivery oil flowed into P1 parallel circuit of
P1 pump opens check valve CT1 and LCb and
flows in boom spool, which exerts on boom up
operation.
The delivery oil flowed into travel straight spool of
P1 pump opens check valve CT2 because the
travel straight spool is shifted, and flows in boom
conflux spool and exerts on boom up operation
with the internal oil conflux.
(In travel straight operation, P1 pump delivery oil
exerts on swing operation of attachment.)
3. The delivery oil flowed into P2 tandem circuit of

22-26
 ［22. HYDRAULIC SYSTEM］

22

COMBINED CIRCUIT : Boom up & Travel forward 1st speed operation, Travel straight function.

22-27
［22. HYDRAULIC SYSTEM］

In this section, the independent operation is omitted This operation is called "Swing Priority Circuit".
and describes difference in combined operation.
(3) Swing / Arm in light load, pilot circuit Position of arm 2 spool
(4) Swing / Arm in, swing priority main circuit

22.10.3 SWING / ARM IN LIGHT LOAD,

PILOT CIRCUIT
(1) Operation:

1. On operating swing (left) and arm in motions

simultaneously, mechatro controller outputs
command current to travel straight solenoid
proportional valve (PSV-C) and arm 2 solenoid
inverse proportional valve (PSV-A) according to
signal processing, and this proportional valve
outputs secondary pressure, which acts on PTb
port and PAa2 port of C/V(2).
2. PTb port pressure switches the travel straight
spool 2 steps, and the PAa2 port pressure
switches the arm 2 spool to the forced
recirculation position.

22.10.4 SWING / ARM IN, SWING

PRIORITY MAIN CIRCUIT
(1) Purpose:
Stable swing speed.
(2) Principle:
Raise the oil pressure flowing to arm cylinder,
and give a priority of the delivery of P2 pump to
swing operation.
(3) Operation:

1. The swing main circuit operates with P2 pump

flow. But on P2 pump circuit side, the flow goes
to the swing circuit and arm circuit
simultaneously because the swing circuit and
arm circuit are parallel. Then since the return oil
from arm cylinder rod (R) side is restricted in the
arm 2 spool because the arm 2 spool is switched
to forced recirculation position, the pressure of
return oil is raised, causing the rise of circuit
pressure on the arm cylinder head (H) side.
2. At the same time meter-in of arm 2 spool closes
and arm in conflux is therefore cancelled, and
delivery oil from P2 pump and P1 pump are
combined in the parallel circuit on P2 pump side
because the travel straight spool was switched.
The conflux oil of P1 and P2 delivery oil in high
pressure flows in swing side taking priority over
all others.

22-28
 ［22. HYDRAULIC SYSTEM］

22

COMBINED CIRCUIT : Swing / Arm in operation, swing priority function

22-29
［22. HYDRAULIC SYSTEM］

22.11 PRESSURE DRAINING 2. Unloading proportional valves (PSV-D, PSV-B)

output secondary pressure and the secondary
This section describes the following operations. pressure flows in PCb, PCa ports of C/V(2) and
switches the P1, P2 unloading valves to OPEN
(1) Pressure drain (releasing) pilot circuit position.
(2) Pressure drain (releasing) main circuit
22.11.2 PRESSURE RELEASE MAIN
22.11.1 PRESSURE RELIEVING PILOT CIRCUIT
CIRCUIT
(1) Purpose:
To release the pressure in main circuit for piping
repair works. When the hydraulic pressure releasing is performed,
(2) Principle: make sure to place bucket on the ground.
After the mode is switched to "Pressure Relief
Mode" with switch on gauge cluster, mechatro (1) Operation:
controller outputs the following commands. When the operating lever is shifted to neutral
during engine running, "DRAINING HYD.
1. Minimum tilting command value to pump PRESS." is displayed on the gauge cluster while
proportional valve (PSV-P1, PSV-P2). the mode switch is changed to pressure relieving
2. Output "Pressure relief control speed command mode. In this time the intermittent buzzer sounds
value" at ECU. (Electric system) continuously. When right and left operating levers
3. Stand-by command value to P1, P2 unloading are operated 4 or 5 times to their full stroke,
proportional valves pressure is relieved.
After draining pressure is completed, turn off the
How to switch to "Pressure release mode" starter key and buzzer sound stops. If the pump
1. Select the service diagnosis mode. pressure is determined to be more than 1 MPa
(Keeping pressing of the "BUZZER STOP (145 psi) by the output value of the high pressure
SWITCH" on gauge cluster, turn the starter key sensor or the high pressure sensors (SE-22,23)
on.) are broken, "FAIL DRAIN HYD. PRESS" is
2. Select the service adjustment mode 1. displayed and the buzzer sounds continuously. In
(Under the condition that "Screen No.1" of that case, also the buzzer is not stopped unless
"Service diagnosis mode 1" is indicated, keeping the engine key is turned to OFF. Repeat the
pressing of the "BUZZER STOP SWITCH", press pressure releasing procedure once again.
the "SELECT SWITCH" 3 times. When (2) Hydraulics :
"LANGUAGE/LOGO", "ADJUSTING MODE 1" Unload spool is switched to open position, and
and "PRESET BY FACTORY" are displayed, the oil delivered by each pump is unloaded to the
press [▲] or [▼] switch, and highlight tank passage.
"ADJUSTING MODE 1", and then press "Selector If the spools are switched by pilot operation, the
Switch" again.) remaining pressure from the actuators may be
3. When "ADJUSTING MODE 1" screen is displayed, relieved to the tank circuit, i.e. the main circuit
press [▲] or [▼] switch, and "DRAIN HYD. pressure may be released.
OFF" screen appears.
4. Press "Selector Switch" and highlight "OFF", and
press [▲] switch to change to "DRAIN HYD. ON",
and then press "Selector Switch" again.

(3) Operation:

1. Pump proportional valve reduces the pump flow

rate to the minimum.

22-30
 ［22. HYDRAULIC SYSTEM］

22

PRESSURE DRAIN (RELEASE) CIRCUIT : At pressure release mode.

22-31
［22. HYDRAULIC SYSTEM］

22-32
 ［23. ELECTRICAL SYSTEM］

23. ELECTRICAL SYSTEM

TABLE OF CONTENTS

23.1 ELECTRIC CIRCUIT DIAGRAM ………………………………………………………………………………23-3

23.2 ELECTRICAL EQUIPMENT & HARNESS …………………………………………………………………23-10
23.3 HARNESS ………………………………………………………………………………………………………23-11
23.3.1 HARNESS LIST ……………………………………………………………………………………………23-11
23.3.2 INSTRUMENT PANEL ASSY ……………………………………………………………………………23-12
23.3.3 CONTROLLER INSTALL …………………………………………………………………………………23-13
23.3.4 OPERATOR'S CONTROL (SWITCH INSTALL) ………………………………………………………23-14
23.3.5 UPPER ELECTRIC ASSY ………………………………………………………………………………23-15
23.3.6 UPPER HARNESS ASSY ………………………………………………………………………………23-16
23.3.7 UPPER HARNESS ASSY (FLOOR) …………………………………………………………………23-33
23.3.8 ENGINE HARNESS ASSY ………………………………………………………………………………23-42
23.3.9 CAB INSTALL ………………………………………………………………………………………………23-42
23.3.10 WASHER TANK ASSY …………………………………………………………………………………23-44
23.3.11 CAB HARNESS ASSY …………………………………………………………………………………23-45
23.3.12 BOOM HARNESS ASSY ………………………………………………………………………………23-48
23.3.13 BOOM LIGHT INSTALL …………………………………………………………………………………23-48
23.3.14 UPPER LIGHT INSTALL ………………………………………………………………………………23-49
23.3.15 FLASHER LAMP INSTALL ……………………………………………………………………………23-50

23

Book Code No. S5YP2301E02

23-1
［23. ELECTRICAL SYSTEM］

Issue Date of Issue Applicable Machines Remarks

S5YP2301E01
First Edition July, 2009 SK140LC-8 : YP09-05001~
(SE Asia)
S5YP2301E02
SK140LC-8 : YP09-05001~
(SE Asia)
Revision January, 2010 SK130-8 : LP09-20001~
(NZL)
SK130L-8 : LX07-11001~
(Thailand)

23-2
 ［23. ELECTRICAL SYSTEM］

23.1 ELECTRIC CIRCUIT DIAGRAM

23

23-3
［23. ELECTRICAL SYSTEM］

23-4
［23. ELECTRICAL SYSTEM］

23

23-5
［23. ELECTRICAL SYSTEM］

23-6
［23. ELECTRICAL SYSTEM］

23

23-7
［23. ELECTRICAL SYSTEM］

23-8
［23. ELECTRICAL SYSTEM］

23

23-9
［23. ELECTRICAL SYSTEM］

23.2 ELECTRICAL EQUIPMENT &

HARNESS

23-10
 ［23. ELECTRICAL SYSTEM］

23.3 HARNESS

23.3.1 HARNESS LIST

23

23-11
［23. ELECTRICAL SYSTEM］

23.3.2 INSTRUMENT PANEL ASSY

23-12
 ［23. ELECTRICAL SYSTEM］

23.3.3 CONTROLLER INSTALL

23

23-13
［23. ELECTRICAL SYSTEM］

23.3.4 OPERATOR'S CONTROL (SWITCH

INSTALL)

23-14
 ［23. ELECTRICAL SYSTEM］

23.3.5 UPPER ELECTRIC ASSY

23

23-15
［23. ELECTRICAL SYSTEM］

23.3.6 UPPER HARNESS ASSY (1/6)

23-16
 ［23. ELECTRICAL SYSTEM］

23.3.6 UPPER HARNESS ASSY (2/6)

23

23-17
［23. ELECTRICAL SYSTEM］

23.3.6 UPPER HARNESS ASSY (3/6)

23-18
 ［23. ELECTRICAL SYSTEM］

23.3.6 UPPER HARNESS ASSY (4/6)

23

23-19
［23. ELECTRICAL SYSTEM］

23.3.6 UPPER HARNESS ASSY (5/6)

23-20
 ［23. ELECTRICAL SYSTEM］

23.3.6 UPPER HARNESS ASSY (6/6)

23

23-21
［23. ELECTRICAL SYSTEM］

23.3.6.1 UPPER HARNESS (1/8) : LP13E01029P3

23-22
 ［23. ELECTRICAL SYSTEM］

23.3.6.1 UPPER HARNESS (2/8) : LP13E01029P3

23

23-23
［23. ELECTRICAL SYSTEM］

23.3.6.1 UPPER HARNESS (3/8) : LP13E01029P3

23-24
 ［23. ELECTRICAL SYSTEM］

23.3.6.1 UPPER HARNESS (4/8) : LP13E01029P3

23

23-25
［23. ELECTRICAL SYSTEM］

23.3.6.1 UPPER HARNESS (5/8) : LP13E01029P3

23-26
 ［23. ELECTRICAL SYSTEM］

23.3.6.1 UPPER HARNESS (6/8) : LP13E01029P3

23

23-27
［23. ELECTRICAL SYSTEM］

23.3.6.1 UPPER HARNESS (7/8) : LP13E01029P3

23-28
 ［23. ELECTRICAL SYSTEM］

23.3.6.1 UPPER HARNESS (8/8) : LP13E01029P3

23

23-29
［23. ELECTRICAL SYSTEM］

23.3.6.2 BATTERY CABLE : YY13E01144P1

23-30
 ［23. ELECTRICAL SYSTEM］

23.3.6.6 ECU HARNESS(1/2) : LP13E01028P1

23

23-31
［23. ELECTRICAL SYSTEM］

23.3.6.6 ECU HARNESS(1/2) : LP13E01028P1

23.3.6.7 FLOOR GROUND CABLE : LE13E01006P1
23.3.6.8 HARNESS : LC13E01193P1

23-32
 ［23. ELECTRICAL SYSTEM］

23.3.7 UPPER HARNESS ASSY (FLOOR)

(1/3)

23

23-33
［23. ELECTRICAL SYSTEM］

23.3.7 UPPER HARNESS ASSY (FLOOR) (2/3)

23-34
 ［23. ELECTRICAL SYSTEM］

23.3.7 UPPER HARNESS ASSY (FLOOR) (3/3)

23

23-35
［23. ELECTRICAL SYSTEM］

23.3.7.1 FLOOR HARNESS (1/5) : LP13E01030P4

23-36
 ［23. ELECTRICAL SYSTEM］

23.3.7.1 FLOOR HARNESS (2/5) : LP13E01030P4

23

23-37
［23. ELECTRICAL SYSTEM］

23.3.7.1 FLOOR HARNESS (3/5) : LP13E01030P4

23-38
 ［23. ELECTRICAL SYSTEM］

23.3.7.1 FLOOR HARNESS (4/5) : LP13E01030P4

23

23-39
［23. ELECTRICAL SYSTEM］

23.3.7.1 FLOOR HARNESS (5/5) : LP13E01030P4

23-40
 ［23. ELECTRICAL SYSTEM］

23.3.7.3 FLOOR GROUNDING CABLE : LE13E01005P1

23.3.7.4 CAB SUB HARNESS: LC13E01186P1

23

23-41
［23. ELECTRICAL SYSTEM］

23.3.8 ENGINE HARNESS ASSY

23.3.8.4 ENGINE SUB CABLE : YY16E01010P1

23-42
 ［23. ELECTRICAL SYSTEM］

23.3.9 CAB INSTALL

23.3.9.1-1 CAB ASSY : YN02C00131F1

23

23-43
［23. ELECTRICAL SYSTEM］

23.3.9.1-49 HARNESS : YN02C03098P1

23.3.10 WASHER TANK ASSY

23-44
 ［23. ELECTRICAL SYSTEM］

23.3.11 CAB HARNESS ASSY

23

23-45
［23. ELECTRICAL SYSTEM］

23.3.11.1 CAB HARNESS (1/2) : YN14E01111P2

23-46
 ［23. ELECTRICAL SYSTEM］

23.3.11.1 CAB HARNESS (2/2) : YN14E01111P2

23.3.11.5 KEY SWITCH GROUND HARNESS :
YN14E01106P1

23

23-47
［23. ELECTRICAL SYSTEM］

23.3.12 BOOM HARNESS ASSY

23.3.12.1 BOOM HARNESS : YY15E01021P1
23.3.13 BOOM LIGHT INSTALL

23-48
 ［23. ELECTRICAL SYSTEM］

23.3.14 UPPER LIGHT INSTALL

23

23-49
［23. ELECTRICAL SYSTEM］

23.3.15 FLASHER LAMP INSTALL

23-50
 ［24. COMPONENTS SYSTEM］

24. COMPONENTS SYSTEM

TABLE OF CONTENTS

24.1 HYDRAULIC COMPONENTS …………………………………………………………………………………24-3

24.1.1 HYDRAULIC PUMP - REGULATOR……………………………………………………………………24-3
24.1.2 CONTROL VALVE …………………………………………………………………………………………24-22
24.1.3 PILOT VALVE (ATT)………………………………………………………………………………………24-59
24.1.4 PILOT VALVE (TRAVEL)…………………………………………………………………………………24-63
24.1.5 SWING MOTOR UNIT ……………………………………………………………………………………24-66
24.1.6 TRAVEL MOTOR …………………………………………………………………………………………24-78
24.1.7 TRAVEL MOTOR (FOR L SPEC.) ……………………………………………………………………24-89
24.1.8 SWIVEL JOINT ……………………………………………………………………………………………24-103
24.1.9 CYLINDER …………………………………………………………………………………………………24-105
24.2 ELECTRICAL EQUIPMENT ……………………………………………………………………………………24-111
24.2.1 ELECTRICAL EQUIPMENT LIST ………………………………………………………………………24-111
24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT ………………………………………………………24-114

24

Book Code No. S5YP2401E02

24-1
［24. COMPONENTS SYSTEM］

Issue Date of Issue Applicable Machines Remarks

S5YP2401E01
First Edition July, 2009 SK140LC-8 : YP09-05001~
(SE Asia)
S5YP2401E02
SK140LC-8 : YP09-05001~
(SE Asia)
Revision January, 2010 SK130-8 : LP09-20001~
(NZL)
SK130L-8 : LX07-11001~
(Thailand)

24-2
 ［24. COMPONENTS SYSTEM］

24.1 HYDRAULIC COMPONENTS

24.1.1 HYDRAULIC PUMP - REGULATOR

24.1.1.1 SUMMARY
(1) Outside view and Hydraulic port

24

Hydraulic pump - regulator

24-3
［24. COMPONENTS SYSTEM］

(2) Hydraulic circuit diagram

Hydraulic circuit diagram of pump

(3) Specifications

24-4
 ［24. COMPONENTS SYSTEM］

24.1.1.2 HYDRAULIC PUMP

24.1.1.2.1 CONSTRUCTION
(1) Main pump

24

24-5
［24. COMPONENTS SYSTEM］

(2) Gear pump (For pilot)

No. Parts Q'TY No. Parts Q'TY

307 Poppet 1 433 Flange socket; M8X40 2
308 Seat 1 434 Flange socket; M8X55 2
309 Ring 1 435 Flange socket; M8X20 4
310 Spring 1 466 VP plug ; PF1/4 1
311 Adjust screw 1 700 Ring 1
312 Lock nut ; M14X1.5 1 710 O-ring 1
351 Gear case 1 725 O-ring ; 1B P11 1
353 Drive gear 1 732 O-ring ; 1B P16 1
354 Driven gear 1 850 Locking ring 1
355 Filter 1 887 Pin 2
361 Front case 1

24-6
 ［24. COMPONENTS SYSTEM］

(3) PTO gear case (OPT.)

No. Parts Q'TY No. Parts Q'TY

115 Idle shaft 1 435 Flange socket; M10X20 4
117 2nd gear 1 468 VP plug; PF3/4 1
118 3rd gear 1 710 O-ring; 1B G80 1
125 Ball bearing 2 711 O-ring; 1B G85 1
126 Roller bearing 1 728 O-ring; 1B P24 1
128 Bearing spacer 2 825 Snap ring 1
262 Cover 2 826 Snap ring 1
326 Gear case 1 885 Sprig pin 1
414 Capscrew; M10X20 4 886 Pin 2

24

24-7
［24. COMPONENTS SYSTEM］

24.1.1.2.2 OPERATION
The pump assy is equipped with two pumps
arranged on the same axis that are connected
with gear (116) and distribute the rotating power
to the gear trains on a different axis. Thus the
engine rotation is transmitted to front shaft (111)
that drives the two pumps and, at the same
time, drives the auxiliary pump (OPT) arranged
on another shaft.
The pump assy consists largely of the rotary
group, the main part of the pump that makes
rotary on; the swash plate group that changes
the delivery rate; the valve block group that
selects between oil suction and delivery and the
PTO group (OPT) that transmits the drive power
to the auxiliary pump.

Construction of hydraulic pump

(1) Rotary group

The rotary group consists of shaft(111) (113), cylinder block (141), piston (151), shoe (152), plate
(153), spherical bushing (156), bearing spacer (127), and cylinder spring (157).
The shaft is supported by bearings (123) and (124) at its both ends. The shoe, which is caulked to
the piston, forms a spherical joint and relieves it of thrust force that is generated by load pressure.
Further, the piston is provided with a pocket so it moves lightly on shoe plate (211), taking hydraulic
balance.
The sub group of the piston-shoe is pressed against the shoe plate by the cylinder spring, via the
retainer plate and the spherical bushing, so that it moves smoothly over the shoe plate. The cylinder
block (141) is also pressed against valve plate (314) by the action of cylinder spring (157).

Rotary group

24-8
 ［24. COMPONENTS SYSTEM］

(2) Swash plate group

The swash plate group consists of swash plate
(212), shoe plate (211), swash plate support
(251), lock pin (255), set spring (256), tilting
bushing (214), tilting pin (531), and servo piston
(532). The swash plate is the cylindrical part
that is formed on the opposite side of the
shoe sliding surface and is supported by the
swash plate support.
The hydraulic force controlled by the regulator
flows into the hydraulic chamber that is
provided on both sides of the servo piston. This
moves the servo piston to the right and left.
The result is that the swash plate swings on Swash plate group
the swash plate support via the spherical part
of the tilting pin and changes the tilting angle
(a).

(3) Valve block group

The valve block group consists of valve block
(312), valve plates (313 or 314), and spring
pin (886). The valve plates having two
crescent-shaped ports are installed to valve
block (312) to feed oil and recycle it from
cylinder block (141). The oil switched over by
the valve plate is connected with the external
pipe by way of the valve block.

Valve block group

24

24-9
［24. COMPONENTS SYSTEM］

(4) PTO group (OPT)

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

24-10
 ［24. COMPONENTS SYSTEM］

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24

24-11
［24. COMPONENTS SYSTEM］

24.1.1.3 REGULATOR
24.1.1.3.1 CONSTRUCTION

24-12
 ［24. COMPONENTS SYSTEM］

24

24-13
［24. COMPONENTS SYSTEM］

24.1.1.3.2 OPERATION
(1) Control function
Control function ...... Electric flow control.
-Positive flow control.

(2) Summary
The regulator KR76-0E13-V for the in-line type axial piston pump K7V series is composed of the
control mechanism as mentioned below:

1. Electric flow control and positive flow control

The tilting angle of the pump (delivery rate) is controlled by controlling the current command
value of the solenoid proportional reducing valve attached to the regulator. The regulator makes
positive flow control (positive control) that increases the delivery rate as the secondary pressure
of the solenoid proportional reducing valve rises. Since this function permits the output power of
the pump to be varied, it is possible to attain optimum power according to the operating
condition. Also, since the pump delivers only the necessary oil flow, the machine does not
consume excessive power.

24-14
 ［24. COMPONENTS SYSTEM］

(3) Explanation of operation

1. 1. Flow rate electrical control
The pump delivery rate is controlled
according to the command current value
corresponding to the movement of control
devices. This relation is shown in right
figure.
2. Flow increasing action
As the command current I rises, the
secondary pressure of solenoid
proportional reducing valve (079) increases.
This causes spool (652) to move via pilot
piston (643) and stops where the hydraulic
pressure pushing the spool rightwards
balances with the action of pilot spring
(646).

If the spool (652) moves, port CL opens to the tank port. This causes the pressure of the large
diameter part of servo piston (532) to go away. This causes the servo piston (532) to the left by
delivery pressure P1 of the small diameter part, resulting in an increase in the tilting angle.
Feedback lever(611) is linked with the servo piston and sleeve(651). As the servo piston moves to
the left, the feedback lever rotates on point A which causes the sleeve to the right. As the servo
piston moves to the right, the feedback lever rotates on point A to move the sleeve to the right. The
result is that the opening of the spool sleeve begins to close gradually and the servo piston settles
down when the opening of the spool sleeve closes completely.

3. Flow decrease function

As the command current I decreases, the secondary pressure of the solenoid proportional valve
decreases. This causes the spool to move to the left.
When the spool(652) has moved, delivery pressure P1 reaches port CL via spool and is admitted
to the large diameter chamber of the servo piston. Delivery pressure P1 is admitted to the small
diameter part of the servo piston at all times. The servo piston moves rightward by areal
difference to decrease tilting angle. As the servo piston moves to the right, the feedback lever
rotates on point A to move the sleeve to the left. The sleeve keeps moving till the opening of
the spool sleeve closes and settles down when the spool sleeve closes completely.

24

24-15
［24. COMPONENTS SYSTEM］

Regulator operation

24-16
 ［24. COMPONENTS SYSTEM］

24.1.1.3.3 ADJUSTING THE REGULATOR

The regulator may be adjusted in terms of maximum flow, minimum flow, horsepower (at emergency
mode control) control characteristics, flow control characteristics using the adjust screw.

(1) Adjusting the maximum flow (See Fig. "24.1.1.2 HYDRAULIC PUMP")
Adjust the maximum flow by loosening nut (808) and by tightening set screw (954) (or loosening it).
Tightening set screw (954) decreases the delivery rate, as indicated in right Fig.
Only the maximum flow varies, but other control characteristics remain unchanged.

Adjusting the max. delivery flow

(2) Adjusting the minimum flow (See Fig. "24.1.1.2 HYDRAULIC PUMP")
Adjust the minimum flow by loosening nut (808) and by tightening socket screw (953) (or loosening
it). Tightening socket screw increases the delivery rate, as indicated in right Fig.
Other control characteristics remain unchanged in the same way as maximum flow adjustment, care
should be used of the fact that overtightening may increase a required power at the maximum
delivery pressure (at relieving action).

Adjusting the min. delivery flow

24

24-17
［24. COMPONENTS SYSTEM］

(3) Adjusting the flow control characteristics (See Fig. "24.1.1.3 REGULATOR")
Adjust them by loosening nut (801) and socket bolt (924) (or loosening it). Socket bolt causes the
control chart to move to the right as shown in right Fig.

Adjusting the flow control characteristics

24-18
 ［24. COMPONENTS SYSTEM］

24.1.1.3.4CAUSES OF FAULT RESULTING FROM REGULATOR

When trouble due to this regulator occurs, disassemble and inspect it referring to "Chapter UPPER
STRUCTURE"

(1) When the engine is overloaded,

Load every unit of pump, and check on pumps on the right and left sides for possible damages. When
pumps on both sides are failed, check on them for the following failures 1), 2). When pump on the
one side is failed, start checking from para. 3).

1. Check that the power shift command current I is normal.

2. The power shift pressure is high.
-Check the dither of amp.
-Replace solenoid proportional reducing valve.
3. Stick of spool (652) and sleeve (651)
-Disassemble and clean it.
4. Stick of pilot piston (643)
-Disassemble and clean it.

(2) The max. flow rate is not delivered.

1. Check that secondary pressure of solenoid proportional reducing valve is normal.
2. Stick of pilot piston (643)
-Disassemble and clean it.
3. Stick of spool (652) and sleeve (651)
-Disassemble and clean it.

Note : When the damage of part is severe, replace the part with new one.

24

24-19
［24. COMPONENTS SYSTEM］

24.1.1.4 CONTROL CURVE OF PUMP

24-20
 ［24. COMPONENTS SYSTEM］

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24

24-21
［24. COMPONENTS SYSTEM］

24.1.2 CONTROL VALVE

24.1.2.1 SPECIFICATIONS
24.1.2.1.1 OUTSIDE VIEW

Outside view

24-22
 ［24. COMPONENTS SYSTEM］

24.1.2.1.2 PORTS
Port size Tightening torque Ports Description
PF3/4 150~180 N-m (111~133 lbf-ft) (MU1), (MU2) Pluged
T3
Ar Right travel motor port (forward)
Br Right travel motor port (reverse)
AL Left travel motor port (forward)
BL Left travel motor port (reverse)
As Swing motor port (right)
Bs Swing motor port (left)
Ab Boom cylinder head side port (up)
Bb Boom cylinder rod side port (down)
Aa Arm cylinder head side port (in)
Ba Arm cylinder rod side port (out)
Ac Bucket cylinder head side port (digging)
Bc Bucket cylinder rod side port (dump)
Ao Optional pilot port
Bo Optional pilot port
PF1/2 98~120 N-m (72~89 lbf-ft) (P3), (P5) Pluged
(P4), (P6) Pluged
PF3/8 69~78 N-m (51~58 lbf-ft) PAa1 Arm 1 (in) pilot port
PBa1 Arm 1 (out) pilot port
PAb Boom (up) pilot port
PBb Boom (down) pilot port
PAc Bucket (digging) pilot port
PBc Bucket (dump) pilot port
PAL Travel left (forward) pilot port
PBL Travel left (reverse) pilot port
PAr Travel right (forward) pilot port
PBr Travel right (reverse) pilot port
PAs Swing (right) pilot port
PBs Swing (left) pilot port
PAa2 Arm 2 (in) pilot port
PBa2 Arm 2 (out) pilot port
PAo Option pilot port
PBo Option pilot port
DR Drain port
PF1/4 34~39 N-m (25~29 lbf-ft) Pss Swing pilot high pressure select port
PLc2 Lock valve select pilot port
PBp1 Bypass cut valve (P1 side) pilot port
PBp2 Bypass cut valve (P2 side) pilot port
(PL)
PB1 Boom (up) conflux pilot port
PTb Travel straight pilot port
PCa Unload valve (P2 side) pilot port
PCb Unload valve (P1 side) pilot port 24
M10 49~65 N-m (36~48 lbf-ft) P1 Pump port (P1 side)
P2 Pump port (P2 side)
M12 83~110N-m (61~81 lbf-ft) T1 Tank port 1
T2 Tank port 2

24-23
［24. COMPONENTS SYSTEM］

24.1.2.1.3SPECIFICATIONS
Item Specifications
Model KMX13YD/B44004
Maximum flow rate [L/min (gal/min)] 130 (34) X 2
Maximum set pressure [MPa (psi)] 37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)
Main relief valve set pressure [MPa (psi)] Std 34.3 (4970) [at 30 X 2L/min (8 X 2gal/min)]
Overload relief valve set pressure [MPa (psi)] 37.8 (5480) [at 30L/min (8gal/min)]

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 ［24. COMPONENTS SYSTEM］

24.1.2.2 CONSTRUCTION AND OPERATION

24.1.2.2.1 CONSTRUCTION
(1) Control valve

24

Section (1/6)

24-25
［24. COMPONENTS SYSTEM］

Section (2/6)

24-26
 ［24. COMPONENTS SYSTEM］

24

Section (3/6)

24-27
［24. COMPONENTS SYSTEM］

Section (4/6)

24-28
 ［24. COMPONENTS SYSTEM］

24

Section (5/6)

24-29
［24. COMPONENTS SYSTEM］

Section (6/6)

24-30
 ［24. COMPONENTS SYSTEM］

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
101 Casing A 1 309 P1 unload spool 1
102 Casing B 1 310 P2 unload spool 1
25~29 (18~21) 153 Plug 1 311 Option spool 1
220~250 (162~184) 154 Plug PF3/4 2 319 Spring 2
110~130 (81~96) 155 Plug PF1/2 4 320 Spring 2
13~17 (9.6~13) 156 Plug PF1/8 1 321 Spring 5
20~24 (15~18) 157 Plug PF1/4 MEC 1 322 Spring 4
34~39 (25~29) 159 Plug PT1/4 1 325 Spring 6
7.8~9.8 (5.8~7.2) 160 Plug PT1/16 MEC 5 326 Spring 1
161 O-ring : 1B G30 13 327 Spring 2
162 O-ring : 1B G25 6 328 Spring 3
163 O-ring : 1B P18 4 329 Spring 1
164 O-ring : 1B P15 4 330 Spring 1
166 O-ring : 1B P10 7 331 Spring seat 24
167 O-ring : 1B P8 1 16~18 (11.8~13.3)
333 Spacer bolt 12
168 O-ring : 1B P11 1 Loctite #262

201 Cover 6 336 Stopper 6

202 Cover 4 337 Stopper 1
203 Cover 1 339 Stopper 5
204 Sub cover 1 511 Poppet 11
205 Cover 7 512 Poppet 2
206 Cover 1 514 Poppet 2
207 Back pressure check valve cover 1 515 Poppet 1
9.8~14 (7.2~10.3) 211 Lock valve selector sub 2 517 Poppet 1
212 Plate 1 518 Poppet 1
213 Plate 1 521 Spring 11
261 O-ring 12 522 Spring 2
264 O-ring : 1B G35 8 524 Spring 3
266 O-ring : 1B P7 4 527 Spring 1
267 O-ring : 1B 32 2 528 Spring 1
25~34 (18~25) 273 Socket bolt 40 130~150 (96~111) 551 Plug 12
98~120 (72~89) 274 Socket bolt 4 130~150 (96~111) 556 Plug 5
98~120 (72~89) 275 Socket bolt 4 561 O-ring : 1B P20 17
9.8~14 (7.2~10.3) 278 Socket bolt 5 567 O-ring : 1B P24 2
301 Boom spool assy 1 69~78 (51~58) 601 Main relief valve 1
302 Arm 1 spool 1 69~78 (51~58) 602 Port relief valve 5 24
303 Swing spool 1 69~78 (51~58) 604 Relief valve plug assy 2
304 Bucket spool 1 98~120 (72~89) 605 Bypass cut valve 2
305 Boom conflux spool 1 69~78 (51~58) 606 Port relief valve 1
306 Travel spool 2 140~180 (103~133) 973 Socket bolt 9
307 Travel straight spool 1 977 Name plate 1
308 Arm 2 spool assy 1 978 Rivet 2

24-31
［24. COMPONENTS SYSTEM］

(2) Main relief valve (601)

Main relief valve

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
69~78 (51~58) 103 Plug ; M27 1 541 Seat 1
121 C-ring 1 561 O-ring 1
122 Spacer 1 562 Back up ring 1
123 C-ring 1 611 Poppet 1
124 Filter stopper 1 612 Spring seat 1
125 Filter 1 621 Spring 1
163 O-ring 1 651 Adjust screw 1
512 Plunger 1 661 O-ring 1
521 Spring 1 28~31 (21~23) 671 Lock nut ; M14 1

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 ［24. COMPONENTS SYSTEM］

(3) Over load relief valve (602,606)

Over load relief valve

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
69 to 78 (51 to 58) 101 Body; M27 1 541 Seat 1
69 to 78 (51 to 58) 102 Plug; M27 1 561 O-ring 1
161 O-ring 1 562 Backup ring 1
162 O-ring 1 563 O-ring 1
123 C-ring 1 564 Backup ring 1
124 Filter stopper 1 611 Poppet 1
125 Filter 1 612 Spring seat 1
301 Piston 1 621 Spring 1
511 Plunger 1 651 Adjust screw 1
521 Spring 1 661 O-ring 1
522 Spring 1 28 to 31 (21 to 23) 671 Lock nut; M14 1

24

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［24. COMPONENTS SYSTEM］

(4) Arm 2 spool (308)

Arm 2 spool

Tightening
Tightening torque
torque No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft)
N-m (lbf-ft)
308 Spool 1 18~20 (13~15) Loctite #638 350 Plug 1
317 Plunger 2 18~20 (13~15) Loctite #638 351 Plug 1
340 Spring 2 361 O-ring 2
371 Buckup ring 2

(5) Boom spool (301)

Boom spool

Tightening
Tightening torque
torque No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft)
N-m (lbf-ft)
301 Spool 1 18~20 (13~15) Loctite #638 350 Plug 1
317 Plunger 1 361 O-ring 1
340 Spring 1 371 Buckup ring 1

24-34
 ［24. COMPONENTS SYSTEM］

(6) Lock valve selector (211)

Lock valve selector

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
101 Casing 1 10 to 14 (7.4 to 10.3) 171 Socket bolt 3
161 O-ring 4 49 to 59 (36 to 44) 201 Plug 1
164 O-ring 1 321 Spring 1
166 O-ring 1 511 Spool 1
167 O-ring 1 541 Sleeve 1

24

24-35
［24. COMPONENTS SYSTEM］

(7) Bypass cut valve (605)

Bypass cut valve

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
98 to 120 (72 to 89) 101 Plug 1 301 Plunger 1
102 O-ring 1 302 Spring 1
201 Poppet 1 69 to 78 (51 to 58) 401 Plug 1
202 Spring 1 402 O-ring 1

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 ［24. COMPONENTS SYSTEM］

(8) Swing shuttle valve cover (204)

Swing shuttle valve cover

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
166 O-ring 1 542 Seat 1
202 Cover 1 25 to 29 (18 to 21) 554 Plug 1
541 Steel ball 1 7.9 to 9.8 (5.9 to 7.2) 555 Plug 1

24

24-37
［24. COMPONENTS SYSTEM］

24.1.2.2.2 HYDRAULIC CIRCUIT DIAGRAM

Hydraulic circuit diagram

24-38
 ［24. COMPONENTS SYSTEM］

24.1.2.2.3 OPERATION
(1) In neutral position
The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through
unloading valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the
hydraulic tank through tank port T1. And when the operation of unloading valve is impossible due to
failure of electric control system, because the by-pass cut valve (605) located on the downstream of
center by-pass passage (52) opens, the hydraulic oil through hydraulic pump P1 port passes through
travel straight spool (307), and then flows though the center by-pass passage (52) which passes
through travel right, boom, bucket and arm 2 and the by-pass cut valve (605) on P1 side, and flows
into low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank
through tank port T1.
The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low
pressure circuit (D) and boost check valve (517) and returns to the hydraulic tank through tank port T1
similarly to the hydraulic oil from hydraulic pump P1. And when the operation of unloading valve is
impossible, because the by-pass cut valve (605) located on the downstream of center by-pass passage
(55) opens, the hydraulic oil through hydraulic pump P2 port passes through main passage, and then
flows though the center by-pass passage (55) which passes through travel left, swing, arm 1 and
option and the by-pass cut valve (605) on P2 side, and flows into low pressure circuit (D) and boost
check valve (517), and then returns to the hydraulic tank through tank port T1.

In neutral position

24

24-39
［24. COMPONENTS SYSTEM］

(2) Actuation in travel operation

1. In travel independent operation
On starting travel operation (forward) started, the hydraulic oil delivered by hydraulic pump P1 is fed
into travel right motor, and the hydraulic oil delivered by hydraulic pump P2 is fed into travel left
motor. The pilot pressure enters ports PAr and PAL, and the right and left travel spools (306) move
rightward the force of springs (325)(327) and the secondary pressure of solenoid proportional valves
[X1] and [X2] acts on ports PCb and PCa and switches unloading spools (309) (310).
The hydraulic oil delivered by hydraulic pump P1 passes through travel straight spool (307) and flows
into main circuit, and flows through between the perimeter of right travel spool (306) and casing and is
fed into A side of right travel motor through port Ar. The hydraulic oil delivered by hydraulic pump P2
flows through between the perimeter of left travel spool (306) and casing and is fed into A side of
left travel motor through port Ar similarly to the stream of hydraulic oil delivered by hydraulic pump P1.
But in the meantime, the return oil from the B sides of left and right travel operations passes through
between the perimeter of right and left travel spools (306) and casing through ports Br and BL and
flows into low pressure circuit (D), boost check valve (517), and then returns to the hydraulic tank
through tank port T1. On traveling reverse (at the time when the pilot pressure actuates on ports PBr
and PBL of control valve), the actuation is similar to that in forward travel operation.

In left reverse travel (at PBL is pressurized)

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 ［24. COMPONENTS SYSTEM］

2. In travel straight operation

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

Movement of travel straight spool

24

24-41
［24. COMPONENTS SYSTEM］

(3) Actuation in bucket operation

1. In bucket digging operation
On starting bucket digging operation, the pilot pressure enters port PAc, bucket spool (304) moves
leftward the force of springs (319)(320), and simultaneously the secondary pressure of solenoid
proportional valve [XI] acts on port PCb and switches unloading spool (309).
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens
load check valve LCc (511), and flows through between the perimeter of bucket spool (304) and
casing through U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ac).
In the meantime, the return oil from bucket cylinder rod side (R) passes through between the perimeter
of bucket spool (304) and casing, flows through low pressure circuit (D) and boost check valve (517),
and returns to the hydraulic tank through tank port T1.

In bucket digging operation

24-42
 ［24. COMPONENTS SYSTEM］

2. In bucket dumping operation

On starting bucket dumping operation, the pilot pressure enters port PBc and bucket spool (304)
moves rightward the force of springs (319)(320), and simultaneously the secondary pressure of solenoid
proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered
by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc
(511), and flows through between the perimeter of bucket spool (304) and casing through U-shaped
passage, and supplied to bucket cylinder rod side (R) through port (Bc).
In the meantime, the return oil from bucket cylinder head side (H) passes through between the
perimeter of bucket spool (304) and casing and flows through low pressure circuit (D'), boost check
valve (517) and returns to the hydraulic tank through tank port T1.

In bucket dumping operation

24

24-43
［24. COMPONENTS SYSTEM］

(4) Boom
1. In boom up operation
On starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves
rightward against the force of springs (319) (320), and simultaneously the secondary pressure of
solenoid proportional valve [XI] acts on port PCa and switches unloading spool (309).
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens
load check valve LCb (511), and flows through between the perimeter of boom spool (301) and
casing through U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ab).
In the meantime, the return oil from boom cylinder rod side (R) passes through between the perimeter
of boom spool (301) and casing, flows through low pressure circuit (D) and boost check valve (517),
and returns to the hydraulic tank through tank port T1.

In boom up operation (Boom spool)

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 ［24. COMPONENTS SYSTEM］

2. In boom up conflux operation

When boom up operation is performed, the pilot pressure also enters port PB1, and boom conflux
spool (305) is switched by pressure which counters against the force of springs (321) (322).
Simultaneously, secondary pressre of solenoid proportional valve [X2] acts on port PCa and switcheds
unload spool (310).
The hydraulic oil delivered by hydraulic pump P2 passes through travel left spool and enters parallel
passage (56), and pushes and opens load check valve CP2, and flows through between the perimeter
of boom conflux spool (305) and casing from the A side of U-shaped passage, and pushes and opens
conflux check valve CCb (511) and enters port Ab through conflux passage inside of casing and
confluents the hydraulic oil from the hydraulic pump P1 side.

In boom up conflux operation (Boom conflux spool)

24

24-45
［24. COMPONENTS SYSTEM］

3. In boom down operation

On starting boom down operation, the pilot pressure enters port PBb and boom spool (301) moves
leftward against the force of springs (319) (320) and the secondary pressure of solenoid proportional
valve [X1] acts on PCb and switches unloading spool (309). And simultaneously the spool of lock
valve selector (211) is switched, and the poppet (514) is released because the spring chamber of
lock valve poppet CRb (514) is connected to the drain circuit.
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), and pushes and
opens load check valve LCb (511), and flows through between the perimeter of boom spool (301)
and casing through U-shaped passage, and is supplied to boom cylinder rod side (R) through port (Bb).
In the meantime, the return oil from boom cylinder head side (H) enters the control valve through port
(Ab). Because the retention of lock valve poppet CRb (514) which is located on this side of boom
spool (301) is released, the lock valve poppet (514) pushes and opens. And then the return oil enters
BH chamber and passes through between the perimeter of boom spool (301) and casing, and flows
through low pressure circuit (D) and boost check valve (517), and the returns to the hydraulic tank
through tank port T1. And a part of the return oil flows into the inside of boom spool (301) through
circular notch of boom spool (301). Since the return oil contains sufficient pressure with the self
weight of boom, arm, etc. the return oil passes through inside passage of boom spool (301) and
pushes and opens poppet (317) leftward as shown in the figure and flows through the circular notch,
and then supplied to boom cylinder rod (R) side again through port Bb. (Boom recirculation function)

In boom down operation

24-46
 ［24. COMPONENTS SYSTEM］

(5) Arm operation

1. In arm out operation
When arm out operation is performed, the pilot pressure enters ports PBa1 and arm 1 spool (302)
moves rightward against the force of springs (321) (322). Simultaneously the secondary pressure of
solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
And the pilot pressure also enters PBa2, and arm 2 spool (308) is switched against the force of
springs (325) (326) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb
and switches unload spool (309).
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens
load check valve LCa (511), and flows into AR chamber through between the perimeter of arm 1 spool
(302) and casing through U-shaped passage.
In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass
passage (52) and pushes and opens load check valve LCAT2 (511) and enters U-shaped passage,
and pushes and opens load check valve LCAP2 (515) provided with orifice, and flows into U-shaped
passage. And then the hydraulic oil flows through between the perimeter of arm 2 spool (308) and
casing, and enters AR chamber through casing inside passage (RR) and confluences the hydraulic oil
from hydraulic pump P2 side.
The conflux hydraulic oil opens lock valve poppet CRa (514) and is supplied to arm cylinder rod side
(R).
In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of
arm 1 spool (302) and casing and passes though low pressure circuit (D) and casing inside passage
(HH) and then flows into low pressure circuit (D) through between the perimeter of arm 2 spool (308)
and casing.
The return oil in low pressure circuit (D) returns to hydraulic tank through tank port T1 passing through
boost check valve (517).

24
In arm out operation

24-47
［24. COMPONENTS SYSTEM］

2. In arm in operation (At light load: arm recirculation function)

When arm in operation is performed, the pilot pressure enters ports PAa1 and PLc2, and arm 1
spool (302) moves rightward against the force of springs (321) (322). Simultaneously the secondary
pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). At
the same time, since the spool of lock valve selector (211) is switched, the spring chamber of lock
valve poppet CRa (514) is connected to the drain circuit and the retention of poppet (514) is released.
And the pilot pressure enters PAa2 through solenoid proportional valve [XR], and arm2 spool (308)
moves rightward against the force of springs (325) (326) and the secondary pressure of solenoid
proportional valve [X1] acts on port PCb and switches unloading spools (309). But in light load
operation, because the solenoid proportional valve [XR] actuates and arm 2 spool (308) stays in the
position of circuit (I).
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens
load check valve LCa (511), and flows into port (Aa) through between the perimeter of arm 1 spool
(302) and casing through U-shaped passage. In the meantime, the hydraulic oil delivered by hydraulic
pump P1 flows through center by-pass passage (52) and pushes and opens load check valve LCAT2
(511) and enters U-shaped passage, and also the oil from parallel passage (53) pushes and opens
load check valve LCAP2 (515) provided with orifice and flows into U-shaped passage. And then the
hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing from U-shaped
passage and enters port (Aa) through casing inside passage (HH) and confluences the hydraulic oil
from hydraulic pump P2 side.
The conflux hydraulic oil is supplied to arm cylinder head side (H) through port (Aa).
In the meantime, the return oil from arm cylinder rod side (R) enters the control valve through port
(Ba). Because the retention of lock valve poppet CRa (514) which is located on this side of arm 1
spool (302) is released, the return oil pushes and opens lock valve poppet CRa (514) and enters AR
chamber. The return oil in AR chamber flows through between perimeter of arm 1 spool (302) and
casing, and flows through low pressure circuit (D) and boost check valve (517). And finally, the oil
returns to hydraulic oil tank through tank port T1. The return oil in AR chamber is led to arm 2 spool
(308) through casing inside passage (RR), but because arm 2 spool (308) does not connect to low
pressure passage (D) at circuit (I), the entire flow rate flows into arm 1 spool (302).
Further more, the return oil from chamber AR passes through the perimeter of arm 1 spool (302) and
casing, and flows through casing inside passage (RH) and is led to the inside of arm 2 spool (308)
through circular notch (a) of arm 2 spool (308). In light load operation, since the return oil contains
higher pressure than that of arm cylinder head side (H) with the self weight of arm, etc. the hydraulic
oil inside of arm 2 spool (308) passes through check valve (317) and flows into casing inside
passage (HH) and the supplied to arm cylinder head side (H) again. (Arm recirculation function)
And a part of the return oil which was led to arm 2 spool (308) passes through check valve (319),
and flows through boost check valve (517) through low pressure circuit (D) and returns to the hydraulic
tank through tank port T1.

24-48
 ［24. COMPONENTS SYSTEM］

In arm in operation (At light load: arm recirculation function)

24

24-49
［24. COMPONENTS SYSTEM］

3. In arm in operation (In heavy load operation)

The arm recirculation function is effective in actuating arm cylinder quickly in light load operation, but
in heavy load operation (work required large power); the function causes the power loss. This control
valve selects the presence of recirculation function in light and heavy load operation with solenoid
proportional valve [XR]. (Variable recirculation function)
The flow path of hydraulic oil in heavy load operation, the path on the supply side to arm cylinder is
the same as that in light load operation, differs from that of return oil. In heavy load operation,
solenoid proportional valve [XR] actuates and arm 2 spool (308) is positioned to circuit (II). The return
oil from arm cylinder rod side (R) enters the control valve through port (Ba). Because the retention of
lock valve poppet CRa (514) which is located on this side of arm 1 spool (302) is released, the
return oil pushes and opens lock valve poppet CRa (514) and enters AR chamber. The return oil in
AR chamber flows through between perimeter of arm 1 spool (302) and casing, and flows through
low pressure circuit (D) and boost check valve (517). And finally, the oil returns to hydraulic oil tank
through tank port T1. The return oil in AR chamber is led to arm 2 spool (308) through arm 1 spool
(302) and casing inside passage (RR). But because arm 2 spool (308) is connected to low pressure
passage (D) at circuit (II), the return oil passes through between the perimeter of arm 2 spool (308)
and casing and flows through boost check valve (517) through low pressure (D) and returns to the
hydraulic tank through tank port T1.
The return oil from AR chamber passes through between the perimeter of arm 1 spool (302) and
casing and flows through casing inside passage (RH) and then is led to the inside of arm 2 spool
(308) through circular notch (a) of arm 2 spool (308). In heavy load operation, since the pressure on
arm cylinder head side (H) is higher than the rod side, the hydraulic oil in arm 2 spool (308) does not
flow into casing inside passage (HH), but flows through check valve (319) and passes through boost
check valve (517) through low pressure (D) and returns to the hydraulic tank through port T1.

In arm in operation (In heavy load operation)

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 ［24. COMPONENTS SYSTEM］

(6) Swing operation

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

Swing operation

24

24-51
［24. COMPONENTS SYSTEM］

(7) Spool actuation for operation in option

This spool is used to control the attachment in option like Nibbler (Crusher), etc.
Where the pilot pressure acts on port PAo on operating the attachment in option, the pilot pressure
enters ports PAo, and option spool (311) moves against the force of springs (329) (330), and
simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and
switches unloading spool (310).
The hydraulic oil delivered by hydraulic pump P2 flows through parallel passage (56) and pushes and
opens load check valve LCo (511), and flows through between the perimeter of option spool (311)
and casing through U-shaped passage and is supplied to actuator for attachment through port (Ao).
In the meantime, the return oil from actuator for attachment swing passes through between the
perimeter of option spool (311) and casing through port (Bo) and flows through low pressure circuit (D)
and boost check valve (517), and then returns to the hydraulic tank through tank port T1.
The operation where the pilot pressure acts on PBo port is the same as the above.
* The oil passage is branched toward the end side of control valve at the mid course from option
spool (311) to port Ao, but when N&B (Nibbler and Breaker) selector valve is provided on the end
side of control valve, this oil passage is used as passage to connect to N&B selector valve.

Spool actuation for operation in option

24-52
 ［24. COMPONENTS SYSTEM］

(8) Lock valve operation

The lock valve is housed in between each port of the control valve connected to arm cylinder rod side
(R) and arm cylinder head side (H) and the arm spool and boom spool, and reduces the leaking due
to holding pressure caused by each cylinder.

1. At boom spool neutral position (Arm spool makes the same operation.)
When boom spool (301) is set to neutral position, spool (511) of lock valve selector is held on the
left side as shown in the figure. At this position, passages Sa and Sb are connected each other at the
inside of bushing (541) and on the perimeter of spool (511). Therefore in spring chamber (RH) of
lock valve poppet, the holding pressure receiving from boom cylinder head side (H) passes from
passage Sa to bushing (541) spool (511) and is connected through passage Sb, consequently the
lock valve poppet (514) is kept pressed the lower side as shown in the below Fig. and restricts the
leaking to the minimum.

Lock valve operation (At boom spool neutral position)

24

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［24. COMPONENTS SYSTEM］

2. In boom down operation (In arm in operation)

Pilot pressure PBb for boom down operation acts on port PLc of lock valve selector, and the spool
(511) moves rightward as shown in the below Fig.. After the spool (511) was moved, orifice (a) of
bushing (541) first closes and then passages Sa and Sb are blocked, and therefore the holding
pressure receiving from boom cylinder head side (H) does not act on spring chamber (RH) of lock
valve poppet (514).
And after spool (511) was moved, the inside of bushing (541) is connected from port Dr to passage
DR through spring chamber (319).
With this actuation, spring chamber (RH) of lock valve poppet (514) is connected from orifice (b) of
bushing (541) to drain passage Dr through passage Sb, and the force which pushes lock valve
poppet (514) down as shown in the below Fig. is released. And since lock valve poppet (514) receives
holding pressure from boom cylinder head side (H) to the pressure receiving section in ring type
which is made up of guide diameter and seat diameter of lock valve poppet (514), and it is pushed
upward and is open.
The said operation, in boom down operation, is performed before making the opening (meter out
opening) which is used to return the return oil from the boom cylinder head side of boom spool (301)
to the tank open, the operation has no effect on the operability of boom down operation.
In case of arm-in operation, the operation is the same.

Lock valve selector operation (At boom down operation)

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 ［24. COMPONENTS SYSTEM］

(9) By-pass cut valve

This by-pass cut valve is located on the most downstream of center by-pass passage (52) on P1
side and center by-pass passage (55) on P2 side. And this by-pass cut valve controls the flow rate
of hydraulic oil from each center by-pass passage to low pressure passage (D).

1. In normal operation
On starting the engine, the secondary pressure of solenoid proportional valves [X1] and [X2] act on
pilot ports PBp1 and PBp2 of by-pass cut valve (605). This secondary pressure is the same as that
actting on pilot port PCb of P1 unloading spool (309) and pilot port PCa of P2 unloading spool (310).
The following explains the by-pass cut valve on P1 side, the operation of by-pass cut valve on P2
side is the same. The secondary pressure of solenoid proportional valve [X1] enters PBp1 and
plunger (301) moves downward against the force of spring (302). The taper section at the top end of
plunger (301) is seated on the seat of plug (101), shutting off the spring chamber of poppet (201)
and spring chamber (b) of plug (101).
The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and
enters spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring
chamber (b) of plug (101) are disconnected, spring chamber (a) of poppet (201) is the same pressure
as center by-pass passage (52) and poppet (201) is pushed the seat section of casing shutting off
center by-pass passage (52) and low pressure passage (D).
Consequently, in normal operation, center by-pass passage (52) is always disconnected from low
pressure passage (D) and the hydraulic oil delivered by hydraulic pump P1 does not flow through
center by-pass passage (52), but returns to the hydraulic tank through P1 unloading spool (309).

24
By-pass cut valve (In normal operation)

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［24. COMPONENTS SYSTEM］

2. At the time when failure occurred

When the electric system is failed and consequently the secondary pressure of solenoid proportional
valves [X1] and [X2] is not produced, plunger (301) is moved upward by the force of spring (302).
Since the taper section at the top end of plunger (301) is lifted up from the seat section of plug (101),
spring chamber (a) of poppet (201) and spring chamber (b) of plug (101) are connected each other.
The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and
enters spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring
chamber (b) of plug (101) are connected each other, the hydraulic oil in spring chamber (a) of poppet
(201) passes through from seat section of plug (101) to spring chamber (b) and flows into passage
(Dr) through passage (c). Consequently the pressure in spring chamber (a) of poppet (201) lowers,
poppet (201) receives the pressure of center by-pass passage (52) and is lifted up against the force of
spring (202), and the hydraulic oil from center by-pass passage (52) flows into low pressure passage
(D) through poppet (201) of by-pass cut valve (605). Therefore when the electric system is failed, P1
unloading spool (309) is shifted to the neutral position and the passage to low pressure passage (D) is
cut off, but because center by-pass passage (52) is connected to low pressure passage (D) through
by-pass cut valve (605), the abnormal rise of the pump pressure is prevented.

By-pass cut valve (In condition of failure)

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 ［24. COMPONENTS SYSTEM］

(10) Boost check valve, By-pass check valve

1. Boost check valve
The boost check valve is located between low pressure passage (D) and tank port T1 and generates
boost pressure necessary for the low pressure passage.

a. In normal operation
The hydraulic oil from low pressure passage (D) moves the boost check valve (517) upward
against the force of spring (527), and returns to the hydraulic tank through tank port T1. At this
time, the pressure generated by spring (527) is used as the boost pressure for the low pressure
passage.

Boost check valve operation

24

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［24. COMPONENTS SYSTEM］

2. By-pass check valve

Even if the pressure at tank port T1 goes up due to the sudden change of return flow rate, the
by-pass check valve actuates and prevents the pressure at tank port T1 from going up higher than the
specified pressure, and consequently the oil cooler and filter located between tank port T1 and the
hydraulic tank are protected from possible damage.
When the pressure at tank port T1 goes up to the pressure added by spring (528), by-pass check
valve (518) is pushed and opens against the force of spring (528), and the hydraulic oil in tank port
T1 directly returns to the hydraulic tank through tank port T2.

By-pass check valve operation

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 ［24. COMPONENTS SYSTEM］

24.1.3 PILOT VALVE (ATT)

24.1.3.1 OUTLINE
(1) Outside view

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［24. COMPONENTS SYSTEM］

24.1.3.2 CONSTRUCTION

Pilot valve (ATT)

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
101 Casing 1 *218-1 Seat 2
151 Plate 1 *218-2 Seat 2
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
212 Push rod 4 *246 Spring 4
213 Seal 4 47.1 (34.7) 301 Joint: M14 1
214 O-ring: 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (50.6) 312 Adjust nut: M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4

Note) The parts marked * may not be equipped depending on valve type.

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 ［24. COMPONENTS SYSTEM］

24.1.3.3 OPERATION
(1) Lever in neutral (See right Fig.)
The action of spring (509) (for secondary
pressure setting) that determines the output
pressure of the pilot valve does not act upon
spool (201). Therefore, spool (201) (for return)
is pushed up by spring (221) [spring seat
(216)]. The output ports (2,4) connect with the
T port. The result is that the output pressure
is equal to the tank pressure.

Lever in neutral

(2) When the pilot lever is tilted (See right Fig.)

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

When the lever is tilted

(3) Lever held (See right Fig.)

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

When the lever is held

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［24. COMPONENTS SYSTEM］

(4) Operation in the area where the tilting angle of the lever is large.
(varies with the model)
If the lever is inclined beyond a certain angle on certain models, the top end of the spool contacts the
bottom of the bore of the push rod. This keeps the output pressure connected with the P port
pressure.
Furthermore, on a model in which a spring seat and a spring are built in the push rod, the bottom of
the bore of the push rod contacts the spring if the lever is turned beyond a certain angle. This causes
the secondary pressure gradient to change by the spring action. Thereafter, the bottom of the bore of
the push rod contacts the top end of the spring seat, keeping the output pressure connected with the
P port.

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 ［24. COMPONENTS SYSTEM］

24.1.4 PILOT VALVE (TRAVEL)

24.1.4.1 OUTLINE
(1) Outside view

(2) Specifications

(3) Performance characteristics

24

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［24. COMPONENTS SYSTEM］

24.1.4.2 Construction and operation

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

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 ［24. COMPONENTS SYSTEM］

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24

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［24. COMPONENTS SYSTEM］

24.1.5 SWING MOTOR UNIT

24.1.5.1 SPECIFICATION
(1) General view

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 ［24. COMPONENTS SYSTEM］

(2) Specifications
Swing motor unit part No. YY15V00016F1
Type M2X63CHB-13A-36/285-60
Part No. YY15V00018F1
Displacement cm3 (in3) / rev 60 (3.66)
Rated pressure MPa (psi) 28.0 (4060)
Hydraulic motor
Braking torque N-m (lbf-ft) 314 (232)
Release pressure MPa (psi) 2.3 (334)
Relief set pressure MPa (psi) 28.0 (4060) at 110L/min (29 gal/min)
Weight kg (lbs) 29 (64)
Type RG06D19J2
Part No. YY32W00004F1
Gear oil SAE#90~#140 (API class GL-3~4
Lubicate oil
grade)
Reduction unit
Lubicate oil volume L (gal) 1.65 (0.44)
Grease Extreme pressure lithum base #2 grease
Grease volume cm3 (in3) 500 (30.5)
Weight kg (lbs) 79 (174)
Total weight kg (lbs) 113 (249)

24

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［24. COMPONENTS SYSTEM］

24.1.5.2 CONSTRUCTION
(1) Swing motor

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 ［24. COMPONENTS SYSTEM］

Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
101 Drive shaft 1 443 Roller bearing 1
106 Spacer 3 444 Roller bearing 1
111 Cylinder 1 451 Pin 2
113 Retainer (spherical bushing) 1 36 (27) 468 Plug : PF1/4 2
114 Cylinder spring 1 108 (80) 469 Plug : M22 2
116 Push rod 12 471 O-ring : 1B G80 1
117 Spacer 2 472 O-ring 1
121 Piston 9 487 O-ring : 1B P11 2
122 Shoe 9 488 O-ring : 1B P20 2
123 Set plate 1 491 Oil seal 1
124 Shoe plate 1 702 Brake piston 1
131 Valve plate 1 706 O-ring 1
301 Casing 1 707 O-ring 1
303 Casing 1 712 Brake spring 20
304 Front cover 1 742 Friction plate 3
351 Plunger 2 743 Separator plate 4
355 Spring 2 1.7 (1.2) 980 Plug : PF3/8 1
240 (177) 401 Socket bolt : M16X75 4 4.4 (3.3) 981 Plug : PF3/4 1
432 Snap ring 2 0.9 (0.6) 982 Plug : PF1/4 1
433 Ring 1 98 (72) 992 Plug : PT3/4 1
437 Snap ring 1 177 (131) 51 Relief valve : M33 2
438 Snap ring 1 051-1 O-ring : 1B G30 2

24

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［24. COMPONENTS SYSTEM］

(2) Anti-reaction valve

Tightening
torque No. Parts Q'ty
N-m (lbf-ft)
101 Casing 1
9 (6.6) 151 Plug : NPTF1/16 4
161 O-ring : 1B P22 2
29 (21) 171 Socket bolt : M8X60 6
29 (21) 401 Swing reactionless valve : M22 2
401-1 O-ring : 1B P20 2
401-2 Back-up ring 2

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 ［24. COMPONENTS SYSTEM］

(3) Swing reduction unit

Tightening torque Tightening torque Q'T

No. NAME Q'TY No. NAME
N-m (lbf-ft) N-m (lbf-ft) Y
102 Casing 1 402 Roller bearing 1
201 Pinion shaft 1 403 Needle bearing 3
202 Ring gear 1 98 (72) 602 Socket bolt : M12X100 8
203 No.2 planetary gear 4 603 Socket bolt : M12X135 2
204 No.2 sun gear 1 801 Oil seal 1
210 No.1 planetary gear 3 910 Spring pin 4
211 No.1 sun gear 1 911 Retaining ring 3
230 No.2 spider 1 912 Retaining ring 1
231 No.1 spider 1 913 Retaining ring 1

24
282 No.2 pin 4 915 Seal 1
283 No.1 pin 3 65 (48) 920 Adapter : PT1/2 1
285 Side plate t=1 7 108 (80) 921 Hose : PF1/2 1
286 Thrust washer t=2 1 108 (80) 922 Plug : PF1/2 1
287 Side plate t=2 3 925 relief fitting 1
401 Roller bearing 1 926 Grease nipple : PT1/4 1

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［24. COMPONENTS SYSTEM］

24.1.5.3 OPERATION
24.1.5.3.1 OPERATION OF HYDRAULIC MOTOR
If the high pressure oil flows into the cylinder
through the inlet port (a) of valve plate (131),
as shown in the right figure, the hydraulic
pressure acts upon piston (121) and creates
force F in the axial direction.
The force F may be divided into force F1
vertical to shoe plate (124) via shoe (122) and
force F2 at right angles with the shaft.
The force F2 is transmitted to cylinder block
(111) via pistons (121) and causes drive shaft
to turn so as to generate a rotating moment.
The cylinder block (111) has nine pistons
equally arranged. Rotating torque is transmitted
to the drive shaft by turns by pistons connected
to inlet port of high pressure oil.
If the oil supply and discharge directions are
reversed, the drive shaft rotates in the opposite
direction.
Theoretical output torque T can be given by the
following equation.

Operation of hydraulic motor

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 ［24. COMPONENTS SYSTEM］

24.1.5.3.2 VALVE CASING SECTION

(1) Operation of anti-cavitation check plunger
Because the motor of this type does not equip
a counterbalance valve, this motor may be
rotated beyond the oil feed.
To avoid cavitation due to the lack of oil feed,
the check valve (351) is equipped and the
lack of oil is made up.

Operation of anti-cavitation check plunger

(2) Operation of relief valve

1. Operation during pressurizing
a. The pressure at the P and R ports are
equal to the tank pressure at the
beginning as shown in right Fig.

b. Condition shown in right Fig.

When the P port is pressurized, a
pressure is built up in the chamber g via
the orifice m of plunger (301). This
pressure acts upon the pressure-receiving
area (A2 - A3) of the piston (303) and
generates the force which pushes the
piston rightward. And the piston begins to
move rightward when the pushing force
balances with the spring (322) force. The
pressure is called Pg1 at this point. The
pressure in the chamber g is kept the
constant pressure (Pg1) while the piston
(303) is moving rightward.
In this case, the relief pressure (P1) is
expressed as:
24

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［24. COMPONENTS SYSTEM］

c. Condition shown in right Fig.

While the piston (303) is moving rightward, the oil in the dumping chamber (h) is discharged from
the periphery slit of the piston (303) to the R port.
In the middle of the rightward moving, the function of dumping becomes stronger and the pressure
of chamber g rises gradually, because the periphery slit of piston (303) becomes smaller as the
piston (303) moves rightward.
As the equation (1) indicates, while the pressure Pg1 is rising, the relief pressure (P1) rises
too.b. Condition shown in below Fig..
The pressure of chamber g acts upon the pressure-receiving area A3-A4 of piston 1 (302). When
the hydraulic pressure rises above the load of spring (321), the piston 1 begins to move to the
left.
On that occasion, since the machine turns to the left while discharging the oil of chamber h
arranged between piston 1 and adjust plug (401) into chamber g via orifice n provided in piston
1 (302), chamber h serves as a dumping chamber.
The load of the spring increases slowly till piston 1 reaches the end of the adjust plug. The relief
pressure P rises smoothly.

d. Condition shown in right Fig.

After the piston reached to the stroke end,
the pressure of chamber g equals the
pressure of P port.
In this case, the relief pressure (PS) is
expressed as:

In the process of above mentioned paragraph 1 to 4, the relief pressure changes according to right
Fig.

2. Operation during pressure reducing

After the pressurizing force against P port is
reduced to zero, the plunger (301) is pushed
with spring (321), and seated on seat. And the
piston (303) moves leftward by the force of the
spring (322). At this time, the oil is supplied
immediately from the R port to the dumping
chamber (h) via the periphery slit. And the
piston (303) moves leftward promptly. As a Relief valve operation diagram
result, the relief valve returns to the initial
condition.

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 ［24. COMPONENTS SYSTEM］

(3) Operation of anti-reaction valve

Hydraulic circuit diagram for anti-reaction valve.

1. Neutral condition
Right Fig. explains the relationship between
the neutral condition of the anti-reaction valve
and the hydraulic circuit. Now, let us consider a
braking condition of the AM port.

Neutral condition

2. When brake pressure occurs

If the pressure (P) is generated at the AM port,
it flows through the passage, the hole on the
shaft of seat (313), and the passage m of the
plunger (311). And the oil is led to the chamber
n.
When the pressure P rises above the value
(PS) set by spring (321), the plunger (311)
pushes the spring (321) and moves leftward. When brake pressure occurs
The seat (313) is pushed with the plunger
(311), and pushes a weak spring (322). As a
result, the seat (313) moves to left.

24

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［24. COMPONENTS SYSTEM］

3. When anti-reaction valve is actuating

When an inertia load stops moving (Point Y in below Fig. a brake pressure (P) tries to fall.
When Ps becomes larger than P, the plunger (311) moves towards the right return direction. Seat
(313) tries to move rightward by the action of the spring (322). But the return of the seat makes a
time delay with regard to the return of the plunger because the chamber p provides damping function
by orifice g. Consequently, the t of seat opens. This makes a passage of connecting the both AM and
BM ports of the hydraulic motor, and the oil flows through L, t, r, and k in order. As a result, the
pressures at the AM and BM ports become same pressure (PB) rapidly, and the pressure changes to
point Z below Fig. This prevents the swing motor stop reaction which is caused by the closing
pressure of the AM port.

Pressure change diagram of anti-reaction

When anti-reaction valve is actuating
operation

24.1.5.3.3 OPERATION OF BRAKE

The cylinder (111) is jointed through the drive
shaft (101) and a gear. The rotation of
separator plate (743) is restricted in its
circumferential direction by circular grooves
provided in the casing (301).
If the friction plate (742) restricted to the outer
circumference of the cylinder is pressed
against the casing (301) via the separator
plate (743) and the brake piston (702) by the
force of the brake spring (712), the frictional
force is generated between the friction plate Operation of brake chamber
(742) and the casing (301) and between the
separator plate (743) and the brake piston
(702). This frictional force restricts the drive
shaft and applies the brake.
In the meantime, when the brake release
pressure applied to the oil chamber formed
between the brake piston (702) and the casing
(301) overcomes the spring force, the brake is
released as the brake piston (702) moves until
the friction plate (742) is separated from the
casing (301).

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24.1.5.3.4 SWING REDUCTION UNIT

The transmitted power from swing motor drive
shaft is transmitted to the No.2 sun gear (204)
of the 2nd stage through No.1 sun gear (211)
and No.1 carrier (231) of 1st stage.
Similarly, the power of No.2sun gear (204) is
transmitted to the drive shaft (201) through the
No.2 carrier of 2nd stage.
The drive shaft (201) is supported in the casing
(102) by the two bearings (401) (402). To
protect the bearings from the metal powder of
gear abrasion, the oil seal (801) is equipped
at the center of casing (301) because the
bearings are exposed to heavy load. And the
chamber A is lubricated with the inner oil of the
ring gear (202), the chamber B is lubricated
with packed grease.

Operation of REDUCTION UNIT

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24.1.6 TRAVEL MOTOR

24.1.6.1 SPECIFICATIONS
24.1.6.1.1 General view

Travel motor (with reduction unit and brake valve)

24.1.6.1.2SPECIFICATIONS

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 ［24. COMPONENTS SYSTEM］

24.1.6.2 CONSTRUCTION
(1) Outline

24

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［24. COMPONENTS SYSTEM］

(2) Hydraulic motor

24-80
 ［24. COMPONENTS SYSTEM］

No. NAME Q'TY No. NAME Q'TY No. NAME Q'TY

102 Shaft 1 185 Spring 1 341 Parallel pin 1
103 Swash plate 1 201 Valve seat 1 343 Socket bolt 10
104 Cylinder block 1 202 Valve 1 352 Plug 3
105 Piston 1 203 Sleeve 1 353 Ball 2
106 Shoe 1 204 Collar 1 354 Plug 5
107 Retainer plate 1 205 Plug 1 357 Plug 1
108 Thrust ball 1 206 Spring 1 358 O-ring 3
109 Timing plate 1 207 O-ring 1 359 O-ring 1
110 Washer 2 208 Back-up ring 2 363 Spool 1
112 Piston 1 209 O-ring 1 366 Spring 1
113 Spring 10 210 Back-up ring 2 376 Orifice 1
114 Spring 1 211 O-ring 1 377 Filter 1
115 Friction plate 3 212 O-ring 1 378 Ball 1
116 Separator plate 4 213 Shim 1 379 Plug 1
132 Oil seal 1 301 Rear flange 1 380 Plug 2
135 O-ring 1 323 Spool 1 381 Piston 1
139 O-ring 1 324 Plug 2 383 O-ring 2
145 THS snap ring 1 325 Washer 2 384 Orifice 2
149 Bearing 1 326 Plug 2 396 Plug 2
150 Bearing 1 327 Valve 2 398 Plug 8
151 Needle roller 3 328 Spring 2 399 Name plate 1
161 Piston 1 329 Orifice 2
162 Shoe 1 330 Spring 2
167 Pivot 2 331 O-ring 2
171 Parallel pin 2 336 O-ring 2

24

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［24. COMPONENTS SYSTEM］

(3) Reduction unit

No. Parts Q'TY No. Parts Q'TY

1 Hub 1 16 Parallel pin (1) 3
2 Spindle 1 17 Parallel pin (2) 3
3 Spider (1) 1 22 Lock washer 2
4 Sun gear (1) 1 23 Shim 1
5 Planetary gear (1) 3 24 Bearing 2
6 Pin (1) 3 27 Needle bearing 3
7 Spider (2) 1 28 Needle bearing 3
8 Sun gear (2) 1 29 Floating seal 2
9 Planetary gear (2) 3 30 Plug 3
10 Pin (2) 3 31 O-ring 3
11 Thrust washer (1) 6 32 O-ring 1
12 Thrust washer (2) 6 33 O-ring 2
13 Thrust plate 1 34 Parallel pin 2
14 Cover 1 35 Socket bolt 12
15 Coupling 1 36 Snap ring 1

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 ［24. COMPONENTS SYSTEM］

24.1.6.3 OPERATING DESCRIPTION

24.1.6.3.1REDUCTION GEAR
(1) Function
This reduction gear unit is composed of two stage planetary gear mechanism. The reduction gear
reduces the high speed of hydraulic motor and converts it low-speed, high-torque rotation.

(2) Operating Description

The rotation of hydraulic motor shaft is
transmitted to sun gear (4) of the first stage
which is linked with shaft (102) in spline.
At that time, the hub (1) is rotated by the
rotation of the planetary gears (5). The hub (1)
rotation is transmitted to carrier (3) which
connected to planetary gears (5), and that
causes sun gear (6) rotation of the second
stage.
The rotation of sun gear (6) is transmitted to
the hub via three planetary gears (7) of the
second stage.
The generated rotation of reduction gear is
output rotation.

24

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［24. COMPONENTS SYSTEM］

24.1.6.3.2 Reduction unit

(1) Function
1. Hydraulic Motor
This hydraulic motor is a swash plate type axial piston motor, converting the hydraulic force from
the pump to rotary motion.
2. Brake Valve
a. Controls inertia when stopping the hydraulic motor, in order to provide smooth stopping.
b. Prevents runaway rotation when the hydraulic motor is rotated by external force.
This is done by preventing hydraulic cavitation.
c. Prevents the generation of abnormally high pressure when the hydraulic motor is stopped
suddenly.
3. Parking Brake
The parking brake prevents the hydraulic motor from being rotated by external force while stopped.
A friction plate type mechanism is used, constructed so as to form one unit with the hydraulic
motor.
4. High-Low 2-Speed Switching Mechanism
Switches the hydraulic motor between high speed rotation with low torque, and low speed rotation
with high torque.

(2) Operating Principles and Description

1. Hydraulic Motor
Hydraulic fluid fed from the hydraulic pump
enters the GM motor through the rear
flange (101), passes through the brake
valve and timing plate (109) and enters
the cylinder block (104). This hydraulic
fluid is fed only into one side of a line
connecting the upper and lower dead points
(Y1-Y2) of the piston stroke (105). The
hydraulic fluid pushes each of the pistons
(105), creating force F(=PXA). This force
operates on the oblique surface of the
swash plate (103). Force F is separated
into components F2 and F3 according to
the angle θ of the oblique surface. Of the
two components, the radial component force
F3 generates torque (=F3Xri). The sum of
the torque T(= (F3Xri) of each of the
pistons (105) is the rotary force of the
hydraulic motor. This rotary force passes
through the pistons (105) and rotates the
cylinder block (104) and the shaft (102).

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2. Brake Valve

a. Operation (Brake released)

The pressure oil is led to through port (A),
opens valve (327), and led to port (C) on
the section side of hydraulic motor to rotate
hydraulic motor.
At the same time, the pressure oil enters
chamber (a) through orifice (329), and
exerts on the end of spool (323) to
generate the force. Then the force of spring
(328) slides the spool (323) placed on the
neutral position leftward.
The sliding of spool (323) forms the space
(passage) between spool (323) and rear
flange (301) with spool groove.
This passage is connected to port (D) and
port (B) of the return circuit of the hydraulic
motor, and the returns oil returns to tank
side, enabling hydraulic motor to rotate.
Then, the sliding of spool (323) leads
pressure oil to port (E). The pressure oil
led to port (E) moves piston (112) of
parking brake, and releases parking
braking force. (For details, refer to item
"Parking brake".)
If pressurized oil is supplied from port (B),
the movements of spool (323) and valve
(327) are reversed so that the hydraulic
motor is rotated reversely.

b. Self-traveling
While machine is being operated, as the
travel speed is increased due to steep
slope, the oil flow rate of the hydraulic
motor is higher than the supply flow rate of
the hydraulic oil pump.
The rotation of the hydraulic motor in this
case is called a self-traveling. (Overrun)
While self-traveling, the pressure is
lowered similar to the stopping condition.
Then brake valve is moved similar to the
stopping condition, throttles passage in the 24
return side of hydraulic motor, and generate
backing pressure.
In addition, the force of inertia decreases
the revolution of hydraulic motor to
revolution having a balance with the
supply flow rate of pump.

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［24. COMPONENTS SYSTEM］

c. Stop / Stall (Braking Operation)

If pressurized oil supply through the port
(A) is suspended while traveling, the
hydraulic force to push up the spool (323)
is lost, and the spool (323) which is slid
to left side, tries to return to the neutral
position due to the spring (328) force. At
that time, through the oil in the chamber
(a) tries to flow out to the port (A) side
through the orifice (329), its flow is
restricted and some back pressure is
generated by the throttle effect in the orifice
(329) controlling the return speed of the
spool (323). At the same time, the
hydraulic motor tries to rotate with its inertia
force even though the pressurized oil is
suspended, and the return oil from the
hydraulic motor tries to return to the port
(B) side from the port (D) through the
passages on spool groove and rear flange
(301).
When the spool (323) entirely return to
neutral position, the passage on the
hydraulic motor of the oil return side is
completely closed by the spool (323), and
the hydraulic motor ceases its rotation.
While machine working, the brake valve
smoothly stops rotation of-the hydraulic
motor which tries to rotate with its inertia
force, by means of throttling the return
side passage of the hydraulic motor,
generating back pressure due to shape of
the spool groove and controlling the return
speed of the spool.
On the other hand, when braking is
operated, the hydraulic motor tries to
rotate with its inertia force and to intake
oil with its pumping function. However,
because the intake side is closed its
passage with the spool (323), the oil supply
is suspended. This causes cavitation in
the hydraulic motor. To prevent the
cavitation, the valve (327) is operated by
very slight negative pressure to open the
passages of port (A) side and intake port
(C) of the hydraulic motor.
And when pressurized oil is supplied
through the port (B), each motion of the
mentioned parts above becomes
symmetrical right and left to stop the
hydraulic motor.

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3. High-Low 2-Speed Switching Mechanism

a. Low Speed
When the pilot pressure is not supplied
through the port (P), the valve (363) is
pushed up to the upper position due to
the spring (366) force and pressurized oil
through the port (A) or (B), the
pressurized oil is cut off at port (C), and oil
in the chamber (W) is released into the
drain (motor case) through the valve (363).
Accordingly, the tilt angle of the swash
plate (103) becomes the maximum 1
resulting the maximum stroke volume and
low speed rotation of the hydraulic motor.

b. High Speed
When the pilot pressure is supplied
through the port (D), it defeats the spring
(366) force and pressurized oil through the
port (A) or (B) to push down the valve
(363) to lower position, the pressurized oil
at the port (C) is led to the chamber (P)
through the valve (363), and the piston
(161) pushes the swash plate (103) up to
the plane X and maintain it at its position.
At that time, the tilt angle of the swash
plate becomes the minimum 2 resulting
the minimum stroke volume and high speed
rotation of the hydraulic motor.

c. Automatic shifting to low speed during

high speed operation
If the load is increased while high speed
operation, the oil pressure at the port (A)
or (B) is also increased. And when the oil
pressure reaches to specified pressure, it
excesses the pilot pressure, and the valve
(363) is pushed up to upper position, and
oil in the chamber (W) is released into the
drain (motor case) through the valve (363).
At that time, the swash plate (103) gets
touch with the plane Y of spindle, and the 24
tilt angle of swash plate (103) becomes
the maximum 1 and is maintained at its
position resulting low speed rotation.

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24.1.7 TRAVEL MOTOR (FOR "L" SPEC.)

24.1.7.1 SPECIFICATIONS
(1) Appearance

Travel motor (With reduction unit and brake valve)

(2) Specifications
Parts No. YV15V00005F1
Item
Type GM28VL-B-57/100-5
Revolution [rpm] 43.5/25.2
Reduction unit Lube oil Gear oil SAE #90 GL4
Oil level [L (gal)] 4.7 (1.24)
Max. displacement [cc/rev (cu-in/rev)] 56.5/99.6 (3.45/6.1)
Max revoiution [rpm] 2437/1411
Hydraulic motor
System pressure [kgf/cm2(psi)] 350 (5000)
2-speed changeover pressure [kgf/cm2(psi)] 51 (725)
Braking torque [Kgf-m (lbf-ft)] 26 (188)
Parking brake
2
Release pressure [kgf/cm (psi)] 11 (157)
24
Total weight [kg (lbs)] 271 (480)

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［24. COMPONENTS SYSTEM］

24.1.7.2 CONSTRUCTION
(1) Outline

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24

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 ［24. COMPONENTS SYSTEM］

(3) Parts list

24

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［24. COMPONENTS SYSTEM］

24.1.7.3 EXPLANATION OF FUNCTION

24.1.7.3.1 REDUCTION UNIT
(1) Function
This reduction unit is equipped with spur gears (Hereinafter referred as 1st reduction gear section)
and differential gears (Hereinafter referred as 2nd reduction gear section), reduces the high rotation
speed from the Hydraulic motor, converts it to low speed large torque and rotates hub (1) (Casing.)

(2) Explanation of function

1. 1st reduction gear section
The rotation of hydraulic motor shaft is transmitted to input gear (6) which is linked with shaft
(102) in spline.
Then, the rotation speed of three spur gears (7) which are engaged with input gear is reduced.
Also, the reduction rate of 1st reduction gear section is as follows.

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 ［24. COMPONENTS SYSTEM］

2. 2nd reduction gear section

a.Three spur gears are engaged with
crankshaft respectively to transmit the
power from the 1st reduction gear section
to 2nd reduction gear section.
The eccentric bodies of crankshaft a and
b revolve eccentrically (revolution) while
rotating on its axis by rotating crankshaft.
Also, these eccentric bodies a and b and
RV gears "A" (4) and "B" (5) transmit only
the eccentric revolution.
And RV gears A and B revolve in the
same direction and number of revolutions
as spur gear and crankshaft.
b.Teeth number ZR of RV gears A and B
is always engaged with ZP pins (17)
rotating and changing the mesh part in
order, by eccentrically revolving RV gears A
and B.
By eccentrically revolving RV gears A and
B one turn, the pin revolves in the same
direction of eccentrical revolution in the
portion of difference between number of
teeth ZR and number of pins ZP [(ZP-ZR) /
ZP].
This revolution of pin is transmitted to
hub, producing output rotation of reduction
unit.
At this point, the speed ratio of 2nd
reduction gear section is as follows.

24

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［24. COMPONENTS SYSTEM］

24.1.7.3.2 HYDRAULIC MOTOR SECTION (BRAKE VALVE, HIGH AND LOW SPEED CHANGE
MECHANISM)
(1) Function
1. Hydraulic motor is referred to as a swash plate type axial piston motor which converts the
pressure oil power fed by pump into rotary motion.
2. Brake valve
a.Travel motor controls the force of rotational inertia of the body to brake and stop the rotation
smoothly.
b.Check valve function to prevent hydraulic motor from cavitation.
c.Surge cut valve function to control braking power of hydraulic motor, and anti-cavitation valve
function to prevent cavitation.
3. High and low speed change mechanism
The function of selector valve and control piston switches the tilting angle of swash plate. As a
result of the switching, travel motor has high speed low torque motion and low speed high torque
motion.
4. Parking brake
The parking brake is used to the prevent machine from running away or slipping while parking on
a slope using the friction plate type brake mechanism, and is installed on the hydraulic motor.

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 ［24. COMPONENTS SYSTEM］

(2) Operation
1. Hydraulic oil fed by pump enters rear
flange (301) of travel motor, and is led
from timing plate (109) to cylinder block
(104) through brake mechanism. This
pressure oil is led to only the one side of
Y1-Y2 tied between top dead point and
bottom dead point of piston stroke (105).
And the pressure led to one side of
cylinder block pushes 4 or 5 pistons (105),
generating the power (F1 kgf = P kgf/cm2
X A cm2). This power enters on swash
plate (103), but swash plate (103) is fixed
having an angle (α) against axis of drive
shaft (102), and divided into component of
force (F2, F3). And the radial component of
force (F3) generates various torque (T=F3
X ri) against line Y1-Y2. The total torque
[T= (F3 X ri)] is connected to turning effort,
and rotates cylinder block (104) through
piston (105).
This cylinder block (104) is connected with
drive shaft (102) with spline, and rotates
drive shaft (102) to transmit torque.

24

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［24. COMPONENTS SYSTEM］

2. braking

a.Operation (Brake released)

The pressure oil is led to through port (A), opens valve (327), and led to port (C) on the section side
of hydraulic motor to rotate hydraulic motor.
At the same time, the pressure oil enters chamber (b) through passage (a) from the small hole of
spool (323), and exerts on the end of spool to generate the force.
Then the force of spring (328) slides the spool placed on the neutral position leftward.
The sliding of spool forms the space (passage) between spool and rear flange with spool groove.
This passage is connected to port (D) and port (B) of the return circuit of the hydraulic motor, and the
return oil returns to tank side, enabling hydraulic motor to rotate.
Then, the sliding of spool (323) leads pressure oil to port (P) and port (S). The pressure oil led to
port (P) moves piston (112) of parking brake, and releases parking braking force. (For details, refer to
item "Parking brake".)
If pressurized oil is supplied from port (B) the movements of spool (323) and valve (327) are
reversed so that the hydraulic motor is rotated reversely.

b.Self-traveling
While machine is being operated, as the travel speed is increased due to steep slope, the oil flow rate
of the hydraulic motor is higher than the supply flow rate of the hydraulic oil pump. The rotation of the
hydraulic motor in this case is called a self-traveling (Overrun).
While self-traveling, the oil pressure is lowered similar to the stopping condition. Then brake valve is
moved similar to the stopping condition, throttles passage in the return side of hydraulic motor, and
generate back pressure.
In addition, the force of inertia decreases the revolution of hydraulic motor to revolution having a
balance with the supply flow rate of pump.

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 ［24. COMPONENTS SYSTEM］

c.At stop and at loss of speed (braking action)

If the pressurized oil which has been supplied from port (A) during travel action is suspended the
hydraulic force pressing the spool disappears. Then spool (323) which has been moving to the left
tries to return to the right(neutral condition) by the action of spring (328) via spring retainer (325). At
the same time, the hydraulic motor tries to turn by inertia, though the hydraulic oil supply from port (A)
is suspended. The oil discharged from the hydraulic motor has no way to escape, with the result that
the hydraulic oil in port (D) is boosted. The hydraulic oil thus boosted passes through the right-hand
valve (201) and enters the chambers (f) and (g), in that order. The piston (213) moves to the right as
shown in the figure so that the pressure does not rise. In that period, the valve (201) on the right is
pushed open by the pressure of the chamber (D).
Accordingly, the hydraulic oil of chamber (D) flows to the chamber (C) at relatively low pressure and
controls the pressure at chamber (D). At the same time, the hydraulic pressure prevents cavitation of
chamber (C). When the piston (213) arrives at the stroke end, the pressure in chambers (g), (f)
increases. The right-hand valve (210) is closed again. When the right-hand valve (201) is closed, the
oil at port (D) rises further. If the left-hand valve (201) opens, the oil in port (D) acts upon port (C)
and opens the relief valve at a much higher pressure than a set value of it. In this way, the
hydraulic motor is braked smoothly by controlling the pressure in port (D) in two steps.

24

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［24. COMPONENTS SYSTEM］

3. Parking brake

a.The pressure oil led through brake valve

actuates on spool (323) of brake valve on the
hydraulic motor section, opens passage to
parking brake, and is led to cylinder chamber
(a) compressed of spindle (2) and piston (112)
on the reduction gear section.
If the pressure of oil which is 11 kgf/cm2 (157
psi) or higher it exceeds the force of spring
(113) moving piston (112) toward rear flange
(301) side.
This movement of piston (112) reduces the
push power to separator plate (116), (169) and
friction plate (115), and makes the movement of
friction plate (115) which is installed to cylinder
block (104) on hydraulic motor section free
releasing the brake power to cylinder block
(104).

b.Stopping
If pressure oil from brake valve is cut, and the
pressure in cylinder chamber (a) lowers 11
kgf/cm2 (157 psi) or less, the piston (112) goes
to rightward by the force of spring (113).
Also, the force of the spring pushes separator
plate (116), (169) and friction plate (115),
which is in a free state because piston (112)
is pushed, against spindle (2) on the reduction
gear section. The frictional force produced by
the push power stops the rotation of cylinder
block (104), and transmits braking torque 26
kgf-m (188 lbf-ft) to hydraulic motor shaft.
And since oil is controlled through the proper
oil passage, it results in smooth operation.

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 ［24. COMPONENTS SYSTEM］

4. High and low speed change mechanism

a.At low speed

In case the travel 2-speed select pilot pressure
is not supplied from port (P), valve (363) is
pushed up by the action of spring (366) and
the hydraulic pressure from port (A) or (B). This
shuts off the pressure of (C) and the oil in the
S chamber is released to the drain (motor
casing) via the valve (363). The result is that
the swash plate (103) takes the max. tilting
angle θ1 which in turn maximizes the piston
stroke volume, making the hydraulic motor run
at low speed.

b.At high speed

In case the travel 2-speed select pilot pressure
51 kgf/cm2 (725 psi) is supplied from port (P),
valve (363) is pushed down, overcoming the
action of spring (366) and the pressure from
port (A) or (B). The pressurized oil at port (C)
is admitted to chamber S via valve (363).
Piston(161) is pushed till swash plate (103)
hits the surface X and is held.
On that occasion, the swash plate (103) takes
the min. tilting angle θ2 which in turn minimizes
the piston stroke volume to make the hydraulic
motor run at high speed.

c.Automatic selection of low speed during high

speed operation :
The pressure at port (A) or (B) increases as
the load of the hydraulic motor increase during
high speed operation, and when the pressure
arrives at 280 kgf/cm2 (3990 psi), it overcomes
the pilot pressure [51 kgf/cm2 (725 psi)] at port
(P).
Valve (363) is then pushed upward. The oil in
the S chamber is released to the drain (motor
casing) via valve (363).
On that occasion, swash plate (103) hits the
surface Y of the spindle and takes the max.
tilting angle θ1 . The angle is held to make the 24
hydraulic motor run at low speed.

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24.1.8 SWIVEL JOINT

24.1.8.1 GENERAL VIEW

General view of swivel joint

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

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［24. COMPONENTS SYSTEM］

24.1.8.3 CONSTRUCTION

Construction

No. NAME Q'TY No. NAME Q'TY

1 Body 1 7 O-ring(G95 1A) 1
2 Stem 1 8 Capscrew (M8X20) 2
3 Thrust plate 1 9 Capscrew (M8X30) 3
4 Cover 1 12 Plug 1
5 Seal 5 13 O-ring 1
6 Seal 1

24.1.8.4 FUNCTION
The swivel joint consists mainly of body (1) and stem (2) that rotate mutually, thrust plate (3)
preventing both components from falling off, cover (4) closing one side of body (1), seal (5) that
partitions off the circuits and seal assy (6) and O-ring (7) that prevent external leaks. Four ports for
the travel main circuits are provided on body (1) and stem (2). Further, four oil passing grooves are
arranged in the inner surface of body (1), with seal (5) fixed above and below the circumferential
groove. The body (1) and the stem (2) rotate mutually. The oil flowing in from body (1) or stem (2)
keeps on flowing to stem (2) or body (1) past the circumferential groove between body (1) and stem
(2) ; the oil flow is never shut off because of rotation. Further, an oil groove for lubrication that
connects with the drain port is provided, in order to prevent the body (1) from seizure with the stem
(2). This construction keeps on connecting the circuits between the swing bodies by means of a swivel
joint.

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 ［24. COMPONENTS SYSTEM］

24.1.9 CYLINDER
24.1.9.1 SPECIFICATIONS
(1) General View

General view of cylinder

(2) Specifications
Unit : mm (ft-in)
Center
Part No. of Cylinder bore/ distance of pins Dry weight
Use Stroke Cushion
cylinder assy Rod Dia. Full extend B / kg (lbs)
Full retract A
100 dia./ 70 dia. 2,648 / 1,556 With cushion on
Boom YY01V00053F2 1092 (3-7) 101 (223)
(3.94" / 2.76") (8-8.3 / 5-1.3) rod side
115 dia./ 80 dia. 1120 2,835 / 1,715 With cushion on
Arm YY01V00054F3 148 (326)
(4.53" / 3.15") (3-8.1) (9-3.6 / 5-7.5) both sides
95 dia./ 65 dia. 903 2,293 / 1,390 With cushion on
Bucket YY01V00055F3 98 (216)
(3.74" / 2.56") (2-11.6) (7-6.3 / 4-6.7) rod side

24

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［24. COMPONENTS SYSTEM］

24.1.9.2 CONSTRUCTION AND FUNCTION

24.1.9.2.1 Construction
(1) Boom cylinder

Construction of boom cylinder

P/No: YY01V00053F2
No. PARTS Q'TY No. PARTS Q'TY No. PARTS Q'TY
1 CYLINDER TUBE 1 10 BACKUP RING 1 19 DUST RING 1
2 PIN BUSHING 1 11 DUST WIPER 1 20 O-RING 1
3 PISTON ROD 1 12 O-RING: 1B G95 1 21 BACKUP RING 2
4 PIN BUSHING 1 13 BACKUP RING 1 22 PISTON NUT 1
5 ROD COVER 1 14 O-RING: 1B G100 1 23 SETSCREW: M8X16 1
6 BUSHING 1 15 CUSHION RING 1 24 SOCKET BOLT: M14 10
7 RETAINING RING 1 16 PISTON 1 25 WIPER PIN 2
8 BUFFER SEAL 1 17 SLIPPER SEAL 1 26 WIPER PIN 2
9 U-PACKING 1 18 WEAR RING 2

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(2) Arm cylinder

Construction of arm cylinder

P/No: YY01V00054F3
No. PARTS Q'TY No. PARTS Q'TY No. PARTS Q'TY
1 CYLINDER TUBE 1 12 O-RING : 1B G110 1 23 SET SCREW : M8 1
2 PIN BUSHING 2 13 BACK-UP RING 1 24 CUSHION PLUNGER 1
3 PISTON ROD 1 14 O-RING : 1B G115 1 25 STOP RING 1
4 PIN BUSHING 2 15 CUSHION RING 1 26 SOCKET BOLT : M16 10
5 ROD COVER 1 16 PISTON 1 27 CHECK VALVE 1
6 BUSHING 1 17 SLIPPER SEAL 1 28 SPRING 1
7 RETAINING RING 1 18 WEAR RING 2 29 SPRING SUPPORT 1
8 BUFFER SEAL 1 19 DUST RING 2 30 O-RING : 1B P14 1
9 U-PACKING 1 20 O-RING 1 31 PLUG : PT3/8 1
10 BACK-UP RING 1 21 BACK-UP RING 2 32 WIPER RING 4
11 DUST WIPER 1 22 PISTON NUT 1

24

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［24. COMPONENTS SYSTEM］

(3) Bucket cylinder

Construction of bucket cylinder

P/No: YY01V00055F3
No. PARTS Q'TY No. PARTS Q'TY No. PARTS Q'TY
1 CYLINDER TUBE 1 10 BACKUP RING 1 19 DUST RING 2
2 PIN BUSHING 1 11 DUST WIPER 1 20 O-RING 1
3 PISTON ROD 1 12 O-RING: 1B G90 1 21 BACKUP RING 2
4 PIN BUSHING 1 13 BACKUP RING 1 22 PISTON NUT 1
5 ROD COVER 1 14 O-RING: 1B G95 1 23 SETSCREW: M8X16 1
6 BUSHING 1 15 CUSHION RING 1 24 SOCKET BOLT: M14 8
7 RETAINING RING 1 16 PISTON 1 25 WIPER PIN 2
8 BUFFER SEAL 1 17 SLIPPER SEAL 1 26 WIPER PIN 2
9 U-PACKING 1 18 WEAR RING 2

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 ［24. COMPONENTS SYSTEM］

Hydraulic cylinder construction (See Fig. 24.1.8.2 CONSTRUCTION AND FUNCTION)

By construction the hydraulic cylinder consists mainly of cylinder tube assy (1), piston rod assy (3) that
takes out the motion of pistons reciprocating in the cylinder tube assy, and rod cover (5) that serves
as both a lid and a guide. Cylinder tube assy (1) is equipped with a piston mount (clevis) that
connects piston rod assy (3) with other parts.
In addition to these main components, slipper seal (17) and ware ring (18) are located between,
cylinder tube assy (1) and piston rod assy (3) ; buffer seal (8), rod packing (9) and dust seal (11)
are located between piston rod assy (3) and rod cover (5) ; and an O-ring and a back-up ring are
placed between cylinder tube assy (1) and rod cover (5).

24.1.9.2.2 OPERATION
If pressurized oil is fed alternatively to the oil inlet and outlet provided in the cylinder, force acts on
the piston which in turn causes the piston rod (3) to extend and retract.

(1) Operation of cylinder with cushion

1. Cushion on rod side
The cushion mechanism is provided to prevent
the generation of shock when the moving speed
of piston (16) is not reduced and strikes rod
cover (5).
An oil in chamber "A" returns to the tank by
passing through paths "B" and "C" at a fixed
flow rate in a intermediate stroke state (right
Fig.) of pressing bottom side. Next, in a state Cushion mechanism on the rod side
of just before stroke end (right Fig.), cushion
ring (15) plunges into path "B".
At this time, an oil in chamber "A" passes
clearance "D" and mouth gap "C", an oil flow
volume returning to tank suddenly drops and
the piston part movement slows down.

Rod side cushion Cushioning action on the rod side

24

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［24. COMPONENTS SYSTEM］

2. Cushion on head side

This construction is similar to the one of
cushion on rod side. In a state of intermediate
stroke pressing rod side, an oil in chamber "A"
returns to tank by passing through paths "B"
and "C" at a fixed flow rate.
Next, in a state of just before stroke end,
plunger plunges into path "B". At this time, an
oil in chamber "A" path clearance "D" and
restricted path "C", an oil flow volume returning
to tank suddenly drops and the piston part
movement slows down.

Cushioning action on the head side

24-110
 ［24. COMPONENTS SYSTEM］

24.2 ELECTRICAL EQUIPMENT

24.2.1 ELECTRICAL EQUIPMENT LIST

Group Code Part Name Part No.

C - 1 Mechatro controller YN22E00214F1
C - 2 Gauge cluster YN59S00021F3
(C) Controller C - 4 Air-con controler (including panel) YN20M01468P4
C - 8 Engine controller 32G87-01020

D - 4 Diode YN02D01001P1
D - 5 Diode Accessory of relay box
D - 6 Diode
D - 9 Diode
D - 10 Diode
D - 12 Diode
D - 13 Diode
D - 14 Diode
(D) Diode
D - 15 Diode
D - 16 Diode
D - 17 Diode
D - 18 Diode
D - 19 Diode
D - 20 Diode
D - 21 Diode
D - 32 Diode YN02D01001P1
E - 1 Fuse and Relay box YY24E00008F2
E - 2 Alternator 32G68-00100
E - 3 Hour meter YT58S00006P1
E - 5 Horn high LC53S00001D1
E - 6 Horn low LC53S00001D2
E - 10 Receiver dryer YN54S00041P1
(E) Electric fittings
E - 11 Air-con compressor YX91V00001F1
E - 12 Battery 2484U171
E - 14 Cigaratte lighter YN81S00003P1
E - 15 Fusible link YY73S00003P1
E - 27 Accel redumdant volume YN52S00052P1
24
E - 38 Resister LC22E01001D1
L - 1 Boom work light (LH) YW80S00001F1
L - 2 Frame work light (RH) YT80S00002F2
(L) Light L - 3 Swing flasher (LH) YM80S00001F1
L - 4 Swing flasher (RH) YM80S00001F2
L - 5 Room light YT80S00001P1

24-111
［24. COMPONENTS SYSTEM］

Group Code Part Name Part No.

M - 1 Starter motor 32G66-00100
M - 3 Wiper motor YN53C00012F2
(M) Motor M - 4 Washer motor (Tank assy) YT54C00003F1
M - 8 Grease motor LC71V00001P1
M - 9 Roof wiper motor YN76S00005P1
PSV - A Arm 2 speed inverse propo. valve YN35V00049F1
PSV - B P2 unload propo. valve (YY35V00013F1) YN35V00048F1

(P) Proportional PSV - C Travel straight propo. valve Solenoid valve assy
solenoid valve PSV - D P1 unload propo. valve
PSV - P1 P1 pump propo. valve (YN10V00023F1) YN35V00052F1
PSV - P2 P2 pump propo. valve Pump accesory

R - 1 Battery relay YN24S00008F1

R - 2 Starter relay Engine accessory
R - 3 Glow relay 34390-00601
Safety relay Accessor of relay
R - 4
box
R - 5 Horn relay YN24S00010P1
R - 6 Working light relay
R - 19 Flasher relay YY24S00001F2
R - 23 Auto idle stop relay 1 YN24S00010P1
(R) Reray
R - 24 Auto idle stop relay 2
R - 25 Engine emergency stop relay
R - 26 Lever lock relay
R - 28 Alternator relay
R - 29 Wiper motor relay (Normal rotation) YN24S00012P2
R - 30 Wiper motor relay (Reverse rotation)
R - 31 Prevent spark relay
R - 32 Washer motor relay
R - 53 Glow relay (ECU)

24-112
 ［24. COMPONENTS SYSTEM］

Group Code Part Name Part No.

