SERVICE MANUAL

Hydraulic Excavator
SK350-9
Tier 4

S5LC0026E03
APPLICABLE:
KOBELCO CONSTRUCTION MACHINERY AMERICA, LLC. English
245 E NORTH AVENUE Part Number S5LC0026E03 Issued July 2011 SK350-9 . . . . . . . . . . . . . YC12U2400 and higher ~
CAROL STREAM, IL 60188 U.S.A. Printed in U.S.A. • Rac 1st Edition
 HYDRAULIC EXCAVATOR

MAINTENANCE SPECIFICATIONS
SHOP
MANUAL model SK350-9

INDEX
1 SPECIFICATIONS SECTION

SYSTEM
2 MAINTENANCE SECTION
3 SYSTEM SECTION
4 DISASSEMBLY SECTION

DISASSEMBLING
5 TROUBLESHOOTING
6 ENGINE SECTION

E / G TROUBLESHOOTING
7 PROCEDURE OF INSTALLING
OPTIONS SECTION
OPT.

Book Code No.S5LC0026E03

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 the Manufacturer.
authorized Distributor for a replacement.
(5) While operating the machine, be sure to perform
If you have any questions, please consult an autho-
the work with great care, to prevent damage to the
rized Distributor. machine and prevent accidents.
(1) Most accidents that occur during operation are due (6) Continue studying the manual until all Safety, Oper-
to neglect of precautionary measures and safety ation and Maintenance procedures are completely
rules. Sufficient care should be taken to avoid these understood by all persons working with the ma-
accidents. Erroneous operation, lubrication or chine.
maintenance services are very dangerous and may
cause injury or death to 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 the following signal words “DANGER”, “WARN-
ING” 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

Do not operate this machine unless you have

read and understand the instructions in the OP-
The proper and safe lubrication and maintenance
ERATOR’S MANUAL. Improper machine opera-
for this machine, recommended by Manufacturer,
tion is dangerous and could result in injury or
are outlined in the OPERATOR’S MANUAL for the
death.
machine.
Improper performance of lubrication or mainte- (6) Relieve all pressure in air, oil or water systems be-
nance procedures are dangerous and could result fore any lines, fittings or related items are discon-
in injury or death. Read and understand the MANU- nected or removed. Always make sure all raised
AL before performing any lubrication or mainte- components are blocked correctly and be alert for
nance. possible pressure when disconnecting any device
from a system that utilizes pressure.
The serviceman or mechanic may be unfamiliar with
many of the systems on this machine. This makes it (7) Lower the bucket, dozer, or other attachments to
important to use caution when performing service work. the ground before performing any work on the ma-
A knowledge of the system and or components is im- chine. If this cannot be done, make sure the bucket,
portant before the removal or disassembly of any com- dozer, ripper or other attachment is blocked correct-
ponent. ly to prevent it from dropping unexpectedly.

Because of the size of some of the machine compo- (8) Use steps and grab handles when mounting or dis-
nents, the serviceman or mechanic should check the mounting a machine. Clean any mud or debris from
weights noted in this manual. Use proper lifting proce- steps, walkways or work platforms before using. Al-
dures when removing any components. Weight of com- ways face the machine when using steps, ladders
ponents table is shown in the section “Specifications.” and walkways. When it is not possible to use the
designed access system, provide ladders, scaf-
The following is a list of basic precautions that must al-
folds, or work platforms to perform safe repair oper-
ways be observed.
ations.
(1) Read and understand all Warning plates and de-
(9) To avoid back injury, use a hoist when lifting com-
cals on the machine before Operating, Maintaining
ponents which weigh 20kg (45lbs) or more. Make
or Repairing this machine.
sure all chains, hooks, slings, etc., are in good con-
(2) Always wear protective glasses and protective
dition and are the correct capacity. Be sure hooks
shoes when working around machines. In particu-
are positioned correctly. Lifting eyes are not to be
lar, wear protective glasses when using hammers,
side loaded during a lifting operation.
punches or drifts on any part of the machine or at-
(10)To avoid burns, be alert for hot parts on machines
tachments. Use welders gloves, hood/goggles,
which have just been stopped and hot fluids in
apron and the protective clothing appropriate to the
lines, tubes and compartments.
welding job being performed. Do not wear loose fit-
ting or torn clothing. Remove all rings from fingers, (11)Be careful when removing cover plates. Gradually
loose jewelry, and confine long hair and loose cloth- back off the last two capscrews or nuts located at
ing before working on this machinery. opposite ends of the cover or device and carefully
pry cover loose to relieve any spring or other pres-
(3) Disconnect the battery and hang a “Do Not Oper-
sure, before removing the last two capscrews or
ate” tag in the Operators Compartment. Remove ig-
nuts completely.
nition keys.
(12)Be careful when removing filler caps, breathers and
(4) If possible, make all repairs with the machine
plugs on the machine. Hold a rag over the cap or
parked on a firm level surface. Block the machine
plug to prevent being sprayed or splashed by liq-
so it does not roll while working on or under the ma-
uids under pressure. The danger is even greater if
chine. Hang a “Do Not Operate” tag in the Opera-
the machine has just been stopped because fluids
tors Compartment.
can be hot.
(5) Do not work on any machine that is supported only
(13)Always use the proper tools that are in good condi-
by lift, jacks or a hoist. Always use blocks or jack
tion and are suited for the job at hand. Be sure you
stands, capable of supporting the machine, before
performing any disassembly.

0-3
 understand how to use them before performing any been damaged or altered should be checked for
service work. balance before reusing.
(14)Reinstall all fasteners with the same part number. (22)Be careful when servicing or separating the tracks
Do not use a lesser quality fastener if replacements (crawlers). Chips can fly when removing or install-
are necessary. ing a track (crawlers) pin. Wear safety glasses and
(15)Repairs which require welding should be per- long sleeve protective clothing. Tracks (crawlers)
formed only with the benefit of the appropriate ref- can unroll very quickly when separated. Keep away
erence information and by personnel adequately from front and rear of machine. The machine can
trained and knowledgeable in welding procedures. move unexpectedly when both tracks (crawlers)
Determine type of metal being welded and select are disengaged from the sprockets. Block the ma-
the correct welding procedure and electrodes, rods chine to prevent it from moving.
or wire to provide a weld metal strength equivalent
at 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 or 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 the event of a line, tube or
seal failure must be installed correctly.
(21)Do not operate a machine if any rotating part is
damaged or contacts any other part during opera-
tion. Any high speed rotating component that has

0-4
NA INDEX SK350LC-9
Book Code No. Title Index
1
Distribution Year–Month No. 33 25
S5YN0129E01 1

MAINTENANCE SPECIFICATIONS
2010-09 OUTLINE
S5LC0226E01 2
2010-09 SPECIFICATIONS
S5LC0325E01 3
ATTACHMENT DIMENSIONS
2010-09 34 2
S5LC1123E01 11
2010-09
TOOLS
S5LC1226E01 STANDARD MAINTENANCE 12
2010-09 TIME SCHEDULE
S5LC1325E03 MAINTENANCE STANDARD 13
2011-05 AND TEST PROCEDURE 3
51 11
S5LC2125E03 MECHATRO CONTROL 21
2011-05 SYSTEM
S5LC2226E02 22
2011-05 HYDRAULIC SYSTEM
S5LC2326E01 23
SYSTEM
2010-09 ELECTRIC SYSTEM
12
S5LC2426E01 24
2010-09 COMPONENTS SYSTEM
S5LC2525E01 25
2010-09 AIR-CONDITIONER SYSTEM

S5YN3129E01 DISASSEMBLING 31 21 13
DISASSEMBLING

2010-09 & ASSEMBLING

S5LC3226E01 32
2010-09 ATTACHMENT
S5LC3326E01 33
2010-09 UPPER STRUCTURE
S5LC3426E01
TRAVEL SYSTEM 34 46 22
2010-09
S5LC4625E01
E/G TROUBLESHOOTING

BY ERROR CODES 46
2010-09
S5LC4726E01 47
2010-09 BY TROUBLE

_ 23
47 31
_

S5LC5125E02 51
2011-05
ENGINE

_
32 24
_

YC APPLICABLE MACHINES

0-5
NOTE:
This Manual is prepared as a technical document This Manual may be properly revised due to the im-
where the information necessary for the maintenance provement of products, modification of specifications,
and repairing services of our hydraulic excavators are etc. There are cases where the system on an 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 specifications by each
shooting, Engine, and Installation Procedures for country. For the section in which the description is not
Optional Attachment. understood, contact our distributor.

• The Chapter “Specification” describes the specifi- A number is assigned to every part handled in this Man-
cations for the entire machine, and are instructive ual on account of the description, but the parts cannot
for replacement and repairing attachments. be supplied as service parts. Therefore, a parts order
must be placed with respective formal part numbers
• The Chapter “Maintenance” describes the docu-
from the Parts Manual for the applicable machine.
mentation, which is helpful for maintenance service
and adjustments for the entire machine.
• The Chapter “System” describes the operating sys-
tems: hydraulic system, electric system, compo-
nents, and so on.
• The Chapter “Disassembly” describes the removal
and installation of the assembly mounted on the up-
per structure and undercarriage, and the assembly
and disassembly of the associated hydraulic equip-
ment.
• The Chapter “Troubleshooting” describes how to
find the equipment fault.
• The Chapter “Engine” describes the use of the
“Maintenance Manual” provided by the engine sup-
plier.
• The Chapter “Installation Procedures for Optional
Attachment” describes the supplements added on
request as required.

0-6
 1. OUTLINE

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 Data of Issue Applicable Machines Remarks

S5YN0129E01
First edition September, 2010 SK350-9: YC
(NA)

1-2
 1. OUTLINE

1.1 GENERAL PRECAUTIONS FOR MAKING REPAIRS

1.1.1 PREPARATION BEFORE DISASSEMBLING 1

Read Operator's Manual

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 bringing the machines into the service shop. Bringing a soiled
machine into the service shop causes less efficient work and damage to parts.
(3) Inspecting machines
Confirm the disassembling section before starting the work, determine the disassembly procedure, taking the
conditions in work shop into account, and request to procure the necessary parts in advance.
(4) Recording
Record the following items and keep the documentation to prevent malfunction from reacurring.
1. Inspecting date and place.
2. Model name, serial number and records on the hour meter.
3. Trouble condition, place, and cause.
4. Visible oil leaks, water leaks and damage.
5. Clogging of filters, oil level, oil quality, oil contamination and loose fasteners.
6. Examine the problems on the basis of the monthly operation rate with the last inspection date and records on
the 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

WARNING

(1) Safety
1. Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves.
2. Attach a "Do Not Operate" tag on the control lever, and begin a meeting before starting the work.
3. Stop the engine before starting inspection and maintenance.
4. Confirm the position of the first-aid kit and fire extinguisher, and also where to make contact for emergencies.
5. Choose a hard, level and safe place to park the machine, and always put the attachment on the ground.
6. Use hoist, etc. to remove heavy parts that 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 securely supported with supports or
blocks.

1-3
1. OUTLINE

1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT

(1) Removing hydraulic equipment assemblies

1. Before removing tubes and hoses, release the pressure in the 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 and hoses into a pan to prevent the oil from spilling on the ground.
3. Plug or cap hoses, tubes, and fittings 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 the work 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. Place matching marks on parts for easier reassembling.
4. Before disassembling, read disassembling Instructions in advance, and determine if the disassembly and
assembly are permitted or not.
5. For parts that require the use jigs and tools, always use the specified jigs and tools.
6. For parts which cannot be removed in the specified procedure, never force the removal. Check for the cause
first.
7. The removed parts should be put in order and tagged so they can be installed correctly.
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 an 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. Ventilate the room during parts cleaning.
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-rings, back-up rings and oil seals with new ones, and apply oil on them before
assembling.
5. Remove dirt and water on the surfaces where liquid sealants are applied, and apply liquid sealant on them.
6. Remove rust preventives on new parts before assembling.
7. Use special tools to fit bearings, bushings and oil seals.
8. Assemble parts matching the marks made before disassembly.
9. After completion, check that there is no omission of parts.

1-4
 1. OUTLINE

(5) Installing hydraulic equipment

1. Confirm the correct hydraulic oil and lubrication oil.
2. Air pressure release is required in the following cases; 1
a. Hydraulic oil change
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 the hydraulic pump and swing motor, loosen the drain plug on the upper part, start engine, and
run at low idle, then bleed air until hydraulic oil comes out. When the hydraulic oil comes out, tighten plug
securely.
4. For air bleed of travel motors and hydraulic cylinders, start 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 the hydraulic oil check position, and check hydraulic oil level in the tank. Refill oil if the oil
level is lower than the specified level.
How to check oil level in the hydraulic oil tank

Important imformation
Important imformation
LEVEL GAUGE
LEVEL GAUGE
Oil level
Oil level of
of hydraulic
hydraulic oiloil
tank.
tank.
IfIf the
the indicator
indicator isis within
within
level marks,
level marks, the
the oil
oil quantity
quantity
isis acceptable.
acceptable.

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

For cylinders, don't move cylinders to the stroke end at the 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 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 to prevent splashing water on electrical equipment and connectors.
(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 loss of eyesight when adhering on eyes, and causes scald on
skin and clothes. When the fluid has adhered on body parts, 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 splashed 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 has been swallowed; drink milk or water.
-When it has adhered on clothes; Wash clothes immediately.

1-6
 1. OUTLINE

1.1.5 HYDRAULIC PARTS

(1) O-ring
• Check that O-ring is free from flaw and has elasticity before fitting.
• Even if the size of the 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 the proper O-ring.
• Fit O-rings without distortion and bend.
• Floating seals should be put in pairs.

(2) Flexible hose (F hose)

• Even if the connector and length of the 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 that 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 covers.

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 follow 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 when handling oil.
-When oil gets in your eyes ;
Wash your eyes with water until the stimulus is gone.
-When it has been swallowed ;
Don't force the individual to vomit, immediately get medical treatment.
-When it has adhered on skin ;
Wash with soap and water.
(4) Others
For spare parts, grease and oil, use KOBELCO genuine parts and lubricants.

1-7
1. OUTLINE

1.2 INTERNATIONAL UNIT SYSTEM

Introduction Base units

Table 1-1
Although this manual uses the SI units system. Outline of
Derived units
SI units system is described here. Supplemen of base units
Given hereinunder are an excerpt of the units that are SI units tary units Table 1-3
related to this manual : SI unit Table 1-2
system Derived units
1. Etymology of SI Units
Derived bearing peculiar
English : International System of units designations
units
2. Construction of SI Unit System Table 1-4

Prefixes of SI
(n-th power of 10, where n is an integer)
Table 1- 5

(1) Basic Units (4) Derived Units bearing Peculiar Designations

Table1-1 Table1-4
QUANTITIES DESIGNATION SIGN QUANTITY UNIT SYMBOL FORMULA
Length Meter m Frequency hertz Hz 1Hz=1/s
Mass Kilogram kg Force newton N kg • m/s 2
Time Second s Pressure and
pascal Pa N/m2
Current Ampere A Stress
Thermodynamic Kelvin K Energy, Work
temperature and Quantity of joule J N•m
Gram molecule Mol mol heat
Luminous intensity Candela cd Power watt W J/s
Quantity of
(2) Supplementary Units coulomb C A•s
electricity
Table1-2 Electric
QUANTITIES DESIGNATION SIGN potential
Plain angle Radian rad difference,
volt V W/A
Solid angle Steradian sr Voltage, and
Electromotive
(3) Derived Units of Basic Units force
Table1-3 Quantity of
static electricity
QUANTITIES DESIGNATION SIGN farad F C/V
and Electric
Area Square meter m2
capacitance
Volume Cubic meter m3
Electric
Velocity Meter per second m/s ohm V/A
resistance
Acceleration Meter per second / second m/s2
celcius
Density Kilogram per cubic meter kg/m3 Celcius
degree or C
° (t+273.15)K
temperature
degree
Illuminance lux lx l m/m2

1-8
 1. OUTLINE

(5) Prefixes of SI (6) Unit Conversion Table

Table1-5 Table1-6 1
PREFIX QUANTITIES JIS SI REMARKS
POWER
DESIGNATION SIGN Mass kg kg
Giga G 109 Force kgf N 1kgf=9.807N
Mega M 10 6 Torque kgf•m N•m 1kgf•m=9.807N•m
Kilo k 103 Pressure kgf/cm2 MPa 1kgf/cm2=0.098MPa
Hecto h 10 2 Motive power PS kW 1PS=0.7355kW
Deca da 10 Revolution r.p.m min–1 1r.p.m=1min–1
Deci d 10 –1

Centi c 10–2
Milli m 10–3
Micro μ 10–6
Nano n 10–9
Pico p 10–12

1-9
1. OUTLINE

1-10
 2. SPECIFICATIONS

2. SPECIFICATIONS
TABLE OF CONTENTS

2.1 NAME OF COMPONENTS ..................................................................................2-3

2.2 GENERAL DIMENSIONS ....................................................................................2-4
2.2.1 SK350-9 [6.50m (21ft-4in) Boom + 3.30m (10ft-10in) Standard Arm
+ 1.40m3 (1.83cu-yd) Bucket] ......................................................................2-4
2.3 WEIGHT OF COMPONENTS ..............................................................................2-5
2.4 TRANSPORTATION .............................................................................................2-7
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER ...........................2-7
2.4.2 DIMENSIONS OF ATTACHMENT ...............................................................2-8
2.5 SPECIFICATIONS AND PERFORMANCE ..........................................................2-9
2.5.1 SPEED AND CLIMBING CAPABILITY ........................................................2-9
2.5.2 ENGINE .......................................................................................................2-9
2.5.3 HYDRAULIC COMPONENTS .....................................................................2-9
2.5.4 WEIGHT .......................................................................................................2-9
2.6 TYPE OF CRAWLER ...........................................................................................2-10
2.6.1 SK350-9 .......................................................................................................2-10
2.7 COMBINATIONS OF ATTACHMENT ...................................................................2-12
2.8 ENGINE SPECIFICATION ...................................................................................2-13
2.8.1 SPECIFICATIONS .......................................................................................2-13
2.8.2 ENGINE CHARACTERISTIC CURVE (HINO J08E-UV) .............................2-14

Book Code No. S5LC0226E01

2-1
2. SPECIFICATIONS

Issue Data of Issue Applicable Machines Remarks

S5LC0226E01
First Edition September, 2010 SK350-9: YC
NA

2-2
 2. SPECIFICATIONS

2.1 NAME OF COMPONENTS

ARM

ARM CYLINDER

BOOM

BOOM CYLINDER
2

IDLER CAB
LINK BUCKET
CYLINDER SLEWING BEARING

SLEWING MOTOR
BUCKET
LINK
FUEL TANK

CONTROL VALVE
HYDRAULIC TANK

HYDRAULIC
PUMP

BUCKET
GUARD
MONITOR PANEL

SHOE

FRONT IDLER

IDLER ADJUST
ENGINE
UPPER ROLLER

AIR CLEANER
COUNTERWEIGHT

LOWER ROLLER
RADIATOR AND OIL COOLER
BATTERY
TRAVEL MOTOR

2-3
2. SPECIFICATIONS

2.2 GENERAL DIMENSIONS

2.2.1 SK350-9 [6.50m (21ft-4in) Boom + 3.30m (10ft-10in) Standard Arm + 1.40m3
(1.83cu-yd) Bucket]

(2")
50
R3
500
(11
'6")

11200 (36'9") 2980 (9'9")

3500 (11'6")
3420 (11'3")

3210 (10'6")

3210 (10'6")
2750 (9'0")
1190*
(1.18") (3'11")

(19.7")
500*
800
4960 (16'3") 30 (31.5") 3390 (11'2")
5980 (19'7")

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

2-4
 2. SPECIFICATIONS

2.3 WEIGHT OF COMPONENTS

Unit: kg (lb)

Item / Model SK350-9

Machine complete 36,600 (80,700)
1. Upper frame assy (Assembly of following :) 16,100 (35,500)
1.1 Upper frame 2,800 (6,170)
1.2 Counterweight 2
Counterweight (Semi-weighted) 8,800 (19,400)
1.3 Cab 480 (1,060)
1.4 Engine *705 (1,550)
1.5 Hydraulic oil tank *195 (430)
1.6 Fuel tank *220 (490)
1.7 Slewing motor (including reduction unit) *445 (980)
1.8 Control valve *240 (530)
1.9 Boom cylinder *270 (600) X 2
1.10 Pin (for mounting boom) 80 (180)
1.11 Pump *140 (310)
1.12 Radiator (including intercooler) *180 (400)
2. Lower frame assy (Assembly of following :) 13,100 (28,890)
2.1 Lower frame 4,200 (9,260)
2.2 Slewing bearing 555 (1,220)
2.3 Travel motor (including reduction unit) 400 (880) X 2
2.4 Upper roller 30 (70) X 4
2.5 Lower roller 60 (130) X 18
2.6 Front idler 180 (400) X 2
2.7 Idler adjuster 190 (420) X 2
2.8 Sprocket 75 (165) X 2
2.9 Swivel joint *25 (50)
2.10 Track guide 39 (86) X 2
2.11 Track link with 800mm (31.5in) shoes assy 2,610 (5,760) X 2
2.11.1 Track link assy 900 (1,990) X 2
3. Attachment (Assembly of following / STD :) 6,700 (14,770)
{6.50m(21ft-4in)Boom + 3.30m(10ft-10in)Arm+1.40m3(1.83cu-yd)Bucket}
3.1 Bucket assy (STD) 1,075 (2,370)
3.2 STD Arm assy (Assembly of following :) 2,000 (4,410)
3.2.1 STD Arm 1,270 (2,800)
3.2.2 Bucket cylinder *265 (580)
3.2.3 Idler link 30 (70) X 2
3.2.4 Bucket link 140 (310)
3.2.5 Pin (2pcs.for mounting bucket cylinder / 2pcs. for mounting bucket) 115 (250)
3.3 Boom assy (Assembly of following :) 3,600 (7,940)
3.3.1 Boom 2,650 (5,840)
3.3.2 Arm cylinder *505 (1,110)
3.3.3 Pin (Mounting arm • Mounting arm cylinder) 70 (150)

2-5
2. SPECIFICATIONS

Unit: kg (lb)

Item / Model SK350-9

4. Lubricant and water (Assembly of following :) 755 (1,660)
4.1 Hydraulic oil 215 (470)
4.2 Engine oil 25 (55)
4.3 Fuel 485 (1,070)
4.4 Water 30 (66)

Marks * show dry weight.

2-6
 2. SPECIFICATIONS

2.4 TRANSPORTATION

2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER

(1) 6.50m (21ft-4in) Boom+3.30m (10ft-10in) Arm+1.40m3 (1.83cu-yd) Bucket

Item/Model SK350-9
Width 800mm (31.5in) shoes 3,390 (11ft-2in)
2
Weight 36,600kg (80,700 lbs)

11200 (36'9") 2090 (6'10")

4095 (13'5")

(4.5")
77.5

600 1080(3'7")
(3.0")
75

(23.6")

2-7
2. SPECIFICATIONS

2.4.2 DIMENSIONS OF ATTACHMENT

(1) BOOM

Item / Type 6.50m (21ft-4in) Boom

Length X Height X Width 6.75 X 1.84 X 0.83
L X H X W: m (ft-in) (22'2" X 6'0" X 2'9")
Weight: kg (lbs) 3,290 (7,250)

H
L

(2) Arm

Item / Type 3.30 m (10ft-10in) Arm

Length X Height X Width 4.48 X 0.97 x 0.62
L X H X W: m (ft-in) (14'8" X 3'2" X 2'2")
Weight: kg (lbs) 1,830 (4,040)
H

2-8
 2. SPECIFICATIONS

2.5 SPECIFICATIONS AND PERFORMANCE

2.5.1 SPEED AND CLIMBING CAPABILITY

Item / Area & Model SK350-9

Swing speed 10.0 min-1 {10.0 rpm}
Travel speed (1-speed/2-speed) 3.3 / 5.6 km/h (2.05 / 3.5 mile/h)
Gradeability 70 % (35 degree)
2

2.5.2 ENGINE

Engine model HINO J08E-UV

Water-cooled, 4-cycle 6 cylinder direct injection type engine
Type
with intercooler turbo charger
Number of cylinders-BoreXStroke 6 -112 dia. mm X 130 mm(4.41 in X 5.12 in)
Total displacement 7.684 L (468.9 cu-in)
Rated output / Engine speed Net 213 kW (289 PS) / 2,100 min-1 (ISO 14396 : Without fan)
Maximum torque / Engine speed Net 1,017 N-m (750 lbf-ft)/ 1,600 min-1 (ISO 14396 : Without fan)
Starter 24 V / 5.0kW
Alternator 24 V / 60A

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

2.5.4 WEIGHT

Item / Model SK350-9

Fully equipped weight 36,700 (80,920)
Upper structure 16,100 (35,500)
Lower machinery 13,100 (28,890)
6.50m(21ft-4in) Boom+3.30m(10ft-10in)
6,700 (14,770)
Arm+1.40m3 (1.83cu-yd) Bucket

2-9
2. SPECIFICATIONS

2.6 TYPE OF CRAWLER

2.6.1 SK350-9

Overall width of crawler Ground pressure kPa

Shape Shoe width mm (in)
mm (ft-in) (psi)

Grouser shoe 600 (23.6) 3,190 (10'6") 67 (9.72)

700 (27.6) 3,290 (10'10") 58 (8.41)

800 (31.5) 3,390 (11'2") 52 (7.54)

48 LINKS

900 (35.4) 3,490 (11'5") 46 (6.67)

Use 600mm (23.6in) 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.)

2-10
 2. SPECIFICATIONS

2.7 COMBINATIONS OF ATTACHMENT

Bucket Available Arm

Heaped capacity Struck 3.3m (10ft-10in) Arm
Type
m3 (cu•yd) m3 (cu•yd) (STD)

— — —
1.40 (1.83) STD 1.00 (1.31) 2
Hoe bucket
— — —
— — —

Breaker — —
Nibbler — —

Standard combination
General operation : Excavation or loading of sand, gravel, and clay
Light operation : Mainly loading or loose gravel (e.g., cultivation or loading of sand or gravel)
Prohibited combination : There are problems from the view points of strength and stability.

• Use the attachments recommended by NEW HOLLAND KOBELCO.

The trouble due to the use in the condition "Use not allowed" described in the above table is not included in our
responsibility

If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to the arm and
bucket may occur.

2-11
2. SPECIFICATIONS

2.8 ENGINE SPECIFICATION

2.8.1 SPECIFICATIONS

Applicable machine SK350-9

Engine model HINO J08E-UV
Water-cooled, 4 cycle 6 cylinder direct injection type diesel engine with
Type
intercooler turbo-charger
Number of cylinder-Bore X Stroke 6 X 112mm (4.41 in) X 130mm (5.12 in)
Total displacement 7,684cc (469 cu-in)
Compression ratio 17.0
Rated out put Net 213 kW (289 PS) at 2,100 min-1 (ISO 14396 : Without fan)
Maximum torque Net 1,017 N-m (750 lbf-ft) at 1,600 min-1 (ISO 14396 : Without fan)
High idling 2,100 min-1
Low idling 1,000 min-1
Injection starting pressure 3.2 MPa (464 psi)
Thermostat action Start 350 K (170F degrees)/Full open 363 K (194F degrees)
Firing order 1-4-2-6-3-5
Compression pressure 3.4 MPa (493 psi) to 3.7 MPa (537 psi) at 280 min-1
Fuel injection timing Electron type
Valve clearance Open Close
14 deg. before top 30 deg. after bottom
Intake valve 0.3 mm at cool
Valve clearance dead point dead point
54 deg. before top 13 deg. after top
Exhaust valve 0.45 mm at cool
dead point dead point
Starter capacity 24 V X 5.0 kW
Generator capacity (Alternator) 24 V X 60 A
850 dia. (33.5 in) X suction type 6 fans, V-belt drive,
Cooling fan drive method
pulley ratio Crank / Fan= 0.80
Full level 26.0 L (6.87 gal)
Engine oil quantity Low level 20.0 L (5.28 gal)
Total 28.5 L (7.53 gal)
Dry weight kg ( lbs)
Fuel consumption ratio 210 g / kw-h (154 g / PS-h)
Allowable inclination Front / Rear and Right / Left : 35 degrees
1,314 mm X 941 mm X 1,112 mm
Dimension (L X W X H)
(4 ft 3.73 in X 37.1 in X 3 ft 7.8 in)
Rotating direction Counterclockwise seeing from flywheel side

2-12
 2. SPECIFICATIONS

2.8.2 ENGINE CHARACTERISTIC CURVE (HINO J08E-UV)

Condition to be measured: The net value is indicated, measuring with cooling fan.
marks show the rated point

(N.m)

SHAFT TORQUE
1000
2
900
(kW)
240 800

700

200
SHAFT OUTPUT

160

120

80

40

0
1000 1400 1800 2200 2600 3000
ENGINE SPEED (min-1)

Fuel consumption volume

Fuel consumption rate X kW X Load factor ( )
0.835 X 1000
210g/kW.h
X 213kW X
0.835 X 1000 : Standard load factor
. L/h (0.70~0.80)
53.6
Fuel consumption in regular operation
(load factor 0.70~0.80)
37.5 L/h~42.9 L/h

2-13
2. SPECIFICATIONS

2-14
 3. ATTACHMENT DIMENSIONS

3. ATTACHMENT DIMENSIONS
3
TABLE OF CONTENTS

3.1 BOOM .................................................................................................................. 3-3

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

Book Code No. S5LC0325E01

3-1
3. ATTACHMENT DIMENSIONS

Issue Data of Issue Applicable Machines Remarks

S5LC0325E01
First Edition September, 2010 SK350-9: YC
NA

3-2
 3. ATTACHMENT DIMENSIONS

3.1 BOOM

3.1.1 BOOM DIMENSIONAL DRAWING

d4
J

I
d3 K
d1

D C
H G B

E
3
F
K

A
J

d2

SECTION K-K
Boom Dimensional Drawing

STD
5.65M (18ft-6in) BOOM
LC02B00236F1
No. NAME DIMENSIONS: mm (ft-in)
A Boom length 6,500 (21'4")
B Boom foot width 826 (32.5")
C Boom end inner width 405.8 (16.0")
D Boom end outer width 577 (22.7")
E Height of boom cylinder rod pin 1,115 (3'8")
F Height of arm cylinder (head side) pin 1,460.8 (4'9.5")
G Distance between pins of boss R2,955 (9'8")
H Distance between pins of bracket R3,390.5 (11'1.5")
I Arm cylinder (head side) inner width 146 (5.75")
J Outer width of bracket on the boom cylinder (rod side) mounting 564 (22.2")
d1 Boom foot pin dia. 125 dia. (4.92")
d2 Boom cylinder (rod side) pin dia. 110 dia. (4.33")
d3 Pin dia. of boom end. 110 dia. (4.33")
d4 Arm cylinder (head side) pin dia. 110 dia. (4.33")

3-3
3. ATTACHMENT DIMENSIONS

3.1.2 BOOM MAINTENANCE STANDARD

(1) Clearance of pin and bushing on boom section

A
C

Clearance Of Pin And Bushing On Boom Section

Unit : mm (in)
Standard value Clearance
Sym- Bushing Repaira
Item Pin part No. Pin dia. Standard Service Remedy
bol Pin dia. i.d. ble
tolerance value limit
tolerance level
+ 0.020 + 0.226 + 0.246
ø 110 (+0.0008) (+0.0089) (+0.0097)
A Boom foot LC02B01373P1
(4.331) - 0.020 + 0.098 + 0.078
(-0.0008) (+0.0039) (+0.0031)
+ 0.222 + 0.262
0
Boom cylinder ø 100 - 0.040
(+0.087) (0.0103)
B LC02B01344P1
(Head side) (3.937) + 0.105 + 0.0105 More
(-0.0016) Replace
(+0.0041) (+0.0041) than 3.0
bushing
+ 0.230 + 0.250 2.5 (0.12)
or pin
Boom cylinder (+0.0091) (+0.0098) (0.10)
C LC02B01345P1
(Rod side) + 0.020 + 0.105 + 0.085
ø 110 (+0.0008) (+0.0041) (+0.0033)
(4.331) - 0.020 + 0.226 + 0.246
Arm cylinder (-0.0008) (+0.0089) (+0.0097)
D LC02B01337P1
(Head side) + 0.098 + 0.078
(+0.0039) (+0.00031)

3-4
 3. ATTACHMENT DIMENSIONS

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

D
D C

A
L3 L3' X3

B A

3
PL3
X1 L1
SECTION C-C
X4

L4 PL4
PL2 PL2

PL1

SECTION D-D SECTION A-A

X2 L2 L2 X2

SECTION B-B

Clearance In Thrust Direction On The Boom Cylinder Installation Section

Unit : mm (in)
Clearance X adjusted with shim
Basic size Pin length
(total of both sides)
Sec. Item Remedy
Standard Repairable Service
No. Size No. Length
value level limit
826
Boom
(32.5) 0.5 (0.02) 1.0 1.5 1,026
A-A Boom foot L1 PL1
832 or less (0.04) (0.06) (3'4.4")
Upper frame
(32.8)
130
Boom cylinder
Boom cylinder (5.12) 0.6~1.0 2.0 2.5 286
B-B L2 PL2
(Head side) 136 (0.02~0.04) (0.08) (0.10) (11.26)
Upper frame Shim
(5.35)
adjust
130
Boom cylinder L3 ment
Boom cylinder (5.12) 0.6~2.0 3.0 4.0 877
C-C PL3
(Rod side) 564 (0.02~0.08) (0.12) (0.16) (34.5)
Boom L3'
(22.2)
140
Arm cylinder
Arm cylinder (5.51) 0.6~1.0 2.0 2.5 309
D-D L4 PL4
(Head side) 146 (0.02~0.04) (0.08) (0.10) (12.2)
Boom
(5.75)

3-5
3. ATTACHMENT DIMENSIONS

3.2 ARM

3.2.1 ARM DIMENSIONAL DRAWING

VIEW J

SECTION X-X

SECTION Y-Y SECTION Z-Z

Arm Dimensional Drawing

3.30m (10ft-10in)
LC12B00330F1
ARM Unit : mm (ft-in)
Code NAME DIMENSION Code NAME DIMENSION
C Arm length 3,300 (10'10") N Bracket inner width 146 (5.75")
Distance between pins of boss
D R1,010 (3'4") O Bracket inner width 136 (5.35")
and bracket
D1 I.D of boss ø120 (4.72") P Idler link dimension 696 (27.4")
D2 I.D of boss ø95 (3.74") Q Bucket link dimension 686 (27.0")
Height between pins of boss and
D4 I.D of boss ø125 (4.92") R 44 (1.73")
center
Distance between pins of boss
E R2,429.5 (7'12") d1 Pin dia. ø90 (3.54")
and bracket
Distance between pins of boss
F R515 (20.3") d2 Pin dia. ø80 (3.15")
and boss
Height between pins of boss and
G 735.5 (29.0") d3 Pin dia. ø110 (4.33")
bracket
Height between pins of boss and
H 280 (11.0") d4 Pin dia. ø110 (4.33")
bracket
K Arm top end bushing width 380 (15.0") d5 Pin dia. ø90 (3.54")
L Arm link section boss width 390 (15.4")
M Boss width 400 (15.75")

3-6
 3. ATTACHMENT DIMENSIONS

3.2.2 ARM MAINTENANCE STANDARD

(1) Clearance of pin and bushing

E F
D, D'
B

3
C
G

Clearance Of Pin And Bushing On Arm Section

Unit : mm (in)
Standard dimensions Clearance
No. Item Pin part No. Pin dia. Bushing i.d. Standard Repairable Service Remedy
Pin dia.
tolerance tolerance value level limit
+0.272 +0.332
(+0.0107) (+0.0131)
A Arm point
–0.020 +0.095 +0.115
ø90 (-0.0008) (+0.0037) (+0.0045)
LC12B01657P2
(3.5433) –0.060 +0.217 +0.277
Bucket link (-0.0024) (+0.0085) (+0.0109)
B
(Bucket side) +0.071 +0.091
(+0.0028) (+0.0036)
+0.222 +0.262
Idler link
ø80 (+0.0087) (+0.0103)
C (Connected part LC12B01613P1
(3.1496) +0.079 +0.079
of arm) (+0.0031) (+0.0031)
0 +0.219 +0.259
Bucket link (0) (+0.0086) (+0.0102)
D
(Idler link side) –0.040 +0.034 +0.034
Replace
(-0.0016) (+0.0013) (+0.0013) 2.5 3.0
LC12B01614P1 bushing
+0.235 +0.275 (0.10) (0.01)
or pin
Bucket cylinder ø90 (+0.0093) (+0.0108)
D'
(Rod side) (3.5433) +0.074 +0.074
(+0.0029) (+0.0029)
+0.238 +0.258
Bucket cylinder (+0.0094) (+0.0102)
E LC12B01461P1
(Head side) +0.077 +0.057
(+0.0030) (+0.0022)
+0.020 +0.226 +0.246
Arm cylinder (+0.0008) (+0.0089) (+0.0097)
F LC02B01337P1
(Rod side) –0.020 +0.098 +0.078
ø110 (-0.0008) (+0.0039) (+0.0031)
(4.331) +0.200 +0.220
Arm foot
(+0.0079) (+0.0087)
G (Connected part LC12B01468P2
+0.099 +0.079
of boom)
(+0.0039) (+0.0031)

3-7
3. ATTACHMENT DIMENSIONS

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

E
D, D'
B
F
E
B C
D, D' F
A A

C G
G
L3
L1 X3
X1
X5

L5 PL5
X6 L6

PL1
SECTION E-E
PL3
SECTION A-A
SECTION C-C

L2 X4 L4
X2
PL6

SECTION F-F

PL2 X7 L7
X4' L4'
SECTION B-B PL4 PL7
SECTION D-D,D'-D' SECTION G-G

Clearance Of Arm And Cylinder Installing Sections In Thrust Direction

3-8
 3. ATTACHMENT DIMENSIONS

Unit : mm (in)
Clearance X adjusted with shim
Basic size Pin length
(total of both sides)
Sec. Item Remedy
Standard Repairable
No. Size Service limit No. Length
value level
380
Arm
(14.96) 1.0 (0.04) 2.0
A-A Arm point L1 PL1
381 or less (0.08)
Bucket
(15.10) 576
380 (22.7)
Link side
(14.96)
B-B Bucket link L2 — — PL2
382
Bucket
(15.04) 3
390 With in 2.5
Idler link Arm 1.0
C-C L3 (15.35) 0.5 (0.10) PL3
(Arm connection) (0.04)
Link side — (0.02)
Bucket link Rod side —
D-D (Idler link L4 390 505
Link side
connection) (15.35) (19.9)
0.6~1.0 2.0 Shim
130 PL4
Rod side (0.024~0.04) (0.08) adjust
Bucket link (5.12)
D’-D’ L4’ -ment
(Rod side) 136
Link side
(5.35)
130
Head side
Bucket cylinder (5.12) 299
E-E L5 PL5
(Head side) 136 (11.8)
Arm
(5.35) 0.6~2.0 3.0 4.0
140 (0.024~0.08) (0.12) (0.16)
Rod side
Arm cylinder (5.51) 309
F-F L6 PL6
(Rod side) 146 (12.2)
Arm
(5.75)
400
Arm With in
(15.75) 1.0 2.5 577
G-G Arm foot L7 0.5 PL7
405.8 (0.04) (0.10) (22.7)
Boom (0.02)
(15.98)

3-9
3. ATTACHMENT DIMENSIONS

3-10
 11. TOOLS

11. TOOLS
11
TABLE OF CONTENTS

11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS .............................. 11-3

11.2 SCREW SIZE ..................................................................................................... 11-5
11.2.1 CAPSCREW (BOLT) ................................................................................. 11-5
11.2.2 CAPSCREW (SOCKET BOLT) .................................................................. 11-5
11.2.3 SOCKET SET SCREW ............................................................................. 11-5
11.3 TIGHTENING TORQUE FOR HOSE AND FITTING ......................................... 11-6
11.3.1 JOINT (O-RING TYPE) ............................................................................. 11-6
11.3.2 HYDRAULIC HOSE (30 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 UPPER FRAME LIFTING JIG ............................................................................ 11-16
11.11 ENGINE MOUNTING PEDESTAL ..................................................................... 11-17

Book Code No. S5LC1123E01

11-1
11. TOOLS

Issue Data of Issue Applicable Machines Remarks

E385B: LC11-08501~ S5LC1123E01
First Edition March, 2009
E385BLC: YC11-04501~ NHK-RUS (HS Engine)
↑
E385B: LC11-08501~
↑ ↑ NHK-Mid.East & Afr.
E385BLC: YC11-04501~
(HS Engine)
↑
↑ September, 2010 E385CLC: YC
(NHK)
↑
↑ ↑ SK350-9: YC
NA

11-2
 11. TOOLS

11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS

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.

Unit : 1‡POEf‡ft)

COassification 4.8T 7T 10.9T
NoPLQDO size No OXEULFDWLRn OLO OXEUication No OXEULcation 2LO OXEULcation No OXEULFDWLRn OLO OXEULFDWLRn
4.4±0.5 3.7±0.4 9.6±1.0 8.1±0.8 17.4±1.8 14.7±1.5
M6 P=1
3.2±0.4) 2.7±0.3) 7.1±0.7) 6.0±0.6) 12.8±1.3) 0.8±1.1)
10.7±1.1 9.0±0.9 23.5±2.0 19.6±2.0 42.2±3.9 35.3±3.9
M8 P=1.25
.9±0.8) 6.6±0.7) 7.3±1.5) 14.5±1.5) 31.1±2.9) 6.0±2.9)
21.6±2.0 17.9±1.8 46.1±4.9 39.2±3.9 83.4±8.8 70.6±6.9 11
M10 P=1.5
15.9±1.4) 13.2±1.3) 34.0±3.6) 28.9±2.9) 61.5±6.5) 52.1±5.1)
36.3±3.9 31.4±2.9 79.4±7.8 66.7±6.9 143±15 121±12
M12 P=1.75
26.8±2.9) 23.2±2.1) 58.6±5.8) 49.2±5.1) 105±11) 89.2±8.9)
57.9±5.9 49.0±4.9 126±13 106±10 226±20 191±19
M14 P=2
42.7±4.4) 36.1±3.6) 92.9±9.6) 78.2±7.4) 167±15) 141±14)
88.3±8.8 74.5±6.9 191±20 161±16 343±39 284±29
M16 P=2
65.1±6.5) 55.0±5.1) 141±15) 119±12) 253±29) 209±21)
122±12 103±10 265±29 226±20 481±49 402±39
M18 P=2.5
90.0±8.9) 75.8±7.2) 195±21) 167±15) 355±36) 297±29)
172±17 144±14 373±39 314±29 667±69 559±59
M20 P=2.5
27±13) 106±10) 275±29) 232±21) 492±51) 412±44)
226±20 192±20 500±49 422±39 902±88 755±78
M22 P=2.5
67±15) 142±15) 369±36) 311±29) 665±65) 557±58)
294±29 235±29 637±69 520±49 1160±118 941±98
M24 P=3
217±21) 173±21) 470±51) 83±36) 856±87) 694±72)
431±39 353±39 941±98 765±78 1700±167 1370±137
M27 P=3
318±29) 260±29) 694±72) 64±58) 1250±123) 1010±101)
588±59 490±49 1285±127 1079±108 2300±235 1940±196
M30 P=3.5
34±44) 361±36) 948±94) 96±80) 700±173) 1430±145)
794±78 667±69 1726±177 1451±147 3110±314 2610±265
M33 P=3.5
586±58) 492±51) 1270±131) 1070±108) 2290±232) 1930±195)
1030±98 863±88 2226±226 1863±186 4010±402 3360±333
M36 P=4
60±72) 637±65) 1640±167) 1370±137) 2960±297) 2480±246)

Tightening Torque For Metric Coarse Threads (Not Plated)

11-3
11. TOOLS

Torque value Unit : 1‡POEf‡ft)

Classification 4.8T 7T 10.9T
NoPLQDO size No OXEULFDWLRn Oil OXErication No OXEULcation Oil OXEULcation No OXEULFDWLRn Oil OXEULFDWLRn
11.3±1.1 9.5±1.0 24.5±2.0 20.6±2.0 44.1±3.9 37.3±3.9
M8 P=1.0
“) 7.0±0.7) 18.1±1.5) 15.2±1.5) 32.5±2.9) 7.5±2.9)
22.6±2.0 18.7±1.9 48.1±4.9 41.2±3.9 87.3±8.8 73.5±6.9
M10 P=1.25
16.7±1.5) 13.8±1.4) 5.5±3.6) 30.3±2.9) 64.4±6.5) 4.2±5.1)
39.2±3.9 33.3±2.9 85.3±8.8 71.6±6.9 154±16 129±13
M12 P=1.25
28.9±2.9) 24.6±2.1) 2.9±6.5) 52.8±5.1) 114±12) 5.2±9.6)
92.2±8.8 77.5±7.8 196±20 169±17 363±39 304±29
M16 P=1.5
68.0±6.5) 57.2±5.8) 145±15) 125±13) 268±29) 224±21)
186±19 155±16 402±39 333±29 726±69 608±59
M20 P=1.5
137±14) 114±12) 297±29) 46±21) 535±51) 448±44)
314±29 265±29 686±69 569±59 1240±118 1030±98
M24 P=2
232±21) 195±21) 506±51) 420±44) 915±87) 760±72)
637±59 530±49 1390±137 1157±118 2500±255 2080±206
M30 P=2
470±44) 391±36) 1030±101) 853±87) 1840±188) 1530±152)
853±88 706±70 1860±186 1550±155 3350±334 2790±275
M33 P=2
629±65) 521±52) 1370±137) 1140±114) 2470±246) 2060±203)
1070±108 892±88 2330±226 1940±196 4200±422 3500±353
M36 P=3
789±80) 658±65) 1720±167) 1430±145) 3100±311) 2580±260)

Tightening Torques For Metric Fine Threads (Not Plated)

11-4
 11. TOOLS

11.2 SCREW SIZE

11.2.1 CAPSCREW (BOLT)

Nominal B mm Nominal B mm
screw size screw size
Tool size Tool size
(d) (d)
M6 10 M36 55
M8 13 M42 65 d
M10 17 M45 70
M12 19 M48 75
(M14) 22 M56 85
M16 24 (M60) 90 B
(M18) 27 M64 95
11
M20 30 (M68) 100
(M22) 32 M72 105
M24 36 M76 110
(M27) 41 M80 115
M30 46

11.2.2 CAPSCREW (SOCKET BOLT)

Nominal B mm Nominal B mm
screw size screw size
Tool size Tool size
(d) (d)
M6 10 M36 55
M8 13 M42 65 d
M10 17 M45 70
M12 19 M48 75
(M14) 22 M56 85
M16 24 (M60) 90 B
(M18) 27 M64 95
M20 30 (M68) 100
(M22) 32 M72 105
M24 36 M76 110
(M27) 41 M80 115

11.2.3 SOCKET SET SCREW

Nominal B mm Nominal B mm
screw size screw size d
Tool size Tool size
(d) (d)
M2.5 1.27 M8 4
M3 1.5 M10 5
M4 2 M12 6
M5 2.5 M16 8 B
M6 3 M20 10

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11. TOOLS

11.3 TIGHTENING TORQUE FOR HOSE AND FITTING

11.3.1 JOINT (O-RING TYPE)

Size Wrench Tightening torque

(PF) (mm) 1‡P (lbf‡ft)
1/8 14 17±2 (13±1.5)
1/4 19 36±2 (27±1.5)
3/8 22 74±5 (55±4)
1/2 27 108±9.8 (80.0±7)
3/4 36 162±9.8 (119±7)
1 41 255±9.8 (188±7)

11.3.2 HYDRAULIC HOSE (30 DEG. FLARE TYPE)

Size Tightening torque

Wrench(mm) UNION NUT
(PF) 1‡P (lbf‡ft)
1/8 17 15±2.0 (11±1.5)
1/4 19 29±4.9 (21±3.6)
3/8 22 49±4.9 (36±3.6)
1/2 27 78±4.9 (58±3.6)
3/4 36 118±9.8 (87±7.2)
1 41 137±15 (101±11)

11.3.3 JOINT (ORS TYPE)

Tightening Torque CONNECTOR O-RING FITTING

Unified screw size Opposing flats
1‡P (lbf‡ft)
1-14 UNS 30, 32 137±14 (101±10)
36 177±18 (131±13)
1 3 / 16-12 UN
41 206±21 (152±15)
41 206±21 (152±15)
1 7/ 16-12 UN
46 206±21 (152±15) NUT

11.3.4 SPLIT FLANGE

Tightening torque N‡m (lbf‡ft)

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

11-6
 11. TOOLS

11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES

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.

Working Tube size Opposing Tightening torque

pressure OD × thickness flats N‡m (lbf‡ft)
Manufacturer's name
MPa (psi) mm (in) (HEX)
mm
ø10×1.5
19 49.0±9.8 (36±7.2)
(0.394×0.059)
ø15×2.0
27 118±12 (87±8.7)
(0.591×0.079) 11
ø18×2.5
Nippon A.M.C. 29.4 (4270) 32 147±15 (110±11)
(0.709×0.098)
ø22×3.0
36 216±22 (160±16)
(0.866×0.118)
ø28×4.0
41 275±27 (200±20)
(1.10×0.157)
ø35×5.0
Ihara Koatu 29.4 (4270) 55 441±44 (330±33)
(1.38×0.197)

SLEEVE NUT
B

d
d

Tube size Parts No. Tube size Opposing Parts No.

ød Ihara Koatu Nippon A.M.C. ød flats Ihara Koatu Nippon A.M.C.
(HEX) mm
6 ZF93S06000 — 6 14 ZF93N06000 —
8 ZF93S08000 — 8 17 ZF93N08000 —
10 ZF93S10000 ZA93S10000 10 19 ZF93N10000 ZA93N10000
12 ZF93S12000 — 12 22 ZF93N12000 —
15 ZF93S15000 ZA93S15000 15 27 ZF93N15000 ZA93N15000
18 ZF93S18000 ZA93S18000 18 32 ZF93N18000 ZA93N18000
22 ZF93S22000 ZA93S22000 22 36 ZF93N22000 ZA93N22000
28 ZF93S28000 ZA93S28000 28 41 ZF93N28000 ZA93N28000
32 ZF93S32000 — 32 50 ZF93N32000 —
35 ZF93S35000 ZA93S35000 35 55 ZF93N35000 ZA93N35000
38 ZF93S38000 — 38 60 ZF93N38000 —

11-7
11. TOOLS

11.5 PLUGS

11.5.1 PLUG FOR HYDRAULIC PIPE JOINT

(1) Cap nut (Joint plug)

Applicable Cap nut parts Opposing flats

tube T screw
A O. D : A
No.
H1 H
6 ZF83H06000 M12 X 1.5 14 14
8 ZF83H08000 M14 X 1.5 17 17
10 ZF83H10000 M16 X 1.5 17 19
12 ZF83H12000 M18 X 1.5 19 22
H1 T screw H 15 ZF83H15000 M22 X 1.5 24 27
18 ZF83H18000 M26 X 1.5 27 32
22 ZF83H22000 M30 X 1.5 32 36
28 ZF83H28000 M36 X 1.5 38 41

(2) Plug (Tube plug)

Applicable
tube Plug parts No.
O. D : A
A

6 ZF83P06000
8 ZF83P08000
10 ZF83P10000
12 ZF83P12000
Sleeve Nut
Type 15 ZF83P15000
joint body 18 ZF83P18000
22 ZF83P22000

(3) Nut

Applicable
d screw
A

tube Nut parts No. d screw Opposing flats

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

11-8
 11. TOOLS

11.5.2 PLUG FOR HYDRAULIC EQUIPMENT

(1) PF screw

B
O-ring
PF screw Plug parts No. B mm O-ring parts No. Nominal O-ring
PF1/4 ZE72X04000 19 ZD12P01100 1B P11
PF3/8 ZE72X06000 22 ZD12P01400 1B P14
PF1/2 ZE72X08000 27 ZD12P01800 1B P18
PF3/4 ZE72X12000 36 ZD12P02400 1B P24
PF screw PF1 ZE72X16000 41 ZD12P02900 1B P29

(2) PT screw
11
B
PT screw
PT screw Plug parts No. B mm
PT1/8 ZE82T02000 5
PT1/4 ZE82T04000 6
PT3/8 ZE82T06000 8
PT1/2 ZE82T08000 10
PT3/4 ZE82T12000 14
PT1 ZE82T16000 17
PT1 1/4 ZE82T20000 22
PT1 1/2 ZE82T24000 22

(3) Plug for(F)flare hose

PF screw

PF screw Plug parts No. B mm

PF1/4 2444Z2728D1 14
60

PF3/8 2444Z2728D2 17
PF1/2 2444Z2728D3 22
PF3/4 2444Z2728D4 27
Opposing flats B PF1 2444Z2728D5 36

PF screw Plug parts No. E mm F mm

PF PF1/4 2444Z2729D1 14 19
60

screw
PF3/8 2444Z2729D2 17 22
PF1/2 2444Z2729D3 23 27
PF3/4 2444Z2729D4 27 36
Opposing PF1 2444Z2729D5 36 41
Opposing
flats F PF1 1/4 2444Z2729D6 40 50
flats E

11-9
11. TOOLS

(4) Plug for ORS joints

Male

Female

(5) Plug for half clamp

4-oH For standard pressure : 20.6 MPa (2990 psi)

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

ZE12Q16000 52.37 39.75~ ZD12P03400

1 26.19 39.62 11
44.58~
D 1 1/4 ZE12Q20000 58.72 30.18 44.45 11 ZD12P03800

For high pressure : 41.2 MPa (5970 psi)

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

11-10
 11. TOOLS

11.6 SPECIAL SPANNER FOR TUBE

Applicable tube
diameter Part No. HEX (mm) Drawing of a special spanner mm (in)
mm (in)

70(2.76)

16 22
15 (0.591) 2421T160 27 (0.630) (0.315) (0.866)

40(1.57) 12.7 (0.500 )

70(2.76)
42(1.65)
11
19 22
18 (0.709) 2421T138 32 (0.748) (0.866)

12.7 (0.500 )
22(0.866)

70(2.76)
48(1.89) 11.5(0.453)
23 22
22 (0.866) 2421T130 36 (0.906) (0.866)

12.7 (0.500 )

109(4.29)
60(2.36)
14.5(0.571)
29 22
28 (1.10) 2421T115 41 (1.142) (0.866)

12.7 (0.500 )

28 (1.10) 2421T231 46

32 (1.26) 2421T232 50

35 (1.38) 2421T314 55

11-11
11. TOOLS

11.7 SPECIAL TOOLS

No. Tools name Tools No. Shape Applicable

Spanner or
Pump
1 socket ZT22A17000 General tools
install
Nominal B: 17
CUT

Spanner ZT12A36000 Swing motor

2
Nominal S: 36 A,B port

Commercial tool outer width (D) - cut length = Required length

81 (3.19") - 16 (0.63") = 65 (2.56")

Additional M10 X 22
threading
for M10 eye bolt For slinging the
Plug ZE72X16000
3 swing motor
PF1
(M port)

PF1 O-ring

M12 Eye bolt

ZS91C01200 For slinging the

Eye bolt
or swing motor
4 M12×22
commercial &
equivalent Flare hose
22

M12

M8 Eye bolt

Plug
ZF83P22000
(Nominal
tube dia. 22)
5 Reference nut Flare hose
Reference
ZS91C00800
Eye bolt
ZF93N22000 M8 X 18
Nut Addtional
threading for
M8 Eye bolt

11-12
 11. TOOLS

M8 Eye bolt

M8 X 18
Plug Additional
YN01H01001P1
threading
Nominal
6 1-14UNS HEX 27 Flare hose

Eye bolt ZS91C00800

1-14UNS

M8 Eye bolt
M8 X 18
Additional
Plug YN01H01002P1 threading 11
Nominal
7 1 3/16-12UN HEX 36 Flare hose

Eye bolt ZS91C00800

1 3/16-12UN

M12 Eye nut

Plug ZE25F08000
PF1/2 For slinging the
8 Weld
Coupling swivel joint
half Coupling half

PF 1/2

TORX driver 5.49

(with tamper
For instrument
9 proof) — Point shape
panel cover (RH)
T30
(For M6)

11-13
11. TOOLS

11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING

COMPOUND

(1) For general use

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

11-14
 11. TOOLS

11.9 SUCTION STOPPER

11.9.1 COMPONENTS

No. NAME PARTS No. Q'TY

SUCTION STOPPER ASSY 24100P978F2
1 ROD 2420T4660D1 1
1 Rod
2 NUT ZN16C08007 1
3 COVER 2414T2123D2 1
4 O-RING 45Z91D6 1

2 Nut
3 Cover 11

4 O-ring

Components Of Suction Stopper

11.9.2 DIMENSION
50
(1.97")

R
(1 8 O113 (4.45")
.3
15" 2
) M8 NUT (0.08")

O8 (1.315")
600 (23.6")

M8 O100 +0.5
0
(0.787")

(3.94 +0.0197
0 )
O108
20

(4.25")
ROD COVER

Dimension Of Suction Stopper

11.9.3 APPLICABLE MODEL

Applicable
model
٤ E385B

Part No.

24100P978F2

11-15
11. TOOLS

11.10 UPPER FRAME LIFTING JIG

No. NAME Q'TY TYPE

1 MASTER LINK L 1 KITO HL050

2 HIGH COUPLING HC 9 KITO HC020

3 CHAIN 1 8 4.4m(14' 5")

4 CHAIN 2 8 1.5m(4' 11")

5 GRAB HOOK H 1 KITO HH020

6 HOOK 2 KITO HJ050

Upper Frame Lifting Jig

11-16
 11. TOOLS

11.11 ENGINE MOUNTING PEDESTAL

Material : Wood
Unit : mm(inch)

5
1
6
3
2

11

6 6

4
6
6

1X1 set

5X1 set

4X1 set 2X1 set

3X1 set

6X5 sets

Engine Stand

11-17
11. TOOLS

11-18
 12. STANDARD MAINTENANCE TIME TABLE

12. STANDARD MAINTENANCE TIME

TABLE
TABLE OF CONTENTS

12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ... 12-4
12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST ........................... 12-16 12
12.2.1 MEASURING METHOD ............................................................................ 12-16
12.2.2 WORKING CONDITION ............................................................................ 12-16
12.2.3 STANDARD TIME CONSTITUENT ........................................................... 12-17
12.2.4 MEANING OF WORDS IN USE ................................................................ 12-18

Book Code No. S5LC1226E01

12-1
12. STANDARD MAINTENANCE TIME TABLE

Issue Data of Issue Applicable Machines Remarks

S5LC1226E01
First Edition September, 2010 SK350-9: YC
NA

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 operation).
2. Equipment:
Jigs, tools, apparatuses and testers used in field service work will be available commercially. The maintenance
plant will 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 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 team.

(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.
12
2. Items excluded from service time because of uncertainty in time:
Receiving a vehicle into shop, transfer, delivery, inspection on completion, investigation of causes of faults,
diagnosis, and inspection.
3. Indirect time:
Time for: field work, preparation of necessary parts before leaving for work, return for field work, waiting time
because of user's convenience in the field, paper work after returning to shop, and preparation of bills.
4. Special time: Working in the 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 that 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.
Assembly 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
06 Electric Indicates the installing, removing and replacement of single items.
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 0.9
02 -Bucket attaching and detaching Preparation 1 pc. 0.1
position
03 -Bucket attaching pin Detach/attach 1 Include stopper pin. 0.2
04 -Bucket drive pin Detach/attach 1 0.2
05 -Bucket sling and movement Preparation 1 pc. 0.3
06 Bucket (single) O/H 1 pc. Not include attaching and 3.6
detaching
07 -Tooth Replace 1 pc. 0.9
08 -Side cutter Replace 1 pc. 1.8
09 -Bushing Replace 1 pc. 0.9
10 Arm relation See 32.1.3
11 Arm ASSY Detach/attach 1 pc. 1.9
12 -Bucket cylinder attaching and Preparation 1 pc. 0.6
detaching position and piping
13 -Bucket cylinder rod pin Detach/attach 1 pc. Include stopper pin. 0.2
14 -Bucket cylinder head pin Detach/attach 1 pc. Include stopper pin. 0.2
15 -Bucket cylinder assy Detach/attach 1 pc. 0.2 12
16 -Arm cylinder rod pin Detach/attach 1 pc. Include stopper pin. 0.2
17 -Boom top pin Detach/attach 1 pc. Include wire stop pin 0.2
18 -Arm sling and movement Detach/attach 1 pc. 0.3
30 Boom portion See 32.1.4
31 Boom ASSY Detach/attach 1 pc. 2.1
32 -Boom attaching and detaching position Preparation 1 pc. 0.1
33 -Boom cylinder temporary slinging Preparation 2 pcs. 0.3
34 -Boom cylinder rod pin Detach/attach 2 Include two stopper pins. 0.3
35 -Boom cylinder piping Detach/attach 2 pc. 0.3
36 -Arm & bucket piping Detach/attach 1 pc. 0.3
37 -Boom assy temporary slinging Detach/attach 1 pc. 0.1
38 -Boom foot pin Detach/attach 1 Include stopper pin. 0.3
39 -Boom assy slinging Detach/attach 1 pc. 0.2
40 Arm cylinder attaching and detaching Detach/attach 1 pc. 0.7
41 -Arm cylinder piping Detach/attach 1 pc. 0.3
42 -Arm cylinder head pin Detach/attach 1 pc. Include stopper pin. 0.2
43 -Arm cylinder slinging Detach/attach 1 pc. 0.2
50 Boom cylinder attaching and detaching Detach/attach 2 pcs. 1.0
51 -Boom cylinder piping Detach/attach 2 0.4
52 -Boom cylinder head pin Detach/attach 2 pcs. 0.3
53 -Boom cylinder slinging Detach/attach 2 0.3
60 Bucket cylinder O/H 1 4.0
61 -Pin bushing Replace 1 Include seal. 1.5
70 Arm cylinder O/H 1 4.0
71 -Pin bushing Replace 1 set Include seal. 1.5
80 Boom cylinder O/H 2 8.0
81 -Pin bushing Replace 1 set Include seal. 1.5

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. 1.6
12 -Front lower glass, floor mat Detach/attach 1 pc. each 0.1
13 -Seat rear cover top, bottom Detach/attach 1 pc. each 0.3
14 -Right side panel (include A/C duct) Detach/attach 3 0.3
15 -Cable and harness (electric) Detach/attach 6 0.2
16 -Controller (KPSS) Detach/attach 1 pc. 0.2
17 -Cab mounting bolt Detach/attach 8 pcs. 0.2
18 -Cab slinging Detach/attach 3 places 0.3
20 Guard relation See 33.1.4
21 Bonnet assy (F1) Detach/attach 1 pc. 0.3
22 Bonnet assy (F2) Detach/attach 1 pc. 0.3
23 Guard (C1) Detach/attach 1 pc. 0.2
24 Guard (A23) Detach/attach 1 pc. 0.2
25 Guard (A24) Detach/attach 1 pc. 0.2
26 Guard (A17) Detach/attach 1 pc. 0.2
27 Guard (A18) Detach/attach 1 pc. 0.2
28 Guard (D1) Detach/attach 1 pc. 0.2
29 Cover (H4) Detach/attach 1 pc. 0.2
30 Stay (G1) Detach/attach 1 pc. 0.2
31 Stay (E1) Detach/attach 1 pc. 0.2
32 Panel assy (B1) Detach/attach 1 pc. 0.2
33 Panel assy (B2) Detach/attach 1 pc. 0.2
34 Panel assy (B3) Detach/attach 1 pc. 0.2
35 Panel assy (A31) Detach/attach 1 pc. 0.2
36 Guard (A25) Detach/attach 1 pc. 0.2
37 Guard (A26) Detach/attach 1 pc. 0.2
38 Guard (A27) Detach/attach 1 pc. 0.2
39 Guard (D2) Detach/attach 1 pc. 0.2
40 Beam (A7) Detach/attach 1 pc. 0.2
41 Beam (A12) Detach/attach 1 pc. 0.2
42 Pillar (A5) Detach/attach 1 pc. 0.2
43 Bracket assy (A13) Detach/attach 1 pc. 0.2
44 Guard (A14) Detach/attach 1 pc. 0.2
45 Cover assy (C5) Detach/attach 1 pc. 0.2
46 Guard assy (C2) Detach/attach 1 pc. 0.2
47 Guard assy (C3) Detach/attach 1 pc. 0.2
48 Cover (C4) Detach/attach 1 pc. 0.2
49 Plate (A28) Detach/attach 1 pc. 0.2
50 Guard assy (A22) Detach/attach 1 pc. 0.2
51 Cover assy (H1) Detach/attach 1 pc. 0.2

Note: The numbers in the parenthesis like guard (26) 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
58 Cover (10) Detach/attach 1 pc. 0.1
59 Cover (11) Detach/attach 1 pc. 0.1
70 Counterweight relation See 33.1.11
71 Counterweight ASSY Detach/attach 1 pc. 0.9
72 -Counterweight temporary slinging Preparation 1 pc. 0.3
73 -Counterweight mounting bolt Detach/attach 1 pc. 0.3
74 -Counterweight slinging Detach/attach 1 pc. 0.2

Note: The numbers in the parenthesis like cover (2) match the cover 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. 0.4
12 -Hose (3) Detach/attach 1 0.1
13 -Air cleaner mounting bolt Detach/attach 1 set 0.2
14 -Element Replace 1 0.1
20 Exhaust relation See 33.1.10
21 Filter ASSY Detach/attach 1 pc. 0.5
22 -Harness connector Detach/attach 1 pc. 0.1
23 -Hose Detach/attach 1 pc. 0.1
24 -Bracket Detach/attach 1 pc. 0.3
25 -Rubber mount Detach/attach 1 pc. 0.3
30 Radiator relation See 33.1.12
31 Radiator ASSY Detach/attach 1 pc. 5.0
32 -Coolant (LLC) Replace 1 pc. 0.3
33 --Concentration of coolant Measuring 1 pc. 0.2
34 -A/C condenser Moving 1 pc. 0.3
35 -Fuel cooler Moving 1 pc. 0.3
36 -Stay Detach/attach 1 pc. 0.1
37 -Bracket Detach/attach 1 0.3
38 -Sub tank hose Detach/attach 1 pc. 0.1
39 -Fan guard Detach/attach 3 pc. 0.4
40 -Water hose (radiator ~ E/G) Detach/attach 2 0.6
41 -Radiator mounting bolts removing Detach/attach 1 set 0.2
42 -Under cover Detach/attach 1 pc. 0.1
43 -Hydraulic oil tank suction stopper Detach/attach 1 pc. 0.2
44 -Hydraulic oil piping Detach/attach 1 pc. 0.6
-Inter cooler hose & tube Detach/attach 2 pcs. 0.5
45 (E/G to inter cooler)
46 -Radiator lifting or hoisting Detach/attach 1 pc. 0.2
47 -Radiator inter cooler core & oil cooler Cleaning 1 pc. 1.0
50 Fuel relation See 33.1.6
51 Fuel tank ASSY Detach/attach 1 pc. 1.8
52 -Fuel Replace 1 pc. 0.4
53 -Hose (water separator side) Detach/attach 2 0.1
54 -Tube (tank side) Detach/attach 1 0.1
55 -Fuel tank installing bolts Detach/attach 1 pc. 0.3
56 -Tank slinging Detach/attach 1 pc. 0.3
Other necessary works Detach/attach 1 pc. 0.4
Removing and installing
guard
60 Hydraulic oil tank relation See 33.1.7
61 Hydraulic oil tank ASSY Detach/attach 1 pc. 3.0
65 -Cover Detach/attach 1 pc. 0.2
66 -Hydraulic oil Replace 1 pc. 0.6
68 -Pilot drain hose Detach/attach 1 pc. 0.2
69 -Pump suction hose Detach/attach 1 pc. 0.5
70 -Mounting bolt Detach/attach 1 pc. 0.2
71 -Hydraulic oil tank slinging Detach/attach 1 pc. 0.3
72 -Return filter Replace 1 0.2
73 -Suction filter Cleaning 1 0.2

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. 3.2
82 -Hydraulic oil tank cover Detach/attach 1 pc. 0.3
83 -Strainer & stopper Detach/attach 1 pc. 0.3
84 -Piping Detach/attach 1 set 1.0
85 -Guard Detach/attach 5 pcs. 1.0
86 -Pump slinging Detach/attach 1 pc. 0.5
87 -Cleaning Cleaning 1 pc. 0.1
88 -Vent air Adjust 1 pc. 0.1
89 Pump ASSY O/H 1 pc. 4.0
90 Swing motor unit relation See 33.1.18
91 Swing motor ASSY Detach/attach 1 pc. 2.4
92 -Piping Detach/attach 1 set 1.0
93 -Mounting bolt Detach/attach 1 pc. 0.7
94 -Unit slinging Detach/attach 1 pc. 0.5
95 -Cleaning and sealant Cleaning 1 set 0.2
96 Swing motor O/H 1 pc. 4.0
97 Swing reduction gear O/H 1 pc. 5.0
12
100 Swivel joint relation See 33.1.19
101 Swivel joint ASSY Detach/attach 1 2.6
102 -Piping (Top part only) Detach/attach 1 set 0.5
103 -Whirl stop bolt Detach/attach 1 0.2
104 -Cover Detach/attach 1 0.4
105 -Joint & elbow Detach/attach 1 set 0.4
106 -Mounting bolt Detach/attach 1 set 0.4
107 -Swivel joint slinging Detach/attach 1 0.4
108 -Cleaning Cleaning 1 set 0.3
109 Swivel joint O/H 1 set Removing and installing 3.6
guard
Other necessary works Detach/attach 1 set Lower piping 0.6
120 Main control valve See 33.1.15
121 Main control valve ASSY Detach/attach 1 pc. 2.5
122 -Attach tag to port name of pipe Preparation 1 pc. 0.6
123 -Piping Detach/attach 1 set 1.7
124 -Bracket mounting bolt Detach/attach 1 pc. 0.1
125 -Valve slinging Detach/attach 1 pc. 0.1
126 Main control valve ASSY Detach/attach 1 set 6.0
Other necessary works Detach/attach 1 set Guard 0.4

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 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 bolt Detach/attach 1 0.3
140 Engine (E/G) mounting relation See 33.1.13
141 Engine ASSY Detach/attach 1 pc. After removing pump & 2.0
radiator
142 -Harness connector & grounding & Detach/attach 1 pc. 0.3
cable connection
143 -Fuel hose Detach/attach 1 pc. 0.1
144 -Others Detach/attach 1 set 0.5
145 -Mounting bolt Detach/attach 1 pc. 0.5
146 -Engine slinging Detach/attach 1 set 0.3
147 -Cleaning Cleaning 1 pc. 0.5
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 0.9
Counterweight
Detach/attach 1 set Removing and installing 3.2
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 4.0
radiator
150 Upper frame See 33.1.20
151 Upper frame ASSY Detach/attach 1 pc. After removing swivel joint 1.3
152 -Mounting bolt Detach/attach 1 set 0.4
153 -Upper frame slinging Detach/attach 1 pc. 0.4
154 -Cleaning Cleaning 1 pc. 0.3
155 -Sealant Apply 1 pc. 0.2
Other necessary works Detach/attach 1 set Cab 1.4
Detach/attach 1 set Guard 0.4
Detach/attach 1 set Counterweight 0.9
Detach/attach 1 set Boom 2.1

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
01 Track link ASSY Detach/attach One side Include adjustment of 2.0
tension
02 -Track link attaching and detaching Preparation One side 0.1
position
03 -Master pin Detach/attach One side 0.7
04 -Track link extending and winding Detach/attach One side 0.7
05 Shoe plate Replace 1 pc. 0.4
10 Upper roller relation See 34.1.3
11 Lower roller ASSY Detach/attach 1 After removing track link 0.3
12 Lower roller O/H 1 1.0
20 Lower roller relation See 34.1.4
21 Lower roller ASSY Detach/attach 1 0.3
22 Lower roller O/H 1 1.5
30 Front idler relation See 34.1.5
31 Front idler ASSY Detach/attach One side After removing track link 0.8
32 Front idler ASSY slinging Detach/attach One side 0.3 12
33 Front idler ASSY Detaching One side 0.5
34 Idler ASSY O/H One side 1.5

40 Sprocket See 34.1.6

41 Sprocket Replace One side After removing track link 0.9
50 Travel motor relation See 34.1.7
51 Travel motor ASSY Detach/attach One side After removing track link 2.4
52 -Motor cover Detach/attach One side 0.1
53 -Hydraulic piping Detach/attach One side 1.3
54 -Motor mounting bolt Detach/attach One side 0.6
55 -Motor slinging Detach/attach One side 0.2
56 Motor cleaning Cleaning One side 0.2
57 Travel motor O/H One side 4.0
58 Travel reduction gear O/H One side 4.0
60 Swivel joint relation
61 Pipe on swivel joint travel side Detach/attach 1 pc. Include bonnet assy 0.6
removing and installing.
62 Swivel joint O/H 1 pc. See 33.2.6 3.6
70 Swing bearing See 34.1.8
71 Swing bearing ASSY Detach/attach 1 pc. After removing upper 0.8
72 Swing bearing mounting bolt Detach/attach 1 pc. frame 0.6
73 Swing bearing slinging Detach/attach 1 pc. 0.4

12-11
12. STANDARD MAINTENANCE TIME TABLE

06 Electric equipments (1/4)

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-5 Engine coolant level controller Replace 1 1.0
C-8 Engine controller Replace 1 1.0
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-22 Diode Replace 1 0.3
D-23 Diode Replace 1 0.3
D-25 Diode Replace 1 0.3
D-66 Diode Replace 1 0.3
D-67 Diode Replace 1 0.3
Electric equipments
E-1 Fuse & relay box Replace 1 0.3
E-2 Alternator Replace 1 1
E-3 Hour meter Replace 1 0.3
E-5 Horn (High) Replace 1 0.3
E-6 Horn (Low) Replace 1 0.3
E-7 Tuner AM & FM (OPT) Replace 1 0.3
E-8 Speaker left Replace 1 0.3
E-9 Speaker right Replace 1 0.3
E-10 Receiver dryer Replace 1 Include gas sealing. 1
E-11 Air compressor Replace 1 Include Counterweight 1
removing and installing.
E-12 Battery Replace 2 0.4
E-22 DC-DC conveter Replace 1 0.3
E-23 12V socket Replace 1 0.3
E-27 Accel emergency mode volume Replace 1 0.5
E-46 Rear camera Replace 1 0.3
E-49 DC-DC converter (proportional) Replace 1 0.3
E-63 DC-DC converter (for camera) Replace 1 0.3
E-65 24V socket Replace 1 0.3

12-12
 12. STANDARD MAINTENANCE TIME TABLE

06 Electric equipments (2/4)

Work to be Unit:
Group Location Unit Remarks
done Hour
Light
L-1 Boom work light left Replace 1 Bulb 0.2
L-2 Frame working light right Replace 1 0.2
L-5 Room light Replace 1 0.2
L-7 Cab working light front 1 Replace 1 0.2
L-8 Cab working light front 2 Replace 1 0.2
Motor
M-1 Starter motor Replace 1 Include Counterweight 1.2
removing and installing.
M-3 Wiper motor Replace 1 0.5
M-4 Washer motor Replace 1 0.5
Proportional valve
PSV-A Arm 2 speed inverse proportional valve Replace 1 0.5
PSV-B P2 unload proportional valve Replace 1 Include proportional valve 0.5
block removing and
installing.
PSV-C Travel straight proportional valve Replace 1 0.5
PSV-D P1 unload proportional valve Replace 1 0.5 12
PSV-R Controll proportional valve Replace 1 0.5
PSV-P1 P1 pump proportional valve Replace 1 0.5
PSV-P2 P2 pump proportional valve Replace 1 0.5
Relay
R-1 Battery relay Replace 1 0.3
R-2 Starter relay Replace 1 0.3
R-3 Glow relay Replace 1 0.3
R-4 Safety relay Replace 1 0.1
R-5 Horn relay Replace 1 0.1
R-6 Work light relay Replace 1 0.1
R-9 Cab working light relay 1 Replace 1 0.1
R-11 Cab working light relay 2 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-94 Neutral stop relay Replace 1 0.1

12-13
12. STANDARD MAINTENANCE TIME TABLE

06 Electric equipments (3/4)

Work to be Unit:
Group Location Unit Remarks
done Hour
Sensor
SE-1 Pressure sensor: Bucket digging Replace 1 0.3
SE-2 Pressure sensor: Bucket dump Replace 1 0.3
SE-3 Pressure sensor: Boom up Replace 1 0.3
SE-4 Pressure sensor: Boom down Replace 1 0.3
SE-5 Pressure sensor: Swing Replace 1 0.3
SE-7 Pressure sensor: Arm in Replace 1 0.3
SE-8 Pressure sensor: Arm out Replace 1 0.3
SE-9 Pressure sensor: Travel right Replace 1 Include under cover 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 0.5
removing and installing
SE-13 Engine speed sensor Replace 1 Include under cover 0.5
removing and installing
SE-15 Fuel sensor Replace 1 Include guard removing and 0.5
installing
SE-16 Accel potentiometer Replace 1 0.5
SE-20 Pressure sensor: P1 side : P1 side Replace 1 Include under cover 0.5
(OPT.) removing and installing
SE-22 Pressure sensor: P1 pump Replace 1 0.5
SE-23 Pressure sensor: P2 pump Replace 1 0.5
Solenoid
SV-1 Swing parking SOL Replace 1 Include proportional valve 0.5
block removing and
installing.
SV-2 Attachment boost pressure SOL Replace 1 Include proportional valve 0.5
block removing and
installing.
SV-3 2-speed travel SOL Replace 1 Include proportional valve 0.5
block removing and
installing.
SV-4 Safety lever lock SOL Replace 1 Include proportional valve 0.5
block removing and
installing.

12-14
 12. STANDARD MAINTENANCE TIME TABLE

06 Electric equipments (4/4)

Work to be Unit:
Group Location Unit Remarks
done Hour
Switch
SW-1 Key switch Replace 1 0.3
SW-4 Swing parking release switch Replace 1 0.3
SW-5 Hron switch (right) Replace 1 0.3
SW-7 Engine oil pressure switch Replace 1 0.3
SW-8 Clogged air filter switch Replace 1 0.3
SW-10 Horn switch (left) Replace 1 0.3
SW-11 Safety lever lock switch Replace 1 0.3
SW-15 Conflut/single select switch (OPT.) Replace 1 0.3
SW-17 Roof wiper switch Replace 1 0.3
SW-19 Wiper interlock switch Replace 1 0.3
SW-20 Attachment power boost switch (right) Replace 1 0.3
SW-21 Attachment power boost switch (left) Replace 1 0.3
SW-27 Engine cooling coolant level switch Replace 1 0.3
SW-55 Boom work light switch Replace 1 0.3
SW-56 Fuel supply auto stop switch Replace 1 0.3

12

12-15
12. STANDARD MAINTENANCE TIME TABLE

12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST

Preface
This standard working time is based on the work time required for service of the engine, such as disassembly,
check, adjustment and assembly and so on under a following condition.
This standard working time is provided under the following conditions.

12.2.1 MEASURING METHOD

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

12.2.2 WORKING CONDITION

12.2.2.1 TOOLS, INSTRUMENT

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

12.2.2.2 WORKING PROCEDURE

The disassembly and assembly should be carried out according to the working procedure prepared by HINO
Motor's Ltd. Service Technical Dept. Training Group.

12.2.2.3 STANDARD WORKMAN QUALIFICATION

Workmen shall basically acquire 2 to 3 years of maintenance experience on HINO.

12-16
 12. STANDARD MAINTENANCE TIME TABLE

12.2.3 STANDARD TIME CONSTITUENT

12.2.3.1 STANDARD WORKING TIME = NET WORKING TIME + STANDARD TIME + STANDARD
ALLOWANCE TIME
(1) Net working time
The time a workman actually works and the time required for measurement, cleaning, and so on is included, but
the time required for troubleshooting is not included.
(2) Standard time
Time required for preparation to the beginning of work, preparation of a special tool, measuring equipment,
parts and so on, and for the work site clean-up.
(3) Standard allowance time
Calculate the allowance time directly required for workmen from the following equation.
Net standard time X HINO allowance rate
Allowance rate varies within the range of 0.15 to 0.75 according to the work difficulty, contents, working position
and so on.

12.2.3.2 ALLOWANCE RATE, STANDARD PREPARATION TIME

12.2.3.2.1 HINO allowance rate (0.15 to 0.75)
(1) Basic rate: 0.10
(2) Working posture allowance (Fatigue coefficient): Take any one of the followings according to the work contents. 12
Standing work: 0.05
Work in bent posture: 0.10
Work while lying: 0.15
(3) Difficult work allowance: 0.30
(4) Seized rusted section (For new vehicle): 0.50
Take any one of above (3) and (4).
Min. allowance rate = Basic allowance + standing work allowance = 0.1 + 0.05 = 0.15
Max. allowance rate = Basic allowance + work allowance in lying + seized rusted section = 0.1 + 0.15 +
0.5=0.75

12.2.3.2.2 STANDARD WORKING TIME

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

12-17
12. STANDARD MAINTENANCE TIME TABLE

12.2.4 MEANING OF WORDS IN USE

• Completed machine:
When detaching, replacing and adjusting the specified parts; it means the time that is determined by the
addition of the preparation time, net working time and standard allowance time of the work.
• Single unit:
When detaching, replacing and adjusting the specified parts, it means the time in that the preparation time of the
work is omitted and is determined by addition and subtraction to/from the work for "Completed Machine".
• Removal and installation:
The work to remove the specified parts from the machine and to attach the parts, and then to perform the
necessary adjustment.
• Simultaneous replacement:
The work to remove specified parts in 2 types or more from the machine and to attach the spare parts, and then
to perform the necessary adjustment.
• Adjustment:
The work to carry out the necessary adjustment with the specified parts removed or attached:
• Overhaul:
The work to remove specified assembled parts from machine, disassemble and check them, and then to attach
the spare parts to the machine and to perform the necessary adjustment.
• Include:
Explains the contents of the work to make the specified work range clear.
• Exclude:
Shows the work which is not included in the specified primary work.
• Unit:
Time is shown by the hour.

12-18
 12. STANDARD MAINTENANCE TIME TABLE

SK350-9
Q'ty
Work
Work Work unit Works
No. Adding
1 hour by
1 each
Completed Timing adjustment
1 00101 Engine adjustment A set 2.5
machine Valve clearance adjustment
Completed
2 00103 Engine adjustment B set A set and nozzle adjustment -
machine
Include: Engine warm-up, valve
Completed clearance adjustment, removing air
3 00111 Compression measuring 4.3
machine cleaner element and battery
specific gravity measurement
Replacing cylinder, block,
8 99012 piston, ring and liner Single unit From engine is removed condition 31.6
simultaneously
Replacing crank shaft,
9 99013 piston, ring and liner Single unit From engine is removed condition 25.8
simultaneously
12
From engine is removed condition
Include: Valve clearance
Replacing cylinder block Single unit adjustment 30
Exclude: Installing expansion plug
knock pin
11 00126 Replacing crank shaft Single unit From engine is removed condition 22.8
Replacing crank shaft
12 00127 Single unit From engine is removed condition 22.8
main bearing
From engine is removed condition
Include: Adjustment of water pump,
oil pump, valve clearance, valve
lapping and measurement/cleaning
15 00151 Engine overhaul Single unit 44.3
Exclude: Replacing of injection
pump, electrical equipment, water
pressure test, clutch overhaul and
valve guide
16 00152 Compression measuring Single unit 3.1
From piston & connecting rod are
17 00153 Replacing piston Single unit 0.5 0.5
removed conditions
From piston & connecting rod are
18 00154 Replacing piston ring Single unit 0.2 0.2
removed conditions
From piston & connecting rod are
19 00155 Replacing cylinder liner Single unit 0.4 0.4
removed conditions

12-19
12. STANDARD MAINTENANCE TIME TABLE

SK350-9
Q'ty
Work
Work Work unit Works
No. Adding
1 hour by
1 each
From piston & connecting rod are
20 00157 Replacing connecting rod Single unit 0.3 0.3
removed conditions
From connecting rod is a single unit
Replacing piston pin
21 00158 Single unit condition 0.4 0.4
bushing
Include: Reaming
26 00165 Replacing expansion plug Single unit 0.4 0.4
Valve clearance Completed
41 00302 2
adjustment machine
Replacing rocker chamber
42 00305 One set 1.4
cover upper
Replacing rocker chamber Include: Removal and installing
43 00306 One set 4.3
cover lower upper
Replacing rocker chamber
44 00304 One set 1.4
cover gasket
Removal and installing Completed
45 00312 3.3
rocker arm and support machine
Completed
46 00313 Replacing rocker arm 3.4
machine
Replacing rocker arm Completed
47 00314 3.4
support machine
Replacing rocker arm Completed
48 00315 3.4
shaft machine
Excluding: Removal and installing
Removal and installing Completed
50 00322 of nozzle holder or injector and 10.4
cylinder head machine
injector sub harness
Completed Include: Valve lapping
51 00323 Replacing cylinder head 16.9
machine Exclude: Replacing of valve guide
Include: Valve lapping
Completed Exclude: Replacing of valve guide,
52 00324 Overhaul of cylinder head 18.8
machine water pressure test and replacing
valve seat
Replacing cylinder head Completed
53 00325 10.4
gasket machine
Completed
54 00326 Replacing valve Include: Valve lapping 15.6
machine
Completed Exclude: Removal and installing of
55 00327 Replacing valve spring 8.8
machine cylinder head
Completed Exclude: Removal and installing of
57 00328 Replacing valve stem seal 9.4
machine cylinder head

12-20
 12. STANDARD MAINTENANCE TIME TABLE

SK350-9
Q'ty
Work
Work Work unit Works
No. Adding
1 hour by
1 each
Removal and installing
61 00376 One set 1.6 0.2
camshaft housing plug
Removal and installing
Completed
62 00377 camshaft (with camshaft 3.4
machine
gear)
With manifold and nozzle holder
Include: Valve lapping
Replacing cylinder head
Excluding: Removal and installing
63 00352 (one piece and one set Single unit 6.5
of cylinder head, replacing valve
require same hour)
guide, water pressure test and
replacing valve seat
Unit of 1
66 00355 Replacing valve guide 1 0.8
cylinder
72 00361 Replacing expansion plug Single unit 0.4 0.4
12
Replacing rocker arm
Unit of 1
73 00371 (one piece and one set 0.1
cylinder
require same hour)
Replacing rocker arm
support Unit of 1
74 00372 0.1
(one piece and one set cylinder
require same hour)
Replacing rocker arm Unit of 1
75 00373 0.3 0.1
bushing cylinder
From cylinder head is removed
Unit of 1
76 00374 Replacing valve condition 0.5 0.5
cylinder
Include: Valve lapping
Unit of 1 From cylinder head is removed
77 00375 Replacing valve spring 0.2 0.2
cylinder condition
Unit of 1 From cylinder head is removed
78 00330 Replacing valve stem seal 0.3 0.3
cylinder condition
Removal and installing
81 00406 One set Include: Function check 2.3
supply pump
84 00411 Tightening oil pan Single unit From engine is removed condition 0.5
Removal and installing oil
85 00412 Single unit From engine is removed condition 0.5
pan
86 00413 Replacing oil pan Single unit From engine is removed condition 0.7

12-21
12. STANDARD MAINTENANCE TIME TABLE

SK350-9
Q'ty
Work
Work Work unit Works
No. Adding
1 hour by
1 each
87 00414 Replacing oil pan gasket Single unit From engine is removed condition 0.7
Replacing oil pan drain
88 00421 Single unit From engine is removed condition 0.5 0.8
cock
Replacing oil pan drain
89 00422 Single unit From engine is removed condition 0.5 0.4
cock gasket
92 00443 Replacing breather hose Single unit From engine is removed condition 0.2 0.3
93 00444 Replacing oil level gauge Single unit From engine is removed condition 0.1
Replacing oil level gauge
94 00445 Single unit From engine is removed condition 0.2 0.1
guide
Replacing oil level gauge
95 00446 Single unit From engine is removed condition 0.2 0.5
bracket
Replacing fly wheel
102 00512 Single unit From engine is removed condition 3.4 0.2
housing
Replacing fly wheel
103 00541 Single unit From engine is removed condition 5.4 0.3
housing gasket
104 00542 Replacing rear end plate Single unit From engine is removed condition 5.4
Replacing rear end plate
105 00543 Single unit From engine is removed condition 5.4
gasket
Replacing crank shaft rear
106 00515 Single unit From engine is removed condition 5.4
oil seal
Replacing crank shaft rear From fly wheel is removed
119 00552 Single unit 0.2
oil seal condition
131 00613 Replacing intake manifold One set Include: Applying liquid gasket 2.3
Replacing intake manifold
132 00614 One set Include: Applying liquid gasket 2.3
gasket
Removal and installing
133 00636 One set 1.6
intake pipe (manifold side)
Replacing intake pipe
134 00637 One set 1.6
(manifold side)
135 00622 Replacing air intake hose One set 0.4 0.2
136 00623 Replacing air intake pipe One set 0.4 0.2
137 00626 Replacing air intake pipe One set Turbo charger to inter cooler 0.4
138 00627 Replacing air intake pipe One set Air cleaner to turbo charger 0.4 0.2

12-22
 12. STANDARD MAINTENANCE TIME TABLE

SK350-9
Q'ty
Work
Work Work unit Works
No. Adding
1 hour by
1 each
Completed
139 00675 Replacing silencer body 0.3 0.2
machine
Tightening exhaust Completed
142 00641 1.3
manifold machine
Removal and installing Completed
143 00643 With insulator and stud bolt 3.2
exhaust manifold machine
Include: Replacing stud bolt with
Replacing exhaust Completed
144 00644 new one and insulator 3.4
manifold machine
(TI system)
Replacing exhaust Completed
145 00645 3.2
manifold gasket machine
One side of
Replacing exhaust heat Removal and installing of turbo
146 00646 completed 2.6
insulator charger
machine 12
147 00651 Replacing exhaust pipe One set 0.8
Replacing exhaust pipe
148 00653 One set 0.6
gasket
Removal and installing
164 00686 One set 2.5
turbo charger
165 00687 Replacing turbo charger One set Include: Replacing stud bolt 2.5
Replacing turbo charger Include: Removal and installing of
167 00689 One set 0.9
oil return pipe lower insulator
Replacing air intake pipe
174 00624 One set 0.4
upper (cooler to manifold)
Removal and installing
From engine is removed condition
engine and timing gear
188 00701 Single unit Include: Removal and installing of 5.4
cover
cylinder head
(fly wheel housing)
From engine is removed condition
Replacing timing gear
189 00711 Single unit Include: Removal and installing of 5.4
cover (fly wheel housing)
cylinder head
Replacing timing gear
From timing gear cover is removed
190 00712 cover gasket Single unit 0.7
condition
(fly wheel housing)
Replacing timing gear
From timing gear cover is removed
191 00713 cover plate Single unit 1.0
condition
(rear end plate)

12-23
12. STANDARD MAINTENANCE TIME TABLE

SK350-9
Q'ty
Work
Work Work unit Works
No. Adding
1 hour by
1 each
Replacing timing gear
From timing gear cover is removed
192 00714 cover plate gasket (rear Single unit 1.0
condition
end plate gasket)
Replacing idler gear From timing gear cover is removed
193 00725 Single unit 0.2 0.2
(main) condition
From timing gear cover is removed
194 00736 Replacing idler gear (sub) Single unit 0.1 0.2
condition
Replacing idler gear shaft From timing gear cover is removed
195 00726 Single unit 0.2
(main) condition
Replacing idler gear shaft From timing gear cover is removed
196 00737 Single unit 0.1
(sub) condition
Replacing crank shaft
197 00724 Single unit 0.4
gear rear
From timing gear cover is removed
201 00738 Replacing cam idle gear Single unit 0.4
condition
Replacing cam idle gear From timing gear cover is removed
202 00739 Single unit 0.4
shaft condition
From timing gear cover is removed
203 00731 Replacing camshaft Single unit 0.8
condition
From timing gear cover is removed
204 00732 Replacing camshaft gear Single unit 0.8
condition
205 00751 Replacing crank pulley One set 1.9
206 00754 Replacing crank dumper One set 2.8
Replacing crank shaft
207 00755 One set 2.2
front oil seal
Replacing crank shaft
208 00757 One set 2.8
front oil seal retainer
Replacing crank shaft
209 00758 front oil seal retainer One set 2.8
gasket
Completed
211 00801 Checking injection timing 0.3
machine
226 00834 Replacing priming pump One set 0.4
Cleaning fuel feed pump
227 00835 One set 0.4
strainer
Replacing through feed
228 00836 One set 0.4
valve
Replacing fuel injection
230 00838 One set 2.5 0.1
pipe

12-24
 12. STANDARD MAINTENANCE TIME TABLE

SK350-9
Q'ty
Work
Work Work unit Works
No. Adding
1 hour by
1 each
Replacing fuel filter
236 00851 One set 0.5 0.2
assembly
Replacing fuel filter
237 00857 One set 0.3
cartridge
253 00875 Replacing fuel hose One set 0.8
Replacing fuel leakage
254 00876 One set 0.8
pipe
Replacing oil filter
276 00912 One set 0.4
cartridge
Replacing oil filter relief
277 00907 valve (oil filter regulator One set 0.3
valve)
Replacing oil filter relief
278 00908 valve spring (oil filter One set 0.3 12
regulator valve)
Replacing oil filter safety
279 00909 One set 0.3
valve
Replacing oil filter safety
280 00910 One set 0.3
valve spring
00961
Removal and installing fly
(timing
294 wheel housing Single unit From engine is removed condition 6.1
gear
(timing gear cover)
cover)
295 00942 Replacing oil pump Single unit From engine is removed condition 6.3
296 00944 Replacing oil pump gear Single unit From engine is removed condition 6.5
297 00943 Overhaul of oil pump Single unit From engine is removed condition 6.5
298 00946 Replacing suction strainer One set 0.1
Replacing suction strainer
299 00947 One set 0.1
O-ring
301 00951 Replacing oil pipe One set 0.4 0.4
302 00954 Replacing oil hose One set 0.4 0.4
303 00971 Replacing cooling oil jet 1 0.2 0.2
Removal and installing
327 01028 One set Include: Filling engine coolant up 4.0
water pump
328 01029 Replacing water pump One set Include: Filling engine coolant up 4.0

12-25
12. STANDARD MAINTENANCE TIME TABLE

SK350-9
Q'ty
Work
Work Work unit Works
No. Adding
1 hour by
1 each
329 01030 Overhaul of water pump Single unit 0.8
Replacing water pump
330 01031 Single unit 0.6
pulley
Replacing water pump
331 01032 One set Liquid gasket 4.0
casing gasket
332 01036 Replacing cooling fan One set 0.9
Replacing fluid fan
333 01037 One set 0.9
coupling
Replacing thermostat
334 01044 One set Include: Filling engine coolant up 1.3
casing
Replacing thermostat
336 01046 One set Include: Filling engine coolant up 1.0
casing cover
Replacing thermostat
337 01047 One set Include: Filling engine coolant up 1.0
casing cover gasket
Include: Checking for temperature
338 01048 Replacing thermostat One set 1.0
at valve start opening
Include: Checking for temperature
339 01049 Checking thermostat One set 1.0
at valve start opening
341 01053 Replacing coolant hose One set 0.3 0.2
342 01054 Replacing radiator hose One set 0.3 0.2
Replacing fluid fan
343 01071 1 0.3
coupling
344 01072 Replacing cooling fan 1 0.3
From cooling fan is removed
345 01073 Replacing water pump 1 1.7
condition
346 01074 Overhaul of water pump 1 0.8
Removal and installing
402 01401 One set 0.8
alternator
403 01402 Replacing alternator One set 0.9
Replacing alternator
404 01406 One set 1.0
support bracket
405 01408 Replacing V-belt One set 0.3
Removal and installing
438 01801 One set Include: Function check 3.0
supply pump
439 01802 Replacing supply pump One set Include: Function check 3.0

12-26
 12. STANDARD MAINTENANCE TIME TABLE

SK350-9
Q'ty
Work
Work Work unit Works
No. Adding
1 hour by
1 each
Removal and installing
common rail assembly
440 01830 One set Include: Function check 3.8
(with pressure sensor,
pressure limiter)
Replacing common rail
441 01804 assembly (with pressure One set Include: Function check 3.8
sensor, pressure limiter)
Removal and installing Completed
442 01805 Include: Function check 3.5
injector assembly machine
Replacing injector Completed Include: Function check and
443 01806 4.0
assembly machine reprogramming
Removal and installing
444 01807 One set Include: Function check 1.9 0.2
injector assembly
Replacing injector Include: Function check and 12
445 01808 One set 2.4 0.2
assembly reprogramming
Removal and installing
446 01809 injector sub harness One set Include: Function check 1.9
assembly
Replace injector sub
447 01810 One set Include: Function check 1.9
harness assembly
Removal and installing
448 01811 One set Include: Function check 1.2 0.3
flow dumper
449 01812 Replacing flow dumper One set Include: Function check 1.2 0.3
Removal and installing
450 01813 One set Include: Function check 1.2
pressure limiter
451 01814 Replacing pressure limiter One set Include: Function check 1.2
Replacing common rail
452 01815 One set Include: Function check 1.2
pressure sensor
Replacing main engine
453 01816 One set Include: Function check 1.2
speed sensor
Replacing sub engine
454 01817 One set Include: Function check 1.2
speed sensor
Replacing coolant
455 01818 One set Include: Function check 1.2
temperature sensor
Replacing fuel
456 01819 One set Include: Function check 1.2
temperature sensor

12-27
12. STANDARD MAINTENANCE TIME TABLE

SK350-9
Q'ty
Work
Work Work unit Works
No. Adding
1 hour by
1 each
457 01820 Replacing accel sensor One set Include: Function check 1.5
Removal and installing
460 01823 1 Include: Function check 0.3
pressure sensor
Removal and installing
461 01824 1 Include: Function check 0.3
pressure limiter
463 01826 Replacing injection pipe One set Include: Function check 1.2 0.1
Replacing fuel pipe
464 01827 (common rail to supply One set Include: Function check 1.2 0.1
pump)
Replacing fuel leakage
465 01828 One set Include: Function check 1.7
pipe
Checking leakage of
469 01840 One set Include: Function check 1.2
pressurized fuel
Replacing main engine
471 01901 One set Include: Function check 1.2
speed sensor
Replacing sub engine
472 01902 One set Include: Function check 1.2
speed sensor
Replacing coolant
473 01903 One set Include: Function check 1.2
temperature sensor
474 01904 Replacing accel sensor One set Include: Function check 1.5
Removal and installing
475 01908 One set Include: Function check 2.5
EGR valve
476 01909 Replacing EGR valve One set Include: Function check 2.5
Removal and installing
479 01916 One set 1.8
EGR cooler
480 01917 Replacing EGR cooler One set 1.8
Removal and installing
481 01918 One set 0.3
closed ventilator
Replacing closed
482 01919 One set 0.3
ventilator

12-28
 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 .................................................... 13-4
13.3 MEASUREMENT OF ENGINE SPEED .......................................................................... 13-6
13.3.1 MEASUREMENT OF ENGINE SPEED ................................................................. 13-6
13.4 MEASUREMENT OF HYDRAULIC PRESSURE ........................................................... 13-7
13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE ...................................... 13-7
13.4.2 PLACE TO INSTALL PRESSURE GAUGE ........................................................... 13-7
13.4.3 PRESSURE ADJUSTMENT POSITION ............................................................... 13-8
13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE ................................................ 13-10
13.5 MEASURING TRAVEL PERFORMANCES .................................................................... 13-12
13.5.1 TRAVEL SPEED .................................................................................................... 13-12 13
13.5.2 DEVIATION OF TRAVEL ....................................................................................... 13-12
13.5.3 PERFORMANCES OF PARKING BRAKE ............................................................ 13-13
13.5.4 DRAIN RATE OF TRAVEL MOTOR ...................................................................... 13-14
13.6 MEASURING SWING PERFORMANCES ..................................................................... 13-15
13.6.1 SWING SPEED ..................................................................................................... 13-15
13.6.2 PERFORMANCE OF SWING BRAKE .................................................................. 13-15
13.6.3 PERFORMANCE OF SWING PARKING BRAKE ................................................. 13-16
13.6.4 DRAIN RATE OF SWING MOTOR ........................................................................ 13-17
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES .................................... 13-18
13.7.1 OPERATING TIME OF CYLINDERS .................................................................... 13-18
13.7.2 OIL TIGHTNESS OF CYLINDERS ........................................................................ 13-19
13.8 MEASURING PERFORMANCES OF SWING BEARING .............................................. 13-20
13.9 MECHATRO CONTROLLER .......................................................................................... 13-22
13.9.1 ENGINE CONTROL INPUT / OUTPUT ................................................................. 13-22
13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT
(A-B-C ADJUSTMENT) ......................................................................................... 13-22
13.9.3 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF
MECHATRO CONTROLLER ................................................................................. 13-29
13.10 EXHAUST GAS POST-CLEANING DEVICE
(DPF (DIESEL PARTICULATE FILTER)) ........................................................................ 13-30
13.10.1 HANDLING OF EXHAUST GAS POST-CLEANING DEVICE ............................... 13-30
13.10.2 INSPECTION ......................................................................................................... 13-31
13.10.3 MAINTENANCE STANDARD ................................................................................ 13-31
13.10.4 DPF (DIESEL PARTICULATE FILTER) ................................................................. 13-32

Book Code No. S5LC1325E03

13-1
13. MAINTENANCE STANDARD AND TEST PROCEDURE

Issue Data of Issue Applicable Machines Remarks

S5LC1325E01
First Edition September, 2010 SK350-9: YC
(NA)
S5LC1325E02
Revision February, 2011 SK350-9: YC
(NA)
S5LC1325E03
Revision May, 2011 SK350-9: YC
(NA)

13-2
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.1 HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS

(1) Application
1. When the machine is new:
Confirm 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 other components.

(2) Terminology
1. Standard values:
Values to be used to service 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 where 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 where reconditioning is impossible without replacement of parts. If the value is expected to
exceed the service limit before the next inspection and correction are performed; replace the parts immediately.
The operation over the specified values causes damage to increase and requires the down time of the machine,
and also causes safety problems.
13
(3) Cautions to be Exercised at Judgment
1. Evaluation of measured data:
Disagreement of measuring conditions, variations of data peculiar to a new machine, and measuring errors are
to be evaluated. Determine generally at what levels measured values are located, instead of determining
whether or not values fall within or run out of the reference values.
2. Determining correction, adjustment or replacement:
Machine performances deteriorate with time as parts wear and some deteriorated performances may be
restored to new levels. Therefore, determine correction, adjustment or replacement, depending upon the
operating hours, kind of work and circumstances in which the machine is placed, and condition the machine
performances to its most desirable levels.

(4) Other Cautions to be Exercised

1. Parts liable to degrade:
Rubber products, such as, hydraulic hoses:
O-rings and oil seals deteriorate with time; replace them at regular intervals or at overhauls.
2. Parts requiring regular replacement:
For 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 oil and grease:
In performing maintenance, it is necessary for the user to familiarize himself with how to handle the machine
safely, cautions to be exercised and inspection/lubrication procedures. Refer to the operators manuals as well.

13-3
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.2 PERFORMANCE INSPECTION STANDARD TABLE

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

Measuring Position Standard Tolerance Adjusting Measuring

Inspection Item Unit
Position Size Port value Hi Lo Point condition
Standard Measuring condition

Class
NAS 8
Cleanliness of hydraulic oil Hydraulic oil in tank — — — Sampling
or less
Hydraulic oil temperature Tank surface 50 (122) + 5 (41) - 5 (23) ° C — Atmospheric temp
Water temperature Radiator surface 75 (167) + 15 (59) - 15 (5) (°F) — 50°C~-10°C (122°F~14°F)

H mode Lo idle 1000 + 30 - 30 LOW throttle

Engine speed

not required
Measure the engine

Adjustment
H mode Hi idle 2100 + 30 - 30 Full throttle (HI idle)
H mode Decel speed at multi display on 1050 + 30 - 30 min-1 Perform all
the gauge cluster. measurement with
S mode Hi idle 1850 + 30 - 30 the air-conditioner
E mode Hi idle 1700 + 30 - 30 "OFF".
Pilot primary pressure circuit G pump a4 5.0 (725) + 0.5 (+73) 0 PR1 HI idle
valve pressure

P1 a1
ATT MR1 Boom up
Main relief

34.3 (4970) + 0.7 (+100) - 0.5 (-73)

P2 a2
P1 a1
Boost 37.8 (5480) + 0.5 (+73) 0 MR1 Boom up
P2 a2
R 37.8 (5480) 0 - 4.0 (-580) OR4 Boom down
Boom a1
High pressure circuit

H 39.7 (5760) 0 - 5.9 (-855) OR3 Boom up

Over load relief valve pressure

R 39.7 (5760) 0 - 5.9 (-855) OR8 Arm out

Main pump

Arm a2
H PF1/4 37.8 (5480) 0 - 4.0 (-580) MPa OR7 Arm in
R 37.8 (5480) 0 - 4.0 (-580) (psi) OR2 Bucket dump
Bucket a1
H 39.7 (5760) 0 - 5.9 (-855) OR1 Bucket digging
RH 29.0 (4205) + 6.0 (+870) 0 OR6 Swing RH
Swing a2
LH 29.0 (4205) + 6.0 (+870) 0 OR5 Swing LH
FW —
RH a1 35.8 (5190) 0 - 2.0 (-290) Simultaneous
Travel

RV —
operation of travel
FW —
LH a2 35.8 (5190) 0 - 2.0 (-290) RH and LH
RV —

13-4
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

Standard
Inspection item Unit
value
Track link revolution 1st speed 34.3 ~ 30.7
(RH,LH) LC sec / 3 rev
(H mode) 2nd speed 20.4 ~ 18.0
Up 3.0 ~ 3.7
Boom
Down 2.5 ~ 3.2
Operating speed

Operating time of
In 3.6 ~ 4.2
cylinder Arm sec (At no load)
Out 3.3 ~ 3.9
(At no load)
Digging 2.9~ 3.6
Bucket
Dumping 2.1 ~ 2.7
RH
Swing speed 17.9 ~ 20.0 sec / 3 rev
LH
1st speed Iron shoe 21.0 ~ 26.5
Travel speed sec / 20 m
2nd speed Iron shoe 13.0 ~ 15.2
Amount of travel
2nd speed 0 ~ 240 mm / 20 m
deviation
Parking brake drift 15 degree gradient 0 mm / 5 min
Performance of Swing Neutral position after
Performance

72 ~ 112 degree
brake 180° full speed swing
Performance of Swing
15 degree gradient 0 mm
parking brake
Tip of the bucket tooth 120
ATT amount of drift Boom cylinder 4.2 mm / 5min (At no load)
Arm cylinder 6 13
Amount of horizontal play at the bucket tooth 27 ~ 53 mm

The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation numbers in
advance.
(1) Bucket digging, (2) Bucket dump, (3) Boom up, (4) Boom down
(5) Swing left, (6) Swing right, (7) Arm in, (8) Arm out

13-5
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.3 MEASUREMENT OF ENGINE SPEED

13.3.1 MEASUREMENT OF ENGINE SPEED

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

RED

WHITE

BLUE

(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 to No.2, No.3....each time the "Up Arrow Switch" on the gauge cluster is pushed.
4. The screen returns to No.45, No.44....each time the "Down Arrow Switch" is pushed.
5. The display does not disappear unless the starter switch is turned to"OFF".

NO.2 ENG
G-3 SPEED SET 2205
MEAS 1 2201
MEAS 2 2201
G-5 ENG OIL PRS. LIVE
WATER TEMP. 100 OFF
F
MODE HM
ATT MODE BRK
H-1 ACCEL. VOLT. 4.2V
UP ARROW POS 100%
SWITCH ECU OUTPUT 0.5V
BUZZER Service Diagnosis for E/G Speed Measuring
STOP
(Example)
SWITCH

DOWN ARROW
SWITCH
Switch for E/G Speed Indication

13-6
 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 A3 a5
analysis: 1 set
(2) Measuring cleanliness of hydraulic oil A2
PSV2 (A1)
(PSV1)
Dr3
B3

B1

a1 a2
Gauge Port On Main Pump

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

13.4.2 PLACE TO INSTALL PRESSURE GAUGE

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

13-7
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.4.3 PRESSURE ADJUSTMENT POSITION

(1) Main control valve

PLUG FOR
OR8 : ARM (R) OPTIONAL RELIEF

MACHINE
FRONT

MR1 : MAIN RELIEF OR3 : BOOM (H) OR2 : BUCKET (R)

(ATT & TRAVEL)

VIEW FROM THE TOP OF THE MACHINE

OR4 : BOOM (R) OR1 : BUCKET (H)

MACHINE
FRONT

OR7 : ARM (H) PLUG FOR OPTIONAL RELIEF

VIEW FROM THE BOTTOM OF THE MACHINE

Relief Valve Position On Main Control Valve

13-8
 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.

A3

a5

Dr3

B3
PR1 ADJUST SCREW
FOR PILOT RELIEF

Pilot Relief Valve Position

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

PLUGS FOR PRESSURE

MEASUREMENT
2-PT1/4
A B
PA
PB
13
DB

OR5
OR6 SWING LEFT
SWING RIGHT OVERLOAD RELIEF
OVERLOAD RELIEF

Swing Over Load Relief Position

13-9
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

No. of turns of adjust screw Pressure change MPa (psi)

1 turn Approx. 2.1 (305)

LOCK NUT HEX24

311
Pilot Relief Valve

(2) 2-stage main relief valve

(Commom for travel and ATT sections)
Start from the boosting side first. Loosen nut (1), adjust the pressure with adjusting screw (2) and tighten nut (1)
after completion of the adjustment on the boosting side.
Then, loosen nut (3), adjust the pressure on the standard side with adjusting screw (4) and tighten nut (3) after
completion of the adjustment.
Tools: Spanner: 32 mm,
Tightening torque : 27.4 to 31.4 N-m (20 to 23 lbf-ft)
Tools: Spanner: 22 mm,
Tightening torque : 27.4 to 31.4 N-m (20 to 23 lbf-ft)
Tools: Spanner: 19 mm, Adjust screw
Tools: Allen wrench: 6 mm

HEX32 HEX19
No. of turns of adjust screw Pressure change MPa (psi) 1 2

Boosting side 1 turn Approx. 17.6 (2560)

STD side 1 turn Approx. 17.6 (2560)

4 3
HEX22
Main Relief Valve (Travel Section, Att Common
Section)

13-10
 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 to 31.4 N-m (20 to 23 lbf-ft)
Tools: Allen wrench: 6 mm

No. of turns of adjust screw Pressure change MPa (psi)

1 turn Approx. 17.7 (2560)

2 1
HEX22
Over Load Relief Valve (Boom, Bucket, Arm
Sections)

(4) Over load relief valve (Swing)

When the adjustment of pressure 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

HEX38 HEX30
1 2
No. of turns of adjust screw Pressure change MPa (psi)
1 turn Approx. 10 (1450)

13
3
R
Swing Over Load Relief Valve

(5) Travel over load relief valve

This valve was adjusted by valve maker. Do not
replace any inner parts except for O-rings.

Travel Over Load Relief Valve

13-11
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 tensioned
evenly.

One Side Lifted Position

(3) Preparation
Attach the reflection panel shoe plate.
Swing the swing frame 90° as shown in above
REFLECTION
Fig. and raise one side of the tracks off the ground PANEL
using the attachment.

Adhering Position Of Reflection Panel

(4) Measurement
Engine revolution: High idle Track link revolution Unit : sec / 3 rev.
2-speed travel switch: 1st-speed and 2nd-speed Standard Reference value Service
Measurement item value for remedy limit
Measuring points : Right and left
H mode 1st speed 33.2~36.4 42.5~46.6 57.2~
Method, example LC
Measure the revolutions visually.
H mode 2nd speed 19.7~21.7 25.2~27.8 31.1~

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 BOOM FOOT PIN
hydraulic pump and the travel motor of the travel
drive system.
(2) Condition
Hydraulic oil temperature:
45 to 55C degrees (113 to 131F degrees) ARM TOP PIN
RH and LH crawler are tensioned evenly.
Firm, level ground Travel position
Engine revolution: High idle

13-12
 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).
A
20m (66ft)

Measuring Method

(4) Measurement
1. Measure the max. deviation distance of the Travel deviation Unit : mm (in) / 20m (66ft)
circular arc in the 20 m (66 ft) length, excluding Measuring Reference value
position Standard value for remedy Service limit
the preliminary run of 3 to 5 m (10 to 16 ft).
A 240 (9.45) or less 480 (18.9) 720 (28.4)
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 approximately a 15° gradient and a BOOM FOOT PIN
stopped condition in a no-load travel position.
(3) Preparation
ARM TOP PIN
Place an angle meter on the shoe plate and confirm
that it makes an angle more than 15°.
Hang a perpendicular in parallel with the guide 15 degree slope 13
frame rib on the track frame and put a mark
(matching mark) on the shoe plate. Parking Brake Operating Position

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

C ANGLE METER
GUIDE FRAME
Method of Measurement

Parking brake Unit : mm(in)/5min

Measuring Reference value
position Standard value for remedy Service limit
C 0 1 (0.04) 2 (0.08)

13-13
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 FORWARD 90 o 10
(3.54") (0.394")
confirm the performances of the travel motor.
o 22 PIPE 40
(2) Conditions (0.866") (1.57")
Hydraulic oil temperature:
45 to 55C degrees (113 to 131F degrees) RIB "A" 150
STOPPER (5.91")
Engine revolution: Hi idle "B"

o 90
(3.54")
ROTARY DIRECTION
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 to the drain port on the travel
motor and drain oil into a container.

Method Of Measuring The Drain Rate Of Travel

Motor

(4) Measurement : at Travel Lock

1. Start the engine and relieve pressure at the full Travel deviation Unit : L(gal)/30sec
stroke of the travel lever. Measuring Reference value
position Standard value for remedy Service limit
2. Measure the drain rate for 30 seconds of Drain rate 7.0 (1.8) 14.0 (3.7) 21.0 (5.5)
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.)

13-14
 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.
(2) Conditions
Hydraulic oil temperature:
45 to 55C degrees (113 to 131F degrees)
Firm, level ground
Engine revolution: High idle
(3) Preparation
With the bucket empty and extend the boom, arm
and bucket cylinder fully.
Swing Speed Measuring Position (at the min.
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 a 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 speed Unit : sec/3 rev
swing relief valve. Measuring Reference value
13
position Standard value for remedy Service limit
(2) Conditions Right 17.9~20.0 21.9~24.4 27.2~
Hydraulic oil temperature: Left 17.9~20.0 21.9~24.4 27.2~
45 to 55C degrees (113 to 131F degrees)
Firm, level ground
Engine revolution: High idle

(3) Preparation
1. With the bucket empty, retract the arm cylinder
fully and extend the bucket cylinders fully. Move ARM TOP BOOM FOOT
the boom so the arm top pin is positioned at the PIN PIN
same height as the boom foot pin.
2. Put a matching mark on the outer circumference
of the swing bearing on the upper frame side and
on the track frame side. Place two poles (flags)
on the front and back of the extended line on the
matching mark. Swing Brake Performance Measuring Position

13-15
13. MAINTENANCE STANDARD AND TEST PROCEDURE

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

Amount of deflection of Swing brake performance Unit : degree

Swing drift matching marks [m (ft-in)] Measuring Reference value
angle ( ) = X 360 position Standard value for remedy Service limit
Circumferential length of
swing race [m (ft-in)] Swing 180 112 or less 123 134

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 a 15° incline.
Stop the machine at right angles with the slope.
With the bucket empty, retract the arm cylinder fully
and extend the bucket cylinder fully. Move the
boom so the arm top pin is positioned at the same
height as the boom foot pin.

Swing Parking Brake Performance Measuring

Position

(3) Preparation
Place the angle meter on the shoe plate and make MEASUREING THE LENGTH OF THE ARC OVER
THE OUTER CIRCUMFERENCE OF OUTER RACE
sure that the angle is more than 15°.
MATCHING MARKS ON
Put a matching mark on the outer race side and on OUTER RACE
the inner race side.

MATCHING MARKS
ON INNER RACE
Measuring Position Of Swing Parking Brake
Performances

(4) Measurement
When five minutes has passed after the engine is Performance of swing parking brake Unit : mm(in)/5min
shut off, measure the length of the movement of the Measuring Reference value
position Standard value for remedy Service limit
matching marks. C 0 1 (0.04) 2 (0.08)

13-16
 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 performance of the swing motor.
(2) Conditions
Hydraulic oil temperature: 45 to 55C degrees (113
to 131F degrees)
Firm, level ground
Engine revolution: High 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 the Travel deviation Unit : L(gal)/30sec
bucket against the inside of the right or left shoe Measuring Reference value
position Standard value for remedy Service limit
plates. Drain rate 2.1 (0.55) 5.2 (1.4) 6.2 (1.6)
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. 13

13-17
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.

30cm (1ft)
Measuring Position For Bucket Digging And
Dump

(2) Condition
Hydraulic oil temperature: 45 to 55C degrees (113 Condition :
Arm cylinder most retracted
to 131F degrees) Bucket cylinder most extended

Engine revolution: High idle

Operating time excluding the cushion stroke.

Measuring Position For Boom Up And Down

Motions

(3) Preparation
Firm level ground with the bucket empty
(4) Measurement 1: Boom up and down
With the boom operating lever at full stroke,
measure the required operating time of the bucket
between the ground surface and its highest
position. 30cm (1ft)

Measuring Position For Arm In And Out Motions

Measurement 2: Arm in and out, bucket digging and

dump
In a position in which the tooth of the bucket rises to a Cylinder Operating time Unit : sec
level of about 30 cm (1ft) above ground, measure the Measuring Reference value
position Standard value for remedy Service limit
full stroke operating time required with the arm and
bucket operating levers at full stroke. 2.9~3.6 3.7~4.5 4.8~
2.1~2.7 2.7~3.5 3.6~
3.0~3.7 3.8~4.6 5.0~
2.5~3.2 3.2~4.0 4.2~
3.6~4.2 4.5~5.2 5.7~
3.3~3.9 4.1~4.9 5.3~

When lowering the boom, lower the bucket onto soft ground or cushioning such as rubber tires. Never put the
bucket against concrete or other solid material.

13-18
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.7.2 OIL TIGHTNESS OF CYLINDERS

(1) Purpose
Confirm that the cylinder oil is 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 out air from the cylinders before checking for oil tightness.
Retract the arm cylinder rod 50 mm (2 in) from stroke end so the piston does not match the same range of the
cushioning mechanism.
(3) Preparation
With the bucket empty. Retract the arm cylinder rod 50mm (2in) from the most retracted position. And extend
the bucket cylinders fully. Then hold the boom so the arm top pin is positioned at same height as the boom foot
pin.
(4) Measurement
Measure the items five minutes after the engine is turned off.

B
Oil tightness of cylinder Unit : mm/5min
BOOM FOOT PIN Measuring Reference value
C position Standard value for remedy Service limit

A A 4 (0.16 in) 5 (0.2 in) 7 (0.28 in)

B 6 (0.24 in) 7.5 (0.3 in) 10 (0.4 in)
D C - - -
ARM TOP PIN
D 120 (4.7 in) 150 (5.9 in) 200 (7.9 in)

13

13-19
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.8 MEASURING PERFORMANCES OF SWING BEARING

(1) Purpose
Measure the gap between the lower frame and the LOCATION OF BEARING
MOUNTING BOLTS
bottom face of the swing bearing and estimate the
degree of wear of the swing bearing.
(2) Condition SWING BEARING
Firm, level ground. A
The swing bearing mounting bolts are not
loosened.
DIAL INDICATOR
The swing bearing is lubricated well and not making
abnormal sounds during swinging. LOWER FLAME

How To Measure The Axial Play Of Swing Bearing

(3) Preparation
1. Install a dial indicator to the magnetic base and
attach it to the lower frame.
2. Direct the upper swing body and the lower frame 90 ~100
toward the travel direction, bring the probe of the
dial indicator in contact with the bottom surface
of the outer race on the swing body side and set
30cm (1ft)
the reading at zero.
Measuring Position 1

(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 ARM TOP BOOM FOOT
PIN PIN
degrees to 110 degrees and the crawler front is
lifted by attachment about 30cm (1ft)] and in
position 2, using a dial indicator.

Measuring Position 2

Axial play of swing bearing Unit : mm (in)

Measuring Reference value
position Standard value for remedy Service limit
0.8~1.8 2.3~3.3 3.6~
A (0.03~0.07) (0.09~0.13) (0.14)

13-20
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

(5) Measurement 2 (Measuring position 3)

1. Retract the arm cylinder fully and extend the ARM TOP BOOM FOOT
bucket cylinder fully. Move the boom so the arm PIN PIN

top pin is positioned at the same height as the

boom foot pin. Then swing the bucket right and
left by man power. In this case, the gap of the
attachment is included.

Measuring Position 2

Right and left movement of the tip of bucket Unit : mm (in)

Measuring Reference value
position Standard value for remedy Service limit
Bucket 50 (1.97) 100 (3.94) 120 (4.72)

13

13-21
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.9 MECHATRO CONTROLLER

13.9.1 ENGINE CONTROL INPUT / OUTPUT

E-27:
C-8: EMERGENCY
ACCEL
ENGINE CONTROLLER
INJECTOR

E-1:
C-2: FUSE&RELAY
GAUGE CLUSTER BOX

ENGINE
ENGINE SPEED
SENSOR

PUMP
PROPORTIONAL
C-1: VALVE
STARTER ACCEL MECHATRO CONTROLLER
SWITCH POTENTIO METER
Input / Output

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

13.9.2.1 PURPOSE OF THE ADJUSTMENT

There are 2 kinds of adjustment of mechatro controller as shown below: every adjustment is an essential function
to ensure performance of the machine.
(1) Adjustment of pump ("B" adjustment)
This adjustment is performed to correct the output variation by coordinating the output hydraulic pressure with
the engine rated output.
(2) Adjustment of unloading valve ("C" adjustment)
This adjustment is performed to correct the open variation of the 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 the unloading valve.

13-22
 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 conditioner OFF.
(3) Turn the starter key switch OFF to stop the engine.
When the mechatro controller is 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 the Error Code List.

For machines equipped with a lifting magnet, turn the generator OFF.