SE - 1 Pressure sensor : Bucket digging YX52S00013P1
SE - 2 Pressure sensor : Bucket dump
SE - 3 Pressure sensor : Boom up
SE - 4 Pressure sensor : Boom down
SE - 5 Pressure sensor : Swing
SE - 7 Pressure sensor : Arm in
SE - 8 Pressure sensor : Arm out
SE - 9 Pressure sensor : Travel RH
(SE) Sensor SE - 10 Pressure sensor : Travel LH
SE - 11 Pressure sensor : P2 OPT.
SE - 13 E/G speed sensor Engine accessory
SE - 15 Fuel sensor YN52S00045F1
SE - 16 Accel potentiometer YN52S00032P1
SE - 20 Pressure sensor : P1 OPT. YX52S00013P1
SE - 22 Pressure sensor : Pump P1 LS52S00015P1
SE - 23 Pressure sensor : Pump P2
SE - 29 Opt. selector detect sensor YX52X00013P1
SV - 1 Swing parking brake SOL. YN35V00051F1
SV - 2 - (YY35V00013F1) -
(SV) Solenoid
SV - 3 Two speed select SOL Solenoid valve assy YN35V00050F1
SV - 4 Safety lock lever SOL
SW - 1 Key switch YN50S00026F1
SW - 4 Swing parking brake release switch YN50S00047P1
SW - 5 Horn switch (RH) YN50E00017P1
SW - 8 Air filter clogging switch YR11P00008S005
SW - 10 Horn switch (LH) YN50E00017P1
SW - 11 Safety lock lever switch YN50S00041P1
(SW) Switch SW - 15 Conflux/single select switch YN50S00040DD
SW - 17 Skylight wiper switch YN50S00040D9
SW - 19 Wiper interlock switch YT50S00004P1
SW - 22 KPSS release switch YX50S00001F1
SW - 36 Water separator restrlction switch 32G90-00300
SW - 55 Boom work light switch YN50S00040D1
SW - 111 Attachment mode select switch (OCEANIA) PY50S00003P2

24

24-113
［24. COMPONENTS SYSTEM］

24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT

24-114
 ［24. COMPONENTS SYSTEM］

24

24-115
［24. COMPONENTS SYSTEM］

24-116
 ［24. COMPONENTS SYSTEM］

24

24-117
［24. COMPONENTS SYSTEM］

24-118
 ［24. COMPONENTS SYSTEM］

24

24-119
［24. COMPONENTS SYSTEM］

24-120
 ［24. COMPONENTS SYSTEM］

24

24-121
［24. COMPONENTS SYSTEM］

24-122
 ［24. COMPONENTS SYSTEM］

24

24-123
［24. COMPONENTS SYSTEM］

24-124
 ［24. COMPONENTS SYSTEM］

24

24-125
［24. COMPONENTS SYSTEM］

24-126
 ［24. COMPONENTS SYSTEM］

24

24-127
［24. COMPONENTS SYSTEM］

24-128
 ［24. COMPONENTS SYSTEM］

24

24-129
［24. COMPONENTS SYSTEM］

24-130
 ［25. AIR-CONDITIONER SYSTEM］

25

25. AIR-CONDITIONER SYSTEM

TABLE OF CONTENTS

25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER) ………………………………25-3

25.1.1 AIR CYCLE …………………………………………………………………………………………………25-3
25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE ……………………………………………………25-4
25.2 COMPONENT AND CONSTRUCTION ………………………………………………………………………25-5
25.2.1 COMPONENT ………………………………………………………………………………………………25-5
25.2.2 CONSTRUCTION …………………………………………………………………………………………25-6
25.3 PIPING ……………………………………………………………………………………………………………25-9
25.3.1 AIR CONDITIONER ………………………………………………………………………………………25-9
25.3.2 AIR DRYER ASSY ………………………………………………………………………………………25-12
25.4 FUNCTION ………………………………………………………………………………………………………25-13
25.4.1 MECHANISM OF COOLING CIRCUIT …………………………………………………………………25-13
25.4.2 COOLING CIRCUIT ………………………………………………………………………………………25-15
25.4.3 COMPONENT PARTS ……………………………………………………………………………………25-16
25.5 DISASSEMBLY AND ASSEMBLY……………………………………………………………………………25-20
25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION ……………………………………………25-20
25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT …………………………………………………………25-22
25.6 CHARGING REFRIGERANT …………………………………………………………………………………25-26
25.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION ……………………………………………25-26
25.6.2 OPERATING PROCEDURE ……………………………………………………………………………25-28
25.6.3 CHARGING PROCEDURE ………………………………………………………………………………25-29
25.7 ELECTRIC CIRCUIT ……………………………………………………………………………………………25-34
25.7.1 WIRING DIAGRAM AND CONNECTORS ……………………………………………………………25-34
25.7.2 STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION
…………………………………………………………………………………………………………………………25-36
25.8 TROUBLESHOOTING …………………………………………………………………………………………25-39
25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL ………………………………………………25-46
25.9.1 POSITION OF INDICATION FOR FAILURE …………………………………………………………25-46
25.9.2 EXPLANATION OF INDICATION FOR FAILURE ……………………………………………………25-46
25.9.3 EXPLANATION OF MONITOR MODE …………………………………………………………………25-48

Book Code No. S5YP2501E01

25-1
［25. AIR-CONDITIONER SYSTEM］

Issue Date of Issue Applicable Machines Remarks

S5YP2501E01
First Edition July, 2009 SK140LC-8 : YP09-05001~
(SE Asia)

25-2
 ［25. AIR-CONDITIONER SYSTEM］

25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR

CONDITIONER)
25
Air-conditioner is the unit which places evaporator and heater core parallel, and unifies a blower fan
and an inside / outside air switching unit. And this unit changes hot air to cool air.

25.1.1 AIR CYCLE

・ Heater
Inside air or outside air is taken in through intake port and the air is passing through filter and
heat exchange is performed with hot air (heating) at the heater core of air-con unit, and then the
heated air blows off from grille through duct.
・ Cooler
Inside air or outside air is taken in through intake port and the air is passing through filter and
heat exchange is performed with cold air (dehumidifying and cooling) at the evaporator of air-con
unit, and then the cooled air blows off from grille through duct.
・ Heater system
The heater recycles (circulates) the cooling water in the engine, and the hot water delivered by
the engine flows in the heater core of air-con unit and then heat exchange is performed.
The intake air is heated and the heated air blows off from the grille provided on the inside of cab.
The blow off air temperature is controlled by the temperature control switch on the control panel,
and the operation is controlled by air mixing damper on the air-con unit.

25-3
［25. AIR-CONDITIONER SYSTEM］

25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE

25-4
 ［25. AIR-CONDITIONER SYSTEM］

25.2 COMPONENT AND CONSTRUCTION

25
25.2.1 COMPONENT

Air-conditioner group

A/C ASSY: LP20M00009F1 (02)

No. Parts Q'ty No. Parts Q'ty No. Parts Q'ty
27 Air-conditioner assy 1 33 Pulley 1 35-7 L hose 1
27-1 Air-conditioner unit 1 34 Condenser 1 35-8 L hose: 15 dia. 1
27-2 Hose 2 35 Air dryer assy 1 35-9 S tube: 16 dia. 1
27-3 Clamp 2 35-1 Receiver dryer 1 35-10 L tube: 8.5 dia. 1
27-4 Filter 1 35-2 Bracket 1 35-11 D tube: 12 dia. 1
30 Panel assy 1 35-5 S hose: 24 dia. 1 39 Filter 1
32 Compressor 1 35-6 D hose 1 40 Solar radiation sensor 1

25-5
［25. AIR-CONDITIONER SYSTEM］

25.2.2 CONSTRUCTION
(1) Air conditioner unit

Air conditioner unit (1/2)

25-6
 ［25. AIR-CONDITIONER SYSTEM］

25

Air conditioner unit (2/2)

25-7
［25. AIR-CONDITIONER SYSTEM］

Air conditioner unit: YN20M00107F5 (06)

No. Parts Q'ty No. Parts Q'ty No. Parts Q'ty
1 Screw M5X16 23 24 Screw M5X40 2 63 O-ring 1
2 Main harness 1 26 Thermistor holder 1 77 Packing 1
3 MA air mix 3 27 Heater core 1 78 Tube 1
4 Blower controller 1 28 Pipe holder 1 79 Tube 1
6 Air mix door 1 31 Screw M4X30 9 82 Tube 1
7 Air mix lever 1 36 Foot door 1 83 Bracket 1
9 Air mix door sub 1 37 Vent door 1 84 Lower casing 1
10 Air mix lever sub 1 38 Face door 1 85 Thermistor 1
11 Blower 1 39 KK box upper packing 1 86 Upper casing 1
12 Lever MA air mix 1 40 KK-box lower packing 1 87 Lower casing 1
13 Intake door 1 41 Vent lever 1 88 MA mode lever 1
14 MA intake lever 1 42 Face lever 1 89 Face lever cam 1
15 Intake lever 1 43 Foot joint lever 1 90 Vent lever cam 1
16 Intake rod 1 45 Foot lever 1 91 Foot rod 1
17 Air mix rod 1 49 Vent rod 1 92 Plate 1
18 Air mix rod sub 1 50 Foot rod 1 93 Upper casing 1
19 Relay 2 51 Plate 1 94 Thermistor 1
20 Evaporator 1 54 Capscrew 1 95 Packing 3
21 Expansion valve 1 60 Evaporator packing 1 96 Packing 1
22 O-ring 1 61 Casing packing A 1 97 Packing 1
23 O-ring 2 62 Casing packing B 1

(2) Receiver dryer

Receiver dryer

25-8
 ［25. AIR-CONDITIONER SYSTEM］

25.3 PIPING

25
25.3.1 AIR CONDITIONER

Air conditioner piping (1/2)

25-9
［25. AIR-CONDITIONER SYSTEM］

Air conditioner piping (2/2)

25-10
 ［25. AIR-CONDITIONER SYSTEM］

Air conditioner: LP20M00009F1 (02)

Tightening Tightening
torque No. Parts Q'ty torque No. Parts Q'ty 25
N-m (lbf-ft) N-m (lbf-ft)
1 Hose : L = 2700 1 35 Air dryer assy 1
2 Hose : L = 3200 1 39 Filter 1
3 Bracket 2 40 Solar radiation sensor 1
4 V-belt 1 49 Clip 1
3.92~4.9 (2.9~3.6) 5 Clip 4 50 Connector 1
46.5 (33.3) 6 Sems bolt : M10X25 5 51 Connector 1
4.9 (3.6) 7 Sems bolt : M6X20 2 46.5 (33.3) 53 Sems bolt : M10X20 2
23.0 (16.9) 8 Sems bolt : M8X20 7 54 Grommet 1
23.0 (16.9) 9 Capscrew : M8X100 4 55 Grommet 1
10 Washer : M8 8 58 Tube : L = 100 1
12 Tube for heater : L = 1700 1 59 Bracket 1
13 Tube for heater : L = 2100 1 60 Pulley 1
14 Tube for D hose : L = 2500 1 46.5 (33.3) 61 Capscrew : M10X25 6
15 Tube for S hose : L = 2000 1 62 Washer : M10 6
16 Bracket 1 63 Clip 1
17 Tube for L hose : L = 1100 1 23.0 (16.9) 66 Nut 2
46.5 (33.3) 22 Sems bolt : M10X45 4 67 Bracket 1
23.0 (16.9) 23 Sems bolt : M8X25 6 70 Clip 1
24 Clip 4 9.7 (7.2) 71 Nut : M6 4
25 Clip 16 72 Washer 4
26 Clip 3 73 Washer 4
27 Air conditioner assy 1 74 Rubber 4
30 Panel 1 23.0 (16.9) 75 Capscrew : M8X55 4
32 Compressor assy 1 76 Washer : M8 4
46.5 (33.3) 33 Pulley assy 1 77 Bracket 2
34 Condenser 1

25-11
［25. AIR-CONDITIONER SYSTEM］

25.3.2 AIR DRYER ASSY

Air dryer assy: LP96V00002F1 (01)

Tightening torque Tightening torque
No. Parts Q'ty No. Parts Q'ty
N-m (lbf-ft) N-m (lbf-ft)
1 Receiver dryer 1 7 L hose 1
2 Bracket 1 8 L hose 1
3 Capscrew 2 9 S tube 1
4 Capscrew 2 10 L tube 1
5 S hose 1 11 D tube 1
6 D hose 1

25-12
 ［25. AIR-CONDITIONER SYSTEM］

25.4 FUNCTION

25
25.4.1 MECHANISM OF COOLING CIRCUIT
(1) Mechanism of Cooling
In the cooling process, the refrigerant that
flows through the cooling circuit changes its
phases from liquid to gas and vice versa during
which process heat is transferred from the low
temperature part (compartment) to the high
temperature part (outside of the vehicle).

1. Kind of Refrigerant
Many kinds of refrigerants that change in that
way are available, but the following equirements
are needed for use in such applications:

・ Latent heat of vaporization (heat of vaporization) is large.

・ It is easy to liquefy (condense). (It dose not require very high pressure for condensation.)
・ It is easy to gasify (evaporate). (It evaporates sufficiently at not too low pressure, i.e. cools down
an object.)
・ It has small specific heat. (Since the refrigerant itself is cooled by the expansion valve, the loss
resulting from it must be held down to a minimum.)
・ It has a high critical temperature and a low solidification point.
・ It is stable chemically and does not corrode and permeate into the circuit parts.
・ It is free from toxicity, objectionable odor, flammability and explosiveness and excels in thermal
conductivity and electric insulation.
・ It has small specific volume.
・ It is easy to find out leakage.
Out of refrigerants meeting the above-mentioned requirements, ones having characteristics that
suit the intended cooling unit are chosen and used. If a refrigerant other that those designated is
used, sufficient refrigeration will not be performed or the equipment in which the refrigerant is used
may be broken. Therefore, always use a designated refrigerant for the cooling unit.
Table shows the principal characteristics of the R134a refrigerant that is used in this machine.

25-13
［25. AIR-CONDITIONER SYSTEM］

(2) Characteristics of Refrigerant (Right Fig.)

In general, the fluid (general term of gas and
liquid) has the following qualities:
1.
As a gas under certain pressure is cooled
down, it begins to condensate at a certain
temperature to take a liquid state. The
temperature at which condensation begins is
unique to each substance (fluid) at a given
pressure. The temperature determined by a
given pressure is called saturation temperature.
Pressure-temperature characteristics of R134a

2.
Inversely to 1) above, the pressure at which a gas condenses for a temperature is determined. This
pressure is called saturation pressure.
above Fig. 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 above Fig. the refrigerant take a gaseous state, while at the
temperature and the pressure on the upper lefthand side of the curve, the refrigerant takes a liquid
state.
Let us think of a case where an air-conditioner is operated in the midst of summer. As the refrigerant
evaporates, it absorbs evaporation heat from the air of the compartment. In order to cool the inside of
the compartment down to 25C degrees (77F degrees), the refrigerant must transform (evaporate) from
a liquid to a gaseous state at a lower temperature. It can be seen from above Fig. that R134a under
a pressure above the atmospheric pressure is capable of cooling the inside of the compartment
sufficiently. (If a refrigerant that requires a pressure below the atmospheric pressure to cool it to a
required temperature is used, air is mixed into the circuits, thereby deteriorating the performance of the
cooling unit.) In the process in which gaseous refrigerant is brought back to a liquid state, the
refrigerant is cooled and condensed by the outer air exceeding 35C degrees (95F degrees).
Accordingly the refrigerant is capable of condensing at a pressure exceeding 1 MPa (145psi), as seen
from above Fig.

25-14
 ［25. AIR-CONDITIONER SYSTEM］

25.4.2 COOLING CIRCUIT

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

25-15
［25. AIR-CONDITIONER SYSTEM］

25.4.3 COMPONENT PARTS

(1) Evaporator (See right Fig.)
The evaporator is an important heat exchanger
that absorbs the heat of the compartment air
(object) by the utilization of the latent
vaporization heat of the low-temperature,
low-pressure liquid-state refrigerant. Therefore,
it is necessary that satisfactory heat transfer
between the object and the refrigerant take
place in the evaporator.
To that end, the evaporator is equipped with
fins on the air side in order to increase the
heat transfer area of the air side and thereby
perform excellent thermal transfer between the
refrigerant and the air.
The humidity in the air condenses as the air
cools down and adheres to the outside of the
evaporator as water drops. The cooling effect
deteriorates if the water drops freeze. Therefore,
how to discharge water is an important point.
The amount of refrigerant supplied to the
evaporator is controlled by the expansion valve
which is described in the following. In order to
attain proper control, it is necessary to reduce
the pressure drop of the refrigerant of the
evaporator. Accordingly, reducing the pressure
drop is one element that makes the evaporator
attain its full performances.

(2) Expansion Valve

In order for the evaporator to fulfill its performances, a proper amount of low-pressure low-temperature
liquid refrigerant must be fed to the evaporator.
If the feed rate is too low, the refrigerant completes vaporization early in the evaporator which results
in deterioration of the cooling effect. If the feed rate is too high, unvaporized liquid refrigerant returns
to the compressor (liquid back). This not only deteriorates the cooling effect, but also damages the
compressor valves.
The expansion valve feeds the flowing high-pressure high-temperature liquid refrigerant to the
evaporator as low-pressure low-temperature liquid refrigerant (damp vapor of low dryness). The
expansion valve controls the feed rate of the refrigerant at the same time.

25-16
 ［25. AIR-CONDITIONER SYSTEM］

Right Fig. shows how the block type

expansion valve is constructed. The temperature
sensing part is provided in the shaft of the
25
expansion valve to directly detect the
refrigerant temperature at the outlet of the
evaporator.
The diaphragm contains R134a in saturated
state. The pressure in the diaphragm changes
according to the temperature detected by the
sensor. The change in the pressure causes
the force acting upon the diaphragm to vary
accordingly.
The high-pressure high-temperature liquid
refrigerant that is fed from the receiver side
reduces the pressure abruptly as it passes
through the valve (throttling action). On that Block type expansion valve
occasion, part of the refrigerant evaporates by
the very heat of the refrigerant and cooled off.
The result is that low-pressure low-temperature
damp refrigerant vapor 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 under the pressure in the evaporator, the
refrigerant is properly overheated (3 to 8C
degrees ) and goes out of the evaporator. This
action is carried out by sensing the refrigerant
temperature at the outlet of the evaporator as
against the inlet pressure of the evaporator
and consequently controlling the feed rate of
the refrigerant.

This means that if the refrigerant pressure

drop in the evaporator is excessive, it is difficult
to control the overheating or the feed rate of
the refrigerant. For this reason, the smaller the
pressure drop of the evaporator, the better.
The expansion valve senses the pressure and
the temperature at the outlet of the evaporator
and controls the overheating of the refrigerant
Expansion valve outside view
and the refrigerant supply to the evaporator
more securely. The air-conditioner of this
machine adopts a block type expansion valve.

25-17
［25. AIR-CONDITIONER SYSTEM］

(3) Compressor (See right Fig.)

The compressor performs the following three
functions in the cooling circuit:
1) Suction action
2) Pumping action
3) Compressive action

1. The suction action, as combined with the throttling action, works to decrease the refrigerant
pressure in the evaporator. This permits the refrigerant to vaporize at low temperature in order to
perform cooling effect.
2. The pumping action serves to cause all the refrigerant to circulate in the cooling circuit. This
enables enables continuous cooling.
3. The compressive action, as combined with the 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 35C degrees (77F degrees)
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 right Fig.)

This is a heat exchanger that cools the
vaporized refrigerant at high temperature and
high pressure by the use of outer air and
condenses the refrigerant. The direction in
which heat moves is from the refrigerant to air,
the opposite to the case of the evaporator. Fins
are equipped on the outer air side to improve
thermal transfer. If the refrigerant is not cooled
well by the condenser, the air in the
compartment can not be cooled sufficiently by
the evaporator. For that purpose, it is necessary
to secure ventilation required for the cooling of
the refrigerant. Condenser

25-18
 ［25. AIR-CONDITIONER SYSTEM］

(5) Receiver dryer (See right Fig.)

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

25-19
［25. AIR-CONDITIONER SYSTEM］

25.5 DISASSEMBLY AND ASSEMBLY

25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION

(1) Special Refrigerator Oil
This air-conditioner uses special refrigerator oil
SP20 for use with new refrigerant R134a. Oils
other than SP20 may not be used. Since
SP20 tends to absorb moisture and may
corrode paint and resin, the following points
must be noted:
1.
Do not keep open all pipe connections on a
new compressor and the component parts of
the installed refrigeration circuit
(Remove valves and caps at the pipe openings
of the compressor, just before connecting pipes.
If you have removed a pipe joint for repair,
put a cap to both ports immediately.)
2.
Use care so SP20 does not adhere to the
painted surface and resin parts. In case SP20
has adhered to such surfaces, wipe it off
immediately.

(2)
The receiver dryer is filled with desiccant to
absorb moisture in the circuit. Therefore,
remove the valve at the pipe port immediately
before connecting pipes.

(3)
Tightening Torque
1. Pipe Joints
When connecting pipe joints, coat the O-ring
with special oil (SP20) and fasten to the
tightening torque indicated in the table, using a
double spanner.
2. Screws and Bolts
Fasten to the tightening torque indicated in the
table

25-20
 ［25. AIR-CONDITIONER SYSTEM］

(4)
Amount of Oil for Compressor
The compressor SD7H (HD type) is filled with
25
135cc (8.2cu-in) of oil. If the oil volume is
small, seizure at high revolution and shortening
of service life will occur. If the oil volume is
large, the cooling ability will be deteriorated.
Once the air-conditioner is operated, part of
the oil is dispersed in the refrigeration circuit.
Therefore, when replacing the parts in right
Table, 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.

25-21
［25. AIR-CONDITIONER SYSTEM］

25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT

(1) Removing inner air filter
Slide the inner air filter leftward and remove it
from the unit.

(2) Removing selector box

Remove 6 plus screws, remove connector
connected to the mode actuator on mode
selector box, and separate the mode selector
box from the unit.

(3) Removing main harness

Pull out 3 harness clamps from the unit, and
disconnect all connected connectors and remove
harness on the body from the unit.

(4) Removing upper unit case

1.
Remove air MIX rod and air MIX rod sub from
air MIX lever.
2.
Remove 12 plus screws which are used to
install the upper and lower unit casings.
Pull out the upper unit casing upward giving
attention to the thermistor harness so as not
to be caught by the casing.

25-22
 ［25. AIR-CONDITIONER SYSTEM］

(5) Replacing blower controller

1.
Remove 2 plus screws and remove the blower
25
controller from the upper unit casing.
2.
Install new blower controller by the reverse
procedure of removal.

* Do not disassemble the blower controller.

(6) Removing heater core

1.
After draining the coolant, remove heater hose
from the heater core.
2.
Remove 1 plus screw, and remove pipe clamp
which is used to secure the heater core and
then remove the heater core from the lower unit
casing.
3.
Install it by the reverse procedure of removal.

(7) Replacing blower motor

1.
Disconnect connector which is connected to
the blower motor and remove the blower motor
from the lower unit casing.

* Do not remove the fan from the blower motor.

2.
Install it by the reverse procedure of removal.

(8) Replacing evaporator and expansion valve

1.
Take the evaporator with expansion valve off
from the lower casing.
2.
Remove evaporator sensor with sensor holder
from the removed evaporator.
3.
Insert the sensor holder into the new evaporator
at the position shown in right Fig. and install
the evaporator sensor again.

25-23
［25. AIR-CONDITIONER SYSTEM］

4.
Remove 2 socket bolts M5X40 with Allen
wrench (4mm) and remove the expansion
valve from the evaporator.
5.
Fit O-ring (NF O-ring 5/8 and 1/2 one each) to
new evaporator.
* When assembling again, fit O-ring paying
attention so as not to be caught with others.
(Socket bolt M5X40 (2 pcs.) Tightening torque
: 6.9Nom (5.1lbfoft)
* Do not apply undue force to pipe of
evaporator outlet. This undue stress causes
the leak of refrigerant from "A" part of
evaporator.
Moreover, when tube (78), (79) (see Structual
chart of air conditioner unit) connected with
expansion valve is disconnected from
expansion valve, similar careful work is
necessary.

(9) Replacing motor actuator

1. Replacing mode actuator
a.
Remove connector connected to the motor
actuator.
b.
Remove FACE rod and VENT rod which is
used to connect MA mode lever and mode cam
from the holder.
c.
Remove 3 plus screws and remove the motor
actuator with lever MA mode from the unit.
d.
Remove the lever MA mode from the removed
motor actuator, and install it on new motor
actuator by the reverse procedure of removal.

25-24
 ［25. AIR-CONDITIONER SYSTEM］

2. Replacing air mixing actuator

a.
Remove connector connected to the motor
25
actuator.
b.
Remove rod air MIX which is used to connect
the motor actuator and the lever MA air MIX.
c.
Remove 3 plus screws and remove the motor
actuator with MA lever air MIX from the unit.
d.
Remove the MA lever air MIX from the
removed motor actuator, and install it on new
motor actuator by the reverse procedure of
removal.

3. Replacing inner and outer air switching

actuator
a.
Disconnect connector connected to the motor
actuator.
b.
Remove intake rod from MA intake lever.
c.
Remove 3 plus screws and remove the motor
actuator with MA intake lever from the unit.
d.
Remove the MA intake lever from the removed
motor actuator, and install it on new motor
actuator by the reverse procedure of removal.

25-25
［25. AIR-CONDITIONER SYSTEM］

25.6 CHARGING REFRIGERANT

25.6.1 PRECAUTIONS TO BE EXERCISED IN OPERATION

(1) Always assign a person in charge of handling refrigerant.
Refrigerant charge operation involves dangers as it handles high pressure gas. Always assign a person
familiar with how work is done for handling refrigerant.

- Wear protective goggles. (You may lose your sight if the refrigerant gets in your eyes.)
- The refrigerant in liquid state is at very low temperature [approx. -26C degrees (-15F degrees)].
Therefore, handle it with care. (You may get a frostbite if the refrigerant is sprayed over your skin.)

(2) Storage and Transportation

1. Keep the service can (hereinafter called can) less than 40C degrees (104F degrees). 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 40C degrees (104F degrees).
2. For storage, choose a cold dark place not exposed to direct sunlight.
3. If the can is placed near a fire source, it is subject to radiation heat and gets hot. This causes
the inside pressure to rise and may cause the can to blow out. Do not bring the can close to a
fire.
4. The inside of the closed compartment gets very hot as the radiation heat of the sunlight enters
the compartment. The areas of the compartment which are exposed to direct sunlight may rise to
a dangerous temperature level. Do not bring the can into the compartment. Also, the inside of
the trunk room may rise to a dangerous temperature level even in the summer time. Use sufficient
care, therefore, taking the above into account.
5. Note that if the can has scratches, dents and distortion, the strength of the can will deteriorate.
a. Do not drop or knock on the can.
b. 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 40C
degrees (104F degrees 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.

25-26
 ［25. AIR-CONDITIONER SYSTEM］

(4) Others
Reuse of service cans is prohibited by law; never use them again. Do not allow foreign matter to
enter the air-conditioner circuit. Air, water and dust are detrimental to the refrigeration cycle. Install the
25
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 the specified torque.

25-27
［25. AIR-CONDITIONER SYSTEM］

25.6.2 OPERATING PROCEDURE

(1)
Refrigerant charge into the air-conditioner consists mainly of "vacuum making operation", and "gas
charge operation".

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

(2) Operation Chart

(3) Tools

25-28
 ［25. AIR-CONDITIONER SYSTEM］

25.6.3 CHARGING PROCEDURE

25.6.3.1 VACUUM MAKING OPERATION 25
(1) Connecting gauge manifold (See right Fig.)
1.
Close the high pressure valve (HI) and the low
pressure valve (LO) of the gauge manifold.
2.
Connect the charging hoses (red and blue)
with the service valves of the compressor.
Red hose :
High pressure side (HI) of the gauge manifold
--> high pressure side (DIS) of compressor
Blue hose :
Low pressure side (LO) of gauge manifold -->
low pressure side (SUC) of compressor

Do not mistake the high pressure hose for the low pressure hose in any circumstances when
connecting them. Put the hose in firmly till a clicking sound is heard.

3.
Connect the center valve of the gauge
manifold with the charging hose of the vacuum
pump.

Connecting gauge manifold

Some kinds of gauge manifolds are not equipped with an open/close valve in the center.

25-29
［25. AIR-CONDITIONER SYSTEM］

(2) Vacuum making (See right Fig.)

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.
3.
When vacuum making for a specified duration
is over (degree of vacuum : less than - 750
mmHg), close the high pressure valve and the
low pressure valve of the gauge manifold.
4.
Then turn off the vacuum pump.

Vacuum making operation

(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 indication does not return toward 0.

If the gauge indication goes toward 0, there is somewhere that is leaking. Retighten pipe joints,
make vacuum again and make sure of no leakage.

25-30
 ［25. AIR-CONDITIONER SYSTEM］

25.6.3.2 GAS CHARGING OPERATION

(1) Charging from high pressure side (See right Fig.)
1.
25
After making vacuum repeatedly, change the
charging hose (yellow) of the gauge manifold
from the vacuum pump to the service can.

2.
Air purge
Open the service can valve. (However, close
the high and low pressure valves of the gauge
manifold.) Then push the gas valve of the side
Gas charging operation
service port on the low pressure side of the
gauge manifold, using a screw driver, in order
to let out the air in the charging hose by the
pressure of the refrigerant. (See right Fig.)
(The operation ends when a hissing sound is
heard.)

3.
Open the high pressure valve of the gauge
manifold and charge in refrigerant. [Charge in
gaseous refrigerant to a gauge pressure of
0.1MPa (14psi).]
After charging, close the high pressure valve
of the gauge manifold and the service and
valve. (See right Fig.)

Gas charging operation (High pressure side)

Do not run the compressor during this work, (Otherwise the refrigerant flow in reverse direction which
causes the service can and the hoses to rupture. This is very dangerous.)

(2) Checking for gas leak

Check for gas leak in the cycle, using a gas leak detector (electric type). Retighten and correct leaking
points.

Always use the leak tester for R134a. (Do not use one for flon gas service as it provides poor
sensitivity.)

25-31
［25. AIR-CONDITIONER SYSTEM］

(3) Charging from low pressure side (See right Fig.)

1.
Make sure that the high-pressure and
low-pressure valves of the gauge manifold and
the service can valve are closed.
2.
Start the engine and run the revolution to
1500 to 100rpm and fully close the cab door
and the windows.
3.
Turn on the air-conditioner switch, set the fan
switch to Max and the temperature control
switch to cool Max.
4.
When charging gas, set the discharge pressure
Gas charging operation (Low pressure side)
of the compressor to 1.4 to 1.6 MPa (200 to
230psi).

5.
Open the low pressure valve of the gauge
manifold and the service can valve and fill in
refrigerant till air bubbles of the sight glass of
the receiver go away. (See Fig. "Gas charging
operation")
[Total amount of gas to be charged:
820g to 920g (1.18 to 2.03 lbs)]
6.
When refrigerant charge is over, close the low
pressure valve of the gauge manifold and the
service can valve. Receiver dryer

- Do not open the high pressure valve of the gauge manifold in any circumstances.
- Never place the service can upside down. (The compressor valve may be scored because the
refrigerant is sucked in a liquid state.)

25-32
 ［25. AIR-CONDITIONER SYSTEM］

(4) Criterion for checking the amount of refrigerant filled in

25

- If the air-conditioner is run with poor refrigerant R134a, it has adverse effect on the compressor.
- If the refrigerant is charged too much (overcharged), the cooling performance is deteriorated.
Moreover, the circuit pressure gets abnormally high: Always keep a proper level.

(5) Removing Gauge Manifold

When the refrigerant level has been checked, disconnect the charging hoses from the compressor in
the following manner:

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

25-33
［25. AIR-CONDITIONER SYSTEM］

25.7 ELECTRIC CIRCUIT

25.7.1 WIRING DIAGRAM AND CONNECTORS

Electric diagram (1/2)

25-34
 ［25. AIR-CONDITIONER SYSTEM］

25

Electric diagram (2/2)

25-35
［25. AIR-CONDITIONER SYSTEM］

25.7.2 STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE

INSPECTION
(1) Control panel and control unit
The control unit is integrated into control panel,
and processes the signal input by each
sensor, etc. and the signal input by each switch
through control panel with the function of the
built-in micro computer, and comprehensively
controls each actuator (Inner and outer air flow
select, air mix), fan motor and compressor on
the output side.
And the self-diagnosis performance is provided
to facilitate the trouble shooting.

(2) Blower controller (TKS-B215A1)

The power transistor shifts the fan motor into
variable speed with base current from the
control unit.

In normal operation
1.
Disconnect the connector of blower amplifier.
2.
Check continuity between terminals on the
blower amplifier side.

* The installing position is provided on the left

side of air-con unit.

25-36
 ［25. AIR-CONDITIONER SYSTEM］

(3) Relay
Four-electrode relay is used for the blower OFF relay and compressor relay.

25
1. Blower OFF relay
The blower OFF relay turns on after
receiving the signal from the control
amplifier.
When the blower OFF relay turns on, the
source voltage is supplied to the blower
motor and the blower motor starts running.
2. Compressor relay
The relay ON-OFF is tripped by the
control amplifier and electronic thermostat
control.
3. Relay inspecting items
a. Relay (24-4PE)
b. Coil resistance: 320 ohms
c. Specified voltage: DC20V to 30 V
d. Be careful about the coil side of relay
because this relay has polarity.
e. Inspection:
Inspect the continuity between 3 and 4
according to the conditions mentioned
below.
20 to 30 V applied between terminals 1-2:
Continued
20 to 30 V not applied between terminals
1-2: Not continued

(4) Air mix actuator

Air mix actuator is installed at the center of
air-con unit, and opens and closes air mix
damper through the link.
The air mix actuator contains potentiometer
which is switched by being coupled to the
shaft of actuator.
When the target air mix door position is
determined through the temperature control
switch, the control unit reads the level of
potentiometer of the actuator, and determines
the rotating direction of motor in either normal
rotation or reverse rotation. Then as the motor
rotates, the contact point is moved, and when
the contact point is detached or the output
signal of control unit turns OFF, the motor
stops rotating.

25-37
［25. AIR-CONDITIONER SYSTEM］

(5) The actuator for inner and outer

The actuator for inner and outer air flow select
is installed on the blower intake unit, and opens
and closes inner and outer air damper through
the link. The actuator for inner and outer air
flow select contains position detection switch
which is switched with the movement of shaft
of the actuator. When the inner and outer
damper position is set by the inner and outer
switch on the control panel, the control unit
reads the signal of the position detection
switch in the actuator and determines the
rotation direction of motor in either normal
rotation or reverse rotation. Then as the motor
rotates, the position detection switch also
rotates and makes it stop at the set position
of the inner and outer air damper.

(6) Evaporator sensor

This sensor is used to control the evaporator
outlet temperature with the compressor
ON-OFF to protect the evaporator from freezing,
and this evaporator sensor functions as a
sensor of this control.
- Evaporator sensor inspecting items
(Specification)
Terminal resistanc:
at 0 degree C: 7.2 kilo-ohms
at 25 degree C: 2.2 kilo-ohms

(7) Dual pressure switch

This dual pressure switch is attached on L-hose and is used to turn OFF the compressor, and
employs dual type (for high and low pressure control) to protect the cooler cycle from possible failure
at the time when abnormal pressure was generated on the high pressure side.

(8) Solar radiation sensor

This solar radiation sensor, which is used to
correct the solar radiation to the auto air
conditioner detects the strength and solar
orientation of sunbeam after transforming them
into current by means of photo diode.
Inspection: Check for the continuity between
terminals.

25-38
 ［25. AIR-CONDITIONER SYSTEM］

25.8 TROUBLESHOOTING

25

25-39
［25. AIR-CONDITIONER SYSTEM］

25-40
 ［25. AIR-CONDITIONER SYSTEM］

25

25-41
［25. AIR-CONDITIONER SYSTEM］

25-42
 ［25. AIR-CONDITIONER SYSTEM］

25

25-43
［25. AIR-CONDITIONER SYSTEM］

25-44
 ［25. AIR-CONDITIONER SYSTEM］

25

25-45
［25. AIR-CONDITIONER SYSTEM］

25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL

The failure of motor actuator and each sensor can be identified on the display of panel.

25.9.1 POSITION OF INDICATION FOR FAILURE

25.9.2 EXPLANATION OF INDICATION FOR FAILURE

(1) Failure of Motor Actuator

25-46
 ［25. AIR-CONDITIONER SYSTEM］

(2) Failures of sensors

25

(3) Communication error of control amplifier and panel

25-47
［25. AIR-CONDITIONER SYSTEM］

25.9.3 EXPLANATION OF MONITOR MODE

When error of 25.9.2 (2) sensors is displayed, the monitor mode is available to identify the sensor
condition (disconnection, short circuit).

(1) Position of monitor mode indication

(2) Operation of monitor mode

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

25-48
 ［25. AIR-CONDITIONER SYSTEM］

5.
The monitor display is terminated by pressing the inner and outer air flow select switch (R/F) and
ON/OFF switch for 1 second again, or turning off the main switch of excavator.
25

1.
The air conditioner is turned off while the monitor mode is in operation, and all switches are not
available for operation and setting until the monitor mode is cancelled.

2.
Even if each sensor is corrected while the monitor mode is in operation, the error display is
memorized. Therefore turn on ON/OFF switch again, and the error display is disappeared.

(3) Contents of monitor mode display

Refer to the list of segment display exclusively used for monitor and the list of segments in three
digits.

1. Example 1

2. Example 2

3. Example 3

25-49
［25. AIR-CONDITIONER SYSTEM］

4. List of 3 segments

25-50
 ［31. DISASSEMBLING AND ASSEMBLING］

31. DISASSEMBLING AND ASSEMBLING

TABLE OF CONTENTS

31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY ………………………………31-3

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

31

Book Code No. S5YN3129E01

31-1
［31. DISASSEMBLING AND ASSEMBLING］

Issue Date of Issue Applicable Machines Remarks

SK200-8 : YN12-56001~ S5YN3129E01
First Edition December, 2008
SK210LC-8 : YQ12-08001~ (SE Asia & Oceania)
SK330-8 : LC11-08501~
January, 2009
SK350LC-8 : YC11-04501~ (SE Asia & Oceania)

February, 2009 SK200-8 : YN12-T0301~

TKCM

SK200-8 : YN12-T0301~
TKCM (HS Engine)
E215B : YN12-56001~
E215BLC : YQ12-08001~ NHK-RUS (HS Engine)

E215B : YN12-56001~
NHK-Mid.East & Afr.
E215BLC : YQ12-08001~
(HS Engine)
E215B : YN12-56001~
E215BLC : YQ12-08001~ (NHK-TUR)

SK330-8 : LC11-08501~
SE Asia (HS Engine)
E265B : LQ13-07001~
E265BLC : LL13-06001~ NHK-RUS (HS Engine)

E265B : LQ13-07001~
NHK-Mid.East & Afr.
E265BLC : LL13-06001~
(HS Engine)
E265B : LQ13-07001~
E265BLC : LL13-06001~ (NHK-TUR)
SK460-8 : LS11-02501~
SK480LC-8 : YS11-02001~ (SE Asia & Oceania)
E385B : LC11-08501~
March, 2009
E385BLC : YC11-04501~ NHK-RUS (HS Engine)

E385B : LC11-08501~
NHK-Mid.East & Afr.
E385BLC : YC11-04501~
(HS Engine)

SK850LC : LY02-
(SE Asia)
SK460-8 : LS11-02501~
SK480LC-8 : YS11-02001~ SE Asia (HS Engine)
E235BSR : YF06-02501~
April, 2009
E235BSR(N)LC : YU06-03001~ (NHK-EUR)

SK235SRLC-2 : YU06-03001~
(NA)
SK235SR-2 : YF06-02501~
May, 2009
SK235SRLC-2 : YU06-03001~ (OCE)
SK125SR : YV06-05501~
SK125SRL : LD06-01801~
June, 2009
SK135SR-2 : YY06-15001~ (SE Asia & Oceania)
SK135SRLC-2 : YH06-08001~

July, 2009 SK140LC-8 : YP09-05001~

(SE Asia)

31-2
 ［31. DISASSEMBLING AND ASSEMBLING］

31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY &

ASSEMBLY

31.1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY

This chapter is consist of 3-Section as follows.

(1) ATTACHMENTS : Chapter 32

1) Removing and Installing
2) Disassembling and Assembling
a. Cylinder
(2) UPPER STRUCTURE : Chapter 33
1) Removing and Installing
2) Disassembling and Assembling
a. Hydraulic pump
b. Control Valve
c. Pilot Valve (ATT)
d. Pilot Valve (Travel)
e. Slewing Motor
f. Swivel Joint
(3) TRAVEL SYSTEM : Chapter 34
1) Removing and Installing
2) Disassembling and Assembling
a. Travel Motor

31.1.2 INDICATION OF TIGHTENING TORQUE

Tightening torque is indicated as follows, for example ;
T=98N-m(72 lbf-ft)
Tolerance is to 10% unless otherwise specified.

・ Refer to "Chapter 11 TOOLS" for standard tightening torque.

31

31-3
［31. DISASSEMBLING AND ASSEMBLING］

31-4
 ［32. ATTACHMENTS］

32. ATTACHMENTS
TABLE OF CONTENTS

32.1 REMOVING AND INSTALLING ………………………………………………………………………………32-3

32.1.1 ATTACHMENT ASSY ……………………………………………………………………………………32-3
32.1.2 BUCKET ……………………………………………………………………………………………………32-3
32.1.3 ARM …………………………………………………………………………………………………………32-6
32.1.4 BOOM ………………………………………………………………………………………………………32-9
32.2 DISASSEMBLING AND ASSEMBLING ……………………………………………………………………32-14
32.2.1 CYLINDER …………………………………………………………………………………………………32-14

32

Book Code No. S5YP3201E02

32-1
［32. ATTACHMENTS］

Issue Date of Issue Applicable Machines Remarks

S5YP3201E01
First Edition July, 2009 SK140LC-8 : YP09-05001~
(SE Asia)
S5YP3201E02
SK140LC-8 : YP09-05001~
(SE Asia)
Revision January, 2010 SK130-8 : LP09-20001~
(NZL)
SK130L-8 : LX07-11001~
(Thailand)

PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of 2 sections. "Removing and Installing", and "Disassembling and
Assembling".
(3) The removing and installing can be performed in the procedure specified in Table of Contents,
but in view of actual repairing or time saving some process can be omitted.
(4) The removing and installing procedure does not completely cover all possible situations because of
differences of field condition and defective section.
(5) Please be aware that the procedure to be followed must be determined according to the above
conditions.
When disassembly and assembly are required, select the necessary section, itemize the work
contents with good understanding, then starts working.

32-2
 ［32. ATTACHMENTS］

32.1 REMOVING AND INSTALLING

32.1.1 ATTACHMENT ASSY

Front attachment and position

32.1.2 BUCKET
32.1.2.1 REMOVING BUCKET
(1)
Put the machine in position to remove bucket.

Position to remove bucket

(2)
Removing pin (2)
Expand slit of ring (1) with screwdriver, and
remove it. Push out the pin (2) with flat-blade
screwdriver .
32

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 loaded, adjust bucket
link, and pull out bucket attaching pin (K).

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).
Store the removed pin (J) in original position
again.

Removing bucket drive pin

32.1.2.2 ATTACHING BUCKET

(1) Attaching bucket drive pin (J)
Attach bucket drive pin (J) first, then
continue in the reverse procedure of
removing.

Attaching bucket

-When aligning the pin holes, do not put your finger in the pin holes, but align them visually.
-Check the seals for damaged and replace as necessary.
-When inserting the pin, coat the shaft with grease.

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-adjusting 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 than
1.0 mm (0.04 in).
(5) An average of 5 shims (9) of 1mm
(0.04in) thickness are set in the plate (8)
fixed by the three capscrews (11). The
clearance can be decreased by 1mm Adjusting clearance between bucket and arm
(0.04in) if one shim is removed.
Tools: Socket: 22 mm,
Tightening torque : 181 N-m (133 lbf-ft)
(6) After adjustment, tighten the capscrews
evenly.
-The gap exceeding the specified dimension
causes early wear.
(7) Operate the bucket and confirm that the
total sum of both clearance is within 1.0
mm (0.04 in).
(8) Replace O-ring (3) on its original position.

-When shifting O-ring (3) by means of a spatula, use care so as not to damage O-ring (3).
-Remove shims (9), push out bushing (7) rightwards by means of three capscrews (11) and adjust
clearance (B) so it settles within the standard value evenly all round.

32

32-5
［32. ATTACHMENTS］

32.1.3 ARM
32.1.3.1 REMOVING ARM
(1) Put the machine in position to remove arm.
Extend the arm cylinder, retract the bucket
cylinder and bring the arm down on the ground.

Position to remove arm

(2) Disconnecting piping of bucket cylinder

Release pressure of hydraulic tank, place oil
pan to prepare for oil leaking, and disconnect
pipes.
When the removal of bucket cylinder is not
required, skip to procedure (6).

Disconnecting piping of bucket cylinder

Plug both end of disconnected pipes.

Plug:
Tools section 11.5.2-(4)
Tools section 11.5.2-(5)

(3) Removing bucket cylinder rod pin (H)

Loosen nut (9), remove capscrew M14X115 (8), and push out pin (H).

Tools: Spanner: 22mm

Detail of bucket cylinder rod pin (H)

32-6
 ［32. ATTACHMENTS］

(4) Removing cylinder head pin (G)

Loosen nut (3), remove capscrew M16X130
(2), and push out pin (G).

Tools: Spanner: 24mm

Detail of bucket cylinder head pin (G)

(5) Removing bucket cylinder

Sling tube of bucket cylinder with nylon sling,
and remove it.
Bucket cylinder weight: 82 kg (181 lbs)

Slinging bucket cylinder

(6) Removing arm cylinder rod pin (E)

Put a wooden block between the arm cylinder and the boom.
Loosen nut (3), remove capscrew M16X130 (2), and push out arm cylinder rod pin (E).

Tools: Spanner: 24 mm

Retract arm cylinder rod, and return pin (E) to the original position (hole).

Detail of arm cylinder rod pin (E)

32

32-7
［32. ATTACHMENTS］

(7) Removing boom top pin (F)

Loosen capscrew M12X45 (2), and pull out
boom top pin (F).

Tools: Spanner: 19 mm

Insert pin (F) into the original hole.

Detail of boom top pin (F)

(8) Slinging arm assy

Sling arm with nylon sling and remove it.

Arm weight: 380 kg (838 lbs)

Slinging arm assy

32.1.3.2 ATTACHING ARM

Instal the arm in the reverse order of removing, paying attention to the following:

1. When aligning the pin holes, do not put

your finger in the pin holes, but align them
visually.
2. Check the seals for damage and replace
as necessary.
3. When inserting the pin, coat the shaft with
grease.
4. Pin lock nut handling procedure

Tools: Spanner: 22-24 mm

5. When installing the arm and the cylinder,

inspect the clearance in the thrust
direction of the pins and decide the
thickness of shims by referring to the
Maintenance Standard.
6. Tightening torque

32-8
 ［32. ATTACHMENTS］

32.1.4 BOOM
32.1.4.1 PREPARATION FOR REMOVING AND ATTACHING BOOM
When removing and attaching boom in the position shown in below Fig. to remove and attach boom
foot pin (A), removing and attaching of cab and guard are required.

32.1.4.2 REMOVING BOOM

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

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

Lifting up boom cylinder temporarily

(3)
Press the boom cylinder rod pin (C)
At the one side of pin (C), loosen nut (5),
remove capscrew (3) (M14X135), and remove
boss (4). And push pin (C) to the end of boom
boss.

Tools: Spanner: 22 mm

(4)
Preparing for disconnecting cylinder pipes
Retract the above mentioned cylinder rod, and
place one side of cylinder on stand. (See right Detail of boom cylinder rod pin (C)
Fig.) 32

32-9
［32. ATTACHMENTS］

(5)
Disconnecting the arm cylinder and bucket cylinder pipings
Release pressure from arm and bucket circuit and bleed air in hydraulic tank, and then disconnect
pipe at (A1), (A2), (A3), (A4) and 4 hoses.

Tools: Spanner: 27mm , 36 mm

After disconnection of pipe, plug every pipe.

ORS Plug: See Tools 11.5.2-(4).

Boom piping disconnection

(6)
Lifting up boom assy temporarily
Lift up boom cylinder with nylon sling so that boom foot pin (A) is not loaded.

Weight of single boom:

1,250 kg (2,760 lbs)

32-10
 ［32. ATTACHMENTS］

(7)
Removing boom foot pin (A)
1. Loosen nut (3) or washer (4) and remove
capscrew (2).

2. Draw out pin (A).

Details of boom foot pin (A) section

(8)
Hoisting boom assy
Hoist and remove boom assy.

Weight of single boom:

1,250 kg (2,760 lbs)

(9)
Completion of removal of front attachments
When the removing and attaching of cylinder are not required, the work is finished.

32

32-11
［32. ATTACHMENTS］

(10)
Removing and installing arm cylinder

1. Lift up arm cylinder (2) with nylon sling so

that the head of cylinder is not loaded.
2. Disconnect hose (F1) and (F2) at position
A. After disconnection of hose, plug both
ends of hose.

Plug: TOOLS
11.5.2-(4) Plugs for ORS fitting
Tools: Spanner: 27 mm, 30 mm, 32 mm,
36 mm
3. Removing arm cylinder head pin (D)
Loosen nut (3), remove capscrew
M16X130 (2) and pull out pin (D).

Tools: Spanner: 24 mm
4. Removing arm cylinder (2)
Weight of arm cylinder: 140 kg (309 lbs)

Removing arm cylinder

(11) Removing and installing boom cylinder

1.
Release pressure from boom circuit and bleed
air in hydraulic tank.
2.
Sling boom cylinder (2) using nylon sling
temporally not to act the weight of cylinder
upon the cylinder head.
3.
Disconnect each two hoses (C2) and (C3).
And plug their both ends.
Plug: TOOLS 11.5.2-(4) Plugs for ORS fitting
Tools: Spanner: 27,32 mm
Removing and installing boom cylinder

4.
Removing boom cylinder foot pin (B)
(See right Fig., below Fig.)
Loosen nut (5), remove capscrews M10X20 (3)
and pull out pin (B).
Tools: Spanner: 17 mm
5.
Remove boom cylinder (2).
Weight of boom cylinder: 96 kg (212 lbs)
6.
Remove another boom cylinder the same way.
Removing and installing boom cylinder head
pin (B)

32-12
 ［32. ATTACHMENTS］

32.1.4.3 ATTACHING BOOM

(1) Attaching boom foot pin (A)
First of all, insert boom foot pin (A) and install the boom assy.
Attach it in the reverse procedure of removing, paying attention to the following points.

1. When aligning the pin holes, do not put

your finger in the pin holes, but align them
visually.
2. Check that the dust seals is not damaged
and replace as necessary.
3. When inserting the pin, coat the shaft with
grease.
4. M16 capscrew tightening torque : 279
(3.11) N-m (205 lbf-ft)
5. When installing boom and cylinder, check
the clearance of mounting section in thrust
direction, and decide the thickness of shim
according to the maintenance standard.
Install plastic shim first, and insert iron Boom foot pin (A)
shim into remaining gap. Regarding the
position of shim, refer to details of boom
foot pin (A) section.

32

32-13
［32. ATTACHMENTS］

32.2 DISASSEMBLING AND ASSEMBLING

32.2.1 CYLINDER
32.2.1.1 PREPARATION BEFORE DISASSEMBLY
Before assembly, secure a dustfree workshop and necessary equipment and facilities.

32.2.1.1.1 WORK AREA

The following working area is required for disassembly:
(1) Ample space
For the disassembly of the hydraulic cylinder, the cylinder tube and the piston rod must be drawn
out. For this reason, the first condition is that the working area is long enough for the work. In
terms of width, it is also necessary to keep sufficient space to disassembly, cleaning and
measuring equipment are placed and the work can be performed.
(2) Suitable working environment
The hydraulic cylinder is a precision-machined product that uses seals and packings made of
rubber and plastic materials. For this reason full care should be exercised so the hydraulic cylinder
is free from dust, dirt, and in particular, such hard particles as sand, metal chips, and weld slag
(spatter). If the hydraulic cylinder is assembled with hard particles adhered on such components
as the cylinder tube and the piston rod, the tube inner surface and the rod surface are scratched
as the cylinder operates, consequently disabling it in worst cases. Damage to the piston seals
and the rod seals will result in oil leaks. For this reason, grinding and welding operation should
not be performed in the neighborhood of the working area to keep it clean.

32.2.1.1.2 APPARATUS
The following equipment are required for disassembly:
(1) Hoist or crane
The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must
also be capable of making level and liner movement under load for retracting and extending the
piston rod and the tube.
(2) Work bench
The work bench must have strength and rigi-dity capable of accommodating the total length of
the cylinder in its most retracted condition and of withstanding the repulsive force of the
tightening torques of the cylinder head and the piston nut. Since a vise is attached to the bench,
the width of the work bench must be sufficiently large.
(3) Support stand
If the piston rod is fully extended in a free condition, the bushing and the seals may be
damaged as the rod bushing and the piston are twisted due to the weight of the rod. A stand is
required to support the rod to prevent damage of seals.
(4) Hydraulic source
A Hydraulic source is required for disassembly and assembly of the cylinder head and piston nut
and for oil leak tests after completion of assembly.
(5) Jet air source
It is used for drying after oil draining and cleaning of the cylinder.
(6) Cleaning bath, cleaning oil and detergent
(7) Oil pan and oil reservoir
An oil pan is necessary to contain oil drained from the cylinder and oil spilt during work.
(8) Others
Oil extracting hoses, wooden blocks, clean cloths and sawdust in which oil soaked are also
necessary.

32-14
 ［32. ATTACHMENTS］

32.2.1.1.3 NECESSARY TOOLS

List of Tools and Jigs
Tool/Jig Remarks Tool/Jig Remarks
Hammer 1. Steel hammer Spatula Metallic one with smooth corners.
2. Wooden or plastic hammer
Screwdriver A few types of large and small sizes Gimlet A sharp-point tool may be used in
place of a gimlet.
Chisel Flat chisel Special jig 1. For piston nut.
2. For inserting and reforming seal.
3. For inserting rod cover.
4. For press fitting bushing.
(See para 32.2.1.9 for detail)
Vise One having an operation wide enough to Rust
hold cylinder head O.D. and tube remover
mounting pins (clevis)
Wrench 1. Eye wrench Measuring 1. Slide caliper
2. Allen wrench instruments 2. Micrometer
3. Extension pipe for wrenches 3. Cylinder gauge (Fig. "Cylinder gauge")
4. V-block

・ For the details of special tools and jigs, refer to the back pages of this manual.

32.2.1.1.4 EXTERNAL CLEANING

The cylinder taken off the excavator has dust
and foreign matter, and grease is usually
adhered to the clevis part. For this reason,
Cylinder gauge
remove external soil and contamination from the
cylinder with water and steam before bringing
it into the workshop.
-The following describes the construction of
boom cylinder. When disassembling and
servicing the cylinder, confirm the construction
of cylinder referring to Parts Manual.

32.2.1.1.5 DISCHARGING OIL

Place a wooden-block on the work bench and
place the 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

Preparation

32-15
［32. ATTACHMENTS］

32.2.1.2 CONSTRUCTION OF CYLINDER (GENERAL EXAMPLE OF CYLINDER)

P/No YY01V00054F3
No. Parts name Q'TY No. Parts name Q'TY No. Parts name Q'TY
1 Cylinder tube 1 12 O-ring : 1B G110 1 23 Set screw : M8 1
2 Oiles bush 2 13 Back-up ring 1 24 Cushion plunger 1
3 Rod assy 1 14 O-ring : 1B G115 1 25 Stop ring 1
4 Oiles bush 2 15 Cushion ring 1 26 Socket bolt : M16 10
5 Rod cover 1 16 Piston 1 27 Check valve 1
6 DD-bushing 1 17 Slip seal 1 28 Spring 1
7 Retaining ring 1 18 Wear ring 2 29 Spring 1
8 Buffer seal 1 19 Dust ring 2 30 O-ring : 1B P14 1
9 U-packing 1 20 O-ring 1 31 Plug : PT3/8 1
10 Back-up ring 1 21 Back-up ring 2 32 Wiper ring 4
11 Dust seal 1 22 Piston nut 1

Note: In case of piston with piston nut type, the parts with * are not used.

32-16
 ［32. ATTACHMENTS］

32.2.1.3 DISASSEMBLY
・ When disassembling and servicing the cylinder, check the construction and the availability of
service parts as well as necessary tools and jigs on separate Parts Manual.
・ The figures in parentheses after part names correspond to those in Fig. "construction of general
cylinder"
・ The following explanation and quantities are for a general use cylinder which has separated
piston and piston nut.
In case that piston and piston nut are combined, the construction differs from separated type, refer
to the sentence in parenthesis.

32.2.1.3.1 REMOVING ROD COVER AND PISTON ROD

(1)
Hold the clevis section of the tube in a vise.
(2)
Pull out piston rod (3) about 200 mm (8in).
Because the piston rod is heavy, finish
extending it with air pressure after the
above-mentioned oil draining operation.

Use mouth pieces so as not to damage the machined surface of the cylinder tube. Do not make use
of the outside piping as a locking means.

(3)
Loosen and remove socket bolts (26) of the rod
cover in sequence.
(4)
Strike the corner of the rod cover flange by
means of a plastic mallet till rod cover (5)
comes off.

Cover the extended piston rod (3) with cloths to prevent it from being accidentally damaged during
operation.

・ At this time, the weight of piston rod (3)

is loaded on rod cover (5). Therefore, lift 32
the top end of the piston rod with a hoist
to the extent that only the rod weight may
be held.

Drawing out piston rod assy (2).

32-17
［32. ATTACHMENTS］

(5)
Draw out the piston rod assy from cylinder tube
(1).

Method of drawing out the piston rod assy

Since the piston rod assy is heavy in this case, lift the tip of the piston rod (3) with a hoist and
draw it out. However, when piston rod (3) has been drawing out to approximately two thirds of its
length, lift it in its center to draw it completely. However, since the plated surface of piston rod (3) is
lifted, do not use a wire rope which may score the surface, but use a strong cloth belt or a rope.

(6)
Place the removed piston rod on a horaizontal
wooden V-block.

-Cover a V-block with cloths.

Method of placing the piston rod

(7)
Remove slide ring (18) and dust ring (19) from
piston (16).

Remove slide ring (18) and dust ring(19)

32-18
 ［32. ATTACHMENTS］

32.2.1.3.2 REMOVING PISTON ASSY

(1)
Fix piston rod (3) by holding its clevis section
in a vise. Fix the piston rod (3) securely as
piston nut (22) is tightened to a high torque.

How to loosen piston nut (22)

-Note that the tightening torque differs with the type, the working pressure and the mounting method of
the piston (16), though the rod diameter remains the same.
-It is also necessary to place a suitable supporting block near the piston (16). In case a V-block is
used, put cloths or something over the rod to prevent it from damage.

(2)
Scrape off the caulked part of setscrew (23) of
piston nut (22) by means of a hand drill and
loosen setscrew (23).
Tools: Allen wrench: 4 mm

Removing setscrew (23)

(3)
Loosen and remove piston nut (21).

How to loosen piston nut (22)

32

Since piston nut (22) is tightened to a high torque, use a hook wrench suitable for the outside
diameter of piston nut (22). Use care so the hook of the wrench is positively fixed in the groove of
the piston nut perimeter.

32-19
［32. ATTACHMENTS］

(4)
Loosen piston (16) with a pin wrench as
shown in right Fig. utilizing the two holes in the
side face of the piston. If the O-ring (20) comes
off, the piston may be turned easily by hand.
When removing the last thread of the piston,
hold the piston by hand to receive the weight
Removing piston (16)

If the piston is dropped with a bang, the O-ring seal face on the piston interior may be damaged with
the threads.

(5)
After removing cushion ring (15), separate rod
cover (5) from piston rod (3). If it is too hard to
slide it, knock the flanged part of rod cover (5)
with a plastic mallet. But when drawing it out,
lift rod cover (5) by hoist and pull it straight
horizontally.

Removing rod cover (5)

Take care so rod bushing (6) and the lip of packings (8,9,10,11) may not be damaged by thread of
the piston rod (3).

32-20
 ［32. ATTACHMENTS］

32.2.1.3.3 DISASSEMBLING PISTON ASSY

(1)
Remove piston seal (17).

Removing piston seal (17)

Cut the seal ring (17-1) by tapping it with a screwdriver or a chisel. Take care not to strike it too
hard, otherwise the groove may be damaged.

(2)
Separate O-ring (20) and back-up ring (21) from
piston (16).
After removing two back-up rings (21), remove
O-ring (20). The back-up ring (21). comes off
easily if the slit on its circumference is
extended. O-ring (20) can be taken off by
stretching it with an earpick-like spatula.

Removing back-up ring (21) and O-ring(20)

32.2.1.3.4 DISASSEMBLING ROD COVER ASSY

(1)
Remove O-ring (12) and back-up ring (13).
Remove back-up ring (13) and O-ring (12) in
that order. Remove back-up ring (13) and
O-ring (12) by pulling and stretching them with
an spatula like earpick. 32
Removing the outer circumferential seal of
rod cover (5)

32-21
［32. ATTACHMENTS］

(2)
Remove buffer ring (8), U-ring (9) and back-up
ring (10). Each seal is fixed in the groove on
the bore and removing in flawless is impossible.
Stab each seal with a gimlet and pull it out of
the groove.

Removing the inner circumferential seal of

rod cover (5)

Take care in this operation not to damage the grooves.

(3)
Remove wiper ring (11). When taking out
wiper ring (11), fix rod cover (5) in a vise.

Removing wiper ring (11)

(4)
Remove circlip (7) and rod bushing (6).
After taking out snap ring (7) in the same way
as mentioned above, remove rod bushing (6).
Rod bushing (6) is impossible to remove as it
is press fitted in rod cover (5). Machine the
bushing thin on a lathe, insert a steel spatula
hard into the gap at the chamfered edge of
the remaining bushing and pry it up.
Removing rod bushing (6)

Center the work on a lathe sufficiently so the bushing may be shave on a lathe as thin as possible.

32-22
 ［32. ATTACHMENTS］

32.2.1.3.5 REMOVING PIN BUSHING

(1) Apply driver to wiper ring (32) of cylinder
tube (1) and piston rod (3), and strike it
by hammer lightly.
(2) Push out pin bushing (4) press fitted in
cylinder tube (1) and piston rod (3) with
press.

Drawing out pin bushing (4)

32.2.1.3.6 REMOVING CHECK VALVE (ARM CYLINDER ONLY)

(1)
Using allen wrench, remove check valve plug
(31), and remove the internal parts (27, 28 and
29)
Tools: Allen wrench: 8mm

Removing of check valve

32.2.1.4 CLEANING
(1) After disassembly the cylinder, wash all parts with commercial detergent.
(2) Do not use the used oil seal, O-ring, back-up ring, etc. even if they are not damaged after
inspection.
(3) After cleaning, dry all parts by compressed air, and put them on the working bench taking care
not to damage them.

Never use benzene(gasoline, thinner, etc.) because it may be damage the rubber, etc.

32.2.1.5 ASSEMBLING PIN BUSHING

Start assembling the following sub assy 32
-Cylinder tube assy
-Piston assy
-Rod cover assy

32-23
［32. ATTACHMENTS］

32.2.1.5.1 ASSEMBLING PIN BUSHING

(1) Press fit pin bushing (4) in cylinder tube (1)
and piston rod (3) respectively with press.
(2) Press fit wiper ring (32) in the upper and
lower sides of cylinder tube (1) and piston
rod (3) respectively with press.

Press fitting of pin bushing (4)

-Before press fitting, apply grease on wiper ring and boss hole.
-Before press fitting the pin bushing, align the position of oil hole.

32-24
 ［32. ATTACHMENTS］

32.2.1.5.2 ASSEMBLING OF PISTON ASSY

(1) Fit back ring (17-2) of piston seal as if it
slips in with driver the corner is rounded.
(2) And fit seal ring (17-1) with fitting jig.

Attaching seal ring (17-1)

Since it is hard to deform seal ring (17-1) in room temperature, immerse and soften it in hydraulic oil
heated about 150 to 180 C degrees. Therefore slip it in piston seal groove quickly with fitting jig so as
not to be cooled.
To avoid burn, wear gloves when fitting the heated seal ring (17-1), and fit it quickly. And the
hydraulic oil must be heated with electric heater. (Do not use fire. There is a danger.)

(3) Shrink the seal ring (17-1) to the original

size using correcting jig.
(4) Fit back-up rings (17-3) to both sides of
seal ring.

Correction of seal ring (17-1)

Direction of components

Make sure about the fitting direction of back-up ring.

(5) Fit O-ring and back-up ring (2 places) to the bore side.

32

32-25
［32. ATTACHMENTS］

32.2.1.5.3 ASSEMBLING ROD COVER ASSY

(1)
Press fit bushing (6) in rod cover (5) with
bushing press-fitting jig (A). Then, fit snap ring
(7) in the groove. Apply hydraulic oil on internal
surface of rod cover (5).

The snap ring (7) can not be fitted when the bushing (6) is not press-fitted fully to the stop end.

(2)
Apply grease to dust seal (11) or the hole of
rod cover (5), and fit dust seal (11) to the
bottom of the hole. At this moment, press the
metal ring of dust seal (11) with a jig.

Pressing in rod bushing (6)

(3)
Fit buffer seal (8), back-up ring (10) and rod packing (9) in their grooves in that order. Before setting
packings, coat them with hydraulic oil (or vaseline if not available). If you forget the coating, the
packings may be scored. When attaching seals, deform them in a heart shape as illustrated.

Inserting a seal into the inner circumference

of rod cover.

How to fit rod packing (9)

32-26
 ［32. ATTACHMENTS］

-Rod packing (9) is harder than other packing and it would be difficult to deform them in a heart
shape. In such a case, put a U-ring in the groove obliquely by hand as deep as possible and push
in the last part with a push bar till it is set with a click.
-Buffer ring (8) should be fitted taking care of the fitting direction. The reverse fitting may cause
deformation, damage, etc. of the piston due to high pressure generated between the buffer ring and
Rod packing (9).
-If Rod packing (9) is set upside down, the lip may be damaged. Check that it is positioned correctly.
-Attach back-up ring (13) on the open air side of O-ring (12). (See above Fig.).

32.2.1.5.4 INSERTING ROD COVER ASSY TO PISTON ROD

Inserting rod cover (5) to piston rod assy by the following procedure.

(1) Fix piston rod assy on working bench.

(2) Install rod cover (5) on piston rod (3) with
inserting guide jig (I) as shown in right
Fig. paying attention for the lip section of
Rod packing not to be caught on the
stepped section.
Inserting rod cover (5)

-For the rod the outer diameter of piston installing section is small, insert spacer on the faucet
section of rod first, and attach inserting guide jig.
-Apply hydraulic oil on the inserting guide jig and outer surface of piston rod lightly to make the
insertion smooth.

32

32-27
［32. ATTACHMENTS］

32.2.1.5.5 ASSEMBLING PISTON ASSY ONTO PISTON ROD

(1) Inset in cushion ring and install the piston assy to piston rod (3).

(2) Apply hydraulic oil or grease to the inside

of the piston assembly and to the piston
mounting part of piston rod (3). Then install
the piston assembly as shown in right Fig.
exercising care not to damage O-ring (20)
and the seal.
Always tighten the piston to a specified
torque

Tightening piston assy

(3) Piston nut (22) till it gets tight.

Always tighten the piston nut (22) to a
specified torque (Refer to 32.2.1.7.3.)

Tightening piston nut (22)

Always correct the threads of the tapped hole in piston nut (22) before fixing piston nut, using a tap.

32-28
 ［32. ATTACHMENTS］

(4)
Screw in and set setscrew (23).

Tools: Allen wrench: 4 mm

After tightening the setscrew to a specified
torque of 15 N-m (11 lbf-ft), caulk the two
places of the screw threads of the piston nut
side to secure the setscrew.

Attaching setscrew (23)

(5)
Attach two wear rings (18) and dust rings (19).
Take off vinyl tape wound around the
perimeter of piston (16), apply high-quality
grease (or vaseline) to wear ring (18) and dust
ring (19) and attach the wear rings in a manner
that they may be coiled around the groove.
Set the wear rings about 90 degrees apart
with each other so that the 45 degree slits may Attaching wear ring (18)
not point to the same direction.

32

32-29
［32. ATTACHMENTS］

32.2.1.5.6 OVERALL ASSEMBLY

(1) Place a V-block on a work bench (A wooden V-block is preferable.). Place the cylinder tube assy
(1) on it and fix the assy by passing a wooden bar through the clevis pin hole to lock the assy.
(2) Insert the piston rod assy into the cylinder tube assy, while lifting and moving the piston rod assy
with a hoist. In this operation, apply hydraulic oil (or vaseline) to the inner surface of the tube
mouth and the circumference of the piston. Align the center of the piston rod assy with the
center of the cylinder tube assy and put it in straight forward. When inserting, make sure that
wear rings (18), dust rings(19) on the perimeter of the piston is not out of the groove.
(3) Tighten socket bolt (26). Match the bolt holes of the rod cover flange to the threaded holes in
the cylinder assy, and screw in socket bolts (26) one by one. Tighten the bolts to a specified
torque, taking care so the bolts may not be tightened unevenly. See para. 32.2.1.7.3 for torque.

Tools: Allen wrench: 14 mm, 12 mm

Inserting piston rod assy

Tightening socket bolts (26)

Take care so as not to damage the rod surface by accidentally slip a wrench. Covering the rod
surface with cloth is recommended to prevent damage to it.

32-30
 ［32. ATTACHMENTS］

32.2.1.6 INSPECTION AFTER ASSEMBLY

(1) No-load functional test
Place the cylinder level at no load, operate the
piston rod 5 to 6 strokes by the directional
valve and make sure that it operates without
failure.

External leak test

-Do not raise the hydraulic pressure above the maximum pressure of 34.3MPa (4974psi) for the
cylinder of the machine.
-Grease coated on the O-rings and the seals of the rod cover may come out. Wipe it off and retest
the cylinder in such a case.

(2) Leak test

1. Apply a test pressure to the retracting and extending sides of the cylinder for three minutes
independently, and check that the rod section and the welds have external leaks and permanent
deformation. For an internal leak test, connect the cylinder with a test unit as shown in below Fig.
2. After completing the test, apply a plug to each port and store the cylinder. (Below Fig.)

・ For storage, place the cylinder on wooden V-blocks and bring the cylinder to the most retracted
condition.

How to store the cylinder

Internal leak test

32

32-31
［32. ATTACHMENTS］

32.2.1.7 MAINTENANCE STANDARDS

32.2.1.7.1 INSPECTION AFTER DISASSEMBLY
Visually inspect all parts after cleaning to see that excessive wear, crack and other damage that are
detrimental to use are not present.

(1) Inspection Item

Parts Name Inspecting Portion Inspection Item Remedy
1. Neck of rod pin Presence of crack Replace
2. Weld on rod hub Presence of crack Replace
3. Stepped part to which
Presence of crack Replace.
piston is attached
4. Threads Presence of seizure Recondition or replace
Measure degree of bend (See Refer to Table "Example of
5. Bend
Fig. "Measuring method") measurement"
6. Plated surface Check that:
Piston rod
1) Plating is not worn off to 1) Replace or replate
base metal
2) Rust is not present on 2) Replace or replate
plating.
3) Scratches are not present. 3) Recondition, replate or
replace.
Recondition, replate or
7. Rod Wear of O. D.
replace.
8. Bushing at mounting part Wear of I. D. Replace
1. Weld on bottom Presence of crack Replace
2. Weld on head Presence of crack Replace
Cylinder tube 3. Weld on hub Presence of crack Replace.
4. Tube interior Presence of damage Replace if oil leak is seen.
5. Bushing at mounting part Wear on inner surface Replace
1.Bushing 1) Wear on inner surface 1) See para. 32.2.1.7.2
Rod cover 2) Flaw on inner surface 2) Replace if score is
deeper than coating.

(2) Repair method

Check all seals and parts to see that they do not show excessive damage and wear. For correction of
scores on the piston rod, observe the following procedure:

1. Correct very fine longitudinal scratches with an oilstone. Replace the piston rod if the scratch is so
deep as may be caught by your nail.
2. In case of a smooth indention, recondition by removing the sharp area around the indention with
an oilstone. If the score or the indention is excessive, replace or replate the damaged part.

・ Always regrind after replating. The thickness of the plating must be maximum 0.1 mm (0.004 in).
・ In case plating is removed to the base metal during reconditioning with an oilstone, do not fail to
replate the surface.

32-32
 ［32. ATTACHMENTS］

32.2.1.7.2 LIMIT OF SERVICEABILITY

Serviceability limits represent the limits of wear on the sliding surfaces of the cylinder tube and the rod
that have no such damage as may degrade the sealing effect.

(1) Clearance between piston rod and rod bushing

Replace the bushing if the clearance between the piston rod and the rod bushing exceeds 0.25mm
(0.01in).
(2) Bend of piston rod
The allowable bend of the rod is maximum 1mm / 1m (0.04"/3'3"). For measurement, support
both ends of the parallel section of the piston rod with V-blocks, set a dial indicator in the center
between the two V-block turn the piston rod, and read the difference between the maximum and
minimum deflection on the dial indicator.
Table shows an example of measurement.

Measuring Method

Even if the bend is within the above limit, the cylinder may not operate smoothly because of localized
bend. Beware of it during function test after assembly. Replace the rod if the cylinder makes a
squeaking noise or dose not operate smoothly.

32.2.1.7.3 TIGHTENING TORQUE

32.2.1.7.4 VOLUME OF OIL LEAK

The oil leak rates as mentioned in 1.6 (2) of Inspection after Assembly are as shown in INSPECTION
AFTER ASSEMBLY 32.2.1.6 (2).

Cylinder Volume of Internal Oil Leak

Boom 2.0 cc (0.12 cu-in) or below / 10 min
32
Arm 2.3 cc (0.14 cu-in) or below / 10 min
Bucket 1.9 cc (0.11 cu-in) or below / 10 min

32-33
［32. ATTACHMENTS］

32.2.1.8 TROUBLESHOOTING

32-34
 ［32. ATTACHMENTS］

32.2.1.9 TOOLS AND JIGS LIST

The tool and jig list provides the materials and the dimensions of tools and jigs so that they may be
utilized in manufacturing in a service shop. Follow the directions given below in selecting,
manufacturing and using the tools and jigs.

(1) For the rod cover, piston nut and others that require large tightening torques, use eye wrenches
as much as possible.
The tools and the jigs are so designed dimensionally that they can withstand the maximum
tightening torques even if material SS400 (JIS) is used. However, the hook of the tool may be
distorted if struck with a hammer. If such occurs, apply reinforcement weld and finish it by grinding.
(2) The pin section of pin wrenches and pin hook wrenches is loaded with large shearing force.
Therefore, take care when selecting pin material and welding the pin to the body. It is
recommended to use the shank section of disused drills (Below Fig)

32.2.1.9.1 ALLEN WRENCH AND SPANNER WRENCH

Unit: mm (in)
For piston nut For check valve For 1/8 grease For 1/4 grease
CYLINDER For cover bolt
set screw plug nipple nipple
ARM 14 (0.55) 4 (0.16) 8 (0.32) 14 (0.55)
BOOM 12 (0.47) 4 (0.16) - 10 (0.39) 14 (0.55)
BUCKET 12 (0.47) 4 (0.16) - -

32.2.1.9.2 DUST SEAL PRESSING JIG (FOR ROD COVER)

Dust seal pressing jig

32

32-35
［32. ATTACHMENTS］

32.2.1.9.3 EYE WRENCH (FOR PISTON NUT)

Eye wrench

32.2.1.9.4 WRENCH (FOR PISTON)

Wrench

32-36
 ［32. ATTACHMENTS］

32.2.1.9.5 ROD COVER INSERTING JIG

Rod cover inserting jig

32.2.1.9.6 PISTON (SLIPPER) SEAL FIXING JIG

Piston (slipper) seal fixing jig

32

32-37
［32. ATTACHMENTS］

32.2.1.9.7 PISTON SEAL HOLDING-DOWN JIG

Piston seal holding-down jig

32.2.1.9.8 PIN BUSHING PRESSING JIG

Pin bushing pressing jig

32-38
 ［32. ATTACHMENTS］

32.2.1.9.9 ROD BUSHING PRESSING JIG

Rod bushing pressing jig

32

32-39
［32. ATTACHMENTS］

32-40
 ［33. UPPER SLEWING STRUCTURE］

33

33. UPPER SLEWING STRUCTURE

TABLE OF CONTENTS

33.1 REMOVING AND INSTALLING ………………………………………………………………………………33-3

33.1.1 OPERATOR SEAT…………………………………………………………………………………………33-3
33.1.2 CAB …………………………………………………………………………………………………………33-4
33.1.3 BATTERY ……………………………………………………………………………………………………33-7
33.1.4 GUARD ………………………………………………………………………………………………………33-9
33.1.5 UNDER COVER ……………………………………………………………………………………………33-14
33.1.6 FUEL TANK…………………………………………………………………………………………………33-15
33.1.7 HYDRAULIC TANK ………………………………………………………………………………………33-17
33.1.8 HYDRAULIC PUMP ………………………………………………………………………………………33-21
33.1.9 AIR CLEANER ……………………………………………………………………………………………33-26
33.1.10 MUFFLER …………………………………………………………………………………………………33-28
33.1.11 COUNTERWEIGHT ………………………………………………………………………………………33-30
33.1.12 RADIATOR & OIL COOLER……………………………………………………………………………33-31
33.1.13 ENGINE ……………………………………………………………………………………………………33-38
33.1.14 CONSOLE COVER ………………………………………………………………………………………33-41
33.1.15 CONTROL VALVE ………………………………………………………………………………………33-42
33.1.16 PILOT VALVE (FOR ATT) ……………………………………………………………………………33-45
33.1.17 PILOT VALVE (FOR TRAVEL) ………………………………………………………………………33-47
33.1.18 SWING MOTOR UNIT …………………………………………………………………………………33-49
33.1.19 SWIVEL JOINT……………………………………………………………………………………………33-51
33.1.20 UPPER FRAME …………………………………………………………………………………………33-54
33.2 DISASSEMBLING AND ASSEMBLING ……………………………………………………………………33-56
33.2.1 HYDRAULIC PUMP - REGULATOR……………………………………………………………………33-56
33.2.2 CONTROL VALVE …………………………………………………………………………………………33-77
33.2.3 PILOT VALVE (ATT)………………………………………………………………………………………33-111
33.2.4 PILOT VALVE (FOR TRAVEL) …………………………………………………………………………33-124
33.2.5 SWING MOTOR UNIT ……………………………………………………………………………………33-134
33.2.6 SWIVEL JOINT ……………………………………………………………………………………………33-173

Book Code No. S5YP3301E01

33-1
［33. UPPER SLEWING STRUCTURE］

Issue Date of Issue Applicable Machines Remarks

S5YP3301E01
First Edition July, 2009 SK140LC-8 : YP09-05001~
(SE Asia)

PREFACE
(1) This Manual describes all the procedures from removing to installing, arranging them by item.
(2) This Manual consists [Removing and installing], and [Disassembling and assembling].
(3) The removing and installing can be performed in the procedure specified in Table of Contents,
but in view of 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) Recognize well that the service man must decide a work procedure before proceeding to repair.
When deciding the work procedure, choose an item that is needed, familiarize yourself with the
contents of the work and itemize the work procedure, before starting work.
(6) Disconnect the negative terminal of battery first, when the removing and the installing of the
electric component and wiring are performed.
(7) The explanatory note and figure of this manual may differ from the actual machine by the
difference in specification.

33-2
 ［33. UPPER SLEWING STRUCTURE］

33.1 REMOVING AND INSTALLING

33
33.1.1 OPERATOR SEAT
33.1.1.1 REMOVAL
(1) Preparation for removal
1. Remove the head rest (A1-1) of the operator's seat (A1) to ease handling.
2. Move the whole control stand to its foremost position.
3. Move the operator's seat to its forward end.
4. Incline the reclining seat as forward as possible.

(2) Remove operator's seat. (Include upper rail.)

1. With the above-mentioned condition, remove
two cap screws (B2) M8X20 from the upper
rail. Then move the control stand to its
rearmost end and remove two capscrews
(B2) M8X20.
Tools: Allen wrench: 6 mm
2. Remove the operator's seat. [about 10 kg
(22 lbs).]
Carry out the following operations as
required.
3. Remove sems-bolt (M10X25) (C2) and
seat belt (C1).
4. Remove bracket assy (9), rail (10).

Disassembling and Assembling seat

33.1.1.2 INSTALLATION
Install it in reverse procedure of removing according to the tightening torque table.

Reference: Movement on rail

Upper rail.....Fixed on lower surface of seat
[Forward 80 mm (0.26 in), backward 80 mm
(0.26 in)]
Lower rail.....Fixed on seat stand.
[Forward 60 mm (0.19 in), backward 60 mm
(0.19 in)]
Amount of adjustment of seat height
[Up; 23 mm (0.07 in), down; 37 mm (0.16 in)]
Suspension stroke
[Up; 37.5mm (1.48in), down; 37.5mm (1.48in)]

33-3
［33. UPPER SLEWING STRUCTURE］

33.1.2 CAB
33.1.2.1 REMOVAL
(1)
Remove floor mat.
(2)
Remove cover (A1-2)
Lift cover (A1-2) upwards and remove it.
(Fixed with 2 clips)
(3)
Remove cover assy (A1)
1.
Loosen 4 sems bolts (A22) M6X16 and lift
cover assy (A1) up.
2.
Disconnect each connector for both speakers.
Disassembly and assembly of cover assy (A1)
Then remove cover assy (A1).

(4)
Remove the harness connector (See Chapter
23)
1.
Disconnect connectors of cab harness (CN-515),
(CN-518), (CN-71), (CN-72) and (CN-500) at
rear right of cab.
2.
Disconnect antenna cable coming from backside
of tuner at rear left of cab.
(5)
Remove the plastic tube for the window
washer from the rear left of cab.
(6)
Remove the right panel of cab
1.
Remove 2 caps (A29) loosen 2 sems bolts
(A40) M6X30 and 1 sems bolt (A39) M6X16.
And right panels (A4) and (A4-3) are freed.
Tools: TORX driver T30
2.
Lift cover (A3) upwards and remove it. (Fixed
with 3 clows and 2 clips)
3.
Unfix 3 harness clips of inside on right panel Disassembly and assembly of right panels
(A4-3). And free the harnesses connected to (A4-3), (A3) and (A5-2)
key switch.

33-4
 ［33. UPPER SLEWING STRUCTURE］

4.
With harnesses are connected condition, install
key switch cover (A3) to bracket (A1) of rear
33
cab temporally. (See Right Fig.)
5.
Disconnect harness connectors of work light
switch on right panel (A4), air conditioner
panel and cigarette lighter, and remove right
panel (A4) and (A4-3). (See Chapter 23)
6.
Loosen sems bolts (A22) M6X16 and (A23)
M6X45 one each, and remove front panel
Move switch cover assy
(A5-2) with air conditioner duct.
Tools: Plus driver

(7) Remove cab attaching bolt

1.
5 capscrews (A1) M12X65 and 1 capscrew (A3)
M12X30. (Mark △)
2.
4 nuts (B3) M16 (Mark ○)

(8) Slinging cab

1.
Remove two plastic plugs at the front of the
Removing and installing cab mounting bolts.
ceiling of the cab.
Then place a wire sling with eye rings and a
hook around the cab, as shown in slinging cab.
2.
Then lift up slowly avoiding interference with
surroundings.
Wire with hook;
Length 1.5 m (4ft 11 in) X Dia. 8 mm (0.315
in) X3 pcs.
Weight of cab ;Approx. 250 kg (550 lbs)

33-5
［33. UPPER SLEWING STRUCTURE］

33.1.2.2 Installation
Install it in reverse order of removing according to the Tightening Torque Table.

Slinging cab

33-6
 ［33. UPPER SLEWING STRUCTURE］

33.1.3 BATTERY
33.1.3.1 REMOVING 33
(1) Open panel assy (C1).
1.
Unlock with starter switch key.
2.
Open panel assy (C1).
3.
Keep panel assy open with stay.

Opening and closing of panel assy (1)

(2) Remove battery cover

1.
Remove cable (A4) [between the earth and
battery (-)].
(Always remove (-) terminal first and install it at
last.)
2.
Remove cable (A2) [between battery (+) and (-)]
3. Removing and installing battery
Remove cable (A3) [between battery (+) and
battery relay]
Tools: Spanner: 13 mm

(3) Remove battery (B1)

1.
Loosen nut (A6) M10 and remove cover (A1)
and spacer (A5).
2.
Loosen 2 capscrews (A3) M12X200.
Tools: Socket: 17 mm
3.
Remove plate (A2).
4.
Remove battery (B1).

Follow the battery removal order.

Start removing battery from grounding side, and finish attaching to grounding side. If this order is
missed, short-circuits may occur.

33-7
［33. UPPER SLEWING STRUCTURE］

33.1.3.2 INSTALL
(1) Install the battery in the reverse order of
removing.
Hold down plate (A2) against battery (B1),
and tighten capscrew (A3).
Tools: Socket: 19 mm,
Tightening torque : 10.8 N-m (8.0 lbf-ft)
(2) Installing grounding cable
Install grounding cable (A4) last. Especially
care must be taken that the grounding
face is free from painting, rust, etc.
Tools: Spanner: 13 mm
(3) Installing the cover (A1) and nut (A6) M10.
Tools: Spanner: 17 mm
Tightening torque : 15.7 N-m (11.6 lbf-ft)
Removing battery

33-8
 ［33. UPPER SLEWING STRUCTURE］

33.1.4 GUARD
33.1.4.1 PREPARATION FOR REMOVAL 33
(1) Remove guard in the following procedure.
Remove the guards in the order of
(B1)-->(C8)-->(A4)-->(G1)-->(A1)-->(C1)-->(C2)
-->(A2)-->(F1) and (E1).
(2) All the locked cover, open them using
starter key.

Arrangement of guard assy

33.1.4.2 REMOVE GUARD

(1) Remove bonnet assy (B1)
1.
Unlock the lock (B1-6), and open bonnet
(B1).
2.
Remove four nuts (B4) M12.
3.
Remove bonnet (B1).
Tools: Socket: 19 mm
Weight: 20 kg (44 lbs)

Removing bonnet assy (B1)

(2) Remove guard (C8)

1.
Remove 3 sems bolts (C9) M12X25 on
upper side.
2.
Remove 5 sems bolts (C9) M12X25 on
the lower side.
3.
Remove a sems bolt (C10) M12X20 on
the lower side.
4.
Remove guard (C8) Removing guard (C8)
Tools: Socket: 19 mm
Weight: 12 kg (26.4 lbs)

33-9
［33. UPPER SLEWING STRUCTURE］

(3) Remove guard (A4) and guard assy (A2).

1.
Remove 4 sems bolts (A32) M12X25.
2.
Remove 2 sems bolts (A29) M12X25.
3.
Remove guard (A4).
4.
Remove 3 sems bolts (A32) M12X25.
5.
Remove guard (A2).
Tools: Socket: 19 mm
Removing guard (A4) and (A2)

(4) Remove stay (G1)

1.
Remove 2 sems bolts (G3) M12X25.
2.
Remove 2 capscrews (G4) M12X70.
3.
Remove stay (G1).
Tools: Socket: 19 mm

Removeing stay (G1)

(5) Remove guard (A1)

1.
Remove 2 sems bolts (A32) M12X25.
2.
Remove connector for right side deck light.
3.
Remove guard (A1).
Tools: Socket: 19 mm

Removing guard (A1)

(6) Remove panel assy (C1)

1.
Unlock panel assy (C1).
2.
Remove 4 nuts (C3) M10.
3.
Remove panel assy (C1).
Tools: Socket: 17 mm
Weight: 16 kg (35.2 lbs)

Removing panel assy (C1)

33-10
 ［33. UPPER SLEWING STRUCTURE］

(7) Remove panel assy (C2)

1.
Unlock and open panel assembly (C2).
33
2.
Remove 4 nuts (C3) M10.
3.
Remove panel assy (C2).
Tools: Socket: 17 mm
Weight: 17 kg (34.7 lbs)

Removing panel assy (C2)

(8) Remove guard assy (A8), (A12) and guard

(A9), (A10), (A11).
1.
Remove 16 sems bolts (A32) M12X25 and
guard assy (A8), (A12), (A9), (A10), (A11)
in order.
Tools: Socket: 19 mm

Removing guard assy (A8), (A12) and guard

(A9), (A10), (A11)

(9) Remove pillar (A6) and (A7).

1.
Remove 6 sems bolts (A32) M12X25, (A37) M12X35 and remove pillar.
Tools: Socket: 19 mm
2.
Remove pillar (A6) and (A7).

Removing pillar (A6) and (A7)

33-11
［33. UPPER SLEWING STRUCTURE］

(10) Remove pillar (A17), (A18)

Remove battery relay box in advance and
remove pillar (A18). (See Chapter 23)
1.
Loosen 4 sems bolts (A32) M12X25.
2.
Remove pillar (A17), (A18).

Removing and installing of pillar (A17),(A18)

(11) Remove plate assy (A14) and guard (A16)

1.
Loosen 3 sems bolts (A32) M12X25, and
remove plate (A14).
2.
Loosen 2 sems bolts (A32) M12X25, and
remove guard assy (A16).
Tools: Socket:19 mm
(12) Remove bracket (A36)
Loosen 2 sems bolts (A32) M12X25, and
remove bracket (A36).

Removing and installing of guard assy and

guard

(13) Remove guard assy (D2)

1.
While air cleaner is removed, loosen hose
clamp of engine intake and disconnect the
hose.
2.
Loosen 6 sems bolts (D4) M12X20, and
remove guard assy (D2).
Tools: Socket: 19 mm
(14) Remove guard assy (D1)
Loosen 3 sems bolts (D5) M12X30, and Removing and installing of cover and guard
remove guard assy (D1). assy
Tools: Socket: 19 mm
Weight: 20 kg (44 lbs)
(15) Remove guard assy (D3)
Loosen 4 sems bolts (D4) M12X20, and
remove guard assy (D3).
Tools: Socket: 19 mm
Weight: 8 kg (17.6 lbf-ft)

33-12
 ［33. UPPER SLEWING STRUCTURE］

(16) Remove guard assy (F1)

Loosen 3 sems bolts (F2) M12X25, and
remove guard assy (F1).
33
Tools: Socket: 19 mm
Weight: 15 kg (33 lbs)

Removing and installing of guard assy (F1)

(17) Remove guard (H1)

Loosen 5 sems bolts (H3) M12X25, and
remove guard (H1).

Removing guard (H1)

(18) Remove cover assy (E1)

1.
Unlock the locks and open cover (1-2).
2.
Remove 4 sems bolts (E2) M12X25.
3.
Remove cover assy (E1).
Tools: Socket: 19 mm
Weight: 30 kg (66 lbf-ft)

(19) Remove other brackets, as required.

Removing cover assy (E1)

33.1.4.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
(2) Tightening torque

33-13
［33. UPPER SLEWING STRUCTURE］

33.1.5 UNDER COVER

33.1.5.1 REMOVAL
(1) Remove under cover (1,2,3,4,5,6,7)
1. Remove any relevant sems bolts (9) M12X30 and (8) M12X25.
2. Remove covers.
Tools: Socket: 19 mm

Under cover assy

33.1.5.2 INSTALLATION
(1) Install under cover (1,2,3,4,5,6,7)
Tools: Socket: 19 mm
Tightening torque: 80 N-m (60.5 lbf-ft)

33-14
 ［33. UPPER SLEWING STRUCTURE］

33.1.6 FUEL TANK

33.1.6.1 PREPARATION FOR REMOVAL 33
(1) Draining fuel. (See below Fig.)
1.
Unlock cap (B2) with a starter key and
open it.
2.
Loosen valve (A7) under the tank.
3.
Draining fuel
Capacity of tank: 275 L (73 gal)
(2) Remove cover assy (E1) and guard (A1).
(3) Remove stay (G1).
(4) Remove under cover (1),(2).
(5) Remove the connector for level sensor (A4).
(6) Remove fuel hose
1.
Loosen clip (17),(18) and draw out hoses
(8) and (29).
2. Removing fuel hose (8), (29) and fuel filter
Put in plugs that match the hose bore. assy

33.1.6.2 REMOVAL
(1) Remove 4 capscrews (A1) M16X40.
Tools: Socket: 24 mm
(2) Hook the wire to the lifting eye on the
fuel tank assy (B1) and remove the fuel
tank.
Weight: 105 kg (231 lbs)
(3) Remove shim (A3).

Removing fuel tank

Record the shim locations.

33-15
［33. UPPER SLEWING STRUCTURE］

33.1.6.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
Tank attaching bolt (A1) M16X40
Tools: Socket: 24 mm, Apply Loctite #262
Tightening torque: 191 N-m (140 lbf-ft)

If the gap (looseness) between tank mount and frame exceeds 1 mm (0.04 inch), adjust the gap with
shim (A3) and tighten capscrew (A1) to install the tank.

(2) Tightening torque

When the stop valves (A7) was loosened, replace the seal tape with new one. On the occasion of this
work, prevent entry of dust.

33-16
 ［33. UPPER SLEWING STRUCTURE］

33.1.7 HYDRAULIC TANK

33.1.7.1 PREPARATION FOR REMOVAL 33
(1) Remove panel assy (C2), guard assy (A2)(A4) and bonnet assy (B7).

(2) Release internal pressure of tank

Remove cap on air breather and push
valve (head of bolt) by your finger.

Bleeding internal pressure of tank

Keep pressing until the hissing stops.

(3) Remove cover (B3).

1. Remove 6 sems bolts (B9) M10X25.
Tools: Socket: 17 mm
2. Remove cover (B3)
3. Remove suction strainer (B4).
(4) Remove cover (B2).
1. Remove 6 sems bolts (B9) M10X25.
Tools: Socket: 17 mm
2. Remove cover (B2).
3. Remove filter element (B7).
(5) Turn the handle of element assy (B), and
disassemble the removed filter element (B7).
Disassemble parts: (B), (C), (D), (E), (F)
(6) Draining hydraulic oil
Place pump in tank and drain hydraulic oil.
Capacity of tank: 148.7 L (39.7 gal) Remove cover (B6), (B7)

33.1.7.2 REMOVAL
(1) Draw out the suction hose (3)
Remove 2 clips (20) of the tank side and
pull out hose (3).
Tools: 2: Flat-blade screwdriver

Removing the suction hose

33-17
［33. UPPER SLEWING STRUCTURE］

(2) Disconnecting the main pipe return hose

Disconnect return hose (A2). Disconnect
hose (A9) returning to oil cooler.
Tools: Spanner: 41 mm
(3) Disconnect pump drain hose (A6) of pump
Tools: Spanner: 27 mm
(4) Disconnect makeup hose (A7) of swing
motor.
Tools: Spanner: 27 mm

Removing main piping return hose

(5) Disconnecting pilot return hose

1. Remove pilot hose (A9).
Tools: Spanner: 22 mm

2. Remove pilot hose (A13).

Tools: Spanner: 22 mm

3. Remove pilot hose (A4).

Tools: Spanner: 22 mm

Remove pilot return hose

(6) Remove drain hose (B2) of pilot pump

Tools: Spanner: 22 mm

Removing pump drain hose

33-18
 ［33. UPPER SLEWING STRUCTURE］

(7) Remove hydraulic tank attaching bolt

Remove 4 capscrews (A1) M16X40.
Tools: Socket: 24 mm
33
(8) Slinging hydraulic oil tank
Place a wire sling, using the lifting plate on
top of the tank.
Tank weight: Approx : 107 kg (236 lbs)
(9) Remove shim (A3).

Removing hydraulic tank

Record the shim locations.

33-19
［33. UPPER SLEWING STRUCTURE］

33.1.7.3 INSTALLATION
(1) Cleaning hydraulic oil tank
(2) Cleaning suction hose
(3) Cleaning mount of tank.
Installing is done in the reverse order of removing.
(4) Install 4 mounting capscrews (A1) M16X40. (See Fig. "Removing hydraulic tank".)
Tools: Socket: 24 mm, Apply Loctite # 262
Tightening torque: 191 N-m (40 lbf-ft)

If the gap (looseness) between tank mount and frame exceeds 1mm (0.04inch), adjust the gap with
shim (A3) and tighten capscrew (A1) to install the tank.

(5) Connection of suction hose (3)

(See Fig. "Removing the suction hose".)
1. Apply PERMATEX on pipe side of hose
connection and insert it.
2. Put the hose with clip (20).
Tightening torque: 5.39 N-m (4.0 lbf-ft)
(6) Assembling return element
Assemble filter element by the use of
element kit (B7-600). (See Fig. "Remove
cover", Right Fig.)
(7) Install return element. (B7)(See Fig.
"Remove cover")
(8) Installing suction strainer (B1)
(9) Tighten sems bolts (B9) M10X25 that
attach tank covers (B3), (B2).
M10 Tightening torque : 46.5 N-m (34 lbf-ft)

Element & suction strainer

1. Replace O-ring (C) and packing (F) with new ones respectively.

Replace O-ring fitted on the back side of tank cover with new one.

33-20
 ［33. UPPER SLEWING STRUCTURE］

33.1.8 HYDRAULIC PUMP

33.1.8.1 PREPARATION FOR REMOVAL 33
(1) Release pressure in hydraulic oil tank.
(See 33.1.7HYDRAULIC TANK)
(2) Remove six capscrews (B9) M10X25.
(3) Remove cover (B3)
Tools: Socket: 17 mm
(4) Take out suction strainer.
(5) Install suction stopper.
For suction stopper, see chapter 11. Tools.
(6) Remove counterweight (See "33.1.11
COUNTERWEIGHT")

Suction stopper installing

33.1.8.2 REMOVAL
(1) Loosen sems bolts (17) M10X35 and
remove half clamp (21). And disconnect 2
hoses (1), (2) from the delivery side.
Tools: Spanner: 17 mm
(2) Remove pilot pump suction hose (A3)
(See below Fig.)
Tools: Spanner: 36 mm
(3) Remove suction hose (3) and drain hose
(B2)
1. Remove 4 capscrews (A2) M12X30.
Tools: Allen wrench: 10 mm
2. Remove elbow (A1) of suction hose (3)
from pump.
3. Remove drain hose (B2).
Tools: Spanner: 36 mm

Removing and installing of suction and

delivery hose

33-21
［33. UPPER SLEWING STRUCTURE］

(4) Removing other hoses

1. Disconnect hoses of the following ports.
2. Attach tags to hoses to identify.
3. Put a plug in the hoses and the pump.

Removing other hoses

Remove the parts marked * only if necessary.

(5) Remove connector

Remove 4 connectors of all pressure sensors and proportional valves.

Removing connector

33-22
 ［33. UPPER SLEWING STRUCTURE］

(6) Remove main pump

1. Put a wire sling on the hydraulic pump and

33
tension the wire sling a little. Loosen 8
capscrews (4) M10X30.
Tools: Socket: 17 mm
2. Draw out the power take-off assy from the
flywheel housing slowly, adjusting the
tension of the wire rope.
On that occasion, the assembly is drawn
out with the insert NA (2-3) remaining on
the flywheel side.
3. Remove element (2-1) from the tip of the
spline shaft.
4. Remove 4 capscrews (2-6) M16X45 that
fasten insert R (2-4) and remove insert R
(2-4).
Tools: Allen wrench: 14 mm
5. Remove hub (2-2)
If you loosen 2 set screws (2-7) M16X18,
hub comes off from the spline shaft of the
pump.
Tools: Allen wrench: 8 mm Removing pump
6. Remove 4 capscrews (2-5) M16X55 that
fasten the insert NA (2-3) with the engine
side flywheel, as necessary. Then remove
and spring pin (2-8) from insert NA (2-3).
Tools: Allen wrench: 14 mm
7. Removing bracket (1)
Loosen 2 capscrews (3) M20X50, and
remove bracket (1) from pump (0).

33-23
［33. UPPER SLEWING STRUCTURE］

33.1.8.3 INSTALLATION
Installing is done in the reverse order of removing.
(1) Installing bracket (1)
Tighten bracket (1) with capscrew (3) and install bracket temporarily.
Tools: Allen wrench: 14 mm
Tightening torque: 191 N-m (141 lbf-ft)
Apply Loctite #262
(2) Installing hub (2-2)
Put hub (2-2) into the pump spline till it enters 5mm (0.12 in) from the end face of the spline
(See below Fig. Detail aa). Then install two set screws (2-7) and fix them together.
Tools: Allen wrench: 8 mm
Tightening torque: 110 N-m (81 lbf-ft)
(3) Installing insert R (2-4)
Install insert R (2-4) into hub (2-2) by means of capscrews (2-6).
Tools: Allen wrench: 14 mm
Tightening torque : 210~230 N-m (155~170 lbf-ft)
(4) Installing element (2-1)
Put element (2-1) into hub (2-2) and insert R (2-4).
(5) Installing insert NA (2-3)
Put spring pin (2-8) into insert NA (2-3) and install it to the engine flywheel by means of
capscrews (2-5).
Tools: Allen wrench: 14 mm
Tightening torque: 210 to 230 N-m (155 to 170 lbf-ft)
(See Fig."Removing pump" about above mentioned (1) to (5).)

(6) Installing the pump (See Fig. "Removing

pump", right Fig.
Lift the pump with bracket (1). Place
coupling (2) in the groove of element (2-1)
so as to receive insert NA (2-3).
(7) Coat 8 capscrews (4) M10X30 with Loctite
#262 and put them in place.
Tools: Socket: 17 mm
Tightening torque : 64.7N-m (48 lbf-ft)
(8) Fasten hoses (1), (2) on the delivery side
with half clamp (12) and sems bolt (17)
M10X35.
(See Fig."Removing and installing of")
Tools: Spanner: 17 mm
Tightening torque: 57 N-m (42 lbf-ft)
(9) Install suction hose (3) with 4 capscrews
(A15) M12X30. (See Fig."suction and
delivery hose")
Tools: Allen wrench: 10 mm
Tightening torque : 66.7 N-m (49 lbf-ft)
(10) Install the hydraulic piping by referring to
"HYDRAULIC SYSTEM". Installing hydraulic pump

33-24
 ［33. UPPER SLEWING STRUCTURE］

(11) Installing the hose (See Fig."Removing other hoses")

33

(12) Installing pressure sensor connector and proportional valve connector.

(13) Remove suction stopper
(14) Install suction strainer

When the pump is replaced, replenish more than 1L (0.26 gal) of hydraulic oil from the drain port (Dr).

(15) Bleed air in pump

Bleed air by loosening the drain port (Dr).
(16) Check hydraulic oil level.
(17) Start engine and check it for oil leak and
noise.
(18) Attach drain down pipe under engine
muffler.
(19) Install counterweight.
(See Fig." 33.1.11 COUNTERWEIGHT") Bleed air port (Dr) in pump

33-25
［33. UPPER SLEWING STRUCTURE］

33.1.9 AIR CLEANER

33.1.9.1 PREPARATION FOR REMOVAL
(1) Opening bonnet assy (B1).
(See 33.1.4 GUARD)
(2) Open panel assy (C1).
(3) Unplug terminals on indicator (1-7) wiring.
(See right Fig.)