13

13-23
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.9.2.4 ADJUSTING PROCEDURE

MULTI DISPLAY

WORK MODE SELECT SWITCH UP ARROW SWITCH

MENU SWITCH
BUZZER STOP SWITCH

DOWN ARROW SWITCH

Gauge Cluster
(1) Adjustment of pump ("B" adjustment)
Procedure
1. Turn the starter key switch ON, keep the work
MULTI DISPLAY
mode selector switch on the gauge cluster pressed, (EXAMPLE)
and hold it for 5 to 10 seconds, and then release it. S 12:15

(If the engine is started, the following indication is

not displayed. Therefore do not start the engine.)
E F

2. Keep the buzzer stop switch on the gauge cluster

pressed for 5 seconds and release it, and the
screen for selecting the adjustment is displayed.
ADJUST OUTPUT FIN
When adjustment data is not entered in mechatro ADJUST UNLOAD FIN

controller; "READY" is indicated. If the adjustment ADJUST CRANE

ADJUST 0 CRANE
---

---

operation is once performed, "FIN" is indicated. ADJUST LMN ---

ADJ INTERFE PREV ---

And the lever lock solenoid is automatically ADJUST INITIAL ---

released, disabling all operations.

3. Press the menu switch on the gauge cluster to

START
display "START ENGINE". ENGINE
"Engine SPEED", P1 and P2 "PUMP PRESSURE" ENGINE 2040

and "STEP" (acceleration command voltage) are STEP 0

ECU OUTPUT 120

indicated. P1 PUMP 350

P2 PUMP 350

P1 UNLOAD 750

P2 UNLOAD 750

P1 PRESSURE 250

P2 PRESSURE 11

13-24
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

4. After engine starting, press the menu switch on the

gauge cluster, and "MEMORY PUMP" is displayed. MEMORY
PUMP
And the adjustment shifts to pump adjustment
ENGINE 2290
automatically. Then the speed shifts from LOW STEP 0

idling to HIGH idling. And "MEMORY PUMP" is ECU OUTPUT

P1 PUMP
360

390

displayed. And the unloading proportional valve P2 PUMP 390

P1 UNLOAD 360
and pump proportional valve actuate, accordingly P2 UNLOAD 360

P1 PRESSURE 341
the loading of the pump is increased. P2 PRESSURE 340

The "ENGINE SPEED", P1 and P2 "PUMP

PRESSURE", and P1 and P2 pump "PROPO-
VALVE" current (command value) are indicated.

5. After detection of the engine rated speed, the

adjustment of the pump is automatically completed. FINISH
PUMP
And "FINISH PUMP" is displayed.
ENGINE 2040
(Press the buzzer stop switch on the gauge cluster STEP 0

while this display appears and the adjustment is ECU OUTPUT 120

P1 PUMP 350

completed. The unloading adjustment required P2 PUMP 350

P1 UNLOAD 750
later is not performed, and default value is written.) P2 UNLOAD 750

P1 PRESSURE 250

P2 PRESSURE 11

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

Procedure
1. The adjustment shifts from pump to unloading, and 13
the unloading valve actuates, accordingly the pump MEMORY
UNLOAD
pressure is detected. And "MEMORY UNLOAD" is
ENGINE 2290
displayed. STEP 0

The "ENGINE SPEED", P1 and P2 "PUMP ECU OUTPUT

P1 PUMP
360

390

PRESSURE", and P1 and P2 "PROPO-VALVE" P2 PUMP 390

P1 UNLOAD 360
voltage (command value) are indicated. P2 UNLOAD 360

P1 PRESSURE 341

P2 PRESSURE 340

2. When the unloading valve operates to the specified

value, the adjustment of the unloading proportional FINISH
UNLOAD
valve is automatically terminated. And "FINISH
ENGINE 2040
UNLOAD" is displayed. STEP 0

The speed is shifted to the speed corresponding to ECU OUTPUT

P1 PUMP
120

350

the acceleration potentiometer. P2 PUMP 350

P1 UNLOAD 750
The adjusting current value is indicated on the P2 UNLOAD 750

P1 PRESSURE 250
display of the current of P1 and P2 unloading P2 PRESSURE 11

proportional valves. The adjusting range is usually

520 to 635 mA.

Stop the engine. (The adjusted data is

automatically stored.)

13-25
13. MAINTENANCE STANDARD AND TEST PROCEDURE

(3) Corrective actions taken when the adjustment cannot be performed:

1. In cases where the adjustment of the pump cannot
be performed: And "ERROR PUMP" is displayed. ERROR
PUMP
Judging Condition 1:
ENGINE 2290
P1 and P2 average pump pressure at the time STEP 0

ECU OUTPUT 360

when the adjustment is completed is 25MPa or P1 PUMP 390

less. P2 PUMP 390

P1 UNLOAD 360

Judging Condition 2: P2 UNLOAD 360

P1 PRESSURE 341
The adjustment does not complete although the P2 PRESSURE 340

pump proportional valve current reaches 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 pressure leaks.
-Check that the pressure sensor functions normally.
And so on.
b. Identify the reason why the actual flow rate does not increase,
-Check that the pump proportional valve operates normally.
-Check that the pump regulator operates normally.
And so on.

2. In cases where the unloading valve cannot be

performed: And "ERROR UNLOAD" is displayed. ERROR
UNLOAD
Judging Condition 1:
ENGINE 2290
The pump pressure does not increase up to the STEP 0

ECU OUTPUT 360

pressure in the range of the specified adjustment. P1 PUMP 390

Or the increased pressure is held as it is. P2 PUMP 390

P1 UNLOAD 360

Judging Condition 2: P2 UNLOAD 360

P1 PRESSURE 341
Pressure sensor of either the P1 pump or P2 pump P2 PRESSURE 340

has failed.

Normally the pump pressures of the 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 pressure leaks.
-Check that the pressure sensor functions normally.
And so on.

13-26
 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 service the machine, and perform the adjustment work.
2. In the condition where a large load is constantly applied to engine, the adjustment cannot be performed
normally.

For machines equipped with a lifting magnet, turn the generator OFF.

(5) When the adjustment of the unloading valve only is performed: ("C" adjustment)
In the event where only the unloading valve and unloading proportional valve are replaced, perform the
adjustment of the unloading valve only.

Procedure
1. Turn the starter switch ON, keep the work mode
MULTI DISPLAY
selector switch on the gauge cluster pressed, and (EXAMPLE)
hold it for 5 to 10 seconds, and then release it. S 12:15

(If the engine is started, the following indication is

not displayed. Therefore do not start the engine.)
E F

2. Keep the buzzer stop switch on the gauge cluster

pressed for 5 seconds and release it, and the
screen for selection of the adjustment type is
13
ADJUST OUTPUT FIN
displayed. And "ADJUST" is displayed. ADJUST UNLOAD FIN

ADJUST CRANE ---

When adjustment data is not entered in the ADJUST 0 CRANE ---

mechatro controller, "READY" is indicated. If the ADJUST LMN ---

ADJ INTERFE PREV ---

adjustment operation is once performed, "FIN" is ADJUST INITIAL ---

indicated.
And the lever lock solenoid is automatically
released, disabling all operations.

3. Change the adjusting items with the up arrow

switch (UP) and down arrow switch (DOWN), and
select "ADJUST UNLOAD". (See Fig. "Gauge
ADJUST OUTPUT FIN

cluster") ADJUST UNLOAD FIN

ADJUST CRANE ---

Like the output adjustment, when adjustment data ADJUST 0 CRANE ---

is not entered in the mechatro controller, "READY" ADJUST LMN

ADJ INTERFE PREV

---

---

is indicated. If the adjustment operation has been ADJUST INITIAL ---

performed, "FIN" is indicated.

13-27
13. MAINTENANCE STANDARD AND TEST PROCEDURE

4. Press the menu switch on the gauge cluster to

display "START ENG". START
ENGINE
"ENGINE SPEED", P1 and P2 "PUMP
ENGINE 2040

PRESSURE" and "STEP" (acceleration command STEP 0

ECU OUTPUT 120

voltage) are indicated. P1 PUMP 350

P2 PUMP 350

P1 UNLOAD 750

P2 UNLOAD 750

P1 PRESSURE 250

P2 PRESSURE 11

5. After starting engine, press the menu switch on the

gauge cluster and "MEMORY UNLOAD" is MEMORY
UNLOAD
indicated, the engine speed is automatically ENGINE 2290

increased and the adjustment of the unloading STEP 0

ECU OUTPUT 360

valve is performed. P1 PUMP 390

"ENGINE SPEED", P1 and P2 "PUMP P2 PUMP

P1 UNLOAD
390

360

PRESSURE" and "PROPO-VALVE" (acceleration P2 UNLOAD 360

P1 PRESSURE 341
command current) are indicated. P2 PRESSURE 340

6. When the unloading proportional valve operates to

the specified value, the adjustment of the unloading FINISH
UNLOAD
proportional valve automatically completes.
ENGINE 2040
"FINISH UNLOAD" is indicated. STEP 0

The speed is shifted to the speed corresponding to ECU OUTPUT

P1 PUMP
120

350

the acceleration potentiometer. P2 PUMP 350

P1 UNLOAD 750
The value of the adjusting current is indicated on P2 UNLOAD 750

P1 PRESSURE 250
the display of the current for the P1 and P2 P2 PRESSURE 11

unloading proportional valves. The adjusting range

is usually 520 to 635 mA.

Stop the engine. (The adjusted data is

automatically stored.)

13-28
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.9.3 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO

CONTROLLER
(1) Engine emergency mode
When the trouble occurs and the control of the engine is impossible, the engine speed can be controlled by
operating the emergency acceleration (E-27) provided on the rear side of the seat.

Operating procedure:
1. Set the emergency acceleration to the NORMAL position.
2. Start engine.
3. Turn the emergency acceleration to High side and control the engine speed.
4. When stopping the engine, set the emergency acceleration to the NORMAL position before stopping.

Never increase the engine speed immediately after starting engine. It is dangerous.
To avoid this danger, repeat the above procedure, or the engine speed will not increase.
When the machine does not operate, set the emergency acceleration to the NORMAL position.

(2) Pump emergency mode

In the event where a failure of the P1 or P2 pump proportional valve represented in items of self diagnosis is
indicated on the multi display provided on the gauge cluster, the full power control of the pump and positive
control through the mechatro controller are unavailable. Then the P1 and P2 pumps are automatically switched
to emergency mode, making the operation with the power shift control of the pump and the constant power
control by means of self-pressure possible. But be careful, in emergency mode, the accuracy of inching
becomes poor and the frequency of engine down is increased, and the engine stalls in the LOW speed
condition.

13
The emergency mode should be used only in case of emergency. We recommend that the defective section is
repaired by troubleshooting as soon as possible.

13-29
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.10 EXHAUST GAS POST-CLEANING DEVICE (DPF (DIESEL

PARTICULATE FILTER))

13.10.1 HANDLING OF EXHAUST GAS POST-CLEANING DEVICE

After about 10 hours of operating time, some quantity of soot is trapped by filter. And the soot is deposited in the
exhaust gas post-cleaning device. The exhaust gas post-cleaning device is changed to regeneration mode
automatically. This regeneration system uses soot combustion to generate.
To avoid malfunction of the exhaust gas post-cleaning device, observe the following points. (According to working
conditions, this deposition time varies.)
During automatic soot combustion for regeneration, the exhaust sound changes, but this change of sound does not
show any malfunction of system.

When some quantity of soot is trapped by the filter and deposits in the exhaust gas post-cleaning device, this
device starts combustion treatment (Regeneration) automatically. This function prevents abnormal deposits of soot,
and keeps the purification capacity in good condition at all times. We make soot combustion during working
possible by use of a high-performance catalyst and common rail fuel injection system.

A. Do not use unspecified fuel.

Use the low-sulfur diesel fuel (S50: Sulfur content 50 ppm or lower). In cold areas, use appropriate low-sulfur diesel
fuel. If you use unspecified fuel, it adversely affects the engine and the exhaust gas post-cleaning device, and it
causes white smoke and malfunction.

B. Use recommended brand engine oil.

To maintain the function of the exhaust gas post-cleaning device for long periods, use the recommended brand of
engine oil.

C. Do not modify the tail-pipe.

To avoid adverse effect, do not modify the tail-pipe. If the tail-pipe direction or length is modified, it causes an
adverse effect to the exhaust gas post-cleaning device.

13-30
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

D. The exhaust gas post-cleaning device burns trapped soot automatically. (Regeneration)

Immediately after the machine is operated and during regeneration, the temperature of the exhaust pipe, muffler
and exhaust gas are very high. It causes fire: remove all flammable materials from these hot parts. And also, you
can get burned by hot exhaust gas.

Depending on the condition of operation, the combustion of trapped soot (regeneration) may not be completed.
When the demand of regeneration operation is displayed on the gauge cluster (monitor), push the regeneration
switch and start the combustion of soot (regeneration).

When the regeneration operation is performing, the engine speed is set to a constant speed and the pump relief
may not function. But this is not a malfunction. This raises the temperature of the exhaust gas and the purpose of
purification of the exhaust gas.

13.10.2 INSPECTION
1. Check for damage of the sensor wiring/hoses that are located on the main unit of the exhaust gas post-cleaning
device.

13

To avoid burns, immediately after the machine operation, do not check of wirings and hoses of the sensor.

2. If damage (Cracks etc.) is found on the surface of the hose for the sensor, replace the hose immediately.

Replace the hoses for the sensor with a new one about every two years.
Replace the mounts for the sensor with new oneed about every two years.

13.10.3 MAINTENANCE STANDARD

1. Check the DPF backpressure every 4,500 hours and determine whether maintenance is required or not.

When other than HINO genuine oil and irregular fuel are used, it is not warrantable at the maintenance interval.

See the 10-14 page in chapter 51 engine.

13-31
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.10.4 DPF (DIESEL PARTICULATE FILTER)

1. Routine inspection items
(1) Confirm that there is no abnormal increase of the engine oil in the oil pan.

If the engine oil quantity has increased abnormally, it is possible that there is a malfunction in the injection system
or that unburned fuel has leaked through the gap between the piston rings and the cylinder liner into the engine oil
pan.

See the 10-14 page in chapter 51 engine.

13-32
 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 .................................................. 21-8
21.1.4 BOOM UP CONFLUX CONTROL ............................................................. 21-10
21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL ................................ 21-12
21.1.6 ARM-IN ANTI-CAVITATION CONTROL .................................................... 21-14
21.1.7 ARM-OUT CONFLUX CONTROL ............................................................. 21-16
21.1.8 BUCKET DIGGING (DUMP) CONFLUX CONTROL ................................. 21-18 21
21.1.9 BUCKET DIGGING ANTI-CAVITATION CONTROL .................................. 21-20
21.1.10 SWING PRIORITY CONTROL .................................................................. 21-22
21.1.11 TRAVEL STRAIGHT CONTROL ............................................................... 21-24
21.1.12 PRESSURE RELEASE CONTROL ........................................................... 21-26
21.1.13 N&B SWITCH CONTROL (OPTION) ........................................................ 21-28
21.1.14 OPTION CONFLUX CONTROL (OPTION) ............................................... 21-30
21.2 MECHATRO CONTROLLER ............................................................................. 21-33
21.2.1 SUMMARY OF MULTI DISPLAY ............................................................... 21-33
21.2.2 SELF DIAGNOSIS DISPLAY ..................................................................... 21-46
21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION .......................................... 21-48
21.2.4 TROUBLE HISTORY DIAGNOSIS ............................................................ 21-59
21.2.5 SET PROCEDURE OF MAINTENANCE SCHEDULE .............................. 21-60
21.2.6 ADJUSTING PROCEDURE OF DISPLAY ................................................ 21-62
21.2.7 MECHATRO CONTROL EQUIPMENT ..................................................... 21-65

Book Code No. S5LC2125E03

21-1
21. MECHATRO CONTROLLER

Issue Data of Issue Applicable Machines Remarks

S5LC2125E01
First Edition September, 2010 SK350-9: YC
(NA)
S5LC2125E02
Revision February, 2011 SK350-9: YC
(NA)
S5LC2125E03
Revision May, 2011 SK350-9: YC
(NA)

21-2
 21. MECHATRO CONTROLLER

PREFACE
This manual explains machines with the electro hydraulic conversion only with the 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

21-3
21. MECHATRO CONTROLLER

21.1 SUMMARY OF MECHATRO CONTROL SYSTEM

21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL
ELECTRIC
CONTROLLER INPUT SIGNAL
HYDRAULIC VOLTAGE OUTPUT L1
PILOT SECONDARY PRESSURE
SOLENOID PROPORTIONAL VALVE SECONDARY PRESSURE
SOLENOID PROPORTIONAL VALVE PRIMARY PRESSURE MAIN CIRCUIT

LH RH LH RH
OPTION PILOT VALVE

PILOT VALVE
PILOT VALVE FOR TRAVEL
FOR ATT

SE-9
SE-10

SE-11
MULTI CONTROL VALVE OR SENSOR BLOCK

LOW PRESSURE SENSOR

SE-4
(4)
GAUGE CLUSTER
SE-3
LCD DISPLAY (3) L2
FOR SELECTION SE-2 L3
FUEL GAUGE (2)
COOLANT TEMP. GAUGE SE-1
LOWER SW. (1)
SCREEN CHANGE
BUZZER STOP SE-8
(8)
MODE SE-7
WASHER (7)
L4
WIPER
TRAVEL (6)
DIGGING MODE
NIBBLER MODE SE-5
(5)
OUTPUT VOLTAGE

BREAKER MODE
DECEL ATTACHMENT
MODE SELECT SW

SW-111
CAN COMMUNICATION

ACCEL DIAL

SE-16
SE-23

HIGH PRESSURE SENSOR

C-1 SE-22 L5
MECHATRO CONTROLLER A1 A2 A3
ENGINE
INJECTOR SPEED SENSOR
SE-13

PSV -P1
P1 PUMP PROPORTIONAL VALVE
: HIGH PRESSURE SENSOR
(FOR P1,P2 : 2pcs) PSV -P2
: INJECTOR P2 PUMP PROPORTIONAL VALVE

: E/G SPEED SENSOR CAN COMMUNICATION L6

C-8
: LOW PRESSURE SENSOR ENGINE CONTROLLER
(ATT : 7pcs, TRAVEL : 2pcs) ENGINE SPEED L7
COMMAND CURRENT
VOLTAGE 24V
: ACCEL DIAL POTENTIOMETER PROPORTIONAL COMMAND CURRENT
E-27
EMERGENCY MODE ACCEL DIAL

21-4
 21. MECHATRO CONTROLLER

MAIN CONTROL VALVE

L1

SE-29

ARM OUT DUMP DOWN FORWARD FORWARD LEFT ARM OUT

(8) (2) (4) (3) (6) (8) SV-13

P1 UNLOAD

ATTACHMENT BOOST

SELECTOR VALVE
CONFLUX
BOOM UP
BOOM LOW SPEED

TRAVEL RIGHT
ARM 2 SPEED

ARM 1 SPEED
TRAVEL LEFT

N&B
BUCKET

P2 UNLOAD

OPTION
STRAIGHT

SWING
TRAVEL

PL1
SOL

P1 P2
(1) (3) (5) (7)
DIGGING UP REVERSE REVERSE RIGHT ARM IN
L2 SOLENOID VALVE
L3

L4

SWING MOTOR PARKING RELEASE

21

TRAVEL MOTOR 1,2 SPEED SELECT

BOOM CYLINDER
BOOM DOWN RECIRCULATION
BOOM CONFLUX
SWING PARKING BRAKE

SAFETY LOCK LEVER

ATTACHMENT BOOST

TRAVEL 1,2 SPEED

TRAVEL STRAIGHT
ARM IN 2 SPEED

L5
P1 UNLOAD

P2 UNLOAD

ARM CYLINDER
ARM OUT CONFLUX
ARM IN CONFLUX
PSV PSV PSV PSV SV SV SV SV
-A -D -C -B -2 -3 -1 -4

(7)
ARM IN
L6 BUCKET CYLINDER
DIGGING / DUMP CONFLUX

L7
PROPORTIONAL VALVE
SOLENOID VALVE ) BLOCK

21-5
21. MECHATRO CONTROLLER

21.1.2 UNLOAD VALVE CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION
VALVE

SWING

BOOM
STRAIGHT
SOLENOID

TRAVEL
P2 UNLOAD
P2 P1

PILOT PILOT
(LEFT) (RIGHT) VALVE VALVE
OPTIONAL
PILOT VALVE
PILOT VALVE
FOR TRAVEL

LOW LOW
SE-11 PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

MECHATRO
PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE

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

21-6
 21. MECHATRO CONTROLLER

This page is blank for editing convenience.

21

21-7
21. MECHATRO CONTROLLER

21.1.3 POSITIVE CONTROL & P-Q CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
P2 UNLOAD
SOLENOID

TRAVEL
OPTIONAL
PILOT VALVE
P2 P1

SE-23 SE-22

SE-11

(LEFT) (RIGHT) PILOT PILOT

VALVE VALVE

PILOT VALVE
FOR TRAVEL

LOW LOW
PRESSURE PRESSURE
SE-10 SE-9 SENSOR SENSOR
SE-1~4 SE-5,7,8

pi
PILOT SIGNAL
PROCESS P2 PUMP P2 PUMP
PROPORTIONAL PROPORTIONAL
VALVE COMMAND VALVE PSV-P2

PILOT SECONDARY PRESSURE

pi

pi

P1 PUMP P1 PUMP
PROPORTIONAL PROPORTIONAL
PILOT SIGNAL VALVE COMMAND VALVE PSV-P1
PROCESS
PILOT SECONDARY PRESSURE MECHATRO
pi : PROPORTIONAL VALVE
CONTROLLER
SECONDARY PRESSURE

21-8
 21. MECHATRO CONTROLLER

(1) Positive control

1. On starting any one of the operations, the pilot secondary pressure switches each spool and is input to each low
pressure sensor.
2. The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller
processes pilot signal and output commands 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 the
mechatro controller and changes the tilting angle of each pump and controls the delivery rate.
4. With this operation, the delivery rate according to the 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 the high pressure sensor provided on each pump line is input to the mechatro controller
and the mechatro controller processes the pilot signal and operates the command according to the input voltage
(load pressure).
(2) The lower value between command values calculated by the positive control and operated value found by the
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 the
mechatro controller and changes the tilting angle of each pump and controls the delivery rate.
(4) With this operation, the delivery rate according to the lever manipulated movement is fed to the actuator and
consequently the working speed will be obtained according to lever movement.

POSITIVE CONTROL P-Q CONTROL

PILOT SIGNAL PROCESS PILOT SIGNAL PROCESS

SECONDARY PRESSURE

SECONDARY PRESSURE
PUMP PROPORTIONAL

PUMP PROPORTIONAL

21

PILOT PRESSURE PUMP DELIVERY PRESSURE

21-9
21. MECHATRO CONTROLLER

21.1.4 BOOM UP CONFLUX CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
PILOT P2 P1
VALVE

LOW
PRESSURE
SENSOR
SE-3

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER
pi : PROPORTIONAL VALVE
BOOM UP PILOT SECONDARY PRESSURE SECONDARY PRESSURE

21-10
 21. MECHATRO CONTROLLER

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

21

21-11
21. MECHATRO CONTROLLER

21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED

ARM 2 SPEED
N&B
SELECTOR

BUCKET
OPTION

SWING

BOOM
VALVE

STRAIGHT
P2 UNLOAD
SOLENOID

TRAVEL
PILOT
VALVE
P2 P1

LOW
LOW
PRESSURE
PRESSURE
SENSOR
SE-1~6 SENSOR
SE-7

CONTROL PROCESS
FOR 2 SPEED
pi PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

ARM IN PILOT SECONDARY PRESSURE

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

PILOT SECONDARY PRESSURE

PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

ARM IN PILOT SECONDARY PRESSURE

P1 UNLOAD
pi PROPORTIONAL
VALVE PSV-D

PILOT SECONDARY PRESSURE

pi
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
VALVE CONTROL VALVE FOR ARM
PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL
ARM PILOT SECONDARY
PRESSURE

P2 PUMP PRESSURE MECHATRO pi : PROPORTIONAL VALVE

CONTROLLER SECONDARY PRESSURE

21-12
 21. MECHATRO CONTROLLER

(1) Recirculation and Conflux (Low loading)

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

(2) Recirculation Cut

The voltage output by the high pressure sensor on the P2 side is input to the mechatro controller, and when the
load is raised during arm operation the mechatro controller processes pilot signal processing according to the
pressure detected by the high pressure sensor and output commands to cut recirculation into the reverse
proportional valve for the arm-in 2 spool.
The reverse proportional valve for the arm-in 2 spool outputs pilot secondary pressure according to the command 21
output by the mechatro controller and switches the arm 2 spool to recirculation cut position, and consequently the
recirculation passage is blocked.

21-13
21. MECHATRO CONTROLLER

21.1.6 ARM-IN ANTI-CAVITATION CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
PILOT
VALVE

P2 P1

LOW
PRESSURE ACCEL
SENSOR POTENTIO
SE-7

pi pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

ARM IN PILOT SECONDARY PRESSURE

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

ARM IN PILOT SECONDARY PRESSURE

pi
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
VALVE FOR ARM VALVE FOR ARM 2 SPOOL
2 SPOOL COMMAND PSV-A pi

ENGINE SPEED (COMMAND VALUE) MECHATRO

CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE

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

21-14
 21. MECHATRO CONTROLLER

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21

21-15
21. MECHATRO CONTROLLER

21.1.7 ARM-OUT CONFLUX CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
PILOT P2 P1
VALVE

LOW
PRESSURE
SENSOR
SE-8
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

ARM OUT PILOT SECONDARY PRESSURE

pi

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

ARM OUT PILOT SECONDARY PRESSURE

pi
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

ARM OUT PILOT SECONDARY PRESSURE

pi
P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
CONTROLLER
pi : PROPORTIONAL VALVE
ARM OUT PILOT SECONDARY PRESSURE
SECONDARY PRESSURE

21-16
 21. MECHATRO CONTROLLER

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

21

21-17
21. MECHATRO CONTROLLER

21.1.8 BUCKET DIGGING (DUMP) CONFLUX CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
PILOT
VALVE P2 P1

LOW
PRESSURE
SENSOR
SE-1(2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS TRAVELSTRAIGHT
PROPORTIONAL
VALVE PSV-C
MECHATRO
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE

21-18
 21. MECHATRO CONTROLLER

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

21

21-19
21. MECHATRO CONTROLLER

21.1.9 BUCKET DIGGING ANTI-CAVITATION CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED

ARM 2 SPEED
N&B
SELECTOR

BUCKET
OPTION

SWING

BOOM
VALVE

STRAIGHT
P2 UNLOAD
SOLENOID

TRAVEL
PILOT
VALVE
P2 P1

LOW
PRESSURE
SENSOR
SE-1 (2)
pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

BUCKET DIGGING PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

BUCKET DIGGING PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
ACCEL VALVE PSV-B
POTENTIO
BUCKET DIGGING PILOT SECONDARY PRESSURE
pi PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

BUCKET DIGGING PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C

BUCKET DIGGING PILOT SECONDARY PRESSURE

PILOT SIGNAL
pi PROCESS
BUCKET ATT BOOST
ANTI-CAVITATION SOLENOID VALVE
PROCESS SV-2

ENGINE SPEED (COMMAND VALUE)

MECHATRO
CONTROLLER
P1 PUMP PRESSURE pi : PROPORTIONAL VALVE
SECONDARY PRESSURE

21-20
 21. MECHATRO CONTROLLER

(1) On starting the bucket digging (dump) operation, the bucket digging operating pilot pressure switches the
bucket spool and is input to the low pressure sensor.
(2) The engine speed command output by the accel potentiometer is input to the mechatro controller.
(3) The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller
processes the pilot signal and output commands according to the input voltage to the P1 and P2 pump
proportional valves, the P1 and P2 unload proportional valves and the travel straight proportional valve.
(4) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output
by the mechatro controller and changes the P1 and P2 pump delivery rate and switches the P1 and P2 unload
valves and the travel straight valve of the control valve.
(5) The tandem passage is connected to the P2 port because of the travel straight valve being switched and the P1
pump delivery oil confluxes the P2 pump delivery oil because of the P2 unload valve being switched.
(6) The ATT boost solenoid valve turns the solenoid valve on according to the engine speed, and outputs
secondary pressure, and the actuate stroke limiter and then controls the stroke of the bucket spool.
The control of the spool stroke makes the prevention of cavitation possible even if the engine speed is low and
the pump delivery rate is low.
(7) When the P1 pump pressure was raised at the cylinder stroke end, etc., the solenoid valve is closed according
to the pump pressure, and when the pump pressure is high, the boost solenoid valve does not work to control
the stroke limit of the bucket spool.

21

21-21
21. MECHATRO CONTROLLER

21.1.10 SWING PRIORITY CONTROL

BOOM UP CONFLUX

P1 UNLOAD
PILOT

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
VALVE

TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
P2 P1

LOW
PRESSURE
SENSOR

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2
P1 PUMP
ARM IN PILOT SECONDARY PRESSURE PROPORTIONAL
pi PILOT SIGNAL VALVE PSV-P1
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

P1 UNLOAD
PROPORTIONAL
ARM IN PILOT SECONDARY PRESSURE VALVE PSV-D
pi
TRAVEL STRAIGHT TRAVEL STRAIGHT
PROPORTIONAL COMMAND
VALVE COMMAND PROPORTIONAL
VALVE PSV-C
REVERSE PROPORTIONAL REVERSE PROPORTIONAL
SWING PILOT SECONDARY PRESSURE VALVE CONTROL VALVE FOR ARM
pi PROCESS FOR ARM 2 SPOOL PSV-A
2 SPOOL

MECHATRO pi : PROPORTIONAL VALVE

SWING PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE

21-22
 21. MECHATRO CONTROLLER

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

21

21-23
21. MECHATRO CONTROLLER

21.1.11 TRAVEL STRAIGHT CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
OPTIONAL

ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
PILOT VALVE N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
P2 UNLOAD
SOLENOID

TRAVEL
(LEFT) (RIGHT) PILOT PILOT
VALVE VALVE P2 P1
PILOT VALVE
FOR TRAVEL

SE-11 LOW
SE-10 SE-9
PRESSURE
SENSOR

TRAVEL STRAIGHT SIGNAL

pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROPORTIONAL
VALVE PSV-C

PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D
MECHATRO
pi : PROPORTIONAL VALVE
PILOT SECONDARY PRESSURE CONTROLLER
SECONDARY PRESSURE

21-24
 21. MECHATRO CONTROLLER

(1) Judgment travel straight

1. During travel operation (right and left), the pilot pressure switches each spool and is input to the low pressure
sensor on carrying out the attachment system operation.
2. The mechatro controller turns the travel straight on receiving the input according to the combination shown in
the table from the low pressure sensor and turns the travel straight signal on.
3. On turning the travel straight signal on, the following commands are output to each proportional valve.
(2) Operation of each proportional valve
(Basically the attachment operation is actuated by the P1 pump and the travel operation is actuated by the P2
pump in the 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.

21

21-25
21. MECHATRO CONTROLLER

21.1.12 PRESSURE RELEASE CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
GAUGE CLUSTER PILOT
VALVE
P2 P1

SE-23 SE-22

ENGINE

PRESSURE
RELEASE
CONTROL ENGINE SPEED
CONTROL

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

pi
PILOT SIGNAL
P1 UNLOAD
PROCESS PROPORTIONAL
VALVE PSV-D
MECHATRO
pi : PROPORTIONAL VALVE
CONTROLLER SECONDARY PRESSURE

21-26
 21. MECHATRO CONTROLLER

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

21

21-27
21. MECHATRO CONTROLLER

21.1.13 N and B SWITCH CONTROL (OPTION)

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
PRESSURE SENSOR N&B
FOR BREAKER SELECTOR

BUCKET
OPTION
SE-29

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
P2 P1

NIBBLER
MODE

BREAKER
MODE

ATTACHMENT MODE

pi

BREAKER MODE SWITCH MECHATRO

CONTROLLER

pi : OUTPUT OF N&B SELECTOR SOLENOID

21-28
 21. MECHATRO CONTROLLER

(1) Nibbler circuit

1. Select nibbler mode by pressing the nibbler mode switch located on the gauge cluster.
2. The nibbler display appears on the gauge cluster.
3. The return oil from the nibbler passes through the selector valve and the option spool and is led to the tank line
of main the control valve.
4. When selecting the nibbler mode through the select switch, the breaker pressure sensor has no function to
output.
It is normal when there is no output from the sensor in nibbler mode, and in cases of other than above, an error
display is output to the gauge cluster.
(2) Breaker circuit
1. Select breaker mode by pressing the breaker mode switch located on the gauge cluster.
2. Breaker display appears on the gauge cluster.
3. The return oil from the breaker passes through the selector valve and directly returns into the hydraulic oil tank.
4. When selecting breaker mode through the select switch, the breaker pressure sensor outputs signal.
It is normal when there is an output from the sensor in breaker mode, and in cases of other than above, an error
display is output to the gauge cluster.

21

21-29
21. MECHATRO CONTROLLER

21.1.14 OPTION CONFLUX CONTROL (OPTION)

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD
PILOT VALVE

TRAVEL
P2 P1

LOW
PRESSURE
SENSOR
SE-11

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
P1 UNLOAD
PROCESS PROPORTIONAL
VALVE PSV-D

OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C
MECHATRO pi : PROPORTIONAL VALVE
OPTION PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE

21-30
 21. MECHATRO CONTROLLER

(1) Using the "OPTION SETTING" display located on the "USER MENU" screen, the flow rate is adjusted. At this
time, if the setting flow rate is larger than the one pump flow rate, the flow becomes automatically confluent flow.
(2) On starting option operation, option operating pilot pressure switches the option spool and is input to the low
pressure sensor.
(3) The output voltage of the low pressure sensor is input to the mechatro controller and the mechatro controller
processes the pilot signal and output commands according to the input voltage to the P1 and P2 pump
proportional valves, the P1 and P2 unload pressure proportional valves and the travel straight proportional
valve.
(4) Each proportional valve output pilot proportional valve secondary pressure according to the command output by
the mechatro controller and changes the P1 and P2 pump delivery rate and switches the P1 and P2 unload
valves and the travel straight valve of the control valve.
(5) The parallel passage on the P2 side is connected to the P1 port because of the travel straight valve being
switched and the P1 pump delivery oil confluxes the P2 pump delivery oil because of the P2 unload valve being
switched.

21

21-31
21. MECHATRO CONTROLLER

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21-32
 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

GAUGE
CLUSTER

SAFETY RIGHT
LOCK CONTROL
LEVER LEVER
WITH ATT
BOOST SW.

STARTER SWITCH
FUSE &
ACCEL DIAL RELAY BOX

B
DETAIL A
SWING PARKING
EMERGECY ACCEL DIAL BRAKE RELEASE
SWITCH
21

DETAIL B

(2) Gauge cluster

No. Name
1 Engine coolant temperature gauge
18 S 12:15 2 2 Fuel level gauge
3 Screen change switch
4 Buzzer stop switch
1
5 Work mode select switch
E F
6 Washer switch
7 Wiper switch
8 Travel high speed, low speed select switch
9 Auto accel switch
9 11 6 10 Menu switch
11 Digging mode switch
12 Nibbler mode switich
8 7
13 Breaker mode switch
5 13
14 Up arrow switch
4 16
10 15 Down arrow switch
16 Next arrow switch
17 Back arrow switch
17 3 14 15 12 18 Multi display (LCD)

21-33
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" to
"E" to "H" to "S" each time the work mode select switch is pressed.
Select the proper work mode shown below according to the work condition and the purpose. For the selected work
mode, refer to the upper left corner of the display.

• S mode: For standard excavating work

• ECO mode: For low fuel consumption excavating work
S 12:15
• H mode: For heavy duty excavating work

E F

S mode

S 12:15 "S mode" is suitable for standard digging and loading works and is saving fuel
consumption and is in good balance to the workload.

E F

ECO mode

E 12:15 "Eco mode" is the mode focusing on better fuel economy, allowing for normal digging
operation with lower fuel consumption than S mode.

E F

H mode

H 12:15 "H mode" is suitable for heavy duty digging work which gives priority to the workload at
high speed.

E F

21-34
 21. MECHATRO CONTROLLER

(4) Screen selection by attachment mode switich

This switch is used for switching the attachment mode.

Attachment mode display
Press the Digging mode switch (1) to select Digging mode S 12:15

from the attachment modes. And selected Digging mode

is indicated. Press the Nibbler mode switch (2) to select
Nibbler mode from the attachment modes. And the
selected Nibbler mode is indicated. Press Breaker mode E F

switch (3) to select the Breaker mode from the attachment

modes. And selected Breaker mode is indicated.
Depending on the attachment employed, select the
applicable mode from "Digging", "Nibbler" and "Breaker". 2
Before working, confirm whether the appropriate
attachment has been selected.

1. Digging mode switch

2. Nibbler mode switch 3
3. Breaker mode switch
1

Attachment Mode Switch Position Displays of Multi-Display Selection of Attachment

S 12:15

Digging Mode Select in case of digging

E F

21
S 12:15

Select conflux flow when the

Nibbler Mode attachment like a nibbler
requires conflux flow circuit
E F

S 12:15

Select single flow when the

Breaker Mode attachment like a breaker
requires single flow circuit
E F

21-35
21. MECHATRO CONTROLLER

(5) Procedure of setting a flow rate and an option relief pressure at the Nibbler/Breaker mode

1: Buzzer Stop Switch

2: Menu Switch
3: Nibbler Mode Switch S 12:15

4: Breaker Mode Switch

5: Up Arrow Switch
6: Down Arrow Switch
7: Next Arrow Switch E F

8: Back Arrow Switch

According to some attachments, it is required to change
the flow rate and relief pressure for the service circuit.
Regarding the adjustment of the flow rate and relief 3
pressure for the Nibbler and Breaker, the settings of 10
patterns are available.

4
1 7
2

8 5 6

SET 1 SET 2 SET 3 SET 4 SET 5 SET 6 SET 7 SET 8 SET 9 SET 10
Flow rate L/min 588 530 470 410 350 294 270 240 210 180
Nibbler
Pressure A MPa Not set yet Not set yet Not set yet Not set yet Not set yet 25 Not set yet Not set yet Not set yet Not set yet
(Crusher)
Pressure B MPa Not set yet Not set yet Not set yet Not set yet Not set yet 25 Not set yet Not set yet Not set yet Not set yet

SET 1 SET 2 SET 3 SET 4 SET 5 SET 6 SET 7 SET 8 SET 9 SET 10
Flow rate L/min 294 270 240 210 180 150 120 90 60 30
Breaker
Pressure B MPa 30 Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet Not set yet

Both Nibblers are set in conditions "SET 6" as factory a default in the above table at shipping.
Both Breakers are set in conditions "SET 1" as factory a default in the above table at shipping.
* The meaning of "Not set yet" shows that 50MPa as pressure is temporary value.

Set the flow rate and relief pressure in accordance with next procedure.
These setting values in the above adjustment are selectable by using the after-mentioned "Flow Rate and Relief
Pressure Selection".

21-36
 21. MECHATRO CONTROLLER

1) When using Nibbler

TURN STARTER KEY

SWICH ON (a) (b) (C) (d) (e)
+ No.1
or
+ NIBBLER NIBBLER
MAIN CONT. P/N
XLB22E00026F1 SERVICE MENU SERVICE ADJUST1-2
PRIGRAM VERSION
1-VER 00.07 SETTING SETTING
2-VER 00.00
SERVICE DIAGNOSIS AUTO ACCEL SET1 472
L/min
25
MPa
25
MPa
SET1 472
L/min
25 MPa
25
MPa
SERVICE DIAG 1

CLUSTER DIAG 1
TROUBLE HISTORY START MODE SET2 443
L/min
50
MPa
50
MPa
SET2 443
L/min
50 MPa
50
MPa

CLUSTER GAUGE P/N

LANGUAGE & LOGO SETTING CANCEL LOW TEMP SET3 394
L/min
50
MPa
50
MPa
SET3 394
L/min
50 MPa
50
MPa
YN59S00028F1
PROGRAM VERSION SERVICE ADJUST 1 CANCEL MODE SET4 344
L/min
50
MPa
50
MPa
SET4 344
L/min
50 MPa
50
MPa
01.00
SERVICE ADJUST 2 CHECK INJECTOR SET5 295
L/min
50
MPa
50
MPa
SET5 295
L/min
50 MPa
50
MPa

FACTORY PRESET PRESS DRAIN SET6 246

L/min
25
MPa
25
MPa
SET6 246
L/min
25 MPa
25
MPa

FAULT DIAG MODE NIBBLER SETTING SET7 221

L/min
50
MPa
50
MPa
SET7 221
L/min
50 MPa
50
MPa

BREAKER SETTING SET8 197

L/min
50
MPa
50
MPa
SET8 197
L/min
50 MPa
50
MPa

CAMERA 1 SETTING SET9 172

L/min
50
MPa
50
MPa
SET9 172
L/min
50 MPa
50
MPa

CAMERA 2 SETTING SET10 148

L/min
50
MPa
50
MPa
SET10 148
L/min
50 MPa
50
MPa

BACK ON NEXT BACK ON NEXT BACK ON NEXT BACK ON NEXT

DOWN DOWN HOME DOWN DOWN RESET

(g) (f)

NIBBLER NIBBLER
SETTING SETTING
SET1 472
L/min
25
MPa
25
MPa
SET1 472
L/min
25
MPa
25
MPa

SET2 443
L/min
50
MPa
50
MPa
SET2 443
L/min
50
MPa
50
MPa

SET3 394
L/min
50
MPa
50
MPa
SET3 394
L/min
50
MPa
50
MPa

SET4 344
L/min
50
MPa
50
MPa
SET4 344
L/min
50
MPa
50
MPa

SET5 295
L/min
50
MPa
50
MPa
SET5 295
L/min
50
MPa
50
MPa

SET6 246
L/min
25
MPa
25
MPa
SET6 246
L/min
25
MPa
25
MPa

SET7 221
L/min
50
MPa
50
MPa
SET7 221
L/min
50
MPa
50
MPa

SET8 197
L/min
50
MPa
50
MPa
SET8 197
L/min
50
MPa
50
MPa

SET9 172
L/min
50
MPa
50
MPa
SET9 172
L/min
50
MPa
50
MPa

SET10 148
L/min
50
MPa
50
MPa
SET10 148
L/min
50
MPa
50
MPa

BACK ON NEXT BACK ON NEXT

DOWN RESET DOWN RESET

21
1. Turn the starter switch ON. After pressing the Nibbler mode switch (3) to select the Nibbler mode, turn the
starter switch OFF.
2. Hold down the buzzer stop switch (1) and turn the starter switch ON. The service diagnosis screen (a) is
displayed.
3. Start the engine.
4. Hold down the buzzer stop switch (1) and press the menu switch (2) 3 times. "SERVICE MENU" screen (b) is
displayed.
5. Using the switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), point the cursor to "SERVICE
ADJUST 1" display (b). Press "NEXT ARROW SWITCH" (7), and SERVICE ADJUST 1-2 (c) is displayed.
6. Using the switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), point the cursor to the
"NIBBLER SETTING" display (c). Press the menu switch (2), and NIBBLER SETTING (d) is displayed.
7. There are 10 steps from "SET 1" to "SET 10". Using the switch "UP ARROW SWITCH" (5) or "DOWN ARROW
SWITCH" (6), and select the desired set number. To set the desired set number, press "NEXT ARROW
SWITCH" (7).
8. Using the switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), set the desired flow rate. Then
press menu switch (2) and the cursor is pointed to the pressure display (f).
9. During pressing the rear (heel side) of the optional right pedal (P2 pump optional operation), use switch "UP
ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), and adjust pump pressure. When the value of
pressure reaches the desired pressure, press menu switch (2) to set. (If you fail to press rear (heel side) of
optional right pedal, 0MPa is displayed.)
10.Then, the cursor is pointed to pressure (see display (g)). Use the switch "UP ARROW SWITCH" (5) or "DOWN
ARROW SWITCH" (6), and adjust pump pressure. When the value of pressure reaches the desired pressure,
press menu switch (2) to set. (If you fail to press front (toe side) of the optional right pedal, 0MPa is displayed.)
11.Then, the display returns to "SERVICE ADJUST 1-2" screen (c).

21-37
21. MECHATRO CONTROLLER

2) When using Breaker

TURN STARTER KEY

SWICH ON (a) (b) (C) (d) (e)
+ No.1
or
+ BREAKER BREAKER
MAIN CONT. P/N
XLB22E00026F1 SERVICE MENU SERVICE ADJUST1-2
PRIGRAM VERSION
1-VER 00.07 SETTING SETTING
2-VER 00.00
SERVICE DIAGNOSIS AUTO ACCEL SET1 246
L/min
25
MPa
SET1 246
L/min
25
MPa
SERVICE DIAG 1

CLUSTER DIAG 1
TROUBLE HISTORY START MODE SET2 221
L/min
30
MPa
SET2 221
L/min
30
MPa

CLUSTER GAUGE P/N

LANGUAGE & LOGO SETTING CANCEL LOW TEMP SET3 197
L/min
30
MPa
SET3 197
L/min
30
MPa
YN59S00028F1
PROGRAM VERSION SERVICE ADJUST 1 CANCEL MODE SET4 172
L/min
30
MPa
SET4 172
L/min
30
MPa
01.00
SERVICE ADJUST 2 CHECK INJECTOR SET5 148
L/min
30
MPa
SET5 148
L/min
30
MPa

FACTORY PRESET PRESS DRAIN SET6 123

L/min
30
MPa
SET6 123
L/min
30
MPa

FAULT DIAG MODE NIBBLER SETTING SET7 98

L/min
30
MPa
SET7 98
L/min
30
MPa

BREAKER SETTING SET8 74

L/min
30
MPa
SET8 74
L/min
30
MPa

CAMERA 1 SETTING SET9 49

L/min
30
MPa
SET9 49
L/min
30
MPa

CAMERA 2 SETTING SET10 30

L/min
30
MPa
SET10 30
L/min
30
MPa

BACK ON NEXT BACK ON NEXT BACK ON NEXT BACK ON NEXT

DOWN DOWN DOWN RESET DOWN RESET

(f)

BREAKER
SETTING
SET1 246
L/min
25
MPa

SET2 221
L/min
30
MPa

SET3 197
L/min
30
MPa

SET4 172
L/min
30
MPa

SET5 148
L/min
30
MPa

SET6 123
L/min
30
MPa

SET7 98
L/min
30
MPa

SET8 74
L/min
30
MPa

SET9 49
L/min
30
MPa

SET10 30
L/min
30
MPa

BACK ON NEXT
DOWN RESET

1. Turn starter switch ON. After pressing the Breaker mode switch (4) to select Breaker mode, turn the starter
switch OFF.
2. Hold down the buzzer stop switch (1) and turn the starter switch ON. The service diagnosis screen (a) is
displayed.
3. Start the engine.
4. Hold down the buzzer stop switch (1) and press menu switch (2) 3 times. "SERVICE MENU" screen (b) is
displayed.
5. Using the switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), point the cursor to "SERVICE
ADJUST 1" display (b). Press "NEXT ARROW SWITCH" (7), and SERVICE ADJUST 1-2 (c) is displayed.
6. Using the switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), point the cursor to "BREAKER
SETTING" display (c). Press "NEXT ARROW SWITCH" (7), and BREAKER SETTING (d) is displayed.
7. There are 10 steps from "SET 1" to "SET 10". Using the switch "UP ARROW SWITCH" (5) or "DOWN ARROW
SWITCH" (6), and select the desired set number. To set the desired set number, press the "NEXT ARROW
SWITCH" (7).
8. Using the switch "UP ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), set the desired flow rate. Then
press the menu switch (2) and the cursor is pointed to pressure display (f).
9. During pressing the front (toe side) of the optional right pedal (P2 pump optional operation), use switch "UP
ARROW SWITCH" (5) or "DOWN ARROW SWITCH" (6), and adjust pump pressure. When you reach the
desired pressure, press the menu switch (2) to set. (If you fail to press the front (toe side) of the optional right
pedal, 0MPa is displayed.)
10.Then, the display returns to "SERVICE ADJUST 1-2" screen (c).

21-38
 21. MECHATRO CONTROLLER

(6) Pump flow rate adjustment (Nibbler mode / Breaker mode) (Option)
6 7 4 5
1: Screen Change Switch
2: Buzzer Stop Switch
3: Work Mode Select Switch 3 9
4: Washer Switch
5: Wiper Switch
6: Travel Speed Select Switch
7: Auto Accel Switch
8: Menu Switch
9: Attachment Mode Select Switch 2
10: Arrow Switch

1 10 8

Nibbler mode
S 12:15 S 12:15
USER MENU USER MENU NIBBLER
SETTING
FLOW RATE 780 L/min MAINTENANCE MAINTENANCE SET1 472
L/min
25
MPa
25
MPa

PRESSURE A 50 Mpa SWITCH STATUS SWITCH STATUS SET2 443

L/min
50
MPa
50
MPa

OPTION SETTING OPTION SETTING SET3 394 50 50

PRESSURE B 50 Mpa L/min MPa MPa

CONSUMPTION CONSUMPTION SET4 344

L/min
50
MPa
50
MPa
E F E F
SCREEN SETTING SCREEN SETTING SET5 295
L/min
50
MPa
50
MPa

CLOCK SETTING CLOCK SETTING SET6 246

L/min
25
MPa
25
MPa
L/min
SET7 221
L/min
50
MPa
50
MPa

30
SET8 197
L/min
50
MPa
50
MPa

15 SET9 172
L/min
50
MPa
50
MPa

SET10 148 50 50
30 25 20 15 10 5 0
0
or L/min MPa MPa

MIN BACK UP NEXT BACK UP NEXT BACK UP NEXT

AVERAGE 0.0 L/h RESET HOME DOWN HOME DOWN HOME DOWN

(a) (b) (c) (d) (e)

In breaker mode
S 12:15
S 12:15
21
USER MENU USER MENU BREAKER
SETTING
FLOW RATE 480 L/min MAINTENANCE MAINTENANCE SET1 246
L/min
30
MPa

PRESSURE A 50 Mpa SWITCH STATUS SWITCH STATUS SET2 221

L/min
30
MPa

OPTION SETTING OPTION SETTING SET3 197

L/min
30
MPa

E F CONSUMPTION CONSUMPTION SET4 172

L/min
30
MPa
E F
SCREEN SETTING SCREEN SETTING SET5 148
L/min
30
MPa

CLOCK SETTING CLOCK SETTING SET6 123

L/min
30
MPa
L/min
SET7 98
L/min
30
MPa

30
SET8 74
L/min
30
MPa

15 SET9 49
L/min
30
MPa

SET10 30 30
30 25 20 15 10 5 0
0
or L/min MPa

MIN BACK UP NEXT BACK UP NEXT BACK UP NEXT

AVERAGE 0.0 L/h RESET HOME DOWN HOME DOWN HOME DOWN

(b) (c) (d) (e)

1. After turning the starter key switch ON, the main screen (a) appears.
2. When the display is in main screen (a), change the attachment mode from "DIGGING MODE" to "NIBBLER
MODE" or "BREAKER MODE". The flow rate indication screen (b) appears.
3. When the display displays the flow rate indication screen (b), press "Menu Switch" to enter into "USER MENU"
display (c).
4. Move the cursor to "OPTION SETTING", and press "NEXT" to enter into the "OPTION SETTING" display (e).
5. When the display displays the "OPTION SETTING" display (e), move the cursor to the desired flow rate. And
press the menu switch to set the target flow rate.

If there is no switching operation for 20 seconds, this display returns to main display.

21-39
21. MECHATRO CONTROLLER

(7) Maintenance screen displays

This screen displays the remaining time to the end of

recommended replacement/change interval specified for
filter/oil.

EXCHANGE
S 12:15
INTERVAL REMAINDER
DAY
After turning the starter key switch ON or starting the USER MENU ENGINE OIL 500Hr 500Hr 08/12/12

engine, the display returns to "SERVICE ADJUST 1-2" MAINTENANCE

FUEL FILTER 500Hr -100Hr 08/12/12

screen (c). SWITCH STATUS HYD. FILTER 1000Hr 500Hr 08/12/12

OPTION SETTING HYD. OIL 3000Hr 3000Hr 08/12/12
This display shows the recommended replacement time of E F
CONSUMPTION
SCREEN SETTING
engine oil, time for next engine oil change and date of CLOCK SETTING
previous engine oil change.
INTERVAL REMAINDER
EXCHANGE
DAY

ENGINE OIL 500Hr 500Hr 08/12/12

BACK
HOME
UP
DOWN
NEXT
FUEL FILTER 500Hr -100Hr 08/12/12

HYD. FILTER 1000Hr 500Hr 08/12/12

(a)
HYD. OIL 3000Hr 3000Hr 08/12/12

INTERVAL REMAINDER
EXCHANGE INTERVAL REMAINDER
EXCHANGE
DAY DAY

ENGINE OIL 500Hr 500Hr 08/12/12 ENGINE OIL 500Hr 500Hr 08/12/12

FUEL FILTER 500Hr -100Hr 08/12/12 FUEL FILTER 500Hr -100Hr 08/12/12

HYD. FILTER 1000Hr 500Hr 08/12/12 HYD. FILTER 1000Hr 500Hr 08/12/12

HYD. OIL 3000Hr 3000Hr 08/12/12 HYD. OIL 3000Hr 3000Hr 08/12/12

For the initial set value of the 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 5,000 Hr

This menu is available for confirmation of the following items.

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

INTERVAL REMAINDER
EXCHANGE
DAY
1. Remaining time display to the engine oil change. ENGINE OIL 500Hr 500Hr 08/12/12

This display shows the remaining time of "INTERVAL, FUEL FILTER 500Hr 500Hr 08/12/12

REMAINING TIME, EXCHANGE DAY". HYD. FILTER 1000Hr 1000Hr 08/12/12

HYD. OIL 5000Hr 5000Hr 08/12/12

21-40
 21. MECHATRO CONTROLLER

INTERVAL REMAINDER
EXCHANGE
DAY
2. Remaining time display to the coming fuel filter ENGINE OIL 500Hr 500Hr 08/12/12

replacement FUEL FILTER 500Hr 500Hr 08/12/12

This display shows the remaining time of "INTERVAL, HYD. FILTER 1000Hr 1000Hr 08/12/12

REMAINING TIME, EXCHANGE DAY". HYD. OIL 5000Hr 5000Hr 08/12/12

INTERVAL REMAINDER
EXCHANGE
DAY
3. Remaining time display to the coming hydraulic oil filter ENGINE OIL 500Hr 500Hr 08/12/12

replacement FUEL FILTER 500Hr 500Hr 08/12/12

This display shows the remaining time of "INTERVAL, HYD. FILTER 1000Hr 1000Hr 08/12/12

REMAINING TIME, EXCHANGE DAY". HYD. OIL 5000Hr 5000Hr 08/12/12

INTERVAL REMAINDER
EXCHANGE
DAY
4. Remaining time display to the coming hydraulic oil ENGINE OIL 500Hr 500Hr 08/12/12

change FUEL FILTER 500Hr 500Hr 08/12/12

This display shows the remaining time of "INTERVAL, HYD. FILTER 1000Hr 1000Hr 08/12/12

REMAINING TIME, EXCHANGE DAY". HYD. OIL 5000Hr 5000Hr 08/12/12

For the setting procedure of the maintenance time to be performed to the coming oil change in each type and filter
replacement, see the 21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE.

21

21-41
21. MECHATRO CONTROLLER

(8) Gauge cluster display

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

MACHIN CONDITION CLOCK DISPLAY

S

E F
SELF DIAGNOSIS / WARNING

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 an abnormality is detected on the mechatro system like sensor, proportional valve, etc., this displays the
error code.
1.3 Warning display:
When the machine was thrown into a dangerous state, or has failed, the warning display displays warning contents
with the symbol and a statement.

. Warning These descriptions indicate error codes.

CAUTION LOW ENG OIL

W009 W005 PREHEAT W011
ATTACHMENT PRESS.

POWER BOOST HIGH ENG

WATER TEMP.
W006 CHARGE ERROR
ON

LOW ENG WATER

WARM FINISH WARM-UP LEVEL
W004 LOW FUEL LEVEL

DATA
CPU COMMUNICATION CLOGGED AIR FLTR W008 WARM AUTO WARMING UP
ERROR

SWING BRAKE
ENGINE STOP CHANGE ENG OIL
DISENGAGED

CHANGE LIFT UP LOCK LEVER

ENG PREHEAT
FUEL FLTR BEFORE ENGINE START

CHANGE HYD. CHANGE HYD.

OIL FLTR OIL

1. LIFT UP LOCK LEVER

2. PUSH REGENERATION SW.

REGENERATION

1. LIFT UP LOCK LEVER

2. PUSH REGENERATION SW.
EXHAUST GAS AFTER TREATMENT
EQUIPMENT WILL BE DAMAGED

EXHAUST GAS AFTER TREATMENT

EQUIPMENT FAILURE

21-42
 21. MECHATRO CONTROLLER

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

1. Machine condition display:

Displays machine operating condition.

2. Display function for maintenance:

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

3. Failure history display function:

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

4. Mechatro adjustment display:

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

5. Service diagnosis display:

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

21

21-43
21. MECHATRO CONTROLLER

(9) Rearview camera

1) Setting of display picture of rearview camera

1: Buzzer Stop Switch

2: Menu Switch
3: Up Arrow Switch
4: Down Arrow Switch
5: Next Arrow Switch 5
6: Back Arrow Switch

6 3 4 2

TURN STARTER KEY

SWICH ON (a) (b) (C) (d) (e)
+ No.1

+
MAIN CONT. P/N
XLB22E00026F1 SERVICE MENU SERVICE ADJUST1-2 SERVICE ADJUST1-2 SERVICE ADJUST1-2
PRIGRAM VERSION
1-VER 00.07
2-VER 00.00
SERVICE DIAGNOSIS AUTO ACCEL AUTO ACCEL AUTO ACCEL
SERVICE DIAG 1
TROUBLE HISTORY START MODE START MODE START MODE
CLUSTER DIAG 1

CLUSTER GAUGE P/N

LANGUAGE & LOGO SETTING CANCEL LOW TEMP CANCEL LOW TEMP CANCEL LOW TEMP
YN59S00028F1
PROGRAM VERSION SERVICE ADJUST 1 CANCEL MODE CANCEL MODE CANCEL MODE
01.00
SERVICE ADJUST 2 CHECK INJECTOR CHECK INJECTOR CHECK INJECTOR

FACTORY PRESET PRESS DRAIN PRESS DRAIN PRESS DRAIN

FAULT DIAG MODE NIBBLER SETTING NIBBLER SETTING NIBBLER SETTING

BREAKER SETTING BREAKER SETTING BREAKER SETTING

CAMERA 1 SETTING OFF CAMERA 1 SETTING OFF CAMERA 1 SETTING ON

CAMERA 2 SETTING OFF CAMERA 2 SETTING OFF CAMERA 2 SETTING OFF

BACK ON NEXT BACK ON NEXT BACK ON BACK ON

DOWN DOWN OFF OK OFF OK

1. Hold down the buzzer stop switch (1) and turn the starter switch ON. The service diagnosis screen (a) is
displayed.
2. Hold down the buzzer stop switch (1) and press the menu switch (2) 3 times. "SERVICE MENU" screen (b) is
displayed.
3. Using the "UP" switch (3) or "DOWN" switch (4), point the cursor to the "SERVICE ADJUST 1" display (b).
Press the "NEXT" switch (5), and SERVICE ADJUST 1-2 (c) is displayed.
4. Using the "UP" switch (3) or "DOWN" switch (4), point the cursor to the "CAMERA 1 SETTING" display (c).
5. Press the "NEXT" switch (5), and the cursor is pointed to "OFF" on the display (d).
6. Press the "UP" switch (3), and it points to "ON" of the display (e).
7. Press the menu switch (2), and the rearview camera is set.
8. After that screen returns to "SERVICE ADJUST 1-2" (c).
9. Turn off the starter key switch.

21-44
 21. MECHATRO CONTROLLER

2) Troubleshooting
1. The gauge cluster is powered on but the picture does not appear and it shows a blue screen.

No. Parts Parts/Normal Condition Corrective Action

Make sure the connector between the
Power-supply box to Cab
1 power-supply box and cab harness is Check connections.
harness
connected.
Make sure the connector between the cable
2 Cable to Cab harness Check connections.
and cab harness is connected.
Make sure the connector between the cable
3 Cable to Camera cable Check connections.
and camera cable is connected.
Make sure the No. 30 fuse (5A) did not melt
4 Fuse & Relay box Replace fuse.
down.
Make sure the camera (1) of the service
5 Setting of camera adjustment 1 is on, and camera (2) and Check the setting.
camera (3) are off.

2. Gauge cluster is powered on but the picture does not appear and it shows the fuel consumption graph or logo.

No. Parts Parts/Normal Condition Corrective Action

Make sure the camera (1) of the service
1 Setting of camera Check the setting.
adjustment 1 is on.

21

21-45
21. MECHATRO CONTROLLER

21.2.2 SELF DIAGNOSIS DISPLAY

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

CONTROL
Pressure sensor, Engine controller CAN COMMUNICATION
INPUT Proportional valve, Battery relay Gauge cluster
Selector valve (SOL) (Buzzer sound)

(3) Self diagnosis display items

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

S Alphabet: Decide system failure occurred.

B 01 3 Last 2nd and 3rd digits: Specifies failed section.

Last 1 digit: Specifies failure type.

E F

B013

A B C D E F G H I K P R Z
Last 2,3 Controller Low pressure High pressure Proportional Proportional Solenoid Speed sensor Potentiometer Communication Battery relay Engine ECU Relay output
digits memory sensor sensor valve for valves valve for pumps valve etc
Engine Boom up P1 pump P1 unload P1 pump ATT boost Acceleration Battery relay Wiper ark Common rail
01 adjust data prevention relay press.
Torque Boom down P2 pump P2 unload P2 pump Swing parking Boom angle Wiper ark forward
02 adjust data rotation relay
Unload Arm out Boom head Travel straight Travel 1,2 Angle sensor Arm angle Wiper ark reverse
03 adjust data speed for shovel rotation relay
Boom up Arm in Boom rod Option Angle sensors for Washer motor
04 adjust data selector shovel & ECU
Arm in Bucket Bucket stroke
05 adjust data digging limit
Arm out Bucket Arm 2 spool
06 adjust data dump for arm in
Swing
07
08
Travel right Fuel sensor
09
Refer to next page (Engine)
Travel left
10
Selector position CAN
11 detection communication

12
Swing flasher
13 right relay
Swing flasher
14 left relay
Travel alarm
15 relay
P1 side option AIS relay 2
16
P2 side option Engine stop
17 relay
Safety lock
18 lever relay

19
Adjustment Safety relay
21 data sector 1
Adjustment
22 data sector 2
Hourmeter
23 sector 1
Hourmeter
24 sector 2
Proportional
25 valve adjust data

31
Refer to next page (Engine)

Larger than Larger than Abnormal

0 normal range normal range
Transistor OFF CAN error
failure / Grounding
1 - short circuit
Wrong output Wrong output Transistor Transistor Over run
2 - ON failure ON failure
Disconnection Disconnection Disconnection Disconnection Transistor ON Disconnection Disconnection Time is over
failure /
3 - Disconnection
Power source Power source Power source Contact point is Power source
4 - short circuit short circuit short circuit melted and adhered short circuit

21-46
 21. MECHATRO CONTROLLER

ERROR CODE OF ENGINE

We left this page blank because we did not receive the manufacturer’s instructions yet.

21

21-47
21. MECHATRO CONTROLLER

21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION

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

(1) Service diagnosis display screen operating procedure

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

Buzzer Stop Switch

2. After logo mark is displayed, the screen changes to 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.22
• Mode No.2 : Screen No.1, Screen No.23 to No.27
• Mode No.3 : Screen No.1, Screen No.28 to No.32
3. The screen changes each time each switch is pressed from now on.

Up Arrow Switch

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

Down Arrow Switch

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

Next Arrow 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-->...)

Back Arrow 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 the key switch OFF and the display of the service diagnosis mode is closed.

21-48
 21. MECHATRO CONTROLLER

(2) Service diagnosis display screen (Example)

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

1) Service diagnosis mode No.1

No. Displays Contents No. Displays Contents

1 5
NO.1 NO.4 RELAY
MAIN CONT. P/N
YN22E00001F1 P/No. indication K-1 AIS RELAY 2 OFF Indicated value
PROGRAM VERSION K-2 SAFETY RLY OFF Indicated value
1-VER 11.11 Program version indication K-3 ENG STOP OFF Indicated value
2-VER 00.00 MERIT controller program version KEY SWITCH OFF Key switch
START SWITCH OFF Starter switch
SERVICE DIAG 1 Service diagnosis mode CHARGE LIVE Alternator
K-4 LOCK LEVER OFF Indicated value
CLUSTER GAUGE P/N SWITCH OFF Switch
YN59S00028F1 P/NO. indication
PROGRAM VERSION
02.00 Program Version indication

2 6
NO.2 ENG NO.5 PRESS.SENSOR
G-3 SPEED SET 2205 No load setting rpm B-1 BOOM RAISE
MEAS1 2201 Actual rpm 1 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS2 2201 Actual rpm 2 (Engine controller) B-2 BOOM LOWER
G-5 ENG PRS. LIVE Engine oil pressure 3.5V 2.6M Sensor voltage / Pressure converted value
WATER TEMP 100 OFF Coolant temperaturre sensor B-3 ARM OUT
MODE HM Work mode 3.5V 2.6M Sensor voltage / Pressure converted value
ATT MODE BUCKET Attachment mode B-4 ARM IN
H-1 ACCEL VOLT. 4.2V Potentiometer voltage 3.5V 2.6M Sensor voltage / Pressure converted value
POS. 100% Voltage % indication B-5 BUCKET DIG
ECU OUTPUT 0.5V Accel output voltage to engine 3.5V 2.6M Sensor voltage / Pressure converted value
controller B-6 BUCKET DUMP
3.5V 2.6M Sensor voltage / Pressure converted value
B-7 SWING
3.5V 2.6M Sensor voltage / Pressure converted value
B-9 TRAVEL(R)
4 3.5V 2.6M Sensor voltage / Pressure converted value
NO.3 SOL.VALVE
F-1 POWER BOOST B-10 TRAVEL(L)
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-16 P1 OPT.
SWITCH OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
F-2 SWING-BRAKE B-17 P2 OPT.
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value
RELEASE SW OFF Switch
F-3 1/2-TRAVEL
COMP. OFF Set value in computer
21
MEAS. OFF Measured value
SWITCH OFF Switch

21-49
21. MECHATRO CONTROLLER

No. Displays Contents No. Displays Contents

7 14
NO.6 P.SENSOR PROPO-V NO.13 PRESS.SENSOR
C-1 PUMP 1 B-11
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
C-2 PUMP 2 B-12
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
C-3 BOOM-HEAD B-13
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
C-4 BOOM-ROD B-14
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
E-1 P1 PUMP B-15
COMP. 600mA 4.5M Set value in computer / Converted value from pressure 3.5V 12.6M Sensor voltage / Pressure converted value
MEAS. 600mA 4.5M Measured value / Converted value from pressure B-18 DOZER 1
POWER SHIFT 100mA Power shift 3.5V 12.6M Sensor voltage / Pressure converted value
FLOW RATE 100L Flow rate of pump P1 B-19 DOZER 2
E-2 P2 PUMP 3.5V 12.6M Sensor voltage / Pressure converted value
COMP. 600mA 4.5M Set value in computer / Converted value from pressure B-20
MEAS. 600mA 4.5M Measured value / Converted value from pressure 3.5V 12.6M Sensor voltage / Pressure converted value
POWER SHIFT 100mA Power shift C-5
FLOW RATE 100L Flow rate of pump P2 3.5V 12.6M Sensor voltage / Pressure converted value
C-6
8 NO.7 PROPO-VALVE 3.5V 12.6M Sensor voltage / Pressure converted value
D-1 P1 UN-LOAD(BP-CUT) C-7
COMP. 600mA 4.5M Set value in computer / Converted value from pressure 3.5V 12.6M Sensor voltage / Pressure converted value
MEAS. 600mA 4.5M Measured value / Converted value from pressure C-8
D-2 P2 UN-LOAD(BP-CUT) 3.5V 12.6M Sensor voltage / Pressure converted value
COMP. 600mA 4.5M Set value in computer / Converted value from pressure
MEAS. 600mA 4.5M Measured value / Converted value from pressure
D-3 S-TRAVEL
COMP. 600mA 4.5M Set value in computer / Converted value from pressure
MEAS. 600mA 4.5M Measured value / Converted value from pressure
D-6 ARM IN-2-SPEED
COMP. 600mA 4.5M Set value in computer / Converted value from pressure
MEAS. 600mA 4.5M Measured value / Converted value from pressure
E-3 OPT RELIEF 1
COMP. 600mA 14.5M Set value in computer / Converted value from pressure
MEAS. 600mA 14.5M Measured value / Converted value from pressure
E-4 OPT RELIEF 2
COMP. 600mA 14.5M Set value in computer / Converted value from pressure
MEAS. 600mA 14.5M Measured value / Converted value from pressure

9 15
NO.8 SENSOR,SWITCH NO.14 DIGITAL INPUT
H-9 FUEL LEVEL DI1 OFF ON/OFF indication
4.5V 90% Fuel level DI2 OFF ON/OFF indication
H-10 HYD.OIL TEMP DI3 OFF ON/OFF indication
4.5V 30 Hydraulic oil temperature DI4 OFF ON/OFF indication
GLOW OFF Glow switch DI5 OFF ON/OFF indication
AIR FILTER LIVE Air filter clogging DI6 OFF ON/OFF indication
See
WATER SEPA. LIVE Water separator clogging DI7 OFF ON/OFF indication
Mechatro
ENG OIL FILTER LIVE Engine oil filter clogging DI8 OFF ON/OFF indication
controller
FRONT WINDOW OFF Front window open/close switch DI9 OFF ON/OFF indication
connector
DOUBLE FLOW ON Conflux/Single flow select switch DI10 OFF ON/OFF indication
KPSS SW OFF KPSS switch DI11 OFF ON/OFF indication
HEATER OFF Command from air heater DI12 OFF ON/OFF indication
ENG OIL LEVEL LIVE Engine oil level DI13 OFF ON/OFF indication
COOLANT LEVEL LOW Coolant level DI14 OFF ON/OFF indication
FUEL DIST 9999 Fuel dist DI15 OFF ON/OFF indication
FUEL TEMP -100 Fuel temperture DI16 OFF ON/OFF indication
DI17 OFF ON/OFF indication
10 NO.9 SOL.VALVE DI18 OFF ON/OFF indication
F-4 OPT SELECT DI19 OFF ON/OFF indication
COMP. OFF Set value in computer DI20 OFF ON/OFF indication
MEAS. OFF Measured value (Feed back value) DI21 OFF ON/OFF indication
SPOOL POS. NIB Spool position DI22 OFF ON/OFF indication
SELECT SWITCH NIB Mode of selector valve DI23 OFF ON/OFF indication
F-5 FAN PUMP DI24 OFF ON/OFF indication
COMP. OFF Set value in computer DI25 OFF ON/OFF indication
MEAS. OFF Measured value DI26 OFF ON/OFF indication
F-6
COMP. OFF Set value in computer
MEAS. OFF Measured value

11 16 NO.15 DIGITAL INPUT

DI27 OFF ON/OFF indication
DI28 OFF ON/OFF indication
I29 OFF ON/OFF indication
DI30 OFF ON/OFF indication
DI31 OFF ON/OFF indication
DI32 OFF ON/OFF indication
DI33 OFF ON/OFF indication
DI34 OFF ON/OFF indication
DI35 OFF ON/OFF indication
DI36 OFF ON/OFF indication
DI37 OFF ON/OFF indication
DI38 OFF ON/OFF indication
DI39 OFF ON/OFF indication
13 NO.12 PROPO-VALVE DI40 OFF ON/OFF indication
D-11 P1 I-TRAVEL DI41 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI42 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure
D-12 P2 I-TRAVEL
COMP. 600mA 4.5M Set value in computer / Converted value from pressure
MEAS. 600mA 4.5M Measured value / Converted value from pressure
D-14 FAN DRIVE
COMP. 600mA 4.5M Set value in computer / Converted value from pressure
MEAS. 600mA 4.5M Measured value / Converted value from pressure
D-15
COMP. 600mA 4.5M Set value in computer / Converted value from pressure
MEAS. 600mA 4.5M Measured value / Converted value from pressure
D-16
COMP. 600mA 4.5M Set value in computer / Converted value from pressure
MEAS. 600mA 4.5M Measured value / Converted value from pressure

21-50
 21. MECHATRO CONTROLLER

No. Displays Contents No. Displays Contents

17 NO.16 DIGITAL OUTPUT 20 NO.19 WIPER SYSTEM
DO1 COMP. OFF Set value in computer WIPER SW OFF Wiper switch
MEAS. OFF Measured value RISEUP SW OFF Wiper rise-up switch
DO2 COMP. OFF Set value in computer REVERSE SW OFF Wiper reverse rotation switch
MEAS. OFF Measured value PREVENT ARC OFF Wiper motor ark prevention
DO3 COMP. OFF Set value in computer CW MOTOR RLY OFF relay
MEAS. OFF Measured value CCW MOTOR RLY OFF Wiper normal rotation relay
DO4 COMP. OFF Set value in computer WASHER SW OFF Wiper reverse rotation relay
MEAS. OFF Measured value MOTOR RELAY OFF Washer switch
DO5 COMP. OFF Set value in computer Washer motor relay
MEAS. OFF Measured value
DO6 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO7 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO8 COMP. OFF Set value in computer
MEAS. OFF Measured value 22 NO.21 MERIT SYSTEM
DO9 COMP. OFF Set value in computer
MEAS. OFF Measured value COMMUNICATION OFF Status of communication in MERIT controller
DO10 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO11 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO12 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO13 COMP. OFF Set value in computer
MEAS. OFF Measured value

18 23
NO.17 DIGITAL OUTPUT NO.22 ENG CONT.
DO14 COMP. OFF Set value in computer TRANS.COUNT. 100 Counted number of transmission error
MEAS. OFF Measured value RECEIVE COUNT. 100 Counted number of reception error
DO15 COMP. OFF Set value in computer DIAG STATUS 9 Diagnosis status
MEAS. OFF Measured value NUMBER OF DIAG 100 Numbers of error
DO16 COMP. OFF Set value in computer BOOST PRESS. 100 Boost pressure
MEAS. OFF Measured value BOOST TEMP. -100 Boost temperature
DO17 COMP. OFF Set value in computer BAROMETRIC P. 100 Atmospheric pressure
MEAS. OFF Measured value FUEL TEMP. -100 Fuel temperature
DO18 COMP. OFF Set value in computer FUEL CONS. 200 Fuel consumption
MEAS. OFF Measured value INTAKE TEMP. -100 Intake air temperature
DO19 COMP. OFF Set value in computer ENG PRESS. 300 Common rail pressure
MEAS. OFF Measured value GLOW OFF Glow output from ECU
DO20 COMP. OFF Set value in computer ENG STOP OFF Engine stop command from ECU
MEAS. OFF Measured value TORQUE 1000 Calculated torque of ECU
DO21 COMP. OFF Set value in computer BUZZER ON
MEAS. OFF
DO22 COMP. OFF
Measured value
Set value in computer
CLOG 10
REGENE NO ON
Clogging
Information for Prevention of regeneration
21
MEAS. OFF Measured value FORCED REGENE ON Information for regeneratio
DO23 COMP. OFF Set value in computer ENG. RAIL PRESS 1000 Engine rail pressure
MEAS. OFF Measured value UREA LEVEL 100 UREA level
DO24 COMP. OFF Set value in computer UREA TEMP. 100 UREA temperature
MEAS. OFF Measured value
DO25 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO26 COMP. OFF Set value in computer
MEAS. OFF Measured value

19
NO.18 DIGITAL OUTPUT
DO27 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO28 COMP. OFF Set value in computer
MEAS. OFF Measured value

21-51
21. MECHATRO CONTROLLER

2) Service diagnosis mode No.2

No. Displays Contents No. Displays Contents

1 26
NO.1 NO.25 BUCKET
MAIN CONT. P/N C-1 P1-PRES 13.9M Pump pressure sensor
YN22E00001F1 P/No. indication C-2 P2-PRES 13.9M Pump pressure sensor
PROGRAM VERSION E-1 P1-PSV 600mA Command current
1-VER 11.11 Program version indication E-2 P2-PSV 600mA Command current
2-VER 00.00 MERIT controller program version D-1 P1-UL(BPC) 600mA Command current
D-2 P2-UL(BPC) 600mA Command current
SERVICE DIAG 2 Service diagnosis mode D-3 S-TRAVEL 600mA Command current
B-5 BUCKET DIG 1.9M Bucket digging pressure sensor
CLUSTER GAUGE P/N B-6 BUCKET DUMP 1.9M Bucket dump pressure sensor
YN59S00028F1 P/NO. indication G-3 ENG SPEED 2205 Engine actual speed
PROGRAM VERSION POWER SHIFT 100mA Power shift current
02.00 Program Version indication

24 NO.23 BOOM
27
NO.26 TRAVEL
C-1 P1-PRES 13.9M Pump pressure sensor C-1 P1-PRES 13.9M Pump pressure sensor
C-2 P2-PRES 13.9M Pump pressure sensor C-2 P2-PRES 13.9M Pump pressure sensor
E-1 P1-PSV 600mA Command current E-1 P1-PSV 600mA Command current
E-2 P2-PSV 600mA Command current E-2 P2-PSV 600mA Command current
D-1 P1-UL(BPC) 600mA Command current D-1 P1-UL(BPC) 600mA Command current
D-2 P2-UL(BPC) 600mA Command current D-2 P2-UL(BPC) 600mA Command current
B-1 BOOM RAISE 1.9M Boom up pressure sensor D-3 S-TRAVEL 600mA Command current
B-2 BOOM LOWER 1.9M Boom down pressure sensor B-9 TRAVEL(R) 13.9M Travel right pressure sensor
G-3 ENG SPEED 2205 Engine actual speed B-10 TRAVEL(L) 13.9M Travel left pressure sensor
POWER SHIFT 100mA Power shift current Pi-P1 13.9M Pilot pressure at travel straight (P1 side)
Pi-P2 13.9M Pilot pressure at travel straight (P2 side)
G-3 ENG SPEED 2205 Engine actual rpm
POWER SHIFT 100mA Power shift current

25 28
NO.24 ARM,SWING NO.27 OPT
C-1 P1-PRES 13.9M Pump pressure sensor C-1 P1-PRES 13.9M Pump pressure sensor
C-2 P2-PRES 13.9M Pump pressure sensor C-2 P2-PRES 13.9M Pump pressure sensor
E-1 P1-PSV 600mA Command current E-1 P1-PSV 600mA Command current
E-2 P2-PSV 600mA Command current E-2 P2-PSV 600mA Command current
D-1 P1-UL(BPC) 600mA Command current D-1 P1-UL(BPC) 600mA Command current
D-2 P2-UL(BPC) 600mA Command current D-2 P2-UL(BPC) 600mA Command current
D-3 S-TRAVEL 600mA Command current D-3 S-TRAVEL 600mA Command current
D-6 ARM-IN-2 600mA Command current E-3 OPT RELIEF 600mA Command current
B-3 ARM OUT 13.9M Arm out pressure sensor B-16 P1 OPT 1.9M P1 side option pressure sensor
B-4 ARM IN 13.9M Arm in pressure sensor B-17 P2 OPT 1.9M P2 side option pressure sensor
B-1 BOOM RAISE 13.9M Boom up pressure sensor F-4 OPT SELECT NIB Optional selector SOL (Nibbler line)
B-7 SWING 13.9M Swing pressure sensor DOUBLE FLOW SW NIB Conflux/ Single selector switch
G-3 ENG SPEED 2205 Engine actual speed G-3 ENG SPEED 2205 Engine actual rpm
POWER SHIFT 100mA Power shift current POWER SHIFT 100mA Power shift current

21-52
 21. MECHATRO CONTROLLER

3) Service diagnosis mode No.3

No. Displays Contents No. Displays Contents

1 32
NO.1 NO.31 MACHINE-INFORM.
MAIN CONT. P/N PUMP PRESS.
YN22E00001F1 P/No. indication TOTAL 10Hr Pump pressure distribution (%)
PROGRAM VERSION LEVEL1 24% 22% Total / In the last 10 hours
1-VER 11.11 Program version indication LEVEL2 50% 50% Total / In the last 10 hours
2-VER 00.00 MERIT controller program version LEVEL3 25% 25% Total / In the last 10 hours
LEVEL4 1 % 3% Total / In the last 10 hours
SERVICE DIAG 3 Service diagnosis mode
WATER TEMP.
CLUSTER GAUGE P/N TOTAL 10Hr Coolant temperature distribution (%)
YN59S00028F1 P/NO. indication LEVEL1 24% 22% Total / In the last 10 hours
PROGRAM VERSION LEVEL2 50% 50% Total / In the last 10 hours
02.00 Program Version indication LEVEL3 25% 25% Total / In the last 10 hours
LEVEL4 1 % 3% Total / In the last 10 hours

FUEL TEMP.
29 TOTAL 10Hr Pump pressure distribution (%)
NO.28 ADJUSTMENT 1
ENG LEVEL1 24% 22% Total / In the last 10 hours
HI-IDLE 2205 Engine speed high idle LEVEL2 50% 50% Total / In the last 10 hours
PUMP LEVEL3 25% 25% Total / In the last 10 hours
ACT I 515mA Current at pump adjustment LEVEL4 1 % 3% Total / In the last 10 hours
I 15mA Current correction at pump adjustment
PUMP P 35.0M Pressure at pump adjustment HYD. OIL TEMP.
ESS N 2040 Engine speed sensor rpm TOTAL 10Hr Coolant temperature distribution (%)
UN-LOAD LEVEL1 24% 22% Total / In the last 10 hours
P1 600mA P1 unload corrective current LEVEL2 50% 50% Total / In the last 10 hours
P2 600mA P2 unload corrective current LEVEL3 25% 25% Total / In the last 10 hours
BOOM 137 137 Angle adjustment LEVEL4 1 % 3% Total / In the last 10 hours
ARM 137 137 Angle adjustment
OFFSET 137 137 Angle adjustment
INTER-B 137 137 Angle adjustment
31 NO.30 MACHINE-INFORM.
HOUR METER 3550 Hour meter of controller
TRIP METER 3500 Trip meter of controller
OPERATION 3300 All accumulated operating time
TRAVEL 300 All accumulated traveling time
SWING 3000 All accumulated swing time
HAMMER 100 All accumulated breaker operating time
CRANE 100 All accumulated high-reach crane operating time
STARTER 1200 All accumulated starter operating time

21

21-53
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 this data to
decide normal/abnormal status.
• The values in the following display are reference values with a standard attachment attached to the machine.
• The value of the pressure sensor is calculated taking variations into account. When compared to the
performance check reference criteria, measure it with the aid of a calibrated measuring instrument.
• The current of the proportional valve is not the measured value, but the command value. The measured value
should be confirmed by the value in the displayed value for each proportional valve.
• The current value of the pump proportional valve is a reference value because it varies according to the pump
pressure and adjusted torque value.
• The value in the display during operation shows the value in a steady state, rather than, at start of operation.
• Check on the machine after sufficiently warming up the machine.
• The value in the display may differ according to the software version. Contact our dealer/distributor.

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

H mode High idle S mode High idle
No.24 ARM, SWING No.24 ARM, SWING
C-1 P1-PRES 0.2 to 2.0 M C-1 P1-PRES 0.2 to 2.0 M
C-2 P2-PRES 0.2 to 2.0 M C-2 P2-PRES 0.2 to 2.0 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
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 2070 to 2130 G-3 ENG SPEED 1870 to 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 High idle H mode High idle
No.23 BOOM No.23 BOOM
C-1 P1-PRES 33.0 to 35.8 M C-1 P1-PRES 13.0 to 18.0 M
C-2 P2-PRES 33.0 to 35.8 M C-2 P2-PRES 13.0 to 18.0 M
E-1 P1-PSV 470 to 585 mA E-1 P1-PSV 630 to 770 mA
E-2 P2-PSV 470 to 585 mA E-2 P2-PSV 630 to 725 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 2050 to 2200 G-3 ENG SPEED 2050 to 2200
POWER SHIFT 0 mA POWER SHIFT 0 mA

21-54
 21. MECHATRO CONTROLLER

Operation No.5:
Boom down in full lever operation & in operation
H mode High idle
No.23 BOOM
C-1 P1-PRES 5.0 to 9.0 M
C-2 P2-PRES 0.2 to 2.0 M
E-1 P1-PSV 600 to 620 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 427 to 477 mA
D-2 P2-UL(BPC) 750 mA
B-1 BOOM RAISE 0.0 M
B-2 BOOM LOWER 3.0 M
G-3 ENG SPEED 2050 to 2200
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 High idle H mode High idle
No.24 ARM, SWING No.24 ARM, SWING
C-1 P1-PRES 33.0 to 35.8 M C-1 P1-PRES 9.0 to 13.0 M
C-2 P2-PRES 33.0 to 35.8 M C-2 P2-PRES 9.0 to 13.0 M
E-1 P1-PSV 470 to 585 mA E-1 P1-PSV 750 to 770 mA
E-2 P2-PSV 470 to 585 mA E-2 P2-PSV 750 to 770 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-2 395 mA 21
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 2050 to 2200 G-3 ENG SPEED 2050 to 2200
POWER SHIFT 0 mA POWER SHIFT 0 mA

21-55
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 High idle H mode High idle
No.24 ARM, SWING No.24 ARM, SWING
C-1 P1-PRES 33.0 to 35.8 M C-1 P1-PRES 15.0 to 22.0 M
C-2 P2-PRES 33.0 to 35.8 M C-2 P2-PRES 15.0 to 22.0 M
E-1 P1-PSV 470 to 585 mA E-1 P1-PSV 570 to 680 mA
E-2 P2-PSV 470 to 585 mA E-2 P2-PSV 570 to 680 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 2050 to 2200 G-3 ENG SPEED 2050 to 2200
POWER SHIFT 0 mA POWER SHIFT 0 mA

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

Operation No.10: Operation No.11:

Swing in full lever operation & relief Swing in full lever operation & in operation
H mode High idle H mode High idle
No.24 ARM, SWING No.24 ARM, SWING
C-1 P1-PRES 0.2 to 2.0 M C-1 P1-PRES 0.2 to 2.0 M
C-2 P2-PRES 28.0 to 35.8 M C-2 P2-PRES 10.0 to 15.0 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 615 to 770 mA E-2 P2-PSV 770 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 2050 to 2200 G-3 ENG SPEED 2050 to 2200
POWER SHIFT 0 mA POWER SHIFT 0 mA

21-56
 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 High idle H mode High idle
No.25 BUCKET No.25 BUCKET
C-1 P1-PRES 33.0 to 35.8 M C-1 P1-PRES 7.0 to 11.0 M
C-2 P2-PRES 33.0 to 35.8 M C-2 P2-PRES 7.0 to 11.0 M
E-1 P1-PSV 470 to 585 mA E-1 P1-PSV 670 to 770 mA
E-2 P2-PSV 470 to 585 mA E-2 P2-PSV 600 to 620 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 720 mA D-3 S-TRAVEL 720 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 2050 to 2200 G-3 ENG SPEED 2050 to 2200
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 High idle H mode High idle
No.25 BUCKET No.25 BUCKET
C-1 P1-PRES 33.0 to 35.8 M C-1 P1-PRES 15.0 to 24.0 M
C-2 P2-PRES 33.0 to 35.8 M C-2 P2-PRES 15.0 to 24.0 M
E-1 P1-PSV 470 to 585 mA E-1 P1-PSV 550 to 770 mA
E-2 P2-PSV 470 to 585 mA E-2 P2-PSV 550 to 770 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 720 mA D-3 S-TRAVEL 720 mA 21
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 2050 to 2200 G-3 ENG SPEED 2050 to 2200
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
A mode High idle B mode High idle
No.27 OPT No.27 OPT
C-1 P1-PRES 22.5 to 26.0 M C-1 P1-PRES 0.2 to 1.5 M
C-2 P2-PRES 22.5 to 26.0 M C-2 P2-PRES 22.5 to 26.0 M
E-1 P1-PSV 530 to 665 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 530 to 665 mA E-2 P2-PSV 770 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 to 2.6 M B-17 P2 OPT 2.0 to 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 2050 to 2200 G-3 ENG SPEED 2050 to 2200
POWER SHIFT 0 mA POWER SHIFT 0 mA

* Conflux switch is ON. Relief set pressure is value at shipping.

* Conflux switch is OFF. Relief set pressure is value at 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 High idle H mode High idle
No.26 TRAVEL No.26 TRAVEL
C-1 P1-PRES 7.0 to 13.0 M C-1 P1-PRES 0.2 to 1.5 M
C-2 P2-PRES 0.2 to 2.0 M C-2 P2-PRES 7.0 to 13.0 M
E-1 P1-PSV 770 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 350 mA E-2 P2-PSV 770 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 to 2.5 M B-9 TRAVEL(R) 0.0 M
B-10 TRAVEL(L) 0.0 M B-10 TRAVEL(L) 2.0 to 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 2050 to 2200 G-3 ENG SPEED 2050 to 2200
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 the mechatro controller self diagnosis function are stored in the mechatro controller
as one of history. And the errors are able to be indicated on the multi display.
The warning content is recorded partially in the "Travel History Screen".
The error code for self diagnosis is stored.

(1) How to display

1. Turn starter switch on.
2. While holding down the menu switch, press the (Example)
buzzer stop switch 3 times. And select "TROUBLE No errors NO ERROR
HISTORY" to display the trouble history diagnosis.
3. Transmit trouble history data (One or many) and
hour meter to the gauge cluster.
-Hour meter and 10 failure data are displayed on Error detected
the screen. in the past
-In case of more than 10 data failures, turn a page
to check next data.
4. Paging (Up and down)
-Press "UP ARROW SWITCH" to move the item
up.
-Press "DOWN ARROW SWITCH" to move the
item down.
5. Turn the starter switch OFF, and the display
disappears.

(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. 21
3. When "NO ERROR" is displayed, the deletion is completed.
4. Turn the 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 SET PROCEDURE OF MAINTENANCE SCHEDULE

Travel speed select switch Wiper switch
This machine is equipped with a multi-display which Auto accel switch Washer switch
makes confirmation of remaining time to the coming
replacement/change time of the engine oil, fuel filter, Work mode
hydraulic oil filter and hydraulic oil. When the remaining select switch
time reaches Zero (0), replace or change them and
perform the initial setting in the following order.

Buzzer
stop switch

Screen change switch Menu switch

Interval of replacement parts is mentioned below.

-Engine oil: 500 Hr
-Fuel filter: 500 Hr
-Hydraulic filter: 1,000 Hr
-Hydraulic oil: 5,000 Hr

1. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does not
sound.
2. The fuel filter change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does not
sound.
3. The hydraulic oil filter change time is displayed on the multi-display by 1000 hours as a warning, but the buzzer
does not sound.
4. The hydraulic oil change time is displayed on the multi-display by 5000 hours as a warning, but the buzzer does
not sound.

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 21. MECHATRO CONTROLLER

Procedure Operating Procedure Display on Multidisplay

After several
seconds, display is S 12:15

changed to clock
automatically

1 Turn starter key switch ON. E F

S 12:15
USER MENU

MAINTENANCE
SWITCH STATUS
OPTION SETTING
Press "MENU SWITCH" located on the CONSUMPTION
multi-display, the display changes to
E F
SCREEN SETTING
CLOCK SETTING
2 "USER MENU" display.

BACK UP NEXT
HOME DOWN

INTERVAL REMAINDER
EXCHANGE
DAY
USER MENU ENGINE OIL 500Hr 500Hr 08/12/12

MAINTENANCE
FUEL FILTER 500Hr -100Hr 08/12/12

SWITCH STATUS HYD. FILTER 1000Hr 500Hr 08/12/12

OPTION SETTING HYD. OIL 3000Hr 3000Hr 08/12/12
Press "NEXT" switch once to enter into CONSUMPTION
"MAINTENANCE". At this time, "INTERVAL" SCREEN SETTING
CLOCK SETTING
3 box is indicated in blue.
21
BACK UP NEXT
HOME DOWN

INTERVAL REMAINDER
EXCHANGE INTERVAL REMAINDER
EXCHANGE
DAY DAY
ENGINE OIL 500Hr 500Hr 08/12/12 ENGINE OIL 500Hr 500Hr 08/12/12

4 Press "NEXT" switch once more, and FUEL FILTER 500Hr -100Hr 08/12/12 FUEL FILTER 500Hr -100Hr 08/12/12
"REMAINING TIME" box is indicated in blue. HYD. FILTER 1000Hr 500Hr 08/12/12 HYD. FILTER 1000Hr 500Hr 08/12/12

HYD. OIL 3000Hr 3000Hr 08/12/12 HYD. OIL 3000Hr 3000Hr 08/12/12

INTERVAL REMAINDER
EXCHANGE INTERVAL REMAINDER
EXCHANGE
Using switch "DOWN" or "UP", and get the DAY
or
DAY
ENGINE OIL 500Hr 500Hr 08/12/12 ENGINE OIL 500Hr 455Hr 08/12/12
desired time until the replacement. Press FUEL FILTER 500Hr -100Hr 08/12/12 FUEL FILTER 500Hr -100Hr 08/12/12

5 "MENU SWITCH" once to return to default HYD. FILTER 1000Hr 500Hr 08/12/12 HYD. FILTER 1000Hr 500Hr 08/12/12

setting time. HYD. OIL 3000Hr 3000Hr 08/12/12 HYD. OIL 3000Hr 3000Hr 08/12/12

INTERVAL REMAINDER
EXCHANGE INTERVAL REMAINDER
EXCHANGE
DAY DAY
ENGINE OIL 500Hr 455Hr 08/12/12 ENGINE OIL 500Hr 455Hr 08/12/12

6 Press "NEXT" switch to fix the value. FUEL FILTER 500Hr -100Hr 08/12/12 FUEL FILTER 500Hr -100Hr 08/12/12

HYD. FILTER 1000Hr 500Hr 08/12/12 HYD. FILTER 1000Hr 500Hr 08/12/12

HYD. OIL 3000Hr 3000Hr 08/12/12 HYD. OIL 3000Hr 3000Hr 08/12/12

EXCHANGE
INTERVAL REMAINDER
DAY S 12:15
ENGINE OIL 500Hr 450Hr 08/12/12

FUEL FILTER 500Hr -100Hr 08/12/12

HYD. FILTER 1000Hr 500Hr 08/12/12

HYD. OIL 3000Hr 3000Hr 08/12/12

Press "Screen Change Switch" once, and the E F
7 display returns to main display (a).

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21. MECHATRO CONTROLLER

21.2.6 ADJUSTING PROCEDURE OF DISPLAY

(1) For operator
1) Clock Adjustment Switches
6 7 4 5
1: Screen Change Switch
2: Buzzer Stop Switch
3: Work Mode Select Switch 3
4: Washer Switch
5: Wiper Switch
6: Travel Speed Select Switch
7: Auto Accel Switch
8: Menu Switch
9: Arrow Switch 2

1 9 8

S 12:15
USER MENU USER MENU CLOCK CLOCK
SETTING SETTING
MAINTENANCE MAINTENANCE YEAR 10 YEAR 10
SWITCH STATUS SWITCH STATUS MONTH 01 MONTH 01
OPTION SETTING OPTION SETTING DATE 01 DATE 01
CONSUMPTION CONSUMPTION HOUR 13 HOUR 13
E F
SCREEN SETTING SCREEN SETTING MINUTE 25 MINUTE 25
CLOCK SETTING CLOCK SETTING

or
BACK UP NEXT BACK UP NEXT BACK UP NEXT BACK UP NEXT
HOME DOWN HOME DOWN HOME DOWN HOME DOWN

(a) (b) (c) (d) (e)

Selcet Year / Month / Increase / Decrease

Day / Hour / Minute

1. After turning the starter key switch ON, the main screen (a) appears. Press "MENU SWITCH" to enter into
"USER MENU" display (b).
2. Using switch "DOWN" or "UP", move the cursor to "CLOCK SETTING" display. Press "NEXT" to select "CLOCK
SETTING" display (d).
3. Using switch "DOWN" or "UP", select "YEAR/MONTH/DAY/HOUR/MINUTE" display. Press "NEXT" to select
the desired item.
4. Using switch "DOWN" or "UP" to get the desired value.
5. After adjustment, press "Menu Switch". The adjusted values are stored as memory and the clock setting is
completed. Press "Screen Change Switch", and the display returns to the main display (a).

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 21. MECHATRO CONTROLLER

2) Contrast Adjustment Switches

6 7 4 5
1: Screen Change Switch
2: Buzzer Stop Switch
3: Work Mode Select Switch 3
4: Washer Switch
5: Wiper Switch
6: Travel Speed Select Switch
7: Auto Accel Switch
8: Menu Switch
9: Arrow Switch 2

1 9 8

S 12:15
USER MENU USER MENU SCREEN SCREEN
SETTING SETTING
MAINTENANCE MAINTENANCE CONTRAST 5 CONTRAST 5
SWITCH STATUS SWITCH STATUS Brightness(day) 100 Brightness(day) 100
OPTION SETTING OPTION SETTING Brightness(night) 5 Brightness(night) 5
CONSUMPTION CONSUMPTION
E F
SCREEN SETTING SCREEN SETTING
CLOCK SETTING CLOCK SETTING

or
BACK UP NEXT BACK UP NEXT BACK UP NEXT BACK UP
HOME DOWN HOME DOWN HOME DOWN HOME DOWN

(a) (b) (c) (d) (e)

Increase / Decrease
21

1. After turning the starter key switch ON, the main screen (a) appears. Press "Menu Switch" to enter into "USER
MENU" display (b).
2. Move the cursor to "SCREEN SETTING" display. Press "NEXT" to select "SCREEN SETTING" display (d).
3. Move the cursor to "CONTRAST" display (d) on the "SCREEN SETTING" display. Press "NEXT" to select
desired value.
4. Use cursor, and get the desired values. Step of the adjustable range is from 1 to 10.
Example: 1 (Faint) to 10 (Clear)
* Default is set to 5.
5. After adjustment, press "Menu Switch" and the adjusted values are stored as memory and the "CONTRAST"
setting is completed. Press "Screen Change Switch", and the display returns to the main display (a).

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21. MECHATRO CONTROLLER

(2) Function for service

The following items are provided for adjustment of the service function.

Item CONTENTS
Language Language selection
Rise-up wiper Wiper control change (When cab is changed)
Idle stop ON/OFF of auto idle stop (ON/OFF of adjustment for user) and time adjust
P1 option pressure sensor ON/OFF of self diagnosis for P1 option pressure sensor
P2 option pressure sensor ON/OFF of self diagnosis for P2 option pressure sensor
Swing alarm ON/OFF of swing alarm (ON/OFF of adjustment for user)
Left pedal for rotation of 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

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 21. MECHATRO CONTROLLER

21.2.7 MECHATRO CONTROL EQUIPMENT

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

2 1 6 2 1 4 2 1 8 2 1
10
16
26
34

27 22 18 16 12 28 22
CN101 CN102 CN103 CN104

CN105 CN106 CN107 CN108 CN109

9 21 7 2 16 21 9 21 7 21

21

31 10 16 8 12 7 28 10 22 8
22 24 17 17 13 19 20 15 16

2) List of connectors

Connector No. Pin No. Port name Function Input/Output Signal level
CN101 1 GA 0V
2 A1 Boom up Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5
6
A2
GA
Boom down Input 0.5~4.5V
0V
21
7 GA 0V
8 A3 Arm in Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A4 Arm out Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A5 Bucket digging Input 0.5~4.5V
15 +5VA Power output 5V
16 +5VA Power output 5V
17 A6 Bucket dump Input 0.5~4.5V
18 GA 0V
19 TXD1 Spare Transmission RS232C communication
20 RXD1 Reception RS232C communication
21 GP 0V
22 SHG1 Shield GND
23 TXD3 Down load Transmission RS232C communication
24 RXD3 Reception RS232C communication
25 DL EARTH / OPEN(5V)
26 GP 0V
27 CANH1 E/G ECU CAN communication
28 CANL1 E/G ECU CAN communication
29 DO 20 Spare Output EARTH/OPEN
30 DO 21 Safety relay Output EARTH/OPEN
31 DO 22 Spare Output EARTH/OPEN
32 DO 23 Rotary light (yellow) Output EARTH/OPEN
33 DO 24 Rotary light (green) Output EARTH/OPEN
34 DI 36 Heavy lift Input EARTH/OPEN

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21. MECHATRO CONTROLLER

Connector No. Pin No. Port name Function Input/Output Signal level
CN102 1 GA 0V
2 A8 Travel right Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A9 Travel left Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A10 Accelation Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A13 P1 option Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A14 P2 option Input 0.5~4.5V
15 +5VA Power output 5V
16 +5VA Power output 5V
17 A27 Spare Input 0.5~4.5V
18 GA 0V
19 GA 0V
20 A28 Spare Input 0.5~4.5V
21 +5VA Power output 5V
22 D1 37 Spare Input GND / OPEN

Connector No. Pin No. Port name Function Input/Output Signal level
CN103 1 GA 0V
2 A Swing Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A11 P1 pump Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A12 P2 pump Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A15 Boom angle Input 0.5~4.5V
12 GA 0V
13 GA 0V
14 A16 Arm angle Input 0.5~4.5V
15 +5VA Power output 5V
16 Reserved

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 21. MECHATRO CONTROLLER

Connector No. Pin No. Port name Function Input/Output Signal level
CN104 1 GA 0V
2 A17 Boom head Input 0.5~4.5V
3 +5VA Power output 5V
4 +5VA Power output 5V
5 A18 Boom rod Input 0.5~4.5V
6 GA 0V
7 GA 0V
8 A19 Extra pressure source Input 0.5~4.5V
9 +5VA Power output 5V
10 +5VA Power output 5V
11 A20 Spare Input 0.5~4.5V
12 GA 0V
13 A21 Spare Input 0.5~4.5V
14 GA 0V
15 A22 Fuel level Input 0.5~4.5V
16 GP 0V
17 A23 Spare Input 0.5~4.5V
18 GA 0V
19 GA 0V
20 A24 Selector detection Input 0.5~4.5V
21 +5VA Power output 5V
22 +5VA Power output 5V
23 A25 Spare Input 0.5~4.5V
24 GA 0V
25 GA 0V
26 A26 Spare Input 0.5~4.5V
27 +5VA Power output 5V
28 DI 1 Cab slow up and down Input GND / OPEN

Connector No. Pin No. Port name Function Input/Output Signal level
CN105 1 +24V Battery relay output side 20~32V 21
2 +24V Battery relay output side 20~32V
(sensor analog output)
3 +24V Battery relay output side 20~32V
4 DO 7 Travel 1,2 speed select valve Output 24V/OPEN
5 DO 8 Swing P/B select valve Output 24V/OPEN
6 DO 9 Travel 1,2 speed select valve Output 24V/OPEN
7 DO 11 Attachment boost select valve Output 24V/OPEN
8 GND Battery (-) 0V
9 GND Battery (-) 0V
10 D10+ OPT changeable relief 1 Output +0~800mA
11 D1+ P1 unload Output +0~800mA
12 D1- -0~800mA
13 D2+ P2 unload Output +0~800mA
14 D2- -0~800mA
15 D3+ Travel straight Output +0~800mA
16 D3- -0~800mA
17 D4+ Arm in Output +0~800mA
18 D4- -0~800mA
19 D5+ P1 pump Output +0~800mA
20 D5- -0~800mA
21 GND Battery (-) 0V
22 D10- OPT changeable relief 1 Output -0~800mA
23 D6+ P2 pump Output +0~800mA
24 D6- -0~800mA
25 D7+ Spare Output +0~800mA
26 D7- -0~800mA
27 D8+ Boom cushion Output +0~800mA
28 D8- -0~800mA
29 D9+ Arm cushion Output -0~800mA
30 D9- +0~800mA
31 +24V Battery direct connection 20~32V

21-67
21. MECHATRO CONTROLLER

Connector No. Pin No. Port name Function Input/Output Signal level
CN106 1 +24V Battery relay secondary side 0 20~32V
2 SHGF Shield GND
3 F1+ Accel motor A phase (spare) Output +24V 1.5A
4 F1- Accel motor A phase (spare) Output +24V 1.5A
5 F2+ Accel motor B phase (spare) Output +24V 1.5A
6 F2- Accel motor B phase (spare) Output +24V 1.5A
7 OIL Oil level (spare) 0
8 OILG
9 D11+ OPT changeable relief 2 Output +0~800mA
10 D11- -0~800mA
11 D12+ Spare Output +0~800mA
12 D12- -0~800mA
13 D13+ Spare Output +0~800mA
14 D13- -0~800mA
15 D14+ Spare Output +0~800mA
16 D14- -0~800mA
17 GND Battery (-) 0V
18 D12+ Spare Output +0~800mA
19 D12- -0~800mA
20 E1+ E/G speed sensor Input XX~XXVp-p
21 E1- 0V
22 SHG3 Shield GND
23 CANH2 Gauge cluster CAN communication
24 CANL2 CAN communication

Connector No. Pin No. Port name Function Input/Output Signal level
CN107 1 DI 3 Key switch (GLOW) Input +24V/OPEN
2 DI 8 Spare Input EARTH / OPEN
3 DI 9 E/G oil pressure Input EARTH / OPEN
4 DI 10 Air filter Input EARTH / OPEN
5 DI 11 Stroke end check Input EARTH / OPEN
6 DI 12 Spare Input EARTH / OPEN
7 DI 13 E/G coolant level Input EARTH / OPEN
8 DI 14 Spare Input EARTH / OPEN
9 DI 15 Spare Input EARTH / OPEN
10 DI 20 ECU main relay Input EARTH / OPEN
11 DI 28 Spare Input EARTH / OPEN
12 DI 32 Hand control nibbler Input EARTH / OPEN
13 DI 38 Quick coupler Input EARTH / OPEN
14 DI 39 Extra pressure Input EARTH / OPEN
15 DI 40 Spare Input EARTH / OPEN
16 DI 41 Spare Input EARTH / OPEN
17 Reserved

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 21. MECHATRO CONTROLLER

Connector No. Pin No. Port name Function Input/Output Signal level
CN108 1 DI 2 Key switch (ON) Input +24V / OPEN
2 DI 4 Spare Input +24V / OPEN
3 DI 5 Swing P/B release Input GND / OPEN
4 DI 6 E/G start Input +24V / OPEN
5 DI 7 High reach(hoisting at fixed position) Input GND / OPEN
6 DI 16 Wiper rise up Input GND / OPEN
7 DI 17 Wiper reverse Input GND / OPEN
8 DI 18 ATT boost Input GND / OPEN
9 DI 19 Nibbler open check SW Input GND / OPEN
10 DI 21 Working light SW Input +24V / OPEN
11 DI 22 Spare Input +24V / OPEN
12 DI 23 Lever lock Input +24V / OPEN
13 DI 24 Hand control rotation / Input
clamp open or close GND / OPEN
14 DI 25 Front window open or close Input GND / OPEN
15 DI 26 Hand control breaker Input GND / OPEN
16 DI 27 Manual playback signal Input GND / OPEN
17 DI 29 Overload select Input GND / OPEN
18 DI 30 High reach (hoist at travel) Input GND / OPEN
19 Reserved
20 GP
21 DI 33 Charge Input ~12V / 12V~
22 DI 34 Manual playback switch Input +24V / OPEN
23 DI 35 Spare Input +24V / OPEN
24 Reserved Reserved
25 H1+ Accel signal 1 0~5V
26 H2- 0V
27 H2+ Accel signal 2 0~5V
28 H2- 0V

Connector No. Pin No. Port name Function Input/Output Signal level
21
CN109 1 DO 1 Wiper arc prevention Output GND / OPEN
2 DO 2 Wiper normal moving Output GND / OPEN
3 DO 3 Wiper reserve moving Output GND / OPEN
4 DO 4 Washer motor Output GND / OPEN
5 DO 5 Bucket move limitation Output GND / OPEN
6 DO 6 Reserved Output GND / OPEN
7 DO 12 Rotary light (RH) Output GND / OPEN
8 DO 13 Swing flasher (RH) Output GND / OPEN
9 DO 14 Swing flasher (LH) Output GND / OPEN
10 DO 15 Travel alarm Output GND / OPEN
11 DO 16 Auto idle stop relay Output GND / OPEN
12 DO 17 Engine stop Output GND / OPEN
13 DO 18 Lever lock Output GND / OPEN
14 DO 19 Extra pressure release Output GND / OPEN
15 Reserved
16 GP IT controller 0V
17 TXD2 Transmission RS232C communication
18 RXD2 Reception RS232C communication
19 RTS Spare RS232C communication
20 CTS Spare RS232C communication
21 SHG2 Shield GND
22 DO 10 Forced playback signal SV 24V/OPEN

21-69
21. MECHATRO CONTROLLER

(2) Gauge cluster (symbol C-2)

1) General view

NIBBLER MODE
SWITCH

BREAKER MODE
SWITCH

CN-600
MULTI
DISPLAY LCD 1 2 3 4
5 6 7 8

HARNESS SIDE
AMP 040 (8P)
DIGGING MODE
HOUSING : 174044-2
SWIHCH
TERMINAL : 173681-2
WORK MODE
SWIHCH
BUZZER STOP
SWITCH
BACK ARROW
SWITCH NEXT ARROW SWITCH
MENU SWITCH CN-601
SCREEN CHANGE HARNESS SIDE
DOWN ARROW SWITCH 1 2 3 4 5 6 AMP 040 (12P)
SWITCH
UP ARROW SWITCH 7 8 9 10 1112 HOUSING : 174045-2
TERMINAL : 173681-2
2) Connector CN-600 (Harness side)

No. Item name Wire color No. Item name Wire color
1 Reserved - 5 Source (+24V) White
2 Reserved - 6 GND Black
3 Reserved - 7 Source (+24V) White
4 Reserved - 8 Reserved -

3) Connector CN-601 (Harness side)

No. Item name Wire color No. Item name Wire color
1 Reserved - 7 Reserved -
2 Reserved - 8 Reserved -
3 Reserved - 9 Reserved -
4 Rearview camera video signal White 10 GND Black
5 Reserved - 11 Reserved -
Mechatro-controller --> Gauge cluster -->
6 Gauge cluster (CAN Red 12 Mechatro-controller (CAN White
communication) communication)

4) 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.

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 21. MECHATRO CONTROLLER

5) Summary of display and drive item

No. Item Remarks

1 Monitar display LCD dot 120X168
2 -
3 -
4 Buzzer Piezo-electricity type
5 Screen change switch
6 Buzzer stop switch
7 Work mode select switch
8 Digging mode switch
9 Nibbler mode switch
10 Breaker mode switch
11 Up arrow switch
12 Down arrow switch
13 Next arrow switch
14 Back arrow switch
15 Back light LED

21

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21. MECHATRO CONTROLLER

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

1) General view

(Overhead view of box)

LABEL INSIDE

Note) These circles indicate the parts

which are used in standard specification

1 10
1 14 1 14 1 12 1 3 1 3
CN16 CN17

20 20 CN4-1 17 CN5 15 6 2 6
CN2-1 CN2-2 2

11 22 1 3 1 3
13 26 13 26 9 20 CN14 CN15

1 13 1 7 2 6 2 6
1 9
CN4-2 1 3 1 3
17
CN3-1 CN3-2 12
6 12 3 CN12 CN13
1
2 6 2 6
12 24 8 16 1 CN1
1 2 1 2 CN2-3 2 1 2
CN8 CN9 2 4 CN10
3

LOCATION OF CONNECTORS (Seen from backside)

LOCATION OF RELAY & FUSE

LABEL OF RELAY & FUSE BOX

No. CODE IN CIRCUIT PARTS NAME

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 21. MECHATRO CONTROLLER

2) Circuit diagram

21

21-73
21. MECHATRO CONTROLLER

21-74
 21. MECHATRO CONTROLLER

21

21-75
21. MECHATRO CONTROLLER

(4) High pressure sensor: LS52S00015P1

ECONOSEAL SERIES MARK (+)> SPECIFICATION :

3POLES CAP
MATING HOUSING174357-2 PRESSURE RANGE : 0 50 MPa (0 7110 psi)
POWER SOURCE VOLTAGE : 5.0+0.5V DC
COMMON OUTPUT : 1/10Vs-9/10Vs
OUTPUT (+) (Vs=5V DC 0.5 4.5V DC)
POWER SOURCE (+) INSURANCE RESISTANCE : 100M OR MORE
HOUSING (BETWEEN CASING AND ALL IN/OUT
TERMINAL
TERMINALS AT 50V DC MEGGER)
PLASTIC POTTING CONDENSER

COVER
ELECTRIC CONNECTING DIAGRAM
DIE
CASING (Ex. Construction of internal controller)
FLEXIBLE BOARD
CIRCUIT DIAPHRAGM

O-RING P14 PIPE

JIS B2401 CLASS1B
THREAD
PF 3/8
Tightening torgue STRUCTURE
73.5N.m (54.2lbf.ft)

(5) Low pressure sensor: LC52S00019P1

A AMP MQS CONNECTOR 3 POLE (B TYPE)

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

CONNECTOR TERMINAL POSITION

TERMINAL No.
1 COM
2 OUT PUT (+)
3 POWER (+)

VIEW A

19 21.9 HEX

O-RING P11
PF1/4 Tightening torgue
34.3N.m (25.3lbf.ft)

DETAIL OF SENSOR CONNECTOR SPECIFICATION :

PRESSURE RANGE : 0 3.0 MPa (0 448 psi)
RATED VOLTAGE : 5.0+0.5V DC
INSURANCE RESISTANCE : 100M OR MORE
(BETWEEN BODY AND EACH TERMINAL AT
50V DC MEGGER)

21-76
 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
22.10COMBINED CIRCUIT ........................................................................................ 22-26
22.11 PRESSURE DRAINING ..................................................................................... 22-30

22

Book Code No. S5LC2226E02

22-1
22. HYDRAULIC SYSTEM

Issue Date of Issue Applicable Machines Remarks

S5LC2226E01
First Edition September, 2010 SK350LC-9 : YC
NA
S5LC2226E02
Revision May, 2011 SK350LC-9 : YC
NA

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.

Perfor- Device
mance Function Features

Travel straight Travel straight at combined operation

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

Auto parking brake Automatic braking when parking

Motor overrun protection Prevents overrunning of travel motor on the down hill slope.
Travel pilot operation Prevents hunting by the built in travel shockless mechanism
Reverse rotation protective function Easy positioning to protect it from swinging back when stops swinging.
Swing

Swing priority circuit Easy operation of stable swing speed, arm slanted leveling,
(simultaneous operation of arm in and swing motions) swing press digging
Easy operability and safety

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

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

Return circuit To prevent hydraulic oil from contamination

Cooling hydraulic oil by oil cooler To prevent hydraulic oil from being deteriorated.
Pressure draining circuit To release the main circuit pressure for piping repair work.
Main control valve with optional valve Optional piping and additional work are easy
Switching of return line for N&B machine in the cab Switching of return line for N&B machine is able to
(Option) change with a switch in the cab
22
Electric flow controlled variable displacement pump Pump delivery rate control by a current command to the
Mass handling capability

solenoid proportional valve of the variable displacement pump

Pump

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

Arm conflux circuit Speed up of arm operation

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

speed when control lever is in neutral position.

computer
Low fuel

Micro

22-3
22. HYDRAULIC SYSTEM

22.2 HYDRAULIC CIRCUITS AND COMPONENTS

STD. SCHEMATIC HYD. LINES LC01Z00092P1

Item Component name Part No. Model No.
1 Hyd. pump assy LC10V00029F2 K5V140DTP (with PTO.)
2 Control valve (main) LC30V00039F1 KMX15YE
3 Swing motor unit LC15V00022F2 M5X180-CHB
4 Travel motor unit LC15V00031F1 GM60VA
5 Boom cylinder (RH & LH) LC01V00044F1 100 dia. X 140 dia. X 1550
6 Arm cylinder LC01V00054F1 120 dia. X 170 dia. X 1788 (SE.Asia)
7 Bucket cylinder LC01V00055F1 100 dia. X 150 dia. X 1193 (SE.Asia)
8 Swivel joint YN55V00053F1
9 Pilot valve (ATT) LQ30V00033F1 PV48K2058
10 Pilot valve (travel) YN30V00105F1 6TH6 NRZ
11 Inline filter YN50V00020F1 Y-457400
12 Suction strainer LC50V00006F2 SB281J0A023A
13 Solenoid valve assy YN35V00047F2 8KWE5A-30
14 Return filter LC52V01002F1 FZ1F180A001C
15 Air breather YN57V00005F1
16 Restrictor YN21V00005F4 07745-00000

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

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT

15 PL
CMR1
CT1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL

14 AL SE1 SE2 SE3 SE4 SE7 SE8

12 CT2 CP2
BOOM
BL
SENSOR
BLOCK 1
P P
2
P P
3 4 5 6 7
P P
8
T3
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa 1 2 3 4 5 6 7 8
HYD.TANK NOTES 1
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs

As
(ROD)Bb
37.8MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab

SOL/V BLOCK
ARM 1
PBa1
BUCKET
22
PAb
P1 CYLINDER
LEVER
A1 LOCK XAb 39.7MPa 37.8MPa
SV-4
Aa (HEAD)
7
BUCKET LCc
PCc P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1

TRAVEL
(ROD)Bc
37.8MPa
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
16
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

16
A8 ARM2
PSV-A

T2 P2
LC01Z00092P1 01
13

22-5
22. HYDRAULIC SYSTEM

22.2.2 N&B SPECIFICATION (OPTION)

N&B specification YN01Z00162P1
NO. PARTS PART No. MODEL No.
50 SELECTOR VALVE YN30V00104F1 VBY-174B
51 STOP VALVE 24100P3133F1
52 PILOT VALVE YN30V00080F1 16030-00000
53 RELIEF VALVE YN22V00035F1 KRBP13C

P2 P1 T1 T2 NOTE:
1. THIS HYDRAULIC CIRCUIT IS USED TO ADD TO STANDARD CIRCUIT.
PTb 2. SELECTION CONDITION AND PROPORTIONAL VALVE COMMAND WHEN ANY OF NIBBLER SINGLE & CONFLUX FLOW OR BREAKER IN SERVICE.
TRAVEL
P1 UNLOAD PRIORITY COMMAND SIGNAL OF SOLENOID PROPORTIONAL VALVE
PCb SELECTION
(W: , W/O: )
CONFLUX / SINGLE FLOW ELECTROMAGNETIC COMMAND SIGNAL P1 P2 TRAVEL
M CHANGEOVER SWITCH OF SELECTOR VALVE (ITEM 50)(W:O,W/O:-) PUMP PUMP STRAIGHT P1 UNLOAD P2 UNLOAD

P2 UNLOAD CONFLUX FLOW OF NIBBLER CONFLUX "ON"

SINGLE FLOW OF NIBBLER CONFLUX "OFF"
MAIN PUMP
BREAKER CONFLUX "OFF"
PCa

3. WHEN USING NIBBLER, ACCORDING TO SPECIFICATION OF NIBBLER INSTALLED,

CHOOSE CONFLUENCE OR SINGLE FLOW BY CONFLUENCE FLOW CHANGEOVER SWITCH.
4. ADJUST OVERLOAD RELIEF VALVE OF OPTIONAL PORT TO CUSTOMIZE SPECIFICATION ORDINARY SET PRESSURE.
51
LEFT NIBBLER

RIGHT
HYD.TANK 53 BREAKER

PBo

OPTION
PAo
52
NIBBLER & BREAKER
PILOT VALVE
PSV E
Ao
Bo T
PSV I P

B
SOL/V BLOCK LEVER
C1 C2 A
A1 LOCK P
SE-11

50 SV-13
Ps C PL
P
SE-29

YN01Z00189P1 02

22-6
 22. HYDRAULIC SYSTEM

22.2.3 EXTRA SPECIFICATION (OPTION)

N&B specification LC01Z00086P1
NO. PARTS PART No. MODEL No.
50 GEAR PUMP YN10V00019F1 SGP2A20F1H1-R144
51 CONTROL VALVE YN30V00107F1 KMC10-1025
52 SOLENOID VALVE YN35V00010F2 16084-00000
53 SOLENOID VALVE PW35V00002F1 2KWE5A-30/G12R-278
P2 P1 T1 T2 54 SHUTTLE VALVE YB26V00002F1

M
50

20.3cc / rev

HYD. TANK

53
54
PSV-8

A A2
SW
C 22
SW-98
B
TO EXTRA
A1
SOL / V BLOCK LEVER ATT ATT
A1 LOCK RIGHT LEFT PSV-9
SIDE SIDE P T
26.5MPa
B1
A1 26.5MPa
Pb1
Pa1
51

24.5MPa
PL 52
A
P Dr G
P
SE-28
P T

LC01Z00086P1 02

22-7
22. HYDRAULIC SYSTEM

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

22-8
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG
651
652 M

1 29.0MPa
611 D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

643
a3
532 8
646 a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL

14 AL SE1 SE2 SE3 SE4 SE7 SE8

12 CT2 CP2
BOOM
BL
SENSOR
BLOCK 1
P P
2
P P
3 4 5 6 7
P P
8
T3
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa 1 2 3 4 5 6 7 8
HYD.TANK NOTES 1
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs

As
(ROD)Bb
37.8MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
BUCKET
P1 LEVER
A1 LOCK
PAb

XAb 39.7MPa 37.8MPa

CYLINDER 22
SV-4
Aa (HEAD)
7
BUCKET LCc
PCc P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1

TRAVEL
(ROD)Bc
37.8MPa
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
16
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
Ao RIGHT TRAVEL FORWARD (OCEANIA)
PSV-B Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

16
A8 ARM2
PSV-A

T2 P2
LC01Z00092P1 01
13
NEUTRAL CIRCUIT : Positive Control Function At Safety Lock Lever Down (Unlocked Position)

22-9
22. HYDRAULIC SYSTEM

22.5 TRAVEL CIRCUIT 22.5.2 2-SPEED TRAVEL SOLENOID

COMMAND CIRCUIT AND AUTO
This section describes the following.
1st SPEED RETURN FUNCTION
(1) Travel forward pilot simultaneous operation circuit (1) Purpose:
(2) 2 speed travel solenoid command circuit and auto Change travel motor speed with switch.
1-speed return function (2) Principle:
(3) Travel main circuit If the switch is turned, an electric signal is issued. It
(4) Travel motor function energizes the 2-speed travel solenoid which in turn
converts the primary pilot pressure and the self
pressure to a tilting angle of the variable
22.5.1 TRAVEL FORWARD PILOT displacement motor.
SIMULTANEOUS OPERATION (3) Operation:
CIRCUIT If the rabbit marked switch on the gauge cluster is
pressed, the solenoid (SV-3) of the proportional
(1) Purpose:
valve block (13) is energized and changes the
Light operating force and shockless operation
proportional valve. Then the solenoid command
(2) Mechatronics:
pressure is issued from port A3, enters the P port of
1. If the travel lever with damping mechanism is
the travel motor (4), opens the oil passage to the
operated for travel right, left and forward motions;
2nd speed select piston, and causes the motor to
the secondary pilot proportional pressure comes
run in the 2nd speed tilting mode by its self
out of the 3 and 1 ports of P/V (10). The higher of
pressure. However, when the main circuit pressure
the pressures is selected, and comes out of the 6
rises above 28 MPa (4060 psi), the motor's self
and 5 ports and acts upon the low pressure sensors
pressure pushes the 2nd speed select piston back
(SE9) (SE-10).
to the 1st speed.
2. The pilot secondary pressure flows to PAr and PAL
ports of the control valve (2), moves the travel
spool, and switches the main circuit.
3. The low pressure sensor output voltage is input into 22.5.3 TRAVEL MAIN CIRCUIT
the mechatro controller. The mechatro controller (1) Operation:
performs signal processing and outputs current The delivery oil from Pump A1 and A2 ports by
corresponding to the increase of flow rate to the P1 changing the travel spool with the operation of the
pump proportional valve (PSV-P1) and P2 pump travel pilot flows in each VA port on the left side of
proportional valve (PSV-P2), and at the same time the travel motor (4) throughthe C and D ports of the
the command current is output to the P1 unloading swivel joint (8) from AL and AR ports of the C/V,
valve (PSV-D) and P2 unloading valve (PSV-B). and rotates the travel motor.
4. The secondary pressures output by the P1 pump
proportional valve (PSV-P1) and P2 pump
proportional valve (PSV-P2) exert on the pump 22.5.4 TRAVEL MOTOR FUNCTION
regulator, actuating the pump on the delivery flow
rate increase side. (1) Function:
5. The secondary pressure delivered in the P1 1. Prevents the motor from over running on a slope.
2. Check valve that prevents cavitation of the
unloading valve (PSV-D) and P2 unloading valve
(PSV-B) is fed to PBp1, Pcb, PBp2 and PCa ports hydraulic motor.
provided in the control valve (2). 3. Shockless relief valve and anti cavitation valve
when inertia force stops.
The secondary pressure from the proportional
valve which has exerted on PBp1 and PBp2 ports 4. High/Low 2 step speed change mechanism and
holds the by-pass cut spool on the CLOSE side, auto 1st speed return at high load.
5. Travel parking brake.
like the operation in the lever neutral position.
The secondary pressure from the proportional
valve which has exerted on PCb and PCa ports
switches the unloading spool in the CLOSE side.

22-10
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL

14 AL SE1 SE2 SE3 SE4 SE7 SE8

12 CT2 CP2
BOOM
BL
SENSOR
BLOCK 1
P P
2
P P
3 4 5 6 7
P P
8
T3
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa 1 2 3 4 5 6 7 8
HYD.TANK NOTES 1
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs

As
(ROD)Bb
37.8MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
BUCKET
P1 LEVER
A1 LOCK
PAb

XAb 39.7MPa 37.8MPa

CYLINDER 22
SV-4
Aa (HEAD)
7
BUCKET LCc
PCc P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1

TRAVEL
(ROD)Bc
37.8MPa
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
16
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

16
A8 ARM2
PSV-A

T2 P2
LC01Z00092P1 01
13
TRAVEL CIRCUIT : Travel 2nd Speed, RH & LH Simultaneous Operation.

22-11
22. HYDRAULIC SYSTEM

22.6 BUCKET CIRCUIT port provided in the control valve (2) and shifts the the travel straight valve, and goes into the bucket 3. With the function of the pilot circuit, the oil flow is
travel straight valve. spool. (Confluence of oil from 2 pumps) switched from the bucket spool, and is fed into the
bucket cylinder head side through the AC port of C/
This section describes the following.
V (2). On the other hand, the return oil from the
(1) Bucket digging pilot circuit 22.6.2 AUTO ACCELERATION
cylinder rod (R) side is throttled by the bucket spool
(2) Auto accel operation OPERATION
and returns to the tank circuit from the BC port of C/
(3) Flow control in the work mode
(1) Principle: V (2).
(4) Bucket digging travel straight main circuit
Auto acceleration actuates according to signals References:
(5) Bucket spool stroke limiter
from the low pressure sensor. • In bucket dumping operation, the travel straight
(2) Operation: valve also switches like the digging operation,
<When the lever is set to neutral position> resulting in confluence with the travel straight.
22.6.1 PILOT CIRCUIT FOR BUCKET In the event where the sensor does not receive • When the bucket operation and an other operation
DIGGING signal for 4 seconds or more even though the are simultaneously performed, the travel straight
(1) Mechatronics: acceleration dial is set to MAX position, the engine valve does not actuate, resulting in single flow of
1. When the operation for bucket digging is speed should rise to 1000 rpm. the bucket circuit.
performed, the pilot proportional secondary <When the lever is operated>
pressure is delivered through port 1 of the right pilot When the pressure 0.6 MPa (87 psi) is input to the
V (9), flows to PAc port, and acts on the low low pressure sensor in the STD specification
22.6.5 BUCKET SPOOL STROKE
pressure sensor (SE-1), and at the same time the (travel, bucket, swing, arm), the proportional
LIMITER
bucket spool is switched. voltage from the low pressure sensor inputs in the
mechatro controller, and then the engine speed (1) Purpose :
2. The voltage output by the low pressure sensor
returns to the dial set position corresponding to the To secure simultaneous operability of the boom and
inputs in the mechatro controller. The mechatro
lever operation. arm on the boosting up attachment pressure (Pump
controller performs signal processing and outputs
flow rate decreases) and to prevent cavitations at
current corresponding to the increase of the pump
low engine speed.
flow rate to the pump proportional valves (PSV-P1)
(2) Operation:
and (PSV-P2) on the P1 and P2 pump sides; and at 22.6.3 STAND-BY CURRENT CONSTANT
On boosting up attachment pressure, the pilot
the same time the command current is output to the CONTROL
primary pressure exerts on PCc port of C/V(2)
P1 unloading valve (PSV-D), P2 unloading valve
(1) Principle: through the attachment booster solenoid valve,
(PSV-B) and travel straight proportional valve
When the engine speed is at intermediate speed or operates stroke limiter of the bucket spool, and
(PSV-C).
lower, the command current value to have the throttle oil path of the spool. As a result, the P1
In the following pages, the relation of operation of
pump delivery rate constant is output. pump pressure increases, making the simultaneous
the low pressure sensor to both the increase of the
(2) Operation: operation of boom up and bucket digging possible.
pump flow rate and unloading proportional valve is
Even if the engine speed specified by the Even though the engine speed is low, similarly the
the same. Therefore the explanation is omitted.
acceleration potentiometer is low speed, as the cavitations can be prevented by actuating the
3. The secondary pressure output by the P1 pump
delivery rate corresponds to the intermediate stroke limiter.
proportional valve (PSV-P1) and P2 pump
speed, the actuator moves earlier than the
proportional valve (PSV-P2) exerts on the pump
movement equivalent to the control lever angle rate
regulator, actuating the pump onto the delivery flow
in light load operation.
increase side.
4. The secondary pressure delivered in the P1
unloading valve (PSV-D) and P2 unloading valve
(PSV-B) is led to PBp1, PCb, PBp2 and PCa ports
22.6.4 BUCKET DIGGING AND TRAVEL
provided in the control valve (2).
STRAIGHT CONFLUENCE
The secondary pressure from the proportional
(CONFLUX) MAIN CIRCUIT
valve which has exerted on PBp1 and PBp2 ports (1) Operation:
holds the by-pass cut spool on the CLOSE side, 1. The oil delivered through the A1 port of the P1
like the operation in the lever neutral position. pump goes into the P1 port of C/V (2), opens the
The secondary pressure from the proportional load check valve LCc through the parallel circuit
valve which has exerted on PCb and PCa ports and enters in the bucket spool.
switches the unloading spool in the CLOSE side. 2. On the other hand, the oil delivered through the P2
5. The secondary pressure delivered in the travel port of the P2 pump goes into the P2 port of C/V
straight proportional valve (PSV-C) is led to PTb (2), confluences with oil from the P1 pump through

22-12
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL

14 AL SE1 SE2 SE3 SE4 SE7 SE8

12 CT2 CP2
BOOM
BL
SENSOR
BLOCK 1
P P
2
P P
3 4 5 6 7
P P
8
T3
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa 1 2 3 4 5 6 7 8
HYD.TANK NOTES 1
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs

As
(ROD)Bb
37.8MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
BUCKET
P1 LEVER
A1 LOCK B
PAb

XAb 39.7MPa 37.8MPa

CYLINDER 22
SV-4
Aa (HEAD)
7
BUCKET LCc
PCc P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1

TRAVEL
(ROD)Bc
37.8MPa
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
16
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

16
A8 ARM2
PSV-A

T2 P2
LC01Z00092P1 01
13
BUCKET CIRCUIT : Bucket Digging (Travel Straight Conflux), Auto-Accelation and Standby Flow Rate Constant Control

22-13
22. HYDRAULIC SYSTEM

22.7 BOOM CIRCUIT

(1) Boom up pilot circuit

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

22.7.1 BOOM RAISE PILOT CIRCUIT

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

22.7.2 BOOM UP 2 PUMPS CONFLUX

MAIN CIRCUIT IN C/V
(1) Purpose:
Boom up speed up
(2) Principle:
Confluxing oil from 2 pumps
(3) Operation:
1. The oil delivered through the A1 port of the P1
pump flows into the C/V (2) P1 port, and branches
into the bypass circuit and parallel circuit. Since the
P1 unloading valve is closed, the boom spool is
moved and the bypass circuit is closed, the oil
opens the load check valve LCb through the
parallel circuit and flows into the boom spool.
2. Then the oil passes through the boom spool, opens
the lock valve of the boom lock valve CRb, and is
led into the H side of the 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 of 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 the boom cylinder R side flows
into the tank circuit through the boom spool from C/
V (2) Bb port.

22-14
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL

14 AL SE1 SE2 SE3 SE4 SE7 SE8

12 CT2 CP2
BOOM
BL
SENSOR
BLOCK 1
P P
2
P P
3 4 5 6 7
P P
8
T3
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa 1 2 3 4 5 6 7 8
HYD.TANK NOTES 1
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs

As
(ROD)Bb
37.8MPa Bs
PAa1
9
LCa RH LH
(HEAD)Ab CRb
ARM 1
SOL/V BLOCK PBa1
BUCKET
P1 LEVER
A1 LOCK
PAb

XAb 39.7MPa 37.8MPa

CYLINDER 22
SV-4
Aa (HEAD)
7
BUCKET LCc
PCc P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1

TRAVEL
(ROD)Bc
37.8MPa
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
16
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

16
A8 ARM2
PSV-A

T2 P2
LC01Z00092P1 01
13
BOOM CIRCUIT: Boom Up Operation, Confluence Function

22-15
22. HYDRAULIC SYSTEM

This section describes boom lower operation. 22.7.5 CONSTANT RECIRCULATION

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

22-16
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL

14 AL SE1 SE2 SE3 SE4 SE7 SE8

12 CT2 CP2
BOOM
BL
SENSOR
BLOCK 1
P P
2
P P
3 4 5 6 7
P P
8
T3
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa 1 2 3 4 5 6 7 8
HYD.TANK NOTES 1
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs

As
(ROD)Bb
37.8MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
BUCKET
P1 LEVER
A1 LOCK
PAb

XAb 39.7MPa 37.8MPa

CYLINDER 22
SV-4
Aa (HEAD)
7
BUCKET LCc
PCc P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1

TRAVEL
(ROD)Bc
37.8MPa
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
16
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

16
A8 ARM2
PSV-A

T2 P2
LC01Z00092P1 01
13
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 pump
(1) Swing left pilot circuit enters the P2 port of C/V (2) and is branched off
(2) Swing auto parking brake into the bypass line and the parallel circuit.
(3) Swing main circuit However, since the bypass line is closed as the
(4) Swing motor circuit swing spool is shifted, the oil pushes the load check
valve LCs open through the parallel circuit, enters
the B port of the swing motor via the Bs port of C/V
22.8.1 PILOT CIRCUIT FOR LEFT SWING (2), and rotates the swing motor counterclockwise.

(1) Operation:
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 the left pilot V (9), and the (1) Anti cavitation circuit at swing deceleration
secondary pressure acts on the PBs port of C/V (2), (2) Shockless relief valve that prevents the swing
and simultaneously flows out from Pss port of C/V motor from being reversed.
and acts on the 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 the PBs 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 energizes 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-energized 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 energized 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 energized the moment the
pressure of the arm in the low pressure sensor (SE-
7) is reduced to zero. This causes the mechanical
brake to operate.

22-18
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL

14 AL SE1 SE2 SE3 SE4 SE7 SE8

12 CT2 CP2
BOOM
BL
SENSOR
BLOCK 1
P P
2
P P
3 4 5 6 7
P P
8
T3
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa 1 2 3 4 5 6 7 8
HYD.TANK NOTES 1
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs

As
(ROD)Bb
37.8MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1

P1 LEVER
PAb

39.7MPa
BUCKET
CYLINDER 22
A1 LOCK XAb 37.8MPa
SV-4
Aa (HEAD)
7
BUCKET LCc
PCc P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1

TRAVEL
(ROD)Bc
37.8MPa
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
16
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

16
A8 ARM2
PSV-A

T2 P2
LC01Z00092P1 01
13
SWING CIRCUIT: Swing Operation (LH)

22-19
22. HYDRAULIC SYSTEM

22.9 ARM CIRCUIT 22.9.2 ARM-IN, LIGHT-LOAD VARIABLE Reference:

NORMAL RECIRCULATION, In light-load arm-in operation (normal recirculation,
INTERNAL CONFLUX MAIN conflux), when the attachment to which the circuit in
This section describes the following operations. the P1 pump side is applied and operated, the meter-in
(1) Arm in, light-load operating pilot circuit CIRCUIT path of the arm 2 spool is closed, resulting in single
(2) Arm in, light-load variable normal recirculation main (1) Operation: flow operation.
circuit / internal conflux main circuit 1. The P2 pump delivery oil flows in the travel left
section through the P2 port of C/V (2) and is Spool position at arm in,
branched off in the by-pass circuit and parallel light load and combined operation
(This position is not shown in hydraulic diagram)
22.9.1 ARM IN, LIGHT-LOAD OPERATING circuit, but because the arm 1 spool is switched, the
Neutral position Meter-in passage
PILOT CIRCUIT delivery oil which goes through the parallel circuit (Close)
opens the load check valve LCa and flows into the
(1) Purpose:
arm 1 spool.
Speed-up and Anticavitation when the arm is at
2. On the other hand, the P1 pump delivery oil flows in
light loaded.
the P1 port of C/V (2), and flows in the travel Normal recirculation opsition
(2) Principle: Arm 2 spool
straight section and travel right tandem path. Then
The oil returning from the arm cylinder rod (R) is
because the arm 2 spool was switched, the delivery
recirculated variably to the head (H) at the arm 2
oil opens the load check valve LCAT2, goes
spool in C/V.
through the arm 2 spool, and confluences with the
(3) Operation:
P2 pump delivery oil in the valve section, and then
1. When the arm in operation is performed, the
flows into the arm cylinder head (H) side through
secondary pilot proportional pressure flows out of
the Aa port of C/V (2).
port 7 of the left pilot valve (9) and acts upon the
3. The return oil from the arm cylinder (R) side flows in
low pressure sensor (SE-7).
the Ba port of C/V (2) and passes through the Ba
At the same time, the pressure is branched off in
port because the arm lock valve CRar is open, and
two flows, acts upon the Paa1 port and the PLc2
flows into the arm 2 spool through the arm 1 spool.
port, changes over the arm spool and the arm lock
4. Because the arm 2 spool is switched to the normal
valve CRar releases.
recirculation position, causing restriction of
2. The output voltage by the low pressure sensor is
passage to tank, the return oil from the arm cylinder
input into the mechatro controller, and is pilot signal
(R) side flows into arm cylinder (H) side.
processed, and is output to the P1 and P2 pump
-Because, at light load, the pressure in the cylinder
proportional valves (PSV-P1 and PSV-P2) and the
rod (R) side is higher than that in the head (H) side,
arm 2 inverse proportional valve (PSV-A).
it opens the check valve housed-in arm 2 spool and
3. The secondary pressure from the pilot proportional
is recirculated in the head (H) side, resulting in the
valve, which is reduced by the arm 2 inverse
speed up of arm-in operation at light load.
proportional valve (PSV-A) switches the arm 2
5. Cavitations prevention control in arm-in operation
spool.
Command current is output to arm 2 solenoid
proportional valve by signal processing of E/G
speed and arm-in pilot pressure, accordingly the
arm 2 spool is switched to the neutral (cavitations
prevention) position, resulting in cavitation
prevention.

Position Of Arm 2 Spool

Neutral position
(Anticavitation position)
Normal recirculation position

Recirculation

From arm out

P/V
From arm 2 inverse
proportional valve

22-20
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL

14 AL SE1 SE2 SE3 SE4 SE7 SE8

12 CT2 CP2
BOOM
BL
SENSOR
BLOCK 1
P P
2
P P
3 4 5 6 7
P P
8
T3
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa 1 2 3 4 5 6 7 8
HYD.TANK NOTES 1
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs

As
(ROD)Bb
37.8MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
BUCKET
P1 LEVER
A1 LOCK
PAb

XAb 39.7MPa 37.8MPa

CYLINDER 22
SV-4
Aa (HEAD)
7
BUCKET LCc
PCc P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1

TRAVEL
(ROD)Bc
37.8MPa
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
16
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

16
A8 ARM2
PSV-A

T2 P2
LC01Z00092P1 01
13
ARM CIRCUIT: Arm in (Light Load) Operation, Arm Variable Recirculation & Anti Cavitation Function

22-21
22. HYDRAULIC SYSTEM

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

Position of Arm 2 Spool

22.9.3 ARM IN, HEAVY LOAD
OPERATING PILOT CIRCUIT Neutral position Recirculation cut position

(1) Operation:
1. The left pilot valve actuation due to arm-in From arm out
P/V
operation is equivalent to that at light load
operation. From arm 2 inverse
proportional valve
2. In arm-in operation, when the heavy loading is
applied to the arm and the P2 pump pressure
increases to the set pressure, the voltage output by
the P2 pump pressure sensor (SE-23) is converted
to a signal (signal processing) by the mechatro
controller, consequently the current of the 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.

22.9.4 ARM IN, HEAVY LOAD

OPERATING RECIRCULATION
CUT MAIN CIRCUIT
(1) Purpose:
Speed up for arm in operation
(2) Principle:
Cut the recirculation and reduce rod pressure.
(3) Operation:
1. P2 pump delivery oil flows in the travel left section
through the P2 port of C/V (2) and is branched off in
the by-pass circuit and parallel circuit.
Consequently the arm spool is switched, pushes
and opens the load check valve LCa through the
parallel circuit, and flows in the arm spool.
2. On the other hand, the P1 pump delivery oil flows in
the P1 port of C/V (2), and flows in the travel right
tandem passage through the travel straight section.
Then because the arm 2 spool was switched, the
delivery oil opens the load check valve LCAT2, and
confluences with the P2 pump delivery oil in the
valve section, and is flows into the arm cylinder
head (H) side through the Aa port of C/V(2).
3. The return oil from the arm cylinder (R) side flows in
the Ba port of C/V(2) and flows to the arm lock
valve CRar, but because the arm lock valve CRar is

22-22
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL

14 AL SE1 SE2 SE3 SE4 SE7 SE8

12 CT2 CP2
BOOM
BL
SENSOR
BLOCK 1
P P
2
P P
3 4 5 6 7
P P
8
T3
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa 1 2 3 4 5 6 7 8
HYD.TANK NOTES 1
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs

As
(ROD)Bb
37.8MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
BUCKET
P1 LEVER
A1 LOCK
PAb

XAb 39.7MPa 37.8MPa

CYLINDER 22
SV-4
Aa (HEAD)
7
BUCKET LCc
PCc P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1

TRAVEL
(ROD)Bc
37.8MPa
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
16
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

16
A8 ARM2
PSV-A

T2 P2
LC01Z00092P1 01
13
ARM CIRCUIT: Arm In (Heavy Load) Operation, Arm Confluence & Recirculation Cut Function

22-23
22. HYDRAULIC SYSTEM

This section describes the following operations. 22.9.7 NATURAL FALL PROTECTION
WITH ARM LOCK VALVE
(5) Arm out pilot circuit
(6) Arm out 2 pumps conflux main circuit (1) Purpose:
(7) Natural fall protection with arm lock valve To prevent the arm from falling naturally by the
weight of the arm and bucket.
(2) Principle:
Complete seat of the return circuit against the arm
22.9.5 ARM OUT PILOT CIRCUIT
spool of the arm cylinder (R) side circuit.
(1) Operation: (3) Operation:
1. When the arm out operation is performed, the 1. When the secondary pressure for arm operation
secondary pilot proportional pressure flows out of disappears and the arm cylinder stops, the
port 8 of the left pilot valve (9), and acts upon the pressure on the rod (R) side passes through the
low pressure sensor (SE-8). At the same time, the selector of the lock valve from the Ba port of C/V,
oil is branched off in two flows and acts upon the acts the back pressure on the lock valve CRar and
PBa1 and Pba2 ports of C/V (2). seats the lock valve.
2. The operating proportional secondary pressure 2. Since the oil flow into the arm spool from the lock
flows in the Pba1 port of C/V (2) and switches the valve is shut off completely; natural fall of the arm
arm 1 spool. due to oil leaks through the arm spool is prevented.
3. Then, the operating secondary pressure flows in
the PBa2 port of C/V (2) and 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
the oil delivered by the P2 pump in C/V (2).
(3) Operation:
1. The P1 pump delivery oil opens the load check
valve (LCAT2) by switching the arm 2 spool and
confluxes with the P2 pump delivery oil just short of
the arm lock valve.
2. And, the P2 pump delivery oil flows through the arm
1 spool and confluences with the P1 delivery oil,
opens the lock valve of the arm lock valve CRar
with free flow and flows into the arm cylinder rod
(R) side through the Ba port of C/V(2).
3. On the other hand, the return oil from the arm
cylinder (H) side flows in the Aa port, and returns
into the tank circuit through the arm 1 spool and
arm 2 spool.
The return line which does not pass through the
boost check valve is used for this return circuit to
reduce the pressure loss.

22-24
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
BOOST
CHECK ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL

14 AL SE1 SE2 SE3 SE4 SE7 SE8

12 CT2 CP2
BOOM
BL
SENSOR
BLOCK 1
P P
2
P P
3 4 5 6 7
P P
8
T3
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa 1 2 3 4 5 6 7 8
HYD.TANK NOTES 1
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs

As
(ROD)Bb
37.8MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
BUCKET
P1 LEVER
A1 LOCK
PAb

XAb 39.7MPa 37.8MPa

CYLINDER 22
SV-4
Aa (HEAD)
7
BUCKET LCc
PCc P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1

TRAVEL
(ROD)Bc
37.8MPa
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
16
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

16
A8 ARM2
PSV-A

T2 P2
LC01Z00092P1 01
13
ARM CIRCUIT: Arm Out Operation, Confluence Function

22-25
22. HYDRAULIC SYSTEM

22.10 COMBINED CIRCUIT 3. The delivery oil flow into the P2 tandem circuit of
the P2 pump and flows in the left travel spool to
travel leftward.
This section describes only the difference in combined
The delivery oil flow into the travel straight spool of
operation.
(1) Boom up / travel, pilot circuit the P2 pump flows in the right travel spool because
(2) Boom up / travel, main circit the travel straight spool is shifted and exerts on the
right travel operation.
(In travel straight operation, P2 pump delivery oil
exerts on travel operation.)
22.10.1 BOOM UP / TRAVEL, PILOT
4. However, a portion of the flow is led to the travel
CIRCUIT
straight spool notch restriction. The speed of
(1) Operation: attachments like travel, boom, etc. is adjusted by
<Operation: Different point of pilot circuit from the circuit of restriction.
independent operation >
1. The mechatro controller outputs command current
to the travel straight solenoid proportional valve
after signal processing, and the solenoid valve
outputs secondary pressure and acts on the PTb
port of C/V (2).
2. Then the pressure of the 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. The P1 pump delivery oil flows through the P1 port
of C/V(2) and branches off in the P1 parallel circuit
and travel straight spool.
The P2 pump delivery oil flows through the P2 port
of C/V(2) and branches off in the P2 tandem circuit
and travel straight spool.
2. The delivery oil flows into the P1 parallel circuit of
the P1 pump opens the check valve CT1 and LCb
and flows in the boom spool, which exerts on the
boom up operation.
The delivery oil flows into the travel straight spool of
the P1 pump opens the check valve CT2 because
the travel straight spool is shifted, and flows in the
boom conflux spool and exerts on the boom up
operation with the internal oil conflux.
(In travel straight operation, the P1 pump delivery
oil exerts on the swing operation of the
attachment.)

22-26
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL

14 AL SE1 SE2 SE3 SE4 SE7 SE8

12 CT2 CP2
BOOM
BL
SENSOR
BLOCK 1
P P
2
P P
3 4 5 6 7
P P
8
T3
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa 1 2 3 4 5 6 7 8
HYD.TANK NOTES 1
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs

As
(ROD)Bb
37.8MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
BUCKET
P1 LEVER
A1 LOCK
PAb

XAb 39.7MPa 37.8MPa

CYLINDER 22
SV-4
Aa (HEAD)
7
BUCKET LCc
PCc P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1

TRAVEL
(ROD)Bc
37.8MPa
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
16
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

16
A8 ARM2
PSV-A

T2 P2
LC01Z00092P1 01
13
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 Position of Arm 2 Spool

and describes the difference in combined operation.

(3) Swing / Arm in light load, pilot circuit Position of forced recirculation
(4) Swing / Arm in, swing priority main circuit Neutral position Meter-in passage
(Close)

From From arm 2

arm out inverse
22.10.3 SWING / ARM IN LIGHT LOAD, proportional valve
P/V
PILOT CIRCUIT Normal recirculation opsition
Arm 2 spool
(1) Operation:
1. When operating swing (left) and arm-in motions
simultaneously, the mechatro controller outputs
command current to the travel straight solenoid
proportional valve (PSV-C) and the arm 2 solenoid
inverse proportional valve according to signal
processing, and this proportional valve outputs
secondary pressure, which acts on the PTb port
and PAa2 port of C/V(2).
2. The 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 the arm cylinder,
and give a priority of the delivery of the P2 pump to
swing operation.
(3) Operation:
1. The swing main circuit operates with P2 pump flow.
But on the 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 the 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 the return oil
is raised, causing the rise of the 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 the P2 pump side
because the travel straight spool was switched.
The conflux oil of P1 and P2 delivery oil in high
pressure flows in the swing side taking priority over
all others.
This operation is called "Swing Priority Circuit".

22-28
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL

14 AL SE1 SE2 SE3 SE4 SE7 SE8

12 CT2 CP2
BOOM
BL
SENSOR
BLOCK 1
P P
2
P P
3 4 5 6 7
P P
8
T3
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa 1 2 3 4 5 6 7 8
HYD.TANK NOTES 1
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs

As
(ROD)Bb
37.8MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
BUCKET
P1 LEVER
A1 LOCK
PAb

XAb 39.7MPa 37.8MPa

CYLINDER 22
SV-4
Aa (HEAD)
7
BUCKET LCc
PCc P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1

TRAVEL
(ROD)Bc
37.8MPa
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
16
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

16
A8 ARM2
PSV-A

T2 P2
LC01Z00092P1 01
13
COMBINED CIRCUIT: Swing / Arm In Operation, Swing Priority Function

22-29
22. HYDRAULIC SYSTEM

22.11 PRESSURE DRAINING 22.11.2 PRESSURE RELEASE MAIN

CIRCUIT
This section describes the following operations.
(1) Pressure drain (releasing) pilot circuit
(2) Pressure drain (releasing) main circuit
When the hydraulic pressure releasing is performed,
make sure to place the bucket on the ground.

22.11.1 PRESSURE RELIEVING PILOT

(1) Operation:
CIRCUIT
When the operating lever is shifted to neutral during
(1) Purpose: engine running, "DRAINING HYD. PRESS." is
To release the pressure in the main circuit for piping displayed on the gauge cluster while the mode
repair works. switch is changed to pressure relieving mode. In
(2) Principle: this time the intermittent buzzer sounds
After the mode is switched to "Pressure Relief continuously. When the right and left operating
Mode" with the switch on the gauge cluster, the levers are operated 4 or 5 times to their full stroke,
mechatro controller outputs the following pressure is relieved.
commands. After draining pressure is completed, turn off the
1. Minimum tilting command value to pump starter key and the buzzer sound stops. If the pump
proportional valve (PSV-P1 and PSV-P2). pressure is determined to be more than 1 MPa (145
2. Output "Pressure relief control speed command psi) by the output value of the high pressure sensor
value" at ECU. (Electric system) or the high pressure sensors (SE-22,23) are
3. Stand-by command value to P1 and P2 unloading broken, "FAIL DRAIN HYD. PRESS." is displayed
proportional valves and the buzzer sounds continuously. In that case,
How to switch to "Pressure Release Mode" also the buzzer is not stopped unless the engine
1. Select the service diagnosis mode. key is turned to OFF. Repeat the pressure releasing
(Hold down the "BUZZER STOP SWITCH" on the procedure once again.
gauge cluster, turn the starter key switch on.) (2) Hydraulics:
2. Select the service adjustment mode 1. If the travel straight valve is turned to the pressure
(Under the condition that "Screen No.1" of "Service release position, the oil delivered by each pump is
Diagnosis Mode 1" is indicated, hold down the unloaded to the tank passage. If the spools are
"BUZZER STOP SWITCH", press the "MENU switched by pilot operation, the remaining pressure
SWITCH" 3 times. When "SERVICE MENU" is from the actuators may be relieved to the tank
displayed, using "UP" switch or "DOWN" switch, circuit, i.e. the main circuit pressure may be
select "SERVICE ADJUST 1". Press "NEXT" released.
switch, to select "SERVICE ADJUST 1-2".)
3. Using "UP" switch or "DOWN" switch, and select
"PRESS DRAIN".
Then press "NEXT" switch, and cursor points to
"OFF".
4. Press "UP" switch to display "ON", and press
"MENU" switch.
5. Screen of gauge cluster changes to ordinary
display, and "DRAINING HYD. PRESS." is
appears.
(3) Operation:
1. Pump proportional valve reduces the pump flow
rate to the minimum.
2. The unloading proportional valves (PSV-D and
PSV-B) output secondary pressure and the
secondary pressure flows in PCb and PCa ports of
C/V(2) and switches the P1 and P2 unloading
valves to the OPEN position.

22-30
 22. HYDRAULIC SYSTEM

SE22 SE23 P MB MB P
a1 P P
MAIN PUMP PSV1 A1 A2 a2 PSV2
PH1 PH2

PSV-P1 PSV-P2
4
Pcr Pcr
35.8~37.8
MPa VB VB
35.8~37.8
MPa 3 SWING

PG
VA VA DB

REG REG

1 29.0MPa
D MA MA D
PB PA
TRAVEL RIGHT TRAVEL LEFT

a3
8
a4
Dr

5.0MPa
M A B
a5
203kw B1
/2100min-1 B3 Dr3 A3

11 2
MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
ARM OUT
CMR1
CT1 ARM IN
PL
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL

14 AL SE1 SE2 SE3 SE4 SE7 SE8

12 CT2 CP2
BOOM
BL
SENSOR
BLOCK 1
P P
2
P P
3 4 5 6 7
P P
8
T3
TRAVEL RIGHT P2UNLOAD CONFLUX
PAr PB1

BR CP1
AR PCa 1 2 3 4 5 6 7 8
HYD.TANK NOTES 1
PBr CCb
PAs
Dr SE5
BOOM LCb LCs Pss
SWING P
PBb PBs

As
(ROD)Bb
37.8MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
ARM 1
SOL/V BLOCK PBa1
BUCKET
P1 LEVER
A1 LOCK
PAb

XAb 39.7MPa 37.8MPa

CYLINDER 22
SV-4
Aa (HEAD)
7
BUCKET LCc
PCc P T P T
SWING PBc BOOM ARM
A2 P/B & BUCKET & SWING
SV-1

TRAVEL
(ROD)Bc
37.8MPa
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
16
BOOM
A5 P2UNLOAD CYLINDER 3 6 4 1 5 2
PSV-B Ao RIGHT TRAVEL FORWARD
Bo P SE9 P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL LEFT TRAVEL REVERSE
A6 PRIORITY
PSV-C

A7 P1UNLOAD
PSV-D (P3) (P4)

16
A8 ARM2
PSV-A

T2 P2
LC01Z00092P1 01
13
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 LIST ...................................................................... 23-9
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 OPERATORS CONTROLS ....................................................................... 23-14
23.3.5 UPPER ELECTRIC ASSY ......................................................................... 23-16
23.3.6 UPPER HARNESS ASSY ......................................................................... 23-17
23.3.7 UPPER HARNESS ASSY (BHL MULTI) ................................................... 23-37
23.3.8 UPPER HARNESS ASSY (FLOOR PLATE) ............................................. 23-38
23.3.9 CAB HARNESS ASSY .............................................................................. 23-47
23.3.10 BOOM HARNESS ASSY ........................................................................... 23-54
23.3.11 BOOM LIGHT INSTALL ............................................................................. 23-54
23.3.12 UPPER LIGHT INSTALL .......................................................................... 23-55
23.3.13 FLASHER LAMP INSTALL ........................................................................ 23-56
23.3.14 TRAVEL ALARM ASSY ............................................................................. 23-56

23

Book Code No. S5LC2326E01

23-1
23. ELECTRICAL SYSTEM

Issue Date of Issue Applicable Machines Remarks

S5LC2326E01
First Edition September, 2010 SK350-9: YC
NA

23-2
 23. ELECTRICAL SYSTEM

23.1 ELECTRIC CIRCUIT DIAGRAM

23

(1/8)
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23-3
23. ELECTRICAL SYSTEM

(2/8)
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23. ELECTRICAL SYSTEM

23

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(4/8)
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23. ELECTRICAL SYSTEM

23

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23. ELECTRICAL SYSTEM

(6/8)
LC03Z00046P1 03

23-8
 23. ELECTRICAL SYSTEM

23.2 ELECTRICAL EQUIPMENT LIST

GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No.
MECHATRO CONTROLLER YN22E00214F1 L-1 BOOM WORK LIGHT LEFT YW80S00001F1 R-26 LEVER LOCK RELAY YN24S00010P1
C-1
(TCO-60-2) (HARD) L-2 FRAME WORK LIGHT RIGHT YT80S00002F2 R-28 ALTERNATOR RELAY

(C) CONTROLLER
C-2 GAUGE CLUSTER YN59S00028F1 L-3 SWING FLASHER LEFT & WORKING UNIT YM820S00001F1 R-29 WIPER MOTOR RELAY YN24S00012P2
C-4 AIR CONDITIONER AMP AIR CON ACCESSORY L-4 SWING FLASHER RIGHT & WORKING UNIT YM80S00001F2 R-30 WIPER MOTOR REVERSING RELAY
RADIATOR COOLANT LEVEL L-5 ROOM LIGHT YT80S00001P1 R-31 PREVENT SPARK RELAY

(R) RELAY
C-5 ENGINE ACCESSORY

(L) LIGHT
CONTROLLER L-7 CAB WORKING LIGHT FRONT 1 YT80S00002F2 R-32 WINDOW WASHER MOTOR RELAY
C-6 AUTO GREASE CONTROLLER LC22E00081P1 L-8 CAB WORKING LIGHT FRONT 2 R-36 ROTARY LIGHT RELAY (RED) (OPT RELAY 2) YN24S00010P1
C-7 IT CONTROLLER YN22E00238F1 L-10 HIGH REACH ROTARY LIGHT 2456R457 R-37 ROTARY LIGHT RELAY (YELLOW) (OPT RELAY 3)
C-8 ENGINE CONTROLLER ENGINE ACCESSORY L-15 CAB WORKING LIGHT FRONT 3 - R-38 ROTARY LIGHT RELAY (GREEN) (OPT RELAY 4)
L-16 CAB WORKING LIGHT FRONT 3 - R-44 WIPER MOTOR RELAY YR24S00002P1
D-4 DIODE YN02D01001P1 L-19 HIGH REACH THREE COLORS ROTARY LIGHT EZ53E00013F1 R-94 NEUTRAL STOP RELAY YN24S00010P1
D-5 DIODE ACCESSORY OF RELAY BOX L-20 ROTARY LIGHT 2456R457
D-6 DIODE SE-1 PRESSURE SENSOR : BUCKET DIGGING LC52S00019P1
D-9 DIODE M-1 STARTER MOTOR ENGINE ACCESSORY SE-2 PRESSURE SENSOR : BUCKET DUMP
D-10 DIODE M-3 WIPER MOTOR LQ53C00003S001 SE-3 PRESSURE SENSOR : BOOM RAISING

(M) MOTOR
D-12 DIODE M-3 WIPER MOTOR YN46S00006P1 SE-4 PRESSURE SENSOR : BOOM LOWRING
D-13 DIODE M-4 WASHER MOTOR YT54C00003F1 SE-5 PRESSURE SENSOR : SWING
D-14 DIODE M-8 GREASE MOTOR LC71V00001P1 SE-7 PRESSURE SENSOR : ARM IN
D-16 DIODE M-9 ROOF WINDOW WIPER MOTOR YN76S00005P1 SE-8 PRESSURE SENSOR : ARM OUT
(D) DIODE

D-17 DIODE M-11 FUEL SUPPLY PUMP YF22P00009P1 SE-9 PRESSURE SENSOR : TRAVEL RIGHT
D-18 DIODE YN02D01001P1 SE-10 PRESSURE SENSOR : TRAVEL LEFT
D-19 DIODE PSV-A ARM TWO-SPEED INVERSE PROPORTIONAL SOL. YN35V00049F1 SE-11 PRESSURE SENSOR : P2 OPT.
D-20 DIODE ACCESSORY OF RELAY BOX PSV-B P2 UN-LOAD PROPORTIONAL SOL. YN35V00048F1 SE-13 ENGINE REVOLUTION SENSOR ENGINE ACCESSORY

(SE) SENSOR
D-21 DIODE PSV-C TRAVEL PRIORITY PROPORTIONAL SOL. SE-15 FUEL SENSOR YN52S00045F1
D-22 DIODE PSV-D P1 UN-LOAD PROPORTIONAL SOL. SE-16 ACCEL POTENTIO. YN52S00032P1

(P) PROPORTIONAL
SOLENOID VALVE
D-23 DIODE PSV-E OPT. RELIEF ADJUSTMENT PROPORTIONAL SOL. 1 YN22V00035F1 SE-17 BOOM POTENTIO. YR52S00016P1
D-25 DIODE YN20D01001P1 PSV-I OPT. RELIEF ADJUSTMENT PROPORTIONAL SOL. 2 SE-19 ARM POTENTIO.
D-66 DIODE PSV-R CONTROLL PROPORTIONAL SOL. YN35V00052F1 SE-20 PRESSURE SENSOR : P1 OPT. LC52S00019P1
D-67 DIODE PSV-P1 PUMP P1 PROPORTIONAL SOL. SE-22 PRESSURE SENSOR : PUMP P1 YN52S00048P1
PSV-P2 PUMP P2 PROPORTIONAL SOL. SE-23 PRESSURE SENSOR : PUMP P2
E-1 FUSE & RELAY BOX YN24E00016F2 PSV-6 NIBBLER OPEN PROPORTIONAL SOL. (RIGHT SLIDE) YN10V00023F1 PRESSURE SENSOR : BOOM HEAD
SE-24
E-2 ALTERNATOR ENGINE ACCESSORY PSV-7 NIBBLER OPEN PROPORTIONAL SOL. (LEFT SLIDE) (FOR OVER LOAD ALARM)
E-3 HOUR METER LQ58S00002P1 PSV-8 EXTRA (A2) PROPORTIONAL SOL. (RIGHT SLIDE) SE-25 PRESSURE SENSOR : BOOM ROD
E-5 HORN HIGH LC53S00001D1 PSV-9 EXTRA (A1) PROPORTIONAL SOL. (LEFT SLIDE) SE-28 EXTRA PRESSURE
E-6 HORN LOW LC53S00001D2 SE-29 OPT. SELECTOR DETECT SENSOR LC52S00019P1
E-7 TUNER AM & FM YN54S00044P1 R-1 BATTERY RELAY YN24S00008F1 SUCTION TEMPERATURE SENSOR/
SE-62 -
E-8 SPEAKER LEFT YN54S00006P1 R-2 STARTER RELAY ENGINE ACCESSORY AIR FLOW METER
E-9 SPEAKER RIGHT R-3 GLOW RELAY
(E) ELECTRIC FITTINGS

E-10 RECEIVER DRIER YN54S00041P1 R-4 SAFETY RELAY YN24S00010P1 SV-1 SWING PARKING BRAKE SOL. YN52S00048P1
E-11 AIR-CON COMPRESSOR YX91V00001F1 R-5 HORN RELAY SV-2 POWER BOOST SOL. YN35V00051F1
E-12 BATTERY YN72S00010P1 R-6 WORK LIGHT RELAY SV-3 TWO-SPEED SELECT SOL. YN35V00050F1 23
E-13 TRAVEL ALARM YN53S00004F1 R-8 TRAVEL ALARM RELAY 1 YN24S00010P1 SV-4 OPERATING LEVER LOCK SOL.
E-15 FUSIBLE LINK LE73E00001S001 R-9 CAB WORKING LIGHT RELAY SV-6 BUCKET DUMP CUT SOL.
(R) RELAY

E-16 ONE WAY CALL AMP 2447R145 R-10 BACKET CONTROL RELAY SV-7 REVOLUTION RIGHT SOL. LE35V00001F2

(SV) SOLENOID
E-17 ONE WAY CALL SPEAKER LC54S00004P1 R-11 TRAVEL ALARM RELAY 2 SV-9 REVOLUTION LEFT SOL. LC35V00004F3
E-22 DC-DC CONVETER YN77S00033P1 R-12 REVOLUTION RIGHT RELAY SV-10 NIBBLER OPEN SOL.
E-23 12V SOCKET YN81S01002P1 R-13 REVOLUTION LEFT RELAY SV-11 NIBBLER CLOSE SOL.
E-24 GPS ANTENNA YN54S00047P1 R-15 NIBBLER OPEN RELAY SV-13 EXTRA DIS-PRESSURE SOL. YN35V000010F2
E-25 PDC ANTENNA YN54S00048P1 R-16 NIBBLER CLOSE RELAY SV-14 OPT. SELECTOR SOL. -
E-27 ACCEL REDUNDANT VOLUME YN52S00052P1 R-17 EXTRA DIS-PRESS. RELAY QUICK COUPLER OPERATION SOL. -
E-46 REAR CAMERA EZ55S00023F1 R-19 FLASHER RELAY YY24S00001P2
E-49 DC-DC CONVETER (PROPORTIONAL) YN77S00033P1 R-23 AUTO IDLE STOP RELAY 1 YN24S00010P1
E-63 DC-DC CONVETER (FOR CAMERA) YN77S00040P1 R-24 AUTO IDLE STOP RELAY 2
E-65 24V SOCKET LQ81S01001P1 R-25 ENGINE EMERGENCY STOP RELAY
NOTE : The parts number may be changed due to the improvement of machine, so use the number for reference only. (7/8)
LC03Z00046P1 03

23-9
23. ELECTRICAL SYSTEM

GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No.
SW-1 KEW SWITCH YN50S00029F1
SW-4 SWING PARKING RELEASE SWITCH YN50S00047P1
SW-5 HORN SWITCH RIGHT YN50E00017P1
SW-7 ENGINE OIL PRESS SWITCH ENGINE ACCESSORY
SW-8 AIR FILTER RESTRICTION SWITCH YR11P00008S005
SW-10 HORN SWITCH LEFT YN50E00017P1
SW-11 LEVER LOCK SWITCH YN50S00055F1
SW-12 OVER LOAD ALARM SELECT SWITCH YN50S00040D6
SW-13 TRAVEL ALARM SWITCH YN50S00040DF
SW-17 ROOF WIPER SWITCH YN50S00040D9
SW-19 WIPER INTERLOCK SWITCH YT50S00004P1
SW-20 POWER BOOST SWITCH RIGHT YN50E00017P1
SW-21 POWER BOOST SWITCH LEFT
SW-26 CAB WORK LIGHT SWITCH YN50S00040D4
(SW) SWITCH

SW-27 RADIATOR COOLANT LEVEL SWITCH ENGINE ACCESSORY

SW-29 NIBBLER OPEN SWITCH LF03M01005F2
SW-30 NIBBLER CLOSE SWITCH
SW-33 REVOLUTION RIGHT SWITCH
SW-34 REVOLUTION LEFT SWITCH
SW-35 HEAVY LIFT SWITCH YN50S00040D5
SW-37 INDEPENDENT TRAVEL SWITCH YN50S00040DB
SW-40 ROTARY LIGHT SWITCH YN50S00040D2
SW-41 HIGH REACH CRANE SWITCH PY50S00003P2
SW-55 BOOM, DECK WORKING SWITCH YN50S00040D1
SW-56 FUEL SUPPLY AUTO STOP SWITCH YF52S00004P1
SW-64 QUICK COUPPLER OPERATION SWITCH YN50S00043D5
SW-96 DRAIN PRESSURE SWITCH LV50S00003D5
SW-98 PRESS SWITCH (PROPORTIONAL) GB50S00049F2
SW-99 NIBBLER OPEN-CLOSE SWITCH YY03M01239F1
SW-100 EXTRA (A1, A2) SWITCH YY03M01240F2
SW-112 FUEL FILTER RESTRICTION SWITCH -
SW-131 MANUAL REPRODUCTION SWITCH LV50S00003D9

NOTE : The parts number may be changed due to the improvement of machine, so use the number for reference only. (8/8)
LC03Z00046P1 03

23-10
 23. ELECTRICAL SYSTEM

23.3 HARNESS

23.3.1 HARNESS LIST

DIVISION DRAWING No. HARNESS

REMARKS
POSITION ITEM NAME ASSEMBLY No. CODE No. NAME DRAWING No.

3.2 INSTRUMENT PANEL ASSY YN17M00121F1

3.3 CONTROLLER INSTALL LC22E00210F1
3.4 OPERATORS CONTROLS YN03M00318F1 7-7 CABLE YN17M01072P1
3.5 UPPER ELEC ASSY LQ03E00014F1
3.6 UPPER HARNESS ASSY LC13E00099F1 1 HARNESS LC13E01406P1 UPPER
2 CABLE LQ13E01248P1 BATTERY TO BATTERY
3 CABLE LC13E01407P1 BATTERY TO RELAY
4 CABLE LC13E01408P1 BATTERY TO GROUND
UPPER FRAME

5 CABLE LC13E01410P1 STARTER

6 CABLE LC13E01413P1 ENGINE GROUND
7 CABLE LE13E01006P1 FLOOR GROUND
8 CABLE LC13E01180P2 GLOW RELAY TO STARTER RELAY
9 HARNESS LQ13E01209P1 TOOL BOX MODULE
10 HARNESS LC13E01193P1 AIR FILTER MODULE
11 HARNESS LC13E01415P1 AIR FOLW
3.7 UPPER HARNESS ASSY LC13E00100F1 1 HARNESS LC13E01412P1
(BHL MULTI)
3.8 UPPER HARNESS ASSY LC13E00102F1 1 HARNESS LC13E01414P1 FLOOR
(FLOOR PLATE) 9 CABLE LE13E01005P1 CAB SUB
13 HARNESS LC13E01428P1 FLOOR GROUND
3.9 CAB HARNESS ASSY LS14E00007F1 1 HARNESS LS14E01013P1 CAB
CAB

6 HARNESS YN11E01205P1 HOUR METER

23
7 HARNESS YN13E01580P1 POWER SUPPLY SOCKET
BOOM 3.10 BOOM HARNESS ASSY LC15E00051F1 1 HARNESS LC15E01053P1 BOOM LIGHT
3.11 BOOM LIGHT INSTALL LC80E00004F1 BOOM LIGHT
LIGHT

3.12 UPPER LIGHT INSTALL LQ80E00014F1 DECK LIGHT

3.13 FLASHER LAMP INSTALL LC80E00025F1 FLASHER LAMP

ALARM 3.14 TRAVEL ALARM ASSY LC53E00008F1

The parts number may be changed due to the improvement of machine, so use the number for reference only.

23-11
23. ELECTRICAL SYSTEM

23.3.2 INSTRUMENT PANEL ASSY

INSTRUMENT PANEL ASSY YN17M00121F1 (01)
ADJUST FOR THE CENTER OF THE ROTATOIN OF THO
RING NUT SHUTTER TO CENTER THE RANGE OF THIS AREA CENTER OF
ITEM PART NAME PART No. Q'TY REMARKS WITH 0~1 PLAIN WASHERS OF ACCESSORY (t0.8) ROTATION
1 INSTRUMENT PANEL ASSY YN17M00119F1 (01) AND 0~2 WASHERS OF WASHER (t0.3).
PLAIN SHUTTER
1-17 GAUGE CLUSTER YN59S00028F1 1 WASHER (t0.8)
1-22 RING NUT
1-19 KEY SWITCH YN50S00026F1 1 K250 WITH LOGO TIGHTENING TORQUE
WAVE WASHER 4.9 N.m (3.61 lbf.ft)
1-22 POTENTIO METER LQ52S00025P1 1
1-25 HOUR METER LQ58S00002P1 1 WASHER

1-41 SOCKET YN81S01002P1 1 12V

2 SWITCH INSTALL YN50E00061F1 (01)
1-19
2-2 SWITCH YN50S00040D1 1 WORKING LIGHT

1-19
1-17 TIGHTENING TORQUE VIEW I SECTION BB
9.7 N.m (7.15 lbf.ft)
TIGHTENING TORQUE INSTALL TO CAB.
5.0 N.m (3.69 lbf.ft) TIGHTENING TORQUE
SEMS-BOLT 5.0 N.m (3.69 lbf.ft)
SEMS-BOLT SEMS-BOLT
TIGHTENING TORQUE
1.0 N.m (0.74 lbf.ft) HANG IT ON
TAPPING SCREW THE CAB.

SEMS-BOLT
INSTALL TO CAB.
TIGHTENING TORQUE
23 N.m (16.96 lbf.ft)
TAPPING SCREW
TIGHTENING TORQUE
1-41 5.0 N.m (3.69 lbf.ft)
2 PLACES
SEMS-BOLT TIGHTENING TORQUE
FORWARD TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft) SEMS-BOLT
INSTALL TO CAB. 5.0 N.m (3.69 lbf.ft) INSTALL TO SUPPORT ELEC.
TIGHTENING TORQUE TIGHTENING TORQUE
INSTALL TO CAB. SEMS-BOLT 1.5 N.m (1.1 lbf.ft)
9.7 N.m (7.15 lbf.ft) SEMS-BOLT
BEFORE SIGS ITEM 1-1, 1-6 AND ASSEMBLY SECTION AA
TIGHTENING TORQUE
5.0 N.m (3.69 lbf.ft)
INSTALL TO CAB.
SEMS-BOLT TIGHTENING TORQUE
TIGHTENING TORQUE 5.0 N.m (3.69 lbf.ft)
5.0 N.m (3.69 lbf.ft) HANG IT ON THE CAB. TIGHTENING TORQUE INSTALL TO CAB.
SEMS-BOLT 5.0 N.m (3.69 lbf.ft) SEMS-BOLT
4 PLACES 2-1 INSTALL TO CAB.
1-17 TIGHTENING TORQUE SEMS-BOLT
5.0 N.m (3.69 lbf.ft)
INSTALL TO CAB.
SEMS-BOLT

TIGHTENING TORQUE
5.0 N.m (3.69 lbf.ft)
FORWARD INSTALL TO CAB.
SEMS-BOLT
SEMS-BOLT FORWARD
INSTALL TO CAB. SEMS-BOLT
TIGHTENING TORQUE INSTALL TO CAB.
5.0 N.m (3.69 lbf.ft) TIGHTENING TORQUE
5.0 N.m (3.69 lbf.ft)
NUT
TIGHTENING TORQUE
5.0 N.m (3.69 lbf.ft)
SEMS-BOLT SEMS-BOLT
INSTALL TO INSTALL TO SEMS-BOLT
FLOOR PLATE. FOOT DUCT. INSTALL TO CAB.
TIGHTENING TORQUE TIGHTENING TORQUE TIGHTENING TORQUE
5.0 N.m (3.69 lbf.ft) 5.0 N.m (3.69 lbf.ft) TAPPING SCREW
9.7 N m (7.15 lbf.ft)
. TIGHTENING TORQUE
SEMS-BOLT 1.0 N.m (0.74 lbf.ft)
INSTALL TO CAB.
1-25 TIGHTENING TORQUE SEMS-BOLT
5.0 N.m (3.69 lbf.ft)
SEMS-BOLT TIGHTENING TORQUE
INSTALL TO FLOOR PLATE. 5.0 N.m (3.69 lbf.ft)
SEMS-BOLT TIGHTENING TORQUE
FORWARD TIGHTENING TORQUE 2 PLACES
5.0 N.m (3.69 lbf.ft)
5.0 N.m (3.69 lbf.ft) VIEW II

23-12
 23. ELECTRICAL SYSTEM

23.3.3 CONTROLLER INSTALL

ASSEMBLE WITH THE NUT
OF THE ACCESSORY. TRIM TRIM
CONTROLLER INSTALL LC22E00210F1 (01)
TIGHTENING TORQUE
1.47 N.m (1.081 lbf.ft) STICK TO SUPPORT STICK TO SUPPORT
ITEM PART NAME PART No. Q'TY REMARKS 1-6 CLIP CLIP
1 CONTROLLER INSTALL YN22E00423F1 (02)
1-4
1-4 SWITCH YN50S00047P1 1 SLEWING PARKING RELEASE TIGHTENING TORQUE
1.7 N.m (1.25 lbf.ft)
1-6 POTENTIO METER YN52S00052P1 1 SLEWING PARKING RELEASE TIGHTEN THE SET SCREW ASSEMBLE WITH THE
AFTER INSERTING A DIAL NUT OF THE ACCESSORY.
2 CONTROLLER LC22E00206F1 (01) IN THE DIRECTION FROM SUPPORT
WHICH A SET SCREW IS
2-1 CONTROLLER YN22E00425F1 1 MECHATRO ON THE PLACE SIDE OF
A SHAFT.
3 RELAY BOX ASSY YN24E00031F1 (01) CLIP
TIGHTENING TORQUE
5 N.m (3.67 lbf.ft) STICK TO SUPPORT
3-1 RELAY BOX ASSY YN24E00016F3 1 DETAIL aa
4-1 SEMS-BOLT
4 CONTPOLLER INSTAL YN22E00424F1 (01)
4-1 CONTROLLER ENGINE ACSSESSORY 1 COOLANT LEVEL
5 RELAY ASSY YN24E00030F1 (01)
5-1 FLASHER RELAY YY24S00001P2 1
6 CONVERTER YN77S00053F1 (01)
6-1 CONVERTER YN77S00017P1 1 CLIP
STICK TO MECHATRONICS
TIGHTENING TORQUE CONTROLLER.
23 N.m (17 lbf.ft)
TIGHTEN THE BOLT USED BY INSTALLATION CLIP AND TRIM
SUB-ASSY (MARK ) AGAIN.
CAPSCREW CAPSCREW UPPER
HEXAGON NUT INSTALL THE CORNER
VIEW III IN THIS DIRECTION.
TIGHTENING TORQUE TOOTHED
TIGHTENING TORQUE
23 N.m (17 lbf.ft) 5 N.m (3.67 lbf.ft)
LOCK WASHER
INSTALL TO CAB. INSTALL TO CAB. HORN
SEMS-BOLT SEMS-BOLT WASHER
4 PLACES

VIEW I VIEW II LOWER

TIGHTENING TORQUE HEXAGON
5.0 N.m (3.69 lbf.ft) NUT
SEMS-BOLT
1-4
SECTION AA
ENGAGE AND FIX. 5-1 TIGHTENING TORQUE
CLIP 9.7 N.m (7.15 lbf.ft)
SEMS-BOLT 6-1
2
ENGAGE
AND FIX. CLIP
CLIP ENGAGE AND FIX.

SEMS-BOLT
23
3
SEMS-BOLT
TIGHTENING TORQUE
5 N.m (3.67 lbf.ft)
3 PLACES
SEMS-BOLT
TIGHTENING TORQUE
46.5 N.m (34.3 lbf.ft)

CONNECT WITH CONNECTOR SEMS-BOLT

FOR SWING FLASHER RELAY TIGHTENING TORQUE
TIGHTENING TORQUE OF CAB HARNESS. 2.9 N.m (2.14 lbf.ft)
46.5 N.m (34.3 lbf.ft) SEMS-BOLT 2PLACES
FORWARD SEMS-BOLT FORWARD AFTER INSTALL TO CAB
TIGHTEN THE BOLT USED BY
SUB-ASSY (MARK ) AGAIN.
TIGHTENING TORQUE
23 N.m (17 lbf.ft) FORWARD
CASE OF INSTAL TO SUB-ASSY (FLOOR) CASE OF INSTAL TO CAB

23-13
23. ELECTRICAL SYSTEM

23.3.4 OPERATORS CONTROLS (1/2)

OPERATORS CONTROLS YN03M00318F1 (01)

3-1 3-2
ITEM PART NAME PART No. Q'TY REMARKS
3 GRIP ASSY YN03M02138F1 (01)

3-1 GRIP ASSY YN03M02139F2 1 R/H POWER BOOST

3-1-3 SWITCH ASSY YN50E00017P1 1
3-2 GRIP ASSY YN03M02139F1 1 L/H HORN
3-2-3 SWITCH ASSY YN50E00017P1 1
4 SWITCH INSTAL YN50E00059F1 (01)

4-2 SWITCH LV50E00003D5 1

7 RADIO INSTAL YN54E00033F1 (02) 3-1-3
7-2 RADIO YN54S00045P2 1 3-2-3
GRIP
7-7 CABLE YN17M01072P1 1
GRIP
CASE

CASE
CAPSCREW
TIGHTENING TORQUE
2.7 N.m (2.0 lbf.ft)
CAPSCREW
TIGHTENING TORQUE
DRAIN PRESSURE 2.7 N.m (2.0 lbf.ft)
4-2
LEVER LEVER
CAP

TIGHTENING TORQUE
41.2 N.m (30.4 lbf.ft)
NUT
2 PLACES
DETAIL OF GRIP ASSY

HANG TO PROJECTION
PART OF CONSOL.

SECTION AA

ADJUST THE CLEARANCE SO AS TO PROVIDE

4.5 0.5mm WHEN THE LIMIT SWITCH IS
POSITIONED AT THE STROKE END.

PROCEDURE FOR ADJUSTING THE LIMIT SWITCH

23-14
 23. ELECTRICAL SYSTEM

23.3.4 OPERATORS CONTROLS (2/2)

23.3.4.7 RADIO INSTALL : YN54E00033F1 (02)

)
A.
DI
ER

23.3.4.7-7 CABLE : YN17M01072P1 23

in) INN
78 (
.3
(0

(0.197 in)
(0
.5
12 PLUS SIDE CLICK TYPE
in
)

BURIED CONDENSER 150PF

(0.125 in)

23-15
23. ELECTRICAL SYSTEM

23.3.5 UPPER ELECTRIC ASSY

THE RELAY (GLOW & STARTER)
UPPER ELECTRIC ASSY LQ03E00014F1 (01) TO THE OF BRACKET
TIGHTENING TORQUE
ITEM PART NAME PART No. Q'TY REMARKS 23.5 N.m (17.3 lbf.ft)
SEMS-BOLT
1 BATTERY RELAY YN24S00008F1 1
2 HORN LC53S00001D1 1 HIGH
3 HORN LC53S00001D2 1 LOW
GLOW RELAY
BRACKET
COVER

SEMS-BOLT
TIGHTENING TORQUE
15.5 N.m (11.4 lbf.ft) TIGHTENING TORQUE
10.7 N.m (7.9 lbf.ft)
2 PLACES
SEMS-BOLT

E-6 :
HORN LOW NUT STARTER RELAY
COVER
TIGHTENING TORQUE
17.5 N.m (12.9 lbf.ft) B TERMINAL

E-5 : C TERMINAL
HORN HIGH

BATTERY RELAY BOX SEMS-BOLT

TIGHTENING TORQUE
11.7 N.m (8.6 lbf.ft MAX)

GROUND SECTION AA VIEW III

HORN (HIGH) (DETAIL OF BATTERY RELAY BOX) (DETAIL OF COVER FITTING)
HORN (LOW)

CONNECT AS SHOWN TIGHTENING TORQUE

SO AS TO AVOID SHORT 10.7 N.m (7.9 lbf.ft) CONNECT AS SHOWN
CIRCUIT ON POWER TIGHTEN AFTER SO AS TO AVOID SHORT
SOURCE LINE. GND CHECKING NO PAINT CIRCUIT ON POWER
SEMS-BOLT SOURCE LINE.
TIGHTEN FROM
THE FOWARD GND TERMINAL
BRACKET
SEMS-BOLT

B B
(BLACK) (BLACK)

HORN STAY
GO GO
(GREEN ORANGE) (GREEN ORANGE)

SET THE GND TERMINAL

BETWEEN THE HONE
VIEW II STAY AND THE SEMS-BOLT. 2 3
VIEW I

23-16
 23. ELECTRICAL SYSTEM

23.3.6 UPPER HARNESS ASSY (1/7)

UPPER HARNESS ASSY LC13E00099F1 (05)

ITEM PART NAME PART No. Q'TY REMARKS

1 HARNESS LC13E01406P1 1 UPPER
2 CABLE LQ13E01248P1 1 BATTERY - BATTERY
3 CABLE LC13E01407P1 1 BATTERY - RELAY
4 CABLE LC13E01408P1 1 BATTERY - GROUND
5 CABLE LC13E01410P1 1 STARTER
6 CABLE LC13E01413P1 1 ENGINE GROUND
7 CABLE LE13E01006P1 1 FLOOR GROUND
8 CABLE LC13E01180P2 1 GROW RELAY - STARTER RELAY
9 CABLE LQ13E01209P1 1 TOOL BOX MODULE
10 HARNESS LC13E01193P1 1 AIR FILTER MODULE
11 HARNESS LC13E01415P1 1 AIR FOLW

FLOOR HARNESS GROUND

NEUTRAL STOP RELAY
REVOLUTION LEFT SW.
HORN SW. LEFT
POWER BOOST SW. LEFT
SPLICE
SPLICE
NIBBLER CLOSE SW.
12V / 24V SOCKET
DRAIN PRESSURE SW.
HORN SW. RIGHT
POWER BOOST SW. RIGHT
REVOLUTION RIGHT SW.
QUICK COUPPLER OPERATION SW.
HIGH REACH CRANE SW. (OPT.)
23
TUNER AM & FM

23-17
23. ELECTRICAL SYSTEM

23.3.6 UPPER HARNESS ASSY (2/7)

23-18
 23. ELECTRICAL SYSTEM

23.3.6 UPPER HARNESS ASSY (3/7)

23

23-19
23. ELECTRICAL SYSTEM

23.3.6 UPPER HARNESS ASSY (4/7)

23-20
 23. ELECTRICAL SYSTEM

23.3.6 UPPER HARNESS ASSY (5/7)

23

23-21
23. ELECTRICAL SYSTEM

23.3.6 UPPER HARNESS ASSY (6/7)

23-22
 23. ELECTRICAL SYSTEM

23.3.6 UPPER HARNESS ASSY (7/7)

23

23-23
23. ELECTRICAL SYSTEM

23.3.6-1 UPPER HARNESS (1/10) : LC13E01406P1

23-24
 23. ELECTRICAL SYSTEM

23.3.6-1 UPPER HARNESS (2/10) : LC13E01406P1

23

23-25
23. ELECTRICAL SYSTEM

23.3.6-1 UPPER HARNESS (3/10) : LC13E01406P1

23-26
 23. ELECTRICAL SYSTEM

23.3.6-1 UPPER HARNESS (4/10) : LC13E01406P1

23

23-27
23. ELECTRICAL SYSTEM

23.3.6-1 UPPER HARNESS (5/10) : LC13E01406P1

23-28
 23. ELECTRICAL SYSTEM

23.3.6-1 UPPER HARNESS (6/10) : LC13E01406P1

23

23-29
23. ELECTRICAL SYSTEM

23.3.6-1 UPPER HARNESS (7/10) : LC13E01406P1

23-30
 23. ELECTRICAL SYSTEM

23.3.6-1 UPPER HARNESS (8/10) : LC13E01406P1

23

23-31
23. ELECTRICAL SYSTEM

23.3.6-1 UPPER HARNESS (9/10) : LC13E01406P1

23-32
 23. ELECTRICAL SYSTEM

23.3.6-1 UPPER HARNESS (10/10) : LC13E01406P1

23

23-33
23. ELECTRICAL SYSTEM

23.3.6-2 BATTERY CABLE : LQ13E01248P1

23.3.6-3 BATTERY RELAY CABLE : LC13E01407P1
23.3.6-4 BATTERY GROUNDING CABLE : LC13E01408P1
23.3.6-5 STARTER CABLE : LC13E01410P1
23.3.6-6 ENGINE GROUNDING CABLE : LC13E01413P1
BATTERY CABLE : LQ13E01248P1 STARTER CABLE : LC13E01410P1

2580 (8'5.6")
")
16 0.33
70 320 820 360 220 70 (0.63") 8.4(
170 (6.69") (2.76") (12.6") (32.28") (14.17") (8.66") (2.76")

(0.89")
22.5
FUSE BOX

BATTERY RELAY CABLE : LC13E01407P1

FUSE

640 (25.19") 20 (0.79")

ENGINE GROUNDING CABLE : LC13E01413P1

370 (14.57")
BATTERY GROUNDING CABLE : LC13E01408P1
")
380 (14.96") .33
(0
4
8.
(0.89")
22.5

16
(0.63")

23-34
 23. ELECTRICAL SYSTEM

23.3.6-7 FLOOR GROUNDING CABLE : LE13E01006P1

23.3.6-8 RELAY CABLE : LC13E01180P2
23.3.6-9 TOOL BOX HARNESS : LQ13E01209P1

FLOOR GROUNDING CABLE : LE13E01006P1 TOOL BOX HARNESS : LQ13E01209P1

TOWARO THE END OF TERMINAL

100 (3.94")

LA308 5B E E 5B E

120 (4.72") 1PAM

YAZAKI 7122-3010

TOWARO THE CENTER OF

THE HOLE OF LA TERMINAL

TAPING TAPING

WHITE TAPING WHITE TAPING WHITE TAPING

BATTERY CABLE : LQ13E01248P1

TAPED DOUBLY
180 (7.09")

CAP TO BE INSTALLED
CAP
YAZAKI 7034-1280

TERMINAL TERMINAL
HEAT SHRINKAGE TUBE TO BE INSTALLED

23

23-35
23. ELECTRICAL SYSTEM

23.3.6-10 AIR CLEANER HARNESS : LC13E01193P1

23.3.6-11 AIR FOLW HARNESS : LC13E01415P1

AIR CLEANER HARNESS : LC13E01193P1 AIR FOLW HARNESS : LC13E01415P1

SW-8 :
AIR FILTER CLOGGING
SWITCH

WHITE TAPING

WHITE TAPING

23-36
 23. ELECTRICAL SYSTEM

23.3.7 UPPER HARNESS ASSY (BHL MULTI)

23.3.7.1 HARNESS (BHL MULTI) : LC13E01412P1
UPPER HARNESS ASSY(BHL MULTI) HARNESS (BHL MULTI) : LC13E01412P1

UPPER HARNESS ASSY LC13E00100F1

ITEM PART NAME PART No. Q'TY REMARKS
1 HARNESS LC13E01412P1 1

SET THE WHITE TAPING PART

TO THE WHITE TAPING PART
UPP HARNESS AND FIX WITH CLIP
CLIP
FORWARD

WHITE TAPING

SE-4 :
1 PRESS SENSOR :
BOOM LOWERING WHITE TAPING
CLIP
CLIP CLIP SE-8 :
WHITE TAPING PRESS SENSOR :
WASHER TANK ARM OUT
VIEW I
SE-3 :
FIX A HARNESS WITH PRESS SENSOR :
WASHER TUBE BY CLIP BOOM RAISING
WASHER TUBE SE-7 :
PRESS SENSOR :
ARM IN FORWARD

CLIP
CLIP
WHITE TAPING
WHITE TAPING
VIEW III 23
VIEW II
SE-3 : PRESS SENSOR :
BOOM RAISING
CONNECT TO SE-4 : PRESS SENSOR :
BOUNDLED TO FLOOR HARNESS BOOM LOWERING
FLOOR HARNESS SE-7 : PRESS SENSOR :
FIX A HARNESS WITH CLIP ARM IN
WASHER TUBE BY CLIP FLOOR HARNESS SE-8 : PRESS SENSOR :
WHITE TAPING ARM OUT

VIEW IV
23-37
23. ELECTRICAL SYSTEM

23.3.8 UPPER HARNESS ASSY (FLOOR PLATE) (1/3)

SW-40 :
UPPER HARNESS ASSY LC13E00102F1 (03) FIX WITH ROTARY LIGHT SW.
TILTED LEVER. (RED TAPING)
ITEM PART NAME PART No. Q'TY REMARKS CLIP SW-96 :
DRAIN PRESSURE SW. SW-40 :
1 HARNESS LC13E01414P1 1 FLOOR (YELLOW TAPING) ROTARY LIGHT SW.
SW-59 : (RED TAPING)
9 CABLE LE13E01005P1 1 FLOOR HARNESS GROUND E-7 : QUICK COUPPLER
TUNER OPERATION SW.
13 HARNESS LC13E01428P1 1 CAB SUB HARNESS (BLUE TAPING) (EU)
SW-96 :
SW-131 : DRAIN PRESSURE SW.
MANUAL (YELLOW TAPING)
REPRODUCTION
SW.
FIX POSITION TO VINYL TUBE. (BROWN TAPING)
E-1 : SW-20 :
FUSE & RELAY BOX POWER BOOST SW. RIGHT (YELLOW TAPING)
SW-33 : FIX WHITE TAPING
REVOLUTION RIGHT SW. (OPT) (RED TAPING) POSITION.
SW-5 : TIGHTENING TORQUE
HORN SW. RIGHT (OPT) (BLUE TAPING) 9.6 N.m (7.08 lbf.ft)
SW-29 : SEMS-BOLT
SW-1 : NIBBLER OPEN SW. (OPT) (GREEN TAPING)
KEY SW.
CLIP
FIX A CLIP ON HOLE
OF STAND BOAD. FRONT

FIX TO THE PILOT HOSE. FRONT

CLIP

PILOT HOSE PLATE CLIP

FIX WHITE TAPING
FLOOR POSITION.
HARNESS

VIEW I

FIX WITH TILTED LEVER.

CLIP
SW-10 :
HORN SW. LEFT (BLUE TAPING)
IT BUNDLES AND CLIP SW-21 :
FIX WITH TILTED LEVER. POWER BOOST SW. LEFT (OPT) (YELLOW TAPING)
CLIP SW-30 :
NIBBLER CLOSE SW. (OPT) (GREEN TAPING)
SW-34 :
REVOLUTION LEFT SW. (OPT) (RED TAPING)

SW-11 :
LEVER LOCK SW.

FIX TO THE PILOT HOSE. CLIP TO LOCK POSITION

OF CONNECTOR
FIX A CONNECTOR TO THE
FRONT CLIP LEVER LOCK SW.

FLOOR CLIP FIX WHITE TAPING

HARNESS CLIP POSITION.
PILOT HOSE
FIX WHITE TAPING
POSITION.

VIEW II

23-38
 23. ELECTRICAL SYSTEM

23.3.8 UPPER HARNESS ASSY (FLOOR PLATE) (2/3)

CLIP CLIP
SE-20 :
TIGHTEN AFTER PRESS SENSOR :
CHECKING NO PAINT. P1 OPT. CLIP
TIGHTENING TORQUE
10.7 N.m (7.89 lbf.ft)
GND
NUT
LOCK WASHER
WASHER
TO PRESS. SENSOR.

9
FLOOR HARNESS GROUND
NEUTRAL STOP RELAY
REVOLUTION LEFT SW. FIX WHITE TAPING POSITION.
HORN SW. LEFT
POWER BOOST SW. LEFT CONNECT WITH EARTH
NIBBLER CLOSE SW. CABLE OF UPP FRAME.
12V / 24V SOCKET
DRAIN PRESSURE SW. SE-10 :
HORN SW. RIGHT PRESS SENSOR :
POWER BOOST SW. RIGHT TRAVEL LEFT.
REVOLUTION RIGHT SW.
QUICK COUPPLER OPERATION SW.
SE-9 :
HIGH REACH CRANE SW. (OPT.)
PRESS SENSOR :
TUNER AM & FM
TRAVEL RIGHT.

SE-11 :
PRESS SENSOR :
P2 OPT.

FIX WHITE TAPING POSITION. 1 TO THE FRONT SIDE OF FLOOR PLATE.

VIEW FROM THE BACK SIDE OF FLOOR PLATE.

SE-3 : CLIP USES TWO CLIPS CASE

PRESS SENSOR : BY SENSOR TOWER.
BOOM RAISING. CLIP

SE-4 :
PRESS SENSOR :
BOOM LOWERING.

SE-1 :
23
PRESS SENSOR : SE-1 :
BUCKET DIGGING. PRESS SENSOR :
BUCKET DIGGING.
SE-2 : SE-7 :
PRESS SENSOR : PRESS SENSOR : SE-2 :
BUCKET DUMP. ARM IN. PRESS SENSOR :
BUCKET DUMP.
SE-8 : SE-3 :
PRESS SENSOR : PRESS SENSOR :
ARM OUT. BOOM RAISING.

SE-7 : SE-4 :
PRESS SENSOR : PRESS SENSOR :
ARM IN. BOOM LOWERING. FIX WHITE CLIP
CLIP CLIP CLIP TAPING POSITION.
FASTEN HARNESS BY CLIP BUNDLE AFTER SE-8 :
WITH BRACKET OF MULTI. HARNESS DIVERGES. PRESS SENSOR :
ARM OUT.
VIEW VI

DETAIL OF aa : CASE OF MULTI DETAIL OF aa : CASE OF SENSOR TOWER

23-39
23. ELECTRICAL SYSTEM

23.3.8 UPPER HARNESS ASSY (FLOOR PLATE) (3/3)

FIX A CABSUB HARNESS
TO THE FLOOR HARNESS.
FIX WHITE TAPING POSITION.
FIX TO THE FUSE & FIX TO THE BRACKET.
CLIP RELAY BOX BRACKET. UPP HARNESS
CLIP
CLIP
FIX A CLIP OF FLOOR FIX WHITE
FLOOR HARNESS HARNESS ATTACHED TAPING POSITION.
TO PLATE.
FLOOR HARNESS
CABSUB HARNESS
SECTION BB CLIP
SECTION AA
CLIP
FIX A CABSUB HARNESS
E-1 : TO THE FLOOR HARNESS.
FUSE & RELAY BOX
13
C-1 :
MECHATORO CONTROLLER
FIX A CABSUB HARNESS
TO THE FLOOR HARNESS.
CLIP
SW-4 :
ROTATION PARKING
CANCEL SW. CLIP
CONNECT THE YELLOW FIX TO A HIGH NUT.
TAPING OF CONNECTOR
WITH CAB HARNESS.

CONNECT THE BROWN

TAPING OF CONNECTOR
WITH CAB HARNESS.

CONNECT THE GREEN

TAPING OF CONNECTOR CLIP
WITH UPP HARNESS. VIEW VI
VIEW V

FIX A CLIP AFTER

OFFICIAL ASSEMBLING
CLIP
NOTE : 1. ATTACHMENT OF WELDING CLIP
WITHOUT DIRECTIONS IS MADE
INTO THE FOLLOWING.
FIX WHITE TAPING
POSITION.
CLIP
CLIP
FIX TO THE HARNESS
OF AIR CONDITIONER UNIT. HARNESS

TO RIGHT 34P CONNECTOR 22P CONNECTOR

INST-PANEL.
22P CONNECTOR 28P CONNECTOR
TO UNDER VIEW IV
FLOOR.

CONNECT CONNECTOR WITH CONNECT CONNECTOR WITH CONNECT CONNECTOR WITH

"CN2-1" TAG OF ITEM 1 : HARNESS "CN2-2" TAG OF ITEM 1 : HARNESS "CN17" TAG OF ITEM 1 : HARNESS

CONNECT THE YELLOW FIX WHITE TAPING

TAPING OF CONNECTOR POSITION.
WITH CAB HARNESS. CLIP

FRONT
PLATE
FIX TO THE HARNESS
OF AIR CONDITIONER UNIT. TO LEFT
CLIP INST-PANEL. FRONT
SEMS-BOLT
FRONT TIGHTENING TORQUE
9.6 N.m (7.08 lbf.ft) CONNECT CONNECTOR CONNECT CONNECTOR
WITH "CN3-1" TAG OF CONNECT CONNECTOR WITH "CN2-3" TAG OF
ITEM 13 : HARNESS WITH "CN3-2" TAG OF ITEM 1 : HARNESS
ITEM 13 : HARNESS

DETAIL OF FUSE & RELAY BOX CONNECTION VIEW III

23-40
 23. ELECTRICAL SYSTEM

23.3.8-1 FLOOR HARNESS (1/5) : LC13E01414P1

23

23-41
23. ELECTRICAL SYSTEM

23.3.8-1 FLOOR HARNESS (2/5) : LC13E01414P1

23-42
 23. ELECTRICAL SYSTEM

23.3.8-1 FLOOR HARNESS (3/5) : LC13E01414P1

23

23-43
23. ELECTRICAL SYSTEM

23.3.8-1 FLOOR HARNESS (4/5) : LC13E01414P1

23-44
 23. ELECTRICAL SYSTEM

23.3.8-1 FLOOR HARNESS (5/5) : LC13E01414P1

23

23-45
23. ELECTRICAL SYSTEM

23.3.8-9 FLOOR GROUNDING CABLE : LE13E01005P1

23.3.8-13 CAB SUB-HARNESS : LC13E01428P1

FLOOR GROUNDING CABLE : LE13E01005P1

TOWARO THE END OF LA TERMINAL

100 (3.94")

100 (3.94")

120 (4.72") 1PAF

YAZAKI 7123-3010

TOWARO THE CENTER OF

THE HOLE OF LA TERMINAL

CAB SUB-HARNESS : LC13E01428P1

23-46
 23. ELECTRICAL SYSTEM

23.3.9 CAB HARNESS ASSY (1/2)

SW-35 :
CAB HARNESS ASSY LS14E00007F1 (01) FIX TO WITH TOGETHER HEAVY LIFT SW.
UPP HARNESS, FLOOR HARNESS CONNECT WITH
ITEM PART NAME PART No. Q'TY REMARKS AND AIR CONDITIONER HARNESS. NAME TAG OF
CLIP SW-37 : "HEAVY". SW-17 :
INDEPENDENT ROOF WIPER SW.
1 HARNESS LS14E01013P1 1 FIX TO FLOOR HARNESS. WHITE TAPING
TRAVEL SW.
CLIP CONNECT WITH
CONNECT WITH NAME NAME TAG OF
6 HARNESS YN11E01205P1 1 HOUR METER TAG OF "TRAVEL". "WIPER".
7 HARNESS YN13E01580P1 1 POWER SUPPLY SOCKET
AIR CONDITIONER
HARNESS
CONNECT WITH CONNECT WITH
FLOOR HARNESS NAME TAG OF NAME TAG OF
"BOOM, DECK". "CAB LIGHT".
SE-16 : SW-55 : SW-26 :
UPP HARNESS SW-1 : BOOM, DECK
ACCEL CAB WORK LIGHT SW.
KEY SW. POTENTIO WORKING LIGHT SW.
CONNECT THE CONNECTOR
WITH YELLOW TAPING TAG
TO THE FLOOR HARNESS.
CONNECT TO THE
CLIP EARTH OF KEY SW.
CONNECT WITH FIX TO AIR CONDITIONER
CONNECT WITH WIPER HARNESS.
INTERLOCK SW. SPEAKER. CLIP

TO ROOF WIPER. CONNECT WITH

CAB WORK LIGHT.

CONNECT TO THE
ACCEL POTENTIO.
DETAIL OF aa

DETAIL OF THE SWITCH JOINT.

POWER
SUPPLY SOCKET

CONNECT WITH NAME

TAG OF " "

CLIP
WHITE TAPING CONNECT THE
CONNECTOR TO
THE HOUR METER.

23
CONNECT WITH
NAME TAG OF "E"
6
C-2 :
GAUGE CLUSTER 7
CLIP
FIX TO THE DUCT.

E-3 :
HOUR METER
CLIP ITEM 1 HARNESS
M-3 : WHITE
WIPER MOTOR TAPING

CONNECT TO
FLOOR HARNESS.

DETAIL OF A POWER SUPPLY SOCKET. DETAIL OF HOUR METER.

23-47
23. ELECTRICAL SYSTEM

23.3.9 CAB HARNESS ASSY (2/2)

190 438 185 20 (0.79")

(7.48") (17.2") (7.28")
THE 6P CONNECTOR
FIX TO WHITE FIX TO BRACKET
C-2 :
GAUGE CLUSTER THE INT. TAPING THE 2P CONNECTOR
CLIP CLIP CONNECT WITH CAB
WHITE TAPING SIDE HARNESS
CLIP CLIP
BUNDLED WHITE TAPING TIGHTENING TORQUE
CONNECT WITH 4.4 N.m (3.25 lbf.ft)
SPEAKER CONNECTOR OF
HARNESS FIX TO BRACKET TIGHTEN AFTER CHECKING
DC-DC CONVERTER. CLIP NO PAINT.
BY CLIP.
THIGHTEN WITH

25 (0.98")
FIX A BRANCH HARNESS TWO EYELET TERMINALS.
TO THE MAIN HARNESS E-3 :
DOWNWARD. HOUR SEMS-BOLT
METER GND
CLIP

CLIP
WHITE CLIP

435 (17.1")
415 (16.3")
TAPING WHITE
CLIP TAPING
WHITE TAPING WHITE TAPING

CONNECT WITH
CAB WORK LIGHT.
CONNECT WITH
ROOM LIGHT. M-3 :
WIPER MOTOR

FIX TO THE CLIP OF CAB. CONNECT THE CONNECTOR

TO AIR WITH RED TAPING TAG TO
WHITE CONDITIONER UPP HARNESS.
VIEW II CLIP TAPING UNIT.
CONNECT THE CONNECTOR CONNECT THE CONNECTOR
WITH YELLOW TAPING TAG TO WITH BLUE TAPING TAG TO
A CABSUB HARNESS. UPP HARNESS.

CONNECT THE CONNECTOR

VIEW I WITH BROWN TAPING TAG TO
A CABSUB HARNESS.
P-13 CAB HARNESS GROUND
WIPER INTERLOCK SW.
FIX TO BRACKET HOUR METER
CLIP WIPER MOTOR
IT CONTROLLER
DC-DC CONVERTER
CAB WORKING LIGHT SW.
FLASHER RELAY
CAB WORKING LIGHT FRONT 1
GAUGE CLUSTER
DC-DC CONVERTER (FOR CAMERA)
KEY SW. EARTH
CLIP AIR CONDITIONER UNIT
WHITE TAPING DC-DC CONVERTER (KCMA)
FIX TO THE CLIP OF CAB. P-19 CAB HARNESS GROUND
OVER LOAD ALARM SELECT SW. (EU)
VIEW V INDEPENDENT TRAVEL SW. (KCMA)
VIEW III VIEW IV CAB WORKING LIGHT
BOOM,DECK WORKING LIGHT SW.

23-48
 23. ELECTRICAL SYSTEM

23.3.9.1 CAB HARNESS (1/4) : LS14E01013P1

23

23-49
23. ELECTRICAL SYSTEM

23.3.9.1 CAB HARNESS (2/4) : LS14E01013P1

23-50
 23. ELECTRICAL SYSTEM

23.3.9.1 CAB HARNESS (3/4) : LS14E01013P1

23

23-51
23. ELECTRICAL SYSTEM

23.3.9.1 CAB HARNESS (4/4) : LS14E01013P1

23.3.9.6 HOUR METER HARNESS : YN11E01205P1

CAB HARNESS (4/4) : LS14E01013P1 HOUR METER HARNESS : YN11E01205P1

23-52
 23. ELECTRICAL SYSTEM

23.3.9.7 POWER SUPPLY SOCKET HARNESS : YN13E01580P1

23

23-53
23. ELECTRICAL SYSTEM

23.3.10 BOOM HARNESS ASSY

23.3.10-2 BOOM HARNESS : LC15E01053P1
23.3.11 BOOM LIGHT INSTALL
BOOM HARNESS ASSY BOOM LIGHT INSTALL

BOOM HARNESS ASSY LC15E00051F1 BOOM LIGHT INSTALL LC80E00004F1 (04)

ITEM PART NAME PART No. Q'TY REMARKS ITEM NAME PARTS No. Q'TY REMARKS
1 HARNESS LC15E01053P1 1 BOOM HARNESS 1 LIGHT YW80S00001F1 2

FIX WHITE TAPING PART aa

I II 1
FIX WITH FIX WITH
FIX WITH WELDED CLIP.
WELDED CLIP. WELDED CLIP.

FIX WHITE
TAPING PART
1 FIX WHITE TAPING
DETAIL OF aa PART TO THE HOSE
FOR GREASE
CLIP

FIX WHITE FIX TO

TAPING PART FIX WHITE THIS POSITION
FIX WITH TAPING PART
WELDED CLIP. CONNECT WITH
FIX WITH MAIN HARNESS
WELDED CLIP.
TO CENTER OF BUCKET
VIEW I VIEW II

BOOM HARNESS : LC15E01053P1

F-8

WHITE TAPING
SPLICE 85A AND 85C
WHITE TAPING WHITE TAPING

LOCK WASHER
REMOVE LOCK WASHER ATTACHED TO LIGHT
F-7 CN-110M

SECTION AA

NOTE: TIGHTENING TORQUE: 18.6N.m(13.7 lbf.ft)

23-54
 23. ELECTRICAL SYSTEM

23.3.12 UPPER LIGHT INSTALL

UPPER LIGHT INSTALL

UPPER LIGHT INSTALL LQ80E00014F1 (02)

ITEM PART NAME PART No. Q'TY REMARKS

1 LIGHT YT80S00002F2 1

NUT
(SUPPLIED EITH LIGHT)

BRACKET

LIGHT HARNESS SEMS-BOLT

TIGHTENING TORQUE
46.1 N.m (34 lbf.ft)
SECTION AA
23

GROMMET

VIEW I
NOTE
1. TIGHTENING TORQUE OF ITEM 1 TO BE 18.6 N.m (13.72 lbf.ft)

23-55
23. ELECTRICAL SYSTEM

23.3.13 FLASHER LAMP INSTALL

23.3.14 TRAVEL ALARM ASSY
FLASHER LAMP INSTALL TRAVEL ALARM ASSY

FLASHER LAMP INSTALL LC80E00025F1 (01) ALARM ASSY LC53E00008F1 (01)

ITEM PART NAME PART No. Q'TY REMARKS ITEM NAME PARTS No. Q'TY REMARKS
1 FLASHER LAMP YM80S00001F1 1 FOR LH 1 ALARM YN53S00004F1 1
2 FLASHER LAMP YM80S00001F2 1 FOR RH 3 RELAY YN24S00010P1 1

I aa 2

bb 1
III

CLIP
REST HARNESS IS BUNDLED
THIS POSITION AND FASTEN.

UPP
TO SWING HARNESS
DETAIL aa FLASHER
COUNTER
WEIGHT FORWARD
CONNECT WITH CONNECTOR TIGHTENING TORQUE :
OF SWING FLASHER E-13: 23.5 N-m (17.3 lbf-ft)
(SUPPLIED WITH UPP HARNESS) TRAVEL ALARM
SEMS-BOLT
CLIP 1
REST HARNESS IS BUNDLED VIEW II
DETAIL bb THIS POSITION AND FASTEN.
CLIP
UPP HARNESS FIX TO THE CONNECTOR
WITH CLIP REMAINING
LENGTH OF THE ALARM
SIDE HARNESS.

CONNECT WITH CONNECTOR

CLIP OF SWING FLASHER
(SUPPLIED WITH UPP HARNESS) CLIP
TO SWING
FLASHER UPP 3
TO SWING TRAVEL ALARM RELAY
UPP HARNESS FLASHER
HARNESS TO SWING
IV FLASHER UPP DETAIL OF FUSE & RELAY BOX
HARNESS
FORWARD CLIP II
COUNTER
WEIGHT FORWARD

FORWARD
VIEW III VIEW IV VIEW I VIEW I

23-56
 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) ...................................................................................24-60
24.1.4 PILOT VALVE (TRAVEL) ...........................................................................24-64
24.1.5 SWING MOTOR UNIT ...............................................................................24-66
24.1.6 TRAVEL MOTOR .......................................................................................24-77
24.1.7 SWIVEL JOINT ..........................................................................................24-91
24.1.8 CYLINDER .................................................................................................24-93
24.2 ELECTRICAL EQUIPMENT ...............................................................................24-99
24.2.1 ELECTRICAL EQUIPMENT LIST ..............................................................24-99
24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT ........................................24-102

24

Book Code No. S5LC2426E01

24-1
24. COMPONENTS SYSTEM

Issue Data of Issue Applicable Machines Remarks

S5LC2426E01
First Edition September, 2010 SK350-9: YC
NA

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

5
EYE BOLT (M10)

a3 PSV2
Dr

A3 2X4-M12
Depth 22

A1 A2
B3

a4 VIEW
PSV1
MAX. FLOW RATE ADJUSTING SCREW
PH1 PH2
4 PSV1 4
PSV2 PSV2

MIN. FLOW 2 MIN. FLOW RATE

RATE
2 ADJUSTING SCREW
ADJUSTING a3
SCREW
PH1 PH2 PH2 PH1
a4
a1 3 a1
a2
a2 B3
B3
B1
Dr B1
A3

Dr3 a5
A1 A2 5
1 A2
Dr3

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

24-3
24. COMPONENTS SYSTEM

(2) Hydraulic circuit diagram

(FRONT) PSV1 a1 A1 PH1 PH2 A2 a2 PSV2 (REAR)

(KDRDE5K) (KR3S-YT2K-V) (KR3S-YT2K-V) (KDRDE5K)

Solenoid proportional Solenoid proportional

reducing valve (PSV-1) reducing valve (PSV-2)

Regulator Regulator

a3 Dr a4
Engine Gear pump for pilot
a5
Main pump
B1 B3 Dr3 A3

PTO gear case (Option)

Hydraulic Circuit Diagram Of Pump
(3) Specifications

Main pump
Item Gear pump
With PTO. Without PTO.
Pump assy LC10V00030F2 LC10V00029F2 -
Parts No.
Single Pump LC10V00033F1 YN10V00014F3
Pump model K5V140DTP119R-YT0K-HV ZX10LGRZ2-07G
Max.displacement capacity cm3 140 X 2 10
Revolution Rated min-1(Clockwise seen from shaft end) 2100
Rated 34.3 (4980)
Pressure MPa (psi) 5.0 (725)
ATT boost pressure 37.8 (5480)
Max. flow L/min (gal/min) 294 (78) X 2 at 7.8MPa (1130 psi) 21 (5.5)
Max. input horse power kW (PS) 195 (265) 3.4 (4.6)
Max. input torque N.m (lbf.ft) 886 (653) 14.7 (10.8)
Part No. LC10V01005F2
Model KR3S-YT2K-V
Regulator Electric flow control, positive flow control,
Control function
total power control at emergency mode and power shift control

Others With solenoid proportional reducing valve (KDRDE5K-31/30C50)

Weight kg (lb) 141 (310) 143 (315)

24-4
 24. COMPONENTS SYSTEM

24.1.1.2 HYDRAULIC PUMP

24.1.1.2.1 CONSTRUCTION
(1) Main pump

953 806 789 532 Apply adhesive (Three Bond No.1305N) 724 901 808 954 717 151 152 211
886 214 548 531 702 792 534 A
535 732
717
261
406

824
774
111

B B

127
123
710 04
212
401 251 490 271 153 156 157 468 313 124 710 116 467 466 312 885 314 141 271 113
728 727 725
Tightening torque 05

Tightening torque
Item number Thread size
N.m (lbf.ft) 546
401 M20 430 (317) 414 326
406 M8 29 (21) 725
407 M6 12 (8.9) 727
414 M10 57 (42)
466 PF 1/4 36 (27)
467 PF 3/8 74 (55)
468 PF 3/4 170 (125)
490 NPTF1/16 11 (8.1)
531,532 M24X2 240 (177) 407 325
806 M16 130 (96) SECTION B-B SECTION B-B (Option)
VIEW A
808 M20 240 (177)
No. Parts Q'ty No. Parts Q'ty No. Parts Q'ty
111 Drive shaft (F) 1 314 Valve plate (L) 1 724 O-ring ; 1B P8 16
113 Drive shaft (R) 1 325 Sensor block 1 725 O-ring ; 1B P11 9
116 Gear #1 1 326 Cover 1 727 O-ring ; 1B P14 3
123 Roller bearing 2 401 Socket bolt ; M20X210 8 728 O-ring ; 1B P24 4
124 Needle bearing 2 406 Socket bolt ; M8X20 4 732 O-ring ; 1B P18 2
127 Bearing spacer 3 407 Socket bolt ; M6X55 3 774 Oil seal 1
141 Cylinder block 2 414 Socket bolt ; M10X20 4 789 Back up ring ; P18 2
151 Piston 18 466 VP plug ; PF1/4 2 792 Back up ring ; G35 2
152 Shoe 18 467 VP plug ; PF3/8 2 806 Nut ; M16 2
153 Retainer plate 2 468 VP plug ; PF3/4 4 808 Nut ; M20 2
156 Spherical bushing 2 490 Plug ; NPTF1/16 32 824 Snap ring 2
157 Cylinder spring 18 531 Tilting pin ; M24X2 2 885 Valve plate pin 2 24
211 Shoe plate 2 532 Servo piston ; M24X2 2 886 Spring pin 4
212 Swash plate 2 534 Stopper(L) 2 901 Eye bolt ; M10 2
214 Tilting bushing 2 535 Stopper(S) 2 953 Socket screw ; M16X35 2
251 Swash plate support 2 546 Spacer 2 954 Set screw ; M20 2
261 Seal cover (F) 1 548 Feed back pin 2 04 Gear pump 1
271 Pump casing 2 702 O-ring ; 1B G35 2 05 PTO unit (Option) 1
312 Valve block 1 710 O-ring ; 1B G95 2
313 Valve plate (R) 1 717 O-ring ; 1B G145 4
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.

24-5
24. COMPONENTS SYSTEM

(2) Gear pump (For pilot)

700 354 351

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

434

Delivery port : PF1/2

Tightening torque :
53N.m (39.1 lbf.ft)

311

312

732 307 850

434 355
Drain port : PF3/8 310 308 309 466
725
710 435 361 353 Tightening torque :
34.3N.m (25.3 lbf.ft)

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

307 Poppet 1 361 Front case 1
308 Seat 1 433 Flange socket; M8X40 2
309 Ring 1 434 Flange socket; M8X55 2
310 Spring 1 435 Flange socket; M8X20 4
311 Adjust screw 1 466 VP plug; PF1/4 1
312 Lock nut; M14X1.5 1 700 Ring 1
351 Gear case 1 710 O-ring; 1B G95 1
353 Drive gear 1 725 O-ring; 1B P11 1
354 Driven gear 1 732 O-ring; 1B P16 1
355 Filter 1 850 Locking ring 1

24-6
 24. COMPONENTS SYSTEM

(3) PTO gear case (Option)

125
711 468
118 825 710 728

117
126
326 262
115
128
826

414
435
886

885

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 Spring 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
REGULATOR
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 116
plate group that changes the delivery rate; the valve
block group that selects between oil suction and
111
delivery and the PTO group (OPT) that transmits the
drive power to the auxiliary pump.

PTO GEAR CASE

OPT
AUXILIARY PUMP
(OPT)
Construction Of Hydraulic Pump

(1) Rotary group

The rotary group consists of shaft(111), cylinder block (141), piston (151), shoe (152), plate (153), spherical
bushing (156), 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 (313) by the action of cylinder spring (157).

313
124

312

111

116
124
314
141
157
156
151
. 153
152
211

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), tilting 532
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 531
214 211
supported by the swash plate support.
The hydraulic force controlled by the regulator flows 212
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 251
swings on the swash plate support via the spherical
part of the tilting pin and changes the tilting angle (a).

Swash Plate Group

(3) Valve block group

The valve block group consists of valve block (312),
valve plates (313 or 314), and valve plate pin (885).
The valve plates having two crescent-shaped ports are
installed to valve block (312) to feed oil and recycle it 313
from cylinder block (141). The oil switched over by the 312
valve plate is connected with the external pipe by way
of the valve block.
116
111
314
141
885

Valve Block Group

(4) PTO group (Option)

The PTO group is composed of 1st gear (116), 2nd
gear (117) and 3rd gear (118). The 2nd and the 3rd 117
gear are supported by bearings (125) and (126)
respectively and installed to the valve block. 126
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 deg. and a motion toward the valve plate (oil
delivery process) in the remaining 180 deg. If the 118
swash plate is not inclined (zero tilting angle), the 125
piston does not stroke i.e. delivers no oil.
24
The shaft rotation is taken up by the 1st gear (116)
and transmitted to the 2nd gear (117) and the 3rd gear
125
(118), in that order, to drive the gear pump that is
linked to the 3rd gear.
PTO Group

24-9
24. COMPONENTS SYSTEM

24.1.1.3 REGULATOR

24.1.1.3.1 CONSTRUCTION

PSV B PSV 418

413
079
757 D
439
438

725
730
a3
656 643

438 924
D
801

722 543 755 545 541 724 B 466, 755 708 644 646 645 728
VIEW C SECTION B-B

641 655 654 836 651 652 601

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

614 631 627

C
613
898 802
875
A 732
611 753

733

756
622 621 623 625 626 887 763
SECTION A-A

At start and
emergency mode
Tightening torque
662 642 Tightening torque
Item No. Thread size
N.m (lbf-ft)
543 545 541
466 412,413 M8 29 (21)
At normal
438,439 M6 12 (8.9)
755 E 418 M5 6.9 (5.1)
466 PF 1/4 36 (27)
496 NPTF1/16 8.8 (6.5)
496 630 M30X1.5 160 (118)
755 E
801 M8 16 (12)
802 M10 19 (14)
SECTION E-E SECTION D-D

24-10
 24. COMPONENTS SYSTEM

No. Parts Q'ty No. Parts Q'ty No. Parts Q'ty

412 Socket bolt ; M8X50 2 628 Adjusting screw (C) 1 732 O-ring ; 1B P16 1
413 Socket bolt ; M8X70 2 629 Cover (C) 1 733 O-ring 1
418 Socket bolt ; M5X12 2 630 Lock nut ; M30X1.5 1 734 O-ring ; 1B G25 1
438 Socket bolt ; M6X20 8 631 Sleeve (For PF) 1 753 O-ring ; 1B P9 1
439 Socket bolt ; M6X25 5 641 Pilot cover 1 755 O-ring ; 1B P11 7
466 VP plug ; PF1/4 3 642 Spool 1 756 O-ring ; 1B P26 1
496 Plug ; NPTF1/16 17 643 Pilot piston 1 757 O-ring ; 1B P12.5 1
541 Seat 2 644 Spring seat (Q) 1 763 O-ring ; 1B G35 1
543 Stopper 1 2 645 Adjusting stem (Q) 1 801 Nut ; M8 1
545 Ball 2 646 Pilot spring 1 802 Nut ; M10 1
601 Casing 1 651 Sleeve 1 814 Snap ring 1
611 Feed back lever 1 652 Spool 1 836 Snap ring 1
612 Lever (1) 1 653 Spring seat 1 858 Snap ring 2
613 Lever (2) 1 654 Return spring 1 874 Pin ; 4X11.7L 1
614 Fulcrum plug 1 655 Set spring 1 875 Pin ; 4X8L 2
615 Adjusting plug 1 656 Block cover 1 876 Pin ; 5X8L 2
621 Compensating piston 1 662 Spring 1 887 Pin 1
622 Piston case 1 708 O-ring ; 1B G75 1 897 Pin ; 5X19L 1
623 Compensating rod 1 722 O-ring ; 1B P6 3 898 Pin ; 11.5X11.8L 1
624 Spring seat (C) 1 724 O-ring ; 1B P8 8 924 Socket screw ; M8X20 1
625 Outer spring 1 725 O-ring ; 1B P10 1 041 Sub-check valve 2
626 Inner spring 1 728 O-ring ; 1B P18 1 079 Solenoid proportional reducing valve 1
627 Adjusting stem (C) 1 730 O-ring ; 1B P22 1
The codes in a rectangle represent adjust screws.
Do not tamper with the adjust screws as much as possible.

24

24-11
24. COMPONENTS SYSTEM

24.1.1.3.2 OPERATION
(1) Control function

Control function ...... Electric flow control.

-Positive flow control.
-Total horsepower control.
Emergency mode control.
-Hydraulic positive control.
-Hydraulic total horsepower control.

(2) Summary
The regulator KR3S-YT0K for the in-line type axial piston pump K5V series is composed of the control mechanism
as mentioned below:

1. Electric flow control and positive flow control

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

2. Constant power control at emergency mode

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

24-12
 24. COMPONENTS SYSTEM

(3) Explanation of operation

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

Delivery flow rate Q

shown in right figure.

Command current I

a. Flow rate increase (See right Fig.)

As the command current value I rises, the
CL port :
secondary pressure P2 of electromagnetic Connect with large
diameter chamber of
proportional pressure-reducing valve rises, and by servo piston

pressing pilot piston (643) in (A) direction it stops at 652

646
the position the secondary pressure P2 balances
B 613
the pilot spring force (646). The movement of pilot
D 876 F 897
piston is transferred to lever 2 (613) through pin
875
(875), and rotates at (B) fulcrum in arrow direction.
A 611
Furthermore the lever 2 movement is transferred to 643
feedback lever (611) through pin (897) and rotates C
at (C) fulcrum in the same arrow direction as (B).
E 532
Consequently the spool (652) connected to
(KDRDE5K) Psv A
feedback lever moves towards (D). When the spool
moves towards (D), the port CL connected to tank
port is open and the pressure in servo piston large
bore diameter chamber is released, consequently
the servo piston (532) moves towards (E)
according to delivery pressure Pd1 in small bore
diameter piston chamber, resulting in the rise of
flow rate. Since the feed back lever is connected to
the servo piston and spool, the feed back lever Pd1
CL port
rotates at (F) fulcrums with the movement of the
a3
servo piston towards (E), consequently the spool is
Hydraulic circuit diagram
returned to the original position. With this
B
movement, the opening of spool sleeve gradually
closes, and the servo piston stops at the position
the opening closes completely.

24

24-13
24. COMPONENTS SYSTEM

b. Flow rate decrease (See right Fig.)

As the command current value I is reduced, the 613
CL port :
secondary pressure P2 of electromagnetic Connect with large
diameter chamber of
proportional pressure-reducing valve is reduced, servo piston
652 G
and by pressing pilot piston (643) in (G) direction it
stops at the position the pilot spring force (646) 646
balances the secondary pressure P2. The H
J 876 L 897
movement of pilot piston is transferred to lever 2
875
(613) through pin (875), and rotates at (H) fulcrum
611
in arrow direction. Furthermore the lever 2
643
movement is transferred to feedback lever (611) I
through pin (897) and rotates at (I) fulcrum in the K
532
same arrow direction as (H). Consequently the
(KDRDE5K) Psv A
spool (652) connected to the feedback lever moves
towards (J). When the spool moves towards (J), the
delivery pressure Pd1 is led in servo piston large
bore diameter chamber through spool and port CL.
The servo piston small bore diameter chamber
constantly receives delivery the pressure Pd1,
consequently the servo piston moves towards (K)
according to the difference of area resulting in the
Pd1
reduction of tilt angle, and finally the flow rate is
CL port
reduced. Since the feed back lever is connected to
a3
servo piston and spool, the feed back lever rotates
at (L) fulcrum with the movement of servo piston Hydraulic circuit daigram
B
towards (K), consequently the spool is returned to
the original position. With this movement, the
opening of spool sleeve gradually closes, and the
servo piston stops at the position the opening
closes completely.

3. Power control (In emergency mode)

When the load pressure rises, the pump tilt angle is
reduced preventing the overloading of engine as
shown in right Fig.
Delivery flow rate Q

The operation of power control is the same as the

flow rate control, and is explained below.

Delivery output (Pd1)

24-14
 24. COMPONENTS SYSTEM

a. Overload prevention operation (See right Fig.)

Because the delivery pressure Pd1 acts on the 897 896 625
compensating rod stepped section with the rise of R N 612 626
CL port :
Connect with large
self pump delivery pressure Pd1 the compensating diameter chamber of
rod (623) is pushed towards (M), and moves to the servo piston G
652
position the delivery pressure Pd1 balances the
spring force of outer spring (625) and inner spring H
646
(626). The movement of compensating rod is P 875
M
transferred to lever 1 (612) through pin (875), and 623
621
rotates at (N) fulcrum in arrow direction. 611
Furthermore the lever 1 (612) movement is O
transferred to feedback lever (611) through pin Q
(897) and rotates at (O) fulcrum in the same arrow 532
direction as (N). Consequently the spool (652) (KDRDE5K) Psv A

connected with feedback lever moves towards (P).

When the spool moves towards (P), the delivery
pressure Pd1 is led in servo piston large bore
diameter chamber through spool and CL port.
Since the delivery pressure Pd1 is constantly led to
servo piston large bore diameter chamber, the
servo piston moves towards (Q) according to the
Pd1
difference of area, resulting in the reduction of tilt
CL port
angle, consequently the flow rate is also reduced.
a3
Since the feed back lever is connected with servo
Hydraulic circuit daigram
piston and spool, the feed back lever rotates at (R)
B
fulcrum with the movement of the servo piston
towards (Q), consequently the spool is returned to
the original position. With this movement, the
opening of spool sleeve gradually closes, and the
servo piston stops at the position the opening
closes completely.

24

24-15
24. COMPONENTS SYSTEM

b. Flow rate recovery operation (See right Fig.)

Because the compensating rod (623) is pushed 897 876 625
towards (S) with the force of outer spring (625) and X T 612 626
CL port : S
inner spring (626) with reduction of self pump Connect with large
diameter chamber of
delivery pressure Pd1, and moves to the position servo piston G
the spring force of outer spring (625) and inner 652

spring (626) balances the delivery pressure Pd1. H

The movement of compensating rod is transferred J 875
V
to lever 1 (612) through pin (875), and rotates at (T) 623
fulcrum in arrow direction. 621
611
Furthermore the lever 1 (612) movement is
U
transferred to feedback lever (611) through pin W
(897) and rotates at (T) fulcrum in the same arrow 532
direction as (N). Consequently the spool (652) (KDRDE5K) Psv A

connected to feedback lever moves towards (V).

As the spool moves towards (V), CL port is open
and connected to tank port, the pressure of servo
piston large bore diameter chamber is released and
the servo piston (532) moves towards (W) with
delivery pressure Pd1 in small bore diameter
chamber, and consequently the flow rate is raised.
Since the feed back lever is connected to servo Pd1
CL port
piston and spool, the feed back lever rotates at (X)
a3
fulcrum with the movement of the servo piston
towards (W), consequently the spool is returned to Hydraulic circuit daigram
B
the original position.
With this movement, the opening of spool sleeve
gradually closes, and the servo piston stops at the
position the opening closes completely.

3. Priority mechanism of low tilt angle (low flow rate) command

As the said explanation, the tilting commands of flow rate control and power control are transferred to feedback
lever (611) and spool (652) through the large bore section of lever 1 (612) and lever 2 (613), but because the pin
(dia 5) is extruded in large bore (dia 9), pin (897) on the side where making tilt angle smaller contacts with it,
consequently the bore (dia 9) of lever on the side where larger tilt angle command is given is free without
contact with pin (897). In this mechanical selecting manner, the command on the side of low tilt angle of the flow
rate control and power control has a priority.

24-16
 24. COMPONENTS SYSTEM

4. Power shift control

As shown in right Fig., the pump set power is
controlled according to the movement of control by
power shift pressure Pf.

Delivery flow rate Q

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

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 construction Fig.)

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.

Adjust screw no. 954

No. of turns for tightening 1/4
Delivery flow rate Q

Pilot pressure Pi (Input current I) No change

Min. increase in delivery flow L/min (gal/min) 5.8 (1.5)

Input current I (Pilot pressure Pi)

Adjusting The Max. Delivery Flow

24

24-17
24. COMPONENTS SYSTEM

(2) Adjusting the minimum flow (See construction Fig.)

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

Adjust screw no. 953

No. of turns for tightening 1/4

Delivery flow rate Q

Pilot pressure Pi (Input current I) No change
Min. increase in delivery flow L/min (gal/min) 4.6 (1.2)

Input current I (Pilot pressure Pi)

Adjusting The Min. Delivery Flow

(3) Adjusting the input horsepower

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

1. Adjusting the Outer Spring (See constuction Fig.)

(At emergency mode)
Adjust it by loosening lock nut (630) and by tightening adjust screw (628) (or loosening it). Tightening the adjust
screw shifts the control chart to the right and increases the input horsepower, as indicated in right Fig..
Since turning the adjust screw C (628) by N turns changes the setting of the inner spring (626), return the adjust
screw C (627) by NX1.48 turns at first.

Adjust screw no. 628

No. of turns for tightening 1/4
Delivery flow rate Q

Increase delivery pressure MPa (psi) 2.06 (299)

Increase in input torque N.m (lbf.ft) 50 (36.9)

Delivery pressure (Pd1)

Adjusting The Input Horsepower (1)

24-18
 24. COMPONENTS SYSTEM

2. Adjusting the Inner Spring (See construction Fig.)

(At emergency mode)
Adjust it by loosening nut (802) and by adjust screw (C) (627) (or loosening it). Tightening the adjust screw
increases the flow and then the input horsepower, as indicated in right Fig.. And the input torque raises.

Adjust screw no. 627

No. of turns for tightening 1/4

Delivery flow rate Q

Increase inflow L/min (gal/min) 12 (3.2)
Increase in input torque N.m (lbf.ft) 58.7 (43.3)

Delivery pressre (Pd1)

Adjusting The Input Horsepower (2)

(4) Adjusting the flow control characteristics (See construction Fig.)

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..

Adjust screw no. 924

No. of turns for tightening 1/4

Delivery flow rate Q

Increase Pilot pressure MPa (psi) 0.18 (26)
Decrease in delivery flow L/min (gal/min) 18.5 (4.9)

Input current I (Pilot pressure Pi)

Adjusting The Flow Control Characteristics

24

24-19
24. COMPONENTS SYSTEM

24.1.1.3.4 CAUSES OF FAULT RESULTING FROM REGULATOR

When trouble due to this regulator occurs, disassemble and inspect it referring to "Chapter LC33-II"

(1) When the engine is overloaded,

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

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

2. The power shift pressure is low.
-Check the dither of amp.
-Replace solenoid proportional reducing valve.
3. Stick of compensating piston (621) and compensating rod (623)
-Disassemble and clean it.
4. Stick of pin (898)
-Disassemble and clean it.

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

1. Check that pilot differential pressure Pi is normal.
2. Stick of pilot piston (643)
-Disassemble and clean it.
3. Stick of spool (652)
-Disassemble and clean it.
4. Stick of pin (898)
-Disassemble and clean it.

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

24-20
 24. COMPONENTS SYSTEM

24.1.1.4 CONTROL CURVE OF PUMP

300 1471
(79) (1085)
2100min-1: Hmode Input revolution ;2100 min-1
Q Input horse power ;195 kW (265ps)
1900min-1: S Input torque ;886 N.m (653lbf.ft)
250
(66) [1]
Reference value in ( ).
[2] Two pumps are loaded at the same time
[3]
Delivery flow rate Q [ L/min ](gal/min)

200 981
(53) (724)

150
(40)
[1] 183kW (249ps) H mode at traveling or optional working
[2] 154kW (209ps) H mode at operating attachment
[3] 149kW (203ps) S mode at operating attachment
100 490
(26) (360)

Tin N.m (lbf.ft)

Input torque
50
(13)
Min.Flow(at 2100min-1)

0 5 10 15 Delivery 20 25 30 35 40[MPa]
(725) (1450) (2175) pressure (2900) (3625) (4350) (5075) (5800)(psi)
300 725mA Pd
1471
(79) 290L(77gal) (1085)
Q 2000min-1
300mA 12.0MPa [4] 156kW (212ps) (Pf=0MPa) (72 gal)
(1740psi) : At emergency mode
288L Input revolution ;2100 min-1 271L
250 (76gal)
(P t e

(66) Input horse power ;195 kW (265ps)

f= me
A
4. rg

Input torque ;886 N.m (653lbf.ft)

9M e

[4]
Pa ncy

I-Q Curve
)(7 m

Pd=7.8MPa at Qmax Reference value in ( ).

10 od
Delivery flow rate Q [ L/min ](gal/min)

200 (1131psi) 981

ps e

(53)
Two pumps are loaded at the same time (724)
i)

Pf:Power shift pressure (Reference value)

23.8MPa
147L
150 (39gal)
(40)

100 490
(26) (360)
Tin N.m (lbf.ft)

38.0MPa
Input torque

Tin (5510psi)
50 84L
24
(13) (22gal)
Min.Flow(at 2100min-1)
400mA
30L
(8gal)
0 5 10 15 Delivery 20 25 30 35 40[MPa]
(725) (1450) (2175) pressure (2900) (3625) (4350) (5075) (5800)(psi)
Pd
0 1 2 3 Pilot pressure 4 [MPa]
(145) (290) (435) Pi (580)(ps)

24-21
24. COMPONENTS SYSTEM

24.1.2 CONTROL VALVE

24.1.2.1 SPECIFICATIONS
24.1.2.1.1 OUTSIDE VIEW

PTb

PBL

CT2
P2
(P6) CP2

CT1 (P5)
P1

Pcb PAL

(P6) (P6) (P5)

PTb CT1 T2 T1
CT2
Travel PL PCb PCb PAL PAL Travel left PBL
straight AL BL
CMR1 SMR2 P1 unload CP2
Ar PCa
PBr PAr PB1 PB1 Boom
Br Dr
Ar Travel PAr
CP1 Ab right confluence CCb P2 unload
Bs
(HEAD) As
PAb Bb Boom PBb PBs PBs Swing PAs
(ROD) Pss LCs
LCb CRb Aa
PCc PBb
PAc Bucket PCc PBa1 Pss (HEAD)
Ac Bc PBc PBa1 Arm 1 PLc2 CRa PAa1
(HEAD) (ROD) LCa
LCc Ba
PBa2 (ROD)
Arm 2 MU PAo PAo Option
PAa2 PBa2 PBo
LCAP2 LCAT2 LCo
Ao Bo

PBa2 PAo

PAa2
Arm 2 Option
PBo
PAc
PAa1
Bucket Arm 1
PAa
PAs
Boom Swing
PAb
PBr PCa
Travel right P2 unload
(T3)
Travel PTb PBL
Travel left
straight
(CT2)

PBo
PAa2 (P6) (P5)

A
VIEW A
Outside View

24-22
 24. COMPONENTS SYSTEM

24.1.2.1.2 PORTS

Port size Tightening torque Ports Description

PF3/4 150 to 180 N-m (111 to 133 lbf-ft) MU
(T3) Pluged
(P5) Pluged
(P6) Pluged
PF3/8 69 to 78 N-m (51 to 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
PBL Travel left (reverse) 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 to 39 N-m (25 to 29 lbf-ft) Pss Swing pilot high pressure select port
PLc2 Lock valve select pilot port
PAL Travel left (forward) pilot port
PAr Travel right (forward) pilot port
PL Attachment boost port
PB1 Boom (up) conflux pilot port
PTb Travel straight pilot port
PCa Unload valve (P2 side) pilot port
PCb Unload valve (P1 side) pilot port
PCc Bucket (digging) stroke limiter pilot port
M12 83 to 110 N-m (61 to 81 lbf-ft) P1 Pump port (P1 side)
P2 Pump port (P2 side)
T1 Tank port 1
T2 Tank port 2
M10 49 to 65 N-m (36 to 48 lbf-ft) Ar Right travel motor port (forward)
Br Right travel motor port (reverse)
AL Left travel motor port (forward)
BL Left travel motor port (reverse)
As Swing motor port (right)
Bs Swing motor port (left)
Ab Boom cylinder head side port (up)
Bb Boom cylinder rod side port (down)
Aa Arm cylinder head side port (in)
Ba Arm cylinder rod side port (out)
Ac Bucket cylinder head side port (digging)
Bc Bucket cylinder rod side port (dump)
Ao Optional pilot port
Bo Optional pilot port 24

24-23
24. COMPONENTS SYSTEM

24.1.2.1.3 SPECIFICATIONS

Item Specifications
Model KMX15YD/B44131
Maximum flow rate [L/min (gal/min)] 294 (78)X2
Maximum set pressure [MPa (psi)] 37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)
Main relief valve set pressure Std 34.3 (4970) [at 135X2L/min (36X2gal/min)]
[MPa (psi)] When power boost pressure 37.8 (5480) [at 125X2L/min (33X2gal/min)]
Overload relief valve set pressure 39.7 (5760) [at 30L/min (8gal/min)]
(Boom head, Bucket head, Arm rod) [MPa (psi)]
Overload relief valve set pressure 37.8 (5480) [at 30L/min (8gal/min)]
(Boom rod, Bucket rod, Arm head) [MPa (psi)]

24-24
 24. COMPONENTS SYSTEM

24.1.2.2 CONSTRUCTION AND OPERATION

24.1.2.2.1 CONSTRUCTION
(1) Control valve

154 164 101

(P5)
P2

T2 T1

PAL PBL

PB1 PCa

PBs PAs

Pss

PBa1 PAa1

PAo PBo

163 162 163 162

SECTION A A
154 164
(P6)
P1
102

973 973

PTb PCb

973
973
PBr PAr

973
PAb PBb

973 PBc 973

PCc
PAc

974 973
PAa2 PBa2
24

974

162 162 163 162

SECTION B B

Section (1/6)

24-25
24. COMPONENTS SYSTEM

A
B
(P6)

H 273x10 273x10 H

P1 unload PCb PAL

(Travel straight) Travel left
C C
977
PAr PB1
Boom confluence
Travel right
(P2 unload)
D 978x2 D
PBs

Boom Swing
E PBb E
PCc Pss
PBa1

Bucket Arm 1
F F
PBa2 PAo
PA

MU
Arm 2 Option
G G
K K

B A

PBa2 PAo

274x4 275x4
213

212

PBo

273x10 273x10
PAa2

Section (2/6)

24-26
 24. COMPONENTS SYSTEM

202 P1 unload Travel left

333 202
331 PCb PAL
336 333
329 331
327
336
601 MR 324
331
261 323
309
PL 331
261
306
159 AL 163
162

512 511
521
522 CP2
CMR2 551
552 164
562 162
562 CMR1 BL
552
522 163
512
307
261
331 PBL 264
327 205
329 SECTION C-C
336
331
333 Travel straight
202 PTb

202 Travel right Boom conflux

333 202
331 PAr PB1
333
336 331
324
323 339
326
331 325
261
331
306 261
511
161 521
CCb
163 Ar 551
164
511
305
521
CP1
551 551
164 164
163 Br
161
310

(T3)
164 24
264 154
PBr
261
205 331
SECTION D-D 327
329
336
PCa 331
P2 unload 333
202
Section (3/6)

24-27
24. COMPONENTS SYSTEM

Swing 204
203 PBs
333 Boom
331 PBb Pss
333
336
322 331
321
603 336
AbR
331
211 322
L 261 L 321
266 266
160
160 331
514 261
524 303
CRb As 161
556 162
164 Ab
163
511 511
521 523
LCb LCs
551 556
164 164
Bb
Bs 162

161

301
266
264
264
Q Q
602 BbR 160 PAs 206
PAb
SECTION E-E
210 164 551
Bucket

209
216 PCc
201
333 Arm 1 333
331 PBa1
PBc
331
336 336
322 322
321 321
BaR
602 BcR
603
331 331
261 L L 261
211
304
160
514
524
CRa
Bc 556
Ba 164
511 511
521 521
LCc LCa
551 551
164 164
Ac

162 Aa

161

264 302
603 PAc PAa1 264
205 AcR SECTION F-F 205
AaR 602
Section (4/6)

24-28
 24. COMPONENTS SYSTEM

201
333 Arm Option 201
331 PBa2 PAo 333
340
328 331
321
336
331
324
261
AoR 323
604
MU 331
308
162 261
162 311
162
511 Ao

521
LCAT2 511
551
164 521
515 LCo
521 LCAP2 551
551 164
164
Bo
162

161

604
BoR
264 264
Q Q PBo
205
210 PAa2
SECTION G-G

T2

161

P1
T1
511
521 163
CT1
551
163
164
162
P2 511
521
CT2
551 24
164

SECTION H-H

Section (5/6)

24-29
24. COMPONENTS SYSTEM

207
160
278x5 266
606 606
264 264

527 528
T2 T1
517 163
518

SECTION J-J

SECTION K-K

563

564

SECTION L-L SECTION Q-Q

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 1 311 Option spool 1
102 Casing B 1 321 Spring 5
220~250(162~184) 154 Plug PF3/4 3 322 Spring 4
Plug PT1/4 MEC 323 Spring 3
20~24(15~18) 159 1
(Pre-coat bolt) 324 Spring 3
Plug PT1/16 MEC 325 Spring 1
7.8~9.8(5.8~7.2) 160 5
(Pre-coat bolt) 326 Spring 1
161 O-ring 7 327 Spring 3
162 O-ring 15 328 Spring 1
163 O-ring 11 329 Spring 3
164 O-ring 19 331 Spring seat 24
201 Cover 3 16~18(11.8~13.3)
333 Spacer bolt 12
202 Cover 6 Loctite #262
203 Cover 1 336 Stopper 10
204 Sub cover 1 339 Stopper 1
205 Cover 5 340 Stopper 1
206 Cover 1 511 Poppet 11
Back pressure 512 Poppet 2
207 1
check valve cover 514 Poppet 2
209 Cover 2 515 Poppet 1
210 Cover 2 517 Poppet 1
Lock valve selector 518 Poppet 1
9.8~14(7.2-10.3) 211 2
sub 521 Spring 11
212 Plate 1 522 Spring 2
213 Plate 1 523 Spring 1
25~34(18~25) 216 Piston 1 524 Spring 2
261 O-ring 12 527 Spring 1
264 O-ring 10 528 Spring 1
266 O-ring 4 230~260(170~192) 551 Plug 13
273 Socket bolt 40 130~150(96~111) 552 Plug 2
98~120(72~89) 274 Socket bolt 4 230~260(170~192) 556 Plug 3
98~120(72~89) 275 Socket bolt 4 562 O-ring 2
25~34(18~25) 278 Socket bolt 5 13~17(9.59~12.5) 563 Plug 2
301 Boom spool sub 1 564 O-ring 2
302 Arm 1 spool 1 69~78(51~58) 601 Main relief valve 1
303 Swing spool 1 69~78(51~58) 602 Port relief valve 3
304 Bucket spool 1 69~78(51~58) 603 Port relief valve 3
24
305 Boom conflux spool 1 69~78(51~58) 604 Relief valve plug assy 2
306 Travel spool 2 98~120(72~89) 606 Bypass cut valve 2
307 Travel straight spool 1 140~180(103~133) 973 Socket bolt 8
308 Arm 2 spool sub 1 140~180(103~133) 974 Socket bolt 2
309 P1 unload spool 1 977 Name plate 1
310 P2 unload spool 1 978 Rivet 2

24-31
24. COMPONENTS SYSTEM

(2) Main relief valve (Two step relief) (601)

Main Relief Valve (Two Step Relief)

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) 103 Plug; M27 1 562 Back up ring 1
104 Adjust screw 1 611 Poppet 1
121 C-ring 1 613 Stopper 1
122 Spacer 1 614 Piston 1
123 C-ring 1 621 Spring 1
124 Filter stopper 1 652 Adjust screw 1
125 Filter 1 661 O-ring 1
163 O-ring 1 663 O-ring 1
512 Plunger 1 664 O-ring 1
521 Spring 1 28 to 31 (21 to 23) 671 Lock nut; M14 1
541 Seat 1 46 to 52 (34 to 38) 673 Lock nut; M24 1
561 O-ring 1

24-32
 24. COMPONENTS SYSTEM

(3) Over load relief valve (602,603)

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

24-33
24. COMPONENTS SYSTEM

(4) Arm 2 spool (308)

308 318 341 362 372 352

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 33 to 35 (24 to 26) Loctite #638 351 Plug 1
318 Plunger 1 362 O-ring 1
341 Spring 1 372 Buckup ring 1

(5) Boom spool (301)

301 317 340 361 371 350

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 16 to 18 (12 to 13) Loctite #638 350 Plug 1
317 Plunger 1 361 O-ring 1
340 Spring 1 371 Buckup ring 1

(6) Travel straight spool (307)

307 361 371 350

Travel Straight Spool

Tightening
Tightening torque
No. NAME Q'TY torque No. NAME Q'TY
N-m (lbf-ft)
N-m (lbf-ft)
307 Spool 1 361 O-ring 1
16 to 18 (12 to 13) Loctite #638 350 Plug 1 371 Buckup ring 1

24-34
 24. COMPONENTS SYSTEM

(7) 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

(8) Bypass cut valve (606)

202 301

T Dr

102 101 201

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 1 202 O-ring 1
102 O-ring 1 25 to 29 (18 to 21) 301 Lock nut 1
25 to 29 (18 to 21) 201 Adjusting screw 1

24-36
 24. COMPONENTS SYSTEM

(9) 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

(10)Boost check valve (517)

104

107

102

101

Boost Check Valve

Tightening
Tightening torque
torque No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft)
N-m (lbf-ft)
101 Poppet 1 20 to 29 (15 to 21) Loctite #262 104 Plug 1
102 Poppet 1 107 Spring 1

24-38
 24. COMPONENTS SYSTEM

24.1.2.2.2 HYDRAULIC CIRCUIT DIAGRAM

P1 (P6) T1 (P5) T2 P2
CT1
CMR1

PL CMR2
PTb PBL

Travel straight
PCb PAL Travel left
P1 unload
AL
BL
CT2 CP2
(T3)
Boom confluence
Travel right PAr PCa
P2 unload
CP1
Br
Ar PB1
PBr CCb
PBs
Dr
LCb LCs Pss

Boom PAb PAs Swing

As
Bs

(RO D) Bb PBa1
CRb LCa

(HE AD) Ab

PAa1
Arm 1
PBb

LCc Aa (HEAD)

PAc
Bucket
CRa
PLc2
(ROD) Bc
(HEAD) Ac
Ba (ROD)

PCc
PBc
LC AT2
LCo
LCAP2
PAa2 PAo
Option
Arm 2
Ao
Bo

PBo
PBa2
MU

Hydraulic Circuit Diagram

24

24-39
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 (606) located on the downstream of center by-pass passage (52) opens, the hydraulic oil
through hydraulic pump P1 port passes through travel straight spool (306), and then flows though the center by-
pass passage (52) which passes through travel right, boom, bucket and arm 2 and the by-pass cut valve (606) on
P1 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank
through tank port T1.
The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure circuit (D)
and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to the hydraulic oil from
hydraulic pump P1. And when the operation of unloading valve is impossible, because the by-pass cut valve (606)
located on the downstream of center by-pass passage (55) opens, the hydraulic oil through hydraulic pump P2 port
passes through main passage, and then flows though the center by-pass passage (55) which passes through travel
left, swing, arm 1 and option and the by-pass cut valve (606) on P2 side, and flows into low pressure circuit (D) and
boost check valve (517), and then returns to the hydraulic tank through tank port T1.