Preparation for removal

33.1.9.2 REMOVAL
(1) Pulling out hose (2).
1. Loosen clips (7), (8) on both sides of
hose (2).
2. Pulling out hose (2)
Tools: Flat-blade screw driver
(2) Pulling out hose (4).
1.Loosen clip (8) on hose (4).
2.Pulling out hose (4).
Tools: Flat-blade screw driver
(3) Remove air cleaner assy (1)
1. Loosen 4 sems bolts (9) M8X16
Tools: Socket: 13 mm
2. Remove air cleaner assy (1) from
bracket.

33-26
 ［33. UPPER SLEWING STRUCTURE］

33

Removing air cleaner

33.1.9.3 INSTALLATION
(1) Installing is the reverse order of removing with attention paid to the following items:
1. Put in air hoses (2), (3) to the end as shown in Fig."Removing air cleaner".
2. Tightening torque:

33-27
［33. UPPER SLEWING STRUCTURE］

33.1.10 MUFFLER
33.1.10.1 PREPARATION FOR REMOVAL
(1) Remove bonnet assy (B1) and guard (A9).
(See Fig. "Remove bonnet assy (H3)".)

Preparation for removal

33.1.10.2 REMOVAL
(1) Remove hose (5).
1. Loosen sems bolt (12) M12X20, clip (11)
and remove hose (5).
(2) Remove U bolt (4).
1. Remove 4 nuts (9) M8.
Tools: Socket: 13 mm
2. Remove 2 U bolts (4).
(3) Remove clamp assy (3)
1. Remove 2 capscrews (6) M10X35
Tools: Socket: 17 mm
2. Separate clamp assy (3) from muffler (1).
(4) Removing other parts
1. Remove 4 sems bolts (13) M10X25.
2. Remove brackets (2) as necessary.
Tools: Socket: 17 mm Removing and installing the muffler

33-28
 ［33. UPPER SLEWING STRUCTURE］

33.1.10.3 INSTALLATION
Installing is the reverse order of removing with attention paid to the following items:
(1) Procedure of fastening U bolt (4) (See Fig."Removing and installing the muffler")
33
1. Tighten 4 nuts (A) till there is no space and make sure that the dimension C is even all around.
2. Tighten nuts (A) to specified torque and confirm the C dimensions on the right and left once again.
3. Tighten nuts (B) to specified torque and make sure that U bolts are not inclined.
(Decide C dimension after checking the piece-to-piece variations in related parts.)
4. Tightening torque
Nut A: 8.8 N-m (6.5 lbf-ft)
Nut B: 10.8 N-m (8.0 lbf-ft)

(2) Installing clamp assy (3)

1. Place the end of clamp (3) 10mm (0.40 in) away from the tip of the muffler slit so the joint of
clamp does not extend over the slit in the muffler. (See Fig."Removing and installing the muffler")
2. Install the clamp assy (3) in the illustrated direction.

(3) Tightening torque:

No. Name Tightening torque N-m (lbf-ft)

6 Capscrew M10 68.6~98 (50.6~72.3)
12 Sems bolt M12 66.7 (49.2)
13 Sems bolt M10 64.7 (47.7) (Apply Loctite #262)

(4) Replacing parts

Name Part No.

Muffler (1) LP12P00015P1

33-29
［33. UPPER SLEWING STRUCTURE］

33.1.11 COUNTERWEIGHT
33.1.11.1 PREPARATION FOR REMOVAL
Remove plug (A3) on the counterweight and
attach 2 M36 eye bolts (See chapter 11) to the
counterweight.
Tools: Spanner: 55 mm

Lifting up counterweight

33.1.11.2 REMOVAL
(1) Lifting up counterweight temporarily
Hook wire rope to slinging jig, and lift it
and stretch wire rope to the degree where
it is providing no slack temporarily.
Weight of counterweight;
Approx. 2,600 kg (5,730 lb)
Wire more than 10 dia. (0.39 inch);
1.5m (5ft)X2 pcs.
(2) Removing counterweight
1. Remove slewing flasher harness (B2)
connector.
2. Remove 4 capscrews (A1) M24X280.
Tools: Socket: 36 mm
3. Remove shim (A4), (A5), (A6). (Select)
4. Remove counterweight (B3).

Removing counterweight

33.1.11.3 INSTALLATION
(1) Install counterweight in the reverse order of removing.
(2) Install shim (A4), (A5), (A6) as it was. (select)
(3) Slinging counterweight
Check that the attaching bolts can be screwed in by hand.
(4) Apply Loctite #262 on capscrews (A1), and tighten them with washers (A2).
Tools: Socket: 36 mm
Tightening torque : 873±49 N-m (646±36 lbf-ft)
(5) Remove slinging tools, and attach plugs (A3).
(6) Install slewing flasher harness connector.

33-30
 ［33. UPPER SLEWING STRUCTURE］

33.1.12 RADIATOR & OIL COOLER

33.1.12.1 PREPARATION FOR REMOVAL 33
(1) Bleed air from the hydraulic tank and install the suction stopper. (See 33.1.7 and 33.1.8)
(2) Remove counterweight. (See 33.1.11 COUNTERWEIGHT)
(3) Remove guard assy (F1). (See Fig. "Removing duct assy (F1)")
(4) Removing under cover installed on lower side of radiator.
Remove under cover (5),(6),(7). (See Fig. 33.1.5)
(5) Drain down of radiator
Put container 18L (4.8gal) under drain valve hose for draining water.
[Water capacity of radiator : 6.6L (1.7gal)]

Do not loosen the joints of the hoses related to the air-conditioner. Otherwise the refrigerant leaks.

(6) Move air-conditioner condenser and receiver

tank
1. Loosen 6 sems bolts (23) M8X25.
Tools: Socket: 13 mm
2. Move a set of air-conditioner condenser
and receiver dryer.

Moving condensers and receiver dryer

33-31
［33. UPPER SLEWING STRUCTURE］

33.1.12.2 REMOVAL
(1) Remove radiator stay (B1),(B4).
1.
Remove 2 sems bolts (B2) M12X30.
Tools: Spanner: 19 mm
2.
Remove 2 sems bolts (B3) M12X45.
3.
Remove 2 stays (B1),(B4).
(2) Remove water hose (2),(3).
1.
Loosen the 2 hose bands (18) for water
hose (2).
Tools: Flat-blade screwdriver
2.
Remove hose (2).
3.
Loosen 2 hose band (18) on water hose (3) Removing radiator assy
Tools: Flat-blade screwdriver
4. Remove hose (3).
(3) Remove sub tank tube (25).
1.
Remove clip (23), (24).
Tools: Flat-blade screwdriver
2.
Loosen sub tank tube (25).

(4) Remove hoses (4)(5)(6) for inter-cooler

1.
Remove a fixing U-bolts (14) from tube (12).
Tools: Spanner: 13 mm
2.
Loosen sems bolt (15) M8X20.
Tools: Spanner: 13 mm
3.
Loosen tow hose bands (19) and remove
hose (4).
Tools: Flat-blade screwdriver
4.
Loosen hose bands (18), (19) and remove
hose (6).
Tools: Flat-blade screwdriver
5.
Loosen 2 hose bands (18) and remove
hose (5).
Tools: Flat-blade screwdriver
(5) Remove guard (9), (10) (See right Fig.)
1. Remove 4 sems bolts (15) M8X20.
2. Remove guard (9), (10).
Tools: Spanner: 13 mm Removing hose for radiator/inter-cooler

33-32
 ［33. UPPER SLEWING STRUCTURE］

(6) Disconnecting hydraulic oil hose (A8) and

hose (A1)
1.
33
Loosen a capscrew (A22) M12X55 for
attaching clamp (A28).
2.
Place an oil pan under the hose joint.
Loosen 2 sems bolts (A25) M12X30, and
remove hose (A1) and support (A13).
3.
Loosen 2 sems bolts (A23) M12X35, and
remove tube (A8).
4.
Loosen 2 sems bolts (A25) M12X30, and
remove hose (A1) and support (A12).
(7) Remove radiator assy.
1.
Remove 4 sems bolts (B2) M12X30.
Tools: Spanner: 19 mm
Tools: Socket: 19 mm
2.
When lifting the engine fan, shift the
radiator so it does not interfere with the
engine fan.
3.
Plug up pipe ends with clean cloth, etc.
4.
Removing radiator
Place a wire sling in the lifting eyes of the
radiator assy and remove the assy by
Removing hydraulic oil tube (A1), (A8)
crane.
Weight: 96 kg (212 lbs)

33-33
［33. UPPER SLEWING STRUCTURE］

33.1.12.3 INSTALLATION
(1) Installing is done in the reverse order of removing. And removed clips of hose should be
clamped at original position.
(2) Install radiator assy
Place a wire sling in the lifting eyes of the radiator and move it to original position temporally.
And install hydraulic hose, radiator hose and hose of inter-cooler. Regarding Inserting width of
hose. (See Fig."Allow ance of hose in sertion")
(3) Radiator attaching bolt
Apply Loctite #262 on 4 sems bolts (B2) M12X30.
Tools: Socket: 19 mm
Tightening torque : 120.6 N-m (88.9 lbf-ft)
(4) Installing radiator stays (B1), (B4)
Install radiator stays (B1), (B4) with 2 sems bolts (B2) M12X30 and 2 sems bolts (B3) M12X45.
Tighten circular hole side of stay with a sems bolt (B3) to upper frame.
(5) Adjust the clearance between the fan and the radiator shroud all around the circumference, as
below :
Circumferential direction:
15 to 25mm (0.6 in to 1.0 in)
18 to 28mm (0.7 in to 1.1 in)
(6) Clean the plastering area of the insulation thoroughly before plastering it.
(7) Making up hydraulic oil and LLC (Long Life Coolant)
After completion of other installation, make up hydraulic oil and water.
Coolant volume of engine body : 6 L (1.6 gal)
Coolant capacity of radiator : 6.6 L (1.7 gal)
Hydraulic oil capacity of oil cooler : 2.1 L (0.55 gal)

Adjusting position of radiator

33-34
 ［33. UPPER SLEWING STRUCTURE］

33

Allowance of hose insertion

33-35
［33. UPPER SLEWING STRUCTURE］

33.1.12.4 PROCEDURE OF DISASSEMBLING AND ASSEMBLING THE RADIATOR/INTER COOLER

CORE
(1) Preparation for disassembly and assembly
1.
Remove one under cover at the bottom of the
radiator.
2.
Wait till the engine coolant cools down so you
do not get burned. Then remove the cap of the
radiator, discharge the coolant by opening the
drain valve located at the lower of engine and
receive it in a container.
* In case of removing inter cooler only, the
above mentioned work is not necessary.

(2) Disassembly
1.
Loosen each 6 capscrews (19) at head and
bottom of shroud, remove upper plate (17) and
lower plate (18).
2.
Loosen 2 sems bolts (28) M10X30 attaching
radiator core.
3.
After confirming that the coolant has been
drained out completely, loosen and remove
only the radiator side of hose bands (17) at the
top and bottom of the radiator. (See 33.1.12.2)
4.
Lift and remove radiator core using lifting eyes
and hoist on the radiator core.
Weight: 13 kg (29 lbs)
Confirm the missing of rubber bushing (27)
under the radiator core.
5.
Loosen 2 sems bolts (28) M10X30 attaching the
top of the inter-cooler core.
6.
Loosen and remove only the inter-cooler side of
hose bands (18) at the top and bottom of the
inter-cooler. (See 33.1.12.2)

Removing radiator and inter-cooler

33-36
 ［33. UPPER SLEWING STRUCTURE］

7.
Lift and remove inter-cooler using lifting eyes and hoist on the inter-cooler.
Weight : 4.8kg (11 lbs)
33
Confirm the missing of rubber bushing under the inter-cooler.
8.
Disconnection of oil cooler tube Disconnect tube (A8), (A1) from upper and lower of cooler, and drain
hydraulic oil. (See 33.1.12.2)
9.
Lift cooler temporally using cooler head flange for slinging.
10.
Loosen 4 bolts (19) M8X25 attaching oil cooler.
11.
Lift the oil cooler.

There is no predetermined sequential order in removing radiator core, inter-cooler core and oil cooler.
Removing these components can be done as necessary.

(3) Installing
Installing is done in the reverse order of removing.

33-37
［33. UPPER SLEWING STRUCTURE］

33.1.13 ENGINE
33.1.13.1 PREPARATION FOR REMOVING
(1) Remove battery ground (See 33.1.3 BATTERY)
(2) Remove bonnet and guard (See 33.1.4 GUARD ) Remove under cover (See 33.1.5 UNDER
COVER)
(3) Remove air cleaner hose (See 33.1.9 AIR CLEANER)
(4) Remove counterweight (See 33.1.11 COUNTERWEIGHT)
(5) Remove radiator hose and inter-cooler hose (See 33.1.12 RADIATOR & OIL COOLER)
(6) Remove fuel hose and heater hose, and if necessary disconnect air-con hose.
(7) If necessary, remove pump, muffler and radiator.
(8) Remove harness connector (Refer to ELECTRIC SYSTEM)
1. Remove E/G ground cable
2. Starter cable-Starter B terminal
3. Remove the connector that connects the upper harness with the engine and ECU harness.
4. Upper harness

Prepare a stand, which withstands the weight of the engine assy and can place the removed engine
firmly. (Refer to Tools)

Outside view of engine

33-38
 ［33. UPPER SLEWING STRUCTURE］

33.1.13.2 REMOVAL

33

Dismantling and mounting engine

(1) Loosen engine mounting bolt of flame

1. Loosen a nut (11) M18 and a capscrew (10) M18X150.
Tools: Socket: 27 mm
2. Loosen 3 other capscrews (10) M18X150 and remove them.
Tools: Socket: 27 mm
3. Remove each 4 plates (7).
4. Remove upper rubber mounts (4) 4 each.
(2) Slinging engine body

Prepare a stand, which withstands the weight of the engine assy and can place the removed engine
firmly. (Refer to "Tool".)

1. Sling engine hooking wire to lifting lugs on the front and rear sides.
Weight: Approx. 400 kg (882 lbs)
Wire: 6 dia. (0.236")X1m (3ft 3in) - 2pcs.
(3) Position engine on the stand stably.

33-39
［33. UPPER SLEWING STRUCTURE］

33.1.13.3 INSTALLATION
Installing is done in the reverse order of removing.
(1) Tightening torque

33-40
 ［33. UPPER SLEWING STRUCTURE］

33.1.14 CONSOLE COVER

33.1.14.1 REMOVAL 33
(1) Removing right-hand console cover
1. During pushing 4 locked claws of boot
retaining plate (4) with flat-blade screw
driver, lift the plate (4) and remove it.
Tools: Flat-blade screwdriver
2. Loosen 3 sems bolts (A5) M6X16.
Tools: Plus screw driver
3. During lifting right upper console cover
(A4-5) up; disconnect connector of tuner
and antenna. Move boot (3) upwards and
remove console cover (A4-5).
-Removing of boot and lever is Removing plate (4)
unnecessary.
4. Loosen 3 sems bolts (15A) M6X16 and
remove lower console (3).
Tools: Plus screw driver

(2) Removing left-hand console cover

1. Remove the boot retaining plate (4) in the
same way as right-hand console cover.
(See above Fig.)
Tools: Flat-blade screwdriver
2. Loosen 4 sems bolts (15B) M6X16.
Tools: Plus screw driver
3. Remove the left upper console cover (4X)
in the same way as right-hand console
cover.
4. Loosen 2 sems bolts (15) M6X16 while
lifting left under console cover (5X) up,
and remove left lower console cover.

Removing console covers

33.1.14.2 INSTALLATION
Install it in reverse order of removing according to the tightening torque table.

33-41
［33. UPPER SLEWING STRUCTURE］

33.1.15 CONTROL VALVE

33.1.15.1 PREPARATION FOR REMOVING
(1) Remove guard (A4), (A2).
(See Fig. 33.1.4 GUARD)
(2) Remove plate (A14) and guard (A16).
(See Fig. 33.1.4 GUARD)
(3) Remove pillar (A17), (A18) and bracket
(A36).
(See Fig. 33.1.4 GUARD)
(4) Install the suction stopper to the hydraulic
oil tank.
(5) Remove the hoses in Fig. "Control valve
ports (1/2)" and Fig. "Control valve ports
(2/2)".

Removing the standard main control valve

Mark each hose with a port name before removing it.

33.1.15.2 REMOVAL
(1) Remove 3 capscrews (4) M16X45, and remove control valve (1) by hoist.
Tools: Spanner: 24 mm
Weight: Approx. 155 kg (342 lbs)

33.1.15.3 INSTALLATION
(1) Installing is done in the reverse order of remove.
1. Install control valve by tightening 3 capscrews (4) M16X45.
Tools: Spanner: 24 mm
Tightening torque: 235 N-m (173 lbf-ft)
2.

(2) Check for oil leak and operation.

33-42
 ［33. UPPER SLEWING STRUCTURE］

33

Control valve ports (1/2)

33-43
［33. UPPER SLEWING STRUCTURE］

Control valve ports (2/2)

33-44
 ［33. UPPER SLEWING STRUCTURE］

33.1.16 PILOT VALVE (FOR ATT)

33.1.16.1 PREPARATION FOR REMOVING 33
The removing procedure for right and left is the same, so the preparation for left side is described
here.

(1) Put attachment on ground, stop engine

and release pressure in tank.
(2) Remove left console cover (4X), (5X) assy
referring to Section 33.1.14CONSOLE
COVER.
(3) Disconnect harness connector for horn at *
position.
(4) Attach a tag to the hose to make assembly
work easier.
Tools: Torx driver

Installing and removing boot and lever part

33.1.16.2 REMOVAL
(1) Remove hoses from your side to far side in
order.
Tools: Spanner: 19 mm, 22 mm
(2) Move the boot (3) up and loosen nut (5).
(See above Fig.)
Tools: Spanner: 22 mm
(3) Turn and loosen lever (2-1) tightened in
pilot valve, and remove lever assy in a set.
(See above Fig.)
(4) Remove 4 capscrews (A14) M6X25. (See
right Fig.)
Tools: Allen wrench: 5 mm
(5) Remove pilot valve.
(6) Plug hose ends.
Plug PF1/4, PF3/8
Pilot valve connector

33-45
［33. UPPER SLEWING STRUCTURE］

33.1.16.3 INSTALLATION
Install it in the reverse order of removal and
tighten it.
Tools: Allen wrench: 5 mm T = 11.8 N-m (11
lbf-ft) capscrew (A14)

Pilot valve port position (from upper side)

Make sure the tightening torque for capscrews, because pilot valve is made of aluminum.

33-46
 ［33. UPPER SLEWING STRUCTURE］

33.1.17 PILOT VALVE (FOR TRAVEL)

33.1.17.1 PREPARATION FOR REMOVING 33
(1) Release pressure in hydraulic oil tank
(See 33.1.7 HYDRAULIC TANK)
(2) Remove under cover (3) (See 33.1.5
UNDER COVER)
(3) Remove floor mat (B1).

Removing floor mat, pedal and and lever

33.1.17.2 REMOVAL
(1) Separate the two pressure sensors SE-9
(A9) and SE-10 (A9) at the connector.
Tools: Spanner: 24 mm
(2) Attach tag, and discount connectors and
hoses (A2), (A3), (A4), (A5)
Tools: Spanner: 19 mm (P port)
Tools: Spanner: 19 mm, 22 mm (T port, 1
to 4 port)
(3) Plug hose ends
Plug PF1/4, PF3/8
(4) Remove 4 sems bolts (A8) M8X25, and
remove right and left pedals (A5), (A6).
Tools: Spanner: 13 mm
(5) Remove 4 sems bolts (A7) M10X20 and
remove right and left lever (A1), (A2).
Tools: Socket: 17 mm
(6) Remove 4 sems bolts (A12) M10X30.
Tools: Spanner: 17 mm
(7) Remove pilot valve lifting it upward.
(8) Stop up holes with plugs PF1/4.

Installing and Removing pilot valve

33-47
［33. UPPER SLEWING STRUCTURE］

33.1.17.3 INSTALLATION
Install it in the reverse order of removal and tighten it.
Sems bolt (A12)
Tools: Spanner: 17 mm T = 37 N-m (27.3 lbf-ft)
Sems bolt (A7)
Tools: Spanner: 17 mm T = 46.1 N-m (34.0 lbf-ft)
Sems bolt (A8)
Tools: Socket: 13 mm T = 23.5 N-m (17.3 lbf-ft)
Pressure sensor
Tools: Spanner: 24 mm T = 16.7 N-m (12.3 lbf-ft)

33-48
 ［33. UPPER SLEWING STRUCTURE］

33.1.18 SWING MOTOR UNIT

33.1.18.1 PREPARATION FOR REMOVING 33
(1) Park machine on firm level ground and place attachment on ground.
(2) Remove bracket (5) for engine bonnet gas damper. (See "33.1.4 GUARD")
(3) Remove top cover of swing motor and guard assy. (See "33.1.4 GUARD")
(4) Operate the switch on gauge cluster and select the pressure release mode, and then release the
inner pressure in circuit by operating control lever. (See 22.11 HYDRAULIC SYSTEM PRESSURE
DRAINING(RELEASING) CIRCUIT)
(5) Bleed air from the hydraulic oil tank and attach to each hose a tag showing port name and other
information.

33.1.18.2 REMOVAL
(1) Remove hose.
1. Remove hose (A6) from the connector in
the makeup port C.
Tools: Spanner: 36 mm
2. Remove hose (A4), (A7) from the elbow in
the drain port DB.
Tools: Spanner: 27 mm
3. Remove hose (18) from the elbow of the PG
port (For swing parking brake)
Tools: Spanner: 19 mm
4. Remove 2 hoses (21), (22) from the
connectors of the A, B port.
Tools: Spanner: 32 mm
Put in plugs PF3/4, PF1/2, PF3/8 and PF1/4
into the removed ports.
Removing swing unit piping

(2) Removing the swing unit

1. Loosen clip (5).
2. Remove 9 capscrews (7) M20X55.
Tools: Socket: 30 mm
3. Remove two plastic caps (2) M10 at the
top of the swing motor and install eye bolts.
Tools: Flat-blade screwdriver
4. Put a wire sling in the eye bolts and remove
the swing motor unit.
Weight of swing motor unit ;
Approx. 113kg (249 lbs) (Include reduction assy)

Removing swing unit

33.1.18.3 PREPARATION FOR INSTALL

(1) Clean mating surfaces of swing motor unit and upper frame.
Tools : spatula, wash oil
(2) Apply Loctite #515 on entire mounting surface of swing motor unit.

33-49
［33. UPPER SLEWING STRUCTURE］

33.1.18.4 INSTALLATION
Install the swing motor unit in the reverse order of disassembly, confirming the orientation of the
swing motor unit.

(1) Tighten 9 capscrews (5) M20X55.

Tools: Socket: 30 mm
Tightening torque : 539 N-m (400 lbf-ft) Apply Loctite #262
(2) Fill inside from motor drain port to casing with hydraulic oil before piping for drain

Installing swing motor unit

33.1.18.5 PREPARATION FOR DRIVE

(1) Before starting operation, check that gear oil #90 (API grade GL-4) level of swing reduction is
sufficient.
Amount of oil : 1.65L (0.44gal)
(2) When starting operation, operate motor in low idling and at low speed for several minutes, and
check it for possible oil leak and noise.

33-50
 ［33. UPPER SLEWING STRUCTURE］

33.1.19 SWIVEL JOINT

33.1.19.1 PREPARATION FOR REMOVING 33
Remove boom piping hose

33.1.19.2 REMOVAL
(1)
Remove travel motor hose and tube
1. Remove 2 hoses (A15). (E port : PF1/2)
Tools: Spanner: 27 mm, Tightening torque : 78.5 N-m (58 lbf-ft)
2. Remove tubes (A3), (A4). (C, D port : PF1)
Tools: Spanner: 36 mm, Tightening torque : 216 N-m (159 lbf-ft)
3. Remove tubes (A1), (A2). (A, B port : PF1)
Tools: Spanner: 36 mm, Tightening torque : 216 N-m (159 lbf-ft)
4. Remove 2 hoses (A16). (H,I port : PF1/4)
Tools: Spanner: 19 mm, Tightening torque : 29.4 N-m (22 lbf-f)

Removing piping (lower side)

33-51
［33. UPPER SLEWING STRUCTURE］

(2)
Disconnecting the hoses on the top part of
swivel joint
1. Remove drain hoses (A7). (E port : PF1/2)
Tools: Spanner: 27 mm
Tightening torque: 78 N-m (58 lbf-ft)
2. Remove hoses (27), (23).
(C, D port : 1-14UNS)
Tools: Spanner: 32 mm
Tightening torque: 137 N-m (101 lbf-ft)
3. Remove hoses (24), (22).
(A, B port : 1-14UNS)
Tools: Spanner: 32 mm
Tightening torque: 137 N-m (101 lbf-ft)
4. Remove hose (19).
(Travel 2-speed change over port : PF1/4)
Tools: Spanner: 19 mm
Tightening torque: 29 N-m (21 lbf-ft) Disconnecting the hoses on the top part of
swivel joint

(3)
Remove whirl-stop of swivel joint.
1. Loosen the nut (23) M24.
2. Remove a capscrew (22)M24X140.
Tools: Spanner: 36 mm

Removing whirl-stop nut & the capscrew

(4)
Remove joint for piping (See Fig. 33-77,Fig.
33-78)
1. Remove 2 connectors (1). (F,G port)
2. Remove elbow (5) (F port) for travel 2-speed
change over. (PF1/4)
Tools: Spanner: 19 mm
(5)
Remove seal (B25)
1. Remove 6 sems bolts (B29) M10X25.
Tools: Socket: 17 mm
2. Remove clip (B28). Removing seal (B25)
Tools: Flat-blade screwdriver
3. Remove seal (B25).

33-52
 ［33. UPPER SLEWING STRUCTURE］

(6)
Remove sems bolts for installation
Attach eye bolt, lift it up temporarily, and
33
remove 3 sems bolts (D2) M12X25.
Tools: Socket: 19 mm
(See 11.7 SPECIAL TOOLS No.9 Plug)

Removing sems bolts for installation

(7)
Slinging the swivel joint
Weight: Approx. 63 kg (139 lbs)

33.1.19.3 INSTALLATION
(1) Installing is done in the reverse order of
removing.
Piping tightening torque
(2) Check for oil leak and the hydraulic oil
level.
(3) Check for operating.

33-53
［33. UPPER SLEWING STRUCTURE］

33.1.20 UPPER FRAME

33.1.20.1 PREPARATION FOR REMOVING
(1) Remove attachment
(See chapter 32)
(2) Remove cab (See 33.1.2 CAB)
(3) Remove guard (See 33.1.4 GUARD)
(4) Remove counterweight
(See 33.1.11 COUNTERWEIGHT)
(5) Remove swivel joint
(See 33.1.19 SWIVEL JOINT)

Temporarily lift upper frame

33.1.20.2 REMOVAL
(1) Lifting up upper frame temporarily
Attach 2 upper-frame hoisting jigs to
attaching holes of counterweight. Attach 2
chain blocks to holes of boom foot pin
and use these four points and hoist
upper-frame.
Wire rope;
16 dia. (0.630")X2.5 m(8 ft-2 in), 2 pcs.
16 dia. (0.630")X1.5 m(4 ft-11 in), 2 pcs Matching mark on swing bearing and upper
Chain block; For 1,000 kg (2,205 lbs) 2 frame
pcs.
(2) Marking match marks on swing bearing
Put match marks on upper frame and
swing bearing.

(3) Removing upper frame attaching bolts

Remove 33 capscrews (B15) M16X85 and
a reamer bolt (B13) used to install swing
bearing and upper frame.
Tools: Socket: 24 mm
(4) Slinging upper frame
Sling according to above Fig, and remove
upper frame and put it on a stand.
Weight: Approx. 5 ton (11,000 lbs)

Removing upper frame attaching bolts

33-54
 ［33. UPPER SLEWING STRUCTURE］

33.1.20.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
(2) Cleaning mating surfaces of upper frame and swing bearing.
33
(3) Apply Loctite #515 to the inside of the capscrews on the contact surface.
(4) Slinging upper frame
Match marks and install it with a reamer bolt (B13) and a washer (B14) temporarily.
Tools: Socket: 24 mm Apply Loctite #262
Tightening torque : 256 N-m (189 lbf-ft)
Apply Loctite #262
(5) Install swing bearing
Install 33 capscrews (B31) M16X85.
Tools: Socket: 24 mm Apply Loctite #262
Tightening torque : 256 N-m (189 lbf-ft)
Install a reamer bolt (B30).
Tools: Socket: 24 mm
Tightening torque : 256 N-m (189 lbf-ft)

Bearing mount

Reamer bolt position (*) Apply Loctite to

shaded area

Confirm the reamer bolt positions referring to above Fig.

33-55
［33. UPPER SLEWING STRUCTURE］

33.2 DISASSEMBLING AND ASSEMBLING

33.2.1 HYDRAULIC PUMP - REGULATOR

33.2.1.1 HYDRAULIC PUMP
33.2.1.1.1 Structural exploded view
(1) Main pump

Structural exploded view of main pump

33-56
 ［33. UPPER SLEWING STRUCTURE］

33

33-57
［33. UPPER SLEWING STRUCTURE］

(2) Gear pump (For pilot)

No. Parts Q'ty No. Parts Q'ty

307 Poppet 1 433 Flange socket; M8X40 2
308 Seat 1 434 Flange socket; M8X55 2
309 Ring 1 435 Flange socket; M8X20 4
310 Spring 1 466 VP plug ; PF1/4 1
311 Adjust screw 1 700 Ring 1
312 Lock nut ; M14X1.5 1 710 O-ring 1
351 Gear case 1 725 O-ring ; 1B P11 1
353 Drive gear 1 732 O-ring ; 1B P16 1
354 Driven gear 1 850 Locking ring 1
355 Filter 1 887 Pin 2
361 Front case 1

33-58
 ［33. UPPER SLEWING STRUCTURE］

33.2.1.1.2 Disassembly and assembly of main pump

(1) Tools
The right list shows the tools required for
33
remove and install.

(2) Disassembling procedure

1.
Selecting a place for disassembly.
-Choose a clean place.
-Spread rubber sheet or cloth on work bench to
protect parts from damaging.
2.
Cleaning
Remove dust and rust, etc. on pump surface
with wash oil.

3.
Drain oil
Drain out the oil in the pump casing by
removing drain port plug (468).
Tools: Allen wrench: 10mm
-Drain out oil from the plug of the front pump
and the rear pump.
4.
Removing regulator and PTO cover
Remove the socket bolts [414, 415 (See
Fig."Structural exploded view of main pump",
Fig."Regulator exploded view")]. Then remove
the regulator and the PTO cover (326).
Tools: Allen wrench: 6 mm, 8 mm
-Regarding the disassembly of the regulator,
refer to article of Regulator.

33-59
［33. UPPER SLEWING STRUCTURE］

5.
Remove gear pump
Remove the socket bolts (435). Then remove
the gear pump (04).
Tools: Allen wrench: 6 mm
6.
Remove socket bolt (401), (402)
Loosen socket bolts (401), (402) that fasten
pump casing (271), (272) and valve block (312).
Tools: Allen wrench: 14 mm
Remove socket bolt (401),(402)

7.
Disassembling the pump casing and the valve
block
Place the pump level on a work bench with its
mounting surface of the regulator facing down.
Then separate pump casing (271) and valve
block (312).

-When facing the mounting surface of the

regulator down, place a rubber sheet on a work Disassembling the pump casing (271) and the
bench so as not to score the mounting surface. valve block (312)
-When the pump casing has been separated
from the valve block, draw out the 1st gear
(116) at the same time.

8.
Drawing out the cylinder assy
Draw out cylinder (141) out of pump casing
(271), (272) in parallel to shaft (111), (113). At
the same time draw out piston sub (151), (152),
plate (153), spherical bushing (156) and cylinder
spring (157).

-Use care so as not to score the sliding

surface of the cylinder block, spherical
bushing, shoe and the swash plate.
Drawing out the cylinder assy

33-60
 ［33. UPPER SLEWING STRUCTURE］

9.
Remove seal cover (F)
Remove socket bolt (406) M8 and seal cover
33
(F) (261).
Tools: Allen wrench: 6 mm

-The seal cover (F) may be drawn out with

ease if it is taken out by flat bladed driver in
the notch of the seal cover (F).
-An oil seal is fitted to seal cover (F).
Therefore, use care so as not to score the oil
seal. Removing seal cover (F) (261)

10.
Drawing out the shaft
Tap lightly the shaft end (111, 113) by means
of a plastic hammer and draw out the shaft
from the pump casings (271),(272).

Drawing out the shaft (111), (113)

11.
Remove shoe plate and swash plate
Draw out shoe plate (211) and swash plate
(212) from pump casings (271),(272).

Removing shoe (211) and swash plate (212)

12.
Insert wire into hole to keep pressing lock pin
(255) which locks swash plate support (251).
(See Fig. 33.2.1 HYDRAULIC
PUMP-REGULATOR). And free the swash
plate support from locking, and rotate it in
counterclockwise. Then remove swash plate
support (251) from pump casing.

-When pressing with wire, do not mistake the

hole for lock release and small hole (oil Removing swash plate support (251)
passage) on arc of swash plate support.
-Be careful of jumping out of lock pin and set
spring, during removal of swash plate support.

33-61
［33. UPPER SLEWING STRUCTURE］

13.
Remove valve plate
Remove valve plate (313, 314) from valve block
(312).

-The valve plate may come off during the

operation under 7).

Removing valve plates (313), (314)

14.
Remove other parts
If necessary, remove Q min-plug (533), stopper
(L) (534), stopper (S) (535), servo piston (532)
and tilting pin (531) from pump casing
(271),(272), and remove needle bearing (124)
from valve block (312).

-When removing the tilting pin, use care so as

not to score the head of the tilting pin, using a
jig.
-It is hard to separate the tilting pin from the
servo piston in some cases as Loctite is coated
on the mating part between them. Use care so
as not to score the servo piston by applying Removing other parts
undue force.
-Do not draw out needle bearings except when
their service life has ended.
-Do not loosen Q min-plug (533) of valve
block (312). A set flow rate changes.

33-62
 ［33. UPPER SLEWING STRUCTURE］

(3) Installing procedure

1. Precautions to be exercised in installation
Assembly is a reverse order of disassembly, but notice the following.
33
1. Repair scored parts at disassembly. Get replacements ready beforehand.
2. Wash parts sufficiently in cleaning oil and dry them with jet air.
3. Do not forget to coat the sliding areas and bearings with clean hydraulic oil.
4. In principle, replace sealing parts such as O-rings and oil seals.
5. Tighten socket bolts and plugs to specified torques in this manual, using a torque wrench.
6. Do not mix up front pump parts with rear pump parts.

2. Installing swash plate support

Install set spring (256) and lock pin (255) in
pump casing (271). Then align swash plate
support (251) with spigot of pump casing, and
rotate it in clockwise. And fix swash plate
support (251) with lock pin.

-When the servo piston, the tilting pin, the

stopper (L), the stopper (S) and the Q
min-plug have been removed, install them to
the pump casing beforehand..
-When tightening servo piston and tilting pin,
use a jig so as not to damage the head of
the tilting pin and feedback pin.
Coat the screwed part with Loctite #262.

Installing swash plate support (251)

3. Installing swash plate

Install shoe plate (211) on swash plate (212).
Then insert tilting bushing of swash plate into
tilting pin (531), and fix swash plate (212) and
shoe plate (211) to swash plate support (251)
properly.

-Confirm by the fingers of your both hands

that swash plate moves smoothly.
-The shaft be installed easily if grease is
applied to the sliding parts of swash plate and
swash plate support.
-Do not damage the sliding surface of shoe
Installing swash plate (212)
plate.

33-63
［33. UPPER SLEWING STRUCTURE］

4. Installing shaft
Install shaft (111) (113) fitted with bearing (123),
bearing spacer (127) and snap ring (824), to
swash plate support (271) (272).

-Do not knock on the shaft with a hammer or

something.
-Fix the bearing by lightly tapping the outer
race of it by means of a plastic hammer and
set it exactly to the end by using a steel rod
and others.

Installing shaft (111)

5. Installing seal cover

Assemble seal cover (F) (261) to pump casing
(271) and fix it with socket bolts (406).
Tools: Allen wrench: 6 mm
Tightening torque: 12 N-m (8.9 lbf-ft)

-Coat the oil seal in seal cover (F) with a thin

film of grease.
-Handle the oil seal with sufficient care so it is
not scored.

Installing seal cover F (261)

6. Inserting piston cylinder sub

Assemble the piston cylinder sub [cylinder
block (141), piston (151), shoe (152), plate
(153), spherical bushing (156) and cylinder
spring (157)].
Align the spherical bushing with the cylinder
spline and insert them into the pump casing.

Inserting piston cylinder sub

33-64
 ［33. UPPER SLEWING STRUCTURE］

7. Installing valve plate

Install valve plate (313), (314) to valve block
(312) by aligning pin.
33
-Do not mistake the suction and delivery sides
of the valve plate.

Installing valve plates (313), (314)

8. Installing valve block

Install valve block (312) to pump casing (271),
(272) and fasten them together with socket
bolts (401).
Tools: Allen wrench: 14 mm
Tightening torque ; 240 Nom (177 lbfoft)
-Work will be promoted if assembly is started
from the rear pump.
-Exercise care so as not to mistake the
direction of the valve block (312). (Install it so
the regulator comes up as seen from the front Installing valve block (312)
side and the suction flange comes on the right.)
-Insert the 1st gear into the valve block
beforehand and connect it with the spline of the
shaft.

9. Installing gear pump

Install gear pump (04) and fasten them together
socket bolts (435).
Tools: Allen wrench: 6 mm,
Tightening torque; 17 N-m (12.5 lbf-ft)
10. Installing regulator and PTO cover
Pinch feedback pin of tilting pin in feedback
lever of the regulator and PTO cover (326),
install the regulator and fasten socket bolt.
(See Fig."Regulator exploded view"]
Installing regulator and PTO cover
Socket bolt (415): For regulator
Tools: Allen wrench: 6 mm,
Tightening torque; 29 N-m (21 lbf-ft)
Socket bolt (414): PTO Cover (326)
Tools: Allen wrench: 8 mm,
Tightening torque; 57 N-m (42 lbf-ft)

-Do not mistake the front regulator for the rear regulator.
11. Installing drain port plug
The work is complete when drain port VP plugs (468) have been set.
Tools: Allen wrench: 10 mm
Tightening torque; 110 N-m (81 lbf-ft)

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［33. UPPER SLEWING STRUCTURE］

33.2.1.1.3 Maintenance standards

(1) Replacement standards for abrasive parts
Replace or readjust parts that exceed the following standards of wear.
However, always replace such parts that show excessive damage on appearance.

Recommended
Standard
Part name and inspection item value Remedy
dimension
forreplacement
0.032 0.056
Clearance between piston and cylinder bore (D-d) Replace piston or cylinder.
(0.0013 ) (0.0022 )
Gap between piston and caulked part of 0 - 0.1 0.3
(δ ) Replace piston shoe assy.
shoe (0.004 ) (0.012 )
3.9 3.7
Thickness of shoe (t) Replace piston shoe assy.
(0.154 ) (0.146 )
41.1 40.3
Free height of cylinder spring (L) Replace cylinder spring.
(1.618 ) (1.587 )
Combined height of retainer plate and 17.0 15.8 Replace spherical bushing or
(H-h)
spherical bushing (0.669 ) (0.622 ) retainer plate.

(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face)

Valve plate (sliding section) Surface roughness requiring correction 3 - Z

Swash plate (shoe plate face)
Standard surface roughness
Cylinder (sliding section) Less than 0.4Z (lapping)
(correction value)
Roughness of each surface

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 ［33. UPPER SLEWING STRUCTURE］

33.2.1.1.4 Troubleshooting
(1) Locating causes of troubles
The pump is usually fitted with a regulator, auxiliary valves and auxiliary pumps, and this makes fault
33
location extremely difficult. However, faults would be found out easily if the following check items were
attended to.

1. Inspecting the filter and drain oil

Inspect the filter element to check for abnormal contaminations. Some metallic particles will be
deposited on it as the shoe and the cylinder wear off. In case metallic particles are found in
large quantity, the elements may be damaged. In that case check the drain oil in the pump casing
as well.
2. Checking for abnormal vibration and sound
Check that the pump does not vibrate and make an abnormal sound.
Check that the hunting of the regulator and the attached valveAfs relief valve are of regular
frequency. In case vibration and sound are abnormal, the pump may be making a cavitation or
internally broken.
3. When two pumps are used
In case two single pumps or motors are used or when a double pump is used. change pump
pipelines. This will make clear that the pumps are faulty or the circuit after the pumps is faulty.
4. Pressure measurements
If the problem is related to control functions, avoid disassembling the pumps carelessly, but look
for causes by measuring pressures.

(2) Troubleshooting
1. Overloading to engine

Cause Remedy Remarks

1. 1)
Revolution and pressure are Set pressure to specified value.
higher than set values.
2. 2) 2)
Regulator torque is set higher than Readjust regulator. Refer to Regulator Manual.
normal.
3. 3) 3)
PumpAfs internal parts are seized Replace damaged parts. Check filter and drain oil to see if
or broken. abnormal wear particles are present.
4. 4)
Regulator is piped incorrectly. Pipe regulator correctly.

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［33. UPPER SLEWING STRUCTURE］

2. Pump's oil flow rate is extremely low and delivery pressure is not available.

Cause Remedy Remarks

1. 1) 1)
Regulator is out of order Repair regulator. Refer to Regulator Manual.
2. 2) 2)
Pump's internal parts are seized or Replace damaged parts. Check filter and drain oil.
broken.
3. 3) 3)
Attached pump is out of order Replace damaged parts. Remove attached pump and check
shaft joint.
4. 4) 4)
Attached valve is out of order. Replace attached valve. Refer to Manual for Attached Valve.
5. 5)
Regulator is piped incorrectly. Pipe correctly.

3. Abnormal Sound and Vibration

Cause Remedy Remarks

1. 1) 1-1)
Cavitation Prevent cavitation. The boost pressure is low.
Check that hydraulic oil is not 1-2)
clouded. The attached pump is in trouble.
1-3)
The suction pipe is inhaling air.
1-4)
The suction resistance is high.
2. 2)
Caulked part of shoe is broken. Replace piston shoe and shoe
plate.
3. 3)
Cylinder is cracked Replace cylinder.
4. 4)
Pump is installed improperly. Correct installation.
5. 5) 5)
Regulator is hunting. Repair regulator, See Regulator Manual.
6. 6) 6)
Relief valve in attached valve is Repair attached valve. See the Manual for Attadched Valve.
hunting.

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 ［33. UPPER SLEWING STRUCTURE］

33.2.1.2 REGULATOR
33.2.1.2.1 Structural exploded view
33

Structural exploded view of regulator

33-69
［33. UPPER SLEWING STRUCTURE］

33.2.1.2.2 Disassembly and assembly

(1) Tools
The right list shows the tools required for remove and install.

(2) Disassembling procedure

1.
Selecting a place for disassembly.

-Choose a clean place.

-Spread rubber sheet or cloth on work bench to
protect parts from damaging.

2.
Cleaning
Remove dust and rust, etc. on regulator surface
with wash oil.

3.
Remove regulator (See Fig."Regulator exploded
view")
Remove socket bolts (415) and separate the
regulator from the pump body.
Tools: Allen wrench: 6 mm

Take care so as not to lose O-rings and check valve sub (541), (543), and (545).

4.
Remove ROH-plug
Remove ROH-plug (466) for a port of valve
casing (601). And remove ROH-plug (466) for
psv port too.
(In case of KR76-0E13PV)

Removing ROH-plug (466)

33-70
 ［33. UPPER SLEWING STRUCTURE］

5.
Remove valve casing (See Fig."Regulator
exploded view")
33
Remove socket bolts (407) and remove valve
casing (325) with solenoid proportional reducing
valve (079).
Tools: Allen wrench: 5 mm

Removing valve casing (325)

6.
Remove cover (See Fig. "Regulator exploded
view")
Remove socket bolt (402) and cover (656).
Tools: Allen wrench: 5 mm

Removing cover (656)

The cover is assembled with set screw (924) and hex nut (801), but do not loosen them. If they are
loosened, the pressure settings change.

7.
Remove Pi sleeve and pilot piston
(See Fig."Regulator exploded view")
Draw out sleeve (631) and pilot piston (643)
from the regulator body.

Removing Pi sleeve (631) and pilot piston

(643)

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［33. UPPER SLEWING STRUCTURE］

8.
Removing looseness prevention plug (616).
-Removing of looseness prevention plug may
cause damage of plug. (But in this case, there
is no functional problem.)

Removing plug (616)

9.
Remove fulcrum plug and feedback lever
(See Fig."Regulator exploded view")
Remove fulcrum plug (614) and feedback lever
(611).

Removing fulcrum plug and feedback lever

(611)

10.
Drawing out the spool and the sleeve (See
Fig."Regulator exploded view")
Draw out spool (652) and sleeve (651) from the
sleeve hole of the regulator casing.

Removing spool (652) and sleeve (651)

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 ［33. UPPER SLEWING STRUCTURE］

11.
Remove plunger, pilot spring and spring seat
(See Fig."Regulator exploded view")
33
Draw out plunger (627). Then take out pilot
spring (646) and spring (624).

Removing plunger (627), pilot spring (646)

and spring seat (624)

The plunger comes off easily if an M4 bolt is used.

12.
Drawing out the check valve (See Fig."Regulator exploded view")
The disassembly is complete when the check valve [seat (541), ball (545), and stopper (543)] have
been drawn out.

The check valves are placed on two places; the mating surface of the pump casing and on the
matching surface of the valve casing.

Do not lose the parts because they are small.

33-73
［33. UPPER SLEWING STRUCTURE］

(3) Installing procedure :

Assembly is a reverse order of disassembly, but notice the following.

・ Do not fail to correct parts damaged during disassembly and get replacement parts ready
beforehand.
・ Entry of foreign matter causes faulty functions; clean parts thoroughly, dry them with jet air and
work in a clean place.
・ Do not fail to coat the sliding parts with clean hydraulic oil, before proceeding to assembly.
・ In principle, replace seals such as O-rings with new ones.
・ Using torque wrench, the bolts and plugs should be tightened to the specified torques that is
indicated in "Maintenance Standard".

1.
Placing the check valve (See Fig."Regulator exploded view")
Install the check valve to casing (601) [Seat (541), ball (545) and stopper (543)].

Assemble the check valve into the matching surface of the pump casing and the matching surface of
the valve casing.

2.
Fitting the sleeve and the spool (See
Fig."Regulator exploded view")
Place sleeve (651) and spool (652) into the
sleeve hole of casing (601).

Fitting sleeve (651) and spool (652).

-Make sure the spool and the sleeve slide smoothly in the casing without catching.
-Make sure the direction of the spool is correct.

33-74
 ［33. UPPER SLEWING STRUCTURE］

3.
Installing feedback lever (See Fig."Regulator
exploded view")
33
lnsert pin (897) of feedback lever (611) into
the pin hole of the sleeve and fix the
feedback lever with fulcrum plug (614).

Installing feedback lever (611)

Operate the feedback lever and make sure that it does not have much looseness and that it operates
without catching.

4.
Installing plug
Place the prevention plug (616).

Installing plug (616)

5.
Installing spring seat, pilot spring and plunger
(See Fig."Regulator exploded view")
Place spring seat (624), pilot spring (646) and
plunger (627) into the hole in the sleeve.

6.
Installing cover (See Fig."Regulator exploded
view")Attach cover (656) to casing (601) and
fasten them together with socket bolts (402).
Installing spring seat (624),pilot spring (646)
and plunger (627)

The cover is fitted with adjusting screw (924) and hex nut (801).

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［33. UPPER SLEWING STRUCTURE］

7.
Assembling the Pi sleeve and the pilot piston
(See Fig."Regulator exploded view")
Assemble Pi sleeve (631) and pilot piston
(643) into casing (601).

Assembling the sleeve (631) and the pilot

piston (643).

8.
Installing valve casing (See Fig."Regulator
exploded view")
Attach valve casing (325) fitted with solenoid
proportional reducing valve (079) to casing (601)
and fasten them together with socket bolts
(407).

Installing valve casing (325)

9.
Installing ROH-plug
Install ROH-plug (466) to A port of valve casing
(601). And install ROH-plug (466) to Psv port
too.
(In cased KR76-0E13PV)

This completes assembly.

Installing ROH-plug (466)

33-76
 ［33. UPPER SLEWING STRUCTURE］

33.2.2 CONTROL VALVE

33.2.2.1 SECTIONAL VIEW 33
1. Outside view

Section (1/6)

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［33. UPPER SLEWING STRUCTURE］

Section (2/6)

33-78
 ［33. UPPER SLEWING STRUCTURE］

33

Section (3/6)

33-79
［33. UPPER SLEWING STRUCTURE］

Section (4/6)

33-80
 ［33. UPPER SLEWING STRUCTURE］

33

Section (5/6)

33-81
［33. UPPER SLEWING STRUCTURE］

Section (6/6)

33-82
 ［33. UPPER SLEWING STRUCTURE］

Tightening torque Tightening torque

No. Parts Q'ty No. Parts Q'ty
N-m (lbf-ft) N-m (lbf-ft)
101 Casing A 1 309 P1 unload spool 1 33
102 Casing B 1 310 P2 unload spool 1
25~29 (18~21) 153 Plug 1 311 Option spool 1
220~250 (162~184) 154 Plug PF3/4 2 319 Spring 2
110~130 (81~96) 155 Plug PF1/2 4 320 Spring 2
13~17 (9.6~13) 156 Plug PF1/8 1 321 Spring 5
20~24 (15~18) 157 Plug PF1/4 MEC 1 322 Spring 4
34~39 (25~29) 159 Plug PT1/4 1 325 Spring 6
7.8~9.8 (5.8~7.2) 160 Plug PT1/16 MEC 5 326 Spring 1
161 O-ring : 1B G30 13 327 Spring 2
162 O-ring : 1B G25 6 328 Spring 3
163 O-ring : 1B P18 4 329 Spring 1
164 O-ring : 1B P15 4 330 Spring 1
166 O-ring : 1B P10 7 331 Spring seat 24
167 O-ring : 1B P8 1 16~18 (11.8~13.3)
333 Spacer bolt 12
168 O-ring : 1B P11 1 Loctite #262

201 Cover 6 336 Stopper 6

202 Cover 4 337 Stopper 1
203 Cover 1 339 Stopper 5
204 Sub cover 1 511 Poppet 11
205 Cover 7 512 Poppet 2
206 Cover 1 514 Poppet 2
207 Back pressure check valve cover 1 515 Poppet 1
9.8~14 (7.2~10.3) 211 Lock valve selector sub 2 517 Poppet 1
212 Plate 1 518 Poppet 1
213 Plate 1 521 Spring 11
261 O-ring 12 522 Spring 2
264 O-ring : 1B G35 8 524 Spring 3
266 O-ring : 1B P7 4 527 Spring 1
267 O-ring : 1B 32 2 528 Spring 1
25~34 (18~25) 273 Socket bolt 40 130~150 (96~111) 551 Plug 12
98~120 (72~89) 274 Socket bolt 4 130~150 (96~111) 556 Plug 5
98~120 (72~89) 275 Socket bolt 4 561 O-ring : 1B P20 17
9.8~14 (7.2~10.3) 278 Socket bolt 5 567 O-ring : 1B P24 2
301 Boom spool assy 1 69~78 (51~58) 601 Main relief valve 1
302 Arm 1 spool 1 69~78 (51~58) 602 Port relief valve 5
303 Swing spool 1 69~78 (51~58) 604 Relief valve plug assy 2
304 Bucket spool 1 98~120 (72~89) 605 Bypass cut valve 2
305 Boom conflux spool 1 69~78 (51~58) 606 Port relief valve 1
306 Travel spool 2 140~180 (103~133) 973 Socket bolt 9
307 Travel straight spool 1 977 Name plate 1
308 Arm 2 spool assy 1 978 Rivet 2

33-83
［33. UPPER SLEWING STRUCTURE］

33.2.2.2 PREPARATION FOR DISASSEMBLY

(1) General precautions
1. As all the hydraulic components are precisely machined, it is essential to carry out disassembly
and reassembly in an especially clean location.
2. When handling the control valve, take special care to prevent the entry of foreign matter, such as
dust or sand.
3. Cap each port of the control valve before removing the valve from the machine. Before
disassembly, confirm that each cap is in place and then clean the exterior of the assembly.
Use a workbench. Lay a clean sheet of paper or rubber mat over the workbench.
4. When carrying or moving the control valve, hold the body, and never put pressure on a lever, an
exposed spool, or the end cover. Handle the valve with care.
5. Tests(for relief characteristics, leaks, overload valve setting, flow resistance, etc.) that are desired
after disassembly and reassembly require hydraulic testing apparatus.
For this reason, do not disassemble hydraulic units that you are capable of disassembling but
cannot test or adjust.
Prepare beforehand washing fluid, hydraulic oil, grease, etc. .

(2) Tools
Prepare the following tools before disassembling the control valve.

No. Tools Q'TY Remarks

a Vise 1
b Box end wrench 1 of each size 19mm, 24mm, 27mm, 32mm
c Allen wrench 1 of each size 5mm, 6mm, 10mm, 12mm, 14mm, 22mm
d Spanner 1 32 mm
e Loctite #262 1
f Spatula 1
g Pincers 1
h Adjustable wrench 1

33.2.2.3 DISASSEMBLY
The figures in parentheses after part names in
this manual represent those item numbers in
the structural sectional drawing under
Fig."Section(1/6)"to Fig."Section(6/6)"
(1)
Place the control valve on a work bench so
as to locate back pressure check valve upwards.

Preparation for disassembly

Disassemble the valve in a clean place, and be careful not to damage flange surfaces or plate
mounting surfaces.

33-84
 ［33. UPPER SLEWING STRUCTURE］

33.2.2.3.1 Disassembling P1 unload spool

(1)
Loosen the socket bolts (273) and remove the
33
spring cover (202) and the O-ring (261) for P1
unload spool.

Removing spring cover (202) for P1 unload

spring cover

(2)
Draw out, from casing B (102), as a assy of
P1 unload spool (309), spring seat (331),
springs (325), (328), stopper (336) and bolt
(333).

Drawing out P1 unload spool assy (309)

When drawing out the spool assy, use care so as not to score casing B (102).

(3)
Fix the P1 unload spool assy with vise via a
protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring seat
(331), springs (325), (328) and stopper (336)
from P1 unload spool (309).

Disassembling P1 unload spool assy (309)

33-85
［33. UPPER SLEWING STRUCTURE］

33.2.2.3.2 Disassembling the travel spool (left travel and right travel)
(1)
Loosen the socket bolts (273) and remove the
spring cover (201) and the O-ring (261) for
travel.

Removing spring cover (201)

(2)
Draw out the assy of travel spool (306), spring
seat (331), springs (325), (327), stopper (339)
and bolt (333) from casing A (101) or casing B
(102).

Drawing out travel spool (306) assy

When drawing out the spool assy, take care so as not to score the casing A (101) or the casing B
(102).

(3)
Fix the travel spool assy with vise via a protective plate (aluminum plate, etc.). Remove bolt (333)
and separate spring seat (331), springs (325), (327) and stopper (339) from travel spool (306).

Removing right travel spring cover (201) Disassembling travel spool (306) assy

33-86
 ［33. UPPER SLEWING STRUCTURE］

33.2.2.3.3 Disassembling the boom conflux spool

(1)
Loosen socket bolts (273) and remove spring
33
cover (202) for boom conflux and O-ring (261).

(2)
Draw out the assy of boom conflux spool (305),
spring seat (331), springs (321), (322), stopper
(339) and bolt (333) from casing A (101).

Removing spring cover (202)

When drawing out the spool assy, use care so as not to score casing A (101).

(3)
Fix the boom conflux spool with vise via a
protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring seat
(331), springs (321), (322) and stopper (339)
from boom conflux spool (305).

Drawing out boom conflux spool (305) assy

33.2.2.3.4 Disassembling the boom spool

(1)
Loosen socket bolts (273) and remove spring
cover (203) for boom spool and O-ring (261),
(266).

(2)
Draw out the assy of boom spool (301), spring
seat (331), springs (319), (320), stopper (339)
and bolt (333) from casing B (102).

Removing spring cover (203)

When drawing out the spool assy, take care so as not to score casing B (102).

33-87
［33. UPPER SLEWING STRUCTURE］

(3)
Fix the boom spool assy with vise via a
protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring seat
(331), springs (319), (320) and stopper (336)
from boom spool (301). Do not disassemble
boom spool (301) further unless there is special
reason.

Drawing out boom spool (301) assy

33.2.2.3.5 Disassembling the swing spool

(1)
Loosen the socket bolts (273) and remove the
spring cover sub (204) and the O-ring (261),
(266) for swing. Do not disassemble spring
cover sub (204) further unless there is special
reason.

(2)
Draw out the assy of swing spool (303), spring
seat (331), springs (321), (322), stopper (336)
and bolt (333) from casing A (101).
Removing spring cover sub (204)

When drawing out the spool assy, use care so as not to score casing A (101).

(3)
Fix the swing spool assy with vise via a
protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring seat
(331), springs (321), (322) and stopper (336)
from swing spool (303).

Drawing out swing spool (303) assy

33-88
 ［33. UPPER SLEWING STRUCTURE］

33.2.2.3.6 Disassembling bucket spool

(1)
Loosen socket bolts (273) and remove bucket
33
spring cover (201) and O-ring (261).

Removing spring cover (201)

(2)
Draw out the assy of bucket spool (304), spring
seat (331), springs (319), (320), stopper (339)
and bolt (333) from casing B (102).

Drawing out bucket spool (304) assy

When drawing out the spool assy, use care so as not to score casing B (102).

(3)
Fix the bucket spool assy with vise via a protective plate (aluminum plate, etc.) and remove bolt (333).
Then separate spring seat (331), springs (319), (320) and stopper (339) from bucket spool (304).

33-89
［33. UPPER SLEWING STRUCTURE］

33.2.2.3.7 Disassembling arm 1 spool

(1)
Loosen socket bolts (273), and remove spring
cover (201) and O-ring (261) of arm 1 spool.

(2)
Draw out the assembly which is consist of arm
1 spool (302), spring seat (331), spring (321,
322), stopper (336) and bolt (333) from casing
A (101).

Removing arm 1 spring cover (201)

When drawing out the spool assy, use care so as not to score casing A (101).

(3)
Fix the arm 1 spool assy with vise via a
protective plate (aluminum plate etc.) and
remove bolt (333). Then remove spring seat
(331), spring (321, 322) and stopper (336)
from arm 1 spool (302).

Disassembling arm 1 spool (302) assy

33.2.2.3.8 Disassembling arm 2 spool

(1)
Loosen socket bolts (273), and remove spring
cover (201) and O-ring (261) of arm 2 spool.

(2)
Draw out the assembly which is consist of arm
2 spool (308), spring seat (331), spring (325,
326), stopper (339) and bolt (333) from casing
B (102).

Removing arm 2 spring cover (201)

When drawing out the spool assy, use care so as not to score casing B (102).

33-90
 ［33. UPPER SLEWING STRUCTURE］

(3)
Fix the arm 2 spool assy with vise via a
protective plate (aluminum plate etc.) and
33
remove bolt (333). Then remove spring seat
(331), spring (325, 326) and stopper (339)
from arm 2 spool (308). Do not disassemble
arm 2 spool (308) further unless there is
special reason.

Disassembling arm 2 spool (308) assy

33.2.2.3.9 Disassembling option spool

(1)
Loosen socket bolts (273), and remove spring
cover (201) and O-ring (261) of option spool.

(2)
Draw out the assembly which is consist of
option spool (311), spring seat (331), spring
(329, 330), stopper (337) and bolt (333) from
casing A (101).

Removing option spring cover (201)

When drawing out the spool assy, use care so as not to score casing A (101).

(3)
Fix the option spool assy with vise via a
protective plate (aluminum plate etc.) and
remove bolt (333). Then remove spring seat
(331), spring (329, 330) and stopper (337)
from option spool (311).

Drawing out option spool assy (311)

33-91
［33. UPPER SLEWING STRUCTURE］

33.2.2.3.10 Disassembling travel straight spool

(1)
Loosen the socket bolts (273) and remove the
spring cover (202) and the O-ring (261) for
travel straight.

(2)
Draw out the assy of travel straight spool (307),
spring seat (331), springs (325), (328), stopper
(336) and bolt (333) from casing B (102).

Drawing out travel straight spool (307) assy

When drawing out the spool assy, take care so as not to score the casing B (102).

(3)
Fix the travel straight spool assy with vise via a protective plate (aluminum plate, etc.). Remove bolt
(333) and separate spring seat (331), springs (325, 328) and stopper (336) from travel straight spool
(307).

33.2.2.3.11 Disassembling P2 unload spool

(1)
Loosen socket bolts (273), and remove spring
cover (202) of P2 unload spool and O-ring
(261).

(2)
Draw out the assembly which is consist of P2
unload spool (310), spring seat (331), spring
(325, 328), stopper (336) and bolt (333) from
casing A (101).

Removing P2 unload spring cover (202)

When drawing out the spool assy, use care so as not to score casing A (101).

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 ［33. UPPER SLEWING STRUCTURE］

(3)
Fix the P2 unload spool assy with vise via a
protective plate (aluminum plate etc.) and
33
remove bolt (333). Then remove spring seat
(331), spring (325, 326) and stopper (336)
from P2 unload spool (310).

Drawing out P2 unload spool assy (310)

33.2.2.3.12 Removing spool covers

(1)
Travel, boom, bucket, arm 1, arm 2 and option
Loosen socket bolts (273) and remove spool
cover (205) and O-ring (264).

(2)
Swing
Loosen socket bolts (273) and remove spool
cover (206) and O-ring (264), (266). Do not
disassemble spool cover (206) further unless
there is special reason.
Removing spool cover (205),(206)

33-93
［33. UPPER SLEWING STRUCTURE］

33.2.2.3.13 Removing relief valve and plug assy for relief valve hole
(1)
Remove the main relief valve (601) and
overload relief valve (602), (606) and relief
hole plug (604) from the casing.

Removing main relief valve (601)

-Distinguish overload relief valve between (602) and (606) with a tag to prevent them from being
confused during reassembly, as they are the same in appearance and shape but differ in pressure
setting.
-Regarding the disassembly of the relief valves themselves, do not disassemble it.

Removing overload relief valve (602) and (606) Removing plug assy (604) for relief valve hole

33-94
 ［33. UPPER SLEWING STRUCTURE］

33.2.2.3.14 Removing by-pass cut valve

(1)
Remove by-pass cut valve (605) from the
33
casing.

Removing by-pass cut valve (605)

Remove the by-pass cut valve, giving particular attention to the poppet (605-201) and spring (605-202)
which may be remained on the inside of casing.

33.2.2.3.15 Removing lock valve selector valve sub

(1)
Loosen socket bolt (211-171) and remove lock
valve selector valve sub (211) from the casing.
Further disassembly of the lock valve selector
sub is not allowed.

Removing lock valve selector sub (211)

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［33. UPPER SLEWING STRUCTURE］

33.2.2.3.16 Removing back pressure check valve

(1)
Loosen socket bolt (278) and remove back
pressure check valve (207) from the casing.

Removing back pressure check valve cover

(207)

(2)
Remove springs (527), (528), boost check
valve poppet sub (517) and by-pass check
valve poppet (518) from the casing. The
further disassembly of boost check valve poppet
sub (517) is not allowed.

Replace control valve so that the spool cover

face directs downward.

Removing boost check valve sub (517) and

by-pass check valve poppet (518)

When replacing, take care so as not to score the spool cover.

33.2.2.3.17 Removing plate

(1)
Loosen socket bolts (274), (275) and remove
plates (212), (213).
(2)
After removing plates, remove all O-rings
(161), (164) remained on the casing side.

Removing plate (212),(213)

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33.2.2.3.18 Removing check valve

(1)
Remove plugs of load check valve, conflux
33
check valve, etc. and then remove poppet (511)
and spring (521).
(2)
Load check valve on the swing section
Remove plug (556) and then remove poppet
(511) and spring (524).
(3)
Load check valve on arm 2 section
Remove plug (551) and then remove poppet
Removing plug (551),(556)
(515) and spring (521).

-The plug and spring in use differ from the above (1). Do not mix the parts when assembling parts
again.
-The poppet in use differs from the above (1). Do not mix the parts when assembling parts again.

(4)
Lock valve
Remove plug (556) and then remove poppet
(514) and spring (524).
(5)
Main relief valve
Remove plug (556) and then remove poppet
(512) and spring (522).

Removing poppet (511),(512),(514),(515)

-The plug, poppet and spring in use differ from the above (4). Do not mix the parts when assembling
parts again.
-The plug, poppet and spring in use differ from the above (5). Do not mix the parts when assembling
parts again.

The plugs in which the procedure for disassembly is not included in the above procedure are usually
used to block auxiliary holes and holes caused by casting. Do not disassemble further if unnecessary.

33.2.2.3.19 Disassembling casing

Further disassembly of the casing is not allowed.

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33.2.2.3.20 Inspection after disassembly

Thoroughly clean all disassembled parts with wash oil, and dry them with jet air. Place each part on a
clean sheet of paper or cloth for inspection.

(1) Control valve

1. Inspect the entire surface of each part for burrs, scratches, cuts, and other defects.
2. Confirm that the O-ring groove surface of the casing or the block is free from foreign matter, dents
or rust.
3. If the check valve seat of the casing or the block has dents or damage on its surface, smooth it
by lapping.
4. Confirm that O-ring or the outer circumference of the sliding part of a manual spool is free from
scratches, dents, and the like. Remove any small defects with an oil stone or lapping compound.
5. Manually confirm that all sliding and fitted parts move smoothly. Confirm that all grooves and
passages are free from foreign matter.
6. Replace any broken or deformed spring with new one.
7. Of a relief valve malfunctions, repair it by following the relief valve disassembly and reassembly
procedures.
8. Replace all O-ring with new ones.

Take care not leave lapping compound behind in the casing or block.

(2) Relief valve

1. Make sure that the poppet and the seat surface at the tip of the seat are without fault and that
the contact surface is even all over.
2. Manually confirm that the main poppet slides smoothly onto and off the seat.
3. Confirm that the outer circumference of the main poppet and the inner circumference of its seat
are free from defects such as scratches.
4. Confirm that each spring is free from breakage, deformation, and excessive wear.
5. Confirm that the orifices of the main poppet and its seat are not clogged.
6. Replace all O-rings with new ones. (Between casing and seal)

33.2.2.4 REASSEMBLY
(1) Here, only the reassembly procedures are described. Regarding drawings, refer to the disassembly
procedures.
(2) Figures in parentheses after part names in this instruction represent those item numbers in the
structural sectional drawing. (Fig."Section(1/6)" to Fig."Section(6/6)")
(3) Precautions on reassembling O-ring

1. Confirm that O-rings are free from defects caused by poor handling.
2. Apply thin coat of grease or hydraulic oil to O-rings and their mating parts.
3. Do not stretch O-rings to the extent that they become permanently set.
4. When installing O-rings, do not roll them into place. Twisted O-rings do not easily untwist by
themselves after installation, and can cause oil leaks.
5. Use a torque wrench to tighten each attaching bolt. Tighten to the specified torque in
"Maintenance Standards."

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 ［33. UPPER SLEWING STRUCTURE］

33.2.2.4.1 Installing check valve

(1) Load check valve, conflux check valve, and so on
Attach poppet (511) and spring (521) in place, place O-ring (561) in plug (551) and tighten them
33
to the specified torque. (8 places)
(2) Load check valve of swing section
Attach poppet (511) and spring (524) in place, place O-ring (561) in plug (556) and tighten them
to the specified torque. (1 place)
(3) Load check valve of arm 2 section
Attach poppet (515) and spring (521) in place, place O-ring (561) in plug (551) and tighten them
to the specified torque. (1 place)
(4) Lock valve section
Attach poppet (514) and spring (524) in place, place O-ring (561) in plug (556) and tighten them
to the specified torque. (2 places)
(5) Main relief valve section
Attach poppet (512) and spring (522) in place, place O-ring (561) in plug (556) and tighten them
to the specified torque. (2 places)

Take care to prevent misassembling of parts and assembling position error because the parts in (1)
to (5) are similar in shape.

33.2.2.4.2 Assembling plate

(1) Place O-rings (162), (164) in casing.
(2) Attach plates (212), (213) and tighten socket bolts (274), (275) to the specified torque.

Replace control valve so that this plate face directs downward.

33.2.2.4.3 Assembling back pressure check valve

(1) Attach boost check valve poppet sub (517), by-pass check valve poppet (518) and springs (527),
(528).
(2) Attach O-rings (267) in back pressure check valve cover, attach it to casing A (101) and tighten
socket bolt (278) to the specified torque.

33.2.2.4.4 Assembling lock valve selector sub

(1) Attach lock valve selector sub (211) to the casing and tighten socket bolt (211-171) to the
specified torque.

33.2.2.4.5 Assembling by-pass cut valve

(1) Attach by-pass cut valve (605) to casing and tighten it to the specified torque.

Take care to prevent drop of poppet (605-201) and spring (605-202) when attaching by-pass cut valve.

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33.2.2.4.6 Assembling relief valve and relief valve hole plug assembly
(1) Tighten main relief valve (601), port relief valves (602), (606) and relief valve hole plug assembly
(604) in respective place to the specified torque.

Assemble it giving attention to the label attached when disassembling to prevent mistake because the
port relief valves (602), (606) are similar in shape.

33.2.2.4.7 Assembling p2 unload spool

(1) Hold the mid section of P2 unload spool (310) with vise provided with protection plate (aluminum
plate, etc.), fit spring seat (331), springs (325), (328) and stopper (336) and tighten bolt (333) to
the specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform P2 unload spool (310) because of careless over clamping.

(2) Place P2 unload spool assembly in item (1) in casing A (101).

Place P2 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover (202) with O-ring (261) attached to the spring side of P2 unload spool
assembly and tighten socket bolt (273) to the specified torque.

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33.2.2.4.8 Assembling travel straight spool

(1) Hold the mid section of travel straight spool (307) with vise provided with protection plate
(aluminum plate, etc.), fit spring seat (331), springs (325), (328) and stopper (336) and tighten
33
bolt (333) to the specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform travel straight spool (307) because of careless over clamping.

(2) Place travel straight spool assembly in item (1) in casing B (102).

Place travel straight spool assembly in casing B (102) carefully. Do not squeeze it into place.

(3) Attach spring cover (202) with O-ring (261) attached to the spring side of travel straight spool
assembly, and tighten socket bolt (273) to the specified torque.

33.2.2.4.9 Assembling spool in option

(1) Hold the mid section of spool in option (311) with vise provided with protection plate (aluminum
plate, etc.), fit spring seat (331), springs (329), (330) and stopper (337) and tighten bolt (333) to
the specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform option spool (311) because of careless over clamping.

(2) Place spool assembly in option in item (1) in casing A (101).

Place option spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover (201) with O-ring (261) attached to the spring side of spool assembly in option
and tighten socket bolt (273) to the specified torque.

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33.2.2.4.10 Assembling arm 2 spool

(1) Hold the mid section of arm 2 spool (308) with vise provided with protection plate (aluminum plate,
etc.), fit spring seat (331), springs (325), (326) and stopper (339) and tighten bolt (333) to the
specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform arm 2 spool (308) because of careless over clamping.

(2) Place arm 2 spool assembly in option in item (1) in casing B (102).

Place arm 2 spool assembly in casing B (102) carefully. Do not squeeze it into place.

(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 2 spool assembly
and tighten socket bolt (273) to the specified torque.

33.2.2.4.11 Assembling arm 1 spool

(1) Hold the mid section of arm 1 spool (302) with vise provided with protection plate (aluminum plate,
etc.) and fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the
specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform arm 1 spool (302) because of careless over clamping.

(2) Place arm 1 spool assembly in item (1) in casing A (101).

Place arm 1 spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 1 spool assembly,
and tighten socket bolt (273) to the specified torque.

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33.2.2.4.12 Assembling bucket spool

(1) Hold the mid section of bucket spool (304) with vise provided with protection plate (aluminum
plate, etc.), fit spring seat (331), springs (319), (320) and stopper (339) and tighten bolt (333) to
33
the specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform bucket spool (304) because of careless over clamping.

(2) Place bucket spool assembly in item (1) in casing B (102).

Place bucket spool assembly in casing B (102) carefully. Do not squeeze it into place.

(3) Attach spring cover (201) with O-ring (261) attached to the spring side of bucket spool assembly
and tighten socket bolt (273) to the specified torque.

33.2.2.4.13 Assembling swing spool

(1) Hold the mid section of swing spool (303) with vise provided with protection plate (aluminum
plate, etc.), fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to
the specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform swing spool (303) because of careless over clamping.

(2) Place swing spool assembly in item (1) in casing A (101).

Place swing spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover sub (204) with O-rings (261), (266) attached to the spring side of swing spool
assembly and tighten socket bolt (273) to the specified torque.

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33.2.2.4.14 Assembling boom spool

(1) Hold the mid section of boom spool (301) with vise provided with protection plate (aluminum
plate, etc.), fit spring seat (331), springs (319), (320) and stopper (339) and tighten bolt (333) to
the specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform boom spool (301) because of careless over clamping.

(2) Place boom spool assembly in item (1) in casing B (102).

Place boom spool assembly in casing B (102) carefully. Do not squeeze it into place.

(3) Attach spring cover (203) with O-rings (261), (266) attached to the spring side of boom spool
assembly and tighten socket bolt (273) to the specified torque.

33.2.2.4.15 Assembling boom conflux spool

(1) Hold the mid section of boom conflux spool (305) with vise provided with protection plate
(aluminum plate, etc.), fit spring seat (331), springs (321)(322) and stopper (336) and tighten bolt
(333) to the specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform boom conflux spool (305) because of careless over clamping.

(2) Place boom conflux spool assembly in item (1) in casing A (101).

Place boom conflux spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover (202) with O-ring (261) attached to the spring side of boom conflux spool
assembly and tighten socket bolt (273) to the specified torque.

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33.2.2.4.16 Assembling travel spool (travel right and left)

(1) Hold the mid section of travel spool (306) with vise provided with protection plate (aluminum
plate, etc.), fit spring seat (331), springs (325), (327) and stopper (339) and tighten bolt (333) to
33
the specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform travel spool (306) because of careless over clamping.

(2) Place travel spool assembly in item (1) in casing A (101) or casing B (102).

Place travel spool assembly in casing A (101) or casing B (102) carefully. Do not squeeze it into
place.

(3) Attach spring cover (201) with O-ring (261) attached to the spring side of travel spool assembly
and tighten socket bolt (273) to the specified torque.

33.2.2.4.17 Assembling P1 unload spool

(1) Hold the mid section of P1 unload spool (309) with vise provided with protection plate (aluminum
plate, etc.), fit spring seat (331), springs (325), (328) and stopper (336) and tighten bolt (333) to
the specified torque.

-Apply Loctite #262 when tightening bolt (333).

-Take care not to deform P1 unload spool (309) because of careless over clamping.

(2) Place P1 unload spool assembly in item (1) in casing A (101).

Place P1 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover (202) with O-ring (261) attached to the spring side of P1 unload spool
assembly and tighten socket bolt (273) to the specified torque.

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33.2.2.4.18 Assembling spool cover, and so on

(1) Travel, boom, bucket, arm 1, arm 2, option
Place O-ring (264) in spool cover (205) and tighten socket bolt (273) to the specified torque.
(2) Swing
Place O-rings (264), (266) in spool cover (206) and tighten socket bolt (273) to the specified
torque.

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33.2.2.5 MAINTENANCE STANDARDS

33.2.2.5.1 Inspection of components
Parts name Inspection item Criterion and remedy 33
Casing 1. 1.
Look for scratches, rusting and corrosion. If any of the following parts are damaged,
replace the casing.
-Sliding part of casing hole and spool,
particularly the land, to which holding
pressure is applied.
-Area of sealing part that is in contact with
O-ring.
-Sealing and seating part of main or
overload relief valve.
-Area of seating part or sliding part of
poppet.
-Sealing part of plug.
-Defects of other parts that seem to
prevent normal function.
Spool 1. 1.
Look for scratches, galling, rusting and If a detectable defect with your fingernail is
corrosion. found on the sliding part of the outer
circumference, replace the spool.
2. 2.
Insert the spool in the casing bore, and If the spool damages the O-ring or does
move it while turning it. not move smoothly, repair or replace the
spool.
Poppet If spring is damaged, replace it.
1. 1.
Look for damage on the poppet and the If the seat of poppet or spring are
spring. damaged, correct or replace it.
2. 2.
Insert the poppet in the casing, and move If the poppet moves lightly without catching,
it. it is normal.
Spring and related 1. 1.
parts Look for rust, corrosion, deformation, and If damaged heavily, replace.
breakage of the spring, spring seat,
stopper, spacer bolt and cover.
Main relief valve 1. 1.
Port relief valve Look for rust and damage on outer surface. Replace.
By-pass cut valve 2. 2.
Inspect the contact face of the valve seat. If damaged, replace.
3. 3.
Inspect the O-ring, backup ring, and seal. As a general rule, replace all parts with
new ones. (Between casing and seal)

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33.2.2.6 TROUBLESHOOTING
(1) If an abnormal condition is noticed, check to see if the problem is with the control valve itself, one
of the main pumps, the gear pump, or a circuit. To this end, you will need to measure pilot
pressure, pump delivery pressure, load pressure, etc. If any part of the system is to be
disassembled for inspection, follow the disassembly and reassembly procedures in this manual.
(2) Dust is the enemy of hydraulic components. Pay strict attention to protection from dust. If any
part of the system is to be disassembled, take dust protection measures beforehand.
(3) Moving parts must be handled with care. If they are damaged, smooth the damage using an oil
stone or the like.
(4) Take care not to damage the contact face of O-rings. A damaged contact face will certainly
cause oil leaks.

33.2.2.6.1 Control valve

Trouble Cause Remedy
1. 1) 1)
Travel does not Malfunctioning main relief valve. Check travel relief valve pressure
occur. -Foreign matter between main poppet and -Disassemble and clean. If damaged
Slow to start up seat. heavily, replace the assy as a unit.
(or poor power). -Foreign matter between poppet and seat. -Same as above.
Slow response. -Sticking main poppet. -Correct sticking part with oil stone.
-Broken or deformed spring. -Replace spring.
-Clogged main poppet throttle. -Remove foreign matter.
-Loosened adjusting screw -Readjust, and tighten lock nut to specified
torque.
2. 1) 1)
Machine does not Malfunctioning travel straight valve. Check pilot pressure.
move straight -Sticking spool. -Correct sticking part with oil stone.
during simultaneous -Broken or deformed spring. -Replace spring.
operation of travel -Clogged small hole in spool. -Remove foreign matter.
and attachment. 2) 2)
Malfunctioning main relief valve. Remove main relief valve.
3. 1) 1)
Excessive natural Excessive clearance between casing and Replace spool.
falls of attachment spool.
under its own 2) 2)
weight when spool Spool is not completely in neutral position. Check secondary pilot pressure.
is in neutral. -Foreign matter between casing and spool, -Disassemble, clean and smooth sticking
or sticking spool. part with oil stone.
-Broken or deformed spring. -Replace spring.
-Clogged pilot circuit. -Remove foreign matter.
3) 3)
Malfunctioning overload relief valve. Refer Check overload relief valve pressure.
to item 1. 1) above. (See 33.2.2.3.20 (2)) (See 33.2.2.3.20 (2))
-Foreign matter between valve seat and -Clean and check damage on seat surface.
casing.
4) 4)
Lock valve function is faulty. (Arm, boom) Replace
-Foreign matter between poppet seat and -Disassemble, clean.
casing. -Correct stuck part with oil stone or replace.
-Poppet is stuck. -Replace spring.
-Broken or deformed spring. -Replace lock valve selector assy.
-Selector spool is stuck.

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Trouble Cause Remedy

4. 1) 1)
When raising Malfunctioning load check valve. 33
attachment, at first it -Foreign matter between poppet and casing. -Disassemble and clean. If heavily
drops. -Sticking poppet. damaged, replace control valve.
-Broken or deformed spring. -Correct sticking part with oil stone.
-Replace spring.
5. 1) 1)
Bucket, boom, arm Malfunctioning main spool. Check secondary pilot pressure.
or swing does not -Excessive clearance between casing and -Replace spool.
operate. spool. -Disassemble and clean.
Slow to start up -Foreign matter between casing and spool. -Correct stuck part with oil stone.
(or poor power).Slow -Sticking spool. -Replace spring.
response. -Broken or deformed return spring. -Remove foreign matter.
-Clogged pilot circuit.
2) 2)
Malfunctioning main relief valve. Refer to Check main relief valve pressure. Refer to
item 1. 1) above. item 1. 1) above.
(See 33.2.2.3.20 (2)) (See 33.2.2.3.20 (2))
3) 3)
Malfunctioning overload relief valve. Refer Check overload relief valve pressure.
to item 1. 1) above. (See 33.2.2.3.20 (2))
(See 33.2.2.3.20 (2))
6. 1) 1)
Boom conflux does Malfunctioning conflux valve. Measure pilot pressure.
not operate. -Excessive clearance between casing and -Replace spool.
spool. -Disassemble and clean.
-Foreign matter between casing and spool. -Correct stuck part with oil stone.
-Sticking spool. -Replace spring.
-Broken or deformed return spring. -Remove foreign matter.
-Clogged pilot circuit.

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33.2.2.6.2 Relief valve

Trouble Cause Remedy
1. Main or pilot poppet of relief valve is Check for foreign matter on each poppet.
No pressure rise. sticking and valve is open, or there is Confirm that each component slides
foreign matter on valve seat. smoothly.
If failure is found, replace it in an
assembly.
2. Main or pilot poppet of relief valve seat is If failure is found, replace it an assembly.
Unstable relief damaged.
pressure.
3. 1) 1)
Incorrect relief Wear due to foreign matter. Replace damaged assembly
pressure setting. 2) 2)
Loosened locknut or adjusting screw. Adjust pressure.
4. Confirm that each component operates
Oil leak. smoothly. Replace damaged or worn
1) component.
Damaged seat. 1)
Damaged O-ring. If failure is found, replace it an assembly.
2) 2)
Sticking component due to foreign matter. Confirm that there are no scratches,
scores, or foreign matter present before
reassembling.
If failure is found, replace it an assembly.

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33.2.3 PILOT VALVE (ATT)

33.2.3.1 CROSS-SECTIONAL VIEW 33

Pilot valve (For ATT)

Apply loctite #277 to areas marked ☆

Tightening torque Tightening torque
No. Parts Q'ty No. Parts Q'ty
N-m (lbf-ft) N-m (lbf-ft)
101 Casing 1 *218-1 Seat 2
151 Plate 1 *218-2 Seat 2
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
212 Push rod 4 *246 Spring 4
213 Seal 4 47.1 (35) 301 Joint: M14 1
214 O-ring; 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (51)☆ 312 Adjust nut: M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4

Note) The parts marked * might not be equipped depending on valve type.

33-111
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33.2.3.2 DISASSEMBLY
(1) Plug each port of pilot valve, and clean it
with kerosine.
P port: PF1/4
1 to 4 and T port: PF3/8
(2) Fix pilot valve with vise via a protective
plate (Alminum plate etc.), and remove
boots (501).

Removing boot (501)

(3) Remove adjusting nut (312) applying

spanners to adjusting nut (312) and
circular plate (302).
Tools: Spanner: 22 mm, 32 mm

Removing adjusting nut (312)

33-112
 ［33. UPPER SLEWING STRUCTURE］

(4) Remove circular plate (302)

Tools: Spanner: 32 mm

33

Removing circular plate (302)

Circular plate is removed

Installing Jig A

(5) Turn joint (301) in counterclockwise with Jig

A to remove.
Jig A: See page 33.2.3.7(1).
Tools: Spanner: 24 mm

Removing joint (301)

When the force of return springs (221) is strong, never loosen joint (301). If loosened, it might result in
jumping out of plate (151), plug (211) and push rod (212).
Remove joint (301) pressing plate (151) downward with two fingers.

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(6) Remove plate (151)

-When the force of return springs (221)
are strong, press plate to let it come up
slowly.

Removing plate (151)

-When the force of return springs (221) are

weak, plug is left in casing (101) due to
sliding resistance of O-ring (214).
Tools: Pull plug (211) out with a driver.

Removing plug (211)

To prevent personal injury, plug (211) must be removed slowly and evenly until the return spring
(221) force is completely released.

(7) Remove push rod (212), plug (211),

pressure reducing valve assy (spool),
return springs (221) from casing (101).

Removing push rod, plug, pressure reducing

valve and spring

Record combination of port holes on casing and the pulled out parts. The stroke differs according to
direction.

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(8) Push springs (241-1), (241-2) in the range

of 7 mm (0.276 in) that the movement of
spring seats (216-1), (216-2) and shift the
33
seats (216) in a side direction, and
remove spools (201-1), (201-2) through the
larger hole of seat.

Removing spool (201)

Never push down spring seat (216-1) in 7 mm (0.276 in) or more. (For port 1,3)
Never push down spring seat (216-2) in 9.4 mm (0.370 in) or more. (For port 2,4)

(9) Remove spool (201-1), (201-2), spring seats

(216-1), (216-2), spring (241-1), (241-2)
and washer (217).

Disassembling pressure reducing valve

(10) Remove spring (*246), spring seat

(*218-1), (*218-2) from push rod (212).

Disassembling push rod

The parts marked * might not be equipped depending on valve type.

33-115
［33. UPPER SLEWING STRUCTURE］

(11) Pull out push rod (212) from plug (211).

(12) Remove O-ring (214) from plug (211).

Removing push rod (212)

(13) Remove inside seal (213) from plug (211)

with small driver.

Removing seal (213)

33.2.3.3 CLEANING PARTS

(1) Clean parts with wash oil roughly.
(2) Clean parts with wash oil completely.
(3) Dry parts by swabbing clean rag.
(4) Apply rust preventives on parts.

33.2.3.4 ASSEMBLING
(1) Fit washer 2 (217), springs (241-1), (241-2),
spring seats (216-1), (216-2) to spool
(201-1), (201-2).

Assembling pressure reducing valve

33-116
 ［33. UPPER SLEWING STRUCTURE］

(2) Push spring (241-1), (241-2) in the range of

that the movement of spring seats (216-1),
(216-2) in a side direction, and install
33
spools (201-1) through the larger hole of
spring seat. (See Fig."Removing spool(201)")

Installing spools (201-1), (201-2)

Never push down spring seat (216-1) in 7 mm (0.276 in) or more. (For port 1,3)
Never push down spring seat (216-2) in 9.4 mm (0.370 in) or more. (For port 2,4)

(3) Place spring (221) into ports 1,3 of casing

(101), and then install pressure reducing
valve assy in it.
Place springs (221) into ports 2,4 and
install it.

Installing pressure reducing valve assy

Install the removed respective assy into respective holes.

33-117
［33. UPPER SLEWING STRUCTURE］

(4) Fit O-ring (214) and seal (213) into plug (211).
-Apply hydraulic oil on surface of push rod.

Installing O-ring (214) and seal (213)

(5) Insert push rod (212) in plug (211) and

install spring (*246) and spring seat
(*218-1) to push rod (212) on port 1,3 side.
And install spring seat (*218-2) to push
rod on port 2,4 side.

Assembling push rod, spring (246) and seat

(218)

The parts marked * might not be equipped depending on valve type.

(6) Fit plug (211) assy to casing (101).

1.
When the force of spring (211) is weak, it
stops at the position where it is pushed in
by the sliding resistance of O-ring (214).

Installing plug assy

33-118
 ［33. UPPER SLEWING STRUCTURE］

2.
When the force of spring (221) is strong, attach
plate (151) and press 4 push rods by hand at
33
the same time, and tighten joint (301)
temporarily.
-Install spool (201) straight and evenly into the
hole of casing (101).
-Take care so that plug (211) and plate (151)
do not jump out of casing (101).

Installing plug assy and plate (151)

(7) Install joint (301) on casing (101) with jig A

securely.
Jig A : See 33.2.3.7 JIG.
Tightening torque : 47.1 N-m (32.8 to 37.2
lbf-ft)

Installing joint (301)

(8) Install circular plate (302) to joint (301)

(9) Screw adjusting nut (312) in until it touches
circular plate (302), and tighten it applying
spanner to stop circular plate returning.
Tools: Spanner: 32 mm
Tools: Socket: 22 mm
-Apply Loctite #277 to threads of joint.
Tightening torque: 68.6 N-m (51 lbf-ft)

Installing circular plate (302)

-Screw it in until it comes in contact with 4 push rods (212) equally.

-The exceeding of screw in may cause malfunction of machine.

33-119
［33. UPPER SLEWING STRUCTURE］

(10) Apply heat-resisting grease to joint (301)

rotating section and the top of push rod
(212).
(11) Cover it with boots.
(12) Spray rust preventives through each port
and attach plug respectively.

Applying grease to joint section and push rod

33-120
 ［33. UPPER SLEWING STRUCTURE］

33.2.3.5 MAINTENANCE STANDARDS

Check item Standard Remarks
When leakage quantity reaches to 1000 cc/ 33
min. or more where handle is set in neutral
Conditions
position, or to 2000 cc/min. or more in
Leakage Primary pressure 2.94 MPa (426 psi)
operation, replace spool with new one.
Hydraulic oil viscosity 23 cSt
If leaked, even if the spool is replaced,
replace pilot valve assy with new one.
When the wear of sliding section is 10 μm
This condition may be the same as the
Spool more than the that of non sliding section,
above.
replace it with new one.
Push rod When the wear of top is 1 mm (0.04 in) or more, replace it with new one.
When looseness of 2 mm (0.08 in) or more
Looseness of control on circular plate (302) on control section and In case of the looseness due to the
section joint section (301) due to wear is pro- duced, loosening on tightening section, adjust it.
replace them with new ones.
When trouble such as noise, hunting, drop of
primary pressure, etc. has occurred in op-
eration, and it does not restore after taking
Stability of operation
corrective action according to below 33.2.3.6
(TROUBLESHOOTING), replace pilot valve
assy with new one.

-O-ring, etc. should be replaced with new one at every disassembling.

-If socket bolt (125) was loosened, seal washer (121) should be replaced.

33-121
［33. UPPER SLEWING STRUCTURE］

33.2.3.6 TROUBLESHOOTING
It is very difficult to find defective section. The following table explains the several estimated causes.
For repair, refer to the estimated causes and corrective actions.
The following table explains general phenomenon, estimated causes and corrective actions. However,
most machine problems are not caused by the failure of only one part, but involve relations with
other parts. Therefore corrective action other than those described in this table is often required. The
following table does not cover causes and corrective actions for all the troubles. So it may be
necessary to perform further investigation of troubles and causes.

Phenomenon Possible Cause Corrective action

1. 1.
Primary pressure is insufficient. Secure primary pressure.
2. 2.
Secondary pressure springs (241) are Replace with new ones.
broken or fatigued.
Secondary pressure
3. 3.
does not rise.
Clearance between spool (201) and cas-ing Replace spool (201).
(101) is abnormally large.
4. 4.
Handle has a looseness. Disassembly and reassembly or replace
handle section.
1. 1.
Sliding parts are caught. Repair the unsmoothed section.
Secondary pressure 2. 2.
is unstable. Tank line pressure varies. Bring pressure directly to oil tank.
3. 3.
Air has mixed into pipeline. Bleed air by operating it several times.
1. 1.
Secondary pressure Tank line pressure is high. Bring pressure directly to oil tank.
is high. 2. 2.
Sliding parts are caught. Correct.

33-122
 ［33. UPPER SLEWING STRUCTURE］

33.2.3.7 JIG
(1) Jig for removing and installing joint (301)
33

33-123
［33. UPPER SLEWING STRUCTURE］

33.2.4 PILOT VALVE (FOR TRAVEL)

33.2.4.1 CONSTRUCTION

Exploded view of pilot valve

No. Parts Q'TY No. Parts Q'TY

5 Rubber boots 2 12-x Seal 14dia.X20dia.X3dia. 6
6 Foot pedal (Switch plate) (2) 12-y Wiper ring 6
6-d Switch plate 2 13 Damper spring 4
6-f Regulation screw M8X28 4 14 Check valve kit (2)
6-g Set screw M5X8 4
7 Retaining plate kit (1) 14-q Plug M8 2
7-h Plate 1 14-r Ball M6, 35 2
7-i Capscrew M10X20 2 15 Orifice (4)
7-j Shaft 2 15-u Plug M6 4
7-k Set screw M4X10 2 15-t Orifice M6, 0.6dia. 4
8 Flange kit 4 17 Shuttle valve kit (2)
10 Control spool 4 17-w' Shuttle valve & orifice 2
11 Return spring 4 17-r Ball M6, 35 2
12 Damper flange kit (4) 17-z Orifice M5, 0.8dia. 2
12-o Damper plunger o14 4 21 Plug 4

33-124
 ［33. UPPER SLEWING STRUCTURE］

33.2.4.2 DISASSEMBLY AND ASSEMBLY

(1) Boot replacement
33

The pilot control unit does not need to be removed from the machine to perform this operation.

1. Remove both faulty boots.

(using a flat screw driver if necessary)
2. Replace both boots with a new one.
* Reassembly:
-First fit the lower part of the rubber boot
on the retaining plate between the 2 switch
plates
-Then put the lower part in the external
groove of the retaining plate
-Finish by fitting the upper part of the
rubber boot on the switch plate.

(2) Switch plate removal

1. Remove:
-The pilot control unit from the machine.
-Both rubber boots (See 33.2.4.2 (1))
2. Remove the screw locking the axis using
a 2 mm socket wrench. (See right Fig.
No.1)
* Reassembly:
-Apply a droplet of Loctite #262 on the
locking screw thread.
-Torque :1.2 N-m (0.89 lbf-ft)
3. Fit a M3 screw on the switch plate axis in
order to remove it
(Using pliers if necessary). (See right Fig.
No.2)
* Reassembly:
-Position the axis so that the hole is
aligned with the locking screw as shown on
the picture (See right Fig. No.3)
4. Mark out the position of the switch plate
before removing it.
5. Repeat the operation for the second switch
plate.
6. Reassemble parts in reverse order.

33-125
［33. UPPER SLEWING STRUCTURE］

(3) Switch plate adjustment

If the switch plate is replaced, it is necessary to adjust the regulation screws.

1. Unscrew the 2 locking screws using a 2,5

mm socket wrench (See right Fig.)
* Reassembly:
-Apply a droplet of Loctite #262 on the
locking screw thread.
-Torque :3N-m 2.2 (lbf-ft)
2. Set the switch plate horizontally.
3. Screw on simultaneously both regulation
screws using a flat screw driver (5,5X150)
until feeling some resistance.

Do not misadjust the two damping screws. (See below Fig.)

4. Tighten the locking screws to hold the

regulation screws in position.
5. Repeat the operation for the second
switch plate making sure both switch
plates are parallel. (See above Fig.)

33-126
 ［33. UPPER SLEWING STRUCTURE］

(4) Retaining plate removal

1. Remove
-The pilot control unit from the machine.
33
-Both rubber boots (See 33.2.4.2 (1))
-Both switch plates (See 33.2.4.2 (2))
2. Unscrew simultaneously both screws holding
the retaining plate using a 8 mm socket
wrench.
(See right Fig.)
* Reassembly:
-Apply a droplet of Loctite #262 on the
screw thread.
-Torque :30N-m (22 lbf-ft)

3. Lift the retaining plate to remove it.

(See right Fig.)
* Reassembly:
-Use the retaining plate to insert the 4
guides into the body simultaneously and
perpendicularly.
(See right Fig. left side)
4. Reassemble parts in reverse order.
5. Drain the pilot control unit (See 33.2.4.3).

(5) Damping plunger seals replacement

1. Remove
-The pilot control unit from the machine.
-Both rubber boots. (See 33.2.4.2 (1))
-Both switch plates (See 33.2.4.2 (2))
-The retaining plate (See 33.2.4.2 (4))

2. Remove the wiper ring of the damping

plunger (1).
(See right Fig. No.1)
* Reassembly:
-Replace with a new wiper ring.
3. Remove the damping plunger (2).
(Rihgt Fig. No.2)

33-127
［33. UPPER SLEWING STRUCTURE］

Always place the damping plunger prior to the wiper ring, and make sure the wiper ring is correctly
positionned.

4. Using a needle, remove the seal placed

inside the body (See right Fig. No.3, 4)
* Reassembly :
-Replace with a new seal and grease it.

169

-Squeeze the seal between your fingers to

obtain a 8-shape.
(See right Fig. No.5)
-Insert the seal within the groove with your
fingers (lip in bottom position).
(See right Fig. No.6, 7)
-Push the seal against the side using the round
head of a small socket wrench. (Right Fig.
No.8)

5. Repeat the operation for the other 3 assemblies.

6. Extract the damping springs from the body (using flat nose pliers).
7. Inspect the damping springs. If defects are detected, replace the 4 springs.
8. Reassemble parts in reverse order.

During the reassembly, make sure the seal is correctly positionned, and pay attention not to damage
nor twist it.

33-128
 ［33. UPPER SLEWING STRUCTURE］

(6) Guide/plunger and regulation unit replacement

1. Remove
-The pilot control unit from the machine.
33
-Both rubber boots (See 33.2.4.2 (1))
-Both switch plates (See 33.2.4.2 (2))
-The retaining plate (See 33.2.4.2 (4))
2. Guide/plunger replacement:
-Insert the end of a thin screwdriver
between the guide and the body, carefully
lift the guide to remove it from the body.
3. Remove the guide / plunger assembly.
4. Repeat the operation for the other 3
sub-assemblies.
5. Visually check that the guides / plungers
are in good condition. If defects are
present, replace the 4 sub-assemblies.

Hold the guides with the other hand during the extraction operation to limit the effect of the return
spring.

6. Guide/plunger and relulation unit

replacement
-Extract the regulation units from the body
(using flat nose pliers).
-Inspect the regulation units. If defects are
detected on the parts, replace the 4 units.
7. Return spring replacement :
-Extract the return springs from the body
(using flat nose pliers).

33-129
［33. UPPER SLEWING STRUCTURE］

-Inspect the return springs. If defects are detected, replace the 4 springs.

8. Reassemble parts in reverse order.

(7) Throttle kit replacement

1. Remove
-The pilot control unit from the machine
-Both rubber boots (See 33.2.4.2 (1))
-Both switch plates (See 33.2.4.2 (2))
-The retaining plate (See 33.2.4.2 (4))
-The damping plungers and springs (See
33.2.4.2 (5))

2. Unscrew the screw using a 3mm socket

wrench.
(See right Fig.)
* Reassembly:
-Apply a droplet of Loctite #262 on the
screw thread
-Screw on until it sets just above the body.
(See right Fig.)
3. Unscrew the throttle using a 3 mm socket
wrench.
* Reassembly:
-Torque:4N-m (3 lbf-ft)
4. Repeat the operation for the other 3
assemblies.
5. Replace with new screws and new throttles.
6. Reassemble parts in reverse order.

33-130
 ［33. UPPER SLEWING STRUCTURE］

(8) Shuttle valve kit removal

1. Remove the pilot control unit from the
machine
33

The pilot control unit does not need to be disassembled to perform this operation.

2. Unscrew the shuttle valve using a 4 mm

socket wrench. (See right Fig.)
* Reassembly:
-Thoroughly clean the body to remove any
trace of loctite.
-Apply a droplet of Loctite #242 on the
shuttle valve thread.
-Torque :4N-m (3 lbf-ft)

Wait for 8 hours before using the machine to let the Loctite #242 dry completely.

3. Turn the body up-side-down to remove the

shuttle valve and the ball. (See below Fig.)
4. Unscrew the throttle using a 2,5 mm socket
wrench.
* Reassembly:
-Hand tighten.
5. Repeat the operation for the other
subassemblies.
6. Inspect the shuttle valves, balls and
throttles. If defects are detected, replace
all the assemblies.

33-131
［33. UPPER SLEWING STRUCTURE］

7. Reassemble parts in reverse order.

(9) Check valve kit removal

1. Remove the pilot control unit from the machine

The pilot control unit does not need to be disassembled to perform this operation.

2. Unscrew the check valve plug using a 4

mm socket wrench.
(See right Fig.)
* Reassembly:
-Drain the pilot control unit
(See 33.2.4.3)
-Torque: 5N-m (3.7 lbf-ft)
3. Turn the body up-side-down to remove the
ball.
4. Repeat the operation for the second check
valve kit.

5. Inspect the check valve plugs, O-rings and

balls. If defects are detected, replace all
the assemblies. (See right Fig.)
6. Reassemble parts in reverse order.

33-132
 ［33. UPPER SLEWING STRUCTURE］

33.2.4.3 DRAIN OF HYDRAULIC PILOT CONTROL UNIT

(1) When removing the retaining plate, the
throttle kit or the shuttle valve kit, it is
33
necessary to drain the pilot unit.
(2) Reassemble the pilot unit control completely.
(3) Install the pilot unit control in the machine.
(4) Slightly unscrew the check valve plug
using a 4mm socket wrench. (See right
Fig.)
(5) Switch on the machine.
(6) Operate gently the pedal until the bubbles
disappear.
(7) Tighten the check valve plug.
-Torque: 5 N-m (3.7 lbf-ft)
(8) Repeat the operation for the other check
valve plug.