(D)
606
Pss

517 52
306

YP1 YS1 YT1

YA1 YBG1

T1

P2
P1

P2-20
YAG2 YK2 Y B2 YT1
P1-20

309
310
55 606
(D)
PBc

Connected to low
pressure circuit of
PCc

P2 side casing

In Neutral Position

24-40
 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
(323)(324) and the secondary pressure of solenoid proportional valves [X1] and [X2] acts on ports PCb and
PCa and switches unloading spools (309) (310).
The hydraulic oil delivered by hydraulic pump P1 passes through travel straight spool (307) and flows into main
circuit, and flows through between the perimeter of right travel spool (306) and casing and is fed into A side of
right travel motor through port Ar. The hydraulic oil delivered by hydraulic pump P2 flows through between the
perimeter of left travel spool (306) and casing and is fed into A side of left travel motor through port Ar similarly
to the stream of hydraulic oil delivered by hydraulic pump P1.
But in the meantime, the return oil from the B sides of left and right travel operations passes through between
the perimeter of right and left travel spools (306) and casing through ports Br and BL and flows into low pressure
circuit (D), boost check valve (517), and then returns to the hydraulic tank through tank port T1. On traveling
reverse (at the time when the pilot pressure actuates on ports PBr and PBL of control valve), the actuation is
similar to that in forward travel operation.

In Left Reverse Travel (At PBL Is Pressurized)

24

24-41
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

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

53
216

PAc

PCc PBc

Bc Ac
LCc

321 (D)
322 304 511

(R) (H)
In Bucket Digging Operation (Stroke Limiter ON)

24

24-43
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 (321)(322), and simultaneously the secondary pressure of solenoid proportional
valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered by hydraulic pump
P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and flows through between
the perimeter of bucket spool (304) and casing through U-shaped passage, and supplied to bucket cylinder rod
side (R) through port (Bc).
In the meantime, the return oil from bucket cylinder head side (H) passes through between the perimeter of
bucket spool (304) and casing and flows through low pressure circuit (D'), and returns to the hydraulic tank
through tank port T1. The return oil does not pass through boost check valve (517).

In Bucket Dumping Operation

24-44
 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 (321) (322), and simultaneously the secondary pressure of solenoid proportional
valve [XI] acts on port PCa and switches unloading spool (309).
And the pilot pressure enters port PB1 and boom conflux spool (305) is switched against the force of springs
(325) (326) and the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches
unloading spools (310).
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.

(R) (R)

(H) (H)

301 53 511 321

(D) 514 322
BH chamber
LCb CRb
Bb Ab

PAb PBb

In Boom Up Operation (Boom Spool)

24

24-45
24. COMPONENTS SYSTEM

2. In boom up conflux operation

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

In Boom Up Conflux Operation (Boom Conflux Spool)

24-46
 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 (321) (322) and the secondary pressure of solenoid proportional valve [X1] acts on
PCb and switches unloading spool (309). And simultaneously the spool of lock valve selector (211) is switched,
and the poppet (514) is released because the spring chamber of lock valve poppet CRb (514) is connected to
the drain circuit.
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), and pushes and opens load
check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing through U-
shaped passage, and is supplied to boom cylinder rod side (R) through port (Bb).
In the meantime, the return oil from boom cylinder head side (H) enters the control valve through port (Ab).
Because the retention of lock valve poppet CRb (514) which is located on this side of boom spool (301) is
released, the lock valve poppet (514) pushes and opens. And then the return oil enters BH chamber and passes
through between the perimeter of boom spool (301) and casing, and flows through low pressure circuit (D) and
boost check valve (517), and the returns to the hydraulic tank through tank port T1. And a part of the return oil
flows into the inside of boom spool (301) through circular notch of boom spool (301). Since the return oil
contains sufficient pressure with the self weight of boom, arm, etc. the return oil passes through inside passage
of boom spool (301) and pushes and opens poppet (317) leftward as shown in the figure and flows through the
circular notch, and then supplied to boom cylinder rod (R) side again through port Bb. (Boom recirculation
function)

(R)
(R)

(H) (H)

53 511 321
317 514 322
301 BH chamber
LCb CRb
Bb Ab

PAb PBb

(D)

In Boom Down Operation 24

24-47
24. COMPONENTS SYSTEM

(5) Arm operation

1. In arm out operation
On starting arm out operation, the pilot pressure enters ports PBa1 and PBa2, and arm 1 spool (302) moves
rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid
proportional valve [X2] acts on port PCa and switches unloading spool (310).
And the pilot pressure also enters PBa2, and arm 2 spool (308) is switched against the force of springs (321)
(328) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and switches unloading
spools (309).
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 CRar (514) and is supplied to arm cylinder rod side (R).
In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of arm 1
spool (302) and casing and passes though low pressure circuit (D') and casing inside passage (HH) and then
flows into low pressure circuit (D') through between the perimeter of arm 2 spool (308) and casing.
The return oil in low pressure circuit (D') returns to hydraulic tank through tank port T1 without passing through
boost check valve (517).

(R) (H) 302

AR
322 321 chamber 514
211 CRar
511 LCa
Ba Aa

56
PBa1 PAa1 P1

(D')
Arm 1 (D) LCAT2 LCAP2

RH (D') P1
RR HH PAa2 PBa2
52 Dr Dr
(D')
Arm 2 To arm 1 spoo
Aa (HEAD)
PAa2 Ba
PBa2 (ROD)
To pilot cut valve
53

MU

515
328
321 308 511 LCAT2 LCAP2
In Arm Out Operation

24-48
 24. COMPONENTS SYSTEM

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

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

24

24-49
24. COMPONENTS SYSTEM

(R) (H) 302

AR
322 321 chamber 514
211 CRar 511 LCa
Ba Aa

56
PBa1 PAa1 P1

(D')
Arm 1 (D) LCAT2 LCAP2
(D') P1
RR 52 RH PAa2 PBa2
(D) HH Dr Dr

Arm 2
(a) To arm 1 spool
Aa (HEAD)
PBa2 PAa2
[XR] Ba
(ROD)
53 To pilot cut valve

MU Circuit (I)
317
328 515
308 (D)
321 319 511 LCAT2 LCAP2
In Arm In Operation (At light load: Arm Recirculation Function)

24-50
 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 CRar (514) which is
located on this side of arm 1 spool (302) is released, the return oil pushes and opens lock valve poppet CRar
(514) and enters AR chamber. The return oil in AR chamber is led to arm 2 spool (308) through arm 1 spool
(302) and casing inside passage (RR). But because arm 2 spool (308) is connected to low pressure passage
(D) at circuit (aU), almost all the return oil passes through between the perimeter of arm 2 spool (308) and
casing and flows through boost check valve (517) through low pressure (D) and returns to the hydraulic tank
through tank port T1.
The return oil from AR chamber passes through between the perimeter of arm 1 spool (302) and casing and
flows through casing inside passage (RH) and then is led to the inside of arm 2 spool (308) through circular
notch (a) of arm 2 spool (308). In heavy load operation, since the pressure on arm cylinder head side (H) is
higher than the rod side, the hydraulic oil in arm 2 spool (308) does not flow into casing inside passage (HH),
but flows through check valve (319) and passes through boost check valve (517) through low pressure (D) and
returns to the hydraulic tank through port T1.

(R) (H) 302

AR
322 321 chamber 514
211
CRar
511 LCa
Ba Aa

56

PBa1
PAa1
P1

Arm 1 (D')
(D') (D)
LCAT2 LCAP2
RR 52 RH P1
(D) HH
PAa2 PBa2
Dr Dr
Arm 2 (a)

PBa2 PAa2 To arm 1 spool

[XR] Aa (HEAD)
53 Ba
(ROD)
MU To pilot cut valve
Circuit (II)
317
328 515 24
308 319 (D) LCAP2
321 511 LCAT2
In Arm In Operation (In Heavy Load Operation)

24-51
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

24-52
 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 (323) (324), and simultaneously the secondary
pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310).
The hydraulic oil delivered by hydraulic pump P2 flows through parallel passage (56) and pushes and opens load
check valve LCo (511), and flows through between the perimeter of option spool (311) and casing through U-
shaped passage and is supplied to actuator for attachment through port (Ao).
In the meantime, the return oil from actuator for attachment swing passes through between the perimeter of option
spool (311) and casing through port (Bo) and flows through low pressure circuit (D) and boost check valve (517),
and then returns to the hydraulic tank through tank port T1.
The operation where the pilot pressure acts on PBo port is the same as the above.
* The oil passage is branched toward the end side of control valve at the mid course from option spool (311) to port
Ao, but when N&B (Nibbler and Breaker) selector valve is provided on the end side of control valve, this oil
passage is used as passage to connect to N&B selector valve.

Spool Actuation For Operation In Option

24

24-53
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)

24-54
 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 (321).
With this actuation, spring chamber (RH) of lock valve poppet (514) is connected from orifice (b) of bushing
(541) to drain passage Dr through passage Sb, and the force which pushes lock valve poppet (514) down as
shown in the 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), lock valve poppet (514) is pushed upward and is open.
The said operation, in boom down operation, is performed before making the opening (meter out opening)
which is used to return the return oil from the boom cylinder head side of boom spool (301) to the tank open, the
operation has no effect on the operability of boom down operation.
In case of arm-in operation, the operation is the same.

Return oil from RH CHAMBER

boom cylinder head
514 Lock valve selector
511
BH CHAMBER 541
Sb
CRb PLc
Ab Dr
(a) (b) 321

A A PLc Sa Sb Dr

SECTION A-A
Sa

321 322

PBb

(D)
301
Dr
Lock Valve Selector Operation (At Boom Down Operation)

24

24-55
24. COMPONENTS SYSTEM

(9) By-pass cut valve

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

1. In normal operation
Adjusting screw (201) is tightened up to end in normal operation. Tapered end of adjusting screw (202) is
seated on the seat of casing, and flow between center by-pass passage (52) and low pressure passage (D) is
blocked.
Consequently, in normal operation, center by-pass passage (52) is always blocked from low pressure passage
(D). And the hydraulic oil delivered by pump P1 does not flow through center by-pass passage (52), but returns
to hydraulic tank through P1 unload spool (309).

201

Dr

(D)

52

By-Pass Cut Valve (In Normal Operation)

24-56
 24. COMPONENTS SYSTEM

2. At the time when failure occurred

When the electric system is failed, P1 unload spool (309) stops at neutral position. Hydraulic oil entered from P1
pump is blocked with P1 unload spool (309). And pump pressure rises to set pressure of main relief valve
because oil flows through center by-pass passage (52) and it is blocked with by-pass cut valve (606).
Meanwhile, the hydraulic oil flows from center by-pass passage (52) flows low pressure passage (D) through
by-pas cut valve (606).
Therefore when the electric system is failed, P1 unloading spool (309) is shifted to the neutral position. And
passage to low pressure passage (D) is blocked, but because center by-pass passage (52) is connected to low
pressure passage (D) through by-pass cut valve (606), the abnormal rise of the pump pressure is prevented.

201

301

Dr

(D)

52

By-Pass Cut Valve (In Condition Of Failure)

24

24-57
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.
But the return oil used for the arm out and bucket dumping operation does not pass through boost check valve
(517), but returns from low pressure passage (D') to hydraulic tank through tank port T1.

b. In make up operation
When supplying to make up the flow rate through low pressure passage (D) after the swing operation is
suspended, if the hydraulic oil quantity in low pressure passage (D) is not enough, the deficient hydraulic oil is
made up from hydraulic tank into low pressure passage (D).
When the deficient hydraulic oil in low pressure passage (D) is not sufficient, the pressure of low pressure
passage (D) is lowered. If the pressure of low pressure passage (D) is lowered to the pressure at tank port T1,
poppet (102) housed in boost check valve (517) receives the pressure at tank port T1 on the receiving section in
ring type which is made up of guide diameter and seat diameter of poppet (102), and is pushed upward and
opens, and the hydraulic oil flows from the hydraulic tank to low pressure passage (D) to make up the deficient
flow rate.

Boost Check Valve Operation

24-58
 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.

527

528
(D') T2
518
T1
102

517
(D)

By-Pass Check Valve Operation

24

24-59
24. COMPONENTS SYSTEM

24.1.3 PILOT VALVE (ATT)

24.1.3.1 OUTLINE
(1) Outside view

5-PF3/8
Single operating angle Single operating angle T=49.0 (36.1)
(Port 2, 4) (Port 1, 3)

The adjust nut

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

Part No. LQ30V00033F1

Model PV48K2058
Operating torque Refer to the curve below
Max. primary pressure 6.9 MPa (1000 psi)
Primary pressure 5.0 MPa (725 psi)
Rated flow 20 L/min (5.3gal/min)
Weight Approx. 1.9 kg (4.2 lbs)
A

PORTS 1, 3 PORTS 2, 4
(580)4.0 4.0(3.0) (580)4.0 4.0(3.0)
Secondary pressure [MPa (psi)]

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

SECONDARY PRESSURE
Secondary pressure [MPa (psi)]

SECONDARY PRESSURE
(493)3.4 (493)3.4
Operation torque [N.m (lbf.ft)]

(435)3.0 3.0(2.2) (435)3.0 3.0(2.2)

(377)2.6 (377)2.6
SINGLE OPERATING TORQUE 2.19(1.62) 2.28(1.68)
SINGLE OPERATING TORQUE
(290)2.0 2.0(1.5) (290)2.0 2.0(1.5)
1.91(1.41)

(145)1.0 1.0(0.74) (145)1.0 1.0(0.74)

0.83(0.61) 0.83(0.61)
(87)0.6 1.05(152)
(87)0.6 1.05(152)
0.86(125) 0.86(125)
0 0 0
0 0.8 2 4 6 6.4 7 0 0 0.8 2 4 6 8 8.8 9.4
PUSH ROD STROKE (mm) PUSH ROD STROKE (mm)

0 5 10 15 19 0 5 10 15 20 25
Operating angle (deg.) Operating angle (deg.)

P T

1 3 2 4
HYDRAULIC SYMBOL

24-60
 24. COMPONENTS SYSTEM

24.1.3.2 CONSTRUCTION

Apply Loctite #277

312

302
Apply grease on
501 rotating and sliding sections.
301 Be careful the
assembling direction
Apply grease on top section *246-1
212
*246-2 213
151
*218
211
214

216-2 216-1

241-2 241-1

201-2
Secondary 201-1
pressure 217
adjusting shim
101 221

PORTS 2, 4 PORTS 1, 3
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 Seat 4
151 Plate 1 221 Spring 4
201-1 Spool 2 241-1 Spring 2
201-2 Spool 2 241-2 Spring 2
211 Plug 4 *246-1 Spring 2
212 Push rod 4 *246-2 Spring 2
213 Seal 4 47.1 (34.7) 301 Joint: M14 1
214 O-ring: 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (50.6) 312 Adjust nut: M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4

Note) The parts marked * may not be equipped depending on valve type.
24

24-61
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.
216

509

221

201

PORT (2,4) PORT (1,3)

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. 511

216

201
PORT (2,4) PORT (1,3)
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 509

the T port close. Thus the secondary pressure is

kept constant. T PORT

P PORT

PORT (2,4) PORT (1,3)

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.

24

24-63
24. COMPONENTS SYSTEM

24.1.4 PILOT VALVE (TRAVEL)

24.1.4.1 OUTLINE
(1) Outside view

Tightening torque
Port size N.m (lbf.ft) Port name Function
1 LH travel forward port
2 LH travel reverse port
PF3/8 30 (22) 3 RH travel forward port
4 RH travel reverse port
T Tank port
5 LH travel pressure sensor port
PF1/4 16.7 (12.3) 6 RH travel pressure sensor port
P Pilot primary pressure port

(2) Specifications
P T
Item Specifications
Part No. YN30V00105F1
Type 6TH6NRZ
Primary pressure 4.9MPa (711psi)
Secondary pressure 0.54~2.35MPa (78~341 psi)
Rated flow 25 L/min (6.6 gal/min)
Weight Approx. 8kg (18 lbs)
1 5 2 3 6 4
Hydraulic symbol
(3) Performance characteristics
Secondary pressure
[MPa (psi)] Secondary pressure

2.35 + 0.15
(340 + 22)

0.54 + 0.1
(78 + 15) 0
1 30' 11 30' Pedal angle (degree)
(4.7 + 0.5) 2 30' 12 30'
6.4 + 0.64
7.7 + 0.77
(5.7 + 0.6)
12.7 + 1.27
(9.4 + 0.9)
Operating Operating torque
torque
[N.m (lbf.ft)] Control diagram

24-64
 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).

5
3

8 10
3
11 12
4
10

9
9

7 6
2

control ports 1-3 P line control ports 2-4

T line

24

24-65
24. COMPONENTS SYSTEM

24.1.5 SWING MOTOR UNIT

24.1.5.1 SPECIFICATION
(1) General view

Tightening
Symbol Port name Port size torque
N.m (lbf.ft)
A,B Main port SAE 3/4"
DB Drain port PF1/2 108 (80)
M Make-up port PF1 216 (159)
PA,PB Pressure measuring port 2-PF1/4 36 (27)
PG Parking brake release port PF1/4 36 (27)
Gear oil level gauge or
IP,L,AR Air breather port or PT3/4 98 (72)
Gear oil filling port
IP, L, AR
12- 22 Through

DB
B
PB

M
PG PA
A

THREAD FOR
EYE BOLT 2-M12

PG

DB
RELIEF VALVE
PB PA
M DB

A,B
M
PA PB PG

A B

Hydraulic diagram

24-66
 24. COMPONENTS SYSTEM

(2) Specifications

Swing motor unit part No. LC15V00027F2

Type M5X180CHB-10A-60D/295
Part No. LC15V00022F2
Displacement cm3 (in3) 180.1 (11.0)
Working pressure MPa (psi) 32.4 (4700)
Hydraulic motor Max. flow L/min (gal/min) 294 (77.7)
Braking torque N-m (lbf-ft) 860-1120 (634-827)
Release pressure MPa (psi) 2.4~5.0 (348~725)
Relief set pressure MPa (psi) 29 (4205)
Weight kg (lbs) 72.5 (160)
Type 2KAR6P72/240-712
Anti-reaction valve block
Weight kg (lbs) 2.5 (5.5)
Hydraulic motor assy weight kg (lbs) 75 (165)
Part No. LC32W00011F1
Speed reduction type Planetary 2-stage
Reduction ratio 27.143
Lubicate oil Gear oil SAE90 (API class GL-4 grade)
Reduction unit
Lubicate oil volume L (gal) 7.4 (1.96)
Grease Extreme pressure lithium base #2 grease
Grease volume kg (lbs) Approx. 1.7 (3.7)
Weight kg (lbs) 371 (818)
Total weight kg (lbs) 446 (983)

24

24-67
24. COMPONENTS SYSTEM

24.1.5.2 CONSTRUCTION
(1) Swing motor

702 712

351

ARRANGEMENT OF BRAKE SPRING

355

401

488 469
051-1 051

100
151
162 052 161 171 163

303 A A 984
985 391 390 444
131
451
472 400-1
400-2
712 400 052

702 707
SECTION A-A
706

986

742

743
994

111

491 101
121 123 122 124 114 301 443

24-68
 24. COMPONENTS SYSTEM

Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
177 (130) 051 Relief valve; M33-P1.5 2 69 (51) 400 Anti-reaction valve; M22- 2
P1.5
051-1 O-ring; 1B G30 2 400-1 O-ring; 1B P20 2
052 Anti-reaction valve sub 1 400-2 Backup ring 2
100 Casing for anti-reaction 1 431 (318) 401 Socket bolt; M20X45 4
valve
101 Drive shaft 1 443 Roller bearing 1
111 Cylinder 1 444 Roller bearing 1
114 Spring plate 1 451 Pin 2
121 Piston 9 539 (398) 469 ROMH plug; M36-P1.5 2
122 Shoe 9 472 O-ring; W1516,WG44 1
123 Set plate 1 488 O-ring; 1B P34 2
124 Shoe plate 1 491 Oil seal 1
131 Valve plate 1 702 Brake piston 1
36 (27) 151 Plug; PF1/4 2 706 O-ring; W1516,WG42 1
161 O-ring; 1B P11 2 707 O-ring; W1516,WG45 1
162 O-ring; 1B P12 2 712 Brake spring 14
163 O-ring; 1B P6 2 742 Friction plate 3
29 (21) 171 Socket bolt; M8X55 4 743 Separator plate 4
301 Casing 1 2.7 (2.0) 984 Plug; PF1/2 1
303 Valve casing 1 5.6 (4.1) 985 Plug; PF1 1
351 Plunger 2 0.9 (0.66) 986 Plug; PF1/4 1
355 Spring 2 98 (72) 994 Plug; PT3/4 1
390 Name plate 1
391 Rivet 2

24

24-69
24. COMPONENTS SYSTEM

(2) Swing reduction unit

20

22 11 27 25 24 3
4
5 SURFACE
OF LUBE OIL
10 3 34

23 6
7 8 3 VIEW
11 15
26 12
9 17 30 35, 36, 37, 38
14 31
3
28
29 18

33 32
13
21 19 16
2
1
DETAIL aa

aa

Tightening torque Tightening torque

No. Parts Q'TY No. Parts Q'TY
N-m (lbf-ft) N-m (lbf-ft)
1 Pinion 1 20 Plate 1
2 Shaft 1 21 Ring 1
3 #1 Sungear 1 22 Thrust washer 6
4 #1 Planetary pinion 3 23 Thrust washer 8
5 #1 Spider assy 1 24 Snapring 1
6 #2 Sungear 1 25 Snapring 3
7 #2 Planetary pinion 4 26 Spring pin 4
8 Ring gear 1 539±54 (398±40)*1 27 Capscrew ; M20X200 12
9 #2 Spider assy 1 28 Grease fitting 1
10 Shaft 4 29 Relief fitting 1
11 Needle bearing 11 69.1±4.4 (51±3)*2 30 Tube 1
12 Roller bearing 1 69.1±4.4 (51±3)*2 31 Elbow 1
13 Roller bearing 1 69.1±4.4 (51±3)*2 32 Plug 1
14 Oil seal 1 33 Cap 2
15 Housing 1 279±30 (206±22)*1 34 Capscrew 3
16 Oil seal 1 35 Shim ; t=0.1 1
17 Sleeve 1 36 Shim ; t=0.2 1
18 Sleeve 1 37 Shim ; t=0.3 1
19 Plate 1 38 Shim ; t=0.5 1

*1 : Apply Three Bond #1360K.

*2 : Apply seal tape or Loctite #577.
*3 : Apply Loctite #515.

24-70
 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 on the
figure on the right, 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
produce a rotating moment.
The cylinder block (111) has nine pistons equally
arranged. Rotating torque is transmitted to 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

24

24-71
24. COMPONENTS SYSTEM

24.1.5.3.2 VALVE CASING SECTION

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

Operation Of Anti-Cavitation Check Plunger

(2) Operation of relief valve

1. Consider where the relief valve is pressurized.
The pressure at the P, R ports is equal to the tank pressure at the beginning, as shown in below Fig..
The relief valve begins to operates when the hydraulic pressure that is determined by the product of the
pressure-receiving area A1 of plunger(301) and the pressure P balances the hydraulic pressure that is
determined by the product of the pressure-receiving area A2 of the plunger(301) and the pressure Pg of
chamber g.
Thereafter, the pressure of chamber g rises and the piston 1 (302) begins to stroke. The load to spring (321)
increases by this movement of the piston.
As the result, the relief pressure P is raised and controlled in the pressure boost time t1 from P1 till Ps.
This process is explained in the following in the relationships between the movements of the components
shown in (2) to (4) of below Fig. and the relief pressure :

Functional Explanation Of Relief Valve (1) Functional Explanation Of Relief Valve (2)

a. Condition shown in above Fig..

If the P port of the relief valve is pressurized, pressure is built up in chamber g via the restrictor m of plunger
(301).
The hydraulic pressure acting on plunger (301) increases and when it balances the load Fsp of spring (321), the
relief valve performs relieving action by the pressure P1.
This relationship is expressed as :
P1XA1=FSP1+Pg1XA2
where FSP1 :
primary set load value of spring (321)

24-72
 24. COMPONENTS SYSTEM

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.

P P

R R

Functional Explanation Of Relief Valve (3) Functional Explanation Of Relief Valve (4)

c. Condition shown in above Fig..

The machine does not travel to the left further when piston 1 (302) arrives at the end of adjust plug (401).
Therefore, the relief valve keeps its normal relieving action whereby the relief pressure is held at P2. In the
processes 1 to 3 above, the relief pressure changes as shown in above Fig..

(4)
PS
(3)

P1 (2)
(1)
t1

Condition
2. Function when the relief valve pressure is reduced
Let us consider the pressure of the P port is reduced.
When the pressure at port P is reduced to zero, the pressure of chamber g falls to the tank pressure level. The
result is that the plunger (301) which is now open moves to the left and is seated on seat (341). At the same
time, the piston 1 (302) moves to the right by the action of spring (321) and returns to the condition of above
Fig..

24

24-73
24. COMPONENTS SYSTEM

(3) Operation of anti-reaction valve

Hydraulic Circuit Diagram For Anti-reaction Valve

1. Neutral condition:
Above Fig. illustrates the relationship between the
neutral condition of the anti-reaction valve and the
hydraulic circuits. Now, let us consider a braking
condition in which brake pressure generates on the L
AM port side.

k
322 313 321 311
Neutral Condition

2. When brake pressure occurs:

If pressure (P) generates at the AM port, it passes m n
through the passage L, the hole on the shaft of seat
(313) and the passage m of plunger (311) and is led
P=PS
to the n chamber.
When the pressure P rises above a value (Ps) set L
by spring (321), plunger (311) compresses spring
(321) and shifts it to the left.
Seat (313) compresses weak spring (322) as 322 313 321 311
pushed by plunger (311) and moves to the left. When Brake Pressure Occurs

24-74
 24. COMPONENTS SYSTEM

3. At anti-reaction action
When inertia load stops moving (point Y below Fig.), brake pressure (P) tries to fall.
When P<Ps, plunger (311) moves toward the right return side by the action of spring (321). Seat (313) tries to
move to the right by the action of spring (322), but since chamber p provides damping action by orifice g, the
return of the seat makes a time delay with regard to the return of the plunger.
Consequently, seat t opens. This makes a passage connecting the AM port and BM ports or both ports of the
hydraulic motor by way of L--> t--> r--> k. The result is that the pressures at the AM and BM ports become equal
(Pb), falling into the condition at point Z in below Fig..
This prevents the hydraulic motor from swing shock by the closing pressure of the AM port.

p t P Y
PS
P<PS
PB
L X
Z
k T
Pressure Change Diagram Of Anti-reaction
322 313 g r 321 311
Operation
At anti-reaction action

24.1.5.3.3 OPERATION OF BRAKE SECTION

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

24

24-75
24. COMPONENTS SYSTEM

24.1.5.3.4 SWING REDUCTION UNIT

The swing reduction unit is used to reduce the rotating
speed which is transmitted by the hydraulic motor and
to convert it to the strong turning force (torque).
This swing speed reduction unit is equipped with
planetary speed reducing mechanism.
The planetary mechanism is made up of sun gear,
planetary pinion, planetary shaft, spider and ring gear,
as shown in right Fig..

Planetary Mechanism

For the operation of the 1st stage planetary, the

hydraulic motor rotates #1 sun gear (3). Sun gear (3) is Swing motor
engaged with planetary pinion (4) and rotates, but
since ring gear (8) is fixed, planetary pinion (4) 4 3
revolves about sun gear (3) with the planetary shaft 8
and spider (5).
5
The role of spider is to hold the planetary pinion and 6
planetary shaft and transmits the power from the
planetary pinion to the spider through the planetary 9
shaft.
The #1 spider (5) is linked with #2 sun gear (6) by the Housing
involute spline, and transmits the power to the 2nd
7
stage planetary mechanism. Bearing
For the operation of the 2nd stage planetary, the power
is transmitted to #2 sun gear (6)→#2 planetary pinion 2
(7)→ #2 spider (9) similarly to the 1st stage. The #2
spider (9) is linked with pinion shaft (2) by the involute
spline, and pinion (1) is engaged with the swing gear
fixed on the undercarriage (lower frame) and rotates. Bearing 1

Function Of Reduction Unit

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 24. COMPONENTS SYSTEM

24.1.6 TRAVEL MOTOR

24.1.6.1 SPECIFICATION
(1) Appearance
PRESSURE MEASUREMENT PORT
2-G (PF)1/4
(MB,MA)

PILOT PORT
G(PF) 1/4 (P)

BEARING CENTER

VALVE PORT
2-G (PF) 1
(VA,VB)
DRAIN PORT
2-G (PF)1/2
18-M24 (D1,D2)

G (PF) 3/4
FILL PORT
LEVEL PORT OIL LEVEL

G (PF) 3/4
DRAIN PORT VIEW Y
Travel Motor
Rotation direction

Rotation direction
Oil inlet port Oil outlet port
(Viewed from valve port side)
VA VB Right (Clockwise)
VB VA Left (counter clockwise)
24
Tightening torque
Port name Port size Function
N-m (lbf-ft)
P PF1/4 36 (26.6) Pilot (2 speed changeover) port
D1, D2 PF1/2 98.1 (72.4) Drain port
VA, VB PF1 255 (188) Motor drive port
MA, MB PF1/4 29.4 (21.7) Pressure measurement

24-77
24. COMPONENTS SYSTEM

(2) SPECIFICATIONS

Part No. LC15V00031F1

TRAVEL MOTOR UNIT
Type M4V290 / 170F-RG6.5G
Part No. —
Type —
Reduction ratio 40.467
Reduction unit Number of reduction stages 2
Lube oil capacity L (gal) 9.5 (2.5)
Lube oil capacity specification Gear oil SAE90API GL4 or GL5
Weight kg (lbs) —
Part No. LC15V00032F1
Type M4V290 / 170F
cc/rev
Max. displacement 290.7 (17.7)
(cu•in/rev)
cc/rev
Min. displacement 170.1 (10.4)
(cu•in/rev)
Relief valve set pressure MPa (psi) 35.0 (5075)
Travel motor
2 peed changeover pilot
MPa (psi) 5.0 (725)
pressure
Parking brake torque N•m (lbf•ft) 902 or more (665)
Parking brake release pressure MPa (psi) Less than 1.54 (223)
Working 0.2 (29)
Allowable drain pressure MPa (psi)
Surge 0.98 (142)
Weight kg (lb) —
Unit weight (with oil) kg (lb) 399 (880)

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 24. COMPONENTS SYSTEM

24.1.6.2 CONSTRUCTION

24.1.6.2.1TRAVEL MOTOR

Travel Motor

No. NAME No. NAME No. NAME

1 Casing 21 Brake piston 41 Restrictor spring(brake valve)
2 NPT 1/16 plug 22 D-ring (small dia.) 42 G1/8 plug
3 Oil seal 23 D-ring (big dia.) 43 O-ring 1B P8
4 Retaining ring IRTW68 24 Rear cover 44 Check valve

Expander plug 25 NPT 1/16 plug (MEC) 45 Check valve spring

5
MB800-040 26 Spool assy (M4V RBV) 46 M6 restrictor (0.6)
6 Shifter piston 27 Spring holder (M4V RBV) 47 O-ring 1B P12.5
7 Piston seal 28 Spring (M4V150RBV) 48 M6 restrictor (0.8)
8 Steel ball 25 29 M42 plug (M4V RBV) 49 O-ring 1B P15
9 Shaft 30 O-ring 1B G40 50 O-ring 215.57X2.62
10 Bearing HR33209J Pilot valve spool 51 Bearing HR32207C
31
11 Pivot 10dia.(M4V290) 52 Shim
12 Swash plate 32 Pin (MRC03) 53 Parallel pin M68X12
13 Cylinder block 33 Spring holder (MRC03) 54 Valve plate
14 Cylinder spring 34 Spring (MRC03) 55 Brake spring 24
15 Spring holder 35 G3/8 pilot valve plug 56 HEX. socket head bolt M18X50
16 Ball joint 36 O-ring 1B P14 57 Overload relief valve ORV-240L
17 Shoe retainer 37 Connector (MRC03) 58 Coupling
18 Piston assy 38 G1/4 plug 59 Retaining ring C-type 40
19 Separating plate 39 O-ring 1B P11 60 G1/2 plug
20 Friction plate 40 Restrictor (brake valve) 61 O-ring 1B P18

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24. COMPONENTS SYSTEM

24.1.6.2.2 REDUCTION UNIT

Reduction Unit

No. NAME No. NAME No. NAME

1 Housing 10 Thrust washer 2 19 Carrier pin 1
2 Bearing 245BA35S1GS 11 Needle bearing FBNP-608660 20 Spring pin 6X36
3 Ring gear 12 Carrier pin 2 21 Sun gear 1
4 HEX.socket head bolt M18X110 13 Spring pin 10X50 22 Thrust plate
5 Floating seal 368 14 Sun gear 2 23 Cover
6 Shim 15 Carrier 1 24 HEX.socket head bolt M10X30
7 Lock washer 16 Planetary gear 1 25 Plug G3/4
8 Carrier 2 17 Thrust washer 1 26 O-ring 1B P24
9 Planetary gear 2 18 Needle bearing FBNP-406040

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 24. COMPONENTS SYSTEM

24.1.6.3 MAKEUP OF TRAVEL MOTOR

The travel motor consists mainly of the rotary group that generates rotating power, the parking brake that prevents
the machine from moving by itself while it is parked, the variable displacement mechanism that switches over the
motor capacity to the large or small mode, the overload relief valve that is built in the rear cover, and the brake
valve (counterbalance valve) that controls the hydraulic circuits.

(1) Rotary group

Cylinder block (13) is inserted in the gear tooth grooves of the spline of shaft (9) that is supported by bearings
(10, 51) at it both ends. The cylinder block (13) is pressed against rear cover (24) with valve plate (54) by the
action of spring (14).
9 piston assy (18) slide over shoe plate (12), while stroking in cylinder block (13).
A bearing retainer is arranged at the end face of piston assy (18) to reduce the sliding resistance. The action of
spring (14) is transmitted to spring retainer (15), ball joint (16), and shoe retainer (17) and presses the end face
of piston assy (18) against shoe plate (12) so the piston assy moves close to the surface of shoe plate (12).
(2) Parking brake
Seven separator plates (19) and six friction plates (20) are inserted by turns in the spline grooves in the outer
surface of cylinder block (13) and are pressed against casing (1) by the action of 14 springs (55) via brake
piston (21).
(3) Variable displacement mechanism
The variable displacement mechanism consists of pivot (11) supporting shoe plate (12) that is put in two
semispherical concaves provided in shoe plate tilting piston (6) that tilts shoe plate on pivot (11) tilting stopper
(H) supporting the piston at a certain position; the pilot valve that admits the pressurised oil to the tilting piston
(6) by an external command; and three check valves (44) that take out the highest of the external command
activated pilot pressure, the motor inlet pressure and the motor outlet pressure and that sends it to the pilot
valve.
(4) Overload relief valve
The overload relief valve consists of socket (57-1) that has valve seat (57-3) metallically seating rear cover (24)
of the motor and screwed up in rear cover (24) valve (57-2) engaged with socket (57-1) that is tangential in
contact with valve seat (57-3) by the action of adjust spring (57-9) connecting piston (57-4) that is inserted in
valve (57-2) and serves also as an oil path to pilot body (57-6) piston (57-7) that is put in pilot body (57-6) and
pressed against plug (57-5) and shim (57-8).

No. NAME No. NAME

57-2 57-9 57-13 57-8 57-10 57-6 57-7 57-1 SOCKET 57-8 SHIM
57-3 57-1 57-12 57-4 57-12 57-11 57-5 57-2 VALVE 57-9 SPRING
57-3 VALVE SEAT 57-10 O RING 1B P7
57-4 CONNECTING PISTON 57-11 BACKUP RING
57-5 CAP 57-12 O RING 1B G25
57-6 PILOT BODY 57-13 BACKUP RING
57-7 PISTON
Construction Of Overload Relief Valve

24

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24. COMPONENTS SYSTEM

(5) Brake valve portion

1. Spool
By shifting the spool (26), the discharged oil from hydraulic motor is automatically shut off or restricted
according to the condition and give the effect of holding, accelerating, stopping and counterbalance operations.
2. Check valve (built in the spool)
This valve is located in the oil supplying passage to hydraulic motor, and at the same time functions to lock oil
displacement. Therefore, this valve serves as not only a suction valve but also a holding valve for hydraulic
motor.

Brake Valve Portion

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 24. COMPONENTS SYSTEM

24.1.6.4 FUNCTION OF TRAVEL MOTOR

(1) Motor
High pressure oil delivered from hydraulic pump is led to inlet port that is provided in the brake valve portion
and, through the rear cover (24) and valve plate (54), led to cylinder block (13).
As shown in below Fig. (a), high pressure oil is supplied to the pistons which are on one side of the line Y-Y that
connects upper and lower dead points and produces force F1.
F1=PXA (P : pressure, A : area of piston section)
The swash plate (12) with inclined angle of divides this force F1 into thrust force F2 and radial force F31-F34
(or F35). [below Fig. (b)] This radial force is applied to axis Y-Y as turning force and generate drive torque of T.
T=r1•F31+r2•F32+r3•F33+r4•F34
(In case high pressure oil is applied to five pieces of pistons, r5 F35 should be added.)
This drive torque is transmitted via cylinder block (13) to driving shaft (9).

(a) (b)

(2) Parking Brake

Parking brake is released when high pressure oil, selected by the brake valve portion that is connected directly
to the rear cover (24), is applied to the brake piston (21). Otherwise the braking torque is always applied.
This braking torque is generated by the friction between the separating plates (19), inserted into the casing (1),
and friction plates (20), coupled to cylinder block (13) by the outer splines.
When no pressure is activated on the brake piston (21), it is pushed by the brake springs (55) and it pushes
friction plates (20) and separating plates (19) towards casing (1) and generates the friction force which brakes
the rotation of cylinder block (13) and hence the shaft (9).

24

Parking Brake Portion

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24. COMPONENTS SYSTEM

(3) Capacity Control Mechanism

Below Fig. typically shows the capacity control mechanism.
When high speed pilot line is charged with the pressure PA that overcome the spring (34), the spring (34) is
compressed and spool (31) shifts to the right to connect the port P and port C.
Then, the highest pressure is selected by the check valve (44) from inlet and outlet pressure of the motor and
high speed pilot line pressure and pushes shifter piston (6). As a result, swash plate (12) turns around the line L
which connect the two pivots (11) as shown by dotted lines. The turn stops at the stopper (1-1) of casing and
swash plate (12) keeps the position.
In this case, the piston stroke become shorter and motor capacity become smaller and motor rotates faster,
around 1.71 times, by the same volume of oil.
When no pressure is in the high speed pilot line PA, spool (31) is pushed back by the spring (34) and pressure
that pressed the shifter piston (6) is released to the hydraulic tank through restrictor (46).
Here, nine pistons are there and they equally spaced on the swash plate (12). The force that summed up those
of pistons comes to almost the center of the swash plate (12) as shown. Since the pivots (11) are off-set by S
from the center, the rotating force of product S and the force moves swash plate (12) to the former position and
the speed returns to low.
When the power demand exceeds the engine power, such as in steep slope climbing or turning at high speed
mode, the system step down to the low speed automatically. The mechanism is that: pump pressure is led to the
port PB (below Fig.) and this pressure activate on pin (32). When the pressure at PB exceeds predetermined
value, spool (31) returns to the left by the counter-pressure against pin (32) and the pressure on the shifter
piston (6) through port C is released to the tank and the motor comes to low speed.
When PB goes down, the spool (31) moves to the right and the speed become high.

TO COUNTERBALANCE VALVE
(BRAKE VALVE)

HIGH SPEED PILOT LINE

(EXTERNAL PILOT)

LOAD
APPLICATION POINT

Capacity Control Mechanism

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 24. COMPONENTS SYSTEM

(4) Function of overload relief valve

Two pieces of overload valves are located at cross-over position in the counterbalance circuit of brake valve and
have the following functions:

1. When hydraulic motor starts, keep the driving pressure below predetermined value and while accelerating,
bypasses surplus oil to return line.
2. When stopping the motor, keep the brake pressure, that develops on the outlet side of motor, under the
predetermined value to stop the inertial force.
3. To accelerate sharply while starting, and to mitigate the braking shock while stopping. For these purposes, the
developed pressure is kept comparatively low for a short period, then keep the line pressure as normal value.
While the pressure is low, meshing of reduction gears, crawler and sprocket etc. can be smoothly done and the
shock are absorbed.

When starting, "A" port pressure of overload valve increases, this pressure is applied to the effective diameter of
valve (57-2) which seats on the valve seat (57-3) and, at the same time, is delivered, via small hole, to the
connecting piston (57-4) located inside the valve (57-2) and the piston bore pressure increases up to "A" port
pressure. The valve (57-2) opposes to adjusting spring (57-9) by the force of the pressure exerted on the area
difference between valve seat's effective diameter and piston bore and keep the predetermined pressure.
When hydraulically braking, the piston (57-7) is at the left position by the driving pressure, and when "A" port
pressure increases, the pressure is applied also to the piston (57-7) through the small hole in the valve (57-2)
and piston (57-7) moves rightward until it touches the cap (57-5). In this while, the valve (57-2) maintains "A"
port pressure at comparatively low against the adjusting spring (57-9) force and exhaust oil to "B" port side.
After the piston reached to the plug, the valve acts the same as at starting.

Function Of Overload Relief Valve

24

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24. COMPONENTS SYSTEM

(4) Function of brake valve

1. Holding operation (see below Figure)

When the control valve is at neutral position, VA and VB ports are connected to the tank, and the spring (28)
located on both spool ends holds the spool (26) at central position. Therefore, the passages from VA to MA and
VB to MB are closed, which result in closing MA and MB ports connected to hydraulic motor.
Since the passage to parking brake is connected to the tank line, the brake cylinder pressure is equal to the tank
pressure and the brake is applied by the springs. Thus, the rotation of the motor is mechanically prevented. If
external torque is exerted on the motor shaft, the motor would not rotate as usual by this parking brake.
In case the brake should be released for some reason, pressure is built on MA or MB port. But, due to oil
leakage inside hydraulic motor or so, high-pressure oil escapes from the closed circuit and motor rotates a bit.
So, the cavitation tends to occur in the lower pressure side of the closed circuit. Then, the check valve, built in
the spool (26), operates to avoid the cavitation and opens the passage from VA to MA or from VB to MB. Then
the oil equivalent to the leakage is sucked from the tank line to the closed circuit.

SPRING SPRING

Holding Operation

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 24. COMPONENTS SYSTEM

2. Accelerating operation (see below Figure)

When VA and VB ports are connected respectively to pump and tank by operating the control valve, hydraulic oil
from pump is forwarded through VA port to push open the check valve provided inside spool (26), and oil flows
to motor via MA port to rotate the motor.
Therefore, the pressure increases and negative brake is released by the pressure supplied from pump. At the
same time, the pressure of pilot chamber increases to push and move the spool (26) leftwards, overcoming the
spring (28) force. Thus, the return line from MB to VB opens to rotate the motor.
In case inertia load is too big to start rotation, accelerating pressure reaches the set pressure of relief valve and
high pressure oil is being relieved while the motor gains the rotational speed. As the rotational speed goes up,
the relieved volume decreases, and finally the motor rotates at a fixed speed.

Accelerating Operation

24

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24. COMPONENTS SYSTEM

3. Stopping operation (see below Figure)

Returning the control valve to neutral position while running the motor, the oil supply is cut off and VA and VB
ports are connected to the tank line. Then the pressure of the pilot chamber located on both spool ends become
equal, and the spool (26) returns to the neutral position by spring (28) force. Thus, the passage from MA to VA
is closed.
Owing to the inertia force of the load, the hydraulic motor tends to continue the rotation. Here, the motor
functions as a pump and forwards the oil to MB port but the passage is blocked and MB port pressure
increases. Then the relief valve opens to relieve the pressure and rotational speed decelerates and at last the
motor stops.
Negative brake release pressure is gradually lowered due to the restrictor and finally the brake works and the
motor is mechanically stopped.

Stopping Operation

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 24. COMPONENTS SYSTEM

4. Counterbalance operation (see below Figure)

Counterbalance operation is required to decelerate slowly the hydraulic motor while absorbing inertia force.
In case the hydraulic oil is gradually decreased from pump to VB port, the drive shaft of hydraulic motor tends to
rotate faster than that matched to the volume of oil supply. Consequently, the pilot chamber pressure on MB to
VB side decreases and the spring (28) force moves the spool (26) leftwards towards neutral position.
Therefore, the area of passage from MA to VA becomes smaller and the pressure on MA side rises due to
increased resistance in the passage and the motor receives hydraulic braking effect.
If the motor rotates slower than that matched to the volume of supplied oil, the pilot chamber pressure on VB
port increases, and spool (26) moves rightwards to enlarge the area of passage from MA to VA. Therefore the
braking effect becomes smaller and the rotational speed of motor is controlled to correspond to the volume of
supplied oil. In order to give stable counterbalance operation, the restrictors (40) are set in the pilot chamber to
damp the spool (26) movement.
The parking brake is released during pressure adjusting action of the spool (26).

CHECK VALVE CHECK VALVE WITH RESTRICTOR

WITH RESTRICTOR

PILOT CHAMBER PILOT CHAMBER

SPRING
SPRING

Counterbalance Operation

24

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24. COMPONENTS SYSTEM

24.1.6.5 FUNCTION OF REDUCTION GEAR

Reduction unit slows down the rotating speed of motor
and converts motor torque to strong rotating force.
This reduction unit utilizes two stages, planetary
reduction system.
Planetary reduction system consists of sun gear,
planetary gears, (planetary) carriers, and ring gear.
When the sun gear (s) is driven through input shaft,
planetary pinions (b), rotating on their center, also
move, meshing with fixed ring gear (a), around sun
gear (s).
This movement is transferred to carrier (k) and deliver
the torque.
This mechanism is called planetary gear mechanism.

Planetary Gear Mechanism

See Fig. on the right.

When the sun gear S1 is driven by input shaft,
a
planetary action occurs among gears S1, a and b and
revolution of gear b transfers the rotation of carrier K1
to second sun gear S2, and also evokes planetary b d
action between gear S2, a and d.
This time, because carrier K2 is fixed to frame, gear d
drives ring gear a and then ring gear a rotates to drive S1 S2
sprocket.

K1 K2

Two Stages Reduction Gear

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 24. COMPONENTS SYSTEM

24.1.7 SWIVEL JOINT

24.1.7.1 GENERAL VIEW

General View Of Swivel Joint

24.1.7.2 SPECIFICATIONS

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

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24. COMPONENTS SYSTEM

24.1.7.3 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

24.1.7.4 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

24.1.8 CYLINDER

24.1.8.1 SPECIFICATIONS
(1) General View

B A
ngth ngth
e d le d le
nd cte
exte r e tra
ll y lly
Fu Fu

Part No. and Manufacturing No.

Stamp position

General View Of Cylinder

(2) Specifications

Center distance of
Stroke
Part No. of Cylinder bore/Rod Dia. pins Full extend B Dry weight
Use mm Cushion
cylinder assy mm (ft-in) / Full retract A kg (lbs)
(ft-in)
mm (ft-in)
140 dia./100 dia. 1,550 3,651 / 2,101 With cushion 269
Boom LC01V00044F1
(5.51"/3.94") (5'1") (11'12" / 6'11") on rod side (593)
With cushion
170 dia./120 dia. 1,788 4,281 / 2,493 504
Arm LC01V00054F1 on both
(6.69"/4.72") (5'10") (14'1" / 8'2") (1,111)
sides
150 dia./100 dia. 1,193 3,005 / 1,812 With cushion 265
Bucket LC01V00055F1
(5.91"/3.94") (3'11") (9'10" / 5'11") on rod side (584)

24

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24. COMPONENTS SYSTEM

24.1.8.2 CONSTRUCTION AND FUNCTION

24.1.8.2.1 Construction
(1) Boom cylinder

T= Tightening torque ; N.m (lbf.ft)

25 24 12 T=367 (271) 22 23

B
-0.5

-0.5
130 0

130 0
With hole
DETAIL B (1 place) DETAIL C
T=8000 (5900)
T=56.9 (42.0)

9 8 7 6 3 4 5 11 10 2 1 13 14 16 17 18 19 15 20 21

Slit
Orientation of cut off part
of cushion bearing (13)

Construction Of Boom Cylinder

P/No: LC01V00044F1

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

1 Cylinder tube 1 10 O-ring 1 19 Slide ring 2
2 Piston rod 1 11 Backup ring 1 20 Set screw; M14 1
3 Rod cover 1 12 Socket bolt; M18X80 12 21 Steel ball 1
4 Bushing 1 13 Cushion bearing 1 22 Pin bushing 1
5 Snap ring 1 14 Cushion seal 1 23 Wiper ring 2
6 Buffer ring 1 15 Piston 1 24 Pin bushing 1
7 U-ring 1 16 Seal ring 1 25 Wiper ring 2
8 Backup ring 1 17 Backup ring 2
9 Wiper ring 1 18 Slide ring 2

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 24. COMPONENTS SYSTEM

(2) Arm cylinder

T= Tightening torque ; N.m (lbf.ft)

T=711 (524)
29 28 12 28 29

B
-0.5

-0.5
140 0

140 0
Stake 2 places after tightening
DETAIL B T=96.6(71)

T=17000(12540)

9 7,8 6 4 5 3 12 10,11 22
2 1 13 15 16 19 21 23 27 25 24
14 17 18 20 26

With hole
(1 place)

Orientation of
cut off part of
cushion
bearing (13)
SLIT SLIT
Construction Of Arm Cylinder
P/No: LC01V00054F1

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

1 Cylinder tube 1 11 Backup ring 1 21 Piston nut 1
2 Piston rod 1 12 Socket bolt; M22X95 12 22 Set screw; M16 1
3 Rod cover 1 13 Cushion bearing 1 23 Steel ball 1
4 Bushing 1 14 Cushion seal 1 24 Cushion bearing 1
5 Snap ring 1 15 Piston 1 25 Cushion seal 1
6 Buffer ring 1 16 Seal ring 1 26 Stopper 2
7 U-ring 1 17 Backup ring 2 27 Snap ring 1
8 Backup ring 1 18 Slide ring 2 28 Pin bushing 2
9 Wiper ring 1 19 Slide ring 2 29 Wiper ring 4
10 O-ring 1 20 Shim 1

24

24-95
24. COMPONENTS SYSTEM

(3) Bucket cylinder

T= Tightening torque ; N.m (lbf.ft)

24 23 12 T=520 (384) 23 24

B
-0.5

-0.5
130 0

130 0
Stake 2 places after tightening
DETAIL B
T=56.9(42)

T=10000(7376)

21
9 8 7 6 3 4 5 12 11,10 2 1 13 14 15 16 17 18 19 20 22

With hole
(1 place)

Orientation of cut off part

of cushion bearing (13)

Construction Of Bucket Cylinder

P/No: LC01V00055F1

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

1 Cylinder tube 1 9 Wiper ring 1 17 Slide ring 2
2 Piston rod 1 10 O-ring 1 18 Slide ring 2
3 Rod cover 1 11 Backup ring 1 19 Shim 1
4 Bushing 1 12 Socket bolt; M20X95 12 20 Piston nut 1
5 Snap ring 1 13 Cushion bearing 1 21 Set screw; M14 1
6 Buffer ring 1 14 Piston 1 22 Steel ball 1
7 U-ring 1 15 Seal ring 1 23 Pin bushing 4
8 Backup ring 1 16 Backup ring 2 24 Wiper ring 4

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 24. COMPONENTS SYSTEM

HYDRAULIC CYLINDER CONSTRUCTION (See structure Fig.)

By construction the hydraulic cylinder consists mainly of cylinder tube assy (1), piston rod assy (2) that takes out
the motion of pistons reciprocating in the cylinder tube assy, and cylinder head (3) that serves as both a lid and a
guide. Cylinder tube assy (1) is equipped with a pin mount (clevis) that connects piston rod assy (2) with other
parts. In addition to these main components, seal ring (16) and back-up ring (17) are located between cylinder tube
assy (1) and piston rod assy (2); buffer ring (6), U-ring (7) back-up ring (8) and wiper ring (9) are located between
piston rod assy (2) and cylinder head (3); and an O-ring (10) and a back-up ring (11) are placed between cylinder
tube assy (1) and cylinder head (3)

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 Cushion bearing (13) Chamber "A" Passege "B"
which in turn causes the piston rod (2) to extend and Tank
retract. Piston (15)
Rod (2)

Rod side
Head side

Rod cover (3)

Cushion stroke

Cushion Mechanism On The Rod Side

(1) Operation of cylinder with cushion

1. Cushion on rod side
The cushion mechanism is provided to prevent the Tank
Clearance "D"
generation of shock when the moving speed of
piston (15) is not reduced and strikes cylinder head
(3). An oil in chamber "A" returns to the tank by
passing through passage "B" at a fixed flow rate in Mouth Gap C
a intermediate stroke state (Right Fig.) of pressing
head side. Next, in a state of just before stroke end
(Right Fig.), cushion ring (13) plunges into passage
"B". At this time, an oil in chamber "A" passes
clearance "D" and mouth gap "C", an oil flow Cushioning Action On The Rod Side
volume returning to tank suddenly drops and the
piston part movement slows down.

2. Cushion on head side (See right Fig.)

This construction is similar to the one of cushion on Camber "A"
rod side. In a state of intermediate stroke pressing Cushion seal (25)
rod side, an oil in chamber "A" returns to tank by Passage "B" Tank Cushion bearing (24)
passing through passage "B" at a fixed flow rate.
Next, in a state of just before stroke end, cushion
bearing (24) plunges into passage "B". At this time,
the oil in chamber "A" flows only through clearance
"D" and mouth gap "C" of cushion seal (25). So the
returning oil volume drops suddenly and the piston
movement slows down. Clearance "D"
24
Mouth gap C

Cushion seal (25)

Cushion Mechanism On The Head Side

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24. COMPONENTS SYSTEM

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 24. COMPONENTS SYSTEM

24.2 ELECTRICAL EQUIPMENT

24.2.1 ELECTRICAL EQUIPMENT LIST

Group Code Part Name Part No.

C-1 Mechatro controller YN22E00425F1
C-2 Gauge cluster YN59S00028F1
(C) Controller C-4 Air conditioner AMP. (including panel) LQ20M01328P1
C-5 Engine coolant level controller VHS834701230
C-8 Engine controller VH89661E0062
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 - 15 Diode ↑
D - 16 Diode ↑
(D) Diode
D - 17 Diode ↑
D - 18 Diode YN02D01001P1
D - 19 Diode ↑
D - 20 Diode Accessory of relay box
D - 21 Diode ↑
D - 22 Diode ↑
D - 23 Diode ↑
D - 25 Diode YN02D01001P1
D - 66 Diode ↑
D - 67 Diode ↑
E-1 Fuse and Relay box YN24E00016F2
E-2 Alternator VH27060E0040
E-3 Hour meter LQ58S00002P1
E-5 Horn high LC53S00001D1
E-6 Horn low LC53S00001D2
E-8 Speaker left YT54S00006P1
(E) Electric fittings 24
E-9 Speaker right ↑
E - 10 Receiver dryer YN54S00041P1
E - 11 Air-con compressor YX91V00001F1
E - 12 Battery 2411U22
E - 22 DC-DC Converter YN77S00017P1
E - 23 12V Socket YN81S01002P1

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24. COMPONENTS SYSTEM

Group Code Part Name Part No.

E - 27 Accel redundant volume YN52S00052P1
E - 46 Rear camera EZ55S00023F1
(E) Electric fittings E - 49 DC-DC Converter (proportional) YN77S00017P1
E - 63 DC-DC Converter (for camera) YN77S00040P1
E - 65 24V Socket LQ81S01001P1
L-1 Boom work light (LH) YW80S00001F1
L-2 Frame work light (RH) YT80S00002F2
L-3 Swing flasher left YM80S00001F1
(L)Light L-4 Swing flasher right YM80S00001F2
L-5 Room light YT80S00001P1
L-7 Cab working light front 1 YT80S00002F2
L-8 Cab working light front 2 ↑
M-1 Starter motor VH28100E0080
(M) Motor M-3 Wiper motor LQ53C00003S001
M-4 Washer motor YT54C00003F1
PSV - A Arm 2 speed inverse propo. valve YN35V00049F1
PSV - B P2 unload propo. valve (YN35V00047F2) YN35V00048F1
PSV - C Travel straight propo. valve Solenoid valve assy ↑
(P) Proportional
PSV - D P1 unload propo. valve ↑
solenoid valve
PSV - R Controll propo. YN35V00052F1
PSV - P1 P1 pump propo. valve (LC10V00030F2) ↑
PSV - P2 P2 pump propo. valve Pump ↑
R-1 Battery relay YN24S00008F1
R-2 Starter relay VH283001271
R-3 Glow relay VHS286201420
R-4 Safety relay YN24S00010P1
R-5 Horn relay ↑
R-6 Working light relay ↑
R-9 Cab working light relay 1 YN24S00010P1
R - 11 Cab working light relay 2 ↑
R - 23 Auto idle stop relay 1 YN24S00010P1
(R) Relay
R - 24 Auto idle stop relay 2 ↑
R - 25 Engine emergency stop relay ↑
R - 26 Lever lock relay ↑
R - 28 Alternator relay ↑
R - 29 Wiper motor relay (Normal rotation) YN24S00012P2
R - 30 Wiper motor relay (Reverse rotation) ↑
R - 31 Wiper motor relay (Arc prevention) ↑
R - 32 Washer motor relay ↑
R - 94 Neutral stop relay YN24S00010P1

24-100
 24. COMPONENTS SYSTEM

Group Code Part Name Part No.

SE - 1 Pressure sensor : Bucket digging LC52S00019P1
SE - 2 Pressure sensor : Bucket dump ↑
SE - 3 Pressure sensor : Boom up ↑
SE - 4 Pressure sensor : Boom down ↑
SE - 5 Pressure sensor : Swing ↑
SE - 7 Pressure sensor : Arm in ↑
SE - 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 VH894101590
SE - 15 Fuel sensor YN52S00045F1
SE - 16 Accel potentiometer YN52S00032P1
SE - 20 Pressure sensor : P1 OPT. LC52S00019P1
SE - 22 Pressure sensor : Pump P1 YN52S00048P1
SE - 23 Pressure sensor : Pump P2 ↑
SV - 1 Swing parking brake SOL. YN35V00051F1
SV - 2 Power boost SOL (YN35V00047F2) YN35V00050F1
(SV) Solenoid
SV - 3 Two speed select SOL Solenoid valve assy ↑
SV - 4 Safety lock lever SOL ↑
SW - 1 Key switch YN50S00029F1
SW - 4 Swing parking brake release switch YN50S00047P1
SW - 5 Horn switch (RH) YN50E00017P1
SW - 7 E/G oil pressure switch VH83530E0220
SW - 8 Air filter clogging switch YR11P00008S005
SW - 10 Horn switch (LH) YN50E00017P1
SW - 11 Safety lock lever switch YN50S00055F1
SW - 17 Skylight wiper switch YN50S00040D9
(SW) Switch
SW - 19 Wiper interlock switch YT50S00004P1
SW - 20 Power boost switch (RH) YN50E00017P1
SW - 21 Power boost switch (LH) ↑
SW - 26 Cab work light switch YN50S00004D4
SW - 27 Coolant level switch VHS834601510
SW - 37 Independent travel switch YN50S00040DB 24
SW - 55 Boom work light switch YN50S00040D1
SW - 56 Fuel supply auto stop switch YF52S00004P1

- The part number may be changed owing to modification, use them only for reference.

24-101
24. COMPONENTS SYSTEM

24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT

Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine

C-1 Maker Sinko Electric Co. Ltd

Rated voltage DC24V
Controller
Weight 4.0 kg (8.8 lbs)

YN22E00425F1

Mechatro controller

YC

C-2 Maker Nippon seiki Co., Ltd

Rated voltage DC24V
Controller
Insulation More than 3M at 500V megger

YN59S00028F1

Gauge cluster

YC

C-4 Maker Sanden Corp.

Maker's P/No. TKS-CP21580
Controller
Controller and panel are all in one.
LQ20M01328P4

Air-con Controller

YC

24-102
 24. COMPONENTS SYSTEM

Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine

C-5

Controller

VHS834701230

Controller

YC

C-8

Controller

VH89661E0062

Engine controller

YC

24

24-103
24. COMPONENTS SYSTEM

Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine

D - 4, 25 Maker's part No. 7321-9822

Repetitive peak voltage 400V
Diode
Mean output current 3A
YN02D01001P1
Surge current 200A

Switch etc.

YN12 - 56001 ~
YQ12 - 08001 ~
LQ13 - 07001 ~
LL13 - 06001 ~
LC11 - 08501 ~
YC11 - 04501 ~
YC

E-1 Fuse capacity and circuit

Fuse & Relay box

YN24E00016F2

Fuse & Relay

YN12 - 56001 ~
YQ12 - 08001 ~
LQ13 - 07001 ~
LL13 - 06001 ~
LC11 - 08501 ~
YC11 - 04501 ~ Front side of machine
YC

E-2

Alternator

VH27060E0040

Generator

YC

24-104
 24. COMPONENTS SYSTEM

Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine

E-3 Movement Quarts

Operating voltage 9~64VC
Hour meter

LQ58S00002P1

Service meter

YC
TERMINALS TO ACCEPT TERMINAL
GM TERMINAL 2962447 TERMINAL
AND GM CONNECTOR
2962447 EQUIVALENT ENABLE TERMINAL

E - 5, 6 Type Bottom L : Low sound

H : High sound
Rated voltage DC24V STAMP
Horn
Operating voltage range DC20~30V
LC53S0001D1 (High) Sound level 113+5dB(A)/2m
LC53S0001D2 (Low) 420+20Hz high sound
Basic frequency 350+20Hz low sound
Warning sound
Insulation resistance More than 3M /DC500V
YN12 - 56001 ~
YQ12 - 08001 ~
LQ13 - 07001 ~ o 8.5
LL13 - 06001 ~
LC11 - 08501 ~
YC11 - 04501 ~
YC

E - 8, 9 Maker ESPERIA Co,.Ltd.

Model SX-M1024K
Speaker
Rated input 8W
Impedance 4
YT54S00006P1
Frequency 33.3Hz
Radio

YN12 - 56001 ~
YQ12 - 08001 ~
LQ13 - 07001 ~
LL13 - 06001 ~
LC11 - 08501 ~
YC11 - 04501 ~
YC

E - 10 Maker Sanden Corp.

Airtight test pressure 3.5MPa (508 psi)
Receiver dryer
Pressure proof test pressure 5.3MPa (769 psi)
Outlet (To unit)
24
Breaking test pressure 9.8MPa (1420 psi)
YN54S00041P1
Desiccant moisture 17% or over than the
weight of desiccant
adsorption capability (Include initial absorption 2%)
Air-con
Refrigerant HFC-134a
YN12 - 56001 ~ Inner volume/Desiccant 578cm3/300g
YQ12 - 08001 ~ Inlet (From condenser)
LQ13 - 07001 ~
LL13 - 06001 ~
LC11 - 08501 ~
YC11 - 04501 ~
YC

24-105
24. COMPONENTS SYSTEM

Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine

E - 11 Maker's part No. 7360-6000

Rated voltage DC24V
Air-con compressor
Max. revolution 4000rpm
V belt Type B
YX91V00001F1
Refregerant R-134a
Air-con Oil SP-20:135cc
Cover (Clutch)
YX03 - 01601 ~
YX04 - 01773 ~
YX05 - 02001 ~
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
YN12 - 56001 ~
YQ12 - 08001 ~
LQ13 - 07001 ~
LL13 - 06001 ~
LC11 - 08501 ~
YC11 - 04501 ~
YC

E - 12 Voltage 12V
Capacity (5HR) 130Ah
Battery
Weight (Incl. fluid) Approx. 46kg (101 lbs)

2411U22

Power

YC

24-106
 24. COMPONENTS SYSTEM

Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine

E - 22, 49 Effective input voltage

Exit voltage
DC-DC converter
Max. currentin exit

YN77S00017P1

DC24V DC12V
1 2 3
YC 6 5 4

DETAIL OF CONNECTOR
PINOUT OF THE CONVERTER.

E - 27 Resistance 2
Rated voltage DC 5V
Resistance 2 TOCOS
Parts E-27 RA30YME20FB202
Accel redundant volume

YN52S00052P1 After soldering,

insulate this part
with heat shrinkable tube
Accel redundant volume Clip

Adhesive
YN12 - 56001 ~
YQ12 - 08001 ~
LQ13 - 07001 ~ Fix this resistance with tape HOUSING : 172131-5
LL13 - 06001 ~ PVC tube (Black) TERMINAL : 170340-1
LC11 - 08501 ~ Dial
YC11 - 04501 ~ VIEW I
YC

E - 46 Maximum rating
power-supply voltage GND-0.5~ 17V
Rear camera

EZ55S00023F1

Rear camera

YC

24

24-107
24. COMPONENTS SYSTEM

Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine

E - 63 Use conditions
power-supply voltage 20~32V
DC-DC Converter
(for camera)

YN77S00040P1

DC24V DC8V

YC

BODY
PC-GF20

CONNECTOR
AMP 175783

L - 1, 6 Type BL84-130
Bulb DC24V, 70W
Light (Halogen)

YW80S00001F1 CA104
Boom work light
(LH, RH)
YN12 - 56001 ~
YQ12 - 08001 ~ M14 X 1.5
LQ13 - 07001 ~
LL13 - 06001 ~
LC11 - 08501 ~
YC11 - 04501 ~
YC

L-2 Type BL84-200

Bulb DC 24V,70W
Light (Halogen)
Effective area of lens 71cm2
YT80S00002F2

Frame work light

Boom work light (RH)
YN12 - 56001 ~
YQ12 - 08001 ~
LQ13 - 07001 ~
LL13 - 06001 ~
LC11 - 08501 ~
YC11 - 04501 ~
YC

24-108
 24. COMPONENTS SYSTEM

Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine

L-3 Meker Knight beam (Imasen)

Type BL46-146
Light
Bulb DC 24V, 25W
Lighting cycle 90 times / min
YM80S00001F1

Flasher lamp (LH) AV0.85 W

Rear work light AV0.85 Y REAR WORKING
YC SWING LIGHT LIGHT
AMP PART NO.
HOUSING : 174259-2
TERMINAL : 171661-1
AV0.85 R
HARNESS SEAL : 176886-2 AV0.85 B SWING LIGHT
LOCK PLATE : 1-174260-1 GND
VIEW I
L-4

Light

YM80S00001F2

Flasher lamp (RH)

Rear work light SECTION A-A
YC

L-5 Bulb 24V,5W Body

Note) Equivalent to 2456Z322F1 Lens
Light

YT80S00001P1

Room light
Bulb
YN12 - 56001 ~
YQ12 - 08001 ~
LQ13 - 07001 ~
LL13 - 06001 ~ SECTION A-A
LC11 - 08501 ~ Switch Door
YC11 - 04501 ~
YC

L - 7, 8 Type NS-1184FF
Bulb DC 24V, 70W
Light (Halogen)
24
YT80S00002F2

Cab working light

(front 1, 2)
YC
CA104 OR EQUVALENT
R
CA104 OR EQUVALENT
W
VINYL TUBE (BLACK)

24-109
24. COMPONENTS SYSTEM

Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine

M-1

Motor

VH28100E0080

Starter motor

YC

M-3
Purch. source 191-11H0-D

Motor

LQ53C00003S001

Wiper motor

YC

M-4 Rated voltage DC 24V

Injection flow 1.2L (0.32 gal) / min or more
Motor (Tank) Capacity 1.5L (0.4 gal)
Time rated Max. continuous 60 sec.
YT54C00003F1
Injection nozzle 1 X 2 pcs.
Window washer

YN12 - 56001 ~
YQ12 - 08001 ~
LQ13 - 07001 ~
LL13 - 06001 ~
LC11 - 08501 ~
YC11 - 04501 ~ PUMP
YC

24-110
 24. COMPONENTS SYSTEM

Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine

R-1 At start 24V2000A(0.1 sec)

Rated voltage / current At charge 28V120A(Continuous) VIEW A
Terminal A

Relay Exciting current 0.4A or less / 24V

Lock section
Contact pressure 37.2N {8.4 lb} or more Terminal A
YN24S00008F1 Closed circuit voltage 16V or less VIEW I
Terminal B
Open circuit voltage 7V or less HOUSING AMP
GND terminal
Battery relay 174359-2
Insulation resistance 3M or more/500V megger RETAINER AMP
1-174360-7
YN11 - 45001 ~ TERMINAL AMP
171661-1
YQ11 - 06001 ~ WIRE PROOF PLUG AMP
172888-2
LC10 - 07001 ~
YC10 - 03501 ~ VIEW Z Terminal L
Flowing direction of
YN12 - 56001 ~ main current
o 9 X 30L F HOUSING YAZAKI
YQ12 - 08001 ~ Terminal A Terminal B Terminal B AVS 1.25G
Heart shrinkage tube 7123-4210-30
F TERMINAL YAZAKI
LQ13 - 07001 ~ AVS 1.25B 7116-3251*
z GND wire
WIRE PROOF PLUG
LL13 - 06001 ~ I Terminal B Terminal L 7157-3580-60
LC11 - 08501 ~ F HOUSING YAZAKI AVS 1.25L Terminal B
YC11 - 04501 ~ 7123-4220-30
F TERMINAL YAZAKI
YC P coil 7116-3251
REAR HOLDER YAZAKI
7157-6801-30
H coil WIRE PROOF PLUG
7157-3580-60

Bracket groud
Circuit diagram
o 7.0 X 150L
Corrugete tube (Black)

Fusible link assy B o 7.0 X 150L

Fusible link assy A Corrugete tube (Black)

R-2

Relay

VH283001271

Starter relay

YC

24

24-111
24. COMPONENTS SYSTEM

Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine

R-3

Relay

VHS286201420

Glow relay

YC

R - 4,5,6,9,11,23,24,
25,26,28,94 Maker Tyco Electronics
Maker's p/No. V23074-A2002-A403
Relay
Type Micro relay A
Rated voltage DC 24V
YN24S00010P1
Contact 1C
Safety relay
* Accessory of relay box
Horn realy
Work light relay
Auto idle stop relay 1, 2
Engine emergency stop relay
Pin assignment
Lever lock relay
Alternator relay

YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
YN12 - 56001 ~
YQ12 - 08001 ~
LQ13 - 07001 ~ Terminal arrangement
LL13 - 06001 ~
LC11 - 08501 ~
YC11 - 04501 ~
YC

24-112
 24. COMPONENTS SYSTEM

Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine

R - 29,30,31,32 Maker's P/No. V23134-A0053-C643

Parts name Relay
Relay
Rated voltage DV 24V
Contact 1C
YN24S00012P2
* Accessory of relay box

Pin assignment
YN12 - 56001 ~
YQ12 - 08001 ~
LQ13 - 07001 ~
LL13 - 06001 ~
LC11 - 08501 ~
YC11 - 04501 ~
YC

SE - 1 ~ 5, 7 ~ 11,20 Pressure range 0~3MPa (435 psi)

Pressure sensor Rated voltage 5+0.5V DC
(Low pressure) Insulation resistance 50M or more /DC50V megger

LC52S00019P1
AMP MQS TYPE CONNECTOR
3P (B TYPE)
Bucket dig and dump, OPPOSITE CONNECTOR (FEMALE)
Boom up and down, TERMINAL No. CONNECTION HOUSING : 2-967642-1
TERMINAL : 965906-5
Swing, 1 COM (GOLD PLATED)
HEX 19
Arm in and out, 2 OUTPUT(+)
HARNESS SEAL : 967067-1
Travel RH and LH and other
3 POWER(+)
LQ13 - 07001 ~
LL13 - 06001 ~ O-RING
LC11 - 08501 ~ 1B P11 PF1/4
YC11 - 04501 ~
YC

SE - 13

Speed sensor

VH894101590

E/G speed sensor

YC

24

24-113
24. COMPONENTS SYSTEM

Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine

SE - 15 Float operation
Float Resistance
+0.1
Fuel sending unit FULL 10 -0.6
3/4 (19)
YN52S00045F1
1/2 32+5
1/4 (49.5)
Fuel level
EMPTY 85 +10
0
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
YN12 - 56001 ~
YQ12 - 08001 ~
LQ13 - 07001 ~ Machine side controller
LL13 - 06001 ~
LC11 - 08501 ~
YC11 - 04501 ~
YC

Float

Electric diagram VIEW A

SE - 16 Total resistance value

Effective electric angle
Potentio meter
Number of notches
Source voltage
YN52S00032P1
Notch part
Accel dial
Potentio
YN12 - 56001 ~ 3MA JM II + AMP
YQ12 - 08001 ~ Bracket HOUSING : 174359-2
LQ13 - 07001 ~ TERMINAL : 171661-1
LL13 - 06001 ~
LC11 - 08501 ~
YC11 - 04501 ~ Dial
YC

Electric diagram (Arrangement)

SE - 22, 23 Pressure range 0~50MPa (7250 psi)
Pressure sensor Max. allowable press. 120MPa (17400 psi)
(High pressure) Operating source voltage 5+0.5V DC
100M or more/DC50V megger
YN52S00048P1 Insulation resistance
(Between casing and terminal)

P1 pump
P2 pump
YC

P3/8 Source (+)

Tightening torque Output (+) Econo seal J series
: 73.5 N.m O ring P14 Common (+) (Mark II (+)
(54.2 lbf.ft) JIS B2401 3 pole

24-114
 24. COMPONENTS SYSTEM

Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine

PSV - A, B, C, D
Proportional solenoid
valve
Hydraulic solenoid valve
Hydraulic symbol A5 to A8
(YN35V00047F2)
YN35V00048F1
YN35V00049F1

YC
T2

A1

P2
P1

HYDRAULIC SYMBOL

Arm 2 speed

P1 unload

Travel straight

P2 unload

Attachment boost

Travel 1,2 speed

Swing parking

Lever lock
PSV - R, P1, P2 Type KDRDE-5K AMP MARK II
Max. feed press 13.7MPa (1987 psi) HOUSING : 174354-2
Solenoid TERMINAL : 173706-1
Rated feed press 5.0MPa (725 psi) Orifice Spring
HEX 10
Allowable back press 1MPa (145 psi) Spool T=7.4N.m
YN35V00052F1 (5.5lbf.ft)
Control pressure range 0~2.7MPa (392 psi)
Pump P1, P2 Rated voltage DC 24V
proportional valve
YN12 - 56001 ~
YQ12 - 08001 ~
LQ13 - 07001 ~ O-ring Seal nut
Sleeve Solenoid
LL13 - 06001 ~ 1B P20
LC11 - 08501~
YC11 - 04501 ~
YC

SV - 1, 2, 3, 4 Rated pressure 5.0 MPa (725 psi)

Solenoid directional
Solenoid directional pressure Rated voltage DC 24V
valve (8 spool) assy Solenoid proportional Dither current 100Hz,200mA P-P
Hydraulic symbol valve Coil resistance 17.5 (at 20C)
A1 to A4 AMP MARK II
P1, P2, T, A1, A8 port PF3/8 24
Connector specification HOUSING 174354-2 A2~A7 port PF1/4
(YN35V00047F2) TERMINAL 173706-1 AMP MARK II
YN35V00050F1
YN35V00051F1
YC

24-115
24. COMPONENTS SYSTEM

Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine

Auto return
SW - 1
Connection
Switch Terminal
Position
Auto return
YN50S00029F1

Starter switch
VIEW A Terminal
YC arrangement

SW - 4 Type ST110D Insulation tape

Rated DC30V, 10A R B W
Switch
Insulation resistance

YN50S00047P1
Vinyl tube
Swing parking brake T No. YAZAKI
release Contact construction : Position Red (2) 7122-2237
7114-2020
YN12 - 56001 ~ Swing parking release
YQ12 - 08001 ~
LQ13 - 07001 ~ Normal
LL13 - 06001 ~
LC11 - 08501 ~
YC11 - 04501 ~ White (3) Blue (1)
YC

SW - 5, 10, 20, 21 Type Buried in left grip SW-10 : Buried in left grip
Right and left switches are same.
Switch assy YN50E00017P1
Switch
Rating 125V 3A AC
YN03M02139F2 Insuration resistance More than 100M /
DC500V megger
(Right grip)
YN03M02139F1
(Left grip)

Horn, ATT Power boost

YC Sumitomo wiring systems HOUSING : 6090-1031 (2P male)

Sumitomo wiring systems TERMINAL : 8230-4282
Lead wire (Sumitomo wiring systems Robo top DP3)

SW - 7 Type Normal close

Working pressure 39.2~58.8kPa (5.7~8.5psi)
Switch
Rating DC 24V/12W
Insulation resistance More than 100M /
VH83530E0220 DC500V megger

E/G oil pressure switch

YN12 - 56001 ~
YQ12 - 08001 ~
LQ13 - 07001 ~
LL13 - 06001 ~
LC11 - 08501 ~
YC11 - 04501 ~
YC

24-116
 24. COMPONENTS SYSTEM

Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine

SW - 8

Switch
Inlet
YR11P00008S005 Connection port

Air cleaner
Clogging switch
YN12 - 56001 ~
YQ12 - 08001 ~
LQ13 - 07001 ~ Outlet
LL13 - 06001 ~
LC11 - 08501 ~
YC11 - 04501 ~
YC

SW - 11 Type STARTING IND. H802 000

Switch

YN50S00055F1

Lock lever

YC

SW - 17 Rated voltage DC 24V

Single pole single throw
Type (alternate)
Switch
More than 1M /
Insulation resistance DC500V megger UP
YN50S00040D9

Roof window wiper

Terminal connector
switch (OPT) Connector
YN12 - 56001 ~ Position
YQ12 - 08001 ~
LQ13 - 07001 ~
LL13 - 06001 ~
LC11 - 08501 ~
YC11 - 04501 ~
YC

SW - 19 Rated voltage DC 12V

Rated load 1A
Switch
Voltage drop 0.2V or less
Insulation resistance 5M or more
YT50S00004P1
Operation force Initial motion 0.8+0.3
24
0 kg
Wiper inter lock

YN12 - 56001 ~
YQ12 - 08001 ~
LQ13 - 07001 ~
LL13 - 06001 ~
LC11 - 08501 ~
YC11 - 04501 ~ Max. stroke
YC

24-117
24. COMPONENTS SYSTEM

Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine

SW - 26 Rated voltage DC 24V

Single pole single throw
Type (alternate)
Switch
Insulation resistance More than 1M /
DC500V megger UP
YN50S00040D4

Roof window wiper

Terminal connector
switch (OPT) Connector

YC Position

SW - 27

Switch

VHS834601510

Coolant level switch

YC

SW - 37 Rated voltage DC 24V

Single pole single throw
Type (alternate)
Switch
More than 1M /
Insulation resistance DC500V megger UP
YN50S00040DB

Independent travel
Terminal connector
switch Connector

YC Position

SW - 55 Rated voltage DC 24V

Single pole single throw
Type (alternate)
Switch
Insulation resistance More than 1M /
DC500V megger UP
YN50S00040D1

Boom work light switch Terminal connector

Connector
YN12 - 56001 ~ Position

YQ12 - 08001 ~
LQ13 - 07001 ~
LL13 - 06001 ~
LC11 - 08501 ~
YC11 - 04501 ~
YC

24-118
 24. COMPONENTS SYSTEM

Code No.
Parts Name
Parts No. Specifications Description
Use
Applicable Machine

Maker's P/N ESL-003 MAX.CONTACT CAPACITY

SW - 56
MAX.OPENING AND CLOSING VOLTAGE
MAX.OPENING AND CLOSING CURRENT
Switch MAX.CONTINUOUS CURRENT
INSULATION RESISTANCE
YF52S00004P1
ON
BLACK OR EQUIVALENT OFF
Fuel supply auto
stop switch M27X1.5
YN12 - 56001 ~ WORKING POINT
YQ12 - 08001 ~ FLOAT DIAMETER FLUID SPECIFIC GRAVITY ON (Amm) OFF (Bmm)
LC11 - 08501 ~ OIL 0.80~0.88 10.5mm or less 2.0mm or more
YC11 - 04501 ~ WHEN THE QUANTITY OF FLUID DECREASE FLOAT DROPS
AND POWER SUPPLY OFF.
YC

24

24-119
24. COMPONENTS SYSTEM

24-120
 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 COMPONENTS AND CONSTRUCTION ...........................................................25-6
25.3 FUNCTION .........................................................................................................25-8
25.3.1 MECHANISM OF COOLING CIRCUIT ......................................................25-8
25.3.2 COOLING CIRCUIT ...................................................................................25-10
25.3.3 COMPONENT PARTS ...............................................................................25-11
25.4 DISASSEMBLY AND ASSEMBLY .....................................................................25-15
25.4.1 PRECAUTIONS TO BE EXERCISED IN OPERATION .............................25-15
25.4.2 DISASSEMBLY AND ASSEMBLY OF UNIT ..............................................25-17
25.5 CHARGING REFRIGERANT .............................................................................25-22
25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION .............................25-22
25.5.2 OPERATING PROCEDURE ......................................................................25-23
25.5.3 CHARGING PROCEDURE ........................................................................25-24
25.6 ELECTRIC CIRCUIT ..........................................................................................25-30
25.6.1 WIRING DIAGRAM AND CONNECTORS .................................................25-30
25.6.2 STRUCTURE AND OPERATION OF EACH PARTS .................................25-32
25.7 TROUBLESHOOTING .......................................................................................25-36
25.8 SELF-DIAGNOSIS .............................................................................................25-43

Book Code No. S5LC2525E01

25-1
25. AIR CONDITIONER SYSTEM

Issue Data of Issue Applicable Machines Remarks

S5LC0325E01
First Edition September, 2010 E385CLC: YC
NHK
↑
↑ ↑ SK350-9: YC
NA

25-2
 25. AIR CONDITIONER SYSTEM

25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER)

The air-conditioner is the unit that places evaporator and heater core parallel, and unifies a blower fan and internal 25
/ external air switching unit. This unit changes hot air to cool air.

25.1.1 AIR CYCLE

• Heater
Internal air or external air is taken in through inlet and the air is passing through the filter and heat exchange is
performed with hot air (heating) at the heater core of the air-conditioner unit, and then the heated air is blown
through the ducts.
• Cooler
Internal air or external air is taken in through inlet and the air is passing through the filter and heat exchange is
performed with cold air (dehumidifying and cooling) at the evaporator of the air-conditioner unit, and then the
cooled air is blown through the ducts.
• 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 the air-conditioner unit and then heat exchange is performed.
The internal air is heated and the heated air blows through the grille provided on the inside of cab.
The blown air temperature is controlled by the temperature control switch on the control panel, and the
operation is controlled by the air mixing damper on the air-conditioner unit.

25-3
25. AIR CONDITIONER SYSTEM

25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE

AIR CONDITIONER CONTROL PANEL

COMPRESSOR

SOLAR RADIATION SENSOR COMPRESSOR DRIVE SOURCE

REFRIGERANT
AIR MIXED DAMPER SIGNAL PRESSURE SWITCH

AIR-CON BLOWER REVOLUTION SIGNAL

AIR OUTLET SWITCHING SIGNAL CONTROLLER

INNER AIR SENSOR

EVAPORATION SENSOR
INNER AIR AND OUTER AIR
SWITCHING SIGNAL

OUTER AIR INTAKE

MOTOR
VENT ACTUATOR
INNER AIR
MOTOR
ACTUATOR

AIR CONDITIONER UNIT FACE

FOOT MOTOR BLOWER

ACTUATOR CONTROLLER

25-4
 25. AIR CONDITIONER SYSTEM

25

This page is blank for editing convenience.

25-5
25. AIR CONDITIONER SYSTEM

25.2 COMPONENTS AND CONSTRUCTION

9 21

16
23
33 26 31
48 22 20 35 11
50 49 25 32 36
34 10
47
20 35 18
14 1 47 282924 4729 36
30 27
46
47 35
15 47 39 47 19

38 4 47
45
44 47 37
17 47
51 42 40

7 41

6 47
3 5
12
8 2 47
20 43
13 47
47

25-6
 25. AIR CONDITIONER SYSTEM

AIR-CONDITIONER UNIT

No. Parts Q'ty No. Parts Q'ty

1 HEATER CORE GEN ASM 1 27 JOINT FOOT 1
25
2 CASE INTAKE 1 28 JOINT DEF 1
3 LINER FILTER 1 29 ROD COMMON 2
4 PACKING INTAKE 1 30 LEVER MODE MAL 1
5 LINER INTAKE MAL 1 31 LEVER AM MAIN 1
6 LEVER INTAKE 1 32 LEVER AM SUB 1
7 DAMPER INTAKE ASSY 1 33 LINK MODE 1
8 INCAR SENSOR 1 34 MAIN ROD 1
9 DUCT JOINT ASM 1 35 DAMPER MODE ASSY A 3
10 CASE HEATER R 1 36 DAMPER MODE ASSY B 2
11 CASE HEATER L 1 37 DAMPER AIR MIX ASSY 1
12 CASE DRAIN 1 38 RELAY 24Å|4PE 2
13 CLIP PS HARNESS 1 39 FAN DRIVER 1
14 COVER LINK 1 40 EVAPORATOR ASM 1
15 FILTER REC ASM 1 41 TXV(EXPANSION VALVE) 1
16 PACKING DUCT OUTLET A 2 42 EVA SENSOR 1
17 PACKING DUCT OUTLET B 1 43 SOCKET BOLT M5X40 2
18 COOLING HOSE 1 44 HERNESS HOLDER 1
19 BLOWER MOTOR ASM 1 45 THERMISTOR HOLDER 1
20 MOTER ACTUATOR 3 46 TAPPING SCREW 5X14(T1) 3
21 HARNESS ASM 1 47 TAPPING SCREW 4X16(T1) 36
22 LEVER VENT 1 48 BUSH D3PIN 4
23 LEVER FACE 1 49 ROD HOLDER 2
24 LEVER FOOT 1 50 TAPPING SCREW 4X16 1
25 LEVER DEF 1 51 INSULATION 2
26 JOINT VENT 1

25-7
25. AIR CONDITIONER SYSTEM

25.3 FUNCTION

25.3.1 MECHANISM OF COOLING CIRCUIT

(1) Mechanism of Cooling
In the cooling process, the refrigerant that flows
through the cooling circuit changes its phases from
Item HFC-134a (R134a)
liquid to gas and vice versa. During this process heat
Chemical formula CH2FCF3
is transferred from the low temperature part Molecular weight 102.03
(compartment) to the high temperature part (outside of Boiling point -26.19 (-15.14 )
the vehicle). Critical temperature 101.14 (214.05 )
Critical pressure 4.065 MPa (41.45kgf/cm2 1)
1. Kind of Refrigerant Critical density 511 kg/m3 (31.9lb/ft3)
Many kinds of refrigerants that change in that way are Density of saturated
available, but the following requirements are needed
1206 kg/m3 (75.3lb/ft3)
liquid[25 (77.0 )]
for use in such applications: Specific volume of saturated
0.0310 m3/kg (0.496ft3/lb)
vapor [25 (77.0 )]
Latent heat of
197.5 KJ/kg {47.19kcal/kg}
vaporization [0 (32 )]
Flammability Nonflammable
Ozone destruction
0
coefficient
1 : 1MPa (mega pascal) equals 10.1972kgf/cm2
(145psi)

• 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.

25-8
 25. AIR CONDITIONER SYSTEM

(2) Characteristics of Refrigerant (Right Figure)

In general, the fluid (general term of gas and liquid)
has the following qualities: PRESSURE
1. MPa(psi) 25
As a gas under certain pressure is cooled down, it R134a
4(580)
begins to condensate at a certain temperature to take
a liquid state. The temperature at which condensation 3(435)
begins is unique to each substance (fluid) at a given LIQUID
pressure. The temperature determined by a given
2(290)
pressure is called saturation temperature.
1(145) GAS
0.5(75)
TEMPERATURE
[ ( )]
0 0 15 18 35 50 100
(32) (59)(64) (95) (122) (212.0)
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.
The Figure 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 Figure, the refrigerant takes 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 the above Figure 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 the
above Figure.

25-9
25. AIR CONDITIONER SYSTEM

25.3.2 COOLING CIRCUIT

This Figure illustrates the cooling circuit of a car air-
conditioner.
In this circuit diagram, the portion that cools the air of
the compartment is the evaporator. The object air is INSIDE OF COMPARTMENT(CAB)
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 where
vaporization of the refrigerant takes place is the
EVAPORATOR EXPANSION
evaporator, cooled air is constantly delivered to the
BLOWER VALVE
circumference of the evaporator by the blower fan. In
the meantime, liquid refrigerant (slightly wet vaporized
refrigerant) is fed into the evaporator, when "cooling"
INSIDE OF ENGINE
effect is attained. S D ROOM
For instance, in order to cool the air to 15C degrees COMPRESSOR COOLING FAN
(59F degrees), the refrigerant can not absorb
evaporation heat from the air unless it evaporates at a
temperature lower than 15C degrees (59F degrees).
For that purpose, it can be seen from this Figure that RECEIVER
the pressure of the refrigerant in the evaporator must DRYER
be less than 0.51 MPa (74psi). CONDENSER
Furthermore, the cooling effect deteriorates unless the
feed rate of the refrigerant is controlled so that all of Schematic Diagram Of Cooling Circuit
the refrigerant supplied to the evaporator vaporizes
and turns into dry vapor.
Consequently, the cooling circuit is constructed so the
evaporator can cool down an object (air in this case)
sufficiently (i.e. so as to decrease the pressure in the
evaporator) and 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.

25-10
 25. AIR CONDITIONER SYSTEM

25.3.3 COMPONENT PARTS

(1) Evaporator (See right Figure)
The evaporator is an important heat exchanger that 25
absorbs the heat of the compartment air (object) by the
utilization of the latent vaporization heat of the low-
EVAPORATOR
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
O-RING
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 EXPANSION VALVE
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 SOCKET BOLT M5X40(2 PCS.)
refrigerant of the evaporator. Accordingly, reducing the
pressure drop is one constituent factor 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.

25-11
25. AIR CONDITIONER SYSTEM

This Figure shows how the block type expansion valve,

is constructed. The temperature sensing part is
provided in the shaft of the expansion valve to directly
detect the refrigerant temperature at the outlet of the DIAPHRAGM
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 REFRIGERANT
EVAPORATOR OUTLET
pressure causes the force acting upon the diaphragm
SIDE
to vary accordingly.
The high-pressure high-temperature liquid refrigerant SHAFT
that is fed from the receiver side reduces the pressure
abruptly as it passes through the valve (throttling
action). On this occasion, part of the refrigerant
evaporates by the heat of the refrigerant and is cooled
off. The result is that low-pressure, low-temperature, REFRIGERANT
INLET
damp refrigerant vapor is fed to the evaporator.
The opening of the valve is determined by the balance
between the pressure (low) of the evaporator side, the BALL
VALVE
action of the adjust spring and the pressing force of the
SPRING
diaphragm (the temperature of the refrigerant at the
outlet of the evaporator to be sensed by the Block Type Expansion Valve
temperature sensor). 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 and the
refrigerant supply to the evaporator more securely.
The air-conditioner of this machine adopts a block type
expansion valve.
Expansion Valve Outside View

25-12
 25. AIR CONDITIONER SYSTEM

(3) Compressor (See right Figure)

The compressor performs the following three functions
in the cooling circuit:
1) Suction D HOSE 25
2) Pumping
3) Compression

S HOSE

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 the cooling effect.
2. The pumping action serves to cause all the refrigerant to circulate in the cooling circuit. This 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 external 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 external 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 Figure)

This is a heat exchanger that cools the vaporized
refrigerant at high temperature and high pressure by
the use of external 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 external 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

25-13
25. AIR CONDITIONER SYSTEM

(5) Receiver dryer (See right Figure)

1. Receiver Tank
On the air-conditioner, the revolution of the REFRIGERANT SIGHT GLASS
compressor varies greatly, which causes the proper INLET
flow of refrigerant in the cooling circuit to vary. It is REFRIGERANT
the receiver tank that receives the variations. When OUTLET
the cooling circuit does not need much refrigerant,
the receiver tank stores extra refrigerant
temporarily and supplies it when the cooling circuit
needs more refrigerant. The receiver tank also
stores an extra amount of refrigerant to be used for
filling balance and supplement small amounts of
PRESSURE SWITCH
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 DESICCANT
should be held below a concentration of 30 ppm.
The air-conditioner uses a molecular sieve as
SUCTION
desiccant suited for the circuit, in order to absorb PIPE
water content that intrudes into the circuit when the
dryer is installed or when refrigerant is charged.
3. Sight Glass FILTER
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 RECEIVER
This machine employs pressure switches of high/ TANK
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).

25-14
 25. AIR CONDITIONER SYSTEM

25.4 DISASSEMBLY AND ASSEMBLY

25.4.1 PRECAUTIONS TO BE EXERCISED IN OPERATION 25

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

(2) The receiver dryer is filled with desiccant to absorb

moisture in the circuit. Therefore, remove the valve
Unit : N.m (lbf.ft)
at the pipe port immediately before connecting
pipes. SCREW SIZE TIGHTENING TORQUE

(3) Tightening Torque N4,T4 machine screw, M4 0.78~1.18 (0.58~0.87)

N5,T5 machine screw, M5 1.96~2.45 (1.4~1.8)

1. Pipe Joints
When connecting pipe joints, coat the O-ring with M6 (mounting part of L hose joint) 7.85~11.8 (5.8~8.7)
special oil (SP20) and fasten to the tightening
torque indicated in the table, using a double M6 (except mounting part of L hose joint) 9.8~11.8 (7.2~8.7)
spanner. M8 (mounting part of S,D hose joints) 19.6~24.5 (14~18)
2. Screws and Bolts
Fasten to the tightening torque indicated in the table. M8 (mounting part of A/C unit) 9.8~11.8 (7.2~8.7)

M8 (other than those mentioned above) 11.8~15.7 (8.7~12)

M10 39.2~53.9 (29~40)

25-15
25. AIR CONDITIONER SYSTEM

(4) Amount of Oil for Compressor

The compressor SD7H (HD type) is filled with 135cc
(8.2cu-in) of oil. If the oil volume is small, seizure at REPLACED PARTS AMOUNT TO BE FILLED IN
high revolution and shortening of service life will occur.
EVAPORATOR 40 cc (2.4cu.in)
If the oil volume is large, the cooling ability will be
deteriorated. CONDENSER 40 cc (2.4cu.in)
Once the air-conditioner is operated, part of the oil is
dispersed in the refrigeration circuit. Therefore, when Drain out the volume of oil left in
replacing the parts in shown in the Table, adjust the oil the compressor to be replaced
COMPRESSOR
level to that of table.
from the new compressor.

(5) Before performing operation, stop the engine and RECEIVER DRYER 20 cc (1.2cu.in)
turn off all power supplies to the equipment related to
HOSES 20 cc (1.2cu.in)
the air-conditioner.

(6) After the operation is over, confirm that all faults

have been repaired completely, by operating the air-
conditioner.

25-16
 25. AIR CONDITIONER SYSTEM

25.4.2 DISASSEMBLY AND ASSEMBLY OF UNIT

(1) Disassembly and assembly of blower motor
1. Disassembly 25
- Disconnect cooler hose from A/C unit.
- Loosen 3 tapping screws.
- Remove blower motor as shown.
- Disconnect cooler hose from blower motor. Cooler hose
2. Assembly
Assemble the A/C unit in the reverse order of
disassembly.

b
f ca
aro
Re

Tapping screw A/C unit

Blower motor

(2) Disassembly and assembly of internal/external actuator

1. Disassembly
- Loosen 3 tapping screws. HVAC Unit
- Remove actuator as shown. Groove of
damper lever
2. Assembly Lever pin
Assemble the actuator in the reverse order of Actuator
disassembly.

Tapping screw

Insert lever pin of actuator into groove of damper lever.

(3) Disassembly and assembly of relay

1. Disassembly
- Loosen tapping screws. HVAC Unit
- Remove relay as shown. Tapping screw
2. Assembly Relay
Assemble the relay in the reverse order of
disassembly.

25-17
25. AIR CONDITIONER SYSTEM

(4) Disassembly and assembly of inner air sensor

1. Disassembly Inner air filter
- Press lock of connector 1 and remove the HVAC Unit
connecter from inner air sensor. Lock of sensor
- Press lock of sensor and remove inner air sensor
as shown.
- Remove cord sandwiched between components Inner air sensor
of unit slowly.
- Lift inner air filter upwards and remove it.
- Press lock of connector 2 inwards and remove the
connecter.
2. Assembly
Assemble the inner air sensor in the reverse order Connector 1
Connector 2
of disassembly.

(5) Disassembly and assembly of fan driver

1. Disassembly
- Disconnect connector from fan driver. Connector
- Loosen 2 tapping screws.
HVAC Unit
- Remove fan driver as shown.
2. Assembly
Assemble the fan driver in the reverse order of
disassembly.

Tapping screw Fan driver

(6) Disassembly and assembly of link cover

1. Disassembly
- Loosen 4 tapping screws.
- Remove link cover as shown.
2. Assembly
Assemble the link cover in the reverse order of
Link cover
disassembly.

HVAC Unit
Tapping screw

25-18
 25. AIR CONDITIONER SYSTEM

(7) Disassembly and assembly of mode actuator and air mix actuator
1. Disassembly Rod latch Rod
- Remove link cover. (See item 25.4.6)
- Disconnect connector from 2 actuators.
25
- Turn rod latch of mode actuator in the direction of
arrow as shown. And release link rod.
- Twist link bar of air mix actuator in the direction of
arrow as shown. And remove the link rod from
damper lever.
- Loosen 3 tapping screws fixing each actuator. Air mix actuator
- Remove each actuator as shown.
2. Assembly
Assemble the actuators in the reverse order of
disassembly. Link bar

Mode actuator

Air mix actuator

Mode actuator
HVAC Unit Tapping screw

(8) Disassembly and assembly of heater core

1. Disassembly
- Remove link cover. [See item 25.4.2 (6)] HVAC Unit
- Disconnect connector from air mix actuator. Connector
- Remove heater core as shown.
2. Assembly
Assemble the heater core in the reverse order of Air mix actuator
disassembly.

Heater core

Do not exert excessive load on piping.

25-19
25. AIR CONDITIONER SYSTEM

(9) Disassembly and assembly of evaporator

1. Disassembly
Tapping screw
- Turn HVAC unit upside down.
- Loosen 5 tapping screws. HVAC Unit
- Disconnect connector of evaporator sensor.
- Pull out evaporator as shown.
2. Assembly Tapping screw
Assemble the inner air sensor in the reverse order
of disassembly. EVAPORATOR

HVAC Unit

Connection area of
evaporator sensor connector

To avoid damage, pull out evaporator sensor cord from groove of HVAC unit carefully.

(10)Disassembly and assembly of expansion valve

1. Disassembly
- Loosen 2 socket bolts.
- Remove expansion valve as shown. 27th
rows
9th r of fin Evaporator
ows
of fin

Thermistor holder

73

Stay

Harness holder
Evaporator sensor

O-ring 1/2
O-ring 5/8
Expansion valve

Socket bolt

20mm
Enlarged illustration of sensor
and thermistor holder

25-20
 25. AIR CONDITIONER SYSTEM

Do not exert excessive load on piping. 25

2. Assembly
- Assemble the expansion valve in the reverse order of disassembly.
- Prior to assembly, apply PAG oil to O-ring.

Breakage of O-ring causes gas leak.

(11) Disassembly and assembly of evaporator sensor

1. Disassembly
- Remove harness holder and thermistor holder from evaporator.

To avoid trouble, do not pull cord forcibly.

2. Assembly
- Assemble the evaporator sensor in the reverse order of disassembly.
- Install the harness holder and thermistor holder as shown.
- Install the tip of sensor and thermistor holder as shown.

When the sensor cord is loose fitted, the cord is caught by door.

25-21
25. AIR CONDITIONER SYSTEM

25.5 CHARGING REFRIGERANT

25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION

(1) Assign a person in charge of handling refrigerant.
Refrigerant charge operation involves dangers as it handles high pressure gas. 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 frostbit 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 explode as a result.
It is for this reason why the can temperature must be kept below 40C degrees (104F degrees).
2. For storage, choose dark cold place not exposed to direct sunlight.
3. If the can is placed near a fire, it is exposed 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.
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. Keep can out of 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. If the can is put in hot water or heated by a direct fire, the pressure of the can may rise sharply,
thereby the can explodes.
2. When charging refrigerant while running the engine, to avoid explosion, do not open the high pressure valve
(HI) on the gauge manifold.

(4) Others
Reuse of service cans is prohibited by regulation, do not reuse them. Do not allow foreign matter to enter the air-
conditioner circuit. Air, water and dust are detrimental to the refrigeration cycle. Install the components of the air-
conditioner correctly and speedily. Pay full attention to the entry of water and dust.

- Be careful about overcharge of gas.

- Fasten pipes to the specified torque.

25-22
 25. AIR CONDITIONER SYSTEM

25.5.2 OPERATING PROCEDURE

(1)
Refrigerant charge into the air-conditioner consists mainly of a "vacuum making operation", and "gas charge 25
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 charging refrigerant in the circuit,
make vacuum and allow the water in the circuit to boil and vaporize. Water in the circuit is thus eliminated.
2. The "gas charging operation" consists of filling refrigerant in the circuit after forming vacuum. Filling gas not only
depends upon the cooling performances of the air-conditioner, but also affects the service life of the component
parts of the circuit. Extreme overcharge will make the circuit pressure extremely high and causes the cooling
performance to deteriorate. On the contrary, undercharge causes poor circulation of the lubricating oil of the
compressor and causes seizure of the moving parts of the compressor.
The gas filling operation involves handling of high pressure gas; filling gas according to incorrect operation
procedure is dangerous. Fill refrigerant correctly following the operation procedures and cautions stated in this
manual.

(2) Operation Chart

Vacuum making operation Gas charging operation

More than Leave it as it is,

30 min. for five minutes.
Begin vacuum Stop vacuum Check Charge Check for Charge
making making air-tightness refrigerant gas leak refrigerant
Lower than
-750mmHg Gauge indicates
abnormality
Charge refrigerant gas to a gauge
Check and correct joints pressure of 0.1MPa (14 psi)

(3) Tools

No. Parts Q’ty Sketch Service No. Parts Q’ty Sketch Service
Low pressure
4 Quick joint 1
Gauge side
1 1
manifold For service can
5 T joint 1
valve
Red :
high pressure side
Charging Blue : Service can
2 3 6 2 For service can
hose low pressure side valve
Yellow :
vacuum pump side

Vacuum
High pressure For vacuum
3 Quick joint 1 7 pump 1
side pump
adapter

25-23
25. AIR CONDITIONER SYSTEM

25.5.3 CHARGING PROCEDURE

25.5.3.1 VACUUM MAKING OPERATION

(1) Connecting gauge manifold (See right Figure)
1. Close the high pressure valve (HI) and the low
pressure valve (LO) of the gauge manifold. HIGH
LOW PRESSURE PRESSURE GAUGE
2. Connect the charging hoses (red and blue) with the GAUGE GAUGE MANIFOLD
service valves of the compressor.
(CLOSED)LOW HIGH PRESSURE
Red hose: PRESSURE VALVE VALVE(CLOSED)
High pressure side (HI) of the gauge manifold --> RED
high pressure side (DIS) of compressor BLUE
Blue hose:
HIGH
Low pressure side (LO) of gauge manifold --> PRESSURE YELLOW
low pressure side (SUC) of compressor SIDE
DIS
LOW
PRESSURE
SIDE
SUC

COMPRESSOR VACUUM PUMP(STOP)

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. BLUE
RED

CHARGING
HOSE
(GAS VALVE)
Connecting Gauge Manifold

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

25-24
 25. AIR CONDITIONER SYSTEM

(2) Vacuum making (See right Figure)

1. Open the high pressure valve (HI) and the low
pressure valve (LO) of the gauge manifold. LOW PRESSURE VALVE(OPEN) (CLOSE)
HIGH PRESSURE VALVE(OPEN) More than (CLOSE) 25
30 min
2. Turn on the switch of the vacuum pump and make
vacuum for more than 30 minutes.
GAUGE MANIFOLD
3. When vacuum making for a specified duration is
over (degree of vacuum : less than - 750 mmHg),
close the high pressure valve and the low pressure
valve on the gauge manifold.

4. Then turn off the vacuum pump. DIS

SUC

Vacuum Making Operation

(3) Air-tightness Check

Close the high pressure valve and the low pressure valve on 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 a leak somewhere. Retighten pipe joints, make vacuum again and
make sure of no leakage.

25-25
25. AIR CONDITIONER SYSTEM

25.5.3.2 GAS CHARGING OPERATION

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

3. Open the high pressure valve on 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 on the
LOW PRESSURE HIGH PRESSURE VALVE
gauge manifold and the service valve. (See right VALVE(CLOSE) (OPEN) (CLOSE)
Figure) RED FILL IN 1~1.5 CANS
BLUE OF REFRIGERANT

DIS
YELLOW
SERVICE CAN
VALVE
(OPEN) (CLOSE)
CHARGE
SUC

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 explode. This is very dangerous.

(2) Checking for gas leak

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

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

25-26
 25. AIR CONDITIONER SYSTEM

(3) Charging from low pressure side (See right Figure)

1. Make sure that the high-pressure and low-pressure
valves on the gauge manifold and the service can
valve are closed. 25
2. Start the engine and run the revolution from 1400 to
LOW PRESSURE HIGH PRESSURE
1600 rpm and close the cab door and the windows. VALVE VALVE(CLOSE)
3. Turn on the air-conditioner switch, set the fan switch OPEN CLOSE
WHEN AIR RED (CLOSE SECURELY)
to Max and the temperature control switch to cool BUBBLES IN THE
Max. SIGHT GLASS
DISAPPEAR
4. When charging gas, set the discharge pressure of YELLOW
DIS
the compressor from 1.4 to 1.6 MPa (200 to BLUE
230psi).
SERVICE CAN
VALVE(OPEN)
SUC

COMPRESSOR SERVICE CAN

OPERATION (DO NOT TURN OVER)
Gas Charging Operation (Low Pressure Side)

5. Open the low pressure valve on the gauge manifold SIGHT GLASS
and the service can valve and fill in refrigerant until
air bubbles in the sight glass of the receiver
disappear. (See Figure "Gas Charging Operation")
[Total amount of gas to be charged: 850g to 950g
(1.89 to 2.11 lbs)]
6. When refrigerant charge is completed, close the low
pressure valve on the gauge manifold and the
service can valve.
RECEIVER DRYER

Receiver Dryer

Do not open the high pressure valve of the gauge manifold.

Do not turn over the service can. The compressor valve may be damaged because the refrigerant is sucked in a
liquid state.

25-27
25. AIR CONDITIONER SYSTEM

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

JUDGMENT OF REFRIGERANT LEVEL THROUGH THE SIGHT GLASS OF RECEIVER DRYER

After A/C is turned on, only a little

PROPER LEVEL bubbles are seen and thereafter light
milky white is seen.

After A/C is turned on,

OVERCHARGE no air bubbles are seen.

After A/C is turned on, continuous

UNDERCHARGE
air bubbles are seen.

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

(5) Removing Gauge Manifold

When the refrigerant level has been checked, disconnect the charging hoses from the compressor as follows.

1. Press the "L" shape metal fitting on the charging hose (blue) on the low pressure side against the service valve
of the compressor to avoid leakage of the refrigerant. 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 until 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.

25-28
 25. AIR CONDITIONER SYSTEM

25

This page is blank for editing convenience.

25-29
25. AIR CONDITIONER SYSTEM

25.6 ELECTRIC CIRCUIT

25.6.1 WIRING DIAGRAM AND CONNECTORS

PRESSURE SWITCH
(RECEIVER DRYER)

WORK LIGHT POWER SUPPLY FOR NIGHT LIGHTING

FUSE 20A SWITCH POWER FOR COMPRESSOR CLUTCH
POWER FOR CONTROL AMPLIFIER
A/C MAIN POWER
MAIN KEY SW FUSE 5A

FUSE 5A

FUSE 15A

COMPRESSOR

NOTE) 1. THe double chain lines indicate the wiring

on the excavator side.
2. The connector colors indicate the cord colors seen
from the connecting part.
3. Unless otherwise specified, wire diameters are 0.5.
4. Use the fuses that are specified capacity in this diagram.

LIGHT
PINK WHITE BLACK RED YELLOW GREEN BLUE BROWN GREEN ORANGE

Electric Diagram (1/2)

25-30
 25. AIR CONDITIONER SYSTEM

25

Night lighting signal

Blower OFF relay

Monitor of blower
power source
Evaporator sensor

Blower amplifier output

Amplifier
Air inlet sensor

grounding

Potentio
Potentio
sensor

power source
Potentio
Amplifier

Mg. C output
Solar sensor
AIR INLET
SENSOR

EVA SENSOR

SOLAR
SENSOR

COMPRESSOR RELAY
FUSE (5A)

MOTOR ACTUATER
(FOR AIR MIX)

MOTOR ACTUATER
(FOR MODE)

BLOWER OFF RELAY

BLOWER
MOTOR

FAN DRIVER

MOTOR ACTUATER
(REC/FRESH)

Electric Diagram (2/2)

25-31
25. AIR CONDITIONER SYSTEM

25.6.2 STRUCTURE AND OPERATION OF EACH PARTS

(1) Control panel
The control unit is integrated into the control panel,
and processes the signal input by each sensor, etc.
The signal input by each switch through the control
panel with the function of the built-in micro
computer comprehensively controls each actuator Control Panel
(Air inlet / outlet mode select, air mix), blower motor
and compressor on the output side.
The self-diagnosis performance is provided to
facilitate the trouble shooting.

(2) Fan driver

The power transistor shifts the blower motor into
variable speed with base current from the control 2 3
unit.
1
<Check for fan driver>
Check over the continuities between terminals of
the fan driver.
2

Blower Controller

TERMINAL NO.
CONTINUITY
1 2 3
CONTINUED
TESTER NOT CONTINUED
CONTINUED(DIODE PARALLEL
AND FORWARD DIRECTION FLOW)

25-32
 25. AIR CONDITIONER SYSTEM

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

1. Blower OFF relay

25
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 switched by the control
amplifier and electronic thermostat control.
3. Relay specification and inspection
a. Coil resistance: 320 ohms
b. Specified voltage: DC20V to 30 V
c. Be careful about the coil polarity of relay.
d. Inspection:
Inspect the continuity between terminals 3 and 4 as
follows.
20 to 30 V applied between terminals 1-2:
Continued
20 to 30 V not applied between terminals 1-2: Not
continued

(4) Motor actuator

Air mix actuator is located in at the center of the air-
conditioner unit, and opens and closes the air mix
damper through the link motion.
The air mix actuator incorporates the potentiometer
which is switched by the linked shaft with the
actuator.
When the target air mix door position is determined Control panel Motor actuator
through the temperature control switch, the control
M
unit reads the level of the potentiometer of the
actuator. And it determines the rotating direction of
the motor in either normal rotation or reverse
rotation. And the motor rotates, the contact point is Both Motor Actuators
moved, and when the contact point is detached or
the output signal of the control unit turns OFF, the
motor stops.

25-33
25. AIR CONDITIONER SYSTEM

(5) Mode actuator < Connector arrangement >

The mode actuator is located in the outlet of the air
conditioner unit. And it opens or closes the mode
door through link motion. < Motor input >
The mode actuator incorporates a potentiometer Terminals

which is switched by the linked shaft with the Rotational

direction

actuator.
When the target air mix door position is determined
through the temperature control switch, the control Potentio resistance characteristic
unit reads the level of the potentiometer on the - Between electrodes 120 degrees C Total
resistance 4.7 kilo-ohms
actuator. And it determines the rotating direction of
the motor in either normal or reverse rotation. And
When 5 volt is applied to circuit
the motor rotates, the contact point is detached or between (6) and (4)

between (5) and (4)

the output signal of the control unit turns OFF, the (+ at (6) and - at (4))

Output voltage
motor stops.

Circuit board characteristic

(6) The actuator for air inlet / outlet (12V)

The actuator for inlet and outlet air mode select is
installed on the blower intake unit, and opens and
closes the inlet or outlet air damper through the link
motion. The actuator for the inlet and outlet air
mode select incorporates the position detection
switch which is switched with the movement of the
shaft in the actuator. When the inlet or outlet
damper position is set by the inlet and outlet switch AMPLIFIER MOTOR ACTUATOR

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. INNER AIR SIDE

And the motor rotates, the position detection switch OUTER AIR SIDE

also rotates and makes it stop at the set position of LIMITER

the inlet or outlet air damper.

(7) Evaporator sensor - air inlet 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 and air inlet sensor
specifications
Terminal resistance:
at 0 degree C: 7.2 kilo-ohms Evaporator Sensor - Air Inlet Sensor
at 25 degree C: 2.2 kilo-ohms

25-34
 25. AIR CONDITIONER SYSTEM

(8) Solar sensor

This solar sensor, which is used to correct the solar
radiation to the auto air conditioner detects the 25
strength and solar orientation of sunbeam after
transforming them into current by means of photo
diode. Solar Sensor
<Check for solar sensor>
Disconnect solar sensor connecter from harness.
Using voltmeter, measure the voltage between
connector terminals.
The measured voltage should be varied by intensity
of sunshine. (When there is no sunshine, measured
voltage is almost 0 volt.)

Measure the voltage in the voltage measurement mode (V mode).

Measurement in resistance mode (Ohm mode) causes the damage to components.

(9) Dual pressure switch

This dual pressure switch is attached on the 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.

SPECIFICATION OF DUAL PRESSURE SWITCH

0.02MPa(2.9psi) 0.59MPa(86psi)

ON

OFF
0.20MPa(29psi) 3.14MPa(455psi)
(LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)
Dual Pressure Switch

25-35
25. AIR CONDITIONER SYSTEM

25.7 TROUBLESHOOTING

Air temperature does not fall. Note : M/A is motor

actuator
* is any of the
numbers 0 to 9.
If AUTO switch or A/C switch is pressed,
"HL.E" is indicated on the set temp. display of the panel.
NO YES

*
"HL. " is shown on the set temp. . Connector for air mix M/A is
display of the panel. disconnected or in poor contact.
. Air mix M/A is failed.
NO YES . Main harness shows poor continuity.
A snow mark ( ) on A snow mark ( )
the panel is flashing. on panel is flashing. Check and correct or replace parts.
NO YES

. Inner air sensor or harness is disconnected or shorted. . Both inlet air sensor and
. Inner air sensor connector is disconnected or in poor contact. evaporator sensor are
disconnected or shorted.
See section monitor mode. . Controller failed.

See section monitor mode.

Check and correct or replace parts.

A
NO YES

Outlet temp. falls if temp. is set . Evaporator sensor connector

at LO and the outlet mode is changed is disconnected or in poor contact.
to vent mode. . Evaporator sensor is disconnected or shorted.
NO YES See section monitor mode.

Air mix damper is Cool air flowing

in LO (COOLMAX). into inlet air sensor Check and correct or replace parts.

NO YES
NO YES
M/A stops halfway. Turn compressor clutch
on and off. Check and
correct electric circuits. Controller is faulty Check duct or
or inlet air sensor eliminate cause for
is faulty. cool air intrusion.
Refer to Troubleshooting
for refrigeration cycle.
Check and replace.

NO YES

M/A failed or controller . Check, correct or replace

is out of order. M/A lever link.
. After cleaning lever link,
apply grease.
Replace.

25-36
 25. AIR CONDITIONER SYSTEM

Air temperature does not rise. Note : * is any of 25

the numbers 0 to 9.

HL.E is shown on the set temp. display of the panel.

NO YES

*
"HL. " is shown on the set temp. . Connector for air mix M/A is
display of the panel. disconnected or in poor contact.
. Air mix M/A is failed.
NO YES . Main harness shows poor continuity.
. Inlet air sensor or harness is disconnected or shorted.
. Inlet air sensor connector is disconnected or in poor contact. Check and correct or replace parts.
See section monitor mode.

Check and correct or replace parts.

Outlet temp. rises at FOOT

mode if temp. is set at HI
(HOT MAX).
NO YES

Air mix damper is Warm air is flowing into

in HI (HOT MAX). inlet air sensor.
NO YES
NO YES
M/A action stops, Check warm water piping.
halfway.
Controller or Check duct or
inlet air sensor eliminate causes
is out of order. for warm air entry.

NO YES
Check and replace.

M/A failed or controller . Check, correct or

is out of order. replace M/A lever link.
. Clean lever link and apply grease.
Replace.

25-37
25. AIR CONDITIONER SYSTEM

Blower motor does not run.

At air flow HI, battery voltage acts on

Note 1) both terminals (+) and (-) of blower motor.

NO YES

Battery voltage acts on red Blower motor fails.

(+) and body of blower motor.
NO YES Replace.

Check blower motor relay. Blower motor Voltage acts on yellow wire
Note 2) rotates if green / red wire and red wire of and grounding of blower amplifier.
blower motor relay are directly connected.
NO YES
NO YES

Controller is out of order. Is there continuity between yellow

Wire harness is Replace wire and black wire?
faulty. Check
and correct or replace.
NO YES

Battery voltage acts on white / green

wire and grounding of blower motor relay. Eliminate cause Check and
and replace repair harness.
NO YES blower amplifier.

Check and repair Blower turns if orange wire of blower motor relay
harness or replace. is connected with ground.
NO YES

Replace relay. Check and correct harness

or replace controller.

Note 1)
In the connector connected condition, measure the voltage.
Note 2)
During direct connecting test, turn off starter key switch and work light.

25-38
 25. AIR CONDITIONER SYSTEM

Blower motor speed does not change.

25

CASE (1)

*
"HL. " is shown on the set temp. display of the panel. *
Note) is any of the
numbers 0 to 9.
NO YES

Replace blower . Inlet air sensor or harness is disconnected or shorted.

amplifier controller. . Inlet air sensor connector is disconnected or in poor contact.
See section monitor mode.

Check and correct or replace parts.

25-39
25. AIR CONDITIONER SYSTEM

Magnet clutch does not engage.

Snow mark ( ) lights on,

when A/C switch is pressed.
No Yes

Snow mark ( ) flickers and E is Voltage acts on clutch.

shown on panel display.
No Yes

To A On page 25-36. Voltage is applied to Clutch faulty.

pressure switch harness.
No Yes

Voltage acts on red / blue wire and Pressure switch fails or refrigerant
ground (Black) connector of excavator. pressure is out of order.

No Yes
Refer to troubleshooting
for refrigeration cycle.
Check clutch Check air-conditioner
fuses. harness.
No Yes

Replace harness. Replace controller.

Inlet air and outlet air do not change over.

Inlet / outlet air mode display on

operation panel is flickering.
No Yes

M/A lever does not work due to Connector of inlet/outlet air

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

M/A failed Remove foreign matter

and replace parts. Inspect or replace.

Replace

25-40
 25. AIR CONDITIONER SYSTEM

Modes do not change. 25

Mode display (Mark of body)

on control panel is flickering.
No Yes

M/A rod does not disengage. Mode M/A connector is

disconnected or in poor
No Yes
contact. M/A failed or main
harness is faulty.
Repair. Each damper lever does not disengage.
No Yes Check and replace.

Repair. When rod is removed and cam is operated

by hand, it is heavy.
No Yes

M/A or controller is out of order. . Cam or damper shaft does not

work due to foreign matter or is broken
. Malfunction occurs due to
Replace. contaminated grease.

. Remove foreign matter or replace parts.

. Clean cam and apply new grease.

25-41
25. AIR CONDITIONER SYSTEM

Trouble of refrigeration cycle.

Both high and low pressures are lower.

Low pressure is higher.

NO YES
Air bubbles are seen in sight glass.
Air bubbles are seen in High pressure
sight glass. is lower.
NO YES

Cooling does not work Oil comes out from

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

High pressure
is lower.

Air bubbles are seen in sight glass.

NO YES
High pressure gets Condenser is
lower slowly. contaminated or clogged.

High pressure YES NO

circuit before
receiver is Air bubbles are hard to
clogged up. go out even if water
is poured on condenser.

Remove Clean
clogging or condenser. Air is mixed.
replace parts. Make vacuum and
refill refrigerant.

25-42
 25. AIR CONDITIONER SYSTEM

25.8 SELF-DIAGNOSIS

1. When error occurs in input circuit of motor actuator drive line, the error can be displayed on the 25
monitor of the LCD display.

Detection of wiring disconnection of motor actuator

Location of error Display of failures

Air mixture “HL.E” is displayed on temperature indication

Air outlet mode Human-shaped display is flashing

Internal and external

Recirculation and fresh air selector display is flashing
air selector

2. When error occurs in evaporator sensor and intake air sensor, the error can be displayed on the
monitor of the LCD display.

Detection of evaporator sensor and intake air sensor

Location of error Display of failures

Evaporator sensor “E” is indicated on first decimal place of temperature indication

“HL” is indicated on temperature indication

Intake air sensor “The figure from 0 to 9” is indicated on first decimal place of HL. 0 to HL. 9
temperature indication

3. Detection of each sensor error by monitor mode function (Detection of failure control of control panel)
• When the air conditioner is in operating condition, press the internal and external air selector switch (6) and
main power switch (1) for one second or more simultaneously. And the display of the monitor mode begins. To
return the display to the previous display, operate the two switches according to above mentioned same
operation.
• Normal condition, disconnection and short circuit of intake air sensor, evaporator sensor and solar sensor are
indicated in segment of the display.
• Normal condition and short circuit of the solar sensor is indicated in the segment of the display.
(* Detection of disconnection is not indicated.)

25-43
25. AIR CONDITIONER SYSTEM

7 segments indication of Example :

only use for monitor Special use 7-segment for monitor
Sensor 7 segments 3-digits segment list
indication Second digit of segment
Intake 㪇 㪈 㪉 㪊 㪋 㪌 㪍 㪎 㪏 㪐 㪘 㪙 㪚 㪛 㪜 㪝
air sensor 0
Intake air sensor disconnection indication “0CH0”
Evaporator
sensor 1 㪇 Evaporator sensor disconnection indication “0CH1”
Solar Solar sensor short circuit indication “0CH2”
sensor 2 㪈
Example : 㪉
Error contents of indication Position of digit indication 㪊
Sensor Short circuit Disconnection

Third digit of segment

Second digit : F
indication indication 㪋
Intake 㪌
air sensor 䌆䋶䌈
㪇
䋰䌃䌈
㪇
㪍 Each sensor is normal
Evaporator 㪈 㪈
㪎
sensor 䌆䋶䌈 䋰䌃䌈
㪏
Solar 㪐
sensor 㪇㪚㪟㪉 Third digit : F
㪘
Example: Example: 㪙
Short circuit of solar sensor At normal condition 㪚
㪛
㪜
Intake air sensor short circuit indication “F6H0”
㪝
Evaporator sensor short circuit indication “F6H1”

25-44
 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 Data of Issue Applicable Machines Remarks

SK200-8: YN12-56001~ S5YN3129E01
First Edition December, 2008
SK210LC-8: YQ12-08001~ (SE Asia & Oceania)
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)
↑
↑ ↑ SK70SR-2: YT06-18001~
(SE Asia & Oceania)
↑
↑ August, 2009 SK80MSR-2: LF06-04501~
(Oceania)
SK225SR: YB06-03501~ ↑
↑ September, 2009
SK225SRLC: LA06-02501~ (OCE)
↑
↑ November, 2009 SK850LC: LY02-00151~
(SE Asia)
SK140LC-8: YP09-T0101~
↑
↑ February, 2010 SK130-8: LP09-T0101~
(TKCM)
SK130L-8: LX07-T0101~
↑
↑ June, 2010 SK80CS-2: LF06-04501~
(NA)
↑
↑ ↑ E80BMSR: LF06-04501~
(NHK)
↑
↑ ↑ E70BSR: YT06-18001~
(NHK-EUR)
↑
↑ ↑ SK70SR-2: YT06-18001~
(NA)
↑
↑ July, 2010 E135BSRLC: YH06-08001~
(NHK-EUR)
↑
↑ ↑ SK140SRLC: YH06-08001~
(NA)
↑
SK460-8: LS11-02501~
↑ August, 2010 SE Asia & India
SK480LC-8: YS11-02001~
(HS Engine)
↑
↑ ↑ E235BSR(N)LC: YU06-03001~
(NHK-EUR)
↑
↑ ↑ SK235SRLC-2: YU06-03001~
(NA)
E225BSR: YB06-03501~ ↑
↑ ↑
E225BSRLC: LA06-02501~ (NHK-EUR)
↑
↑ ↑ SK215SRLC: LA06-02501~
(NA)
↑
↑ September, 2010 E385CLC: YC
(NHK)
↑
↑ ↑ SK350-9: YC
NA

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. S5LC3226E01

32-1
32. ATTACHMENTS

Issue Data of Issue Applicable Machines Remarks

S5LC3226E01
First Edition September, 2010 SK350-9: YC
NA

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

32-2
 32. ATTACHMENTS

32.1 REMOVING AND INSTALLING

32.1.1 ATTACHMENT ASSY

(D) ARM CYLINDER HEAD PIN

(C) BOOM CYLINDER ROD PIN
ARM CYLINDER
4. BOOM
(A) BOOM FOOT PIN
(F) BOOM TOP PIN

(E) ARM CYLINDER

ROD PIN

BOOM
2. BUCKET CYLINDER

3. ARM
(G) BUCKET
CYLINDER HEAD PIN
(J) BUCKET DRIVE PIN
BUCKET CYLINDER (I) IDLER LINK PIN BUCKET LINK (H) BOOM CYLINDER
IDLER LINK
HEAD PIN
(H) BUCKET CYLINDER ROD PIN (K) BUCKET ATTACHING PIN
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 capscrew (1)

Loosen the double nut (2) and pull out the capscrew (1).

O-RING
2 32

1
SECTION A-A
Removing Capscrew (1)

32-3
32. ATTACHMENTS

(3) Removing bucket attaching pin (K)

Lift up bucket, position it so the bucket attaching pin
(K) is not loaded, adjust bucket link, and pull out
bucket attaching pin (K). K

Removing Bucket Attaching Pin

(4) Removing bucket drive pin (J)

Put bucket on the ground, position it so the bucket
drive pin (J) is not loaded, adjust bucket link, and
J
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, align them visually.
Check the seals for damage 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) 381
+1.0 +0.039"
-0.5 (15" -0.020" )
(2) When adjusting clearance (B), bring the non- New bucket
11 : WASHER
adjusting side of the bucket in contact with the arm. 8 : LOCK B
(3) Measure clearance (B) and check that it is within WASHER 3 : O-RING

1.0 mm (0.04 in). 7 : CAPSCREW b

a
(4) Adjust clearance (B) where it is more than 1.0 mm
(0.04 in).
(5) An average of 5 shims (10) of 1mm (0.04in)
thickness are set in the plate (13) fixed by the three
capscrews (7). The clearance can be decreased by 12 :
1mm (0.04in) if one shim is removed. BUSHING

Tools: Socket: 30mm,

13 : PLATE
Tightening torque : 314 N-m (232 lbf-ft)
(6) After adjustment, tighten the capscrews evenly.
10 : SHIM 9 : PIN
-The gap exceeding the specified dimension Install pin (9) until the top of pin
causes early wear. is even surface with bushing.

(7) Operate the bucket and confirm that the total sum Adjusting Clearance Between Bucket And Arm
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 (10), push out bushing (12) rightwards by means of three capscrews (7) and adjust clearance (B)
so it settles within the standard value evenly all around.

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

OIL PAN

Disconnecting Piping Of Bucket Cylinder

Plug both ends of disconnected pipes.

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

(3) Removing bucket cylinder rod pin (H)

1. Loosen nut (10), remove capscrew M20X160 (9),
and push out pin (H). After adjustment of shim, the total gap
should be within 0.6~1.0mm (0.02~0.04in).
SHIM
Tools: Spanner: 30mm
9,10
H

SECTION D-D
Detail Of Bucket Cylinder Rod Pin (H)

2. Retract cylinder rod.

A
A
D

32-6
 32. ATTACHMENTS

(4) Removing cylinder head pin (G)

Loosen nut (3), remove capscrew M20X165 (2), 3
2
and push out pin (G).

Tools: Spanner: 30mm

SHIM
After adjustment of shim,
the total gap should be
within 0.6~2.0mm
(0.02~0.08in).

G
SECTION A-A
Detail Of Bucket Cylinder Head Pin (G)

(5) Removing bucket cylinder

Sling the tube of the bucket cylinder with a nylon
sling, and remove it.
Bucket cylinder weight: 260 kg (573 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 M20X180 (2), and push out the arm cylinder rod pin (E).

Tools: Spanner: 30mm

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

BLOCK Install plastic shims Apply grease to inner wall

B to cylinder side. of bushing 2,3

A
A

SHIM
After adjustment of shim, the total gap
should be within 0.6~2.0mm (0.02~0.08in).

SECTION B-B
Detail Of Arm Cylinder Rod Pin (E) 32

32-7
32. ATTACHMENTS

(7) Removing boom top pin (F) Install plastic shims

Loosen capscrew M16X35 (2), plate (1) and pull to arm side.
Apply grease to inner wall
out boom top pin (F). of bushing

Tools: Spanner: 24mm

Insert pin (F) into the original hole.

F
1,2
Apply Loctite #242

After adjustment of shim,

the total gap should be within
0.5mm (0.02in).
SECTION A-A

Detail Of Boom Top Pin (F)

(8) Slinging arm assy

Sling arm with nylon sling and remove it.

Arm weight: 1,275 kg (2,811 lbs)

Slinging Arm Assembly

32.1.3.2 ATTACHING ARM

Install 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, align them visually.
(0.02")

2. Check the seals for damage and replace as

necessary. CLEARANCE
3. When inserting the pin, coat the shaft with grease.
4. Pin lock nut handling procedure
Tools: Spanner: 30mm

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. When attaching the shims, attach the resin shim first and then fill the gap with iron shims.
7. Tightening torque

Tightening torque
Classfication Size
N.m lbf.ft
M16 147 108
M16
Metric threads (BOOM TOP) 279 206
M20 181 133
1/8" 16.7 12.3
PF,PT threads
1/4" 36.3 26.8

32-8
 32. ATTACHMENTS

32.1.4 BOOM

32.1.4.1 PREPARATION FOR REMOVING AND ATTACHING BOOM

When removing and attaching the boom in the position shown in the below Figure. Remove and attach the 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 the boom.
Place the top end of the boom down on block, etc.
giving attention for the arm cylinder rod not to be
extended.

BLOCK

Position To Remove Boom

(2) Lifting up boom cylinder temporarily

Remove the right and left boom cylinders one side
according to the following procedure:
Lift up boom cylinder temporarily to prevent it from
A
dropping.
A

STAND

Lifting Up Boom Cylinder Temporarily

(3) Press the boom cylinder rod pin (C)

Install plastic shim to cylinder side.
At the one side of pin (C), loosen nut (5), remove SHIM
capscrew (4) (M20X190), and remove collar (3). After adjustment of shim,
the total gap should be within
And push pin (C) to the end of boom boss. 0.6~2.0mm (0.02~0.08in).
SHIM
Tools: Spanner: 30mm

3 4

C
3

5
32
SECTION A-A
Detail Of Boom Cylinder Rod Pin (C)

(4) Preparing for disconnecting cylinder pipes

Retract the above mentioned cylinder rod,
and place one side of cylinder on stand. (See right Fig.)

32-9
32. ATTACHMENTS

(5) Disconnecting the arm cylinder and bucket cylinder

pipings
Release pressure from the arm and bucket circuit
and bleed air in hydraulic tank. Then disconnect
pipe at (A1), (A2), (A3), (A4) and hose (5), (6), (8),
(10). A1

Tools: Spanner: 41mm

Tools: Allen wrench: 12mm
A2

After disconnection of pipe, plug every pipe.

A3
ORS Plug: See Tools 11.5.2-(4).
Half clamp: See Tools 11.5.2-(5).
A4
6
8 10 5
Boom Piping Disconnection

(6) Lifting up boom assembly temporarily

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

Weight of single boom: 2,670 kg (5,890 lbs)

Boom Assy Temporary Lift Up Procedure

(7) Removing boom foot pin (A)
1. Remove capscrew (3) M20X60, and plate (2).
Install plastic shims to boom side.
Tools: Spanner: 30mm

After adjustment of shim,

2. Draw out pin (A). the total gap should be within
0.5mm (0.02in).

A
3
Apply loctite
2 #242 to bolt.

Apply grease to inner wall 2

of bushing
SECTION A-A
Details Of Boom Foot Pin (A) Section

32-10
 32. ATTACHMENTS

(8) Hoisting boom assembly

Hoist and remove boom assembly.

Weight of single boom: 2,670 kg (5,890 lbs)

D
D

Boom Assy Hoisting Procedure

(9) Completion of removal of front attachments
When the removing and attaching of cylinders are not required, the work is finished.
(10)Removing and installing arm cylinder
1. 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
11.5.2-(5) Plugs for half clamp
Tools: Spanner: 41mm F2
G1
Tools: Allen wrench: 12mm

2. Removing arm cylinder head pin (D)

Loosen nut (3), remove capscrew M20X180 (2) and
Install plastic F1 A
pull out pin (D). shim to After adjustment of
cylinder side. shim, the total gap
should be within
Tools: Spanner: 30mm 0.6~1.0mm 2,3
(0.02~0.04in).
SHIM Apply
3. Removing arm cylinder grease
to inner
Weight of arm cylinder: 504 kg (1,110 lbs) wall of
bushing

D
SECTION D-D
Removing Arm Cylinder
32

32-11
32. ATTACHMENTS

(11)Removing and installing boom cylinder

1. Disconnect hose (C2) at position B. And plug both
ends.
Plug: Tools 11.5.2-(4) Plugs for ORS fitting
: Tools 11.5.2-(5) Plugs for half clamp
Tools: Spanner: 41mm

D1
C1

E1

C2
C2 B
E2
Removing And Installing Boom Cylinder

2. Removing boom cylinder foot pin (B)

(See right Fig., below Fig.) Apply grease to inner wall
Loosen nut (5), remove capscrews M20X190 (4) of bushing
4,5 B
and pull out pin (B).
Tools: Spanner: 30mm Install plastic
B 4,5 shim to
3. Remove boom cylinder (2).
cylinder side.
Weight of boom cylinder: 269 kg (590 lbs)
4. Remove the other boom cylinder the same way.
After adjustment of shim,
the total gap should be within
0.6~1.0mm (0.02~0.04in).
SECTION B-B
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 assembly.
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, align them visually.
2. Check that the dust seals are not damaged and
replace as necessary.
A
3. When inserting the pin, coat the shaft with grease.
4. Refer to paragraph 32.1.3.2 about installing jam
nuts.
5. When installing boom and cylinder, check the
clearance of the mounting section in the thrust
direction, and decide the thickness of the shim
according to the maintenance standard.
6. When attaching the shims, attach the resin shim Boom Foot Pin (A)
first and then fill the gap with iron shims.
7. Tightening torque

Tightening torque
Classfication Size
N.m lbf.ft
Metric threads M20 181 133
1/8" 16.7 12.3
PF,PT threads 1/4" 36.3 26.8
3/8" 73.5 54.2

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 dust free workshop and the 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 for disassembly. Pay attention to where the cleaning and measuring
equipment are placed and where 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 is 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 linear movement under load for retracting and extending the piston rod and the cylinder
tube.
(2) Work bench
The work bench must have strength capable of accommodating the total length of the cylinder in its most
retracted condition and withstand 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 sufficient.
(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 to 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) Compressed air source
It is used for drying after oil draining and cleaning of the cylinder.
(6) Cleaning bath, cleaning oil and detergent
(7) Oil pan and oil reservoir
An oil pan is necessary to contain oil drained from the cylinder and oil spilt during work.
An oil reservoir is required to collect oil spilt on the floor and waste oil.

(8) Others
Oil extracting hoses, wooden blocks, clean cloths and oil dry to soak up the spilt oil.

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 Metal one with smooth corners.
2. Wooden or plastic mallet
Screwdriver A few types of large and small sizes Gimlet A sharp-point tool may be used in place
of a gimlet.
Chisel Flat chisel Special jig 1. For removing and press-fitting bushing.
(A), (D), (C)
2. For press-fitting wiper ring. (D)
3. For inserting and reforming seal ring.
(E),(F),(G),(H)
(See para 32.2.1.9 for detail)
Vise One having an opening 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, remove external soil and
contamination from the cylinder with water and steam
before bringing it into the workshop.
Cylinder Gauge
The following describes the construction of the boom
cylinder. When disassembling and servicing the
cylinder, confirm the construction of the 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. Blow com- WOODEN BLOCK
pressed air into ports A and B alternately to actuate
the piston rod till the hydraulic oil in the cylinder is PORT B
V BLOCK
drained out. At this time, connect a suitable hose to
each port so that the hydraulic oil will not gush out. PORT A

AIR

OIL PAN
Preparation
32

32-15
32. ATTACHMENTS

32.2.1.2 CONSTRUCTION OF CYLINDER (GENERAL EXAMPLE OF CYLINDER)

25 24 12 24 25

PS1/8
PT1/4
SLIT 15

ONE HOLE
DETAIL 6 DETAIL B
DETAIL C
Piston with piston nut type

9 8 7 6 4 5 3 11 10 2 1 13 14 15 17 16 18 19 *20 *21 22 23

SLIT
C

Construction Of General Cylinder

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

1 Cylinder tube 1 10 O-ring 1 19 Slide ring 2
2 Piston rod 1 11 Back-up ring 1 20 Shim *1
3 Rod cover 1 12 Socket bolt 12 21 Piston nut *1
4 Bushing 1 13 Cushion bearing 1 22 Setscrew; M12 1
5 Snap ring 1 14 Cushion seal 1 23 Steel ball 1
6 Buffer ring 1 15 Piston 1 24 Pin bushing 2
7 U-ring 1 16 Seal ring 1 25 Wiper ring 4
8 Back-up ring 1 17 Back-up ring 2
9 Wiper ring 1 18 Slide ring 2

Note: In case of a piston with a 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 in separate Parts Manual.
• The figures in parentheses after part names correspond to those in the Figure "construction of general cylinder"
• The following explanation and quantities are for a general use cylinder which has separated piston and a piston
nut.
In case that piston and piston nut are combined, the construction differs from the 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 (2) about 200 mm (8in). Because
200mm
the piston rod is heavy, finish extending it with air (8")
pressure after the above-mentioned oil draining
operation.

Use vise 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 the socket bolts (12) on the rod ALLEN WRENCH 12
cover in sequence.
(4) Strike the corner of the rod cover flange by means
of a plastic mallet till rod cover (3) comes off.

Turn counterclockwise

3
Cover here with cloths
2

Cover the extended piston rod (2) with cloths to prevent it from being accidentally damaged.

32

32-17
32. ATTACHMENTS

• At this time, the weight of piston rod (2) is loaded KNOCK THIS EDGE
on rod cover (3). Therefore, lift the top end of the WITH A PLASTIC MALLET.
LIFT HERE.
piston rod with a hoist to the extent that only the rod
weight may be held.

3
2
Drawing Out Piston Rod Assembly (2).

(5) Draw out the piston rod assembly from the cylinder
tube (1). LIFT HERE. 1

PULL STRAIGHT
SIDEWAYS
HORIZONTALLY

OIL PAN

Method Of Drawing Out The Piston Rod Assembly

Since the piston rod assembly is heavy in this case, lift the tip of the piston rod (2) with a hoist and draw it out.
However, when the piston rod (2) has been drawn out to approximately two thirds of its length, lift it in the center to
draw it out completely. However, since the plated surface of the piston rod (2) is lifted, do not use a wire rope that
may score the surface, but use a strong cloth belt or rope.

(6) Place the removed piston rod on a horaizontal

wooden V-block.

PISTON ROD ASSY

-Cover the V-block with cloths.

WOODEN V-BLOCK
(PLACE CLOTHS)
Method Of Placing The Piston Rod

(7) Remove slide ring (18) and (19) from piston (15).
15
Remove slide ring by
widening the slit toward
the arrow

19

18
Remove Slide Ring (18) And (19)

32-18
 32. ATTACHMENTS

32.2.1.3.2 REMOVING PISTON ASSY

(1) Fix piston rod (2) by holding its clevis section in a
vise. Fix the piston rod (2) securely as the piston 3 WOODEN BLOCK
nut (21) is tightened to a high torque. 2
15
21

WOODEN V-BLOCK
(PLACE CLOTHS)

How To Loosen Piston Nut (21)

Note that the tightening torque differs with the type, the working pressure and the mounting method of the piston
(15), though the rod diameter remains the same.
It is also necessary to place a suitable supporting block near the piston (15). In case a V-block is used, put cloths or
something over the rod to prevent it from damage.

(2) Scrape off the caulked part of setscrew (22) on the

piston nut (21) by means of a hand drill and loosen 22 DRILL
the setscrew (22) and remove ball (23).

Tools: Allen wrench: 6mm

21

23

Removing Setscrew (22) And Ball (23)

(3) Loosen and remove piston nut (21) or [piston (15)].

TURN COUNTER
CLOCKWISE.
15
EYE WRENCH
21
How To Loosen Piston Nut (21)
32

Since the piston nut (21) is tightened to a high torque, use a eye wrench suitable for the outside diameter of the
piston nut (21).
In case the piston and piston nut are combined, apply the eye wrench to the hexagonal part of piston and loosen
the piston directly.

32-19
32. ATTACHMENTS

(4) Remove piston (15) by tapping with a plastic mallet,

supporting weight of the piston (15) with hoist.

4 15
Removing Piston (15)

In case the piston and piston nut are combined, the shim (20) is not used.

(5) After removing the cushion bearing (13) and

cushion seal (14), separate the rod cover (3) from LIFT WITH A HOIST. STRIKE WITH
the piston rod (2). If it is too hard to slide it, knock A PLASTIC MALLET.
the flanged part of the rod cover (3) with a plastic
PULL STRAIGHT.
mallet. But when drawing it out, lift the rod cover (3)
by hoist and pull it straight out horizontally. NOTE:
DO NOT
DAMAGE
PISTON ROD
SURFACE.

3 4 6 8,7 9 2
Removing Rod Cover (3)

Take care so the rod bushing (4) and the lip of packings (6,7,8, and 9) are not damaged by the threads on the
piston rod (2).

32-20
 32. ATTACHMENTS

32.2.1.3.3 DISASSEMBLING PISTON ASSY

(1) Remove seal ring (16) and back-up ring (17).
HAMMER

SCREWDRIVER (OR CHISEL)

BACK-UP RING SEAL

17 RING
16

USE CARE NOT

15 TO DAMAGE O-RING
THE GROOVE.
Removing Seal Ring (16) And Back-up Ring (17)

Cut the seal ring (16) by tapping it with a screwdriver or a chisel. Take care not to strike it too hard, otherwise the
groove may be damaged.

32.2.1.3.4 DISASSEMBLING ROD COVER ASSY

(1) Remove O-ring (10) and back-up ring (11).
SPATULA
Remove back-up ring (11) and O-ring (10) in that
order. Remove back-up ring (11) and O-ring (10) by 10
pulling and stretching them with a spatula.
11

Removing The Outer Circumferential Seal Of Rod

Cover (3)

(2) Remove buffer ring (6), U-ring (7) and back-up ring GIMLET
(8). Each seal is fixed in the groove on the bore.
Stab each seal with a gimlet and pull it out of the
8
groove.
3 7

Removing The Inner Circumferential Seal Of Rod 32

Cover (3)

Take care in this operation not to damage the grooves.

32-21
32. ATTACHMENTS

(3) Remove the wiper ring (9). When taking out the HAMMER SCREW- 3
wiper ring (9), fix the rod cover (3) in a vise. DRIVER

WOOD PIECE
WOOD PIECE
VISE

Removing Wiper Ring (9)

(4) Remove the snap ring (5) and bushing (4).

PRESS HERE
Remove snap ring (5) first, and then remove CHUCK ASSY TOOL A
bushing (4). The bushing (4) is press fitted in the
rod cover (3), so push it out with a press with a jig
as shown in the Figure.
See para 32.2.1.9.3 (1) for removing. BUSHING 4

BLOCK TOOL C

Removing Rod Bushing (4)

32.2.1.3.5 REMOVING PIN BUSHING

(1) Apply driver to wiper ring (25) of cylinder tube (1) PUSH WITH A PRESS.
and piston rod (2), and strike it by hammer lightly. JIG J
(2) Push out the pin bushing (24) that is press fitted in
cylinder tube (1) and piston rod (2) with press.

24 BASE

Drawing Out Pin Bushing (24)

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 with compressed air, and put them on the work bench taking care not to damage
them.

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

32-22
 32. ATTACHMENTS

32.2.1.5 ASSEMBLING PIN BUSHING

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

32.2.1.5.1 ASSEMBLING PIN BUSHING

(1) Press fit pin bushing (24) in cylinder tube (1) and
piston rod (2) respectively with press. PUSH WITH A PRESS
2
(2) Press fit wiper ring (25) in the upper and lower
24
sides of the cylinder tube (1) and piston rod (2)
respectively with a press.

OIL HOLE LOCATION

Press Fitting Of Pin Bushing (24)

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

32.2.1.5.2 ASSEMBLING OF PISTON ASSY

(1) The fitting of seal ring (16) requires a special tool as
shown the Figure. The seal ring (16) is pushed in PRESS HERE METAL (G)
by press, etc. with pushing tool as shown in the PRESS JIG (E)
Figure. The O-ring on seal ring (16) and back-up
ring (17) on one side should be installed SLIDE JIG (F)
beforehand.

15

16 O-RING

17

How To Fit Seal Ring (16)

Heat them, and they may soften. But never heat them over 100° C (212° F degrees).

32

32-23
32. ATTACHMENTS

(2) Fit back-up ring (17) on the other side. After fitting,
correct it immediately to prevent it from expansion PRESS HERE
of the seal ring (16) with correcting jig (H) as shown 16 17
in right Figure.
CORRECTIONAL
JIG (H)

Installing Seal Ring (16)

For the piston, stop it once tentatively (for 3 to 5 seconds), and then push it in fully.
After fitting, wind tape around seal ring (16) 2 or 3 times, and remove it immediately before piston (15) is inserted in
cylinder tube (1).
Fit slide rings (18 and 19) at the same time when piston (15) is inserted in cylinder tube (1).

32.2.1.5.3 ASSEMBLING ROD COVER ASSY

(1) Press fit bushing (4) in rod cover (3) with bushing
press-fitting jig (A). Then, fit snap ring (5) in the PRESS HERE. (STRAIGHT DOWN)
groove. Apply hydraulic oil on the internal surface 4 PRESS FITTING JIG (A)
of rod cover (3).
GROOVE FOR
FIXING SNAP RING (5)

Press bushing till bushing

comes in contact with
3
this face.

The snap ring (5) cannot be fitted when the bushing (4) is not press-fitted fully to the stop end.

(2) Apply grease to wiper ring (9), and fit wiper ring (9),
directing the lip side toward the groove of retainer PRESS HERE. (STRAIGHT DOWN)
tool (D). Set retainer tool (D) on rod cover (3) and
press fit wiper ring (9) with press. RETAINER TOOL (D)

U-RING GROOVE

Press Fitting Of Bushing (4)

32-24
 32. ATTACHMENTS

(3) Fit buffer ring (6), back-up ring (8) and O-ring (7) 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.

INSERT U-RING INTO GROOVE FROM THIS SIDE. PUSH BAR (WOOD OR PLASTIC)
10
11
Tube side
3

Inserting A Seal Into The Inner Circumference Of

Rod Cover

7
8
9
How To Fit O-ring (7)

O-ring (7) is harder than other packings and it would be difficult to deform them in a heart shape. In such a case,
put a O-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 (6) 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 O-ring.
If O-ring (7) is set upside down, the lip may be damaged. Check that it is positioned correctly.
Attach back-up ring (11) on the open air side of O-ring (10). (See above Figure).

32.2.1.5.4 INSERTING ROD COVER ASSEMBLY TO PISTON ROD

Inserting rod cover (3) to piston rod assembly by the following procedure.
(1) Fix piston rod assembly on work bench.
(2) Install rod cover (3) on piston rod (2) with inserting
INSERT GUIDE JIG (I) 3
guide jig (I) as shown in Figure. Pay attention that
the lip section of the O-ring is not caught on the PUSH
stepped section.

Inserting Rod Cover (3)

32

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

32-25
32. ATTACHMENTS

32.2.1.5.5 ASSEMBLING PISTON ASSY ONTO PISTON ROD

(1) Install the cushion on the extraction side, cushion bearing (13) and cushion seal (14) by the following procedure.
1. Put the cushion seal (14) on it, directing the slit
machined side toward the piston side. PISTON
2. Fit cushion bearing (13) on it directing the flattening 13
14
side as shown in right Figure.

FLAT SECTION

Direct slit toward

piston side
Cushion Mechanism On Extension Side

(2) When the cushion is installed on the retraction side, fit the cushion bearing (13) and cushion seal (14) by the
following procedure.
1. Fit cushion bearing before fitting piston nut. The nut
attached obstructs the fitting of cushion bearing. Direct slit toward
2. Put cushion seal on it, directing the slit machined thread side
THREADED PART
side toward the piston side.
3. Fit cushion bearing on it directing the flattening side
as shown in the Figure. PISTON ROD
4. Put a stopper in the groove. Push the cushion
bearing to stopper fully, and drive the snap ring.
Use a plastic mallet in order not to damage the rod
and cushion bearing.
SNAP RING
CUSHION SEAL CUSHION STOPPER
(Slit 1 place) BEARING (Divide into 2 portions)
Cushion Mechanism On Retraction Side

The cushion seal and cushion bearing should be fitted taking care of the fitting direction. If they are fitted in the
reverse direction, the cushion is not effective.
After installing the cushion, be sure that the cushion bearing moves up and down, and right and left.

32-26
 32. ATTACHMENTS

(3) Insert shim (20), and tighten piston nut (21) or

[piston (15)] till it gets tight. 21
Always tighten the piston nut (21) or [piston (15)] of
each piston to the specified torque
(Refer to 32.2.1.7.3).
EYE WRENCH

Tightening Piston Nut (21)

In case the piston and piston nut are combined, the shim (20) is not used. Apply the eye wrench to the hexagonal
part of the piston and loosen the piston directly.
Always correct the threads in the piston nut (21) or [piston (15)] before fixing the piston nut, using a tapping.
Insufficient tightening torque causes an inner leak and damage to threads. Over tightening torque causes a bulge
of the cushion bearing and a deformation of the piston contacted surface.
Clean and decrease (with solvent) the parts of the piston assembly, and dry them, then tighten the piston assembly.

(4) Put the steel ball (23) into the hole and tighten
setscrew (22). ANTI-LOOSENING
22 CAULKING 20
Tools: Allen wrench: 6mm 2
23
After tightening the setscrew to a specified torque,
caulk the two places of the thread on the piston nut
side to secure the setscrew.
See para 32.2.1.7.3 for torque.

V-BLOCK
21
Attaching Setscrew (22)

(5) Attach two slide rings (18 and 19). Take off the vinyl
tape wound around the perimeter of piston (15). 22 18 19
2
Apply high-quality grease (or vaseline) to the slide
rings (18 and 19) and attach the slide rings in a
manner that they may be coiled around the groove.
Set the slide rings about 180 degrees apart of each
other so the slits do not point the same direction.

21 V-BLOCK

Attaching Slide Ring (18 and 19)

32

32-27
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 assembly by passing a wooden bar through the clevis pin hole to lock the assembly.
(2) Insert the piston rod assembly into the cylinder tube assembly, while lifting and moving the piston rod assembly
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 assembly with the center of the cylinder tube
assembly and put it in straight. When inserting, make sure that slide rings (18 and 19) on the perimeter of the
piston are not out of the grooves.
(3) Tighten socket bolt (12). Match the bolt holes of the rod cover flange to the threaded holes in the cylinder
assembly, and screw in the socket bolts (12) one by one. Tighten the bolts to a specified torque, taking care so
the bolts are not tightened unevenly. See para. 32.2.1.7.3 for torque.

Tools: Allen wrench: 14mm

1 12

LIFT PLACE CLOTH

STRAIGHT PREVENT TURNING

WITH WOODEN BAR.

ALLEN WRENCH

Inserting Piston Rod Assembly TURN CLOCKWISE

Tightening Socket Bolts (12)

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

32-28
 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. DIRECTIONAL VALVE
PUMP

H R

HYDRAULIC CYLINDER
External Leak Test

Do not raise the hydraulic pressure above the maximum pressure of 37.8MPa (5480psi) for the cylinder.
Grease coatings 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 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 the Figure below.
2. After completing the test, apply a plug to each port and store the cylinder. For storage, place the cylinder on
wooden V-blocks and bring the cylinder to the most retracted condition.

CYLINDER ASSY
MEASURE THE
INTERNAL LEAK.

PLUG PLUG
How To Store The Cylinder

FROM DIRECTIONAL VALVE

Internal Leak Test

32

32-29
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, cracks and other damage 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"

Piston rod 6. Plated surface Check that:

1) Plating is not worn off to base 1) Replace or replate
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 it can
be caught by your finger 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 a maximum of 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.

32-30
 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. Damaged
rods and tubes will damage the seals and O-rings.
(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 a maximum of 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-blocks
and turn the piston rod. Read the difference between the maximum and minimum deflection on the dial
indicator.
Table shows an example of measurement.

Example of Measurement
Distance between Deflection of the dial indicator
V-blocks in the middle of the rod. Remedy
m (ft-in) mm (in)

1 (3’3") 1 (0.04") Replace Measuring Method

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

32.2.1.7.3 TIGHTENING TORQUE

B A C Unit : N.m (lbf.ft)

A B C
Cylinder Piston nut
or [Piston] Socket bolt Setscrew
Boom 8000 (5900) 367 (270) 56.9 (42)
Arm 17000 (12540) 711 (520) 96.6 (71)
Bucket 10000 (7380) 520 (380) 56.9 (42)

32.2.1.7.4 VOLUME OF OIL LEAK

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

Cylinder Volume of Internal Oil Leak

Boom 1.0 cc (0.06 cu-in) or below / 3 min
Arm 1.0 cc (0.06 cu-in) or below / 3 min
Bucket 1.0 cc (0.06 cu-in) or below / 3 min
32

32-31
32. ATTACHMENTS

32.2.1.8 TROUBLESHOOTING
Table32-4
Trouble Failed Parts Cause Remedy
1. Oil leak through sliding 1. Back-up ring 1. Foreign matter is trapped in the 1. Remove foreign matter.
surface of piston rod. Oil bore of back-up ring
ring is formed on piston 2. Lips on outer and inner diameter 2. Replace back-up ring.
rod, and the ring grows up surfaces of back-up ring are
to oil drops, and they drip. scored.
3. Other back-up ring are failed. 3. Replace back-up ring
2. U-ring 1. Foreign matter is trapped in the 1.Remove foreign matter.
OIL LEAKS FROM HERE bore of ring.
2. Score is present on the bore of ring. 2. Replace U-ring.
3. Other rings are failed. 3. Replace U-ring.
3. Buffer ring 1. Foreign matter is trapped in the 1.Remove foreign matter.
bore of ring.
2. Score is present on the bore of ring. 2. Replace buffer ring.
3. Other rings are failed. 3. Replace buffer ring.
4. Wiper ring 1. Foreign matter is trapped in the 1.Remove foreign matter.
bore of wiper ring.
2. Lip on the bore of wiper ring is 2. Replace wiper ring.
scored.
3. Another wiper ring is failed. 3. Replace wiper ring.
5. Piston rod 1. Score is present on the sliding 1.Smooth out the sliding surface with
surface of piston rod. an oilstone. If leakage occurs even
if the sliding surface is finished
below 1.6S, rod packings may be
scored. Disassemble and inspect it
and replace rod packings as
required.
If leak will not stop by that
treatment, replace piston rod.
2. Hard chromium plating has peeled 2. Replate.
off
2. Oil leaks from the 1. O-ring 1. O-ring is damaged. 1. Replace O-ring.
circumference of rod cover. 2. Backup ring 1. Back-up ring is damaged. 1. Replace back-up ring.
3. Cylinder tube 1. Swelling of cylinder tube. 1. Replace cylinder tube.

OIL LEAKS FROM HERE

3. Oil leaks from welds. 1. Cylinder tube 1. Welds of cylinder are broken. 1. Replace cylinder tube.

WELDS
4. Cylinder falls by it-self. 1. Piston seal 1. Foreign matter is trapped in the 1. Remove foreign matter
[When the rod is loaded with sliding surface of seal ring.
a static load equal to the 2. Score is present on the sliding
2. Replace seal ring..
maximum working pressure surface of seal ring.
multiplied by the area of the 1. Sliding surface of slide rings is
2. Slide ring 1. Replace slide ring.
cylinder bore, the maximum scored.
movement of the piston is 3. Piston rod 1. Elongation.Piston rod and piston 1. Replace piston rod.
more than 0.5mm (0.02") in are elongated. (Loose nut)
ten minutes.]

32-32
 32. ATTACHMENTS

32.2.1.9 JIGS LIST

32.2.1.9.1 SPECIAL JIG LIST (POSSIBLE TO SUPPLY)
When assembling, the following jigs are required.

Table32-5
Described
Application Shape
paragraph
A D

For removing and press 32.2.1.3.4,

fitting bushing EDGE OF C 32.2.1.5.2
CHUCK

D
For press fitting wiper
32.2.1.5.2
ring

E H
F

For correcting seal ring 32.2.1.5.2

INSERTING JIG CORRECTING JIG

I
For inserting rod cover 32.2.1.5.4

For above jigs, contact our dealer.

(The Jig No. List provided by cylinder maker is shown on the following page.)

32

32-33
32. ATTACHMENTS

Special Jig No. List

(1) For jigs for rod cover, select jig corresponding to respective rod diameter.
(2) For jigs for piston, select jig corresponding to the cylinder bore.

Application rod diameter [mm (in)] Kit No. of maker

65 (2.56") 3006J-56001
70 (2.76") 3007J-06001
75 (2.95") 3007J-56001
80 (3.15") 3008J-06001
85 (3.35") 3008J-56001
Jig for rod cover
removing & 90 (3.54") 3009J-06001
installing
95 (3.74") 3009J-56001
100 (3.94") 3010J-06001
105 (4.13") 3010J-56001
110 (4.33") 3011J-06001
115 (4.53") 3011J-56001
120 (4.72") 3012J-06001
Application cylinder bore [mm (in)] Kit No. of maker
95 (3.74") 3009J-51001
100 (3.94") 3010J-01001
105 (4.13") 3010J-51001
110 (4.33") 3011J-01001
115 (4.53") 3011J-51001
120 (4.72") 3012J-01001
Jig for seal ring
inserting & 125 (4.92") 3012J-51001
correcting
130 (5.12") 3013J-01001
135 (5.32") 3013J-51001
140 (5.51") 3014J-01001
145 (5.71") 3014J-51001
150 (5.91") 3015J-01001
160 (6.30") 3016J-01001
170 (6.69") 3017J-01001

32-34
 32. ATTACHMENTS

32.2.1.9.2 OTHER SPECIAL JIGS (PREPARED BY SERVICE SHOP)

(1) Bushing removing jig (Symbol J)

80 (3.15") MATERIAL : Mild steel

(0.59")(0.59")
50 15 15 Unit : mm (inch)
(1.97")

12-S
(0.08") d D Cylinder Used
(0.08") 5 (0.2")
C2 R2 R0.2 90 (3.54") 103 (4.06") Bucket
(0.008")
10 12-S
100 (3.94") 113 (4.45") Boom (Head Side)
110 (4.33") 123 (4.84") Arm, Boom (Rod Side)

-0.2 (-0.008")
-0.4 (-0.016")
-0.5 (-0.02")
-1 (-0.04")

25-S
-3 (-0.12")
-4 (-0.16")

Bushing Removing Jig

(2) Wrench for piston nut or [piston]

Unit : mm (inch)
B Cylinder Used
115 (4.53") Boom, Bucket
135 (5.32") Arm

B
Wrench For Piston Nut Or [Piston]

32

32-35
32. ATTACHMENTS

32.2.1.9.3 SPECIAL JIG HANDLING PROCEDURE

(1) How to remove bushing from rod cover.
1. Attaching chuck assembly tool
Insert tool in rod cover slowly until the edge top end of the chuck assembly reaches to the end of the bushing
(4).
• Special attention must be paid so that the inner surface of the rod cover is not damaged by the edge of the tool.
• Attach top in position 5mm (0.2 in) from the bushing end face so that the edge does not protrude from the end
face.

4 5 (0.197")

(CHUCK)

2. Tightening chuck assy tool temporarily

a. Fit allen wrench to the head of adjuster bolt on the top end of tool, and insert lever in the round hole on the rear
end of tool.
b. Fix it with allen wrench and lever to the position where the tool does not drop even if the rod cover is raised,
inclining it forward and rearward.

• Move rod cover onto the work bench with tool attached.
• Be careful not to drop it on your feet, etc.

32-36
 32. ATTACHMENTS

3. Attaching tools for retainer

Put retainer on the press bench directing the wiper
ring fitting section of the rod cover upward, then put
D
the retainer tool (D) on the rod cover.
-Fit retainer tool as shown in the right Figure, FLANGE
directing the large diameter section (flange section)
upward.
-Clean the surface of the press bench, and take
care that the tool bottom face is not damaged by
foreign matter like dust, chips, etc.

4. Cutting into of the edge of chuck

Press the upper section of the retainer tool PRESS HERE
gradually so the edge of chuck tool (A) cuts into the
bushing surface.
Set the pressing force to 2 to 3 tons (4410 to 6615
lbs).

After completion of pressing, tighten the adjuster

bolt again by hand.

-Press it with retainer tool (D).

CHUCKING JIG A

32

32-37
32. ATTACHMENTS

5. Setting of tools for block

Prepare block (C), and put rod cover (3) on it aligning them.
Select the corresponding block (C) in shape, dimensions, etc. from the table shown below.

oD
15 (0.59") 15 (0.59")

od 10

10
Unit : mm (inch)
Class
(Nominal size) d D h
o55 (2.17) 62 (2.44) 88 (3.46) 80 (3.15)
o60 (2.36) 67 (2.64) 96 (3.78) 80 (3.15)
o65 (2.56) 72 (2.83) 96 (3.78) 80 (3.15)
o70 (2.76) 77 (3.03) 100 (3.94) 80 (3.15)
o75 (2.95) 82 (3.23) 110 (4.33) 80 (3.15)
o80 (3.15) 87 (3.43) 112 (4.41) 80 (3.15)
o85 (3.35) 92 (3.62) 124 (4.88) 90 (3.54)
o90 (3.54) 97 (3.82) 135 (5.31) 90 (3.54)
o95 (3.74) 102 (4.02) 145 (5.71) 90 (3.54)
o100 (3.94) 107 (4.21) 145 (5.71) 90 (3.54)
o105 (4.13) 112 (4.41) 150 (5.91) 90 (3.54)
o110 (4.33) 117 (4.61) 165 (6.50) 90 (3.54)
o115 (4.53) 122 (4.80) 170 (6.69) 90 (3.54)
o130 (5.12) 137 (5.39) 190 (7.48) 90 (3.54)

6. Removing bushing
a. Move block (C) and rod cover (3) with tool under
the press.
b. Press the upper part of retainer tool (D) slowly until
bushing (4) is removed from the rod cover (3) (until
there is a sound that the chuck tool (A) drops on the
work bench)
D
-The force of 3 tons (6615 lbs or less) is necessary
to press it out.
The stroke of press ram is about 32 to 52 mm (1.26
in to 2.04 in). (But it varies according to the
difference of dimension of the cylinder head.)

-Press it with retainer tool (D).

When the block and rod cover assembly are not

aligned, interrupt the work and align the block and
rod cover assembly.

32-38
 32. ATTACHMENTS

7. Removing rod cover

a. Remove block (C) with rod cover (3) near side, remove retainer tool (D) from rod cover (3), and then move rod
cover (3).
b. Take out the chuck tool (A) with bushing from block (C).

Do not work under the press because it is very dangerous.

8. Removing bushing

a. Place chuck tool (A) with bushing (4) sideways, and loosen adjuster bolt with allen wrench and lever.
b. Place the chuck tool (A) vertically and turn the adjuster by hand until the wedge is raised about 5mm (0.2 in).
c. Remove the wedge from the edge of chuck

• Clean the surface of work bench, and be careful that the tool is not damaged by foreign matters like dust, chips,
etc.

32

32-39
32. ATTACHMENTS

9. Tightening of adjuster bolt

Tighten the chuck tool (A). The bushing (4) is
removed to the extent that there is no gap between
the chuck and the wedge upper face, turning the
adjuster bolt by hand.

-This special tool differs according to the

corresponding piston rod diameter.
-The chuck edge is an important portion. Take care
of handling and storage.

32-40
 32. ATTACHMENTS

(2) Rod cover bushing press-fitting procedure

1. Temporary setting of head bushing
Put rod cover (3) on the press-working bench directing the tube connection upward.

Set bushing (4) on the inner surface of rod cover (3) temporarily.
• Make sure that the inner and outer surfaces of bushing (4) are free from foreign matter.

2. Setting chuck assy tool (A)

Insert the chuck assy tool (A) in a temporary-set bushing (4) directing the flange downward, and set it on rod
cover (3).
• Be sure that the adjuster bolt is tightened to the extent that there is no gap between the adjuster of the chuck
assembly (A) and wedge.

ADJUSTER BOLT
WEDGE

32

32-41
32. ATTACHMENTS

3. Attaching retainer tool

Put retainer tool (D) on the wedge stepped section
of the chuck assembly tool (A) slowly directing the
flange upward.

-Align chuck assy (A) and the wedge.

4. Preparation for press-fitting

Move the rod cover that the chuck tool (A) and PRESS RAM
retainer tools are attached under the press.

-Adjust it so the press ram is centered to the tool.

RETAINER(D)

CHUCK(A)

BUSHING(4)

BUSHING PRESS-
FITTING PART

32-42
 32. ATTACHMENTS

5. Press-fitting of bushing
Push the head of retainer (D) with the press, and
press fit bushing (4) to the specified position on the
rod cover (3) slowly.

-The pressing force should be held at 5 tons (11025 STEP OF WEDGE

lbs) or less, keeping the required force for the
press-fitting.
-Raise the pressure gradually adjusting the force by
means of a pressure adjusting valve on press unit.
-Be sure that the end face of the bushing is located
on the interior of the groove for the snap ring. When
it is located, press fit and adjust the location again.

LIFTING THREAD

RETAINER JIG (D)

ADJUSTER BOLT

WEDGE

CHUCK TOOL ASSY (A)

CHUCK

BLOCK TOOL (C)

32

Bushing removing and press fitting jig (For reference only)

32-43
32. ATTACHMENTS

32-44
 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 ............................................................................................................33-5
33.1.3 BATTERY ...................................................................................................33-8
33.1.4 GUARD ......................................................................................................33-10
33.1.5 UNDER COVER ........................................................................................33-18
33.1.6 FUEL TANK ...............................................................................................33-19
33.1.7 HYDRAULIC TANK ....................................................................................33-21
33.1.8 HYDRAULIC PUMP ...................................................................................33-25
33.1.9 AIR CLEANER ...........................................................................................33-30
33.1.10 MUFFLER ..................................................................................................33-32
33.1.11 COUNTERWEIGHT ...................................................................................33-34
33.1.12 RADIATOR & OIL COOLER ......................................................................33-35
33.1.13 ENGINE .....................................................................................................33-42
33.1.14 CONSOLE COVER ....................................................................................33-46
33.1.15 CONTROL VALVE .....................................................................................33-47
33.1.16 PILOT VALVE (FOR ATT) ..........................................................................33-50
33.1.17 PILOT VALVE (FOR TRAVEL) ...................................................................33-52
33.1.18 SWING MOTOR UNIT ...............................................................................33-53
33.1.19 SWIVEL JOINT ..........................................................................................33-55
33.1.20 UPPER FRAME .........................................................................................33-58
33.2 DISASSEMBLING AND ASSEMBLING .............................................................33-60
33.2.1 HYDRAULIC PUMP - REGULATOR ..........................................................33-60
33.2.2 CONTROL VALVE .....................................................................................33-86
33.2.3 PILOT VALVE (ATT) ...................................................................................33-119
33.2.4 PILOT VALVE (FOR TRAVEL) ...................................................................33-132
33.2.5 SWING MOTOR UNIT ...............................................................................33-142
33.2.6 SWIVEL JOINT ..........................................................................................33-171

Book Code No. S5LC3326E01

33-1
33. UPPER SLEWING STRUCTURE

Issue Data of Issue Applicable Machines Remarks

S5LC3326E01
First Edition September, 2010 SK350-9: YC
NA

PREFACE
(1) This Manual describes all the procedures from removing to installing, arranging them by item.
(2) This Manual consists of [Removing and Installing] and [Disassembling and Assembling].
(3) The removing and installing can be performed in the procedure specified in the Table of Contents, but in view of
actual repairing or time saving some processes can be omitted.
(4) The removing and installing procedure does not completely cover all possible situations because of differences
of field condition and defective sections.
(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 from the battery first, when the removing and the installing of the electric
component and wiring are performed.
(7) The explanatory notes and figures in this manual may differ from the actual machine by the difference in
specification.

33-2
 33. UPPER SLEWING STRUCTURE

33.1 REMOVING AND INSTALLING

33.1.1 OPERATOR SEAT 33

33.1.1.1 REMOVAL
(1) Preparation for removal
1. Remove the head rest (A1-1) on 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 far 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
A1-1
move the control stand to its rearmost end and
remove two capscrews (B2) M8X20. A1
Tools: Allen wrench: 6 mm C1
2. Remove the operator's seat. [about 28 kg (62 lbs).] 7/16
Carry out the following operations as required. C4
3. Remove seat belt (C1) and bracket (C2).
C4
4. Remove armrest (A3)(A4). 7/16
5. Remove bracket assembly (1), rail (7). B2
C1

C2
C3

Disassembling And Assembling Seat

33-3
33. UPPER SLEWING STRUCTURE

33.1.1.2 INSTALLATION
Install it in reverse procedure of removing according to the tightening torque table.
Allen Tightening torque
Tightening position wrench
HEX N·m (lbf·ft)
A4
Capscrew (B2) 6 23 (17)
Sems bolt (C3) 17 46.5 (34.3) A5
Sems bolt (A6) 13 23 (17) A3
Capserew (A5) 13 23 (17)
A2

A1 A6
A5

A6

Disassembling and Assembling Armrest

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

33-4
 33. UPPER SLEWING STRUCTURE

33.1.2 CAB

33.1.2.1 REMOVAL 33
(1) Remove floor mat.
(2) Remove cover assembly (A8).
1. Remove cover (A9) and loosen 4 sems bolts
(A38) M6X20.
A9
Tools: Phillips screwdrive
A8
2. Disconnect harness connector of power socket
A38
and remove cover assembly (A8).
(3) Removal of cover assembly (A10).
1. Remove cover (A11) and loosen 2 sems bolts
(A38) M6X20.
Tools: Phillips screwdriver
2. Remove cover assembly (A10).
(4) Removal of harness connector.
(See Chapter 23 "Electric System") A38
A38
1. Disconnect connectors on cab harness at rear
right of cab.
A38
2. Disconnect antenna cable for tuner located at A38 A10
rear left of cab.
A1
3. Disconnect harness for cab light located at rear A38
left of cab. A11
(5) Removal of cover assembly (A1). Disassembly And Assembly Of Right Panels (A1),
1. Loosen 2 sems bolts (A38) M6X20. (A8) And (A10)
Tools: Phillips screwdriver
2. Disconnect harness connector of hour-meter and
remove cover assembly (A1).
(6) Remove plastic tube for window washer located at
right front of cab.

(7) Removal of mechatro-controller

1. Loosen 4 sems bolts (B11) M6X25.
MECHATRONICS
2. With harnesses connected, remove the CONTROLLER
mechatro controller, and place it in front of it
temporally. 4 PLACES
B11

RELAY BOX
ASSY

Removal Of Mechatro-Controller

33-5
33. UPPER SLEWING STRUCTURE

(8) Removal of cab attaching bolts

1. Loosen 4 capscrews (C1) M12X35.

C1

C1

C1

C1

Removing And Installing Cab Mounting Bolts

(9) Slinging cab

1. Remove 2 plastic plugs at the front ceiling of the
cab, and attach 3 eyebolts. Then hook slinging
EYE BOLT
wires to eyebolts as shown in figure. M16
2. Then lift up cab slowly, avoiding interference with EYE BOLT
M12
surroundings.
Wire with hook;
Length 1.5m (4ft 11in) X Dia. 12mm (0.4in) X 3pcs.
Weight of cab; Approx. 480kg (1060lbs)

Slinging Cab

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

Allen Tightening torque

Tightening position wrench
N·m (lbf·ft)
HEX(mm)
Capscrew (C1) 19 80 (66)
Sems bolt M6 (A38)(B11) Plus driver 5.0 (3.7)

33-6
 33. UPPER SLEWING STRUCTURE

33.1.3 BATTERY

33.1.3.1 REMOVING 33
(1) Open left panel assembly (B1), (B2).
1. Open it with starter key.
2. Open left panel assembly (B1).
3. Fix it with a stay.
(2) Remove battery cover (3). Loosen sems-bolt (A8)
M10 and remove battery cover (A3).
Tools: Spanner: 17 mm

B2

B1

(3) Remove battery cable

1. Remove cable (C4) [between the earth and
battery (-)].
(Always remove (-) terminal first and install it at
last.)
2. Cable (C2) [between battery (+) and (-)]
3. Cable (C3) [between battery (+) and battery
relay]
Tools: Spanner: 13 mm

C4 C2 C3

Removing And Installing Battery Cable

(4) Remove battery (B1)

A4 A5
1. Loosen 2 capscrews (A5) M10X235.
A3
Tools: Socket 17 mm A8
2. Remove plate (A4).
3. Remove battery (B1). A

A
B1
FRONT OF MACHINE

ISOMETRIC DRAWING

A5 A4 A3
A8

SECTION AA
Removing And Installing Battery

33-7
33. UPPER SLEWING STRUCTURE

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.

33.1.3.2 INSTALL
(1) Install the battery in the reverse order of removing.
Hold down plate (A4) against battery (B1), and tighten capscrew (A5).
Tools: Socket: 17 mm,
Tightening torque : 10.8 N-m (8.0 lbf-ft)

(2) Installing grounding cable

Install grounding cable (C4) last. Especially care must be taken that the grounding face is free from painting,
rust, etc.
Tools: Socket: 13 mm

33-8
 33. UPPER SLEWING STRUCTURE

33.1.4 GUARD

33.1.4.1 PREPARATION FOR REMOVAL 33

(1) Remove guards in the following procedure.
H1, H2, H4 E1 G1
Remove the guards in the order of (F1)-->(F2)-- D1 A18
>(C1)-->(A23)-->(A17)-->(A18)--> A17
B3
(D1)-->(H4)-->(G1)-->(E1)-->(B1)-->(B2)--> A23
(B3)-->(H2)-->(H1).
(2) All the locked covers open with the starter key. C1

F1
F2
F2
B1
Arrangement Of Guard Assembly

33.1.4.2 REMOVE GUARD

(1) Remove bonnet assembly (F1 and F2).

1. Unlock and open bonnet assembly (F1). F1

2. Remove 4 nuts (10) M12. B

B
3. Remove bonnet (F1).
C
A
C
Tools: Socket: 19 mm
A
Weight:
Bonnet (F1) : 31 kg (68 lbs)
Bonnet (F2) : 21 kg (46 lbs)

4. Remove 4 nuts (10) M12 and 2 sems bolts (9)

F2
M12X45.

5. Remove bonnet (F2).

10

SECTION AA

9
SECTION CC

SECTION BB
Removing Bonnet Assembly (F1 and F2)

33-9
33. UPPER SLEWING STRUCTURE

(2) Remove guard (C1) and guard (A23), (A24). C1, 9

1. Remove 8 sems bolts (9) M12X25.

2. Remove guard (C1)

Tools: Socket: 19 mm
Weight:
Guard (C1) : 15 kg (33 lbs)
Guard (A23) : 10 kg (22 lbs)
Guard (A24) : 5 kg (11 lbs)

3. Remove 9 sems bolts (33) M12X25.

4. Remove guard (A23).

A24, 33 A23, 33

5. Remove 2 sems bolts (33) M12X25.

6. Remove guard (A24).

Removing Guard (C1), (A23), (A24)

(3) Remove guard (A17 and A18) and guard assembly A17
(D1).
A18
33
1. Remove 4 sems bolts (33) M12X25.

2. Remove guard (A17). A

3. Remove 4 sems bolts (52) M12X25.

A
4. Remove guard assembly (A18). B
B

5. Remove 17 sems bolts (4) M12X25.

33 52
6. Remove guard (D1).
52

Tools: Socket: 19 mm
Weight:
guard (A17) : 7kg (15 lbs)
guard (A18) : 10kg (22 lbs)
guard (D1) : 15kg (33 lbs)

A17 A18 SECTION BB

SECTION AA

D1, 4
Removing Guard (A17, A18, and D1)

33-10
 33. UPPER SLEWING STRUCTURE

(4) Remove cover (H4).

1. Remove 2 sems bolts (3) M12X25.

33

2. Remove cover (H4).

2 PLACES
Tools: Socket: 19 mm H4, 3
Weight: Cover (H4) : 2.9kg (6.4 lbs)

Removing Cover (H4)

(5) Remove stay (G1) and stay (E1).

G1

1. Remove 4 capscrews (6) M12X65.

2. Remove plate (2 and 7) and stay (G1).

3. Remove 2 capscrews (5) M10X55. aa

E1
4. Remove a capscrews (6) M12X60.

5. Remove 2 capscrews (7) M16X65.

2
6. Remove clamp (3 and 4) and remove stay (E1).

Tools: Socket: 17 mm
Tools: Socket: 19 mm
Tools: Socket: 24 mm bb
Weight:
stay (G1) : 9kg (20 lbs)
stay (E1) : 6kg (13 lbs)
3
7
7

6 3
2 5
DETAIL aa DETAIL bb
Removeing Stay (G1 and E1)

33-11
33. UPPER SLEWING STRUCTURE

(6) Remove panel assembly (B1).

1. Unlock panel assembly (B1).

2. Remove 4 nuts (4) M12.

4
3. Remove panel assembly (B1).
Tools: Socket: 19 mm
Weight: 13 kg (29 lbs) B1

Removing Panel Assembly (B1)

(7) Remove panel assembly (B2). 4

1. Remove 4 nuts (4) M12.

2. Remove panel assembly (B2).

Tools: Socket: 19 mm
Weight: 14 kg (31 lbs)

B2

Removing Panel Assembly (B2)

(8) Remove panel assembly (B3).

B3

1. Unlock and open panel assembly (B3).

2. Remove 4 nuts (4) M12.

3. Remove panel assembly (B3).

Tools: Socket: 19 mm
Weight: 13 kg (29 lbs)
4

Removing Panel Assembly (B3)

33-12
 33. UPPER SLEWING STRUCTURE

(9) Remove panel assembly (A31).

A31, 33

1. Remove 3 sems bolts (33) M12X25. 33

2. Remove panel assembly (A31).
Tools: Socket: 19 mm
Weight: 2 kg (4.4 lbs)

Remoring Panel Assembly (A31)

(10)Remove guard (A25, A26, and A27).

1. Remove 10 sems bolts (33) M12X25 and guard
assembly (A25, A26, and A27) in order.
Tools: Socket: 19 mm
Weight:
guard (A25) : 4.4kg (9.7 lbs)
guard (A26) : 1.1kg (2.4 lbs)
guard (A27) : 2.5kg (5.5 lbs)

A26, 33

A25, 33 A27, 33

Removing Guard (A25, A26, and A27).

(11)Remove guard (D2).

Remove the battery relay box in advance and

remove guard (D2). (See chapter 23).

1. Remove 2 sems bolts (4) M12X25.

2. Remove 5 sems bolts (4) M12X25.

3. Remove guard (D2).

Tools: Socket: 19 mm
Weight:
D2, 4
guard (D2) : 6.3kg (13.9 lbs)
Removing Guard (D2)

33-13
33. UPPER SLEWING STRUCTURE

(12)Remove beam (A7 and A12) and pillar (A5).

1. Remove 6 sems bolts (33) M12X25 and remove

beam (A7).

2. Loosen 2 sems bolts (33) M12X25.

3. Remove pillar (A5).

4. Remove 3 sems bolts (33) M12X25 and remove A5, 33

beam (A12). A12, 33
Tools: Socket: 19 mm
A7, 33
Weight:
Removing And Installing Beam (A7 and A12) And
pillar (A5) : 5.4kg (11.9 lbs) Pillar (A5)
beam (A7) : 8kg (17.6 lbs)
beam (A12) : 6.3kg (13.9 lbs)

(13)Remove bracket assembly (A13) and guard (A14).

33
1. Remove 3 sems bolts (33) M12X25.
A13, 33
2. Remove bracket assembly (A13).

3. Remove 3 sems bolts (33) M12X25.

4. Remove 2 sems bolts (34) M12x30.

5. Remove guard (A14).

Tools: Socket: 19 mm
Weight:
Bracket assembly (A13) : 4.8kg (10.6 lbs)
guard (A14) : 11.4kg (25.1 lbs)

33

A14 34
Removing Bracket Assembly (A13) And Guard
(A14)

(14)Remove cover assembly (C5).

C5, 9
1. Remove 4 sems bolts (9) M12X 25.

2. Remove cover assembly (C5).

Tools: Socket:19 mm
Weight:
Cover assembly (C5) : 0.5kg (1.1 lbs)

Removing Cover Assembly (C5)

33-14
 33. UPPER SLEWING STRUCTURE

(15)Remove guard assembly (C2 and C3).

C3, 9
1. Remove 7 sems bolts (9) M12X25. 33
Tools: Socket: 19 mm

2. Remove guard assembly (C2), (C3).

Weight:
Guard assembly (C2) : 9.6kg (21.2 lbs)
Guard assembly (C3) : 5.5kg (12.1 lbs)

C2, 9
Removing Guard Assembly (C2 and C3)

(16)Remove cover (C4).

Loosen 3 sems bolts (9) M12X25, and

remove cover (C4).
Tools: Socket: 19 mm
Weight: Cover (C4) : 2.9kg (6.4 lbs)

C4 9
Removing Cover (C4)

(17)Remove plate (A28) and guard assembly (A22). A22, 33

1. Remove 2 sems bolts (33) M12X25.

2. Remove plate (A28).

3. Remove 6 sems bolts (33) M12X25.

4. Remove guard assembly (A22).

Tools: Socket: 19 mm
Weight:
Plate (A28) : 0.7 kg (1.5 lbs)
Guard assembly (A22) : 11.1 kg (24.5 lbs)
A28, 33
Remove Plate (A28) And Guard Assembly (A22)

33-15
33. UPPER SLEWING STRUCTURE

(18)Remove cover assembly (H1).

H1-6

1. Remove 4 sems bolts (3) M12X25. H2, 3

H1-6
H1-2
2. Remove plate (H2).
H1, 3
Unlock the locks and cover (H1-2).

3. Remove 4 sems bolts (H1-6) M10X20.

4. Remove cover (H1-2).

5. Remove 4 sems bolts (3) M12X25.

6. Remove cover assembly (H1).

Remove Cover Assembly (H1)

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

Unit : N.m (lbf.ft)

Size Nut Sems bolt
M10 46.5 (34.3) 46.1 (34.0)
M12 - 80 (59)
M16 - 191 (140.9)

33-16
 33. UPPER SLEWING STRUCTURE

33.1.5 UNDER COVER

33.1.5.1 REMOVAL 33
(1) Remove under cover (1, 2, 3, 4, 5, 6, 7, 10, and 11).

1. Remove attaching sems bolts (8) M12X30 and sems bolts (9) M12X40.

2. Remove covers.
Tools: Socket: 19 mm

8, 10

4, 8

3, 8

2, 8 6, 9

1, 8

8, 11

7, 8

5, 9

FORWARD

Q'ty and weight for removing sems bolts of cours

Under cover (1) 6 pcs. 6.3kg (14 lbs)
Under cover (2) 6 pcs. 4.7kg (10 lbs)
Under cover (3) 4 pcs. 0.7kg (1.5 lbs)
Under cover (4) 4 pcs. 1.6kg (3.5 lbs)
Under cover (5) 5 pcs. 4.9kg (11 lbs)
Under cover (6) 7 pcs. 4.7kg (10 lbs)
Under cover assy (7) 4 pcs. 5.0kg (11 lbs)
Under cover (10) 4 pcs. 2.1kg (4.6 lbs)
Under cover (11) 4 pcs. 4.6kg (10 lbs)

Under Cover Assembly

33.1.5.2 INSTALLATION
(1) Install under cover (1, 2, 3, 4, 5, 6, 7, 10, and 11).
Tools: Socket: 19 mm
Tightening torque: 80 N-m (59 lbf-ft)

33-17
33. UPPER SLEWING STRUCTURE

33.1.6 FUEL TANK

33.1.6.1 PREPARATION FOR REMOVAL

(1) Draining fuel. (See Figure).

1. Unlock cap (B2) with a starter key and open it.

2. Loosen valve (A7) under the tank.

3. Draining fuel.
Capacity of tank: 580 L (153 gal)

(2) Remove stay (E1 and G1) and cover (H4). FORWARD
aa
(See 33.1.4 GUARD)

(3) Remove the connector for level sensor (A4).

(See Figure)
12
(4) Remove fuel hose. RETURN 21

SUCTION
1. Loosen clip (21) and remove hoses (8 and 12).

2. Install plugs that match the hose inside diameter.

8
21

DETAIL aa
Removing Fuel Hose (8 and 12)

33-18
 33. UPPER SLEWING STRUCTURE

33.1.6.2 REMOVAL
(1) Remove 6 capscrews (A1) M20X50.
B2
Tools: Socket: 30 mm C1 33
Tank capacity: 580 liters (153 gal)

(2) Hook the wire to the lifting eye on the fuel tank
assembly (C1) and remove the fuel tank. II I
Weight: 191 kg (421 lbs)

(3) Remove shim (A3).

A3

A1

A4, A5
TIGHTENING TORQUE
1.96N.m (1.45 lbf.ft)
5 PLACES

A7
VIEW I VIEW II
Removing Fuel Tank

Record the shim locations.

33.1.6.4 INSTALLATION
(1) Installing is done in the reverse order of removing.
Tank attaching bolt (A1) M20X50
Tools: Socket: 30 mm, Apply Loctite #262
Tightening torque: 370 N-m (273 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

Tightening torque
No. Name Q'ty N.m (lbf.ft)
A1 Capscrew 6 370 (273)
A5 Machine screw 5 1.96 (1.4)
A7 Cock 1 34 (25)

33-19
33. UPPER SLEWING STRUCTURE

33.1.7 HYDRAULIC TANK

33.1.7.1 PREPARATION FOR REMOVAL

(1) Remove bonnet assembly (F1 and F2), panel
assembly (B3), guard (A17 and A18), and the other A17 A18
guards necessary to remove the hydraulic oil tank. F1
(See 33.1.4 GUARD.)
B3

F2
Remove Guard

(2) Release internal pressure of tank.

Remove cap on air breather and push valve (head Cap
of bolt) with your finger.
Push Air breather

Element No.
YN57V00005S002

Bleeding Internal Pressure Of Tank

Keep pressing until the hissing stops.

33-20
 33. UPPER SLEWING STRUCTURE

(3) Remove cover (C3). C9

1. Remove 6 sems bolts (C9) M10X25. C9
C2
Tools: Socket: 17 mm 33
2. Remove cover (C3). C3

3. Remove suction strainer (B4).

(4) Remove cover (C2).

B
1. Remove 6 capscrews (C9) M10X25.
Tools: Socket: 17 mm C
B4
D
2. Remove cover (C2).
B7
D
Air
3. Remove filter element (B7). breather
D
(5) Turn the handle of element assembly (B), and
disassemble the removed filter element (B7). E
F Hyd.tank
Disassemble parts: (B), (C), (D), X3, (E), and (F)

(6) Draining hydraulic oil.

Place pump in tank and draw up hydraulic oil.
Capacity of tank: 386 L (49 gal)

Remove Cover (C2), (C3)

33.1.7.2 REMOVAL
(1) Draw out the suction hose (A3).

Remove 2 clips (A13) on the tank side and pull out

hose (A3).
Tools: 2: Flat-blade screwdriver

A12

A3
At installing suction hose,
apply PERMATEX to the
inner end of both hoses.
A13
Removing And Installing The Suction Hose

(2) Disconnecting the main pipe return hose

4 1
11, 10
1. Remove 2 sems bolts (11) M12X35 and remove
return hose (1).
Tools: Spanner: 19 mm
3
2. Remove drain hose (4) of pump.
Tools: Spanner: 36 mm

3. Remove drain hose (6) of swing motor.

Tools: Spanner: 36 mm

Removing Main Piping Return Hose

33-21
33. UPPER SLEWING STRUCTURE

(3) Disconnecting pilot return hose

1. Remove pilot hose (A1).
Tools: Spanner: 22 mm
A1
2. Remove pilot hose (A11).
Tools: Spanner: 22 mm
C/V
DR A14
3. Remove pilot hose (A14). S/V
Tools: Spanner: 22 mm T
PT
T
A11
Remove Pilot Return Hose

(4) Remove drain hose (4) of pilot pump

Tools: Spanner: 22 mm

Removing Pump Drain Hose

(5) Remove hydraulic tank attaching bolt

Remove 4 capscrews (A1) M20X45.
Tools: Socket: 30 mm

(6) Slinging hydraulic oil tank

Place a wire sling, using the lifting plate on top of
the tank.
Tank weight: Approx : 207 kg (456 lbs)

(7) Remove shim (A3).

A3

A1
Removing Hydraulic Tank

Record the shim locations.

33-22
 33. UPPER SLEWING STRUCTURE

33.1.7.3 INSTALLATION
(1) Cleaning hydraulic oil tank.
33
(2) Cleaning suction hose.

(3) Cleaning mount of tank.

Installing is done in the reverse order of removing.

(4) Install 4 mounting capscrews (A1) M20X45 with Loctite #262. (See Figure "Removing Hydraulic Tank".)
Tools: Socket: 30 mm, Apply Loctite # 262
Tightening torque: 370 N-m (273 lbf-ft)

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

(5) Connection of suction hose (A3). (See Figure

"Removing And Installing The Suction".) O-RING

1. Apply PERMATEX on pipe side of hose

connection and insert it.
C

2. Put the hose with clip (A12).

Tightening torque: 5.39 N-m (4.0 lbf-ft)
B2
(6) Assembling return element SUCTION D
Assemble filter element by the use of element kit STRAINER
LC50V00006F2
(B-200). (See Fig."Remove cover", Right Fig.)

(7) Install return element (B6). (See Fig. "Remove F

ELEMENT KIT
cover") (B-200)
LS52V01002R300
(8) Installing suction strainer (B2). Element And Suction Strainer

(9) Tighten sems bolts (C5) M10X25 that attach tank

covers (C2 and C3).
M10 Tightening torque : 46.5 N-m (34 lbf-ft)

1. Three elements (D) are used as one set.

2. 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.

33-23
33. UPPER SLEWING STRUCTURE

33.1.8 HYDRAULIC PUMP

33.1.8.1 PREPARATION FOR REMOVAL

(1) Release pressure in hydraulic oil tank.
(See 33.1.7 HYDRAULIC TANK) C9

(2) Remove six capscrews (C9) M10X25.

C3

(3) Remove cover (C3). Suction

stopper
Tools: Socket: 17 mm

(4) Take out suction strainer.

Suction
strainer
(5) Install suction stopper.
For suction stopper, see chapter 11. Tools.

Hyd.tank

Suction Stopper Installing

(6) Remove guards

A24 A23
1. Remove bonnet assembly (F1), (F2).

2. Remove panel assembly (B3), guard (A23),

(A24), (A25), (A26), (A27).

3. Remove those parts that are required to remove

the hydraulic pump such as the fuel filter
assembly.

A26

A25
A27
Removing Guards

33-24
 33. UPPER SLEWING STRUCTURE

33.1.8.2 REMOVAL
(1) Loosen 8 capscrews (A15) M12X90 and remove
A15
half clamp (A4). And disconnect 2 hoses (A1 and A4 33
A2) from the delivery side.
Tools: Allen wrench: 10 mm

(2) Remove pilot pump suction hose (1).

(See below Fig.)
Tools: Spanner: 36 m

(3) Remove suction hose (A3) and drain hose (4). A4

1. Remove 4 capscrews (B2) M12X30. A2

Tools: Allen wrench: 10 mm A1

2. Remove elbow (B1) of suction hose (A3) from

pump. B2

B1

A3

Removing Hoses

(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.

Hose
Port No. Tool Remarks
TANK- A3
Dr3
Dr3 4 22 Drain PUMP Dr3
4
*Psv1 4 19 Pilot primary pressure P1 side

*Psv2 3 19 Pilot primary pressure P2 side

B3
3
Psv1 A11 19, 22 Pilot pump delivery

4
Psv2

Psv1

2 A11
PUMP B1- S/V P1-
B1 PUMP B3 PUMP Psv1
P1

Removing Other Hoses

Remove the parts marked * only if necessary.

33-25
33. UPPER SLEWING STRUCTURE

(5) Remove connector.

Fix a harness part
PSV-P1: of coulgated for
Remove 4 connectors on all pressure sensors and P1 pump solenoid of clip.
PSV-P2:
proportional valve CLIP
proportional valves. P2 pump
proportional
valve

Side of
engine

CLIP Control proportional

To guard solenoid.
CLIP
White taping
SE-22:
Pressure sensor : CLIP
P1 pump Fix a harness part of
coulgated for press
SE-23: sensor of clip.
Pressure sensor :
P2 pump
Removing Connector

(6) Remove main pump

1. Put a wire sling on the hydraulic pump and tension
the wire sling a little. Loosen 8 capscrews (4)
M10X35.
Tools: Socket: 17 mm

2. Remove the power take-off assembly from the

flywheel housing slowly, adjusting the tension of the
wire rope.
In this 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) M20X50 that fasten

insert R (2-4) and remove insert R (2-4).
Tools: Allen wrench: 17 mm

5. Remove hub (2-2)

If you loosen 2 set screws (2-7) M20X25, hub
comes off from the spline shaft of the pump.
Tools: Allen wrench: 17 mm

6. Remove 4 capscrews (2-5) M20X60 that fasten the

insert NA (2-3) with the engine side flywheel, as
necessary. Then remove spring pin (2-8) from Removing Pump
insert NA (2-3).
Tools: Allen wrench: 17 mm

7. Removing bracket (1)

Loosen 4 capscrews (3) M20X55, and remove
bracket (1) from pump (0).

33-26
 33. UPPER SLEWING STRUCTURE

33.1.8.3 INSTALLATION
Installing is done in the reverse order of removing.
(1) Installing bracket (1) 33
Tighten bracket (1) with capscrew (3) and install bracket temporarily.
Tools: Allen wrench: 17 mm
Tightening torque: 431 N-m (318 lbf-ft)
Apply Loctite #262
(2) Installing hub (2-2)
Put hub (2-2) into the pump spline till it enters 3mm (0.12 in) from the end face of the spline (See below Figure
Detail aa). Then install two set screws (2-7) and fix them together.
Tools: Allen wrench: 17 mm
Tightening torque: 210 N-m (155 lbf-ft)
(3) Install spring pin (2-9)
Put spring pin (2-9) into hub (2-2).
(4) Installing insert (2-4)
Install insert (2-4) into hub (2-2) by means of capscrews (2-6) coated with Loctite #262.
Tools: Allen wrench: 14 mm
Tightening torque : 465 N-m (343 lbf-ft)
(5) Installing element (2-1)
Put element (2-1) into hub (2-2) and insert (2-4).
(6) 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: 17 mm
Tightening torque: 465 N-m (343 lbf-ft)
(See Figure "Removing Pump" about above mentioned (1) to (5).)

(7) Installing the pump (See Figure "Removing Pump")

Lift the pump with bracket (1). Place coupling (2) in
the groove of element (2-1) to receive insert NA (2-
3). 2-6
(8) Coat 8 capscrews (4) M10X35 with Loctite #262 2
and put them in place.
Tools: Socket: 17 mm
aa
Tightening torque : 64.7N-m (48 lbf-ft)
(9) Fasten hoses (A1 and A2) on the delivery side with
half clamp (A11) and capscrews (A19) M12X40. 2-7
T=210N.m (155 lbf.ft)
(See Fig."Removing hoses") 2-8
SPRING PIN
Tools: Allen wrench: 10 mm (4 places) 3
T=431N.m (318 lbf.ft)
Tightening torque: 62.2 N-m (46 lbf-ft) 1 Apply Loctite #262
T=465N.m (343 lbf.ft)
(10)Install suction hose (A3) with 4 capscrews (B2) Do not use Loctite
(The attached bolts are coated
M12X30. (See Figure "Removing Hoses") with micro capsule coating) 4
T=64.7N.m (48 lbf.ft)
Tools: Allen wrench: 10 mm Apply Loctite #262

Tightening torque : 66.7 N-m (49 lbf-ft)

4
(11)Install the hydraulic piping by referring to
"HYDRAULIC SYSTEM".

3
(0.118") 56 (2.2")
DRAIN HOLE (Bottom)
DETAIL aa VIEW I

Installing Hydraulic Pump

33-27
33. UPPER SLEWING STRUCTURE

(12) Installing the hose (See Figure "Removing Other Hoses")

(13) Installing pressure sensor connector and proportional valve connector.

(14) Remove suction stopper.

(15) Install suction strainer.

When the pump is replaced, replenish more than 1L (0.26 gal) of hydraulic oil from the drain port (Dr).

(16) Bleed air in pump

Bleed air by loosening the drain port (Dr).

(17) Check hydraulic oil level.

(18) Start engine and check it for oil leak and noise.

(19) Attach drain down pipe under engine muffler.

(20) Install guards

(See Figure "Removing Guard Assembly (16) And Guard (14),(15),(17). Figure "Removing Guards")

Dr

Bleed Air Port (Dr) In Pump

33-28
 33. UPPER SLEWING STRUCTURE

33.1.9 AIR CLEANER

33.1.9.1 PREPARATION FOR REMOVAL

(1) Opening panel assembly (B1 and B2).
33
(See 33.1.4 GUARD)
F1
(2) Open bonnet assembly (F1).
(See 33.1.4 GUARD)

(3) Unplug terminals on indicator (1-8) wiring.

(See Figure below)

B2

B1
Preparation For Removal

33.1.9.2 REMOVAL
(1) Pulling out hose (3).
1. Loosen clips (5 and 6) on both sides of hose (3).
2. Pulling out hose (3).
Tools: Flat-blade screw driver
(2) Remove air cleaner assembly (1).
1. Remove 4 sems bolts (7) M10X25
Tools: Socket: 17 mm
2. Remove air cleaner assembly (1) from bracket (4).
CLIP INSTALLATION
CLIP INSTALLATION POSITION
POSITION

5 25(0.98") 25(0.98") 5 FORWARD

1
25
I III
(0.98")

II
45 45
(1.77") (1.77")

7
50
(1.97")
ALLOWANCE FOR
INSERTING HOSE 4
5 3 10
5
5 2 1-8
VIEW I ALLOWANCE
FOR OVERLAP
WITH DUCT
ALLOWANCE FOR 2-MX0.7
INSERTING HOSE TIGHTENING TORQUE
1.68N.m (1.24 lbf.ft)
(1.02")
26

8, 9
30 (1.18")

7 INSERT IN
HOLE OF DUCT
1-8
18
5 (0.71")
1-2
10
A CLIP INSTALLATION 1-3
1 POSITION 1-6
A
VIEW II
VIEW III

Removing Air Cleaner

33-29
33. UPPER SLEWING STRUCTURE

33.1.9.3 INSTALLATION
(1) Installing is the reverse order of removing with attention paid to the following items:

1. Install air hoses (2 and 3) to the end as shown in Figure "Preparatiom For Removal".

2. Tightening torque:

No. Name Tightening torque N.m (lbf.ft)

1-8 Indicator 3.9 (2.9)
7 Sems bolt 39.2 (29) (Apply Loctite #262)
10 Sems bolt 80.0 (59) FILTER ELEMENT (1-3) FILTER ELEMENT (1-2)
5,6 Clip 5.9 (4.4) (LC11P00018S003) (LC11P00018S002)
O-RING (1-6)
(EB11P00001S003)

33-30
 33. UPPER SLEWING STRUCTURE

33.1.10 MUFFLER

33.1.10.1 PREPARATION FOR REMOVAL 33

(1) Remove bonnet assembly (F1 and F2), and guards
C1 A23
(A23 and C1).
F1
(2) Remove panel assembly (B3). B3

(3) Remove guards (A25, A26, and A27).

(See Figure "Removing Guard (A25, A26, and
A27)".)

F2
Preparation For Removal

33.1.10.2 REMOVAL
(1) Remove 2 connectors.
(2) Remove 2 nuts (8) and 2 clips (9).
(3) Remove a nut (21) and a clip (9).
(4) Remove 4 bolts (10).
(5) Remove 5 sems bolts (22) and 2 sems bolts (23).
(6) Remove 4 nuts (7).
(7) Remove filter assembly (1).
(8) Loosen bolts (1-5) located on flanges on both sides, remove only the central filter part.

HOSE
10
1-5
1
A

1-5

8, 9
MAUNT

A 23

FORWARD

22
MAUNT

20, 21
7
SECTION AA

33-31
33. UPPER SLEWING STRUCTURE

33.1.10.3 INSTALLATION
(1) Installing is the reverse order of removing.

(2) Tightening torque:

No. Name Tightening torque N.m (lbf.ft)

7 Nut 51 (38)
8 Nut 22 (16)
10 Bolt 59 (44)
21 Nut 22 (16)
22 Sems bolt 108 (80)
23 Sems bolt 108 (80)

33-32
 33. UPPER SLEWING STRUCTURE

33.1.11 COUNTERWEIGHT

33.1.11.1 PREPARATION FOR REMOVAL 33

(1) Remove bonnet assembly (F1 and F2).
F1
(See 33.1.4 GUARD)

F2
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; (Semi-weighted)
Approx. 8,800kg (19,400 lb)

(2) Removing counterweight (C1)

1. Remove 4 capscrews (A1) M36X420.

Tools: Socket: 55 mm

2. Remove shim (A3, A4, and A5). (Select)

3) Remove counterweight (C1). A3, A4, A5

A1, A2

Removing Counterweight

33.1.11.3 INSTALLATION
(1) Install counterweight in the reverse order of
removing.
(2) Install shim (A3, A4, and A5) as it was. (select) Less than two shim
(3) Slinging counterweight adjustment
A3,A4,A5
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: 55 mm
Tightening torque : 2940 N-m (2170 lbf-ft)
A1,A2
(5) Remove slinging tools, and install bonnet assembly
Fastening The Counterweight Attaching Capscrew
(F1 and F2).

33-33
33. UPPER SLEWING STRUCTURE

33.1.12 RADIATOR & OIL COOLER

33.1.12.1 PREPARATION FOR REMOVAL

(1) Bleed air from the hydraulic tank and install the
10
suction stopper.(See 33.1.7 and 33.1.8)
4
(2) Remove bonnet assembly (F1 and F2) (See 33.1.4
GUARD)

(3) Remove battery (See 33.1.3 BATTERY).

(4) Remove beam (A12), (A-33). (See 33.1.4 GUARD)

Removing Under Cover (4 and 10)

(5) Open panel assembly (21). (See 33.1.4 GUARD)

(6) Removing under cover installed on lower side of

9 12
radiator. 7
FORWARD

1. Remove 8 sems bolts (9) M12X30.

27
2. Remove cover (4 and 10). 26
Tools: Socket: 19 mm

(7) Drain radiator.

Place 18L (4.8 gal) container under drain valve for 20, 21
draining water. 20, 21
[Water capacity of radiator : 11L (2.9 gal)] 18

(8) Remove hose from radiator sub tank (1). 22

Remove clip on radiator cap side and disconnect
hose (9). 29
17
(9) Disconnect hose (7).
1
8

Removing Hose Of Sub Tank (1)

Do not loosen the joints on the hoses related to the air-conditioner. Otherwise the refrigerant leaks.

33-34
 33. UPPER SLEWING STRUCTURE

(10) Move air-conditioner condenser and receiver tank

and fuel cooler.
33
1. Loosen 4 sems bolts (23) M8X25 and 2 sems
bolts (8) M8X20.
Tools: Socket: 13 mm

2. Move a set of air-conditioner condenser and

receiver tank and fuel cooler.

(11) Disconnect coolant level switch (B5). (See Figure

23
"Removing Radiator Assembly")
34 58
8
62 3
23

Moving Condensers And Receiver Tank And Fuel

Cooler

33-35
33. UPPER SLEWING STRUCTURE

33.1.12.2 REMOVAL
(1) Remove radiator stay (A1).

1. Remove 4 sems bolts (A2) M12X35. A1

Tools: Spanner: 19 mm

A2
2. Remove 2 stays (A1 and A6).
A4, A3
(2) Remove water hoses (2 and 3.

1. Loosen the hose bands (23) for water hose (2).

Tools: Flat-blade screwdriver

A1
2. Remove hose (2). A2

A3, A4
3. Loosen hose band (23) on water hose (3).
Tools: Flat-blade screwdriver Removing Radiator Assembly

4.Remove hose (3).

(3) Remove hoses (4 and 6) for inter-cooler. 23

24
1. Loosen 4 sems bolts (28) M8X20 from tube (10).
Tools: Spanner: 13 mm 4
FORWARD

2. Loosen 2 sems bolts (29) M8X25.

Tools: Spanner: 13 mm

3. Loosen hose bands (24 and 25) and remove

hose (4).
Tools: Flat-blade screwdriver 25
24

4. Loosen hose bands (24) and remove hose (5). 23 6

3
23
Tools: Flat-blade screwdriver
FORWARD
5. Loosen hose bands (24) and remove hose (6).
Tools: Flat-blade screwdriver

24
5
24
28

29

10
Removing Hose For Radiator / Inter-Cooler

33-36
 33. UPPER SLEWING STRUCTURE

(4) Remove guards (13, 14, and 15). (See Figure 11

"Removimg Hose Of Sub Tank") 26, 27

FORWARD
30 13 33
1. Remove 2 sems bolts (27) M8X16 from clip (26).
14
18
30
2. Remove 7 sems bolts (30) M10X20
22
15
2. Remove guard (13), (14), (15). 30
Tools: Spanner: 13, 17 mm

Remove Guard (13, 14, and 15)

(5) Disconnecting hydraulic oil hoses (1 and 2). O/C OUT

-TANK
1
1. Place an oil pan under the hose joint. Loosen 4
sems bolts (13) M12X40, and remove hoses (1)
and (2).

(6) Remove radiator assembly. (See Figure "Removing

radiator assembly")

1. Remove 4 sems bolts (A4) M20X45.

Tools: Spanner: 30 mm
Tools: Socket: 30 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. 2

C/V T1
-O/C IN
4. Removing radiator
Place a wire sling in the lifting eyes of the radiator Removing Hydraulic Oil Hose (1 and 2)
assembly and remove the assembly by crane.
Weight: 177 kg (390 lbs)

33-37
33. UPPER SLEWING STRUCTURE

33.1.12.3 INSTALLATION
(1) Installing is done in the reverse order of removing. And removed clips on hoses should be clamped at original
position.
(2) Install radiator assembly.
Place a wire sling in the lifting eyes of the radiator and move it to original position temporally. Install hydraulic
hoses, radiator hoses and hoses on inter-cooler. Regarding inserting width of hose (See Figure "Inserting Width
Of Hose").
(3) Radiator attaching bolt.
Apply Loctite #262 on 4 sems bolts (A4) M20X45.
Tools: Socket: 30 mm
Tightening torque : 500 N-m (369 lbf-ft)
(4) Adjust the clearance between the fan and the radiator shroud all around the circumference, as below :
Back and forth:
82 to 92mm (3.2 in to 3.6 in)
(5) Clean the plastering area of the insulation thoroughly before plastering it.
(6) Add hydraulic oil and LLC (Long Life Coolant) as required.
After completion of other installation, Add hydraulic oil and water as required.
Coolant volume of engine body : 16 L (3.5 gal)
Coolant capacity of radiator : 13.4 L (3.5 gal)
Hydraulic oil capacity of oil cooler : 9.6 L (2.5 gal)

50
(1.
97
")
(2.36")

(1 40
60

.5
8"
)
38 ")
(1.58")

50
40

(1.

3
(1. 0
18"
)
(1.
50 ")
97

50
(1.
97
")
50 7")
9
(1. 40(
1.5
8")

TIGHTEN ITEM 3 BOLT WITH

REGULAR TORQUE, AFTER
LAY TO BE 82 TO 92
(87 mm) (3.2in TO 3.6in) ALL AROUND.
(ALL AROUND)
Inserting Width Of Hose
RADIATOR SHROUD.
PUT THE FAN RUBBER
FAN OVER THE PROJECTION
RUBBER OF E/G FAN RING AT THE
15 ALL CIRCUMFERENCE.

E/G FAN RING

NOT TO RUN ON THE

FAN PROJECTION OF E/G
FAN RING.
0

Back-And-Forth Adjusting Position Of Radiator

33-38
 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 33
radiator. 15 15 15 3
2. Wait till the engine coolant cools down so you do
not get burned. Then remove the cap of the
radiator, discharge the coolant by opening the
drain valve located at the back bottom and
receive it in a container. 6-5 6-5
* In case of removing inter cooler only, the above 6-2 6-4
mentioned work is not necessary.
(2) Disassembly
RADIATOR COOLANT LEVEL SWITCH 18
1. Loosen each 2 bolts (6-5) at head and bottom of
shroud, remove upper plate (6-2) and lower
plate (6-3).
2. Disconnect wiring connector of radiator coolant
level switch.
3. Loosen 6 sems bolts (6-5) M10X20 attaching
plate assembly (6-4), remove plate assembly
(18).
4. Loosen 2 capscrews (15) M10X50 attaching Inter- Radiator Oil
radiator core. cooler cooler
5. After confirming that the coolant has been
drained out completely, loosen and remove only
the radiator side of hose bands (23) at the top
and bottom of the radiator. (See Figure
"Removing Hose For Rafiator/inter-cooler")
6. Lift and remove radiator core using lifting eyes
and hoist on the radiator core.
Weight: 25 kg (55 lbs) DRAIN VALVE
Confirm that the rubber bushing (14) is not
missing under the radiator core.
7. Loosen 2 capscrews (15) M10X50 attaching the
top of the inter-cooler core.
8. Loosen and remove only the inter-cooler side of 14
hose bands (24) at the top and bottom of the
Detail of radiator
inter-cooler. (See Figure "Removing Hose For core mounting part
Radiator/inter-cooler")

6-5
6-3

VIEW A
Removing Radiator And Inter-Cooler

33-39
33. UPPER SLEWING STRUCTURE

9. Lift and remove inter-cooler using lifting eyes and hoist on the inter-cooler.
Confirm that the rubber bushing (14) is not missing under the inter-cooler.

10. Disconnection of oil cooler hose.

Disconnect hoses (1 and 2) from upper and lower areas of the cooler, and drain hydraulic oil. (See Figure
"Removing Hydraulic Oil Hose (1 and 2)"

11. Lift cooler temporally using cooler head flange for slinging.

12. Loosen 4 bolts (3) M10 attaching oil cooler.

13. Lift the oil cooler.

There is no predetermined sequential order in removing radiator core, inter-cooler core and oil cooler. Removing
these components can be done as necessary.

(3) Installing
Installing is done in the reverse order of removing.

33-40
 33. UPPER SLEWING STRUCTURE

33.1.13 ENGINE

33.1.13.1 PREPARATION FOR REMOVING 33

(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.

P22-Alternator B terminal
CN-136-E/G speed sensor
CN-141, CN142-Pump proportional valve
CN-139, CN-140-P1,P2 pump pressure sensor
CN-212-Glow
M-1-Starter motor C terminal

Prepare a stand, which withstands the weight of the engine assembly and can hold the removed engine firmly.
(Refer to Tools)

THERMOSTAT GASKET OIL PLUG ASSY

OIL FILTER
ELEMENT

FUEL FILTER
ALTERNATOR ELEMENT

BELT

BELT STARTER

ENGINE V BELT
(COMPRESSOR)

Outside View Of Engine

33-41
33. UPPER SLEWING STRUCTURE

33.1.13.2 REMOVAL

15

cc 1
aa

16

bb

16

dd

50

42

15

DETAIL aa

26

DETAIL bb DETAIL dd

Dismounting And Mounting Engine (1/2)

33-42
 33. UPPER SLEWING STRUCTURE

33

ee

ff 28

21

40

19
39 27
28

21 25
27
28 DETAIL ee

28
20
21
27

21
25
27
19 20

25
DETAIL cc 25
DETAIL ff

Dismounting And Mounting Engine (2/2)

33-43
33. UPPER SLEWING STRUCTURE

(1) Remove hose on engine oil filter.

Place oil pan under the connection of filter (1), and disconnect hoses (15, 16, and 42) at * positions.
Tools: Spanner: 19 mm, 41 mm

(2) Plug connector and hose on filter side.

(3) Loosen engine mounting bolt on frame.

1. Loosen 4 nuts (25) M18.
Tools: Socket: 27 mm
2. Loosen 4 capscrews (28) M18X130.
3. Remove 4 plates (21).
4. Remove upper rubber mounts (19) and (20) 2 each.

(4) Slinging engine body

1. Sling engine hooking wire to lifting lugs on the front and rear sides.
Weight: Approx. 705 kg (1,555 lbs)
Wire: 6 dia. (0.236")X1 m (3 ft 3 in) - 2 pcs.

Prepare a stand, which withstands the weight of the engine assembly and can hold the removed engine firmly.
(Refer to "Tool".)

(5) Position engine on the stand stably.

(6) Remove 4 rubber mounts (19 and 20).

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

Tightening torque
No. Name Remarks
N.m (lbf.ft)
5 Bolt M12 26.5 (20)
26 Capscrew M10 46.1 (34)
Apply Loctite
50 Sems bolt M10 46.1 (34) #262
Apply Loctite
27 Sems bolt M12 115 (85) #262
Apply Loctite
28 Capscrew M18 226 (167) #271
Apply Loctite
39 Sems bolt M8 35 (26) #262
Apply Loctite
40 Sems bolt M8 35 (26) #262

33-44
 33. UPPER SLEWING STRUCTURE

33.1.14 CONSOLE COVER

33.1.14.1 REMOVAL 33
(1) Removing right-hand console cover
1. Press into the "A" part of rubber boot which is
tucked into console, and remove right rubber boot
(3-4) from console. 3-4

2. Loosen 3 sems bolts (1-18) M6X16 and remove

lower console (1-3). A
Tools: Plus screw driver

Removing Boot (4)

(2) Removing left-hand console cover

1. Remove left boot (3-4) same way as right console
1-18
cover. (See above Figure) 1-18
Tools: Flat-blade screwdriver 1-18 1-3
1-4
2. Loosen 2 sems bolts (1-18) M6X16.
Tools: Plus screw driver

3. Remove the left upper console cover (1-4) in the

same way as right-hand console cover. 1-5
I
4. Loosen 2 sems bolts (1-18) M6X16 while lifting left 1-18
under console cover (1-5) up, and remove left lower
console cover.

1-18
VIEW I
Removing Console Covers

33.1.14.2 INSTALLATION
Install it in reverse order of removing according to the tightening torque table.

Item Bolts Tightening torque N.m (lbf.ft)

1-18 Sems bolt M6 5.0 (3.7)

A6 Sems bolt M8 23.0 (17.0)

A6

Removing Left Armrest

33-45
33. UPPER SLEWING STRUCTURE

33.1.15 CONTROL VALVE

33.1.15.1 PREPARATION FOR REMOVING

(1) Remove guard (8).
(See 33.1.4 GUARD)

(2) Remove under cover (5).

(See 33.1.5 UNDER COVER)
5
(3) Install the suction stopper to the hydraulic oil tank.

(4) Remove the hoses in Figure "Control Valve Ports

(1/2)" and Figure "Control Valve Ports (2/2)".

Tightening torque
284N.m(209 lbf.ft)

3 Tightening torque
235N.m (173 lbf.ft)
Removing The Standard Main Control Valve

Mark each hose with a port name before removing it.

33.1.15.2 REMOVAL
(1) Remove 4 capscrews (3) M16X45, and remove control valve (5) by hoist.
Tools: Spanner: 24 mm
Weight: Approx. 252 kg (556 lbs)

33.1.15.3 INSTALLATION
(1) Installing is done in the reverse order of removal.

1. Install control valve by tightening 4 capscrews (3) M16X45.

Tools: Spanner: 24 mm
Tightening torque: 284 N-m (209 lbf-ft)

Connector / Bolt Hose nut

Tread
size Ports Opposing Tightening Opposing Tightening Remarks
Name torque torque
flats N.m (lbf.ft) flats N.m (lbf.ft)
Pss,PLc2,PAL,Par,PL,
PF1/4 PB1,PTb,PCa,PCb,PCc 19 36 (27) 19 29 (21)
PAa1,PBa1,Pab,PBb,Pac, ORS Joint
PBc,PBL,PBr,Pas,PBs,
PF3/8 PAa2,PBa2,Pao,Pbo,DR,XAb 22 74 (55) 22 49 (36)
PF3/4 MU 36 162 (119) 36 118 (87)
Ar,Br,AL,BL,As,Bs,Aa,Ba,Ac,Bc 14 42.4 (31)
M10 Ab,Bb 14 57 (42)
Sems bolt
P1,P2 17 62.2 (45)
M12 T1,T2 17 96 (70)

33-46
 33. UPPER SLEWING STRUCTURE

(2) Check for oil leaks and operation.

Functions Ports Ports on upper sides Ports Functions 33

LEFT RIGHT

PBa2 Arm 2 out

Option PAo Mu Make-up line
Arm (R) relief valve - - Bucket (R)relief valve

Arm 1 out PBa1 PBb Boom down

Swing (LH) PBs

- Boom (H) relief valve
Boom conflux PB1
PAr Travel right forward
Travel left forward PAL
- Main relief valve
Tank return T2
PCb P1 unload
Ports on rear sides (on machine)
LEFT RIGHT

P1 P1 pump

P2 P2 pump

Ports on right sides (on machine)

UPPER SIDE LOWER SIDE
Bucket dump BC

Bucket dump PBc

Bucket (H) stroke limit PCc

AC Bucket digging

Bb Boom down
Boom up Ab

Drain Dr BR Travel right reverse

Travel right forward AR

ATT power boost PL

Control Valve Ports (1/2)

33-47
33. UPPER SLEWING STRUCTURE

Function Ports Ports on left side (on machine) Ports Function

LOWER UPPER
SIDE SIDE
Option Bo Ao Option

Ba Arm 1 out

Arm 1 in Aa PLc2 Arm in lock release

Swing left Bs Pss Swing low pressure sensor

Travel left reverse BL As Swing right

AL Travel left forward

T1 Tank return

Ports on lower side (on machine)

LEFT SIDE RIGHT SIDE

Travel left reverse PBL PTb Travel straight

P2 unload PCa PBr Travel right reverse

Swing right PAs PAb Boom up

Arm (H) relief valve - - Boom (R) relief valve

Arm in PAa1 - Bucket (H) relief valve

Option PBo PAc Bucket digging

PAa2 Arm 2 in
Control Valve Ports (2/2)

33-48
 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. The preparation for the left side is described here.

(1) Put attachment on ground, stop engine and release

pressure in tank.

(2) Remove left console cover (1-4 and 1-5) assembly 3-4
referring to Section 33.1.14CONSOLE COVER. 3-3

A 3-1-6
(3) Disconnect harness connector for horn at
* position.

(4) Attach a tag to the hose to make assembly work

easier.
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 A16

(2) Move the boot (3-4) up and loosen nut (3-3).

(See above Figure)
Tools: Spanner: 22 mm
PILOT VALVE

(3) Turn and loosen lever (3-1-6) tightened in pilot Tightening torque
49N.m (36 lbf.ft) Tightening torque
valve, and remove lever assembly in a set. (See PF3/8 29.4N.m (22 lbfft)
Valve side Opposing PF1/4
above Figure)
flats 22 Opposing
flats 19
(4) Remove 4 capscrews (A16) M6X25. (See right
Figure) Mark "F"
Tools: Allen wrench: 5 mm PF3/8 PF1/4

(5) Remove pilot valve. P port connector

Hose side (With filter)
1 4,5 8,T port connector
(6) Plug hose ends. Pilot Valve Connector
Plug PF1/4, PF3/8

33-49
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
Tightening torque: 11.8 N-m (11 lbf-ft):
capscrew (A16) THE FRONT OF MACHINE

BUCKET (R) ARM (R)

BOOM (R) SWING (R) (GREEN)
(BLUE) (GRAY) (RED)
2 T T 2 T T
1 1
3 3
P P P
P 4 4 SWING (L)
BUCKET (H) (GRAY)
(RED)
BOOM (H) (GREEN) ARM (H) (BLUE)

RH LH
Pilot Valve Port Position

Make sure of the tightening torque for capscrews, because pilot valve is made of aluminum.

33-50
 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 (1) (See 33.1.5 UNDER A1 A2

COVER).
A5 A6 A9
(3) Remove floor mat (B1). A8
A3 A4
B1

A7
Removing Floor Mat, Pedal And Lever

33.1.17.2 REMOVAL

33.1.17.3 INSTALLATION
Install it in the reverse order of removal and tighten it.
Sems bolt (A7)
Tools: Spanner: 13 mm T = 23.5 N-m (17.3 lbf-ft)
Sems bolt (A8)
Tools: Socket: 17 mm T = 35 N-m (25.8 lbf-ft)
Sems bolt (A9)
Tools: Socket: 13 mm T = 23.5 N-m (17.3 lbf-ft)

33-51
33. UPPER SLEWING STRUCTURE

33.1.18 SWING MOTOR UNIT

33.1.18.1 PREPARATION FOR REMOVING

(1) Park machine on firm level ground and place attachment on ground.
(2) Remove the guard (8). (See 33.1.4 GUARD)
(3) Operate the switch on gauge cluster and select the pressure release mode, and then release the inner pressure
in the circuit by operating the control lever. (See 22.11 HYDRAULIC SYSTEM PRESSURE
DRAINING(RELEASING) CIRCUIT)
(4) Bleed air from the hydraulic oil tank and attach to each hose a tag showing port name and other information.

33.1.18.2 REMOVAL
(1) Remove hose.
1. Remove hose (8) from the connector in the makeup port M.
Tools: Spanner: 41 mm

2. Remove 2 hoses (2), (3) from the Tee in the drain port Dr.
Tools: Spanner: 36 mm

3. Remove hose (A4) from the elbow of the PG port (For swing parking brake) (See below Fig.)
Tools: Spanner: 19 mm

4. Loosen 8 capscrews (A24) M10X30 and remove half clamp (A30). And disconnected A,B port hoses (A7),
(A4) from the motor.
Tools: Allen wrench: 8 mm

Put in plugs half clamp, PF1, PF3/4, PF1/2, and PF1/4 into the removed ports.

S/J E 2
Dr 2
8 C/V
2
Mu
3
A4
M A30 HYD.
A24 TANK
A
B A7

C/V PG 5
A4 As
S/V
C/V A2
Bs

Removing Swing Unit Piping

Removing Swing Unit

(2) Removing the swing unit

Remove 14 capscrews (5) M24X70.
Tools: Socket: 36 mm
1. Remove two plastic caps (2) M10 at the top of the swing motor and install eye bolts.
Tools: Flat-blade screwdriver
2. Put a wire sling in the eye bolts and remove the swing motor unit.
Weight of swing motor unit; Approx. 446kg (983 lbs) (Include reduction assembly)

33-52
 33. UPPER SLEWING STRUCTURE

33.1.18.3 PREPARATION FOR INSTALL

(1) Clean mating surfaces of swing motor unit and upper frame.
Tools : spatula, wash oil 33
(2) Apply Loctite #515 on entire mounting surface of swing motor unit.

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 14 capscrews (5) M24X70.

Tools: Socket: 36 mm
Tightening torque : 932 N-m (687 lbf-ft)
Apply Loctite #262
(2) Fill inside through motor drain port to casing with hydraulic oil before piping for drain.
(3) Piping tightening torque.

Tightening torque
Size Port Tool
N.m (lbf.ft)
Apply loctite #515 Apply to all round
70.6 (52) of mounting face for motor, swing.
M10 A,B : 8mm

PF1/4 PG : 19mm 29 (21)

PF3/4 Dr : 36mm 118 (87)

PF1 M : 41mm 137 (101)

SETTING POSITION OF SWING MOTOR ASSY

Put sealing tape on the thread
portion of tube for level gauge.
Tightening torque 108N.m (80 lbf.ft)
LEVEL GAUGE

5
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 : 7.4 L (2.0 gal)
(2) When starting operation, operate motor in low idling and at low speed for several minutes, and check it for
possible oil leaks and noise.

33-53
33. UPPER SLEWING STRUCTURE

33.1.19 SWIVEL JOINT

33.1.19.1 PREPARATION FOR REMOVING

Remove boom piping hose.

33.1.19.2 REMOVAL
(1) Remove travel motor hose and tube.
1. Remove 2 hoses (A9). (E port: PF1/2)
Tools: Spanner: 27 mm, Tightening torque: 78.5 N-m (58 lbf-ft)

2. Remove tubes (A1), (A2). (C, Dport: PF1)

Tools: Spanner: 41 mm, Tightening torque: 255 N-m (188 lbf-ft)

3. Remove tubes (A3), (A4). (A, B port: PF1)

Tools: Spanner: 41 mm, Tightening torque: 255 N-m (188 lbf-ft)

4. Remove 2 hoses (A10). (F port: PF1/4)

Tools: Spanner: 19 mm, Tightening torque: 29.4 N-m (22 lbf-f)

(LEFT SIDE) (RIGHT SIDE)

A B
(MOTOR) E (MOTOR)
C D
F F
VA (LOW) BACK VA (LOW) BACK
VB (TOP) FORWARD VB (TOP) FORWARD

P P
D2 D1

T : Tightening torque
of connector
N.m (lbf.ft)

SWIVEL JOINT
B A4
F
B2
T=36.3 (26.8)
A2

T=255 (188)

C
T=255
A
(188) D

A10
E
B3

T=108 (79.7)
A3
A1
T=108 (79.7)
B3 A9
E

A9
Removing Piping (Lower Side)

33-54
 33. UPPER SLEWING STRUCTURE

(2) Disconnecting the hoses on the top part of the

A16
swivel joint.
1. Remove drain hose (2). (E port: PF3/4)
33
Tools: Spanner: 36 mm
Tightening torque: 118 N-m (87 lbf-ft)
2
2. Remove hoses (A6 and A8).
(A, C port : 1-3/16-12UN) A9
Tools: Spanner: 36 mm
Tightening torque: 177 N-m (130 lbf-ft)

3. Remove hoses (A9 and A16).

(B, D port : 1-3/16-12UN)
Tools: Spanner: 36 mm
Tightening torque: 177 N-m (130 lbf-ft)

4. Remove hose (A7). A6

(F port : Travel 2-speed change over port: A8
PF1/4)
Tools: Spanner: 19 mm A15
Tightening torque: 29 N-m (21 lbf-ft)
A7

Disconnecting The Hoses On The Top Part Of

Swivel Joint

(3) Remove whirl-stop of swivel joint.

1. Loosen the nut (10) M24. 10 9 Tightening torque
157N.m (116 lbf.ft)

2. Remove a capscrew (9) M24X130.

Tools: Spanner: 36 mm
mm
13 At assembling,
this distance
should be 13mm (0.512in).

Removing Whirl-stop Nut & The Capscrew

(4) Remove joint for piping (See Figure "Removing FOR WATERPROOF,
Piping (Lower Side)", and sbove Figure) APPLY LOCTITE
TIGHTENING TORQUE #572 OR #577.
2 N.m (1.5 lbf.ft)
1. Remove 2 connectors (B2). (F port) TIGHTENING TORQUE
B3 14.7 N.m (11 lbf.ft)
B1 B2 B4
2. Remove connector (A15) (F port) for travel 2-
speed change over. (PF1/4).
Tools: Spanner: 19 mm

(5) Remove seal (B1).

1. Remove 6 sems bolts (B4) M10X25.
Tools: Socket: 17 mm
Removing Seal (B1)
2. Remove clip (B3).
Tools: Flat-blade screwdriver

3. Remove plate (B2), seal (B1).

33-55
33. UPPER SLEWING STRUCTURE

(6) Remove capscrew for installation.

Attach eye bolt, lift it up temporarily, and remove 3

capscrews (C2) M12X25.
Tools: Socket: 19 mm EYE BOLT
(See 11.7 SPECIAL TOOLS No.9 Plug)

LOWER FRAME
C E A
F

C2
CAPSCREW
M12X25
Loctite #262
T=108N.m C1
(80 lbf.ft) SWIVEL JOINT

Removing Capscrew For Installation

(7) Slinging the swivel joint

Weight: Approx. 24 kg (53 lbs)

33.1.19.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
Piping tightening torque Tightening torque N.m (lbf.ft)
Size Tool.
PF HEX O-ring type Hydraulic hose
(2) Check for oil leaks and the hydraulic oil level. Connector
1/4 19 36 (27) 29 (22)
(3) Check for operating. 3/8 22 74 (54) 49 (36)
1/2 27 108 (80) 78 (58)
3/4 36 162 (120) 118 (87)
1 41 255 (180) 137 (100)
1-3/16-12UN 36 - 177 (130)

33-56
 33. UPPER SLEWING STRUCTURE

33.1.20 UPPER FRAME

33.1.20.1 PREPARATION FOR REMOVING 33

(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.
Temporarily lift the unit at three points: the upper MATCH MARK
frame lifting jig (Refer to Tool "chapter 11"), the 2
lifting holes near the boom foot pin and the angle
steel at the back of the upper frame.

(2) Mark matching marks on swing bearing.

Put match marks on upper frame and swing
bearing.

Matching Mark On Swing Bearing And Upper

Frame

(3) Removing upper frame attaching bolts.

Remove 34 capscrews (10) M24X135 and a
reamer bolt (11) used to install swing bearing and
upper frame.
Tools: Socket: 36 mm

(4) Slinging upper frame.

Sling according to above Figure, and remove upper
frame and put it on a stand.
Weight: Approx. 5 ton (11,000 lbs)

Removing Upper Frame Attaching Bolts

33-57
33. UPPER SLEWING STRUCTURE

33.1.20.3 INSTALLATION
(1) Installing is done in the reverse order of removing.

(2) Clean mating surfaces of upper frame and swing bearing.

(3) Apply Loctite #515 to the inside of the capscrews on the contact surface.

(4) Slinging upper frame

Match marks and install it with a reamer bolt (8) temporarily.
Tools: Socket: 36 mm Apply Loctite #262

(5) Install swing bearing

Install 34 capscrews (7) M24X135.
Tools: Socket: 36 mm Apply Loctite #262
Tightening torque : 932 N-m (687 lbf-ft)
Install a reamer bolt (8).
Tools: Socket: 36 mm
Tightening torque : 932 N-m (687 lbf-ft)

Apply Loctite #515 to the race surface OUTER (S) ZONE POSITION
over the whole circumference (shaded area)
on the inside of capscrew.

Apply Loctite #262

equivalent.
T=932N.m (687 lbf.ft)
7, 8
Bearing Mount

Reamer Bolt Position (*) Apply Loctite To Shaded

Area

Confirm the reamer bolt positions referring to above Figure.

33-58
 33. UPPER SLEWING STRUCTURE

33.2 DISASSEMBLING AND ASSEMBLING

33.2.1 HYDRAULIC PUMP - REGULATOR 33

33.2.1.1 HYDRAULIC PUMP

33.2.1.1.1 Structural exploded view
(1) Main pump
983 531
981 . 534
548 792
702
B 532
732 X
789 Z
535 W
886 Y
953 A
806

728
468
113
127
123
127
824 271

325 808
717
04 490 954 546901
251 312
725
401 407 490
C

124
727 886
314
717 D
141 546
157 E
156
151 153 885 727
. 886
152 467
B 725
211 466
214 406
212 261 D
774 E
710
F

A
116
724 710
717
313 326
124 F 414 05

111
C

885
Structural Exploded View Of Main Pump

33-59
33. UPPER SLEWING STRUCTURE

Marks (W), (X), (Y), and (Z) in Figure "Structural Exploded View Of Regulator" show the position where the
regulator is installed.

No. Name Q'ty No. Name Q'ty No. Name No.

111 Shaft(F) 1 314 Valve plate (L) 1 724 O-ring ; 1B P8 16
113 Shaft(R) 1 325 Sensor block 1 725 O-ring ; 1B P11 9
116 1st gear 1 326 Cover 1 727 O-ring ; 1B P14 3
123 Roller bearing 2 401 Socket bolt ; M20X210 8 728 O-ring ; 1B P24 4
124 Needle bearing 2 406 Socket bolt ; M8X20 4 732 O-ring ; 1B P18 2
127 Bearing spacer 3 407 Socket bolt ; M6X55 3 774 Oil seal 1
141 Cylinder block 2 414 Socket bolt ; M10X20 4 789 Backup ring P18 2
151 Piston 18 466 VP plug ; PF1/4 2 792 Backup ring G35 2
152 Shoe 18 467 VP plug ; PF3/8 2 806 Nut ; M16 2
153 Retainer 2 468 VP plug ; PF3/4 4 808 Nut ; M20 2
156 Spherical bushing 2 490 Plug ; NPTF1/16 32 824 Stop ring 2
157 Cylinder spring 18 531 Tilt pin ; M24X2 2 885 Valve plate pin 2
211 Shoe plate 2 532 Servo piston ; M24X2 2 886 Spring pin 4
212 Swash plate 2 534 Stopper (L) 2 901 Eye bolt ; M10 2
214 Tilting bushing 2 535 Stopper (S) 2 953 Socket screw ; M16X35 2
251 Swash plate support 2 546 Spacer 2 954 Set screw ; M20 2
261 Seal cover (F) 1 548 Feed back pin 2 04 Gear pump 1
271 Pump casing 2 702 O-ring ; 1B G35 2 05 PTO gear case 1
312 Valve block 1 710 O-ring ; 1B G95 2
313 Valve plate (R) 1 717 O-ring ; 1B G145 4
The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.

Tightening torque of bolt, plug, nut and servo piston

Tightening torque
No. Thread size
N.m (lbf.ft)
401 M20 430 (317)
406 M8 29 (21)
407 M6 12 (8.9)
414 M10 57 (42)
466 PF 1/4 36 (27)
467 PF 3/8 74 (55)
468 PF 3/4 170 (125)
490 NPTF1/16 8.8 (6.5)
531,532 M24X2 240 (177)
806 M16 130 (95)
808 M20 240 (177)

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 33. UPPER SLEWING STRUCTURE

(2) Gear Pump (For Pilot)

700 354 351

33
Suction port : PF3/4 433
Tightening torque : 73.5N.m
(54.2 lbf.ft)

434

Delivery port : PF1/2

Tightening torque :
53N.m (39.1 lbf.ft)

311

312

732 307 850

434 355
Drain port : PF3/8 310 308 309 466
725
710 435 361 353 Tightening torque :
34.3N.m (25.3 lbf.ft)

No. Parts Q'ty No. Parts Q'ty

307 Poppet 1 361 Front case 1
308 Seat 1 433 Flange socket; M8X40 2
309 Ring 1 434 Flange socket; M8X55 2
310 Spring 1 435 Flange socket; M8X20 4
311 Adjust screw 1 466 VP plug; PF1/4 1
312 Lock nut; M14X1.5 1 700 Ring 1
351 Gear case 1 710 O-ring; 1B G95 1
353 Drive gear 1 725 O-ring; 1B P11 1
354 Driven gear 1 732 O-ring; 1B P16 1
355 Filter 1 850 Locking ring 1

33-61
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 removal and installation.

(2) Disassembling procedure

1. Selecting a place for disassembly.
-Choose a clean place. Tool Part
-Spread rubber sheet or cloth on work bench to
Name Size mm Size Item No.
protect parts.
5 M6 407
2. Cleaning 6 M8 406
Allen wrench
Remove dust and rust, etc. on pump surface with 8 M10 414
wash oil. 14 M16 953
17 M20 401
Eye wrench 19 PF1/4 466
Socket wrench 24 M16 806
Wrench ; Double 30 M20 808, 954
single 36 PF3/4 468
Crescent wrench Medium size 1pc.

Driver Flat bladed 2pcs.

Hammer Plastic
Plier Snap ring
Steel bar 10X8X200
Torque wrench

3. Drain oil.
Drain out the oil in the pump casing by removing REGULATOR
drain port plug (466), (468).
Tools: Spanner: 19 mm, 36 mm

-Drain out oil from the plug of the front pump and
the rear pump.

4. Removing regulator and PTO gear casing.

Remove the socket bolts [412, 413, and 414 (See
Figure "Structural Exploded View Of Main Pump",
Figure "Structural Exploded View Of Regulator")].
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.

33-62
 33. UPPER SLEWING STRUCTURE

5. Remove gear pump.

Remove the socket bolts (435). Then remove the 312 271
gear pump (04). 401 33
Tools: Allen wrench: 6 mm

6. Remove socket bolt (401).

Loosen socket bolts (401) that fasten swash plate
support (251), pump casing (271) and valve block
(312).
Tools: Allen wrench: 17 mm

Remove Socket Bolt (401)

7. Disassembling the pump casing and the valve

block. 312 271
Place the pump level on a work bench with its
mounting surface on the regulator facing down.
Then separate pump casing (271) and valve block
(312).

-When facing the mounting surface of the regulator

down, place a rubber sheet on a work bench so as
not to score the mounting surface.
-When the pump casing has been separated from
the valve block, remove out the 1st gear (116) at Disassembling The Pump Casing (271) And The
the same time. Valve Block (312)

8. Removing the cylinder assembly.

Remove cylinder (141) from pump casing (271) in 271
parallel to shaft (111). At the same time remove 141(151)(157)
piston (151), plate (153), spherical bushing (156)
and cylinder spring (157). 153
156
-Use care so as not to score the sliding surface of
the cylinder, spherical bushing, shoe and the swash
plate.

Drawing Out The Cylinder Assembly

33-63
33. UPPER SLEWING STRUCTURE

9. Remove seal cover (F).

Remove socket bolt (406) M8 and seal cover F 406
(261).
Tools: Allen wrench: 6 mm 261

-The seal cover (F) may be drawn out with ease if it

is taken out by tightening bolts in the tapped holes
(M6 tap) of the seal cover (F).
-An oil seal is fitted to seal cover (F). Therefore, use
care so as not to score the oil seal.

Removing Seal Cover F (261)

10.Separating the swash plate support and the pump

casing.
271
Knock lightly on the mounting flange of swash plate
support (251) from the pump casing (271) side and
separate the swash plate support from the pump
251
casing.

Separating The Swash Plate (251) Support And

The Pump Casing (271)

11. Remove shoe plate and swash plate.

Draw out shoe plate (211) and swash plate (212)
from pump casing (271). 271

212(211)

Removing Shoe (211) And Swash Plate (212)

33-64
 33. UPPER SLEWING STRUCTURE

12.Drawing out the shaft.

Tap lightly the shaft end (111 and 113) by means of
a plastic hammer and draw out the shaft from the 251
33
swash plate support.

111(113)

Drawing Out The Shaft (111 and 113)

13.Remove valve plate.

Remove valve plate (313 and 314) from valve block
(312).

-The valve plate may come off during the operation 312
under 6).

314
(313 :
Opposite Side)

Removing Valve Plates (313 and 314)

14.Remove other parts.

If necessary, remove stopper (L) (534), stopper (S) 531
(535), servo piston (532) and tilting pin (531) from
pump casing (271). And remove needle bearing
(124) from valve block (312). 534
806 535
532
-When removing the tilting pin, use care so as not
to score the head of the tilting pin using the jig.
-It is hard to separate the tilting pin from the servo
piston in some cases as Loctite is coated on the 808
mating part between them. Use care so as not to
score the servo piston by applying undue force. 312
124
-Do not draw out needle bearings except when 271
their service life has ended.
-Do not loosen hex nuts (806 and 808) on valve 251
block (312) and swash plate support (251). A set
flow rate changes.