33-133
［33. UPPER SLEWING STRUCTURE］

33.2.5 SWING MOTOR UNIT

33.2.5.1 CONSTRUCTION
(1) Swing motor

Swing motor

33-134
 ［33. UPPER SLEWING STRUCTURE］

Tightening Tightening
torque No. Parts Q'ty torque No. Parts Q'ty
N-m (lbf-ft) N-m (lbf-ft)
33
101 Drive shaft 1 443 Roller bearing 1
106 Spacer 3 444 Roller bearing 1
111 Cylinder 1 451 Pin 2
113 Retainer (spherical bushing) 1 36 (27) 468 VP plug : PF1/4 2
114 Cylinder spring 1 108 (80) 469 RO plug : M22 2
116 Push rod 12 471 O-ring : 1B G80 1
117 Spacer 2 472 O-ring 1
121 Piston 9 487 O-ring : 1B P11 2
122 Shoe 9 488 O-ring : 1B P20 2
123 Plate 1 491 Oil seal 1
124 Shoe plate 1 702 Brake piston 1
131 Valve plate 1 706 O-ring 1
301 Casing 1 707 O-ring 1
303 Casing 1 712 Brake spring 20
304 Front cover 1 742 Friction plate 3
351 Plunger 2 743 Separator plate 4
355 Spring 2 1.7 (1.2) 980 Plug : PF3/8 1
240 (177) 401 Socket bolt : M16X75 4 4.4 (3.3) 981 Plug : PF3/4 1
432 Snap ring 2 0.9 (0.6) 982 Plug : PF1/4 1
433 Ring 1 98 (72) 992 Plug : PT3/4 1
437 Snap ring 1 177 (131) 51 Relief valve : M33 2
438 Snap ring 1 051-1 O-ring : 1B G30 2

33-135
［33. UPPER SLEWING STRUCTURE］

(2) Swing reduction unit

Sectional view of swing reduction unit

Tightening torque Tightening torque

No. Parts Q'ty No. Parts Q'ty
N-m (lbf-ft) N-m (lbf-ft)
102 Casing 1 402 Roller bearing 1
201 Pinion shaft 1 403 Needle bearing 3
202 Ring gear 1 98 (72) 602 Socket bolt : M12X100 8
203 No.2 planetary gear 4 603 Socket bolt : M12X135 2
204 No.2 sun gear 1 801 Oil seal 1
210 No.1 planetary gear 3 910 Spring pin 4
211 No.1 sun gear 1 911 Retaining ring 3
230 No.2 spider 1 912 Retaining ring 1
231 No.1 spider 1 913 Retaining ring 1
282 No.2 pin 4 915 Seal 1
283 No.1 pin 3 65 (48) 920 Adapter : PT1/2 1
285 Side plate t=1 7 108 (80) 921 Hose : PF1/2 1
286 Thrust washer t=2 1 108 (80) 922 Plug : PF1/2 1
287 Side plate t=2 3 925 relief fitting 1
401 Roller bearing 1 926 Grease nipple : PT1/4 1

33-136
 ［33. UPPER SLEWING STRUCTURE］

33.2.5.2 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR

33.2.5.2.1 TOOLS AND JIGS
(1) Spanner wrench 33
OPPOSING
NAME SIZE APPLICABLE PARTS TOOL
FLATS mm
CAPSCREW M6 10 Selector valve for brake Spanner, Socket wrench
SOCKET BOLT M8 6 Swing shockless valve block Allen wrench
SOCKET BOLT M16 14 Valve casing Allen wrench
PLUG M22 10 RO plug Allen wrench
PLUG PF1/4 6 ROH plug Spanner, Socket wrench
ATTACHING SCREW M22 24 Swing shockless valve Spanner, Socket wrench
ATTACHING SCREW M33 41 Relief valve Spanner, Socket wrench

(2) Other tools and jigs

SPECIFICATION
REMARKS
TOOLS
For snap ring For 35dia. (1.38") shaft
Pliers
For Locking ring For 80dia. (3.15") hole
Screwdriver Flat-bladed type, medium size 2 pcs.
Steel bar 10 x 8 x 200 or so 1pc. (0.394"x 0.315"x 7.87" )
Hammer Plastic hammer Iron hammer 1 each

Torque adjusting range

Torque wrench
For 0.09~24kgf-m (0.65~174 lbf-ft)

Slide hammer bearing puller

Brake piston drawing tool Fig. Brake piston drawing tool

Brake piston drawing tool

33-137
［33. UPPER SLEWING STRUCTURE］

33.2.5.2.2 DISASSEMBLY PROCEDURE

(1) Cleaning the swing motor
Place a wire sling around the motor, lift it up and clean it. After cleaning, dry it with jet air.

Put plugs into all ports to prevent foreign matter from entering the motor and clean the motor to be
free from dirt and dust.

(2) Draining out lube oil

Drain out the oil from the drain port of casing (301).

(3) Fixing the motor to the work bench.

Direct the shaft end of the drive shaft (101)
down and fix it on a bench convenient for
disassembly. On that occasion, leave a
matching mark on the mating part between
casing (301) and valve cover (303).

Fixing the motor to the work bench and

putting a matching mark

Choose a clean place. Place a rubber sheet or a cloth on the work bench. Exercise care so as not to
damage parts.

(4) Remove relief valve

Loosen relief valve (051) and separate it
from valve cover (303).
Tools: Spanner: 41mm

Removing relief valve

33-138
 ［33. UPPER SLEWING STRUCTURE］

(5) Remove swing shockless valve block

Loosen socket bolt (V171) and separate
swing shockless valve block (052) from
33
valve casing (303).
Tools: Allen wrench: 6mm
(6) Removing the anti-cavitation check plunger
Separate RO plug (469) from valve casing
(303) and draw out spring (355) and
plunger (351).
Tools: Allen wrench: 10mm Removing swing shockless valve block

Exercise care so as not to score the plunger seat.

(7) Remove valve casing and valve plate

Loosen socket bolt (401) and separate
valve casing (303) from casing (301).
[If the socket bolt (401) are loosened, the
valve casing floats off casing (301) by the
force of brake spring (712)].
Then separate valve plate (131) from valve
casing (303).
Tools: Allen wrench: 14mm

Removing valve casing No.1

Work with care so the valve seat does not come off from the valve casing.
(In some cases, the valve plate is adhered on the cylinder side.)
When inserting a screwdriver or something between the matching surfaces, use care so as not to
score the matching surfaces.

(8) Remove brake spring

Draw out brake spring (712) from brake
piston (702).

Removing valve casing No.2

33-139
［33. UPPER SLEWING STRUCTURE］

(9) Remove brake piston

Draw out brake piston (702) from casing
(301), using a jig (slide hammer).

Removing brake piston

Hold it upright, utilizing the bolt holes in the brake piston.

(10) Remove cylinder

Place the motor level and draw out the
cylinder (111) from the drive shaft (101).
Then draw out piston (121), retainer plate
(123), spacer (117) and shoe plate (124).

Removing cylinder

-Use care when drawing out the cylinder as push rod (116) tends to come off. Exercise care so as
not to score the sliding surfaces of the cylinder, retainer and shoe.
-In case the shoe plate does not come off, remove it after the work sequence (12).

(11) Remove separator plate

Draw out friction plate (742) and separator
plate (743) from casing (301).

Removing snap ring

33-140
 ［33. UPPER SLEWING STRUCTURE］

(12) Remove front cover

Take off snap ring (437) with pliers and
separate front cover (304) from casing
33
(301).

Removing front cover

-When drawing out the front cover, take care so as not to score the sliding surface of the oil seal.
-You may remove the front cover with the drive shaft.

(13) Remove drive shaft

Separate drive shaft (101) from casing
(301) by lightly tapping the end face of
the valve casing side (303) of drive shaft
(101), using a plastic mallet.

Removing drive shaft

Use care so as not to score the sliding surface of the oil seal.

(14) Remove shoe plate

Draw out shoe plate (124) from the housing side of roller bearing (443) of casing (301) by lightly
tapping it with a steel rod.

33-141
［33. UPPER SLEWING STRUCTURE］

(15) Remove inner race of roller bearing (443)

Remove snap ring (432) and spacer (106)
from drive shaft (101) and draw out the
inner race of roller bearing (443) by
means of a press.

Removing inner race of roller bearing

You may knock on the inner race of the roller bearing with a steel bar, but knock on it evenly all
around so the bearing is not damaged.
Do not use the removed bearing again.

(16) Remove oil seal

Draw out oil seal (491) from front cover
(304), utilizing the jig.

Removing oil seal

Do not reuse the removed oil seal.

33-142
 ［33. UPPER SLEWING STRUCTURE］

(17) Remove roller bearing

Separate roller bearing (444) from valve
casing (303), using a slide hammer bearing
33
puller.

Removing roller bearing (444)

Do not reuse the removed bearing.

33-143
［33. UPPER SLEWING STRUCTURE］

33.2.5.2.3 ASSEMBLY PROCEDURE

(1) Holding casing
Place the casing (301) facing its valve
casing (303) downward.

Holding casing

(2) Installing inner race of roller bearing

Fit snap ring (432) and spacer (106) to drive shaft (101), insert the inner race of roller bearing
(443), and shrinkage fit the inner race.
Put spacer (106) in and fix snap ring (432).

Installing snap ring (432)

Installing roller bearing (443)

Beware of the orientation of the inner race of the roller bearing.

33-144
 ［33. UPPER SLEWING STRUCTURE］

(3) Shrinkage fitting inner race of roller bearing

(444)
Shrinkage-fit the inner race of roller
33
bearing (444) to drive shaft (101). Then fit
snap ring (433).
(4) Installing outer race of roller bearing (443)
Place drive shaft (101) with roller bearing
(443) on its output shaft, and insert the
drive shaft into casing (301). Then lightly
knock on the outer race of roller bearing
(443) via a steel bar, using a hammer. Shrinkage fitting inner race

Knock on the outer circumference of the outer race evenly all round till it stops at the step of the
casing.

(5) Insert oil seal

Put oil seal (491) into front cover (304),
using a jig.

Inserting oil seal

-Be careful about the direction of the oil seal.

-Fix the oil seal till it stops at the step of the casing.

(6) Fit O-ring

Fit O-ring (471) to casing (301).

Fitting O-ring
Wind tape around the spline of the drive shaft

33-145
［33. UPPER SLEWING STRUCTURE］

(7) Installing front cover

Fit front cover (304) to casing (301) by
lightly tapping the cover with a plastic mallet

Coat the lip of the oil seal with a thin film of grease and put it in with care so as not to score the lip
of it. (Wind tape on the spline of the drive shaft so the lip of it is not scored by the spline.)
Tap the outer circumference evenly round to prevent it from being scored.

(8) Fitting the snap ring

Fit snap ring (437) to casing (301), using pliers.

(9) Put shoe plate (124) into casing (301).

Inserting shoe plate

Put the larger chamfer side of the shoe plate into the casing side.
Coat the matching surface with a thin film of grease to prevent the shoe plate from falling off.

33-146
 ［33. UPPER SLEWING STRUCTURE］

(10) Insert push rod

Put push rod (116) in cylinder (111).

33

Inserting push rod

Use care so as not to score the sliding surface of the cylinder.

(Put two push rods into one hole.)

(11) Installing retainer

Then mount retainer (113) fitted with spacer
(117) on the cylinder.

Installing retainer

(12) Installing the piston sub assy to the plate

Set piston sub assy (121,122) to plate
(123).

Installing the piston sub assy to the plate

33-147
［33. UPPER SLEWING STRUCTURE］

(13) Assembling the piston sub assy into the

cylinder
Assemble piston sub assy (121,122) with
plate (123) into cylinder (111) and insert it
in place, aligning it with the spline of drive
shaft (101).

Assembling the piston sub assy into the

cylinder

The drive shaft can be set easily if the phase of the retainer (113) and the cylinder spline is matched.

(14) Installing separator plate and friction plate

Replace casing (301) so front cover (304) side faces down. Then Assemble separator plate (743)
and friction plate (742) into casing (301), in that order.
Fit four separate plates and three friction plates.

Installing separator plate Installing friction plate

Assemble four notches in the gear teeth of friction plate so the same phases are aligned up and
down.
Fix notches in the four claws of separator plate in the position in Fig. "Installing separator plate".

33-148
 ［33. UPPER SLEWING STRUCTURE］

(15) Fit O-ring

Fit O-rings (706)(707) to casing (301).

33

Fitting O-ring

In that case, coat the O-rings with grease beforehand. This will prevent the O-rings from breaking
when inserting brake piston.

(16) Installing brake piston

Fit brake piston (702) to casing (301).

Installing brake piston

Install the brake piston so four slits of it are positioned as shown in the figure on the right. (Match the
M8 screws to the figure on the right.)
If brake piston is hard to enter because of the resistance of the O-rings, screw in socket bolt M8 into
the brake piston and knock on it evenly by means of a plastic mallet.

33-149
［33. UPPER SLEWING STRUCTURE］

(17) Installing brake spring

Fit brake spring (712) to brake piston (702).

Installing brake spring

At that time, make sure that the spring is set snugly in the spotface of the brake piston.

(18) Insert outer race of roller bearing

Insert the outer race of roller bearing (444)
into valve casing (303), knocking it lightly
by means of a steel bar.

Inserting outer race of roller bearing

Knock on the outer circumference of the outer race evenly around and fix it so it stops at the step of
the valve casing.

(19) Installing valve plate

Assemble valve plate (131) into valve
casing (303) and then fit O-ring (472) in
place.

Installing valve plate

Coat the contact surface of the valve plate with a thin film of grease. (To prevent it from falling off.)

33-150
 ［33. UPPER SLEWING STRUCTURE］

(20) Installing valve casing

Attach valve casing (303) to casing (301)
and fasten it with socket bolt (401).
33
Tools: Allen wrench: 14 mm
Tightening torque : 240N-m (170 lbf-ft)

Installing valve casing

Beware of the direction of the valve casing.

-Be careful so the valve plate does not come off.
-Use care so the brake spring does not fall down.
-Fasten the socket bolts evenly all around.

(21) Fitting plunger

Place plunger (351) and spring (355) into
valve casing. Fasten RO plug (469) with
O-ring (488) into valve casing.
Tools: Allen wrench: 10 mm
Tightening torque : 108N-m (80 lbf-ft)

Fitting plunger

Make sure that the plunger moves smoothly.

(22) Installing relief valve

Fit backup ring (162) and O-ring (161) to
relief valve (051) and fasten the relief valve
against valve casing (303).
Tools: Spanner: 41 mm
Tightening torque : 177Nom (130 lbf-ft)

Installing relief valve

33-151
［33. UPPER SLEWING STRUCTURE］

(23) Installing plugs (464),(468)

Fit O-ring (487) to plug (468), attach it to valve casing (303), fit O-ring (485) to plug (464) and
fasten it against casing (301).
Tools: Spanner: 19 mm
Tightening torque : 36N-m (27 lbf-ft)

(24) Installing swing shockless valve block

Fit O-ring (V161) to the swing shockless
valve block. Then fasten the valve block
against valve casing (303) with socket bolts
(V171).
Tools: Allen wrench: 6 mm
Tightening torque : 29N-m (22 lbf-ft)

lnstalling swing shockless valve block

33-152
 ［33. UPPER SLEWING STRUCTURE］

33.2.5.3 DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT

33.2.5.3.1 TOOLS AND JIGS
(1) Tools 33
NAME REMARKS
Allen wrench Opposing flats 6,10mm
Socket wrench
Adjust wrench
Double ended wrench
Hammer
Plastic mallet
Screwdriver
Torque wrench
Liquid packing Three-Bond #1104B
Oil container for shrinkage fit work 80~100degress C (176~212degrees F)

(2) Jigs

33-153
［33. UPPER SLEWING STRUCTURE］

33.2.5.3.2 DISASSEMBLY PROCEDURE

(1) Remove swing motor unit and drain oil
Remove the swing motor unit from the machine, loosen plug (902) at the oil outlet, discharge the
gear oil and place the unit on a work bench.

Receive gear oil in a clean container and inspect for the presence of worn particles.

(2) Remove hydraulic motor

Loosen socket bolts (602) and remove the hydraulic motor.
Tools: Allen wrench: 10 mm

(3) Remove No.1 sun gear (211)

Removing No.1 sun gear

(4) Remove No.1 carrier assy

Remove the No.1 carrier assy with the
No.1 planetary gear (210) and others.

Removing No.1 carrier assy

33-154
 ［33. UPPER SLEWING STRUCTURE］

(5) Disassembly No.1 carrier assy

33

Put a matching mark on each of the planetary gears and pins so combination and pairing do not
change.

1. Remove snap ring (911). Then remove side

plate (287) at the top.

Removing snap ring

2. Remove No.1 planetary gear (210) and

needle bearing (403).

Removing needle bearing

3. Remove side plate (285) under the

planetary gear.

Removing side plate

33-155
［33. UPPER SLEWING STRUCTURE］

4. After removing three No.1 planetary gears

(210), remove thrust washer (286) in the
center.

Removing thrust washer

-Do not remove No.1 pin (283) from No.1 carrier (231) unless there is anything wrong.
-If the No.1 pin is removed, you need a special caulking tool at reassembly.
However, make sure that the o2(0.079") oil hole of No.1 pin (283) is directed outwards with respect
to the center of No.1 carrier (231).
(Refer to Fig. right.)

(6) Remove No.2 sun gear (204)

Removing No.2 sun gear

(7) Remove No.2 carrier assy

Removing No.2 carrier assy

33-156
 ［33. UPPER SLEWING STRUCTURE］

(8) Disassembly No.2 carrier assy

1. Push spring pin (910) in further and draw

33
out No.2 pin (282).
2. Draw out No.2 planetary gear (203) and
side plate (285) sideways.

Removing No.2 pin

Do not disassemble the No.2 carrier assy further unless there is anything wrong. In this condition,
inspect the parts according to the inspection procedure specified under 33.2.5.4.2 (1).
As mentioned above, it is recommended that the No.2 carrier assy be replaced as a pair, but in case
part of it must be replaced for an unavoidable reason, do it as below:

Do not reuse the removed No.2 pin.

(9) Remove ring gear (202)

The bottom of the two holes is provided
with M12 screw threads to draw out the
ring gear. Utilise motor mounting socket
bolts (602) to draw it out.
Tools: Allen wrench: 10 mm

Removing ring gear

33-157
［33. UPPER SLEWING STRUCTURE］

(10) Separate snap ring (913) from drive shaft

(201).
(11) Remove drive shaft
Support the flanged part of the drive shaft
so the shaft end faces down and place
the drive shaft on a work bench. Draw out
the shaft downwards, while tapping the
center of it with a plastic mallet.

Removing snap ring

-Do not disassemble it further unless there is anything wrong.

At this stage, inspect the parts according to the inspection procedure specified under 33.2.5.4.2 (1).
As mentioned above, we recommend that the drive shaft assy be replaced as a set. In case part of
it must be replaced for an unavoidable reason, do as follows:
-If nothing faulty is discovered on inspection at this stage, no further disassembly is needed.

(12) Remove roller bearing

As shown on Fig. right on the right,
support the drive shaft assy, and draw out
bearing seal (915) and roller bearing (401),
using a press.

Removing roller bearing

-Roller bearing (402) is left in the casing. Since the shaft falls down, use care so as not to damage it.
-The removed oil seal and the bearing seal can not be used again.

33-158
 ［33. UPPER SLEWING STRUCTURE］

(13) Remove oil seal (801) from casing (102).

33

Removing oil seal

33-159
［33. UPPER SLEWING STRUCTURE］

33.2.5.3.3 ASSEMBLY PROCEDURE

(1) Assembly drive shaft assy

1. Insert bearing seal

Insert bearing seal (915) into drive shaft
(201).

Assembling drive shaft

2. Press-fitting roller bearing

Coat the inside of roller bearing (401) with
sufficient grease and press it into the drive
shaft, using a press. Set the inner race
firm into the shaft by knocking on the
steel bar, till the hammer springs back.
Then apply grease so it reaps as shown
in Fig. right.

Applying grease to roller bearing

-Grease :EP type

(Shell Alvania grease EP2)
-Roller bearing (401) has a bank in the middle. Push grease in to both sides before assembling the
bearing into the shaft.

(2) Place casing (102) on a level bench.

33-160
 ［33. UPPER SLEWING STRUCTURE］

(3) Installing drive shaft assy

Lift the drive shaft assy upright, using the
screw in the end of the shaft and put it
33
into the casing.
Thread size : M10, Depth 20mm

Installing drive shaft assy

Lightly tap the outer race of the bearing so it is completely level. If the outer race is tilted, it does
not enter by light tapping in some cases. On such occasion, pull it out once, place it level and do
the job once again.

(4) Place the casing by supporting the flanged part so the shaft end faces down.

(5) Installing oil seal

Insert oil seal (801) into casing (102).

-Use the jig 1) under 33.2.5.2.1 (2).

-Place the oil seal level and fix it so the lip is not scored.

(6) Press-fitting roller bearing

Insert roller bearing (402) by using the jig
that holds down both the inner race and
the outer race and also using a press.
Always use the jig 33.2.5.2.1 (2) and set it
properly.

Press-fitting roller bearing

33-161
［33. UPPER SLEWING STRUCTURE］

(7) Fit snap ring (913)

(8) Fitting the oil filling plug
Fill up the oil inlet with grease, wind seal
tape around plug (902) and set it to the
casing.
Grease : EP type (Shell Alvania EP2)
Grease volume : about 500cc (31 cu-in)
Tools: Allen wrench: 6 mm
Tightening torque : 220N-m (160 lbf-ft)

Fitting snap ring

(9) Assembly No.2 carrier assy

1. Place side plate (285) by matching it to the

pin holes.
2. Put No.2 planetary gear (203) in.
3. Check the hole location, peeping through it
from above. Match the No.2 pin (282) with
the hole for spring pin (910) and the hole
in the No.2 carrier and set the pin, while
tapping it lightly. Assembling No.2 carrier assy

(10) Apply liquid packing to the matching surface between casing (102) and ring gear (202).

Three-Bond #1104B

(11) Installing ring gear

Install ring gear (202) to casing (102),
checking the location of the matching marks
and temporarily fasten them together by
means of four capscrews or socket bolts
M12X100. (Tightening torque : 78Nom (58
lbfoft) or over). Always place plain
washers on the bolts so the matching
surface of the motor is not scored.
Tools: Spanner: 19mm or Tools: Allen
wrench: 10mm Installing ring gear

33-162
 ［33. UPPER SLEWING STRUCTURE］

(12) Installing No.2 carrier assy

Install the No.2 carrier assy into the ring
gear.
33
(13) Installing No.2 sun gear
Put in No.2 sun gear (204).

Installing No.2 carrier assy

(14) Assembly No.1 carrier assy

1. Place No.1 carrier (231) on a level bench.

2. Make sure that all three 2dia (0.079" ) oil holes of No.1 pin (283) are directed outwards with
respect to the center of No.1 carrier (231), as shown in the figure.

Assembling No.1 carrier assy

3. Installing thrust washer

Put in thrust washer (286) in the center.

Installing thrust washer

33-163
［33. UPPER SLEWING STRUCTURE］

4. Installing side plate

Put in side plates (285).

Installing side plate and needle bearing

The upper and lower side plates differ in thickness; take care so as not to mistake one for another.

5. Installing needle bearing and No.1 planetary

gear
Fit needle bearing (403) and No.1 planetary
gear (210).

Installing planetary gear

6. Installing side plate

Put side plate (287) in and fit snap ring
(911).

Installing side plate and snap ring

(15) Installing No.1 carrier assy

Assemble the No.1 carrier assy. Make
sure that thrust washer (286) in the center
sits in the convex part of No.2 sun gear
(204).

Installing No.1 carrier assy

33-164
 ［33. UPPER SLEWING STRUCTURE］

(16) Installing No.1 sun gear

Assemble No.1 sun gear (211).
(17) Apply liquid packing
33
Remove the temporarily fastened bolts and
coat the mounting surface of the hydraulic
motor of ring gear (202) with liquid
packing (Three-Bond #1104B).
(18) Installing hydraulic motor
Fit snap ring (912) to the drive shaft of
the hydraulic motor, lower it vertically,
assemble the hydraulic motor in place, Installing No.1 sun gear
while matching it with the spline position
and fasten it with socket bolt (602).
Tools: Allen wrench: 10 mm
Tightening torque : 98N-m (72 lbf-ft)

(19) Wind seal tape around oil drain plug (902) and fit it to the casing.
Tools: Allen wrench: 6 mm
Tightening torque : 22N-m (16 lbf-ft)
(20) Filling oil
Fill in gear oil through the oil inlet.
Lubricating oil: SAE#90~#140, API class GL3>~
(Shell Spirax 90EP filled up at shipping)
Lubricant volume : 1.7L (0.45gal)

Temporarily fit the level bar to the pipe and check the level.

33-165
［33. UPPER SLEWING STRUCTURE］

33.2.5.4 MAINTENANCE STANDARDS

33.2.5.4.1 SWING MOTOR
(1) Replacement standards for parts
If part are worn out beyond the below standards, replace or recondition them. However if they show
excessive damage on their surface, replace them.

33-166
 ［33. UPPER SLEWING STRUCTURE］

(2) Standard for correcting sliding surfaces

If the surface roughness of the sliding surface of a part exceeds the following standard, correct it or
replace the part.
33
Standard for correcting sliding surfaces
Surface roughness requiring
Name of parts Standard surface roughness
correction
SHOE 0.8-Z (Ra=0.2) (lapping) 3-Z (Ra=0.8)
SHOE PLATE 0.4-Z (Ra=0.1) (lapping) 3-Z (Ra=0.8)
CYLINDER 1.6-Z (Ra=0.4) (lapping) 12.5-Z (Ra=3.2)
VALVE PLATE 0.8-Z (Ra=0.2) (lapping) 6.3-Z (Ra=1.6)

-Lap each sliding surface to a standard roughness level or finer.

-If the sliding surface of the cylinder block, valve plate, retaining plate or spherical bushing is
roughened, replace parts in pairs.

33-167
［33. UPPER SLEWING STRUCTURE］

33.2.5.4.2 Swing reduction gear

(1) Parts inspection and replacement standards
1. If pitching is seen on the tooth surface of the sun gear, the planetary gear and the ring gear;
(Single pit is more than o1mm(0.039in) and the area occupancy of all pits is more than 5%.)
2. Oil seal
Replace the oil seal if the lip face of it is scored and worn.
Always replace when the reduction gear is disassembled for inspection or some reason.
3. Drive shaft roller bearing (Front side)
Inspect as below without drawing it out from the drive shaft:
A. Inspect the race surface and the rollers as far as you can see and make sure that there is
no pitching and flaking.
B. Inspect the following as well:
a. The gear oil does not contain large worn particles.
b. Large worn particles are not deposited between the roller and the retainer.
c. The bearing turns smoothly by hand.
Replace it if there is any fault on the above inspection.
Do not reuse the bearings drawn out of the shaft.
4. Drive shaft roller bearing (Rear side)
Replace the bearing if the race surface and the rollers show pitching and flaking.
5. No.2 planetary gear
Check for the circumferential gap between the No.2 planetary gear and the No.2 pin without
disassembling the No.2 carrier assy. Replace the planetary gear if the gap is more than 0.5.
6. Thrust plate and thrust washers
Replace the gear if the sliding surface in contact with the No.2 sun gear is extremely scored.
7. If pitching and flaking are seen on the rolling surfaces of the needle cage and the No.1 pin that
support the No.1 planetary gear; Replace such faulty parts.

33-168
 ［33. UPPER SLEWING STRUCTURE］

(2) Table of parts to be replaced together

33

Replace the inner race and the outer race of the roller bearing together.

33-169
［33. UPPER SLEWING STRUCTURE］

33.2.5.5 TROUBLESHOOTING
33.2.5.5.1 SWING MOTOR
(1) Hydraulic motor does not rotate.
Trouble Cause Remedy
Pressure does 1. 1.
not rise. Relief valve pressure in circuit is not Set to correct value.
adjusted correctly.
2. 2.
Malfunction of relief valve.
2-1. 2-1.
Sticking plunger. Correct the stuck areas or replace the plunger.
2-2. 2-2.
Orifice on plunger is clogged. Disassemble and clean.
3. 3.
Plunger seat is faulty. Check the seat surface and replace the
plunger if scored.
4. 4.
Swing shockless valve seat is faulty. Replace the swing shockless valve cartridge or
block.
Pressure rises 1. 1.
Overload. Eliminate overload.
2. 2.
Moving parts are seized. Inspect and repair piston, shoe and cylinder
valve plate.
3. 3.
Brake release pressure is not working on Check circuit and correct it.
the motor
4. 4.
Brake piston is stuck. Disassemble and check.
5. 5.
Friction plate is seized. Disassemble, check and repair.
Replace one that is seized.

(2) Rotating direction is reverse.

Trouble Cause Remedy
Rotating direction 1. Motor's assembling direction is reversed. 1. Assemble correctly.
is reverse. 2. Piping inlets and outlets are reversed. 2. Pipe correctly.

(3) Revolution does not rise to set value.

Trouble Cause Remedy
Revolution does 1. 1.
not rise to set Oil inflow is deficient. Check pump's delivery rate and circuits to
value motor.
2. 2.
Oil leaks are excessive due to high Lower oil temperature.
temperature.
3. 3.
Sliding surfaces are worn or damaged. Replace.

33-170
 ［33. UPPER SLEWING STRUCTURE］

(4) Brake torque is insufficient.

Trouble Cause Remedy
Brake torque 1. 1. 33
isinsufficient. Friction plate is worn. Disassemble and check. Replace if wear is
beyond standard value.
2. Brake piston is stuck. 2. Disassemble and check.
3. Brake release pressure is not released. 3. Check and correct circuit.
4. 4.
Spline of friction plate is damaged. Disassemble and check.
Replace broken part.

(5) The swing motor drifts much.

Check the drain rate of the hydraulic motor. If it is less than 200cc/min(12cu-in/min), you should
think that the motor is not faulty.

Trouble Cause Remedy

The swing 1. 1.
motor drifts Relief valve malfunctions. Same as (1).
much when it is Same as (1).
actuated by 2. 2.
external Plunger seat is faulty. Replace.
torques. (e.g. 3. 3.
Machine is on a Seat of the swing shockless valve is no Replace the swing shockless valve cartridge or
slope.) good. block.

(6) Oil leaks

1) Oil leak from oil seal
Trouble Cause Remedy
Oil leaks from oil 1. 1.
seal Lip of seal contains dirt and damaged. Replace oil seal.
2. 2.
Shaft is damaged or worn. Shift the lip and shaft positions or replace oil
seal.
3. 3.
Casing inner pressure has risen Repair drain piping if clogged up.
abnormally high, with the result that lip of
oil seal has turned up.
4. 4.
Shaft is rusted. Disassemble and correct.

2) Oil leak from matching surface

Trouble Cause Remedy
Oil leak from 1. O-ring is missing. 1. Set O-ring correctly and assemble it.
matching surface 2. O-ring has a scratch. 2. Replace.
3. Seal surface has a scratch. 3. Disassemble and correct.
4. Bolt is loose or damaged. 4. Tighten to specified torque or replace.

33-171
［33. UPPER SLEWING STRUCTURE］

33.2.5.5.2 Reduction unit

33-172
 ［33. UPPER SLEWING STRUCTURE］

33.2.6 SWIVEL JOINT

33.2.6.1 CONSTRUCTION VIEW 33

Construction of swivel joint

No. Part name Q'TY No. Part name Q'TY

1 Body 1 7 O-ring (G95 1A) 1
2 Stem 1 8 Socket bolt (M8X20) 2
3 Thrust plate 1 9 Socket bolt (M8X30) 3
4 Cover 1 12 Plug 1
5 Seal 5 13 O-ring (P80) 2
6 Seal assy 1

33-173
［33. UPPER SLEWING STRUCTURE］

33.2.6.2 DISASSEMBLY AND ASSEMBLY

33.2.6.2.1 Tools

33.2.6.2.2 Apparatus
(1) Hoist or crane
The lifting device should be capable of lifting the swivel joint assy.
(2) Work bench
The work bench should have an area of 1.2mX1.5m (4ftX5ft).
(3) Others
Also prepare cloth, wooden block and oil pan.

33.2.6.2.3 Cleaning outside

Clean the swivel joint to be free from dirt and dust, using steam and cleaning oil.

・ Keep all ports plugged up while cleaning.

33-174
 ［33. UPPER SLEWING STRUCTURE］

33.2.6.2.4 Disassembly
The part numbers used in this disassembly
procedure correspond to those of a
33
construction drawing in Fig."Construction of
swivel joint".
(1) Removing cover
1.
Mark cover (4) and body (1) with matching
marks for convenient reassembly.
2.
Place a V-block on a work bench, place a
swivel joint set on the side, fix it and loosen
socket bolt (9) by means of a pipe and wrench. Removing cover (4)
Alternately, the swivel joint may be fixed by
holding stem (2) in a vise.
Tools: Allen wrench:6 mm

3.
Remove cover (4) from body (1) and draw out
O-ring (7) from cover (4).

Removing O-ring (7)

(2) Removing thrust plate

Loosen socket bolt (8) fastening thrust plate (3),
in the same manner as the removing of the
above-mentioned cover.
Tools: Allen wrench:6 mm

Removing thrust plate (3)

When removing thrust plate (3) by fixing body (1), support stem (2) so it may not fall down.

33-175
［33. UPPER SLEWING STRUCTURE］

(3) Removing stem

Place body (1) on a V-block. Put a wooden
block against stem (2) via the body so about
half of the stem is covered by the wooden
block and knock it out using a mallet.
By hitting out the stem over about 1/2 from
the body, it can be easily pulled out by hand.
Stem weight: 10.5 kg (23 lbs)

Drawing out stem (2)

(4) Removing sealing parts

1.
Remove rings (13) of seal assemblies (6) and
(5) with spatula (f).

Removing O-ring (13)

Pay attention to the body (1) not to be damaged by the top edge of spatula (f).

2.
Pierce slipper ring of seal assemblies (6) and
(5) with pin (e) and remove them from the
seal groove. Right Fig. shows only one pin,
but use two pins to remove it securely.

Removing out seal assy (5)(6)

33-176
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33.2.6.2.5 Assembly
Prior to assembly, clean each parts (excluding the O-ring and seal), and arrange in the sequence of
assembly.
33
Apply grease on the groove of seal to be installed on seal assembly (6) and O-ring (13).
(1) Assembling seals to body
1.
Apply hydraulic oil to O-ring (13) thinly and insert it in O-ring groove.
Check the twist of O-ring

2.
Slipper ring is assembled, after first inserting
the backup ring, by slightly-distorting the shape
as shown in Right Fig. Also after inserting all of
the seals, be certain that these are installed in
the seal groove by use of the spatula.
3.
Assemble seal (5) by the same procedure
above mentioned. Inserting slipper ring (6)

Remove grease, hydraulic oil and vaseline from the groove of seal.
And insert seal (5).
Seals (5) have no back-up ring.

(2) Assembling stem

Lightly coat the outer circumference of stem
(2) and the inner surface of body (1) with
grease or vaseline and slowly insert stem (2)
into body (1).

Inserting stem (2)

-If stem (2) is pressed in too fast, the seal may be damaged. Do it slowly.
-The clearance between body (1) and stem (2) is about 0.1mm (0.004in). Push stem straight along
the shaft center.

33-177
［33. UPPER SLEWING STRUCTURE］

(3) Assembling thrust plate

1.
While holding stem (2) and body (1), match
the hole of thrust plate (3) and the stem (2)
hole.
2.
Next, after removing any oil from the thread of
socket bolt (8), coat it with Loctite #242 and
tighten to stem (2). Tightening socket bolt (8)
Tools: Allen wrench:6 mm,
Tightening torque: 30.4 N-m (22 lbf-ft)

(4) Assembling cover

After installing O-ring (7) to cover (4) and
aligning the matching marks of the cover (4)
and body (1), coat socket bolt (9) with Loctite
#242 and tighten it which will then complete
assembly.
Tools: Allen wrench:6 mm,
Tightening torque : 30.4 N-m (22 lbf-ft)

Tightening socket bolt (9)

33-178
 ［33. UPPER SLEWING STRUCTURE］

33.2.6.3 MAINTENANCE STANDARDS

33.2.6.3.1 Inspection procedure and remedy
Interval Check Item Checking Procedure Remedy 33
Seal for oil leakage Replace O-ring or dust seal , if any
2,000hr Check oil leakage outside
outside oil leakage can be found.
4,000hr In Replace all sealing parts such as
principle, All sealing parts slipper seal with back-up ring and
disassemble O-ring.
and check
Check abnormal wear, scoringor
regardless of Repair or replace referring to their
All sliding parts corrosion caused by
oil leakage or limit of service.
foreignmatters or seizure.
not.
When Check them for seizure, Repair or replace referring to their
disassembled All parts foreignmatters, abnormal wear, limit of service. O-rings and dust seal
for repair anddefect of seals. should be replaced.

33.2.6.3.2 Service limit of the parts

Parts Maintenance Standards Remedy
Sliding surface with Plating worn or peeled due to seizure or
Replace
sealing sections contamination.
1.
Worn abnormally or damaged more than 0.1
Sliding surface Replace
mm (0.004 in) in depth due to seizure or
between body and
contamination.
stem other than
sealing sections 2.
Smooth with oilstone.
Body, Stem Damaged less than 0.1 mm (0.004 in) in depth.

1.
Replace
Worn more than 0.5 mm (0.02 in) or abnormality.
2.
Sliding surface with Smooth
Worn less than 0.5 mm (0.02 in).
thrust plate
3.
Damage due to seizure or contamination Smooth
repairable within wear limit 0.5 mm (0.02 in).
1.
Replace
Worn more than 0.5 mm (0.02 in) or abnormality.
2.
Sliding surface with Smooth
Cover Worn less than 0.5 mm (0.02 in).
thrust plate
3.
Damage due to seizure or contamination Smooth
repairable within wear limit 0.5 mm (0.02 in).

33-179
［33. UPPER SLEWING STRUCTURE］

33-180
 ［33. UPPER SLEWING STRUCTURE］

33.2.6.3.3 Inspection after assembly

After completion of assembly, inspection for oil
leakage, pressure resistance, etc., using a
33
device as shown in Right Fig.

(1) High pressure port (A,B,C,D and F port)

Install a directional valve and pressure gauge to
the stem side port and body side port
respectively, and while watching the pressure
gauge (for high pressure) installed on the body
side and also by regulating high pressure relief
valve (7), gradually increase the pressure and
when the pressure has reached 1.5 times the
maximum working pressure, close stop valve (3)
and lock in the hydraulic oil in the swivel. Keep
stop valve (6) on the low pressure relief valve
side closed at this time.
Check that it is free from looseness,
deformation, breakage, etc. under three minutes
pressurizing.
And, the oil leakage must be checked for the
first 1 minute, and if there be a pressure drop Hydraulic circuit for inspection equipment
for any reason, the pressure drop should be in
10% of the trapped pressure.
This checking must be carried out for every
circuit.

(2) Low pressure port (E port)

Similar to the high pressure port, install a
directional valve and pressure gauge on each
port of the stem side and body side.
Open stop valve (6) on the side of low
pressure relief valve (5) and while watching
the pressure gauge (for low pressure)
connected to the body side and also by
regulating low pressure relief valve (5), gradually
increase the pressure and check for outside
leakage with a color check at a pressure of
0.49 MPa (71 psi).

33-181
［33. UPPER SLEWING STRUCTURE］

33.2.6.3.4 TROUBLESHOOTING
Trouble Cause Remedy
1. Defective O-ring & seal Replace all seals.
External leakage of hydraulic oil
2. 1) 1)
Internal leakage of hydraulic oil Defective slipper seal Replace all seals.
2) 2)
Sliding face worn excessively Replace assy.
3. 1) 1)
Swivel stem seized Stem and body seized Grind and hone.
Replace assy, if stem and body are too
loose and causing oil leakage.
2) 2)
Inappropriate swivel stopper Reinstall
bracket Secure 2 to 3 mm (0.08 to 0.12 in)
allowance for bolt stopper.
4. Socket bolt tightened Retighten.
Loose swivel stem and cover insufficiently.

33-182
 ［34. TRAVEL SYSTEM］

34
34. TRAVEL SYSTEM
TABLE OF CONTENTS

34.1 REMOVING AND INSTALLING ………………………………………………………………………………34-3

34.1.1 TRAVEL SYSTEM …………………………………………………………………………………………34-3
34.1.2 CRAWLER …………………………………………………………………………………………………34-3
34.1.3 UPPER ROLLER …………………………………………………………………………………………34-10
34.1.4 LOWER ROLLER …………………………………………………………………………………………34-18
34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) …………………………………………………………34-27
34.1.6 SPROCKET …………………………………………………………………………………………………34-40
34.1.7 TRAVEL MOTOR …………………………………………………………………………………………34-45
34.1.8 SWING BEARING …………………………………………………………………………………………34-48
34.2 REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT ………………………………………34-53
34.2.1 CONSTRUCTION OF TRAVEL MOTOR ………………………………………………………………34-53
34.2.2 TOOLS AND JIGS…………………………………………………………………………………………34-58
34.2.3 PREPARATION FOR DISASSEMBLY …………………………………………………………………34-62
34.2.4 ASSEMBLY …………………………………………………………………………………………………34-85
34.2.5 MAINTENANCE STANDARD ……………………………………………………………………………34-109

Book Code No. S5YP3401E02

34-1
［34. TRAVEL SYSTEM］

Issue Date of Issue Applicable Machines Remarks

S5YP3401E01
First Edition July, 2009 SK140LC-8 : YP09-05001~
(SE Asia)
S5YP3401E02
SK140LC-8 : YP09-05001~
(SE Asia)
Revision January, 2010 SK130-8 : LP09-20001~
(NZL)
SK130L-8 : LX07-11001~
(Thailand)

PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of first part. Removing and attaching, and sequel. Disassembling and
assembling.
(3) The removing and attaching can be performed in the procedure specified in Table of Contents, but
in view of actual repairing or time saving some process can be omitted.
(4) The removing and attaching procedure does not completely cover all possible situations because of
differences of field condition and defective section.
(5) Please be aware that the procedure to be followed must be determined according to the above
conditions.
When disassembly and assembly are required, select the necessary section, itemize the work
contents with good understanding, then starts working.

34-2
 ［34. TRAVEL SYSTEM］

34.1 REMOVING AND INSTALLING

34.1.1 TRAVEL SYSTEM

34

Designation and location of undercarriage

34.1.2 CRAWLER
34.1.2.1 REMOVING CRAWLER
(1) Position the machine to remove crawler.
(2) Pushing out master pin.
1.
Find the master pin and place it in its
removing/fixing position in below Fig..
2.
Loosen the grease nipple and slacken crawler.
Tools: Socket: 19 mm

Crawler removing position

-When loosening the grease nipple of the adjuster, do not loosen it more than one turn.
-Where grease does not come out well, move the machine back and forth. The over loosening of
grease nipple may cause it to jump out incurring danger of injury. So be careful not to over loosen
the grease nipple.

34-3
［34. TRAVEL SYSTEM］

3.
Pushing out master pin
Apply jig on master pin and strike it out with a
mallet.
(Refer to Fig. "Press fitting of master pin")

Removing/fixing position of master pin

When using a big hammer, wear protective goggles and a long-sleeved uniform so you do not injure
yourself by flying objects.

(3) Removing crawler

Put attachment on ground so that weight is
not loaded to the lower frame, and remove
track link assy rotating sprocket.

Removing crawler

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.

34-4
 ［34. TRAVEL SYSTEM］

34.1.2.2 INSTALLING
Installing is done in the reverse order of
removing.
(1)
Checking crawler installation direction.
Place the track links on the ground so they
converge, facing the front idler, as shown in the
figure on the right.
34
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 a crowbar into the master pin hole, lift
the lower frame 1 to 2cm above the ground
level by holding it by hand so the machine
body weight is not exerted on the shoe. Retract
the sprocket to help push the back winding of
the crawler. Winding crawler

(3) Preparation for press fitting master pin

1. Preparing for installation
Put square wood under the shoe plate.
2. Aligning master pin holes
Aligning master pin holes through fine
adjustment turning sprocket.

-When using a big hammer, exercise care so you are not injured by flying objects the same way as
when pushing out the master pin.
-Coat the master pin with molybdenum disulfide grease, before pressing it in.

(4) Press fitting of master pin

Apply press fitting jig on master pin, and strike
it with a mallet to press fit.

Press fitting of master pin

34-5
［34. TRAVEL SYSTEM］

(5) Adjusting crawler tension (See right Fig.)

After installing, adjust tension of crawler.
Tools: Socket: 19 mm

Adjusting crawler tension

34-6
 ［34. TRAVEL SYSTEM］

34.1.2.3 CONSTRUCTION

34

Track link assy and shoe plate

34-7
［34. TRAVEL SYSTEM］

34.1.2.4 MAINTENANCE STANDARDS

A. STD, LC

34-8
 ［34. TRAVEL SYSTEM］

B. L SPEC.

34

34.1.2.5 TOOLS AND JIGS

(1) Tightening tools (2) Jig

34-9
［34. TRAVEL SYSTEM］

34.1.3 UPPER ROLLER

34.1.3.1 UPPER ROLLER ASSY
L SPEC. YN64D00032F1
ASSY
LC YY64D00004F1
No.
STD YY64D00016F1
No. NAME Q'TY REMARKS
1 ROLLER ASSY 2 4 - YY64D01002F1
ROLLER ASSY - - 4 YN64D01068F1
2 CAPSCREW (SEMS SCREW) 2 4 - M20XP2.5X110
CAPSCREW (SEMS SCREW) - - 4 M20XP2.5X100
3 NUT 2 4 4
4 WASHER 4 8 4

34.1.3.2 REMOVING
(1) Preparation for removal
Remove crawler (Above mentioned).
(2) Removing upper roller (1)
1.
Remove nuts on support tightening
section, and also remove capscrew (2)
M20X110.
Tools: Socket: 30 mm

Removing upper roller

34-10
 ［34. TRAVEL SYSTEM］

34.1.3.3 INSTALLING
Installing is done in the reverse order of
removing.
(1) Inspection
Before reassembling, check it that it rotates
smooth manually and for leak.

(2) Installing upper roller (1)

1. 34
To install the upper roller, turn up socket bolts
(2) toward the center of machine.

2.
Insert it until collar comes in contact with
support.

3.
Fit it directing the countersinking mark of shaft
end upward.

4.
Installing upper roller
Apply Loctite #262 on capscrew M20X110, and
tighten it to the specified torque.
Tools: Socket: 30 mm
Tightening torque: 539 N-m (400 lbf-ft)

34.1.3.4 CONSTRUCTION

Construction of upper roller

Construction of upper roller

34-11
［34. TRAVEL SYSTEM］

34.1.3.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
1.
Draining out oil
Remove plug (11) and drain out oil.
Tools: Allen wrench: 6 mm

2.
Removing snap ring (10)
Mount the end face inside upper roller (1) on
stand jig (f) and separate snap ring (10), using
snap ring pliers.

3.
Removing cover (5)
Take off cover (5) upwards, utilizing the Construction of upper roller
screwed hole for the plug.

4.
Removing O-ring (8)
Separate O-ring (8) from cover (5).

5.
Removing plate (4)
Loosen 2 socket bolts (9) and draw out plate
(4) from roller (1).
Tools: Allen wrench: 10mm

6.
Removing shaft (2)
Put the extrusion jig (h) against the end face of
shaft (2) and push shaft (2) with collar (3) for
floating seal (7), using a press or hammer.

Extruding shaft

7.
Removing floating seal (7).
Take out floating seal (7) from roller (1).

Taking out floating seal

34-12
 ［34. TRAVEL SYSTEM］

8.
Removing floating seal (7).
Remove from collar (3), floating seal (7) that is
located on the side from which shaft (2) was
disassembled.

34
Removing floating seal and extruding bushing

Collar (3) is press fitted into shaft (2). Therefore do not disassemble it.

9.
Removing bushing (6)
Since the bushing is thin, machine it on a lathe
or scrape it off, take care so as not to
damage the bore of roller (1).
If the bushing is not worn much, mount upper
roller (1) on jig (f), insert jig (g) into the end
face of bushing (6) and push it out with a
press.

(2) Assembly
Assembly of the upper roller is done in the
reverse order of disassembly.
Pushing in bushing
1.
Place upper roller (1) on the top end face of jig
(f), with its floating seal setting side facing
down.

2.
Confirm that the outer surface of bushing (6)
is not scuffed and coat the outer surface of
the inserting side of the bushing, with
molybdenum disulfide grease.

3.
Put jig (i) into bushing (6) and press it in, using
the bore of the bushing and the bore of the
Fixing floating seal
roller as guides.

If you fail in this operation by pressing the bushing unevenly, the bushing is distorted and gets
unserviceable. In that case, do not re-use the bushing as it may develop malfunctioning after assembly.

34-13
［34. TRAVEL SYSTEM］

4. Installing floating seals (7)

Two floating seals (7) make a pair. Attach one
floating seal to retainer fixed in shaft (2), and
another to the inside of upper roller (1).

-Prior to placing floating seal (7) in, apply

engine oil lightly to seal surface.

5. Inserting shaft (2)

Coat shaft (2) with a thin film of oil and insert
it into upper roller (1).
Inserting shaft

6. Installing plate (4)

Mount upper roller (1) on the stand jig (f) and
attach plate (4) to the end face of the shaft
with bolt (9).
Tools: Allen wrench: 8 mm,
Tightening torque: 65.7 N-m (48 lbf-ft)

7. Installing O-ring (8)

Fit O-ring (8) to the groove of cover (5).
-Apply grease to O-ring.

8. Installing cover (5)

Attach cover (5) to upper roller (1). Use a
press in this operation as a press fit is used.

9. Installing snap ring (10)

Fix snap ring (10) into upper roller (1), using Installing cover
snap ring pliers.

10. Filling oil

Fill in 20cc (1.22cuoin) of engine oil API grade
CD #30 through the plug hole in cover (5).

11. Installing plug (11)

Wind seal tape around plug (11) and screw it
into the plug hole of cover (4).
Tools: Allen wrench: 6mm,
Tightening torque: 21.6~24.5 N-m (16~18.1 lbf-ft)

-After assembling the upper roller, confirm that

oil is not leaking from it and that it rotates
smoothly by hand.

Filling oil

34-14
 ［34. TRAVEL SYSTEM］

34.1.3.6 MAINTENANCE STANDARD

STD, LC

34

34-15
［34. TRAVEL SYSTEM］

L SPEC.

34-16
 ［34. TRAVEL SYSTEM］

34.1.3.7 TOOLS AND JIGS

(1) Tightening tools

(2) Jigs 34

34-17
［34. TRAVEL SYSTEM］

34.1.4 LOWER ROLLER

34.1.4.1 LOWER ROLLER ASSY

Lower roller assy and track guide

34.1.4.2 REMOVAL
(1) Preparation for removal
1.
Loosen the tension of the crawler, lift up the
lower frame by the front attachment and stop
the engine in that condition.
2.
Place a safety block (wood) at the front and
back of the lower frame. Preparation for removal

(2) Remove lower roller

Remove capscrews (2) and remove lower roller
(1).
Tools: Socket STD, LC: 24 mm
Tools: Socket L SPEC.: 27 mm,
Weight of lower roller:
STD, LC Approx. 25 kg (55 lbs)
L SPEC. Approx. 32 kg (70 lbs)

Installing lower roller

34.1.4.3 INSTALLATION
(1) Installation of lower roller
Coat mounting capscrews (2) with Loctite #262 and fasten all 4 capscrews temporarily. Then
tighten them to a specified torque.
Tools: Socket STD, LC: 24 mm
Tools: Socket L SPEC.: 27 mm,
Tightening torque STD, LC: 279 N-m (206 lbf-ft)
Tightening torque L SPEC.: 397 N-m (292 lbf-ft)
(2) Adjusting tension of crawler
Tighten grease nipple and fill it with grease.
Tools: Socket: 19 mm,
Tightening torque: 59 N-m (43 lbf-ft)

34-18
 ［34. TRAVEL SYSTEM］

34.1.4.4 CONSTRUCTION

Construction of lower roller 34

Construction of lower roller

34-19
［34. TRAVEL SYSTEM］

34.1.4.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
1. Drain oil
Remove plug (8) and drain out oil.
Tools: Allen wrench: 6mm

2. Removing pin (4)

Put both ends of lower roller assy on the
V-shaped blocks (K), apply push-out bar (L) on
upper end face of pin (4), and push pin (4)
out striking with mallet.

Pushing out collar fixing pin (4)

3. Removing collar (7), O-ring (6)

Put lower roller on jig (M) for repair stand so
that the shaft (2) is perpendicularly located,
apply push-out jig (P) on shaft end on upper
side, and push shaft (2) until the O-ring (6)
separate from collar (7) with press or mallet,
and take out collar (7) and O-ring (6).

4. Removing shaft (2)

In addition, push out and remove shaft (2)
together with the lower collar (7) and O-ring (6).

Removing shaft (2), collar (7), O-ring (6)

The shaft (2) extrusion operation may cause the remaining lube oil to flow out. Prepare an oil
container beforehand.

5. Removing collar (7), O-ring (6)

Remove O-ring (6) from shaft (2) that was
drawn out in the previous paragraph.

6. Removing floating seal (5)

Remove floating seal (5) from collar (7).

Removing floating seal (5)

34-20
 ［34. TRAVEL SYSTEM］

7. Removing floating seal (5)

Remove floating seal (5) from roller (1).

Removing floating seal (5) 34

8. Removing bushing (3)
Since thickness of bushing (3) is thin
[thickness is 2.0mm (0.079in)], remove it
through lathe or strip it with care not damage
inner hole of roller. When the wear of bushing
is not large, place upper roller (1) on jig (M) for
repair 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.

Extruding bushing (3)

Hammer the inside surface of roller lightly so as not to damage the surface. Put the extrusion jig (N)
uniformly over the circumference of bushing (3) and extrude it perpendicularly little by little.

(2) Installing
1. Attach O-ring (6) to one side
Install O-ring (6) to groove on shaft.

-Grease O-ring.
Attach O-ring (6) to one side
-Replace O-ring with new one without fail at
reassembling.

2. Press fitting bushing (3)

Align inner hole of roller (1) and bushing (3)
and press fit it vertically in capacity of press fit
load, 5ton (11000 lbs), in the condition that
bushing push-in jig (Q) is inserted into bushing
(3).

-Apply molybdenum disulfide grease on

Press fitting bushing (3)
press-fit section of bushing, and press fit it in
ordinary temperature.
-Bushing which fails to press-fit because of the
one-side pressing should not be fitted.

34-21
［34. TRAVEL SYSTEM］

3. Press fitting collar (7)

Fit O-ring (6) to the one side of shaft (2)
mating pin hole of collar (7) on which floating
seal (5) is fit with pin hole of shaft (2) in
advance. Use the press of capacity 17 ton
(37500 lbs) or more.

-Care should be taken not to damage O-ring (6)

while press-fitting collar (7) to shaft (2).
Press fitting collar (7)

4. Inserting pin (4)

Press-fit pin (4) to pin hole on aligning pin
holes of shaft (2) and collar (7).

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.

6. Inserting roller (1)

Insert roller (1) from the side where collar (7),
Inserting roller (1)
O-ring (6) is not press-fitted to the shaft (2).

34-22
 ［34. TRAVEL SYSTEM］

7. Installing O-ring (6)

Install O-ring (6) to groove on shaft.

-Grease O-ring.
-Replace O-ring with new one without fail at
reassembling.

8. Press fitting collar (7)

Press-fit collar (7) to shaft (2). 34
-Press-fit collar (7) on aligning pin (4) hole.

9. Inserting pin (4)

Press-fit pin (4) in to the pin hole mating pin
hole of collar (7) with pin hole on the end
side of shaft (2).

Installing O-ring (6), collar (7)

10. Filling oil

Remove plug (8) and fill in 150cc (9.2cu-in)
(STD, LC) 160cc (9.8cu-in) (L SPEC.) of engine
oil API grade CD #30.

11. Check it for leakage

Before tightening plug (8), check it for leakage
in the condition of air pressure 0.2MPa (29psi).
Installing filling oil plug (8)

12. Installing plug (8)

Apply oil resistant sealant on plug (8), and
tighten it in the plug hole on the collar (7) end
face.
Tools: Allen wrench: 6 mm,
Tightening torque:
21.6 to 24.5 N-m (16 to 18.1 lbf-ft)

After assembling the lower roller, confirm that oil is not leaking and that the roller rotates smoothly by
hand.

34-23
［34. TRAVEL SYSTEM］

34.1.4.6 MAINTENANCE STANDARD

STD, LC

Lower roller (Track roller)

34-24
 ［34. TRAVEL SYSTEM］

L SPEC.

34

Lower roller (Track roller)

34-25
［34. TRAVEL SYSTEM］

34.1.4.7 TOOLS AND JIGS

(1) Tightening tools

(2) Jig

34-26
 ［34. TRAVEL SYSTEM］

34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY)

34.1.5.1 FRONT IDLER ASSY

34

Front idler assy

34.1.5.2 REMOVING
(1) Preparation for removal
Remove crawler. (Above mentioned)

(2) Removing idler assy

Sling idler assy, and push it forward with bar.
Weight of front idler assy:
132 kg (291 lbs) (STD, LC)
204 kg (450 lbs) (L SPEC.)

(3) Installing
Installing is done in the reverse order of
removing.

Removing and installation the front idler

Keep away from the front side of front idler.

34-27
［34. TRAVEL SYSTEM］

(4)
Where idling assy (1-1) has to be separated
Loosen capscrew (1-4), and separate idler
assy (1-1) from idler adjuster assy (1-2).
Tools: Socket STD, LC: 19 mm
Tools: Socket L SPEC.: 24 mm
Weight of idler assy :
74 kg (163 lbs) (STD, LC)
106 kg (234 lbs) (L SPEC.)
Weight of idler adjuster assy:
58 kg (128 lbs) (STD, LC)
97 kg (214 lbs) (L SPEC.)
Separating idler assy (1-1) from idler adjuster

-The separated idler assy (1) should be placed

on square timbers.

34.1.5.3 IDLER ASSY

34.1.5.3.1 CONSTRUCTION

Idler assy

Idler assy

34-28
 ［34. TRAVEL SYSTEM］

34.1.5.3.2 REMOVING AND INSTALLING

(1) Removing
1. Drain oil
Remove plug (8) on the side of collar (4) to
drain.
Tools: Allen wrench: 5 mm

2. Removing pin (5)

Apply pin push bar (jig R) to the top of pin, Removing pin (5) 34
and push out striking bar (jig R) lightly by
hammer.

3. Removing collar (4)

Put idler (1) on stand (U), apply push-out jig
(S) on shaft (2), push out shaft (2) with collar
(4), then remove collar (4).

Removing collar (4)

4. Removing collar (4) from shaft (2)

If removal of collar (4) on the opposite side is
required, turn over front idler and proceed with
the procedure described in Par. 3.

Removing collar (4)

5. Removing bushing (3)

With idler (1) mounted on the stand, tap
bushing (3) lightly by hammer, while placing the
bushing drawing rod (T) against the end face of
bushing (3) evenly all round, till it comes out.

6. Removing floating seals (6)

Take out floating seals (6) from idler (1), collar
(4). If you intend to re-use floating seals (6),
confirm that there is no scoring and rusting on Removing bushing (3)
the contact surface and store the floating seals
in pairs by placing card board between the
sealing faces.

34-29
［34. TRAVEL SYSTEM］

7. Removing O-ring (7)

Separate O-ring (7) from shaft (2).

(2) Assembly
1. Pressing in bushing (3)
Align inner hole of idler (1) and bushing (3) and
press fit it vertically with press so that jig (V)
for bushing press-fitting is inserted into bushing
(3).

2. Installing O-ring (7)

Pressing in bushing (3)
Fit O-ring (7) to O-ring groove on shaft (2).

-Apply grease to O-ring

3. Installing collar (4) (See right Fig.)

Press fit the O-ring (7) installed side of shaft
(2) into collar (4), and drive pin (5).

4. Installing floating seal (6)

Fit the half of floating seal (6) on each side of
collar (4) and idler (1).

Installing collar (4), shaft (2)

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).

Inserting idler (1) and installing floating seal

(6)

7. Installing collar (4)

Fit the half of floating seal (6) on the other
collar (4), press fit it in shaft (2), and drive pin
(5) in with hummer.

8. Filling oiloInspection
Fill in 200cc (12.2cu-in) of engine oil API
grade CD #30 through the plug hole of collar
(4), wind seal tape and tighten plug (8). Installing collar (4) and filling oil
Tools: Allen wrench: 5 mm

-After installing the idler assy to the idler adjuster assy, make certain that no oil leaks from floating
seal and plug (8) and that idler (1) rotates smoothly.

34-30
 ［34. TRAVEL SYSTEM］

34.1.5.3.3 MAINTENANCE STANDARD

STD, LC

34

Front idler

34-31
［34. TRAVEL SYSTEM］

L SPEC.

Front idler

34-32
 ［34. TRAVEL SYSTEM］

34.1.5.3.4 TOOLS AND JIGS

(1) Tightening tools

(2) Jigs 34

34-33
［34. TRAVEL SYSTEM］

34.1.5.4 IDLER ADJUSTER ASSY

34.1.5.4.1 CONSTRUCTION

Idler adjuster assy

Idler adjuster assy

34.1.5.4.2 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
1. Spring set special jig
Before disassembling and assembling the idler
adjuster assy, prepare spring setting jig (V).
Capacity of hydraulic jack : more than 20 tons
(44000 lbs)
Tools: Spanner: 46 mm

2. Preparation for working

Place a hydraulic jack between the jig base
and the stand.
Loosen the holding-down nuts of the jig and Spring set special jig (V)
draw out the retainer plate upward.
Tools: Spanner: 46 mm

Large power is needed to set the spring. Prepare a special jig before disassembly and assembly.

34-34
 ［34. TRAVEL SYSTEM］

3. Draw out grease cylinder (See Fig. "Idler

adjuster assy".)
Draw out piston (6) from grease cylinder (1) of
the idler adjuster assy.

4. Removing U-packing (8), O-ring (7)

(See Fig. "Idler adjuster assy".)
Remove U-packing (8) and O-ring (7) from
grease cylinder (1). 34
5. Slinging work idler adjuster
Set the idler adjuster assy on the stand of the
jig, with its bracket side facing up. Slinging work idler adjuster

6. Fixing idler adjuster assy

Fit retainer plate to bracket (2), tighten
holding-down nuts alternately, and secure idler
adjuster assy.
Tools: Spanner: 46 mm

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).
Tools: Bar 7.5 dia.X120 dia.
Tools: Socket: 85 mm

Compression of spring (5)

8. Removing bracket (2)

Allow the hydraulic jack to retract slowly till the
spring is extended to its free length. Remove
the retainer plate and take off bracket (2), cover
(10).
The free length of the spring:
427 mm (16.8 in) (STD, LC)
531.1 mm (20.9 in) (L SPEC.)

Removing retainer plate, bracket (2)

34-35
［34. TRAVEL SYSTEM］

9. Removing spring (5), grease cylinder (1)

Hook lifting eye nut (W) to screw M45XP3 on
grease cylinder (1) top end and hoist it. Then,
remove the set of grease cylinder (1) and
spring (5) using crane from the jig.
Remove spring (5), grease cylinder (1), in that
order.

Removing spring (5), grease cylinder (1)

(2) Assembly
Assembly is done in the reverse order of
disassembly.

1. Installing spring (5), grease cylinder (1)

Insert grease cylinder (1), collar (7) into spring
(5) and attach lifting eye nut (W) to screw
M45XP3 (STD, LC), M52XP3 (L SPEC.) at the
tip of the grease cylinder. Lift the grease Attach spring (5) and grease cylinder (1) to
cylinder by crane and erect it in the center of the jig
the jig stand upright.

2. Fixing idler adjuster assy

Install bracket (2), cover (10) on top of spring
(5). Center the rod of grease cylinder (1) and
the holes in bracket (2). Attach the retainer
plate and four holding-down nuts. Fasten the
nuts evenly all round and fix the idler adjuster
assy to the jig body.
Tools: Spanner: 46 mm

3. Compressing spring (5) and tightening 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: 354.8 mm (14.0 in)

4. Installing spring pin (4)

Tighten nut (3) till the holes for locking spring
pins (4) are aligned. Then fit spring pin (4).
Tools: Socket STD, LC: 70 mm
Tools: Socket L SPEC.: 80 mm

Compression of spring (5), and attaching nut

(3) and spring pin (4)

34-36
 ［34. TRAVEL SYSTEM］

5. Removing idler adjuster assy

Remove idler adjuster assy from jig.

34

Removing idler adjuster assy

6. Installing U-packing (8), O-ring (7)

Fit U-packing (8) and O-ring (7) to grease
cylinder (1).
-Grease oil seal (8) and O-ring (7).

7. Filling grease cylinder(1) with grease.

Fill up grease in cylinder (1), remove the
grease nipple from piston (6) to discharge the
inside air, and press in the piston by hand. Grease cylinder (1)
-Direct grease nipple hole downward to make
air discharge easier.

8. Installing grease nipple

Tighten grease nipple to piston (6).
Tools: Socket: 19 mm,
Tightening torque:
49.2 ~ 68.4 N-m (36.32 ~ 50.48 lbf-ft)

34-37
［34. TRAVEL SYSTEM］

34.1.5.4.3 MAINTENANCE STANDARD

STD, LC
No. ITEM STANDARD VALUE
A Installed length of spring 354.8 mm (14.0 in)
B Free length of spring Approx. 427 mm (16.8 in)
C Stroke 39.4 mm (1.55 in)
D Set length 686 mm (27 in)
E Outside view of piston Nor scoring and rusting
F Tightening torque of grease nipple 58.8±9.6 N-m (43.4±7.08 lbf-ft)

34-38
 ［34. TRAVEL SYSTEM］

L SPEC.
No. ITEM STANDARD VALUE
A Installed length of spring 429 mm (16.9 in)
B Free length of spring Approx. 531.1 mm (20.9 in)
C Stroke 51.8 mm (2.04 in)
D Set length 716 mm (28.2 in)
E Outside view of piston Nor scoring and rusting
F Tightening torque of grease nipple 58.8±9.8 N-m (43.4±7.23 lbf-ft) 34

34-39
［34. TRAVEL SYSTEM］

34.1.6 SPROCKET
34.1.6.1 REMOVING
(1) Preparation for removal
Remove crawler referring to "34.1.2 CRAWLER",
lift up crawler frame with attachment, and put
it on square timbers to float and stabilize.

Preparation for removal

(2) Removing sprocket

Loosen 18 capscrews (3) M16X45 (STD, LC),
21 capscrews (3) M16X50 (L SPEC.) for the
attaching of the sprocket by means of a
socket and remove the sprocket (2).

Weight of sprocket STD, LC: 39 kg (86 lbs)

Weight of sprocket L SPEC.: 65 kg (143 lbs)
Tools: Socket: 24 mm

Removing sprocket

34.1.6.2 INSTALLING
(1) Check before installing
Check the mating portion of the travel
reduction unit and the sprocket, eliminate
burrs and contamination thoroughly and
install the sprocket.
(2) Installing sprocket temporarily
Coat the sprocket attaching capscrews
with Loctite #262 and fasten the sprocket
temporarily.
(3) nstalling sprocket completely
Remove the wooden blocks under the
truck frame, bring the machine down on the Installing sprocket completely
ground and tighten the sprocket.
Tools: Socket: 24 mm
Tightening torque: 279 N-m (206 lbf-ft)

34-40
 ［34. TRAVEL SYSTEM］

34.1.6.3 MAINTENANCE STANDARD

STD, LC (YN51D01006P1)
86.69mm NUMBER OF
PITCH 21
(3.4130in) TEETH
SPECIFICATION
Dia. 50.67 mm 581.669
ROLLER DIA. PITCH DIA.
(1.9950in) (22.9in)

34

Sprocket

34-41
［34. TRAVEL SYSTEM］

L SPEC. (2404N427)
96.07mm NUMBER OF
PITCH 21
(3.78in) TEETH
SPECIFICATION
Dia. 58.72 mm 644.602
ROLLER DIA. PITCH DIA.
(2.31in) (25.38in)

Sprocket

34.1.6.4 TOOLS AND JIGS

(1) Tools

34-42
 ［34. TRAVEL SYSTEM］

(2) Sprocket tooth profile gauge: W

STD, LC (YN51D01006P1)

34

Tooth profile gauge (Full scale)

34-43
［34. TRAVEL SYSTEM］

L SPEC. (2404N427)

Tooth profile gauge (Full scale)

34-44
 ［34. TRAVEL SYSTEM］

34.1.7 TRAVEL MOTOR

34.1.7.1 TRAVEL MOTOR

34

Installing travel motor

34.1.7.2 REMOVING
(1) Preparation for removal
Remove crawler, lift up crawler frame using
attachment, and put it on square timbers to
float and stabilize.

(2) Removing cover (1)

Remove sems bolt (4) M12X25 and also
remove covers (1).
Tools: Socket: 19 mm

(3) Preparation of oil pan Removing and installing cover (1)

(4) Removing hydraulic pipe

Release pressure from travel circuit, and bleed
air in hydraulic oil tank, then remove all pipes
connecting to travel motor. Then plug up all
pipes and joint section to protect them from
entry of dust.
Tools: Spanner: 19 mm, 27 mm, 36 mm
Refer to "Hydraulic pipe plug" 5.1
(See Chapter 11. TOOLS)
"Plug for flare hose" 5.2 (3) (See Chapter 11.
Removing and installing hydraulic pipe
TOOLS)

34-45
［34. TRAVEL SYSTEM］

(5) Removing sprocket

Removing capscrews (3A) M16.
Tools: Socket: 24 mm

Removing and installing sprocket

(6) Loosening travel motor attaching bolts (3)

Apply match marks on travel motor and
crawler frame, and remove capscrews (3) M16.
Tools: Socket: 24 mm

Removing and installing travel motor

attaching bolts

(7) Slinging travel motor assy

Sling travel motor with nylon sling applied on
the side close to sprocket installing section
and remove the motor.

Weight of motor: About. 145 kg (320 lbs)

Slinging travel motor

34-46
 ［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 crawler frame is free from burr and
stain.
2. Tightening torque
Tighten capscrew and hydraulic pipes to 34
the torque specified in "Tightening Torque".
3. Fill inside from motor drain port to casing
with hydraulic oil before piping for drain.
When starting operation, operate motor in
low idling and at low speed for several
minutes, and check it for possible oil
leakage and noise.

34-47
［34. TRAVEL SYSTEM］

34.1.8 SWING BEARING

34.1.8.1 SWING BEARING ASSY

Swing bearing assy

34.1.8.2 REMOVING
(1) Matchmarks
Remove upper structure, apply matchmarks on
inner race of swing bearing and lower frame.

(2) Remove 36 capscrews (2) M16X45 for

installation inner race.
Tools: Socket: 24 mm
Matchmarks

(3) Removing grease

Remove grease in grease bath.

(4) Removing swing bearing

Attach eyebolt on swing bearing and sling it.

Weight of swing bearing: 150 kg (331 lbs)

Removing and installing swing bearing

34-48
 ［34. TRAVEL SYSTEM］

34.1.8.3 INSTALLING
(1) Cleaning
Clean it completely so that installing surfaces of
swing bearing and lower frame are free from
dust and dirt.

(2) Installing
Install swing bearing on lower frame meeting
the matchmarks and positioning the S mark on 34
inner race as shown in the right Fig..

(3) Temporary fastening of inner race

Coat the threads of the capscrews (2) with
Loctite #262 and tighten all the capscrews (2)
temporarily.
Tools: Socket: 30 mm Location of S mark on swing bearing

(4) Regular tightening of inner race

Tighten the capscrews (2) at 180 degrees
intervals alternately to a specified torque.
Tools: Socket: 24 mm,
Tightening torque: 279 N-m (206 lbf-ft)

(5) Filling grease

Fill grease bath with 8.2kg (18 lbs) of grease Removing and installing capscrew (2)
"NIHON GREASE CO.LTD EP-2K" or equivalent.

34.1.8.4 CONSTRUCTION

Sectional view of swing bearing

34-49
［34. TRAVEL SYSTEM］

34.1.8.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
1.
Remove seal (5) fitted in the groove in the
outer circumference under inner race (2) and
seal (5) fitted in the groove in the inner
circumference on top of outer race (1) and
place them level on a square wooden block or
something.
2. Disassembling swing bearing
Remove taper pin (1-3), using a hammer and
an extrusion rod.
3.
Remove plug (1-2), utilizing an pull bolt inserted
in the screwed hole (M10) in the center of the
plug and using a puller.

4.
While rotating outer race (1) little by little, take
out ball (3) and retainer (4) through plug hole,
in that order.

Removing balls (3) and retainers (4)

(2) Installing
1.
Thoroughly degrease the groove for seal (5)
located on the inner surface of outer race (1)
and the groove for seal (5) located on the outer
surface of inner race (2). Coat the grooves with
adhesive Cyano Bond PX-3000 and fit seal
(5). Then direct the seal (5) side downward and
place it on wood blocks horizontally.
Fitting balls (3)

2.
Lower outer race (1) to the position where
upper surface of inner race (2) and lower
portion of seal groove is mated, put adjusting
washer under outer race (1) so that outer
raceway surface of ball (3) aligns with inner
raceway, and support it.
3.
Insert ball (3) and retainer (4), on which
grease is applied, through plug (1-2) hole on Fitting retainer (4)
outer race (1), alternately.

34-50
 ［34. TRAVEL SYSTEM］

To insert ball (3) and retainer (4), use a push rod, etc., to protect persons from injury from inserting
fingers into plug hole.

4.
Fit plug (1-2) to outer race (1) while checking it for direction and position of taper pin hole.
5. 34
Coat seal (5) with adhesive Cyano Bond PX-3000, and apply Cyano Bond PO-X to joint of seal and
glue seal together.
6.
After completion of assembly, caulk the edge of taper pin (1-3) by punching.
7.
Check that grease nipple (9) is properly fitted, and fill it with grease. Then, check bearing for smooth
rotation and flaws on seal lip portion.
-Shell Albania EP#2 ; 140cc (8.54cu-in)

34.1.8.5 MAINTENANCE STANDARD

Maintenance standard concerning wear of swing bearing is described in the section 13.6 MEASURING
SWING PERFORMANCES of "Maintenance Standard and Test Procedure" in this manual.

34-51
［34. TRAVEL SYSTEM］

This page is blank for editing convenience.

34-52
 ［34. TRAVEL SYSTEM］

34.2 REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT

34.2.1 CONSTRUCTION OF TRAVEL MOTOR

34.2.1.1 CROSS-SECTIONAL VIEW OF TRAVEL MOTOR ASSEMBLY

34

Cross-sectional view of travel motor unit assembly (1/2)

34-53
［34. TRAVEL SYSTEM］

Cross-sectional view of travel motor unit assembly (2/2)

34-54
 ［34. TRAVEL SYSTEM］

34.2.1.2 EXPLODED VIEW OF REDUCTION UNIT

34

34-55
［34. TRAVEL SYSTEM］

34.2.1.3 EXPLODED VIEW OF HYDRAULIC MOTOR

34-56
 ［34. TRAVEL SYSTEM］

Q'T Q'T Q'T

No. Parts No. Parts No. Parts
Y Y Y
1 HUB 1 105 PISTON 1 213 SHIM 1
2 SPINDLE 1 106 SHOE 1
CARRIER 1 ASSY 1 104 CYLINDER BLOCK 1 REAR FLANGE ASSY 1
3 CARRIER 1 1 107 RETAINER PLATE 1 REAR FLANGE KIT 1
5 PLANETARY GEAR 1 3 108 THRUST BALL 1 SPOOL ASSY 1
6 CARRIER PIN 1 3 109 TIMING PLATE 1 323 SPOOL 1 34
11 THRUST WASHER 1 6 110 WASHER 2 326 PLUG 2
16 PARALLEL PIN 1 3 112 PISTON 1 327 VALVE 2
27 NEEDLE ROLLER BEARING 3 113 SPRING 10 330 SPRING 2
CARRIER 2 ASSY 1 114 SPRING 1 331 O-RING 2
7 CARRIER 2 1 115 FRICTION PLATE 3 301 REAR FLANGE 1
9 PLANETARY GEAR 2 3 116 MAITING PLATE 4 324 PLUG 2
10 CARRIER PIN 2 3 132 OIL SEAL 1 325 WASHER 2
12 THRUST WASHER 2 6 135 O-RING 1 328 SPRING 2
17 PARALLEL PIN2 3 139 O-RING 1 329 ORIFICE 2
28 NEEDLE ROLLER BEARING 3 145 SNAP RING 1 336 O-RING 2
4 SUN GEAR 1 1 149 BALL BEARING 1 352 PLUG 3
8 SUN GEAR 2 1 150 BALL BEARING 1 353 BALL 2
13 THRUST PLATE 1 151 NEEDLE ROLLER 3 354 HEXAGON SOCKET PLUG 5
14 COVER 1 PISTON ASSY 1 357 PLUG 1
15 COUPLING 1 161 PISTON 1 358 O-RING 3
22 LOCK WASHER 2 162 SHOE 1 359 O-RING 1
23 SHIM 1 167 PIVOT 2 363 SPOOL 1
24 ANGULAR BALL BEARING 2 171 PARALLEL PIN 2 366 SPRING 1
FLOATING SEAL KIT 1 185 SPRING 1 376 ORIFICE 1
29 FLOATING SEAL 2 377 FILTER 1
30 PLUG 3 RELIEF ASSY 2 378 BALL 1
31 O-RING 3 201 VALVE SEAT 1 379 PLUG 1
32 O-RING 1 202 VALVE 1 380 PLUG 2
33 O-RING 2 203 SLEEVE 1 381 PISTON 1
34 PARALLEL PIN 2 204 COLLAR 1 383 O-RING 2
35 HEXAGON SOCKET BOLT 12 205 PLUG 1 384 ORIFICE 2
36 SNAP RING FOR HOLE 1 206 SPRING 1 396 HEXAGON SOCKET PLUG 2
207 O-RING 1 398 HEXAGON SOCKET PLUG 8
102 SHAFT 1 208 BACK-UP RING 2 399 NAME PLATE 1
103 SWASH PLATE 1 209 O-RING 1 341 PARALLEL PIN 1
CYLINDER & PISTON KIT 1 210 BACK-UP RING 2 343 HEXAGON SOCKET BOLT 10
PISTON KIT 1 211 O-RING 1
PISTON ASSY 9 212 O-RING 1

34-57
［34. TRAVEL SYSTEM］

34.2.2 TOOLS AND JIGS

(1) Standard tools
NAME SIZE Q'ty
2.5 (For M5), 3 (For M6),
4 (For NPTF1/16), 5 (For PF1/8),
HEXAGON WRENCH 1 each
6 (For PF1/4), 8 (For M10, PF3/8),
10 (For M12, PF1/2)
SOCKET WRENCH
(Ratchet handle) Barrel type 1
(JIS B 4641)
Dial type : Approx. 50N
TORQUE WRENCH Dial type : Approx. 100N
1 each
(JIS B 4650) Dial type : Approx. 300N
Dial type : Approx. 560N
TORQUE WRENCH ADAPTER 1 each
HEXAGON SOCKET Opposite side : 24 mm, 41 mm 1 each
EXTENSION BAR
150 mm 1
(JIS B 4637)
HAND HAMMER Various kinds 1 each
PLASTIC HAMMER Approx. L=400 mm 1 each
FLAT-BLADE SCREWDRIVER Approx. 50 mm
1
(JIS B 4609) Approx. 150 mm
For shafts
SNAP RING PLIERS 1 each
For holes
CUTTING PLIER
200 mm 1
(JIS B 4623)
Lifting load 2940N (662 lb) or more 1
Eyeboly (For M16) (2)
LIFTING TOOL Eyeboly (For M12) (3)
Eyeboly (For PF1/2) (2)
Wire with hook (1)
RECEPTACLES Volume : W450XD300XH120mm 2
LEATHER GLOVES 1 pair

(2) Bolts
No. NAME TYPE / DIMENSIONS Q'TY
HEXAGON SOCKET
1 CAPSCREW Approx. M12 (P1.5)X40mm 2
(JIS B 1176)

34-58
 ［34. TRAVEL SYSTEM］

(3) TIGHTENING TORQUE

APPLICATION BOLT NUT OPPOSING TIGHTENING
Q'T
ITEM FLATS TORQUE
NAME SIZE Y
(No.) (mm) N-m (lbf-ft)
30,357 PLUG PF1/2 10 4 98.1 (72.4)
HEXAGON SOCKET
35 M10 (P1.5) 8 12 66.7 (49.2)
CAPSCREW
203 SLEEVE PF1/2 24 2 98.1 (72.4)
205 PLUG PF1/4 6 2 29.4 (21.7)
34
324 PLUG M36 (P1.5) 41 2 441 (325)
HEXAGON SOCKET
343 M12 (P1.75) 10 10 102 (75.2)
CAPSCREW
352 PLUG PF1/8 5 3 12.3 (9.07)
HEXAGON SOCKET
354 NPTF1/16 4 5 9.81 (7.24)
CAPSCREW
380 PLUG PF3/8 8 2 58.8 (43.4)
HEXAGON SOCKET
396 PT1/4 6 2 29.4 (21.7)
CAPSCREW
HEXAGON SOCKET
398 PT1/8 5 6 12.3 (9.07)
CAPSCREW

(4) Tools
NAME SIZE APPLICATION ITEM (No.)
GENERAL WORK BENCH Product disassembly / assembly
WASHING TANK For rough and finish washing Product / parts washing
24 : Press capacity
9800N (2205 lb) or more
104 : Press capacity
PRESS MACHINE 24, 104, 149
1960N (441 lb) or more
149 : Press capacity
1960N (441 lb) or more
Heating capacity : over 100 degrees C
(212 degrees F)
HEATING TANK 149
Volume : 500 X 500 X 500
(19.7" X 19.7" X 19.7") or more
COMPRESSED AIR Pressure : 0.29~0.49MPa (42~71 psi) For drying washed parts

34-59
［34. TRAVEL SYSTEM］

(5) Jigs

34-60
 ［34. TRAVEL SYSTEM］

34

34-61
［34. TRAVEL SYSTEM］

34.2.3 PREPARATION FOR DISASSEMBLY

34.2.3.1 GENERAL PRECAUTIONS FOR DISASSEMBLY

-Internal parts are covered with hydraulic fluid and gear oil during disassembly and are slippery.
If a part slips out from your hand and falls, it could result in bodily injury or could damage the part.
Be very careful for handling.
-It combustibles such as white kerosene are used for washing parts, be careful for handling.
These combustibles are easily ignited, and could result in fire or injury.
Be careful for handling.

(1) Before disassembling, perform inspections and confirm clearly the indication of no abnormality,
which may be occurring, and work according to the disassembly procedure.
(2) All parts are manufactured precisely.
Be careful for handling.
Avoid rough contact or drop of parts.
(3) Do not bang or remove parts forcefully.
Such act could cause burs or damages on the parts, which leads to failure of assembling or
inferior performance.
(4) If you leave parts disassembled parts or with partially disassembling, rust could develop on the
parts due to moisture or dirt.
If you have to interrupt the work before completion, take measures to protect against rust or dust.
(5) Place a counter mark on mating faces of parts when disassembling.
(6) Tidy removed parts when disassembling so as not to damage or lose the parts while working.
(7) As a rule, once any type of seal are disassembled, they should be replaced with new ones even
if they show no signs of damage.
You should ready new parts before disassembling.
New parts shall be provided prior to disassembling.
(8) The photographs and drawings contained in the manual are of representative models.
However, disassembly procedure is not affected even if the disassembled product are different
from this manual.

34.2.3.2 CLASSIFICATION OF DISASSEMBLY

This travel motor assembly consists of hydraulic motor, reduction unit, brake valve, and parking brake
as one assembly.
The disassembly works consist of the following items basically.
Select the required parts to disassemble between hydraulic motor, reduction unit, brake valve, and
parking brake. Decide the order of parts to be disassembled, and perform a service work according to
the respective maintenance procedure.

Don't perform unnecessary disassembly.

34-62
 ［34. TRAVEL SYSTEM］

34.2.3.3 DISASSEMBLY PROCEDURE

(1) Cleaning travel motor.
(2) Place travel motor.
(3) Drain lubricating oil.
(4) Remove cover.
(5) Remove thrust plate.
(6) Remove 1st stage planetary gears.
(7) Remove coupling.
(8) Remove 2nd stage planetary gears. 34
(9) Remove lock washer.
(10) Remove hub.
(11) Remove floating seal.
(12) Remove angular ball bearing.
(13) Remove rear flange.
(14) Remove parts installing rear flange.
(15) Disassemble brake valve section on rear fiange.
(16) Disassemble the 2-speed selector valve.
(17) Disassembling the piston.
(18) Disassembling the check ball.
(19) Disassembling the parking brake.
(20) Disassemble hydraulic motor.
(21) Take out spring from cylinder block.
(22) Pull out shaft (102).
(23) Remove the ball bearing (149) inner race.
(24) Remove the ball bearing (149).
(25) Remove spindle.
(26) Rough cleaning of every part.
(27) Finish clean.

34.2.3.4 WEIGHT OF COMPONENT

NAME Weight [kg (lbs)]
TRAVEL MOTOR ASSY Approx. 145 (320)
HUB Approx. 46 (101)
SPINDLE Approx. 27 (60)
CARRIER 1 ASSY Approx. 12 (26)
CARRIER 2 ASSY Approx. 24 (53)
REAR FLANGE ASSY Approx. 13 (29)

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34.2.3.5 REMOVING
(1) Cleaning travel motor
1. Tighten the eye bolts into the tapped
holes of the spindle (2).
Eye bolt ; M16

Attaching eye bolt

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.
Travel motor assy weight : Approx. 144kg (320 lbs)

3. Clean the travel motor with a car brush.

Cleaning travel motor

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.

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(2) Installing travel motor

1. Placing travel motor on working bench.

34

Placing travel motor on working bench

Align threaded holes of hub (1) and working bench, and place travel motor in fixing hole of working
bench slowly.

2. Fix travel motor with two socket bolts on

working bench.
Tools: Allen wrench: 14 mm

Fixing travel motor on working bench

Tighten 2 socket bolts securely. Failure to tighten securely, when the travel motor is reversed, it falls
and causes injury.

(3) Draining lubricating oil

If you want to disassemble only the rear flange, go to (6) 1).

1. Turn over the travel motor.

Loosen plug (30) slowly to avoid spurt of lubricating oil.

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［34. TRAVEL SYSTEM］

2. Loosen and remove two socket plugs (30)

to release inner pressure.
Tools: Allen wrench: 10 mm

Removing plug (30)

When draining out the lubricating oil, place a container under the work bench.

3. Draw out the lube oil by reversely turning the travel motor slowly.
4. Remove O-rings (31) from removed plugs.

Do not reuse removed O-ring (31).

(4) Removing cover

1. Turn over the travel motor.
2. Remove ten socket bolts (35).
Tools: Allen wrench: 10 mm
3. Because sealant is applied between cover
(14) and hub (1), hit upward the corner of
cover with a hammer using soft metal to
protect the cover.

Removing cover (14)

The cover (14) may jump and remove suddenly by hitting. Be careful not to drop the cover to avoid
injury.

4. Place a hook and a wire sling on the PT eye bolts, lift it up and remove cover (14).

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(5) Removing thrust plate

1. Removing thrust plate (13)

34

Removing thrust plate (13)

(6) Removing 1st stage reduction gear

1. Remove sun gear 1 (4) by hand.

Removing sun gear 1 (4)

Be careful not to drop sun gear 1(4) it could be slippery by lubricant.

2. Fasten 3 eyebolts to the tapped holes of

carrier 1 (3). And attach wire slings and
hook in the eye bolts. Lift the carrier (1)
assembly with hoist.

Removing carrier 1 (3) Assy

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［34. TRAVEL SYSTEM］

When carrier (1) assembly is lifted with hoist, the edge of planetary gear 1 (5) may damage the
internal teeth of hub (1).
Align center line of hub (1) with that of carrier 1 assembly, lift carrier 1 slowly and straightly.

(7) Removing coupling

1. Remove coupling (15) from shaft (102)

Removing coupling (15)

(8) 2nd stage reduction gear removal

1. Fasten three eyebolts to the tapped holes
of carrier 2 (7).
Place a wire sling and hook in the
eyebolts, lift carrier 2 assembly by crane.

Removing carrier 2 assy (7)

When carrier 2 assy is lifted by crane, the edge of planetary gear 2 (9) could damage the internal
teeth of hub (1).
Lift up slowly, and carefully.

2. Remove sun gear 2 (8) by hand.

Be careful not to drop sun gear 2 (8).

If could be slippery by lubricant.

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(9) Removing lock washer

1. Fix hub (1) and workbench with using three
holes (14 dia.) of hub (1).

34

Removing hub (1) and lock washer

2. Put a flathead screwdriver into the

clearance between two lock washers (22),
and widen the clearance.
Place the tip of the screwdriver to the one
end of the lock washers (22), tap it by
hammer, and remove two lock washers (22).

Removing lock washer (22)

(10) Removing hub

1. Remove the hexagon socket bolts, which
fixed hub (1) and workbench.
2. Fasten two eyebolts on the tapped holes of
spindle (101).
Place a wire sling and hook in the
eyebolts. Lift hub (1) by crane.

Removing hub (1)

Lift up hub (1) slowly and carefully.

If hub (1) is inclined against spindle (2), for the interference, wire sling or eyebolts could be
destroyed and hit the worker. If hub (1) does not come out smoothly, do not pull forcefully. Instead,
use other tools such as press machine.

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(11) Removing floating seal

1. Grasp inner side of floating seal (29) and
lift it up by hand.

Removing floating seal (29)

Use work gloves to prevent from cutting hands at the edge of floating seal (29). If lifting up by hand
is difficult by mudpack or such reason, use flat head screwdriver as a lever.

(12) Removing angular ball bearing

1. Put a steel rod on the inner race of
angular bearing (24), tap 3 or 4 points
evenly to take care not to damage the
bearing.

Removing angular ball bearing (24)

-Do not remove the angular ball bearing (24), except for replacing the bearing.
When the outer race of angular ball bearing (24) separates from fitness hub (1), angular ball bearing
(24) falls from hub (1 ).
-Please place a container under the workbench and cover with the rubber mat on it so that angular
ball bearing (24) does not get damage.

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(13) Removing rear flange

1. Turn over GM motor. (Rear flange (301) is on top.)

This work is carrying out to remove easily the pugs (324) at the following work.
Do not loosen the plugs (324) if the inside of rear flange assembly is not disassembled.
34
2. Temporarily loosen plugs (324) (2 plugs).

Removing plugs (324)

3. Temporarily loosen plugs (380) (2 plugs).

Removing plugs (380), (352), (357)

This work is carrying out to remove easily the pugs (380) at the following work.
Do not loosen the plugs (380) if the inside of rear flange assembly is not disassembled.

4. Temporarily loosen plugs (352) (2 plugs).

This work is carrying out to remove easily the pugs (352) at the following work.
Do not loosen the plugs (352) if the inside of rear flange assembly is not disassembled.

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5. Temporarily loosen plugs (357).

This work is carrying out to remove easily the pug (357) at the following work.
Do not loosen the plug (357) if the inside of rear flange assembly is not disassembled.

6. Temporarily loosen relief valve assy (203

others) (2pcs).
7. Loosen the relief valve assemblies (203
others) (2 pcs).

Temporarily loosen relief valve Assy (203)

8. Remove the relief valve assemblies (203

others) (2 pcs).

Removing the relief valve Assy (203)

Do not reuse O-ring (207), (209), (212) and backup ring (208), (210) which have been removed.

9. Loosen and remove hexagon socket bolts

(343) (10 pcs) from rear flange (301).
Tools: Allen wrench: 8 mm

Removing socket bolts (343)

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 ［34. TRAVEL SYSTEM］

10. Remove rear flange (301) from spindle (2).

34
Removing rear flange (301)

Hold rear flange (301) with both hands, hold up rightly and gently, and remove it.
Timing plate (109) could fall off and get damaged during this work.

11. Removing ten springs (113).

12. Removing parallel pins (341) from spindle (2).
13. Removing O-ring (27), (30) from spindle (2).

Do not reuse O-ring (27), (30) which have been removed.

14. Pull out parallel pins (34) (2 pcs) from

spindle (2).

Removing parallel pins (34)

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15. Remove O-ring (32), (33) (2 pcs) from

spindle (2).

Removing O-ring (32), (33)

Do not reuse O-ring (32), (33) which have been removed.

(14) Removing the rear flange fittings

1. Place rear flange (301) on a work bench, with the mating surface for spindle (2) facing up.
2. Remove timing plate (109) from rear flange (301).

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. Then the rear flange comes off. If a sharp tool like screwdriver is put into the mating
surface, the mating surface is scored, causing an oil leakage ; do not use sharp tools.

3. Remove parallel pins (341) from rear flange (301).

4. Remove ball bearing (150) from rear flange

(301).

Removing ball bearing (150)

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(15) Removing the brake valve from the rear flange

1. Remove two plugs (324) from rear flange
(301).
Tools: Socket: 36 mm
2. Remove O-ring (336) from plug (324).

34

Removing plug (324)

Do not reuse removed O-ring (336).

3. Remove two spring retainer (325) and two

springs (328) from rear flange (301).
4. Remove spool (323) from rear flange (301).

Removing spool (323)

To remove spool (323), place your hand on one part of the plug port of rear flange (301) and tilt it
down. Then spool (323) falls down. Hold the tip and remove it.

(16) Disassemble the 2-speed selector valve

1. Remove plug (357) from rear flange (301).
Tools: Allen wrench: 10 mm

Removing plug (357)

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［34. TRAVEL SYSTEM］

2. Remove spool (363) and spring (366) from

rear flange (301).
3. Remove O-ring (359) from plug (357).

Removing spool (363) and spring (366)

Do not reuse removed O-ring (359).

(17) Removing piston

1. Remove plugs (380) (2 pcs) from rear
flange (301).
2. Remove O-ring (383) from plug (380).

Removing plug (380)

Do not reuse removed O-ring (383)

3. Remove piston (381) from rear flange (301).

Removing piston (381)

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(18) Disassembling ball check part

1. Remove plugs (352) (2 pcs) from rear
flange (301).
2. Remove O-ring (358) from plug (352).

34

Removing plug (352)

Do not reuse O-ring (358) which have been removed.

3. Remove steel balls (353) from rear flange

(301).

Removing ball (353)

When it is hard to remove steel balls (353), remove them using the magnet etc.

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(19) Disassembling parking brake

The sudden blowing of compressed air may cause parts to fly out incurring the danger of injury. Cover
piston (112) for protection.

1. Blow jet air into the passage hole for the

parking brake of the spindle (2) and
remove the piston (112) from the spindle
(2).

Blowing jet air

2. Remove O-ring (135),(139) from piston

(112).

Removing piston (112)

Do not reuse removed O-ring (135), (139).

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(20) Disassembling the hydraulic motor section

When placing the travel motor on its side, oil spills ; place a container under the travel motor.

1. Lay down the travel motor through 90

degrees.
2. Drain out the oil of the travel motor. 34
3. Hold cylinder block (104) by hand, turn it
both ways a few times alternately and
separate shoe (106) from swash plate (103).

Removing cylinder block (104)

If cylinder block (104) is drawn out in that condition, shoe (106) stays with swash plate (103). Then
parts (pistons, shoes, etc.) attached to cylinder block (104) come off from cylinder block (104) and fall
into spindle (2). Care should be used about it.

4. Hold the cylinder block (104) and remove the shaft (102).

Also, friction plate (115) and separator plate (116) are also removed with cylinder block (104).

5. Remove friction plate (115) and separator

plate (116), (117) attached on the removed
cylinder block (104).
6. Remove piston assy [piston (105) and
shoe (106)] and retainer plate (107) from
cylinder block (104).

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［34. TRAVEL SYSTEM］

-When removing the cylinder block, hold the retainer plate (107) by both hands and remove it with
the piston assy.
-Cylinder block (104) and piston assy [piston (105) and shoe (106)] are the minimum parts unit as
cylinder & piston kits. When they have to be replaced, replace the cylinder & piston kit as a set.
(Refer to the parts manual.)

7. Remove the piston assy (105),(106) from

retainer plate (107). [Nine pistons]
8. Remove thrust ball (108) from cylinder
block (104).
9. Draw out washer (111) from cylinder block
(104).
10. Remove three needle rollers (151) from
cylinder block (104).

Removing roller (151)

(21) Remove spring from inside of cylinder block

1. Place cylinder block (104) on the press bench.

-Do not remove the spring except when spring is replaced.

-When removing the spring, align the Jig (I) with the washer in order to prevent the cylinder block
from being damaged by contact.
-Put a plastic sheet over the sliding surface of the cylinder block so as not to damage it.

2. Place the retainer metal jig (I) on washer

(110) and remove snap ring (145) from
the snap ring groove of cylinder block (104)
by means of snap ring pliers, while
holding down the jig (I).

Removing snap ring (145)

If the press is loosened too suddenly, the spring jumps out and injure yourself. Always loosen the
press slowly.

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 ［34. TRAVEL SYSTEM］

3. Loosen the press slowly till the spring

action is released.
4. Remove the snap ring (145), washer
(110), spring (114), and washer (110) from
inside the cylinder block (104).

34
Removing spring (114)

(22) Removing out shaft (102)

1. Removing swash plate (103) from spindle
(2).

Removing shaft (102)

When removing it, check that pivot (167) is not adhered on swash plate.

2. Draw out shaft (102) from spindle (2). On

that occasion, the inner race of ball bearing
(149) comes off with the shaft.
3. Draw out two pivots (167), two parallel pins
(171) and the outer race of ball bearing
(149) from spindle (2).
4. Draw out the 2-speed switch piston assy
[piston (161) and shoe (162)] and spring
(185) from spindle (2).

Removing 2-speed switching piston assy

(23) Removing ball bearing (149)

Ball bearing (149) is removed only when replacing.

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［34. TRAVEL SYSTEM］

1. Place holder (II) on the press bench and

put shaft (102) into the holder (II).
2. Remove ball bearing (149) from shaft
(102) by pressing on the shaft end with
press.

Removing ball bearing (149)

Do not reuse the removed ball bearing (149).

(24) Removing spindle fittings

1. Remove shim (23) from spindle (2).

Removing shim (23)

2. Remove floating seal (29) from spindle (2).

Removing floating seal (29)

Do not reuse floating seal (29) which have been removed.

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3. Remove oil seal (132) from spindle (2).

34
Removing oil seal (132)

Do not reuse oil seal (132) which have been removed.

(25) Rough washing of parts

1. Distinguish the four parts ; hub (1),
spindle (2), cover (8), and rear flange (101)
from other parts (hereafter called built-in
parts).
2. Put the hub, spindle, cover and rear
flange in a cleaning bath and clean them.

Rough washing of parts

-Soil and sand are adhered to the outer surface of parts in some cases ; clean them and remove
soil and sand from the parts.
-Wash oil is combustible. Be careful not to cause fire and get burns.
-Before cleaning stained parts, immerse them in wash oil until dust and stain become soft and are
floated to protect them from damaging when cleaning.

3. Put the built-in parts in a rough cleaning container containing wash oil and clean the parts.

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(26) Finish cleaning

1. Put parts in a finish cleaning container
containing wash oil and clean them well,
turning them slowly.
2. Blow parts with dry air to remove cleaning
oil.

Finish cleaning

Finish cleaning

-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.
-Inner surface of rear flange (101), hydraulic motor components, 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 four pins (17) or lose them while handling.

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34.2.4 ASSEMBLY
34.2.4.1 GENERAL PRECAUTIONS FOR ASSEMBLY
(1) Assembly it by reversing the procedure of disassembly.
(2) Assemble it in clean air condition.
(3) Don't use cloth gloves during assembly.
(4) 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. 34
(5) Clean every part sufficiently, and blow them with compressed air don't use waste cloth.
(6) Prior to assembling, apply clean hydraulic oil to moving and sliding portions of hydraulic motor
valve.
(7) Tighten bolt and plug to the specified torque using torque wrench.
(8) 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.
(9) 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.
(10) After assembly, plug every port to protect the entry of dust, etc.

34.2.4.2 PREPARATORY ARRANGEMENT FOR ASSEMBLY

(1) 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 pre-load adjustment of bearing is required.
HUB (1)
SPINDLE (2)
Bearing (24)

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.

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［34. TRAVEL SYSTEM］

34.2.4.3 ASSEMBLING PROCEDURE

(1) Assembling hub
1. Place hub (1) on the press bench.
2. Place angular ball bearing (24) on hub (1),
and press in by using the main plate and a
press machine.
3. Turn over hub (1).
4. Insert angular ball bearing (24) into hub
(1) in the same way 2).

Inserting ball bearing (24)

Make sure that the installing direction of angular ball bearing (24) is correct.

5. Apply grease on the O-ring of floating seal

(29), and fit the O-ring into the floating seal
groove on hub (1).

Installing floating seal (29)

-When applying grease to the O-ring, remove the O-ring from floating seal (29), and then, apply grease
thinly to entire surface.
-Use floating seal installation tool (I) and (II).
Make sure to keep the parallel tolerance 1mm (0.039") to end surface of the groove.
If not, it could cause seizure on floating seals (29) or oil leak.

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(2) Assembling spindle

1. Apply grease on the O-ring of floating seal
(29), and fit the O-ring into the floating seal
groove on spindle (2).

34

Installing floating seal (29)

When applying grease to the O-ring, remove the O-ring from floating seal (29), and then, apply
grease thinly to entire surface.
Use floating seal installation tool (II) and (III).
Make sure to keep the parallel tolerance 1mm (0.039") to end surface of the groove.
If not, it could cause seizure on floating seals (29) or oil leak.

2. Install eyebolts to spindle (2) so they are

symmetrically positioned.
3. Fix spindle (2) on workbench with two
hexagon socket bolts, which should locate
symmetrically.

Installing spindle (2)

Tighten the hexagon bolts securely.

Failure to do so could result in injury if GM motor is inverted and falls.

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(3) Clearance adjustment procedure for angular ball bearing

If any of hub (1), angular ball bearing (24) or spindle (2) is replaced, clearance adjustment should be
conducted.
If not, angular ball bearings (24) could break in short period.

1. Insert lock washers (22) for measuring the

dimensions, and measure the distance C.

Measurement dimension C

2. Measure the distance D.

Measurement dimension D

Rotate hub assembly for stabilizing the distance D.

3. Select one of the classified shim (23) which makes the distance "C - D" from -0.17 to
-0.13mm (-0.0051"~0.0067").
Shim (23) thickness shall be refer to the following table.