Removing Other Parts

33-65
33. UPPER SLEWING STRUCTURE

(3) Installing procedure

1. Precautions to be exercised during installation.
Assembly is the reverse order of disassembly, but notice the following.

a. Repair scored parts at disassembly. Get replacements ready beforehand.

b. Wash parts sufficiently in cleaning oil and dry them with compressed air.
c. Do not forget to coat the sliding areas and bearings with clean hydraulic oil.
d. In principle, replace sealing parts such as O-rings and oil seals.
e. Tighten socket bolts and plugs to specified torques in this manual, using a torque wrench.
f. Do not mix up front pump parts with rear pump parts.

2. Installing swash plate support.

Attach swash plate support (251) to pump casing 271
(271) by tapping the swash plate support lightly
with a plastic hammer.

-When the servo piston, the tilting pin, the stopper,

(L) and stopper (S) have been removed, install
them to the pump casing beforehand.

-When tightening servo piston and tilting pin, use a

jig so as not to damage the head of the tilting pin
and feedback pin. 251
Coat the screwed part with Loctite #262.

Installing Swash Plate Support (251)

3. Installing swash plate.

Place the pump casing with its mounting surface of 251
the regulator facing down, insert the tilting bushing 271(531)
of the swash plate into tilting pin (531), and fit
swash plate (212) to swash plate support (251)
properly.

-Confirm by the fingers of your hands that swash

plate moves smoothly.
-The shaft should install easily if grease is applied 212
to the sliding parts of swash plate and swash plate
support.
-Do not damage the sliding surface of shoe plate.

Installing Swash Plate (212)

33-66
 33. UPPER SLEWING STRUCTURE

4. Installing shaft.
Install shaft (111) fitted with bearing (123), bearing
spacer (127) and snap ring (824), to swash plate 33
support (251).
251
-Do not knock on the shaft with a hammer.
-Fix the bearing by lightly tapping the outer race of
it by means of a plastic hammer and set it exactly to 123
the end by using a steel rod.
127,824

111

Installing Shaft (111)

5. Installing seal cover.

Assemble seal cover (F) (261) to pump casing
(271) and fix it with socket bolts (406).
271
Tools: Allen wrench: 6 mm
Tightening torque: 29 N-m (22 lbf-ft) 261

-Coat the oil seal in seal cover (F) with a thin film of 406
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), 141(151,152,157)
spherical bushing (156) and cylinder spring (157)].
Align the spherical bushing with the cylinder spline 156
and insert them into the pump casing.
153

Inserting Piston Cylinder Sub

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33. UPPER SLEWING STRUCTURE

7. Installing valve plate.

Install valve plate (313 and 314) to valve block
(312) by aligning pin.

-Do not mistake the suction and delivery sides of 312

the valve plate.
314
(313 :
Opposite Side)

Installing Valve Plates (313 and 314)

8. Installing valve block.

Install valve block (312) to pump casing (271) and 312 271
fasten them together with socket bolts (401). 401
Tools: Allen wrench: 17 mm
Tightening torque ; 430 N-m (320 lbf-ft)

-Work will be promoted if assembly is started from

the rear pump.
-Exercise care so as not to mistake the direction of
the valve block (312). (Install it so the regulator is
up as seen from the front side and the suction
flange is on the right.)
-Insert the 1st gear into the valve block beforehand Installing Valve Block (312)
and connect it with the spline of the shaft.
9. Installing gear pump.
Install gear pump (04) and fasten together with
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 REGULATOR
the regulator and PTO cover (326). Install the
regulator and fasten socket bolts (412 and 413).
(See Figure "Structural Exploded View Of
Regulator"]
Socket bolt (412)(413): 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) Installing Regulator And PTO Cover

-Do not mistake the front regulator for the rear

regulator.

11. Installing drain port plug.

The work is complete when drain port VP plugs (466 and 468) have been set.
Tools: Allen wrench: 19 mm, 36 mm
Tightening torque; 36 N-m (27 lbf-ft)
Tightening torque; 170 N-m (125 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. 33
However, always replace such parts that show excessive damage on appearance.

Recommende
Standard
Part name and inspection item dvalue Remedy
dimension
forreplacement
Clearance between piston and cylinder 0.039 0.067
(D-d) Replace piston or cylinder.
bore (0.0015 ) (0.0026 )
Gap between piston and caulked part of 0 - 0.1 0.3 Replace piston shoe assem-
( )
shoe (0.004 ) (0.012 ) bly.
4.9 4.7 Replace piston shoe assem-
Thickness of shoe (t)
(0.193 ) (0.185 ) bly.
41.1 40.3
Free height of cylinder spring (L) Replace cylinder spring.
(1.618 ) (1.587 )
Combined height of retainer plate and 23.0 22.0 Replace a set of spherical
(H-h)
spherical bushing (0.906 ) (0.866 ) bushing or retainer plate.

d H
h

Combination of retainer plate and spherical

Clearance between piston and
bushing Height=H-h
cylinder bore : D-d

L
Gap between piston and shoe :
thickness of shoe : t Free height cylinder spring : L

(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)
Cylinder (sliding section) Standard surface roughness
Less than 0.4Z (lapping)
Roughness of each surface (correction value)

33-69
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 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 quantities, 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 valve’s relief valve are of regular frequency. In case
vibration and sound are abnormal, the pump may be making a cavitation or is 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 are faulty.
4. Pressure measurements.
If the problem is related to control functions, avoid disassembling the pumps carelessly, but look for causes by
measuring pressures.

(2) Troubleshooting
1. Overloading to engine

Cause Remedy Remarks

1. Revolution and pressure are 1) Set pressure to specified value.
higher than set values.
2. Regulator torque is set higher 2) Readjust regulator. 2) Refer to Regulator Manual.
than normal.
3. Pump’s internal parts are seized 3) Replace damaged parts. 3) Check filter and drain oil to see if
or broken. abnormal wear particles are
present..
4. Regulator is piped incorrectly. 4) Pipe regulator correctly.

33-70
 33. UPPER SLEWING STRUCTURE

2. Pump's oil flow rate is extremely low and delivery pressure is not available.

Cause Remedy Remarks

33
1. Regulator is out of order 1) Repair regulator. 1) Refer to Regulator Manual.
2. Pump's internal parts are seized 2)Replace damaged parts. 2)Check filter and drain oil.
or broken.
3. Attached pump is out of order 3) Replace damaged parts. 3) Remove attached pump and
check shaft joint.
4. Attached valve is out of order. 4) Check attached valve. 4) Refer to Manual for Attached
Particularly poppet, seat and Valve.
spring.
5. Regulator is piped incorrectly. 5) Pipe correctly.

3. Abnormal Sound and Vibration

Cause Remedy Remarks

1. Cavitation 1) Prevent cavitation. 1-1) The boost pressure is low.
Check that hydraulic oil is not 1-2) The attached pump is in
clouded. trouble.
1-3) The suction pipe is inhaling air.
1-4) The suction resistance is high.
2. Caulked part of shoe is broken. 2) Replace piston shoe and shoe
plate.
3. Cylinder is cracked 3) Replace cylinder.
4. Pump is installed improperly. 4) Correct installation.
5. Regulator is hunting. 5) Repair regulator, 5) See Regulator Manual.
6. Relief valve in attached valve is 6) Repair attached valve. 6) See the Manual for Attached
hunting. Valve.

33-71
33. UPPER SLEWING STRUCTURE

This page is blank for editing convenience.

33-72
 33. UPPER SLEWING STRUCTURE

33.2.1.2 REGULATOR
33.2.1.2.1 Structural exploded view
33
626
625
624
753
627
623
621 D 728
B 645
611
622 F
874 646
733 613
732 875 644
631 612
898
652 875
A 643
651
836 G E
897 C
655
654
653
814
630
438

629

763
802
628
756
801
924
412
656 413

438 757

Y
W
Z D
418 079 E
041 876
755 X 615
601 755
722 858
466 496 734
755 G
887
708 F

A 876
662 B 724 614
439 C
642 730 725 8-724 755
858
041 755
755 466
466 755

641

Structural Exploded View Of Regulator

33-73
33. UPPER SLEWING STRUCTURE

Marks (W), (X), (Y), and (Z) in Figure "Structural Exploded View Of Main Pump" the position where the regulator is
installed.

No. Name Q'ty No. Name Q'ty No. Name No.

412 Socket bolt ; M8X50 2 628 Adjust screw (C) 1 732 O-ring ; 1B P16 1
413 Socket bolt ; M8X70 2 629 Cover (C) 1 733 O-ring 1
418 Socket bolt ; M5X12 2 630 Lock nut ; M30X1.5 1 734 O-ring ; 1B G25 1
438 Socket bolt ; M6X20 8 631 Sleeve (For PF) 1 753 O-ring ; 1B P9 1
439 Socket bolt ; M6X25 5 641 Pilot cover 1 755 O-ring ; 1B P11 7
466 VP plug ; PF1/4 3 642 Spool 1 756 O-ring ; 1B P26 1
496 Plug ; NPTF1/16 17 643 Pilot piston 1 757 O-ring ; 1B P12.5 1
541 Seat 2 644 Spring seat (Q) 1 763 O-ring ; 1B G35 1
543 Stopper 1 2 645 Adjust stem (Q) 1 801 Nut ; M8 1
545 Ball 2 646 Pilot spring 1 802 Nut ; M10 1
601 Casing 1 651 Sleeve 1 814 Snap ring 1
611 Feed back lever 1 652 Spool 1 836 Snap ring 1
612 Lever (1) 1 653 Spring seat 1 858 Snap ring 2
613 Lever (2) 1 654 Return spring 1 874 Pin ; 4X11.7L 1
614 Fulcrum plug 1 655 Set spring 1 875 Pin ; 4X8L 2
615 Adjust plug 1 656 Block cover 1 876 Pin ; 5X8L 2
621 Compensating rod 1 662 Spring 1 887 Pin 1
622 Piston case 1 708 O-ring ; 1B G75 1 897 Pin ; 4X19L 1
623 Compensating rod 1 722 O-ring ; 1B P6 3 898 Pin ; 7.5X11L 1
624 Spring seat (C) 1 724 O-ring ; 1B P8 8 924 Socket screw ; M8X20 1
625 Outer spring 1 725 O-ring ; 1B P10 1 041 Check valve sub 2
626 Inner spring 1 728 O-ring ; 1B P18 1 079 Solenoid proportional 1
627 Adjusting stem (C) 1 730 O-ring ; 1B P22 1 reducing valve

The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.

Tightening torque of bolt, plug and nut

Tightening torque
No. Thread size
N.m (lbf.ft)
412,413 M8 29 (21)
438,439 M6 12 (8.9)
418 M5 6.9 (5)
466 PF 1/4 36 (26)
496 NPTF1/16 8.8 (6.5)
630 M30X1.5 160 (118)
801 M8 16 (12)
802 M10 19 (14)

33-74
 33. UPPER SLEWING STRUCTURE

33.2.1.2.2 Disassembly and assembly

(1) Tools
The right list shows the tools required for removal and installation.
33
(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 Figure "Structural Exploded

View Of Regulator") 438 656 413 412
Remove socket bolts (412 and 413) and separate
the regulator from the pump body.
Tools: Allen wrench: 6 mm 629
4. Remove port plate (See Figure "Structural
Exploded View Of Regulator")
Remove socket bolt (438) and separate the port
plate (656). 438
Tools: Allen wrench: 5 mm
601

Removing Regulator

5. Remove cover (See Figure "Structural Exploded

View Of Regulator").
Remove socket bolts (438) and remove cover (C)
(629).
Tools: Allen wrench: 5 mm

-The cover is equipped with adjust screws (628),

624,625,626
adjust stem (627), lock nut (630), hex nut (801) and
set screw (924). Do not loosen these screws and 627
nuts. If they are loosened, preadjusted set pressure 801
and flow values change. 629( 628 )

630 924
Removing Cover (C) (629)

33-75
33. UPPER SLEWING STRUCTURE

6. Remove compensating parts.

(See Figure "Structural Exploded View Of M4 BOLT 645
Regulator" (D) section, See Figure "Removing 644,646
Cover (C) (629), Figure "Removing Compensating
Parts")
After removing the cover (C) (629) sub assembly, 629
take out outer spring (625), inner spring (626) and
spring seat (624) from the compensating part. Then
take out adjust stem (645), pilot spring (646) and
spring seat (644) from the pilot part.
-Adjust stem (645) comes out easily if an M4 bolt is
used.
Removing Compensating Parts

7. Remove pilot cover and the set spring.

Remove socket bolt (439) and pilot cover (641).
Once the pilot cover comes off, separate set spring
(655) from the pilot section.
(Figure "Structural Exploded View Of Regulator" (A
and B) section)
Tools: Allen wrench: 5 mm

439
641
Removing Pilot Cover (641) And Set Spring (655)

8. Remove spring seat, return spring and sleeve.

(Figure "Structural Exploded View Of Regulator" (A
section)
Remove snap ring (814). Then remove spring seat 814(653)
(653), return spring (654) and sleeve (651).

-Sleeve (651) is equipped with snap ring (836). 654,

-When removing snap ring (814), return spring 651(836)
(654) comes out: Use care so as not to lose it.

Removing Spring Seat (653), Return Spring (654)

And Sleeve (651)

33-76
 33. UPPER SLEWING STRUCTURE

9. Remove adjust plug.

(Figure "Structural Exploded View Of Regulator" (F and G section) remove snap ring (858) and take out fulcrum
plug (614) and adjust plug (615). 33
-Fulcrum plug (614) and adjust plug (615) come off easily if a M6 bolt is used.

858 614

615

614

Removing Fulcrum Plug (614)

Removing Adjust Plug (615)

10.Remove lever (Figure "Structural Exploded View Of

Regulator" (G section)
Remove lever 2 (613).
Do not draw out pin (875).

-The work is eased if tweezers is used.

613(875)

Removing Lever 2 (613)

11. Remove feedback lever.

Draw out pin (874) and remove feedback lever (611).

-Push out pin (874) [pin dia : o4mm (0.157in)] from above with a slender steel rod so as not to interfere with
lever 1 (612).

874

611

Removing Feedback Lever (611) [1] 611

Removing Feedback Lever (611) [2]

33-77
33. UPPER SLEWING STRUCTURE

12.Remove lever (Figure "Structural Exploded View Of

Regulator" (F section).
612
Remove lever 1 (612). 611
Do not draw out pin (875). 874
897
875 613
13.Remove pilot piston and spool. 875
(Figure "Structural Exploded View Of Regulator" (C
and A section)
Draw out pilot piston (643) and spool (652).

643

14.Remove piston casing, compensating piston and

compensating rod (Figure "Structural Exploded 623
View Of Regulator" (B section)
622 621
Draw out piston casing (622), compensating piston
(621) and compensating rod (623). 733
732
-Piston casing (622) comes out from the opposite 631
side of the piston casing if compensating rod (623) 898 652
is pushed out. 651
836
655
654
653
814

Part Of Exploded View Of Regulator

15.Remove spool (642) and spring (662).

Remove VP plug (466) from pilot cover (641), and 466
draw out spool (642) and spring (662).

This completes disassembly.

662
642

466

641
Part Of Exploded View Of Regulator

33-78
 33. UPPER SLEWING STRUCTURE

(3) Installing procedure:

Assembly is the reverse order of disassembly. Do the work paying attention to the following:

• Repair those parts that were damaged during disassembly and prepare replacement parts beforehand.
33
• If foreign matter enters, it causes malfunction; clean parts thoroughly in cleaning oil, blow them with com-
pressed air and assemble parts in a clean place.
• Always tighten bolts and plugs to the specified torque. The tolerance of torque should be within 10%.
• Do not fail to coat the moving parts with clean hydraulic oil before assembly.
• In principle, replace seals such as O-rings.

1. Installing compensating rod (Figure "Structural

Exploded View Of Regulator" (B section). 623
Assemble compensating rod (623) into the 612
compensating hole of casing (601). 611
874
2. Assembling lever. 897
Put the pin pressed in lever 1 (612) into the groove 875 613
of the compensating rod (623). Then assemble the 875
lever to the pin (875) that is pressed in the casing.

Part Of Exploded View Of Regulator

3. Assembling spool and sleeve (See Figure

"Structural Exploded View Of Regulator" (A PIN (874)
section).
Assemble spool (652) and sleeve (651) into the
spool hole of the casing.

-Make sure that the spool and the sleeve move (652) SPOOL FEEDBACK LEVER (611)
smoothly in the casing.
-Beware of the direction of the spool. Direction Of The Spool (652)

4. Assembling feedback lever.

Assemble feedback lever (611). Then put pin (874) FEEDBACK LEVER (611)
into the pin hole of the feedback lever.

-The work is eased if the pin is put in the feedback

LEVER 2 (613) SIDE
lever a little beforehand. (FULCRUM PLUG AND
LEVER 1
-Take care so as not to mistake the direction of the (612) SODE ADJUST PLUG SIDES)
feedback lever.

Assembling Feedback Lever (611)

33-79
33. UPPER SLEWING STRUCTURE

5. Assembling pilot piston (See Figure "Structural

Exploded View Of Regulator" (C section).
Assemble pilot piston (643) into the positive control
hole of the casing.
-Make sure that the pilot piston moves smoothly.

6. Assembling lever (See Figure "Structural Exploded 613(875)

View Of Regulator" (G section).
Place pin (875) pressed in lever 2 (613) into the
groove of the pilot piston and assemble lever 2
(613).

Assembling Lever 2 (613)

7. Installing fulcrum plug (See Figure "Structural

Exploded View Of Regulator" (F section).
Assemble fulcrum plug (614) so pin (875) pressed
in the fulcrum comes in the pin hole of lever 2
(613). Then fit snap ring (858). 614(875,858)

Installing Fulcrum Plug (614)

8. Installing adjust plug (See Figure 33-111 (G

section).
Insert adjust plug (615) and fit a snap ring (858).
858

-Use care so as not to mistake the holes into which

the fulcrum and adjust plug are inserted. 615
-At this point, operate the feedback lever and make
sure that the gap is not too much and that the lever 614
moves smoothly.

Installing Adjust Plug (615)

9. Installing return spring and the spring seat

(See Figure "Structural Exploded View Of
652
Regulator" (A section).
Assemble return spring (654) and spring seat (653) 814
into the spool hole and fit snap ring (814). 653

654

Installing Return Spring (654) And Spring Seat

(653)

33-80
 33. UPPER SLEWING STRUCTURE

10.Assembling compensating parts (See Figure

"Structural Exploded View Of Regulator" (A and B
section) 33
Assemble set spring (655) into the spool hole.
Place compensating piston (621) and piston casing
(622) into the compensating hole and attach pilot
cover (641). Then fasten them together with socket
bolts (438 and 439).
Tools: Allen wrench: 5 mm
Tightening torque; 12 N-m (8.7 lbf-ft) 622(621)
Assembling Compensating Parts

11. Installing spool and spring.

Assemble spool (642) and spring (662) into pilot 466
cover (641), and tighten VP plugs (466).

662
642

466

641
Assembling Spool (642)

12.Assembling into the pilot hole and the

compensating hole (See Figure "Structural 644,645,646
Exploded View Of Regulator" (E and D) section). 626
Put spring seat (644), pilot spring (646) and adjust
stem (645) into the pilot hole. Then assemble 625(624)
spring seat (624), inner spring (626) and outer
spring (625) into the compensating hole.
-Do not mistake the direction of the spring seat.

Assembling Into The Pilot Hole And Compensating

Hole

13.Installing cover.
Attach cover (C) (629) fitted with adjust screws
(628 and 925), adjust stem (627), lock nut (630),
nut (801) and socket bolt (924). Then fasten them
with socket bolts (438).
Tools: Allen wrench: 5 mm
Tightening torque; 12 N-m (8.7 lbf-ft)
624,625,626
14.Installing block cover (See Figure "Removing
Regulator"). 627
Attach block cover (656). 801
Tools: Allen wrench: 5 mm 629( 628 )
Tightening torque; 12 N-m (8.7 lbf-ft)
This completes assembly.
630 924
Installing Cover (C) (629)

33-81
33. UPPER SLEWING STRUCTURE

33.2.1.3 PTO GEAR CASING (Option)

33.2.1.3.1 Structural exploded view

Tightening torque Tightening torque

No. Parts Q'ty No. Parts Q'ty
N-m (lbf-ft) N-m (lbf-ft)
115 Idle shaft 1 33 (25) 435 Flange socket; M10X20 4
117 2nd gear 1 74 (54) 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 casing 1 885 Spring pin 1
33 (25) 414 Socket bolt; 4 886 Pin 2
M10X20

33-82
 33. UPPER SLEWING STRUCTURE

33.2.1.3.2 Disassembly and assembly

(1) Tools
The right list shows the tools required for removal and
installation. Tool name Dimension 33
Allen wrench Opposing flats 8,10mm
For snap ring RR-20
Plier
For snap ring RR-72

(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: Spanner: 27 mm
-Drain out the oil from the plugs of the front pump and the rear pump.
4. Remove cover
Remove the socket bolts (414). Then remove the cover (262).
Tools: Allen wrench: 8 mm
5. Remove PTO gear casing
Remove flange socket (435) and PTO gear casing.
Tools: Allen wrench: 8 mm

Removing PTO Gear Casing

Removing Gear Pump

6. Removing the 2nd gear, the roller bearing and the

bearing spacer.
Draw out the spring pin (885) and remove idle shaft
(115). Then draw out 2nd gear (117), roller bearing
(126) and bearing spacer (128).
-Roller bearing (126) can not be separated from
2nd gear (117).

Removing 2nd Gear (117)

33-83
33. UPPER SLEWING STRUCTURE

7. Removing the 3rd gear and the ball bearing.

Remove snap ring (825) and draw out 3rd gear
(118) and ball bearing (125).
-Ball bearing (125) can not be separated from 3rd
gear (118).

Removing 3rd Gear (118) And Ball Bearing (125)

(3) Installing procedure

Assembly is a reverse order of disassembly, but notice the following.

1. Repair scored parts at disassembly. Get replacements ready beforehand.

2. Wash parts sufficiently in cleaning oil and dry them with compressed air.
3. Do not forget to coat the sliding areas and bearings with clean hydraulic oil.
4. In principle, replace sealing parts such as O rings and oil seals.
5. Tighten socket bolts and plugs to specified torques in Service Standard, using a torque wrench.
6. Do not mix up front pump parts with rear pump parts.

33.2.1.3.3 Maintenance standards

In case a pitching (1 pit is more than 1mm (0.039in), while the area ratio is more than 5%.) is seen on the gear
tooth surface of 2nd gear (117) and 3rd gear (118), replace the gears. Replace the gears also in case they show
excessive damage.

33-84
 33. UPPER SLEWING STRUCTURE

33.2.2 CONTROL VALVE

33.2.2.1 SECTIONAL VIEW 33

1. Outside view

154 164 101

(P5)
P2

T2 T1

PAL PBL

PB1 PCa

PBs PAs

Pss

PBa1 PAa1

PAo PBo

163 162 163 162

SECTION A A
154 164
(P6)
P1
102

973 973

PTb PCb

973
973
PBr PAr

973
PAb PBb

973 PBc 973

PCc
PAc

974 973
PAa2 PBa2

974

162 162 163 162

SECTION B B

Section (1/6)

33-85
33. UPPER SLEWING STRUCTURE

A
B
(P6)

H 273x10 273x10 H

P1 unload PCb PAL

(Travel straight) Travel left
C C
977
PAr PB1
Boom confluence
Travel right
(P2 unload)
D 978x2 D
PBs

Boom Swing
E PBb E
PCc Pss
PBa1

Bucket Arm 1
F F
PBa2 PAo
PA

MU
Arm 2 Option
G G
K K

B A

PBa2 PAo

274x4 275x4
213

212

PBo

273x10 273x10
PAa2

Section (2/6)

33-86
 33. UPPER SLEWING STRUCTURE

202 P1 unload Travel left

333 202
331 PCb PAL
333
33
336 331
329
327
336
601 MR 324
331
261 323
309
PL 331
261
306
159 AL 163
162

512 511
521
522 CP2
CMR2 551
552 164
562 162
562 CMR1 BL
552
522 163
512
307
261
331 PBL 264
327 205
329 SECTION C-C
336
331
333 Travel straight
202 PTb

202 Travel right Boom conflux

333 202
331 PAr PB1
333
336 331
324
323 339
326
331 325
261
331
306 261
511
161 521
CCb
163 Ar 551
164
511
305
521
CP1
551 551
164 164
163 Br
161
310

(T3)
164
264 154
PBr
261
205 331
SECTION D-D 327
329
336
PCa 331
P2 unload 333
202
Section (3/6)

33-87
33. UPPER SLEWING STRUCTURE

Swing 204
203 PBs
333 Boom
331 PBb Pss
333
336
322 331
321
603 336
AbR
331
211 322
L 261 L 321
266 266
160
160 331
514 261
524 303
CRb As 161
556 162
164 Ab
163
511 511
521 523
LCb LCs
551 556
164 164
Bb
Bs 162

161

301
266
264
264
Q Q
602 BbR 160 PAs 206
PAb
SECTION E-E
210 164 551
Bucket

209
216 PCc
201
333 Arm 1 333
331 PBa1
PBc
331
336 336
322 322
321 321
BaR
602 BcR
603
331 331
261 L L 261
211
304
160
514
524
CRa
Bc 556
Ba 164
511 511
521 521
LCc LCa
551 551
164 164
Ac

162 Aa

161

264 302
603 PAc PAa1 264
205 AcR SECTION F-F 205
AaR 602
Section (4/6)

33-88
 33. UPPER SLEWING STRUCTURE

201
333 Arm Option 201
331 PBa2 PAo 333
33
340
328 331
321
336
331
324
261
AoR 323
604
MU 331
308
162 261
162 311
162
511 Ao

521
LCAT2 511
551
164 521
515 LCo
521 LCAP2 551
551 164
164
Bo
162

161

604
BoR
264 264
Q Q PBo
205
210 PAa2
SECTION G-G

T2

161

P1
T1
511
521 163
CT1
551
163
164
162
P2 511
521
CT2
551
164

SECTION H-H

Section (5/6)

33-89
33. UPPER SLEWING STRUCTURE

207
160
278x5 266
606 606
264 264

527 528
T2 T1
517 163
518

SECTION J-J

SECTION K-K

563

564

SECTION L-L SECTION Q-Q

Section (6/6)

33-90
 33. UPPER SLEWING STRUCTURE

Tightening torque Tightening torque

No. NAME Q'TY No. NAME Q'TY
N-m (lbf-ft) N-m (lbf-ft)
33
101 Casing A 1 311 Option spool 1
102 Casing B 1 321 Spring 5
220~250(162~184) 154 Plug PF3/4 3 322 Spring 4
Plug PT1/4 MEC 323 Spring 3
20~24(15~18) 159 1
(Pre-coat bolt) 324 Spring 3
Plug PT1/16 MEC 325 Spring 1
7.8~9.8(5.8~7.2) 160 5
(Pre-coat bolt) 326 Spring 1
161 O-ring 7 327 Spring 3
162 O-ring 15 328 Spring 1
163 O-ring 11 329 Spring 3
164 O-ring 19 331 Spring seat 24
201 Cover 3 16~18(11.8~13.3)
333 Spacer bolt 12
202 Cover 6 Loctite #262
203 Cover 1 336 Stopper 10
204 Sub cover 1 339 Stopper 1
205 Cover 5 340 Stopper 1
206 Cover 1 511 Poppet 11
Back pressure 512 Poppet 2
207 1
check valve cover 514 Poppet 2
209 Cover 2 515 Poppet 1
210 Cover 2 517 Poppet 1
Lock valve selector 518 Poppet 1
9.8~14(7.2-10.3) 211 2
sub 521 Spring 11
212 Plate 1 522 Spring 2
213 Plate 1 523 Spring 1
25~34(18~25) 216 Piston 1 524 Spring 2
261 O-ring 12 527 Spring 1
264 O-ring 10 528 Spring 1
266 O-ring 4 230~260(170~192) 551 Plug 13
273 Socket bolt 40 130~150(96~111) 552 Plug 2
98~120(72~89) 274 Socket bolt 4 230~260(170~192) 556 Plug 3
98~120(72~89) 275 Socket bolt 4 562 O-ring 2
25~34(18~25) 278 Socket bolt 5 13~17(9.59~12.5) 563 Plug 2
301 Boom spool sub 1 564 O-ring 2
302 Arm 1 spool 1 69~78(51~58) 601 Main relief valve 1
303 Swing spool 1 69~78(51~58) 602 Port relief valve 3
304 Bucket spool 1 69~78(51~58) 603 Port relief valve 3
Relief valve plug as-
305 Boom conflux spool 1 69~78(51~58) 604 2
sembly
306 Travel spool 2 98~120(72~89) 606 Bypass cut valve 2
307 Travel straight spool 1 140~180(103~133) 973 Socket bolt 8
308 Arm 2 spool sub 1 140~180(103~133) 974 Socket bolt 2
309 P1 unload spool 1 977 Name plate 1

33-91
33. UPPER SLEWING STRUCTURE

310 P2 unload spool 1 978 Rivet 2

33-92
 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 33
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 a 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 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 Figure "(Section 1/6) to Figure 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.

33-93
33. UPPER SLEWING STRUCTURE

33.2.2.3.1 Disassembling P1 unload spool

(1) Loosen the socket bolts (273) and remove the
spring cover (202) and the O-ring (261) for P1
unload spool.

Removing Spring Cover (202) For P1 Unload

Spring Cover

(2) Draw out, from casing B (102), as a assembly of P1

unload spool (309), spring seat (331), springs (327
and 329), stopper (336) and bolt (333).

Drawing Out P1 Unload Spool Assembly (309)

When drawing out the spool assembly, use care so as not to score casing B (102).

(3) Fix the P1 unload spool assembly with a vise via a

protective plate (aluminum plate, etc.) and remove
bolt (333). Then separate spring seat (331), springs
(327), (329) and stopper (336) from P1 unload
spool (309).

Disassembling P1 Unload Spool Assembly (309)

33-94
 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.
33

Removing Spring Cover (201)

(2) Draw out the assembly of travel spool (306), spring

seat (331), springs (323 and 324), stopper (336)
and bolt (333) from casing A (101) or casing B
(102).

Drawing Out Travel Spool (306) Assembly

When drawing out the spool assembly, take care so as not to score casing A (101) or casing B (102).

(3) Fix the travel spool assembly with a vise via a protective plate (aluminum plate, etc.). Remove bolt (333) and
separate spring seat (331), springs (323 and 324) and stopper (336) from travel spool (306).

Removing Right Travel Spring Cover (201) Disassembling Travel Spool (306) Assembly

33-95
33. UPPER SLEWING STRUCTURE

33.2.2.3.3 Disassembling the boom conflux spool

(1) Loosen socket bolts (273) and remove spring cover
(201) for boom conflux and O-ring (261).

(2) Draw out the assembly of boom conflux spool

(305), spring seat (331), springs (325), (326),
stopper (339) and bolt (333) from casing A (101).

Removing Spring Cover (202)

When drawing out the spool assembly, 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
(325 and 326) and stopper (339) from boom conflux
spool (305).

Drawing Out Boom Conflux Spool (305) Assembly

33.2.2.3.4 Disassembling the boom spool

(1) Loosen socket bolts (273) and remove spring cover
(203) for boom spool and O-rings (261 and 266).

(2) Draw out the assembly of boom spool (301), spring

seat (331), springs (321 and 322), stopper (336)
and bolt (333) from casing B (102).

Removing Spring Cover (203)

When drawing out the spool assembly, take care so as not to score casing B (102).

33-96
 33. UPPER SLEWING STRUCTURE

(3) Fix the boom spool assembly with a vise via a

protective plate (aluminum plate, etc.) and remove
bolt (333). Then separate spring seat (331), springs 33
(321 and 322) and stopper (336) from boom spool
(301). Do not disassemble boom spool (301)
further unless there is special reason.

Drawing Out Boom Spool (301) Assembly

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-rings (261 and
266) for swing. Do not disassemble spring cover
sub (204) further unless there is special reason.

(2) Draw out the assembly of swing spool (303), spring

seat (331), springs (321 and 322), stopper (336)
and bolt (333) from casing A (101).

Removing Spring Cover Sub (204)

When drawing out the spool assembly, use care so as not to score casing A (101).

(3) Fix the swing spool assembly with a vise via a

protective plate (aluminum plate, etc.) and remove
bolt (333). Then separate spring seat (331), springs
(321 and 322) and stopper (336) from swing spool
(303).

Drawing Out Swing Spool (303) Assembly

33-97
33. UPPER SLEWING STRUCTURE

33.2.2.3.6 Disassembling bucket spool

(1) Loosen socket bolts (273) and remove bucket
spring cover (209) and O-ring (261).

Removing Spring Cover (209)

(2) Draw out the assembly of bucket spool (304),

spring seat (331), springs (321 and 322), stopper
(336) and bolt (333) from casing B (102).

Drawing Out Bucket Spool (304) Assembly

When drawing out the spool assembly, use care so as not to score casing B (102).

(3) Fix the bucket spool assembly with a vise via a

protective plate (aluminum plate, etc.) and remove
bolt (333). Then separate spring seat (331), springs
(321 and 322) and stopper (336) from bucket spool
(304).

(4) When needed to disassemble the spring cover of

bucket spool, loosen plug (551) with casing B
(102) installed. After removed cover (209) from
casing B (102), remove plug (551) and then take
out piston (216).

Disassembling Bucket Spring Cover (209)

33-98
 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.
33
(2) Draw out the assembly that consists 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 assembly, use care so as not to score casing A (101).

(3) Fix the arm 1 spool assembly with a vise via a

protective plate (aluminum plate etc.) and remove
bolt (333). Then remove spring seat (331), springs
(321 and 322) and stopper (336) from arm 1 spool
(302).

Disassembling Arm 1 Spool (302) Assembly

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 consists of arm 2

spool (308), spring seat (331), spring (321 and
328), stopper (340) and bolt (333) from casing B
(102).

Removing Arm 2 Spring Cover (201)

When drawing out the spool assembly, use care so as not to score casing B (102).

33-99
33. UPPER SLEWING STRUCTURE

(3) Fix the arm 2 spool assembly with a vise via a

protective plate (aluminum plate etc.) and remove
bolt (333). Then remove spring seat (331), spring
(321 and 328) and stopper (340) from arm 2 spool
(308). Do not disassemble arm 2 spool (308)
further unless there is special reason.

Disassembling Arm 2 Spool (308) Assembly

33.2.2.3.9 Disassembling option spool

(1) Loosen socket bolts (273), and remove spring
cover (201) and O-ring (261) from option spool.

(2) Draw out the assembly that consists of option spool

(311), spring seat (331), spring (323 and 324),
stopper (336) and bolt (333) from casing A (101).

Removing Option Spring Cover (201)

When drawing out the spool assembly, use care so as not to score casing A (101).

(3) Fix the option spool assembly with a vise via a

protective plate (aluminum plate etc.) and remove
bolt (333). Then remove spring seat (331), springs
(323 and 324) and stopper (336) from option spool
(311).

Drawing Out Option Spool Assembly (311)

33-100
 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.
33

(2) Draw out the assembly of travel straight spool

(307), spring seat (331), springs (327 and 329),
stopper (336) and bolt (333) from casing B (102).

Drawing Out Travel Straight Spool (307) Assembly

When drawing out the spool assembly, take care so as not to score the casing B (102).

(3) Fix the travel straight spool assembly with a vise via a protective plate (aluminum plate, etc.). Remove bolt (333)
and separate spring seat (331), springs (327 and 329) 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 that consists of P2 unload
spool (310), spring seat (331), springs (327 and
329), stopper (336) and bolt (333) from casing A
(101).

Removing P2 Unload Spring Cover (202)

When drawing out the spool assembly, use care so as not to score casing A (101).

33-101
33. UPPER SLEWING STRUCTURE

(3) Fix the P2 unload spool assembly with a vise via a

protective plate (aluminum plate etc.) and remove
bolt (333). Then remove spring seat (331), springs
(327 and 329) and stopper (336) from P2 unload
spool (310).

Drawing Out P2 Unload Spool Assembly (310)

33.2.2.3.12 Removing spool covers

(1) Travel, 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-rings (264 and 266). Do not
disassemble spool cover (206) further unless there
is special reason.
(3) Boom
Loosen socket bolts (273) and remove spool cover
(206) and O-ring (264). Do not disassemble spool
cover (208) further unless there is special reason.
Removing Spool Cover (205, 206, and 208)

33-102
 33. UPPER SLEWING STRUCTURE

33.2.2.3.13 Removing relief valve and plug assembly for relief valve hole
(1) Remove the main relief valve (601) and overload
relief valve (602 and 603) from the casing.
33

Removing Main Relief Valve (601)

Distinguish overload relief valve between (602) and (603) 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 (603)

Removing Plug Assembly (604) For Relief Valve

Hole

33-103
33. UPPER SLEWING STRUCTURE

33.2.2.3.14 Removing by-pass cut valve

(1) Remove by-pass cut valve (606) from the casing.

Removing By-Pass Cut Valve (606)

33.2.2.3.15 Removing lock valve selector valve sub

(1) Loosen socket bolts (211 thru 171) and (279), and
remove lock valve selector sub (211) and
emergency cab manual lowering device (215) from
the casing.
Further disassembly of the lock valve selector sub
(211) and emergency boom manual lowering
device (215) is not allowed.

Removing Lock Valve Selector Sub (211)

33-104
 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.
33

Removing Back Pressure Check Valve Cover (207)

(2) Remove springs (527 and 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 the spool cover face

directs downward.

Removing Boost Check Valve Sub (517) And By-

Pass Check Valve Poppet (518)

When replacing, be careful not to score the spool cover.

33.2.2.3.17 Removing plate

(1) Loosen socket bolts (274 and 275), and remove
plates (212 and 213).
(2) After removing plates, remove all O-rings (162 and
163) remaining on the casing side.

Removing Plate (212 and 213)

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33.2.2.3.18 Removing check valve

(1) Remove plugs from load check valve, conflux
check valve, etc. and then remove poppet (511)
and spring (521).
(2) Load check valve on the swing section.
Remove plug (556) and then remove poppet (511)
and spring (523).
(3) Load check valve on arm 2 section.
Remove plug (551) and then remove poppet (515)
and spring (521).

Removing Plug (551, 556, and 552)

The plug and spring in use differ from the above (1). Do not mix the parts when assembling parts.
The poppet in use differs from the above (1). Do not mix the parts when assembling parts.

(4) Lock valve

Remove plug (556) and then remove poppet (514)
and spring (524).
(5) Main relief valve
Remove plug (552) and then remove poppet (512)
and spring (522).

Removing Poppet (511, 512, 514, and 515)

The plug, poppet and spring in use differ from the above (4). Do not mix the parts when assembling parts.
The plug, poppet and spring in use differ from the above (5). Do not mix the parts when assembling parts.

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.

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 compressed air. Place each part on a
clean sheet of paper or cloth for inspection.
33
(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 a new one.
7. If a relief valve malfunctions, repair it by following the relief valve disassembly and reassembly procedures.
8. Replace all O-rings with new ones.

Take care not to 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. (Figure "Section 1/6)" to Figure "Section 6/6)"
(3) Precautions on reassembling O-ring.
1. Confirm that O-rings are free from defects caused by poor handling.
2. Apply a 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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33.2.2.4.1 Installing check valve

(1) Load check valve, conflux check valve, and so on.
Attach poppet (511) and spring (521) in place, place O-ring (164) in plug (551) and tighten them to the specified
torque. (9 places)
(2) Load check valve of swing section
Attach poppet (511) and spring (523) in place, place O-ring (164) 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 (164) 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 (164) 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 (562) in plug (552) 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 and 163) in casing.
(2) Attach plates (212 and 213) and tighten socket bolts (274 and 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 and 528).
(2) Attach O-rings (264 and 266) in back pressure check valve cover, attach it to casing A (101) and tighten socket
bolt (278) to the specified torque.

33.2.2.4.4 Assembling lock valve selector sub

(1) Attach lock valve selector sub (211) to the casing and tighten socket bolt (211 thru 171) to the specified torque.

33.2.2.4.5 Assembling by-pass cut valve

(1) Attach by-pass cut valve (606) to casing and tighten it to the specified torque.

Take care to prevent dropping poppet (606-201) and spring (606-202) 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 and 603) and relief valve hole plug assembly (604) in
respective place to the specified torque. 33

Assemble it giving attention to the label attached when disassembling to prevent mistake because the port relief
valves (602 and 603) are similar in shape.

33.2.2.4.7 Assembling p2 unload spool

(1) Hold the mid section of P2 unload spool (310) with vise provided with protection plate (aluminum plate, etc.), fit
spring seat (331), springs (327 and 329) and stopper (336) and tighten bolt (333) to the specified torque.

Apply Loctite #262 when tightening bolt (333).

Take care not to deform the 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 the travel straight spool (307) with a vise provided with protection plate (aluminum plate,
etc.), fit spring seat (331), springs (327 and 329) and stopper (336) and tighten bolt (333) to the specified
torque.

Apply Loctite #262 when tightening bolt (333).

Take care not to deform the travel straight spool (307) because of careless over clamping.

(2) Place the travel straight spool assembly in item (1) in casing B (102).

Place the 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 the 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 the spool in option (311) with a vise provided with a protection plate (aluminum plate,
etc.), fit spring seat (331), springs (323 and 324) and stopper (336) 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 the option spool assembly 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 the option spool assembly 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 the arm 2 spool (308) with a vise provided with protection plate (aluminum plate, etc.), fit
spring seat (331), springs (321 and 328) and stopper (340) and tighten bolt (333) to the specified torque. 33

Apply Loctite #262 when tightening bolt (333).

Take care not to deform the arm 2 spool (308) because of careless over clamping.

(2) Place the arm 2 option spool assembly 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 the 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 the arm 1 spool (302) with a vise provided with a protection plate (aluminum plate, etc.)
and fit spring seat (331), springs (321 and 322) and stopper (336), and tighten bolt (333) to the specified torque.

Apply Loctite #262 when tightening bolt (333).

Take care not to deform the arm 1 spool (302) because of careless over clamping.

(2) Place the 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 the 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 a vise provided with a protection plate (aluminum plate, etc.), fit
spring seat (331), springs (321 and 322) and stopper (336) and tighten bolt (333) to 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 the bucket spool assembly in item (1) in casing B (102).

Place the bucket spool assembly in casing B (102) carefully. Do not squeeze it into place.

(3) Attach spring cover (209) with O-ring (261) attached to the spring side of the bucket spool assembly and tighten
the socket bolt (273) to the specified torque.
(4) Attach piston (216) to spring cover (209), place O-ring (164) in plug (551) and tighten to the specified torque.

33.2.2.4.13 Assembling swing spool

(1) Hold the mid section of swing spool (303) with a vise provided with a protection plate (aluminum plate, etc.), fit
spring seat (331), springs (321 and 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 the swing spool assembly in item (1) in casing A (101).

Place the swing spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover sub (204) with O-rings (261 and 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 a vise provided with a protection plate (aluminum plate, etc.), fit
spring seat (331), springs (321 and 322) and stopper (336) and tighten bolt (333) to the specified torque. 33

Apply Loctite #262 when tightening bolt (333).

Take care not to deform boom spool (301) because of careless over clamping.

(2) Place the 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 the spring cover (203) with O-rings (261 and 266) attached to the spring side of the boom spool
assembly and tighten the socket bolt (273) to the specified torque.

33.2.2.4.15 Assembling boom conflux spool

(1) Hold the mid section of the boom conflux spool (305) with a vise provided with a protection plate (aluminum
plate, etc.), fit spring seat (331), springs (325 and 326) and stopper (339) and tighten bolt (333) to the specified
torque.

Apply Loctite #262 when tightening bolt (333).

Take care not to deform the boom conflux spool (305) because of careless over-clamping.

(2) Place the boom conflux spool assembly in item (1) in casing A (101).

Place the boom conflux spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach the spring cover (202) with O-ring (261) attached to the spring side of the boom conflux spool assembly
and tighten the 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 the travel spool (306) with a vise provided with a protection plate (aluminum plate, etc.),
fit spring seat (331), springs (323 and 324) and stopper (336) and tighten bolt (333) to the specified torque.

Apply Loctite #262 when tightening bolt (333).

Take care not to deform the travel spool (306) because of careless over clamping.

(2) Place the travel spool assembly in item (1) in casing A (101) or casing B (102).

Place the 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 the 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 the P1 unload spool (309) with a vise provided with a protection plate (aluminum plate,
etc.), fit spring seat (331), springs (327 and 329) and stopper (336) and tighten bolt (333) to the specified
torque.

Apply Loctite #262 when tightening bolt (333).

Take care not to deform the P1 unload spool (309) because of careless over-clamping.

(2) Place the P1 unload spool assembly in item (1) in casing A (101).

Place the P1 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach the spring cover (202) with O-ring (261) attached to the spring side of the P1 unload spool assembly and
tighten socket bolt (273) to the specified torque.

33.2.2.4.18 Assembling spool cover, and so on

(1) Travel, bucket, arm 1, and 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 and 266) in spool cover (206) and tighten socket bolt (273) to the specified torque.
(3) Boom
Place O-ring (264) in spool cover (208) 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
33
Parts name Inspection item Criterion and remedy
Casing 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 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.
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 Look for damage on the poppet and the If spring is damaged, replace it.
spring. If the seat of poppet or spring are
damaged, correct or replace it.
Insert the poppet in the casing, and move If the poppet moves lightly without
it. catching, it is normal.
Spring and related Look for rust, corrosion, deformation, and If damaged heavily, replace.
parts breakage of the spring, spring seat,
stopper, spacer bolt and cover.
Main relief valve Look for rust and damage on outer surface. Replace.
Port relief valve Inspect the contact face of the valve seat. If damaged, replace.
By-pass cut valve 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. 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 assembly 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. Machine does not Malfunctioning travel straight valve. Check pilot pressure.
move straight during Sticking spool. Correct sticking part with oil stone.
simultaneous Broken or deformed spring. Replace spring.
operation of travel Clogged small hole in spool. Remove foreign matter.
and attachment.
Malfunctioning main relief valve. Remove main relief valve.
3. Excessive natural Excessive clearance between casing and Replace spool.
falls of attachment spool.
under its own weight
Spool is not completely in neutral position. Check secondary pilot pressure.
when spool is in
Foreign matter between casing and spool, Disassemble, clean and smooth sticking
neutral.
or sticking spool. part with oil stone.
Broken or deformed spring. Replace spring.
Clogged pilot circuit. Remove foreign matter.
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.
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 assembly.
Selector spool is stuck.

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 33. UPPER SLEWING STRUCTURE

Trouble Cause Remedy

4. When raising Malfunctioning load check valve. Disassemble and clean. If heavily
33
attachment, at first it Foreign matter between poppet and damaged, replace control valve.
drops. casing. Correct sticking part with oil stone.
Sticking poppet. Replace spring.
Broken or deformed spring.
5. Bucket, boom, Malfunctioning main spool. Check secondary pilot pressure.
arm or swing does Excessive clearance between casing and Replace spool.
not operate. spool. Disassemble and clean.
Slow to start up (or Foreign matter between casing and spool. Correct stuck part with oil stone.
poor power).Slow Sticking spool. Replace spring.
response. Broken or deformed return spring. Remove foreign matter.
Clogged pilot circuit.
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))
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. Boom conflux Malfunctioning conflux valve. Measure pilot pressure.
does 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. No pressure rise. Main or pilot poppet of relief valve is Check for foreign matter on each poppet.
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. Unstable relief Main or pilot poppet of relief valve seat is If failure is found, replace it an assembly.
pressure. damaged.
3. Incorrect relief Wear due to foreign matter. Replace damaged assembly
pressure setting.
3. Excessive natural Loosened locknut or adjusting screw. Adjust pressure.
falls of attachment
under its own weight
when spool is in
neutral.
4. Oil leak. Damaged seat. Confirm that each component operates
Damaged O-ring. smoothly. Replace damaged or worn
component.
If failure is found, replace it an assembly.
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

Apply Loctite #277

312

302
Apply grease on
501 rotating and sliding sections.
301 Be careful the
assembling direction
Apply grease on top section *246-1
212
*246-2 213
151
*218
211
214

216-2 216-1

241-2 241-1

201-2
Secondary 201-1
pressure 217
adjusting shim
101 221

PORTS 2, 4 PORTS 1, 3
Pilot Valve (For ATT)

Tightening torque Tightening torque

No. Parts Q'ty No. Parts Q'ty
N-m (lbf-ft) N-m (lbf-ft)
101 Casing 1 *218 Seat 4
151 Plate 1 221 Spring 4
201-1 Spool 2 241-1 Spring 2
201-2 Spool 2 241-2 Spring 2
211 Plug 4 *246-1 Spring 2
212 Push rod 4 *246-2 Spring 2
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 * might not be equipped depending on valve type.

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33.2.3.2 DISASSEMBLY
(1) Plug each port of the pilot valve, and clean it with
kerosine.
P port: PF1/4 501
1 to 4 and T port: PF3/8
(2) Fix the pilot valve with a 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
312

302

Removing Adjusting Nut (312)

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 33. UPPER SLEWING STRUCTURE

(4) Remove circular plate (302)

Tools: Spanner: 32 mm
302
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

301

Removing Joint (301)

When the force of return springs (221) are 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. 151

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.

211

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 assembly (spool), and return
springs (221) from casing (101).
212

211

221

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 and 241-2) in the range of 7

mm (0.276 in) so that the movement of the spring
216-1
seats (216-1 and 216-2) and shift the seats (216) in 216-2 33
a side direction, and remove spools (201-1 and
201-2) through the larger hole of the seat.

201-1
201-2
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 spools (201-1 and 201-2), spring seats

(216-1 and 216-2), spring (241-1 and 241-2), and
241-1 216-1
washer (217).
241-2 216-2

217

201-1
201-2

Disassembling Pressure Reducing Valve

(10)Remove springs (*246-1 and *246-2) and spring

seat (*218) from push rod (212).
*246-1 214
*246-2
*218

212
211

Disassembling Push Rod

The parts marked * might not be equipped depending on valve type.

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(11)Pull out push rod (212) from plug (211).

(12)Remove O-ring (214) from plug (211).

212

Removing Push Rod (212)

(13)Remove inside seal (213) from plug (211) with

small driver.

213
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 (217), springs (241-1 and 241-2), and
spring seats (216-1 and 216-2) to spools (201-1
201-1 241-1 216-1
and 201-2). 216-2
201-2 241-2

217

Assembling Pressure Reducing Valve

33-124
 33. UPPER SLEWING STRUCTURE

(2) Push spring (241-1 and 241-2) in the range so that

the movement of spring seats (216-1 and 216-2) in
216-1
a side direction, and install spool (201-1) through 33
216-2
the larger hole of spring seat. (See Figure
"Removing Spool (201)"

201-1
201-2

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 and 3 of casing

(101), and then install pressure reducing valve
PRESSURE REDUCING
assembly in it. VALVE ASSY
Place springs (221) into ports 2 and 4 and install it.
221

101

Installing Pressure Reducing Valve Assembly

Install the removed respective assembly into respective holes.

33-125
33. UPPER SLEWING STRUCTURE

(4) Fit O-ring (214) and seal (213) into plug (211).
-Apply hydraulic oil on surface of push rod.

PLUG (211)
211
SEAL (213)
214 213
-RING (214)

PUSH ROD
(212) Apply hydraulic oil

For the assembling

direction of seal (213).

Installing O-ring (214) and Seal (213)

(5) Insert push rod (212) in plug (211) and install spring
(*246-1) and spring seat (*218) to push rod (212)
on port 1 and 3 side.
Insert push rod (212) in plug (211) and install spring
(*246-2) and spring seat (*218) to push rod (212)
on port 2 and 4 side.

*246-1
212 211 *246-2 *218
Assembling Push Rod, Spring (*246-1 and *246-2)
and Seat (*218)

The parts marked * might not be equipped depending on valve type.

(6) Fit plug (211) assembly to casing (101).

1. When the force of spring (211) is weak, it stops at
the position where it is pushed in by the sliding
resistance of O-ring (214).

101 211
Installing Plug Assembly

33-126
 33. UPPER SLEWING STRUCTURE

2. When the force of spring (221) is strong, attach

plate (151) and press 4 push rods by hand at the same
time, and tighten joint (301) temporarily. 301
-Install spool (201) straight and evenly into the hole of 33
casing (101).
Take care so that plug (211) and plate (151) do not
jump out of casing (101).

151

Installing Plug Assembly 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)

101
A

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
312
Tools: Socket: 22 mm
Apply Loctite #277 to threads of joint.
Tightening torque: 68.6 N-m (51 lbf-ft)
302

Installing Circular Plate (302)

Screw it in until it comes in contact with 4 push rods (212) equally.

Over screwing it in may cause malfunction of machine.

33-127
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 GREASE
attach plug respectively.

301
212
Applying Grease To Joint Section And Push Rod

33-128
 33. UPPER SLEWING STRUCTURE

33.2.3.5 MAINTENANCE STANDARDS

Check item Standard Remarks 33

When leakage quantity reaches to 1000 cc/ Conditions
min. or more where handle is set in neutral Primary pressure 2.94 MPa (426 psi)
position, or to 2000 cc/min. or more in Hydraulic oil viscosity 23 cSt
Leakage
operation; replace spool with new one.
If leaking, even if the spool is replaced,
replace pilot valve assembly 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 on In case of the looseness due to the
Looseness of circular plate (302) on control section and joint loosening on tightening section, adjust
control section section (301) due to wear; replace them with it.
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
assembly with new one.

O-rings, etc. should be replaced with new ones at every disassembling.

If socket bolt (125) was loosened, seal washer (121) should be replaced.

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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 are 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. Primary pressure is insufficient. 1. Secure primary pressure.
2. Secondary pressure springs (241) are 2. Replace with new ones.
broken or fatigued.
Secondary pressure
3. Clearance between spool (201) and cas- 3. Replace spool (201).
does not rise.
ing (101) is abnormally large.
4. Handle has a looseness. 4. Disassembly and reassembly or replace
handle section.
1. Sliding parts are caught. 1. Repair the unsmoothed section.
Secondary pressure
2. Tank line pressure varies. 2. Bring pressure directly to oil tank.
is unstable.
3. Air has mixed into pipeline. 3. Bleed air by operating it several times.
Secondary pressure 1. Tank line pressure is high. 1. Bring pressure directly to oil tank.
is high. 2. Sliding parts are caught. 2. Correct.

33-130
 33. UPPER SLEWING STRUCTURE

33.2.3.7 JIG
(1) Jig for removing and installing joint (301)
33

33-131
33. UPPER SLEWING STRUCTURE

33.2.4 PILOT VALVE (FOR TRAVEL)

33.2.4.1 CONSTRUCTION

T=Tightening torgue
N.m (lbf.ft) 12-o

12-o

7-h
12-o
12-y
5 12-y
12-x 12-x

13

6 8
f

d
Loctite 262 10
g
T=3
g
14
q 11
T=5 (3.7) r 15
u
t T=4 (3)
7-i T=30 (22)
15
7-k T=1.2 (0.9)
7-h u
15 t T=4 (3)
7-j t 14
u
r
q
17 21 T=5 (3.7)
Loctite 262 21
21
z
r 21
w' T=3~5 (2.2~3.7)
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 14 dia. 4 21 Plug 4

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 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.

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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.)

Regulation Damping screws

screws to already adjusted
adjust and glued

SWITCH PLATE
The figure is shown
from the backside.

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 33. UPPER SLEWING STRUCTURE

(4) Retaining plate removal

1. Remove
The pilot control unit from the machine.
Both rubber boots (See 33.2.4.2 (1))
33
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))

WIPER RING
1 2 DAMPER PLUNGER

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)

33-135
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.

3 4
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 6

7 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.

33-136
 33. UPPER SLEWING STRUCTURE

(6) Guide/plunger and regulation unit replacement

1. Remove
The pilot control unit from the machine.
Both rubber boots (See 33.2.4.2 (1))
33
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 regulation 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).

33-137
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.

33-138
 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. Put 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.

33-139
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. Put the body up-side-down to remove the ball.
4. Repeat the operation for the second check valve
kit.

5. Inspect the check valve plugs, O-rings and balls. If

defects are detected, replace all the assemblies.
(See right Fig.)
6. Reassemble parts in reverse order.

33-140
 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 necessary to drain the 33
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 the pedal gently 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.

33-141
33. UPPER SLEWING STRUCTURE

33.2.5 SWING MOTOR UNIT

33.2.5.1 CONSTRUCTION
(1) Swing motor

702 712

351

ARRANGEMENT OF BRAKE SPRING

355

401

488 469
051-1 051

100
151
162 052 161 171 163

303 A A 984
985 391 390 444
131
451
472 400-1
400-2
712 400 052

702 707
SECTION A-A
706

986

742

743
994

111

491 101
121 123 122 124 114 301 443
Swing Motor

33-142
 33. UPPER SLEWING STRUCTURE

Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY 33
N-m (lbf-ft) N-m (lbf-ft)
177 (130) 051 Relief valve; M33-P1.5 2 69 (51) 400 Anti-reaction valve; M22- 2
P1.5
051-1 O-ring; 1B G30 2 400-1 O-ring; 1B P20 2
052 Anti-reaction valve sub 1 400-2 Backup ring 2
100 Casing for anti-reaction 1 431 (318) 401 Socket bolt; M20X45 4
valve
101 Drive shaft 1 443 Roller bearing 1
111 Cylinder 1 444 Roller bearing 1
114 Spring plate 1 451 Pin 2
121 Piston 9 539 (398) 469 ROMH plug; M36-P1.5 2
122 Shoe 9 472 O-ring; W1516,WG44 1
123 Set plate 1 488 O-ring; 1B P34 2
124 Shoe plate 1 491 Oil seal 1
131 Valve plate 1 702 Brake piston 1
36 (27) 151 Plug; PF1/4 2 706 O-ring; W1516,WG42 1
161 O-ring; 1B P11 2 707 O-ring; W1516,WG45 1
162 O-ring; 1B P12 2 712 Brake spring 14
163 O-ring; 1B P6 2 742 Friction plate 3
29 (21) 171 Socket bolt; M8X55 4 743 Separator plate 4
301 Casing 1 2.7 (2.0) 984 Plug; PF1/2 1
303 Valve casing 1 5.6 (4.1) 985 Plug; PF1 1
351 Plunger 2 0.9 (0.66) 986 Plug; PF1/4 1
355 Spring 2 98 (72) 994 Plug; PT3/4 1
390 Name plate 1
391 Rivet 2

33-143
33. UPPER SLEWING STRUCTURE

(2) Swing reduction unit

20

22 11 27 25 24 3
4
5 SURFACE
OF LUBE OIL
10 3 34

23 6
7 8 3 VIEW
11 15
26 12
9 17 30 35, 36, 37, 38
14 31
3
28
29 18

33 32
13
21 19 16
2
1
DETAIL aa

aa
Sectional View Of Swing Reduction Unit

Tightening torque Q'T Tightening torque Q'T

No. Parts No. Parts
N-m (lbf-ft) Y N-m (lbf-ft) Y
1 Pinion 1 20 Plate 1
2 Shaft 1 21 Ring 1
3 #1 Sungear 1 22 Thrust washer 6
4 #1 Planetary pinion 3 23 Thrust washer 8
5 #1 Spider assembly 1 24 Snapring 1
6 #2 Sungear 1 25 Snapring 3
7 #2 Planetary pinion 4 26 Spring pin 4
8 Ring gear 1 539±54 (398±40)*1 27 Capscrew ; M20X200 12
9 #2 Spider assembly 1 28 Grease fitting 1
10 Shaft 4 29 Relief fitting 1
11 Needle bearing 11 69.1±4.4 (51±3)*2 30 Tube 1
12 Roller bearing 1 69.1±4.4 (51±3)*2 31 Elbow 1
13 Roller bearing 1 69.1±4.4 (51±3)*2 32 Plug 1
14 Oil seal 1 33 Cap 2
15 Housing 1 279±30 (206±22)*1 34 Capscrew 3
16 Oil seal 1 35 Shim ; t=0.1 1
17 Sleeve 1 36 Shim ; t=0.2 1
18 Sleeve 1 37 Shim ; t=0.3 1
19 Plate 1 38 Shim ; t=0.5 1

33-144
 33. UPPER SLEWING STRUCTURE

33.2.5.2 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR

33.2.5.2.1 Tools
33
Tools Remarks
Socket wrench Relief valve M33 P1.5 41mm
Anti-reaction valve M22 P1.5 24mm
M8, M20 6,10,12,17mm
Allen wrench ROMH PLUG M36 P1.5 17mm
ROH PLUG PF1/4, PF1/2, PF1 6mm, 8mm, 14mm
Screwdriver Flat-bladed type, medium size 2 pcs.
10 8 200(0.39" 0.31" 7.87")
Steel bar
(key material) 1 pc.
Hammer Plastic hammer 1 pc.
10~45 (7.2~33)
Torque wrench N•m (lbf•ft) 40~180 (29~130)
120~480 (87~350)
Slide hammer bearing puller
14 (0.551")

85 (3.35")
75 (2.95")
30 (1.18")
15 (0.591")

35 (1.38")
" )
92
.4
M16 (0
Through
Brake piston drawing tool
100 (3.94")

30 (1.18")
14 (0.55")
44 (1.73")
8 (0.315")

M16
(0.158")

DRAWING TOOL

o 8 (0.315") BRAKE PISTON

CASING

33-145
33. UPPER SLEWING STRUCTURE

33.2.5.2.2 Disassembly
(1) General cautions
1. Hydraulic components are precision products and have small clearance. Therefore, assemble and disassemble
in a less dusty clean place. Use clean tools and cleaning oil and handle components with full care.
2. If a component is removed from the main body, clean the area around the ports thoroughly and plug them up so
no dust and water can enter. When fitting them back to the body, do not remove the plugs till piping is
completed.
3. Study the structural drawing before the work begins and prepare necessary parts according to your purpose and
the scope of work. Seals and O-rings once removed can not be used again.
Some parts cannot be supplied as single parts and are available only in sub assemblies. Prepare such parts
according to the parts manual.
4. The piston and the cylinder block are shop fitted when new. If you intend to reuse them, put a matching mark on
the piston and the cylinder block.

(2) Disassembly procedure

The figures in parentheses after part names in this manual represent those item numbers in Figure "Swing Motor".

1. Draining oil
Remove the drain plug and drain hydraulic oil from 052
casing (301). 051
303
2. Preparation for removing the valve casing.
Fix the motor on a work bench so the drive shaft
712
(101) end comes down. On that occasion, put a
matching mark on the mating parts of casing (301) 702
and valve casing (303).
Choose a clean place, and lay with a rubber sheet
or a cloth on a work bench. Handle the valve casing
with care so parts do not get damaged.

301
101
Removing Valve Casing (303)

3. Loosen relief valve (051) and separate it from valve

casing (303).
Tools: Spanner: 41 mm
4. Loosen anti-reaction valve sub assembly (052) and
remove from valve casing (303). (See above Fig.)
Tools: Allen wrench: 6 mm
5. Separate ROMH plug (469) from valve casing (303)
and draw out spring (355) and plunger (351).
Tools: Allen wrench: 17 mm

Removing Relief Valve (051), Anti-Reaction Valve

(052), Anti-Cavitation Plunger (351) And Valve
Casing (303)

33-146
 33. UPPER SLEWING STRUCTURE

6. Loosen socket bolt (401) and separate valve casing

(303) from casing (301). If the socket bolt (401) is
loosened, the valve casing floats off the casing 33
(301) by the force of the brake spring (712).
Then separate valve plate (131) from valve casing
(303).
Tools: Allen wrench: 17 mm
7. Draw out brake spring (712) from brake piston
(702).

Removing Brake Piston (702)

8. Put the claw of the brake piston removing jig in the

concaved part of brake piston (702).
Tighten 2 bolts of jig simultaneously, and draw out 123 121 111
the brake piston (702) with the jig, from the casing. 122
9. Lay the motor on its side again and draw out
cylinder block (111) from drive shaft (101). Then
draw out piston (121), set plate (123), spring (114) 124

and shoe plate (124). 101

301 742 743

Drawing Cylider Block (111), Piston Sub Assembly,

Friction Plate (742) And Separator Plate

Handle the parts with care so you do not score the sliding surfaces of cylinder block (111) and shoe (122).

33-147
33. UPPER SLEWING STRUCTURE

10.Draw out friction plate (742) and separator plate

(743) from casing (301).
11. Draw out drive shaft (101) from casing (301), while
lightly tapping the side face of valve casing (303) in
drive shaft (101), using a plastic mallet.

-Do the following work as required.

Removing Drive Shaft (101)

a. Draw the inner race of roller bearing (443) from

drive shaft (101) using a press.
Do not reuse the removed bearing.
b. Draw out the outer race of roller bearing (443) from
casing (301), by lightly tapping a steel rod from the
oil seal (491) housing side.
(Do not reuse the bearing.)
c. Separate the outer race of roller bearing (444) from
valve casing (303), using a slide hammer bearing
puller.

Removing Inner Race Of Roller Bearing (443)

33-148
 33. UPPER SLEWING STRUCTURE

33.2.5.2.3 Assembly
(1) General precautions
1. Repair those parts damaged after disassembly and prepare replacement parts before hand.
33
2. Clean all parts thoroughly in cleaning oil and dry them with compressed air.
3. Always coat the moving parts with clean hydraulic oil before assembly.
4. Replace such seals as O-rings and oil seals in principle.
5. Tighten socket bolts and plugs to specified torques, using a torque wrench.

(2) Assembly procedure

The figures in parentheses after part names in this manual represent those item numbers in the Figure "Swing
Motor".

1. Preparation for assembly

Place casing (301) on a proper bench so the valve
casing (303) faces upward.
This operation is necessary only when the roller
bearing is removed.

2. Shrink fit the inner race of roller bearing (443) into

drive shaft (101).

Assembling The Inner Race Of Bearings (443 and

444)

3. Shrink fit the inner race of roller bearing (444) to

drive shaft (101).
This operation is necessary only when the oil seal
is removed.
Fit oil seal (491) to casing (301). On this occasion,
coat the lip of the oil seal with grease and check the
direction of it before fixing it.

4. Assemble the outer race of roller bearing (443) into

casing (301) by lightly tapping the steel rod.

5. Attach drive shaft (101) to casing (301).

443 491
101 301
Fitting Oil Seal (491), Outer Race Of Roller Bearing
(443), And Drive Shaft (101)

33-149
33. UPPER SLEWING STRUCTURE

6. Place casing (301) as shown in Right Fig. and

insert shoe plate (124).
On this occasion, the shoe plate does not come off
if it is coated with grease.

Inserting Shoe Plate (124)

7. Set the set plate (123) and spring (114), then set
piston sub-assembly (121 and 122).
8. Assemble piston sub assembly (121 and 122) fixed
in retainer plate (123) into cylinder (111). Match it to
the spline of drive shaft (101) and insert it in place.

Inserting Cylinder Assembly

9. Replace casing (301) with oil seal (491) facing

downward and assemble separator plate (743) and
friction plate (742) into casing (301), in that order. 743
Assemble four separator plates and three friction
742
plates.

491 301

Position of
separator plate (743)

PG PORT
Installing Of Separator Plate (743), Friction Plate
(742)

33-150
 33. UPPER SLEWING STRUCTURE

Assemble the same phases of four slits in the gears of friction plate (742). 33
Assemble four slits in the four claws of separator plate (743) in the position shown in Figure "Installing Of Separator
Plate (743), friction Plate (742)."

10.Fit O-rings (706 and 707) to casing (301). In this

case, if the O-rings are coated with grease, they
are hard to tear off when brake piston (702) is
inserted.
11. Assemble brake piston (702) into casing (301).
12.Assemble brake spring (712) into brake piston
(702). In this case, make sure the spring is placed
securely in the spot faced part of the brake piston.
This operation is necessary only when the roller
bearing (444) is removed.

Assembling Brake Piston

13.Insert the outer race of roller bearing (444) into valve casing (303), while lightly tapping the steel rod placed on
the outer race, using a hammer.

14.Assemble valve plate (131) into valve casing (303) and fit O-ring (472) in it.

15.Install valve casing (303) to casing (301) and fasten them with socket bolts (401).
Tools: Allen wrench: 17 mm,
Tightening torque: 431 N-m (320 lbf-ft)

16.Fit plunger (351) and spring (355) to valve casing (303). Then tighten ROMH plug (469) fitted with O-ring (488)
against valve casing (303).
Tools: Allen wrench: 17 mm,
Tightening torque: 539 N-m (398 lbf-ft)

17.Fit relief valve (051) to valve casing (303).

Tools: Spanner: 41 mm,
Tightening torque: 177 N-m (130 lbf-ft)

18.Fit anti-reaction sub assembly (052) to valve casing (303).

Tools: Allen wrench: 6 mm,
Tightening torque: 29 N-m (22 lbf-ft)

33-151
33. UPPER SLEWING STRUCTURE

33.2.5.3 DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT

33.2.5.3.1 Tools

Code Tool name Remarks

Material : Mild steel Q520 (20.5")

Q390 (15.4")

230 (11.8")
a Stand

o 180 (7.1")
o 153 (6.0")
Spherical bearing (13)
b

130 (5.1")
removing jig

t=4.5 (0.177")
Spherical bearing (12) 0
c 10 4")
removing jig o .9
(3

Q190 (7.48")

(0.354")
Material : Mild steel
Oil seal (16) Q162 (6.38")
d

9
installing jig

o 150 (5.91")
o 132 (5.2")

Spherical bearing (13)

120 (4.72")
e

or more
press-fit jig

o 186 (7.32")
(0.354")

Oil seal (14) o 160 (6.3")

f
9

installing jig
(2.36")
60

Spherical bearing (12)

g o 125
press-fit jig (4.92")
o 195 (7.68")

33-152
 33. UPPER SLEWING STRUCTURE

Code Tool name Remarks

i Snap ring plier For shaft
33
j Torque wrench 140 N-m (100 lbf-ft) class
k Plastic hammer (Wooden mallet)
m Press 30 ton (66150 lb) class
n Flat-bladed screw driver
p General tools Allen wrench, Steel bar
Thread sealant Three Bond #1360K
q
Sealant Loctite #515

33.2.5.3.2 Disassembly
The numbers in parentheses correspond to the ones in construction drawings Figure "Swing Motor."

(1) Preparation
1. Before disassembly, clean the outside of the reduction unit thoroughly and check for damage and scoring.
2. Drain gear oil from the reduction unit.
3. Disconnect the drain tube.
4. Matching Mark
To facilitate the reassembly of the unit, put a matching mark on the joining parts of the housing before
disassembly.

(2) Disassembling swing motor from reduction unit

1. Preparation for disassembly.
Place the reduction unit assembly on a stable work
bench as shown in Right Figure. Remove plug (32),
drain out oil and put a matching mark on the 27
matching surface shown in the figure on the right.
2. Removing swing motor assembly.
Loosen all socket bolts (27) (M20). Attach eye bolts
(M12) in the lifting bolt holes in the top surface of
MATCHING
the swing motor and lift the assembly by crane. MARK
If it is hard to remove the swing motor assembly
from the reduction unit, float it by inserting a flat-
blade screwdriver in the groove of the flange. 32
Tools: Allen wrench: 17 mm

Removing Swing Motor Assembly

33-153
33. UPPER SLEWING STRUCTURE

(3) Disassembling reduction unit

1. Remove #1 sun gear (3).
2. Removing #1 spider assembly (5). 5
3
The spider assembly (5) [consisting of thrust
washer (22), #1 pinion (4), needle bearing (11) and
snap ring (25)] can be removed from the spline 4
8
easily if it is lifted up in this position.

15

Removing #1 Sun Gear And #1 Spider Assembly

3. Removing ring gear (8).

Attach eye bolts (M16) to the top surface of ring
gear (8) and lift the ring gear lightly with a wire
sling. #2 SPIDER ASSY
Put a flat-blade screwdriver (n) into the matching
8
surface of ring gear (8) and housing (15) and
remove ring gear (8) by lightly tapping the outer
circumference of the ring gear with a plastic mallet
(k).
15

Removing Ring Gear (8)

4. Remove #2 sun gear and #2 spider assembly.

Draw out #2 sun gear (6) and remove the #2 spider #2 SPIDER ASSY
assembly. 6
Regarding the disassembly of the #2 assembly,
refer to paragraph (4) which will come up later.

Removing #2 Spider Assembly

Particularly if no failure is found, the further

disassembly (under condition shown in Right Fig.) is
not allowed. Check on parts for possible failure
according to the inspection procedure shown in item
33.2.5.4.2 separately in this condition. And we
recommend that the pinion shaft and housing assem-
bly are replaced together as one set. But if it is
unavoidably necessary to replace a part of them,
follow the procedure shown below.
If no failure is found in this step, the disassembly later
is not required.

33-154
 33. UPPER SLEWING STRUCTURE

5. Remove pinion (1)

Place housing (reduction) (15) upwards. EYE BOLT (M8)
34
Loosen 3 capscrews (M16X40) and remove plate 20 33
(20). Attach eyebolt (M8) to pinion (1) and hoist
1
pinion (1).
Tools: Socket: 24mm
16

When oil seal (16) is separated from housing (15),

oil seal (16) and pinion (1) are removed together.

15

6. Remove plate (19)

Remove ring (21) from groove of housing (15)
DRIVER
using flat blade driver (n).
19
And remove plate (19). 21

15

Removing Plate (19)

7. Pulling out shaft

Pull shaft (2), sleeve (18) and spherical bearing PRESS
(lower) (13) out by means of press while supporting 2
housing (15) as shown in the figure.
12
Spherical bearing (upper) (12) and oil seal (14) are
left in the housing. 14
18
15
13

JIG (a)

Pulling Out Shaft (2)

33-155
33. UPPER SLEWING STRUCTURE

8. Removing spherical bearing (lower) (13).

Pull sleeve (18) and spherical bearing (lower) (13) PRESS
out by means of jigs (b) while supporting pinion PLATE
shaft assembly as shown in the figure.
Press force : 30t JIG (b)
Do not use the removed bearing.

18

13

Removing Spherical Bearing (Lower) (11)

9. Removing spherical bearing (upper)

Set housing (15) as shown in the figure, insert jig HAMMER (k)
(c) between bearing (12) and oil seal (14) and
FLAT-BLADE
remove bearing (12) by striking it from the upper STEEL BAR SCREWDRIVER
side.
10.Remove oil seal (14) from housing (15). 14

Do not use the removed oil seal and bearing.

12

15

JIG (c)
Removing Spherical Bearing (Upper) (12) And Oil
Seal (14)

(4) Disassembling spider assembly

(1) Disassembling #1 spider assembly
a. Remove retaining ring (25) with a plier (i).
b. Remove thrust washers (22), pinion (4), and 25 11 22
needle bearing (11). 4

22 5

Disassembling #1 Spider Assembly

33-156
 33. UPPER SLEWING STRUCTURE

The shaft attached to spider assembly (5) is caulked. When replacing parts, replace the spider assembly as a set. 33
Pinions (4) cannot be replaced separately. Replace them it in a set of three.

(2) Disassembling #2 spider assembly

a. Drive spring pin (26) into shaft (10) using steel bar
8 to 9 in diameter. 10 9
23
b. Draw out shaft (10) from spider (9) and remove 7
thrust washer (23), pinion (7) and needle bearing
(11).
11

23

26
Disassembling #2 Spider Assembly

Pinions (7) cannot be replaced separately. Replace them it in a set of four.

33-157
33. UPPER SLEWING STRUCTURE

33.2.5.3.3 Assembly
(1) Preparation
1. Sufficiently clean every part with wash oil and dry it with compressed air.
2. Check on every part for failure.

(2) Assembling pinion (1), shaft (2)

1. Attach oil seal (16) to pinion (1) by means of jig (d).
16 JIG (d)

Attaching Oil Seal (16)

2. Applying gear oil.

Apply gear oil to the perimeter of the axis of shaft (2)
lightly to prevent seizure.
3. Fitting spherical bearing (lower)
Seal sufficient grease in spherical bearing (lower)
(13) and after inserting sleeve (18), press fit it in
shaft (2) by means of jig (e).
Press force : 4~5t

Since the bearing is formed with a partition at the

center section, seal grease in it from both sides.

Fitting Spherical Bearing (Lower)

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 33. UPPER SLEWING STRUCTURE

4. Apply sufficient grease to the pinion shaft assem-

bly.
Grease : Lithium extreme-pressure grease 33
(SHELL Albania EP2 or equivalent): 1.7kg (3.75 lbf)

Apply Grease

(3) Placing shaft assembly.

1. Place housing (15) on level bench.
2. Attach eye bolt to screw (M10) at the axis end of
shaft assembly, and perpendicularly hang up pinion
shaft assembly and place it in the housing.

Horizontally orient the outer race of spherical

bearing and insert it in by striking lightly.
If the outer race is tilted, it is hard to insert even if
striking. Then do not force to insert it in, but take it
away once and horizontally orient the outer race 15
twice and insert it in again.

Placing Pinion Shaft Assembly

3. Assembling plate (19).

Place plate (19) and attach ring into groove of
housing, and fix plate.
19 21

15

Assembling Plate (19)

33-159
33. UPPER SLEWING STRUCTURE

4. Installing pinion (1)

Attach eyebolt (M18) to pinion (1), and hoist it, then a
b
24
insert into shaft (2). 20
Install pinion (1) securely by hammering.
1
Attach plate (20) to shaft (2) by tightening 3
capscrews (34) (M16X40), and install it on pinion 2
(1).
Tools: Socket: 24mm 15
Tightening torque : 279N-m (206 lbf-ft)
(Apply Three Bond #1360K)

Adjust this gap to be within

20 0.05 to 0.15mm (0.002 to 0.006 inch)
by shim.

34 SHIM
VIEW b DETAIL a
Installing Pinion (1)

5. Set housing assembly so that the pinion directs

downward. JIG (f)
6. Fit oil seal (14) in housing (15) by means of jig (f).

Apply Loctite #515 to the perimeter of oil seal.

Fill one third (1/3) of the space of the groove-
14
shaped section provided on the oil seal (12) lip with
grease. 15
Insert it horizontally giving attention to the lip on oil
seal so it is not damaged.

7. Press fit spherical bearing (upper) (12) in shaft (2)

and housing (15) at the same time by means of jig
(g).
In this case insert sleeve (17) in advance.

Spherical Bearing (Upper) Press-Fitting

33-160
 33. UPPER SLEWING STRUCTURE

(4) Assembling spider assembly

1. Assembling #1 spider assembly
a. Coat the bore surface of pinion (4) with grease. Put
pinion (4) on thrust washer (22) and assemble 25 11 22
33
needle bearing (11) into the bore surface. 4

22 5

Assembling #1 Spider Assembly

b. Fit thrust washers (22) and pinion (4) as in below Fig. and fit snap ring (25) by means of pliers (i).

SNAP RING (25)

Motor side

22

25 4
Fixing Snap Ring

Fix the snap ring with the sharp edge on the motor side (top side in the position of above Fig.).

2. Assembling #2 Spider assembly

a. Coat the bore surface of pinion (7) with grease. Put
pinion (7) on thrust washer (23) and fit needle GEAR SIDE SLIT
Caulk two
bearing (11) to the bore surface. points with
b. Fit thrust washer (23) and pinion (7) as in Right Fig. a punch.
Beware the direction
insert shaft (10) into spider (9) and drive spring pin of spring pin
(26).

6~7mm 6~7mm
(0.24~0.28 in) (0.24~0.28 in)
VIEW I
10 9
23
7

11

23

26
Assembling #2 Spider Assembly

33-161
33. UPPER SLEWING STRUCTURE

Insert shaft (10) into spider (9) so spring pin hole (26) is aligned.
In this case, direct the oil hole of shaft (10) to outside of spider assembly.

(5) Installing #2 spider assembly

Insert #2 spider assembly in spline axis of shaft (2).
#2 SPIDER ASSY

Assembling #2 Spider Assembly

(6) Installing #2 sun gear (3)

Install #2 sun gear (3) directing the spline upward.
3

Installing #2 Sun Gear (3)

(7) Installing ring gear (8)

Apply a thin film of sealant Loctite #515 to the
matching surface of housing (15) and ring gear (8) and
assemble them, aligning the gear teeth according to
the matching marks made before disassembly. #2 SPIDER ASSY

Align
maching
marks.
15

Installing Ring Gear (8)

33-162
 33. UPPER SLEWING STRUCTURE

(8) Installing #1 spider assembly

1. Mesh the #1 spider assembly with ring gear (8) and
set them in place.
2. Mesh #1 sun gear (3) with #1 pinion (4) and set #1 SPIDER ASSY
33
3
them in place.
8

15

Installing #1 Spider Assembly

(9) Fit drain tube (30) and plug (32).

Tools: Allen wrench: 10 mm

(10)Filling Lube Oil

Fill in 7.4L (2.0gal) of gear oil SAE90 (API Service Grade GL-4).

(11) Installing swing motor assembly.

Attach eye bolts (M12) in the tapped holes of the swing
motor and put a wire sling in them.
Coat the matching surface of ring gear (8) with sealant
Loctite #515. Insert the spline joint of the swing motor M20 X 200
27
and match the matching marks.
Coat socket bolts (27) with sealant Three-Bond 1360K
and fasten them.
Tools: Allen wrench: 17 mm,
Tightening torque: 539 N-m (398 lbf-ft)
MACHING
MARKS

Installing Swing Motor Assembly

33-163
33. UPPER SLEWING STRUCTURE

33.2.5.4 MAINTENANCE STANDARDS

33.2.5.4.1 Swing motor
(1) Replacement standards for parts
The following are the standards to determine whether or not parts may be reused from values taken at
disassembly. These are only general standards and in case the motor displays poor performance or parts show
extreme damage and discoloration before disassembly, it is important to determine how many parts should be
replaced, depending upon the purpose of disassembly and the remaining service life of the motor that the user
expects.

Recommended
Standard
Value for
Item Dimension Remedy
Replacement
mm (in)
mm (in)
Clearance between piston and
cylinder bore
(D-d)
0.032 0.062
Replace piston or cylinder.
(0.0013) (0.0024)

Gap between piston and caulked part

of shoe ( )

0.3
0 Replace piston and shoe assy.
(0.0112)

Thickness of shoe (t)

6.0 5.8
Replace piston and shoe assy.
(0.236) (0.228)

Thickness of friction plate

4.0 3.6
Replace.
(0.157) (0.142)

33-164
 33. UPPER SLEWING STRUCTURE

(2) Standard for correcting sliding surfaces

If the surface roughness of the sliding surface of parts exceeds the following standard, correct it or replace the
parts.
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 spherical sliding surface of the spring (114) and cylinder (111) are roughened, replace parts in pairs.

33-165
33. UPPER SLEWING STRUCTURE

33.2.5.4.2 Swing reduction gear

(1) Inspection at disassembly
1. Spacer and thrust washer
a. Inspect that the parts are not seized or worn abnormally or unevenly.
b. Inspect and measure the parts to see that the wear does not exceed the allowable values.
2. Gears
a. Inspect that the gear teeth do not show pitting and seizure.
b. Inspect by dye penetrant examination that the bottom of the teeth do not show cracks.

3. Bearing
Turn the bearing and check that it does not develop abnormal sounds, catching and other faults.
Do not reuse spherical bearing.
4. O-rings and oil seals
Do not reuse O-rings and oil seals; always replace them with new ones at reassembly.

(2) Inspection after assembly

1. Operation
Check to see that the #1 sun gear (3) is not faulty when turned by hand.
2. Checking for oil leaks and oil condition
Check for oil leak.
Check the oil level by level gauge and confirm that the oil is not dirty. If the oil is short, replenish with gear oil
SAE90 (API Service Grade GL-4).

33-166
 33. UPPER SLEWING STRUCTURE

(3) Maintenance standards

33
LUBE OIL LEVEL

Unit : mm (in)
Code Item Repairable level Service Limit Remedy
0 0
A Wear in #1 planetary shaft ø43 -0.009 1.693" -0.0004" Replace entire spider assy.
No flaking
0 0
B Wear in #2 planetary shaft ø43 -0.009 1.693" -0.0004" Replace four shafts as a set.
There should be no pitting
Replace
Condition of tooth face exceeding 1.6mm (0.0630in) dia,
C Gears (Planetary pinion should be
abnormal wear or seizure.
replaced in a set of four.)
Condition of tooth flank There should be no cracks.
+0.1 +0.0039"
D Thickness of thrust washer 1.6 -0.1 0.063" 0.0039" 1.4 0.0551" Replace
+0.1 +0.0039"
E Thickness of thrust washer 1.6 -0.1 0.063" 0.0039" 1.4 0.0551" Replace
Wear in shaft
0 0
F (Diameter of part coming in contact ø150 -0.100 5.91" -0.0004" ø149.9 5.90" Replace
with oil seal )
Apply Three-Bond 1360K and
G Socket bolt tightening torque M20 — 539 N•m (398 lbf•ft)
tighten to specified torque.
Gear oil SAE90
H Lube oil 7.4 L (2.0 gal) Replenish or replace.
(API Service Grade GL-4)

33-167
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. Relief valve pressure in circuit is not 1. Set to correct value.
not rise. adjusted correctly.
2. Malfunction of relief valve. 2. Correct the stuck areas or replace the
2-1. Sticking plunger. plunger.
2-2. Orifice on plunger is clogged. 2-1. Correct the stuck areas or replace the
3. Plunger seat is faulty. plunger.
2-2. Disassemble and clean.
4. Anti-reaction valve seat is faulty. 3. Check the seat surface and replace the
plunger if scored.
4. Replace the anti-reaction valve cartridge or
block.
Pressure rises 1. Overload. 1. Eliminate overload.
2. Moving parts are seized. 2. Inspect and repair piston, shoe and cylinder
3. Brake release pressure is not working valve plate.
on the motor 3. Check circuit and correct it.
4. Brake piston is stuck. 4. Disassemble and check.
5. Spool for releasing brake is stuck. 5. Disassemble and check.
6. Friction plate is seized. 6. Disassemble, check and repair.

(2) Rotating direction is reverse.

Trouble Cause Remedy

Rotating 1. Motor's assembling direction is 1. Assemble correctly.
direction is reversed.
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. Oil inflow is deficient. 1. Check pump's delivery rate and circuits to
not rise to set 2. Oil leaks are excessive due to high motor.
value temperature. 2. Lower oil temperature.
3. Sliding surfaces are worn or damaged. 3. Replace.

33-168
 33. UPPER SLEWING STRUCTURE

(4) Brake torque is insufficient.

Trouble Cause Remedy

33
Brake torque 1. Friction plate is worn. 1. Disassemble and check. Replace if wear is
isinsufficient. beyond standard value.
2. Brake piston is stuck. 2. Disassemble and check.
3. Brake release pressure is not released. 3. Check and correct circuit.
4. Break release spool is stuck. 4. Disassemble and check.
5. Spline of friction plate is damaged. 5. Disassemble and check. Replace damaged
part.
(5) The swing motor drifts much.
Check the drain rate of the hydraulic motor. If it is less than 4 L/min (1.1 gal/min), you should think that the motor is
not faulty.

Trouble Cause Remedy

The swing motor 1. Relief valve malfunctions. Same as (1). 1. Replace. Same as (1).
drifts much when 2. Plunger seat is faulty. 2. Replace.
it is actuated by 3. Seat of the anti-reaction valve is no 3. Replace the anti-reaction valve cartridge or
external torques. good. block.
(e.g. Machine is
on a slope.)

(6) Oil leaks

1) Oil leak from oil seal

Trouble Cause Remedy

Oil leaks from oil 1. Lip of seal catches contaminant and 1. Replace oil seal.
seal damaged.
2. Shaft is damaged or worn. 2. Shift the lip and shaft positions or replace oil
seal.
3. Casing inner pressure has risen 3. Repair drain piping if clogged up.
abnormally high, with the result that lip of
oil seal is flipped.
4. Shaft is rusted. 4. Disassemble and correct.

2) Oil leak from matching surface

Trouble Cause Remedy

Oil leak from 1. O-ring is missing. 1. Set O-ring correctly and assemble it.
matching 2. O-ring has a scratch. 2. Replace.
surface 3. Seal surface has a scratch. 3. Disassemble and correct.
4. Bolt is loose or damaged. 4. Tighten to specified torque or replace.

33-169
33. UPPER SLEWING STRUCTURE

33.2.5.5.2 Reduction unit

33-170
 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 assembly 1

33-171
33. UPPER SLEWING STRUCTURE

33.2.6.2 DISASSEMBLY AND ASSEMBLY

33.2.6.2.1 Tools

No. Tool Name Used for Remarks

Hammer 1. Steel hammer
a
2. Wooden or plastic mallet
b Rubber mat Disassembly 750 mm (30in) square or more
Wrench Assembly 1. Allen wrench
c 2. Double-ended and single-ended wrench
3. Extension pipe
d Torque wrench Assembly 98 N•m (72 lbf•ft)
Pin Grind the tip of "a nail" to shape
as a screwdriver.
e Disassembly

Spatula Make from a hack-saw blade

Disassembly Approx. 120mm (4.72in)

f
Assembly

Remove the edge completely

Vinyl tape and make corner round smooth.

Disassembly
g Vise Vise movable over 150mm (6in)
Assembly
h Loctite # 242
i Lubricating oil Hydraulic oil or vaseline
j Cleaning oil

33.2.6.2.2 Apparatus
(1) Hoist or crane
The lifting device should be capable of lifting the swivel joint assembly.
(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.

33-172
 33. UPPER SLEWING STRUCTURE

33.2.6.2.4 Disassembly
The part numbers used in this disassembly procedure correspond to those on a construction drawing in Figure
"Construction Of Swivel Joint".
33
(1) Removing cover
1. Mark cover (4) and body (1) with matching marks
for convenient reassembly.
2. Place a V-block on a work bench, place a swivel
joint set on the side, fix it and loosen socket bolt (9)
by means of a pipe and wrench. Alternately, the
swivel joint may be fixed by holding stem (2) in a
vise.
Tools: Allen wrench:6 mm

Removing Cover (4)

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 does not fall down.

33-173
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) so it is not 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 Assembly (5)(6)

33-174
 33. UPPER SLEWING STRUCTURE

33.2.6.2.5 Assembly
Prior to assembly, clean each part (excluding the O-ring and seal), and arrange in the sequence of assembly.
Apply grease on the groove of seal to be installed on seal assembly (6) and O-ring (13).
33
(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 as
above.

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.

33-175
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).
Tools: Allen wrench:6 mm,
Tightening torque: 30.4 N-m (22 lbf-ft)

Tightening Socket Bolt (8)

(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 the assembly.
Tools: Allen wrench:6 mm,
Tightening torque : 30.4 N-m (22 lbf-ft)

Tightening Socket Bolt (9)

33-176
 33. UPPER SLEWING STRUCTURE

33.2.6.3 MAINTENANCE STANDARDS

33.2.6.3.1 Inspection procedure and remedy
33
Interval Check Item Checking Procedure Remedy
Seal for oil leakage Replace O-ring or dust seal , if any oil
2,000 hr Check oil leakage outside
outside leakage can be found.
4,000 hr In Replace all sealing parts such as
principle, All sealing parts slipper seal with back-up ring and O-
disassemble ring.
and check
regardless of Check abnormal wear, scoring
Repair or replace, referring to their
oil leakage or All sliding parts or corrosion caused by foreign
limit of service.
not. debris or seizure.

When Check them for seizure, foreign Repair or replace, referring to their
disassembled All parts debris, abnormal wear, and limit of service. O-rings and dust
for repair defective seals. 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 mm (0.004 in) in depth due to seizure or Replace
between body and contamination.
stem other than
sealing sections 2. Damaged less than 0.1 mm (0.004 in) in Smooth with
Body, Stem depth. oilstone.
1. Worn more than 0.5 mm (0.02 in) or
Replace
abnormally.
Sliding surface with
2. Worn less than 0.5 mm (0.02 in). Smooth
thrust plate
3. Damage due to seizure or contamination
Smooth
repairable within wear limit 0.5 mm (0.02 in).
1. Worn more than 0.5 mm (0.02 in) or
Replace
abnormally.
Sliding surface with
Cover 2. Worn less than 0.5 mm (0.02 in). Smooth
thrust plate
3. Damage due to seizure or contamination
Smooth
repairable within wear limit 0.5 mm (0.02 in).

33-177
33. UPPER SLEWING STRUCTURE

Parts Maintenance Standards Remedy

1) Protruded excessively from seal groove.

Replace
(With back-up ring)

2) Slipper ring 1.5mm (0.06in) narrower than seal groove,

or narrower than back-up ring.

Replace
Slipper ring
(With back-up ring)
1.5mm (0.02in)
(max.)

BACKUP RING
3) Worn unevenly more than 0.5mm (0.02in)

Replace
(With back-up ring)

33-178
 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 device as shown in Right
Fig.
33
(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 the 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 of pressurizing.
And, the oil leakage must be checked for the first 1
minute, and if there is a pressure drop for any
reason, the pressure drop should be in 10% of the
trapped pressure.
This checking must be carried out for every circuit.

Hydraulic Circuit For Inspection Equipment

(2) Low pressure port (E port)

Similar to the high pressure port, install a
directional valve and pressure gauge on each port
of the stem side and body side.
Open stop valve (6) on the side of low pressure
relief valve (5) and while watching the pressure
gauge (for low pressure) connected to the body
side and also by regulating the 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).

33-179
33. UPPER SLEWING STRUCTURE

33.2.6.3.4 TROUBLESHOOTING

Trouble Cause Remedy

1. External leakage of Defective O-ring & seal Replace all seals.
hydraulic oil
2. Internal leakage of hydraulic 1) Defective slipper seal 1) Replace all seals.
oil 2) Sliding face worn 2) Replace assembly.
excessively
3. Swivel stem seized 1) Stem and body seized 1) Grind and hone.
Replace assembly, if stem and body are
too loose and causing oil leakage.
2) Inappropriate swivel stopper 2) Reinstall
bracket Secure 2 to 3 mm (0.08 to 0.12 in)
allowance for bolt stopper.
4. Loose swivel stem and cover Socket bolt tightened Retighten.
insufficiently.

33-180
 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 .......................................................................................34-8
34.1.4 LOWER ROLLER ......................................................................................34-15
34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) ..............................................34-23
34.1.6 SPROCKET ...............................................................................................34-29
34.1.7 TRAVEL MOTOR ......................................................................................34-32
34.1.8 SWING BEARING ......................................................................................34-35
34.2 DISASSEMBLING AND ASSEMBLING OF EQUIPMENT .................................34-39
34.2.1 TRAVEL MOTOR .......................................................................................34-39
34.2.2 CONSTRUCTION OF REDUCTION UNIT ................................................34-41
34.2.3 TRAVEL MOTOR ASSEMBLY ...................................................................34-42
34.2.4 TRAVEL MOTOR ASSEMBLY ...................................................................34-50
34.2.5 TRAVEL MOTOR .......................................................................................34-55
34.2.6 TRAVEL MOTOR TROUBLESHOOTING ..................................................34-58
34.2.7 REDUCTION UNIT DISASSEMBLY ..........................................................34-61
34.2.8 ASSEMBLING ............................................................................................34-67
34.2.9 MAINTENANCE STANDARD ....................................................................34-73

Book Code No. S5LC3426E01

34-1
34. TRAVEL SYSTEM

Issue Data of Issue Applicable Machines Remarks

S5LC3426E01
First Edition September, 2010 SK350-9: YC
NA

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 processes can be omitted.
(4) The removing and attaching procedure does not completely cover all possible situations because of differences
in field conditions and defective sections.
(5) Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then start working.

34-2
 34. TRAVEL SYSTEM

34.1 REMOVING AND INSTALLING

34.1.1 TRAVEL SYSTEM

34
8. SWING BEARING
2. CRAWLER

7. TRAVEL MOTOR

5. FRONT IDLER 6. SPROCKET

GUARD
LOWER FRAME
GREASE NIPPLE OF 3. UPPER ROLLER
THE TRACK SPRING
ADJUSTER 4. LOWER ROLLER
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 shown in right Figure.

2. Loosen the grease nipple and slacken crawler

tracks.
Tools: Socket: 19 mm

Crawler Removing Position

When loosening the grease nipple of the adjuster, do not loosen it more than one turn.

34-3
34. TRAVEL SYSTEM

Where grease does not come out well, move the machine back and forth. The over loosening of grease nipple may
cause it to jump out incurring danger of injury. So be careful not to over loosen the grease nipple.

3. Pushing out master pin.

Remove stopper pin at the end of the master pin,

hold a tool against the master pin, and hit it with a
hammer.
(Refer to Fig. "Press Fitting Of Master Pin")
STOPPER PIN

REMOVING /
FIXING POSITION
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 Tracks

Crawler track end section may fall 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 track installation direction.
Place the track links on the ground so they
converge, facing the front idler, as shown in the
figure on the right. Front
idler side

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 2 cm above the ground level by
holding it by hand so the machine body weight is
not exerted on the shoe. Retract the sprocket to
help push the back winding of the crawler.
(3) Preparation for press fitting master pin.
1. Preparing for installation. Winding Crawler
Put square wood under the shoe plate.
2. Aligning master pin holes.
Aligning master pin holes through the 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 the press fitting jig on master pin, and strike
it with a mallet to press fit.

Press fitting jig

on master pin
Press Fitting Of Master Pin

34-5
34. TRAVEL SYSTEM

(5) Set the stopper pin.

(6) Adjusting crawler track tension (See right Fig.)

After installing, adjust tension of crawler.
Tools: Socket: 19 mm

Adjusting Crawler Track Tension

34.1.2.3 CONSTRUCTION

1-3
1-8 1

1-1
1-7 7
1-4
1-2 3,4,5
1-6

1-5
1-9 1-10
1-11 6

Track Link Assy And Shoe Plate

SK350LC-9
SHOE LC60D00011F3
ASSY LC60D00011F1
No. NAME Q'TY
2 .Link assy LC62D00004F2 1 1
2-1 ..Track link R 46 46
2-2 ..Track link L 46 46
2-3 ..Master link R 2 2
2-4 ..Master link L 2 2
2-5 ..Bushing 46 46
2-6 ..Pin 46 46
2-7 ..Master bushing 2 2
2-8 ..Master pin 2 2
2-9 ..Collar 4 4
2-10 ..Seal 92 92
2-11 ..Pin 2 2
3 .Shoe 600mm 48 -
5 .Shoe 800mm - 48
6 .Bolt LC60D01001P1 192 192
7 .Nut 2420Z1414 192 192

34-6
 34. TRAVEL SYSTEM

34.1.2.4 MAINTENANCE STANDARDS

E F
G D D
B

A 34

C
H

REPAIRABLE SERVICE REMEDY

No. ITEM STANDARD VALUE
LEVEL LIMIT

215.9 0.15 220 224

A Link pitch
(8.5000 0.0059) (8.66) (8.82) Replace the link
assy if the service
+0.05 +0.0020
B O.D. of bushing 68.0 0 (2.6772 0 ) 64 (2.52) 63 (2.48) limit is exceeded
C Height of link 124 0.25 (4.8819 0.0098) 118 (4.65) 116 (4.57)
Basic
Tolerance Fit Fit
dimension

D Interference between bushing

and link +0.05 Interference
68.0 Interference
Shaft (+0.0020) 0.05
(2.6772) 0
0 (0.0020) Replace

+0.05 Interference
E Interference between track pin 46.0 Interference
Shaft (+0.0020) 0.05
and link (1.8110) 0
0 (0.0020)

+0.05 Interference
F Interference between master 45.63 Interference
Shaft (+0.0020) 0.05 Replace link
pin and link (1.7965) 0
0 (0.0020)

1.5 (0.06) 8 (0.32) 10 (0.39)

G Clearance between links Replace
(both side) (both side) (both side)
H Tightening torque of shoe bolt 1180 N.m (870 ft.lbs) Reassembly

34.1.2.5 TOOLS AND JIGS

(1) Tightening tools (2) Jig
Unit : mm NAME SHAPE
NAME OPPOSING FLATS

19, 32 Master pin fixing jig for iron

Socket
crawler

34-7
34. TRAVEL SYSTEM

34.1.3 UPPER ROLLER

34.1.3.1 UPPER ROLLER ASSY

UPPER ROLLER ASSY No. LC64D00003F1

ITEM NAME Q'TY REMARKS
1 ROLLER ASSY 4 24100N7035F3
2 CAPSCREW 4 M20X150
3 WASHER 8
4 NUT 4

34.1.3.2 REMOVING
(1) Preparation for removal.
Remove crawler (Above mentioned). 4 3 3 2
(2) Removing upper roller (1).
1. Remove nuts on support tightening section, and
also remove capscrew (2) M20X150.
Tools: Socket: 30 mm

Removing Upper Roller

34.1.3.3 INSTALLING
Installing is done in the reverse order of removing.
(1) Inspection
Before reassembling, check that it rotates smooth Center of machine
manually and for leaks.
(2) Installing upper roller (1).
1. To install the upper roller, turn up nut (4) toward
3,4
the center of machine. 1
2. Insert it until collar comes in contact with support.
3. Apply Loctite #262 on capscrew M20X150, and
tighten it to the specified torque.
Tools: Socket: 30 mm 2,3
Tightening torque: 539 N-m (400 lbf-ft)

Installing Upper Roller

34-8
 34. TRAVEL SYSTEM

34.1.3.4 CONSTRUCTION

ROLLER ASSY PART No. 24100N7035F3 5 4 1 13 3 2

No. NAME Q’TY No. NAME Q’TY
1 ROLLER 1 8 O-RING 1A P95 1
2 SHAFT 1 9 SOCKET BOLT 2
3 COLLAR 1 10 PLUG PT1/4 1 10
4 PLATE 1 11 SNAP RING 1
5 COVER 1 13 FLOATING SEAL 1
6 BUSHING 1
34

11 8 6

Construction Of Upper Roller

34.1.3.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
1. Draining out oil. 11
Remove plug (10) and drain out oil. 9 8
Tools: Allen wrench: 6 mm 4
10
2. Removing snap ring (11).
5
Mount the end face inside upper roller (1) on stand
jig (f) and separate snap ring (11), using snap ring
pliers.
3. Removing cover (5).
Take off cover (5) upwards, utilizing the screwed
hole for the plug.
f

Construction Of Upper Roller

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) h
from roller (1).
Tools: Allen wrench: 10mm
2
6. Removing shaft (2).
Put the extrusion jig (h) against the end face of 13
shaft (2) and push shaft (2) with collar (3) for 3
floating seal (13), using a press or hammer.

Extruding Shaft

34-9
34. TRAVEL SYSTEM

7. Removing floating seal (13).

(Upper roller side)
13
Take out floating seal (13) from roller (1).
1

Taking Out Floating Seal

8. Removing floating seal (13). (Shaft side)

Remove from collar (3), floating seal (13) that is
located on the side where shaft (2) was 13
disassembled.
3

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 Push with press.
scrape it off, take care not to damage the bore of i
roller (1).
If the bushing is not worn much, mount upper roller
6
(1) on jig (f), insert jig (g) into the end face of
bushing (6) and push it out with a press.
1

Pushing In Bushing

34-10
 34. TRAVEL SYSTEM

(2) Assembly
Assembly of the upper roller is done in the reverse order of disassembly.

1. Place upper roller (1) on the top end face of jig (f), with its floating seal setting side facing down.

2. Confirm that the outer surface of bushing (6) is not

scuffed and coat the outer surface of the inserting
side of the bushing, with molybdenum disulfide 13 13
grease.
3 1
3. Put jig (i) into bushing (6) and press it in, using the 34
bore of the bushing and the bore of the roller as 2
guides.

Fixing Floating Seal

If you fail in this operation by pressing the bushing unevenly, the bushing is distorted and gets unserviceable. In
that case, do not reuse the bushing as it may develop malfunctioning after assembly.

4. Installing floating seals (13).

Two floating seals (13) make a pair. Attach one
2
floating seal to retainer fixed in shaft (2), and
another to the inside of upper roller (1).

1
Prior to placing floating seal (13) 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

34-11
34. TRAVEL SYSTEM

6. Installing plate (4).

Mount upper roller (1) on the stand jig (f) and attach 11
plate (4) to the end face of the shaft with bolt (9). 9 8
Tools: Allen wrench: 10 mm,
4
Tightening torque: 114.7 N-m (85 lbf-ft)
7. Installing O-ring (8) 5
Fit O-ring (8) to the groove of cover (5).
Apply grease to O-ring.
1
8. Installing cover (5).
Attach cover (5) to upper roller (1). Use a press in
this operation as a press fit is required.
9. Installing snap ring (11).
Fix snap ring (11) into upper roller (1), using snap
ring pliers.
f

Installing Cover

10.Filling oil.
Fill in 100cc (6.1cu-in) of engine oil API grade CD
#30 through the plug hole in cover (5).
11. Installing plug (10).
Wind seal tape around plug (10) and screw it into
the plug hole of cover (4).
Tools: Allen wrench: 6mm, 5
Tightening torque: 23 N-m (17 lbf-ft)
1
After assembling the upper roller, confirm that oil is
not leaking from it and that it rotates smoothly by
hand.

Filling Oil

34-12
 34. TRAVEL SYSTEM

34.1.3.6 MAINTENANCE STANDARD

C
D D

A 34
B

F
J H

Unit : mm (in)
SERVICE
No. ITEM STANDARD VALUE REMEDY
LIMIT
A Dia. 185 (7.28) 175 (6.89)
Reinforcement
B Tread dia. 160 (6.30) 150 (5.91) weld, repair or
C Width 95 (3.74) 85 (3.35) replace
D Flange width 19 (0.748) 15 (0.591)
Basic
Tolerance Standard Limit
dimension
Clearance between -0.025
E shaft and bushing 65 (-0.0010) Clearance Clearance
Shaft
(2.5591) -0.040 㧙 0.8 (0.0315) Replace bushing.
(-0.0016)

+0.030
Interference between 70 Interference Clearance
F Hole (+0.0012)
roller and bushing (2.7559) 㧙 0
0
Tightening torque of
H socket bolt 114.7 N.m (85 lbf.ft) Apply loctite #262

J Oil Engine oil API grade CD #30, 100cc (6.1cu.in) Refill or replace
Roller rotation Roller rotates smoothly by hand.

34-13
34. TRAVEL SYSTEM

34.1.3.7 TOOLS AND JIGS

(1) Tightening tools

Unit : mm
NAME OPPOSING FLATS

30
Socket

Allen wrench 6, 10

(2) Jigs

Unit : mm (in)
No. NAME SHAPE
160 (6.30")
120 (4.72")

200 (7.87")
f Stand jig

50(1.97")
For extruding
h
(1.18")

shaft
(1.953" +0.004" )
+0.1
0

0
69.5
(2.74")

64.6

Bushing fixing
i
jig
20 65 (2.56")
(0.787")
85
(3.35")

34-14
 34. TRAVEL SYSTEM

34.1.4 LOWER ROLLER

34.1.4.1 LOWER ROLLER ASSY

ROLLER ASSY LC LC64D00004F3

No. NAME Q'TY REMARKS
1 LOW ROLLER 18 LC64D00005F1
2 CAPSCREW 72 M22 X 105 1
34
2 Apply loctite #262
T=731N.m (540 lbf.ft)
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 position.

2. Place a safety block (wood) at the front and back

of the lower frame.
SAFETY BLOCK
(SQUARE
TIMBERS)

Preparation For Removal

(2) Removing track guide.

Remove capscrews (8) M24X52 and remove track guide (5).
Tools: Socket: 36 mm,
Weight of track guide : Approx. 39 kg (86 lbs)

LOWER GROUP SK350LC-9 LC LC01F00034F1

No. NAME Q'TY
2 TRACK GUIDE ; LC63D00004P1 2
2 5
5 CAPSCREW ; M24 X 52 8
SK350LC-9

Installing Track Guide

(3) Remove lower roller.

Remove capscrews (2) and remove lower roller (1).
Tools: Socket: 32 mm,
Weight of lower roller: Approx. 57 kg
(126 lbs)

Installing Lower Roller

34-15
34. TRAVEL SYSTEM

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: 32 mm,
Tightening torque: 731 N-m (540 lbf-ft)
(2) Installation of track guide.
Capscrews (5) with Loctite #262 and fasten all 4 capscrews temporarily. Then tighten them to a specified
torque.
Tools: Socket: 36 mm,
Tightening torque: 932 N-m (690 lbf-ft)
(3) Adjusting tension of crawler.
Tighten grease nipple and fill it with grease.
Tools: Socket: 19 mm,
Tightening torque: 59 N-m (43 lbf-ft)

34.1.4.4 CONSTRUCTION

Lower roller LC64D00005F1 4 1 6 7 5 2 8

No. Name Q'ty Remarks

1 ROLLER 1
2 COLLAR 2
3 SHAFT 1
4 BUSHING 2
5 PIN 2
2 3
6 FLOATING SEAL 2
Construction Of Lower Roller
7 O-RING 2 1A G70
8 PLUG 2 PT1/4

34-16
 34. TRAVEL SYSTEM

34.1.4.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
1. Remove plug (8) and drain out oil.
Tools: Allen wrench: 6mm
2. Removing pin (5). L
Put both ends of lower roller assembly on the V-
shaped blocks (K), apply push-out bar (L) on upper
2
end face of pin (5), and push pin (5) out striking
with mallet.
5
34

Pushing Out Collar Fixing Pin (5)

3. Removing collar (2), O-ring (7).

Put lower roller on jig (M) for repair stand so that
the shaft (3) is perpendicularly located, apply push-
out jig (P) on shaft end on upper side, and push
shaft (3) until the O-ring (7) separate from collar (2) 7 Jig P
with press or mallet, and take out collar (2).
4. Removing shaft (3) 2
Reverse the top and bottom of the lower roller,
push shaft (3), and remove collar (2) and O-ring (7) 1
as one unit.
3

Jig M

Removing Shaft (3), Collar (2)

The shaft (3) extrusion operation may cause the remaining lube oil to flow out. Prepare an oil container beforehand.

5. Removing collar (2), O-ring (7).

Remove O-ring (7) from shaft (3) that was drawn 6
out in the previous paragraph.
6. Removing floating seal (6).
Remove floating seal (6) from collar (2).

Removing Floating Seal (6)

34-17
34. TRAVEL SYSTEM

7. Removing floating seal (6).

Remove floating seal (6) from roller (1). 6

Removing Floating Seal (6)

8. Removing bushing (4).

Since thickness of bushing (4) is thin [thickness is
3.9mm (0.154in)], remove it with a lathe or strip it
with care, so as not to damage inner hole of roller. N
When the wear of bushing is not too much, place
upper roller (1) on jig (M) for repair stand and apply
1
the end of push-out jig (N) on the end face of
bushing (4) end, and push it out striking it with
mallet.
4

Jig M

Extruding Bushing (4)

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 (4) and extrude it perpendicularly little by little.

(2) Installing
1. Attach O-ring (7) to one side.
Install O-ring (7) to groove on shaft. 7 3

Grease O-ring.
Replace O-ring with new one without fail at
reassembling.
Attach O-ring (7) To One Side

34-18
 34. TRAVEL SYSTEM

2. Press fitting bushing (4).

Align inner hole of roller (1) and bushing (4) and Jig Q
press fit it vertically in capacity of press fit load of 5
ton (10,000 lbs), in the condition that bushing push-
4
in jig (Q) is inserted into bushing (4).

Apply molybdenum disulfide grease on press-fit

section of bushing, and press fit it in ordinary
temperature. 34
Bushing which fails to press-fit because of the one-
side pressing should not be fitted.

Press Fitting Bushing (4)

3. Press fitting collar (2).

Fit O-ring (7) to the one side of shaft (3) mating pin PRESS
hole of collar (2) where floating seal (6) is fit with
pin hole of shaft (3) in advance. Use the press
PIN HOLE
capacity of 17 ton (37500 lbs) or more.
2
6
Care should be taken not to damage O-ring (7)
PIN HOLE
while press-fitting collar (2) to shaft (3). 3 7

Press Fitting Collar (2)

4. Inserting pin (5).

Press-fit pin (5) to pin hole on aligning pin holes of 6
shaft (3) and collar (2).
5

Inserting Pin (5)

5. Attach floating seal (6) to roller side.

Fit floating seal (6) to inner holes on both ends of
roller (1). 1

Check that the seal surface is free from flaws, rust,

etc. before reusing the floating seal. 6

6. Inserting roller (1).

Insert roller (1) from the side where collar (2) is not
3
press-fitted to the shaft (3).
2
7
Inserting Roller (1)

34-19
34. TRAVEL SYSTEM

7. Installing O-ring (7).

Install O-ring (7) to groove on shaft. Press
Grease O-ring.
Replace O-ring with new one without fail at
reassembling.
2
8. Press fitting collar (2). PIN HOLE
Press-fit collar (2) to shaft (3). 7
Press-fit collar (2) on aligning pin (5) hole.

9. Inserting pin (5). 3

Press-fit pin (5) in to the pin hole mating pin hole of
collar (2) with pin hole on the end side of shaft (3).

Installing O-Ring (7), Collar (2)

10.Filling oil.
Remove plug (8) and fill in 430cc (26.14cu-in) of 8 Apply anaerobic sealant
engine oil API grade CD #30. Tightening torque
23N.m (17 lbf.ft)
11. Check it for leaks.
Before tightening plug (8), check it for leaks with air
pressure of 0.2MPa (29psi).
12.Installing plug (8).
Apply oil resistant sealant on plug (8), and tighten it
in the plug hole on the collar (2) end face.
Tools: Allen wrench: 6 mm,
2
Tightening torque:
21.6 to 24.5 N-m (15.9 to 18.1 lbf-ft)

Installing Filling Oil Plug (8)

After assembling the lower roller, confirm that oil is not leaking and that the roller rotates smoothly by hand.

34-20
 34. TRAVEL SYSTEM

34.1.4.6 MAINTENANCE STANDARD

C C
G

34

A
E
B

Lower Roller (Track Roller)

Unit : mm (in)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A O.D. of flange 216 (8.50) 㧙 㧙
Reinforcement
B Tread dia. 175 (6.89) 160 (6.30) 154 (6.06) weld, repair or
C Flange width 27 (1.06) 㧙 㧙 replace
Basic
Tolerance Fit Fit
dimension
Clearance between
D shaft and bushing -0.060
(Wrapped bushing) 75 (-0.0024) Clearance Clearance
Shaft
(2.9528) -0.090 0.7 (0.276) 1.0 (0.394) Replace bushing.
(-0.0035)

Interference between 83 0.030 Interference Clearance

E Hole
roller and bushing (3.2677) ( 0.0012) 0.01 (0.0004) 0

F Oil Engine oil API grade CD #30, 430cc (26.14cu.in) Refill

Execute air leak test at 0.2MPa (28psi)
G Plug (8)
before tightening the plug.
Roller rotation Rotates smoothly by hand. Reassembly

34-21
34. TRAVEL SYSTEM

34.1.4.7 TOOLS AND JIGS

(1) Tightening tools

Unit : mm
NAME OPPOSING FLATS

19, 32, 36
Socket

Allen wrench 6

(2) Jig

Unit : mm (in)
No. NAME SHAPE

K V-block 6.5 (0.26")

150 (5.91")
Pin (5)
L
extrusion rod
16 (0.630")

300 (11.8")
Bushing
N
extrusion rod

400 (15.7")
150 (5.91")

175 (6.89")

M Stand jig

400 (15.7")
Shaft
P
(2.91")

extrusion jig
74

104 (4.09")
(1.18")
30
100 (3.94")
70 (2.76")

Bushing
Q
fixing jig

74.6 +0.1
0
(2.94" +0.004
0 )

34-22
 34. TRAVEL SYSTEM

34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY)

34.1.5.1 FRONT IDLER ASSY

Apply loctite #262 or equivalent

FRONT IDLER ASSY LC52D00026F4 T=540N.m (400 lbf.ft)
No. Name Q'ty Remarks 1

1 IDLER ASSY 1 LC52D00032F1 3 7

3 CAPSCREW 2 M20 X 55
4 GREASE NIPPLE 1
7 IDLER ADJUST ASSY 1 LC54D00009F4
34
The grease nipple is on the
outer side of the frame 4
T=58.8N.m (43 lbf.ft)

Front Idler Assembly

34.1.5.2 REMOVING
(1) Preparation for removal.
Remove crawler. (Above mentioned)
(2) Removing idler assembly.
Sling idler assembly, and push it forward with bar.
Weight of front idler assembly (one side): 362 kg
(798 lbs).
BAR
(3) Installing
Installing is done in the reverse order of removing.

Removing And Installing The Front Idler

Keep away from the front side of front idler.

(4) Where idling assembly (1) has to be separated. 1

Loosen capscrew (3), and separate idler assy (1)
from idler adjuster assy (7).
Tools: Socket: 30 mm
Weight of idler assy : 176 kg (388 lbs)
Weight of idler adjuster assy : 190 kg (419 lbs) 7

The separated idler assy (1) should be placed on

square timbers.

Separating Idler Assy (1) From Idler Adjuster

34-23
34. TRAVEL SYSTEM

34.1.5.3 IDLER ASSY

34.1.5.3.1 CONSTRUCTION

IDLER ASSY LC52D00032F1

No. NAME Q'TY REMARKS 8
6
1 IDLER 1 LC52D00033P1 2
2 COLLAR 2 LC52D01017P1 7
5
3 SHAFT 1 3 I
4 BUSHING 2
5 PIN 2
4 VIEW I
6 FLOATING SEAL 2 1
7 O-RING 2 1A G80
8 PLUG 2 PT1/8

Idler Assembly

34.1.5.3.2 REMOVING AND INSTALLING

(1) Removing
1. Drain oil. 5
Remove plug (8) on the side of collar (2) to drain. R
Tools: Allen wrench: 5 mm
2. Removing pin (5).
Apply pin push bar (jig R) to the top of pin, and
push out striking bar (jig R) lightly with hammer.

Removing Pin (5)

3. Removing collar (2). Push with press

Put idler (1) on stand (U), apply push-out jig (S) on
shaft (3), push out shaft (3) with collar (2), then S
3 2
remove collar (2).
1

U
2

Removing Collar (2)

4. Removing collar (2) from shaft (3). Push with press

If removal of collar (2) on the opposite side is
required, turn over front idler and proceed with the S
3 2
procedure described in Par. 3.

Removing Collar (2)

34-24
 34. TRAVEL SYSTEM

5. Removing bushing (4).

With idler (1) mounted on the stand, tap bushing (4) 1 T 4
lightly by hammer, while placing the bushing
drawing rod (T) against the end face of bushing (4)
evenly all around, till it comes out.
6. Removing floating seals (6).
Take out floating seals (6) from idler (1) and collar
(2). If you intend to re-use floating seals (6), confirm
that there is no scoring and rusting on the contact 34
U
surface and store the floating seals in pairs by
placing card board between the sealing faces.
7. Removing O-ring (7). Removing Bushing (4)
Separate O-ring (7) from shaft (3).

(2) Assembly
1. Pressing in bushing (4).
Align inner hole of idler (1) and bushing (4) and 1
Push with press V
press fit it vertically with press so that jig (V) for 4
bushing press-fitting is inserted into bushing (4).
2. Installing O-ring (7).
Fit O-ring (7) to O-ring groove on shaft (3).
Apply grease to O-ring.

Pressing In Bushing (4)

3. Installing collar (2).

Press fit the O-ring (7) installed side of shaft (3) into PRESSING
collar (2), and drive pin (5).
3
4. Installing floating seal (6).
Fit the half of floating seal (6) on each side of collar
(2) and idler (1).
2
5

Installing Collar (2), Shaft (3)

5. Inserting idler (1).

Insert floating seal (6) fitted side of idler (1) into 3
shaft (3). 6
6. Installing floating seal (6).
Fit floating seal (6) on the other side of idler (1). 1

Inserting Idler (1) And Installing Floating Seal (6)

34-25
34. TRAVEL SYSTEM

7. Installing collar (2)

Fit the half of floating seal (6) on the other collar (2), 8 2
press fit it in shaft (3), and drive pin (5) in with
5
hummer.
8. Filling oil-Inspection
Fill in 350cc (21.36cu-in) of engine oil API grade 1
CD #30 through the plug hole of collar (2), wind
seal tape and tighten plug (8).
Tools: Allen wrench: 5 mm
Tightening torque : 17 N-m (12 lbf-ft)
Installing Collar (2) And Filling Oil

After installing the idler assy to the idler adjuster assy, make certain there are no oil leaks from floating seal and
plug (8) and that idler (1) rotates smoothly.

34.1.5.3.3 MAINTENANCE STANDARD

204 (8.03")
C

F
E

D
A
B

Front Idler
Unit : mm (in)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Dia. Of idler projection 609 (24.0) 㧙 㧙
B Tread dia. 564 (22.2) 557 (21.9) 554 (21.8) Replace
C Flange width 102 (4.02) 96 (3.78) 94 (3.70)
Basic
dimension Tolerance Fit Fit
Clearance between -0.072
D 85 (-0.0028) Clearance Clearance
shaft and bushing Shaft
(3.3465) -0.126 1.5 (0.059) 2.0 (0.079)
(-0.0050) Replace bushing.
+0.035 Interference
Interference between 89 (+0.0014) Clearance
E Hole 0.01
idler and bushing (3.504) 0 0
(0.0004)
(0)
F Oil Engine oil API grade CD #30, 350cc (21.4cu.in) Refill
Idler rotation Rotates smoothly by hand. Reassembly

34-26
 34. TRAVEL SYSTEM

34.1.5.3.4 TOOLS AND JIGS

(1) Tightening tools

Unit : mm
NAME OPPOSING FLATS

30
Socket

Allen wrench 5
34
(2) Jigs

Unit : mm (in)
No. NAME SHAPE
18 (0.71")

(1.18")
30
R Pin striking jig
150 15
(5.91") (0.591")
400 (15.7") (3.31")

S Shaft push out jig

84
(0.63)
16

350 (13.8")

T Bushing drawing rod

Applox 200 (8")

Applox
800 (32")

U Stand
Applox
500 (20")

2 Piece
(0.71")

115 (4.53")
18
100 (3.94")

Bushing press fitting

82 (3.23")

V
jig

+0.1
84.6 0

(3.33" +0.004
0 )

120 (4.72")

W Collar press fitting jig

(1.18")
30

34-27
34. TRAVEL SYSTEM

34.1.5.4 IDLER ADJUSTER ASSY

34.1.5.4.1 CONSTRUCTION

IDLER ADJUSTER ASSY LC54D00009F4 3 4 5 10 2 1 6 7 8

No. Name Q'ty Remarks
1 GREASE CYLINDER 1
2 SPRING 1
3 BRACKET 1
4 NUT 1 M64 X P3
5 SPRING PIN 1 10 X 90 9
6 OIL SEAL 1 Idler Adjuster Assembly
7 O-RING 1 1B G90
8 PISTON 1
9 PIN 2
10 COLLAR 1

34.1.5.4.2 MAINTENANCE STANDARD

No. ITEM STANDARD VALUE

A Installed length of spring 554mm (21.8in)
B Free length of spring About. 660.5mm (26.0in)
C Stroke 53mm (2.09in)
D Set length 797mm (31.4in)
E Outside view of piston Nor scoring and rusting
F Tightening torque of grease nipple 59N-m (43 lbf-ft)

C F
A, B
D

34-28
 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.