ITEM T(mm) ITEM T(mm)

A 0.9(0.035") G 1.5(0.059")
B 1.0(0.040") H 1.6(0.063")
C 1.1(0.043") I 1.7(0.067")
D 1.2(0.047") J 1.8(0.071")
E 1.3(0.051") K 1.9(0.075")
F 1.4(0.055") L 2.0(0.079")

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 ［34. TRAVEL SYSTEM］

4. Attach shim (23) to spindle (2).

34

Installing shim (23)

(4) Assembling hub

1. Insert hub (1) into angular ball bearing
(24) assembled in spindle (2) with keeping
both center axes parallely.

Assembling hub

2. Fix hub (1) to the workbench with three

long hexagon socket bolts.
3. Put steel rod on the inner race of angular
ball bearing (24) located on reduction
gear, and tap softly by hammer to
stabilize angular ball bearing (24).

Fix hub (1) to the workbench

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4. Place lock washers (22) to the groove of

spindle (2).

Fitting lock washer (22)

5. Fit lock washers (22) into the groove of

spindle (2) by using installation tool

Fitting lock washer (22)

Insert lock washers (22) fully into the groove so as not to interfere with carrier 2 (7).

6. Remove the long hexagon socket bolts, which fix hub (1) and the workbench.
7. Rotate hub (1) two or three times.

Contacting state between both sliding surface of floating seal (29) will be improved by rotating spindle
(2), and prevent initial oil leak.

8. Turn over spindle (2).

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(5) Assembling spindle fittings

1. Drive oil seal (132) into spindle (2) by
using the holder (III) to prevent it from
being inclined.

34

Installing oil seal (132)

Apply lithium grease around the lip portion of oil seal (132) when mounting.
Be careful in the inclusion direction of oil seal (132).

2. Install two parallel pins (171) into the pin holes of spindle (2).
3. Apply lithium grease to hemispherical surface of two pivots (167), and fit it into parallel pins (171)
of spindle (2).

4. Apply lithium grease to spring (185), and

install spring (185) into the piston kit (piston
(161) and shoe (162)).
5. Apply hydraulic fluid to the sliding surface
of the piston kit, install it into the piston
hole of spindle (2).
6. Install two parallel pins (34) into the pin
holes of spindle (2).

Installing piston (161) and shoe (162)

(6) Assembling shaft

Wear thick leather groves in handling the heated ball bearing (149).

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［34. TRAVEL SYSTEM］

1. Put ball bearing (149) in a heating tank to

heat it at 90 to 110 degrees C [194 to 230
degrees F] for ten minutes and then insert
it onto shaft (102).

Installing ball bearing (149)

2. Turn the workbench 90 degrees.

3. Insert shaft (102) to spindle (2).

Installing shaft (102)

Take care not to scratch or cut the lip portion of oil seal (132) in place with the splined foremost end
of shaft (102).

(7) 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.
3. Assemble the outer race (with roller) of
bearing (149) into spindle (2).

Pressing oil seal (132)

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 ［34. TRAVEL SYSTEM］

4. Insert swash plate (103) into spindle (2).

34

Installing swash plate (103)

Apply lithium grease on swash plate (103) where mating surface of spindle (2).
Make sure that the locating pivots (167) of spindle (2) enter pivots' holes of swash plate (103).

(8) Assembling cylinder block interior

-The sharp edge of snap ring (145) is turned and put into the entrance side of cylinder block (104).
-Washer (110) which touches snap ring (145) turns and puts its sharp edge side into snap ring side.

1. Insert washer (110), spring (114), washer

(110) and snap ring (145) in that order
into cylinder block (104).
2. Place cylinder block (104) on the press
bench.

Inserting spring (114)

When mounting snap ring (145), if the tip of the pliers slips out of the hole of snap ring (145), snap
ring (145) could jump out.

Press force of spring (114) is 1128N (254 lb) or more.

Protect by covering cylinder block (104) with a vinyl sheet so the contact surface with timing plate
(109) of cylinder block (104) does not become damaged.

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3. Place holder (I) on washer (110), and while

clamping with the press, fit snap ring
(145) in the snap ring groove of cylinder
block (104) with the snap ring pliers.

Installing snap ring (145)

(9) Assembling hydraulic motor

1. Put three rollers (151) into the holes of
cylinder block (104) and place washers
(111) and thrust balls (108) on them.
2. Fit nine piston assy to retainer plate (107).

Installing rollers (151)

After fixing it, immerse the whole unit in hydraulic oil.

3. Fit retainer plate (107) and 9 piston assy to

cylinder block (104).

Assembling piston assy and retainer plate

(107)

Match retainer plate (107) with the spherical part of thrust ball (108) and install them.

34-94
 ［34. TRAVEL SYSTEM］

4. Assemble cylinder block (104) fitted with

swash plate (103), thrust ball (108),
washer (111), retainer plate (107), piston
assy (105), (106) and roller (151), to shaft
(102) that is placed level. (to make a
hydraulic motor assy)
5. Installing cylinder block (104) into shaft
(102).
34

Installing cylinder block (104)

Install cylinder bock (104) into the spline of shaft (102) by aligning the spine hole with the spline of
shaft (102).

6. After installing cylinder block (104), turn it

by hand and make sure that it fits properly.
If not, inspect it.

Check for play of cylinder block (104)

Cylinder block (104) is not flattered after installing it.

If cylinder block (104) is flattered, thrust ball (108) is separated and GM motor does not rotate
normally.

34-95
［34. TRAVEL SYSTEM］

(10) Installing parking brake

Immerse friction plate (115) in hydraulic oil before fitting it.

1. Assemble separator plate (117) into the

inner groove of spindle (2) that houses
cylinder block (104).
2. Assemble three friction plates (115) and
separator plates (116), by turns, into the
outer groove of cylinder block (104) and
into the inner groove of spindle (2). On that
occasion, fix the friction plates first and
then the separator plates.
3. Fit O-rings (135),(139) to the O-ring
Fitting friction plate and separator plate
grooves of piston (112). In that case, coat
O-rings (135), (139) with a thin film of
grease.
4. Fitting piston (112) into spindle (2).

Fitting piston (112)

-If it is hard to fit the piston (112) into the spindle (2) due to the resistance of O-rings (135),(139),
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).

34-96
 ［34. TRAVEL SYSTEM］

(11) Attaching two-speed spool

1. Insert spring (366) and spool (363) into rear
flange (301).
2. Fit O-ring (359) to plug (357).

34

Inserting spring (366) and spool (363)

Apply grease to O-ring (359).

3. Attach plug (357) to rear flange (301).

4. Temporarily tighten plug (357) into rear
flange (301) by hexagon wrench.

Installing plug (357)

(12) Attaching ball check part

1. Fit two O-rings (358) to two plugs (352).

Apply grease to O-ring (358).

34-97
［34. TRAVEL SYSTEM］

2. Insert steel ball (353) into rear flange (301).

Installing steel ball (353)

3. Temporarily tighten plugs (352) into rear

flange (301) by hexagon wrench.

Temporally fastening plug (352)

(13) Attaching piston

1. Fit two O-rings (383) to two plugs (380).

Apply grease to O-ring (383).

2. Insert piston (381) into rear flange (301).

Installing piston (381)

34-98
 ［34. TRAVEL SYSTEM］

3. Temporarily tighten plugs (380) into rear

flange (301) by hexagon wrench.

34

Temporally fastening plug (380)

(14) Assembling brake valve parts in rear flange

1. Insert spool (323) into rear flange (301).

Installing spool (323)

Apply hydraulic fluid to spool (323) and insert spool (323) into rear flange (301).
To insert spool (323), align the hole of rear flange (301) with spool shaft center so as to prevent the
inner surface of rear flange (301) and the outer surface of spool (323) from being damaged due to
interference.
Otherwise internal leaks will occur after reassembly, resulting in performance deterioration of GM motor.

2. Fit two O-rings (336) to two plugs (324).

Installing O-ring (336)

34-99
［34. TRAVEL SYSTEM］

Apply grease to O-ring (336).

3. Attach washer (325) (2 pcs) and spring (328) (2 pcs) to plug (324) (2 pcs).

4. Attach plug (324) (2 pcs) to rear flange

(301).

Installing plug (324)

When attach plug (324) to rear flange (301), insert carefully so as not to deform spring (328).

5. Temporarily tighten plug (324) (2 pcs) into rear flange (301).

(15) Assembling rear flange mounted parts

1. Apply hydraulic fluid to ball bearing (150),
and fit ball bearing (150) into rear flange
(301).
2. Insert two parallel pins (341) in the pin
holes of rear flange (301).
3. Apply grease to the mating face of timing
plate (109) in contact with rear flange (301)
of timing plate (109).

Installing ball bearing (150)

34-100
 ［34. TRAVEL SYSTEM］

4. Fit timing plate (109) on rear flange (301)

using parallel pins (341) as the guide.

34

Installing timing plate (109)

Fitting of timing plate (109) is carried out until timing plate (109) adheres to rear flange (301).
Adhesion prevents from dropping timing plate (109) from rear flange (301) when mounting rear flange
(301) on spindle (2).

5. Mount ten springs (113) on the hole of rear

flange (301).

Installing spring (113)

Apply grease to springs (113) in order to prevent from dropping springs (113) from rear flange (301).

(16) Assembling rear flange

1. Fit O-rings (32), (33) (2pcs) in the O-ring
grooves of spindle (2).

Installing O-ring (32), (33)

34-101
［34. TRAVEL SYSTEM］

Fit O-ring (32) without applying grease.

If reassembled with grease applied, the grease may bleed from mating face of rear flange (301) and
spindle (2) when GM motor is running.

2. Put 1.0 litters of hydraulic fluid in spindle (2).

3. Install rear flange (301) on spindle (2) so

that two parallel pins (34) on spindle (2)
enter the pin holes in rear flange (301).
4. Temporarily tighten hexagon socket bolts
(343) (10 pcs) into spindle (2) by hexagon
wrench.

Installing rear flange (301)

(17) Tightening bolts

1. Tighten hexagon socket bolt (343) (10
pcs) with the specified torque.
Tightening torque : 86.3~117.7 N-m (64~86
lbf-ft)

Tightening hexagon socket bolt (343)

2. Tighten plugs (324) with the specified

torque.
Tightening torque : 401~480.2 N-m
(296~354 lbf-ft)

Tightening plug (324)

34-102
 ［34. TRAVEL SYSTEM］

3. Tighten plugs (380) with the specified

torque.
Tightening torque : 48.99~68.61 N-m
(36~50 lbf-ft)

34

Tightening plug (380)

4. Tighten plugs (352) with the specified

torque.
Tightening torque : 9.85~14.75 N-m (7~11
lbf-ft)

Tightening plug (352)

5. Tighten plugs (357) with the specified

torque.
Tightening torque : 78.5~117.7N-m (58~86
lbf-ft)

Tightening plug (357)

34-103
［34. TRAVEL SYSTEM］

(18) Attaching relief valve assembly

1. Attach relief valve assembly (203 others)
(2 pcs) to rear flange (301).

Installing relief valve assy

2. Tighten relief valve assembly (203 others)

(2 pcs) with the specified torque.
Tightening torque : 78.5~117.7N-m (58~86
lbf-ft)

Tightening relief valve assy

(19) Assembling 2nd stage planetary gears

1. The workbench is rotated and the
reduction-gears side is turned upward.
2. Attach sun gear 2 (8) to carrier 2 (7).
3. Fasten three eyebolts to the tapped holes
of carrier 2 (7).
Place a wire sling and hook in the
eyebolts, place carrier 2 assembly slowly
in hub (1).

Installing carrier 2 assy

When inserting carrier (2) assembly, take care so as not to damage internal teeth of hub (1) by the
egge of planetary gears 2 (9).

34-104
 ［34. TRAVEL SYSTEM］

Arrange these planetary gears 2 (9) should be located as shown below.

34

(20) Attaching coupling

1. Attach coupling (15) to shaft (102).

Installing coupling (15)

(21) Assembling 1st stage planetary gears

1. Place carrier (1) assembly slowly in hub (1).

Installing carrier 1 assy

When inserting carrier (1) assembly, take care so as not to damage internal teeth of hub (1) by the
edge of planetary gears 1 (5).

34-105
［34. TRAVEL SYSTEM］

2. Insert sun gear 1 (4) with aligning spline

portion to coupling (15) first, then gear
portion second.

Installing sun gear 1 (4)

If the gear portion of sun gear 1 (4) does not engage with planetary gears 1 (5), lift carrier (1)
assembly until the spline of sun gear 2 (8) is disengaged.
Insert sun gear 1 (4) first, then engage the spline of sun gear 2 (8).

3. Place thrust plate (13) on carrier 1 (3).

Installing thrust plate (13)

(22) Assembling cover

1. Apply "Loctite #515" to the mating surface
of hub (1) for cover (14).

Apply Loctite #515

"Loctite #515" should be applied around the mating surface without discontinuation.

34-106
 ［34. TRAVEL SYSTEM］

2. Fasten two eyebolts to the tapped holes

(PF1/2) of cover (14).
Place a wire sling and hook in the
eyebolts, place cover (14) on hub (1) with
aligning the position of bolt holes.

34

Installing cover (14)

3. Apply "Loctite #242" to hexagon socket

bolt (35) (12 pcs).
Tighten hexagon socket bolts (35) (12 pcs)
with the specified torque.
Tightening torque : 62.78~70.62 N-m
(46~52 lbf-ft)

Installing hexagon socket bolt (35)

(23) Filling lubrication oil

1. Fill gear oil (lubrication oil) into the filling
port.

Filling lubrication oil

Supply 2.1 litters of gear oil.

2. Attach plugs (30) to ports of cover (14), tighten them with the specified torque.
Tightening torque : 78.5~117.7N-m (58~86 lbf-ft)

34-107
［34. TRAVEL SYSTEM］

(24) Removing reassembled GM motor from the workbench

1. Turn the workbench upside down.
(The motor side of GM motor is turned up.)
2. Remove the bolts securing GM motor to
the workbench.
3. Fasten two eyebolts (Ml6) to spindle (2).
4. Place a wire sling and hook in the
eyebolts, remove GM motor from the
workbench with the crane.

Removing reassemble travel motor

34-108
 ［34. TRAVEL SYSTEM］

34.2.5 MAINTENANCE STANDARD

34.2.5.1 PART MAINTENANCE STANDARD
(1) Replace all seals
Seal parts (O-ring, oil seal floating seal) should be replaced once disassembled even though no
damage is observed.
(2) Maintenance criteria for wearing parts
1.Replace any parts if they have severe damage on appearance.
2.Replace any parts if they have the following abnormalities. 34

REFERENCE ALLOWANCE
No. PARTS TROUBLE
VALUE VALUE
1 HUB Severe damage on appearance.
Pitting on ring gear teeth. - -
Abnormal wear such as scoring.
2 SPINDLE Severe damage on appearance.
- -
Abnormal wear such as scoring.
3,7 CARRIER ASSY Abnormal wear such as scoring.
- -
others
4 SUN GEAR 1 Pitting on ring gear teeth.
8 SUN GEAR 2 Flaking on the outer race for needle roller
- -
5 PLANETARY GEAR 1 bearing.
9 PLANETARY GEAR 2
24 ANGULAR BALL Dent, flaking or uneven wear on contact
- -
BEARING surface.
301 REAR FLANGE Many scratch on sliding surfaces between spool
- -
(323) and piston (381).
102 SHAFT Abnormal wear on contact surface between oil
seal (132). - -
Abnormal wear on spline.
103 SWASH PLATE Mark of sticking. - -
104 CYLINDER BLOCK Abnormal wear on spline.
Abnormal wear on bore surface.
- -
Scratch or uneven wear on sliding surface
with timing plate (109).
105 PISTON ASSY Abnormal clearance in the axial direction Clearance Clearance
106 PISTON between piston (105) and shoe (106). 0.05mm 0.15mm
SHOE Abnormal wear on shoe (106). (0.002") (0.006")
107 RETAINER PLATE Uneven wear on sliding surface with shoe
(106).
- -
Scratch or uneven wear on sliding surface
with thrust ball (108).
108 THRUST BALL Uneven wear on sliding surface with retainer
- -
plate (107).
109 TIMING PLATE Sticking or uneven wear on sliding surface. - -
115 FRICTION PLATE Uneven wear on both contact surface. Braking torque Braking torque
116 MAITING PLATE Specified torque cannot be obtained. 206N m 206N m
Mark of sticking. (152 lbf ft) (152 lbf ft)
or over or over
105 PISTON Scratch on sliding surface. - -

34-109
［34. TRAVEL SYSTEM］

REFERENCE ALLOWANCE
No. PARTS TROUBLE
VALUE VALUE
149 BALL BEARING Dent, flaking or uneven wear on contact surface.
- -
150
161 1st-2nd SPEED Uneven wear on both sliding surface.
162 PISTON KIT Abnormal wear on shoe (162).
- -
PISTON
SHOE
323 SPOOL Abnormal and uneven wear on the outer
363 circumference. - -
Severe scratch on the circumference.
381 PISTON Severe scratch on the circumference. - -

34-110
 ［34. TRAVEL SYSTEM］

34.2.5.2 PERFORMANCE CONFIRMATION TEST

After servicing GM motor, perform the following tests by the following procedure.

(1) Required measuring devices

1 Press gauge for 3.43MPa (500psi) 2 pcs.
2 Graduated cylinder for 5L (1.32gal) 1 pc.
3 Stopwatch 1 pc.

34
(2) Test procedure

34-111
［34. TRAVEL SYSTEM］

34.2.5.3 TROUBLESHOOTING

34-112
 ［34. TRAVEL SYSTEM］

34

34-113
［34. TRAVEL SYSTEM］

34-114
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

46. TROUBLE SHOOTING

(BY ERROR CODES)
TABLE OF CONTENTS

46.1 JUDGMENT OF ACTUAL THING AT SITE ………………………………………………………………46-3

46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING …………………………………………46-4
46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER ……………………………………………………46-5
46.4 TROUBLESHOOTING BY ERROR CODE …………………………………………………………………46-6

46

Book Code No. S5YY4618E01

46-1
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Issue Date of Issue Applicable Machines Remarks

SK125SR : YV06-05501~
SK125SRL : LD06-01801~ S5YY4618E01
First Edition June, 2009
SK135SR-2 : YY06-15001~ (SE Asia & Oceania)
SK135SRLC-2 : YH06-08001~

July, 2009 SK140LC-8 : YP09-05001~

(SE Asia)

Preface
Troubleshooting provides process locating for
the cause of trouble in the order that trouble
occurred. This manual describes how to solve
the specific phenomenon systematically as
early as possible. For troubleshooting
concerning the inside of equipment, refer to
troubleshooting for each manual of equipment.
Attending the field to verify actual thing.

46-2
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

46.1 JUDGMENT OF ACTUAL THING AT SITE

(1) Get to the site as quickly as possible.

Verify model, serial number, situation of trouble
and field, and notify person of arrival time.
(2) Verify background of trouble occurred
1. Model name and serial number
2.
Kind of attachment
Check that the combination of attachment is
proper or that the operating method is not
unreasonable.
3. Operating time by hour-meter
Verifying background of trouble occurred.
4.
History of trouble occurred and additional works.
5.
Recurrence of past trouble, or problems on the
additional works.

(3) How to diagnose trouble

1. Verify defective part
2. Make the condition of trouble again
3.
Where defective parts can not be verified,
surmise causes systematically.
4. Verify reasons for surmise
5.
Report methods, procedure, and period for
repairing to user.

Confirm the symptoms of the trouble. 46

(4) Explanation of the cause of trouble

1.
Explain the cause of trouble to clients. For
example, oil leak through piston is caused by
flaws on the piston rod. And the method of
using the machines should be explained so that
the same kind of trouble does not reoccur. Diagnosing fail by means troubleshooting.
2.
Treatment of damaged parts
The damaged parts to be claimed and
returned are evidence so they should be
handled with care. Protect them from entry of
water, soils, etc. into port of hydraulic unit, etc.
and return them. And also use care not to
flaw and damage those surfaces.

46-3
［46. TROUBLE SHOOTING (BY ERROR CODES)］

46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING

Classify failures into the following 3 types and carry out the troubleshooting.

No. Classes of failure Troubleshooting

A When error code after self-diagnosis is displayed Carry out troubleshooting according to the error code.
on gauge cluster
B When no failure is detected currently but error When it is hard to recreate the failure situation,
code after self diagnosis is remained in trouble cancel the data in the history and reproduce the
history failed situation or suppose the cause according to
the troubleshooting by error code, and then repair it.
C When error code after self diagnosis is not -Carry out troubleshooting according to instructions in
displayed or is not remained in the history Chapter 47 "TROUBLESHOOTING BY TROUBLE".
-Carry out troubleshooting according to instructions in
Chapter 48 "TROUBLE DIAGNOSIS MODE".

46-4
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER

If the fuse of mechatro controller has blown, the following display appears on the gauge cluster.

(1) The blown fuse of mechatro controller

a. Blown fuse 5A of mechatro controller :

"DATA COMMUNICATION ERROR" is displayed on the gauge cluster in the condition where the
controller program is not executed.
b. Blown fuse 20A of mechatro controller
The controller functions normally but the power supply applied when the controller drives the
solenoid, etc. stops.
Many error codes are displayed on the gauge cluster.
D013, D023, D033, D063,
E013, E023, F021

46

46-5
［46. TROUBLE SHOOTING (BY ERROR CODES)］

46.4 TROUBLESHOOTING BY ERROR CODE

When error code was displayed on the gauge cluster with the aid of self-diagnosis display function,
carry out the troubleshooting referring to applicable page in the contents of error codes.

Error Code Trouble

A025 Pump propo. valve adjustment (B adjustment) is not adjusted yet or is failed.
A035 Unload valve adjustment (C adjustment) is not adjusted yet or is failed.
A215 Written data of ROM adjustment data is incorrect.
A225 Writing of ROM adjustment data is incorrect.
A235 Written data of ROM hour meter data is incorrect.
A245 Writing of ROM hour meter data is incorrect.
A255 Writing of proportional valve adjustment data is incorrect.
B012 Incorrect output of boom up pressure sensor
B013 Disconnection of boom up pressure sensor
B014 Short-circuit of boom up pressure sensor
B022 Incorrect output of boom down pressure sensor
B023 Disconnection of boom down pressure sensor
B024 Short-circuit of boom down pressure sensor
B032 Incorrect output of arm out pressure sensor
B033 Disconnection of arm out pressure sensor
B034 Short-circuit of arm out pressure sensor
B042 Incorrect output of arm in pressure sensor
B043 Disconnection of arm in pressure sensor
B044 Short-circuit of arm in pressure sensor
B052 Incorrect output of bucket digging pressure sensor
B053 Disconnection of bucket digging pressure sensor
B054 Short-circuit of bucket digging pressure sensor
B062 Incorrect output of bucket dump pressure sensor
B063 Disconnection of bucket dump pressure sensor
B064 Short-circuit of bucket dump pressure sensor
B072 Incorrect output of swing pressure sensor
B073 Disconnection of swing pressure sensor
B074 Short-circuit of swing pressure sensor
B092 Incorrect output of travel right pressure sensor
B093 Disconnection of travel right pressure sensor
B094 Short-circuit of travel right pressure sensor
B102 Incorrect output of travel left pressure sensor
B103 Disconnection of travel left pressure sensor
B104 Short-circuit of travel left pressure sensor
B113 Disconnection of pressure sensor of optional selector positioning
B114 Short-circuit of pressure sensor of optional selector positioning

46-6
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Error Code Trouble

B162 Incorrect output of P1 optional side pressure sensor
B163 Disconnection of P1 side optional pressure sensor
B164 Short-circuit of P1 side optional pressure sensor
B172 Incorrect output of P2 optional side pressure sensor
B173 Disconnection of P2 side optional pressure sensor
B174 Short-circuit of P2 side optional pressure sensor
C012 Incorrect output of P1 pump pressure sensor
C013 Disconnection of P1 pump pressure sensor
C014 Short-circuit of P1 pump pressure sensor
C022 Incorrect output of P2 pump pressure sensor
C023 Disconnection of P2 pump pressure sensor
C024 Short-circuit of P2 pump pressure sensor
C033 Disconnection of boom head pressure sensor
C034 Short-circuit of boom head pressure sensor
D012 Failure of output transistor ON at P1 unload proportional valve
D013 Disconnection of P1 unload proportional valve
D022 Failure of output transistor ON at P2 unload proportional valve
D023 Disconnection of P2 unload proportional valve
D032 Failure of output transistor ON at travel straight proportional valve
D033 Disconnection of travel straight proportional valve
D062 Failure of output transistor ON at arm in high speed proportional valve
D063 Disconnection of arm in high speed proportional valve
E012 Failure of output transistor ON at P1 pump proportional valve
E013 Disconnection of P1pump proportional valve
E022 Failure of output transistor ON at P2 pump proportional valve
E023 Disconnection of P2 pump proportional valve
F021 Failure of output transistor OFF and GND short of swing parking SOL valve 46
F023 Failure of output transistor ON and disconnection of swing parking SOL valve
F031 Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve
F033 Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve
F041 Failure of output transistor OFF and GND short of optional selector SOL valve
F043 Failure of output transistor ON and disconnection of optional selector SOL valve
G032 Overrun of speed sensor of direct input Mechatro-controller
G033 Disconnection of speed sensor of direct input Mechatro-controller
G042 Overrun of speed sensor of direct input Mechatro-controller and received data from E/G controller.
Disconnection of speed sensor of direct input Mechatro-controller and received data from E/G
G043
controller.
H013 Disconnection of acceleration potentio
H014 Power short-circuit of acceleration potentio
H091 Failure of GND short-circuit of fuel sensor
H093 Disconnection of fuel sensor

46-7
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Error Code Trouble

I111 Received error of CAN1 communication (passive error)
I113 Received error of CAN1 communication (time-out)
I313 Received error of cluster communication (time-out error)
K014 Adhesion of battery relay terminal
R014 Failure of arc prevention relay of wiper motor
R024 Failure of normal rotation relay of wiper motor
R034 Failure of reverse rotation relay of wiper motor
R044 Failure of washer motor relay
R134 Failure of swing right flasher relay
R144 Failure of swing left flasher relay
R154 Failure of travel alarm relay
R164 Failure of auto idling stop relay 2
R174 Failure of engine forcible stop relay
R184 Failure of lever lock relay

46-8
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-1
Error code A025
Trouble Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment)
Judging Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value
condition within the adjusting range.
Symptom Deviated from the rated output, but no problem in normal operation
Control in the
Workable with the default proportional valve output.
event of failure
Returned in
The pump proportional valve adjustment is completed normally.
normal condition

Service Screen No. 9 E-1 P1 PUMP

diagnosis Screen No. 9 E-2 P2 PUMP
checking screen Screen No.
Checking object Checking contents and remedy
1 -Checking Carry out pump adjustment (B adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the
section "Adjustment procedure - Measures to be taken with the
adjustment failed"
2 -Mechatro controller Check that the error is corrected after replacement of controller.
3

Table 46-2
Error code A035
Trouble Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment)
Judging The adjustment of unload valve is missed. Or the adjusting value can not be set in the
condition adjusting range.
Symptom It is not normal output, but no problem in normal operation
Control in the
Work with the aid of output by default proportional valve.
event of failure 46
Returned in
The adjustment of unload valve is completed normally.
normal condition

Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)

diagnosis Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
checking screen Screen No.
Checking object Checking contents and remedy
1 -Checking Carry out adjustment of unload valve (C adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the
section "Adjustment procedure - Measures to be taken with the
adjustment failed"
2 -Mechatro controller Check that the error is corrected after replacement of controller.
3

46-9
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-3
Error code A215
Trouble The data of ROM adjustment is written incorrectly.
Judging Check adjustment data, and judge the content of memory is correct or not. (Trouble history
condition only)
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3

Table 46-4
Error code A225
Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the data is correct or not.
condition
Symptom It is not normal output, but no problem in normal operation
Control in the
Control can be done by default value.
event of failure
Returned in
It does not regain. Replace controller.
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3

46-10
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-5
Error code A235
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is correct or not. (Trouble history only)
condition
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3

Table 46-6
Error code A245
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is incorrect.
condition
Symptom The hour meter data which was judged as error is taken as 0 Hr. No problem in normal
operation
Control in the
Normal control is available.
event of failure
Returned in
It does not regain. Replace controller.
normal condition 46
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3

46-11
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-7
Error code A255
Trouble The data of proportional valve adjustment is written incorrectly.
Judging
Check proportional valve adjustment data, and judge the data is incorrect.
condition
Symptom It is not normal output, but no problem in normal operation
Control in the
Using fixed value of proportional valve correction data, usual control is done.
event of failure
Returned in
It does not regain. Replace controller.
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3

Table 46-8
Error code B012
Trouble Boom up pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor
condition after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The boom up operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 5 B-1 BOOM RAISE

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Boom up pressure sensor When B012 is cancelled and other error occurs by turning starter switch
SE-3 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between boom up When B012 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-126F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-12
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-9
Error code B013
Trouble Boom up pressure sensor's wiring disconnects.
Judging
The input voltage from boom up pressure sensor is less than 0.1V.
condition
Symptom The boom up speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency
event of failure mode)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-1 BOOM RAISE

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Boom up pressure sensor When B013 is cancelled and other error occurs after exchanging the
SE-3 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between boom up When B013 is displayed after the connector is exchanged with other
pressure sensor and controller sensor.
CN-126F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-10
Error code B014
Trouble Boom up pressure sensor's power source is shortcut.
Judging
The input voltage from boom up pressure sensor is 4.7V or more.
condition
Symptom The boom up speed slows down. 46
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-1 BOOM RAISE

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Boom up pressure sensor When B014 is cancelled and other error occurs after exchanging the
SE-3 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between boom up When B014 is displayed after the connector is exchanged with other
pressure sensor and controller sensor.
CN-126F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-13
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-11
Error code B022
Trouble Boom down pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor
condition after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The boom down operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 5 B-2 BOOM LOWER

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch
SE-4 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between boom down When B022 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-127F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-12
Error code B023
Trouble Boom down pressure sensor's wiring is disconnecting.
Judging
The input voltage from boom down pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to constant current.
event of failure (Current value in all operation is neutral.)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-2 BOOM LOWER

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the
SE-4 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between boom down When B023 is displayed after the connector is exchanged with other
pressure sensor and controller sensor.
CN-127F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-14
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-13
Error code B024
Trouble Boom down pressure sensor's power source is shortcut.
Judging
The input voltage from boom down pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to constant current.
event of failure (Current value in all operation is neutral.)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-2 BOOM LOWER

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch
SE-4 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between boom down When B024 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-127F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-14
Error code B032
Trouble Arm-in pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor
condition after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom All operation speed slows down. 46
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 5 B-3 ARM OUT

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Arm-out pressure sensor When B032 is cancelled and other error occurs by turning starter switch
SE-8 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between arm-out When B032 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-131F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-15
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-15
Error code B033
Trouble Arm-out pressure sensor's wiring is disconnecting.
Judging
The input voltage from arm-out pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to constant current.
event of failure (Current value in all operation is neutral.)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-3 ARM OUT

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Arm-out pressure sensor When B033 is cancelled and other error occurs after exchanging the
SE-8 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between arm-out When B033 is displayed after the connector is exchanged with other
pressure sensor and controller sensor.
CN-131F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-16
Error code B034
Trouble Arm-out pressure sensor's power source is shortcut.
Judging
The input voltage from arm-out pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to constant current.
event of failure (Current value in all operation is neutral.)
Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-3 ARM OUT

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Arm-out pressure sensor When B034 is cancelled and other error occurs by turning starter switch
SE-8 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between arm-out When B034 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-131F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-16
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-17
Error code B042
Trouble Arm-in pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the arm-in
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The arm-in operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 5 B-4 ARM IN

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Arm-in pressure sensor When B042 is cancelled and other error occurs by turning starter switch
SE-7 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between arm-in When B042 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-130F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-18
Error code B043
Trouble Arm-in pressure sensor's wiring is disconnecting.
Judging
The input voltage from arm-in pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to constant current. 46
event of failure (Current value in all operation is neutral.)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-4 ARM IN

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Arm-in pressure sensor When B043 is cancelled and other error occurs after exchanging the
SE-7 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between arm-in When B043 is displayed after the connector is exchanged with other
pressure sensor and controller sensor.
CN-130F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-17
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-19
Error code B044
Trouble Arm-in pressure sensor's power source is shortcut.
Judging
The input voltage from arm-in pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to constant current.
event of failure (Current value in all operation is neutral.)
Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-4 ARM IN

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Arm-in pressure sensor When B044 is cancelled and other error occurs by turning starter switch
SE-7 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between arm-in When B044 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-130F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-20
Error code B052
Trouble Bucket digging pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket
condition digging pressure sensor after starter switch ON is in the range of 1.4V or more to less than
4.7V.
Symptom The bucket digging operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 5 B-5 BUCKET DIG

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Bucket digging pressure When B052 is cancelled and other error occurs by turning starter switch
sensor on after exchanging the connector with other sensor.
SE-1 Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between bucket digging When B052 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-18
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-21
Error code B053
Trouble Bucket digging pressure sensor's wiring is disconnected.
Judging
The input voltage from bucket digging pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to constant current.
event of failure (Current value in all operation is neutral.)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-5 BUCKET DIG

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Bucket digging pressure When B053 is cancelled and other error occurs by turning starter switch
sensor on after exchanging the connector with other sensor.
SE-1 Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between bucket digging When B053 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-22
Error code B054
Trouble Bucket digging pressure sensor's power source is shortcut.
Judging
The input voltage from bucket digging pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down. 46
Control in the Set proportional valve output rate of P1 and P2 pumps to constant current.
event of failure (Current value in all operation is neutral.)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-5 BUCKET DIG

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Bucket digging pressure When B054 is cancelled and other error occurs by turning starter switch
sensor on after exchanging the connector with other sensor.
SE-1 Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between bucket digging When B054 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-19
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-23
Error code B062
Trouble Bucket dump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket
condition dump pressure sensor after starter switch ON is in the range of 1.4V or more to less than
4.7V.
Symptom The bucket dump operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 5 B-6 BUCKET DUMP

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Bucket dump pressure sensor When B062 is cancelled and other error occurs by turning starter switch
SE-2 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between bucket dump When B062 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-125F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-24
Error code B063
Trouble Bucket dump pressure sensor's wiring is disconnected.
Judging
The input voltage from bucket dump pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to constant current.
event of failure (Current value in all operation is neutral.)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-6 BUCKET DUMP

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Bucket dump pressure sensor When B063 is cancelled and other error occurs by turning starter switch
SE-2 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between bucket dump When B063 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-125F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-20
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-25
Error code B064
Trouble Bucket dump pressure sensor's power source is shortcut.
Judging
The input voltage from bucket dump pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to constant current.
event of failure (Current value in all operation is neutral.)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 5 B-6 BUCKET DUMP

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Bucket dump pressure sensor When B064 is cancelled and other error occurs by turning starter switch
SE-2 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between bucket dump When B064 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-125F Check wiring for possible failure according to the wiring checking
CN-101F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-26
Error code B072
Trouble Swing pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the swing
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The swing operability becomes poor. 46
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 6 B-7 SWING

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Swing pressure sensor When B072 is cancelled and other error occurs by turning starter switch
SE-5 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between swing When B072 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking
CN-103F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-21
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-27
Error code B073
Trouble Swing pressure sensor's wiring is disconnected.
Judging
The input voltage from swing pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to constant current.
event of failure (Current value in all operation is neutral.)
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 6 B-7 SWING

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Swing pressure sensor When B073 is cancelled and other error occurs by turning starter switch
SE-5 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between swing When B073 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking
CN-103F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-28
Error code B074
Trouble Swing pressure sensor's power source is shortcut.
Judging
The input voltage from swing pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to constant current.
event of failure (Current value in all operation is neutral.)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 6 B-7 SWING

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Swing pressure sensor When B074 is cancelled and other error occurs by turning starter switch
SE-5 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between swing When B074 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking
CN-103F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-22
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-29
Error code B092
Trouble Travel right pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel
condition right pressure sensor after starter switch ON is in the range of 1.4V or more to less than
4.7V.
Symptom The travel right operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 6 B-9 TRAVEL (R)

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Travel right pressure sensor When B092 is cancelled and other error occurs by turning starter switch
SE-9 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between travel right When B092 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking
CN-102F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-30
Error code B093
Trouble Travel right pressure sensor's wiring is disconnected.
Judging
The input voltage from Travel right pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down. 46
Control in the Set proportional valve output rate of P1 and P2 pumps to constant current.
event of failure (Current value in all operation is neutral.)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 6 B-9 TRAVEL (R)

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Travel right pressure sensor When B093 is cancelled and other error occurs by turning starter switch
SE-9 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between travel right When B093 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking
CN-102F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-23
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-31
Error code B094
Trouble Travel right pressure sensor's power source is shortcut.
Judging
The input voltage from Travel right pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to constant current.
event of failure (Current value in all operation is neutral.)
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 6 B-9 TRAVEL (R)

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Travel right pressure sensor When B094 is cancelled and other error occurs by turning starter switch
SE-9 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between travel right When B094 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking
CN-102F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-32
Error code B102
Trouble Travel left pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel
condition left pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The travel left operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 6 B-10 TRAVEL (L)

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Travel left pressure sensor When B102 is cancelled and other error occurs by turning starter switch
SE-10 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between travel left When B102 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking
CN-102F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-24
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-33
Error code B103
Trouble Travel left pressure sensor's wiring is disconnected.
Judging
The input voltage from Travel left pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to constant current.
event of failure (Current value in all operation is neutral.)
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 6 B-10 TRAVEL (L)

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Travel left pressure sensor When B103 is cancelled and other error occurs by turning starter switch
SE-10 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between travel left When B103 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking
CN-102F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-34
Error code B104
Trouble Travel left pressure sensor's power source is shortcut.
Judging
The input voltage from Travel left pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down. 46
Control in the Set proportional valve output rate of P1 and P2 pumps to constant current.
event of failure (Current value in all operation is neutral.)
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 6 B-10 TRAVEL (L)

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Travel left pressure sensor When B104 is cancelled and other error occurs by turning starter switch
SE-10 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between travel left When B104 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking
CN-102F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-25
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-35
Error code B113
Trouble Option selector position detect pressure sensor's wiring is disconnected.
Judging
The input voltage from option selector position detect pressure sensor is 0.1V or less.
condition
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 16 B-11

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Option selector position When B113 is cancelled and other error occurs by turning starter switch
detect pressure sensor on after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between option When B113 is displayed after turning the starter switch on after the
selector position detect connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking
CN-162F procedure and repair it if necessary.
CN-104F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-36
Error code B114
Trouble Option selector position detect pressure sensor's wiring is disconnected.
Judging
The input voltage from selector position detect pressure sensor is 4.7V or more.
condition
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 16 B-11

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Option selector position When B114 is cancelled and other error occurs by turning starter switch
detect pressure sensor on after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between option When B114 is displayed after turning the starter switch on after the
selector position detect connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking
CN-162F procedure and repair it if necessary.
CN-104F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-26
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-37
Error code B162
Trouble P1 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than
4.7V.
Symptom The P1 side option operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 6 B-16 P1 OPT.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P1 side option pressure When B162 is cancelled and other error occurs by turning starter switch
sensor on after exchanging the connector with other sensor.
SE-20 Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between P1 side option When B162 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor. Check wiring for possible
CN-304F failure according to the wiring checking procedure and repair it if
CN-102F necessary.
Check wiring for possible failure according to the wiring checking
procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46

46-27
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-38
Error code B163
Trouble P1 side option pressure sensor's wiring is disconnected.
Judging
The input voltage from P1 side option pressure sensor is 0.1V or less.
condition
Symptom The P1 side option does not work. All operation speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 6 B-16 P1 OPT.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P1 side option pressure When B163 is cancelled and other error occurs by turning starter switch
sensor on after exchanging the connector with other sensor.
SE-20 Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between P1 side option When B163 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-304F Check wiring for possible failure according to the wiring checking
CN-102F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-28
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-39
Error code B164
Trouble P1 side option pressure sensor's wiring is disconnected.
Judging
The input voltage from P1 side option pressure sensor is 4.7V or more.
condition
Symptom The P1 side option does not work. All operation speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 6 B-16 P1 OPT.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P1 side option pressure When B164 is cancelled and other error occurs by turning starter switch
sensor on after exchanging the connector with other sensor.
SE-20 Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between P1 side option When B164 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-304F Check wiring for possible failure according to the wiring checking
CN-102F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46

46-29
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-40
Error code B172
Trouble P2 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than
4.7V.
Symptom The P2 side option operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 6 B-17 P2 OPT.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P2 side option pressure When B172 is cancelled and other error occurs by turning starter switch
sensor SE-11 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between P2 side option When B172 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor. Check wiring for possible
CN-303F failure according to the wiring checking procedure and repair it if
CN-102F necessary.
Check wiring for possible failure according to the wiring checking
procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-30
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-41
Error code B173
Trouble P2 side option pressure sensor's wiring is disconnected.
Judging
The input voltage from P2 side option pressure sensor is 0.1V or less.
condition
Symptom The selection of conflux does not work. All operation speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to constant current.
event of failure (Current value in all operation is neutral.)
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 6 B-17 P2 OPT.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P2 side option pressure When B173 is cancelled and other error occurs by turning starter switch
sensor on after exchanging the connector with other sensor.
SE-11 Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between P2 side option When B173 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-303F Check wiring for possible failure according to the wiring checking
CN-102F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-42
Error code B174
Trouble P2 side option pressure sensor's wiring is disconnected.
Judging
The input voltage from P2 side option pressure sensor is 4.7V or more.
condition
Symptom The selection of conflux does not work. All operation speed slows down. 46
Control in the Set proportional valve output rate of P1 and P2 pumps to constant current.
event of failure (Current value in all operation is neutral.)
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 6 B-17 P2 OPT.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P2 side option pressure When B174 is cancelled and other error occurs by turning starter switch
sensor SE-11 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between P2 side option When B174 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-303F Check wiring for possible failure according to the wiring checking
CN-102F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-31
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-43
Error code C012
Trouble P1 pump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1
condition pump pressure sensor after starter switch ON is in the range of 1.4V or more to less than
4.7V.
Symptom The P1 pump operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 7 C-1 PUMP P1

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P1 pump pressure sensor When C012 is cancelled and other error occurs by turning starter switch
SE-22 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between P1 pump When C012 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking
CN-103F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-44
Error code C013
Trouble P1 pump pressure sensor's wiring is disconnected.
Judging
The input voltage from P1 pump pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down.
Control in the
P1 pump pressure is controlled to 25 MPa.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 7 C-1 PUMP P1

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P1 pump pressure sensor When C013 is cancelled and other error occurs by turning starter switch
SE-22 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between P1 pump When C013 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking
CN-103F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-32
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-45
Error code C014
Trouble P1 pump pressure sensor's power source is shortcut.
Judging
The input voltage from P1 pump pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down.
Control in the
P1 pump pressure is controlled to 25 MPa.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 7 C-1 PUMP P1

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P1 pump pressure sensor When C014 is cancelled and other error occurs by turning starter switch
SE-22 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between P1 pump When C014 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking
CN-103F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-46
Error code C022
Trouble P2 pump pressure sensor outputs error.
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2
condition pump pressure sensor after starter switch ON is in the range of 1.4V or more to less than
4.7V.
Symptom The P2 pump operability becomes poor. 46
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 7 C-2 PUMP P2

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P2 pump pressure sensor When C022 is cancelled and other error occurs by turning starter switch
SE-23 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between P2 pump When C022 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking
CN-103F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-33
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-47
Error code C023
Trouble P2 pump pressure sensor's wiring is disconnected.
Judging
The input voltage from P2 pump pressure sensor is 0.1V or less.
condition
Symptom All operation speed slows down.
Control in the
P2 pump pressure is controlled to 25 MPa.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 7 C-2 PUMP P2

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P2 pump pressure sensor When C023 is cancelled and other error occurs by turning starter switch
SE-23 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between P2 pump When C023 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking
CN-103F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-48
Error code C024
Trouble P2 pump pressure sensor's power source is shortcut.
Judging
The input voltage from P2 pump pressure sensor is 4.7V or more.
condition
Symptom All operation speed slows down.
Control in the
P2 pump pressure is controlled to 25 MPa.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 7 C-2 PUMP P2

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P2 pump pressure sensor When C024 is cancelled and other error occurs by turning starter switch
SE-23 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between P2 pump When C024 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking
CN-103F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-34
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-49
Error code C033
Trouble Boom head pressure sensor's wiring is disconnected.
Judging
The input voltage from boom head pressure sensor is 0.1V or less.
condition
Symptom Overload alarm is not actuated.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 7 C-3 BOOM-HEAD

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Boom head pressure sensor When C033 is cancelled and other error occurs by turning starter switch
SE-24 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between boom head When C033 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-706F Check wiring for possible failure according to the wiring checking
CN-104F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-50
Error code C034
Trouble Boom head pressure sensor's power source is shortcut.
Judging
The input voltage from boom head pressure sensor is 4.7V or more.
condition
Symptom Overload alarm is not actuated.
Control in the
Normal control
46
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 7 C-3 BOOM-HEAD

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Boom head pressure sensor When C034 is cancelled and other error occurs by turning starter switch
SE-24 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between boom head When C034 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-706F Check wiring for possible failure according to the wiring checking
CN-104F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-35
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-51
Error code D012
Trouble P1 unload proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Option conflux can not be done.
Control in the
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P1 unload proportional valve When D012 is cancelled and other error occurs by turning starter switch
PSV-D on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between P1 unload When D012 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-120F Check wiring for possible failure according to the wiring checking
CN-105F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-52
Error code D013
Trouble P1 unload proportional valve's wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 150mA or less, judging is not done.)
Symptom Option conflux can not be done.
Control in the
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P1 unload proportional valve When D013 is cancelled and other error occurs by turning starter switch
PSV-D on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between P1 unload When D013 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-120F Check wiring for possible failure according to the wiring checking
CN-105F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-36
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-53
Error code D022
Trouble P2 unload proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P2 unload proportional valve When D022 is cancelled and other error occurs by turning starter switch
PSV-B on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between P2 unload When D022 is displayed after turning the starter switch on after the
proportional valve and controller connector is exchanged with other sensor.
CN-118F Check wiring for possible failure according to the wiring checking
CN-105F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-54
Error code D023
Trouble P2 unload proportional valve's wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 150mA or less, judging is not done.)
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
46
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P2 unload proportional valve When D023 is cancelled and other error occurs by turning starter switch
PSV-B on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between P2 unload When D023 is displayed after turning the starter switch on after the
proportional valve and controller connector is exchanged with other sensor.
CN-118F Check wiring for possible failure according to the wiring checking
CN-105F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-37
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-55
Error code D032
Trouble Travel straight proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 8 D-3 S-TRAVEL

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Travel straight proportional When D032 is cancelled and other error occurs by turning starter switch
valve on after exchanging the connector with other sensor.
PSV-C Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between Travel straight When D032 is displayed after turning the starter switch on after the
proportional valve and controller connector is exchanged with other sensor.
CN-119F Check wiring for possible failure according to the wiring checking
CN-105F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-56
Error code D033
Trouble Travel straight proportional valve's wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 150mA or less, judging is not done.)
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 8 D-3 S-TRAVEL

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Travel straight proportional When D033 is cancelled and other error occurs by turning starter switch
valve on after exchanging the connector with other sensor.
PSV-C Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between Travel straight When D033 is displayed after turning the starter switch on after the
proportional valve and controller connector is exchanged with other sensor.
CN-119F Check wiring for possible failure according to the wiring checking
CN-105F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-38
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-57
Error code D062
Trouble Arm-in spool 2 proportional valve and output transistor ON are failure.
Judging condition The feed-back value from proportional valve is 1000mA or more.
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 8 D-6 ARM IN-2-SPEED
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Arm-in spool 2 proportional When D062 is cancelled and other error occurs by turning starter switch
valve on after exchanging the connector with other sensor.
PSV-A Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between Arm-in spool 2 When D062 is displayed after turning the starter switch on after the
proportional valve and controller connector is exchanged with other sensor.
CN-121F Check wiring for possible failure according to the wiring checking
CN-105F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-58
Error code D063
Trouble Arm-in spool 2 proportional valve's wiring is disconnected.
Judging condition The feed-back value from proportional valve is 100mA or less.
(If output is 150mA or less, judging is not done.)
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
46
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 8 D-6 ARM IN-2-SPEED
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Arm-in spool 2 proportional When D063 is cancelled and other error occurs by turning starter switch
valve on after exchanging the connector with other sensor.
PSV-A Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between Arm-in spool 2 When D063 is displayed after turning the starter switch on after the
proportional valve and controller connector is exchanged with other sensor.
CN-121F Check wiring for possible failure according to the wiring checking
CN-105F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-39
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-59
Error code E012
Trouble P1 pump proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom All operation speed slows down.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 9 E-1 PUMP P1

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P1 pump proportional valve When E012 is cancelled and other error occurs by turning starter switch
PSV-P1 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 -Wiring between P1 pump When E012 is displayed after turning the starter switch on after the
proportional valve and controller connector is exchanged with other sensor.
CN-141F Check wiring for possible failure according to the wiring checking
CN-105F procedure and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-40
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-60
Error code E013
Trouble P1 pump proportional valve's wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 150mA or less, judging is not done.)
Symptom All operation speed slows down.
Control in the
Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 9 E-1 PUMP P1

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P1 pump proportional valve When E013 is cancelled and other error occurs by turning starter switch
PSV-P1 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 -Wiring between P1 pump When E013 is displayed after turning the starter switch on after the
proportional valve and controller connector is exchanged with other sensor.
CN-141F Check wiring for possible failure according to the wiring checking
CN-105F procedure and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46

46-41
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-61
Error code E022
Trouble P2 pump proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom All operation speed slows down.
Control in the
Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 9 E-2 PUMP P2

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P2 pump proportional valve When E022 is cancelled and other error occurs by turning starter switch
PSV-P2 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 -Wiring between P2 pump When E022 is displayed after turning the starter switch on after the
proportional valve and controller connector is exchanged with other sensor.
CN-142F Check wiring for possible failure according to the wiring checking
CN-105F procedure and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-42
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-62
Error code E023
Trouble P2 pump proportional valve's wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 150mA or less, judging is not done.)
Symptom All operation speed slows down.
Control in the
Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.

Service Screen No. 9 E-2 PUMP P2

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -P2 pump proportional valve When E023 is cancelled and other error occurs by turning starter switch
PSV-P2 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 -Wiring between P2 pump When E023 is displayed after turning the starter switch on after the
proportional valve and controller connector is exchanged with other sensor.
CN-142F Check wiring for possible failure according to the wiring checking
CN-105F procedure and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46

46-43
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-63
Error code F021
Trouble Swing parking solenoid valve and output transistor OFF are failure, and grounding is
short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Swing parking is not available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition

Service Screen No. 3 F-2 SWING-BRAKE

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Swing parking solenoid valve When F021 is cancelled and other error occurs by exchanging the
SV-1 connector for other solenoid valve. Check solenoid valve unit for
possible failure. If failure found, replace it.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 -Wiring between swing parking When F021 is displayed after the connector is exchanged with other
solenoid valve and controller solenoid valve.
CN-123F Check wiring for possible failure according to the wiring checking
CN-105F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-64
Error code F023
Trouble Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Swing parking is not available or is leaving available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is output.
normal condition

Service Screen No. 3 F-1 POWER BOOST

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Swing parking solenoid valve When F023 is cancelled and other error occurs by exchanging the
SV-1 connector for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 -Wiring between swing parking When F023 is displayed after the connector is exchanged with other
solenoid valve and controller solenoid valve.
CN-123F Check wiring for possible failure according to the wiring checking
CN-105F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-44
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-65
Error code F031
Trouble Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is
short-circuit.
Judging condition The feed-back signal is grounding level while exciting command is output.
Symptom Travel 2 speed is not obtainable.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Screen No. 3 F-3 1/2-TRAVEL
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Travel 1, 2speed solenoid valve When F031 is cancelled and other error occurs by exchanging the
SV-3 connector for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 -Wiring between travel 1, 2speed When F031 is displayed after the connector is exchanged with other
solenoid valve and controller solenoid valve.
CN-122F Check wiring for possible failure according to the wiring checking
CN-105F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-66
Error code F033
Trouble Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Judging condition The feed-back signal is 24V level while exciting command is not output.
Symptom Travel 2 speed is not obtainable or is keeping 1 speed.
Control in the
event of failure
Normal control
46
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Screen No. 3 F-3 1/2-TRAVEL
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Travel 1, 2speed solenoid valve When F033 is cancelled and other error occurs by exchanging the
SV-3 connector for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 -Wiring between travel 1, 2speed When F033 is displayed after the connector is exchanged with other
solenoid valve and controller solenoid valve.
CN-122F Check wiring for possible failure according to the wiring checking
CN-105F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-45
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-67
Error code F041
Trouble Option selector solenoid valve and output transistor OFF are failure, and grounding is
short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Option selector valve does not change to breaker side.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is ground level while exciting command is output.
normal condition

Service Screen No. 11 F-4 OPT SELECT

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Option selector solenoid valve When F041 is cancelled and other error occurs by exchanging the
SV-13 connector for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 -Wiring between option selector When F041 is displayed after the connector is exchanged with other
solenoid valve and controller solenoid valve.
CN-251F Check wiring for possible failure according to the wiring checking
CN-105F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-68
Error code F043
Trouble Option selector solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Option selector valve does not change to breaker side or it does not change from breaker to
nibbler.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is ground level while exciting command is not output.
normal condition

Service Screen No. 11 F-4 OPT SELECT

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Option selector solenoid valve When F043 is cancelled and other error occurs by exchanging the
SV-13 connector for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 -Wiring between option selector When F043 is displayed after the connector is exchanged with other
solenoid valve and controller solenoid valve.
CN-251F Check wiring for possible failure according to the wiring checking
CN-105F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-46
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-69
Error code G032
Trouble Mechatro controller direct input speed sensor is overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)

diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 -Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6 to 2.0 kilo-ohms
2 -Wiring between engine Check wiring for possible failure according to the wiring checking
speed sensor and controller procedure and repair it if necessary.
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
3 -Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)

Table 46-70
Error code G033
Trouble Mechatro controller direct input speed sensor, Disconnection
Judging
Voltage of alternator is 12V or more, and speed sensor indicates excess low engine rpm.
condition
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
46
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)

diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 -Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6 to 2.0 kilo-ohms
2 -Wiring between engine Check wiring for possible failure according to the wiring checking
speed sensor and controller procedure and repair it if necessary.
CN-136F
CN-106F
3 -Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)

46-47
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-71
Error code G042
Trouble Mechatro controller direct input speed sensor and received data from engine controller are
overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operate without problem.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)

diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 -Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6 to 2.0 kilo-ohms
2 - Wiring between engine Check wiring for possible failure according to the wiring checking
speed sensor and controller procedure and repair it if necessary.
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
3 -Wiring between ECU engine Check wiring for possible failure according to the wiring checking
speed sensor and controller procedure and repair it if necessary.
pressure sensor and controller Especially check wiring for false disconnection and noise included.
4 -Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)
5 -Engine controller Check that the error is corrected after replacement of controller.

46-48
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-72
Error code G043
When cranking is executed for five seconds or more, this error code might be displayed. In
case that the engine does not start, check by the table of "Section 47.3 Engine related
Troubleshooting". Execute the following check when the error code G043 is displayed after
starting the engine.
Trouble Mechatro controller direct input speed sensor and received data from engine controller are
disconnected.
Judging Voltage of alternator is 12V or more, and speed sensor and receipt data from engine
condition controller indicate excess low engine rpm.
Symptom Engine speed down may cause extension by abrupt loading.
Control in the
Enter 0 rpm for engine speed. Enter 0 for ESS power shift command.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)

diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 -Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6 to 2.0 kilo-ohms
2 -Wiring between engine Check wiring for possible failure according to the wiring checking
speed sensor and controller procedure and repair it if necessary.
CN-136F
CN-106F
3 -Wiring between ECU engine Check wiring for possible failure according to the wiring checking
speed sensor and controller procedure and repair it if necessary.
pressure sensor and controller
4 -Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)
5 -Engine controller Check that the error is corrected after replacement of controller. 46

46-49
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-73
Error code H013
Trouble Accel potentiometer is disconnected.
Judging
The input voltage from accel potentiometer is 0.1V or less.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 2 H-1 ACCEL VOLT.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Accel potentiometer Measure the resistance between terminals of speed sensor. Normal
SE-16 value: 1.6 to 2.4 kilo-ohms
Turn the potentiometer and measure resistance between signal and GND.
2 -Wiring between accel Check wiring for possible failure according to the wiring checking
potentiometer and controller procedure and repair it if necessary.
CN-402F
CN-102F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-74
Error code H014
Trouble Accel potentiometer's power source is shortcut.
Judging
The input voltage from accel potentiometer is 4.7V or more.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 2 H-1 ACCEL VOLT.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Accel potentiometer Measure the resistance between terminals of accel potentiometer.
SE-16 1.6 to 2.4 kilo-ohms
Turn the potentiometer and measure resistance between signal and GND.
2 -Wiring between accel Check wiring for possible failure according to the wiring checking
potentiometer and controller procedure and repair it if necessary.
CN-402F
CN-102F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-50
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-75
Error code H091
Trouble Fuel sensor grounding is short-circuited.
Judging
The input voltage from fuel sensor is 0.1V or less.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 10 H-9 FUEL LEVEL

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 - Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ohms to FULL 5 ohms
2 -Wiring between fuel Check wiring for possible failure according to the wiring checking
sensor and controller procedure and repair it if necessary.
CN-152F
CN-104F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-76
Error code H093
Trouble Fuel sensor's wiring is disconnection.
Judging
The input voltage from fuel sensor is 4.7V or more.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
46
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 10 H-9 FUEL LEVEL

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 - Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ohms to FULL 5 ohms
2 -Wiring between fuel Check wiring for possible failure according to the wiring checking
sensor and controller procedure and repair it if necessary.
CN-152F
CN-104F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-51
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-77
Error code I111
Trouble Reception of CAN1 communication is abnormal. (Passive error)
Judging
Reception from engine controller can not receive correctly.
condition
Symptom It has been affected little.
Control in the
Keep the last receiving condition.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Wiring between ECU Check wiring for possible failure according to the wiring checking
and controller procedure and repair it if necessary.
CN-3F (There is a possibility of false disconnection.)
CN-101F
2 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-78
Error code I113
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Reception from gauge cluster can not receive correctly. It has been affected little.
condition
Symptom It has been affected little.
Control in the
It can be operated in condition that coolant temperature is 20C degrees.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No. 2 G-5 WATER TEMP

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Wiring between ECU Check wiring for possible failure according to the wiring checking
and controller procedure and repair it if necessary.
CN-3F
CN-101F
2 -Mechatro controller Check that the error is corrected after replacement of controller.

46-52
 ［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-79
Error code I313
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Reception from gauge cluster can not receive correctly.
condition
Symptom Switch operation of gauge cluster can not be done.
Control in the
Keep the condition after immediately key-on is operated.
event of failure
Returned in
It returns automatically in normal condition.
normal condition

Service Screen No.

diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 -Wiring between gauge cluster Check wiring for possible failure according to the wiring checking
and controller procedure and repair it if necessary.
CN-600F
CN-101F
2 -Mechatro controller Check that the error is corrected after replacement of controller.

46

46-53
［46. TROUBLE SHOOTING (BY ERROR CODES)］

Table 46-80
Error code K014
Trouble Battery relay contact welded
Judging The power 24V is continuously supplied to controller for 40 seconds or more while the key
condition switch ON signal turned OFF
Symptom The power on the battery relay secondary side does not turn OFF even if the key switch is
turned OFF.
Control in the
Normal control with key switch OFF
event of failure
Returned in Turn key switch ON.
normal condition Or when the power supply 24V to mechatro controller is stopped

Service Screen No. 4 K-1 AIS RELAY 2

diagnosis Screen No. 4 K-3 KEY SWITCH OFF
checking screen Screen No.
Checking object Checking contents and remedy
1 -Battery relay Turn key switch off and disconnect the connector (CN-256F) on the
R-1 battery relay coil. If 24V power lives on battery relay secondary side,
CN-256F check on battery relay for failure and replace it if failed.
2 -Auto idle stop relay 2 Turn off the key switch, and remove the connector (CN-256F) on the
R-24 battery relay coil side. If power of battery relay on secondary side falls,
-Alternator relay remove either auto idling stop relay 2 or alternator relay.
R-28 The failure may be occurred in case where the power falls after the
relay was removed, and therefore check on the relay unit and replace it
with new one if failed.
3 -Wiring between auto idle stop When K014 is left displayed with the relay removed
relay/alternator relay and Check that no power 24V is produced on relay (-) line according to the
controller wiring checking procedure and replace it if necessary.
CN-109F, CN2-1 When no failure found after checking on wiring and K014 is left displayed
-Fuse & relay box Replace fuse/relay box.
E-1
4 -Mechatro controller Check that the error is corrected after replacement of controller.

46-54
［46. TROUBLE SHOOTING (BY ERROR CODES)］

46

46-55
［46. TROUBLE SHOOTING (BY ERROR CODES)］

46-56
［46. TROUBLE SHOOTING (BY ERROR CODES)］

46

46-57
［46. TROUBLE SHOOTING (BY ERROR CODES)］

46-58
［46. TROUBLE SHOOTING (BY ERROR CODES)］

46

46-59
［46. TROUBLE SHOOTING (BY ERROR CODES)］

46-60
 ［47. TROUBLESHOOTING (BY TROUBLE)］

47. TROUBLESHOOTING
(BY TROUBLE)
TABLE OF CONTENTS

47.1 HYDRAULIC SYSTEM …………………………………………………………………………………………47-3

47.2 ELECTRIC SYSTEMS …………………………………………………………………………………………47-36
47.2.1 WIRING CHECKING PROCEDURE ……………………………………………………………………47-36
47.2.2 TROUBLE……………………………………………………………………………………………………47-39
47.3 ENGINE RELATED TROUBLESHOOTING …………………………………………………………………47-43

47

Book Code No. S5YY4718E01

47-1
［47. TROUBLESHOOTING (BY TROUBLE)］

Issue Date of Issue Applicable Machines Remarks

SK125SR : YV06-05501~
SK125SRL : LD06-01801~ S5YY4718E01
First Edition June, 2009
SK135SR-2 : YY06-15001~ (SE Asia & Oceania)
SK135SRLC-2 : YH06-08001~

July, 2009 SK140LC-8 : YP09-05001~

(SE Asia)

47-2
 ［47. TROUBLESHOOTING (BY TROUBLE)］

47.1 HYDRAULIC SYSTEM

Preface:
The troubleshooting for the failures shown below is explained here.
Identify the failure and trouble and carry forward the troubleshooting in order of the failure item number.

(1) All controls do not function/slow

(2) Engine down/stalled
(3) Move at lever neutral position
(4) Poor fine operability
(5) Slow boom up, insufficient power
(6) Slow boom down, insufficient power for lifting up body
(7) Slow arm in, insufficient power
(8) Slow independent arm out (in the air)
(9) Slow bucket digging
(10) Slow bucket dumping
(11) Swing operation not functioned/slow
(12) Noise during swing operation
(13) Swing on a slope drifts when control lever is in neutral position
(14) Swing drifts when swing operation is stopped
(15) Slow travel speed/weak
(16) Travel deviation
(17) Travel 1st/2nd speed not changed
(18) Travel parking on a slope is not held
(19) Travel does not run straightly when both crawlers and attachment operated simultaneously.
(20) Slow breaker (crusher) operation, weak power
(21) Option selector valve malfunction: not switched to breaker circuit
(22) Option selector valve malfunction: not switched to nibbler circuit

47

47-3
［47. TROUBLESHOOTING (BY TROUBLE)］

(1) All controls do not function/slow

No. Sections Contents/normal value Corrective action, others
1 Fuse Check fuse No.4 If the fuse is blown out,
(10A) check on the
short-circuited section.
2 Safety lever lock Carry out service No.4 K-4 switch: Check action of switch
switch diagnosis Push down the lever and it turns by tester, or check that
on, push up and it turns off. the power voltage is
lowered by pushing the
lever down.
3 Safety lever lock Check that the Measure both terminals of Check solenoid unit for
switching solenoid is solenoid connector. 24V by pushing possible failure.
switched correctly the lever down, 0V by pushing it Check harness for
up possible failure.
4 Safety lever lock Carry out service No.4 K-4 lock lever: Check action of relay by
relay diagnosis Push down the lever and it turns tester
off, push up and it turns on.
5 Pilot pressure -Stop engine stop and key is on Check 5V power for
sensor position. All pilot low pressure controller
sensors are 0MPa to 0.1MPa.
6 Solenoid valve for Measure About 0MPa by pushing the lever Replace solenoid valve
safety lock lever pressure of up, and 4MPa or more by push it
solenoid A1 port down.
7 Pilot line filter Disassemble and Check filter for clogging Clean filter
check it visually
8 Pilot gear pump Measure pilot Check that it is 4MPa or more in Check gear pump and the
primary pressure high idling relief valve for possible
at gear pump failure
9 Multi control valve Change position Since all are blocked due to poor
(in case that switching performance, check that
travel is operable) the lever select pattern is set to
the proper position.
10 Actual measuring Carry out service -No.8 In case where the reading
current value of diagnosis D-1 P1 unload valve (cut valve) is largely differed from the
P1/P2 unload D-1 P2 unload valve (cut valve) actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.3 Boom up full lever and controller for possible
& relief failure.
11 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary 0.5 to 1.2MPa in boom up full
pressure directly lever and high idling operation
at the ports A7
and A5 of 8
sections solenoid
block

47-4
 ［47. TROUBLESHOOTING (BY TROUBLE)］

No. Sections Contents/normal value Corrective action, others

12 Actual measuring Carry out service -No.9 In case where the reading
current value of diagnosis. E-1 P1 pump is largely differed from the
P1/P2 pump E-2 P2 pump actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.18 Travel right full and controller for possible
lever & idling failure.
Operation No.19 Travel left full
lever & idling
13 Secondary pressure Measure the Check that pump proportional Replace proportional valve
of pump pump valve secondary pressure is
proportional valve proportional valve 2.7MPa or more in right (left) travel
secondary full lever and high idling operation
pressure directly Right travel: P1 pump proportional
in idling operation. valve
(Ports a3, a4) Left travel: P2 pump proportional
valve
14 Main relief pressure Carry out service -See Service Diagnosis Data List Measure the relief
diagnosis Operation No.3 Boom up full lever pressure actually
& relief
15 Check set Check that P1 and P2 pump Reset or replace
pressure pressures are 32MPa in boom up
full lever, high idling and H mode
operation.
16 Pump regulator Visual check When removing, free from Replace
abnormal resistance against sliding.
Free from abnormal damage, etc
on outside surface
Spring free from breakage,
damage, etc.
17 Pump Visual check When removing, inside parts Replace
(cylinder block, piston, valve plate,
shaft, etc.) are free from abnormal
resistance against sliding,
abnormal damage, etc.

47

47-5
［47. TROUBLESHOOTING (BY TROUBLE)］

(2) Engine down/stalled

No. Sections Contents/normal value Corrective action, others
1 Actual measuring Carry out service -No.9 In case where the reading
current value of diagnosis E-1 P1 pump is largely differed from the
P1/P2 pump E-2 P2 pump actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No. 1 Operation is nil and controller for possible
failure.
2 Secondary pressure Measure the Check that P1/P2 pump Replace proportional valve
of P1, P2 pump pump proportional valve pressures are
proportional valve proportional valve within the range of 0.5 to 1.0MPa
secondary in control lever neutral and high
pressure directly idling operation.
(Ports a3, a4)
3 Pressure sensor Check pressure -See Service Diagnosis Data List Check pressure sensor
of P1, P2 pump Operation No.1 Operation is nil and replace it if necessary
Operation No.3 Boom up full lever
& relief
4 Pump regulator Visual check When removing, free from Replace
abnormal resistance against sliding
Free from abnormal damage, etc
on outside surface
Spring free from breakage,
damage, etc.
5 Pump Visual check When removing, inside parts Replace
(cylinder block, piston, valve plate,
shaft, etc.) are free from abnormal
resistance against sliding,
abnormal damage, etc.

47-6
 ［47. TROUBLESHOOTING (BY TROUBLE)］

(3) Move at lever neutral position

No. Sections Contents/normal value Corrective action, others
1 Pilot pressure Carry out service Check that targeted pilot pressure Check remote control
sensor diagnosis of sensor is 0MPa in high idling valve
2 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
3 Main spool Check targeted Check that spool is free from Replace
spool visually abnormal damage and spring is
free from breakage
4 Over load relief Check targeted Free from dust entered in port Replace
valve spool visually relief valve. Seat is free from
abnormality
5 Lock valve poppet Check targeted Seat is free from abnormality Replace
(in case of boom poppet visually
and arm)
6 Lock valve selector Exchange lock Check that the trouble is reversed Replace
(in case of boom valve selector of
and arm) boom/arm and
boom/arm
7 Holding valve spool Check that Free from abnormal resistance Replace
for boom smooth sliding of against sliding Do not pull spool out of
(in case of boom) spool in sleeve sleeve forcibly.
8 Holding valve Check targeted Filter free from abnormal Replace
relief valve for spool visually contamination
boom
(in case of boom)
9 Cylinder Check targeted Make sure of no problem of seals Replace cylinder or seals
cylinder visually by disassembling and investigation

47

47-7
［47. TROUBLESHOOTING (BY TROUBLE)］

(4) Poor fine operability

No. Sections Contents/normal value Corrective action, others
1 Pressure sensor Carry out service -See Service Diagnosis Data List Replace pressure sensor
diagnosis Operation No. 1 Operation is nil
-All low pressure sensors are
0MPa to 0.1MPa
2 Actual measuring Carry out service -No.8 In case where the reading
current value of diagnosis D-1 P1 unload valve (cut valve) is largely differed from the
P1/P2 unload D-1 P2 unload valve (cut valve) actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No. 1 Operation is nil and controller for possible
failure.
3 Secondary pressure Measure the Check that P1/P2 unloads Replace proportional valve
of unload proportional valve secondary pressures is within the
proportional valve secondary range of 2.7MPa or more in control
pressure directly lever neutral and high idling
at the ports A7 operation
and A8 of 8
sections solenoid
block
4 Actual measuring Carry out service -No.9 In case where the reading
current value of diagnosis E-1 P1 pump is largely differed from the
P1/P2 pump E-2 P2 pump actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No. 1 Operation is nil and controller for possible
failure.
5 Secondary pressure Measure the Check that P1/P2 pump Replace proportional valve
of P1, P2 pump pump proportional valve pressures are Check regulator
proportional valve proportional valve within the range of 0.5 to 1.0MPa
secondary in control lever neutral and high
pressure directly. idling operation
(Ports a3, a4)
6 Slow return check Visual check Check that slow return check Clean and replace
valve of pilot line valve installed on pilot line is free
(in case of boom from dust entered
up or arm out)

47-8
 ［47. TROUBLESHOOTING (BY TROUBLE)］

(5) Slow boom up, insufficient power

No. Sections Contents/normal value Corrective action, others
1 Boom up pressure Carry out service -See Service Diagnosis Data List Check and replace
sensor diagnosis Operation No.3 boom up full lever pressure sensor
and relief Check remote control
valve
2 Remote control Measure directly Check that pressure is 3.0MPa or Check remote control
valve remote control more in boom up full lever and valve
pressure of boom high idling operation When equipped with
up multi control valve, check
it while changing lever
pattern
3 Pump pressure Carry out service -See Service Diagnosis Data List When there is difference
sensor diagnosis for P1, Operation No.4 boom up full lever between P1 and P2 pump
P2 pump and in operation pressures, check high
pressures in pressure sensor.
operation.
4 Actual measuring Carry out service -No.8 In case where the reading
current value of diagnosis D-1 P1 unload valve (cut valve) is largely differed from the
P1/P2 unload D-1 P2 unload valve (cut valve) actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.3 Boom up full lever and controller for possible
& relief failure.
5 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary 0.5 to 1.2MPa in boom up full
pressure directly lever and high idling operation
at the ports A7
and A5 of 7
sections solenoid
block
6 Actual measuring Carry out service -No.9 In case where the reading
current value of diagnosis E-1 P1 pump is largely differed from the
P1/P2 pump E-2 P2 pump actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.4 boom up full lever and controller for possible
& in operation failure.
7 Secondary pressure Measure the Check that P1/P2 pump Replace proportional valve
of P1, P2 pump pump proportional valve pressures are 47
proportional valve proportional valve within the range of 1.8 to 3.0MPa
secondary in boom up full lever and high
pressure directly idling operation
(Ports a3, a4)
8 P2 by-pass cut Visual check No problem for sliding ability of Clean and replace
valve main poppet and no contamination
<Trouble> on orifice
Only P2 pressure No problem for sliding ability of
is low. internal piston (Check it through
PBp2 port.)
9 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage

47-9
［47. TROUBLESHOOTING (BY TROUBLE)］

No. Sections Contents/normal value Corrective action, others

10 Lock valve Visual check When removing, free from Replace
poppet<Trouble>Bot abnormal resistance against sliding (Check on the casing side
h P1 and P2 Free from abnormal damage, etc for damage)
pressures are low. on outside surface
11 Conflux check valve Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
Only P2 pressure Free from abnormal damage, etc for damage)
is high. on outside surface
12 Holding valve for Visual check When removing, free from Replace
boom (poppet) abnormal resistance against sliding (Check on the casing side
<Trouble> Free from abnormal damage, etc for damage)
Both P1 and P2 on outside surface
pressures are high.
13 Boom spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
Only P1 pressure Spring is free from breakage. for damage)
is high.
14 Check boom Disassembly and Free from abnormal resistance Replace spool assembly
spool and investigation against sliding
recirculation Spring is free from breakage.
<Trouble>
Only P1 pressure
is low.
15 Conflux spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
Only P2 pressure Spring is free from breakage. for damage)
is high. Free from abnormal damage, etc
on outside surface
16 Main relief valve Check set -See Service Diagnosis Data List Reset or replace
<Trouble> pressure Operation No.3 boom up full lever
Relief pressure is and relief
low.
17 Over load relief Visual check Pressure is 32MPa or more in When only relief
valve (Head side) boom up full lever and high idling. pressure of boom up is
<Trouble> Free from dust entered in over low, replace valve
Relief pressure is load relief valve. Seat is free from
low. abnormality

47-10
 ［47. TROUBLESHOOTING (BY TROUBLE)］

(6) Slow boom down/insufficient power for lifting up body

No. Sections Contents/normal value Corrective action, others
1 Boom down Carry out service -See Service Diagnosis Data List Check and replace
pressure sensor diagnosis Operation No.5 boom down full pressure sensor.
lever & in operation Check remote control
valve.
2 Remote control Measure remote Check that pressure is 3.0MPa or Check remote control
valve control pressure more in boom down full lever and valve
of boom down high idling operation When equipped with
directly multi control valve, check
it while changing lever
pattern.
3 Actual measuring Carry out service P1 unload valve (cut valve) In case where the reading
current value of P1 diagnosis -See Service Diagnosis Data List is largely differed from the
unload proportional Operation No.5 boom down full actually measured value,
valve lever & in operation check proportional valve
and controller for possible
failure.
4 Secondary pressure Measure the Check that P1 unload secondary Replace proportional valve
of P1 unload proportional valve pressures are within the range of
proportional valve secondary 0.8 to 1.2MPa in boom down full
pressure directly lever and high idling operation
at the ports A7 of
7 sections
solenoid block.
5 Actual measuring Carry out service -No.9 In case where the reading
current value of P1 diagnosis E-1 P1 pump is largely differed from the
pump proportional -See Service Diagnosis Data List actually measured value,
valve Operation No.5 boom down full check proportional valve
lever & in operation and controller for possible
failure.
6 Secondary pressure Measure the Check that P1 pump proportional Replace proportional valve
of P1 pump pump valve pressures are within the
proportional valve proportional valve range of 2.0 to 2.5MPa in boom
secondary down full lever and high idling
pressure directly operation
(Ports a3, a4)
7 Actual measuring Carry out service Check that the value is not change -Check pressure sensor of
current value of diagnosis regardless of operation travel 47
travel straight -See Service Diagnosis Data List -In case where the
proportional valve Operation No. 1 Operation is nil reading is largely differed
Operation No.18 Travel right full from the actually
lever & idling measured value, check
Operation No.19 Travel left full proportional valve and
lever & idling controller for possible
failure.
8 Travel straight Measure directly High idling pressure is 0.8MPa or Replace proportional valve
proportional valve the travel straight less regardless neutral/operation
secondary pressure proportional valve
secondary
pressure.

47-11
［47. TROUBLESHOOTING (BY TROUBLE)］

No. Sections Contents/normal value Corrective action, others

9 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
10 Lock valve poppet Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
Boom down is low. Free from abnormal damage, etc for damage)
on outside surface
11 Holding valve Visual check When removing, free from Replace
(poppet) abnormal resistance against sliding (Check on the casing side
<Trouble> Free from abnormal damage, for damage)
Boom down is etc on outside surface
slow.
12 Boom spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
Boom down is Free from abnormal damage, etc for damage)
slow. on outside surface
Spring is free from breakage.
13 Check boom Disassembly and Free from abnormal resistance Replace spool assembly
spool and investigation against sliding
recirculation Spring is free from breakage.
<Trouble>
Machine can not
be lifted by
supporting with
boom.
14 Main relief valve Check set -See Service Diagnosis Data List Reset or replace
<Trouble> pressure Operation No.3 boom up full lever
Relief pressure is and relief
low.
15 Over load relief Visual check Free from dust entered in port Replace
valve relief valve.
<Trouble> Seat is free from abnormality
Machine can not
be lifted by
supporting with
boom.

47-12
 ［47. TROUBLESHOOTING (BY TROUBLE)］

(7) Slow arm in, insufficient power

No. Sections Contents/normal value Corrective action, others
1 Arm in pressure Carry out service -See Service Diagnosis Data List Check and replace
sensor diagnosis Operation No.6 arm in full lever pressure sensor
and relief Check remote control
valve
2 Remote control Measure directly Check that pressure is 3.0MPa or Check remote control
valve pressure remote control more in arm in full lever and high valve
pressure of arm in idling operation When equipped with
multi control valve, check
it while changing lever
pattern
3 Pump pressure Carry out service -See Service Diagnosis Data List When there is difference
sensor diagnosis for P1, Operation No.7 arm in full lever between P1 and P2 pump
P2 pump and in operation pressures, check high
pressures in pressure sensor
operation.
4 Actual measuring Carry out service -No.8 In case where the reading
current value of diagnosis D-1 P1 unload valve (cut valve) is largely differed from the
P1/P2 unload D-1 P2 unload valve (cut valve) actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.6 Arm in full lever & and controller for possible
relief failure.
5 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary 0.5 to 1.2MPa in arm in full lever
pressure directly and high idling operation.
at the ports A7
and A5 of 7
sections solenoid
block.
6 Actual measuring Carry out service -No.9 In case where the reading
current value of diagnosis E-1 P1 pump is largely differed from the
P1/P2 pump E-2 P2 pump actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.7 Arm in full lever & and controller for possible
in operation failure.
7 Secondary pressure Measure the Check that P1/P2 pump Replace proportional valve
of P1, P2 pump pump proportional valve pressures are 47
proportional valve proportional valve 2.0MPa or more in arm in full lever
secondary and high idling operation.
pressure directly. (Secondary pressure is affected by
(Ports a3, a4) oil temperature and attachment
weight)
8 Actual measuring Carry out service -See Service Diagnosis Data List In case where the reading
current value of diagnosis Operation No.1 Operation is nil is largely differed from the
arm in spool 2 Operation No.6 Arm in full lever & actually measured value,
proportional valve relief check proportional valve
Operation No.7 Arm in full lever & and controller for possible
in operation failure.

47-13
［47. TROUBLESHOOTING (BY TROUBLE)］

No. Sections Contents/normal value Corrective action, others

9 Secondary pressure Measure directly Check that secondary pressure of Replace proportional valve
of arm in spool 2 the proportional proportional valve secondary
proportional valve valve secondary pressures are within the range of
pressure at the following
ports A8 (arm 2 Lever neutral: 0MPa
spool) of 7 Motion in the air: 1.7 to 2.2MPa
sections solenoid Arm in relief: 2.5MPa or more
block.
10 Actual measuring Carry out service Check that the value is not change -Check pressure sensor of
current value of diagnosis regardless of operation travel
travel straight -See Service Diagnosis Data List -In case where the
proportional valve Operation No. 1 Operation is nil reading is largely differed
Operation No.18 Travel right full from the actually
lever & idling measured value, check
Operation No.19 Travel left full proportional valve and
lever & idling controller for possible
failure.
11 Secondary pressure Measure directly 0.8MPa or less in high idling Replace proportional valve
of travel straight the proportional operation regardless of
proportional valve valve secondary neutral/operation
pressure at the
ports A6 (travel
straight) of 7
sections solenoid
block
12 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
13 Main relief valve Check set -See Service Diagnosis Data List Reset or replace
<Trouble> pressure Operation No.3 boom up full lever
Relief pressure is and relief
low.
14 Over load relief Visual check Pressure is 32MPa or more in When only relief
valve (Head side) arm in and relief. pressure of arm in is
<Trouble> Free from dust entered in over low, replace valve
P1, P2 pressure is load relief valve.
low. Seat is free from abnormality
15 Over load relief Visual check (Rod Pressure is 32MPa or more in When only relief
valve side) arm out and relief. pressure of arm out is
<Trouble> Free from dust entered in over low, replace valve
P1, P2 pressure is load relief valve.
low. Seat is free from abnormality.
16 Arm 1 spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P1, P2 pressure is Free from abnormal damage, etc for damage)
high. on outside surface
Spring is free from breakage.

47-14
 ［47. TROUBLESHOOTING (BY TROUBLE)］

No. Sections Contents/normal value Corrective action, others

17 Arm 2 spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P1, P2 pressure Free from abnormal damage, etc for damage)
is high or low. on outside surface
Spring is free from breakage.
18 Check arm 2 spool Disassembly and Free from abnormal resistance Replace spool assembly
and recirculation investigation against sliding
<Trouble> Spring is free from breakage.
Arm in power is
poor.
19 Check lock valve Visual check Free from abnormal resistance Replace
poppet against sliding (Check on the casing side
<Trouble> Free from abnormal damage, etc for damage)
Both P1, P2 on outside surface
pressures are high.

47

47-15
［47. TROUBLESHOOTING (BY TROUBLE)］

(8) Slow independent arm out (in the air)

No. Sections Contents/normal value Corrective action, others
1 Arm out pressure Carry out service -See Service Diagnosis Data List Check and replace
sensor diagnosis Operation No.8 arm out full lever pressure sensor
and relief Check remote control
valve
2 Remote control Measure directly Check that pressure is 3.0MPa or Check remote control
valve remote control more in arm out full lever and high valve
pressure of arm idling operation When equipped with
out multi control valve, check
it while changing lever
pattern
3 Pump pressure Carry out service -See Service Diagnosis Data List When there is difference
sensor diagnosis for P1, Operation No.9 arm out full lever between P1 and P2 pump
P2 pump and in operation pressures, check high
pressures in pressure sensor
operation.
4 Actual measuring Carry out service -No.8 In case where the reading
current value of diagnosis D-1 P1 unload valve (cut valve) is largely differed from the
P1/P2 unload D-1 P2 unload valve (cut valve) actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.8 Arm out full lever & and controller for possible
relief failure.
5 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary 0.5 to 1.2MPa in arm out full
pressure directly lever and high idling operation
at the ports A7
and A5 of 7
sections solenoid
block
6 Actual measuring Carry out service -No.9 In case where the reading
current value of diagnosis E-1 P1 pump is largely differed from the
P1/P2 pump E-2 P2 pump actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.9 Arm out full lever & and controller for possible
in operation failure.
7 Secondary pressure Measure the Check that P1/P2 pump Replace proportional valve
of P1, P2 pump pump proportional valve pressures are
proportional valve proportional valve within the range of 1.5 to 2.7MPa
secondary in arm out full lever and high idling
pressure directly operation
(Ports a3, a4) (Secondary pressure is affected by
oil temperature and attachment
weight)

47-16
 ［47. TROUBLESHOOTING (BY TROUBLE)］

No. Sections Contents/normal value Corrective action, others

8 Actual measuring Carry out service Check that the value is not change -Check pressure sensor of
current value of diagnosis regardless of operation travel
travel straight -See Service Diagnosis Data List -In case where the
proportional valve Operation No. 1 Operation is nil reading is largely differed
Operation No.18 Travel right full from the actually
lever & idling measured value, check
Operation No.19 Travel left full proportional valve and
lever & idling controller for possible
failure.
9 Secondary pressure Measure directly 0.8MPa or less in high idling Replace proportional valve
of travel straight the proportional operation regardless of
proportional valve valve secondary neutral/operation
pressure at the
ports A6 (travel
straight) of 7
sections solenoid
block
10 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
11 Main relief valve Check set -See Service Diagnosis Data List Reset or replace
<Trouble> pressure Operation No.3 boom up full lever
Relief pressure is and relief
low.
12 Over load relief Visual check (Rod Pressure is 32MPa or more in When only relief
valve side) arm out and relief. pressure of arm out is
<Trouble> Free from dust entered in over low, replace valve
P1, P2 pressure is load relief valve. Seat is free from
low. abnormality
13 Arm 1 spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P2 pressure is Free from abnormal damage, etc for damage)
high. on outside surface
Spring is free from breakage.
14 Arm 2 spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P1 pressure is Free from abnormal damage, etc for damage)
high. on outside surface 47
Spring is free from breakage.
15 Check arm 2 spool Disassembly and Free from abnormal resistance Replace spool assembly
and recirculation investigation against sliding
<Trouble> (spring side) Spring is free from breakage.
Both P1, P2
pressures are low.
16 Check lock valve Visual check Free from abnormal resistance Replace
poppet against sliding (Check on the casing side
<Trouble> Free from abnormal damage, etc for damage)
Both P1, P2 on outside surface
pressures are high.

47-17
［47. TROUBLESHOOTING (BY TROUBLE)］

(9) Bucket digging is slow

No. Sections Contents/normal value Corrective action, others
1 Bucket digging Carry out service -See Service Diagnosis Data List Check and replace
pressure sensor diagnosis Operation No.12 bucket digging pressure sensor
full lever and relief Check remote control
valve
2 Remote control Measure directly Check that pressure is 3.0MPa or Check remote control
valve remote control more in bucket digging full lever valve
pressure of bucket and high idling operation When equipped with
digging multi control valve, check
it while changing lever
pattern
3 Pump pressure Carry out service -See Service Diagnosis Data List When there is difference
sensor diagnosis for P1, Operation No.13 Bucket digging full between P1 and P2 pump
P2 pump lever and in operation pressures, check high
pressures in pressure sensor
operation.
4 Actual measuring Carry out service -No.8 In case where the reading
current value of P1 diagnosis D-1 P1 unload valve (cut valve) is largely differed from the
unload proportional -See Service Diagnosis Data List actually measured value,
valve Operation No.12 Bucket digging full check proportional valve
lever & relief and controller for possible
failure.
5 Secondary pressure Measure the Check that P1 unload secondary Replace proportional valve
of P1, unload proportional valve pressures are within the range of
proportional valve secondary 0.5 to 1.2MPa in bucket digging
pressure directly full lever and high idling operation
at the ports A7
and A5 of 7
sections solenoid
block
6 Actual measuring Carry out service -No.9 In case where the reading
current value of P1 diagnosis E-1 P1 pump is largely differed from the
pump proportional -See Service Diagnosis Data List actually measured value,
valve Operation No.13 Bucket digging full check proportional valve
lever & in operation and controller for possible
failure.
7 Secondary pressure Measure the Check that P1 pump proportional Replace proportional valve
of P1, pump pump valve pressures is 2.7MPa or
proportional valve proportional valve more in bucket digging full lever
secondary and high idling operation.
pressure directly
(Ports a3, a4)
8 Actual measuring Carry out service -See Service Diagnosis Data List In case where the reading
current value of diagnosis Operation No.12 Bucket digging full is largely differed from the
travel straight lever & relief actually measured value,
proportional valve check proportional valve
and controller for possible
failure.

47-18
 ［47. TROUBLESHOOTING (BY TROUBLE)］

No. Sections Contents/normal value Corrective action, others

9 P2 by-pass cut Visual check No problem for sliding ability of Clean or replace
valve main poppet and no contamination
<Trouble> on orifice
Only P2 pressure No problem for sliding ability of
is low. internal piston (Check it through
PBp2 port.)
10 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
11 Main relief valve Check set -See Service Diagnosis Data List Reset or replace
pressure Operation No.3 Boom up full lever
and relief
12 Travel straight spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P2 pressure is Free from abnormal damage, etc for damage)
high. on outside surface
Spring is free from breakage.
13 Bucket spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
Both P1, P2 Free from abnormal damage, etc for damage)
pressures are high. on outside surface
Spring is free from breakage.
14 Over load relief Check targeted Free from dust entered in over Replace
valve spool visually load relief valve.
Seat is free from abnormality.

47

47-19
［47. TROUBLESHOOTING (BY TROUBLE)］

(10) Bucket dump is slow

No. Sections Contents/normal value Corrective action, others
1 Bucket dump Carry out service -See Service Diagnosis Data List Check and replace
pressure sensor diagnosis Operation No.14 Bucket dump full pressure sensor
lever and relief Check remote control
valve
2 Remote control Measure directly Check that pressure is 3.0MPa or Check remote control
valve remote control more in bucket dump full lever and valve
pressure of bucket high idling operation When equipped with
dump multi control valve, check
it while changing lever
pattern
3 Pump pressure Carry out service -See Service Diagnosis Data List When there is difference
sensor diagnosis for P1, Operation No.15 Bucket dump full between P1 and P2 pump
P2 pump lever and in operation pressures, check high
pressures in pressure sensor
operation.
4 Actual measuring Carry out service -No.8 In case where the reading
current value of P1 diagnosis D-1 P1 unload valve (cut valve) is largely differed from the
unload proportional -See Service Diagnosis Data List actually measured value,
valve Operation No.14 Bucket dump full check proportional valve
lever & relief and controller for possible
failure.
5 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, unload proportional valve pressures are within the range of
proportional valve secondary 0.5 to 1.2MPa in bucket dump full
pressure directly lever and high idling operation.
at the ports A7 Replace proportional valve
and A5 of 7
sections solenoid
block
6 Actual measuring Carry out service -No.9 In case where the reading
current value of P1 diagnosis E-1 P1 pump is largely differed from the
pump proportional -See Service Diagnosis Data List actually measured value,
valve Carry out Operation No.15 Bucket dump full check proportional valve
service diagnosis. lever & in operation and controller for possible
failure.
7 Secondary pressure Measure the Check that P1 pump proportional Replace proportional valve
of P1, pump pump valve pressures is 2.7MPa or
proportional valve proportional valve more in bucket dump full lever and
secondary high idling operation.
pressure directly
(Ports a3, a4)
8 Actual measuring Carry out service -See Service Diagnosis Data List In case where the reading
current value of diagnosis Operation No.14 Bucket dump full is largely differed from the
travel straight lever & relief actually measured value,
proportional valve check proportional valve
and controller for possible
failure.

47-20
 ［47. TROUBLESHOOTING (BY TROUBLE)］

No. Sections Contents/normal value Corrective action, others

9 Secondary pressure Measure directly Check that travel straight secondary Replace proportional valve
of travel straight the proportional pressure is 2.7MPa or more in
proportional valve valve secondary bucket dump full lever and high
pressure at the idling operation
ports A6 (travel
straight) of 7
sections solenoid
block
10 P2 by-pass cut Visual check No problem for sliding ability of Clean and replace
valve main poppet and no contamination
<Trouble> on orifice
Only P2 pressure No problem for sliding ability of
is low. internal piston (Check it through
PBP2 port.)
11 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
12 Main relief valve Check set -See Service Diagnosis Data List Reset or replace
<Trouble> pressure Operation No.3 Boom up full lever
Relief pressure is and relief
low.
13 Travel straight spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P2 pressure is Free from abnormal damage, etc for damage)
high. on outside surface
14 Bucket spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
Both P1, P2 Free from abnormal damage, etc for damage)
pressures are high. on outside surface
Spring is free from breakage.
15 Over load relief Check targeted Free from dust entered in over Replace
valve spool visually load relief valve.
Seat is free from abnormality.

47

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［47. TROUBLESHOOTING (BY TROUBLE)］

(11) Swing does not move/slow

No. Sections Contents/normal value Corrective action, others
1 Swing pressure Carry out service -See Service Diagnosis Data List Check and replace
sensor diagnosis Operation No.11 Swing full lever pressure sensor
and in operation Check remote control
valve
2 Remote control Measure directly Check that pressure is 3.0MPa or Check remote control
valve remote control more in boom up full lever and valve
pressure of swing high idling operation When equipped with
multi control valve, check
it while changing lever
pattern
3 Swing parking Carry out service No.3 F-2 SWING-BRAKE Check swing pressure
brake solenoid diagnosis Lever neutral: COMP ON, MEAS sensor
ON Check harness
Swing: COMP OFF, MEAS OFF
4 Swing parking Measurement of Lever neutral: 0MPa Replace solenoid valve
brake solenoid solenoid valve A2 In operation: 4MPa or more
port
5 Shuttle valve Visual check No contamination on spool cover Clean or replace
<Trouble> (short side) and orifice
Pilot pressure is No damage on spool cover (long
low. side) and shuttle
6 Pump pressure Carry out service -See Service Diagnosis Data List Check high pressure
sensor diagnosis for P2 Operation No.11 Swing full lever sensor
pump pressures in and in operation
operation
7 Actual measuring Carry out service -No.8 D-2 P2 unload valve (cut In case where the reading
current value of P2 diagnosis valve) is largely differed from the
unload proportional -See Service Diagnosis Data List actually measured value,
valve Operation No.11 Swing full lever check proportional valve
& in operation and controller for possible
failure.
8 Secondary pressure Measure the Check that P2 unload secondary Replace proportional valve
of P2 unload proportional valve pressures are within the range of
proportional valve secondary 0.5 to 1.2MPa in swing full lever
pressure directly and high idling operation
at the ports A5 of
7 sections
solenoid block
9 Actual measuring Carry out service -No.9 E-2 P2 pump In case where the reading
current value of P2 diagnosis -See Service Diagnosis Data List is largely differed from the
pump proportional Operation No.11 Swing full lever actually measured value,
valve & in operation check proportional valve
and controller for possible
failure.
10 Secondary pressure Measure the Check that P2 pump proportional Replace proportional valve
of P2 pump pump valve pressure is 2.7MPa or more
proportional valve proportional valve in swing full lever and high idling
secondary operation
pressure directly
(Ports a3, a4)

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 ［47. TROUBLESHOOTING (BY TROUBLE)］

No. Sections Contents/normal value Corrective action, others

11 Actual measuring Carry out service Check that the value is not change -Check pressure sensor of
current value of diagnosis regardless of operation travel
travel straight -See Service Diagnosis Data List -In case where the
proportional valve Operation No. 1 Operation is nil reading is largely differed
(Check this Operation No.18 Travel right full from the actually
trouble by only lever & idling measured value, check
swing operation) Operation No.19 Travel left full proportional valve and
lever & idling controller for possible
failure.
12 Secondary pressure Measure directly 0.8MPa or less in high idling Replace proportional valve
of travel straight the proportional operation regardless of
proportional valve valve secondary neutral/operation
(Check this pressure at the
trouble by only ports A6 (travel
swing operation) straight) of 7
sections solenoid
block
13 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
14 Travel straight spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P2 pressure is low. Free from abnormal damage, etc for damage)
on outside surface
Spring is free from breakage.
15 Swing spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P2 pressure is Free from abnormal damage, etc for damage)
high. on outside surface
Spring is free from breakage.
16 Swing relief valve Check set -See Service Diagnosis Data List Reset or replace
<Trouble> pressure Operation No.10 Swing full lever
Relief pressure is and relief
low.
17 Swing motor Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be free
from abnormal resistance against
sliding. 47
Free from abnormal damage, etc
on outside surface (brake plate etc)
18 Swing reduction Take sample oil Sampling oil does not include a Disassemble and inspect
gear oil from swing lot of metal powder. reduction gear
reduction gear
drain
19 Swing reduction Visual check Tooth surface is not worn Replace
abnormally and is not chipped.

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［47. TROUBLESHOOTING (BY TROUBLE)］

(12) Noise occurred at swing operation

No. Sections Contents/normal value Corrective action, others
1 Swing parking Carry out service No.3 F-2 SWING-BRAKE Check swing pressure
brake solenoid diagnosis Lever neutral: COMP ON, MEAS sensor
ON Check harness
Swing: COMP OFF, MEAS OFF
2 Measurement of Lever neutral: 0MPa Replace solenoid valve
solenoid valve A2 In operation: 4MPa or more
port
3 Boost check valve Visual check When removing, free from Replace
(Sound of abnormal resistance against sliding
cavitation at Spring is free from breakage.
stopping)
4 By-pass check Visual check When removing, free from Replace
valve abnormal resistance against sliding
(Sound of Spring is free from breakage.
cavitation at
stopping)
5 Swing motor Visual check Disassemble and inspect abnormal Replace
(Brake valve/friction wear and scuffing
plate)
6 Swing motor piston Visual check When removing, free from Replace
abnormal resistance against sliding
Spring is free from breakage.
7 Swing reduction Take sample oil Sampling oil does not include a Disassemble and inspect
gear oil from swing lot of metal powder. reduction gear
reduction gear
drain.
8 Swing reduction Visual check Tooth surface has no abnormally Replace
worn and chipped.

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 ［47. TROUBLESHOOTING (BY TROUBLE)］

(13) Swing drifts on a slope while swing control lever is in neutral position
No. Sections Contents/normal value Corrective action, others
1 Swing pressure Carry out service -Engine stop & starter key ON Check and replace
sensor diagnosis All pilot low pressure sensors are pressure sensor
within range of 0 to 0.1MPa.
2 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
3 Swing parking Carry out service No.3 F-2 SWING-BRAKE Check swing pressure
brake solenoid diagnosis Lever neutral: COMP ON, MEAS sensor
ON Check harness
Swing: COMP OFF, MEAS OFF Check parking brake
release switch
4 Measurement of Lever neutral: 0MPa Replace solenoid valve
solenoid valve A2 In operation: 4MPa or more
port
5 Swing motor Visual check Disassemble and inspect abnormal Replace
(Brake valve/friction wear and scuffing
plate)
6 Parking brake Visual check Piston and friction plate do not Replace
have abnormal resistance against
sliding
Free from spring damage

(14) Swing drifts at stopping

No. Sections Contents/normal value Corrective action, others
1 Shuttle valve Visual check No contamination on spool cover Clean or replace
<Trouble> (short side) and orifice. No damage
Pilot pressure is on spool cover (long side) and
low shuttle.
2 Swing pressure Carry out service -Engine stop & starter key ON Replace pressure sensor
sensor diagnosis All pilot low pressure sensors are
within range of 0 to 0.1MPa.
3 Swing relief valve Check set -See Service Diagnosis Data List Reset or replace
<Trouble> pressure Operation No.10 Swing full lever
Relief pressure is and relief
low.
47
4 Anti-reaction valve Visual check Free from dirt entering Clean or replace
Sliding part should be free from
foreign matter entering, abnormal
damage and wear.
5 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
6 Swing motor Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be free
from abnormal resistance against
sliding.
Free from abnormal damage, etc
on outside surface (brake plate etc)

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［47. TROUBLESHOOTING (BY TROUBLE)］

(15) Travel speed is slow/poor

No. Sections Contents/normal value Corrective action, others
1 Travel right and left Carry out service -See Service Diagnosis Data List Check and replace
pressure sensor diagnosis Operation No.18 Travel right full pressure sensor
lever and idling Check remote control
Operation No.19 Travel left full valve
lever and idling
2 Remote control Measure directly Check that pressure is 2.1MPa or Check remote control
valve remote control more in travel right (left), forward valve
pressure of travel (reverse) full lever and high idling
right and left operation
3 Actual measuring Carry out service -No.9 In case where the reading
current value of diagnosis D-1 P1 unload valve (cut valve) is largely differed from the
P1/P2 unload D-1 P2 unload valve (cut valve) actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.18 Travel right full and controller for possible
lever & idling failure.
Operation No.19 Travel left full
lever & idling
4 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary followings in travel right (left),
pressure directly forward (reverse) full lever and high
at the ports A7 idling operation
and A5 of 7 Travel right (P1 unload): 0.5 to
sections solenoid 1.0MPa
block Travel left (P2 unload): 0.5 to
1.0MPa
5 Actual measuring Carry out service -No.9 In case where the reading
current value of diagnosis E-1 P1 pump is largely differed from the
P1/P2 pump E-2 P2 pump actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.18 Travel right full and controller for possible
lever & idling failure.
Operation No.19 Travel left full
lever & idling
6 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 pump pump pressures are within the range of
proportional valve proportional valve followings in travel right (left),
secondary forward (reverse) full lever and high
pressure directly idling operation
(Ports a3, a4) Travel right (P1 pump): 2.7MPa or
more
Travel left (P2 pump): 2.7MPa or
more

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 ［47. TROUBLESHOOTING (BY TROUBLE)］

No. Sections Contents/normal value Corrective action, others

7 Actual measuring Carry out service Check that the value is not change -Check voltage of low
current value of diagnosis regardless of operation pressure sensor other
travel straight -See Service Diagnosis Data List than sensor for travel*-In
proportional valve Operation No. 1 Operation is nil case where the reading is
Operation No.18 Travel right full largely differed from the
lever & idling actually measured value,
Operation No.19 Travel left full check proportional valve
lever & idling and controller for possible
failure
8 Secondary pressure Measure directly 0.8MPa or less in high idling Replace proportional valve
of travel straight the proportional operation regardless of
proportional valve valve secondary neutral/operation
pressure
9 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
Check sealing ability of shuttle
valve and entry of dust in orifice
10 Travel straight spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P1 pressure is Free from abnormal damage, etc for damage)
high. on outside surface
Spring is free from breakage.
11 Travel spool Visual check of When removing, free from Replace
<Trouble> targeted spool abnormal resistance against sliding (Check on the casing side
Pump pressure is Free from abnormal damage, etc for damage)
high. on outside surface
Spring is free from breakage.
12 Travel motor relief Check set Check P1 and P2 pump pressures If P1 is low, right travel
valve pressure are 32MPa or more in right and motorAfs relief valve is
left travel levers full lever (relief failed.
operation at locked crawler belt) If P2 is low, left travel
and high idling motorAfs relief valve is
failed.
13 Travel motor Visual check Inner parts (piston, cylinder block, Replace
valve plate, brake valve spool) are
to be free from abnormal
resistance against sliding. 47
Free from abnormal damage, etc
on outside surface (brake plate etc)
14 Parking brake in Visual check When removing, free from Replace
travel motor abnormal resistance against sliding
No sticking on friction plate and
separator plate
15 Travel reduction Take sample oil Sampling oil does not include a Disassemble and inspect
gear oil from travel lot of metal powder. reduction gear
reduction gear
drain
16 Travel reduction Visual check Tooth surface is not worn Replace
abnormally and is not chipped.