34

Preparation For Removal

(2) Removing sprocket.

Loosen 26 capscrews (3) M20X55, for the
attaching of the sprocket by means of a socket and
remove the sprocket (1).

Weight of sprocket: 75 kg (165 lbs)

Tools: Socket: 30 mm

1
3

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 (3) with
Loctite #262 and fasten the sprocket temporarily.
(3) Installing sprocket completely.
Remove the wooden blocks under the frame, bring
the machine down on the ground and tighten the
sprocket.
Tools: Socket: 30 mm
Tightening torque: 539 N-m (400 lbf-ft)
Installing Sprocket Completely

34-29
34. TRAVEL SYSTEM

34.1.6.3 MAINTENANCE STANDARD (LC51D01008P1)

215.9 mm NUMBER OF
PITCH 21
(8.5 in) TEETH
SPECIFICATION
ø 68 mm ø 732.47 mm
ROLLER DIA. PITCH DIA.
(2.68 in) (28.8 in)

C
A
Sprocket

Unit : mm (in)
STANDARD REPAIRABLE SERVICE
No. NAME Remedy
VALUE LEVEL LEVEL

A O.D. of sprocket 755 (29.7) 747 (29.4) 745 (29.3) Reinforcement weld,
repair or replace.
0 0
B Width of sprocket teeth 85 -4 (3.35 -0.157) 79 (3.11) 77 (3.03) Replace.

C O.D. of sprocket bottom 664.05 (26.1) 656 (25.8) 654 (25.7) Reinforcement weld,
repair or replace.

34.1.6.4 TOOLS AND JIGS

(1) Tools

Unit : mm
NAME OPPOSING FLATS

30
Socket

34-30
 34. TRAVEL SYSTEM

(2) Sprocket tooth profile gauge: W

34

775 0
-4 (30.
5" 0
-0.15 )
7"
0.591")

P.C.D 732.47 (28.84")

1.5 (8.50"

(0.256")

+2
.21 0
R34 +0.08" )
6.5

5" 0
(1.3
215.9

60

R34
.
(1.3 21 +02
6.5
(0.256")

5" +0.08
0 "
)
")
664.05 (26.14

R-5
(0.2")

Tooth Profile Gauge (Full Scale)

34-31
34. TRAVEL SYSTEM

34.1.7 TRAVEL MOTOR

34.1.7.1 TRAVEL MOTOR

Apply loctite #262

TRAVEL MOTOR LC53D00012F1 or equivalent
1-1 T=539N.m
No. NAME Q'TY REMARKS (400 lbf.ft)
1 1-3
TRAVEL MOTOR ASSY (2) LC53D00013F1
1-1 TRAVEL MOTOR ASSY 2 LC15V00031F1
1-2 SPROCKET 2 LC51D01008P1 1-2
1-3 CAPSCREW 52 M20 X 55
2
2 CAPSCREW 36 M24 X 65 Apply loctite #262
or equivalent
T=932N.m
(690 lbf.ft)

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.
To release inner pressure from the hydraulic circuit
after stopping the engine. Put the starter switch in
the "ON" position and, with the safety lock lever in
operating condition, operate the left / right travel 6
lever in full stroke several times and press the Apply loctite #262
1
or equivalent
travel 1-2 speed change switch several times to T=115N.m
release the inner pressure from the hydraulic (85 lbf.ft)

circuit. Removing And Installing Cover (1)

When you press the valve from above the gum cap
of the air breather on top of the hydraulic tank, the
internal pressure of the hydraulic tank is released.
(2) Removing cover (1).
Remove sems bolt (6) M12X25 and also remove
covers (1).
Tools: Socket: 19 mm
(3) Preparation of oil pan.

34-32
 34. TRAVEL SYSTEM

(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, 32 mm, 41 mm
Refer to "Hydraulic pipe plug" 5.1
(See Chapter 11. TOOLS)
"Plug For Flare Hose" 5.2 (3) (See Chapter 11. 34
TOOLS)

Removing And Installing Hydraulic Pipe

(5) Removing sprocket.

Removing twenty two (one side) capscrews (6-3)
M20.
Tools: Socket: 30mm

6-3

Removing And Installing Sprocket

(6) Loosening travel motor attaching bolts (3).

Apply match marks on travel motor and crawler REMOVE PIPES (DISCONNECT)
frame, and remove eighteen (one side) capscrews
(3) M24.
Tools: Socket: 36mm

Removing And Installing Travel Motor Attaching

Bolts

(7) Slinging travel motor assembly.

Sling travel motor with nylon sling applied on the
side close to sprocket installing section and remove
the motor.

Weight of motor: About. 400 kg (882 lbs)

Slinging Travel Motor

34-33
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 the contact surface of travel motor and Tightening
TOOLS
crawler frame are free from burr and stain. NAME SIZE No. torque REMARKS
HEX N.m (lbf.ft)
2. Tightening torque.
SEMS BOLT M12 19 6 83 (61)
Tighten capscrew and hydraulic pipes to the torque
Apply
specified in "Tightening Torque". 932+93 Loctite
M24 36 3 (690+69)
3. Fill inside from motor drain port to casing with CAPSCREW #262
hydraulic oil before piping for drain. When starting M20 30 6 3 539+54
(398+40)
operation, operate motor in low idling and at low
FLARELESS PF1/4 19 29.4 (21.7)
speed for several minutes, and check it for possible NUT FOR
PF3/4 36 118 (87)
oil leakage and noise. PIPES,
SLEEVE 35 X 5.0 55 441 (325)
PF1/4 19 36 (26.6)
PF1/2 27 108 (80)
CONNECTOR
PF3/4 36 162 (120)
PF1 41 255 (188)

34-34
 34. TRAVEL SYSTEM

34.1.8 SWING BEARING

34.1.8.1 SWING BEARING ASSY

SWING BEARING ASSY LC40F00019F1

No. NAME Q'TY REMARKS
1 SWING BEARING 1 LC40F00018F1
2 CAPSCREW 36 M24 X 80
34
Front

Inner S zone position

of swing bearing

SECTION AA
Swing Bearing Assembly

34.1.8.2 REMOVING
(1) Matchmarks.
Remove upper structure, apply matchmarks on SWING BEARING
inner race of swing bearing and lower frame.
OUTER RACE
(2) Remove 36 capscrews (2) M24X80 for installation
of inner race.
INNER RACE
Tools: Socket: 36 mm
MATCHMARKS

Matchmarks

(3) Removing grease.

Remove grease in grease bath. SWING BEARING
(4) Removing swing bearing.
EYE BOLT
Attach eyebolt on swing bearing and sling it.
Weight of swing bearing: 540 kg (1190 lbs)

GREASE BATH
Removing And Installing Swing Bearing

34-35
34. TRAVEL SYSTEM

34.1.8.3 INSTALLING
(1) Cleaning.
Clean it completely so that installing surfaces of
swing bearing and lower frame are free from dust
and dirt.
(2) Installing.
Install swing bearing on lower frame meeting the
matchmarks and positioning the S mark on inner Front
race as shown in the right Figure.
(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: 36 mm

Inner S zone position

of swing bearing
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. 1
Tools: Socket: 36 mm,
Tightening torque: 932 N-m (690 lbf-ft)
(5) Filling grease. 2 Apply Loctite #262 or equivalent
Fill grease bath with 28.7 g (63 lbs) of grease T=932N.m (690 lbf.ft)
"NIPPON Grease NIGLUBE EP-2K" or equivalent.
SECTION AA
Removing And Installing Capscrew (2)

34.1.8.4 CONSTRUCTION

6
ASSY PART No. LC40F00018F1
1
No. NAME Q'TY No. NAME Q'TY 8
9
1 OUTER RACE 1 6 SEAL 1 7
2 INNER RACE 1 7 TAPER PIN 1 3,4
3 BALL 105 8 PLUG 1
4 RETAINER 105 9 GREASE NIPPLE 1 5
(PT1/8) 2
5 SEAL 1
Sectional View Of Swing Bearing

34-36
 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 (6)
fitted in the groove in the inner circumference on EYE BOLT
6 2
top of outer race (1) and place them level on a 7
square wooden block or something.
1
2. Remove taper pin (7), using a hammer and an
SQUARE WOODEN
extrusion rod. BLOCK 34
3. Remove plug (8), utilizing a pull bolt inserted in the
screwed hole (M10) in the center of the plug and 8
using a puller. 5

Disassembling Swing Bearing

4. While rotating outer race (1) little by little, take out

ball (3) and retainer (4) through plug hole, in that 1
order.

2
4
3
Removing Balls (3) And Retainers (4)

(2) Installing
1. Thoroughly remove the grease from the groove of
seal (6) located on the inner surface of the outer
race (1) and from the groove of the seal (5) located
on the surface of the inner race (2).
Apply the adhesive (Cyano Bond PX-3000 or
equivalent) to the seal (5) and stick the seal (5) into 1
the groove continuously. PUSH ROD 6
Then place the inner race (2) on wood blocks flatly.
2
SQUARE 3
WOODEN BLOCK 5

Fitting Balls (3)

2. Lower outer race (1) to the position where upper

surface of inner race (2) and lower portion of seal EYE BOLT
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.
HOOKED ROD
3. Insert ball (3) and retainer (4), where grease is
applied, through plug (8) hole on outer race (1),
alternately.
4
SQUARE
WOODEN BLOCK
Fitting Retainer (4)

34-37
34. TRAVEL SYSTEM

To insert ball (3) and retainer (4), use a push rod, etc., to protect from injury from inserting fingers into plug hole.

4. Fit plug (8) to outer race (1) while checking it for direction and position of taper pin hole.
5. Apply adhesive (Cyano Bond PX-3000 or equivalent) to the seal (6) and stick the seal to the groove of outer
race (1) continuously. Join each joint of the seal (6) with adhesive (Cyano Bond PX-3000 or equivalent).
6. After completion of assembly, caulk the edge of taper pin (7) by punching.
7. Check that grease nipple (9) is properly fitted, and fill it with grease. Then, check bearing for smooth rotation
and flaws on seal lip portion.
Shell Albania EP#2; 240 cc (14.64 cu-in)

34.1.8.5 MAINTENANCE STANDARD

Maintenance standard concerning wear of swing bearing is described in the section 13.6 MEASURING SWING
PERFORMANCES in "Maintenance Standard and Test Procedure" in this manual.

34-38
 34. TRAVEL SYSTEM

34.2 DISASSEMBLING AND ASSEMBLING OF EQUIPMENT

34.2.1 TRAVEL MOTOR

34

Travel Motor

No. NAME No. NAME No. NAME

1 Casing 23 D-ring (big dia.) 44 Check valve
2 NPT 1/16 plug 24 Rear cover 45 Check valve spring
3 Oil seal 25 NPT 1/16 plug (MEC) 46 M6 restrictor (0.6)
4 Retaining ring IRTW68 26 Spool assy (M4V RBV) 47 O-ring 1B P12.5
5 Expander plug MB800-040 27 Spring holder (M4V RBV) 48 M6 restrictor (0.8)
6 Shifter piston 28 Spring (M4V150RBV) 49 O-ring 1B P15
7 Piston seal 29 M42 plug (M4V RBV) 50 O-ring 215.57X2.62
8 Steel ball 25 30 O-ring 1B G40 51 Bearing HR32207C
9 Shaft 31 Pilot valve spool dia. 52 Shim
10 Bearing HR33209J Ǿ10 (M4V290) 53 Parallel pin M6 8X12
11 Pivot 32 Pin (MRC03) 54 Valve plate
12 Swash plate 33 Spring holder (MRC03) 55 Brake spring
13 Cylinder block 34 Spring (MRC03) 56 HEX. socket head bolt M18X50
14 Cylinder spring 35 G3/8 pilot valve plug 57 Overload relief valve ORV-
15 Spring holder 36 O-ring 1B P14 58 240L
Coupling
16 Ball joint 37 Connector (MRC03) 59 Retaining ring C-type 40
17 Shoe retainer 38 G1/4 plug 60 G1/2 plug
18 Piston assy 39 O-ring 1B P11 61 O-ring 1B P18
19 Separating plate 40 Restrictor (brake valve)
20 Friction plate 41 Restrictor spring (brake valve)
21 Brake piston 42 G1/8 plug
22 D-ring (small dia.) 43 O-ring 1B P8

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34. TRAVEL SYSTEM

• Overload relief valve

Structure Of Overload Relief Valve

No. Name No. Name

57-1 Socket 57-8 Shim
57-2 Valve 57-9 Adjusting spring
57-3 Valve seat 57-10 O-ring 1B P7
57-4 Coupling piston 57-11 Backup ring T2 P7
57-5 Cap 57-12 O-ring 1B G25
57-6 Pilot body 57-13 Backup ring T2 G25
57-7 Piston

34-40
 34. TRAVEL SYSTEM

34.2.2 CONSTRUCTION OF REDUCTION UNIT

34

Reduction Unit

No. NAME No. NAME No. NAME

1 Housing 10 Thrust washer 2 19 Carrier pin 1
2 Bearing 245BA35S1GS 11 Needle bearing FBNP-608660 20 Spring pin 6X36
3 Ring gear 12 Carrier pin 2 21 Sun gear 1
4 HEX.socket head bolt M18X110 13 Spring pin 10X50 22 Thrust plate
5 Floating seal 368 14 Sun gear 2 23 Cover
6 Shim 15 Carrier 1 24 HEX.socket head bolt M10X30
7 Lock washer 16 Planetary gear 1 25 Plug G3/4
8 Carrier 2 17 Thrust washer 1 26 O-ring 1B P24
9 Planetary gear 2 18 Needle bearing FBNP-406040

34-41
34. TRAVEL SYSTEM

34.2.3 TRAVEL MOTOR ASSEMBLY

34.2.3.1 TOOLS

Name Specifications etc.

Hex. key Width across flat 5, 6, 8, 10, 14 mm
Snap ring plier For bore Dia. 32mm - 58mm, for shaft.... Dia. 60mm - 80mm
Plastic hammer 1 piece
Screw driver Minus (-), medium size, 2 pieces
Torque wrench For 98.1N䍃m, 324N䍃m, 441N䍃m (72.4 lbf䍃ft, 239 lbf䍃ft, 325 lbf䍃ft)
Gear (bearing) puller Work size : dia. 75 X width 45 can be handled(e.g. Asahi-tool GP75)

Others Seal tape, kerosene, grease, hydraulic oil, shop cloth, Compressed
air, etc.
21 (0.83") e.g. Supertool co., ltd unicrump FT-6

10 (0.394") 160 (6.3")

(2.76")
(0.79")
20

70
100 (3.94")

(1.46")
37
P.C.D. 251 (9.88")

o 215 (8.47")

o 195 (7.68")
o 280 (11.0")

Jig for pulling out brake piston (2pieces)

Hex. socket head bolt 2-M6 X100 (3.94") o 12 (0.47")

o 60 (2.36")

(1.58")
(0.95")
o 40
o 24
2-M18X35 (1.38")
(0.26")
o 6.5

2 - 20 (0.79")
drill hole 20 (0.79")
100 (3.94")

Jig for pulling out brake piston (2pieces)

25 (0.98") ")
08
(0.
R2
In case of using Hex. socket
head bolt for mounting
100 (3.94")

rear cover M18 25

50 (1.26")
100
(1.97") (3.94")
15 (0.59")
Guide pin for rear cover (2 pieces)
10 - Plain washer 18
120 (4.72")
2-M18X50 (1.97")
o 42 (1.65")
10mm (0.394")

(1.42")

o 55 (2.17")
3 (0.12")
8.2 (0.32")

o 36

.5 )
R0 .02"
More than

Jig for inserting brake piston o 87.5 (3.45")

(0
o 90 (3.54")
3
(0.12")
Jig for inserting oil seal Jig for inserting rear bearing

34-42
 34. TRAVEL SYSTEM

34.2.3.2 DISASSEMBLY
a. GENERAL INSTRUCTIONS
(1) Generally, hydraulic equipment is precisely manufactured and clearances between each part is very narrow.
Therefore, disassembling and assembling work should be performed in a clean place where dust does not
gather.
Tools and kerosene to wash parts should also be clean and handled with great care.
(2) When motor is removed from the host machine, wash around the ports sufficiently, and insert plugs so that no
dust and / or water may invade.
Take off these plugs just before the piping work when reassembling it to the host machine. 34
(3) Before disassembling, review the sectional drawing and prepare the required parts, depending on the purpose
and the range of disassembling.
Seals, O-rings, etc., if once disassembled, are not reusable. There are some parts that should be replaced as a
sub-assembly.
Consult with the parts book in advance.
(4) The piston can be inserted to whichever cylinder block for the initial assembling.
However, their combination should not be changed if they are once used. To reuse them, put the matching mark
on both pistons and cylinder block before disassembling.
(5) Take great care not to pinch your hand between parts while disassembling nor let parts fall on your foot while
lifting them.

b. DISASSEMBLY PROCEDURES
(1) Removing accessory valves.
Before disassembling motor, remove accessory valves.

According to disassembling purpose, select the valves to be removed.

However, you cannot disassemble the motor without removing the overload relief valve (57).

Disassemble motor after cooling it to ambient temperature to prevent burns.

34-43
34. TRAVEL SYSTEM

1. Remove M42 plug (29) and O-ring (30).

2. Remove spring (28), spring holder (27) and spool assy (26).

Put the matching mark on both spool assy (26) and rear cover (24) so that spool assy (26) should not be reversed
on re-assembling.
It is impossible to disassemble this spool assy (26) further because spool assy (26) is fixed by adhesive.

3. Remove plug (42), O-ring (43), check restrictor spring (41) and restrictor (40).
4. Remove overload relief valves (57).

When removing overload relief valve (57), valve seat (57-3) easily comes off, so take great care not to fall into the
rear cover (24) or lose it.

5. Remove pilot valve plug (35) and then, remove O-ring (36), pilot valve spring (34), spring holder (33), pilot valve
spool (31) and pin (32).
6. Remove coupling (58).

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 34. TRAVEL SYSTEM

(7) Disassembling motor.

1. Place the motor with the shaft horizontal, remove
Hex. socket head bolts M18X50 (56) of rear cover
Hole for releasing
(24) leaving two on the diagonally upper and lower brake (Left) GUIDE PIN
positions.
Tools: Allen wrench: 14mm
2. Install two guide pins diagonally into rear cover
(24).
(Purpose: Prevention of falling rear cover)
3. Loosen slowly and simultaneously the remaining
34
two Hex. socket head bolts M18X50 (56).
4. Remove rear cover (24) and brake springs (55),
taking care cylinder block (13) is not coming out
stuck with rear cover (24).

Removing Rear Cover

Do not fall, at this moment, valve plate (54), brake springs (55), outer race of rear bearing (51) and/or O-rings (50),
(47), and (49).
There are shims (52) under the outer race of rear bearing (51). Do not to lose them.

5. Remove valve plate (54) without pulling out cylinder block (13).

Put the matching mark on both valve plate (54) and rear cover (24) so that valve plate (54) is not reversed on
reassembling.

6. Using removed Hex. socket head bolts M18 X50

(56), fasten two mount metals so as to push in
cylinder block (13) without damaging it; then inner
race of rear bearing (51) comes out. (See right Fig.)
7. Put two fingers of gear (bearing) puller under the
inner race of rear bearing (51), and remove the
race.

51

Removing Rear Bearing

34-45
34. TRAVEL SYSTEM

8. Attaching a hand on brake piston (21), supply com-

pressed air through oil hole for releasing brake and
push out the piston (21).
Hole for releasing brake

Enlargement Figure Of Matching Surface Of

Casing

Be aware of brake piston (21) popping out.

In case of using jig for pulling out brake piston (21), install jigs to M6 thread (2 places) of brake piston (21) and pull
out brake piston (21).

9. Put a mark on piston assembly (18), and put a

matching mark on cylinder block (13) so that they
can be reassembled at the same position as
before.
10.Remove rotary group: cylinder block (13), spring
holder (15), nine piston assys (18), shoe retainer
(17), ball joint (16) and cylinder spring (14) as an
assembly.
11. Remove separating plates (19) and friction plates
(20).
12.Remove nine piston assemblies (18), shoe retainer
(17) and ball joint (16) from rotary group
simultaneously.
13.Remove spring holder (15) and cylinder springs
(14).

Paper pipe

Matching
mark

Removing Cylinder Block

34-46
 34. TRAVEL SYSTEM

Put piston assemblies (18) into the cylinder block (13) matching the matching mark with shoe retainer (17) as if
assembled.
The purpose is to put piston assemblies (18) in the same bore of cylinder block (13) as before when reassembled.
Take care not to scratch sliding surfaces.
Do not reuse damaged ones.
It is impossible to disassemble piston and shoe because they are calked together.

34

Above disassembling is mentioned as a motor only and naturally can be applied to the motor with reduction gears.
The situation is easier for motors with reduction gears because the shaft is rather restricted by a gear to move.

14.Remove swash plate (12).

15.Do not detach shifter piston assy (6), (7), and (8).
If it needs to be detached; attach a hand on shifter
Hole for shifting shifter piston
piston and supply plant air through the hole shown
in Fig.19 and push it out.

Enlargement Figure Of Matching Surface Of

Casing

Be aware of shifter piston (6) popping out.

16.Shaft (9) can come out now.

17.If front bearing (10) happen to be changed, remove
inner races and outer races using bearing puller if
needed and exchange to new ones as an
assembly.

Remove Swash Plate

34-47
34. TRAVEL SYSTEM

When changing bearings (10 and 51); shaft (9), casing (1) or rear cover (24), it affects the clearance of the
bearings.
Therefore, shim (52) should be adjusted.
Shim (52) adjustment should be performed by measuring correctly the clearance for shim and change to a shim
that meets the clearance. (See Fig. "Deciding Shim Thickness")
Other jigs and tools are needed to measure and decide the thickness of the shim.
Do not remove pivots (11). If you need to disassemble them, put matching marks on pivots (11) with swash plate
(12).
Never detach oil seal (3) only for the purpose of inspecting it. If disassembled, remove retaining ring IRTW68 (4)
first and remove oil seal (3). Never fail to replace oil seal (3) with a new one.

18.Deciding shim (52) thickness for tapered roller

bearings.

Deciding Shim Thickness

This work should be done only when you have changed bearings (10 and 51), shaft (9), casing (1) or rear cover
(24).

1. Measure the assembling width "E" (See above Figure).

Take care not to incline shaft (9).

2. Measure the depth "F" of rear cover (24).

Measure them at 4 places on the circuit, then calculate their mean value.

3. When thickness of shim (52) to be used is placed as "S", the clearance "Y" can be calculated as follows:
Y=F-(E+S)
4. Select one or two shims (52) so as the clearance "Y" to comes to 0-0.1 mm (0~0.004") (clearance) on this unit.

34-48
 34. TRAVEL SYSTEM

(3) Disassembling overload relief valve.

As a rule, overload relief valve (57) should be handled as one service part. If there is any trouble with the
overload relief valve (57) , replace as an assembly.

34

Disassembling Overload Relief Valve

Valve seat (57-3) is fitted in bore of socket (57-1) at clearance fit.

When removing overload relief valve (57), valve seat (57-3) easily comes off, so take great care not to lose it.
When assembling overload relief valve (57) to rear cover (24), apply grease sufficiently on engagement part, to
prevent valve seat (57-3) from dropping.

GREASE

Engagement Part

34-49
34. TRAVEL SYSTEM

34.2.4 TRAVEL MOTOR ASSEMBLY

34.2.4.1 GENERAL INSTRUCTIONS

(1) Wash each part sufficiently with kerosene, and blow them with compressed air.
(2) Assemble sliding parts after coating clean hydraulic oil on them.
(3) Take great care not to pinch your hand between parts or tools while assembling, or let parts fall on your foot
while lifting them.

34.2.4.2 ASSEMBLING PROCEDURES

(1) Coat outer surface of oil seal (3) and inner face of
casing (1) with grease. Using jig, rightly and evenly
press in the oil seal (3) into casing (1).
(2) Fix oil seal (3) with retaining ring (4). Jig for Inserting oil seal
(3) Put the outer race of bearing (10) on casing (1) (this
fit is loose), and press the inner race on shaft (9)
(this fit is tight).

Inserting Oil Seal

It is easier to fit inner race if the inner race is heated or boiled under 100 degrees centigrade.
Never over heat!

(4) Insert shaft (9) into casing (1) after coating grease on the contact surface to oil seal (3) lip.
(5) Put shifter piston assy (6), (7), and (8) into casing (1).

Insert shifter piston assembly so it is not tilted.

When inserting shifter piston assy, apply grease sufficiently on piston seal (7) and take a great care not to cut
piston seal (7).

34-50
 34. TRAVEL SYSTEM

(6) Insert pivots (11) into the casing (1).

Take care to match the matching mark with casing

(1) and also to coincide the direction of the sliding
traces on sphere surface with those contact traces
on the swash plate (12) if the motor was operated.

(7) Apply grease sufficiently on three spherical

recesses of swash plate (12) and assemble it in 34
casing (1).

Assembling Swash Plate

(8) Insert piston assemblies (18), shoe retainer (17),

ball joint (16), spring holder (15), and cylinder
spring (14) onto cylinder block (13) as shown, and
then insert the whole assembly to shaft (9).

Assembling Rotary Group

Piston assemblies (18) should be inserted into the same bore as before.

34-51
34. TRAVEL SYSTEM

(9) Rightly knock in the inner race of rear bearing (51)

to the rear end of shaft (9) by using jig (A1) and Plastic
hammer
plastic hammer (A2).
(10)Install all the separating plates (19) and friction
plates (20) alternately between casing (1) and
cylinder block (13), adjusting on the notches and
splines. Separating plates (19) come both first and
last.
(11)Insert brake piston (21) into casing (1) using
inserting jig (B) after attaching D-rings (22 and 23)
to brake piston (21).

Jig for inserting

rear bearing Or

Jig for inserting

brake piston

10 - Plain washer 18

Inserting Brake Piston

Apply grease sufficiently on D-rings (22 and 23). Insert brake piston (21) by using inserting jig, not to tilt.
Two kinds of D-rings are used on brake piston (21). The larger one (23) is first inserted into the hole, then the
smaller one (22) enters.
It is impossible to see how the smaller ring goes into the hole. Therefore, never push it forcibly into the hole.
Otherwise, it may be scraped off by the edge of the hole of casing (1).

When changing bearings (10 and 51), shaft (9), casing (1) or rear cover (24), it affects the clearance of the
bearings. Therefore, shim (52) should be adjusted. Refer to Chapter 34.2.3.2 b (2)-18) "Deciding Shim (52)
Thickness For Tapered Roller Bearings" and decide shim (52) thickness.

34-52
 34. TRAVEL SYSTEM

(12)Install two guide pins diagonally on casing (1).

(Purpose: Guide for installing rear cover)
(13)Lay down rear cover (24) to mount valve plate (54) Guide pin

coinciding matching mark made prior to

disassembling and also place brake springs (55)
with ample grease to be attached to rear cover (24)
while assembling. Also set shim (52), outer race of 34
rear bearing (51) and O-rings (50), (47), and (49)
on rear cover (24).
(14)Insert rear cover (24) to casing (1) along the guide
pin, and install two Hex. socket head bolts M18X50
(56) diagonally upper and lower position and
tighten them to assemble rear cover (24) parallel.
Then, install the rest of the Hex. socket head bolts
M18X50 (56) and remove guide pin and install the
two the remaining bolts.
Tools: Allen wrench: 14mm,
Tightening torque :324N-m (239 lbf-ft) Inserting Brake Piston

When removing outer race of rear bearing (51); install shim (52) without fail.
Confirm that O-rings (47), (49), and (50) are installed to rear cover (24).

(15)Assemble coupling (58).

(16)Assemble spring (34), spring holder (33), pilot
valve spool (31) and pin (32) to rear cover (24), and
then install pilot valve plug (35) with O-ring (36).
Tightening torque : 49.0~58.8N-m (36.1~43.4 lbf-ft)
(17)Assemble overload relief valves (57).
Tools: Spanner : 32 mm
Tightening torque : 98~117.6N-m (72.3~86.7 lbf-ft)

Assembling Accessory Valves

Valve seat (57-3) is fitted in bore of socket (57-1) at clearance fit. When assembling overload relief valve (57) to
rear cover (24); valve seat (57-3) easily comes off, so take great care not to lose and apply grease sufficiently on
engagement part so valve seat (57-3) does not drop off.

34-53
34. TRAVEL SYSTEM

(18)Assemble restrictor (40) and restrictor spring (41) to rear cover (24), and then install G1/8 plug (42) with O-ring
(43).
Tightening torque : 14.7N-m (10.8 lbf-ft)

In case of assembling NEW restrictor (40), fit valve seat of restrictor (40) with rear cover (24).
After inserting restrictor (40) to rear cover (24), knock restrictor (40) slightly by hammer.

(19) Inserting spool assy (26) to rear cover (24) coinciding matching mark made prior to disassembling, and then
assemble spring holder (27) and spring (28).

Spool assembly (26) is not symmetrical. Insert spool assy (26) in an appropriate direction.

(20) Assemble M42 plug (29) with O-ring (30).

Tightening torque : 441~461N-m (325~329 lbf-ft)

34.2.4.3 INITIAL PRE-CONDITIONING OPERATION

(1) Drain charge.
Fill up hydraulic oil in the motor casing after assembling.
The M4V290/170F motor has two drain ports (G1/2). Bleed air in motor casing from un-piping port (upper side).
(2) Initial Pre-conditioning operation.
Operate motor 5 minutes at low speed mode and low-idle, check if there are abnormal noises or leaks of oil.

34-54
 34. TRAVEL SYSTEM

34.2.5 TRAVEL MOTOR

34.2.5.1 MAINTENANCE STANDARD OF PARTS

The followings are the general maintenance standards. However, it is important to determine which parts should be
replaced, depending on the characteristics before disassembling, damage and discoloration of exterior view, the
purpose of disassembling, the expected remaining service life, etc..

ITEM & MEASURING METHOD JUDGING CRITERIA & DISPOSITION

(1) Sliding surface of: cylinder block, Allowable 34
Check Items Criteria Disposition
valve plate and swash plate Roughness
Measure the surface roughness by Surface roughness;
roughness tester. cylinder block Replace or
below 0.4Z below 3.0Z
valve plate Repair
Measure the surface hardness of
swash plate by hardness tester. swash plate

Lap together the surfaces of both cylinder block and valve plate to
remedy their roughness. (Lap with #1200 powder)

Allowable
Check Items Criteria Disposition
Hardness
Swash plate Over HS78 HS74 Replace
(2) Clearance between piston and Allowable
Check Items Criteria Disposition
cylinder block Clearance
Outer diameter of 0.01mm (0.0004") 0.05mm
Measure outer dia. of piston and piston d max - d min (0.0020")
bore of cylinder block at least 3
places in the longitudinal direction Inner diameter of 0.01mm (0.0004") 0.022mm
Replace piston
with micrometer, and obtain: cylinder bore (0.0009")
or cylinder block
D max - D min
max. outer dia. = d max Clearance D-d 0.037~0.047mm 0.065mm
min. outer dia. = d min (0.0015"~0.0019") (0.0026")
min. inner dia. = D min
max. inner dia. = D max

In exchanging pistons, replace all of nine pistons at the same time

34-55
34. TRAVEL SYSTEM

ITEM & MEASURING METHOD JUDGING CRITERIA & DISPOSITION

(3) Play between piston and shoe Allowable
Check Items Criteria Disposition
Roughness
With the jig of Fig, hold down the
shoe on work stand, and pull up
the piston vertical direction to Play between calked 0~0.1mm 0.3mm
measure the play between piston Replace piston
piston and shoe (0~0.004") (0.018")
and shoe.
(See Fig)

(1.34" +0.008"
+0.004" )
Dial gauge o34 ( +0.2
+0.1)

85 (3.35")
Piston

Jig
MagnetStand Shoe

26 (1.02")
Work stand

o32 (1.26")
Method Play
o43 (1.69")

Jig
Method

Allowable
ITEM & MEASURING METHOD Check Items Criteria Disposition
Roughness
(4) Parking brake torque
After completion of assembly, Replace all
set the torque wrench on the 902N㨯m 812N㨯m separator and
Parking brake torque
shaft end, and measure the (670 lbf㨯ft) (600 lbf㨯ft) friction plates
braking torque generated when springs
the shaft starts to rotate.

Standard of replacing friction and

separating plate.
When measuring parking brake Standard of replacing friction and separating plate
torque, it needs to disassemble
Measure the total thickness of 6 pieces of friction plate and 7 pieces of
traveling unit to motor and
separating plate. And if the total thickness is below the following allowable
reduction gear portion, and it's so
value, replace all separating and friction plates and springs.
hard.
The right allowable value is a
standard of replacing friction and Criteria: 33.04 mm (1.30") (Dimension in the drawing)
separating plate Allowable Thickness : 31.5 mm (1.24")
If it is impossible to disassemble
traveling unit, refer to the right
value.

34-56
 34. TRAVEL SYSTEM

ITEM & MEASURING METHOD JUDGING CRITERIA & DISPOSITION

(5) Shaft If the depth of shaft wear is less than 0.05 mm (0.002"), the shaft is reusable.
Measure the wear at contacting
surface of oil seal (3) with the
surface roughness tester.
• In case of replacing the shaft (9), replace oil seal (3) at the same time.

(6) Bearing Replace bearings (10), (51) before hour meter of host machine indicates
Replace bearing (10), (51) after 10,000 hours.
34
decided hours.

• In case replacing the bearings(10), (51), replace both inner and outer
races at the same time.
• Also the bearing shims (52) must be re-adjusted when replaced shaft (9)
and/or bearings (10), (51). Contact dealers for jigs and tools required.

(7) Splines If the wear of splines is less than 0.3 mm (0.012"), the spline is reusable.
Replace if the wear of splines
exceeds the allowable value.

(8) Overload relief valve Replace relief valve part as an assembly each time the host machine works
Do not try to adjust the valve, for 10,000 hours.
since special hydraulic test bench
is required for inspecting and
adjusting the pressure.

34.2.5.2 TIGHTENING TORQUE

Item Description Size Tightening torque N䍃m (lbf䍃ft)

(29) Plug M42 441~461 (325~340)
(35) Plug (Pilot valve) G3/8 49.0~58.8 (36.1~43.4)
(38) Plug G1/4 29.4 (21.7)
(42) Plug G1/8 14.7 (10.8)
(56) Hex. socket head bolt M18 324 32.4 (239 23.9)
(57) Overload relief valve M27 98.1~118 (72.4~87.0)
(60) Plug G1/2 98.1 (72.4)

34-57
34. TRAVEL SYSTEM

34.2.6 TRAVEL MOTOR TROUBLESHOOTING

CAUSE OF TROUBLE AND REMEDY
The followings are the general instructions to be followed when some troubles occur with hydraulic motors.

34.2.6.1 GENERAL INSTRUCTIONS

(1) Judge the nature of abnormality before trouble shooting, and ascertain if the same symptom has occurred
before or not.
Review if the motor itself is actually the issue.
(2) In many cases, the wear is caused by dust.
Take great care to prevent dust from entering in disassembling and assembling.
(3) All the parts especially those of moving parts should be carefully handled, and be careful not to score or scratch
the sliding surfaces.
(4) Be careful not to score the seating surface for O-rings, etc..
We recommend you to replace O-rings with the new ones, if once disassembled.

34.2.6.2 CAUSE OF TROUBLE AND REMEDY

(1) Hydraulic motor never starts

Symptom Cause Remedy

Pressure never Malfunction of built-in relief valve. Repair or replace relief valve
increases
Pressure increases 1. Parking brake is not released 1. After inspection of clogging, repair or
(Clogging of restrictor) replace
2. Parking brake is not released 2. Re-install the spool in correct direction
(Spool is installed in wrong direction)
3. Stuck friction or separating plate of 3. Replace friction and separating plate
parking brake portion
4. Stuck brake piston 4. Repair outer dia. of brake piston or replace
it.
5. Seizure of sliding portion 5. Check, repair or replace piston shoe,
swash plate, cylinder block valve plate etc.
6. Malfunction of spool 6. Repair or replace
(Stick between spool and body)
(Clogging of restrictor)

34-58
 34. TRAVEL SYSTEM

(2) Hydraulic motor rotates weakly

Symptom Cause Remedy

Set pressure of Malfunction of spool Repair or replace
overload valve is (Stick between spool and body)
correct, but brake is
released belated
Parking brake is High oil viscosity. Raise oil temperature or change the
released, but motor is hydraulic oil
hard to start 34
Parking brake is 1. Parking brake is not completely 1. Check clogging of choke
released, but motor released.
starts weakly (Clogging in choke of pressure
release passage)
2. Relief valve catches small particles 2. Wash relief valve, check or replace seat
3. Seizure of sliding portion 3. Check, repair or replace sliding portion

(3) Drive shaft never rotate up to the set value

Symptom Cause Remedy

Rotation of drive shaft 1. Shortage of oil coming in 1. Check oil flow or hydraulic circuit to motor.
never reaches the set 2. Large wear or flaw made on shoe, 2. Check, repair or replace the parts
value cylinder block or valve plate

(4) Brake refuses to work

Symptom Cause Remedy

Brake refuses to work Malfunction of parking brake Check, repair or replace brake piston, friction
1. Worn friction plate plate, spring, etc.
2. Broken spring
Brake works on counter Malfunction of spool Repair or replace, or clean up
lever operation 1. Stick between spool and body
2. Stick of check valve or that by small
particle
3. Clogging of restrictor

34-59
34. TRAVEL SYSTEM

(5) Oil leakage

Symptom Cause Remedy

Oil leakage 1. Loose Hex. socket head bolt or plug 1. Fasten it with given torque
2. O-ring is torn off 2. Replace O-ring
3. Oil leaks inside gear casing 3. Replace oil seal

(6) Would not shift from high to low

Symptom Cause Remedy

Would not shift from Stick of spool in pilot valve Replace pilot valve assembly
high to low

(7) Abnormal noise

Symptom Cause Remedy

Abnormal noise Malfunction of spool Bleed air
appears together with Air is caught inside brake valve
big vibration when
brake is slowly applied
or oil is supplied to other
circuits while motor is
running
Stick between spool Repair or replace
and body

(8) Hunting occurs while descending the slope

Symptom Cause Remedy

Severe hunting while Malfunction of spool Repair or replace
inching Stick between spool and body
Restrictor is not seated completely
Interference with Repair or replace
parking brake
Permanent set or
broken spring

34-60
 34. TRAVEL SYSTEM

34.2.7 REDUCTION UNIT DISASSEMBLY

34.2.7.1 TOOLS
Jigs and measuring instruments.

No. Tools Application

1 Torque wrench 0~490N䍃m (0~360 lbf䍃ft)
2 Allen wrench Opposing flats 8mm, 14mm
3 Stand 34
500 min
(19.7")

(7.87")
390

200
(15.4")

t=16 (0.63")

4 Micro depth meter 0~15mm (0~0.591")

5 Caliper 0~150mm (0~5.91")
6 Eye bolt M10, M20 3pcs. each
7 Pin Spring pin (14), (21) 5.5X80 (3.15"), 9.5X60 (2.36")
8 Press machine It is used to insert the angular bearing and fix the lock washer.Capacity 3 tons
(6610 lb)
9 Others Cleaning oil, Detergent, Gear oil, Grease,
Loctite#242, #515, Seal tape, rag and others

34.2.7.2 DISASSEMBLY
(1) Preparation before removal
1. The travel unit removed from the machine has dust and mud. Wash them with cleaning oil.
2. Loosen drain or oil filling plug (26) and drain the oil out of the reduction unit.

When oil is hot, pressure is built up inside. Take care as the oil gushes out in some cases.

3. Marking matching marks.

Put a matching mark on the outside of each matching surface so it may be installed where it was.

The numbers in the parentheses after part names correspond to those in the assembly drawing in Fig.
"Reduction Unit".

34-61
34. TRAVEL SYSTEM

(2) Setting reduction unit (or whole propelling unit) on work stand
1. Remove Hex. socket head bolts M10X30 (24) at 3
places from cover (23) almost equally apart from
each other, then install M10 eye bolts. Lift up the
unit using them and place it on work stand with
cover (23) upward.

Setting Propelling Unit On Work Stand

Take great care not to pinch your hand between parts while disassembling or let parts fall on your foot while lifting
them.
Lift the parts up horizontally.

(3) Removing cover.

1. Remove the rest of Hex. socket head bolts M10X30
(24) that secure cover (23).
Tools: Allen wrench: 8mm
2. As the cover (23) is adhered to ring gear (3),
remove cover (23) by lightly hammering slantwise 24
upward with wooden bar aiming at projection of
cover (23). 23

Removing Bolts

23

16

Removing Cover

34-62
 34. TRAVEL SYSTEM

(4) Removing carrier 1 assembly

1. Remove thrust plate (22).
2. Screw three M10 eye bolts in carrier 1 (15) and lift
up and remove carrier 1 as sub-assy (15), (16),
(17), (18), (19), (20).
15
3. Remove sun gear 1 (21).

16
(17,18,19,20)

34

Removing Carrier 1 Assembly

(5) Removing carrier 2 assembly

1. Remove sun gear 2 (14).
2. Screw three M10 eye bolts in carrier 2 (8) and lift up
and remove carrier 2 as sub-assy (8), (9), (10),
8
(11), (12), and (13).

9
(10,11,12,13)

Removing Carrier 2 Assembly

(6) Disassembling housing assy

1. Take off lock washers (7) by tapping on screw
driver or on similar tool placed at parting surface of
them.

Removing Lock Washer

34-63
34. TRAVEL SYSTEM

2. Screw three M10 eye bolts in ring gear (3) almost

equally apart from each other, then lift it up
horizontally and remove housing assembly
including ring gear (3), housing (1), angular bearing
(2), a piece of floating seal (5) and Hex. socket
head bolts M18X110 (4) together.

Removing Housing Assembly

(7) Disassembling housing assembly

1. Screw three M20 eye bolts in housing (1) almost
equally apart from each other. Lift up the housing
assy and place it on work stand with housing (1)
upward.
Put a matching mark outside of housing (1) and
ring gear (3).
2. Remove floating seal (5) from housing (1).
3. Remove Hex. socket head bolts M18X110 (4),
Over 300 (11.8")

leaving two of them diagonally.

Tools: Allen wrench: 14mm
4. Loosen the rest two Hex. socket head bolts
M18X110 (4) and tap lightly on the head of them,
then the ring gear (3) can be easily removed from
housing (1).
Disassembling Housing Assembly

Take care not to damage the sliding surface of floating seal (5) or its O-ring.
Bearings (2) have been tightly press fitted in housing (1). Do not remove the bearings (2), or otherwise their
exchange is required.
In case bearings (2) are removed, do not reuse them.
New bearings (2) should be used and shim (6) adjusting will be required.

34-64
 34. TRAVEL SYSTEM

(8) Removing floating seal

1. Remove a piece of floating seal (5) on motor side.

34
Removing Floating Seal (23)

(9) Disassembling carrier 1 assembly

19

15

Disassembling Carrier 1 Assembly

When carrier pins 1 (19) are to be reused, mark each pin with its mated hole of carrier 1 (15) to assure the same
combination as before.

1. Knock spring pins 6X36 (20) fully into carrier pins 1 20

(19).
2. Tap carrier pins 1 (19) out from carrier 1 (15). 19
3. Remove thrust washers 1 (17), planetary gears 1
(16) and needle bearings (18). 15
4. Knock out spring pins 6X36 (20) from carrier pins 1
(19) for reassembling.
15
15

17

16 18
16
Disassembling Carrier 1 Assembly

When carrier pin 1 (19) or planetary gear 1 (16) is required to be exchanged, three pins or three gears should be all
exchanged.

34-65
34. TRAVEL SYSTEM

(10)Disassembling carrier 2 assy

When carrier pins 2 (12) are to be reused, mark each pin with its mated hole of carrier 2 (8) to assure the same
combination as before.

1. Knock spring pins 10X50 (13) fully into carrier pins

2 (12).
2. Tap carrier pins 2 (12) out from carrier 2 (8).
3. Remove thrust washers 2 (10), planetary gears 2 13

(9) and needle bearings (11). 12

4. Knock out spring pins 10X50 (13) from carrier pins 8
8
2 (12) for reassembling.

8 9

10

11
Disassembling Carrier 2 Assembly

When carrier pin 2 (12) or planetary gear 2 (9) is required to be exchanged, three pins or three gears should be all
exchanged.

34-66
 34. TRAVEL SYSTEM

34.2.8 ASSEMBLING
(1) GENERAL INSTRUCTIONS
1. Clean every part with kerosene and dry them with
compressed air. Surfaces to be applied by Loctite 8
must be degreased with solvent.
2. Check every part for any abnormalilty.
3. Each Hex. socket head bolt should be used with
9 (10,11)
Loctite #242 applied on its threads.
4. Apply gear oil slightly on each part before 34
assembling.
5. Take great care not to pinch your hand between
parts while assembling or let parts fall on your foot
while lifting them. Assembling Carrier Assembly

(2) Assembling carrier 2 assy

1. Install planetary gears 2 (9), needle bearings (11)
and thrust washer 2 (10) into carrier 2 (8). 9 (10,11)
2. Install carrier pins 2 (12) into carrier 2 (8) where the
holes for spring pins 10X50 (13) are to be in line
with those of carrier 2 (8).
3. Install spring pins 10X50 (13) into carrier 2 (8) and 13
at the same time into carrier pins 2 (12). 8
(Sink spring pins of 1 - 2 mm (0.04"~0.08") from
surface)
4. Caulk carrier 2 (8) on diagonally position to prevent
Drive Spring Pin
spring pin 10X50 (13) from coming out.

Refer to right figure "Detail of Calking".

Detail of Calking

34-67
34. TRAVEL SYSTEM

(3) Assembling carrier 1 assy

1. Install planetary gears 1 (16), needle bearings (18)
and thrust washers 1 (17) into carrier 1 (15).
2. Install carrier pins 1 (19) into carrier 1 (15) where
the holes for spring pins are to be in line with those
of carrier 1 (15).
3. Install spring pins 6X36 (20) into carrier 1 (15) and
at the same time into carrier pins 1 (19).
Caulking
(Sink spring pins 1 - 2 mm (0.04"~0.08") from
position
surface)
4. Caulk carrier 1 (15) on diagonally position to
prevent spring pin 6X36 (20) from coming out. 13
Caulking The Spring Pin

(4) Installing main bearing and floating seal

1. Install main bearing (2) to inner surface of housing (1).
2. Install a piece of floating seal (5) on motor casing and also install another piece of floating seal (5) on housing
(1).

5 Correct Incorrect Incorrect

Install Direction Of Floating Seal (5)

Install Floating Seal (5)

34-68
 34. TRAVEL SYSTEM

(5) Assembling housing assy

1. Apply Loctite #515 on mating surfaces of housing
(1) and ring gear (3) without a gap. LOCTITE #515
2. Install three M20 eye bolts equally apart on housing
(1). Using the eye bolts, hang the housing (1) by
wire rope and place it on ring gear (3), coinciding
matching marks.
3. After applying Loctite #242 on the threads of 25
pieces of Hex. socket head bolts M18X110 (4),
tighten them with torque wrench.
34
Tools: Allen wrench: 14mm,
Tightening torque : 377.3N-m (278 lbf-ft)

Assembling Housing Assy

20 (0.79") 20 (0.79")

Soak 20mm (0.79") length from the

tip of bolt in Loctite #242.
How To Apply Loctite #242

Clean the groove for floating seals (5) to eliminate oil, dust, paint or other foreign material.
Apply gear oil slightly on sliding surfaces of floating seals (5) before assembling, but strictly dry on O-rings and on
its grooves.
Confirm that O-ring of floating seals (5) are not twisted and that floating seals are correctly installed. i.e. parallel as
shown to each other between housing (1) and motor casing after assembled. (See Fig. "Install Direction Of Floating
Seal")
-It is recommended to use jig to install floating seal.

(6) Deciding shim thickness for angular bearings

This work should be done only when you have to change motor casing, housing (1), bearings (2) or lock washers
(7). Otherwise use the same shim (6) as before.

34-69
34. TRAVEL SYSTEM

1. Fit in two bearings (2) on housing (1) pressing their

outer races.
2. Press inner races of two bearings (2) lightly and
evenly, measure the assembling width "A" of inner
races.
3. Measure the motor side assembling width "B" for
bearings (2).
4. Measure the groove width "C" of motor casing.
5. Measure the thickness "D" of lock washers (7).

S
D A
C B

Deciding Shim Thickness

Measure them at 4 places evenly apart on the circumferences, then calculate and use those mean values.
Measure them to the accuracy of 0.01 mm (0.0004").

6. When thickness of shim (6) to be used is placed as "S", the clearance "X" can be calculated as follows:
X=(B+C)-(A+D+S)
7. Select a shim (6) so as the clearance X comes to -0.08 mm (interference)~ +0.02 mm
(clearance) (-0.0031"~0.0008") on this unit.

(7) Installing housing assy

1. Place motor on work stand with the shaft upward,
and put the selected shim (6) on the bearing match- Press
ing surface of motor casing.
2. Install three M10 eye bolts on ring gear (3) almost
equally apart and lift it up. Descend it concentric
with motor and place bearings (2) on housing (1)
into motor casing. Use press machine and press
inner race of bearing (2) in to full depth.

Pressing Housing Assy In

34-70
 34. TRAVEL SYSTEM

3. While pressing inner race of bearing (2), install lock

washers (7) into groove.

34

Installing Lock Washer

(8) Assembling carrier 2 assy

1. Install three M10 eye bolts equally apart on carrier
2 (8). CARRIER 2 PLANETARY GEAR 2
Using the eye bolts, hang the carrier 2 assy with
wire rope and place three planetary gears 2 (9) as
shown in right Figure, place carrier 2 assy into ring
gear (3) and mesh the splines to those of the motor.
2. Insert and mesh sun gear 2 (14) on center.

VB VA

NOTCH (CARRIER 2) PORT

Installing Direction Of Carrier 2

SUN GEAR 2 (14)

Assembling Carrier 2 Assy

Positioning carrier 2 assy as shown in Figure "Installing Direction Of Carrier 2" is important to obtain better
lubrication.

34-71
34. TRAVEL SYSTEM

(9) Assembling carrier 1 assy.

Face sharp edged side to cover (23). (See Fig. "Assembling Carrier 1 Assy")

(10)Installing cover.
1. Apply Loctite #515 on mating surfaces of cover (23)
and ring gear (3) and install cover (23) on ring gear
(3). 23
2. After applying Loctite #242 on the threads of 18
pieces of Hex. socket head bolts M10X30 (24), LOCTITE #515
tighten them with torque wrench. 3
Tools: Allen wrench: 8mm,
Tightening torque : 68.6N-m (50.6 lbf-ft)
24
Installing Cover (23)

(11) Filling gear oil.

1. Fill gear oil (SAE #90 API class GL-4 or GL-5, 9.5 litters (2.5 gal)) from two G3/4 ports.
2. Tighten taper screw plugs (25).
Tools: Allen wrench : 14mm
Tightening torque : 147.1N-m (108 lbf-ft)

34-72
 34. TRAVEL SYSTEM

34.2.9 MAINTENANCE STANDARD

34.2.9.1 INSPECTION BEFORE ASSEMBLING

(1) Thrust washer
1. Check if there is seizure, abnormal wear or uneven wear.
2. Check if the wear is over the allowable limit.
(2) Gears
1. Check if there is pitting or seizure on the tooth surface.
2. Check if there are clacks on the root of tooth with a die check. 34
(3) Bearings
Rotate by hand to see if there is something unusual such as noise or uneven rotation.
(4) Floating seal
Check flaw or score on sliding surfaces or on O-rings.

34.2.9.2 MAINTENANCE STANDARD OF PARTS

The following are the general maintenance standards.
However, it is most important to determine which parts D E C
should be replaced, depending on the characteristics
shown before disassembling, damage or discoloration
on exterior view, the purpose of disassembling, the
expected remaining service life etc.
A

Maintenance standards
Mark Items Criteria Allowable limit Disposition
Wear of planetary Smooth, without abnormal Replace 3 pieces
A
shaft wear or seizure as a set
Replace (Replace 3
Condition of tooth Smooth, without abnormal Not over 1.6mm (0.063") of
B pieces as a set for
surface wear or seizure pitching nor cracks at root planetary gears)
Adjust shim
Thrust clearance of From -0.08 mm To 0.02 mm
C thickness
angular bearings (2) (-0.0031"~0.0008")
[Refer to 34.2.8(6)]
Thickness of thrust From 3.3 mm To 3.7 mm 0.1 mm (0.004")
D Replace
washer 1 (18) (0.13"~0.15") of wear
Thickness of thrust 5.5 0.2mm 0.1 mm (0.004")
E Replace
washer 2 (11) (0.21"~0.22") of wear
Thickness of thrust 4.5 0.16mm 0.15 mm (0.006")
F Replace
plate (23) (0.171"~0.183") of wear
G Lubrication oil 2,000 working hours (engine hour meter) Replace

34-73
34. TRAVEL SYSTEM

34.2.9.3 TIGHTENING TORQUE

Use torque wrench when tightening the following Hex. socket head bolts and plugs.

Tightening torque
ITEM Description Size
N䍃m (lbf䍃ft)
378 37.8 (279 28)
4 Hex. socket head bolt M18X110
(with applying Loctite#242)
68.6 6.8 (50.6 5)
25 Hex. socket head bolt M10X30
(with applying Loctite#242)
26 Taper plug G3/4 147 14.7 (108 11)

34.2.9.4 INSPECTION AFTER ASSEMBLED

(1) Quantity of lubrication.
After installing the propelling unit, position the drain port at the lowest position and check if lubrication oil comes
out when loosening the level plug.
(2) Rotating inspection.
Put the unit on the test stand and rotate with no load and check if there are abnormal noises or leaks of oil. Take
care not to overspeed the motor. Rotate within specified flow rate.

34-74
 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. S5LC4625E01

46-1
46. TROUBLE SHOOTING (BY ERROR CODES)

Issue Data of Issue Applicable Machines Remarks

S5LC4625E01
First Edition September, 2010 E385CLC: YC
NHK
↑
↑ ↑ SK350-9: YC
NA

Preface

Troubleshooting provides a process for locating 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 section 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 why trouble occurred.

1. Model name and serial number

2. Kind of attachment
Check that the combination of attachment is proper
or that the operating method is not unreasonable.
3. Operating time by hour-meter
4. History of trouble occurred and additional works.
5. Recurrence of past trouble, or problems on the
additional works.

Verifying Background That Trouble Occurred

(3) How to diagnose trouble.

1. Verify defective part.

2. Make the condition of trouble again.
3. Where defective parts cannot 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

(4) Explanation of the cause of trouble. 46

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.
2. Treatment of damaged parts
The damaged parts to be claimed and returned are
evidence so they should be handled with care. Diagnosing Fail By Means Troubleshooting
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 on Carry out troubleshooting according to the error
gauge cluster. code.
B When no failure is detected currently, but error code When it is hard to recreate the failure situation,
after self diagnosis remains in trouble history. cancel the data in the history and reproduce the
failed situation or suppose the cause according to
the troubleshooting by error code, and then repair it.
C When error code after self diagnosis is not displayed Carry out troubleshooting according to instructions in
or has 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 the mechatro controller has blown, the following display appears on the gauge cluster.

(1) The blown fuse of the 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.

Described
Error Code Trouble
page
A025 Pump propo. valve adjustment (B adjustment) is not adjusted yet or has failed. 46-9
A035 Unload valve adjustment (C adjustment) is not adjusted yet or has failed. 46-9
A215 Written data of ROM adjustment data is incorrect. 46-10
A225 Writing of ROM adjustment data is incorrect. 46-10
A235 Written data of ROM hour meter data is incorrect. 46-11
A245 Writing of ROM hour meter data is incorrect. 46-11
A255 Writing of proportional valve adjustment data is incorrect. 46-12
B012 Incorrect output of boom up pressure sensor. 46-12
B013 Disconnection of boom up pressure sensor. 46-13
B014 Short-circuit of boom up pressure sensor. 46-14
B022 Incorrect output of boom down pressure sensor. 46-14
B023 Disconnection of boom down pressure sensor. 46-15
B024 Short-circuit of boom down pressure sensor. 46-16
B032 Incorrect output of arm out pressure sensor. 46-16
B033 Disconnection of arm out pressure sensor. 46-17
B034 Short-circuit of arm out pressure sensor. 46-18
B042 Incorrect output of arm in pressure sensor. 46-18
B043 Disconnection of arm in pressure sensor. 46-19
B044 Short-circuit of arm in pressure sensor. 46-20
B052 Incorrect output of bucket digging pressure sensor. 46-21
B053 Disconnection of bucket digging pressure sensor. 46-21
B054 Short-circuit of bucket digging pressure sensor. 46-22
B062 Incorrect output of bucket dump pressure sensor. 46-22
B063 Disconnection of bucket dump pressure sensor. 46-23
B064 Short-circuit of bucket dump pressure sensor. 46-24
B072 Incorrect output of swing pressure sensor. 46-24
B073 Disconnection of swing pressure sensor. 46-25
B074 Short-circuit of swing pressure sensor. 46-25
B092 Incorrect output of travel right pressure sensor. 46-26
B093 Disconnection of travel right pressure sensor. 46-26
B094 Short-circuit of travel right pressure sensor. 46-27
B102 Incorrect output of travel left pressure sensor. 46-27
B103 Disconnection of travel left pressure sensor. 46-28
B104 Short-circuit of travel left pressure sensor. 46-28
B113 Disconnection of pressure sensor of optional selector positioning. 46-29

46-6
 46. TROUBLE SHOOTING (BY ERROR CODES)

Described
Error Code Trouble
page
B114 Short-circuit of pressure sensor of optional selector positioning. 46-29
B162 Incorrect output of P1 optional side pressure sensor. 46-30
B163 Disconnection of P1 side optional pressure sensor. 46-31
B164 Short-circuit of P1 side optional pressure sensor. 46-32
B172 Incorrect output of P2 optional side pressure sensor. 46-33
B173 Disconnection of P2 side optional pressure sensor. 46-34
B174 Short-circuit of P2 side optional pressure sensor. 46-35
C012 Incorrect output of P1 pump pressure sensor. 46-35
C013 Disconnection of P1 pump pressure sensor. 46-36
C014 Short-circuit of P1 pump pressure sensor. 46-36
C022 Incorrect output of P2 pump pressure sensor. 46-37
C023 Disconnection of P2 pump pressure sensor. 46-37
C024 Short-circuit of P2 pump pressure sensor. 46-38
C033 Disconnection of boom head pressure sensor. 46-38
C034 Short-circuit of boom head pressure sensor. 46-39
C043 Disconnection of boom rod pressure sensor. 46-39
C044 Short-circuit of boom rod pressure sensor. 46-40
D012 Failure of output transistor ON at P1 unload proportional valve. 46-40
D013 Disconnection of P1 unload proportional valve. 46-41
D022 Failure of output transistor ON at P2 unload proportional valve. 46-41
D023 Disconnection of P2 unload proportional valve. 46-42
D032 Failure of output transistor ON at travel straight proportional valve. 46-42
D033 Disconnection of travel straight proportional valve. 46-43
D062 Failure of output transistor ON at arm in high speed proportional valve. 46-43
46
D063 Disconnection of arm in high speed proportional valve. 46-44
D152 Proportional bypass valve and output transistor ON are failure. 46-44
D153 Proportional bypass valve's wiring is disconnected. 46-45
E012 Failure of output transistor ON at P1 pump proportional valve. 46-45
E013 Disconnection of P1pump proportional valve. 46-46
E022 Failure of output transistor ON at P2 pump proportional valve. 46-47
E023 Disconnection of P2 pump proportional valve. 46-48
E032 Optional relief adjusting proportional valve 1 and output transistor ON failure. 46-49
E033 Optional relief adjusting proportional valve 1's wiring is disconnected. 46-49
E042 Optional relief adjusting proportional valve 2 and output transistor ON failure. 46-50
E043 Optional relief adjusting proportional valve 2's wiring is disconnected. 46-50
F011 Failure of output transistor OFF and GND short of attachment boost SOL valve. 46-51
F013 Failure of output transistor ON and disconnection of attachment boost SOL valve. 46-52
F021 Failure of output transistor OFF and GND short of swing parking SOL valve. 46-52
F023 Failure of output transistor ON and disconnection of swing parking SOL valve. 46-53

46-7
46. TROUBLE SHOOTING (BY ERROR CODES)

Described
Error Code Trouble
page
F031 Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve. 46-53
F033 Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve. 45-54
F041 Failure of output transistor OFF and GND short of optional selector SOL valve. 46-54
F043 Failure of output transistor ON and disconnection of optional selector SOL valve. 46-55
G032 Overrun of speed sensor of direct input Mechatro-controller. 46-55
G033 Disconnection of speed sensor of direct input Mechatro-controller. 46-56
G042 Overrun of speed sensor of direct input Mechatro-controller and received data from E/G 46-57
controller.
G043 Disconnection of speed sensor of direct input Mechatro-controller and received data 46-58
from E/G controller.
H013 Disconnection of acceleration potentio 46-59
H014 Power short-circuit of acceleration potentio. 46-59
H023 Disconnection of boom angle potentio. 46-60
H024 Power short-circuit of boom angle potentio. 46-60
H033 Disconnection of arm angle potentio. 46-61
H034 Power short-circuit of arm angle potentio. 46-61
H091 Failure of GND short-circuit of fuel sensor. 46-62
H093 Disconnection of fuel sensor. 46-62
I111 Received error of CAN1 communication (passive error). 46-63
I113 Received error of CAN1 communication (time-out). 46-63
I121 Transmission of CAN1 communication is abnormal (Busoff). 46-64
I211 Reception of CAN1 communication is abnormal (passive error). 46-64
I213 Reception of CAN2 communication is abnormal (passive error). 46-65
I221 Transmission of CAN2 communication is abnormal (Busoff). 46-65
K014 Adhesion of battery relay terminal. 46-66
R014 Failure of arc prevention relay of wiper motor. 46-67
R024 Failure of normal rotation relay of wiper motor. 46-67
R034 Failure of reverse rotation relay of wiper motor. 46-68
R044 Failure of washer motor relay. 46-68
R134 Failure of swing right flasher relay. 46-69
R144 Failure of swing left flasher relay. 46-69
R154 Failure of travel alarm relay. 46-70
R164 Failure of auto idling stop relay 2. 46-70
R174 Failure of engine forcible stop relay. 46-71
R184 Failure of lever lock relay. 46-71
R214 Failure of safety relay. 46-72
Z010 Common rail pressure error. 46-73

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
Screen No. 9 E-1 P1 PUMP
Service
diagnosis Screen No. 9 E-2 P2 PUMP
checking screen
Screen No.
Checking object Checking contents and remedy.
Carry out pump adjustment (B adjustment).
When "ERROR PUMP" is displayed during adjustment, refer to the
1 -Checking
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 cannot be set in the adjusting
condition range.
Symptom It is not normal output, but no problem in normal operation.
Control in the
Work with the aid of output by default proportional valve. 46
event of failure
Returned in
The adjustment of unload valve has completed normally.
normal condition
Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
Service
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 that 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
Screen No.
Service
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 that 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
Screen No.
Service
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 that the data is incorrect.
condition
The hour meter data which was judged as an error is taken as 0 Hr. No problem in normal
Symptom
operation.
Control in the
Normal control is available.
event of failure
Returned in 46
It does not regain. Replace controller.
normal condition
Screen No.
Service
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
Screen No.
Service
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.
Screen No. 5 B-1 BOOM RAISE
Service
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.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the (Current when all operation is in neutral.)
event of failure Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to
750mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-1 BOOM RAISE
Service
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.

46

46-13
46. TROUBLE SHOOTING (BY ERROR CODES)

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.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the (Current when all operation is in neutral.)
event of failure Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to
750mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-1 BOOM RAISE
Service
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.

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.
Screen No. 5 B-2 BOOM LOWER
Service
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.

46-14
 46. TROUBLE SHOOTING (BY ERROR CODES)

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 The boom down operability becomes poor.
Set proportional valve output rate of P1 pump to constant current.
Control in the (Current when all operation is in neutral.)
event of failure Only on independent operation of boom-up, set output of P1 unload proportional valve to
750mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-2 BOOM LOWER
Service
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

46-15
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 The boom down operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the (Current when all operation is in neutral.)
event of failure Only on independent operation of boom-up, set output of P1 unload proportional valve to
750mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-2 BOOM LOWER
Service
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 The arm-out 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.
Screen No. 5 B-3 ARM OUT
Service
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.

46-16
 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 Shock at stopping of arm-out is great.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the (Current when all operation is in neutral.)
event of failure Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to
750mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-3 ARM OUT
Service
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.

46

46-17
46. TROUBLE SHOOTING (BY ERROR CODES)

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 Shock at stopping of arm-out is great.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the (Current when all operation is in neutral.)
event of failure Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to
750mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-3 ARM OUT
Service
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.

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.
Screen No. 5 B-4 ARM IN
Service
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.

46-18
 46. TROUBLE SHOOTING (BY ERROR CODES)

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
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done
Symptom but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the
bucket bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to constant current.
(Current when all operation is in neutral.)
Control in the
Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to
event of failure
750mA.
Set output of arm 2 arm-in proportional valve to 200mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-4 ARM IN
Service
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

46-19
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
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done
Symptom but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the
bucket bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to constant current.
(Current when all operation is in neutral.)
Control in the
Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to
event of failure
750mA.
Set output of arm 2 arm-in proportional valve to 200mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-4 ARM IN
Service
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.

46-20
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-20

Error code B052

Trouble Bucket digging pressure sensor outputs error
After starter switch ON and engine does not start yet. And the input voltage from the bucket
Judging
digging pressure sensor after starter switch ON is in the range of 1.4V or more to less than
condition
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.
Screen No. 5 B-5 BUCKET DIG
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Bucket digging pressure sensor When B052 is cancelled and other error occurs by turning starter switch
SE-1 on after exchanging the connector with other sensor.
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.

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 The bucket digging speed slows down a little. 46
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the (Current when all operation is in neutral.)
event of failure Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to
750mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-5 BUCKET DIG
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Bucket digging pressure sensor When B053 is cancelled and other error occurs by turning starter switch
SE-1 on after exchanging the connector with other sensor.
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.

46-21
46. TROUBLE SHOOTING (BY ERROR CODES)

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 The bucket digging speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the (Current when all operation is in neutral.)
event of failure Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to
750mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-5 BUCKET DIG
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Bucket digging pressure sensor When B054 is cancelled and other error occurs by turning starter switch
SE-1 on after exchanging the connector with other sensor.
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.

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.
Screen No. 5 B-6 BUCKET DUMP
Service
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.

46-22
 46. TROUBLE SHOOTING (BY ERROR CODES)

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 The bucket dump speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the (Current when all operation is in neutral.)
event of failure Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to
750mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-6 BUCKET DUMP
Service
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

46-23
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 The bucket dump speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the (Current when all operation is in neutral.)
event of failure Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to
750mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-6 BUCKET DUMP
Service
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.
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.
Screen No. 6 B-7 SWING
Service
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.

46-24
 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 The swing operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current when all operation is in neutral.)
event of failure
Only on independent operation of swing, set output of P2 unload proportional valve to 750mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 B-7 SWING
Service
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
46
Symptom The swing operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current when all operation is in neutral.)
event of failure
Only on independent operation of swing, set output of P2 unload proportional valve to 750mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 B-7 SWING
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
When B074 is cancelled and other error occurs by turning starter switch
-Swing pressure sensor
1 on after exchanging the connector with other sensor.
SE-5
Check sensor unit for possible failure. If failure found, replace it.
-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.
2
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.

46-25
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 right
condition 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.
Screen No. 6 B-9 TRAVEL (R)
Service
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 The Travel right operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the (Current when all operation is in neutral.)
event of failure Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to
750mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 B-9 TRAVEL (R)
Service
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.

46-26
 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 The Travel right operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the (Current when all operation is in neutral.)
event of failure Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to
750mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 B-9 TRAVEL (R)
Service
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 left
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V. 46
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.
Screen No. 6 B-10 TRAVEL (L)
Service
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.

46-27
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 The Travel left operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current when all operation is in neutral.)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 B-10 TRAVEL (L)
Service
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 The Travel left operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the (Current when all operation is in neutral.)
event of failure Only on independent operation of boom-up, set output of P1, P2 unload proportional valves to
750mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 B-10 TRAVEL (L)
Service
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.

46-28
 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 Breaker 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
Screen No. 9 F-4
Service
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
46
Symptom When Breaker 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
Screen No. 9 F-4
Service
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.

46-29
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.
Screen No. 5 B-16 P1 OPT.
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -P1 side option pressure sensor When B162 is cancelled and other error occurs by turning starter switch
SE-20 on after exchanging the connector with other sensor.
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.

46-30
 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.
Set proportional valve output rate of P1 and P2 pumps to constant current.
(Current when all operation is in neutral.)
Control in the
Only on independent operation of boom-up, set output of P1 unload proportional valve to
event of failure
750mA.
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-16 P1 OPT.
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -P1 side option pressure sensor When B163 is cancelled and other error occurs by turning starter switch
SE-20 on after exchanging the connector with other sensor.
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

46-31
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.
Set proportional valve output rate of P1 and P2 pumps to constant current.
(Current when all operation is in neutral.)
Control in the
Only on independent operation of boom-up, set output of P1 unload proportional valve to
event of failure
750mA.
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-16 P1 OPT.
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -P1 side option pressure sensor When B164 is cancelled and other error occurs by turning starter switch
SE-20 on after exchanging the connector with other sensor.
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.

46-32
 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.
Screen No. 5 B-17 P2 OPT.
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -P2 side option pressure sensor When B172 is cancelled and other error occurs by turning starter switch
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

46-33
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.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current when all operation is in neutral.)
event of failure
Only on independent operation of swing, set output of P2 unload proportional valve to 750mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-17 P2 OPT.
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -P2 side option pressure sensor When B173 is cancelled and other error occurs by turning starter switch
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 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.

46-34
 46. TROUBLE SHOOTING (BY ERROR CODES)

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.
Set proportional valve output rate of P1 and P2 pumps to constant current.
Control in the
(Current when all operation is in neutral.)
event of failure
Only on independent operation of swing, set output of P2 unload proportional valve to 750mA.
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 5 B-17 P2 OPT.
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -P2 side option pressure sensor When B174 is cancelled and other error occurs by turning starter switch
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.

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 pump
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
46
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.
Screen No. 7 C-1 PUMP P1
Service
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.

46-35
46. TROUBLE SHOOTING (BY ERROR CODES)

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 The delicate operability of P1 pump related attachment becomes poor.
Control in the
Set P1 pump pressure to 25MPa and control pump.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 C-1 PUMP P1
Service
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.

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 The delicate operability of P1 pump related attachment becomes poor.
Control in the
Set P1 pump pressure to 25MPa and control pump.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 C-1 PUMP P1
Service
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.

46-36
 46. TROUBLE SHOOTING (BY ERROR CODES)

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 pump
condition 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.
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.
Screen No. 7 C-2 PUMP P2
Service
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.

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 The delicate operability of P2 pump related attachment becomes poor. 46
Control in the
Set P2 pump pressure to 25MPa and control pump.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 C-2 PUMP P2
Service
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.

46-37
46. TROUBLE SHOOTING (BY ERROR CODES)

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 The delicate operability of P2 pump related attachment becomes poor.
Control in the
Set P2 pump pressure to 25MPa and control pump.
event of failure
Returned in It returns automatically in normal condition.
normal condition
Service Screen No. 6 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.

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 Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 C-3 BOOM-HEAD
Service
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.

46-38
 46. TROUBLE SHOOTING (BY ERROR CODES)

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 Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 C-3 BOOM-HEAD
Service
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.

Table 46-51

Error code C043

Trouble Boom rod pressure sensor's wiring is disconnected.
Judging
The input voltage from boom rod pressure sensor is 0.1V or less.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the 46
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 C-4 BOOM-ROD
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Boom rod pressure sensor When C043 is cancelled and other error occurs by turning starter switch
SE-25 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between boom rod When C043 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-705F 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.

46-39
46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-52

Error code C044

Trouble Boom rod pressure sensor's power source is shortcut.
Judging
The input voltage from boom rod pressure sensor is 4.7V or more.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 6 C-4 BOOM-ROD
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Boom rod pressure sensor When C044 is cancelled and other error occurs by turning starter switch
SE-25 on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between boom rod When C044 is displayed after turning the starter switch on after the
pressure sensor and controller connector is exchanged with other sensor.
CN-705F 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 46-53

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
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 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.

46-40
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-54

Error code D013

Trouble P1 unload proportional valve's wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Option conflux can not be done.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 7 D-1 P1 UN-LOAD (BP-CUT)
Service
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.

Table 46-55

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. 46
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 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.

46-41
46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-56

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 100mA or less, judging is not done.)
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 7 D-2 P2 UN-LOAD (BP-CUT)
Service
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.

Table 46-57

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
Screen No. 7 D-3 S-TRAVEL
Service
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.

46-42
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-58

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 100mA 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
Screen No. 7 D-3 S-TRAVEL
Service
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.

Table 46-59

Error code D062

Trouble Arm-in spool 2 proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Operability of combined operation with arm-in becomes poor. 46
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. 7 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.

46-43
46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-60

Error code D063

Trouble Arm-in spool 2 proportional valve's wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom 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. 7 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.

Table 46-61

Error code D152

Trouble Proportional bypass valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Operability of combined operation with travel becomes poor.
Control in the
Normal control
event of failure
Returned in
Normal control
normal condition
Screen No. 12 D-15
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Proportional bypass valve When D152 is cancelled and other error occurs by turning starter switch
PSV-R on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between Proportional When D152 is displayed after turning the starter switch on after the
bypass valve and controller connector is exchanged with other sensor.
CN-299 Check wiring for possible failure according to the wiring checking
CN-106F 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 46-62

Error code D153

Trouble Proportional bypass valve's wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Operability of combined operation with travel becomes poor.
Control in the
Normal control
event of failure
Returned in
Normal control
normal condition
Screen No. 12 D-15
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Proportional bypass valve When D153 is cancelled and other error occurs by turning starter switch
PSV-R on after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between Proportional When D153 is displayed after turning the starter switch on after the
bypass valve and controller connector is exchanged with other sensor.
CN-299 Check wiring for possible failure according to the wiring checking
CN-106F procedure and repair it if necessary.
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-63

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 The delicate operability of P2 pump related attachment becomes poor. 46
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.
Screen No. 6 E-1 PUMP P1
Service
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.

46-45
46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-64

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 100mA or less, judging is not done.)
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.
Screen No. 6 E-1 PUMP P1
Service
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
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-65

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 The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.
Screen No. 6 E-2 PUMP P2
Service
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

46-47
46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-66

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 100mA or less, judging is not done.)
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on
normal condition it again.
Screen No. 6 E-2 PUMP P2
Service
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.

46-48
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-67

Error code E032

Trouble Optional relief adjusting proportional valve 1 and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Does not relieve at setting pressure.
Control in the
Normal control
event of failure
Returned in
Normal control
normal condition
Screen No. 7 E-3 Optional relief 1
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Optional relief adjusting When E032 is cancelled and other error occurs by turning starter switch
proportional valve 1 on after exchanging the connector with other sensor.
PSV-E Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between Optional relief When E032 is displayed after turning the starter switch on after the
adjusting proportional valve 1 connector is exchanged with other sensor.
and controller Check wiring for possible failure according to the wiring checking
CN-148F procedure and repair it if necessary.
CN-105F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-68

Error code E033

Trouble Optional relief adjusting proportional valve 1 wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
46
Symptom Does not relieve at setting pressure.
Control in the
Normal control
event of failure
Returned in
Normal control
normal condition
Screen No. 7 E-3 Optional relief 1
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Optional relief adjusting When E033 is cancelled and other error occurs by turning starter switch
proportional valve 1 on after exchanging the connector with other sensor.
PSV-E Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between Optional relief When E033 is displayed after turning the starter switch on after the
adjusting proportional valve 1 connector is exchanged with other sensor.
and controller Check wiring for possible failure according to the wiring checking
CN-148F procedure and repair it if necessary.
CN-105F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-49
46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-69

Error code E042

Trouble Optional relief adjusting proportional valve 2 and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Does not relieve at setting pressure.
Control in the
Normal control
event of failure
Returned in
Normal control
normal condition
Screen No. 7 E-4 Optional relief 2
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Optional relief adjusting When E042 is cancelled and other error occurs by turning starter switch
proportional valve 2 on after exchanging the connector with other sensor.
PSV-I Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between Optional relief When E042 is displayed after turning the starter switch on after the
adjusting proportional valve 2 connector is exchanged with other sensor.
and controller Check wiring for possible failure according to the wiring checking
CN-132F procedure and repair it if necessary.
CN-106F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-70

Error code E043

Trouble Optional relief adjusting proportional valve 2 wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Does not relieve at setting pressure.
Control in the
Normal control
event of failure
Returned in
Normal control
normal condition
Screen No. 7 E-4 Optional relief 2
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Optional relief adjusting When E043 is cancelled and other error occurs by turning starter switch
proportional valve 2 on after exchanging the connector with other sensor.
PSV-I Check sensor unit for possible failure. If failure found, replace it.
2 -Wiring between Optional relief When E043 is displayed after turning the starter switch on after the
adjusting proportional valve 2 connector is exchanged with other sensor.
and controller Check wiring for possible failure according to the wiring checking
CN-132F procedure and repair it if necessary.
CN-106F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-50
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-71

Error code F011

Trouble ATT boost solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom ATT boost is not available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Screen No. 3 F-1 POWER BOOST
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -ATT boost solenoid valve When F011 is cancelled and other error occurs by exchanging the
SV-2 connector for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 -Wiring between ATT boost When F011 is displayed after the connector is exchanged with other
solenoid valve and controller solenoid valve.
CN-117F 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

46-51
46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-72

Error code F013

Trouble ATT boost solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom ATT boost is not available or is leaving available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Screen No. 3 F-1 POWER BOOST
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -ATT boost solenoid valve When F013 is cancelled and other error occurs by exchanging the
SV-2 connector for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 -Wiring between ATT boost When F013 is displayed after the connector is exchanged with other
solenoid valve and controller solenoid valve.
CN-117F 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 46-73

Error code F021

Swing parking solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
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
Screen No. 3 F-2 SWING-BRAKE
Service
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.

46-52
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-74

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
Screen No. 3 F-1 POWER BOOST
Service
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.

Table 46-75

Error code F031

Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
46
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, When F031 is displayed after the connector is exchanged with other
2speed solenoid valve.
solenoid valve and controller Check wiring for possible failure according to the wiring checking
CN-122F procedure and repair it if necessary.
CN-105F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-53
46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-76

Error code F033

Trouble Travel 1, 2 speed 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 Travel 2 speed is not obtainable or is keeping 1 speed.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
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, When F033 is displayed after the connector is exchanged with other
2speed solenoid valve.
solenoid valve and controller Check wiring for possible failure according to the wiring checking
CN-122F procedure and repair it if necessary.
CN-105F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-77

Error code F041

Option selector solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
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
Screen No. 7 F-4 OPT SELECT
Service
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.

46-54
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-78

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
Option selector valve does not change to breaker side or it does not change from breaker to
Symptom
nibbler.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is ground level while exciting command is not output.
normal condition
Screen No. 9 F-4 OPT SELECT
Service
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.

Table 46-79

Error code G032

Trouble Mechatro controller direct input speed sensor is overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
46
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
Screen No. 2 G-3 MEAS 1 (for mechatro controller)
Service
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 speed Check wiring for possible failure according to the wiring checking
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.)

46-55
46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-80

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.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 2 G-3 MEAS 1 (for mechatro controller)
Service
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 speed Check wiring for possible failure according to the wiring checking
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.)

46-56
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-81

Error code G042

Mechatro controller direct input speed sensor and received data from engine controller are
Trouble
overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operate without problem.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 2 G-3 MEAS 1 (for mechatro controller)
Service
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 speed Check wiring for possible failure according to the wiring checking
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

46-57
46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-82

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 controller
condition indicate excess low engine rpm.
Symptom Engine speed down may cause extension by abrupt loading.
Control in the
Enter 0 rpm for engine speed. Enter 0 for ESS power shift command.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 2 G-3 MEAS 1 (for mechatro controller)
Service
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 speed Check wiring for possible failure according to the wiring checking
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.

46-58
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-83

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
Screen No. 2 H-1 ACCEL VOLT.
Service
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 46-84

Error code H014

Trouble Accel potentiometer's power source is shortcut.
Judging
The input voltage from accel potentiometer is 4.7V or more.
condition
46
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
Screen No. 2 H-1 ACCEL VOLT.
Service
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.

46-59
46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-85

Error code H023

Trouble Boom angle potentiometer's wiring is disconnected.
Judging condition The input voltage from boom angle potentiometer is 0.1V or less.
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 10 H-2 BOOM
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0 to 6.0 kilo-ohms
Turn the potentiometer and measure resistance between signal and
GND.
Normal value: 0 to all resistance (4.0 to 6.0) kilo-ohms
2 -Wiring between accel Check wiring for possible failure according to the wiring checking
potentiometer and controller procedure and repair it if necessary.
CN-702F
CN-103F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-86

Error code H024

Trouble Boom angle potentiometer's power source is shortcut.
Judging condition The input voltage from boom angle potentiometer is 0.1V or less.
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 10 H-2 BOOM
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0 to 6.0 kilo-ohms
Turn the potentiometer and measure resistance between signal and
GND.
Normal value: 0 to all resistance (4.0 to 6.0) kilo-ohms
2 - Wiring between boom angle Check wiring for possible failure according to the wiring checking
potentiometer and controller procedure and repair it if necessary.
CN-702F
CN-103F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-60
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-87

Error code H033

Trouble Arm angle potentiometer's wiring is disconnected.
Judging condition The input voltage from arm angle potentiometer is 0.1V or less.
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 10 H-3 ARM
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-19 4.0 to 6.0 kilo-ohms
Turn the potentiometer and measure resistance between signal and
GND.
Normal value: 0 to all resistance (4.0 to 6.0) kilo-ohms
2 -Wiring between arm angle Check wiring for possible failure according to the wiring checking
potentiometer and controller procedure and repair it if necessary.
CN-703F
CN-103F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-88

Error code H034

Trouble Arm angle potentiometer's power source is shortcut.
Judging condition The input voltage from arm angle potentiometer is 0.1V or less.
Symptom Indications of rating load and working radius of High-reach crane become abnormal. 46
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 10 H-3 ARM
Service diagnosis
Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-19 4.0 to 6.0 kilo-ohms
Turn the potentiometer and measure resistance between signal and
GND.
Normal value: 0 to all resistance (4.0 to 6.0) kilo-ohms
2 -Wiring between arm angle Check wiring for possible failure according to the wiring checking
potentiometer and controller procedure and repair it if necessary.
CN-703F
CN-103F
3 -Mechatro controller Check that the error is corrected after replacement of controller.

46-61
46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-89

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
Screen No. 8 H-9 FUEL LEVEL
Service
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 46-90

Error code H093

Trouble Fuel sensor's wiring is disconnection.
Judging
The input voltage from fuel sensor is 4.7V or more.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Screen No. 8 H-9 FUEL LEVEL
Service
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.

46-62
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-91

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
Screen No.
Service
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 46-92

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. 46
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.

46-63
46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-93

Error code I121

Trouble Transmission of CAN1 communication is abnormal. (Busoff)
Judging
Transmission from mechatro controller can not receive correctly.
condition
Symptom It has been affected little.
Control in the
Normal control
event of failure
Returned in
Normal control
normal condition
Screen No.
Service
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-12F (There is a possibility of false disconnection.)
CN-101F
2 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-94

Error code I211

Trouble Reception of CAN1 communication is abnormal. (Passive error)
Judging
Reception from gauge cluster can not receive correctly.
condition
Symptom Switch operation of gauge cluster can not be done.
Control in the
Normal control
event of failure
Returned in
Normal control
normal condition
Screen No.
Service
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-601F
CN-106F
2 -Mechatro controller Check that the error is corrected after replacement of controller.

46-64
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-95

Error code I213

Trouble Reception of CAN2 communication is abnormal. (Time-out)
Judging
Reception from gauge cluster can not receive correctly.
condition
Symptom Switch operation of gauge cluster can not be done.
Control in the
Normal control
event of failure
Returned in
Normal control
normal condition
Screen No.
Service
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-601F
CN-106F
2 -Mechatro controller Check that the error is corrected after replacement of controller.

Table 46-96

Error code I221

Trouble Transmission of CAN2 communication is abnormal. (Busoff)
Judging
Transmission from mechatro controller can not receive correctly.
condition
Symptom It has been affected little.
Control in the
Normal control
event of failure
Returned in 46
Normal control
normal condition
Screen No.
Service
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-601F (There is a possibility of false disconnection.)
CN-106F
2 -Mechatro controller Check that the error is corrected after replacement of controller.

46-65
46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-97

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
The power on the battery relay secondary side does not turn OFF even if the key switch is
Symptom
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
Screen No. 4 K-1 AIS RELAY 2
Service
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.

46-66
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-98
Error code R014
Trouble Wiper motor arc prevention relay error
Judging The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the
condition power source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 19 PREVENT ARC
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor arc prevention relay When error is cancelled after removing wiper motor arc prevention relay,
R-31 check relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between wiper motor arc When R014 is left displayed with the relay removed
prevention relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-1 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R014 is left displayed
E-1
Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-99
Error code R024
Trouble Wiper motor forward rotation relay error
Judging The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the
condition power source.
Symptom Wiper does not move.
46
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 19 CW MOTOR RLY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor forward rotation When error is cancelled after removing wiper motor forward rotation relay,
relay check relay unit for failure, replace it with new one if failed.
R-29 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between wiper motor When R024 is left displayed with the relay removed
forward rotation relay and Check that no power 24V is produced on relay (-) line according to the wiring
controller checking procedure and replace it if necessary.
CN-109F, CN2-1 When no failure found after checking on wiring and R024 is left displayed
•Fuse & relay box
Replace fuse/relay box.
E-1
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-67
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-100
Error code R034
Trouble Wiper motor reverse rotation relay error
Judging The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the
condition power source.
Symptom Wiper does not move after forward rotation.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 19 CCW MOTOR RLY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay,
relay check relay unit for failure, replace it with new one if failed.
R-30 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between wiper motor When R034 is left displayed with the relay removed
forward rotation relay and Check that no power 24V is produced on relay (-) line according to the wiring
controller checking procedure and replace it if necessary.
CN-109F, CN2-1 When no failure found after checking on wiring and R034 is left displayed
•Fuse & relay box
Replace fuse/relay box.
E-1
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-101
Error code R044
Trouble Washer motor relay error
Judging
The mechatro controller output line to washer motor relay is short-circuited with the power source.
condition
Symptom Washer motor does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 19 MOTOR RELAY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Washer motor relay When error is cancelled after removing washer motor relay, check relay unit
R-32 for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between washer motor When R044 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-112F, CN2-1 checking procedure and replace it if necessary.
•Fuse & relay box When no failure found after checking on wiring and R044 is left displayed
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-68
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-102
Error code R134
Trouble Swing flasher right relay error
Judging The mechatro controller output line to swing flasher right relay is short-circuited
condition with the power source.
Symptom Right swing flasher does not light.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 16 D13
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher relay,
R-19 check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal condition.

2 • Wiring between swing flasher When R134 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F figure C) according to the wiring checking procedure and replace it if
necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-103
Error code R144
Trouble Swing flasher left relay error
Judging The mechatro controller output line to swing flasher left relay is short-circuited
condition with the power source.
Symptom Left swing flasher does not light.
Control in the 46
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 17 D14
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher relay,
R-19 check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal condition.

2 • Wiring between swing flasher When R144 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F figure B) according to the wiring checking procedure and replace it if
necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-69
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-104
Error code R154
Trouble Travel alarm relay error
Judging
The mechatro controller output line to travel alarm relay is short-circuited with the power source.
condition
Symptom Travel alarm does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 17 D15
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel alarm relay When error is cancelled after removing of travel alarm relay, check relay unit
R-8 for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between travel alarm When R154 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
•Fuse & relay box When no failure found after checking on wiring and R154 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-105
Error code R164
Trouble Auto idle stop relay 2 relay error
Judging The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power
condition source.
Power source for mechatro controller often turns off.
Symptom
Auto idle stop relay 2 does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-1 AIS RELAY 2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Auto idle stop relay 2 relay When error is cancelled after removing of auto idle stop relay 2, check relay
R-24 unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between auto idle When R164 is left displayed with the relay removed
stop relay 2 and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
•Fuse & relay box When no failure found after checking on wiring and R164 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-70
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-106
Error code R174
Trouble Engine forcibly stop relay error
Judging The mechatro controller output line to engine forcibly stop is short-circuited with the power
condition source.
When key switch is turned off but engine does not stop.
Symptom
Engine auto idle stop function does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-3 ENG STOP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine forcibly stop relay When error is cancelled after removing of engine forcibly stop relay, check
R-25 relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between engine When R174 is left displayed with the relay removed
forcibly Check that no power 24V is produced on relay (-) line according to the wiring
stop relay and controller checking procedure and replace it if necessary.
CN-109F, CN2-2 When no failure found after checking on wiring and R174 is left displayed.
• Fuse & relay box Replace fuse/relay box.
E-1
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46

46-71
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-107
Error code R184
Trouble Safety lock lever relay error
Judging The mechatro controller output line to safety lock lever relay is short-circuited with the power
condition source.
Symptom Safety lock lever timer does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-4 LOCK LEVER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Safety lock lever relay When error R184 is cancelled after removing of safety lock lever relay, check
R-26 relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between safety lock When R184 is left displayed with the relay removed
lever relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R184 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.
Table46-108
Error code R214
Trouble Safety relay error
Judging
The mechatro controller output line to safety relay is short-circuited with the power source.
condition
Symptom Safety relay does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-2 SAFETY RLY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Safety lock lever relay When error R214 is cancelled after removing of safety relay, check relay unit
R-26 for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between safety lock When R214 is left displayed with the relay removed
lever relay and controller Check that no power 24V is produced on relay (-) line according to the wiring
CN-109F, CN2-2 checking procedure and replace it if necessary.
• Fuse & relay box When no failure found after checking on wiring and R214 is left displayed.
E-1 Replace fuse/relay box.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-72
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table 46-101

Error code Z010

Trouble Common rail pressure error
Judging
Common rail pressure is low than the specified level.
condition
Usual operation has no problem. However, if the engine continues to drive under this condition,
Symptom
it may cause the engine failure by the breakage of injector.
Control in the
Control the engine usually. (Warning by only error code and buzzer.)
event of failure
After the starter switch is turned off, if the engine is normal, when the starter switch is turned
Returned in
on, the error code is not displayed. And the engine returns to normal condition automatically.
normal condition
When the engine does not return to normal condition, check the injector.
Screen No. 22 Engine oil pressure
Service
diagnosis Screen No.
checking screen
Screen No.
Checking object Checking contents and remedy
1 -Fuel line, pressure sensor for Check the leakage from piping and the failure of pressure sensor for
common rail common rail.
Check the “ENG oil press” of display number 28 on service diagnosis
screen whether the value is within the specified value.
When the value deviates from the specified value, repair the piping or
replace the sensor.
(Contact our service for the specified value.)
2 -Injector By using “HINO DX”, measure the common rail pressure.
Check the all injector, because there is a possibility of failure. If the failure
is found, replace the injector.
(Contact our service for detail.)
3 -Fuel, fuel filter Check clogging of fuel filter, contamination in the fuel tank, and breakage
of the hose. If the failure is found, clean or replace the parts.
And investigate the fuel and filter that are used by customer. In addition,
confirm the user’s handling method for injection nozzle and fuel tank. If
poor handling is found, ask for the improvement. 46

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46. TROUBLE SHOOTING (BY ERROR CODES)

46-74
 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 .................................................................................................. 47-38
47.3 ENGINE RELATED TROUBLESHOOTING ....................................................... 47-41

47

Book Code No. S5LC4726E01

47-1
47. TROUBLESHOOTING (BY TROUBLE)

Issue Data of Issue Applicable Machines Remarks

S5LC4726E01
First Edition September, 2010 SK350-9: YC
NA

47-2
 47. TROUBLESHOOTING (BY TROUBLE)

47.1 HYDRAULIC SYSTEM

Preface:
The troubleshooting for the failures shown below are 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 straight when both crawlers and attachment are 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, check on
(10A) the short-circuited section.
2 Safety lever lock Carry out service No.4 K-4 switch: Check action of switch by
switch diagnosis Push down the lever and it turns tester, or check that the
on, push up and it turns off. power voltage is lowered
by pushing the lever down.
3 Safety lever lock Check that the Measure both terminals of solenoid Check solenoid unit for
switching solenoid is connector. 24V by pushing the possible failure.
switched correctly lever down, 0V by pushing it up Check harness for 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 Check 5V power for controller
sensor and key is on
position. All pilot
low pressure
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 pushing
solenoid A1 port it 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 travel switching performance, check that
is operable) the lever select pattern is set to the
proper position.
10 Actual measuring Carry out service No.7 In case the reading is
current value of P1/ diagnosis D-1 P1 unload valve (cut valve) largely differed from the
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 Measure the Check that P1/P2 unload Replace proportional valve
pressure of P1, P2 proportional valve secondary pressures are within the
unload secondary range of 0.5 to 1.2MPa in boom up
proportional valve pressure directly full 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 the reading is
current value of P1/ diagnosis. E-1 P1 pump largely differed from the
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 Measure the Check that the pump proportional Replace proportional
pressure of pump pump valve secondary pressure is 2.7 valve
proportional valve proportional valve MPa or more in right (left) travel full
secondary 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 Carry out service See Service Diagnosis Data List Measure the relief
pressure diagnosis Operation No.3, Boom up full lever pressure actually
& relief
15 Check set Check that P1 Reset or replace
pressure and P2 pump
pressures are 32
MPa or more 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.6 In case the reading is
current value of P1/ diagnosis E-1 P1 pump largely differed from the
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 Measure the Check that the P1/P2 pump Replace proportional
pressure of P1, P2 pump proportional valve pressures are valve
pump proportional proportional valve within the range of 0.5 to 1.0 MPa
valve secondary in control lever neutral and high
pressure directly idling operation.
(Ports a3, a4)
3 Pressure sensor of Check pressure See Service Diagnosis Data List Check pressure sensor
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 the targeted pilot Check remote control
sensor diagnosis pressure of sensor is 0MPa in high valve
idling
2 Remote control Check targeted Check that the spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
3 Main spool Check targeted Check that the 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 relief Replace
valve spool visually 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 Check that Free from abnormal resistance Replace
spool 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 relief Check targeted Filter free from abnormal Replace
valve for boom spool visually contamination
(in case of boom)
9 Cylinder Check targeted Make sure there is no problem of Replace cylinder or seals
cylinder visually the seals by disassembling and
investigating

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 0
MPa to 0.1 MPa
2 Actual measuring Carry out service No.8 In case the reading is
current value of P1/ diagnosis D-1 P1 unload valve (cut valve) largely differed from the
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 Measure the Check that the P1/P2 unload Replace proportional
pressure of unload proportional valve secondary pressures is within the valve
proportional valve secondary range of 2.7 MPa 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.6 In case the reading is
current value of P1/ diagnosis E-1 P1 pump largely differed from the
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 Measure the Check that the P1/P2 pump Replace proportional
pressure of P1, P2 pump proportional valve pressures are valve
pump proportional proportional valve within the range of 0.5 to 1.0 MPa Check regulator
valve secondary in control lever neutral and high
pressure directly. idling operation
(Ports a3, a4)
6 Slow return check Visual check Check that the slow return check Clean and replace
valve of pilot line valve installed on pilot line is free
(in case of boom from dust
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 the pressure is 3.0 MPa Check remote control
valve remote control or more in boom up full lever and valve
pressure of boom high idling operation When equipped with multi
up 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.7 In case the reading is
current value of P1/ diagnosis D-1 P1 unload valve (cut valve) largely differed from the
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 Measure the Check that the P1/P2 unload Replace proportional
pressure of P1, P2 proportional valve secondary pressures are within the valve
unload secondary range of 0.5 to 1.2 MPa in boom up
proportional valve pressure directly full lever and high idling operation
at the ports A7
and A5 of 8
sections solenoid
block
6 Actual measuring Carry out service No.6 In case the reading is
current value of P1/ diagnosis E-1 P1 pump largely differed from the
P2 pump E-2 P2 pump actual 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 Measure the Check that the P1/P2 pump Replace proportional
pressure of P1, P2 pump proportional valve pressures are valve
pump proportional proportional valve within the range of 2.3 to 3.2 MPa
valve secondary in boom up full lever and high idling 47
pressure directly operation
(Ports a3, a4)
8 P2 by-pass cut Visual check Poppet should be tightened. Clean and replace
valve Seated surface should be free from
<Trouble> damage and entry of foreign
Only P2 pressure matter.
is low.
9 Remote control Check targeted Check that the spool is free from Replace
valve remote control abnormal damage and spring is
valve not broken

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>B abnormal resistance against (Check on the casing side
other P1 and P2 sliding for damage)
pressures are low. Free from abnormal damage, etc
on outside surface
11 Conflux check Visual check When removing, free from Replace
valve abnormal resistance against (Check on the casing side
<Trouble> sliding for damage)
Only P2 pressure Free from abnormal damage, etc
is high. on outside surface
12 Holding valve for Visual check When removing, free from Replace
boom (poppet) abnormal resistance against (Check on the casing side
<Trouble> sliding for damage)
Both P1 and P2 Free from abnormal damage, etc
pressures are high. on outside surface
13 Boom spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against (Check on the casing side
Only P1 pressure sliding for damage)
is high. Spring is free from breakage.
14 Check boom spool Disassembly and Free from abnormal resistance Replace spool assembly
and recirculation investigation against sliding
<Trouble> Spring is free from breakage.
Only P1 pressure
is low.
15 Conflux spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against (Check on the casing side
Only P2 pressure sliding. for damage)
is high. Spring is free from breakage.
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 pressure
valve (Head side) boom up full lever and high idling. of boom up is low, replace
<Trouble> Free from dust entered in over load valve
Relief pressure is 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 the pressure is 3.0 MPa Check remote control
valve control pressure or more in boom down full lever valve.
of boom down and high idling operation When equipped with multi
directly control valve, check it
while changing lever
pattern.
3 Actual measuring Carry out service P1 unload valve (cut valve) In case the reading is
current value of P1 diagnosis -See Service Diagnosis Data List largely differed from the
unload Operation No.5 boom down full actually measured value,
proportional valve lever & in operation check proportional valve
and controller for possible
failure.
4 Secondary Measure the Check that the P1 unload Replace proportional
pressure of P1 proportional valve secondary pressures are within the valve
unload secondary range of 1.1 to 1.4 MPa in boom
proportional valve pressure directly down full lever and high idling
at the ports A7 of operation
8 sections
solenoid block.
5 Actual measuring Carry out service No.6 In case the reading is
current value of P1 diagnosis E-1 P1 pump 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 Measure the Check that the P1 pump Replace proportional
pressure of P1 pump proportional valve pressures are valve
pump proportional proportional valve within the range of 1.9 to 2.5 MPa
valve secondary in boom down full lever and high
pressure directly idling operation
(Ports a3, a4)
7 Actual measuring Carry out service Check that the value has not Check pressure sensor of
current value of diagnosis changed regardless of operation travel
travel straight See Service Diagnosis Data List In case the reading is
proportional valve Operation No. 1, Operation is nil largely differed from the 47
Operation No.18, Travel right full actually measured value,
lever & idling check proportional valve
Operation No.19, Travel left full and controller for possible
lever & idling failure.
8 Travel straight Measure directly High idling pressure is 0.8 MPa or Replace proportional
proportional valve the travel straight less regardless of neutral or valve
secondary proportional valve operation
pressure secondary
pressure.

47-11
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

9 Remote control Check targeted Check that the 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 (Check on the casing side
Boom down is low. sliding. for damage)
Free from abnormal damage, etc
on outside surface.
11 Holding valve Visual check When removing, free from Replace
(poppet) abnormal resistance against (Check on the casing side
<Trouble> sliding. for damage)
Boom down is Free from abnormal damage, etc
slow. on outside surface.
12 Boom spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against (Check on the casing side
Boom down is sliding. for damage)
slow. Free from abnormal damage, etc
on outside surface.
Spring is free from breakage.
13 Check boom spool Disassembly and Free from abnormal resistance Replace spool assembly
and recirculation investigation against sliding.
<Trouble> Spring is free from breakage.
Machine cannot be
lifted by and sup-
ported with boom.
14 Spool of bypass Visual check When removing, there is no Replace the spool
valve abnormal resistance against (Check on the casing side
sliding. for damage.)
Free from abnormal damage etc.
on outside surface.
Spring should be free from
breakage.
15 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.
16 Over load relief Visual check Free from dust entered in port relief Replace
valve valve.
<Trouble> Seat is free from abnormality.
Machine cannot be
lifted and support-
ed 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 3.0 MPa 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.7 In case the reading is
current value of P1/ diagnosis D-1 P1 unload valve (cut valve) largely differed from the
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 Measure the Check that P1/P2 unload Replace proportional
pressure of P1, P2 proportional valve secondary pressures are within the valve
unload secondary range of 0.5 to 1.2 MPa in arm in
proportional valve pressure directly full lever and high idling operation.
at the ports A7
and A5 of 8
sections solenoid
block.
6 Actual measuring Carry out service No.6 In case the reading is
current value of P1/ diagnosis E-1 P1 pump largely differed from the
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 Measure the Check that P1/P2 pump Replace proportional
pressure of P1, P2 pump proportional valve pressures are valve
pump proportional proportional valve 2.7 MPa or more in arm in full lever
valve secondary and high idling operation. 47
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 Measure directly Check that the secondary pressure Replace proportional
pressure of arm in the proportional of proportional valve secondary valve
spool 2 valve secondary pressures are within the range of
proportional valve pressure at ports following:
A8 (arm 2 spool) Lever neutral: 0MPa
of 8 sections Motion in the air: 1.7 to 2.2MPa
solenoid block. Arm in relief: 2.5MPa or more
10 Actual measuring Carry out service Check that the value has not Check pressure sensor of
current value of diagnosis changed regardless of operation travel
travel straight See Service Diagnosis Data List In case the reading is
proportional valve Operation No. 1, Operation is nil largely differed from the
Operation No.18, Travel right full actually measured value,
lever & idling check proportional valve
Operation No.19, Travel left full and controller for possible
lever & idling failure.
11 Secondary Measure directly 0.8 MPa or less in high idling Replace proportional
pressure of travel the proportional operation regardless of neutral/ valve
straight valve secondary operation
proportional valve pressure at the
ports A6 (travel
straight) of 8
sections solenoid
block
12 Remote control Check targeted Check that the 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 32 MPa or more in arm When only relief pressure
valve (Head side) in and relief. of arm in is low, replace
<Trouble> Free from dust in over load relief valve
P1, P2 pressure is valve.
low. Seat is free from abnormality.
15 Over load relief Visual check (Rod Pressure is 32 MPa or more in arm When only relief pressure
valve side) out and relief. of arm out is low, replace
<Trouble> Free from dust entered in over load valve
P1, P2 pressure is relief valve.
low. Seat is free from abnormality.
16 Arm 1 spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against (Check on the casing side
P1, P2 pressure is sliding. for damage)
high. Free from abnormal damage, etc
on outside surface.
Spring is free from breakage.

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 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 (Check on the casing side
P1, P2 pressure is sliding. for damage)
high or low. Free from abnormal damage, etc
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 the pressure is 3.0,MPa Check remote control
valve remote control or more in arm out full lever and valve
pressure of arm high idling operation When equipped with multi
out 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.7 In case where the reading
current value of P1/ diagnosis D-1 P1 unload valve (cut valve) is largely differed from the
P2 unload D-1 P2 unload valve (cut valve) actual 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 Measure the Check that P1/P2 unload Replace proportional
pressure of P1, P2 proportional valve secondary pressures are within the valve
unload secondary range of 0.5 to 1.2,MPa in arm out
proportional valve pressure directly full lever and high idling operation
at ports A7 and
A5 of 8 sections
solenoid block
6 Actual measuring Carry out service No.6 In case the reading is
current value of P1/ diagnosis E-1 P1 pump largely differed from the
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 Measure the Check that P1/P2 pump Replace proportional
pressure of P1, P2 pump proportional valve pressures are valve
pump proportional proportional valve within the range of 1.7 to 2.9 MPa
valve 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 has not Check pressure sensor of
current value of diagnosis changed regardless of operation travel
travel straight See Service Diagnosis Data List In case the reading is
proportional valve Operation No. 1, Operation is nil largely differed from the
Operation No.18, Travel right full actual measured value,
lever & idling check proportional valve
Operation No.19, Travel left full and controller for possible
lever & idling failure.
9 Secondary Measure directly High idling pressure is 0.8 MPa or Replace proportional
pressure of travel the proportional less regardless of neutral/ valve
straight valve secondary operation.
proportional valve pressure at ports
A6 (travel
straight) of 8
sections solenoid
block
10 Remote control Check targeted Check that the 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 32,MPa or more in arm When only relief pressure
valve side) out and relief. of arm out is low, replace
<Trouble> Free from dust entered in over load valve
P1, P2 pressure is relief valve. Seat is free from
low. abnormality.
13 Arm 1 spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against (Check on the casing side
P2 pressure is sliding, for damage)
high. Free from abnormal damage, etc
on outside surface,
Spring is free from breakage.
14 Arm 2 spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against (Check on the casing side
P1 pressure is sliding, for damage)
high. Free from abnormal damage, etc
on outside surface,
Spring is free from breakage. 47
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 the pressure is 3.0 MPa Check remote control
valve remote control or more in bucket digging full lever valve
pressure of and high idling operation When equipped with multi
bucket digging 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 between P1 and P2 pump
P2 pump full lever and in operation pressures, check high
pressures in pressure sensor
operation.
4 Actual measuring Carry out service No.7 In case the reading is
current value of P1/ diagnosis D-1 P1 unload valve (cut valve) largely differed from the
P2 unload D-1 P2 unload valve (cut valve) actual measured value,
proportional valve See Service Diagnosis Data List check proportional valve
Operation No.12, Bucket digging and controller for possible
full lever & relief failure.
5 Secondary Measure the Check that P1/P2 unload Replace proportional
pressure of P1, P2 proportional valve secondary pressures are within the valve
unload secondary range of 0.5 to 1.2 MPa in bucket
proportional valve pressure directly digging full lever and high idling
at ports A7 and operation
A5 of 8 sections
solenoid block
6 Actual measuring Carry out service No.6 In case the reading is
current value of P1/ diagnosis E-1 P1 pump largely differed from the
P2 pump E-2 P2 pump actual measured value,
proportional valve See Service Diagnosis Data List check proportional valve
Operation No.13, Bucket digging and controller for possible
full lever & in operation failure.
7 Secondary Measure the Check that the P1 pump Replace proportional
pressure of P1, P2 pump proportional valve pressures are valve
pump proportional proportional valve 2.7 MPa or more and P2 pump
valve secondary proportional valve pressure is 2.0
pressure directly to 2.6 MPa in bucket digging full
(Ports a3, a4) lever and high idling operation.
8 Attachment boost Carry out service No.3 POWER BOOST Check harness
solenoid command diagnosis Bucket digging COMP OFF, MEAS Replace solenoid valve
OFF
9 Attachment boost Measure Check that the pressure is 0 MPa Replace solenoid valve
solenoid switching valve in bucket digging full lever and high
secondary secondary idling operation
pressure pressure

47-18
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

10 Actual measuring Carry out service See Service Diagnosis Data List In case the reading is
current value of diagnosis Operation No.12, Bucket digging largely differed from the
travel straight full lever & relief actual measured value,
proportional valve check proportional valve
and controller for possible
failure.
11 Secondary Measure directly Check that the travel straight Replace proportional
pressure of travel the proportional secondary pressure is 2.7 MPa or valve
straight valve secondary more in bucket digging full lever
proportional valve pressure at ports and high idling operation
A6 (travel
straight) of 8
sections solenoid
block
12 P2 by-pass cut Visual check Poppet should be tightened. Clean or replace
valve Seated surface should be free from
<Trouble> damage and entry of foreign
Only P2 pressure matter.
is low.
13 Check stroke Visual check When piston is removed from Replace
limiter cover, it is free from abnormal (Check on the casing side
<Trouble> resistance against sliding for damage.)
Both P1, P2 Free from abnormal damage, etc
pressures are high. on outside surface
14 Remote control Check targeted Check that the spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
15 Main relief valve Check set See Service Diagnosis Data List Reset or replace
pressure Operation No.3, Boom up full lever
and relief
16 Travel straight Visual check When removing, free from Replace
spool abnormal resistance against (Check on the casing side
<Trouble> sliding for damage)
P2 pressure is Free from abnormal damage, etc
high. on outside surface
Spring is free from breakage.
17 Bucket spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against (Check on the casing side
Both P1, P2 sliding for damage)
pressures are high. Free from abnormal damage, etc
47
on outside surface
Spring is free from breakage.
18 Over load relief Check targeted Free from dust entered in over load Replace
valve spool visually relief valve.
Seat is free from abnormality.

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 the pressure is 3.0 MPa Check remote control
valve remote control or more in bucket dump full lever valve
pressure of and high idling operation When equipped with multi
bucket dump control valve, check it
while changing lever
pattern
3 Pump pressure Carry out service See Service Diagnosis Data List When there is a
sensor diagnosis for P1, Operation No.15, Bucket dump full difference between P1
P2 pump lever and in operation and P2 pump pressures,
pressures in check high pressure
operation. sensor
4 Actual measuring Carry out service No.8 In case the reading is
current value of P1/ diagnosis D-1 P1 unload valve (cut valve) largely differed from the
P2 unload D-1 P2 unload valve (cut valve) actual measured value,
proportional valve See Service Diagnosis Data List check proportional valve
Operation No.14, Bucket dump full and controller for possible
lever & relief failure.
5 Secondary Measure the Check that the P1/P2 unload Replace proportional
pressure of P1, P2 proportional valve secondary pressures are within the valve
unload secondary range of 0.5 to 1.2 MPa in bucket
proportional valve pressure directly dump full lever and high idling
at ports A7 and operation. Replace proportional
A5 of 8 sections valve.
solenoid block
6 Actual measuring Carry out service No.6 In case the reading is
current value of P1/ diagnosis E-1 P1 pump largely differed from the
P2 pump E-2 P2 pump actual measured value,
proportional valve See Service Diagnosis Data List check proportional valve
Carry out service Operation No.15, Bucket dump full and controller for possible
diagnosis. lever & in operation failure.
7 Secondary Measure the Check that the P1 pump Replace proportional
pressure of P1, P2 pump proportional valve pressure is 2.7 valve
pump proportional proportional valve MPa or more and P2 pump
valve secondary proportional valve pressure is 2.7
pressure directly MPa or more in bucket dump full
(Ports a3, a4) lever and high idling operation.
8 Actual measuring Carry out service See Service Diagnosis Data List In case the reading is
current value of diagnosis Operation No.14, Bucket dump full largely differed from the
travel straight lever & relief actual 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 Measure directly Check that the travel straight Replace proportional
pressure of travel the proportional secondary pressure is 2.7 MPa or valve
straight valve secondary more in bucket dump full lever and
proportional valve pressure at ports high idling operation
A6 (travel
straight) of 8
sections solenoid
block
10 P2 by-pass cut Visual check Poppet should be tightened. Clean and replace
valve Seated surface should be free from
<Trouble> damage and entry of foreign
Only P2 pressure matter.
is low.
11 Check stroke Visual check Free from abnormal damage and Replace
limiter wear on outside of piston inside (Check on the casing side
<Trouble> cover for damage.)
Pilot pressure is
low.
12 Remote control Check targeted Check that the 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 Travel straight Visual check When removing, free from Replace
spool abnormal resistance against (Check on the casing side
<Trouble> sliding for damage)
P2 pressure is Free from abnormal damage, etc
high. on outside surface
15 Bucket spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against (Check on the casing side
Both P1, P2 sliding for damage)
pressures are high. Free from abnormal damage, etc
on outside surface
Spring is free from breakage.
16 Over load relief Check targeted Free from dust entered in over load Replace
valve spool visually relief valve.
Seat is free from abnormality.
47

47-21
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 the pressure is 3.0 MPa Check remote control
valve remote control or 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: 0 MPa Replace solenoid valve
brake solenoid solenoid valve A2 In operation: 4 MPa 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 and in operation
in operation
7 Actual measuring Carry out service No.7 D-2 P2 unload valve (cut In case the reading is
current value of P2 diagnosis valve) largely differed from the
unload See Service Diagnosis Data List actual measured value,
proportional valve Operation No.11, Swing full lever & check proportional valve
in operation and controller for possible
failure.
8 Secondary Measure the Check that P2 unload secondary Replace proportional
pressure of P2 proportional valve pressures are within the range of valve
unload secondary 0.5 to 1.2 MPa in swing full lever
proportional valve pressure directly and high idling operation
at ports A5 of 8
sections solenoid
block
9 Actual measuring Carry out service No.6, E-2 P2 pump In case the reading is
current value of P2 diagnosis See Service Diagnosis Data List largely differed from the
pump proportional Operation No.11, Swing full lever & actual measured value,
valve in operation check proportional valve
and controller for possible
failure.
10 Secondary Measure the Check that the P2 pump Replace proportional
pressure of P2 pump proportional valve pressure is 2.7 valve
pump proportional proportional valve MPa or more in swing full lever and
valve secondary high idling operation
pressure directly
(Ports a3, a4)

47-22
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

11 Actual measuring Carry out service Check that the value has not Check pressure sensor of
current value of diagnosis changed regardless of operation travel
travel straight See Service Diagnosis Data List In case the reading is
proportional valve Operation No. 1, Operation is nil largely differed from the
(Check this trouble Operation No.18, Travel right full actual measured value,
by only swing lever & idling check proportional valve
operation) Operation No.19, Travel left full and controller for possible
lever & idling failure.
12 Secondary Measure directly 0.8 MPa or less in high idling Replace proportional
pressure of travel the proportional operation regardless of neutral/ valve
straight valve secondary operation
proportional valve pressure at ports
(Check this trouble A6 (travel
by only swing straight) of 8
operation) sections solenoid
block
13 Remote control Check targeted Check that the spool is free from Replace
valve remote control abnormal damage and spring is
valve free from breakage
14 Travel straight Visual check When removing, free from Replace
spool abnormal resistance against (Check on the casing side
<Trouble> sliding. for damage)
P2 pressure is low. Free from abnormal damage, etc
on outside surface.
Spring is free from breakage.
15 Swing spool Visual check When removing, free from Replace
<Trouble> abnormal resistance against (Check on the casing side
P2 pressure is sliding. for damage)
high. Free from abnormal damage, etc
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.
Free from abnormal damage, etc 47
on outside surface (brake plate
etc)
18 Swing reduction Take sample oil Sampling oil does not include a lot Disassemble and inspect
gear oil from swing of metal powder. reduction gear
reduction gear
drain
19 Swing reduction Visual check Tooth surface is not worn Replace
abnormally and is not chipped.

47-23
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: 0 Replace solenoid valve
solenoid valve A2 MPa
port In operation: 4
MPa or more
3 Boost check valve Visual check When removing, free from Replace
(Sound of abnormal resistance against
cavitation at sliding.
stopping) Spring is free from breakage.
4 By-pass check Visual check When removing, free from Replace
valve abnormal resistance against
(Sound of sliding.
cavitation at Spring is free from breakage.
stopping)
5 Swing motor Visual check Disassemble and inspect Replace
(Brake valve/ abnormal wear and scuffing
friction 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 lot Disassemble and inspect
gear oil from swing of metal powder. reduction gear
reduction gear
drain.
8 Swing reduction Visual check Tooth surface has no abnormally Replace
worn and chipped.

47-24
 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 0.1 MPa.
2 Remote control Check targeted Check that the 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: Replace solenoid valve
solenoid valve A2 0MPa
port In operation:
4MPa or more
5 Swing motor Visual check Disassemble and inspect Replace
(Brake valve/ abnormal wear and scuffing
friction 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 0.1 MPa.
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)

47-25
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 2.1 MPa 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.7 In case where the reading
current value of P1/ diagnosis D-1 P1 unload valve (cut valve) is largely differed from the
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 Measure the Check that P1/P2 unload Replace proportional
pressure of P1, P2 proportional valve secondary pressures are within the valve
unload secondary range of followings in travel right
proportional valve pressure directly (left), forward (reverse) full lever
at ports A7 and and high idling operation
A5 of 8 sections Travel right (P1 unload): 0.5 to 1.2
solenoid block MPa
Travel left (P2 unload): 0.5 to 1.2
MPa
5 Actual measuring Carry out service No.6 In case the reading is
current value of P1/ diagnosis E-1 P1 pump largely differed from the
P2 pump E-2 P2 pump actual 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 Measure the Check that P1/P2 unload Replace proportional
pressure of P1, P2 pump secondary pressures are within the valve
pump proportional proportional valve range of followings in travel right
valve secondary (left), forward (reverse) full lever
pressure directly and high idling operation
(Ports a3, a4) Travel right (P1 pump): 2.7 MPa or
more
Travel left (P2 pump): 2.7 MPa or
more

47-26
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

7 Actual measuring Carry out service Check that the value has not Check voltage of low
current value of diagnosis changed regardless of operation pressure sensor other
travel straight See Service Diagnosis Data List than sensor for the
proportional valve Operation No. 1, Operation is nil travel*-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
8 Secondary Measure directly 0.8 MPa or less in high idling Replace proportional
pressure of travel the proportional operation regardless of neutral/ valve
straight valve secondary operation
proportional valve pressure
9 Remote control Check targeted Check that the 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 Visual check When removing, free from Replace
spool abnormal resistance against (Check on the casing side
<Trouble> sliding. for damage)
P1 pressure is Free from abnormal damage, etc
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 (Check on the casing side
Pump pressure is sliding. for damage)
high. Free from abnormal damage, etc
on outside surface.
Spring is free from breakage.
12 Travel motor relief Check set Check that the P1 and P2 pump If P1 is low, right travel
valve pressure pressures are 32 MPa or more in motor Afs relief valve has
right and left travel levers full lever failed.
(relief operation at locked crawler If P2 is low, left travel
belt) and high idling motor Afs relief valve has
failed.
13 Travel motor Visual check Inner parts (piston, cylinder block, Replace
valve plate, brake valve spool) are
to be free from abnormal 47
resistance against sliding.
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 Sample oil does not include a lot of Disassemble and inspect
gear oil from travel metal powder. reduction gear
reduction gear
drain
16 Travel reduction Visual check Tooth surface is not worn Replace
abnormally and is not chipped.

47-27
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 the pressure is 2.1 MPa Check remote control
valve remote control or 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 has not Check voltage of low
current value of diagnosis changed 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 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.
4 Secondary Measure directly 0.8 MPa or less in high idling Replace proportional
pressure of travel the proportional operation regardless of neutral/ valve
straight valve secondary operation
proportional valve pressure
5 Actual measuring Carry out service No.7 D-1 P1 unload valve (cut In case the reading is
current value of P1/ diagnosis valve) largely differed from the
P2 unload D-1 P2 unload valve (cut valve) actual 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 Measure the Check that the P1/P2 unload Replace proportional
pressure of P1, P2 proportional valve secondary pressures are within the valve
unload secondary range of following in travel right
proportional valve pressure directly (left), forward (reverse) full lever
at ports A7 and and high idling operation.
A5 of 8 sections Travel right (P1 unload): 0.5 to 1.2
solenoid block MPa
Travel left (P2 unload): 0.5 to 1.2
MPa
7 Actual measuring Carry out service No.6 In case the reading is
current value of P1/ diagnosis E-1 P1 pump largely differed from the
P2 pump E-2 P2 pump actual 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 Measure the Check that the P1/P2 unload Replace proportional
pressure of P1, P2 pump secondary pressures are within the valve
pump proportional proportional valve range of following in travel right
valve secondary (left), forward (reverse) full lever
pressure directly and high idling operation.
(Ports a3, a4) Travel right (P1 pump): 2.7 MPa or
more
Travel left (P2 pump): 2.7 MPa or
more
9 Exchange P1 for Exchange Check the direction of deviation If the direction is
P2 delivery pipe of changed, inspect a pump.
P1 for P2 If the direction has not
changed, inspect a valve
and travel unit.
10 Remote control Check targeted Check that the 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 Visual check When removing, free from Replace
spool abnormal resistance against (Check on the casing side
<Trouble> sliding. for damage)
P1 pressure is Free from abnormal damage, etc
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 (Check on the casing side
Pump pressure is sliding for damage)
high. Free from abnormal damage, etc
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 32 MPa or more in right and left motor Afs relief valve is
travel levers full lever (relief failed.
operation at locked crawler belt) If P2 is low, left travel
and high idling motor Afs 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 lot Disassemble and inspect
gear oil from travel of metal powder. reduction gear
reduction gear
drain
16 Travel reduction Visual check Tooth surface is not worn Replace
abnormally and is not chipped.

47-29
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 traveling under heavy loading (for example traveling on a slope or traveling on a soft ground), the speed
may not change from 1st to 2nd because this machine is equipped with 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: 0 MPa Replace solenoid valve
switching solenoid pressure on In operation: 4 MPa or more
solenoid valve
3 1/2 speed Visual check Check that the 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)

47-30
 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 stopped and starter key Check pressure sensor
sensor diagnosis switch is ON and replace as necessary
Targeted pilot low pressure sensor Check remote control
is in range of 0 to 0.1 MPa 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.7 D-3 S-TRAVEL should be Check voltage of low
current value of diagnosis COMP 730 mA and MEAS 700 to pressure sensor other
travel straight 760 mA in both travel full lever and than travel sensor-In case
proportional valve in boom up full lever at high idling the reading is largely
differed from the actually
measured value, check
proportional valve and
controller for possible
failure.
2 Secondary Measure directly Check secondary pressure is Replace proportional
pressure of travel the proportional within range of 2.7 to 3.0 MPa in valve
straight valve secondary both travel full lever and in boom
proportional valve pressure up full lever at high idling
3 Travel straight Visual check When removing, free from Replace
spool abnormal resistance against (Check on the casing side
sliding for damage)
Free from abnormal damage, etc
on outside surface 47
Spring is free from breakage.