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［47. TROUBLESHOOTING (BY TROUBLE)］

(16) Travel deviation

No. Sections Contents/normal value Corrective action, others
1 Travel right and left Carry out service -See Service Diagnosis Data List Check and replace
pressure sensor diagnosis Operation No.18 Travel right full pressure sensor
lever and idling Check remote control
Operation No.19 Travel left full valve
lever and idling
2 Remote control Measure directly Check that pressure is 2.1MPa or Check remote control
valve remote control more in travel right (left), forward valve
pressure of travel (reverse) full lever and high idling
right and left operation
3 Actual measuring Carry out service Check that the value is not change -Check voltage of low
current value of diagnosis regardless of operation pressure sensor other
travel straight -See Service Diagnosis Data List than sensor for travel
proportional valve Operation No. 1 Operation is nil -In case where the
Operation No.18 Travel right full reading is largely differed
lever & idling from the actually
Operation No.19 Travel left full measured value, check
lever & idling proportional valve and
controller for possible
failure.
4 Secondary pressure Measure directly 0.8MPa or less in high idling Replace proportional valve
of travel straight the proportional operation regardless of
proportional valve valve secondary neutral/operation
pressure
5 Actual measuring Carry out service -No.8 D-1 P1 unload valve (cut In case where the reading
current value of diagnosis valve) is largely differed from the
P1/P2 unload D-1 P2 unload valve (cut valve) actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.18 Travel right full and controller for possible
lever & idling failure.
Operation No.19 Travel left full
lever & idling
6 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary followings in travel right (left),
pressure directly forward (reverse) full lever and high
at the ports A7 idling operation
and A5 of 7 Travel right (P1 unload): 0.5 to
sections solenoid 1.0MPa
block Travel left (P2 unload): 0.5 to
1.0MPa
7 Actual measuring Carry out service -No.9 In case where the reading
current value of diagnosis E-1 P1 pump is largely differed from the
P1/P2 pump E-2 P2 pump actually measured value,
proportional valve -See Service Diagnosis Data List check proportional valve
Operation No.18 Travel right full and controller for possible
lever & idling failure.
Operation No.19 Travel left full
lever & idling

47-28
 ［47. TROUBLESHOOTING (BY TROUBLE)］

No. Sections Contents/normal value Corrective action, others

8 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 pump pump pressures are within the range of
proportional valve proportional valve followings in travel right (left),
secondary forward (reverse) full lever and high
pressure directly idling operation
(Ports a3, a4) Travel right (P1 pump): 2.7MPa or
more
Travel left (P2 pump): 2.7MPa or
more
9 Exchange P1 for Exchange Check the direction of deviation If the direction is
P2 delivery pipe of changed, inspect a
P1 for P2 pump. If the direction is
not changed, inspect a
valve and travel unit.
10 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
Check sealing ability of shuttle
valve and entry of dust in orifice
11 Travel straight spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P1 pressure is Free from abnormal damage, etc for damage)
high. on outside surface
Spring is free from breakage
12 Travel spool Visual check of When removing, free from Replace
<Trouble> targeted spool abnormal resistance against sliding (Check on the casing side
Pump pressure is Free from abnormal damage, etc for damage)
high. on outside surface
Spring is free from breakage
13 Travel motor relief Check set Check P1 and P2 pump pressures If P1 is low, right travel
valve pressure are 32MPa or more in right and motorAfs relief valve is
left travel levers full lever (relief failed.
operation at locked crawler belt) If P2 is low, left travel
and high idling motorAfs relief valve is
failed.
Replace as necessary
14 Travel motor Visual check Inner parts (piston, cylinder block, Replace
valve plate, brake valve spool) are 47
to be free from abnormal
resistance against sliding.
Free from abnormal damage, etc
on outside surface (brake plate etc)
15 Travel reduction Take sample oil Sampling oil does not include a Disassemble and inspect
gear oil from travel lot of metal powder. reduction gear
reduction gear
drain
16 Travel reduction Visual check Tooth surface is not worn Replace
abnormally and is not chipped.

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［47. TROUBLESHOOTING (BY TROUBLE)］

No. Sections Contents/normal value Corrective action, others

17 Pump regulator Visual check When removing, free from Replace
abnormal resistance against sliding
Free from abnormal damage, etc
on outside surface
Spring free from breakage,
damage, etc.
18 Pump Visual check When removing, inside parts Replace
(cylinder block, piston, valve plate,
shaft, etc.) are free from abnormal
resistance against sliding,
abnormal damage, etc.

(17) Travel 1/2 speed cannot be switched

(In case of the traveling under heavy loading (for example traveling on a slope or traveling on a soft
ground), the speed may sometimes does not change from 1st to 2nd because this machine equips the
function of automatic speed change.)

No. Sections Contents/normal value Corrective action, others

1 Travel 1/2 speed Carry out service Switch travel 1/2 speed to 2nd Check pressure sensor
switching solenoid diagnosis speed No.3 F-3 1/2-TRAVEL Check harness
Lever neutral COMP OFF, MEAS Check travel 1/2 speed
OFF switch on gauge cluster
Travel operation COMP ON, MEAS
ON
2 Travel 1/2 speed Measure A3 port Lever neutral: 0MPa Replace solenoid valve
switching solenoid pressure on In operation: 4MPa or more
solenoid valve
3 1/2 speed Visual check Check that spool is free from Replace
switching spool in abnormal damage and spring is (Check on the casing side
travel motor free from breakage for damage)
4 1/2 speed Visual check Free from entry of dust Remove dust or replace
switching orifice in
travel motor
5 Tilting piston in Visual check Free from abnormal wear on piston Replace
travel motor and seal (Check on the casing side
for damage)

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 ［47. TROUBLESHOOTING (BY TROUBLE)］

(18) Machine does not stay on a slope in traveling

No. Sections Contents/normal value Corrective action, others
1 Pilot pressure Carry out service -Engine stop & starter key switch Check pressure sensor
sensor diagnosis is ON and replace as necessary
Targeted pilot low pressure sensor Check remote control
is in range of 0 to 0.1MPa valve
2 Remote control Check targeted Check that spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
3 Parking brake in Visual check When removing, free from Replace
travel motor abnormal resistance against sliding
Spring free from breakage,
damage, etc.
4 Orifice of passage Visual check Free from entry of dust Remove dust or replace
for parking brake
in travel motor

(19) Machine does not travel straight in simultaneous operation of traveling and attachment
No. Sections Contents/normal value Corrective action, others
1 Actual measuring Carry out service No.8 D-3 S-TRAVEL is should be -Check voltage of low
current value of diagnosis COMP 590mA and MEAS 560 to pressure sensor other
travel straight 620mA in both travel full lever than travel sensor-In
proportional valve and in boom up full lever at high case where the reading is
idling largely differed from the
actually measured value,
check proportional valve
and controller for possible
failure.
2 Secondary pressure Measure directly Check secondary pressure is within Replace proportional valve
of travel straight the proportional range of 1.8 to 2.2MPa in both
proportional valve valve secondary travel full lever and in boom up full
pressure lever at high idling
3 Travel straight spool Visual check When removing, free from Replace
abnormal resistance against sliding (Check on the casing side
Free from abnormal damage, etc for damage)
on outside surface
Spring is free from breakage.

47

47-31
［47. TROUBLESHOOTING (BY TROUBLE)］

(20) Breaker works slowly and power is poor

(In case of conflux, check p1 unload/pump and travel straight)

No. Sections Contents/normal value Corrective action, others

1 Pressure sensor for Carry out service -See Service Diagnosis Data List Check and replace
optional attachment diagnosis Operation No.16 P2 side OPT full pressure senso
lever and relief Check remote control
valve
2 Remote control Measure directly Check that pressure is 2.1MPa or Check remote control
valve remote control more in optional attachment full valve0
pressure of travel lever and high idling operation
right and left
3 Actual measuring Carry out service -See Service Diagnosis Data List -In case where the
current value of diagnosis Operation No.16 P2 side OPT full reading is largely differed
P1/P2 unload lever and relief from the actually
proportional valve measured value, check
proportional valve and
controller for possible
failure.
4 Secondary pressure Measure the Check that P1/P2 unload secondary Replace proportional valve
of P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary 0.5 to 1.2MPa
pressure directly
at the ports A7
and A5 of 7
sections solenoid
block
5 Actual measuring Carry out service -See Service Diagnosis Data List -Check voltage of low
current value of diagnosis Operation No.16 P2 side OPT full pressure sensor other
travel straight lever & relief than sensor for optional
proportional valve attachment
-In case where the
reading is largely differed
from the actually
measured value, check
proportional valve and
controller for possible
failure.
6 Secondary pressure Measure directly Check that travel straight secondary Replace proportional valve
of travel straight the proportional pressure is 2.7MPa or more in
proportional valve valve secondary optional attachment full lever and
pressure at the high idling operation
ports A6 (travel
straight) of 7
sections solenoid
block
7 P1 by-pass cut Visual check No problem for sliding ability of Clean or replace
valve main poppet and no contamination
<Trouble> on orifice
Only P1 pressure No problem for sliding ability of
is low. internal piston (Check it through
PBp2 port.)

47-32
 ［47. TROUBLESHOOTING (BY TROUBLE)］

No. Sections Contents/normal value Corrective action, others

8 Relief pressure Check set -See Service Diagnosis Data List Reset or replace
pressure Operation No.16 P2 side OPT full
lever and relief
(Set value of factory shipment is
24.5MPa.)
9 Remote control Check targeted Check sealing ability of shuttle Replace
valve remote control valve and entry of dust in orifice.
valve
10 Travel straight spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against sliding (Check on the casing side
P1 pressure is Free from abnormal damage, etc for damage)
high. on outside surface
Spring is free from breakage.
11 Spool for optional Visual check When removing, free from Replace
attachment abnormal resistance against sliding (Check on the casing side
<Trouble> Free from abnormal damage, etc for damage)
P1, P2 pressures on outside surface
are high. Spring is free from breakage.
12 Over load relief Check targeted Free from dust entered in over Replace
valve spool visually load relief valve
Seat is free from abnormality.

(21) Selector valve for option malfunctions: Breaker circuit is not obtained.
(Indication of failure is displayed. For reference, see "Table : Action of optional selector solenoid valve")

No. Sections Contents/normal value Corrective action, others

1 N&B selector spool Visual check When removing, free from Replace
abnormal resistance against sliding (Check on the casing side
Free from abnormal damage, etc for damage)
on outside surface
Spring is free from breakage
2 N&B selector Screw for Check that the error indication is Replace solenoid valve
solenoid emergency disappeared by turning emergency
screw
3 N&B selector Carry out service -No.11 F-4 Option selector is B Check solenoid valve
solenoid diagnosis mode
COMP ON, MEAS ON
Check harness
47
Spool position BRK
Selector switch BRK
4 N&B selector Carry out service -No.16 B-11 Check pressure sensor
pressure sensor diagnosis Data List Check harness
3.0MPa at B mode and 0.0MPa
at A mode

47-33
［47. TROUBLESHOOTING (BY TROUBLE)］

(22) Selector valve for option malfunctions: Nibbler circuit is not obtained.
(Indication of failure is displayed. For reference, see "Table : Action of optional selector solenoid valve")

No. Sections Contents/normal value Corrective action, others

1 N&B selector spool Visual check When removing, free from Replace
abnormal resistance against sliding (Check on the casing side
Free from abnormal damage, etc for damage)
on outside surface
Spring is free from breakage.
2 N&B selector Carry out service -No.11 F-4 Option selector is A Check solenoid valve
solenoid diagnosis mode Check harness
COMP OFF, MEAS OFF
Spool position NIB
Selector switch NIB

47-34
 ［47. TROUBLESHOOTING (BY TROUBLE)］

Action of optional selector solenoid valve

Safety Safety Optional Selector
lock lock selector valve Failure
Engine Work Spool Warning
No. lever lever valve detecting diagnosis
condition mode position display
SW's relay's COMP. pressure display
input output MEAS. sensor

1 Running ON OFF A OFF Nibbler Normal - -

"SELECTOR [F042]
2 Running ON OFF A ON Breaker Normal VALVE displayed
FAILURE" simultaneously
"SELECTOR
3 Running ON OFF A OFF Breaker Normal VALVE -
FAILURE"
[F042]
4 Running ON OFF A ON Nibbler Normal -
displayed
5 Running ON OFF B ON Breaker Normal - -
"SELECTOR [F043]
6 Running ON OFF B OFF Nibbler Normal VALVE displayed
FAILURE" simultaneously
"SELECTOR
7 Running ON OFF B ON N&B Normal VALVE -
FAILURE"
[F043]
8 Running ON OFF B OFF Breaker Normal -
displayed
"SELECTOR
[B113]
9 Running ON OFF - - - Failure VALVE
displayed
FAILURE"
10 Stopping - - - - - - - -
11 - OFF - - - - - - -
12 - - ON - - - - - -

47

47-35
［47. TROUBLESHOOTING (BY TROUBLE)］

47.2 ELECTRIC SYSTEMS

47.2.1 WIRING CHECKING PROCEDURE

Check for continuity between connector terminals, presence or absences of short-circuit with other
wires, and presence or absences of short-circuit with machine body grounding.

(1)
Checking for disconnection between connectors.
(When both ends measurement is easy because
of short distance between connectors,)
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is zero (0), it is in normal
condition.

(When both ends measurement is difficult

because of long distance between connectors,)
Measure the resistance using tester.
Pull out opposite connector first.
Where the resistance is zero (0), if the
terminal on one side is connected to frame
body grounding with jumper wire, it is in normal
condition.
The resistance is 1M-ohm or more when the
terminal on one side is not connected to frame
body grounding with jumper wire, it is in normal
condition.

(2)
Checking for presence or absence of
short-circuit with machine body
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is 1M-ohm or more, it is
in normal condition.

(3)
Checking for presence or absence of
short-circuit between wirings.
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is 1M-ohm or more, it is
in normal condition.

(4)
Checking connector terminal for contact
Insert male terminal into female terminal unit,
and then check that the inserting force is
equivalent to other female terminals.

47-36
 ［47. TROUBLESHOOTING (BY TROUBLE)］

If looseness is there, replace the female

terminal with new one.
Clean the dirt terminal.

Do not insert the male terminal the thickness differs. It may cause loose connection.

(5)
Caution which should be paid in measuring voltage
When measuring the power supply to electric equipment at connector position with the grounding
terminal contained inside of connector, measure the voltage between grounding inside of connector and
power terminal.
When measuring the voltage between frame body grounding and power source, the disconnection of
wiring to grounding inside of connector cannot be identified.
Since the voltage may vary between with connector connected and with connector not connected.
Measure the voltage with each connector connected whenever possible.

(6)
Checking the general view of connector

a. Check the terminal crimped condition.

Pull one electric cable with the about 3kg
force, and make sure that the cable does
not come out of the terminal.
When came out, replace the terminal and
crimp it again.
b. Check connector for imperfect insertion
Check that all top ends form a line on the
same position as seen from the connector
engaged side.
When moved along, push it in further
through wire inserting hole.
c. Check connector for intruding of water.
Pull out the connector and check that the
inside is free from intruding of water.
47
When water intruding is found, check
rubber plug for damage and also that the
sealing is fitted properly.

(7)
When abnormality occurs at intervals
When the abnormality situation can not be reoccurred during checking operation, try the following
operations.

a. Check that variable of display exists or not on the service diagnosis screen while shaking the
harness or giving shock by operating the machine.
b. Check that variables of resistance and voltage exist or not using tester while shaking the harness.
c. Turn starter switch on and apply electricity continuously, and check it again after the temperature
of wiring and equipment was raised.

47-37
［47. TROUBLESHOOTING (BY TROUBLE)］

(8)
Checking on body grounding
Check attaching bolts of grounding terminal for
loosening.
And also check that there is no loose
connection due to corrosion.

There are multiple groundings like centralized

grounding box shown in the figure and battery
grounding, engine grounding, horn grounding
fixed together with horn, body grounding
placed on attaching section of boom working
light.

47-38
 ［47. TROUBLESHOOTING (BY TROUBLE)］

47.2.2 TROUBLE
(1) Engine does not stop.
(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
(3) Auto accel does not actuate. (The engine speed does not automatically slow down.)
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
(5) Wiper does not function.

47

47-39
［47. TROUBLESHOOTING (BY TROUBLE)］

(1) Engine does not stop.

No. Sections Contents/normal value Corrective action, others
1 Starter key switch Check signal of No.4 K-3 Key switch Check continuity between
starter key switch OFF at starter key switch OFF terminals of starter switch
ON by carrying position using tester
out service ON at starter key switch ON
diagnosis. position
2 Engine forcible When ON is No.4 K-3 Key switch Check on engine forcible
stop relay displayed with OFF at starter key switch OFF stop relay
the starter switch position
OFF, then pull out ON at starter key switch ON
R-25 engine position
forcible stop
relay and carry
out the service
diagnosis.
3 Wiring Voltage between 0V when starter switch is OFF Check harness
line No.62 Check diode D-9
among starter between starter switch
switch, engine and auto idling stop relay
forcible stop relay, 1
mechatro
controller and the
body grounding

(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.

No. Sections Contents/normal value Corrective action, others
1 Fuse No.1 fuse (5A) Not blown fuse Check harness
Replace fuse
2 Mechatro controller Accel control Engine speed varies according to Check mechatro
accel potentiometer operation. controller and replace as
(Use remote control because the necessary
auto accel function is working.)
3 Wiring Transmission See "WIRING CHECKING Repair wiring
circuit line PROCEDURE"
No.770 from
mechatro
controller to
gauge cluster
4 Gauge cluster Gauge cluster Replace gauge cluster

47-40
 ［47. TROUBLESHOOTING (BY TROUBLE)］

(3) Auto accel does not actuate. (The engine speed does not automatically slow down).
No. Sections Contents/normal value Corrective action, others
1 Engine coolant Check engine No.2 G-5 WATER TEMP Replace engine coolant
temperature coolant Auto accel does not work in the sensor
temperature by temperature -15C degrees or less.
carrying out Warm up and raise the coolant
service diagnosis. temperature to -15C degrees or
more
2 Gauge cluster Indication of auto Mark "Display/not display" for auto Replace gauge cluster
accel accel switches by auto accel switch
operation on gauge cluster.
3 Low pressure Service diagnosis Each control pressure of No.5 and Check low pressure sensor
sensor No.6 is in the range of 0 to
0.1MPa at control lever neutral
position.

(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
No. Sections Contents/normal value Corrective action, others
1 Low pressure Service diagnosis Each control pressure of No.5 and Check low pressure sensor
sensor No.6 is raised with control lever
operated.

47

47-41
［47. TROUBLESHOOTING (BY TROUBLE)］

(5) Wiper does not function

47-42
 ［47. TROUBLESHOOTING (BY TROUBLE)］

47.3 ENGINE RELATED TROUBLESHOOTING

47

47-43
［47. TROUBLESHOOTING (BY TROUBLE)］

47-44
［47. TROUBLESHOOTING (BY TROUBLE)］

47

47-45
［47. TROUBLESHOOTING (BY TROUBLE)］

47-46
 ［48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)］

48. TROUBLESHOOTING
(TROUBLE DIAGNOSIS MODE)
TABLE OF CONTENTS

48.1 TROUBLE DIAGNOSIS MODE ………………………………………………………………………………48-3

48

Book Code No. S5YN4829E01

48-1
［48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)］

Issue Date of Issue Applicable Machines Remarks

SK200-8 : YN12-56001~ S5YN4829E01
First Edition December, 2008
SK210LC-8 : YQ12-08001~ (SE Asia & Oceania)
SK250-8 : LQ13-07001~
SK260LC-8 : LL13-06001~
SK200-8 : YN12-56001~
SK210LC-8 : YQ12-08001~ SE Asia (HS Engine)
SK250-8 : LQ13-07001~
SK260LC-8 : LL13-06001~ SE Asia (HS Engine)
SK330-8 : LC11-08501~
January, 2009
SK350LC-8 : YC11-04501~ (SE Asia & Oceania)

February, 2009 SK200-8 : YN12-T0301~

TKCM

SK200-8 : YN12-T0301~
TKCM (HS Engine)
E215B : YN12-56001~
E215BLC : YQ12-08001~ NHK-RUS (HS Engine)

E215B : YN12-56001~
NHK-Mid.East & Afr.
E215BLC : YQ12-08001~
(HS Engine)
E215B : YN12-56001~
E215BLC : YQ12-08001~ (NHK-TUR)

SK330-8 : LC11-08501~
SE Asia (HS Engine)
E265B : LQ13-07001~
E265BLC : LL13-06001~ NHK-RUS (HS Engine)

E265B : LQ13-07001~
NHK-Mid.East & Afr.
E265BLC : LL13-06001~
(HS Engine)
E265B : LQ13-07001~
E265BLC : LL13-06001~ (NHK-TUR)
E385B : LC11-08501~
March, 2009
E385BLC : YC11-04501~ NHK-RUS (HS Engine)

E385B : LC11-08501~
NHK-Mid.East & Afr.
E385BLC : YC11-04501~
(HS Engine)
E235BSR : YF06-02501~
April, 2009
E235BSR(N)LC : YU06-03001~ (NHK-EUR)

SK235SRLC-2 : YU06-03001~
(NA)
SK235SR-2 : YF06-02501~
May, 2009
SK235SRLC-2 : YU06-03001~ (OCE)

July, 2009 SK140LC-8 : YP09-05001~

(SE Asia)

48-2
 ［48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)］

48.1 TROUBLE DIAGNOSIS MODE

The trouble diagnosis mode is used to automatically specify the failed sections for the troubles which
can not be detected by auto diagnosis function (the trouble can be specified by error code) like
disconnection, abnormal output.

(1) Function
There are two types of trouble diagnosis mode.

1. Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system
and engine system.
2. Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not operated, both selector valve and proportional valve are
automatically actuated, the sensor detects the machine condition and the mechatro controller
identifies the normal condition or failed condition of the system.

48

48-3
［48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)］

(2) How to use and flow chart

The operation is performed through gauge cluster.
No.1 Select service adjustment select screen.
(Switch starter key on while pressing buzzer stop switch and press select switch three times while
pressing buzzer stop switch on the service diagnosis screen No.1.)
No.2 Select Trouble diagnosis mode
(Move the cursor to the desired position with screen change switch "▲▼", and press the select
switch.)
No.3 Select either "DIAG MODE 1" or "DIAG MODE 2"
(Move the cursor to the desired position with screen change switch "▲▼", and press the select
switch.)
No.4 Go ahead the operation according to the instructions on the screen of cluster gauge.

48-4
 ［48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)］

Failure diagnosis Mode-1/Diagnosis item

No. Display Contents of diagnosis
Is normal pressure generated in the condition that the flow rate at P1 side is minimum
1 1 P1 UNLOAD
and the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the minimum flow rate is relieved at
2 2 P1 UNLOAD
P1 side?
Is normal pressure generated in the condition that the unload valve is fully opened,
3 3 P1 UNLOAD
and P1 side flow rate is minimum?
Is normal pressure generated in the condition that the unload valve is in emergency
4 1 P2 UNLOAD
position, and P2 side flow rate is minimum?
Is normal pressure generated in the condition that the minimum flow rate is relieved at
5 2 P2 UNLOAD
P2 side?
Is normal pressure generated in the condition that the unload valve is fully opened,
6 3 P2 UNLOAD
and P2 side flow rate is minimum?
Is normal pressure generated in the condition that the flow rate at P1 side is
7 1 P1 PUMP
emergency and the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the unload valve is emergency, and
8 2 P1 PUMP
P1 side flow rate is minimum?

9 3 P1 PUMP
Is normal pressure generated in the condition that the unload valve is in emergency
position, and P1 side flow rate is maximum?
48
Is normal pressure generated in the condition that the flow rate at P2 side is
10 1 P2 PUMP
emergency and the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the unload valve is emergency, and
11 2 P2 PUMP
P2 side flow rate is minimum?
Is normal pressure generated in the condition that the unload valve is in emergency
12 3 P2 PUMP
position, and P2 side flow rate is maximum?

48-5
［48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)］

Failure diagnosis Mode-1/Diagnosis and item

No. Display Contents of diagnosis
Is normal pressure generated in the condition that P1 side flow rate is minimum,
13 1 TRAVEL-S
unload valve is emergency position and travel straight is stroked fully?
Is normal pressure generated in the condition that P2 side flow rate is minimum,
14 2 TRAVEL-S
unload valve is emergency position and travel straight is stroked fully?
Is rated engine speed obtained in the condition that P1 side flow rate increases little
15 1 P1 ENGINE
by little when P1 side flow rate is relieved?
Is rated engine speed obtained in the condition that P2 side flow rate increases little
16 2 P2 ENGINE
by little when P2 side flow rate is relieved?

Failure diagnosis Mode-1/Diagnosis and Remedy

Diagnosis (Display) Possible cause Remedy
Check each pressure sensor by
Disconnection of pressure sensor, Short
SENSOR CHECK NG service diagnosis and replace it if
circuit, Abnormal output
necessary
Secondary pressure is excessive high
against the command Check P1 unload proportional valve
P1 UN-LOAD PSV NG
Secondary pressure is excessive low and replace it if necessary
against the command
Stuck at full-stroke side Check P1 unload spool and replace it
P1 UN-LOAD SPOOL NG
Stuck at neutral side if necessary

Secondary pressure is excessive high

against the command Check P2 unload proportional valve
P2 UN-LOAD PSV NG
Secondary pressure is excessive low and replace it if necessary
against the command
Stuck at full-stroke side Check P2 unload spool and replace it
P2 UN-LOAD SPOOL NG
Stuck at neutral side if necessary

Stuck at closing side Check P1 by-pass cut valve and

P1 B-P CUT NG
Stuck at neutral side replace it if necessary

Stuck at closing side Check P2 by-pass cut valve and

P2 B-P CUT NG
Stuck at neutral side replace it if necessary

Secondary pressure is excessive high

against the command Check P1 pump proportional valve
P1 PUMP PSV NG
Secondary pressure is excessive low and replace it if necessary
against the command
Delivery rate is excessive large against the Check P1 pump regulator and
command replace it if necessary.
P1 PUMP NG
Delivery rate is excessive small against the Check P1 pump and replace it if
command necessary.

Secondary pressure is excessive high

against the command Check P2 pump proportional valve
P2 PUMP PSV NG
Secondary pressure is excessive low and replace it if necessary
against the command
Delivery rate is excessive large against the Check P2 pump regulator and
command replace it if necessary.
P2 PUMP NG
Delivery rate is excessive small against the Check P2 pump and replace it if
command necessary.

48-6
 ［48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)］

Failure diagnosis Mode-1/Diagnosis and Remedy

Diagnosis (Display) Possible cause Remedy
Secondary pressure is excessive high
against the command Check travel straight proportional
S-TRAVEL PSV NG
Secondary pressure is excessive low valve and replace it if necessary
against the command
Stuck at full-stroke side Check travel straight spool and
S-TRAVEL SPOOL NG
Stuck at neutral side replace it if necessary

PUMP 1 PRESS. Check P1 high pressure sensor and

Pressure is recognized lower than it is
SENSOR NG replace it if necessary
PUMP 2 PRESS. Check P2 high pressure sensor and
Pressure is recognized lower than it is
SENSOR NG replace it if necessary
Set pressure decreases Check main relief valve and replace it
MAIN RELIEF NG
Set pressure increases if necessary

Check engine and replace it if

ENGINE NG Output is lowered
necessary
Check engine speed sensor and
E/G R SENSOR NG Characteristics is misaligned
replace it if necessary

48

48-7
［48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)］

48-8
 ［51. ENGINE］

51. ENGINE
PREFACE
51
This service manual explains the single engine. Note that this manual is edited without modification by
based on the service manual of MITSUBISHI HEAVY INDUSTRIES, Ltd.

Book Code No. S5YY5118E01

51-1
［51. ENGINE］

Issue Date of Issue Applicable Machines Remarks

SK125SR : YV06-05501~
SK125SRL : LD06-01801~ S5YY5118E01
First Edition June, 2009
SK135SR-2 : YY06-15001~ (SE Asia & Oceania)
SK135SRLC-2 : YH06-08001~

July, 2009 SK140LC-8 : YP09-05001~

(SE Asia)

About the engine ECU

Eight ranks are set depending on the specification of the engine, that is, "Q-RANK".
Q-RANK of engine ECU corresponds to engine Serial Number, and when engines ECU are replaced, it
is necessary to replace it with the same rank ECU.

51-2
 INTRODUCTION

This service manual describes the specifications, maintenance and service procedures
for Mitsubishi diesel engines.
To maintain the performance of the engine for many years and to ensure safe operation,
it is important to use the engine correctly and conduct regular inspection and maintenance,
and also to take necessary measures which involves the disassembly, inspection, repair and
reassembly of the engine and engine parts.
Read this manual carefully and understand the work procedures fully before
disassembling, inspecting, repairing or reassembling the engine.
The contents of the manual are based on the engine models that are being produced at
the time of publication. Due to improvements made thereafter, the actual engine that you
work on may differ partially from the one described in this manual.

Pub.No.99616-21120
 INTRODUCTION

How to use this manual

This service manual consists of several Groups, which are arranged so as to allow you to make reference quickly to
specifications, maintenance standards, adjustment procedures and service procedures including methods for disassembly,
inspection, repair and reassembly of the Mitsubishi Diesel Engine (standard model for land use).
A short summary describing the content of each Group is given in the General Contents page, and there is also a detailed table
of contents at the beginning of each Group.
Regarding the procedures for operation and periodical maintenance of the engine, refer to the Operation and Maintenance
Manual. For information on the engine components and ordering of service parts, refer to the Parts Catalogue. Structure and
function of the engine are described in the relevant training manuals.

Methods of presentation
(1) Index numbers allotted to parts in exploded views are not only a call-out of part names listed in the text but also an indi-
cation of the sequence of disassembly.
(2) Inspections to be conducted during disassembly process are indicated in boxes in the relevant exploded views.
(3) Maintenance standards required for inspection and repair works are indicated in the appropriate positions in the text.
They are also collectively indicated in Group 2, the General Contents group.
(4) Fasteners to be tightened in “wet” condition, or with engine oil applied, are identified by [Wet] placed after tightening
torque values. If no such indication is suffixed, the fastener should be tightened in “dry” condition, or without lubricating
with engine oil.
(5) In this manual, important safety or other cautionary instructions are emphasized with the following marks headed.

DANGER

Indicates an immediately hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates an immediately hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, can result in property damage.



Emphasizes important matter, or indicates information useful for operation or maintenance of the engine.

I
INTRODUCTION

Terms used in this manual

Nominal
means the rated (design) size or magnitude of a part to be measured.
Standard
means the quantitative requirement for dimension of a part, clearance between parts and performance. This is given in a form of
tolerance. Therefore, the values shown are not in agreement with the design values.
Limit
means that, if this value is reached, the part must be repaired or replaced with a new part.

Abbreviations
• BTDC: Before Top Dead Center
• ATDC: After Top Dead Center
• BBDC: Before Bottom Dead Center
• ABDC: After Bottom Dead Center
• TIR: Total Indicated Runout
• API: American Petroleum Institute
• ASTM: American Society for Testing and Materials
• JIS: Japanese Industrial Standards
• LLC: Long Life Coolant
• MIL: Military Specifications and Standards (U.S.A)
• MSDS: Material Safety Data Sheet
• SAE: Society of Automotive Engineers (U.S.A)

Units of measurement
Measurements are based on the International System of Units (SI), and their converted metric values are indicated in
parentheses {}. For metric conversion, the following rates are used.
• Pressure: 1 MPa ＝ 10.197 kgf/cm²
• Torque: 1 N·m ＝ 0.10197 kgf·m
• Force: 1 N = 0.10197 kgf
• Horsepower: 1 kW = 1.341 HP = 1.3596 PS
• Meter of mercury: 1 kPa = 0.7 cmHg
• Meter of water: 1 kPa ＝ 10.197 cmH2O (cmAq)
• Rotational speed: 1min-1 ＝ 1 rpm

II
 INTRODUCTION

Safety Cautions
WARNING

Fire and explosion

Keep flames away Care about fuel, oil and exhaust gas leakage
Store fuel and engine oil in a well If any fuel, oil or exhaust gas leakage is found, immedi-
ventilated designated area. ately take corrective measures to stop it.
Make sure that the caps of fuel and Such leakages, if left uncorrected, can cause fuel or
engine oil containers are tightly engine oil to reach hot engine surfaces or hot exhaust
closed. gas to contact flammable materials, possibly leading to
Do not use flames, do not smoke, personal injury and/or damage to equipment.
and do not work near a heater or other fire hazard
Use explosion-proof lighting apparatus
where fuel or oil is handled or when cleaning solvent is
When inspecting fuel, engine oil, coolant, battery elec-
being used for washing parts.
trolyte, etc., use a flameproof light. An ordinary light, if
Wipe off spilled fuel, oil and LLC immediately and thor-
accidentally broken, may ignite and cause an explo-
oughly. Spilled fuel, oil and LLC may ignite and cause
sion.
a fire.
Prevent electrical wires from short-circuit-
Keep surrounding area tidy and clean
ing
Do not leave combustible or explosive materials, such
Avoid inspecting or servicing the electrical system with
as fuel, engine oil and LLC, near the engine. Such sub-
the ground cable connected to the battery. Otherwise,
stances can cause fire or explosion.
a fire could result from short-circuiting. Be sure to dis-
Remove dust, dirt and other foreign materials accumu-
connect the battery cable from the negative (-) terminal
lated on the engine and surrounding parts thoroughly.
before beginning with the work procedure.
Such materials can cause fire or the engine to over-
Short-circuits, possibly resulting in fire, may be caused
heat. In particular, clean the top surface of the battery
by a loose terminal or damaged cable/wire. Inspect the
thoroughly. Dust can cause a short-circuit.
terminals, cables and wires, and repair or replace the
Always operate the engine at a position at least 1 m
faulty parts before beginning with the service proce-
[3.28 ft.] away from buildings and other equipment to
dure.
prevent possible fire caused by engine heat.
Keep fire extinguishers and first-aid kit
handy
Keep fire extinguishers handy, and
become familiar with their usage.
Keep a first-aid kit at the designated
place where it is easily accessible
by anyone at any time.
Establish response procedures to
follow in the event of fire or accident. Provide an emer-
gency evacuation route, contact points, and means of
communication in case of emergency.

III
INTRODUCTION

WARNING

Stay clear of all rotating and moving parts

Install protective covers on rotating parts Lockout and Tagout
Make sure the protective covers for Be sure to lockout and tagout before starting inspection
engine rotating parts are properly and maintenance.
installed as intended. Repair loose Lockout and tagout are effective methods of cutting off
or damaged protective covers as machines and equipment from energy sources.
necessary. To accomplish the lockout/tagout, remove the starter
Never remove the covers guarding switch key, set the battery switch to OFF and attach a
personnel from rotating parts, when the engine is oper- "Do Not Run" or similar caution tag to the starter switch.
ating. The starter switch key must be kept by the person who
When combining the engine with the engine-driven ma- performs inspection and maintenance during the work.
chine or radiator, always provide a cover on every ex- In the case of pneumatic starting type, close the main
posed moving part such as driving belt and coupling. valve of the air tank and post a tag saying "Do Not
Never remove protective covers. Open the Valve" or the like.

Ensure safety of neighboring people before Keep engine stopped during servicing
starting engine Be sure to stop the engine before proceeding to inspec-
Before starting the engine, ensure that there is nobody tion and service procedure. Never attempt to make ad-
in the neighborhood and that no tools are left on or near justments on the engine parts while the engine is
the engine. Verbally notify people around the engine or running. Rotating parts such as belt can entangle your
in the work area when starting the engine. body and cause serious injuries.
When the starter device is posted with a sign that pro-
Always restore engine turning tools after
hibits startup operation, do not operate the engine.
use
Stay clear of moving parts during engine Do not forget to remove the tools which have been
running used for turning the engine during inspection or servic-
Do not approach rotating or sliding ing, after the procedure is finished. Remember also
parts of the engine when the engine that the turning gear must be returned to the operating
is in operation. condition before starting the engine.
Keep objects likely to be caught by Starting the engine with the turning tools inserted or
rotating parts away from such parts. with the turning gear in engagement can lead to not
If any part of the clothing or outfit- only engine damage but also personal injuries.
ting is caught by a rotating part, se-
rious bodily injuries could result.

IV
 INTRODUCTION

WARNING WARNING

Be careful of burns Protect ears from noises

Do not touch the engine during or immedi- Wear ear plugs
ately after operation Always wear ear plugs when enter-
Do not touch the engine during or ing the machine room (engine
immediately after operation to room). Combustion sound and me-
avoid risk of burns. chanical noise generated by the en-
To conduct maintenance and in- gine can cause hearing problems.
spection work, wait until the engine
has cooled sufficiently, checking
the temperature gauge.

Slowly and carefully open radiator cap

Never attempt to open the radiator cap while the engine
is running or immediately after the engine stops. Give a
sufficient cooling time to the engine coolant before
opening the cap.
When opening the radiator cap, slowly turn the cap to
release internal pressure. To prevent scalds with steam
gushing out, wear thick rubber gloves or cover the cap
with a cloth.
Close the radiator cap tightly without fail.
The coolant is very hot and under pressure during en-
gine running or just after the engine stops. If the radia-
tor cap is not closed tightly, steam and hot coolant may
gush out and can cause scalds.

Add coolant only after the coolant tempera-

ture dropped
Do not add coolant immediately after the engine stops.
Wait until the coolant temperature lowers sufficiently to
avoid a risk of burns.

V
INTRODUCTION

WARNING CAUTION

Be careful of falling down Be careful of handling fuel, engine

Lift engine correctly oil and LLC
To lift the engine, always use a cor- Use only specified fuel, engine oil and long-
rect wire rope capable of withstand- life coolant (LLC)
ing the engine weight. Use only the fuel, oil and LLC specified in this manual,
Attach the wire rope to the lifting and handle them carefully.
hangers provided on the engine us- Use of any other fuel, oil or LLC, or improper handling
ing a correct sling. may cause various engine problems and malfunctions.
During lifting process, keep the en- Obtain the Material Safety Data Sheets (MSDS) issued
gine in a well-balanced position by taking the center of by the fuel, oil and LLC suppliers, and follow the direc-
gravity of the engine into consideration. tions in the MSDSs for proper handling.
If the wire rope contacts the engine directly, place a
cloth or other soft padding to avoid damage to the en-
Handle LLC (long life coolant) carefully
When handling LLC, always wear rubber gloves and
gine and wire rope.
protective face mask. If LLC or cooling water containing
Do not climb onto the engine LLC comes into contact with your skin or eyes, or if it is
Do not climb onto the engine, nor step on any engine swallowed, you would suffer from inflammation, irrita-
parts located on the lateral sides. tion or poisoning.
To work on parts located on the upper section of en- Should LLC be accidentally swallowed, induce vomit-
gine, use a ladder, stool, etc., that is firmly secured. ing immediately and seek medical attention. Should
Climbing on the engine may not only damage engine LLC enter your eyes, flush them immediately with plen-
parts but also cause parts to fall off and result in per- ty of water and seek medical attention. If LLC splashes
sonal injuries. onto your skin or clothing, wash it away immediately
with plenty of water.
Keep flames away from LLC. The LLC can catch
flames, causing a fire.
Coolant containing LLC is a hazardous material. Do not
dispose of it in unauthorized manner. Abide by the ap-
plicable law and regulations when discarding drained
coolant.

Proper disposal of waste oil and coolant

(LLC)
Do not discharge waste engine oil or coolant into sew-
erage, river, lake or other similar places. Such a way of
disposal is strictly prohibited by laws and regulations.
Dispose of waste oil, coolant and other environmentally
hazardous waste in accordance with the applicable law
and regulations, or consult a Mitsubishi dealer.

VI
 INTRODUCTION

CAUTION CAUTION

Service battery When abnormality occurs

Handle the battery correctly Stop overheated engine after cooling run
• Never use flames or allow sparks Even if the engine comes to overheat, do not stop the
to generate near the battery. The engine immediately. Abrupt stopping of an overheated
battery releases flammable engine can cause the coolant temperature to rise, re-
hydrogen gas and oxygen gas. sulting in seized engine parts. If the engine comes to
Any flames or sparks in the vicin- overheat, run the engine at low idling speed (cooling
ity could cause an explosion. operation), and stop the engine after the coolant tem-
• Do not use the battery the fluid level of which is low- perature lowers sufficiently.
ered below the lower limit line. Sustained use of the Do not add coolant immediately after stopping the en-
battery could result in an explosion. gine. Adding coolant to a hot engine can cause the cyl-
• Do not short the battery terminals with a tool or other inder heads to crack due to sudden change in
metal object. temperature. Add coolant little by little after the engine
• When disconnecting battery cables, always remove cools down to room temperature.
the cable from the negative (-) terminal first. When
Avoid immediate restart after abnormal stop
reconnecting the cables, attach the cable to the posi-
If the engine stops abnormally, do not restart the en-
tive (+) terminal first.
gine immediately. If the engine stops with an alarm,
• Charge the battery in a well-ventilated area, with all
check and remedy the cause of the problem before re-
filling hole plugs removed.
starting. Sustained use of the engine without any rem-
• Make sure the cable clamps are securely installed on
edy could result in serious engine problems.
the battery terminals. A loose cable clamp can cause
sparks that may result in an explosion. Avoid continuous engine operation with too
• Before servicing electrical components or conducting low oil pressure
electric welding, set the battery switch to the [Open/ If an abnormal engine oil pressure drop is indicated,
OFF] position or disconnect the cable from the nega- stop the engine immediately, and inspect the lubrica-
tive (-) battery terminal to cut off the electrical cur- tion system to locate the cause. Continuous engine op-
rent. eration with low oil pressure may cause bearings and
• Electrolyte (battery fluid) contains dilute sulfuric acid. other parts to seize.
Careless handling of the battery can lead to the loss
Stop the engine immediately if the fan belt
of sight and/or skin burns. Also, keep the battery fluid
breaks
off the mouth. If the fan belt breaks, stop the engine immediately.
• Wear protective goggles and rubber gloves when Continuous engine operation with the broken fan belt
working with the battery (when adding water, charg- could cause the engine to overheat and thereby the
ing, etc.). coolant to boil into steam, which may gush out from the
• If electrolyte is spilled onto the skin or clothing, reserve tank or radiator, and cause personal injuries.
immediately wash it away with lots of water. Use
soap to thoroughly clean.
• The battery fluid can cause blindness if splashing
into eyes. If it gets into eyes, immediately flush it
away with plenty of clean fresh water, and seek
immediate medical attention.
• If the battery fluid is accidentally swallowed, gargle
with plenty of water, then drink lots of water, and
seek immediate medical attention.

VII
INTRODUCTION

CAUTION

Other cautions
gine remarkably.
Modification of engine prohibited
Unauthorized modification of the engine will void the Cooling operation before stopping engine
manufacturer’s warranty. Always conduct the cooling operation (low speed
Modification of the engine may not only cause engine idling) for 5 to 6 minutes before stopping the engine.
damage but also produce personal injuries. Abruptly stopping the engine immediately after high-
load operation can cause partial overheating and short-
Pre-operational check and periodic inspec-
en the service life of the engine.
tion/maintenance
During cooling operation, check the engine for abnor-
Be sure to perform the pre-operational checks and pe-
malities.
riodic inspection/maintenance as described in this
manual. Protection of engine against water entry
Neglecting the pre-operational check or periodic in- Do not allow rainwater, etc. to enter the engine through
spection/maintenance can arouse various engine trou- the air inlet or exhaust openings.
bles such as damage to parts, eventually leading to Do not wash the engine while it is operating. Cleaning
serious accidents. fluid (water) can be sucked into the engine.
Starting the engine with water inside the combustion
Break-in operation
chambers can cause the water hammer action which
A new engine needs to be broken in for the first 50
may result in internal engine damage and serious acci-
hours of operation. During this period, do not subject
dents.
the engine to heavy loads.
Operating a new engine under high loads or severe Maintenance of air cleaner or pre-cleaner
conditions during the break-in period can shorten the The major cause of abnormal wear on engine parts is
service life of the engine. dust entering with intake air. Worn parts produce many
problems such as an increase of oil consumption, de-
Warming-up operation
crease of output, and starting difficulties. For effective
After starting the engine, run the engine at low idling
removal of dust from intake air, conduct maintenance
speeds for 5 to 10 minutes for warming-up. Start the
of the air cleaner according to the following instruc-
work after this operation is completed.
tions.
Warm-up operation circulates the lubricant through the
• Do not conduct maintenance of the air cleaner/pre-
engine. Therefore, individual engine parts are well lu-
cleaner while the engine is operating. Engine opera-
bricated before they are subjected to heavy loads. This
tion without the air cleaner/precleaner in place allows
is very important for longer service life, high-perfor-
foreign matters to enter the turbocharger, causing it
mance and economical operation.
to damage seriously.
Do not conduct warm-up operation for a longer time
• Remove the air cleaner/pre-cleaner slowly to prevent
than necessary. Prolonged warm-up operation causes
dust accumulated on the element from falling off.
carbon build-up in the cylinders that leads to incom-
After removing the air cleaner or pre-cleaner, imme-
plete combustion.
diately cover the opening (inlet port in case of air
Avoid engine operations in a overload con- cleaner; port in body in case of pre-cleaner) with
dition plastic sheet or similar means to prevent dust from
If the engine is considered to be in an overloaded con- entering the engine.
dition which is identified by too much black smoke, etc., • Air cleaners equipped with a dust indicator will issue
immediately reduce the load on the engine such that an alarm if the element gets clogged. Service the
the correct output and load conditions may be cleaner as soon as possible if an alarm is issued.
achieved.
Overloading the engine causes not only high fuel con-
sumption but also excessive carbon deposits inside the
engine. Excessive carbon deposits can cause various
engine problems and shorten the service life of the en-

VIII
 INTRODUCTION

Observe safety rules at work site Cautionary instructions for transporting en-
Observe the safety rules established at your workplace gine
when operating and maintaining the engine. When transporting the engine on a truck, consider the
Do not operate the engine if you are feeling ill. engine weight, width and height to ensure safety. Abide
Operation of the engine with reduced awareness may by road traffic law, road vehicles act, vehicle restriction
cause improper operation that could result in accidents. ordinance and other pertinent laws.
In such a case, inform your supervisor of your condi-
Avoid continuous engine operation in a low
tion.
load condition
When working in a team of two or more people, use
Do not operate the engine continuously for more than
specified hand signals to communicate among work-
10 minutes at a load of less than 30%. Engine opera-
ers.
tion in a low load condition increases the emission of
Work clothing and protective gear unburned fuel. Therefore, a prolonged time of engine
Wear a hardhat, face shield, safety shoes, dust mask, operation in a low load condition increases the quantity
gloves and other protective gear as needed. of unburned fuel adhering to engine parts, provoking
When handling compressed air, wear safety goggles, the possibility of engine malfunctioning and shortening
hardhat, gloves and other necessary protective gear. the service life of the engine.
Works without wearing proper protective gear could re-
Ventilation of engine room
sult in serious injuries.
Always keep the engine room well ventilated. Insuffi-
Use of tools optimum for each work cient amount of intake air causes the operating temper-
Always keep in mind to select most appropriate tools ature to rise, resulting in poor output and lowered
for the work to be performed and use them correctly. If performance.
tools are damaged, replace with new tools. It is highly recommended to calculate the required
amount of air supply to the engine and install an ade-
Avoidance of prolonged time of starter oper-
quate ventilation system before installing the engine.
ation
Do not operate the starter for more than 10 seconds at Avoid contact with high-pressured fuel
a time even if the engine does not start. Wait for at least Should fuel leak from a fuel injection pipe, do not touch
30 seconds before next engine cranking. the spouting fuel directly.
Continuous operation of the starter will drain the battery Fuel in the fuel injection pipes is under high pressure. If
power and cause the starter to seize. high-pressured fuel contacts you skin, it penetrates
through the skin and may result in gangrene.
Do not turn off battery switch during opera-
tion
If the battery switch is turned OFF when the engine is
running, not only various meters will stop working but
also the alternator may have its diode and transistor
deteriorated.

IX
INTRODUCTION

CAUTION

About warning labels

Maintenance of warning labels
Make sure all warning/caution labels are legible.
Clean or replace the warning/caution labels when the description and/or illustration are not clear to read.
For cleaning the warning/caution labels, use a cloth, water and soap. Do not use cleaning solvents, gasoline or other
chemicals to prevent the letters from getting blurred or the adhesion from being weakened.
Replace damaged or fractured labels with new ones.
If any engine part on which a warning label is attached is replaced with a new one, attach a new identical warning
label to the new part.

Warning labels

X
 GENERAL CONTENTS

Group Name Contents Group No.

External view
System flow diagrams
General Engine serial number location 1
Main specifications
Tips on disassembling and reassembling
Maintenance service data
Service data 2
Tightening torque table
Service tools Special tools 3
Determining overhaul timing
Determination of overhaul 4
Testing compression pressure
Disassembling and inspecting cylinder head and valve mechanism
Disassembling and inspecting flywheel
Disassembly of basic engine 5
Disassembling and inspecting gear case, timing gear and camshaft
Disassembling and inspection crankcase, crankshaft and piston
Inspecting and repairing cylinder head and valve mechanism
Inspecting and repairing flywheel
Inspection and repair of basic engine 6
Inspecting and repairing timing gear and camshaft
Inspecting and repairing piston, connecting rod, crankshaft and crankcase
Reassembling piston, connecting rod, crankshaft and crankcase
Reassembling timing gear and camshaft
Reassembly of basic engine 7
Reassembling flywheel
Reassembling cylinder head and valve mechanism
Environment of fuel system service
Removing fuel system
Fuel system Disassembling and inspecting fuel pump 8
Disassembling and inspecting common rail
Installing fuel system
Removing and inspecting lubrication system
Lubrication system Disassembling, inspecting and reassembling lubrication system 9
Installing lubrication system
Removing cooling system
Cooling system Inspecting cooling system 10
Installing cooling system
Removing inlet and exhaust system
Inlet and exhaust system Disassembling, inspecting and reassembling inlet and exhaust system 11
Installing inlet and exhaust system
Removing electrical system
Electrical system Disassembling, inspecting and reassembling electrical system 12
Installing electrical system
Adjusting engine
Adjustment and operation Break-in operation 13
Performance test (JIS standard)
GENERAL CONTENTS

Group Name Contents Group No.

Troubleshooting by diagnosis codes
Scan tester (32G91-00800, main unit: 32G91-00811, interconnect cable:
32G91-00812)
Scan tester (32G91-00600)
Troubleshooting 14
Diagnosis code cross reference
Troubleshooting reference chart
Inspecting sensors
Inspecting wiring
 GENERAL
1. External view...................................1-2

2. System flow diagrams .....................1-3

2.1 Fuel system - flow diagram ...................... 1-3
2.2 Lubrication system - flow diagram ........... 1-3
2.3 Cooling system - flow diagram................. 1-4
2.4 Inlet and exhaust system - flow diagram.. 1-4
2.5 Electrical system - wiring diagram ........... 1-5

3. Engine serial number location.........1-6

4. Main specifications..........................1-7

5. Tips on disassembling and

reassembling.................................1-10
5.1 Disassembling........................................ 1-10
5.2 Reassembling ........................................ 1-10

1-1
GENERAL

1. External view

Oil filler
Exhaust manifold
Front hanger Turbocharger
Thermostat

Fan Rear hanger

Front Rear

Alternator

Crankshaft pulley
Starter
Belt
Oil pan

Engine left view

Inlet manifold
Breather
Oil level gauge
Air heater

Oil filter Water pump

Rear Front

Common rail

Fuel pump

Flywheel housing Oil pump

Flywheel

Engine right view

1-2
 GENERAL

2. System flow diagrams

2.1 Fuel system - flow diagram

Injector

Common rail

Fuel pump

To fuel tank

From fuel tank

Fuel system - flow diagram

2.2 Lubrication system - flow diagram

Tappet Turbocharger Valve mechanism

Piston
Camshaft

Piston cooling nozzle

Oil filter

Main gallery
Oil cooler
Timing gear
Relief valve

Oil pump
Crankshaft
Oil strainer
Safety valve

Lubrication system - flow diagram

1-3
GENERAL

2.3 Cooling system - flow diagram

Outlet

Thermostat
Cylinder head
Bypass pipe

Inlet
Oil cooler Water pump
Water jacket

Cooling system - flow diagram

2.4 Inlet and exhaust system - flow diagram

Inlet
Exhaust Turbocharger

Muffler

Cylinder

Inlet and exhaust system - flow diagram

1-4
 GENERAL

2.5 Electrical system - wiring diagram

Injector power supply

Air heater relay
Inlet manifold pressure sensor

Water temperature sensor

Common rail

Common rail pressure sensor

Speed/timing sensor
(Camshaft side)
Speed/timing sensor
(Crankshaft side)
High pressure pump

High pressure pump

Engine oil pressure switch solenoid sensor (MPROP)

Connector

Electronic control unit

Electrical system - wiring diagram

1-5
GENERAL

3. Engine serial number location

The engine serial number is stamped on the side of the
crankcase.

Engine serial number

Stamp location of engine serial number

1-6
 GENERAL

4. Main specifications
Table 1-1 Main specifications (1 / 3)
Engine model D04FR-TAA
Type Water cooled, 4 cycle diesel engine, turbocharged
No. of cylinders - arrangement 4 cylinder in-line
Combustion system Direct injection
Valve mechanism Overhead
Cylinder bore × stroke 102 × 130 mm [4.02 × 5.12 in.]
Displacement 4.249 L [259 cu. in.]

Main Compression ratio 17.8

specification Fuel Diesel fuel
Firing order 1-3-4-2
Direction of rotation Counterclockwise when viewed from flywheel side
Length 911 mm [35.87 in.]
Dimensions
(varies depending on the Width 719 mm [28.3 in.]
specifications)
Height 940 mm [37.0 in.]
Dry weight Approx. 395 kg [870.8 lbs]
Cylinder sleeve Type Dry
Compression rings: 2
Piston ring Number of rings
Oil ring (w/expander): 1
Open BTDC 15°
Inlet valve
Valve timing Close ABDC 45°
Basic engine (when warm) Open BBDC 49°
Exhaust valve
Close ATDC 15°

Internal EGR Open ATDC 21°

Exhaust valve
valve timing Close BBDC 55°
Starting system Starter
Starting aid system Air heater
Type Common rail fuel injection system
Fuel
Model number CP1H
system
Manufacturer Bosch Corporation

1-7
GENERAL

Table 1-1 Main specifications (2 / 3)

Engine model D04FR-TAA
Forced circulation type
Lubricating method
(pressure feed by oil pump)
Standard API classification CF-4 or above class
Engine oil
Engine oil capacity Engine total: approx. 17.5 L [4.62 US gallons]
Type Gear type oil pump
Oil pump 40 L [10.57 US gallons]/min
Delivery capacity
Lubrication (at pump rotation of 1800 min-1)
system Type Piston valve type
Relief valve 0.35 ± 0.05 MPa
Valve opening pressure
{3.5 ± 0.5 kgf/cm²} [50 ± 7 psi]
Oil cooler Type Water-cooled, multi-plate type
Oil filter Type Cartridge type paper element
1.1 MPa
Safety valve Opening pressure
{11 kgf/cm²} [157 psi]
Cooling method Water-cooled, forced circulation
Coolant capacity (Engine water jacket) 6 L [1.6 US gallons] approx.
Type Centrifugal
Water pump 133 L [35 US gallons]/min
Discharge capacity
(at pump rotation of 1800 min-1)
Cooling
Water pump pulley Speed ratio Varies depending on the specifications
system
Fan belt Type Ribbed belt
Fan Type ø600 mm [23.62 in.]
Type Wax type
Thermostat Valve opening
71 ± 2°C [160 ± 3.6°F]
temperature
Inlet and Model number TD04HL
exhaust Turbocharger
system Qty 1

Control ECU Model number EDC16UC40

system (Electronic Control Unit) Manufacturer Bosch Corporation

1-8
 GENERAL

Table 1-1 Main specifications (3 / 3)

Engine model D04FR-TAA
Manufacturer Nikko Electric Industry
Type 0-24000-0188
Pinion meshing type Pinion shift
Output 24V - 5kW
Qty 1
Ring gear and pinion ratio 10/127
Voltage 23V
Starter No-load
Current 85A or below
characteristics
Speed 3300 min-1 or more
Voltage 9V
Load
Current 1400A or below
characteristics
Torque 88.26 N·m {9.0 kgf·m} [65 lbf·ft] or above
Minimam operating
16V or below
Electrical voltage
system Minimam holding voltage 8V or below
Manufacturer Nikko Electric Industry
Model number 0-35000-4838
Output 24V - 50A
Rated speed 5000 min-1
Direction of rotation Clockwise when viewed from pulley side
Alternator
Drive system PK type, V ribbed, 12 ribs
Ground system One conductor (-) side
Regulated voltage 28.5V ± 1V
Temperature range
-30 to +100°C [-22 to +212°F]
tolarance
Type Electric heater
Air heater
Capacity 2.1kW
Heater relay Fuse capacity 127A

1-9
GENERAL

5. Tips on disassembling and reassem-

bling
This service manual specifies the recommended procedures
to be followed when servicing Mitsubishi engines. The
manual also specifies the special tools that are required for
the work, and the basic safety precautions to follow when
working.
Note that this manual does not exhaustively cover potential
hazards that could occur during maintenance, inspection and
service work of engine.
When working on an engine, follow the relevant directions
given in this manual and observe the following instructions:

5.1 Disassembling
(1) Use correct tools and instruments. Serious injury or
damage to the engine will result from using the wrong
tools and instruments.
(2) Use an overhaul stand or work bench if necessary, and
follow the disassembling procedures described in this
manual.
(3) Keep the engine parts in order of removal to prevent
losing them.
(4) Pay attention to assembling marks. Put your marks on
the parts, if necessary, to ensure correct reassembling.
(5) Carefully check each part for defects during
disassembling or cleaning. Do not miss symptoms
which can not be detected after disassembling or
cleaning.
(6) When lifting or carrying heavy parts, exercise utmost
caution to ensure safety. Pay attention to balance of
heavy parts when handling. (Get help, and use jacks,
chain blocks and guide bolts as necessary.)

5.2 Reassembling
(1) Wash all engine parts, except such parts as oil seals, O-
rings and rubber sheets, in cleaning oil and dry them
with compressed air.
(2) Use correct tools and instruments.
(3) Use only high-quality lubricating oils and greases of
appropriate types. Be sure to apply oil, grease or
adhesive to the part wherever specified.
(4) Use a torque wrench to tighten parts correctly when
their tightening torques are specified.
Refer to "Tightening torque table."
(5) Replace all gaskets and packings with new ones unless
specified otherwise. Apply adhesive if necessary. Use
only the proper amount of adhesive.

1-10
 SERVICE DATA
1. Maintenance service data ...............2-2
1.1 General .................................................... 2-2
1.2 Basic engine ............................................ 2-3
1.3 Lubrication system ................................... 2-7
1.4 Cooling system ........................................ 2-7
1.5 Inlet and exhaust system ......................... 2-7
1.6 Electrical system ...................................... 2-7

2. Tightening torque table ...................2-8

2.1 Major bolts and nuts tightening torque..... 2-8
2.1.1 Basic engine...............................................2-8
2.1.2 Fuel system ................................................2-9
2.1.3 Lubrication system .....................................2-9
2.1.4 Cooling system.........................................2-10
2.1.5 Inlet and exhaust system .........................2-11
2.1.6 Electrical system ......................................2-11
2.1.7 Sensors and ECU ....................................2-11
2.2 Standard bolt and nut tightening
torque..................................................... 2-12
2.3 Standard eyebolt tightening torque ........ 2-13
2.4 Standard union nut tightening torque..... 2-13

2-1
SERVICE DATA

1. Maintenance service data

1.1 General
Table 2-1 Maintenance service data table - General Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
-1 -1
Maximum rotation speed 2240 min ± 10 min
-1
Minimum rotation speed 1015 min ± 20 min-1
When oil and water tem-
2.9 MPa 2.6 MPa
-1 peratures
Compression pressure (at 300 min ) {30 kgf/cm²} {27 kgf/cm²}
at 20 to 30°C
[427 psi] {[384 psi]
[68 to 86 °F]
0.2 to 0.4 MPa 0.15 MPa
Rated speed {2 to 4 kgf/cm²} {1.5 kgf/cm²}
[28.4 to 56.9 psi] [21.3 psi] Oil temperature
Lubricating
at 70 to 90 °C
oil pressure 0.1 MPa 0.05 MPa [158 to 194 °F]
Low idling {1 kgf/cm²} {0.5 kgf/cm²}
[14.2 psi] [7.1 psi]
Open BTDC 15°
Inlet
Close ABDC 45° ±3°
Valve timing
Open BBDC 49° (crank angle)
Exhaust
Close ATDC 15°

Internal EGR Open ATDC 21°

Exhaust
valve timing Close BBDC 55°

Valve clearance Inlet 0.25 [0.0098]

(when cold) Exhaust 0.40 [0.0157]
Deflection when the belt
forcefully pressed with a
7 to 9 thumb
Fan belt deflection
[0.276 to 0.354] New fan belt standard
value 4 to 6
[0.158 to 0.236]

2-2
 SERVICE DATA

1.2 Basic engine

Table 2-2 Maintenance service data table - Basic engine (1 / 4) Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
Reface minimum as possible.
Total grinding thickness of
Crankcase Flatness of top surface 0.05 [0.0020] or less 0.20 [0.008] crankcase top and cylinder
head bottom is 0.2 [0.008]
max.
ø 102 102.010 to 102.045 102.700 If limit (102.200 [4.0236]) is
Inside diameter
[4.02] [4.0161 to 4.0175] [4.0433] exceeded, use oversize
Cylinder sleeve, and hone to +0.010 to
Circularity 0.01 [0.0004] or less
sleeve +0.045 [0.0004 to 0.0018].
Use oversize piston and pis-
Cylindricality 0.015 [0.0006] or less
ton ring.
If the measured value
exceeds the standard and is
less than the limit, replace
Clearance between main bearing and 0.050 to 0.118 0.200
bearing.
crank journal [0.0020 to 0.0046] [0.0079]
Main If the limit is exceeded, grind
bearing the crank journal, and use
undersize bearing.
Replace thrust plate. The
Width of thrust journals 0.100 to 0.264 (0.300
limit value means a play in
(Thrust clearance) [0.0039 to 0.0104] [0.0118])
the direction of thrust.
ø 22 22.000 to 22.021 22.100 Repair limit:
Inside diameter
[0.87] [0.8661 to 0.8670] [0.8701] 102.200 [4.0236]
Tappet
hole Replace tappet if diameter of
Clearance between tappet and tappet 0.035 to 0.086 0.120
tappet hole is +0.10 [0.0039]
hole [0.0014 to 0.0034] [0.0047]
or less.
Front 0.04 to 0.09 0.15
Clearance between Middle [0.0016 to 0.0035] [0.0059]
Camshaft Replace bushing.
bushing and cam-
bushing 0.04 to 0.119 0.15 (Ream if necessary.)
shaft journal Rear
[0.0016 to 0.0047] [0.0059]
Reface minimum as possible.
Total grinding thickness of
Cylinder Distortion of bottom surface 0.05 [0.0020] or less 0.20 [0.008] crankcase top and cylinder
head head bottom is 0.2 [0.008]
max.
Compressed thickness of gasket 1.7 [0.07] ±0.05 [0.0020]
7.940 to 7.955 7.900
Inlet
Valve stem ø8 [0.3126 to 0.3132] [0.3110]
outside diameter [0.315] 7.920 to 7.940 7.850
Exhaust
[0.3118 to 0.3126] [0.3091]
Valve
and 0.055 to 0.085 0.150
Clearance between Inlet
valve [0.0022 to 0.0033] [0.0059]
guide valve stem
and guide 0.070 to 0.105 0.200
Exhaust
[0.0028 to 0.0041] [0.0079]
17 17.2 to 17.4
Valve guide mounting dimension
[0.669] [0.6772 to 0.6850]

2-3
SERVICE DATA

Table 2-2 Maintenance service data table - Basic engine (2 / 4) Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
Inlet
Valve seat angle 30°
Exhaust
0.4 0.3 to 0.5 1.1
Inlet Seat width
[0.016] [0.0118 to 0.0197] [0.0433]
Valve sinkage
0.5 0.4 to 0.6 1.1
Exhaust
Valve seat [0.020] [0.0157 to 0.0236] [0.0433]
Inlet Valve Valve
1.4 1.2 to 1.6 1.8 Valve sinkage margin
Seat width
Exhaust [0.055] [0.0472 to 0.0630] [0.071] seat angle

Refacing permissi-
Valve margin 2.13 [0.084] 2.13 [0.084] ble up to 1.2
[0.047]
Free length 56.40 [2.221] 55.00 [2.165]

θ = 2.0°or less
Δ = 2.0 [0.079]
Perpendicularity below Δ = 2.0 [0.079]
at the end Lf
Valve Lf = 56.4 [2.221]
spring

44.0 [1.732]/
44.0 [1.732]/207 N
222.7 to 246.1 N
Set length/set load {21.2 kgf}
{22.7 to 25.1 kgf}
[153.3 lbf]
[164.2 to 181.5 lbf]
ø 20 20.011 to 20.094
Rocker bushing inside diameter
[0.79] [0.7878 to 0.7911]
Rocker ø 20 19.966 to 19.984
Rocker shaft outside diameter
arm [0.79] [0.7861 to 0.7868]
Clearance between rocker bushing 0.027 to 0.128 0.150
and shaft [0.0011 to 0.0050] [0.0059]
Push rod Runout Below 0.4 [0.016] 0.4 [0.016] TIR

2-4
 SERVICE DATA

Table 2-2 Maintenance service data table - Basic engine (3 / 4) Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
0.04 0.10
Runout TIR
[0.0016] or less [0.0039]
If the diameter is the limit or
more, replace bearing.
ø 90 89.95 to 89.97 89.85 If the diameter is less than
Crank journal outside diameter
[3.54] [3.5413 to 3.5421] [3.5374] the limit, grind the journal
and use undersize bearing.
Service limit: 89.10 [3.5079]
ø 65 64.945 to 64.965 64.800
Crankpin outside diameter
[2.56] [2.5569 to 2.5577] [2.5512]
Distance between centers of journal
65 [2.56] ± 0.05 [± 0.002]
and crankpin
Pin maximum defec-
Crank- Parallelism between journal and
tion: 0.01 [0.0004] or
shaft crankpin
less
Roundness of journals and crankpins 0.01 0.03
(diameter difference) [0.0004] or less [0.0012]
Cylindericity of journals and crank-
0.01 0.03
pins
[0.0004] or less [0.0012]
(diameter difference)
Fillet radius of journal R3 [0.12] ± 0.2 [± 0.008]
Fillet radius of pin R4 [0.16] ± 0.2 [± 0.008]
If end play is less than the
limit, replace thrust plates.
0.100 to 0.264 0.300
End play If end play exceeds the limit,
[0.0039 to 0.0104] [0.0118]
replace with oversize thrust
plates.
101.915 to 101.945 101.730
STD
[4.0124 to 4.0136] [4.0051]
Outside diameter 0.25 [0.0098]/ ø 102 102.165 to 102.195 101.980
(at piston skirt) OS [4.02] [4.0222 to 4.0234] [4.0150]
0.50 [0.0197]/ 102.415 to 102.445 102.230
OS [4.0321 to 4.0333] [4.0248]
Bearing clearance check.
Gasket compressed
Protrusion from crankcase 0.8 [0.031]
(installed) thickness:
1.7 ± 0.05 [0.067 ± 0.0020]
Piston Clearance between piston pin hole 0.005 to 0.021 0.050
and piston pin [0.0002 to 0.0008] [0.0020]
Weight difference in one engine 5.0 g [0.2 oz.] or less
No.1
0.08 to 0.12 0.200
compression
[0.0031 to 0.0047] [0.0079]
ring
Clearance between
No.2
piston ring and 0.08 to 0.12 0.150
compression
ring groove [0.0031 to 0.0047] [0.0059]
ring
0.025 to 0.065 0.150
Oil ring
[0.0010 to 0.0026] [0.0059]
Compression 0.30 to 0.45
Piston rings [0.0118 to 0.0177] 1.50
End gap
ring 0.30 to 0.50 [0.0591]
Oil ring
[0.0118 to 0.0197]

2-5
SERVICE DATA

Table 2-2 Maintenance service data table - Basic engine (4 / 4) Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
ø 34 33.991 to 33.997
Outside diameter
[1.34] [1.3382 to 1.3385]
Clearance between pin and connect- 0.023 to 0.054 0.080
Piston pin
ing rod bushing [0.0009 to 0.0021] [0.0031]
ø 34 34.020 to 34.045
Inside diameter of bushing
[1.34] [1.3394 to 1.3404]
0.05/100 0.150
Bend and twist
[0.0020/3.94] or less [0.0059]
Clearance between crankpin and con- 0.035 to 0.100 0.200
Connect- necting rod bearing [0.0014 to 0.0039] [0.0079]
ing rod
0.15 to 0.35 0.50 Replace connecting rod bear-
End play
[0.0059 to 0.0138] [0.0197] ings.
Weight difference in one engine 10 g [0.4 oz.] or less
Flatness 0.15 [0.0059] or less 0.5 [0.0197]
Flywheel
Runout 0.15 [0.0059] or less 0.5 [0.0197]
TIR
0.10
Runout 0.04 [0.0016] or less Repair using a press, or
[0.0039]
replace.
Major axis
+0.1 Major axis - minor
46.911 -0.3 Major axis - minor axis
Inlet axis = 6.189
[1.8469
+0.004 = 6.689 [0.2633]
-0.012 [0.2437] Major axis
]
Cam lift Minor
Major axis axis
+0.1 Major axis - minor
Camshaft 46.256 -0.3 Major axis - minor axis
Exhaust axis = 5.729
[1.8211
+0.004
-0.012
= 6.229 [0.2452]
[0.2256]
]
Front ø 54 53.94 to 53.96 53.90
Middle [2.13] [2.1236 to 2.1244] [2.1220]
Journal diameter
ø 53 52.94 to 52.96 52.90
Rear
[2.09] [2.0842 to 2.0850] [2.0827]
0.10 to 0.25 0.30
End play Replace thrust plate.
[0.0039 to 0.0098] [0.0118]
Clearance between idler bushing and 0.009 to 0.050
0.100 [0.0039] Replace bushing.
shaft [0.0004 to 0.0020]
0.05 to 0.20 0.35
Idler Idler gear end play Replace thrust plate.
[0.0020 to 0.0079] [0.0138]
Interference between shaft and crank- 35 -0.016 to -0.035
case hole [1.38] [-0.0006 to -0.0138]
Between crankshaft gear 0.053 to 0.154 0.25
and idler gear [0.0021 to 0.0061] [0.0098]
Between camshaft gear 0.049 to 0.160 0.25
Timing and idler gear [0.0019 to 0.0063] [0.0098]
gear Replace gear.
backlash Between injection pump idler gear 0.050 to 0.228 0.25
and idler gear [0.0020 to 0.0090] [0.0098]
Between injection pump idler gear 0.044 to 0.163 0.25
and injection pump gear [0.0017 to 0.0064] [0.0098]

2-6
 SERVICE DATA

1.3 Lubrication system

Table 2-3 Maintenance service data table - Lubrication system Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
Backlash between the oil pump idler gear and 0.051 to 0.197 0.35
the idler gear [0.0020 to 0.0078] [0.0138]
Replace gear.
Backlash between the oil pump idler gear and 0.049 to 0.166 0.35
Oil pump
the oil pump drive gear [0.0019 to 0.0065] [0.0138]
0.10 to 0.27
Oil pump idler gear end play
[0.0039 to 0.0106]
0.35 ± 0.05 MPa
Relief valve Valve opening pressure {3.5 ± 0.5 kgf/cm²}
[49.8 ± 7.1 psi]
1.1 MPa
Safety valve Valve opening pressure {11 kgf/cm²}
[157 psi]

1.4 Cooling system

Table 2-4 Maintenance service data table - Cooling system
Inspection point Nominal Standard Limit Remark
Temperature at which valve starts open- 71 ± 2°C
ing [160 ± 3.6°F]
Thermostat
Temperature at which valve lift is 10 85°C
[0.039], minimum [185°F]

1.5 Inlet and exhaust system

Table 2-5 Maintenance service data table - Inlet and exhaust system Unit: mm [in.]
Inspection point Nominal Standard Limit Remarks
Distortion of exhaust manifold Below 0.2 [0.008]

1.6 Electrical system

Table 2-6 Maintenance service data table - Electrical system Unit: mm [in.]
Inspection point Nominal Standard Limit Remark
0.06
Armature shaft runout TIR
[0.0024]
0.10
Runout
[0.0039]
Commutator
0.7 to 0.9 0.2
Undercut depth
Starter [0.028 to 0.035] [0.008]
17 to 18 10
Brush length
[0.67 to 0.71] [0.39]
21.56 to 27.44 N 21.56 N
Tension of brush springs {2.2 to 2.8 kgf} {2.2 kgf}
[15.9 to 20.3 lbf] [15.9 lbf]
Alternator Adjusting voltage 27.5 to 29.5V at 25°C [77°F]

2-7
SERVICE DATA

2. Tightening torque table

2.1 Major bolts and nuts tightening torque
2.1.1 Basic engine
Table 2-7 Major bolts and nuts tightening torque - Basic engine
Threads Tightening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Cylinder head bolt 12 × 1.75 137 ± 5 14 ± 0.5 101 ± 3.6

Rocker cover bolt 8 × 1.25 20 ± 2 2 ± 0.2 14.5 ± 1.4
Rocker shaft bracket bolt 8 × 1.25 20 ± 2 2 ± 0.2 14.5 ± 1.4
Rocker arm adjusting nut 8 × 1.25 20 ± 2 2 ± 0.2 14.5 ± 1.4
Main bearing cap bolt 14 × 2 137 ± 5 14 ± 0.5 101 ± 3.6
Connecting rod cap nut 12 × 1.25 103 ± 5 10.5 ± 0.5 76 ± 3.6
Flywheel bolt 12 × 1.25 83 ± 5 8.5 ± 0.5 62 ± 3.6
Flywheel housing 10 × 1.5 44 ± 5 4.5 ± 0.5 32 ± 3.6
Camshaft thrust plate bolt 8 × 1.25 12 ± 2 1.2 ± 0.2 9 ± 1.4
8 × 1.25 19 ± 2 1.9 ± 0.2 13.7 ± 1.4
Front plate bolt
10 × 1.5 35 ± 5 3.6 ± 0.5 25.3 ± 3.6
8 × 1.25 19 ± 2 1.9 ± 0.2 13.7 ± 1.5
Timing gear case bolt
10 × 1.5 35 ± 5 3.6 ± 0.5 25.3 ± 3.6
Crankshaft pulley nut 30 × 1.5 706 ± 59 72 ± 6 521 ± 43
Idler thrust plate bolt 10 × 1.25 34 ± 5 3.5 ± 0.5 25 ± 3.6
Piston cooling nozzle 12 × 1.25 34 ± 5 3.5 ± 0.5 25 ± 3.6
Oil pan bolt 8 × 1.25 19 ± 2 1.9 ± 0.2 13.7 ± 1.4
Oil pan drain cock 24 × 1.5 49 ± 5 5 ± 0.5 36 ± 3.6
Lifting bolt 12 × 1.75 102 ± 10 10.4 ± 1 75.2 ± 7.2

2-8
 SERVICE DATA

2.1.2 Fuel system

Table 2-8 Major bolts and nuts tightening torque - Fuel system
Threads Tightening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Nozzle gland 8 × 1.25 30 ± 3 3.1 ± 0.3 22.4 ± 2.2

Fuel pump fuel relief joint mouting eye bolt 12 × 1.25 25 ± 3 2.5 ± 0.3 18 ± 2.2
Fuel pump gear nut 14 × 1.5 70 ± 5 7.1 ± 0.5 51.4 ± 3.6
Fuel injection pipe nut
14 × 1.5 25 ± 3 2.5 ± 0.3 18 ± 2.2
(Injector side, Rail side)
Fuel pump fuel supply high pressure pipe
14 × 1.5 25 ± 3 2.5 ± 0.3 18 ± 2.2
(Rail side)
Fuel pump fuel supply high pressure pipe
12 × 1.5 20 ± 2 2 ± 0.2 14.5 ± 1.4
(Pump side)
Fuel filter air bleed plug 14 × 1.5 21 ± 4 2.1 ± 0.4 15.2 ± 2.9
Fuel filter fuel inlet eye bolt 14 × 1.5 21 ± 4 2.1 ± 0.4 15.2 ± 2.9
Fuel filter fuel outlet eye bolt 14 × 1.5 21 ± 4 2.1 ± 0.4 15.2 ± 2.9
Fuel pump mouting bolt 8 × 1.25 19 ± 2 1.9 ± 0.2 13.7 ± 1.4
Common rail mouting bolt 8 × 1.25 20 ± 2 2 ± 0.2 14.5 ± 1.4
Fuel inlet connector 12 × 1.5 25 ± 2 2.6 ± 0.2 18.4 ± 1.4 Width across flats 15 mm
Fuel outlet connector 12 × 1 45 ± 5 4.6 ± 0.5 33.2 ± 3 Width across flats 13 mm
Fuel metering unit mouting Torx screw 5 × 0.8 6.5 ± 0.5 0.65 ± 0.05 4.8 ± 0.3 T 25 bits
Overflow valve 14 × 1.5 20 ± 1.5 2 ± 0.15 14.8 ± 1 Width across flats 16 mm
Rail pressure sensor 18 × 1.5 95 ± 5 9.7 ± 0.5 70 ± 3 Width across flats 27 mm
Pressure limiting valve 20 × 1.5 100 ± 5 10.2 ± 0.5 73.8 ± 3 Width across flats 18 mm
Fuel feed pump mounting Torx screw 6×1 8 ± 0.5 0.8 ± 0.05 6 ± 0.3 T 30 bits

2.1.3 Lubrication system

Table 2-9 Major bolts and nuts tightening torque - Lubrication system
Threads Tightening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Relief valve 22 × 1.5 49 ± 5 5 ± 0.5 36.2 ± 3.6

Relief valve plug 16 × 1.5 44 ± 5 4.5 ± 0.5 32.5 ± 3.6
Safety valve 18 × 2.0 69 ± 5 7 ± 0.5 50.6 ± 3.6
Turbocharger oil feed eye bolt 10 × 1.25 17 ± 2 1.7 ± 0.2 12.3 ± 1.4
Turbocharger oil feed pipe (flare) 12 × 1.0 20 ± 4 2.0 ± 0.4 14.8 ± 2

2-9
SERVICE DATA

2.1.4 Cooling system

Table 2-10 Major bolts and nuts tightening torque - Cooling system
Threads Tightening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Fan and water pump pulley mouting bolt 10 × 1.5 49 ± 5 5 ± 0.5 36.2 ± 3.6

Water pump mouting bolt 8 × 1.25 19 ± 2 1.9 ± 0.2 13.4 ± 1.4

(together with gear case) 10 × 1.25 35 ± 3 3.6 ± 0.3 25.3 ± 2.2
Water pump mouting bolt 8 × 1.25 17 ± 2.9 1.7 ± 0.3 12.5 ± 2

2-10
 SERVICE DATA

2.1.5 Inlet and exhaust system

Table 2-11 Major bolts and nuts tightening torque - Inlet and exhaust system
Threads Tightening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Turbocharger (nut) 10 × 1.25 35 ± 6 3.6 ± 0.3 25.8 ± 4

Turbocharger drain pipe 8 × 1.25 31 ± 3 3.2 ± 0.3 22.8 ± 2
Air heater bend 8 × 1.25 19 ± 2 1.9 ± 0.2 14 ± 1.4
Air heater terminal nut 6×1 9±1 0.9 ± 0.1 6.5 ± 0.7
Inlet manifold bolt 8 × 1.25 19 ± 2 1.9 ± 0.2 13.7 ± 1.4
Exhaust manifold nut 8 × 1.25 19 ± 2 1.9 ± 0.2 13.7 ± 1.4

2.1.6 Electrical system

Table 2-12 Major bolts and nuts tightening torque - Electrical system
Threads TIghtening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Starter mouting bolt 10 × 1.25 35 ± 5 3.6 ± 0.5 25.8 ± 3.6

Starter B terminal 10 × 1.5 18 ± 2 1.8 ± 0.2 13 ± 1.4
Alternator E terminal 6×1 6±1 0.6 ± 0.1 4.3 ± 0.7
Alternator B terminal 6×1 6±1 0.6 ± 0.1 4.3 ± 0.7
Alternator mounting bolt 14 × 1.5 97 ± 10 9.9 ± 1 71.6 ± 7.4
Ajusting plate 10 × 1.5 35 ± 5 3.6 ± 0.5 25.8 ± 3.6
Puller nut (alternator part) 12 × 1.25 66 ± 10 6.7 ± 1 48.7 ± 7.4

2.1.7 Sensors and ECU

Table 2-13 Major bolts and nuts tightening torque - Sensors and ECU
Threads Tightening torque
Description Dia × Pitch Remark
(mm) N·m kgf·m lbf·ft

Water temperature sensor 10 × 1.25 7.5 ± 0.5 0.75 ± 0.05 5.5 ± 0.36
Apply sealing tape to the
Inlet manifold pressure sensor R1/4 19.6 ± 2 2 ± 0.2 14 ± 1.4
thread.
Engine oil pressure switch R1/8 10 ± 2 1 ± 0.2 7.2 ± 1.4
Speed/timing sensor mouting bolt
6 × 1.0 8±1 0.8 ± 0.1 6 ± 0.7
(camshaft, crankshaft)
ECU mouting bolt 6 × 1.0 8±2 0.8 ± 0.2 5.8 ± 1.4
Pickup mouting hexagon bolt 16 × 1.5 30 ± 3 3 ± 0.3 22 ± 2.2

2-11
SERVICE DATA

2.2 Standard bolt and nut tightening torque

Table 2-14 Standard bolt and nut tightening torque
Threads Width Strength classification
Description Dia × Pitch across flats
(mm) (mm) [in.] 7T 10.9

7 10
N·m kgf·m lbf·ft N·m kgf·m lbf·ft
M8 × 1.25 12 [0.47] 17 1.7 13 30 3.1 22
M10 × 1.25 14 [0.55] 33 3.4 24 60 6.1 44
M12 × 1.25 17 [0.67] 60 6.1 44 108 11.0 80
Metric automobile screw thread
M14 × 1.5 22 [0.87] 97 9.9 72 176 17.9 130
M16 × 1.5 24 [0.94] 145 14.8 107 262 26.7 193
M18 × 1.5 27 [1.06] 210 21.4 155 378 38.5 279
M20 × 1.5 30 [1.18] 291 29.7 215 524 53.4 386
M22 × 1.5 32 [1.26] 385 39.3 284 694 70.8 512
M24 × 1.5 36 [1.42] 487 49.7 359 878 89.5 648
M27 × 1.5 41 [1.61] 738 75.3 544 1328 135.5 979

N·m kgf·m lbf·ft N·m kgf·m lbf·ft

M10 × 1.5 14 [0.55] 32 3.3 24 58 5.9 43
M12 × 1.75 17 [0.67] 57 5.8 42 102 10.4 75
Metric course screw thread M14 × 2 22 [0.87] 93 9.5 69 167 17.0 123
M16 × 2 24 [0.94] 139 14.2 103 251 25.6 185
M18 × 2.5 27 [1.06] 194 19.8 143 350 35.7 258
M20 × 2.5 30 [1.18] 272 27.7 201 489 49.9 361
M22 × 2.5 32 [1.26] 363 37.0 268 653 66.6 482
M24 × 3 36 [1.42] 468 47.7 345 843 86.0 622
M27 × 3 41 [1.61] 686 70.0 506 1236 126.0 912

Note: (a) This table lists the tightening torque for standard bolts and nuts.
(b) The numerical values in the table are for fasteners with spring washers.
(c) The table shows the standard values with a maximum tolerance value of ±10%.
(d) Use the tightening torque in this table unless otherwise specified.
(e) Do not apply oil to threaded portions. (Dry)

2-12
 SERVICE DATA

2.3 Standard eyebolt tightening torque

Table 2-15 Standard eyebolt tightening torque
Strength classification
Threads Width
Dia × Pitch across flats 4T
(mm) (mm) [in.]
N·m kgf·m lbf·ft
M8 × 1.25 12 [0.47] 8±1 0.8 ± 0.1 6 ± 0.7
M10 × 1.25 14 [0.55] 15 ± 2 1.5 ± 0.2 11 ± 1.5
M12 × 1.25 17 [0.67] 25 ± 3 2.5 ± 0.3 18 ± 2.2
M14 × 1.5 19 [0.75] 34 ± 4 3.5 ± 0.4 25 ± 3.0
M16 × 1.5 22 [0.87] 44 ± 5 4.5 ± 0.5 32 ± 3.7
M18 × 1.5 24 [0.94] 74 ± 5 7.5 ± 0.5 55 ± 3.7
M20 × 1.5 27 [1.06] 98 ± 10 10.0 ± 1.0 72 ± 7.4
M24 × 1.5 32 [1.26] 147 ± 15 15.0 ± 1.5 108 ± 11.1
M27 × 1.5 41 [1.61] 226 ± 20 23.0 ± 2.0 167 ± 14.8
(Dry)

2.4 Standard union nut tightening torque

Table 2-16 Standard union nut tightening torque
Width
Nominal Cap nut size
across flats N·m kgf·m lbf·ft
diameter M (mm)
(mm) [in.]
63 M14 × 1.5 19 [0.75] 39 4 29
80 M16 × 1.5 22 [0.87] 49 5 36
100 M20 × 1.5 27 [1.06] 78 8 58
120 M22 × 1.5 30 [1.18] 98 10 72
150 M27 × 1.5 32 [1.26] 157 16 116
180 M30 × 1.5 36 [1.42] 196 20 145
200 M30 × 1.5 36 [1.42] 196 20 145
220 M33 × 1.5 41 [1.61] 245 25 181
254 M36 × 1.5 41 [1.61] 294 30 217
(Maximum tolerance value: ±10%, dry condition)

2-13
 SERVICE TOOLS
1. Special tools ....................................3-2

3-1
SERVICE TOOLS

1. Special tools
Table 3-1 Special tool list (1 / 4)
Tool name Part number Illustration Use

Valve guide installer 32F91-00400 Valve guide installation

Valve guide remover 31391-10500 Valve guide removal

36791-00200
(Inlet)
Insert caulking tool Valve seat installation
36791-00300
(Exhaust)

Sleeve installer 34291-00200 Cylinder sleeve installation

Piston ring removal/

Piston ring pliers 30091-07100
installation

Piston guide 34291-00100 Piston installation

Injector remover 32G91-00100 Injector removal

3-2
 SERVICE TOOLS

Table 3-1 Special tool list (2 / 4)

Tool name Part number Illustration Use

Idler shaft puller MH061077 Idler shaft removal

Idler bushing removal/

Idler bushing puller 30091-07300
installation

Connecting rod bushing

Connecting rod bushing installer 32F91-03050
removal/installation

Oil and fuel filters removal/

Oil filter wrench 34591-00100
installation

Fuel injection pump

Universal extension 30091-01101
removal/installation

Socket 58309-73100 Engine turning

Engine compression pres-

Gauge adapter 32G91-00500
sure measurement

3-3
SERVICE TOOLS

Table 3-1 Special tool list (3 / 4)

Tool name Part number Illustration Use

Removal for
crankshaft gear,
Puller assembly 64309-12900
camshaft gear and
crankshaft pulley

Compression pressure mea-

Compression gauge 33391-02100
surement

Oil seal sleeve installation

Rear oil seal installer 34291-00020
on the crankshaft rear side

Camshaft bushing Camshaft bushing removal/

30691-00010
installer set installation

Camshaft bushing removal/

Valve spring pusher 30691-04500
Valve removal/installation

HPP gear remove kit 32G91-01010 Fuel pump gear removal

SC
A
N
TO
IN IAG P

O
SP N
D TU

L
EC OST
SE

EO
TI IC

B
O

D
N

OB
D/O
BD
II/E
OB
D
Sc
ent
oo
l
E
S
C

Scan tester 32G91-00800 Diagnosis code display

3-4
 SERVICE TOOLS

Table 3-1 Special tool list (4 / 4)

Tool name Part number Illustration Use

m
a
s
te
rt
e
c
h
Y
E
S
Scan tester 32G91-00600 Diagnosis codes display

H
E
L
P

N
O
R
C

F
V

1
1
S

E
E

N
N

T
4
D

E
R
4

2
E
X

F
IT

F
7

F
5

3
7

3
F

F
8

6
㧖

6
F

F
0
O

9
F
F

0
Ve

9
O
N
tro

#
n ix

3-5
 DETERMINATION OF OVERHAUL
1. Determining overhaul timing ...........4-2

2. Testing compression pressure ........4-3

4-1
DETERMINATION OF OVERHAUL

1. Determining overhaul timing

In most cases, the engine should be overhauled when the compression pressure of the engine becomes low. An increase in
engine oil consumption and blow-by gas are also considered to evaluate the engine condition. Besides, such symptoms as a
decrease in output, increase in fuel consumption, decrease in oil pressure, difficulty of engine starting and increase in noise are
also considered for judging the overhaul timing, although those symptoms are often affected by other causes, and are not
always effective to judge the overhaul timing. Decreased compression pressure shows a variety of symptoms and engine
conditions, thus making it difficult to accurately determine when the engine needs an overhaul. The following shows typical
problems caused by reduced compression pressure.
(1) Decreased output power
(2) Increased fuel consumption
(3) Increased engine oil consumption
(4) Increased blow-by gas through the breather due to worn cylinder liners and piston rings (Visually check the blow-by
amount)
(5) Increased gas leakage due to poor seating of inlet and exhaust valves
(6) Difficulty in starting
(7) Increased noise from engine parts
(8) Abnormal exhaust color after warm-up operation
The engine can exhibit these conditions in various combinations. Some of these problems are directly caused by worn engine
parts, while others are not. Phenomena described in items (2) and (6) will result from improper fuel injection volume, fuel
injection timing, worn plunger, faulty nozzles and also faulty conditions of electrical devices such as battery and starter. The
most valid reason to overhaul an engine is a decrease in compression pressure due to worn cylinder liners and pistons, as
described in item (4). In addition to this item, it is reasonable to take other problems into consideration for making the total
judgement.

4-2
 DETERMINATION OF OVERHAUL

2. Testing compression pressure

CAUTION
Compression gage
(a) Measure all cylinders for compression pressure. P/N:33391-02100
Do not measure only one cylinder and make
assumption about the other cylinders as it will lead
Gage adapter
to a wrong conclusion. P/N:32G91-00500
(b) Compression pressure varies depending on the
engine speed. When measuring the compression
pressure, be sure to measure the engine speed as
well.
(c) It is important to regularly check the compression
pressure so that you can tell the change with time.
Testing compression pressure
(1) Disconnect the harness connector from the injector
solenoid connector.
(2) Disconnect the harness connector from the MPROP
connector on the fuel pump.
(3) Select a cylinder, and remove the injector in the
cylinder. (Each cylinder is tested one at a time.)
(4) Install a gauge adapter in the same location that the
injector was mounted, and install a compression gauge
to the gauge adapter.
(5) Start the engine using starter. With the engine running
at specified speed, read the compression gauge.
(6) If the measured value is at the limit or below, overhaul
the engine.

Item Standard Limit

Engine speed 300 min-1 -
2.6 MPa
2.9 MPa
{27 kgf/cm²}
Compression pressure {30kgf/cm²}
[384 psi]
[427 psi]
or more

4-3
 DISASSEMBLY OF BASIC ENGINE
1. Disassembling and inspecting cylinder
head and valve mechanism ............5-2
1.1 Removing injector .................................... 5-3
1.2 Removing rocker shaft assembly............. 5-4
1.3 Disassembling rocker shaft assembly...... 5-4
1.4 Removing cylinder head bolt.................... 5-4
1.5 Removing cylinder head assembly .......... 5-5
1.6 Removing valve and valve spring ............ 5-5
1.7 Removing valve stem seal ....................... 5-5

2. Disassembling and inspecting

flywheel ...........................................5-6
2.1 Removing flywheel................................... 5-7
2.2 Removing flywheel housing ..................... 5-7

3. Disassembling and inspecting gear

case, timing gear and camshaft ......5-8
3.1 Removing crankshaft pulley..................... 5-8
3.2 Removing timing gear case ..................... 5-9
3.3 Measuring timing gear backlash .............. 5-9
3.4 Measuring idler gear end play.................. 5-9
3.5 Removing idler gear............................... 5-10
3.6 Removing camshaft ............................... 5-10
3.7 Separating camshaft gear...................... 5-10
3.8 Installing camshaft gear and thrust
plate ....................................................... 5-11
3.9 Removing front plate.............................. 5-11

4. Disassembling and inspection

crankcase, crankshaft and piston..5-12
4.1 Removing connecting rod cap ............... 5-13
4.2 Removing carbon deposits from the
upper part of cylinder liner ..................... 5-13
4.3 Pulling out piston.................................... 5-13
4.4 Removing piston ring ............................. 5-14
4.5 Removing piston pin .............................. 5-14
4.6 Removing main bearing cap .................. 5-14
4.7 Removing crankshaft ............................. 5-15

5-1
DISASSEMBLY OF BASIC ENGINE

1. Disassembling and inspecting cylinder head and valve mechanism

12
8 6
Wear, damage Wear, clogging

Fatigue, damage
11
Wear Wear, damage,
7
bend
13
17
10 18
9 Wear, 19 23 14
clogging 20

Fatigue, damage

3
Local wear
4
22

2
1

5 15 Replace

Crack, damage,
Replace water leak, oil leak,
carbon deposit,
scale deposit

16
21
Local wear, damage,
Local wear fatigue, carbon deposit

21

Disassembling and inspecting cylinder head and valve mechanism

Disassembling sequence

1 Leak off hose 9 Eye bolt, oil pipe 17 Valve cap

2 Nozzle ground 10 Snap ring, spacer 18 Valve cotter
3 Injector 11 Rocker arm 19 Valve retainer
4 Rocker cover 12 Rocker shaft spring 20 Valve spring
5 Rocker cover gasket 13 Rocker shaft 21 Valve, valve seat
6 Adjusting screw 14 Cylinder head bolt 22 Valve guide, stem seal
7 Bolt (short) 15 Cylinder head 23 Push rod
8 Bolt (long) 16 Cylinder head gasket

5-2
 DISASSEMBLY OF BASIC ENGINE

1.1 Removing injector

(1) Hold the injection connector by using a spanner, loosen
Leak off hose connector
the injection pipe nut and remove the injection pipe.
(2) With pushing the pin on top of the injector, remove the Injector Leak off hose
leak off hose. Pin
(3) Disconnect the harness connector of main harness and
Nozzle
injector connector. gland
(4) Using the injector puller, remove the injector and the Injection pipe
nozzle ground at the same time. Injection connector
(5) Remove the gasket from the cylinder head injector
Gasket
insertion opening.
Removing injector

Injector

Push
Pin

Pushing pin on top of injector

Injector puller
P/N:32G91-00100

Injector

Pulling out injector

5-3
DISASSEMBLY OF BASIC ENGINE

1.2 Removing rocker shaft assembly

Adjusting screw
CAUTION
Always loosen shorter bolts first. Failing to do so may
cause the damage to the rocker shaft bracket.
(1) Loosen the rocker arm adjusting screws by rotating
about one turn.
(2) Loosen the shorter rocker bracket bolts first.
Rocker arm
(3) Then, loosen the longer rocker bracket bolts.
(4) Remove the rocker bracket bolts, and remove the
Rocker bracket bolt
rocker shaft assembly from the cylinder head.
(5) Remove push rods. Removing rocker shaft assembly

1.3 Disassembling rocker shaft assembly

(1) Remove eye bolt, oil pipe, and snap ring.
(2) Disassemble the rocker shaft assembly into the rocker
arms, brakets, rocker shaft springs and rocker shaft.
Rocker shaft spring
Note: (a) Be sure to arrange the parts of rocker shaft
assembly in the order of disassembly. Rocker shaft
Reassemble the rocker shaft assembly in the Oil pipe Bracket
reverse order of disassembly by making sure of Rocker arm
the original combination of rocker arm and shaft
Snap ring
assembly so that the same clearance between the
rocker shaft and arms is restored when Eye bolt

reassembling. Disassembling rocker shaft assembly

(b) Do not remove the rocker bush when it is not
faulty, and its inside diameter is not exceed the
limit.

1.4 Removing cylinder head bolt

Loosen cylinder head bolts in the numerical order as shown
in the illustration.
3 7 11 15 16 12 8 4

1 9 17 10 2

5 13 14 6

Removing cylinder head bolt

5-4
 DISASSEMBLY OF BASIC ENGINE

1.5 Removing cylinder head assembly

CAUTION
When removing the cylinder head gasket, be careful
not to damage the cylinder head or crankcase surface
by tools such as a screwdriver.
(1) Remove the cylinder head bolt.
(2) Remove the cylinder head assembly by lifting it up.
Note: If the cylinder head assembly cannot be removed due
to crimping of the cylinder head gasket, tap the thick
area on the side of the cylinder head using a plastic
hammer to give a shock.
Removing cylinder head assembly
(3) Remove the gasket from the cylinder head.
Note: If there is a cylinder head problem, check the bolts for
tightness with a torque wrench before removing the
cylinder head bolts.

1.6 Removing valve and valve spring

Using a valve spring pusher, compress the valve spring Valve spring pusher
evenly and remove the valve cotters. P/N:30691-04500
Note: If valves are reusable, mark each valve seat and the
mating valve guide for identifying their original
positions. Do not mix valve seats with other valve
guides.

Removing valve and valve spring

1.7 Removing valve stem seal

Grab the valve stem seal with pliers and remove.
Note: Be sure to replace the valve stem seal with a new one
when reassembling the valve and valve spring.
Stem seal

Removing valve stem seal

5-5
DISASSEMBLY OF BASIC ENGINE

2. Disassembling and inspecting flywheel

Replace

3
Replace 1

2
Wear, damage, aging

Wear, crack, damage

Disassembling and inspecting flywheel

Disassembling sequence

1 Flywheel 3 Oil seal 5 Speed/timing sensor (crankshaft side),

sensor bracket
2 Flywheel housing 4 Pick up

5-6
 DISASSEMBLY OF BASIC ENGINE

2.1 Removing flywheel

CAUTION
Guide bolt
(a) Be careful not to cut yourself with the ring gear
Crankshaft pulley
when pulling out the flywheel.
Be careful not to drop or hit the flywheel when
removing.
(b) The person who holds the pulley must be very
careful to assure safety by communicating with the
person who is installing the flywheel.
(1) One personnel must firmly hold the pulley with a (Front) (Rear)
wrench to prevent the flywheel from turning.
Removing flywheel
(2) Remove one bolt from the flywheel.
(3) Screw a guide bolt into the threaded hole of the bolt that
has been removed.
(4) Remove remaining bolts from the flywheel.
(5) Hold the flywheel firmly with both hands, and while
moving it back and forth, pull it out straight.
Note: The ring gear is shrink fitted to the flywheel. Do not
remove the ring gear unless it is defective.

2.2 Removing flywheel housing

CAUTION
Be careful not to damage the oil seal.
(1) Remove bolts from the flywheel housing.
(2) Remove the flywheel housing.

Removing flywheel housing

5-7
DISASSEMBLY OF BASIC ENGINE

3. Disassembling and inspecting gear case, timing gear and camshaft

Damage, wear
Flaking, contact, damage, Oil hole clogging, wear
abnormality
Replace

10

7
6 Wear
9
Wear
4 Wear, damage,
8 aging
5 11

Crack, dowel hole defect,

oil hole clogging

Replace
Wear

2
1

Disassembling and inspecting gear case, timing gear and camshaft

Disassembling sequence

1 Crankshaft pulley 5 Idler gear 9 Tappet

2 Timing gear case 6 Thrust plate 10 Fuel pump gear,
Fuel pump idler gear
3 Oil seal 7 Camshaft
4 Thrust plate 8 Camshaft gear 11 Front plate

3.1 Removing crankshaft pulley

Prevent crankshaft
CAUTION from rotating
The bar that stops the crankshaft from turning may
Crankshaft pulley
come off. Pay due attention to safety.
(1) Screw two guide bolts into the threaded holes at the rear
end of the crankshaft. Stick a bar across the guide bolts
to prevent the crankshaft from turning.
(2) Remove the crankshaft pulley.
(3) Take out the woodruff key of the crankshaft. Guide bolt (M12×1.25mm)
(Front) (Rear)

Removing crankshaft pulley

5-8
 DISASSEMBLY OF BASIC ENGINE

3.2 Removing timing gear case

CAUTION Timing gear case

The front plate is bolted to the crankcase from inside
the gear case. Do not attempt to remove the front plate
together with the gear case by tapping.
(1) Remove bolts from the timing gear case.
(2) Remove the timing gear case.
Note: Bolts have different lengths. Pay attention to the
positions of bolts to ensure correct reassembling. Gasket

Removing timing gear case

3.3 Measuring timing gear backlash

Measure the backlash of the timing gears by using one of
the following two methods; measure the gear play with the
dial gauge plunger applied to a tooth flank on the pitch
circle at a right angle to the tooth axis, or measure the
clearance between gears by inserting a feeler gauge between
the gears at the tooth-to-tooth contacting area. Replace the
faulty gear pair if the limit is exceeded.

Item Standard Limit

Backlash crankshaft gear and 0.053 to 0.154 mm 0.25 mm
idler gear [0.0021 to 0.0061 in.] [0.0098 in.]
Measuring timing gear backlash
Backlash camshaft gear and 0.049 to 0.160 mm 0.25 mm
idler gear [0.0019 to 0.0063 in.] [0.0098 in.]

Backlash Fuel injection pump 0.050 to 0.228 mm 0.25 mm

idler gear and idler gear [0.0020 to 0.0090 in.] [0.0098 in.]

Backlash fuel injection pump

0.044 to 0.163 mm 0.25 mm
idler gear and fuel injection
[0.0017 to 0.0064 in.] [0.0098 in.]
pump gear

Note: With the fuel injection pump gear and the fuel
injection pump idler gear attached to the pump, install
the both gears to the front plate.

3.4 Measuring idler gear end play

Using a feeler gauge or dial gauge, measure the end play of
idler gear.
If the measured value exceeds the limit, replace the idler
gear with the new gear.

Item Standard Limit

0.05 to 0.20 mm 0.35 mm
End play
[0.0020 to 0.0079 in.] [0.0138 in.]
Idler gear

Measuring idler gear end play

5-9
DISASSEMBLY OF BASIC ENGINE

3.5 Removing idler gear

(1) Remove the thrust plate bolt.
(2) Remove the idler gear while turning the gear.
Idler gear

Thrust plate

Removing idler gear

3.6 Removing camshaft

CAUTION
Be careful not to damage the cams of camshaft and
the bushings. Camshaft gear

(1) Reverse the crankcase.

(2) Remove the thrust plate bolt.
(3) Remove the camshaft from the crankcase.
(4) Remove the tappet.

Removing camshaft

3.7 Separating camshaft gear

Using a puller, remove the camshaft gear and thrust plate Puller
from the camshaft. P/N: 64309-12900
Note: Do not remove the camshaft gear from the camshaft Camshaft gear
unless the camshaft gear or the thrust plate is
defective.

Separating camshaft gear

5-10
 DISASSEMBLY OF BASIC ENGINE

3.8 Installing camshaft gear and thrust plate

(1) Install the woodruff key and the thrust plate on the
crankshaft.
Note: Be sure to install the thrust plate before installing the
camshaft gear.
(2) Heat the camshaft gear with a gear heater to a
temperature of about 250°C [482°F].
Thrust plate
(3) Install the camshaft gear into the crankcase by tapping
with a plastic hammer. Camshaft gear

Installing camshaft gear and thrust plate

3.9 Removing front plate

(1) Remove the front plate bolts.
(2) Remove the front plate from the crankcase. Front plate
Note: If it is difficult to remove the front plate, lightly tap it
with a plastic hammer.

Removing front plate

5-11
DISASSEMBLY OF BASIC ENGINE

4. Disassembling and inspection crankcase, crankshaft and piston

Wear, scratch, rust

4
Wear, damage
5 Top surface distortion
6 Fatigue
9
Wear Scratch, crack, damage, Scale deposit,
wear, carbon deposit corrosion, flaking
8
7

Wear, crack,
oil hole clogging
19
Wear, oil hole
clogging

10
Damage

3 17
18
Wear, seizure,
flaking, damage
Scratch, crack, dent,
2 Clogging oil hole clogging, wear

1
16

Flaking,
14
local contact 15

Replace

12 13

Scratch, seizure,
flaking Damage
11

Crack

Disassembling and inspection crankcase, crankshaft and piston

Disassembling sequence

1 Nut 8 Piston pin 15 Main bearing (lower)

2 Connecting rod cap 9 Piston 16 Crankshaft
3 Connecting rod bearing 10 Connecting rod 17 Main bearing (upper)
4 No.1 compression ring 11 Main bearing cap bolt 18 Piston cooling nozzle
5 No.2 compression ring 12 Main bearing cap 19 Crankcase
6 Oil ring 13 Side seal
7 Snap ring 14 Thrust plate

5-12
 DISASSEMBLY OF BASIC ENGINE

4.1 Removing connecting rod cap

(1) Lay the engine on its side.
(2) Mark the cylinder number on the connecting rod and Connecting rod cap
connecting rod cap so that their combination is not
changed when reassembling.
(3) Remove the connecting rod caps.
Note: Mark the cylinder No. and upper/lower on connecting
rod bearings to ensure correct reassembling.

Removing connecting rod cap

4.2 Removing carbon deposits from the upper

part of cylinder liner

CAUTION
Be sure to remove carbon deposits from the upper part
of the cylinder liner before removing the piston, as it
could cause damage to the piston and piston ring.
Remove carbon deposits from the upper part of cylinder
liner using a carbon remover.
Note: Be careful not to damage the inner surface of the
cylinder liner.

Removing carbon deposit from cylinder sleeve upper

area

4.3 Pulling out piston

(1) Turn the crankshaft to bring the piston to top dead
center.
(2) Using a piece of wood such a hammer handle, push the
mating surface of the connecting rod cap, and pull the
piston and connecting rod upward from the cylinder.

Pulling out piston

5-13
DISASSEMBLY OF BASIC ENGINE

4.4 Removing piston ring

Remove the piston rings using piston ring pliers. Piston ring pliers
P/N:30091-07100

Removing piston ring

4.5 Removing piston pin

(1) Using snap ring pliers, remove the snap ring.
(2) Remove the piston pin, and separate the piston from the
connecting rod. Snap ring pliers
Note: Heat the piston with a piston heater or in hot water if
the piston pin is stubborn.

Removing piston pin

4.6 Removing main bearing cap

(1) Reverse the engine.
Sliding hammer
(2) Remove the main bearing cap bolt.
(3) Remove the main bearing cap together with the lower
main bearing.
Use a sliding hammer to remove main bearing caps on
the front and rear ends.
Main bearing
Note: (a) Be careful not to damage main bearings. cap bolt
(b) Mark each main bearing for its cylinder number.

Removing main bearing cap

5-14
 DISASSEMBLY OF BASIC ENGINE

4.7 Removing crankshaft

CAUTION
Be careful not to damage bearings when removing the
crankshaft.
(1) Slowly lift the crankshaft straight up.
(2) Arrange the bearings in the order of disassembly so that
their original positions are restored when reassembling.
Note: (a) When raising the crankshaft, do not allow wire or
chain to come into contact with the crankshaft.
To avoid damage to the crankshaft when raising,
use a cloth belt or pad.
Removing crankshaft
(b) Mark the bearings with their cylinder numbers.

5-15
 INSPECTION AND REPAIR OF BASIC ENGINE
1. Inspecting and repairing cylinder head 4. Inspecting and repairing piston,
and valve mechanism .....................6-2 connecting rod, crankshaft and
1.1 Measuring clearance between rocker crankcase ..................................... 6-15
bushing and rocker shaft.......................... 6-2 4.1 Measuring crankcase top surface
1.2 Replacing rocker bushing ........................ 6-2 distortion................................................. 6-15
1.3 Measuring valve stem outside diameter 4.2 Measuring cylinder inside diameter........ 6-16
and valve guide inside diameter .............. 6-3 4.3 Replacing cylinder sleeve ...................... 6-17
1.4 Replacing valve guide.............................. 6-3 4.3.1 Removing cylinder sleeve........................ 6-17
1.5 Inspecting valve face ............................... 6-4 4.3.2 Installing cylinder sleeve.......................... 6-17
1.6 Refacing valve face.................................. 6-4 4.4 Measuring piston outside diameter ........ 6-18
1.7 Refacing valve seat.................................. 6-5 4.5 Measuring piston ring end gap............... 6-18
1.8 Replacing valve seat................................ 6-6 4.6 Measuring clearance between piston ring
1.9 Lapping valve and valve seat................... 6-7 groove and piston ring............................ 6-19
1.10 Measuring perpendicularity and 4.7 Measuring piston pin bore diameter and
free length of valve spring........................ 6-7 piston pin outside diameter .................... 6-19
1.11 Measuring distortion of the bottom surface 4.8 Measuring piston protrusion................... 6-20
of the cylinder head.................................. 6-8 4.9 Measuring clearance between connecting
1.12 Measuring push rod runout ...................... 6-8 rod bearing and crankpin ....................... 6-21
4.10 Measuring clearance between connecting
2. Inspecting and repairing flywheel ....6-9 rod bushing and piston pin ..................... 6-21
2.1 Measuring flatness of flywheel................. 6-9 4.11 Replacing connecting rod bushing ......... 6-22
2.2 Measuring flywheel face and 4.12 Removing connecting rod bushing......... 6-22
radial runouts ........................................... 6-9 4.13 Installing connecting rod bushing........... 6-22
2.3 Inspecting ring gear ................................. 6-9 4.14 Inspecting connecting rod bend and
2.4 Replacing ring gear.................................. 6-9 twist ........................................................ 6-23
2.4.1 Removing ring gear ....................................6-9 4.15 Inspecting connecting rod bearing ......... 6-23
2.4.2 Installing ring gear ......................................6-9 4.16 Measuring connecting rod end play ....... 6-24
4.17 Weight difference of connecting rod
assembly in one engine ......................... 6-24
3. Inspecting and repairing timing gear
4.18 Measuring crankshaft journal
and camshaft.................................6-10
3.1 Measuring timing gear backlash ............ 6-10 outside diameter..................................... 6-24
3.2 Measuring cam lift.................................. 6-10 4.19 Measuring crankshaft crankpin outside
3.3 Measuring camshaft runout ................... 6-10 diameter ................................................. 6-25
3.4 Measuring camshaft journal 4.20 Grinding crankshaft ................................ 6-25
outside diameter .................................... 6-11 4.21 Measuring crankshaft end play .............. 6-26
3.5 Measuring camshaft bushing 4.22 Measuring crankshaft runout.................. 6-26
inside diameter....................................... 6-11 4.23 Replacing crankshaft gear ..................... 6-27
3.6 Replacing camshaft bushing.................. 6-11 4.23.1 Removing crankshaft gear....................... 6-27
3.6.1 Removing camshaft bushing ....................6-11 4.23.2 Installing crankshaft gear......................... 6-27
3.6.2 Installing camshaft bushing ......................6-12 4.24 Replacing front oil seal........................... 6-28
3.7 Measuring front idler bushing inside dia. 4.25 Replacing rear oil seal............................ 6-28
and front idler shaft outside diameter..... 6-12 4.26 Inspecting main bearing surface ............ 6-29
3.8 Replacing idler bushing.......................... 6-13 4.27 Measuring clearance between main
3.9 Replacing idler shaft .............................. 6-13 bearing and crankshaft journal............... 6-29
3.10 Inspecting tappet.................................... 6-13
3.11 Measuring clearance between tappet
and tappet guide hole ............................ 6-14

6-1
INSPECTION AND REPAIR OF BASIC ENGINE

1. Inspecting and repairing cylinder head and valve mechanism

1.1 Measuring clearance between rocker
bushing and rocker shaft
Measure the rocker bushing inside diameter and the rocker
shaft diameter. If the clearance exceeds the limit, replace
either rocker bushing or rocker shaft with a new one.
Measuring
Item Nominal Standard Limit directions

Rocker bushing ø 20 mm 20.011 to 20.094 mm

-
inside diameter [0.7874 in.] [0.7878 to 0.7911 in.]
Measuring
Rocker shaft ø 20 mm 19.966 to 19.984 mm points
-
diameter [0.7874 in.] [0.7861 to 0.7868 in.]

Clearance
between rocker 0.027 to 0.128 mm 0.150 mm Measuring rocker bushing and rocker shaft
-
bushing and [0.0011 to 0.0050 in.] [0.0059 in.]
shaft

1.2 Replacing rocker bushing

To replace rocker bushings, use a hydraulic jack.
Rocker bush installer
With the rocker bushing and the rocker arm oil holes mated,
and the bushing joint faced upward, press fit the rocker
bushing. Oil hole

Replacing rocker bushing

6-2
 INSPECTION AND REPAIR OF BASIC ENGINE

1.3 Measuring valve stem outside diameter and

valve guide inside diameter
Measure the diameter at the top and bottom ends at right Measuring
angles to the outer and inner surfaces, since valve stems and directions
valve guides are more likely to wear at both ends. If the
outside diameter is less than the limit, or the clearance
exceeds the limit, replace either the valve or the valve guide
with a new one. Measuring
points
Item Nominal Standard Limit

Valve ø 8 mm 7.940 to 7.955 mm 7.900mm

Inlet
stem [0.315 in.] [0.3126 to 0.3132 in.] [0.3110 in.]
Measuring valve stem outside diameter
outside ø 8 mm 7.920 to 7.940 mm 7.850 mm
diameter Exhaust
[0.315 in.] [0.3118 to 0.3126 in.] [0.3091 in.]
Measuring
Clearance 0.055 to 0.085 mm 0.150 mm directions
Inlet -
between [0.0022 to 0.0033 in.] [0.0059 in.] Internal micrometer
valve stem
and valve 0.070 to 0.105 mm 0.200 mm
Exhaust -
guide [0.0028 to 0.0041 in.] [0.0079 in.]

Valve guide mount- 17 mm 17.2 to 17.4 mm

-
ing dimension [0.67 in.] [0.6772 to 0.6850 in.]

Measuring
points

Measuring valve guide inside diameter

1.4 Replacing valve guide
Valve guide remover
CAUTION P/N:31391-10500
Because valve guides must be inserted to the speci-
fied amount, be sure to use a valve guide installer.
(1) To remove valve guides, use a valve guide remover.

Removing valve guide

(2) To press-fit valve guides, use a valve guide installer.
(3) Check contacts between valves and valve seats after
17 mm [0.67 in.]

Press Valve guide installer

replacing valve guides. P/N:34491-00400

Press-fitting valve guide

6-3
 INSPECTION AND REPAIR OF BASIC ENGINE

1.5 Inspecting valve face

Apply a thin coat of lead-free coloring paste on the valve
face, and strike the valve face against the valve seat using a
valve lapper to check for contact condition.
If the contact is not even, or any defects are found, or if the
Valve lapper
limit is exceeded, reface or replace the valve.
Note: (a) Inspect the valve face after the valve guide is
repaired or replaced.
(b) Do not rotate the valve when pressing the valve
face coated with Shinmyoutan or equivalent lead- Shinmyoutan
free dye against the valve seat.
(c) Always lap the valve and valve seat after the Inspecting valve face
valve has been refaced or replaced.

Item Standard Limit

Valve seat angle 30° -

0.4 ± 0.1 mm
Inlet
Valve [0.0157 ± 0.0039 in.] 1.1 mm
Valve
sinkage 0.5 ± 0.1 mm [0.043 in.]
seat Exhaust
[0.0197 ± 0.0039 in.]

1.4 ± 0.2 mm 1.8 mm

Seat width
[0.0551 ± 0.0079 in.] [0.071 in.] Good Bad
Refacing permissi-
2.13 mm
Valve margin ble up to 1.2 mm
[0.0839 in.]
[0.047 in.] Contact between valve seat and valve

Seat width

Valve margin
Valve seat
Valve sinkage
angle

Measuring positions of valve seat and valve

1.6 Refacing valve face
If the valve face is significantly worn out, reface the valve Valve refacer
face using a valve refacer.
Note: (a) Grind the valve face using the valve refacer at the
specified angle.
(b) Secure the valve margin width equal to or greater
than the limit. If the dimensions after refacing
does not meet the specified values, replace the Set the valve face
valve with a new one. angle at the specified
angle.

Refacing valve face

6-4
 INSPECTION AND REPAIR OF BASIC ENGINE

1.7 Refacing valve seat

(1) Use the valve seat cutter or valve seat grinder to reface
the valve seat. After refacing, sand the valve seat lightly
using 400 grit sandpaper, inserting it between the cutter
and valve seat.
(2) Lap the valve in the valve seat.
Note: (a) Valve seat refacing should be kept to an absolute
minimum.
(b) If the valve seat width exceeds the limit due to
wear or refacing, replace the valve seat with a
new one.
(c) If the valve sinkage exceeds the limit after Refacing valve seat
refacing, replace the valve seat with a new one.

6-5
INSPECTION AND REPAIR OF BASIC ENGINE

1.8 Replacing valve seat

(1) To remove the valve seat, weld a stud to the valve seat
as illustrated. Then, insert a rod into the valve guide
Weld
hole from the top of the cylinder head, and press out the
Shaft
valve seat with the rod.
Note: Be careful not to allow spatters to adhere to the Valve seat
machined surface of the cylinder head during
welding.
(2) Before inserting a new valve seat, measure the cylinder
head bore diameter and valve seat outside diameter to Stud

make sure the interference meets the specified value.

(3) Cool the valve seat for four minutes or more in liquid Removing valve seat
nitrogen (at approximately -170°C [-274°F]) before
fitting it into the cylinder head, while keeping the Inlet Exhaust Unit: mm [in.]
cylinder head at room temperature. Or heat the cylinder

4
head to 80 to 100°C [176 to 212°F] and cool the valve
seat sufficiently in ether or alcohol mixed with dry ice
before fitting it into the hot cylinder head.
(4) Fit the cold valve seat into the cylinder head using a
insert caulking tool.
9 ± 0.1 9.5 ± 0.1
[0.3543 ± 0.0039] [0.3740 ± 0.0039]

4 0° 45°
ø 48 +0.025
0 [ø 1.89 +0.0010
0 ] ø 39 +0.025
0 [ø 1.54 +0.0010
0 ]

Valve seat fitting bore

Insert caulking tool

(In)P/N:36791-00200
(Ex)P/N:36791-00300

Installing valve seat

6-6
 INSPECTION AND REPAIR OF BASIC ENGINE

1.9 Lapping valve and valve seat

Always lap the valve against the valve seat after refacing the
valve seat or after replacing the valve.
(1) Apply a thin coat of lapping compound evenly to the
valve face.
Note: (a) Do not allow the compound to adhere on the
valve stem.
(b) Compound spreads more evenly if it is mixed Compound
with a small amount of engine oil.
(c) Use medium-grain compound (120 to 150 mesh)
for initial lapping, then use fine-grain compound
(200 mesh or finer) for finishing. Coating valve with lapping
(2) Use a valve lapper for lapping. Strike the valve against
the valve seat while rotating the valve little by little.
(3) Wash off the compound using diesel fuel.
(4) Coat the contact surface of the valve with engine oil,
then lap the valve again.
(5) Check valve-to-seat contact.

Lapping valve and valve seat

1.10 Measuring perpendicularity and free length
of valve spring
Measure the perpendicularity and free length of the valve
spring. If the limit is exceeded, replace the valve spring with
Spring perpendicularity (gap)
a new one.

Item Standard Limit

56.40 mm 55.00 mm Free length
Free length
[2.221 in.] [2.165 in.]

θ = 2.0°
or less
below Δ = 2.0mm
Perpendicu-
larity Δ = 2.0 mm [0.079 in.] Measuring spring perpendicularity and free length
Lf
[0.079 in.] at the end
Lf = 56.4 mm
[2.221 in.]

44.0 mm
44 mm [1.732 in.]
[1.732 in.]
Set length/set /222.7 to 246.1 N
/207 N
force {22.7 to 25.1 kgf}
{21.2 kgf}
[164.2 to 181.5 lbf]
[153.3 lbf]

6-7
INSPECTION AND REPAIR OF BASIC ENGINE

1.11 Measuring distortion of the bottom surface

of the cylinder head

CAUTION
Refacing of cylinder head should be kept to an abso-
lute minimum.
Excessive grinding of the cylinder head may result in
defects such as defective combustion and stamping
(contact between piston and valve).
With a straight edge placed on the bottom face of the
cylinder head, measure the bottom face distortion using a
feeler gauge. If the measurement exceeds the limit, grind the
Measuring distortion of cylinder head bottom surface
bottom face using a surface grinder.

Item Standard Limit

Distortion of bot- 0.05 mm 0.20 mm
tom face [0.0020 in.] or less [0.0079 in.]

Note: Do not grind the surfaces more than 0.2 mm [0.008

in.] in total (cylinder head bottom surface plus
crankcase top surface).

1.12 Measuring push rod runout

Measure the runout of each push rod. Replace if the limit is
exceeded.

Item Standard Limit Remark

Push rod
Push
Below 0.4 mm 0.4 mm
rod TIR
[ 0.016 in.] [0.016 in.]
runout
1/2L 1/2L

Measuring push rod runout

6-8
 INSPECTION AND REPAIR OF BASIC ENGINE

2. Inspecting and repairing flywheel

2.1 Measuring flatness of flywheel
Place the flywheel on a surface plate and move a dial gauge
on the friction surface of the flywheel to measure the
flatness.
Grind the friction surface of the flywheel if the limit is
exceeded.

Item Standard Limit

0.15 mm 0.50 mm
Flywheel flatness
[0.0059 in.] or less [0.0197 in.]

Measuring flatness of flywheel

2.2 Measuring flywheel face and radial runouts
Measure the runouts of the flywheel in the installed
condition. If the measured value exceeds the standard,
check the bolt for looseness as well as the accumulation of
foreign matter on the mounting face.
Face runout
measuring point
Item Standard Limit
Radial runout
Flywheel face runout 0.15 mm 0.50 mm measuring point
and radial runout [0.0059 in.] or less [0.0197 in.]

Measuring flywheel face and radial runout

2.3 Inspecting ring gear

Inspect the ring gear for a missing tooth or worn teeth, and
if defects are found, replace the ring gear.

2.4 Replacing ring gear

2.4.1 Removing ring gear
(1) Heat the ring gear evenly using an acetylene torch or
other appropriate heat source.
Flywheel
(2) With a rod placed on the periphery of ring gear, tap the
rod with a hammer evenly around the ring gear, and
remove the ring gear.

2.4.2 Installing ring gear

(1) Heat the ring gear evenly up to approx. 150°C [176°F] Ring gear
with an appropriate heater.
(2) Install the ring gear onto the flywheel with the no-gear- Removing ring gear
chamfering side faced to the flywheel.
Note: Do not heat the ring gear excessively.

6-9
INSPECTION AND REPAIR OF BASIC ENGINE

3. Inspecting and repairing timing gear and camshaft

3.1 Measuring timing gear backlash
Measure the backlash of the timing gears by using one of
the following two methods; measure the gear play with the
dial gauge plunger applied to a tooth flank on the pitch
circle at a right angle to the tooth axis, or measure the
clearance between gears by inserting a feeler gauge between
the gears at the tooth-to-tooth contacting area. Replace the
faulty gear pair if the limit is exceeded.

Item Standard Limit

Backlash crankshaft gear and 0.053 to 0.154 mm 0.25 mm
idler gear [0.0021 to 0.0061 in.] [0.0098 in.]
Measuring timing gear backlash
Backlash camshaft gear and 0.049 to 0.160 mm 0.25 mm
idler gear [0.0019 to 0.0063 in.] [0.0098 in.]

Backlash Fuel injection pump 0.050 to 0.228 mm 0.25 mm

idler gear and idler gear [0.0020 to 0.0090 in.] [0.0098 in.]

Backlash fuel injection pump

0.044 to 0.163 mm 0.25 mm
idler gear and fuel injection
[0.0017 to 0.0064 in.] [0.0098 in.]
pump gear

Note: With the fuel injection pump gear and the fuel
injection pump idler gear attached to the pump, install
the both gears to the front plate.

3.2 Measuring cam lift

Measure the minor and major axes of cam to determine cam Major axis
lobe lift. If the lift is less than the limit, replace the camshaft
Minor
with a new one.
Measuring Measuring
Item Nominal Standard Limit directions points
Major axis Major axis – Major axis –
+0.1 Minor axis Minor axis
Inlet 46.911 -0.3 mm
+0.004
= 6.689 mm = 6.189 mm
[1.8469 -0.012 in.] [0.2633 in.] [0.2437 in.]
Cam
lift Major axis – Major axis –
Major axis
+0.1 Minor axis Minor axis
Exhaust 46.256 -0.3 mm
+0.004
= 6.229 mm = 5.729 mm
[1.8211 -0.012 in.] [0.2452 in.] [0.2256 in.] Measuring cam lift

3.3 Measuring camshaft runout

Measure the camshaft runout using a dial gauge. If the limit
is exceeded, correct the camshaft using a press, or replace
the camshaft with a new one.
Note: With a dial gauge set on the camshaft, rotate the
camshaft one turn and read the gauge indication.

Item Standard Limit Remark

0.04 mm 0.10 mm
Camshaft runout TIR
[0.0016 in.] or less [0.0039 in.]

Measuring camshaft runout

6-10
 INSPECTION AND REPAIR OF BASIC ENGINE

3.4 Measuring camshaft journal outside diame-

ter Measuring
Measure the diameter of each camshaft journal in two points
direction at right angles to each other. If the limit is
exceeded, replace the camshaft with a new one.

Measuring
Item Standard Limit directions
Front, 53.94 to 53.96 mm 53.90 mm
Camshaft journal Middle [2.1236 to 2.1244 in.] [2.1220 in.]
outside diameter 52.94 to 52.96 mm 52.90 mm
Rear
[2.0842 to 2.0850 in.] [2.0827 in.]

Measuring camshaft journal outside diameter

3.5 Measuring camshaft bushing inside diame-

ter Measuring
With the camshaft bushings installed in the crankcase, directions
measure the inside diameters using a cylinder gauge. If the
limit is exceeded, replace the bushing with a new one.

Item Standard Limit

Clearance between Front, 0.04 to 0.09 mm

camshaft journal Middle [0.0016 to 0.0035 in.] 0.15 mm
and camshaft 0.04 to 0.119 mm [0.0059 in.]
bushing Rear
[0.0016 to 0.0047 in.]

Measuring camshaft bushing inside diameter

3.6 Replacing camshaft bushing

3.6.1 Removing camshaft bushing Adapter
Bushing
(1) Install a camshaft bushing installer set to the camshaft
bushing.
(2) Remove the camshaft bushing by tapping the end of the
rod of camshaft bushing installer set.

Camshaft bushing
installer set Rod
P/N:30691-00010

Removing camshaft bushing

6-11
INSPECTION AND REPAIR OF BASIC ENGINE

3.6.2 Installing camshaft bushing

(1) Install the camshaft bushing to a camshaft bushing Piece Bushing
installer set. Adapter
(2) When driving in a bushing, tap the end of camshaft
bushing installer rod so that the oil hole in the bushing
aligns with the oil hole of the oil gallery.

Camshaft bushing Rod

installer set Oil hole
P/N:30691-00010

Installing camshaft bushing

3.7 Measuring front idler bushing inside dia.

and front idler shaft outside diameter
Measure the front idler bushing inside diameter and the
front idler shaft outside diameter. If the inside diameter of
front idler bushing exceeds the limit, replace the front idler
bushing with a new one. If the outside diameter of front
idler shaft is less than the limit, replace the front front idler
shaft with a new one.

Item Standard Limit

Clearance between 0.009 to 0.050 mm 0.100 mm
idler bushing and idler shaft [0.0004 to 0.0020 in.] [0.0039 in.]

6-12
 INSPECTION AND REPAIR OF BASIC ENGINE

3.8 Replacing idler bushing

(1) Use the idler bushing puller to replace idler bushing.
(2) To install the bushing, drive it from the boss side so that Idler bushing puller
it is flush with the gear boss face. P/N:30091-07300
(3) After installing the bushing, measure the bushing inside
diameter, and if the inside diameter exceeds the
standard, ream the bushing.

Removing Installing

Replacing idler bushing

Idler gear Idler gear bushing

1 mm
[0.039 in.]

Idler bushing press fitting dimension

3.9 Replacing idler shaft
To remove the idler shaft, use the idler shaft puller. Idler shaft puller
Note: When installing the idler shaft into the crankcase, P/N:MH061077
orient the idler shaft so that its oil hole faces the upper
crankcase.

Removing idler shaft

3.10 Inspecting tappet
Inspect the cam contact surface of the tappets. Fit new
tappets if the surface is excessively worn or damaged.

Good Bad Bad

Tappet surface in contact with camshaft

6-13
INSPECTION AND REPAIR OF BASIC ENGINE

3.11 Measuring clearance between tappet and

tappet guide hole Measuring Measuring
Measure clearance between the tappet and tappet hole. points directions
Replace the tappet with a new one if the limit is exceeded.

Item Standard Limit

Tappet hole 22.000 to 22.021 mm 22.10 mm
inside diameter [0.8661 to 0.8670 in.] [0.8701 in.]

Clearance between tappet 0.035 to 0.086 mm 0.12 mm

and tappet hole [0.0014 to 0.0034 in.] [0.0047 in.]

Measuring clearance between tappet and tappet guide

hole

6-14
 INSPECTION AND REPAIR OF BASIC ENGINE

4. Inspecting and repairing piston, connecting rod, crankshaft and crankcase

4.1 Measuring crankcase top surface distor-
tion

CAUTION
Refacing of cylinder head should be kept to an abso-
lute minimum.
Excessive grinding of the cylinder head may result in
defects such as defective combustion and stamping
(contact between piston and valve).
Apply a straight edge to the top surface of the crankcase and
measure its distortion using a feeler gauge. If the distortion
exceeds the limit, grind the crankcase using a surface
Measuring distortion of crankcase top surface
grinder.
Note: Do not overgrind the cylinder head, as the piston
protrusion deviates from the standard value.

Item Standard Limit

0.05 mm 0.20 mm
Flatness of top surface
[0.0020 in.] or less [0.0079 in.]

Note: Do not grind the surfaces more than 0.2 mm

[0.0079 in.] in total (cylinder head bottom surface
plus crankcase top surface).

6-15
INSPECTION AND REPAIR OF BASIC ENGINE

4.2 Measuring cylinder inside diameter

(1) Measure the inside diameter of the cylinder at three Measuring
directions
levels, i.e., upper (with much stepped wear), middle,

11 [0.43]
and lower levels, in both directions parallel to and

65 [2.56]
perpendicular to the crankshaft direction.

150 [5.91]
(2) If the measurement is between the repair limit and
replacement limit, re-bore the cylinder to +0.25 mm
[0.0098 in.] or +0.5 mm [0.0197 in.] oversize. Hone the
re-bored cylinder to the accuracy of the standard. Measuring
points
(3) Use an oversize piston and piston rings to fit the re-
Unit: mm [in.]
bored cylinder.
(4) If the cylinder is worn unevenly, select an oversize Measuring cylinder sleeve inside diameter
diameter that ensures complete roundness when the
cylinder is re-bored to the maximum. All cylinders
must be re-bored to the same oversize diameter if one
cylinder is re-bored.
(5) If the cylinder has a slight wear and is reused after
replacing only the piston rings, remove the steps in
worn portion in the upper part of the cylinder using a
ridge reamer. Hone it as necessary.

Item Standard Limit

Repair limit:
Cylinder sleeve 102.010 to 102.045 mm 102.200 mm [4.0236 in.]
inside diameter [4.0161 to 4.0175 in.] Replacement limit: Refacing using a ridge reamer
102.700 mm [4.0433 in.]

0.01mm
Roundness -
[0.0004 in.] or less

0.015 mm
Cylindericity -
[0.0006 in.] or less

Note: The roughness of cylinder sleeve inner surface is

Ra 6.3 µm [0.248 µ in.]

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 INSPECTION AND REPAIR OF BASIC ENGINE

4.3 Replacing cylinder sleeve

If the inside diameter of a cylinder sleeve exceeds the limit 0.5 mm [0.020 in.]
or a clinder is found defective, replace the cylinder sleeve
only, provided that the defective cylinder has no effects on
the other cylinders.
4.3.1 Removing cylinder sleeve
(1) Set up a boring machine on the crankcase by aligning it
with the center of the less-worn area of the sleeve at the
bottom.
(2) Bore the sleeve until its stock thickness becomes
approximately 0.5 mm [0.020 in.].
(3) Carefully break and remove the sleeve, taking care not Boring cylinder sleeve
to cause damage to the inside surface of crankcase.

Removing cylinder sleeve

4.3.2 Installing cylinder sleeve
(1) Use a cylinder sleeve installer to install a sleeve. Sleeve installer
(2) Put the sleeve into the crankcase, leaving a protrusion P/N:34291-00200
of 0.3 to 0.5 mm [0.012 to 0.020 in.] at the top. Then
make it flush with the crankcase top.
(3) Bore and hone the sleeve to the specified diameter.

Installing cylinder sleeve

6-17
INSPECTION AND REPAIR OF BASIC ENGINE

4.4 Measuring piston outside diameter

(1) Measure the piston outside diameter of the piston skirt
at right angles to the piston pin. If it is less than the
limit, replace the piston with a new piston. When
replacing piston, be sure to select a piston so that the Measuring point
piston weight difference in one engine is kept within
the permissible range.

Measuring piston outside diameter

(2) The piston weight is stamped on the top of piston head.

Weight stamp Number stamp

Item Standard Limit (The prefix letter "F"
101.915 to 101.945 mm 101.730 mm and the last five
STD
[4.0124 to 4.0136 in.] [4.0051 in.] digits of part number)
Piston
outside 102.165 to 102.195 mm 101.980 mm F
0.25 OS
diameter [4.0222 to 4.0234 in.] [4.0150 in.]
(iskirt) Front mark
102.415 to 102.445 mm 102.230 mm
0.50 OS
[4.0321 to 4.0333 in.] [4.0248 in.]

Weight difference per

5g [0.2 oz.] or less -
piston

Piston weight stamp location

4.5 Measuring piston ring end gap

Place the piston ring in a gauge or a new sleeve to measure Gauge inside diameter:
the ring end gap. If the limit is exceeded, replace all the ø 101.5 +0.045
+0.010 mm

rings as a set. [ø 4 +0.0018

+0.0004 in.]

Note: Use a piston to push the piston ring squarely into the
gauge or the sleeve. Piston ring
Feeler gauge

Item Standard Limit

Compres- 0.30 to 0.45 mm
Piston sion ring [0.0118 to 0.0177 in.] 1.50 mm
ring
0.30 to 0.50 mm [0.0591 in.]
end gap Oil ring
[0.0118 to 0.0197 in.]
Measuring piston ring end gap

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 INSPECTION AND REPAIR OF BASIC ENGINE

4.6 Measuring clearance between piston ring

groove and piston ring

CAUTION Feeler gauge

Piston

Remove carbon deposits from pistons and check the

entire circumference of the piston.
(1) Remove deposits such as carbon from each ring groove. Straight edge
(2) Check each ring groove for wear or damage. If it is Piston ring

worn or damaged, replace the piston with a new one.

(3) Insert the piston ring into the piston ring groove. Apply
a straight edge and insert thickness gauges to measure
the clearance between ring and ring groove.
Measuring clearance between piston ring groove and
If the limit is exceeded, replace the piston ring with a piston ring
new one.
(4) When the piston ring has been replaced, measure the
clearance again, and if the limit is exceeded, then
replace the piston with a new one.

Item Standard Limit

No.1 com- 0.08 to 0.12 mm 0.200 mm
pression [0.0031 to 0.0047 in.] [0.0079 in.]
Clearance
between pis- No.2 com- 0.08 to 0.12 mm 0.150 mm
ton ring and pression [0.0031 to 0.0047 in.] [0.0059 in.]
ring groove
0.025 to 0.065 mm 0.150 mm
Oil
[0.0010 to 0.0026 in.] [0.0059 in.]

4.7 Measuring piston pin bore diameter and

piston pin outside diameter
Measure the piston pin bore diameter and piston pin outside
diameter. Replace if the limit is exceeded.

Item Nominal Standard Limit

Piston pin
ø 34 mm 33.991 to 33.997 mm Measuring points Measuring directions
outside -
[1.34 in.] [1.3382 to 1.3385 in.]
diameter

Clearance
between piston 0.005 to 0.021 mm 0.050 mm
-
pin bore and [0.0002 to 0.0008 in.] [0.0020 in.]
piston pin
Measuring piston pin bore and piston pin

6-19
INSPECTION AND REPAIR OF BASIC ENGINE

4.8 Measuring piston protrusion

CAUTION
Piston protrusion must always meet the standard, as
the amount of protrusion not only influences on the
engine performance, but also it is important to prevent
valve interference.
Measure the protrusion of each piston following the
instructions below. If the measured value does not meet the
standard, inspect the clearances between various parts
involved.
(1) Bring the piston to top dead center.
Measuring piston protrusion
(2) Apply the dial gauge plunger to the top surface of the
crankcase, and zero the dial gauge.
(3) Measure the protrusion at four points on the piston
head, and calculate the mean value.
Note: Subtract the mean value from the thickness of the
gasket compressed by tightening the cylinder head,
and the clearance between the piston top and cylinder
head will be determined.

Item Standard
0.8 mm
Piston protrusion
[0.031 in.]
Compressed thickness of 1.7 ± 0.05 mm
cylinder head gasket [0.067 ± 0.0020 in.]

6-20
 INSPECTION AND REPAIR OF BASIC ENGINE

4.9 Measuring clearance between connecting

rod bearing and crankpin Connecting rod cap
tightening torque
CAUTION Measuring Measuring
103 ± 5 N·m
{10.5 ± 0.5 kgf·m}
When grinding crankpins, be sure to grind all the pins directions points
[76 ± 3.6 lbf·ft]
to the same size.
Finish the fillet radius to the specified dimension.
(1) Reassemble the bearing into the big end of the
connecting rod.
(2) Tighten the connecting rod cap bolts to the specified
torque.
(3) Measure the inside diameter of the connecting rod
Measuring connecting rod bearing inside diameter
bearing.
(4) Measure the outside diameter of the crankpin.
(5) Calculate the clearance from the difference between the
inside diameter of the connecting rod bearing and
outside diameter of the crankpin.
(6) Replace the connecting rod bearing if the clearance Measuring Measuring
exceeds the limit. directions points
(7) Measure the clearance between the connecting rod
bearing and the crankpin again. Use the undersize
bearing if the limit is exceeded.
(8) If an undersize bearing is used, grind the crankpin to
the specified undersize. Measuring crankin diameter

Item Nominal Standard Limit

Crankpin outside ø 65 mm 64.945 to 64.965 mm 64.800 mm
diameter [0.026 in.] [2.5569 to 2.5577 in.] [2.5512 in.]

Clearance between
crankpin and 0.035 to 0.100 mm 0.200 mm
-
connecting rod [0.014 to 0.0039 in.] [0.0079 in.]
bearing

4.10 Measuring clearance between connecting

rod bushing and piston pin
Measure the inside diameter of the connecting rod bushing
and the outside diameter of the piston pin. Replace if the
limit is exceeded.
Measuring
Item Nominal Standard Limit directions
Bushing inside ø 34 mm 34.020 to 34.045 mm
- Measuring
diameter [1.34 in.] [1.3394 to 1.3404 in.]
points
Clearance between
0.023 to 0.054 mm 0.080 mm
bushing and piston -
[0.0009 to 0.0021 in.] [0.0031 in.]
pin
Measuring connecting rod bushing inside diameter

6-21
INSPECTION AND REPAIR OF BASIC ENGINE

4.11 Replacing connecting rod bushing

Use a connecting rod bushing installer to replace the
Oil hole
connecting rod bushing.
(1) With the bushing joints oriented as shown in the
40°
illustration, align the oil hole of bushing with the oil
hole of connecting rod, and press-fit the connecting rod
bushing into the connecting rod.
30°
(2) After press-fitting, insert the piston pin, and check for
Oil hole
smooth movement of the connecting rod and piston
without looseness. 30°
Bushing joint

Replacing connecting rod bushing

4.12 Removing connecting rod bushing
(1) Apply engine oil to the inner surface of the connecting Connecting rod Mandrel
rod bushing. bushing installer
Collar A
P/N:32F91-03050
(2) Install the collar A to the connecting rod bushing. Connecting rod
(3) Install the collar A and B to the mandrel, and tighten bushing
the nut.
(4) Align the match mark (red line) on the collar A with the Connecting
rod
match mark on the base.
Collar B
(5) Using a press, apply pressure slowly on the head of the
Align match Nut
mandrel to force out the connecting rod bushing. mark.
Base

Removing connecting rod bushing

4.13 Installing connecting rod bushing

(1) With the oil hole of busing aligned with the match mark Connecting rod Connecting rod
on the collar A, install the new connecting rod bushing bushing installer bushing
P/N:32F91-03050
onto the collar A. Align match
(2) Install the collars A and B to the mandrel, and tighten mark.
the nut.
(3) Apply engine oil to the outer periphery of the
connecting rod bushing. Align the oil hole in the
connecting rod bushing with the match mark (red line)
on the collar, then press the bushing into the connecting Collar A
rod.
Installing connecting rod bushing (1)

Connecting rod Mandrel

bushing installer Collar B
P/N:32F91-03050
Connecting rod
bushing

Connecting
rod
Collar A
Align match Nut
mark.
Base

Installing connecting rod bushing (2)

6-22
 INSPECTION AND REPAIR OF BASIC ENGINE

4.14 Inspecting connecting rod bend and twist

(1) Measure the dimensions of C and L in the illustration to Connecting rod cap tightening torque:
103 ± 5 N·m {10.5 ± 0.5 kgf·m}
check bend and twist of the connecting rod. Straighten [76 ± 3.6 lbf·ft]
the connecting rod with a press to meet the standard. C 0.05 0.002
C [ ]
L 100 3.9
If the standard is exceeded after correction, replace the
L
connecting rod with a new one. L
C 0.05 0.002
Piston [ ] C
(2) In general, a connecting rod aligner is used to check pin L 100 3.9
bend and twist. Twist of
Note: Before checking bend, tighten the connecting rod cap connecting rod
to the specified torque. Bend of
connecting rod Unit: mm [in.]
(3) To inspect the connecting rod with the piston installed,
turn the piston upside down and place it on a surface Inspecting connecting rod bend and twist
plate. Insert a round bar having the same diameter as
the crankpin into the big-end bore, and measure the D
height of the bar using a dial gauge.
C
Item Standard Limit
Connecting rod 0.05/100 mm 0.15 mm C 0.05
bend and twist [0.0020/3.94 in.] or less [0.0059 in.] ҇ A B
D 100

Unit: mm [in.]

Measuring with a dial gauge

4.15 Inspecting connecting rod bearing
Inspect the connecting rod bearings. If any defect is found,
replace it with a new one.

Scratches
Flaking
Fusion

Inspecting connecting rod bearing

6-23
 INSPECTION AND REPAIR OF BASIC ENGINE

4.16 Measuring connecting rod end play

(1) Install the connecting rods onto the respective
crankpins and tighten the connecting rod cap bolts to Connecting rod cap
the specified torque. tightening torque:
(2) Measure the clearance of the crank arm (end play) at 103 ± 5 N·m
{10.5 ± 0.5 kgf·m}
two positions (above and below the crankpin). [76 ± 3.6 lbf·ft]
(3) If the limit is exceeded, replace the connecting rod with
a new one.

Item Standard Limit

0.15 to 0.35 mm 0.50 mm
Connecting rod end play
[0.0059 to 0.0138 in.] [0.0197 in.]
Measuring connecting rod end play

4.17 Weight difference of connecting rod

assembly in one engine
When replacing a connecting rod, be sure to check the
weight rank of the connecting rod. All the connecting rods
must be of the same weight rank in an engine.

Tolerance on
Item Mating mark
weight

A
for assembly
Weight difference of connecting rod 10 g [0.35 oz.]
assembly or less per engine Weight rank mark

Weight difference in connecting rod assembly

4.18 Measuring crankshaft journal outside diam-

eter
Measure the crankshaft journal diameter using a
micrometer. Check the crankshaft journal for circularity,
cylindricity and clearance between the bearing and journal.
If the measurement value is below the repair limit, grind the
Measuring Measuring
journal to fit the undersize bearing. If the measurement directions points
value is below the service limit, replace the crankshaft with
a new one.

Item Nominal Standard Limit

Repair limit = Measuring crankshaft journal outside diameter
ø 90 mm 89.95 to 89.97 mm 89.85 mm [3.5374 in.]
Diameter
[3.54 in.] [3.5413 to 3.5421 in.] Service limit =
89.10 mm [3.5079 in.]

0.01 mm 0.03 mm
Roundness -
[0.0004 in.] or less [0.0012 in.]

Cylinderic- 0.01 mm 0.03 mm

-
ity [0.0004 in.] or less [0.0012 in.]
Deviation of
0.01 mm [0.0004 in.]
Parallelism - -
or less over entire
pin length

6-24
 INSPECTION AND REPAIR OF BASIC ENGINE

4.19 Measuring crankshaft crankpin outside

diameter
Measure the crankpin outside diameter using a micrometer.
Check the crankpin for roundness, cylindricality, and the
clearance with the bearing. If the measurement value is
below the limit, grind the journal to fit the undersize Measuring Measuring
bearing. If the measurement value is below the service limit, directions points
replace the crankshaft with a new one.

Item Nominal Standard Limit

Service limit =
ø 65 mm 64.945 to 64.965 mm
Diameter 64.800 mm
[2.56 in.] [2.5569 to 2.5577 in.] Measuring crankshaft diameter
[2.5512 in.]

0.01 mm 0.03 mm
Roundness -
[0.0004 in.] or less [0.0012 in.]

Cylinderic- 0.01 mm 0.03 mm

-
ity [0.0004 in.] or less [0.0012 in.]

Deviation of
0.01 mm [0.0004 in.] or
Parallelism - -
less over entire pin
length

4.20 Grinding crankshaft

Grind the crankshaft journal (or pin) in the diameter that fit
the inside diameter of the next undersize main (or
connecting) bearing. By doing so, the fitness check with an
actual bearing can be omitted.
When grinding, be careful not to change the fillet radius and
width. If the surface hardness is considered to have been
reduced considerably, re-harden the crankshaft and check
for flaws by means of magnetic particle inspection.
Ensure that the surface finish accuracy of the crankpins and
journals is kept within the standard even after the correction
by grinding.

Item Undersize Finished size

0.25 mm 89.70 to 89.72 mm
[0.0098 in.] [3.5315 to 3.5323 in.]
Crank 0.50 mm 89.45 to 89.47 mm
journal [0.0197 in.] [3.5216 to 3.5224 in.]
0.75 mm 89.20 to 89.22 mm
[0.0295 in.] [3.5118 to 3.5126 in.]
0.25 mm 65.695 to 65.715 mm
[0.0098 in.] [2.5864 to 2.5872 in.]
0.50 mm 65.445 to 65.465 mm
Crankpin
[0.0197 in.] [2.5766 to 2.5774 in.]
0.75 mm 65.195 to 65.215 mm
[0.0295 in.] [2.5667 to 2.5675 in.]

6-25
INSPECTION AND REPAIR OF BASIC ENGINE

4.21 Measuring crankshaft end play

(1) Measure the crankshaft end play (clearance between the
33 +0.039
0 mm
crank arm at the thrust force receiving journal and the [1.3 +0.0015
0 in.]
bearing cap with thrust plate attached). If the limit is
exceeded, replace the thrust plate with a new one.
(2) If the limit is still exceeded after a new thrust plate has
been installed, use an oversize thrust plate.
Note: In general, the rear thrust bearing wears faster than
the front thrust bearing. Therefore, in most cases, the
correction is achieved by replacing the rear thrust
plate with the next oversize one.
Width of crankshaft thrust journal
Item Standard Limit
0.100 to 0.246 mm 0.300 mm
Crankshaft end play
[0.0039 to 0.0104 in.] [0.0118 in.]

Crankshaft thrust size after grinding

OS, used OS, used
Item on one on both Tolerance
side sides
+0.15 mm 33.15 mm 33.30 mm
[+0.0059 in.] OS [1.3051 in.] [1.3110 in.]
+0.039
+0.30 mm 33.30 mm 33.45 mm 0 mm
[+0.0118 in.] OS [1.3110 in.] [1.3169 in.] [
+0.0015
0 in.]
Measuring crankshaft end play
+0.45 mm 33.45 mm 33.60 mm
[+0.0177 in.] OS [1.3169 in.] [1.3228 in.]

4.22 Measuring crankshaft runout

Support the crankshaft at the front and rear journals with V-
blocks, and measure the crankshaft runout at the center
journal using a dial gauge. If the runout deviates from the
standard only slightly, grind the crankshaft to repair. If the
runout exceeds the standard considerably, straighten the
crankshaft using a press.
If the limit is exceeded, replace the crankshaft.
If the crankshaft has been repaired by grinding or pressing,
inspect the crankshaft for cracks and other harmful damage
using a magnetic particle method.
Measuring crankshaft runout
Item Standard Limit Remark
Crankshaft 0.04 mm 0.10 mm
TIR
runout [0.0016 in.] or less [0.0039 in.]

6-26
 INSPECTION AND REPAIR OF BASIC ENGINE

4.23 Replacing crankshaft gear

4.23.1 Removing crankshaft gear
Using a gear puller, remove the gear from the crankshaft.
Note: Do not strike the gear with a hammer. Crankshaft gear

Puller
P/N:64309-12900

Removing crankshaft gear

4.23.2 Installing crankshaft gear

(1) Install the key on the crankshaft.
(2) Press-fit the gear fully in alignment with the key.
Key
Aligning position

Crankshaft gear

Installing crankshaft gear

6-27
INSPECTION AND REPAIR OF BASIC ENGINE

4.24 Replacing front oil seal

CAUTION
Be careful not to damage the crankshaft pulley with a
chisel when breaking the sleeve. Be careful not to dent Crankshaft
or scratch the outer surface of sleeve. pulley
When a oill leaks from the oil seal, replace both sleeve and
oil seal with new ones.
(1) Removing sleeve
Apply a chisel at right angles to the end surface of the
Sleeve
sleeve and strike it with a hammer at three locations to
loosen the sleeve and then remove the sleeve.
Removing front oil seal sleeve
Note: If the sleeve cannot be removed, apply the chisel to
the sleeve in the axial direction of the sleeve and tap it
lightly to make a cut and remove crankshaft-to-sleeve
interference.
(2) Installing sleeve Sleeve
Install the sleeve using a press so that the end of pulley
Crankshaft pulley
becomes flush.

Installing front oil seal sleeve

4.25 Replacing rear oil seal

CAUTION
Be careful not to damage the crankshaft when remov- Rear slinger
ing the rear oil seal. Be careful not to dent or scratch
the outer surface of sleeve.
When a oill leaks from the oil seal, replace the oil seal with
a new one.
(1) Removing rear oil seal
Remove the oil seal with a puller.
(2) Installing rear side oil seal
Apply an oil on the slinger inner surface of oil seal.
Removing rear oil seal sleeve
Install the oil seal with an oil seal installer.
Note: The oil seal is united with the slinger.
Rear oil seal installer
P/N:34291-00020
Oil seal

Installing rear oil seal sleeve

6-28
 INSPECTION AND REPAIR OF BASIC ENGINE

4.26 Inspecting main bearing surface

Check the inside surface of each main bearing shell for
abnormal contact, scratches, corrosion and peeling from Scratch on the inner
foreign material. Also check the outside surface of each and outer circumference,
corrosion, and detachment
bearing shell which comes into contact with the crankcase
or main bearing cap for abnormal seating.

Inspecting main bearing surface

4.27 Measuring clearance between main bear-

ing and crankshaft journal Measuring Measuring
directions points

CAUTION
(a) When grinding crank journals, be sure to grind all
the journals to the same size.
(b) Finish the fillet radius to the specified dimension.
(1) Reassemble main bearings.
(2) Tighten the main bearing caps to the specified torque.
Main bearing cap bolt
(3) Measure the inside diameter of the main bearings. tightening torque:
(4) Measure the outside diameter of the crank journal. 137 ± 5 N·m {14 ± 0.5 kgf·m} [101 ± 3.6 lbf·ft]
(5) Calculate the clearance between the inside diameter of Measuring inside diameter of lower hole of main
the main bearing and outside diameter of the crank bearing
journal.
(6) Replace the main bearing if the clearance exceeds the
limit.
(7) Measure the clearance between the main bearing cap
and the crank journal again. Use the undersize bearing
if the limit is exceeded. Measuring Measuring
(8) If an undersize bearing is used, grind the crank journal directions points
to the specified undersize.

Item Standard Limit

Clearance between main 0.050 to 0.118 mm 0.200 mm
bearing and crankshaft journal [0.0020 to 0.0046 in.] [0.0079 in.]
Measuring crank journal outside diameter

6-29
 REASSEMBLY OF BASIC ENGINE
1. Reassembling piston, connecting rod, 4.11 Adjusting valve clearance ...................... 7-15
crankshaft and crankcase ...............7-2 4.12 Installing rocker cover ............................ 7-15
1.1 Installing main bearing ............................. 7-2
1.2 Installing thrust plate ................................ 7-2
1.3 Installing crankshaft ................................. 7-2
1.4 Installing main bearing caps .................... 7-3
1.5 Inserting side seal .................................... 7-3
1.6 Installing main bearing cap bolt ............... 7-3
1.7 Measuring crankshaft end play ................ 7-4
1.8 Reassembling piston and
connecting rod ......................................... 7-4
1.9 Installing piston ring ................................. 7-5
1.10 Preparation for installing pistons.............. 7-5
1.11 Installing connecting rod bolt and
connecting rod bearing ............................ 7-6
1.12 Installing Pistons ...................................... 7-6
1.13 Installing connecting rod cap ................... 7-7

2. Reassembling timing gear and

camshaft..........................................7-8
2.1 Installing front plate.................................. 7-8
2.2 Installing tappet........................................ 7-8
2.3 Installing camshaft ................................... 7-8
2.4 Installing front idler gear........................... 7-9
2.5 Inspecting and adjusting timing gear
after installation........................................ 7-9
2.5.1 Inspecting backlash and end play ..............7-9
2.6 Installing front oil seal ............................ 7-10
2.7 Installing timing gear case ..................... 7-10
2.8 Installing crankshaft pulley..................... 7-10

3. Reassembling flywheel .................7-11

3.1 Installing flywheel housing ..................... 7-11
3.2 Installing flywheel................................... 7-11

4. Reassembling cylinder head and

valve mechanism ..........................7-12
4.1 Cleaning cylinder head bottom
surface ................................................... 7-12
4.2 Installing valve stem seal ....................... 7-12
4.3 Installing valve and valve spring ............ 7-12
4.4 Installing cylinder head gasket............... 7-13
4.5 Installing cylinder head assembly .......... 7-13
4.6 Tightening cylinder head bolts ............... 7-13
4.7 Inserting push rod .................................. 7-14
4.8 Reassembling rocker shaft assembly .... 7-14
4.9 Installing rocker shaft assembly............. 7-14
4.10 Installing injector .................................... 7-15
7-1
REASSEMBLY OF BASIC ENGINE

1. Reassembling piston, connecting rod, crankshaft and crankcase

1.1 Installing main bearing
Main bearing upper
CAUTION
Do not apply oil to the bearing outer surface, as the oil
may cause bearing seizure.
(1) Press the upper main bearing into position by aligning
its lug to the lug groove on the crankcase.
Note: The oil hole of the main bearing is aligned with the Align with lug groove.
oil hole of the crankcase by installing the upper main
bearing in alignment with the lug groove. Thrust plate
(2) Apply a small amount of engine oil to each bearing.
Installing main bearing upper

1.2 Installing thrust plate

Install the thrust plates to the crankcase outside face of
Thrust plate, upper
rearmost bearing and to the main bearing cap with their
grooves facing outward.

Thrust plate, lower

Thrust plate, lower

Installing thrust plate

1.3 Installing crankshaft

(1) Install the wood ruff key on the crankshaft.
(2) Make sure that the main bearing upper shells that are
installed in the crankcase bores have their inner
periphery (the surface comes into contact with the
journal) lubricated with an even coat of fresh engine
oil.
(3) Wash the crankshaft thoroughly with cleaning oil and
dry it completely by blowing compressed air. Then,
apply an even coat of fresh engine oil to the crankshaft
journals.
Note: When cleaning the crankshaft, pay special attention to Installing crankshaft
the oil holes in the crank journals and crankpins, and
make sure that they are free from any foreign matter.
(4) Sling up the crankshaft horizontally, then move it above
the crankcase and lower it slowly into position.
Note: When lifting the crankshaft with a chain block, do not
attach a metal hook or similar fitting directly onto the
crankshaft. Such metal fittings can damage the
crankshaft easily. Always lift the crankshaft using
cloth belts or pads on the supporting points.

7-2
 REASSEMBLY OF BASIC ENGINE

1.4 Installing main bearing caps

CAUTION
The foremost and rearmost caps should be installed
so that they are flush with the crankcase surface.
Install the main bearing caps from the front side in the order
of the numbers marked on them.
(1) Apply engine oil to lower main bearings and install
them to the main bearing caps.
(2) Apply ThreeBond 1212 to the mating surface of the Apply ThreeBond 1212.
foremost and rearmost caps and the crankcase mating
faces before installing the main bearing caps.
Installing main bearing cap
Note: Do not apply ThreeBond 1212 to any other surface
other than the mating surfaces of the foremost and
rearmost caps and the crankcase mating faces.
(3) Install the main bearing caps and temporarily tighten
bolts.

1.5 Inserting side seal

(1) Apply a sealant to the outer periphery of new side seals.

Crankcase Bearing cap Side seal

Sealant ThreeBond 1212 or 1211

(2) With the round section of the side seals facing outward,
press them partway into the front and rear caps using
hands.
(3) When the side seals are installed partway into caps, use
a tool with flat surface such as flat-head screwdriver to
R section
install completely, taking care not to bend them.

Inserting side seal

1.6 Installing main bearing cap bolt

(1) Tighten the main bearing cap bolts alternately and Main bearing cap bolt tightening torque
progressively to the specified torque. 137 ± 5 N·m {14 ± 0.5 kgf·m}
[101 ± 3.6 lbf·ft]
(2) Make sure that the crankshaft rotates smoothly.

Installing main bearing cap bolt

7-3
REASSEMBLY OF BASIC ENGINE

1.7 Measuring crankshaft end play

Attach a dial gauge to the end of the crankshaft to measure
the end play.
If the end play deviates from the standard value, loosen the
main bearing cap bolts and retighten.
Make sure that the crankshaft turns freely.

Item Standard Limit

0.100 to 0.246 mm 0.300 mm
Crankshaft end play
[0.0039 to 0.0104 in.] [0.0118 in.]

Measuring crankshaft end play

1.8 Reassembling piston and connecting rod

(1) Apply engine oil to the piston pin, and reassemble the
piston and the connecting rod by inserting the piston F

Front
pin, observing the orientation of piston and connecting Piston pin
rod shown in the illustration. Snap ring
Note: The pistons and piston pins are assembled to each
other in clearance fit. However, the piston pins are
more easily inserted into the pistons if the pistons are Apply engine oil
warmed up with a heater or in hot water.
(2) Using ring pliers, install the snap ring. Check the snap
Matching mark
ring for its tension, and make sure the ring fits snugly in
the groove. Reassembling piston and connecting rod

7-4
 REASSEMBLY OF BASIC ENGINE

1.9 Installing piston ring

CAUTION No.1 compression ring

Every piston ring has a top mark such as "R" near the Top mark
end gap. Install all piston rings with this mark facing
upward. No.2 compression ring
If the rings are installed upside down, it could cause
malfunctions such as excessive oil consumption or an
engine seizing.
(1) Install the piston rings to the piston with a ring Oil ring
expander.
(2) Install the oil ring with its end gap 180° away from the
Reassembling piston and piston ring
joint of the coil spring, as shown in the illustration.

Coil spring butted ends

180°

Oil ring abutment

Reassembling oil ring

1.10 Preparation for installing pistons

(1) Lay the engine on its side.
(2) Clean the cylinder inner surface and the crank pin with
a cloth, and apply engine oil.

Cleaning and lubricating cylinder sleeve inner surface

7-5
REASSEMBLY OF BASIC ENGINE

1.11 Installing connecting rod bolt and connect-

ing rod bearing
(1) Press fit the connecting rod bolts into the connecting Lug groove
rod.
Note: When press fitting the bolt, make sure that the bolt
fully contacts its seating position without any
interference with the shoulder of mounting surface.
(2) Install the upper connecting rod bearing with its lug
fitted in the lug groove of connecting rod.
(3) Install the connecting rod bearing with its lug fitted in
the lug groove of connecting rod cap.
(4) Apply engine oil to the inner surface of bearing. Installing connecting rod bolt and upper bearing

Lug groove

Installing lower connecting rod bearing

1.12 Installing Pistons

CAUTION Camshaft side

Do not forcefully insert the piston, as it may cause
No.1
damage to the piston rings and crank pin. 180° compression
(1) Apply engine oil to the circumference of the piston and ring end gap
piston rings.
No.2
(2) Orient the ring end gaps diagonally opposite each other compression Oil ring end gap
avoiding the piston pin direction and its right angle ring end gap 60° 60°
direction.
Combustion chamber side
(3) Turn the crankshaft to bring the crank pin of the
cylinder to the top dead center.
Orientation of piston ring end gap
(4) Orient the front mark on the top of piston toward engine
front.
(5) Using a piston guide, insert the piston from the top face
of crankcase into the cylinder sleeve.

Piston guide
P/N:34291-00100

Installing piston

7-6
 REASSEMBLY OF BASIC ENGINE

1.13 Installing connecting rod cap

(1) When the big end of the connecting rod comes into
Camshaft
contact with the crank pin, turn the crankshaft 180°
Matching mark
while pressing the piston head.
(2) Install the connecting rod cap with its match mark
facing on the same side as the match mark on the Connecting rod cap
connecting rod. nut tightening torque:
(3) Tighten the connecting rod cap nuts evenly and 103 ± 5 N·m
{10.5 ± 0.5 kgf·m}
progressively to the specified torque.
[76 ± 3.6 lbf·ft]
(4) Inspect end play of the connecting rod. If end play is Wood block
small, loosen and retighten the cap nuts.
Installing connecting rod cap

7-7
REASSEMBLY OF BASIC ENGINE

2. Reassembling timing gear and camshaft

2.1 Installing front plate
(1) Clean the mounting surface of the gasket. Front plate bolt tightening torgue:
M10 × 1.5 35 ± 5 N·m {3.6 ± 0.5 kgf·m} [25.3 ± 3.6 lbf·ft]
(2) Apply sealant to the gasket to prevent it from falling. M8 × 1.25 19 ± 2 N·m {1.9 ± 0.2 kgf·m} [13.7 ± 1.4 lbf·ft]
(3) With aligning to the dowel pin, install the gasket and
the front plate. Front plate
(4) Secure the front plate with mounting bolts.

Installing front plate

2.2 Installing tappet
Apply engine oil onto the periphery of tappets, insert them
into the tappet holes.

2.3 Installing camshaft

CAUTION
Be careful not to damage camshaft journals, cams and
camshaft holes during insertion. Camshaft gear

(1) Apply engine oil to the camshaft journals and cams.

(2) Slowly insert the camshaft assembly.
(3) Tighten the thrust plate bolt to the specified torque.
Camshaft thrust plate
(4) Make sure that the camshaft rotates lightly. Move the
bolt tightening torque
camshaft gear back and forth, and make sure there is 12 ± 2 N·m{1.2 ± 0.2 kgf·m}
end play. [9 ± 1.4 lbf·ft]

Installing camshaft

7-8
 REASSEMBLY OF BASIC ENGINE

2.4 Installing front idler gear

(1) Apply engine oil to the idler gear shaft.
Thrust plate bolt
(2) Install the idler gear with all match marks on it aligned tightening torque
with the marks on the other gears. 34 ± 5 N·m
Idler gear
(3) Install the thrust plate with its hole matching the pin of {3.5 ± 0.5 kgf·m}
[25 ± 3.6 lbf·ft]
the idler gear shaft.
(4) Tighten the thrust plate bolt to the specified torque.
(5) Move the idler gear back and forth, and make sure there
is end play.

Thrust plate

Installing idler gear

Injection pump
idler gear
Camshaft gear

 


 

㩩

Injection pump Idler gear

gear Crank gear

Timing gear train

2.5 Inspecting and adjusting timing gear after
installation
Be sure to inspect and adjust the timing gear when the
timing gear has been reassembled.

2.5.1 Inspecting backlash and end play

After installing the timing gears, be sure to inspect and
adjust the backlash and end play between gears.

Idler gear

Measuring idler gear end play

Measuring backlash of timing gear

7-9
REASSEMBLY OF BASIC ENGINE

2.6 Installing front oil seal

Using an installer, install new oil seal in the timing gear
case. Make sure the oil seal is flush with the gear case.

Installing front oil seal

2.7 Installing timing gear case
(1) Install the baffle plate to the front end of crankshaft. Timing gear case tightening torque:
M10 × 1.5 35 ± 5 N·m {3.6 ± 0.5 kgf·m} [25.3 ± 3.6 lbf·ft]
(2) Apply sealant to the gasket to prevent it from M8 × 1.25 19 ± 2 N·m {1.9 ± 0.2 kgf·m} [13.7 ± 1.4 lbf·ft]
displacing, and install the gasket on the front plate.
(3) Apply engine oil to the oil seal lip.
(4) Orient the cutaway of the baffle plate so that the baffle
plate does not overlap the oil pump idler gear.
(5) Install the timing gear case, and secure it with the bolts.

Gasket
Timing gear case

Installing timing gear case

Oil pump idler gear

Baffle plate cutaway

Baffle plate cutaway position

2.8 Installing crankshaft pulley
Crankshaft pulley nut The bar that prevnets
CAUTION tightening torque: crankshaft rotation
706 ± 59 N·m {72 ± 6 kgf·m}
The bar could come off. Be very careful.
[521 ± 43 lbf·ft]
(1) Screw two guide bolts into the threaded holes at the rear Crankshaft pulley
end of the crankshaft. Place a bar across the two guide
bolts so that the crankshaft does not turn.
(2) Install the woodruff key on the crankshaft.
(3) Install the crankshaft pulley and tighten the nuts to the
specified torque. Guide bolt (M12×1.25mm)
(Front) (Rear)

Installing crankshaft pulley

7-10
 REASSEMBLY OF BASIC ENGINE

3. Reassembling flywheel
3.1 Installing flywheel housing
(1) Clean the mounting surface of the gasket.
(2) Apply sealant to the gasket to prevent it from falling
off.
(3) Install the gasket.
(4) Install the flywheel housing, aligning its dowel pin
holes and dowel pins, and tighten the bolts.
Note: When the dowel pins are worn or when the flywheel
housing is replaced, replace the dowel pins with new
ones.

Installing flywheel housing

3.2 Installing flywheel

Flywheel bolt tightening
CAUTION torque:
83 ± 5 N·m {8.5 ± 0.5 kgf·m}
The person who holds the pulley must be very careful
Crankshaft pulley [62 ± 3.6 lbf·ft]
to assure safety by communicating with the person Guide bolt
who is installing the flywheel.
(1) One person must firmly hold the pulley with a wrench
to prevent the crankshaft from turning.
(2) Screw the guide bolt into the rear end of the crankshaft.
(3) Align the bolt hole of flywheel with the guide bolt and
install the flywheel to the crankshaft. Front Rear
(4) Temporarily tighten bolts. Installing flywheel
(5) Remove the guide bolt and temporarily tighten the last
bolt.
(6) Tighten the flywheel bolts to the specified torque.

7-11
REASSEMBLY OF BASIC ENGINE

4. Reassembling cylinder head and valve mechanism

4.1 Cleaning cylinder head bottom surface

CAUTION
Do not use liquid gasket on the cylinder head.
Taking care not to damage the cylinder head bottom surface,
remove residue of old gasket.
Note: First, roughly scrape off residue of old gasket using a
scraper. Then, grind off the remaining residue using
an engine-oil immersed oil stone.

Cleaning cylinder head bottom surface

4.2 Installing valve stem seal

CAUTION Push the shoulder of valve stem seal.

Do not apply oil or liquid gasket to the inner side of ω ω
stem seal that comes in contact with the valve guide.
Valve stem seal
(1) Apply engine oil to the lip of new valve stem seal.
(2) Push the shoulder of the valve stem seal and fit the
valve stem steal into the valve guide. Valve guide
(3) Insert the valve stem seal into the valve guide using the
valve stem seal installer.

Installing valve stem seal

4.3 Installing valve and valve spring
(1) Install the valve spring and retainer on the valve guide. Valve spring pusher
Install the valve cotter using a valve spring pusher. P/N:30691-04500
(2) Tap the top of valve stem lightly several times with a
soft hammer to make sure that the valve spring and
valve cotter are properly installed and seated firmly.

Installing valve and valve spring

Valve cotter

Installing valve cotter

7-12
 REASSEMBLY OF BASIC ENGINE

4.4 Installing cylinder head gasket

CAUTION
Do not use liquid gasket on the cylinder head.
(1) Make sure that there is no dirt or dents on the top
surfaces of the crankcase and pistons.
(2) Place new gasket on the crankcase by aligning it with
dowel pins on the crankcase.

4.5 Installing cylinder head assembly

Install the cylinder head on the crankcase by aligning it with
the dowel pins.
Note: Be careful not to displace the cylinder gasket when
installing.

Installing cylinder head assembly

4.6 Tightening cylinder head bolts

In the numerical order as shown in the illustration, tighten
cylinder head bolts progressively to the specified torque. Cylinder head bolt tightening torque:
137 ± 5 N·m {14 ± 0.5 kgf·m} [101 ± 3.6 lbf·ft]

15 11 7 3 2 6 10 14

17 9 1 8 16

13 5 4 12

Tightening order of cylinder head bolt

7-13
REASSEMBLY OF BASIC ENGINE

4.7 Inserting push rod

(1) Insert each push rod into its hole in the cylinder head.
(2) Make sure that the ball end of each push rod is placed
Push rod
correctly on the tappet cup.

Tappet

Inserting push rod

4.8 Reassembling rocker shaft assembly

(1) Apply engine oil to the rocker shaft.
(2) When reassembling, install the rocker shaft assembly in
the same position as it was.
Rocker shaft spring
Note: If the rocker shaft assembly is not installed as it was,
the clearance becomes different, and it may result in a Rocker shaft
defect such as increased wear. Oil pipe Bracket
(3) After reassembling, make sure the rocker arm and oil Rocker arm
pipe move freely.
Snap ring
Eye bolt

Reassembling rocker shaft assembly

4.9 Installing rocker shaft assembly

(1) Install the valve caps to the valve heads.
(2) Tighten the long bolts of the rocker bracket to the
specified torque.
(3) Tighten the short bolts of the rocker bracket.

Rocker shaft bracket bolt tightening torque:

20 ± 2 N·m {2 ± 0.2 kgf·m} [14.5 ± 1.4 lbf·ft]

Installing rocker shaft assembly

7-14
 REASSEMBLY OF BASIC ENGINE

4.10 Installing injector

(1) Install the gasket to the injector.
Leak off hose connector
(2) Install the injector with the nozzle gland to the cylinder
head. Injector Leak off hose
(3) With the washer spherical side faced toward nozzle Pin
gland, install the washer, and secure it by tightening the
Nozzle
hexagon socket head bolt to the specified torque. gland
(4) Apply engine oil to the O-ring of leak off hose Injection pipe
connector. Injection connector
(5) With pushing the pin on top of the injector, install the
Gasket
leak off hose connector.
(6) Install the injection pipe to the injector. Installing injector
Note: Make sure that the injector is reassembled into the
same cylinder as it was before.

Injector

Push
Pin

Pushing pin on top of injector

4.11 Adjusting valve clearance
Adjust the valve clearance.
For adjusting procedures, refer to "Adjustment and
Operation."

Adjusting valve clearance

4.12 Installing rocker cover
(1) Make sure that the gasket is firmly installed into the Rocker cover bolt tightening torque:
rocker cover. 20 ± 2 N·m {2 ± 0.2 kgf·m}
[14.5 ± 1.4 lbf·ft]
(2) Tighten the rocker cover mounting nuts to the specified
torque.

Installing rocker cover

7-15
 Fuel system
1. Environment of fuel system
service.............................................8-2

2. Removing fuel system.....................8-2

2.1 Removing fuel system (Part 1)................. 8-3
2.2 Removing fuel system (Part 2)................. 8-4

3. Replacing fuel pump, fuel pump gear

and fuel pump idler gear .................8-5
3.1 Removing fuel pump and fuel pump
gear.......................................................... 8-5
3.2 Installing fuel pump and fuel pump
gear.......................................................... 8-6

4. Disassembling and inspecting fuel

pump ...............................................8-7
4.1 Inspecting fuel pump................................ 8-7
4.2 Disassembling fuel pump......................... 8-8
4.2.1 Preparation of disassembling fuel pump ....8-8
4.2.2 Removing feed pump .................................8-8
4.2.3 Removing fuel metering unit ......................8-8
4.2.4 Removing overflow valve ...........................8-9
4.3 Reassembling fuel pump ......................... 8-9
4.3.1 Installing feed pump ...................................8-9
4.3.2 Installing fuel metering unit ......................8-10
4.3.3 Installing overflow valve ...........................8-10
4.3.4 Replacing O ring of overflow valve...........8-10

5. Disassembling and inspecting

common rail...................................8-11
5.1 Inspecting common rail assembly.......... 8-11
5.2 Disassembling common rail assembly... 8-12
5.2.1 Preparation of disassembling common rail
assembly ..................................................8-12
5.2.2 Removing rail pressure sensor ................8-12
5.2.3 Removing pressure limiting valve ............8-12
5.3 Reassembling common rail assembly ... 8-13
5.3.1 Installing rail pressure sensor ..................8-13
5.3.2 Installing pressure limiting valve ..............8-13

6. Installing fuel system.....................8-14

6.1 Installing fuel system (Part 1)................. 8-14
6.2 Installing fuel system (Part 2)................. 8-15

8-1
Fuel system

1. Environment of fuel system service 2. Removing fuel system

To maintain the cleanliness when installing, removing,
inspecting and repairing the fuel system of this engine, WARNING
(a) Keep flame or heat away from the fuel system
observe the following instructions.
before conducting the removal work. It could be
• Clean the engine before conducting the fuel system
cause a fire.
service.
(b) Wipe off any spilled fuel. Spilled fuel could cause a
• Cover the electrical parts and connectors to protect
fire.
the parts, and to prevent the electric leakage and
(c) Do not conduct the work right after the engine stop-
short-circuit.
ping. There are high pressure fuel remaining inside
• Cleaning and drying the fuel system using com-
the fuel system parts such as the fuel pump, com-
pressed air must be done before disassembling the
mon rail and injectors.
fuel system to prevent dust from entering the fuel
(d) Cut the fuel supply from the fuel tank before con-
injection pipes.
ducting the work.
• To keep the parts from contaminants, seal the open-
ings with plugs as soon as the fuel system parts are
CAUTION
removed.
(a) Cover or plug any inlet and outlet openings to pre-
• Disassembling and reassembling work of fuel sys-
vent dust from entering fuel system.
tem parts must be done on the work table that has
(b) If maintenance of the fuel pump, common rail and
stainless-steel table top.
injectors that are not instructed in this manual are
• Always use clean tools when working on the fuel sys-
required, do not conduct the maintenance by your-
tem. After working, clean the tools.
self. For fuel pump, common rail, and injector, have
• When the ventilator is installed in the working area,
a specialized maintenance shop do the mainte-
install the filter to the ventilator. Do not use the elec-
nance work.
tric fan at the working area.
(c) When the contaminant entered in the fuel system,
• Do not wear the fuzzy cloths. Wear clean cloths at
clean inside of the fuel system with clean fuel oil.
the working area. Wear hat to prevent hair falling. Do
not use the hand cream or equivalent. Use the rub-
ber glove for precise manufacture if necessary.

8-2
 Fuel system

2.1 Removing fuel system (Part 1)

Replace: Sealing washer 8

B
O-ring
Gasket
Leak off hose 6

10
2
3
4 1
5 11
16
A
18 14
17 D
15 7 9
B
C 13

C
21

22

12

23
19
D

A 20

Removing fuel system (Part 1)

Removing sequence

1 Pipe clamp 9 Fuel pipe 17 Nozzle ground

2 No.1 injection pipe 10 Bracket 18 Injector
3 No.2 injection pipe 11 Bolt 19 Fuel pump nut
4 No.3 injection pipe 12 Hose clamp 20 Fuel pump flange, fuel pump
5 No.4 injection pipe 13 Fuel hose 21 Head assembly
6 Leak off hose 14 Fuel return pipe 22 Fuel filter element
7 Fuel hose 15 Common rail 23 Water sedimenter
8 Pipe clamp 16 Hexagon bolt

8-3
Fuel system

2.2 Removing fuel system (Part 2)

1
2

Removing fuel system (Part 2)

Removing sequence

1 Fuel pump nut 3 Bolt 5 Fuel pump idler gear, bearing

2 Fuel pump gear 4 Fuel pump

8-4
 Fuel system

3. Replacing fuel pump, fuel pump gear and fuel pump idler gear
3.1 Removing fuel pump and fuel pump gear

CAUTION
Be careful not to damage the fuel metering unit
Put a mating mark
(MPROP) when removing the fuel pump and fuel
pump gear.
(1) Remove the harness connector.
(2) Disconnect the fuel pipes and hoses from the fuel
pump.
(3) Remove the inspection cover for the fuel pump idler Fuel pump Idler gear
idler gear
gear and idler gear.
(4) Put a mating mark on the fuel pump idler gear and idler
gear with white paint. Removing fuel pump
(5) Remove the fuel pump together with the fuel pump
flange from the timing gear case.
(6) Install the baffle jig that is included in the HPP gear
remove kit (32G91-01010) to the fuel pump flange as
shown in the illustration.
(7) Put a mating mark on the fuel pump idler gear and fuel
pump gear with white paint. Baffle
(8) Remove the fuel pump gear mounting nut.
(9) Install the fuel pump gear puller, that is included in the
HPP gear remove kit (32G91-01010), to the fuel pump Fuel pump
gear. Install the one arm of the gear puller to the body
of the gear puller. Insert the installed arm into the Removing fuel pump gear (1)
clearance between the fuel pump gear and fuel pump
flange, and hook the fuel pump gear. Also insert the
Arm of
other arm of gear puller into the clearance, and hook the
gear puller
fuel pump gear. After hook the fuel pump gear, install
the other arm to the body of gear puller. Body of
gear puller
(10)Tighten the jack bolt of gear puller to the specified
torque and remove the fuel pump gear.
(11)Remove the fuel pump from the fuel pump flange.
Jack bolt
CAUTION Tightening torque Fuel pump
(a) Fuel pump gear could come off suddenly. Be care- 10 N·m {0.1 kgf·m}
ful when removing the fuel pump gear with gear
puller. Removing fuel pump gear (2)
(b) When the replacement of the fuel pump idler gear
and/or the bearing is required, replace the fuel
pump flange and fuel pump idler gear as assem-
bly.

8-5
Fuel system

3.2 Installing fuel pump and fuel pump gear

(1) Apply grease to the O ring of fuel pump shaft.
(2) Install the fuel pump into the fuel pump flange.
(3) Install the woodruff key into the fuel pump shaft.

CAUTION
Make sure that the top face of the woodruff key is par-
allelized with the fuel pump shaft when it is installed. If
it is not parallelized, it will be hard to pull out on next
removal.
(4) Install the fuel pump gear with aligning the position of
woodruff key into the fuel pump shaft. Then, mating Installing fuel pump
mark of fuel pump gear and fuel pump gear must be
aligned.
(5) Install the O ring on the fuel pump flange.
(6) With aligning the mating mark of fuel pump idler gear
and idler gear, install the fuel pump flange together
with the fuel pump to the timing gear case.
(7) Install the inspection cover for the fuel pump idler gear
and idler gear to the timing gear case.
(8) Connect the harness connector.
(9) Install the fuel pipes and hoses, and tighten it to the
specified torque.

8-6
 Fuel system

4. Disassembling and inspecting fuel pump

4.1 Inspecting fuel pump
Inspect the fuel pump for following items shown in the illustration after removed from the engine. If defects of parts are found,
replace it with new one.

1 Damage of key groove

and thread
Damage of
mating surface
5

Damage of connector
and terminal
Damage of 2 3
mating surface
Damage of mating surface
and thread

Inspecting fuel pump

1 Fuel backflow connector 3 Fuel outlet connector 5 Eccentric drive shaft

2 Fuel inlet connctor 4 Fuel metering unit (MPROP)

CAUTION
When replacing the fuel pump parts, operate the engine at low idle for 10 minutes after replacement and make sure
no leakage are found. After that, operate the engine again at rated speed for 3 minutes and make sure no leakage
are found.

CAUTION
When replacing the fuel pump parts, put the red or white mark (ø5mm circle) on the new parts to notify the replace-
ment.

8-7
Fuel system

4.2 Disassembling fuel pump

4.2.1 Preparation of disassembling fuel pump Fuel backflow Rubber cap
connector 31A61-01800
(1) Seal the fuel backflow connector, fuel inlet connector
and fuel oultet connctor with plugs. Fuel
(2) Clean the fuel pump with commercial cleaning agent metering
and dry it with compressed air. unit
Fuel inlet
connector
CAUTION Plug
When cleaning the fuel pump, be careful not to allow 31G61-08600
the cleaning agent entering the connector of fuel
Plug Fuel outlet connector
metering unit. 31G61-08700

Preparation of disassembling fuel pump

4.2.2 Removing feed pump

(1) Remove the four Torx screws, and remove the feed
pump from the pump housing carefully. Feed pump
Note: Remove dust from the feed pump mating surface of
the pump housing if there it is.

Torx screw

Removing feed pump

4.2.3 Removing fuel metering unit

(1) Remove the three Torx screws, and remove the fuel
metering unit from the pump housing carefully.
Flat gasket
(2) Remove the flat gasket.
Note: (a) Be careful not to damage the pump housing when Connector
removing the flat gasket.
(b) Do not touch inside of the fuel metering unit
connector.
(c) Do not allow water and oil entering the fuel
Fuel metering unit
metering unit connector.
Torx screw
(d) Remove dust from the fuel metering unit mating
surface of the pump housing if there it is. Removing fuel metering unit

8-8
 Fuel system

4.2.4 Removing overflow valve

(1) Remove the oveflow valve.
Note: Remove dust from the overflow valve mating surface
of the pump housing if there it is.

CAUTION
Be careful not to damage the fuel metering unit con-
nector when removing the overflow valve.

Overflow valve

Removing overflow valve

4.3 Reassembling fuel pump

4.3.1 Installing feed pump
Feed pump
Note: Make sure no dust and damage are found on the feed Shaft hole
pump mating surface of the pump housing.
(1) Apply grease to the seal ring evenly.
(2) Install the seal ring into the ring groove of the feed
pump.
(3) Using the flat blade screwdriver, aling the shaft hole
Seal ring
position as shown in the illustration.
(4) Install the feed pump with aligning the shaft and shaft Shaft
hole.
(5) Tighten the Torx screw in the numerical order as shown Installing feed pump (1)
in the illustration by folloing steps.
a. Tighten by hand.
b. Tighten to 2 ± 1 N·m
c. Tighten to 8 ± 0.5 N·m

Installing feed pump (2)

8-9
Fuel system

4.3.2 Installing fuel metering unit

(1) Apply grease to the O ring, and install the O ing into the
ring groove of fuel metering unit. Flat gasket
Note: (a) Do not install the O ring to wrong position.
(b) Be careful not to damage the O ring when Connector
installing it.
Note: Make sure no dust and damage are found on the fuel
metering unit mating surface of pump housing. Torx screw
(2) Install the flat gasket to the fuel metering unit. Tightening torque
Fuel metering unit 6.5 ± 0.5 N·m
(3) With aligning the thread holes, install the fuel metering {0.65 ± 0.05 kgf·m}
unit together with the flat gasket into the pump housing. [4.8 ± 0.4 lbf·ft]

(4) Tighten the Torx screw to the specified torque. Installing fuel metering unit

4.3.3 Installing overflow valve

Note: Make sure no dust and damage are found on the
overflow valve mating surface of pump housing.
(1) Apply clean oil to the O ring thinly.
(2) Install the overflow valve into the pump housing. Then,
be careful not to damage the O ring.
(3) Tighten the overflow valve to the specified torque.
Note: If the O ring is damaged, replace it.
Overflow valve
Tightening torque
20 ± 1.5 N·m {2.0 ± 0.15 kgf·m} [15 ± 1 lbf·ft]

Installing overflow valve

4.3.4 Replacing O ring of overflow valve

(1) Remove the O ring.
(2) Insert the new O ring into the mouting sleeve.
Mounting
(3) Insert the overflow valve into the mouting sleeve to
sleeve
install the O ring to the ring groove. 32G61-08800

O ring
Overflow valve

Replacing O ring

8-10
 Fuel system

5. Disassembling and inspecting common rail

5.1 Inspecting common rail assembly
Inspect the common rail assembly for following items shown in the illustration after removed from the engine. If defects of rail
pressure sensor are found, replace it with new one. If defects of any other parts are found, replace the common rail assembly
with new one.

Damage of mating surface

and thread
4
1

Damage of
mating surface

Damage of connector
3 and terminal

Damage of mating surface

and thread

Inspecting common rail assembly

1 Fuel inlet connctor 3 Fuel backflow connector

2 Fuel outlet connector 4 Rail pressure sensor

CAUTION
When replacing the common rail assembly parts, operate the engine at low idle for 10 minutes after replacement
and make sure no leakage are found. After that, operate the engine again at rated speed for 3 minutes and make
sure no leakage are found.

CAUTION
When replacing the common rail assembly parts, put the red or white mark (ø5mm circle) on the new parts to notify
the replacement.

8-11
Fuel system

5.2 Disassembling common rail assembly

5.2.1 Preparation of disassembling common rail
Rail sensor connector
assembly
Fuel inlet connector
(1) Seal the four of fuel outlet connectors, rail pressure (Plug 32G61-09300)
sensor connector, fuel backflow connector and fuel
Fuel outlet connector (4)
inlet connector with plugs. (Plug 32G61-09300)
(2) Clean the common rail with commercial cleaning agent
and dry it with compressed air.
Fuel backflow connector
CAUTION
(Plug 32G61-09400)
When cleaning the common rail, be careful not to allow
the cleaning agent entering the connector of rail pres-
Preparation of disassembling common rail assembly
sure sensor.

5.2.2 Removing rail pressure sensor

(1) Remove the rail pressure sensor.
Note: (a) Do not touch inside of the rail pressure sensor Rail pressure sensor
connector.
(b) Do not allow water and oil entering the rail
pressure sensor connector.
(c) Remove dust and burr from the rail pressure
sensor mating surface of common rail if there it
is. If burr or damage that cannot remove are
found, replace the common rail assembly with a
new one.
Removing rail pressure sensor

5.2.3 Removing pressure limiting valve

(1) Remove the pressure limiting valve.
Note: (a) Remove dust and burr from the pressure limiting
valve mating surface of common rail if there it is.
(b) Be careful not to allow peeled paint entering the
common rail.

Pressure limiting valve

Removing pressure limiting valve

8-12
 Fuel system

5.3 Reassembling common rail assembly

5.3.1 Installing rail pressure sensor Rail pressure sensor
(1) Apply clean oil thinly to the mating surface and thread Tightening torque
of rail pressure sensor. 95 ± 5 N·m {9.7 ± 0.5 kgf·m}
[70 ± 4 lbf·ft]
Note: (a) Do not apply grease.
(b) Be careful not to allow the peeled paint entering
the common rail.
(2) Install the rail pressure sensor, and tighten it to the
specified torque.

Installing rail pressure sensor

5.3.2 Installing pressure limiting valve

(1) Apply clean oil thinly to the mating surface, O ring and Pressure limiting valve
thread of pressure limiting valve. Tightening torque
Note: (a) Do not apply grease. 100 ± 5 N·m {10.2 ± 0.5 kgf·m}
[74 ± 4 lbf·ft]
(b) Be careful not to allow the peeled paint entering
the common rail.
(2) Install the pressure limiting valve, and tighten it to the
specified torque.

Installing pressure limiting valve

8-13
Fuel system

6. Installing fuel system

6.1 Installing fuel system (Part 1)

19 ± 2 N·m
{1.9 ± 0.2 kgf·m}
[13.7 ± 1.4 lbf·ft]

70 ± 5 N·m
{7.1 ± 0.5 kgf·m}
[51.4 ± 3.6 lbf·ft]

Installing fuel system (Part 1)

8-14
 Fuel system

6.2 Installing fuel system (Part 2)

Replace: Sealing washer 25 ± 3 N·m B

O-ring {2.5 ± 0.3 kgf·m}
Gasket [18 ± 2.2 lbf·ft]
Leak off hose 20 ± 2 N·m
{2 ± 0.2 kgf·m}
[14.5 ± 1.4 lbf·ft]
30 ± 3 N·m
{3.1 ± 0.3 kgf·m}
[22.4 ± 2.2 lbf·ft]

A
D
25 ± 3 N·m B
{2.5 ± 0.3 kgf·m}
[18 ± 2.2 lbf·ft] C

C
20 ± 2 N·m
{2 ± 0.2 kgf·m}
[14.5 ± 1.4 lbf·ft]

25 +2.5
0 N·m
{2.5 +0.25
0 kgf·m}
+1.8
[18 0 lbf·ft]

Installing fuel system (Part 2)

8-15
 LUBRICATION SYSTEM
1. Removing and inspecting lubrication
system .............................................9-2
1.1 Removing and inspecting oil filter and
oil cooler................................................... 9-2
1.2 Removing and inspecting oil pan and
breather.................................................... 9-3

2. Disassembling, inspecting and

reassembling lubrication system .....9-4
2.1 Inspecting oil pump gear.......................... 9-4
2.1.1 Removing oil pump gear ............................9-4
2.2 Reassembling oil pump gear ................... 9-5
2.2.1 Reassembling oil pump gear......................9-5
2.3 Inspecting oil filter .................................... 9-6
2.4 Inspecting relief valve .............................. 9-6
2.5 Inspecting safety valve............................. 9-6

3. Installing lubrication system ............9-7

3.1 Installing oil filter and oil cooler ................ 9-7
3.2 Installing oil pan and breather.................. 9-8

9-1
LUBRICATION SYSTEM

1. Removing and inspecting lubrication system

1.1 Removing and inspecting oil filter and oil cooler

Clogging, crack
Replace: Every 500 hrs

Replace

Clogging, crack
8 Replace: Every 500 hrs

Replace
1
10

6 3
Replace 5

Replace
4
2
9

Replace

Removing and inspecting oil filter and oil cooler

Removing sequence

1 Oil filter 5 Filter base 9 Oil cover

2 Drain hose 6 Rail bracket 10 Relief valve
3 Filter bracket 7 Oil cooler cover
4 Drain plug 8 Oil cooler element

9-2
 LUBRICATION SYSTEM

1.2 Removing and inspecting oil pan and breather

3
Replace
5 2

Replace Replace

Replace 8

Replace
6

Removing and inspecting oil pan and breather

Removing sequence

1 Breather hose 4 Breather 7 Oil pan

2 Breather pipe 5 Oil level gauge 8 Oil strainer
3 Vinyl tube 6 Drain cock 9 Safety valve

9-3
LUBRICATION SYSTEM

2. Disassembling, inspecting and reassembling lubrication system

2.1 Inspecting oil pump gear

Gear defect, wear

Once removed, replace the gear
with a new one.

Crack, damage

Inspecting oil pump gear

Disassembling sequence

1 Oil pump gear

2.1.1 Removing oil pump gear

Oil pump gear
CAUTION Puller
Once the oil pump gear is removed, the oil pump gear P/N:64309-12900
are no longer reusable. Replace them with new ones.
Remove the oil pump gear with a puller.

Removing oil pump gear

9-4
 LUBRICATION SYSTEM

2.2 Reassembling oil pump gear

Heat to 180 to 220°C [356 to 428°F].

Oil pump gear should be flush with
the shaft. Backlash
Standard: 0.049 to 0.166 mm
[0.0019 to 0.0065 in.]
Limit: 0.35 mm [0.0138 in.]

Make sure the oil pump

gear rotates smoothly

Apply engine oil to every sliding section.

Reassembling oil pump gear

2.2.1 Reassembling oil pump gear

Flush
CAUTION
The oil pump gear is nonreusable parts. Replace the
assembly with a new one.
(1) Heat the oil pump gear between 180 to 220°C [356 to
428°F]
(2) Support the shaft at end and force the gear onto the
shaft until its end face is flush with the end of shaft.

Shaft end surface

Reassembling oil pump gear

9-5
LUBRICATION SYSTEM

2.3 Inspecting oil filter

When replacing the oil filter, sample the oil (500 ml
[30.5 cu.in.]) and check for metal and other particles. If
metal or other particles are found, cut and unfold the
element, and inspect the color and shape of metal particles
trapped in the element to identify the cause.

Inspecting oil filter

2.4 Inspecting relief valve

(1) Check the relief valve and its seat for contact. Check
the spring for fatigue and damage. If faulty, replace the Tightening torque
relief valve with a new one. 49 ± 5 N·m
{5 ± 0.5 kgf·m}
(2) Measure the relief valve opening pressure. If the [36.2 ± 3.6 lbf·ft]
pressure does not fall within the standard range, replace
the relief valve with a new one. Tightening torque
44 ± 5 N·m
Item Standard {4.5 ± 0.5 kgf·m}
[32.5 ± 3.6 lbf·ft]
0.35 ± 0.05 MPa
Relief valve Relief valve
{3.5 ± 0.5 kgf/cm²}
opening pressure
[49.78 ± 7.11 psi]
Inspecting relief valve

2.5 Inspecting safety valve

(1) Make sure that the steel ball inside safety valve slides
smoothly. If faulty, replace the safety valve with new
one.
(2) Measure the safety valve opening pressure. If the
pressure does not fall within the standard range, replace
the safety valve with new one.
Tightening torque
Item Standard 69 ± 5 N·m
Safety valve opening pressure 1.1 MPa {11 kgf/cm² } [157 psi] {7 ± 0.5 kgf·m}
[50.6 ± 3.6 lbf·ft]

Inspecting safety valve

9-6
 LUBRICATION SYSTEM

3. Installing lubrication system

3.1 Installing oil filter and oil cooler

When installing, apply engine

oil to the gasket, and tighten
Replace the filter 3/4 to one turn after
the gasket contacts with the
mounting surface.

Replace Replace

Replace
49 ± 5 N·m
{5 ± 0.5 kgf·m}
[36.2 ± 3.6 lbf·ft}

Replace

Replace

Installing oil filter and oil cooler

To install the lubrication system, follow the removal procedure in reverse order, observing the followings:
(1) Use new gaskets and O-rings when reinstalling.
(2) Clean oil passage of each part thoroughly in wash oil,
and dry it completely using compressed air.
(3) Install the bracket first, then install the oil filter.

9-7
LUBRICATION SYSTEM

3.2 Installing oil pan and breather

Replace

Replace Replace

Replace

69 ± 5 N·m
{7 ± 0.5 kgf·m}
[50.6 ±3.6 lbf·ft}
Replace

Installing oil pan and breather

9-8
 COOLING SYSTEM
1. Removing cooling system .............10-2

2. Inspecting cooling system .............10-3

2.1 Inspecting water pump for smooth
rotation ................................................... 10-3
2.2 Inspecting thermostat............................. 10-3

3. Installing cooling system ...............10-4

10-1
COOLING SYSTEM

1. Removing cooling system

Replace
5

Crack, water leakage, damage

Replace
4

2 3

Crack, wear

Removing cooling system

Removing sequence

1 Fan 3 Belt 5 Thermostat assembly

2 Spacer 4 Water pump assembly

10-2
 COOLING SYSTEM

2. Inspecting cooling system

2.1 Inspecting water pump for smooth rotation
Check to make sure that the impeller and shaft of water
pump rotate smoothly without noise and irregularities. If
faulty, replace the water pump assembly.

2.2 Inspecting thermostat

CAUTION
Be careful of burns or a fire when measuring tempera-
ture, as it involves a high-temperature and open flame.
To test the thermostat operation, immerse the thermostat in a
container filled with water. Heat the water, while measuring
the water temperature. Record the temperature at the
conditions shown in the table below. If the temperatures are
not within the standard range, replace the thermostat.
Note: (a) Stir the water in the container with a stick to
ensure uniform temperature distribution.
Inspecting thermostat
(b) Before installing the thermostat, be sure to check
the valve opening temperature stamped on the
thermostat valve side face.

Item Standard
Temperature at which valve starts 71 ± 2°C
opening [160 ± 3.6°F]
Temperature at which valve lift
85°C [185°F]
becomes 10 mm [0.39 in.] or more.

Note: When assembling, orient the thermostat with its air

breed hole faced upward.

10-3
COOLING SYSTEM

3. Installing cooling system

Replace

Crack, water leakage, damage

Replace

Water pump mounting bolt

M8 × 1.25
17 ± 2.9 N·m {1.7 ± 0.3kgf·m} [12.5 ± 2 lbf·ft]
Water pump mounting bolt
Crack, wear (together with gear case)
M8 × 1.25
19 ± 2 N·m {1.9 ± 0.2 kgf·m} [13.7 ± 1.4 lbf·ft]
M10 × 1.25
35 ± 3 N·m {3.6 ± 0.3 kgf·m} [25.3 ± 2.2 lbf·ft]
Fan and water pump pulley mounting bolt
M10 × 1.5, 49 ± 5 N·m {5 ± 0.5kgf·m} [36.2 ± 3.6 lbf·ft]

Installing cooling system

10-4
 INLET AND EXHAUST SYSTEM
1. Removing inlet and exhaust
system ...........................................11-2
1.1 Removing inlet system........................... 11-2
1.2 Removing exhaust system..................... 11-3

2. Disassembling, inspecting and

reassembling inlet and
exhaust system .............................11-4
2.1 Measuring exhaust manifold distortion .. 11-4

3. Installing inlet and

exhaust system .............................11-5
3.1 Installing inlet system............................. 11-5
3.2 Installing exhaust system....................... 11-6

11-1
INLET AND EXHAUST SYSTEM

1. Removing inlet and exhaust system

1.1 Removing inlet system

Air inlet
Cylinder head

Replace Replace
2

Replace

Removing inlet system

Removing sequence

1 Air inlet elbow 2 Air heater 3 Inlet manifold

11-2
 INLET AND EXHAUST SYSTEM

1.2 Removing exhaust system

Replace 1

Cylinder head

Replace

Removing exhaust system

Removing sequence

1 Turbocharger 2 Exhaust manifold

11-3
INLET AND EXHAUST SYSTEM

2. Disassembling, inspecting and reassembling inlet and exhaust system

2.1 Measuring exhaust manifold distortion
(1) Check the flange for crack.
(2) Check the flange surface for distortion. If the distortion
exceeds the standard, retouch the surface.

Item Standard
Below 0.2 mm
Exhaust manifold distortion
[0.008 in.]

Measuring exhaust manifold distortion

11-4
 INLET AND EXHAUST SYSTEM

3. Installing inlet and exhaust system

3.1 Installing inlet system

19 ± 2 N·m
{1.9 ± 0.2 kgf·m}
[13.7 ± 1.4 lbf·ft]

Air inlet
Cylinder head

Replace Replace

Replace

Installing inlet system

11-5
INLET AND EXHAUST SYSTEM

3.2 Installing exhaust system

Replace

Cylinder head

Replace

19 ± 2 N·m
{1.9 ± 0.2 kgf·m}
[13.7 ± 1.4 lbf·ft]

Installing exhaust system

11-6
 ELECTRICAL SYSTEM
1. Removing electrical system ..........12-2 2.4.5 Removing rotor ...................................... 12-21
1.1 Removing starter.................................... 12-2 2.4.6 Removing front bearing ......................... 12-21
1.2 Inspecting before removing alternator ... 12-3 2.4.7 Removing field coil ................................ 12-22
1.2.1 Inspecting alternator operation.................12-3 2.4.8 Removing stator .................................... 12-22
1.2.2 Handling precaution .................................12-3 2.4.9 Removing rear bracket locked-in parts.. 12-23
1.3 Removing alternator............................... 12-4 2.5 Inspecting alternator............................. 12-24
2.5.1 Inspecting rectifier ................................. 12-24
2. Disassembling, inspecting and 2.5.2 Inspecting condensor ............................ 12-24
reassembling electrical system .....12-5 2.5.3 Inspecting regulator ............................... 12-24
2.1 Disassembling and inspecting starter .... 12-5 2.5.4 Inspecting field coil ................................ 12-25
2.1.1 Removing pinion set.................................12-6 2.5.5 Inspecting stator coil.............................. 12-25
2.1.2 Removing magnetic switch ......................12-7 2.5.6 Inspecting bearings ............................... 12-26
2.1.3 Removing rear bracket .............................12-7 2.6 Reassembling alternator ...................... 12-27
2.1.4 Removing brush holder and brush 2.6.1 Installing rectifier.................................... 12-27
assembly ..................................................12-8 2.6.2 Slodering field coil and regulator ........... 12-27
2.1.5 Removing yoke and armature ..................12-8 2.6.3 Slodering stator coil and rectifier ........... 12-27
2.1.6 Removing planetary gear .........................12-9 2.6.4 Reassembling front bearing................... 12-27
2.1.7 Removing overrunning clutch.................12-10 2.6.5 Reassembling front bracket and rotor ... 12-28
2.1.8 Removing internal gear ..........................12-11 2.6.6 Installing rear bracket ............................ 12-28
2.2 Inspecting and repairing starter ........... 12-12 2.6.7 Installing through bolt ............................ 12-28
2.2.1 Inspecting magnetic switch ....................12-12 2.7 Inspecting after reassembling .............. 12-28
2.2.2 Inspecting magnetic switch contactor ....12-12 2.8 Performance test of alternator.............. 12-29
2.2.3 Measuring armature shaft runout ...........12-12 2.8.1 Measuring regulator adjusting voltage... 12-29
2.2.4 Measuring commutator radial runout .....12-13 2.8.2 Measuring output current....................... 12-29
2.2.5 Measuring undercut depth .....................12-13
2.2.6 Inspecting insulation between 3. Installing electrical system .......... 12-30
commutator and shaft (core) ..................12-13 3.1 Installing starter.................................... 12-30
2.2.7 Inspecting field coil .................................12-14 3.2 Installing alternator............................... 12-31
2.2.8 Inspecting overrunning clutch ................12-14 3.3 Replacing ECU..................................... 12-32
2.2.9 Inspecting reduction gear .......................12-14 3.3.1 Removing ECU...................................... 12-32
2.2.10 Inspecting bearings ................................12-14 3.3.2 Installing ECU........................................ 12-32
2.2.11 Inspecting brushes for wear ...................12-15 3.3.3 Test operation after replacing ECU ....... 12-32
2.2.12 Measuring brush spring load ..................12-15 3.4 Installing sensors ................................. 12-33
2.2.13 Inspecting safety switch .........................12-15
2.3 Reassembling starter ........................... 12-16
2.3.1 Installing E-ring ......................................12-16
2.3.2 Installing shaft lever ...............................12-16
2.3.3 Installing ball ..........................................12-16
2.3.4 Installing cover .......................................12-17
2.3.5 Installing yoke ........................................12-17
2.3.6 Installing pinion ......................................12-18
2.4 Disassembling and inspecting
alternator.............................................. 12-19
2.4.1 Removing cover .....................................12-20
2.4.2 Removing through bolts .........................12-20
2.4.3 Disassembling the alternator to front side
and rear side ..........................................12-20
2.4.4 Removing fan and pulley........................12-21

12-1
ELECTRICAL SYSTEM

1. Removing electrical system

1.1 Removing starter

Removing starter
Removing sequence

1 Starter

12-2
 ELECTRICAL SYSTEM

1.2 Inspecting before removing alternator

1.2.1 Inspecting alternator operation
Locate the cause of faulty charging from malfunctions
described below. Do not remove the alternator for
inspection and repair unless inspection cannot be performed
with the alternator installed on the engine.

Adjusted value of voltage regulator is high.

Overcharge
Faulty battery.
Low adjusted value of voltage relay.
Faulty alternator output.
Over dis-
Electric power consumption is extremely high.
charge
Special load is used.
Faulty wiring.

1.2.2 Handling precaution

Improper handling could cause damage or failure to the
alternator.
(1) Connect battery cables correctly. B terminal is positive
(+), and E terminal is negative (-).
(2) Do not use any high voltage tester such as megger.
(3) Do not disconnect lead wire from B terminal of the
alternator while the engine is running.
(4) Battery voltage is constantly applied to B terminal of
the alternator. Do not ground at this terminal.
(5) Do not short circuit or ground at L terminal. (For a
built-in IC regulator type)
(6) When a steam cleaner is used, do not allow the steam
directly contact the alternator.

12-3
ELECTRICAL SYSTEM

1.3 Removing alternator

Removing alternator
Removing sequence

1 Alternator 2 Adjusting plate 3 Set bolt

12-4
 ELECTRICAL SYSTEM

2. Disassembling, inspecting and reassembling electrical system

2.1 Disassembling and inspecting starter

11
12
4
14
Open or short circuit

25
18
15
16
17 Damage, wear

13
23 Damage, wear
24
22
Damage, wear
3 21
19 Replace

20 Function of
overrunning clutch
2
6
1 Replace
5
Wear
Damage, wear
7

Replace Brush dust accumulation,

8
local wear, rust,
Replace
deterioration, insulation

Open or short circuit

9

Open or short circuit,

10 ground, damage, wear

Disassembling and inspecting starter

Disassembling sequence

1 Clip ring 10 Armature 19 E ring

2 Pinion stopper, pinion, spring 11 Cover 20 Over runnning clutch
3 Bolt 12 Packing 21 Internal gear
4 Magnetic switch 13 Planetary gear 22 Plate
5 Screw 14 Ball 23 Gear shaft
6 Through bolt 15 Packing 24 Front bracket
7 Rear bracket 16 Plate 25 Safety relay
8 Brush holder 17 Spring
9 Yoke assembly 18 Shift lever

12-5
ELECTRICAL SYSTEM

2.1.1 Removing pinion set

(1) Install the jig to hold the pinion.

Removing pinion set (1)

(2) Place an appropriate tube on the pinion stopper.
Hit the tube with a hammer to push the pinion stopper
down.

Removing pinion set (2)

(3) Remove the clip ring using snap ring plier.
Note: Do not reuse the clip ring for reassembly.

Removing pinion set (3)

(4) Remove the pinion stopper, pinion, spring.

Note: Check the pinion for wear and damage.

Removing pinion set (4)

12-6
 ELECTRICAL SYSTEM

2.1.2 Removing magnetic switch

(1) Disconnect the terminal M leads on the magnetic
switch.

Removing magnetic switch (1)

(2) Remove the through bolts, and remove the magnetic
switch.

Removing magnetic switch (2)

2.1.3 Removing rear bracket
(1) Remove the screws from the rear bracket.

Removing rear bracket (1)

(2) Remove the through bolts, and remove the rear bracket.

Removing rear bracket (2)

12-7
ELECTRICAL SYSTEM

2.1.4 Removing brush holder and brush assem-

bly
(1) Remove the brush holder.
(2) Lift the brush spring up, and remove the brush from the
brush holder.

Removing brush

2.1.5 Removing yoke and armature

(1) Remove the yoke, and the armature.

Removing yoke and armature (1)

(2) Remove the front side O-ring and the rear side O-ring.
Do not reuse the removed O-ring. Replace it with new
one.

O-ring O-ring

Removing yoke and armature (2)

12-8
 ELECTRICAL SYSTEM

2.1.6 Removing planetary gear

(1) Remove the cover.

Removing planetaly gear (1)

(2) Remove the packing.

Removing planetaly gear (2)

(3) Remove the planetary gears.

Removing planetaly gear (3)

(4) Remove the balls from the shaft.

Note: Be careful not to lose the ball.

Removing planetaly gear (4)

12-9
ELECTRICAL SYSTEM

2.1.7 Removing overrunning clutch

(1) Remove the packing, the plate and the spring.

Removing overrunning clutch (1)

(2) Remove the shift lever and overrunning clutch from the
front bracket cover.

Removing overrunning clutch (2)

(3) Insert the flat-blade screwdriver to the groove of the E-
ring, then remove the E-ring.

Removing overrunning clutch (3)

(4) Remove the overrunning clutch.

Removing overrunning clutch (4)

12-10
 ELECTRICAL SYSTEM

2.1.8 Removing internal gear

Remove the internal gear.

Removing internal gear

12-11
ELECTRICAL SYSTEM

2.2 Inspecting and repairing starter

2.2.1 Inspecting magnetic switch
Inspect the pressure coil and the holding coil for open
circuit using the tester.
Inspect the electrical continuity between the terminal M and
the case, if there is no electrical continuity between them,
the magnetic switch circuit is an open circuit.

Inspecting magnetic switch

2.2.2 Inspecting magnetic switch contactor

The service limit of the contactor is decided by the S.S
condition of the contact surface. Inspect the contactor by C
following method. B
A
Measure the load current of the starter. If the voltage drop Ammeter
between the terminal B and the terminal M is 0.3 V per 100 C2 C1
M V

Battery
A or more, replace the magnetic switch. F1
Note: (a) When measuring the voltage drop, use a digital Digital voltmeter
volt meter. Measuring by an analog volt meter Ar

results breakage. E
Starter
(b) Be extremely careful when connecting an
ammeter to the starter because of the high current Inspecting magnetic switch contactor
flowing into the starter.

2.2.3 Measuring armature shaft runout

Using a dial gauge, measure the shaft runout. If the runout
exceeds the standard, repair or replace the armature.
Armature shaft
Item Standard
0.06 mm
Armature shaft runout
[0.0024 in.]

Measuring armature shaft runout

12-12
 ELECTRICAL SYSTEM

2.2.4 Measuring commutator radial runout

(1) Inspect the commutator surface. If the surface is rough,
polish it using a 400 to 600 grit sandpaper.
(2) Measure the commutator radial runout with a dial
gauge. If the measured value exceeds the limit, replace
the armature with a new one.

Item Limit
Commutator radial
0.10 mm [0.0039 in.] Commutator
runout

Measuring commutator radial runout

2.2.5 Measuring undercut depth
Measure the depth of undercutting between the commutator
segments.
If the measured value is less than the limit, repair or replace Insufficient recutting
with a new part. Defective Good
(need recutting)

Item Standard Limit

0.7 to 0.9 mm
0.7 to 0.9 mm 0.2 mm [0.028 to 0.035 in.]
Undercutting depth
[0.028 to 0.035 in.] [0.008 in.]

Measuring undercut depth

2.2.6 Inspecting insulation between commutator
and shaft (core)
(1) Inspect the armature coil using a growler. Apply a iron Iron plate
Growler tester
plate to the armature core. Replace the armature if the
iron plate vibrates.

Inspecting armature coil for short circuit

(2) Check the insulation between the commutator and the
shaft with a tester. If faulty, replace the armature with a
new one.

Inspecting insulation between commutator and shaft

12-13
ELECTRICAL SYSTEM

2.2.7 Inspecting field coil

(1) Inspect the field coil for open circuit with a tester. It is
an open circuit if there is no conticuity between the
terminal M of field coil and the bush lead.
(2) Inspect the electrical conticuity between the field coil
and the yoke with a tester.

Inspecting field coil for open circuit

2.2.8 Inspecting overrunning clutch
(1) Rotate the pinion by hand and check that the pinion
rotates lightly to one direction.
(2) Inspect the tooth flank. If wear or damage is found,
replace it with new one.

Inspecting over running clutch

2.2.9 Inspecting reduction gear
Inspect the reduction gear for wear.

Inspecting reduction gear

2.2.10 Inspecting bearings
Rotate the outer race of bearing by hand. Check that the
outer race rotates smoothly. Bearing

Inspecting bearing

12-14
 ELECTRICAL SYSTEM

2.2.11 Inspecting brushes for wear

Measure the length of the brushes. If the measured value is Unit: mm [in.]
less than the limit, replace both the brush holder assembly
and the brush assembly with new ones.

[0.67 to 0.71]
[0.40]
17 to 18
10
Item Standard Limit
17 to 18 mm 10 mm
Brush length
[0.67 to 0.71 in.] [0.40 in.]

Wear limit

Inspecting brush for wear

2.2.12 Measuring brush spring load

Using a new brush, measure the spring load at which the
spring lifts from the brush. If the measured value is less than
the limit, replace the spring with a new one.

Item Standard Limit

21.56 to 27.44 N 21.56 N
Brush spring load
{2.2 to 2.8 kgf} {2.2 kgf}
(when brush is installed)
[15.9 to 20.3 lbf] [15.9 lbf]

2.2.13 Inspecting safety switch

CAUTION Safety relay

ground (E) terminal
When connecting the battery, be sure to connect the
battery in correct polarity. Terminal S

Connect the components as shown and check the operation

of starter and safety switch.
(1) Connect the terminal R to the battery negative terminal.
(2) Turn on the switch and check if the starter operates
Terminal R
(rotates).
(3) While operating the starter, disconnect the terminal R
from the battery negative terminal and connect the Inspecting operation of safety switch
terminal R to the battery positive terminal. Check if the
starter stops.
Note: On some specifications, starter stops operation when
the connection to the battery negative terminal is
disconnected.

12-15
ELECTRICAL SYSTEM

2.3 Reassembling starter

To reassemble the starter, follow the disassembly in reverse order and observe bellow.
2.3.1 Installing E-ring
Install the washer, the center bracket and overrunning clutch
assembly to the shaft, and install the E-ring.
Note: Install the E-ring using a plier.

Installing E-ring

2.3.2 Installing shaft lever

Being careful with the direction, install the shift lever.
Note: Apply grease (Nikko grease R) to the shift lever when
reassembling.

Installing shift lever

2.3.3 Installing ball

Be careful not to forget to install the ball to the shaft before
installing the planetary gears.

Installing ball

12-16
 ELECTRICAL SYSTEM

2.3.4 Installing cover

(1) Be careful with the installation position when installing
the cover.
Notch

Cover

Installing cover

2.3.5 Installing yoke

(1) Install the yoke to the front bracket with aligning the
mark.

Installing yoke (1)

(2) Install the yoke to the rear bracket with aligning the
mark.

Installing yoke (2)

12-17
ELECTRICAL SYSTEM

2.3.6 Installing pinion

(1) Install the spring and the pinion, and install the jig.
(plate)

Plate

Installing pinion (1)

(2) Install the pinion stopper. Insert the clip ring to the jig
(holder) and install the clip ring using the jig. (guide)

Holder

Guide

(3) Using the jig (presser), install the clip ring to the pinion Installing pinion (2)
stopper.

Installing pinion (3)

12-18
 ELECTRICAL SYSTEM

2.4 Disassembling and inspecting alternator

4 5
6
3
3
11 Crack, damage

Rotation
10

9
12
7
17
Coil open circuit, ground
3

14

8 13

Rotation
22 Short or open circuit

16 20

18 19

23
15
Crack, damage
21

2 1

Disassembling and inspecting alternator

Disassembling sequence

1 Screw 9 Retainer 17 Stator coil

2 Cover 10 Front bearing 18 Holder
3 Through bolt 11 Front bracket 19 Regulator
4 Nut, spring washer, plain washer 12 Collar 20 Terminal B
5 Pulley 13 Rear bearing 21 Condensor
6 Fan 14 Rotor 22 Rectifier
7 Collar 15 Screw 23 Rear bracket
8 Screw 16 Field coil

12-19
ELECTRICAL SYSTEM

2.4.1 Removing cover

Remove the screws, and remove the cover.

Removing alternator cover

2.4.2 Removing through bolts
Remove the through bolts which secures front side and rear
side.

Removing through bolt

2.4.3 Disassembling the alternator to front side
and rear side
(1) Disassemble the alternator to front side and rear side. Heat the
Disassemble the alternator with heating the rear bracket bearing case
bearing case. Disassembling the alternator without
heating the rear bracket bearing case cause the damage
of the alternator.
Note: Be sure to heat the rear bracket bearing case only. Do
not heat the other parts.

Disassembling alternator to front side and rear side (1)

(2) Remove the rotor from the front bracket using press.
Then, use the through bolt hole.
Note: Do not hit the alternator with plastic hammer.
Protect the parts
from damage

Disassembling alternator to front side and rear side (2)

12-20
 ELECTRICAL SYSTEM

2.4.4 Removing fan and pulley

Remove the nuts using an inpact wrench, then remove the
spring washer, the plain washer, the pulley, the fan and the
collar.
Note: Fixing the rotor with vice could result the
deformation. Do not use the vice.

Removing fan and pulley

2.4.5 Removing rotor
Remove the rotor from the front bracket.
Note: (a) Remove the rotor using the press.
(b) When working with the rotor, place the buffer
under the rotor to prevent the damage.

Removing rotor
2.4.6 Removing front bearing
(1) Remove the screws, and remove the retainer.

Removing retainer
(2) Remove the front bearing from the front bracket.
Note: Do not reuse the removed front bearing. Replace it
with new one.

Removing bearing

12-21
ELECTRICAL SYSTEM

2.4.7 Removing field coil

(1) Unsolder the field coil and regulator.
Note: Unsoldering must be finished by 5 seconds or less.

(2) Remove the screws, and remove the field coil. Removing field coil (1)

Removing field coil (2)

2.4.8 Removing stator
(1) Unsolder the stator coil and the rectifier.

Removing stator (1)

(2) Remove the stator from the rear bracket.

Removing stator (2)

12-22
 ELECTRICAL SYSTEM

2.4.9 Removing rear bracket locked-in parts

(1) Remove the screws from the rear bracket.
Rectifier
(2) Remove the screws from the regulator, and remove the Terminal B
regulator. Condensor
(3) Remove the screw from the terminal B, and remove the
terminal B.
(4) Remove the screw from the condensor, and remove the
Regulator
condensor.
(5) Remove the rectifier assembly.

Removing rear bracket locked-in parts

12-23
ELECTRICAL SYSTEM

2.5 Inspecting alternator

2.5.1 Inspecting rectifier
Check the rectifier for resistance of forward direction and
reverse direction.
If the resistance of forward direction is low, and the
resistance of reverse direction is high, it is normal.
If test result is not as above, it is faulty. Replace the rectifier
with new one.

Inspecting rectifier

2.5.2 Inspecting condensor

Charge the condensor with a tester. (RangeΩ × 1000)
Connect the tester lead in reverse direction. It is normal that
the pointer moves slightly and return.
If test result is not as above, it is faulty. Replace the
condensor with new one.

Inspecting condensor

2.5.3 Inspecting regulator

Measure the resistance between the regulator connector R
and L with a tester. (Range Ω × 1000)
If the diode of the regulator and the resistor of the regulator
are normal, the resistance of the forward direction is low
and the resistance of the reverse direction is high.
If test result is not as above, it is faulty. Replace the
regulator with new one.

Inspecting regulator

12-24
 ELECTRICAL SYSTEM

2.5.4 Inspecting field coil

(1) Inspect the insulation of the field coil.
Measure the electrical continuity between the terminal
and the core with a tester. (RangeΩ × 1000)
Replace the field coil with new one if electrical
continuity is indicated.

Inspecting field coil (1)

(2) Measure the resistance between the terminals of field
coil.
If measured resistance is Approx 6.62Ω (When 20°C
[68°F]), it is normal.
If test result is not as above, it is faulty. Replace the
field coil with new one.

Inspecting field coil (2)

2.5.5 Inspecting stator coil
(1) Inspect the insulation of the stator coil.
Measure the electrical continuity between the stator coil
and the core with a tester. (RangeΩ × 1000)
Replace the stator coil with new one if electrical
continuity is indicated.

Inspecting stator coil (1)

(2) It is normal that the electrical continuity is indicated
between the stator coil lead N and other three leads.
If test result is not as above, it is faulty. Replace the
stator coil with new one.

Inspecting stator coil (2)

12-25
ELECTRICAL SYSTEM

2.5.6 Inspecting bearings

Inspect the bearing for smooth rotation and abnormal noise.
If abnormality is found, replace the bearing with new one.

Inspecting bearing

12-26
 ELECTRICAL SYSTEM

2.6 Reassembling alternator

To reassemble the alternator, follow the disassembly in reverse order and observe bellow.
2.6.1 Installing rectifier
When reassembling the rectifier, apply rocktite to the
screws.

Installing rectifier
2.6.2 Slodering field coil and regulator
Soldering field coil and regulator must be finished as
quickly as possible.

Soldering field coil and regulator

2.6.3 Slodering stator coil and rectifier
Solder the stator coil and rectifier after caulking.
Soldering must be finished as quickly as possible.

Soldering stator coil and rectifier

2.6.4 Reassembling front bearing
Reassemble the front bearing with heating the front bearing
case.
Reassembling the front bearing without heating the front
bearing case cause the damage of front bearing.

Reassembling front bearing

12-27
ELECTRICAL SYSTEM

2.6.5 Reassembling front bracket and rotor

Use a press to reassemble the front bracket and the rotor.
Note: Be careful not to forget to install the collar when
Collar
reassembling.

Reassembling front bracket and rotor

2.6.6 Installing rear bracket
Reassemble the rear bracket with heating the bearing case.
Note: (a) Reassembling the rear bracket without heating
the bearing case cause the damage of the bearing.
(b) Be sure to heat the bearing case only. Do not heat
the other parts.

Installing rear bracket

2.6.7 Installing through bolt
Install the through bolt with fixing the front side and the rear
side using the alternator installation hole.

Installing through bolt

2.7 Inspecting after reassembling
After reassembling, rotate the pulley by hand to check the
smooth rotation.

Inspecting alternator after reassembling

12-28
 ELECTRICAL SYSTEM

2.8 Performance test of alternator

Measure the adjusting voltage and output current with wiring as schematic bellow.

Terminal B SW1 SW2

+
V R
- CL (24V 3W)
L

Terminal R Terminal L
Terminal E

Electric schematic of IC regulator built-in alternator performace test

2.8.1 Measuring regulator adjusting voltage 2.8.2 Measuring output current

(1) Close the SW1, and operate the alternator at 1500min -1 Close the SW1 and SW2. Measure the maximaum output
for 5 to 10 minutes until the ammeter indicates 6 A or current with a variable resistor operating the alternator at
less. 5000min-1 and keeping the indication of voltmeter at 27 V.
(2) Make sure that ammeter indicates 2 to 6 A or less, then It is normal that the measured output current is 50A or
operate the alternator at 3000 to 4000min-1. more.
If the indication of voltmeter is within the standard
CAUTION
value, the adjusting voltage of the alternator is normal.
(a) Do not disconnect the battery when operating the
(3) If the indication of ammeter is 6 A or more, charge the
alternator.
battery for a while or replace the battery with fully
(b) Do not connect the terminal L when the charge
charged one.
lamp （24V, 3W）is not used. The terminal L and
If the indication of voltmeter is out of the standard
circuit B must not be connected. It causes damege
value, replace the regulator with new one.
of diode.

Item Standard
Adjusting voltage 27.5 to 29.5 V (at 25°C [77°F])

12-29
ELECTRICAL SYSTEM

3. Installing electrical system

3.1 Installing starter

35 ± 5 N·m
{3.6 ± 0.5 kgf·m}
[25.8 ± 3.6 lbf·ft]

Installing starter

12-30
 ELECTRICAL SYSTEM

3.2 Installing alternator

97 ± 10 N·m
{9.9 ± 1 kgf·m}
[71.6 ± 7.4 lbf·ft]

Installing alternator

12-31
ELECTRICAL SYSTEM

3.3 Replacing ECU

3.3.1 Removing ECU
(1) Make sure that the ignition switch is in the OFF
position.
(2) Uplift the lever of the connector, and pull out the
connector. Then, do not pull the harness. Pull out the
connector with holding the connector.
Note: (a) Do not forget to uplift the lever before pulling out
the connector. Do not pull the connector forcedly.
(b) Be careful for the removed connector not to
contact with other parts.
(3) Remove the ECU mouting bolts. Replacing ECU（1）
(4) Remove the ECU.

3.3.2 Installing ECU

(1) Make sure that the Q-Rank number attached on the new
ECU is same as the number attached on the previous
ECU.
Note: If the ECU which has different Q-Rank number is
installed, it causes the excess and deficiency of the
engine power.
(2) Install the ECU and tighten the ECU mouting bolts to
specified torque.
(3) Push the connector into the ECU securely, and push Replacing ECU（2）
down the lever to lock. After connecting, check the
connector for excessive play.

3.3.3 Test operation after replacing ECU

(1) Turn the ignition switch to ON position. If the diagnosis
code is not displayed on the monitor for 2 to 3 minutes,
start the engine and operate the engine in low idle.
(2) Inspect that the diagnosis code is displayed on the
monitor. Inspect the engine for noise, odor and
vibration.

12-32
 ELECTRICAL SYSTEM

3.4 Installing sensors

Inlet manifold pressure sensor

19.6 ± 2 N·m
Pick up {2 ± 0.2 kgf·m} ̪ Apply sealing tape to the thread.
30 ± 3 N·m [14 ± 1.4 lbf·ft]
{3 ± 0.3 kgf·m} Water temperature sensor
[22 ± 2.2 lbf·ft] 7.5 ± 0.5 N·m
{0.75 ± 0.05 kgf·m}
[5.5 ± 0.36 lbf·ft]

Speed/timing sensor
Speed/timing sensor (camshaft side)
(crankshaft side) 8 ± 1 N·m
8 ± 1 N·m {0.8 ± 0.1 kgf·m}
{0.8 ± 0.1 kgf·m} [6 ± 0.7 lbf·ft]
[6 ± 0.7 lbf·ft]

Oil pressure switch

10 ± 2 N·m
{1 ± 0.2 kgf·m}
[7.2 ± 1.4 lbf·ft]

Installing sensors

12-33
 ADJUSTMENT AND OPERATION
1. Adjusting engine............................13-2
1.1 Inspecting and adjusting valve
clearance ............................................... 13-2
1.1.1 Inspecting valve clearance .......................13-2
1.1.2 Adjusting valve clearance ........................13-2
1.2 Inspecting belt and adjusting
belt tension............................................. 13-3
1.2.1 Checking the belt .....................................13-3
1.2.2 Adjusting the belt tension .........................13-3

2. Break-in operation.........................13-4
2.1 Starting up.............................................. 13-4
2.2 Inspecting engine condition
after starting up ...................................... 13-4
2.3 Break-in operation time.......................... 13-4
2.4 Inspection and adjustment after break-in
operation ................................................ 13-4

3. Performance test (JIS standard) ...13-5

3.1 Engine equipment condition................... 13-5
3.2 Test items and purposes........................ 13-5
3.2.1 Operation load test ...................................13-5
3.2.2 Continuous load test ................................13-5
3.2.3 Low idle test .............................................13-5
3.3 Other inspections ................................... 13-5
3.4 Engine output adjustment ...................... 13-5
3.4.1 Standard atmospheric conditions: ............13-5
3.4.2 Calculation of corrected power.................13-6

13-1
ADJUSTMENT AND OPERATION

1. Adjusting engine
1.1 Inspecting and adjusting valve clearance
Inspect and adjust the valve clearance.
The valve clearance should be inspected and adjusted when
the engine is cold.
Note: (a) The inlet values are on the left side and the
exhaust values are on the right side when the
cylinder head is viewed from the camshaft gear
side.
(b) The valve clearance standard values are indicated
on the caution plate on the No.1 cylinder rocker
cover.

Item Standard
0.25 mm
Inlet
[0.0099 in.]
Valve clearance
0.40 mm
Exhaust
[0.0157 in.]

1.1.1 Inspecting valve clearance

(1) Inspect the valve clearance for all cylinders in the firing
Model Firing order Turning angle
order by turning the crankshaft to the specified degrees
D04FR 1-3-4-2 180°
in the normal direction (clockwise when viewed from
engine front side) to bring each piston to the top dead
center on the compression stroke.
"0" graduation mark on
Note: To turn the crankshaft, fit a socket and ratchet handle
crankshaft pulley
on the crankshaft pulley nut.
(2) When the No. 1 piston is at the top dead center on the
0 40
compression stroke, the "0" graduation mark on the
periphery of the crankshaft pulley is aligned with the
pointer on the timing gear case, and neither the inlet Inspecting valve clearance
valve nor the exhaust valve is not lifted off its seat by
the push rod.
(3) Insert a thickness gauge between the rocker arm and
valve cap to inspect the clearance.

1.1.2 Adjusting valve clearance

(1) Insert the feeler gauge of the specified thickness
between the rocker arm and bridge cap, then adjust the
clearance by turning the screw in either direction so that
the gauge is gripped softly between the rocker arm and
bridge cap.
(2) After adjusting the clearance, tighten the lock nut
firmly, and inspect the clearance again.

Adjusting valve clearance

13-2
 ADJUSTMENT AND OPERATION

1.2 Inspecting belt and adjusting belt tension

CAUTION
(a) If defects such as cuts or surface separations are Adjusting bolt
found during inspection, replace the belt. Alternator
(b) Keep oil and grease away from the belt, since they
may cause the belt to slip and shorten the service
life.
(c) Excessive belt tension can cause rapid wear of the Belt
alternator bearing and shorten the service life of
the belt. Adjust the belt tension accurately by fol-
lowing the procedures below.
Adjusting belt tension
1.2.1 Checking the belt
(1) Inspect the belt visually for separation or damage. If
any abnormality is found, replace the belt with a new
one.
(2) Inspect belt tension (deflection).
When pressing the belt strongly at the center of its span,
the deflection for a new belt should be 5±1 mm
[0.20±0.04 in.] and the deflection for the belt that is
reused should be 8±1 mm [0.32±0.04 in.]
Force on the belt: Approximately 98±10 N {10±1 kgf}
[22±2.2 lbf]
If the deflection of belt is not within the standard, adjust
the belt tension.
1.2.2 Adjusting the belt tension
(1) Remove the belt cover.
(2) Loosen all retaining bolts of the alternator and adjusting
plate.
(3) Adjust V-belt tension properly with the adjusting bolt.
(4) Tighten all retaining bolts of the alternator and
adjusting plate.
(5) Install the belt cover.

13-3
ADJUSTMENT AND OPERATION

2. Break-in operation
After the engine is overhauled, install the engine to the 2.3 Break-in operation time
dynamometer, and run the engine for break-in operation and The relationship between the load in break-in operation and
inspection. the operation time is as shown below.

2.1 Starting up Break-in operation time

(1) Before starting the engine, check the levels of coolant, Duration
Engine speed (min-1) Load
engine oil and fuel. Also check the inlet and exhaust (min)
systems. Low
Bleed air from the fuel and cooling systems. 1 rotation 800 to 1100 No-load 5
speed
(2) Stop the fuel supply, and crank the engine with the
starter for about 10 seconds to lubricate the engine. Medium
2 rotation 1200 to 1500 No-load 5
(3) Move the control lever slightly in the fuel increase
speed
direction (but not to the "full injection" position), and
High
then turn the starter switch key to the [START] position
3 rotation 1600 to rated speed No-load 10
to start the engine. speed
(4) After the engine is started, adjust the control lever to let
4 25 % 10
the engine operate at a minimum no-load speed (low
5 50 % 10
idle speed). Rated speed
(5) Turn the starter switch key to the [OFF] position and 6 75 % 30
make sure that the engine is stopped. 7 100 % 20

Note: The table above is provided solely for reference

2.2 Inspecting engine condition after starting
purpose. Run the engine at appropriate speed and
up
During the break-in operation, check the followings. load for the break-in operation of your engine. Be
If any abnormality is found, stop the engine, investigate the sure to perform break-in operation after overhaul or
cause, and take appropriate measures. installation.
(1) The oil pressure must be within the specified value.
2.4 Inspection and adjustment after break-in
(2) The coolant temperature must be within the specified
operation
value.
(1) Valve clearance adjustment
(3) The engine must be free from any leakages such as oil,
(2) Ignition timing inspection
coolant, fuel and gas (air). Pay special attention to oil
leakage from the fitting face of turbocharger lube oil (3) Exterior bolt and nut tightness check
pipe.
(4) Check for an abnormal noise.
(5) Check for the color of smoke and odors.

13-4
 ADJUSTMENT AND OPERATION

3. Performance test (JIS standard)

The following describes the procedures specified in "Earth
moving machinery - Engines - Part 1: Test code of net
power (JIS D0006-1)" and "Earth moving machinery -
Engines - Part 2: Standard format of specifications and
testing methods of diesel engines (JIS D0006-2)."
Other test items may be required in some applications. All
test results should be evaluated comprehensively in order to
determine the engine performance.

3.1 Engine equipment condition

The engine must be equipped with standard auxiliary
devices such as cooling fan, air cleaner and alternator.

3.2 Test items and purposes

3.2.1 Operation load test
Conduct this test to evaluate the engine output, torque, fuel
consumption rate and governor performance under various
load conditions.
3.2.2 Continuous load test
Operate the engine continuously for 10 hours at 90% load
(continuous load application) of nominal net brake power
while the engine speed is maintained at revolutions
corresponding to the nominal brake power. In this test,
evaluate the fuel consumption rate and operating condition,
and confirm that the engine is capable of continuous
operation.
3.2.3 Low idle test
Conduct this test to confirm that the engine can operate
stably at the specified low idle speed.

3.3 Other inspections

Check for gas, coolant and oil leaks; abnormal odors; and
hunting. Make adjustment as needed.

3.4 Engine output adjustment

Diesel engine output is affected by atmospheric pressure,
temperature and humidity. Therefore, correction
calculations must be performed to obtain the value of engine
output under the standard atmospheric conditions.
3.4.1 Standard atmospheric conditions:
Base temperature: 298 K (25°C) [77°F]
Total pressure: 100 kPa (750 mmHg)
Dry pressure: 99 kPa (743 mmHg)

13-5
ADJUSTMENT AND OPERATION

3.4.2 Calculation of corrected power

Multiply the measured brake power or torque by the
calculated diesel engine correction factor to obtain a
corrected value.
If the applicable range of the correction formula is
exceeded, indicate the corrected values and record the test
conditions on the test record.

Colculation output = Correction factor( ) × Measured brake power

Atmospheric conditions during test
Temperature( ):283K(10°C)[50°F] T 313K(40°C )[104°F]
Dry atmospheric pressure( ):80kPa(600mmHg) 110kPa(825mmHg)

=( ) :Atmospheric factor :Engine factor

Range of correction equation use

The range of correction factor( )is as follows:
0.9 1.1.
Calculation of engine factor( )
Calculation of correction factor( ) =0.036 -1.14
Natural aspiration engine and engine with :Corrected fuel supply volume
mechanically driven air charger =
99 0.7
=( )·( ) ( ) × (Fuel flow rate g/s)
298 =
(Stroke volume ) × (Engine speed min-1)
Turbocharged engine without air cooler = 120000(4-cycle engine)
or with air-to-air cooler :Ratio between pressure at turbocharger or
99 0.7 1.2 air cooler outlet and atmospheric pressure
=( ) ·( )
298 ( =1 for natural aspiration engine)
· Applicable range of engine factor( )
Turbocharged engine with air-to-liquid
37.2 65mg/( -cycle)
cooler
99 0.7 0.7 · 37.2mg/(l -cycle): =0.2(constant)
=( ) ·( ) · 65mg/( -cycle) : =1.2(constant)
298

13-6
 TROUBLESHOOTING
1. Troubleshooting by diagnosis 7. Inspecting wiring ......................... 14-36
codes.............................................14-2 7.1 Inspecting connector and harness ....... 14-36
1.1 Outline of control system ....................... 14-2 7.1.1 Inspecting the intermittent fault.............. 14-36
1.2 Diagnosis codes..................................... 14-2 7.1.2 Inspecting connectors............................ 14-36
1.3 Connecting scan tester and ECU........... 14-3 7.1.3 Inspecting harness ................................ 14-36
1.3.1 Scan tester (32G91-00800)......................14-3 7.1.4 Inspect open circuit and short circuit ..... 14-36
1.3.2 Scan tester (32G91-00600)......................14-3 7.2 Pin location of the ECU connector and
1.4 When ECU does not respond ................ 14-3 extension harness connector ............... 14-37

2. Scan tester (32G91-00800,

main unit: 32G91-00811,
interconnect cable:
32G91-00812) ...............................14-4
2.1 Basic operation of scan tester................ 14-4
2.2 Connecting the connector ...................... 14-5
2.3 Diagnostic .............................................. 14-6
2.3.1 Checking engine status ............................14-7
2.3.2 Checking diagnosis codes .......................14-8
2.3.3 Checking freeze data ...............................14-9
2.3.4 Clearing diagnosis codes .......................14-10

3. Scan tester (32G91-00600).........14-11

3.1 Operation of scan tester....................... 14-11
3.1.1 Basic operation of scan tester ................14-11
3.2 Check engine status ............................ 14-12
3.3 Screen of DTC Menu ........................... 14-13
3.3.1 Check diagnosis codes ..........................14-13
3.3.2 Check freeze data ..................................14-13
3.3.3 Clear diagnosis codes ............................14-13

4. Diagnosis code cross reference ..14-14

5. Troubleshooting reference
chart ............................................14-16
5.1 Troubleshooting with diagnosis code... 14-16
5.2 Related diagnosis code........................ 14-30

6. Inspecting sensors ......................14-34

6.1 Speed/timing sensor (crank, cam) ....... 14-34
6.2 Inlet manifold pressure sensor............. 14-34
6.3 Water temperature sensor ................... 14-34
6.4 Engine oil pressure switch ................... 14-35
6.5 Common rail pressure sensor.............. 14-35
6.6 Injector solenoid................................... 14-35
6.7 High pressure pump solenoid sensor
(MPROP) ............................................. 14-35

14-1
TROUBLESHOOTING

1. Troubleshooting by diagnosis codes

1.1 Outline of control system
This engine is controlled by electronic control unit (ECU).
The engine has the control parts and the sensors that
monitors the engine operation.
The ECU monitors the engine operation using the inputs
from various sensors, and controls the injectors and the fuel
injection pump.
This control system can provide appropriate engine control
for operating condition.

1.2 Diagnosis codes

When the ECU detects the abnormal engine operation
receiving signal input from the sensors, the ECU generates
an error code which is called a diagnosis code.
The diagnosis code includes the one which warns the
critical failure, and also the one which warns the light fault.
The diagnosis code can be seen by connecting the scan
tester（32G91-00600, 32G91-00600）to the ECU directly. It
also can be seen on the monitor if the monitor is located on
the vehicle.

14-2
 TROUBLESHOOTING

1.3 Connecting scan tester and ECU

To see the diagnosis code, connect the scan tester to the Scan tester
Scan tester (32G91-00811)
ECU.
connector
1.3.1 Scan tester (32G91-00800) SCANTOOL EOBD

INSPECTION
DIAGNOSTIC

(1) Turn the ignition switch to OFF position. SETUP

(2) When the power (24 V) from ECU is supplied to the OBD/OBDII/EOBD Scentool

ESC

service connector, connect the scan tester (32G91-

00811) connector and service connector directly. When
the power (24 V) from ECU is not supplied to the Service connector
service connector, use a interconnect cable. Connect a
extension harness connector A with a scan tester
connector, and extension harness connector B with a Connecting scan tester and ECU
service connector. Then, the power is supplied from a (32G91-00800, when the power is supplied from ECU)
cigarette.
Service Scan tester
(3) Turn the ignition switch to ON position. Extension harness
connector (32G91-00811)
1.3.2 Scan tester (32G91-00600) connector B
(1) Turn the ignition switch to OFF position. SCANTOOL EOBD

INSPECTION
DIAGNOSTIC
SETUP

(2) Connect the scan tester connector to the service

Scan OBD/OBDII/EOBD Scentool

connector which is located on the vehicle. Extension

ESC

tester
Cigarette plug harness
(3) Turn the ignition switch to ON position. connector
connector A

1.4 When ECU does not respond Connect to the cigarette

on the vehicle
If the scan tester does not display with connecting to the Interconnect cable
service connector, following conditions can be concerned. (32G91-00812)

• The harness and/or the connector between the service Connecting scan tester and ECU
connector and the ECU are faulty. (32G91-00800, when the power is not supplied from
ECU)
• The ECU is faulty.
At first, inspect the harness and connectors between the
Scan tester
service connector and the ECU. For the inspection, refer to Service connector (32G91-00600)
"Inspecting wiring"(14-36). Scan tester mastertech

If the harness and the connectors are not faulty, replace the connector
ECU. For the replacement of ECU, refer to "Replacing
ECU"(12-32).

CAUTION
The engine may operate even if the ECU does not Interface
Vetronix

respond with the scan tester. In this case, it is possible

that there are faults on the CAN circuit (communica-
tion circuit connecting the ECU and vehicle control Connecting scan tester and ECU
unit) inside the ECU. Do not operate the engine except (32G91-00600)
emergency situation, replace the ECU.

14-3
TROUBLESHOOTING

2. Scan tester (32G91-00800, main unit: 32G91-00811, interconnect cable: 32G91-

00812)

SCANTOOL EOBD

EOBD SCANTOOL DIAGNOSTIC

INSPECTION
DIAGNOSTIC INSPECTIONS
SETUP
MEASURE
FAULT CODES
䣅䣑䣏䣏䣗䣐䣋䣅䣃䣖䣋䣑䣐
䣃䣰䣶䣫䣲䣱䣮䣮䣷䣶䣫䣱䣰
OBD/OBDII/EOBD Scantool

ESC
ESC pour quitter CE AND PUSH OK . .

Connection screen DIAGNOSTIC menu

SCANTOOL EOBD

INSPECTIONS
DIAGNOSTIC
SETUP

CE AND PUSH OK . .

Main menu

Scan tester

Scan tester (32G91-00811)

2.1 Basic operation of scan tester
• Press UP key and DOWN key to move the cursor up and OBD/OBDII/EOBD Scantool ESC key
down.
UP key
• When the page number is displayed on the upper right of ESC
the screen, turn the page to use RIGHT key and LEFT
LEFT key ENTER key
key.
• Press ESC key to return to the previous screen.
• Press ENTER key to execute the selected menu. RIGHT key

DOWN key

Key operation

14-4
 TROUBLESHOOTING

2.2 Connecting the connector

(1) Make sure that the ignition key is OFF position. EOBD SCANTOOL
(2) When the power (24 V) from ECU is supplied to the
service connector, connect the scan tester (32G91-
00811) connector and service connector directly. When
the power (24 V) from ECU is not supplied to the 䎦䎲䎰䎰䎸䎱䎬䎦䎤䎷䎬䎲䎱
service connector, use a interconnect cable. Then, the 䎤䏑䏗䏌䏓䏒䏏䏏䏘䏗䏌䏒䏑
power is supplied from a cigarette. For more
information, refer to "Connecting scan tester and
ECU"(14-3). ESC pour quitter
(3) Turn the ignition key to ON position.
(4) The Connection screen is displayed, and then the main Connection screen
menu is displayed.

SCANTOOL EOBD

INSPECTIONS
DIAGNOSTIC
SETUP

CE AND PUSH OK . .

Main menu screen

14-5
TROUBLESHOOTING

2.3 Diagnostic
Using the scan tester, you can check the diagnostic codes
SCANTOOL EOBD
that are occurring presently or occurred in the past, and the
engine status when having trouble with the engine.
(1) Select DIAGNOSTIC from the main menu screen and INSPECTIONS
press ENTER key. (INSPECTIONS and SETUP are not DIAGNOSTIC
used.) SETUP

CE AND PUSH OK . .

Main menu screen

(2) The DIAGNOSTIC menu is displayed.
Note: If ECU is not support the OBD tool, it takes few
DIAGNOSTIC
minutes to display the DIAGNOSTIC menu. Then,
the "ECU does not respond..." message is displayed. INSPECTIONS
MEASURE
FAULT CODES

CE AND PUSH OK . .

DIAGNOSTIC menu screen

14-6
 TROUBLESHOOTING

2.3.1 Checking engine status

(1) Select MEASURE from the DIAGNOSTIC menu and
DIAGNOSTIC
press ENTER key. The MEASURE menu is displayed.
(2) Select INTERNAL MEASURES from the MEASURE INSPECTIONS
MEASURE
menu, and press ENTER key.
FAULT CODES
(3) Each engine status is displayed. Turn the page to use
RIGHT or LEFT key.

Engine status displays 01/03

Screen display (The val- Description (The values CE AND PUSH OK . .
ues are an example) are an example)
Number of codes stored in DIAGNOSTIC menu screen
Number of diagnosis codes
this module
3
3 code(s)
MEASURE
MI commanded ON by the
Warning
module INTERNAL MEASURES
None
NO
OXYGEN SENSORS
Calculated load value Engine torque NO CONTINU TEST
0.0% 0.0%
Engine coolant temperature
Water temperature 19 ℃
19 ℃
Intake manifold absolute
Boost pressure CE AND PUSH OK . .
pressure
1438hPa (Abs)
143kPa Abs
MEASURE menu screen
Engine status displays 02/03
Screen display (The val- Description (The values
INTERNAL MEASURES 01 03
ues are an example) are an example)
Number of codes s. .
Engine speed Engine revolutions 3 code(s)
0 rpm 0 rpm MI commanded ON b . .
NO
Gazol pressure Rail pressure Calculated load v . .
59040 kPa Mano 590400 hPa 0.0 %
Engine coolant te . .
Number of warm-ups since 19 °C
diagnostic trouble codes Q-rank Intake manifold a . .
cleared 4 101 kPa Abs .
4 Number of codes

Barometric pressure Barometrical pressure

100 kPa 1003 hPa Engine status screen

Control module voltage Battery voltage

Note: The full text of the item that has been selected with
24.007 V 24.007 V
the cursor is displayed at the bottom of screen.
Engine status displays 03/03
Screen display (The val- Description (The values
ues are an example) are an example)
Accelerator (D)
Accelerator pedal position D 82.3%
82.3 % (CAN communication sig-
nal)
Accelerator (A)
Accelerator pedal position E
82.3%
82.3%
(Analog signal)

14-7
TROUBLESHOOTING

2.3.2 Checking diagnosis codes

(1) Select FAULT CODES from the DIAGNOSTIC menu
DIAGNOSTIC
and press ENTER key. The FAULT CODES menu is
displayed. INSPECTIONS
MEASURE
FAULT CODES

CE AND PUSH OK . .

DIAGNOSTIC menu screen

(2) Select ACTIVE FAULT CODES from the FAULT
CODES menu and press ENTER key.
FAULT CODES
STORED FAULT CODES
FREEZED FRAME
ACTIVE FAULT CODES
ERASE FAULT CODES

CE AND PUSH OK . .

FAULT CODES menu screen

(3) The registered diagnosis codes are displayed.

ACTIVE FAULTS
P0543
P060D
P060E

CE AND PUSH OK . .

ACTIVE FAULTS screen

(4) Select the code which you want to confirm the content
and press ENTER key. The content of diagnosis code is
ACTIVE FAULTS
displayed. (Unregistered content in the scan tester is not
P0543
displayed.) P0543 Intake Air H
eater A Circuit Op
en

543 Intake Air H

Contents screen

14-8
 TROUBLESHOOTING

2.3.3 Checking freeze data

(1) Select FAULT CODES from the DIAGNOSTIC menu
DIAGNOSTIC
and ENTER key. The FAULT CODES menu is
displayed. INSPECTIONS
MEASURE
FAULT CODES

CE AND PUSH OK . .

DIAGNOSTIC menu screen

(2) Select FREEZED FRAME from the FAULT CODES
menu and press ENTER key. The FREEZED FRAME
FAULT CODES
menu is displayed.
STORED FAULT CODES
FREEZED FRAME
ACTIVE FAULT CODES
ERASE FAULT CODES

CE AND PUSH OK . .

FAULT CODES menu screen

(3) Select READ FREEZED FRAME from the FREEZED
FRAME menu and press ENTER key.
Freezed frame
SERIAL NUM : 000
READ FREEZED FRAME

CE AND PUSH OK . .

FREEZED FRAME menu screen

(4) The FREEZE DATA is displayed. The FREEZE DATA
is a backup data saving the engine status screen of when 01
TRAMES FIXES 02
the diagnosis code is generated. The most important
Fault code that c . .
code in the fault codes that ECU recognizes is P060E
displayed. Turn the page to use RIGHT or LEFT key. Calculated load v . .
0.0 %
Engine coolant te . .
66 °C
Intake manifold a . .
100 kPa Abs .
Engine speed
0 rpm
Fault code that

FREEZED FRAME displaying screen

14-9
TROUBLESHOOTING

2.3.4 Clearing diagnosis codes

(1) Select FAULT CODES from the DIAGNOSTIC menu
DIAGNOSTIC
and press ENTER key. The FAULT CODES menu is
displayed. INSPECTIONS
MEASURE
FAULT CODES

CE AND PUSH OK . .

DIAGNOSTIC menu screen

(2) Select ERASE FAULT CODES from the FAULT
CODES menu.
FAULT CODES
STORED FAULT CODES
FREEZED FRAME
ACTIVE FAULT CODES
ERASE FAULT CODES

CE AND PUSH OK . .

FAULT CODES menu screen

(3) Press ENTER key to delete the diagnosis code.

FAULT CODES
STORED FAULT CODES
FREEZED FRAME
INITIALIZATION
ACTIVE FAULT
DONECODES
S
ERASE FAULT CODES

CE AND PUSH OK . .

Clear DIAG screen

14-10
 TROUBLESHOOTING

3. Scan tester (32G91-00600)

mastertech

Startup screen OBD ΤFUNCTION MENU

YES NO ENTER

F1 F2 F3
HELP
1 2 3

F4 F5 F6
RCV
4 5 6
FUNCTION MENU OBD ΤTEST MENU
F7 F8 F9
SEND
7 8 9

F0 ON
EXIT 㧖 0 #
OFF

Vetronix

Scan tester

SELECT PROGRAM

Scan tester (32G91-00600)

3.1 Operation of scan tester (9) The menu screen of OBD Ⅱ FUNCTIONS is
Use scan tester to check the engine status and the diagnosis displayed.
codes. (10)Press EXIT key to return the previous screen.
3.1.1 Basic operation of scan tester (11)With pressing ON key, press EXIT key to turn off the
(1) Make sure that ignition key is OFF position. scan tester.
(2) Connect the scan tester to the service connector on the (12)Turn the ignition key to OFF position to turn off the
vehicle. ECU.
(3) Turn the ignition key to ON position to energize the
ECU.
(4) Press ON key located on the lower right section of scan
tester to energize the scan tester. When the scan tester is
energized, startup screen is displayed.
(5) Press ENTER key.
(6) FUNCTION MENU is displayed. Select SCAN TEST
and press ENTER key.
(7) SELECT PROGRAM is displayed. Select GLOBAL
OBD Ⅱ and press ENTER key.
(8) OBD Ⅱ TEST MENU is displayed. Select OBD Ⅱ
FUNCTIONS and press ENTER key.

14-11
TROUBLESHOOTING

3.2 Check engine status

(1) Select DATA LIST from the OBD Ⅱ FUNCTIONS
mastertech
menu and press ENTER key.
(2) Select All Data from the PARAMETER SELECTION
menu and press ENTER key.
(3) The engine status is displayed. Check the engine status.

Engine status displays

Vetronix

ECU ID $10
ENGINE SPD Engine speed (rpm)
ECT(°) Water temperature (°C)
Parameter selection screen
Engine load (%)
ENGINE LOAD
(rate against maximum fuel injection)
MAP Boost pressure (kPa(abs)) mastertech

Error status (ON-OFF)

MIL STATUS
(Existence of diagnosis codes)
STORED DTCs Number of diagnosis codes
FRP(G) Rail pressure (MPa)
WARM-UPS Q-rank (1-8) Vetronix

BARO Barometrical pressure (PaA)

CTRL MOD(V) Battery voltage (V)
APP-D CAN accelerator (%) Engine status screen
APP-E Analog accelerator (%)

14-12
 TROUBLESHOOTING

3.3 Screen of DTC Menu

(1) Select DTCs from the OBD Ⅱ FUNCTIONS menu and
mastertech
press ENTER key.
(2) DTC MENU is displayed.

Vetronix

DTC menu screen

3.3.1 Check diagnosis codes
(1) Select Confirmed DTCs from DTC MENU and press
mastertech
ENTER key.
(2) The diagnosis codes are displayed. The diagnosis codes
are displayed in the order of generating. To display the
previous generated codes, press down key.

Vetronix

Diagnosis code screen

3.3.2 Check freeze data
(1) Select Freeze Data from DTC MENU and press
mastertech
ENTER key.
(2) The FREEZE DATA is displayed. The FREEZE DATA
is a backup data saving the engine status screen of when
the diagnosis code is generated.

Vetronix

Freeze data screen

3.3.3 Clear diagnosis codes
(1) Select Clear Diag Info from DTC MENU and press
mastertech
ENTER key.
(2) The confirmation screen is displayed. Press YES key,
and press ENTER key to delete the diagnosis codes.
However, the diagnosis codes cannot be deleted until
the recovery is completed.

Vetronix

Clear DIAG screen

14-13
TROUBLESHOOTING

4. Diagnosis code cross reference

The P code shown in the table below is displayed by connecting the scan tester to the service connector.
The vehicle side code is displayed on the vehicle monitor. Check the corresponding codes by following chart.
For the detail and treatment of diagnosis codes, refer to "Troubleshooting reference chart".
Note: The word "DBV" in the table is an abbreviation of pressure limiting valve.

Table 14-1 Diagnosis code cross reference (2 / 4)

Table 14-1 Diagnosis code cross reference (1 / 4)
J1939 Vehicle
J1939 Vehicle P
P Item code side
Item code side code
code (DTC) code
(DTC) code
Shut off
Discrepancy between P0215 1110-2 1110-4
P0016 228-3 228-1 pass test
crank and cam signal
Shut off
Backup control using P0215 1110-12 1110-8
P0021 635-3 635-1 pass test
cam side signal
MPROP power stage
P0089 DBV valve opening 2041-3 2041-1 P0230 2001-3 2001-1
short-circuit to battery
P0089 DBV kick off 2042-4 2042-2 MPROP power stage
P0231 2002-4 2002-2
P0090 DBV closed sticking 2043-2 2043-4 short-circuit to ground

P0091 DBV pressure is too low 2045-4 2045-2 MPROP power stage open
P0252 2000-2 2000-4
circuit
P0092 DBV pressure is too high 2044-3 2044-1
MPROP power stage over-
P0117 Water temperature sensor 110-4 110-2 P0252 2000-12 2000-8
load
P0118 Water temperature sensor 110-3 110-1 Inlet manifold pressure
P0235 102-12 102-8
sensor
Accelerator signal
P0121 383-12 383-8
diagnosis Inlet manifold pressure
P0237 102-4 102-2
sensor
P0122 Accelerator sensor 1 29-4 29-2
Inlet manifold pressure
P0123 Accelerator sensor 1 29-3 29-1 P0238 102-3 102-1
sensor
Rail pressure governor
P0191 2013-3 2013-1 P0261 Injector No.1 657-2 657-4
deviation
P0262 Injector No.1 657-3 657-1
Rail pressure governor
P0191 2014-3 2014-1
deviation P0263 Injector No.1 657-12 657-8
Rail pressure governor P0264 Injector No.2 659-2 659-4
P0191 2015-3 2015-1
deviation
P0265 Injector No.2 659-3 659-1
P0192 Rail pressure SRC 2011-4 2011-2
P0266 Injector No.2 659-12 659-8
P0193 Rail pressure SRC 2011-3 2011-1
P0267 Injector No.3 661-2 661-4
Rail pressure sensor
P0192 2012-4 2012-2 P0268 Injector No.3 661-3 661-1
offset monitoring
Rail pressure sensor P0269 Injector No.3 661-12 661-8
P0193 2012-3 2012-1
offset monitoring P0270 Injector No.4 663-2 663-4
P0194 Rail pressure governor 2016-3 2016-1 P0271 Injector No.4 663-3 663-1
P0194 Rail pressure governor 2017-3 2017-1 P0272 Injector No.4 663-12 663-8
P0201 Injector No.1 658-2 658-4 Speed/timing sensor
P0336 637-4 637-2
P0202 Injector No.2 660-2 660-4 (crankshaft side)

P0203 Injector No.3 662-2 662-4 Speed/timing sensor

P0339 637-3 637-1
(crankshaft side)
P0204 Injector No.4 664-2 664-4
Speed/timing sensor
P0341 636-4 636-2
Shut off (camshaft side)
P0215 1110-4 1110-2
pass test
Speed/timing sensor
P0344 636-3 636-1
(camshaft side)

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 TROUBLESHOOTING

Table 14-1 Diagnosis code cross reference (3 / 4) Table 14-1 Diagnosis code cross reference (4 / 4)
J1939 Vehicle J1939 Vehicle
P P
Item code side Item code side
code code
(DTC) code (DTC) code
Air heater relay P060B ADC monitoring 2008-4 2008-2
P0540 677-12 677-8
power stage
P060B ADC monitoring 2008-2 2008-4
Air heater relay
P0541 677-4 677-2 P060B ADC monitoring 2008-12 2008-8
power stage
P060D CAN accelerator 91-2 91-4
Air heater relay
P0542 677-3 677-1
power stage P060E APPREQ message time out 1674-2 1674-4
Air heater relay P061C Engine speed 2005-3 2005-1
P0543 677-2 677-4
power stage
Injector
P062D 651-12 651-8
Power supply unit voltage drive bank 1
P0562 1543-4 1543-2
too low
Injector
P062E 653-12 653-8
Power supply unit voltage drive bank 2
P0563 1542-3 1542-1
too high
P062F EEPROM 1235-4 1235-2
P0600 CAN transmitting time out 2028-2 2028-4
P062F EEPROM 1235-2 1235-4
P0600 CAN (A) pass off 1671-3 1671-1
P062F EEPROM 1235-12 1235-8
P0600 CAN (C) pass off 1673-3 1673-1
P0933 Oil pressure switch 19-12 19-8
P0606 SPI communication error 1231-3 1231-1
P0933 Oil pressure switch 100-12 100-8
P0606 Super vision 1484-12 1484-8
Injector
P2047 652-2 652-4
P0607 Recovery occurred 1668-12 1668-8 drive bank 1
P0607 Recovery occurred 1670-12 1670-8 Injector
P2048 651-4 651-2
drive bank 1
P0607 SPI watch dog error 2010-12 2010-8
Injector
P0611 Injector IC 655-3 655-1 P2049 651-3 651-1
drive bank 1
P0611 Injector IC 655-4 655-2
Injector
P2050 654-2 654-4
P0611 Injector IC 655-2 655-4 drive bank 2
P0611 Injector IC 655-12 655-8 Injector
P2051 653-4 653-2
drive bank 2
P0611 Injector IC 656-3 656-1
Injector
P0611 Injector IC 656-4 656-2 P2052 653-3 653-1
drive bank 2
P0611 Injector IC 656-2 656-4
Atmospheric pressure sen-
P2228 108-4 108-2
P0611 Injector IC 656-12 656-8 sor

Sensor supply voltage Atmospheric pressure sen-

P0642 1079-4 1079-2 P2229 108-3 108-1
monitoring 1 sor

Sensor supply voltage

P0643 1079-3 1079-1
monitoring 1
Sensor supply voltage
P0652 1080-4 1080-2
monitoring 2
Sensor supply voltage
P0653 1080-3 1080-1
monitoring 2
Sensor supply voltage
P0698 620-4 620-2
monitoring 3
Sensor supply voltage
P0699 620-3 620-1
monitoring 3
P060A TPU monitoring 2009-12 2009-8
P060B ADC monitoring 2008-3 2008-1

14-15
TROUBLESHOOTING

5. Troubleshooting reference chart

5.1 Troubleshooting with diagnosis code
Note: The diagnosis codes which has * mark in the "Recovery" column recovers when the cause of fault has deleted and the
engine has restarted.

P0016 : Discrepancy between speed/timing sensor P0117 : Water temperature sensor

(crankshaft side/camshaft side) signal Vehicle side code : 110-2
Vehicle side code : 228-1 Faulty part Water temperature sensor
Speed/timing sensor The ECU detects a faulty operation of
Faulty part
(crankshaft side/camshaft side) the water temperature sensor (open cir-
Detail
The ECU detects a discrepancy between cuit, short circuit). The input voltage
Detail speed/timing sensor (crankshaft side/ falls below the limiting value.
camshaft side) signal. Recovery *
Recovery * When engine is operated, the ECU con-
The ECU controls the engine using trols the engine as overheated
speed/timing sensor (crankshaft side) with fixing the temperature 120°C
Control signal. Control (warm mode). When starting the engine,
The ECU limits the maximum power of the ECU controls the engine with fixing
the engine. the water temperature -20°C (cold
mode).
Power limit The maximum power is limited to 50%.
When the water temperature is 100°C or
Inspection Contact a Mitsubishi dealer. Power limit above, the ECU controls the engine as
overheated.
P0021 : Backup control using camshaft side signal
Water temperature sensor, and wiring of
Vehicle side code : 635-1 Inspection
water temperature sensor.
Speed/timing sensor
Faulty part
(crankshaft side) P0118 : Water temperature sensor
The engine is operating without speed/ Vehicle side code : 110-1
timing sensor (crankshaft side) signal. Faulty part Water temperature sensor
Detail
The ECU controls the engine using cam-
shaft side signal only. The input voltage exceeds the limiting
Detail
value.
Recovery *
Recovery *
The ECU limits the maximum power of
Control When engine is operated, the ECU con-
the engine.
trols the engine as overheated
Power limit The maximum power is limited to 50%. with fixing the temperature 120°C
Speed/timing sensor (crankshaft side) Control (warm mode). When starting the engine,
Inspection and wiring of speed/timing sensor the ECU controls the engine with fixing
(crankshaft side). the water temperature -20°C (cold
mode).
When the water temperature is 100°C or
Power limit above, the ECU controls the engine as
overheated.
Water temperature sensor, and wiring of
Inspection
water temperature sensor.

14-16
 TROUBLESHOOTING

P0121 : Accelerator signal diagnosis P0191 : Rail pressure governor deviation

Vehicle side code : 383-8 Vehicle side code : 2013-1
Accelerator signal (CAN signal, analog Faulty part Common rail
Faulty part
signal)
The rail pressure control is abnormal.
Detail
The ECU compares the CAN signal and The target pressure is not achieved.
Detail analog signal, and detects a discrepancy
Recovery *
between them.
The ECU limits the maximum power of
When a discrepancy is deleted, it recov- Control
Recovery the engine.
ers automatically.
Power limit The maximum power is limited to 75%.
Control The ECU warns to the operator.
Inspection Damage on the common rail.
Power limit -
Inspection CAN signal and analog signal wiring.
Vehicle side code : 2014-1
P0122 : Accelerator sensor 1
Faulty part Common rail
Vehicle side code : 29-2
The rail pressure control is abnormal.
Faulty part Accelerator signal (analog signal)
Detail The target pressure is not achieved even
The ECU detects a faulty analog signal fully pressured by fuel pump.
Detail input from vehicle controller. The input
Recovery *
voltage falls below the limiting value.
Control Engine stop
When the input voltage recovers to the
Recovery specified value, it recovers automati- Power limit -
cally.
Inspection Damage on the common rail.
When operating by CAN signal, the
ECU warns to the operator. When oper- P0192 : Rail pressure sensor offset monitoring
Control ating by analog signal, the ECU warns
Vehicle side code : 2012-2
to the operator and the engine operation
switches to the redundancy operation. Faulty part Rail pressure sensor
Power limit - The input voltage falls below the limit-
Detail
ing value.
Inspection Accelerator signal (analog signal)
Recovery *
P0123 : Accelerator sensor 1 Accelerator opening ratio is fixed to
Vehicle side code : 29-1 Control
12%.
Faulty part Accelerator signal (analog signal) Power limit -
The ECU detects a faulty analog signal Rail pressure sensor, and wiring of rail
Detail input from vehicle controller. The input Inspection
pressure sensor.
voltage exceeds the limiting value.
When the input voltage recovers to the
Recovery specified value, it recovers automati-
cally.
When operating by CAN signal, the
ECU warns to the operator. When oper-
Control ating by analog signal, the ECU warns
to the operator and the engine operation
switches to the redundancy operation.
Power limit -
Inspection Accelerator signal (analog signal)

14-17
TROUBLESHOOTING

P0193 : Rail pressure sensor offset monitoring P0202 : Injector No.2

Vehicle side code : 2012-1 Vehicle side code : 660-4
Faulty part Rail pressure sensor Faulty part Injector No.2
The input voltage exceeds the limiting The ECU detects an open circuit of the
Detail Detail
value. injector and/or injector harness.
Recovery * Recovery *
Accelerator opening ratio is fixed to The engine keeps operating if only one
Control
12%. Control injector is faulty. The engine stops if
two or more injectors are faulty.
Power limit -
There is no specific control by the ECU,
Rail pressure sensor, and wiring of rail Power limit
Inspection but the engine power decreases.
pressure sensor.
Inspection Injector, and wiring of injector.
P0194 : Rail pressure governor
Vehicle side code : 2016-1 P0203 : Injector No.3
Vehicle side code : 662-4
Faulty part Common rail
Faulty part Injector No.3
The rail pressure falls below the limiting
Detail
value. The ECU detects an open circuit of the
Detail
injector and/or injector harness.
Recovery *
Recovery *
Control Engine stop
The engine keeps operating if only one
Power limit -
Control injector is faulty. The engine stops if two
Inspection Damage on the common rail. or more injectors are faulty.
There is no specific control by the ECU,
P0201 : Injector No.1 Power limit
but the engine power decreases.
Vehicle side code : 658-4
Inspection Injector, and wiring of injector.
Faulty part Injector No.1
The ECU detects an open circuit of the P0204 : Injector No.4
Detail
injector and/or injector harness. Vehicle side code : 664-4
Recovery * Faulty part Injector No.4
The engine keeps operating if only one The ECU detects an open circuit of the
Detail
Control injector is faulty. The engine stops if two injector and/or injector harness.
or more injectors are faulty.
Recovery *
There is no specific control by the ECU,
Power limit The engine keeps operating if only one
but the engine power decreases.
Control injector is faulty. The engine stops if two
Inspection Injector, and wiring of injector. or more injectors are faulty.
There is no specific control by the ECU,
Power limit
but the engine power decreases.
Inspection Injector, and wiring of injector.

14-18
 TROUBLESHOOTING

P0215 : Shut off pass test P0235 : Inlet manifold pressure sensor
Vehicle side code : 1110-2 Vehicle side code : 102-8
Faulty part ECU Inlet manifold pressure sensor power
Faulty part
supply line
The emergency injection stop circuit
Detail does not operate. The shut-off by watch The ECU detects an open circuit or short
Detail
dog is disabled. circuit of the sensor power supply (5V).
Recovery * Recovery *
Control The ECU warns to the operator. The ECU controls the engine fixing the
Control value to the backup data.(Approx. 1013
Power limit -
hpa)
Inspection Contact a Mitsubishi dealer.
Power limit The maximum power is limited to 75%.
Inlet manifold pressure sensor power
Inspection
Vehicle side code : 1110-4 supply line wiring

Faulty part ECU P0237 : Inlet manifold pressure sensor

The emergency injection stop circuit Vehicle side code : 102-2
Detail does not operate. The shut off by high
Faulty part Inlet manifold pressure sensor
voltage monitoring is disabled.
The ECU detects the faulty operation of
Recovery *
the inlet manifold pressure sensor (open
Control The ECU warns to the operator. Detail circuit, short circuit, characteristic
fault). The input voltage falls below the
Power limit - limiting value.
Inspection Contact a Mitsubishi dealer. Recovery *
The ECU controls the engine using the
Control
backup data.
Vehicle side code : 1110-8
Power limit The maximum power is limited to 75%.
Faulty part ECU
Inlet manifold pressure sensor, and wir-
The emergency injection stop circuit Inspection
ing of inlet manifold pressure sensor.
Detail does not operate. The shut off by low
voltage monitoring is disabled.
P0238 : Inlet manifold pressure sensor
Recovery * Vehicle side code : 102-1
Control The ECU warns to the operator. Faulty part Inlet manifold pressure sensor
Power limit - The input voltage exceeds the limiting
Detail
Inspection Contact a Mitsubishi dealer. value.
Recovery *
P0231 : MPROP power stage short-circuit to ground
The ECU controls the engine using the
Vehicle side code : 2002-2 Control
backup data.
Faulty part MPROP
Power limit The maximum power is limited to 75%.
The ECU detects a short circuit on the
Detail Inlet manifold pressure sensor, and wir-
ground line of the MPROP harness. Inspection
ing of inlet manifold pressure sensor.
Recovery *
Accelerator opening ratio is fixed to
Control
12%.
Power limit -
Inspection MPROP, and wiring of MPROP.

14-19
TROUBLESHOOTING

P0261 : Injector No.1 P0265 : Injector No.2

Vehicle side code : 657-4 Vehicle side code : 659-1
Faulty part Injector No.1 Faulty part Injector No.2
The ECU detects a short circuit of the The injector is faulty. The low side is a
Detail
injector and/or injector harness. There short circuit to the battery (+).
Detail
are short circuits on the high side and
Recovery *
low side.
Control Engine stop
Recovery *
Power limit -
Control Engine stop
Inspection Injector, and wiring of injector.
Power limit -
Inspection Injector, and wiring of injector. P0266 : Injector No.2
Vehicle side code : 659-8
P0262 : Injector No.1
Faulty part Injector No.2
Vehicle side code : 657-1
Unclassifiable error in the injector and/
Faulty part Injector No.1
Detail or the injector harness. The injector is
The injector is faulty. The low side is a disabled.
Detail
short circuit to the battery (+).
Recovery *
Recovery *
Control Engine stop
Control Engine stop
Power limit -
Power limit -
Inspection Injector, and wiring of injector.
Inspection Injector, and wiring of injector.
P0267 : Injector No.3
P0263 : Injector No.1 Vehicle side code : 661-4
Vehicle side code : 657-8
Faulty part Injector No.3
Faulty part Injector No.1
The ECU detects a short circuit of the
Unclassifiable error in the injector and/ injector and/or injector harness. There
Detail
Detail or the injector harness. The injector is are short circuits on the high side and
disabled. low side.
Recovery * Recovery *
Control Engine stop Control Engine stop
Power limit - Power limit -
Inspection Injector, and wiring of injector. Inspection Injector, and wiring of injector.

P0264 : Injector No.2 P0268 : Injector No.3

Vehicle side code : 659-4 Vehicle side code : 661-1
Faulty part Injector No.2 Faulty part Injector No.3
The ECU detects a short circuit of the The injector is faulty. The low side is a
Detail
injector and/or injector harness. There short circuit to the battery (+).
Detail
are short circuits on the high side and
Recovery *
low side.
Control Engine stop
Recovery *
Power limit -
Control Engine stop
Inspection Injector, and wiring of injector.
Power limit -
Inspection Injector, and wiring of injector.

14-20
 TROUBLESHOOTING

P0269 : Injector No.3 P0336 : Speed/timing sensor (crankshaft side)

Vehicle side code : 661-8 Vehicle side code : 637-2
Faulty part Injector No.3 Speed/timing sensor
Faulty part
(crankshaft side)
Unclassifiable error in the injector and/
Detail or the injector harness. The injector is The ECU detects the fault of speed/tim-
disabled. ing sensor (crankshaft side)(open cir-
Detail cuit, short circuit, tooth breakage). The
Recovery *
number of crank pulse and/or crank
Control Engine stop pulse position are faulty.

Power limit - Recovery *

Inspection Injector, and wiring of injector. The ECU controls the engine using the
Control speed/timing sensor (camshaft side) sig-
P0270 : Injector No.4 nal.
Vehicle side code : 663-4 The maximum power is limited to 50%
Power limit
only when starting the engine.
Faulty part Injector No.4
Speed/timing sensor (crankshaft side),
The ECU detects a short circuit of the
Inspection and wiring of speed/timing sensor
injector and/or injector harness. There
Detail (crankshaft side).
are short circuits on the high side and
low side.
P0339 : Speed/timing sensor (crankshaft side)
Recovery * Vehicle side code : 637-1
Control Engine stop Speed/timing sensor
Faulty part
Power limit - (crankshaft side)

Inspection Injector, and wiring of injector. The speed/timing sensor (crankshaft

Detail side) is faulty. The ECU is not receiving
P0271 : Injector No.4 the crank pulse.
Vehicle side code : 663-1 Recovery *
Faulty part Injector No.4 The ECU controls the engine using the
Control speed/timing sensor (camshaft side) sig-
The injector is faulty. The low side is a
Detail nal.
short circuit to the battery (+).
The maximum power is limited to 50%
Recovery * Power limit
only when starting the engine.
Control Engine stop
Speed/timing sensor (crankshaft side),
Power limit - Inspection and wiring of speed/timing sensor
(crankshaft side).
Inspection Injector, and wiring of injector.

P0272 : Injector No.4

Vehicle side code : 663-8
Faulty part Injector No.4
Unclassifiable error in the injector and/
Detail or the injector harness. The injector is
disabled.
Recovery *
Control Engine stop
Power limit -
Inspection Injector, and wiring of injector.

14-21
TROUBLESHOOTING

P0341 : Speed/timing sensor (camshaft side) P0541 : Air heater relay power stage
Vehicle side code : 636-2 Vehicle side code : 677-2
Speed/timing sensor Faulty part Air heater relay
Faulty part
(camshaft side)
The air heater relay and/or connecting
Detail
The ECU detects the fault of speed/tim- harness are short circuits to the ground.
ing sensor (camshaft side) (open circuit,
Recovery *
Detail short circuit, tooth breakage). The num-
ber of cam pulse and/or cam pulse posi- The air heater is disabled. The ECU
tion are faulty. Control
warns to the operator.
Recovery * Power limit -
The ECU controls the engine using Inspection Air heater relay, and wiring of air heater.
Control speed/timing sensor (crankshaft side)
signal. The ECU warns to the operator. P0542 : Air heater relay power stage
Power limit - Vehicle side code : 677-1
Speed/timing sensor (camshaft side), Faulty part Air heater relay
Inspection and wiring of speed/timing sensor (cam-
The air heater relay is faulty. The air
shaft side).
Detail heater relay is a short circuit to the bat-
tery.
P0344 : Speed/timing sensor (camshaft side)
Vehicle side code : 636-1 Recovery *

Speed/timing sensor The air heater is disabled. The ECU

Faulty part Control
(camshaft side) warns to the operator.

The speed/timing sensor (camshaft side) Power limit -

Detail is faulty. The ECU is not receiving the Inspection Air heater relay, and wiring of air heater.
cam pulse.
Recovery * P0543 : Air heater relay power stage
Vehicle side code : 677-4
The ECU controls the engine using
Control speed/timing sensor (crankshaft side) Faulty part Air heater relay
signal. The ECU warns to the operator.
The ECU detects an open circuit of air
Detail
Power limit - heater relay and/or connecting harness.
Speed/timing sensor (camshaft side), Recovery *
Inspection and wiring of speed/timing sensor (cam-
The air heater is disabled. The ECU
shaft side). Control
warns to the operator.
P0540 : Air heater relay power stage Power limit -
Vehicle side code : 677-8 Inspection Air heater relay, and wiring of air heater.
Faulty part Air heater relay
P0562 : Power supply unit voltage too low
The ECU detects an overload of air
Detail Vehicle side code : 1543-2
heater relay and/or connecting harness.
Faulty part ECU
Recovery *
The voltage of the power supply unit
The air heater is disabled. The ECU
Control Detail inside the ECU falls below the limiting
warns to the operator.
value.
Power limit -
Recovery *
Inspection Air heater relay, and wiring of air heater.
Control Engine stop
Power limit -
Inspection Replace the ECU.

14-22
 TROUBLESHOOTING

P0563 : Power supply unit voltage too high P0600 : CAN (C) pass off
Vehicle side code : 1542-1 Vehicle side code : 1673-1
Faulty part ECU Faulty part CAN communication line
The voltage of the power supply unit The CAN communication is faulty. The
Detail
Detail inside the ECU exceeds the limiting ECU detects the CAN (C) pass off.
value.
Recovery *
Recovery *
The ECU uses the analog signal for
Control Engine stop Control backup control. The ECU warns to the
operator.
Power limit -
Power limit -
Inspection Replace the ECU.
Inspection CAN communication line, and ECU.
P0600 : CAN transmitting time out
Vehicle side code : 2028-4 P0606 : SPI communication error
Vehicle side code : 1231-1
Faulty part CAN communication line
Faulty part ECU
The CAN message cannot be transmit-
Detail
ted. There are serial communication errors
Detail
between CPU and other IC.
Recovery *
Recovery *
The ECU uses the analog signal for
Control
backup control. Control Engine stop
Power limit - Power limit -
Inspection CAN communication line, and ECU. Inspection Replace the ECU.

P0600 : CAN (A) pass off P0606 : Super vision

Vehicle side code : 1671-1 Vehicle side code : 1484-8
Faulty part CAN communication line Faulty part ECU
The CAN communication is faulty. The The ECU detects an abnormality by
Detail
Detail ECU detects an open circuit or short cir- using self-diagnosis function.
cuit of CAN line.
Recovery *
Recovery *
Control Engine stop
The ECU uses the analog signal for
Power limit -
Control backup control. The ECU warns to the
operator. Inspection Replace the ECU.
Power limit -
P0607 : Recovery occurred
Inspection CAN communication line, and ECU. Vehicle side code : 1668-8
Faulty part ECU
The recovery occurred by the fault of the
Detail
ECU.
Recovery *
Control The ECU warns to the operator.
Power limit -
Inspection -

14-23
TROUBLESHOOTING

Vehicle side code : 1670-8 Vehicle side code : 655-4

Faulty part ECU Faulty part ECU
The recovery occurred by the fault of the The injector control IC inside the ECU
Detail Detail
ECU. is faulty.
Recovery * Recovery *
Control The ECU warns to the operator. Control Engine stop
Power limit - Power limit -
Inspection - Inspection Replace the ECU.

P0607 : SPI watch dog error

Vehicle side code : 2010-8 Vehicle side code : 655-8
Faulty part ECU Faulty part ECU
The ECU detects an abnormality by The injector control IC inside the ECU
Detail
Detail using self-diagnosis function. Watch dog is faulty.
error.
Recovery *
Recovery occurs. It recovers automati-
Control Engine stop
cally if an error occurs three times in
Recovery two seconds. The engine stops if an Power limit -
error occurs four times or more in two
seconds. Inspection Replace the ECU.

Control Engine stop

Power limit - Vehicle side code : 656-1

Inspection Replace the ECU. Faulty part ECU

The injector control IC inside the ECU
P0611 : Injector IC Detail
is faulty.
Vehicle side code : 655-1
Recovery *
Faulty part ECU
Control Engine stop
The injector control IC inside the ECU
Detail Power limit -
is faulty.
Recovery * Inspection Replace the ECU.

Control Engine stop

Power limit - Vehicle side code : 656-2

Inspection Replace the ECU. Faulty part ECU

The injector control IC inside the ECU
Detail
is faulty.
Vehicle side code : 655-2
Recovery *
Faulty part ECU
Control Engine stop
The injector control IC inside the ECU
Detail Power limit -
is faulty.
Recovery * Inspection Replace the ECU.

Control Engine stop

Power limit -
Inspection Replace the ECU.

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 TROUBLESHOOTING

P0652 : Sensor supply voltage monitoring 2

Vehicle side code : 656-4 Vehicle side code : 1080-2
Faulty part ECU Faulty part ECU
The injector control IC inside the ECU The 5V power supply to the inlet mani-
Detail
is faulty. fold pressure sensor is faulty. The sup-
Detail
ply voltage falls below the limiting
Recovery *
value.
Control Engine stop
Recovery *
Power limit -
The ECU controls the engine using the
Control
Inspection Replace the ECU. backup data.
Power limit The maximum power is limited to 75%.

Vehicle side code : 656-8 Inspection Replace the ECU.

Faulty part ECU P0653 : Sensor supply voltage monitoring 2

The injector control IC inside the ECU Vehicle side code : 1080-1
Detail
is faulty.
Faulty part ECU
Recovery *
The 5V power supply to the inlet mani-
Control Engine stop Detail fold pressure sensor is faulty. The sup-
ply voltage exceeds the limiting value.
Power limit -
Recovery *
Inspection Replace the ECU.
The ECU controls the engine using the
Control
P0642 : Sensor supply voltage monitoring 1 backup data.
Vehicle side code : 1079-2 Power limit The maximum power is limited to 75%.
Faulty part ECU Inspection Replace the ECU.
The 5V power supply to the PTO accel-
Detail erator signal is faulty. The supply volt- P0698 : Sensor supply voltage monitoring 3
age falls below the limiting value. Vehicle side code : 620-2

Recovery * Faulty part ECU

Control The ECU warns to the operator. The 5V power supply to the rail pressure
Detail sensor is faulty. The supply voltage falls
Power limit - below the limiting value.
Inspection Replace the ECU. Recovery *

P0643 : Sensor supply voltage monitoring 1 Control The ECU warns to the operator.
Vehicle side code : 1079-1 Power limit -
Faulty part ECU Inspection Replace the ECU.
The 5V power supply to the PTO accel-
Detail erator signal is faulty. The supply volt-
age exceeds the limiting value.
Recovery *
Control The ECU warns to the operator.
Power limit -
Inspection Replace the ECU.

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TROUBLESHOOTING

P0699 : Sensor supply voltage monitoring 3

Vehicle side code : 620-1 Vehicle side code : 2008-2
Faulty part ECU Faulty part ECU
The 5V power supply to the rail pressure The AD converter inside the ECU is
Detail sensor is faulty. The supply voltage Detail faulty. The standard voltage falls below
exceeds the limiting value. the limiting value.
Recovery * Recovery occurs. It recovers automati-
cally if an error occurs three times in two
Control The ECU warns to the operator.
Recovery seconds. The engine stops if an error
Power limit - occurs four times or more in two sec-
onds.
Inspection Replace the ECU.
Control Engine stop
P060A : TPU monitoring Power limit -
Vehicle side code : 2009-8
Inspection Replace the ECU.
Faulty part ECU
The ECU detects a fault of rotating pulse
Detail Vehicle side code : 2008-4
arithmetic circuit inside the ECU.
Recovery occurs. It recovers automati- Faulty part ECU
cally if an error occurs three times in
The AD converter inside the ECU is
Recovery two seconds. The engine stops if an
Detail faulty. The ECU detects the conversion
error occurs four times or more in two
error by using a test pulse.
seconds.
Recovery occurs. It recovers automati-
Control Engine stop
cally if an error occurs three times in
Power limit - Recovery two seconds. The engine stops if an
error occurs four times or more in two
Inspection Replace the ECU. seconds.

P060B : ADC monitoring Control Engine stop

Vehicle side code : 2008-1 Power limit -
Faulty part ECU Inspection Replace the ECU.
The AD converter inside the ECU is
Detail faulty. The standard voltage exceeds the
limiting value. Vehicle side code : 2008-8
Recovery occurs. It recovers automati- Faulty part ECU
cally if an error occurs three times in
The AD converter inside the ECU is
Recovery two seconds. The engine stops if an Detail
faulty. The conversion time is abnormal.
error occurs four times or more in two
seconds. Recovery occurs. It recovers automati-
cally if an error occurs three times in
Control Engine stop
Recovery two seconds. The engine stops if an
Power limit - error occurs four times or more in two
seconds.
Inspection Replace the ECU.
Control Engine stop
Power limit -
Inspection Replace the ECU.

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 TROUBLESHOOTING

P060D : CAN accelerator P062D : Injector drive bank 1

Vehicle side code : 91-4 Vehicle side code : 651-8
Faulty part ECU communication circuit Faulty part ECU
The ECU detects a fault of accelerator The ECU detects the short circuit of the
Detail
Detail opening (APPREQ) receiving from injector drive circuit inside the ECU.
CAN.
Recovery *
Recovery *
Control Engine stop
The ECU uses the analog signal for
Power limit -
Control backup control. The ECU warns to the
operator. Inspection Replace the ECU.
Power limit -
P062E : Injector drive bank 2
Inspection CAN communication circuit Vehicle side code : 653-8

P060E : APPREQ message time out Faulty part ECU

Vehicle side code : 1674-4 The ECU detects the short circuit of the
Detail
injector drive circuit inside the ECU.
Faulty part ECU communication circuit
Recovery *
The ECU cannot receive the accelerator
Detail
opening (APPREQ) signal. Control Engine stop
Recovery * Power limit -
The ECU uses the analog signal for Inspection Replace the ECU.
Control backup control. The ECU warns to the
operator. P062F : EEPROM
Power limit - Vehicle side code : 1235-2

Inspection CAN communication circuit Faulty part ECU

The ECU detects a read-write error of
P061C : Engine speed Detail the data memory bank inside the ECU.
Vehicle side code : 2005-1 The ECU cannot read the data.
Faulty part ECU Recovery *
The ECU is faulty. The engine speed Control The ECU warns to the operator.
Detail
data is faulty.
Power limit -
Recovery occurs. It recovers automati-
cally if an error occurs three times in Inspection Replace the ECU.
Recovery two seconds. The engine stops if an
error occurs four times or more in two
seconds. Vehicle side code : 1235-4
Control The ECU warns to the operator. Faulty part ECU
Power limit - The ECU detects a read-write error of
the data memory bank inside the ECU.
Inspection Replace the ECU. Detail
The ECU cannot write to the data mem-
ory.
Recovery *
Control The ECU warns to the operator.
Power limit -
Inspection Replace the ECU.

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TROUBLESHOOTING

P2047 : Injector drive bank 1

Vehicle side code : 1235-8 Vehicle side code : 652-4
Faulty part ECU Faulty part ECU
The ECU detects a read-write error of The ECU detects an open circuit of the
Detail
Detail the data memory bank inside the ECU. injector drive circuit inside the ECU.
The ECU is using the substitute data.
Recovery *
Recovery *
Control Engine stop
Control The ECU warns to the operator.
Power limit -
Power limit -
Inspection Replace the ECU.
Inspection Replace the ECU.
P2048 : Injector drive bank 1
P0933 : Oil pressure switch Vehicle side code : 651-2
Vehicle side code : 19-8
Faulty part ECU
Faulty part Oil pressure switch
The ECU detects a short circuit of the
Detail
The oil pressure switch remains OFF injector drive circuit inside the ECU.
Detail position even the engine speed reaches
Recovery *
500min-1.
Control Engine stop
Recovery *
Power limit -
Control The ECU keeps the engine low idling.
Inspection Replace the ECU.
Power limit -
Oil pressure switch, and wiring of oil P2049 : Injector drive bank 1
Inspection
pressure switch. Vehicle side code : 651-1
Faulty part ECU
Vehicle side code : 100-8 The ECU detects a short circuit of the
Detail
injector drive circuit inside the ECU.
Faulty part Oil pressure switch
Recovery *
The oil pressure switch remains OFF
position for 30 second after engine start- Control Engine stop
Detail
ing. The oil pressure switch remains
Power limit -
OFF position during engine operation.
Inspection Replace the ECU.
Recovery *
Control Engine stop P2050 : Injector drive bank 2
Power limit - Vehicle side code : 654-4

Oil pressure switch, and wiring of oil Faulty part ECU

Inspection
pressure switch. The ECU detects an open circuit of the
Detail
injector drive circuit inside the ECU.
Recovery *
Control Engine stop
Power limit -
Inspection Replace the ECU.

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 TROUBLESHOOTING

P2051 : Injector drive bank 2 P2229 : Atmospheric pressure sensor

Vehicle side code : 653-2 Vehicle side code : 108-1
Faulty part ECU Faulty part ECU
The ECU detects a short circuit of the The ECU detects a faulty operation of
Detail
injector drive circuit inside the ECU. the atmospheric pressure sensor (open
Detail circuit, short circuit, characteristic
Recovery *
fault). The input voltage exceeds the
Control Engine stop limiting value.

Power limit - Recovery *

Inspection Replace the ECU. The ECU controls the engine fixing the
Control
value to the backup data.
P2052 : Injector drive bank 2 Power limit The maximum power is limited to 75%.
Vehicle side code : 653-1
Inspection Replace the ECU.
Faulty part ECU
The ECU detects a short circuit of the
Detail
injector drive circuit inside the ECU.
Recovery *
Control Engine stop
Power limit -
Inspection Replace the ECU.

P2228 : Atmospheric pressure sensor

Vehicle side code : 108-2
Faulty part ECU
The ECU detects a faulty operation of
the atmospheric pressure sensor (open
Detail circuit, short circuit, characteristic
fault). The input voltage falls below the
limiting value.
Recovery *
The ECU controls the engine fixing the
Control
value to the backup data.
Power limit The maximum power is limited to 75%.
Inspection Replace the ECU.

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TROUBLESHOOTING

5.2 Related diagnosis code

There are diagnosis codes which are caused by other diagnosis codes, for example, the diagnosis code generated by the fault of
the common rail causes the diagnosis code related to the DBV (pressure limiting valve). These codes can be recovered by
eliminating the fault of the causal diagnosis code.
Causal diagnosis code in the following table must be checked when Related diagnosis code is generated.
Related diagnosis code can be recovered by eliminating the fault of Causal diagnosis code.
Also Related diagnosis code B can be generated by Related diagnosis code A. In this case, Causal diagnosis code and Related
diagnosis code A must be checked.

Table 14-2 Related diagnosis code (1 / 2)

Causal diagnosis Related diagnosis Related diagnosis
Cause A Cause B Remark
code code A code B
There is an open cir-
cuit on the MPROP.
P0089 The MPROP is fully
Vehicle side code : opened and the com-
- - -
P0252 2041-1 mon rail receives
Vehicle side code : DBV opening excessive pressure.
2000-4 The DBV will be
MPROP open circuit opened.
P0089 P0090
The ECU clears P0089
Vehicle side code : MPROP was fully Vehicle side code : The DBV does not
when P0090 is gener-
2042-2 opened for 2 seconds. 2043-4 open.
ated.
DBV kick off DBV closed sticking
There is an overload
on the MPROP. The
P0089 MPROP is fully
Vehicle side code : opened and the com-
- - -
P0252 2041-1 mon rail receives
Vehicle side code : DBV opening excessive pressure.
2000-8 The DBV will be
MPROP overload opened.
P0089 P0090
The ECU clears P0089
Vehicle side code : MPROP was fully Vehicle side code : The DBV does not
when P0090 is gener-
2042-2 opened for 2 seconds. 2043-4 open.
ated.
DBV kick off DBV closed sticking
There is a short circuit
on the MPROP. The
P0089 MPROP is fully
Vehicle side code : opened and the com-
P0230 - - -
2041-1 mon rail receives
Vehicle side code : DBV opening excessive pressure.
2001-1 The DBV will be
MPROP power stage opened.
short circuit to battery
P0089 P0090
The ECU clears P0089
Vehicle side code : MPROP was fully Vehicle side code : The DBV does not
when P0090 is gener-
2042-2 opened for 2 seconds. 2043-4 open.
ated.
DBV kick off DBV closed sticking
The pressure in the
P0089 common rail keeps The ECU clears
Vehicle side code : exceeding the limiting P0089(2042-2) when
- -
P0089 2041-1 value, the engine P0089(2041-1) is gen-
Vehicle side code : DBV opening operation switches to erated.
2042-2 the limp home mode.
DBV kick off P0090
The ECU clears P0089
Vehicle side code : The DBV does not
- - when P0090 is gener-
2043-4 open.
ated.
DBV closed sticking

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 TROUBLESHOOTING

Table 14-2 Related diagnosis code (2 / 2)

Causal diagnosis Related diagnosis Related diagnosis
Cause A Cause B Remark
code code A code B
The pressure in the
P0089 common rail keeps
Vehicle side code : exceeding the limiting
P0191 - - -
2041-1 value, the engine
Vehicle side code : DBV opening operation switches to
2015-1 the limp home mode.
Rail pressure gover-
nor deviation P0089 P0090
The ECU clears P0089
Vehicle side code : MPROP was fully Vehicle side code : The DBV does not
when P0090 is gener-
2042-2 opened for 2 seconds. 2043-4 open.
ated.
DBV kick off DBV closed sticking
The pressure in the
P0089 common rail keeps
If DBV does not open,
Vehicle side code : exceeding the limiting
- - the ECU generates
P0194 2041-1 value, the engine
P0090, not 0089.
Vehicle side code : DBV opening operation switches to
2017-1 the limp home mode.
Rail pressure governor P0089 P0090
The ECU clears P0089
Vehicle side code : MPROP was fully Vehicle side code : The DBV does not
when P0090 is gener-
2042-2 opened for 2 seconds. 2043-4 open.
ated.
DBV kick off DBV closed sticking
An error is detected
by SRC. The ECU
cannot control the
P0192 P0089 engine by feedback
In this case, P0192 and
Vehicle side code : Vehicle side code : from the common rail
- - P0089 are generated at
2011-2 2041-1 pressure sensor. The
the same time.
Rail pressure SRC DBV opening DBV will be opened.
The ECU controls the
engine using backup
data.
An error is detected
by SRC. The ECU
cannot control the
P0193 P0089 engine by feedback
In this case, P0192 and
Vehicle side code : Vehicle side code : from the common rail
- - P0089 are generated at
2011-1 2041-1 pressure sensor. The
the same time.
Rail pressure SRC DBV opening DBV will be opened.
The ECU controls the
engine using backup
data.
After the ECU deter-
P0091 mined that DBV has
Vehicle side code : been opened, the
P0091 is not gener-
2045-2 common rail pressure - -
ated separately.
DBV pressure is too exceeds the limiting
P0089 high value during backup
Vehicle side code : operation.
2041-1 After the ECU deter-
DBV opening P0092 mined that DBV has
Vehicle side code : been opened, the
P0092 is not gener-
2044-1 common rail pressure - -
ated separately.
DBV pressure is too exceeds the limiting
high value during backup
operation.

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TROUBLESHOOTING

P0089 : DBV valve opening P0092 : DBV pressure is too high.

Vehicle side code : 2041-1 Vehicle side code : 2044-1
Faulty part DBV Faulty part DBV
Detail The DBV is opening. The DBV pressure is abnormal. (too
Detail
high)
Recovery *
Recovery *
Accelerator opening ratio is fixed to
Control
12%. Control Engine stop
Power limit - Power limit -
Inspection Contact a Mitsubishi dealer. Inspection Contact a Mitsubishi dealer.

P0089 : DBV kick off P0191 : Rail pressure governor deviation

Vehicle side code : 2042-2 Vehicle side code : 2015-1
Faulty part DBV Faulty part Common rail
Pressure shock requested The rail pressure control is abnormal.
Detail Detail
to apply limp home mode. The pressure exceeds the target value.
Recovery * Recovery *
Accelerator opening ratio is fixed to Accelerator opening ratio is fixed to
Control Control
12%. 12%.
Power limit - Power limit -
Inspection Contact a Mitsubishi dealer. Inspection Damage on the common rail.

P0090 : DBV closed sticking P0192 : Rail pressure sensor SRC (Signal Range
Vehicle side code : 2043-4 Check)
Faulty part DBV Vehicle side code : 2011-2

The DBV does not open. Closed stick- Faulty part Rail pressure sensor
Detail
ing. The ECU detects an open or short circuit
Recovery * of rail pressure sensor and/or sensor har-
Detail
ness. The input voltage falls below the
Control Engine stop limiting value.
Power limit - Recovery *
Inspection Contact a Mitsubishi dealer. Accelerator opening ratio is fixed to
Control
12%.
P0091 : DBV pressure is too low
Power limit -
Vehicle side code : 2045-2
Rail pressure sensor, and wiring of rail
Faulty part DBV Inspection
pressure sensor.
The DBV pressure is abnormal. (too
Detail
low)
Recovery *
Control Engine stop
Power limit -
Inspection Contact a Mitsubishi dealer.

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 TROUBLESHOOTING

P0193 : Rail pressure sensor SRC (Signal Range P0252 : MPROP power stage overload
Check) Vehicle side code : 2000-8
Vehicle side code : 2011-1 Faulty part MPROP
Faulty part Rail pressure sensor The ECU detects an overload of
Detail
The input voltage exceeds the limiting MPROP and/or MPROP harness.
Detail
value. Recovery *
Recovery * Accelerator opening ratio is fixed to
Control
Accelerator opening ratio is fixed to 12%.
Control
12%. Power limit -
Power limit - Inspection MPROP, and wiring of MPROP.
Rail pressure sensor, and wiring of rail
Inspection
pressure sensor.

P0194 : Rail pressure governor

Vehicle side code : 2017-1
Faulty part Common rail
The rail pressure exceeds the limiting
Detail
value.
Recovery *
Accelerator opening ratio is fixed to
Control
12%.
Power limit -
Inspection Damage on the common rail.

P0230 : MPROP power stage short-circuit to battery

Vehicle side code : 2001-1
Faulty part MPROP
The ECU detects a short circuit on the
Detail
battery line of the MPROP harness.
Recovery *
Accelerator opening ratio is fixed to
Control
12%.
Power limit -
Inspection MPROP, and wiring of MPROP.

P0252 : MPROP power stage open circuit

Vehicle side code : 2000-4
Faulty part MPROP
The ECU detects an open circuit of the
Detail
MPROP and/or MPROP harness.
Recovery *
Accelerator opening ratio is fixed to
Control
12%.
Power limit -
Inspection MPROP, and wiring of MPROP.

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6. Inspecting sensors
6.1 Speed/timing sensor (crank, cam)
Measure the resistance between terminal A - B.
Standard value : 860±86Ω
If measured value is out of standard, replace the sensor with
a new one.
C B A

Speed/timing sensor
(crank, cam)
6.2 Inlet manifold pressure sensor
With applying pressure using an air compressor, measure
the voltage between terminal B - C.
Standard value
C A
• at 0 MPa {0 kgf/cm²} : 0.5V
• at 0.34 MPa {3.5 kgf/cm²} : 4.5V
If measured value is out of standard, replace the sensor with
a new one. B

Air compressor

Inspecting inlet manifold pressure sensor (1)

0.5
Air pressure MPa

0.4
0.3
0.2
0.1
0

0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5

Output voltage Vdc

Inspecting inlet manifold pressure sensor (2)

6.3 Water temperature sensor
Put the water temperature sensor to the container filled with
water, measure the output resistance between terminal 1 - 2.
Standard value
• 20°C : 2.38 ～ 2.63kΩ
• 80°C : 0.30 ～ 0.36kΩ
If the sensor is an open circuit, its resistance is infinity. If
measured value is out of standard, replace the sensor with a
new one. 1 2

Inspecting water temperature sensor

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 TROUBLESHOOTING

6.4 Engine oil pressure switch

Apply 50±10 kPa {0.5±0.1 kgf/cm²} [7.11±1.42 psi]
pressure to the sensor using an air compressor.
Check that the micro switch is in ON position. Air compressor
If the switch is not operate, replace the engine oil pressure 50 ± 10 kPa
switch with a new one. {0.5 ± 0.1 kgf/cm²}
[7.11 ± 1.42 psi]
On-Off differences
30 kPa
{0.3 kgf/cm²}
[4.27 psi]

Inspecting oil pressure switch

6.5 Common rail pressure sensor
Apply 5V between terminal A - C, and measure the voltage
at terminal B.
Standard value : Approx. 0.5V
If measured value is out of standard, replace the common
A B C
rail with a new one.

Inspecting common rail pressure sensor

6.6 Injector solenoid
Measure the resistance between terminal 1 - 2.
Standard（at 20 to 70°C [68 to 158 °F]）: 0.215 to 0.295 Ω
If measured value is out of standard, replace the injector
with a new one.

2 1

Inspecting injector solenoid

6.7 High pressure pump solenoid sensor
(MPROP)
Measure the resistance between terminal 1 - 2.
Standard （at 20°C [68 °F]）: 2.6 to 3.15 Ω
If measured value is out of standard, replace the fuel pump
with a new one.

2 1

Inspecting high pressure pump solenoid sensor

(MPROP)

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TROUBLESHOOTING

7. Inspecting wiring
7.1 Inspecting connector and harness
When the ECU generates the diagnosis code for the sensors,
the ECU and the relays, check the wiring that connects these
parts.
The looseness of the harness connection and/or poor
connection of connector may cause the electrical faults. In
these cases, reconnecting the connector and/or the repairing
the harness deletes the fault. Inspect the wiring connecting
to the sensor which causes diagnosis code.

7.1.1 Inspecting the intermittent fault

Wiggle the harness and connector in order to reproduce the Inspecting intermittent fault
intermittent fault.
If the diagnosis code is generated, reset the ECU and repeat
the above procedure. If the intermittent fault exists, replace
the connector and harness.
Ensure locking
7.1.2 Inspecting connectors
(1) Disconnect the connector and inspect the connector for
moisture and wear.
(2) Inspect that the terminals are correctly located in the
connector. Inspect that the terminals are not lost.
Inspect that the terminals does not rattle.
(3) Inspect that the locking wedge works correctly. Inspecting connector

7.1.3 Inspecting harness

(1) Inspect harness visually for wear, nicks and cuts.
Especially the part which is exposed to the engine must
be inspected. Nick
(2) Inspect the harness for pinch point caused by cramp.

7.1.4 Inspect open circuit and short circuit

(1) Remove the connector from either end of the harness. Pinch point
Measure the resistance between both ends of the
harness using tester. If measured value is between 0.1～
0.3 Ω, it is normal. If measured value is not in this Inspecting harness
range, it is an open circuit.
(2) Remove the connector from either end of the harness.
Measure the resistance between all terminals in the
connector. If measured value is 100kΩ or more, it is
normal. If measured value is 100kΩ or less, it is a short
circuit.

Inspecting open circuit and short circuit

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 TROUBLESHOOTING

7.2 Pin location of the ECU connector and extension harness connector
The wirings of the sensors, the injectors and the fuel pump are connected to the ECU through the extension harness connector.
Inspect the pin of the ECU connector and extension harness connector when inspecting the wiring of the sensors, the injectors
and the fuel pump.

ECU terminal A ECU terminal K

46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94
5 6
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
3 4
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

1‫ޓ‬Injector 3, + 1‫ޓ‬ECU power supply, +㧔1㧕

2‫ޓ‬Injector 2, + 2‫ޓ‬ECU ground, -㧔1㧕
7‫ޓ‬Speed/timing sensor (crankshaft side), shield 3‫ޓ‬ECU power supply, +㧔2㧕
8‫ޓ‬Rail pressure sensor, ground 4‫ޓ‬ECU ground, -㧔2㧕
10‫ޓ‬Speed/timing sensor (camshaft side) 5‫ޓ‬ECU power supply, +㧔3㧕
12‫ޓ‬Speed/timing sensor (crankshaft side) 6‫ޓ‬ECU ground, -㧔3㧕
14‫ޓ‬Inlet manifold pressure sensor, power supply 9‫ޓ‬Accelerator㧔1㧕
15‫ޓ‬Heater relay 12‫ޓ‬PTO accelerator, ground
16‫ޓ‬Injector 1, 23‫ޓ‬PTO accelerator, power supply
17‫ޓ‬Injector 4, 25‫ޓ‬K-LINE
19‫ޓ‬MPROP, + 28‫ޓ‬Ignition switch
20‫ޓ‬Speed/timing sensor (camshaft side), shield 36‫ޓ‬PTO accelerator
23‫ޓ‬Inlet manifold pressure sensor, ground 41‫ޓ‬Signal, ground
24‫ޓ‬Heater relay, power supply 54‫ޓ‬Oil pressure switch
26‫ޓ‬Rail pressure sensor, power supply 61‫ޓ‬CAN-L1
27‫ޓ‬Speed/timing sensor (crankshaft side) 62‫ޓ‬CAN-H1
31‫ޓ‬Injector 2, - 72‫ޓ‬Main relay
33‫ޓ‬Injector 4, - 73‫ޓ‬24V power supply
40‫ޓ‬Inlet manifold pressure sensor
41‫ޓ‬Water temperature sensor, ground
43‫ޓ‬Rail pressure sensor
46‫ޓ‬Injector 3, -
47‫ޓ‬Injector 1, -
49‫ޓ‬MPROP, - Point of view
50‫ޓ‬Speed/timing sensor (camshaft side)
58‫ޓ‬Water temperature sensor

Pin location of ECU connector

14-37
TROUBLESHOOTING

Extension harness connector, 16 terminals Extension harness connector, 12 terminals

4 3 2 1
4 3 2 1
8 7 6 5
8 7 6 5
12 11 10 9
12 11 10 9
16 15 14 13

1ࠉSpeed/timing sensor (camshaft side), power supply 1ࠉInjector 1, +

2ࠉSpeed/timing sensor (camshaft side) 2ࠉInjector 1, -
3ࠉSpeed/timing sensor (camshaft side), shieldࠉ 3ࠉInjector 4, +
5ࠉSpeed/timing sensor (crankshaft side), power supply 4ࠉInjector 4, -
6ࠉSpeed/timing sensor (crankshaft side) 5ࠉInjector 3, +
7ࠉSpeed/timing sensor (crankshaft side), shield 6ࠉInjector 3, -
8ࠉMPROP, - 7ࠉInjector 2, +
9ࠉRail pressure sensor, power supply 8ࠉInjector 2, -
10ࠉRail pressure sensor 9ࠉWater temperature sensor
11ࠉRail pressure sensor, ground 10ࠉWater temperature sensor, ground
12ࠉMPROP, + 11ࠉOil pressure switch
13ࠉInlet manifold pressure sensor, power supply 12ࠉOil pressure switch
14ࠉInlet manifold pressure sensorࠉ
16ࠉInlet manifold pressure sensor, ground

Point of view for 16 terminals Connector location Point of view for 12 terminals

Pin location of extension harness connector

14-38