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 Carry out service See Service Diagnosis Data List Check and replace
for optional diagnosis Operation No.16, P2 side OPT full pressure senso
attachment lever and relief Check remote control
valve
2 Remote control Measure directly Check that the pressure is 2.1 MPa Check remote control
valve remote control or more in optional attachment full valve 0
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 reading
current value of P1/ diagnosis Operation No.16, P2 side OPT full is largely differed from the
P2 unload lever and relief actual measured value,
proportional valve check proportional valve
and controller for possible
failure.
4 Secondary Measure the Check that P1/P2 unload Replace proportional
pressure of P1, P2 proportional valve secondary pressures are within the valve
unload secondary range of 0.5 to 1.2 MPa
proportional valve pressure directly
at ports A7 and
A5 of 8 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
actual measured value,
check proportional valve
and controller for possible
failure.
6 Secondary Measure directly Check that the travel straight Replace proportional
pressure of travel the proportional secondary pressure is 2.7 MPa or valve
straight valve secondary more in optional attachment full
proportional valve pressure at ports lever and high idling operation
A6 (travel
straight) of 8
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 Visual check When removing, free from Replace
spool abnormal resistance against (Check on the casing side
<Trouble> sliding for damage)
P1 pressure is high Free from abnormal damage, etc
on outside surface
Spring is free from breakage.
11 Spool for optional Visual check When removing, free from Replace
attachment abnormal resistance against (Check on the casing side
<Trouble> sliding for damage)
P1, P2 pressures Free from abnormal damage, etc
are high on outside surface
Spring is free from breakage
12 Over load relief Check targeted Free from dust entered in over load Replace
valve spool visually 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 (Check on the casing side
sliding for damage)
Free from abnormal damage, etc
on outside surface
Spring is free from breakage
2 N&B selector Screw for Check that the error indication has Replace solenoid valve
solenoid emergency disappeared by turning emergency
screw
3 N&B selector Carry out service No.9, F-4 Option selector is B Check solenoid valve 47
solenoid diagnosis mode Check harness
COMP ON, MEAS ON
Spool position BRK
Selector switch BRK
4 N&B selector Carry out service No.13 B-11 Check pressure sensor
pressure sensor diagnosis Data List Check harness
3.0 MPa at B mode and 0.0 MPa 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 and B selector Visual check When removing, free from Replace
spool abnormal resistance against (Check on the casing side
sliding for damage)
Free from abnormal damage, etc
on outside surface
Spring is free from breakage
2 N&B selector Carry out service No.9, F-4 Option selector is A Check solenoid valve
solenoid diagnosis mode Check harness
COMP OFF, MEAS OFF
Spool position N
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.
CONNECTOR
(1)
Checking for disconnection between connectors.
(When both ends measurement is easy because of short
distance between connectors) WIRE
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is zero (0), it is in normal condition. TESTER

(When both ends measurement is difficult because of long

distance between connectors)
JUMPER
Measure the resistance using tester. WIRE
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 TESTER
wire, it is in normal condition. FRAME BODY GROUNDING
The resistance is 1 M-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 1 M-ohm or more, it is in normal TESTER
condition. FRAME BODY GROUNDING

(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 1 M-ohm or more, it is in normal TESTER
condition.

(4) INSERT
Checking connector terminal for contact
Insert male terminal into female terminal unit, and then
check that the inserting force is equivalent to other female MALE TERMINAL FEMALE TERMINAL
terminals.
If looseness is there, replace the female terminal with new one.
Clean the dirty terminal.

Do not insert the male terminal, the thickness is different. It may cause loose connection.

47-36
 47. TROUBLESHOOTING (BY TROUBLE)

(5)
Caution which should be paid in measuring voltage
When measuring the power supply to electric equipment at connector position with the grounding terminal
contained inside of connector, measure the voltage between grounding inside of connector and power terminal.
When measuring the voltage between frame body grounding and power source, the disconnection of wiring to
grounding inside of connector cannot be identified.
Since the voltage may vary between with connector connected and with connector not connected. Measure the
voltage with each connector connected whenever possible.

(6)
Checking the general view of connector
CRIMPED
PART
a. Check the terminal crimped condition.
Pull one electric cable with about 3 kg force, and make
sure that the cable does not come out of the terminal. RUBBER
PLUG
When it comes out, replace the terminal and crimp it RECEPTACLE.
CONTACT
again.
PLUG
b. Check connector for imperfect insertion SEALING
(is housed in plug)
Check that all top ends form a line on the same DOUBLE LOCK
position as seen from the connector engaged side. PLATE FOR PLUG
DOUBLE LOCK
c. Check connector for imperfect insertion PLATE FOR CAP
Check that all top ends form a line on the same
CAP
position as seen from the connector engaged side.
TAB.CONTACT
RUBBER PLUG
(7)
When abnormality occurs at intervals
When the abnormality situation cannot be reoccurred during checking operation, try the following operations.

a. Check that the 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 the variables of resistance and voltage exist or not using tester while shaking the harness.
c. Turn starter switch on and apply electricity continuously, and check it again after the temperature of wiring and
equipment was raised.

(8)
Checking on body grounding
Check attaching bolts of grounding terminal for loosening.
And also check that there is no loose connection due to
corrosion.

There are multiple groundings like a centralized grounding

box shown in the figure and battery grounding, engine
grounding, horn grounding fixed together with horn, body 47
grounding placed on attaching section of boom working
light.
Block of grounding is located
under floor plate of cab.

47-37
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.

(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 ON OFF at starter, key switch OFF terminals of starter switch
by carrying out position using tester
service diagnosis. ON at starter, key switch ON
position
2 Engine forcible When ON is No.4, K-3 Key switch Check on engine forcible
stop relay displayed with the OFF at starter, key switch OFF stop relay
starter switch OFF, position
then pull out R-25 ON at starter, key switch ON
engine forcible stop position
relay and carry out
the service diagnosis.
3 Wiring Voltage between line 0 V when starter switch is OFF Check harness
No.62 among starter Check diode D-9 between
switch, engine starter switch and auto
forcible stop relay, idling 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 Accel control Engine speed varies according to Check mechatro
controller accel potentiometer operation. controller and replace as
(Use remote control because the necessary
auto accel function is working)
3 Wiring Transmission circuit See "WIRING CHECKING Repair wiring
line No.770 from PROCEDURE"
mechatro controller to
gauge cluster
4 Gauge cluster Gauge cluster Replace gauge cluster

47-38
 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 coolant No.2 G-5 WATER TEMP Replace engine coolant
temperature temperature by auto accel does not work in the sensor
carrying out service temperature -5° C (23° F) or less.
diagnosis. Warm up and raise the coolant
temperature to -5° C (23° F) 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 No.6 is in the range of 0 to 0.1 MPa sensor
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 No.6 is raised with control lever sensor
operated.

47

47-39
47. TROUBLESHOOTING (BY TROUBLE)

(5) Wiper does not function

Wiping range of
forward and
reverse movements

Wiper motor
Rise up (storing) position Rise up limit switch's ON range
Upper reversing position Reverse limit switch's ON range
Lower reversing position

No. Sections Contents/normal value Corrective action, others

1 Fuse Check fuse No.20 Replace fuse
2 SW-19: Service diagnosis No.14 DI25 Check wiper interlock switch
Wiper interlock switch Wiper switch display (DI25) is OFF with front window closed. and repair it if necessary
Check according to "WIRING
CHECKING PROCEDURE" and
repair it if necessary
3 Rise up limit switch built- Service diagnosis No.19 Wiper system Check according to "WIRING
in wiper motor CHECKING PROCEDURE"
Reverse limit switch Switch action in operation

Normal condition
Rise up limit switch ON OFF OFF
Reverse limit switch ON ON OFF

4 R-31: Service diagnosis No.19 Wiper system

Arc prevention relay When started by forward rotation: STOP START (STOP) (REVERSE) (STOP) (FORWARD)
R-29: Arc prevention relay OFF ON ON ON ON OFF ON ON ON OFF ON
Forward rotation relay Forward rotation relay OFF ON ON ON ON OFF OFF OFF OFF OFF ON
Reverse rotation relay OFF OFF OFF OFF OFF OFF ON ON ON OFF OFF
R-30:
Check that the relay is worked as shown in the table. Check that the relay is excited.
Reverse rotation relay * When the limit switch does not change in OFF after 4 seconds Check relay & fuse box and replace it
from the wiper startup, turn OFF all relay's outputs. if necessary.

47-40
 47. TROUBLESHOOTING (BY TROUBLE)

47.3 ENGINE RELATED TROUBLESHOOTING

Checking
Filters Liquid Leak, clogging

Air leak between turbocharger and intake manifold

Factors

Leak, clogging of fuel system and intruding of air

Contamination of water and fuel with oil
Breather hose crushed or clogged
Fan belt slipped, fan pulley worn

Poor or deteriorated battery

Shortage of fuel level

Improper fuel in use

Air cleaner clogged
Fuel filter clogged

Oil level of oil pan

Oil filter clogged

Muffler clogged
Engine oil leak
Coolant level
Trouble

Poor start ability (Take a long time)

Faulty engine starting/engine does not rotate.
Faulty starting

Faulty engine starting/engine rotates but no

exhaust gas (No fuel injection)

Faulty engine starting/exhaust gas is emitted

but engine does not start (With fuel injection)
Poor output Insufficient

Engine poor run-up (Low follow-up ability)

rotation

Rotation in bad condition (hunting)

Engine stalled during operation.
Output is lowered.
Overheating
Exhaust smoke is black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Early contamination of oil
47
Other failures

Larger fuel consumption

Intruding of oil in coolant, back flow, reduction
of coolant quantity
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Vibration

47-41
47. TROUBLESHOOTING (BY TROUBLE)

Checking Electric equipment

Shovel side Shovel side Engine side

Malfunction of unload valve and low pressure sensor

Loose mounting bolts, damage of mounting rubber
Factors

Radiator core clogged/fin clogged and crushed

Peeling of space insulation around radiator

Loose connection of battery cable terminal

Failure of radiator pressure cap

Failure of hydraulic system

Startup circuit wiring

Starter switch key

Hydraulic switch
Starter motor
Battery relay

Safety relay
Glow relay
Glow plug
Alternator
Trouble

Poor start ability (Take a long time)

Faulty engine starting/engine does not rotate.
Faulty starting

Faulty engine starting/engine rotates but no

exhaust gas (No fuel injection)

Faulty engine starting/exhaust gas is emitted

but engine does not start (With fuel injection)
Poor output Insufficient

Engine poor run-up (Low follow-up ability)

rotation

Rotation in bad condition (hunting)

Engine stalled during operation.
Output is lowered.
Overheating
Exhaust smoke is black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Early contamination of oil
Other failures

Larger fuel consumption

Intruding of oil in coolant, back flow, reduction
of coolant quantity
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Vibration

47-42
 47. TROUBLESHOOTING (BY TROUBLE)

Fuel system Intake and Lubrication Cooling

exhaust system system system

Factors

Seizing and interference of turbocharger

Seal of turbocharger worn, damaged
Turbocharger oil drain tube clogged

Leak and crush of hydraulic piping

Failure of thermostat (Not open)

Fuel leak into the head cover
Improper fuel injection time

Failure of regulator valve

Damage of water pump

Damage of EGR cooler
Failure of supply pump

Failure of relief valve

Failure of oil pump
Failure of injector
Trouble

Poor start ability (Take a long time)

Faulty engine starting/engine does not rotate.
Faulty starting

Faulty engine starting/engine rotates but no

exhaust gas (No fuel injection)

Faulty engine starting/exhaust gas is emitted

but engine does not start (With fuel injection)
Poor output Insufficient

Engine poor run-up (Low follow-up ability)

rotation

Rotation in bad condition (hunting)

Engine stalled during operation.
Output is lowered.
Overheating
Exhaust smoke is black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Early contamination of oil
Other failures

Larger fuel consumption 47

Intruding of oil in coolant, back flow, reduction
of coolant quantity
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Vibration

47-43
47. TROUBLESHOOTING (BY TROUBLE)

Engine body
Factors

Wear and damage of rear oil seal and seal surface

Damage and seizing of piston and connecting rod
Damage of engine oil cooler core and O-ring

Damage of cylinder head and head gasket

Wear and failure of valve and valve guide

Wear of piston ring and liner, ring stick

Strainer clogged, damage of oil pipe

Failure of injection holder sleeve

Damage of flywheel gear

Hole due to cavitation

Damage of dumper
Trouble

Poor start ability (Take a long time)

Faulty engine starting/engine does not rotate.
Faulty starting

Faulty engine starting/engine rotates but no

exhaust gas (No fuel injection)

Faulty engine starting/exhaust gas is emitted

but engine does not start (With fuel injection)
Poor output Insufficient

Engine poor run-up (Low follow-up ability)

rotation

Rotation in bad condition (hunting)

Engine stalled during operation.
Output is lowered.
Overheating
Exhaust smoke is black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Early contamination of oil
Other failures

Larger fuel consumption

Intruding of oil in coolant, back flow, reduction
of coolant quantity
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Vibration

47-44
 51. ENGINE

51. ENGINE
51
PREFACE

This service manual explains the single engine. Note that this manual is edited without modification by based on
the service manual of HINO MOTOR.

Book Code No. S5LC5125E02

51-1
51. ENGINE

Issue Date of Issue Applicable Machines Remarks

S5LC5125E01
First Edition September, 2010 SK350-9 : YC
(NA)
S5LC5125E02
Revision May, 2011 SK350-9 : YC
(NA)

51-2
HINO DIESEL ENGINE
WORKSHOP MANUAL

J08E-UV

(Shovel)

KSS-Z4J8-002E

2011.2
 GENERAL 1
STANDARD VALUE 2
PARTS TO BE PREPARED 3
ENGINE MOUNTING/DISMOUNTING 4
FUEL SYSTEM 5
EMISSION CONTROL 6
ELECTRICAL 7
INTAKE 8
ENGINE MECHANICAL 9
EXHAUST 10
COOLING 11
LUBRICATION 12
STARTING AND CHARGING 13
TURBOCHARGER 14
AIR COMPRESSOR 15
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS 16
ENGINE DIAGNOSIS CODE 17

For your information:

This documentation does not contain any descriptions in

regard to the hatched part

"15. Air Compressors".

 GENERAL 1–1

ENGINE

1
1 GENERAL
General information

Warning................................................................... 1-2
How to read this manual ........................................ 1-3
Precautions for work ............................................... 1-8
Tightening of engine bolts and nuts ...................... 1-12
Tightening of flare nuts and hoses........................ 1-14
Taper thread sealant for piping ............................. 1-15
Assembly of joints and gaskets for piping ............. 1-16
Handling of liquid gasket....................................... 1-18
Failure diagnosis table for each problem .............. 1-19
Failure diagnosis procedures................................ 1-20
Failure diagnosis using HinoDX ............................ 1-22
Connection method of HinoDX ............................. 1-26
Engine number ..................................................... 1-27
1–2 GENERAL

Warning
JP30ZCE010102001

Observe the following precautions to work safely and to prevent damage to customers' machine.

This manual is prepared for qualified service engineers who are recognized as technical expert. Those who are not
qualified, who are not appropriately trained, who performs service without appropriate tool or equipment, or who
perform service with the way not specified in this manual may not only damage the vehicle, but also put service
engineers and surrounding people in danger.
• Appropriate service and repair are essential to ensure safety of service engineers and safety and reliability of
vehicles. Be sure to use Hino genuine parts for replacement of parts. Do not use deteriorated parts in quality.
• Items described in this manual are the procedures to be observed in service and repair. For service and repair
according to this procedure, be sure to use the special tools designed for each purpose.
• If a method or a tool not recommended is used, safety of service engineers, and safety and reliability of vehicles
may be impaired. Never use a method or tool not recommended.
• This manual shows “Warning” and “Caution” for items that need to be observed so that accidents may not occur
during service or repair, or that damage to vehicle due to improper method may not impair safety and reliability of
vehicles. These instructions cannot give warning for all possible hazards. Note that items with “Warning” or
“Caution” are not absolute for safety.
 GENERAL 1–3

How to read this manual

JP30ZCE010102002

1. Scope of repair work

(1) Repair work is classified into three large categories of "Diagnosis", "Mounting/removal, replacement,
assembly˜disassembly and inspection˜adjustment" and "Final inspection".
(2) This manual describes "Diagnosis" in the first process and "Mounting/removal, replacement,
assembly˜disassembly and inspection˜adjustment" in the second process. Explanation of "Final inspection"
in the third process is omitted here.
(3) Although the following work is not described in this manual, it should be performed in actual work.
a. Jacking and lifting
b. Cleaning and washing of removed parts as required
c. Visual inspection

2. Standard value
(1) Standard value, limit, action and tightening torque described in the text are summarized in tables.

3. Items to be prepared
(1) Items to be prepared before work are SST, tools, gauges and lubricant, etc. These are listed in the list
section of items to be prepared. Items such as general tools, jack, rigid rack, etc. that are usually
equipped in general service shop are omitted.

4. How to read sections and titles

(1) Sections are classified according to J2008, SAE standard.
(2) For areas that show system names like "Engine control system", "Inspection", "Adjustment",
"Replacement", "Overhaul", etc. of components are described.
(3) For areas that show part names like "Injection pump", "Mounting/removal and disassembly" is described.
(4) Illustrations of the parts catalog are shown for part layout. (Part codes in the parts catalog are described in
the illustration. Major names and tightening torque are listed in the table.)

! CAUTION • The part layouts in this manual are inserted based on illustrations and part numbers of the
parts catalog CD-ROM issued in June, 2010. (Some areas do not show exploded view. They
will be additionally issued when the parts catalog CD is revised.) Be sure to use the parts
catalog for confirmation of illustrations and part numbers and for ordering parts.
1–4 GENERAL

5. How to read troubleshooting

(1) Failure diagnosis in this manual describes Step 2 and Step 3 below :

Hear from customers for conditions and environments of

(1) Question "Step 1"
failures and check the fact.
Perform diagnosis inspection, status inspection,
(2) Pre-inspection function inspection and basic inspection. Check the
"Step 2"
(3) Reproduction method failure status. If it is difficult to reproduce the problem
with status inspection, use the reproduction method.

(4) Troubleshooting for each Summarize inspection results obtained from Step 2.
diagnosis code Perform inspection systematically according to
"Step 3"
(5) Troubleshooting for each troubleshooting procedures for each diagnosis code or
failure status failure status.

Check if failure occurs again after repair. If it is difficult to

(6) Confirmation test "Step 4" reproduce a failure, perform the confirmation test under
the conditions and environment of the failure.

(2) Pre-inspection

• Pre-inspection is performed in the following steps :

Diagnosis inspection o Diagnosis deletion o Failure status check (Use the reproduction
method if not reproduced.) o Diagnosis reconfirmation
• Estimate the failure system before the reproduction test. Attach a tester and evaluate
estimated failure together with failure status. Refer to the troubleshooting chart for
Pre- estimated cause of a failure.
inspection • An error code is displayed if a failure occurs instantaneously. If any specific failure is not
found, perform troubleshooting using the reproduction method.
• Failure status check
If failure is reproduced, perform Step 2 o Step 3 o Step 4.
If failure is not reproduced, use the reproduction method (simulation of external
conditions or check of each wire harness and connector, etc.)
 GENERAL 1–5

6. How to read explanation details

(1) Part layout

Example
ENGINE MECHANICAL [J08E] 9–17

Timing Gear Cover and Flywheel Housing

Part layout
JP04117090402003

Part name code

Part catalog Fig. No.

SAPH041170900182

11308 Flywheel housing 11390 End plate

Description of
11309 Oil seal retainer 9828A Front oil seal* part name code
11357 Gasket* 9828B Rear oil seal*
11357A Gasket*

*Parts not to be reused.

Left: Part name code (nut)
Tightening torque
9069H M14 : 171.5N m{1, 750kgf cm} 9419A M16 : 196N m{2, 000kgf cm}
9069J M12 : 97N m{990kgf cm} 9419B M16 : 196N m{2, 000kgf cm}

It is the ID number for parts to prepare electronic data. It is not required for repair work.

SAPH30ZCE0100043
1–6 GENERAL

7. Definition of terms
Terms in this manual are defined as follows :
(1) Direction (Individual unit)
• Front/back direction
The power input side is front and the output side is back.
• Rotating direction
When viewed from the rear, the clockwise direction is right rotation and the counterclockwise direction is
left rotation.
• Vertical direction
With a unit mounted on the machine main unit, the upward direction is upper and the downward
direction is lower.
• Left/right direction
When viewed from the rear, the left direction is left and the right direction is right.
(2) Standard value ˜˜˜˜˜˜˜Basic dimension excluding tolerance and clearance generated by tolerances when two
parts are joined
(3) Repair limit˜˜˜It is the value requiring repair. Symbol of + or - with the value means increase or decrease to
the standard value.
(4) Operation limit˜˜˜It is the value requiring replacement. Symbol of + or - with the value means increase or
decrease to the standard value.
(5) Warning˜˜˜˜˜˜˜˜˜˜˜It is an item that may result in risk of human life or serious injury by incorrect handling.
(6) Caution˜˜˜˜˜˜˜˜˜˜˜It is an item that should not be performed including inhibited work or an item that require
attention in working procedures.
(7) Reference˜˜˜˜˜˜˜˜˜˜˜It is supplementary explanation in work.
 GENERAL 1–7

8. Unit
(1) SI unit is used in this manual. SI unit is the international unit to unify the conventional different international
units into one unit per quantity and to promote smooth technical communications.
(2) This manual shows both the SI unit and conventional units. The conventional units are shown in { }.

Conversion value*1
Item SI unit Conventional unit
(1[Conventional unit] = X [SI unit])
Force N kgf 1kgf=9.80665N

Torque*2 N˜m kgf˜cm 1kgf˜cm=0.0980665N˜m

1kgf/cm2=98.0665kPa
kgf/cm2
Pressure Pa =0.0980665MPa

mmHg 1mmHg=0.133322kPa

r/min 1rpm=1r/min
Rotational speed rpm
-1
min 1rpm=1min-1
Spring constant N/mm kgf/mm 1kgf/mm=980665N/mm

Volume L cc 1cc=1mL

Efficiency W PS 1PS=0.735499kW

Calorific value W˜h cal 1kcal=1.13279W˜h

Fuel consumption rate g/W˜h g/PS˜h 1g/PS˜h=1.3596g/kW˜h

*1
: X means the value when 1 [Conventional unit] is converted to the SI unit.
It is used as the conversion factor from the conventional unit to the SI unit.
*2
: The conversion value of the torque may vary depending on the unit.
Observe the standard values described for each unit.
1–8 GENERAL

Safety information

Precautions for work

JP30ZCE010101001

1. General precautions
To ensure safety in work and to prevent accidents, observe the following items :
(1) Appearance
a. Wear safety goggles.
b. Do not wear watch, necktie, ring, bracelet, necklace, etc. to prevent accident before work.
c. Bind long hair at the back.
d. Be sure to wear a cap and safety shoes.
(2) Safety work
a. Do not touch radiator, muffler, exhaust pipe, tail pipe, etc. after stop of the engine to prevent burn.
b. Do not put your clothes or tools near the rotating part (in particular, cooling fan or V–belt) during
operation of the engine.
c. Remove the starter key when the engine is not started.
d. Start the engine at a well ventilated place so that carbon monoxide may not be filled.
e. Since gas from the fuel or the battery is flammable, do not spark a fire or smoke a cigarette near the
area.
f. Since the battery fluid is poisonous and corrosive, be careful for handling.
g. Do not short-circuit the cable of the battery or starter. Otherwise, the cable may be burned or burn may occur.
h. If a tool or rag is left in the engine compartment, it may be bounced with a rotating part of the engine,
resulting in injury.
i. To tow a failure machine, refer to “Towing” in the "Operation manual" of the machine.

2. Precautions for service work

Pay attention to the following points before service work
(1) Preparation before disassembly
a. Prepare general tools, special tools and gauges before work.
b. To disassemble a complicated area, put a stamp or match mark on the location not functionally affected
to ease assembly. To repair the electric system, disconnect the cable from the minus terminal of the
battery before work.
c. Perform inspection according to the procedure in the text before disassembly.
(2) Inspection during disassembly
Every time parts are removed, check the area where the parts are assembled and check for deformation,
damage, wear or scratch.
(3) Arrangement of disassembled parts
Place removed parts neatly in order. Separate parts to be replaced from parts to be reused.
(4) Washing of disassembled parts
Clean and wash parts to be reused well.
(5) Inspection and measurement
Inspect and measure parts to be reused as required.
(6) Assembly
a. Keep the specified standard values (tightening torque, adjusting values, etc.) and assemble correct
parts in the correct order.
b. Be sure to use genuine parts for parts to be replaced.
c. Use new packing, gasket, O–ring and cotter pin.
d. Use seal gaskets for some areas where gaskets are used. Apply specified oil or grease to sliding areas
where application of oil is required, and apply specified grease to the oil seal lip before assembly.
(7) Check of adjustment
Make adjustments to the service standard values using a gauge or tester.
 GENERAL 1–9

3. Precautions for electric system

(1) Removal of battery cable

a. In an electric system, remove the cable from the

battery minus (-) terminal to prevent burnout due to
short-circuit.
Loosen
b. When the battery cable is removed, the battery
terminal may be damaged. Loosen the nut completely
and never pry it for removal.

SAPH30ZCE0100002

(2) Handling of electronic parts

a. Do not give impact on electronic parts such as

computer and relay.
b. Do not place electronic parts at a high temperature and
humidity area.
c. Do not expose electronic parts to water in washing of a
vehicle.

SAPH30ZCE0100003

(3) Handling of wire harness

a. Mark clamps and clips to prevent interference of a wire

harness with body edge, sharp edge and bolts. Be sure
to reassemble it to the original position.
b. When parts are assembled, be careful not to pinch a
wire harness.

SAPH30ZCE0100004
1–10 GENERAL

(4) Handling of connector

a. When a connector is removed, hold the connector (as

shown by the arrow in the left) and pull it out. Do not pull
the wire harness.
b. Unlock the locking connector before pulling.
c. Insert the locking connector completely until it clicks.
d. To insert a test lead into the connector, insert it from the
back of the connector.
e. If it is difficult to insert a test lead from the back of the
connector, prepare a harness for inspection.

SAPH30ZCE0100005
 GENERAL 1–11

4. Precautions for electric welding

Inadvertent electric welding on a cab or frame may cause reverse welding current from the grounding
circuit, resulting in damage to electric and electronic parts. Observe the following items for electric
welding.
(1) Turn "OFF" the starter switch.
(2) Make sure that switches are "OFF".
(3) Disconnect the minus (-) terminal of the battery according to the removal procedure of the battery cable.
(4) Disconnect connectors of each computer.
(5) Remove all fuses. (For locations of fuses, refer to "Electrical Chapter".)
(6) Be sure to connect grounding of the electric welding machine near the welding area.
Connect grounding from a bolt (plated bolt) or a frame near the welding area.
Remove paint of the frame for connection of grounding from the frame.
The seal and the bearing etc. that please make sure do not enter between the weld and the ground
section.
(7) Other precautions
a. Put a cover on rubber hoses, wire harnesses, pipes, tires, etc. around the welding area so that they
may not be exposed to spatter.
b. Perform welding under appropriate conditions and minimize heat effect in the peripheral area. Also
maintain welding quality.
(8) After welding, connect and assemble in the order of the fuse and the minus terminal of the battery
disassembled. When paint is removed from a frame or cab, apply rust preventive coating with the same
color.
(9) After reassembly, check the function if it operates correctly.
General information
1–12 GENERAL

Tightening of engine bolts and nuts

JP30ZCE010102003

1. Tightening torque of general standard bolts

(1) For bolts with seatings
Unit : N˜m{kgf˜cm, lbf˜ft}

Screw diameter x Pitch 7T 9T

M8 x 1.25 (Coarse thread) 28.5 {290, 21} 36 {370, 27}

M10 x 1.25 (Fine thread) 60 {610, 44} 74.5 {760, 55}

M10 x 1.5 (Coarse thread) 55 {560, 41} 68.5 {700, 51}

M12 x 1.25 (Fine thread) 108 {1100, 80} 136 {1390, 101}

M12 x 1.75 (Coarse thread) 97 {990, 72} 125 {1280, 93}

M14 x 1.5 (Fine thread) 171.5 {1750, 127} 216 {2210, 160}

M14 x 2 (Coarse thread) 154 {1570, 114} 199 {2030, 147}

Remark Bolt with number “7” on the head Bolt with number “9” on the head

! CAUTION • 8T bolt is in accordance with 7T bolt.

(2) For bolts with washers

Unit : N˜m{kgf˜cm, lbf˜ft}

Screw diameter x Pitch 4T 7T 9T

M6 x 1 (Coarse thread) 6 {60, 4} 10 {100, 7} 13 {130, 9}

M8 x 1.25 (Coarse thread) 14 {140, 10} 25 {250, 18} 31 {320, 23}

M10 x 1.25 (Fine thread) 29 {300, 22} 51 {520, 38} 64 {650, 47}

M10 x 1.5 (Coarse thread) 26 {270, 20} 47 {480, 35} 59 {600, 43}

M12 x 1.25 (Fine thread) 54 {550, 40} 93 {950, 69} 118 {1200, 88}

M12 x 1.75 (Coarse thread) 49 {500, 36} 83 {850, 61} 108 {1100, 80}

M14 x 1.5 (Fine thread) 83 {850, 61} 147 {1500, 108} 186 {1900, 137}

M14 x 2 (Coarse thread) 74 {750, 54} 132 {1350, 98} 172 {1750, 127}

Bolt with number “4” on

the head Bolt with number ”7” on
Bolt with number “9” on
Remark Projection bolt Stud the head Stud with C
the head
with R surface at free surface at free end
end

! CAUTION • 8T bolt is in accordance with 7T bolt.

R surface (4T) C surface (7T)

SAPH30ZCE0100006
 GENERAL 1–13

2. Precoated bolt
Precoated bolt is the bolt with application of seal lock
agent at the thread.

(1) When re-application of lock agent is required

a. When precoated bolts are removed
b. When precoated bolts are moved due to tightening
Seal Lock Agent check (for loosening or tightening)

NOTICE • Check torque with the lower limit of the

SAPH30ZCE0100007 tightening torque allowable value. If
movement is found, tighten the bolt
according to the procedure below.

(2) Re-use method of precoated bolt lock

a. Clean bolt and screw holes. (Clean screw holes for
replacement.)
b. Dry completely by blowing air.
c. Apply the specified seal lock agent to the thread of the
bolt.

3. Plastic region tightening method (angle method)

! CAUTION • Some engines are tightened with the plastic

region tightening method.
• Since it is different from the conventional
method, tighten it according to the instruction
in the text.

Example
One turn by 90q One turn by 90q Two turn by 90q Tighten it 90q
Tighten it 45q (Second time)
One turn by 45q (Second time)
Tighten it 90q
Tighten it 90q Tighten it 90q
(First time) (First time)

SAPH30ZCE0100008

(1) Parts tightened

Cylinder head bolt, crankshaft main bearing cap bolt,
connecting rod bearing cap bolt, etc.

! CAUTION • Measure the overall length of the bolt before

assembly and replace the bolt if the length
exceeds the operation limit.
Apply engine oil to bolt seating and bolt
thread in assembly.

(2) Tightening method after tightening to seating torque

Tightening of 90q, 135q(90qonce and 45qonce) and
180q(90qtwice) is available.
1–14 GENERAL

Tightening of flare nuts and hoses

JP30ZCE010102004

1. Tightening torque of pipe flare nut

Unit : N˜m{kgf˜cm, lbf˜ft}

Pipe outer
diameter I4.76 I6.35 I8 I10 I12 I15

15r5 21r1 32r3 44r5 64r5 66r2.5

Tightening
{153r50, {214r10, {326r31, {449r51, {653r51, {673r25,
torque
11r3.6} 15r0.7} 24r2.2} 32r3.6} 47r3.6} 47r1.8}

2. Tightening torque of hoses

Unit : N˜m{kgf˜cm, lbf˜ft}
Hose outer diameter
Hose outer diameter Hose outer diameter
Type I13, I20, I22, fitting at
I10.5 fitting PF3/8 fitting
packing

21.5r1.5 {215r15, 15r1}

Air hose Only meter gauge 46r2.5 {469r25, 33r1.8} —
10 {100, 7}
Packing
Brake hose 46r2.5 {469r25, 33r1.8} —
51.5r7.5 {525r75, 15r1}

3. Lock nut tightening torque of brass joint

Unit : N˜m{kgf˜cm, lbf˜ft}
Screw nominal
M14 M16 M20 M22 M24
size

48r10 66r13 120r36 130r30 150r30

Tightening
{489r102, {673r204, {1224r367, {1326r306, {1530r306,
torque
35r7} 47r14} 89r26} 96r22} 110r22}
 GENERAL 1–15

Taper thread sealant for piping

JP30ZCE010102005

The taper thread of the air pipe joint has application of sealant
[Loctite # 575 (by Japan Loctite)]. Follow the procedures below for
connection or disconnection of pipes.

1. For disconnection
Removal of joint (Example: Use of magnetic valve)
Magnetic valve
(1) The sealant ( # Loctite 575) has strong sealing feature.
Frame Air pipe (Flare joint) The return torque of the taper joint is increased about 1.5
(No application of sealant)
times the initial tightening torque. When the joint is
Since sealant is
disconnected, use a long wrench for disconnection
applied to this (2) When a joint at a poorly accessible area is replaced,
area, remove
accessories with remove accessories first and disconnect the joint.
the joint attached
Air hose

SAPH30ZCE0100009

2. For connection

(1) For application of sealant ( # Loctite 575), wipe the

1/4 turn Amount of application: 0.1 g/piece
sealing area completely with a rag or thinner. Apply
sealant directly to about three ridges for quarter round
3 threads with offset of one ridge from the end. Tighten it according
1 thread
to the tightening torque in the table below.
Remove dirt completely from the mating part (female)
before tightening.

SAPH30ZCE0100010 ! CAUTION • If your eye or skin comes in contact with

sealant, wash it off immediately with water.

Tightening torque of taper joint Unit : N˜m{kgf˜cm, lbf˜ft}

Screw diameter
Material
1/4 3/8 1/2

49r10 64r15
Steel {500r100, {650r150,
36r7} 47r10}

25r5 34r5 44r5

Aluminum
{250r50, {350r50, {450r50,
or brass
18r3} 25r3} 32r3}

(2) When a sealing tape is replaced with sealant, remove the

tape completely first as in (1).

! CAUTION • Be careful to prevent entry of dirt or foreign

matter in the pipe.

(3) If air leak is found after assembly with application of

sealant, air leak cannot be stopped with additional
tightening. Assemble the part again according to (1) and
(2).
1–16 GENERAL

Assembly of joints and gaskets for piping

JP30ZCE010102006

1. Tightening torque of joints

Unit : N˜m{kgf˜cm, lbf˜ft}

Sealing method

Metal sealing method

Screw size Gasket sealing method
(Flare pipe type, nipple connector type)
(Aluminum + Rubber or Copper)
Type A Type B

M8 13 {130, 9}

M10 20 {200, 14} 11 {110, 8}

M12 25 {250, 18} 20 {200, 14}

M14 25 {250, 18} 31 {320, 23}

M16 29 {300, 22} 39 {400, 29}

M18 39 {400, 29} 59 {600, 43}

M20 *39 {400, 29} 64 {650, 47} 20 {200, 14}

M24 69 {700, 51}

M28 *127 {1300, 94}

2. Joint assembly procedure and subsequent inspection

(1) Before assembly, make sure that there is no dirt or burr on the seating surface (mating part, pipe joint,
gasket, etc.).
(2) Since pipes have some degrees of freedom for assembly, the seating surface tends to incline. Tighten
pipes finally after temporary tightening to prevent leak.
(3) After tightening, apply the specified pressure to each pipe joint to ensure that there is no leak.
(4) Observe the values above for each tightening torque.
*When assembled soft washer # 4840FR-N (aluminum and rubber carbon pressure bonding) is loosened
or removed, be sure to replace it with a new part. This is not necessary for normal retightening.
 GENERAL 1–17

3. Examples of joint methods in various pipes

Metal sealing method

Gasket sealing method Type A Type B
(Flare pipe type) (Nipple connector type)

Joint bolt Sealing surface: 3 places

Flare pipe
Gasket Connector Nut
Flare nut
Connector nipple
Joint bolt

Sealing surface
: 4 places
Flare connector
Gasket
One piece eye joint Gasket
with sleeve
Gasket Sealing surface
Gasket : 5 places Sealing surface: 5 places

Nut
Lock washer Bracket
Joint bolt
Nut

Sealing surface
: 8 places Connector nipple

Sealing surface: 1 place

Sealing surface: 1 place
Flare connector

Nut Lock washer

Box nut
3-way joint
Sealing surface
: 8 places

Joint pipe

Bracket
Sealing surface
: 3 places

One piece eye joint without sleeve

Joint bolt

Sealing surface: 4 places

Joint bolt

Joint pipe

Sealing surface: 6 places

1–18 GENERAL

Handling of liquid gasket

JP30ZCE010102007

1. Application of liquid gasket and part assembly procedure

(1) Remove old liquid gasket on each part and mating part completely. Clean the parts with a rag to prevent
deposit of oil, moisture, dirt, etc.
Be sure to overlap parts at the beginning and at the end of application.
(2) Be careful for offset with the mating part when a part applied with liquid gasket is assembled. Apply the
liquid gasket again if offset occurs.
(3) Assemble parts within 20 minutes after application of the liquid gasket.
If 20 minutes has passed, remove the liquid gasket and apply it again.
(4) Start the engine at least 15 minutes or more after assembly of parts.

2. Removal of parts
(1) When parts are removed, do not pry one place only. Remove parts by prying each other using collar or
clearance on the flange. When gasket is removed, be careful to prevent entry of gasket offal into the
engine.

3. Others
(1) When the liquid gasket is contained in a tube, use the accompanying winding tool. When it is contained in
a cartridge, use the application gun.

Winding tool
Application gun

Tube: 150 g Cartridge type: 300 g

For a tube, desired application width may be obtained from the cut position at the nozzle end.

1 : Approx. 2 mm at the 1st section cut

2 : Approx. 5 mm at the 2nd section cut

Nozzle of tube
General information
Description of function
 GENERAL 1–19

Failure diagnosis table for each problem

JP30ZCE010301001

Engine mechanical Causes and actions are described for each item.
JP03Z01020601001

Status Cause Action

Engine overheat (coolant) Insufficient coolant Replenish coolant
Faulty thermostat Replace thermostat
Water leak from cooling system Correction
Faulty coolant pump Repair or replace
Faulty head gasket Replace head gasket
Engine overheat Clogging of radiator Cleaning of radiator
(radiator) Corrosion of cooling system Clean and repair cooling system
Clogging of radiator core front part Clean radiator
Faulty radiator cap Replace radiator cap
Engine overheat (compression Non-synchronous injection timing Adjust injection timing.
pressure) Faulty fuel injection pressure Adjust injection pressure
Faulty fuel Replace with correct fuel
Faulty injector Replace injector
Engine overheat (lubrication Deterioration of engine oil Replace engine oil
unit) Faulty oil pump Replace oil pump
Insufficient engine oil Replenish engine oil
Large engine oil consumption Wear of piston ring and cylinder Replace piston ring and cylinder
(piston, cylinder liner and piston liner liner
ring) Damage to piston ring Replace piston ring and cylinder
liner
Faulty fixing of piston ring Replace piston ring and cylinder
liner
Faulty assembly of piston ring Replace piston ring and cylinder
liner
Faulty engine oil Replace engine oil
Faulty piston ring joint Reassemble piston ring
Large engine oil consumption Wear of valve stem Replace valve and valve guide
(valve and valve guide) Wear of vavle guide Replace valve guide
Faulty assembly of valve stem seal Replace stem seal
Excessive oil lubrication to rocker Inspection of clearance between
arm rocker arm and rocker arm shaft
Large engine oil consumption Faulty oil level gauge Replace with correct level gauge
(others) Excessive filling of engine oil Fill with appropriate amount of oil.
Leak of engine oil Repair or replace the part of oil
leak.
Piston seizure (in operation) Sudden stop of engine Perform warm-up before stop of
engine
Piston seizure (lubrication unit) Insufficient engine oil Replenish engine oil
Deterioration of engine oil Replace engine oil
Incorrect engine oil Replace with correct engine oil.
Low oil pressure Inspection of lubrication unit
Faulty oil pump Replace oil pump
Piston seizure Abnormal combustion Refer to overheat section.
Piston seizure Cooling unit Refer to overheat section.
SAPH30ZCE0100024
1–20 GENERAL

Failure diagnosis procedures

JP30ZCE010301002

1. Display of failure code

(1) If the system has an error, the failure code is displayed on the multiple display of cluster gauge.

Multiple display

Job mode selecting switch

Buzzer stop switch

SAPH30ZCE0100025

2. Deletion method of past failure

(1) To delete past failures of the engine ECU, use HinoDX on
the PC. (Refer to "HinoDX operation manual".)

SAPH30ZCE0100026

3. Deletion of cluster gauge past failure

(1) Turn "ON" the starter switch during pushing the buzzer
stop switch.

(2) When pushing the enter key 3 times during pushing the
buzzer stop switch, the failure history mode is displayed.
(3) Press work mode selecting switch and the buzzer stop
switch at the same time for 10 seconds or more.
(4) When the display shows "No error", deletion is
completed.
SAPH30ZCE0100027
(5) Turn "OFF" the starter switch.
 GENERAL 1–21

4. How to read troubleshooting for each diagnosis monitor code

(1) "Diagnosis code table" and "Troubleshooting for each code" are described for each system that gives
output of the diagnosis monitor code. When the diagnosis monitor code is known, troubleshooting can be
started from the code list.

ENGINE DIAGNOSIS CODE [Engine Common] 3–15

Failure of main speed sensor (DTC code P0335/diagnosis monitor code 13)
JP03Z01030601004

1 Measurement of resistance between terminals

1. Set the starter key to "LOCK" and connect the signal check
B6 B B7 harness.

2. Remove the ECU side connector of the signal check harness

and meausre the resistance between terminal B6 and terminal
B7. Details of work
Standard value : Approx. 125.5 17 (20 dC)

NG [3] Go to measurement of resistance between sensor terminals.

SAPH03Z010300010

OK

2 Check of diagnosis code

1. Connect the ECU side connector of the signal check harness.

After deleting the past failure, output the diagnosis code again.

Standard : Normal

NG Contact failure of ECU connector, ECU failure,

short-circuit of harness

SAPH03Z010300011

OK

Normal

3 Measurement of resistance between terminals

1. Remove the connector of the main engine speed sensor and

measure the resistance between No. 1 and No. 2 terminals at
the sensor.

Standard value : Approx. 125.5 17 (20 dC)

NG Failure of main engine speed sensor

Indicates replacement of the main

SAPH03Z010300012
engine revolution sensor.

OK
Check the harness of the relevant circuit and repair the faulty area.

Harness disconnection or connector failure

SAPH30ZCE0100028
1–22 GENERAL

Failure diagnosis using HinoDX

JP30ZCE010301003

! CAUTION • HinoDX is used for inspection and adjustment

of the system in addition to failure diagnosis.

1. HinoDX

(1) With HinoDX, failure of the common rail fuel injection

system can be diagnosed. The interface box (Hino-
Bowie) and the special cable are required for connection
to the vehicle.

SAPH30ZCE0100029

2. List of failure diagnosis tools

Part name Part No. External shape General description and function

• Operating system(OS) :
Windows95,
Windows98(IE5.0 or later),
Windows2000(SP3, IE5.0 or later),
PC WindowsXP(SP1a, IE6.0 or later)
—
(DOS/V standard) • CPU and memory :
Conditions that assure operation of the
above operating system
• Display : 800 x 600, 256 colors or
more

• Software and CD-ROM

NOTICE

Hino Diagnostic • Install the software of the Hino

eXplorer — Diagnostic eXplorer (HinoDX)
(HinoDX) in the PC. For the installation
method, refer to the
instruction manual
accompanying the CD.

• PC interface

09993 - E9070 ! CAUTION

• It is necessary to update
hardware.

• The cable between the personal

Hino-Bowie
computer and the Hino-Bowie is
bundled to the Hino-Bowie.
— • Please use either RS-232C or USB.

Cable bundled
to the Hino-Bowie
 GENERAL 1–23

Part name Part No. External shape General description and function

Cable for machine side diagnosis

connector.
Cable between
S0904-21220
machine and Hino-
(09042-1220)
Bowie
Cable between
machine
and Hino-Bowie

Interrupting installation between vehicle

harness and ECU allows inspection with a
Signal check tester rod while the power is supplied.
09843-E4010
harness
1–24 GENERAL

3. Connection of signal check harness

(1) To prevent damage to the ECU connector and to improve accessibility, connect the signal check harness
and put a testing lead on the signal check connector of the signal check harness for meaurement.

Engine ECU

Engine Machine
harness harness

Test lead

Signal check connector

SAPH30ZCE0100037

a. Disconnect the connector from the ECU.

! CAUTION • Do not break the locking tab of the connector.

b. Connect the signal check harness to the engine harness, machine harness and engine ECU.
Part No.
09843 - E4010
Signal check harness (for engine control system)
 GENERAL 1–25

(2) Terminal No.

For the signal check harness connector, the ECU terminal number in the text is treated as follows :

Signal check harness(for engine control system)

Engine ECU

Engine side Machine side

harness harness

Engine Machine
harness harness

SAPH30ZCE0100038
1–26 GENERAL

Connection method of HinoDX

JP30ZCE010301004

1. Removal of the maintenance cover

Maintenance cover (1) Remove the maintenance cover on the rear cover behind
the operator seat by pushing down the tab at the top (at
one location).

NOTICE • The engine fault diagnosis connector (16 P) is

on the inside.

SAPH30ZCE0100039

2. Connection of HinoDX
(1) Connect the engine failure diagnosis connector to the PC
Mechatronic contoroller which installed Hino–DX through the interface box.

Special tool : 09993-E9070 Hino-Bowie

(Interface box)
S0904 - 21220 (09042-1220)
Connecting cable
CD-ROM HinoDX

(2) Set the starter key to "ON" and start HinoDX.

Engine failure
diagnostic connector

SAPH30ZCE0100040

Failure diagnosis connector

Hino-Bowie

Connect to the failure diagnosis Connecting cable

connector at the unit side.
SAPH30ZCE0100041

Setup layout
Layout
 GENERAL 1–27

Engine number
JP30ZCE010401001

1. Engine type and engine number

(Example) (1) Engine type and engine number are stamped at the left
cylinder block when viewed from the cooling fan. For order
of parts, information of this number will facilitate
procedures smoothly.
Ex. J08E TA10003

Stamp position

SAPH30ZCE0100042
 STANDARD VALUE 2–1

ENGINE

2 STANDARD VALUE 2
Specification
System drawing
(performance)

Engine Mounting/Dismounting ................................. 2-2

Standard value........................................................ 2-2
Fuel System ................................................................ 2-2
Tightening torque .................................................... 2-2
Emission Control........................................................ 2-3
Tightening torque .................................................... 2-3
Electrical...................................................................... 2-3
Standard value........................................................ 2-3
Tightening torque .................................................... 2-3
Intake ........................................................................... 2-4
Tightening torque .................................................... 2-4
Engine Mechanical ..................................................... 2-4
Standard value........................................................ 2-4
Tightening torque .................................................. 2-11
Exhaust...................................................................... 2-12
Tightening torque .................................................. 2-12
Cooling ...................................................................... 2-12
Standard value...................................................... 2-12
Lubrication ................................................................ 2-13
Standard value...................................................... 2-13
Tightening torque .................................................. 2-14
Starting and Charging.............................................. 2-15
Standard value (starter) ........................................ 2-15
Tightening torque (starter) .................................... 2-16
Standard value (alternator 60A) ........................... 2-17
Tightening torque (alternator 60A)........................ 2-18
Turbocharger............................................................. 2-19
Standard value...................................................... 2-19
Tightening torque .................................................. 2-19
2–2 STANDARD VALUE

Engine Mounting/Dismounting
Standard value
JP30ZCE020205001

Unit : MPa {kgf/cm2, lbf/in.2}

Inspection item Standard value Repair limit Service limit Action

3.4 - 3.7 3.1 - 3.2

Compression pressure
{35 - 37, — {31 - 32,
(Engine revolution per cylinder: 280 r/min)
494 - 536} 450 - 464}

Fuel System
Tightening torque
JP30ZCE020205002

Unit : N˜m{kgf˜cm, lbf˜ft}

Tightening area Tightening torque Remark

Injector clamp holder fixing bolt 25 {250, 18}

Supply pump - Bearing holder case 28.5 {290, 21}

Bearing holder case - Pump drive 28.5 {290, 21}

Supply pump coupling flange mounting nut 63.7 {650, 47}

Fuel filter (Engine side) air bleeding bolt 1.7 - 2.26 {17.3 - 23, 1.3 - 1.7}

Fuel filter (Engine side) drain plug 6.9 r 2 {70 r 20 , 5.0 r 1.4}

Fuel filter (Engine side) center bolt 29.4 r 4.9 {300 r 50, 21.7 r 3.6}

Fuel filter (Engine side) case mounting bolt 55 {560, 40}

Supply pump drive - Flywheel housing 28.5 {290, 21}

Common rail mounting bolt 28.5 {290, 21}

Fuel filter (Machine side) air vent plug 1.7 - 2.3 {18 - 23, 1.3 - 1.6}

Fuel filter (Machine side) element 10r1 {102r10, 21r0.7}

Fuel filter (Machine side) bowl 10r1 {102r10, 21r0.7}

Fuel filter (Machine side) drain plug 5r1 {51r10, 3.7r0.7}

Bearing holder mounting bolt 6.0-7.5 {60-75, 4.4-5.4}

Coupling mounting bolt 30-36 {305-360, 22-26}

Injection pump
drive housing Drive gear mounting nut 353 {3600, 260}
Injection pump drive housing -
28.5 {290, 21}
Bearing case assembly
 STANDARD VALUE 2–3

Emission Control
Tightening torque
JP30ZCE020205003

Unit : N˜m{kgf˜cm, lbf˜ft}

Tightening area Tightening torque Remark

EGR cooler mounting bolt 36 {367, 26}

EGR cooler - Exhaust manifold 68.5 {700, 51}

EGR pipe A mounting bolt 55 {560, 41}

Electrical
Standard value
JP30ZCE020205004

Inspection item Standard value Remark

3 - 5mm {0.1182 - 0.1968in.} Compression gauge

Deflection (Reference push force 98N S0944-41210
{10kgf, 22lbf}) (09444-1210) is used.
V ribbed belt tension MITSUBOSHI
adjustment BELTING LTD. Belt
1,372 N
Tension Tension Meter
{140kgf, 308 lbf}
(DOCTOR TENSION£
TYPE-III) is used.

Tightening torque
JP30ZCE020205005

Unit : N˜m{kgf˜cm, lbf˜tt}

Tightening area Tightening torque Remark

Starter mounting nut and bolt 154 {1570, 114}

Alternator through bolt 83 {850, 61}

Alternator fixing nut at brace 51 {520, 38}

Alternator adjustment bolt 5.9 {60, 4}

Engine ECU mounting bolt 28.5 {290, 21}

Engine main revolution sensor 10 {102, 7.4}

Engine sub revolution sensor 4 - 6 {41 - 61, 3 - 4.4}

2–4 STANDARD VALUE

Intake
Tightening torque
JP30ZCE020205006

Unit : N˜m{kgf˜cm, lbf˜ft}

Tightening area Tightening torque Remark

Intake manifold mounting bolt 28.5 {290, 21}

Intake throttle valve mounting bolt 28.5 {290, 21}

Intake pipe - Intake manifold 55 {560, 41}

Engine Mechanical
Standard value
JP30ZCE020205007

Unit : mm {in.}

Inspection item Standard value Repair limit Service limit Action

IN 0.30 {0.0118} — —
Valve clearance (cold)
EX 0.45 {0.0177} — —

0.01 - 0.08
Cylinder liner protrusion — —
{0.003 - 0.0013}

117 - 117.008
A — —
{4.6063 - 4.6066}

117.008 - 117.014
Cylinder block inner diameter B — —
{4.6066 - 4.6068}

117.014 - 117.022
C — —
{4.6068 - 4.6072}

116.982 - 116.99
A — —
{4.6056 - 4.6059}

116.99 - 116.996
Cylinder liner outer diameter B — —
{4.6059 - 4.6061}

116.996 - 117.004
C — —
{4.6061 - 4.6064}

Cylinder
112.15
Cylinder liner inner diameter 112 {4.4094} — Replace
{4.4154}
liner
Piston outer diameter
111.9r0.008
(Pin hole 23mm {0.9055 in.} above the — —
{4.4055r0.0003}
lower end of the skirt Square direction)

Cylinder
0.053 - 0.077 Liner
Piston clearance — —
{0.0021 - 0.0030} Replace
piston
 STANDARD VALUE 2–5

Inspection item Standard value Repair limit Service limit Action

0.30 - 0.40
Top — 1.5 {0.0591}
{0.0118 - 0.0157}
Cylinder liner
0.75 - 0.90 Replace
Joint for assembly Second — 1.5 {0.0591}
{0.0295 - 0.0354} piston ring
Clearance
0.15 - 0.30
Oil — 1.2 {0.0472}
Piston {0.0059 - 0.1181}
ring 2.848
Top 2.948 {0.1161} —
{0.1121}

Ring width B 1.9 Replace

Second 2 {0.0787} —
dimension {0.0748} piston ring

3.9
Oil 4 {0.1574} —
{0.1535}
Top Tapered shape — —

2.2
Second 2.0 {0.0787} — Replace
Piston ring groove {0.0866}
piston
4.1
Oil 4.0 {0.1574} —
{0.1614}
Piston 36.96 Replace
Piston pin outer diameter 37 {1.4567} —
{1.4551} piston pin

37.05 Replace
Piston boss inner diameter 37 {1.4567} —
{1.4587} piston

Replace
Clearance between piston pin 0.011 - 0.032 0.05
— piston pin
and piston boss {0.0005 - 0.0012} {0.0020}
or piston

Replace
37.1
Connecting rod bushing inner diameter 37 {1.4567} — connecting
{1.4606}
rod bushing

Replace
0.035 - 0.056 0.08 piston pin or
Connecting rod bushing oil clearance —
{0.0014 - 0.0022} {0.0031} connecting
rod bushing
2–6 STANDARD VALUE

Inspection item Standard value Repair limit Service limit Action

64.3 Replace the

Crank pin outer diameter 65 {2.5590} —
{2.5315} crankshaft.

Replace
bearing for
0.031 - 0.082
Connecting rod oil clearance 0.2 {0.0079} — clearance
{0.0012 - 0.0032}
of 0.3 or
more

0.20 - 0.52 1.0 Replace

Connecting rod end play —
{0.0079 - 0.0204} {0.0394} crankshaft

79.3 Replace
Crank journal outer diameter 80 {3.1496} —
{3.1221} crankshaft
Crank- Replace
shaft bearing for
0.051 - 0.102
Crankshaft oil clearance 0.2 {0.0079} — clearance
{0.0020 - 0.0040}
of 0.3 or
more

37.0 Replace
Center journal width 36 {1.4173} —
{1.4567} crankshaft.

Replace
0.05 - 0.270 0.5 1.270 thrust
Crankshaft end play
{0.0020 - 0.0106} {0.0197} {0.0500} bearing or
crankshaft

0 - 0.1 0.15
Crankshaft runout — Replace
{0 - 0.0039} {0.0059}

Camshaft journal outer 39.85

40 {1.5748} —
diameter {1.5689}
Replace
Camshaft bearing inner 40.15
40 {1.5748} — camshaft
diameter {1.5807}
or bearing
Camshaft bearing oil 0.020 - 0.063
— —
Clearance {0.0008 - 0.0025}

Cam- 49.987
IN 50.067 {1.9711} —
shaft {1.9680}
Cam height
52.024
EX 52.104 {2.0513} —
{2.0482} Replace
(7.987 camshaft
IN 8.067 {0.3176} —
{0.3144})
Cam lift
(10.024
EX 10.104 {0.3978} —
{0.3947})

0.100 - 0.178 Replace

Camshaft end play — —
Cam- {0.0039 - 0.0070} camshaft
shaft 0.04 Replace
Camshaft runout — 0.1 {0.039}
{0.0016} camshaft
 STANDARD VALUE 2–7

Inspection item Standard value Repair limit Service limit Action

21.92 Replace
Rocker shaft outer diameter 22 {0.8661} —
{0.8630} rocker shaft

Replace
22.08
Rocker arm bushing inner diameter 22 {0.8661} — rocker arm
{0.8693}
bushing

Replace
rocker shaft
0.030 - 0.101 0.15
Rocker arm oil clearance — or rocker
{0.0012 - 0.0040} {0.0059}
arm
bushing

IN 7 {0.2756} — — Replace
Valve stem outer diameter
EX 7 {0.2756} — — valve

IN 7 {0.2756} — — Replace
Valve guide inner diameter
EX 7 {0.2756} — — valve guide

0.023 - 0.058
IN — — Replace
Oil clearance between valve guide {0.0009 - 0.0023}
valve or
and valve stem 0.050 - 0.083
EX — — valve guide
{0.0020 - 0.0033}

0.55 - 0.85
IN — 1.1 {0.0433} Replace
{0.0217 - 0.0335}
Valve sink valve and
1.15 - 1.45
EX — 1.7 {0.0669} valve seat
{0.0453 - 0.0571}

IN 30q Allowable angle 30q - 30q35'

Valve seat angle
EX 45q Allowable angle 45q - 45q30'
Correction
IN 30q Allowable angle 29q30 - 30q
Valve face angle
EX 45q Allowable angle 44q30 - 45q
A value
A 3.2 {0.1260} — added C
value or B
value added
Valve spring seat B 5.5 {0.2165} —
C value is
exceeding 1
mm {0.0394
C 1.0 {0.0394} —
in}.
2–8 STANDARD VALUE

Inspection item Standard value Repair limit Service limit Action

Set length 44.8 {1.764} — —

129N
Set load — —
{13.1kgf}
Inner 64.6 61.6 Replace
Free length —
{2.5433} {2.4252} spring
2.0 Replace
Squareness — —
{0.0787} spring
Valve
46.8
spring Set length — —
{1.8252}

314N
Set load — —
{32.0kgf}
Outer
75.7 72.7 Replace
Free length —
{2.9803} {2.8622} spring

2.0 Replace
Squareness — —
{0.0787} spring
 STANDARD VALUE 2–9

Inspection item Standard value Repair limit Service limit Action

Main idle - Pump drive 0.032 - 0.096 0.30

—
idle {0.0013 - 0.0038} {0.0118}

Pump drive idle - 0.020 - 0.083 0.10

—
Pump drive {0.0008 - 0.0033} {0.0039}

0.030 - 0.113 0.30

Main idle - Sub-idle —
Back- {0.0012 - 0.0044} {0.0118}
lash 0.030 - 0.131 0.30
Sub-idle - Oil pump — Replace
{0.0012 - 0.0052} {0.0118}
gear
0.030 - 0.218 0.30
Sub-idle - Cam idle —
{0.0012 - 0.0086} {0.0118}

0.030 - 0.253 0.30

Cam idle - Cam —
{0.0012 - 0.0100} {0.0118}
Shaft outer diameter 57{2.2441} — —

Bushing inner
57{2.2441} — —
diameter

Replace
Clearance between 0.030 - 0.090 0.20
Timing — shaft or
Main shaft and bushing {0.0012 - 0.0035} {0.0079}
gear bushing
idle
Gear width 44 {1.7322} — —

Shaft length 44 {1.7322} — —

Replace
0.114 - 0.160 0.30
End play — shaft or
{0.0045 - 0.0063} {0.0118}
gear
Shaft outer diameter 50 {1.9685} — —

Bushing inner
50 {1.9685} — —
diameter

Replace
Clearance between 0.025 - 0.075 0.20
— shaft or
Sub- shaft and bushing {0.0010 - 0.0030} {0.0079}
bushing
idle
Gear width 22 {0.8661} — —

Shaft length 22 {0.8661} — —

Replace
0.040 - 0.120 0.30
End play — shaft or
{0.0016 - 0.0047} {0.0118}
gear
2–10 STANDARD VALUE

Inspection item Standard value Repair limit Service limit Action

Shaft outer diameter 34 {1.3386} — —

Bushing inner
34 {1.3386} — —
diameter

Clearance between 0.025 - 0.075 0.20 Replace shaft

Cam —
shaft and bushing {0.0010 - 0.0030} {0.0079} or bushing
idle
Gear width 22 {8.6614} — —

Shaft length 22 {8.6614} — —

0.040 - 0.120 0.30 Replace thrust

End play —
Timing {0.0016 - 0.0047} {0.0118} plate or gear
gear Shaft outer diameter 34 {1.3386} — —

Bushing inner
34 {1.3386} — —
diameter

Pump Clearance between 0.025 - 0.057 0.10 Replace shaft

—
drive shaft and bushing {0.0010 - 0.0022} {0.0039} or bushing
idle Gear width 28.5 {0.9605} — —

Shaft length 28.5 {0.9605} — —

0.016 - 0.22
End play — —
{0.0006 - 0.0087}

Longitudinal Grinding is
0.2
direction — inhibited
{0.0079}
0.06 {0.0024} because
backlash
Flatness under cylinder head
between
Flatness above cylinder block
Lateral direction 0.2 cam idle –
— sub-idle
0.03 {0.0012} {0.0079}
gears is
changed.

0.15
Surface runout of flywheel — —
{0.0060}

Camshaft gear mounting bolt 30.0 {1.1811} — 30.5 {1.2010} Replace

108.0
Bearing cap bolt (Crankshaft mounting) 106.8 {4.2047} — Replace
{4.2520}

Connecting rod bolt 67.0 {2.6378} — 68.0 {2.6772} Replace

126.5
Head bolt 126 {4.9606} — Replace
{4.9803}

Valve timing

Exhaust valve open (before BDC) 54q

Exhaust valve close (after TDC) 13q

Intake valve open (before TDC) 14q

Intake valve close (after BDC) 30q

 STANDARD VALUE 2–11

Tightening torque
JP30ZCE020205008

Unit : N˜m{kgf˜cm, lbf˜ft}

Tightening area Tightening torque Remark

Crankshaft pulley mounting bolt 118 {1200, 87}

Head cover mounting bolt 28.5 {290, 21}

Camshaft bearing cap mounting bolt 28.5 {290, 21}

Union bolt of leakage pipe 13.5 {135, 10}

Injector harness mounting nut 28 {290, 21}

Camshaft gear mounting bolt 59 {600, 44}+90q

Camshaft housing mounting bolt 23 {230, 17}

Cylinder plug mounting torx bolt 6 {60, 4}

Rocker arm and crosshead adjusting screw lock

25 {250, 18}
nut

Rocker arm support bolt 59 {600, 44}

59 {600, 44}+90q+90q M12

Head bolt
59 {600, 44} M10

Cam idle gear shaft mounting bolt 108 {1100, 80}

Main bearing cap mounting bolt 69 {700, 51}+90q+45q Refer to the main text.

Connecting rod cap mounting nut 69 {700, 51}+90q+45q

Oil check valve 22 {220, 16}

Sub-idle gear shaft mounting bolt 108 {1100, 80}

Main idle gear shaft mounting bolt 172 {1750, 127}

Flywheel mounting bolt 186 {1900, 137} Refer to the main text.
196 {2000, 145} M16

Flywheel housing mounting bolt 55 {560, 41} M10

36 {370, 27} M8
Flywheel housing stay - Cylinder block 97 {990, 72} M12

Flywheel housing stay - Flywheel housing 171.5 {1750, 127} M14

Rear end plate torx bolt 55 {560, 41}

Supply pump bearing case mounting bolt 28.5 {290, 21}

Pump drive idle gear shaft mounting bolt 108 {1100, 80}
2–12 STANDARD VALUE

Exhaust
Tightening torque
JP30ZCE020205009

Unit : N˜m{kgf˜cm, lbf˜ft}

Tightening area Tightening torque Remark

Exhaust manifold mounting stud bolt 30 {300, 22}

Exhaust manifold mounting nut 53 {540, 40}

DPR cleaner bracket mounting nut 83 {846, 61}

DPR filter - Muffler 35r5 {360r50, 26r3}

DPR cleaner - Turbocharger outlet pipe 68.5 {699, 44}

DPR exhaust temperature sensor 30 {306, 22}

Cooling
Standard value
JP30ZCE020205010

Standard Repair Service

Inspection item Action
value limit limit

74.5 - 78.5qC
Thermostat valve open temperature {166.1 - — — Replace
173.3qF}

Thermostat valve lift 13mm {0.5118

— — Replace
(Set temperature 95 qC) in.} or more

Inspection item Standard value Remark

3 - 5mm {0.1182 - 0.1968in.} Compression gauge

Deflection (Reference push force 98N S0944-41210
{10kgf, 22lbf}) (09444-1210) is used.
V ribbed belt tension MITSUBOSHI
adjustment BELTING LTD. Belt
1,372 N
Tension Tension Meter
{140kgf, 308 lbf}
(DOCTOR TENSION£
TYPE-III) is used.
 STANDARD VALUE 2–13

Lubrication
Standard value
JP30ZCE020205011

Unit : mm {in.}
Repair Service
Inspection item Standard value Action
limit limit

39kPa
Oil pressure warning switch operation pressure {0.4kgf/cm2, — —
5.66lbf/in.2}

Outer diameter of drive gear 54 {2.1260} — —

Cylinder block side
54 {2.1260} — —
Oil pump chamber inner diameter

Clearance between drive gear and cylinder 0.093 - 0.252 0.30 Replace drive
—
block {0.0037 - 0.0099} {0.0118} gear or oil pump

Drive gear width 43 {1.6929} — —

Cylinder block side. Depth of oil pump chamber 43 {1.6929} — —

0.047 - 0.15 0.15 Replace drive

Gasket use —
{0.0019 - 0.0059} {0.0059} gear or oil pump
Drive gear end play
-0.013 - 0.05
No gasket — —
{-0.0005 - 0.0020}

Oil Outer diameter of drive gear shaft 18 {0.7087} — —

pump
Cylinder block hole diameter 18 {0.7087} — —

Clearance between drive gear shaft outer Replace drive

0.040 - 0.099
diameter and bushing inner diameter at — — gear or
{0.0016 - 0.0039}
cylinder block side bushing
Clearance between driven gear shaft outer 0.030 - 0.075 Replace oil
— —
diameter and cylinder block hole diameter {0.0012 - 0.0030} pump

Outer diameter of driven gear shaft 18 {0.7087} — —

Inner diameter of driven gear bushing 18 {0.7087} — —

Clearance between driven gear shaft outer 0.040 - 0.083 0.15 Replace oil
—
diameter and gear bushing inner diameter {0.0016 - 0.0033} {0.0059} pump or bushing

Backlash between drive gear and driven 0.073 - 0.207 0.30 Replace oil
—
gear {0.0029 - 0.0082} {0.0118} pump
2–14 STANDARD VALUE

Tightening torque
JP30ZCE020205012

Unit : N˜m{kgf˜cm, lbf˜ft}

Tightening area Tightening torque Remark

Oil pan mounting bolt 30 {300, 22}

Oil strainer 31 {320, 23}

Oil pan drain valve 41 {420, 30}

Oil pump mounting bolt 28.5 {290, 21}

M14 24.5r4.9 {250r50, 18r4}

M20 24.5r4.9 {250r50, 18r4}

Oil circuit spring plug
Oil cooler M22 29.4r4.9 {300r50, 22r4}

M24 34.3r4.9 {350r50, 25r4}

Coolant drain plug 44.1r4.9 {450r50, 33r4}

Oil cooler case assembly mounting bolt 24.5r4.9 {250r50, 18r4}

Oil cooler element mounting nut 24.5r4.9 {250r50, 18r4}

 STANDARD VALUE 2–15

Starting and Charging

Standard value (starter)
JP30ZCE020205013

Unit : mm {in.}
Standard
Inspection item Service limit Action
value

Resistance between coil lead Replace yoke

Yoke — 1k: or less
wire and yoke assembly
assembly
Brush length 18 {0.7087} 13 {0.5118} or less Replace brush
1k: or less
Resistance between
1M: or more (Use 500V megger
commutator and core
tester)
Replace armature
Commutator outer diameter 36 {1.4173} 34 {1.3386} or less assembly
Armature
Shaft outer diameter A 12 {0.4724} 11.98 {0.4717} or less
assembly
Shaft outer diameter B 9 {0.3543} 8.98 {0.3535} or less

0.5 - 0.8
Undercut depth {0.0197 - 0.2 {0.0079} or less Correction
0.0315}

Resistance between holder Replace holder

Holder — 1k: or less
and plate assembly
assembly
Brush length 18 {0.7087} 13 {0.5118} or less Replace brush

Shaft A 26 {1.0236} 25.9 {1.0197} or less

assembly Replace shaft
outer B 12.1 {0.4764} 12.04 {0.4740} or less assembly
diameter

Clutch assembly inner sleeve outer

25 {0.9843} 24.9 {0.9803} or more Replacement
diameter

Metal bushing inner diameter of pinion case 25 {0.9843} 25.2 {0.9921} or more Replace brush

Metal bushing inner diameter of center Replace center

26 {1.0236} 26.2 {1.0315}
bracket bracket

Metal bushing inner diameter of shaft Replace shaft

9 {0.3543} 9.2 {0.3622}
assembly assembly

Replace
Bearing housing inner diameter of
28 {1.1024} 28.1 {1.1063} or more commutator end
commutator end frame
frame

Start Between C terminal and M

0.12 - 0.14: — Replace start
magnet terminal (P coil)
magnet switch
switch Between C terminal and body
1.13 - 1.25: — assembly
assembly (H coil)
2–16 STANDARD VALUE

Tightening torque (starter)

JP30ZCE020205014

Unit : N˜m{kgf˜cm, lbf˜tt}

Tightening area Tightening torque Remark

C lead wire mounting bolt 3.5 - 5.5 {35 - 55, 3 - 4}

M lead wire mounting nut 12 - 15 {125 - 155, 9 - 11}

Commutator end frame mounting through bolt 15.7 - 17.6 {160 - 179, 12 - 13}

Brush holder set bolts of commutator end frame 3.6 - 4.9 {37 - 49, 3 - 4}

Pinion case set bolts 14 - 16 {140 - 160, 10 - 12}

 STANDARD VALUE 2–17

Standard value (alternator 60A)

JP30ZCE020205015

Standard Service
Inspection item Repair limit Action
value limit

Resistance between stator coil terminals

0.15 - 0.17: — — Replace
(U - V, V - W, W - U)

1M:or
more
Resistance between stator coil core and coil (Use 500V — — Replace
megger
tester)

Resistance of field coil 6.2 - 6.8: — — Replace

1M:or
more
Resistance between field coil core and coil (Use 500V — — Replace
megger
tester)
Ball bearing 25.0mm 24.98mm
—
Shaft outer diameter of insertion area {0.9843 in.} {0.9835 in.}
Replace
rotor assembly Roller bearing 17mm 16.98mm
—
insertion area {0.6693 in.} {0.6685 in.}

Forward Approx.
— —
Resistance between resistance value 10:
Replace
diode and rectifier holder Reverse
Infinite — —
resistance value

Forward Approx.
— —
Resistance between resistance value 10:
Replace
regulator terminals F - E Reverse
Infinite — —
resistance value

Approx.
B-E — —
20: Adjust
Resistance between E-B Infinite — —
terminals B - E and P - E
P-E Approx. 7: — —
Adjust
E-P Infinite — —
2–18 STANDARD VALUE

Tightening torque (alternator 60A)

JP30ZCE020205016

Unit : N˜m{kgf˜cm, lbf˜ft}

Tightening area Tightening torque Remark

Bearing cover mounting bolt 1.9 - 2.5 {20 - 25, 1.4 - 1.8}

Pulley mounting nut 127 - 157 {1300 - 1600, 94 - 116}

Feed coil - End frame 2.9 - 3.9 {30 - 39, 2 - 3}

Rectifier mounting bolt 1.9 - 2.5 {20 - 25, 1.4 - 1.8}

for regulator
1.6 - 2.3 {16 - 23, 1.2 - 1.6}
fix
Regulator mounting bolt
for coil lead 1.0 - 1.4 {10 - 14, 0.8 - 1.0}
for heat sink 1.0 - 1.4 {10 - 14, 0.8 - 1.0}

Inside B terminal mounting nut 4.9 - 5.9 {50 - 60, 3.6 - 4.3}

Driver end frame - End frame 7.8 - 9.8 {80 - 100, 6 - 7}

Cover mounting bolt 3.3 - 4.4 {34 - 44, 2 - 3}

 STANDARD VALUE 2–19

Turbocharger
Standard value
JP30ZCE020205017

Unit : mm {in.}
Inspection item Standard value Repair limit Service limit Action

0.040 - 0.085
Turbine shaft axial play {0.0016 - 0.0033} — —
(Only axial play)

Tightening torque
JP30ZCE020205018

Unit : N˜m{kgf˜cm, lbf˜tt}

Tightening area Tightening torque Remark

Turbocharger mounting nut 56 {571, 41}
 PARTS TO BE PREPARED 3–1

ENGINE

3 PARTS TO BE PREPARED
Special tool (SST)

3
Engine Mounting/Dismounting ................................. 3-2
Special tool ............................................................. 3-2
Fuel System ................................................................ 3-2
Special tool. ........................................................... 3-2
Lubricant, etc. ........................................................ 3-2
Electrical...................................................................... 3-3
Special tool ............................................................. 3-3
Engine Mechanical ..................................................... 3-3
Special tool ............................................................. 3-3
Instruments ............................................................. 3-6
Lubricant, etc. ........................................................ 3-6
Exhaust........................................................................ 3-7
Lubricant, etc. ......................................................... 3-7
Cooling ........................................................................ 3-7
Special tool ............................................................. 3-7
Lubrication .................................................................. 3-7
Special tool ............................................................. 3-8
Lubricant, etc. ........................................................ 3-8
Starting and Charging................................................ 3-8
Jig (reference dimensional drawing for manufacture)
............................................................................... 3-8
Instruments ............................................................. 3-9
Lubricant, etc. ........................................................ 3-9
Turbocharger............................................................... 3-9
Special tool ............................................................. 3-9
Engine Failure Diagnosis......................................... 3-10
Special tool ........................................................... 3-10
3–2 PARTS TO BE PREPARED

Engine Mounting/Dismounting
Special tool
JP30ZCE030901001

Shape Part No. Description Remark

S0949–11010
Wire rope For engine lifting
(09491–1010)

S0955–21030
Compression gauge adapter
(09552–1030)

S0955–21060
Compression gauge adapter
(09552–1060)

S0955–21110
Compression gauge adapter
(09552–1110)

Fuel System
Special tool
JP30ZCE030901002

Shape Part No. Name Remark

S0965–01101 For injection pump drive

Bearing puller
(09650–1101) housing

S0965–01310 For injection pump drive

Bearing puller
(09650–1310) housing

Lubricant, etc.
JP30ZCE030901017

Name Remark

Guide bolt SZ105–08067(9069–08180) For supply pump positioning

 PARTS TO BE PREPARED 3–3

Electrical
Special tool
JP30ZCE030901003

Shape Part No. Name Remark

S0944–41210 For V ribbed belt tension

Compression gauge
(09444–1210) adjustment

MITSUBOSHI BELTING LTD.

For V ribbed belt tension
– Belt Tension Meter (DOCTOR
adjustment
TENSION£ TYPE-III)

Engine Mechanical
Special tool
JP30ZCE030901004

Shape Part No. Name Remark

S0942–01731 For crankshaft front oil seal

Oil seal puller
(09420–1731) removal

S0940–71030 For crankshaft front oil seal

Oil seal press
(09407–1030) press-fit

S0943–31070 For assembly/disassembly

Eye bolt
(09433–1070) of cylinder head

S0947–01170 For assembly/disassembly

Valve spring press
(09470–1170) of valve spring retainer

S0947–11520
Guide For valve guide press-fit
(09471–1520)
3–4 PARTS TO BE PREPARED

Shape Part No. Name Remark

S0947–21210
Bar For nozzle seat clamping
(09472–1210)

For nozzle seat clamping

9800–06100 Steel ball (together with S0947–21210
(09472–1210)

S0943–11020
Valve lapping tool For valve adjustment
(09431–1020)

S0947–22100 For valve stem seal

Bar
(09472–2100) mounting

S0942–02100 For removal and inspection

Cylinder liner puller
(09420–2100) of cylinder liner

S0944–21011 For assembly/disassembly

Piston ring expander
(09442–1011) of piston ring

For mounting of connecting

rod small end bushing
SH691–20825 (together with
Bolt
(9191–08252) S0940–21480(09402–1480)
or S0940–21540
(09402–1540))

For assembly/disassembly
S0940–21530
Press sub-assembly of connecting rod small end
(09402–1530)
bushing

For assembly/disassembly
of connecting rod small end
SL271–01036
Wing nut bushing (together with
(9233–10360)
09402–1530
(S0940-21530))
 PARTS TO BE PREPARED 3–5

Shape Part No. Name Remark

For assembly/disassembly
of connecting rod small end
S0948–11130
Guide bushing (together with
(09481–1130)
S0940–21540
(09402–1540))

For assembly/disassembly
S0940–21540
Spindle of connecting rod small end
(09402–1540)
bushing

For mounting of connecting

S0948–11540 rod small end bushing
Guide
(09481–1540) (together with S0940–21540
(09402–1540))

S0944–11370
Piston ring holder For piston mounting
(09441–1370)

S0948–11340 For assembly/disassembly

Guide
(09481–1340) of flywheel

S0942–01742 For crankshaft rear oil seal

Oil seal puller
(09420–1742) removal

For main/sub idle gear

S0942–01100
Sliding hammer assembly and cam idle gear
(09420–1100)
shaft removal

S0941–11300 For assembly/disassembly

Socket wrench
(09411–1300) of Torx bolt
3–6 PARTS TO BE PREPARED

Shape Part No. Name Remark

S0940–71040 For crankshaft rear oil seal

Oil seal press
(09407–1040) press-fit

S0947–11490
Guide For insertion of cylinder liner
(09471–1490)

SZ910–24098 For cooling jet inspection

Check bolt
(9001–24262) and adjustment

For cooling jet inspection

09219–E4010 Gauge
and adjustment

Instruments
JP30ZCE030901005

Name Remark

Micrometer For measurement of part outer diameter

Cylinder gauge For measurement of part inner diameter

Thickness gauge For measurement of each clearance

Dial gauge For measurement of parts

Lubricant, etc.
JP30ZCE030901006

Name Remark

Liquid gasket (Threebond TB1207B or equivalent :

For sealing of parts
Black)

Liquid gasket (Threebond TB1207D or equivalent :

For sealing of parts
Silver)

Liquid gasket (Threebond TB1211 or equivalent : White) For sealing of parts

Red lead Valve adjustment

Dye penetrant For inspection of crack

 PARTS TO BE PREPARED 3–7

Exhaust
Lubricant, etc.
JP30ZCE030901007

Name Remark

Anti-seize (NEVER-SEEZ Nickel Special Grade,

For installing DPR exhaust temperature sensor
BOSTIC FINDLEY (U.S.A.))

Cooling
Special tool
JP30ZCE030901008

Shape Part No. Name Remark

S0944–41210 For V ribbed belt tension

Compression gauge
(09444–1210) adjustment

MITSUBOSHI BELTING LTD.

For V ribbed belt tension
– Belt Tension Meter (DOCTOR
adjustment
TENSION£ TYPE-III)

Lubricant, etc.
JP30ZCE030901009

Name Remark

Liquid gasket (Threebond TB1207B or equivalent :

For sealing of parts
Black)
3–8 PARTS TO BE PREPARED

Lubrication
Special tool
JP30ZCE030901010

Shape Part No. Name Remark

S0950-31110
Oil filter wrench
(09503–1110)

Lubricant, etc.
JP30ZCE030901011

Name Remark

Liquid gasket (Threebond TB1207D or equivalent :

For sealing of parts
Silver)

Liquid gasket (Threebond TB1211 or equivalent : White) For sealing of parts

Starting and Charging

Jig (reference dimensional drawing for manufacture)
JP30ZCE030901012

This is used for assembly of alternator bearing. Reference dimensions are shown in the figures below:

Jig A (Roller bearing insertion jig) Jig B (Support jig) Unit : mm{in.}
φ23{20.827} φ25{0.984}
1C{0.039}

35{1.378}
50{1.964}

70{2.756}

50{1.964}
1C{0.039}
10 - 20 φ50{1.969}
+0.5{0.0196} {0.394 - 0.787}
φ19{0.748}
0
φ30{1.181}

Jig C Jig D
φ34{1.339} φ41{1.614}

20{0.787} 20{0.787}

40{1.575} 40{1.575}

10{0.394} 10{0.394}
φ54{2.126} φ64{2.520}
φ60{2.362} φ70{2.756}

SAPH30ZCE0300034
 PARTS TO BE PREPARED 3–9

Instruments
JP30ZCE030901013

Alternator

Name Remark

Circuit tester For measurement of parts

Micrometer For measurement of parts

Regulator checker (G&M Machinery ICD-101D or

For inspection of regulator
equivalent)

Megger tester For insulation

. Starter

Name Remark
Circuit tester For measurement of parts

Micrometer For measurement of part outer diameter

Growler tester For inspection of armature

Cylinder gauge For measurement of part inner diameter

Megger tester For insulation

Lubricant, etc.
JP30ZCE030901014

Starter

Name Remark

Kyodo Yushi Multemp AC-N For lubrication of parts

Nisseki Mitsubishi Pyroknock #2 For lubrication of parts

Turbocharger
Special tool
JP30ZCE030901015

Shape Part No. Name Remark

09444-1800 Tool assembly

3–10 PARTS TO BE PREPARED

Engine Failure Diagnosis

Special tool
JP30ZCE030901016

Shape Part No. Name Remark

• Operating
system(OS):Windows95,
Windows98(IE5.0 or
later),
Windows2000(SP3,
IE5.0 or later),
WindowsXP(SP1a, IE6.0
– Personal computer (DOS-V) or later)
• CPU and memory:
Conditions that assure
operation of the above
operating system
• Display: 800 x 600, 256
colors or more

Hino Diagnostic eXplorer Failure diagnosis software

–
(Hino DX) (CD-ROM)

Used together with the

cable between the vehicle
09993–E9070
and Hino-Bowie (09042-
1220)

Hino-Bowie (Interface box)

This is installed as
interruption between
— machine harness and the
ECU. Tester inspection is
Cable bundled allowed in energized status.
to the Hino-Bowie

Cable for diagnostic

S0904-21220 Cable between the machine
connecting to the machine
(09042-1220) and the Hino-Bowie
side.
Cable between
machine
and Hino-Bowie
 PARTS TO BE PREPARED 3–11

Shape Part No. Name Remark

This is installed as
interruption between
09843–E4010 Signal check harness machine harness and the
ECU. Tester inspection is
allowed in energized status.
 ENGINE MOUNTING/DISMOUNTING 4–1

ENGINE

4 ENGINE MOUNTING/DISMOUNTING
Service procedure
Overhaul item

Inspection Before Service ......................................... 4-2

Measurement of compression pressure ................. 4-2 4
Engine Mounting/Dismounting ................................. 4-4
Removal.................................................................. 4-4
Installation............................................................... 4-6
Work after installation ............................................. 4-6
4–2 ENGINE MOUNTING/DISMOUNTING

Inspection Before Service

Measurement of compression pressure
JP30ZCE040702001

NOTICE • Measure the compression pressure before

disassembly of the engine and record the result.
Regular measurement of the compression
pressure can tell the engine status.

1. Preparation before measurement

(1) Charge the battery completely.
(2) Check the valve clearance and adjust it when exceeding
the standard value.
(3) Warm the engine and set the water temperature to 80
qC{176qF}.
(4) Remove the air cleaner.
(5) Remove the head cover.
(6) Remove all injectors.
(7) To prevent spread of engine oil, attach a jig which cuts a
head cover in half. (Cut it so that the camshaft may be
covered.

2. Measurement

(1) Attach a special tool to the nozzle sheet of the cylinder

where the compression pressure is measured with nozzle
clamp and clamp fixing bolts.

Special Special tool : Compression gauge adapter

tool
Engine
Part No. Parts tightened
S0955–21110 Insert in the injector
SAPH30ZCE0400002 (09552–1110) mounting area
S0955–21030
(09552–1030)
Adjusting to screw size of
(3/4-16 UNF)
air gauge, the adapter
S0955-21060
which it selects
(09552-1060)
(W16 ridges 18)

(2) Turn the starter and measure the compression pressure.

! CAUTION • Do not operate the starter for 15 seconds or

more.
• Since the air cleaner is removed, prevent
entry of dirt.
ENGINE MOUNTING/DISMOUNTING 4–3

(3) Measure the compression pressure of each cylinder

continuously.

Engine revolution 280r/min

Unit kPa {kgf/cm2, lbf/in2}

Standard value Service limit

3.4 - 3.7 3.1 - 3.2
{35 - 37, 494 - 536} {31 - 32, 450 - 464}

(4) If the compression pressure is the service limit or less or if

the difference between cylinders is over the standard
value, overhaul the engine.
(5) After measurement, reassemble the removed parts.
4–4 ENGINE MOUNTING/DISMOUNTING

Engine Mounting/Dismounting
Removal
JP30ZCE040702002

1. Preliminary work before removal of engine

(1) Place the machine on a level ground.
(2) Remove the battery cable from the battery minus terminal.

2. Drain of coolant and engine oil

Right side of engine
(1) Drain coolant from the radiator drain cock and the oil
cooler drain plug.

NOTICE • Removal of the filler cap facilitates quick

drain.
• Connection of an appropriate hose to the oil
cooler drain pipe facilitates drain of coolant
Oil cooler drain plug
without spread.
SAPH30ZCE0400003

! CAUTION • To prevent burn, drain coolant after the

temperature is sufficiently low.
• To dispose coolant, observe the specified
method (waste disposal) or the method with
attention to environment.

(2) Drain engine oil from the oil pan drain cock as required.

! CAUTION • To prevent burn, drain coolant after the

temperature is sufficiently low.
• Dispose coolant according to the specified
method (waste treatment) or with a method
considering the environment.

Drain cock
SAPH30ZCE0400004

3. Removal of intake hose, intercooler hose and exhaust

pipe

(1) Loosen the clamp and remove the intake hose.

Intake manifold
(2) Remove nuts and remove the exhaust pipe.

! CAUTION • Close the opening of the intake manifold with

a packing tape to prevent entry of dirt inside
Cylinder head
Cover
the engine.

SAPH30ZCE0400005
 ENGINE MOUNTING/DISMOUNTING 4–5

4. Disconnection of fuel hose

(1) Remove the fuel hoses (feed side and return side). Wrap
the removed hose with a plastic sheet with its end facing
upward to prevent spill of fuel.

! CAUTION • Wipe spilled fuel with a rag.

5. Disconnection of water, engine oil pipes, etc.

SAPH30ZCE0400006
(1) Disconnect the hose between the radiator and the engine.
(2) Disconnect the car heater pipe.
(3) Disconnect the oil filter pipe.

! CAUTION • Wipe off spilled water and engine oil with

waste.

6. Engine lifting (Lifting the engine single unit)

(1) Place a commercially available shackle and a special tool
wire rope with the engine hanger.

SAPH30ZCE0400007

Special tool : S0949–11010(09491–1010) Wire rope

NOTICE • When only the rear of the engine is to be

hoisted, use the 2 hanger bolts shown in the
figure.

(2) Keep a little slack of the wire rope.

! CAUTION • Keep the wire inclination 30q from the vertical

line.
4–6 ENGINE MOUNTING/DISMOUNTING

(3) When the wire is completely tense, make sure that the
Image wire is firmly engaged with the engine hanger. Then, lift
the engine slowly.

! CAUTION • Work carefully so that the engine may not

come in contact with the frame and others.

SAPH30ZCE0400008

Installation
JP30ZCE040702003

1. Connection of fuel hose

(1) Insert a fuel hose and fix it with a hose band.

Work after installation

JP30ZCE040702004

1. Inspection of engine oil

(1) Make sure that the drain cock is closed.

(2) Pour engine oil.
(3) Check the amount of oil with an oil level gauge.
Engine oil amount (L{us gal})

Oil pan Oil filter and etc

Approx. 26{6.87} Approx. 2.5{0.66}

Filler cap

SAPH30ZCE0400009 Oil quality

JASO DH-2

API CJ-4

ACEA E-6

HINO recommends these oil to the I-Tier 4 regulation

countries, and use ultralow sulfur fuel only.

! CAUTION • In order to maintain a trouble-free functioning

of the DPR (exhaust gas after treatment
system) for a long time, it is recommended to
use the specified (recommended) brand of
engine oil.
 ENGINE MOUNTING/DISMOUNTING 4–7

Viscosity recommendations (SAE)

-40 -22 -4 14 32 50 66 88 104 °F
-40 -30 -20 -10 0 10 20 30 40 °C

SAE 20W-50

SAE 15W-40, SAE 10W-30

SAE 30

SAE 40

2. Air bleeding of fuel system

Please use the machine side priming pump. (1) Loosen the air venting bolt of the fuel filter, move the
priming pump forward and back to discharge the air from
the fuel system.

! CAUTION • The maintenance method differs according to

the fuel filter type.
Carefully check the type, then perform the
Do not use this priming pump. maintenance work.
SAPH30ZCE0400011 • Machine side fuel filter.
Refer to the “5 FUEL SYSTEM, Fuel filter (Machine
side), Replacement of fuel filter element”
 FUEL SYSTEM 5–1

ENGINE

5 FUEL SYSTEM
Setup layout
Layout

Fuel System ................................................................ 5-2

Fuel system diagram............................................... 5-2
Part layout ............................................................... 5-3
Fuel filter 5
(Machine side)............................................................ 5-5
Part layout ............................................................... 5-5
Water draining......................................................... 5-6
Replacement of fuel filter element .......................... 5-8
Fuel filter
(Engine side) ............................................................ 5-11
Part layout ............................................................. 5-11
Overhaul ............................................................... 5-13
Supply pump............................................................. 5-19
Part layout ............................................................. 5-19
Replacement......................................................... 5-20
Injector....................................................................... 5-32
Part layout ............................................................. 5-32
Replacement......................................................... 5-33
Common rail.............................................................. 5-41
Part layout ............................................................. 5-41
Inspection of the common rail ............................... 5-42
Replacement......................................................... 5-43
5–2 FUEL SYSTEM

Fuel System
Fuel system diagram
JP30ZCE050402001

Positive pressure
Negative pressure
Injector Return
Common rail

Supply pump

Suction
Feed pump
control valve

Engine mount
fuel filter

Over flow valve Fuel filter element

Engine side

Chassis side

Priming pump
Machine mount
Fuel filter fuel filter

Fuel cooler Fuel tank

SAPH30ZCE0500001
 FUEL SYSTEM 5–3

Part layout
JP30ZCE050402002

SAPH30ZCE0500002

23766 Through feed pipe 23811A Fuel feed pipe No.1

23803 Return pipe No.1 Z4300 Gasket*
23803A Return pipe Z4300A Gasket*
23811 Pressure feed pipe Z4301C Gasket*
*Parts not to be reused.
5–4 FUEL SYSTEM

SAPH30ZCE0500003

11334 Bearing holder case 23704 Injection pipe

22100 Supply pump 23705 Injection pipe
22611 Coupling flange 23706 Injection pipe
22670 Coupling 23810 Common rail assembly
23670 Injector SN732-10493 O-ring*
23701 Injection pipe Z2090 Gasket*
23702 Injection pipe Z3010 O-ring*
23703 Injection pipe

*Parts not to be reused.

Tightening torque
22815 28.5N˜m {290 kgf˜cm, 21 lbf˜ft} SH552-10885 28.5N˜m { 290kgf˜cm, 21 lbf˜ft}
22825 63.7N˜m {650 kgf˜cm, 47 lbf˜ft} Z1782 353N˜m { 3,600kgf˜cm, 260 lbf˜ft}
SH552-10825 28.5N˜m { 290kgf˜cm, 21 lbf˜ft} Z9102B 108N˜m {1,100 kgf˜cm, 80 lbf˜ft}
SH552-10840 28.5N˜m { 290kgf˜cm, 21 lbf˜ft} Z9102C 25N˜m {250 kgf˜cm, 18 lbf˜ft}
SH552-10845 28.5N˜m { 290kgf˜cm, 21 lbf˜ft}
 FUEL SYSTEM 5–5

Fuel filter (Machine side)

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Part layout
JP30ZCE050402003

! CAUTION • The maintenance method differs according to the fuel filter type. Carefully check the type,
then perform the maintenance work.

SAPH30ZCE0500004

23300 Fuel filter assembly S2330A Water cup

S2330 Fuel filter head S2340 Fuel filter element

Tightening torque
S2330A Refer to the main text. S2340 Refer to the main text.
5–6 FUEL SYSTEM

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Water draining
JP30ZCE050704001

! CAUTION • As air enters into the fuel piping during the

work, air bleeding must be performed after
completion of the work.

1. Advance preparation
(1) Prepare a water container under the drain pipe.

2. Air bleeding of the fuel filter

Air bleeding bolt
(1) Loosen the fuel filter air bleeding bolt and the drain valve.
Discharge water at the bottom of the fuel filter case.

Priming pump ! CAUTION • Since discharged water contains fuel,

observe the local disposal procedure for
disposal.

Drain valve

SAPH30ZCE0500005

NOTICE • Perform water draining when the float ring of

Water cup
the water cup has risen to the red line.

Red line
Float ring

SAPH30ZCE0500006

(2) Close the drain valve.

 FUEL SYSTEM 5–7

3. Air bleeding of the fuel system

! CAUTION • Take care that no dirt or water get into the

system during the work.

(1) Operate the priming pump and bleed the air from the
system.

! CAUTION • Make sure that the fuel filter air bleeding bolt
has been loosened.
• The air bleeding bolt has as a slit (groove) as
shown in the figure. As air will bleed out even
when the bolt is not removed completely,
perform priming work with the bolt loosened
to an intermediate position in order to prevent
the entry of foreign matter to the fuel system.

SAPH30ZCE0500007

(2) Tighten the fuel filter air bleeding bolt.

Tightening torque :
1.7 - 2.26 N˜m {17.3 - 23 kgf˜cm, 1.3 - 1.7 lbf˜ft}

! CAUTION • After work, wipe off spilled water or fuel. After

start of the engine, make sure that there is no
fuel leak.
5–8 FUEL SYSTEM

Replacement of fuel filter element

JP30ZCE050704002

! CAUTION • The frequency for water draining and replacement of the fuel filter element differs
according to the fuel situation in the use region.
Replace the fuel filter element every 500 hours or when the engine output decreases,
whichever occurs first.
• Inspection of the fuel filter element and draining of water should be performed before each
start of operation.
• Always use HINO genuine parts filter element.
• Complete the work for removal and installation quickly to prevent entry of foreign matter to
the fuel system.
• Take care that no dirt or water get into the system during the work.
• As air enters into the fuel piping during the work, air bleeding must be performed after
completion of the work.
• Before assembly, make sure that there is no dirt the seating surface of the parts.

1. Removal of water cup

(1) First bleed water from the fuel filter and then remove the water cup of the fuel filter.
Refer to the "Fuel filter (Machine side), Water draining“

! CAUTION • Completely remove any dust around the water cup.

2. Removal of fuel filter element

(1) Remove the fuel filter element.

! CAUTION • Completely remove any dust around the fuel filter head and especially around the air vent
bolt.
• Since the filter contains diesel oil, prepare a tray.
 FUEL SYSTEM 5–9

3. Installation of fuel filter element and water cup

! CAUTION • Fuel filter element is not reused.

• As the gasket is included in the element kit, do not use a gasket again after it has been
removed once.
• The gasket is smaller on the side of the fuel filter head (approx. I90 mm{3.5433in.}) than on
the side of the water cup (approx. I105 mm{4.1339in.}). Take care not to install it the wrong
way round.
• Install the gasket after applying fuel to the surface of the gasket.
• Do not use a tool, but tighten by hand.

(1) The soiling and the foreign material of the clamp face are removed.
(2) Install the fuel filter element to the fuel filter head and turn the element 7/8 of a turn after the gasket comes
into contact with the fuel filter head.

Fuel filter head

Gasket

Element

Turn the element

7/8 turns
after the gasket comes
into contact.

SAPH30ZCE0500008
5–10 FUEL SYSTEM

(3) Install the water cup to the fuel filter element and turn the cup 3/4 of a turn after the gasket comes into
contact with the fuel filter element.

Element

Turn the water cup

3/4 turns
after the gasket comes
into contact. Gasket

Water cup

SAPH30ZCE0500009

(4) Confirm that the drain valve has been tightened.

4. Bleeding air from the fuel system

Refer to the “Fuel filter (Machine side), Water draining”
 FUEL SYSTEM 5–11

Fuel filter (Engine side)

Part layout
JP30ZCE050704003

SAPH30ZCE0500002

23300 Fuel filter case 23814 Fuel feed pipe No.2

23803A Return pipe No.2 Z4300 Gasket*
23804 Fuel feed pipe No.3 Z4301C Gasket*
23811A Fuel feed pipe No.1 Z4301D Gasket*

*Parts not to be reused.

Tightening torque
Z4011A 30N˜m{305kgf˜cm, 22 lbf˜ft} Z9102A 30N˜m{305kgf˜cm, 22 lbf˜ft}
5–12 FUEL SYSTEM



< 

SAPH30ZCE0500010

23300 Fuel filter 90070 Center bolt

23316 Air bleeding plug (Drain plug) 90075 Cap
23386 O-ring*1 Z0104 O-ring*1
23401 Element*1 Z0106 Priming pump*2

*1Parts not to be reused.

*2Do not use this priming pump. Please use the machine side priming pump for air bleeding of the fule
system.
Tightening torque
23316 6.9r2N˜m 90070 29.4r4.9N˜m
{70r20kgf˜cm, 5.0r1.4 lbf˜ft} {300r50kgf˜cm, 21.7r3.6 lbf˜ft}
 FUEL SYSTEM 5–13

Overhaul
JP30ZCE050704004

Replace of the element

! CAUTION • Always use HINO genuine parts fuel filter

element.
• Take care that no dirt or water gets into the
system during the work.
• Before assembly, make sure that there is no
dirt on the seating surface of the parts.
• Always do air bleeding after replacing an
element.

1. Fuel discharging
(1) Prepare a container under the drain pipe.

Air breeding (2) Loosen the drain plug and the fuel filter air bleeding plug.
plug Discharge fuel from the drain pipe.
After discharging fuel completely and tighten the drain
Drain pipe plug.
Tightening torque :
Drain plug 6.9r2 N˜m {70r20 kgf˜cm, 5.0r1.4 lbf˜ft}

SAPH30ZCE0500011 ! CAUTION • To dispose fuel, observe the specified method

(waste disposal) or the method with attention
to environment.
• Make sure that the drain plug is not damage
or corrosion.

2. Removal of the element

Cap (1) Remove the center bolt, and remove the O-rings (2 pcs.)
Center bolt
and caps from the fuel filter case.

Element (2) Remove the element.

O-ring
! CAUTION • When draining the fuel, drain all fuel from
inside the filter. When the element is replaced
Fuel filter case
without draining all fuel, there is the
possibility that unfiltered fuel remains in the
SAPH30ZCE0500012 filter and flows to the engine side.
• Prepare a container for catching dripped fuel
from the filter that the fuel remains in the
case.
5–14 FUEL SYSTEM

3. Installation of the element

Cap (1) Remove any dust around the fuel filter case inside and the
Center bolt
element fitting point of the cap inside.
(2) Install a new element in to the fuel filter case.
Element
O-ring
! CAUTION • When the element is replaced without
draining all fuel from the fuel filter case,
Fuel filter case unfiltered fuel remains in the fuel filter case;
make sure that the filter case does not
contain any remaining fuel.
SAPH30ZCE0500013

(3) Applying fuel to a new O-ring and install them to the fuel
filter case groove.

! CAUTION • Do not reuse the fuel filter element.

• As the O-ring is included in the element kit, do
not use an O-ring again after it has been
removed once.

(4) Align the match mark and set the cap to the fuel filter case
Center bolt Cap
and tighten the center bolt.
Match mark
Tightening torque :
29.4r4.9 N˜m {300r50 kgf˜cm, 21.7r3.6 lbf˜ft}

! CAUTION • Be careful to prevent twisted damage of the

O-ring.
Fuel
filter case • Make sure the O-ring is fitted to the clamp
face.
SAPH30ZCE0500014
• Match the match mark of the fuel filter cap at
the fuel filter case .

4. Air bleeding of the fuel system

Please use the machine side priming pump. (1) Move the priming pump forward and back to discharge the
air from the fuel system.

Refer to “Fuel filter (Machine side), Water draining“

Do not use this priming pump.

SAPH30ZCE0500087
 FUEL SYSTEM 5–15

Removal of the fuel filter case

! CAUTION • Take care that no dirt or water gets into the

system during the work.
1. Fuel discharging
(1) Prepare a container under the drain pipe.

Air breeding (2) Loosen the drain plug and the fuel filter air bleeding plug.
plug Discharge fuel from the drain pipe.
After discharging fuel completely and tighten the drain
Drain pipe plug.
Tightening torque :
Drain plug 6.9r2 N˜m {70r20 kgf˜cm, 5.0r1.4 lbf˜ft}

SAPH30ZCE0500011 ! CAUTION • To dispose fuel, observe the specified method

(waste disposal) or the method with attention
to environment.

2. Disconnecting the harness

Water level warning switch
(1) Disconnect the connector of the water level warning
switch and the fuel temperature sensor.

Fuel
Engine harness temperature senser
SAPH30ZCE0500015

3. Removal of the fuel pipes

(1) Remove the union bolts (2pcs.) and disconnect the return
pipe No.2 from the fuel filter case.

Return pipe
No.㧞 NOTICE • Prepare a container and a rug under the fuel
pipe.

SAPH30ZCE0500016

(2) Remove the union bolts (2pcs.) and disconnect the fuel
Fuel filter case feed pipe No.3 and the gasket from the fuel filter case.
Fuel feed pipe No.3
NOTICE • Prepare a container and a rug under the fuel
pipe.

(3) Remove the nuts and remove the clips.

Supply pump
SAPH30ZCE0500017
5–16 FUEL SYSTEM

(4) Remove the union bolts (2pcs.) and remove the fuel feed
pipe No.2 and the gasket from the fuel filter case.

Fuel feed pipe No.2 NOTICE • Prepare a container and a rug under the fuel
pipe.

(5) Remove the nuts and remove the clips.

SAPH30ZCE0500018

4. Removal of the fuel filter case

Fuel filter case (1) Remove the bolts (2pcs.) and remove the fuel filter case.

! CAUTION • Prepare a container for catching the fuel that

the fuel remains in the case.

Bolt
SAPH30ZCE0500019
 FUEL SYSTEM 5–17

Installation of the fuel filter case

! CAUTION • Take care that no dirt or water gets into the

system during the work.
• Make sure that there is no dirt on the parts
connecting surface.
• As air enters into the fuel piping during the
work, air bleeding must be performed after
completion of the work.

1. Installation of the fuel filter case

Fuel filter case (1) Install the fuel filter case with bolts (2pcs.).

Tightening torque : 55 N˜m {560 kgf˜cm, 40 lbf˜ft}

Bolt
SAPH30ZCE0500019

2. Installation of the fuel pipes

(1) Replace the gaskets by new ones and connect the fuel
feed pipe No.2 to the fuel filter case and fuel filter case
Fuel feed pipe No.2 with union bolts (2pcs.).

Tightening torque : 30 N˜m {305 kgf˜cm, 22 lbf˜ft}

(2) Install the clips and secure the fuel feed pipe No.2.
Tightening torque :
25 N˜m {255 kgf˜cm, 18 lbf˜ft} (Supply pump side)

SAPH30ZCE0500018

(3) Replace the gaskets by new ones and connect the fuel
Fuel filter case feed pipe No.3 to the supply pump and the fuel filter case
Fuel feed pipe No.3 with union bolts (2pcs.).

Tightening torque :
30 N˜m {305 kgf˜cm, 22 lbf˜ft}
(Fuel filter side)
17.2r2.4 N˜m {175r25 kgf˜cm, 12.6r1.8 lbf˜ft}
(Supply pump side)
Supply pump
SAPH30ZCE0500017
5–18 FUEL SYSTEM

(4) Replace the gaskets for new ones and connect the return
pipe No.2 to the fuel filter case with union bolts (2pcs.).

Tightening torque : 30 N˜m {305 kgf˜cm, 22 lbf˜ft}

Return pipe
No.㧞 NOTICE • The union bolt on the side of the return pipe
No. 2 has a different thread pitch. The top of
the bolt is marked.

SAPH30ZCE0500016

3. Connecting the harness

Water level warning switch
(1) Connect the connector of the water level warning switch
and the fuel temperature sensor.

! CAUTION • Before connecting the connector, confirm that

there are no signs of sparking on the terminal.

Fuel
Engine harness temperature senser
SAPH30ZCE0500015

4. Air bleeding of the fuel system

Please use the machine side priming pump. (1) Move the priming pump forward and back to discharge the
air from the fuel system.

Refer to “Fuel filter (Machine side), Water draining“

Do not use this priming pump.

SAPH30ZCE0500087
 FUEL SYSTEM 5–19

Supply pump
Part layout
JP30ZCE050704005

SAPH30ZCE0500003

11334 Bearing holder case 22670 Coupling

13610 Injection pump drive housing SN732-10493 O-ring*
22100 Supply pump Z3010 O-ring*
22611 Coupling flange
*Parts not to be reused.
Tightening torque
22815 28.5N˜m {290 kgf˜cm, 21 lbf˜ft} SH552-10825 28.5N˜m {290kgf˜cm, 21 lbf˜ft}
5–20 FUEL SYSTEM

Replacement
JP30ZCE050704006

Removal of the supply pump

! CAUTION • Take care that no dirt or water get into the

system during the work.

1. Fuel draining
(1) Prepare a water container under the drain pipe.
(2) Loosen the drain plug and the fuel filter air bleeding plug.
Air breeding Discharge fuel from the drain pipe.
plug
After discharging fuel completely and tighten the drain
Drain pipe
plug.

Tightening torque : 6.9r2.0 N˜m

Drain plug {70r20 kgf˜cm, 5r1.5 lbf˜ft}

SAPH30ZCE0500011 ! CAUTION • To dispose fuel, observe the specified method

(waste disposal) or the method with attention
to environment.

2. Removal of the fuel filter case

(1) Remove the fuel filter case and fuel pipe.
Refer to the "Fuel filter (Engine side), Overhaul“.

3. Removal of the intake pipes

(1) Remove the intake pipes.
Refer to the “8 INTAKE“.

4. Disconnection of the wiring harness

Fuel temperature sensor (1) Disconnect the connectors of the suction control valve
and the fuel temperature sensor at the supply pump.

Suction control valve

SAPH30ZCE0500020

5. Removal of the fuel pipes

(1) Remove the nuts and remove the clips.

(2) Remove the union bolts and disconnect the return pipe
No.1 connected to the pressure limiter, inlet manifold and
the supply pump.
Return pipe No.1

NOTICE • Prepare a container and waste cloth under the

Supply pump fuel pipe.

SAPH30ZCE0500021
 FUEL SYSTEM 5–21

6. Removal of the pressure feed pipe

(1) Remove the nuts and remove the clips.
(2) Loosen the nuts and remove the pressure feed pipe.
Pressure feed pipe
NOTICE • Prepare a container and waste cloth under the
fuel pipe.

SAPH30ZCE0500022

7. Compression Top Dead Center setting of the No.1 cylinder

(1) Remove the nuts and remove the flywheel housing cover
from the flywheel housing.

Flywheel housing
cover

SAPH30ZCE0500023

(2) Turn the flywheel clockwise in the engine direction and

align the No.1 cylinder mark to the pointer in the flywheel
housing inspection opening.
Flywheel
Refer to the "9 ENGINE MECANICAL, Cylinder head,
Replacement “.
1
Flywheel housing

SAPH30ZCE0500024

(3) Remove the inspection window plug in the bearing holder

Bearing holder case
case of the supply pump.
Close
contact (4) Tighten the guide bolt very gently and make sure that the
٤ bolt seating comes in close contact with the bearing
SST holder.
Special tool : SZ105-08067 (9069-08180) Guide bolt
Raised
˜

SAPH30ZCE0500025
5–22 FUEL SYSTEM

! CAUTION • If it is raised, there must be contact other than

the stopper key for the coupling flange. Do
not tighten hard.

• If SST (guide bolt) is not touch the flange,

No.1 cylinder is not setting to the
Compression Top Dead Center.
Remove the SST (guide bolt), and rotate the
engine and then check again.
• When you rotate the crankshaft, always
remove the SST (guide bolt).
• Do not rotate the crankshaft with the SST
(guide bolt) inserted.

8. Removal of the supply pump

! CAUTION • Take care that no dirt or water get into the

Do not remove
the pipe A system during the work.
• Do not remove pipes A and B.

• Do not apply any force to pipes A and B of the

supply pump (The twist of the pipes causes
the fuel leakage.).
Do not remove
the pipe B • Do not carry the supply pump by holding
SAPH30ZCE0500088
pipes A and B.

(1) Remove the bolts and remove the supply pump, coupling
Bearing holder case Coupling and O-ring from the injection pump drive housing.
Bolt
! CAUTION • When removing the supply pump remove the
supply pump together with the bearing holder
case.

Supply pump
O-ring Injection pump
drive housing
SAPH30ZCE0500089

(2) Fix the coupling flange with a vice to prevent turning and
Bearing holder case
remove the coupling flange.

Shaft

Nut

Coupling flange

SAPH30ZCE0500028
 FUEL SYSTEM 5–23

(3) Remove the bearing holder case and the O-ring from the
Supply pump
supply pump.

O-ring

Bolt

Bearing holder case

SAPH30ZCE0500029

Inspection of the supply pump

1. Inspection of the suction control valve and fuel

Fuel temperature sensor temperature sensor
(1) Inspect operation of the suction control valve and the fuel
temperature sensor using Hino DX.
Suction control valve
If it is faulty, replace the supply pump.
(Refer to “Hino DX operation manual”)

SAPH30ZCE0500030

2. Inspection of the suction control valve

(1) Measure the resistance between terminals with a circuit
Suction control valve
tester. If the value exceeds the standard value, replace
the supply pump.

Standard value
7.65 - 8.15:
(at 20qC {68qF})

SAPH30ZCE0500031

3. Inspection of the fuel temperature sensor resistance

Fuel
temperature sensor (1) Measure the resistance between terminals with a circuit
tester. If the value exceeds the standard value, replace
the supply pump.

Temperature (qC {qF}) Resistance (k:)

-20 {-4} 13.84 - 16.33

20 {68} 2.32 - 2.59

SAPH30ZCE0500032 80 {176} 0.310 - 0.326

110 {230} 0.1399 - 0.1435

5–24 FUEL SYSTEM

Overhaul of the injection pump drive housing

(If necessary when the injection pump was
removed)

1. Removal of the injection pump drive housing

(1) Remove the oil pipe from the injection pump drive
housing.
Oil pipe

Injection pump drive housing

SAPH30ZCE0500033

(2) Remove the bolts (6pcs.) and remove the injection pump
One bolt from bearing case side drive housing from the bearing case on the flywheel
Injection pump O-ring housing.
drive housing

NOTICE • One bolt is installed from the bearing case

side.

Other bolts from housing side

SAPH30ZCE0500034

2. Disassembly of the injection pump drive housing

Injection pump drive housing (1) Clamp the drive gear with aluminum plates using a vise,
Drive gear
and remove the nut and plate.

! CAUTION • Be careful not to damage the drive gear.

SAPH30ZCE0500035

(2) Remove the injection pump drive gear from the injection
pump drive housing using the special tool.

Special tool : S0965-01101 (09650-1101)

Bearing puller

SAPH30ZCE0500036
 FUEL SYSTEM 5–25

(3) Remove the bearing holder mounting bolts.

(4) Remove the upper cover.

Upper cover (5) Remove the coupling.

Coupling

Mounting bolts

SAPH30ZCE0500037

(6) Press out the shaft from the coupling side with the bearing
holder using a press.

! CAUTION • Not to dropped the shaft and not to damage

the shaft.

SAPH30ZCE0500038

(7) Tap the bearing holder using a plastic hammer, and

remove the bearing holder from the shaft.

Shaft

Bearing holder

SAPH30ZCE0500039

(8) Remove the main bearings (both sides) from the shaft
using the special tool.

Special tool Special tool : S0965-01101 (09650-1101)

Bearing puller (Supply pump side)

Special tool : S0965-01310 (09650-1310)

Main bearing Bearing puller (Drive gear side)

SAPH30ZCE0500090
5–26 FUEL SYSTEM

3. Inspection of the main bearings

(1) Hold the bearing inner race by hand and rotate the outer
race slowly. if it is not rotate smooth replace it.

SAPH30ZCE0500041

4. Assembly of the injection pump drive housing

Hammer (1) Install the main bearings to the shaft (both sides) using a
installing jig and hammer.

Installing jig
Main bearing

Shaft

Main bearing

SAPH30ZCE0500042

(2) Install the bearing holder to the shaft using a copper

hammer.

(3) Install the assembled shaft and bearing holder to the

crank case and tighten the bolts.

SAPH30ZCE0500043

(4) Install the bearing holder mounting bolts.

Tightening torque : 6.0 - 7.5 N˜m
Upper cover {60 - 75 kgf˜cm, 4.4 - 5.4 lbf˜ft}

(5) Install the coupling and tighten the bolts.

Coupling Tightening torque : 30 - 36 N˜m
{305 - 360 kgf˜cm, 22 - 26 lbf˜ft}
Mounting bolts (6) Install the upper cover.

SAPH30ZCE0500037
 FUEL SYSTEM 5–27

(7) Put the key to the shaft, and insert the drive gear to the
Injection pump drive housing shaft correctly, and clamp the drive gear by a vise using a
Drive gear
aluminum plate, and tighten the nut.

Tightening torque : 353 N˜m {3,600 kgf˜cm, 260 lbf˜ft}

! CAUTION • Prevent faulty conditions on the drive gear

such as deformation, scratch, etc.

SAPH30ZCE0500035

5. Installation of the injection pump drive housing

(1) Set the No.1 cylinder to the Compression Top Dead
Center.
Refer to the "9 ENGINE MECANICAL, Cylinder head,
Replacement “.

(2) Match the mark of the injection pump drive housing

casting mark to the coupling "O" mark.

"O" mark
carved seal

Casting mark

SAPH30ZCE0500091

(3) Install a new O-ring to the groove of the injection pump

Injection pump
dirve housing drive housing.

! CAUTION • Make sure that there is no foreign matter in

the O-ring groove or other circumference.

If foreign matter is found clean it.

O-ring
SAPH30ZCE0500045

(4) Install the injection pump drive housing to the bearing

One bolt from bearing case side case assembly on the flywheel housing.
Injection pump O-ring
drive housing Tightening torque : 28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

! CAUTION • Install the gear so as not to change the

position of the No.1 Top Dead Center.
• Take care not to drop the O-ring.

Other bolts from housing side

SAPH30ZCE0500092
5–28 FUEL SYSTEM

(5) Replace gaskets by new ones and install the oil pipe to
the injection pump drive housing.

Oil pipe

Injection pump drive housing

SAPH30ZCE0500033

Installation of the supply pump

! CAUTION • Before assembly, make sure that there is no

dirt the seating surface of the parts.
• Take care that no dirt or water get into the
system during the work.
• As air enters into the fuel piping during the
work, air bleeding must be performed after
completion of the work.

1. Compression Top Dead Center setting of the No.1 cylinder

(1) Turn the flywheel clockwise in the engine direction so the
engraving of the cylinder is aligned with the pointer in the
Flywheel
flywheel housing inspection opening.
Refer to the "9 ENGINE MECANICAL, Cylinder head,
1
Flywheel housing Replacement “.

! CAUTION • Make sure that the No.1 cylinder is positioned

at the top dead center point of the
SAPH30ZCE0500024
compression stroke.

2. Setting at the Top of the injection pump drive housing

(1) Match the casting mark of the supply pump drive with the
0 mark stamp "0" mark stamped at the front of the coupling.
at the front

Casting mark

SAPH30ZCE0500093
 FUEL SYSTEM 5–29

3. Installation of the supply pump

Supply pump
(1) Replace the O-ring by new one and install the bearing
holder case to the supply pump.
O-ring
Tightening torque : 28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

Bolt

Bearing holder case

SAPH30ZCE0500094

(2) Install the coupling flange to the shaft.

Bearing holder case
(3) Fix the supply pump and install the coupling flange to the
shaft. Tighten nuts while fixing with a vice to prevent
Shaft
turning.

Tightening torque : 63.7 N˜m {650 kgf˜cm, 47 lbf˜ft}

Nut
! CAUTION • Do not use the guide bolt for stopper key of
the shaft.
Coupling flange

SAPH30ZCE0500028

(4) Put the guide bolt into the bearing holder case to come in
Bearing holder case contact with the stopper key hole of the coupling flange.
Special tool : SZ105-08067 (9069-08180) Guide bolt

! CAUTION • Do not tighten the guide bolt by contact not

with the stopper key hole of the coupling or
Guide bolt do not use the stopper key with the non-
Coupring flange
specified guide bolt.
Stopper key hole • The specified guide bolt is designed to
SAPH30ZCE0500095 prevent contact of the guide bolt end with the
deep end of the stopper key hole. (The end
clearance is 2 mm{0.0788in.})

(5) Replace the O-ring by new ones, install the supply pump
Bearing holder case Coupling drive, supply pump and coupling, then tighten the bolt.
Bolt
Tightening torque : 28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

! CAUTION • When installing the supply pump, do not

change the position "Compression Top Dead
Center setting of the No.1 cylinder" and
Supply pump "Injection pump drive housing casting mark"
O-ring Injection pump
drive housing and "O-mark at the front of the coupling".
SAPH30ZCE0500096
5–30 FUEL SYSTEM

(6) After confirming No.1 cylinder is a Compression Top Dead

Bearing holder case Center, remove the SST (guide bolt) and install the timing
check cover.

! CAUTION • Always install the timing check cover when

after completing assembly.
• When you rotate the crankshaft, always
SST
remove the SST (guide bolt).

SAPH30ZCE0500051

(7) Install the flywheel housing cover to the flywheel housing

with bolts.

Flywheel housing
cover

SAPH30ZCE0500023

4. Installation of the pressure feed pipe

(1) Install the new pressure feed pipe.

Tightening torque :
Pressure feed pipe
44 N˜m {450 kgf˜cm, 32.5 lbf˜ft}
(Supply pump side)
44 N˜m {450 kgf˜cm, 32.5 lbf˜ft}
(Common rail side)

! CAUTION • Always replace the pressure feed pipe by a

SAPH30ZCE0500052 new one because the pipe is subjected to high
pressure; reusing the same pipe may result in
a fuel leak.

(2) Fit the clips (2pcs.) and fix the pressure feed pipe.

5. Installation of the fuel pipe

(1) Replace the gasket by new ones, install the return pipe
No.1 to the supply pump, inlet manifold and the pressure
limiter.

Tightening torque :
Return pipe No.1
10.3r2.4 N˜m {105r25 kgf˜cm, 7.5r1.8 lbf˜ft}
(Supply pump side)
Supply pump
30 N˜m {305 kgf˜cm, 22 lbf˜ft}
(Inlet manifold side)
SAPH30ZCE0500097
20 N˜m {205 kgf˜cm, 15 lbf˜ft}
(Pressure limiter side)
(2) Fit the clips (2pcs.) and fix the return pipe.
 FUEL SYSTEM 5–31

6. Connecting of the wiring harness

Fuel temperature sensor (1) Connect the connectors to the fuel temperature sensor
and suction control valve of the supply pump.

! CAUTION • Before connecting the connector, confirm that

the terminal shows no signs of sparking.

7. Installation of the intake pipe

(1) Install the intake pipe.
Suction control valve
Refer to the “8 INTAKE“.
SAPH30ZCE0500020

8. Installation of the fuel filter case

(1) Install the fuel filter case and the fuel pipes.
Refer to the "Fuel filter (Engine side), Overhaul“.

9. Air bleeding of the fuel system

Please use the machine side priming pump. (1) Move the priming pump to discharge the air from the fuel
system.

Refer to the “Fuel filter (Machine side), Water

draining“.

10. Update of supply pump learning value

(1) When the supply pump is replaced, update the learning
Do not use this priming pump.
value memorized in the engine ECU with the failure
SAPH30ZCE0500087
diagnosis tool (Hino DX) using PC. (Refer to "Hino DX
operation manual".)

! CAUTION • If learning value is not updated, correct

common rail pressure is not controlled,
resulting in engine stall or high common rail
pressure. Therefore, when the supply pump is
replaced, be sure to update the learning
value.

• After work, start the engine and trial run,

make sure that there is no fuel leak around
the supply pump.
5–32 FUEL SYSTEM

Injector
Part layout
JP30ZCE050704010

SAPH30ZCE0500055

22835 Union bolt 23670 Injector

22877 Gasket*

*Parts not to be reused.

 FUEL SYSTEM 5–33

êÆî óvóÃ
åšä²óvóÃçÄñe

Replacement
JP30ZCE050704009

Removal of the injector

! CAUTION • Take care that no dirt or water get into the

system during the work.

1. Removal of the head cover

(1) Remove the head cover.
Refer to the “9 ENGINE MECHANICAL, Cylinder
head”.
2. Removal of the leakage pipe
Union bolts Union bolts (1) Remove the union bolts (7pcs.), and remove the leakage
pipe and the gaskets (7pcs.).

! CAUTION • The leakage pipe is twisted easily, be careful

for handling.

Leakage pipe

SAPH30ZCE0500056

3. Removal of the injector harness

Injector (1) Disconnect the connectors from the each injectors.
harness Connector
bracket (2) Remove the nuts (7pcs.) and remove the injector harness
together with the injector harness bracket.
Injector
harness Nut
! CAUTION • The injector harness bracket is twisted easily,
be careful for handling.

SAPH30ZCE0500098

NOTICE • Removal becomes easier when the connector

Connector part of the camshaft housing is disconnected
last.

Injector Camshaft
harness housing

SAPH30ZCE0500058
5–34 FUEL SYSTEM

4. Removal of the injection pipes

(1) Remove the nuts (6pcs.) and remove the clips.

SAPH30ZCE0500059

(2) Loosen the nuts of the injection pipes, and remove the
injection pipes (6pcs.) from the injector and common rail.

NOTICE • Prepare a container and waste cloth under the

fuel pipe.

! CAUTION • Do not reuse the injection pipe.

SAPH30ZCE0500060

5. Removal of the injector

(1) Remove the bolts (2pcs.) and remove the injection pipe oil
Plate seals (6pcs.) and plates (6pcs.) from the cylinder head.

Injecton pipe
oil seal

Bolt

SAPH30ZCE0500061

(2) Remove the mounting bolts of the injectors clamps, and

Injector remove the injectors and injector clamps.
Mounting
bolt

Injector
clamp

SAPH30ZCE0500062
 FUEL SYSTEM 5–35

Unit inspection

1. Resistance check
Megger tester (1) Measure the resistance between the one side injector
terminal (No polarity) and upper body of the injector using
1,000V megger tester.
Upper body

! CAUTION • Do not measure between the terminal to

terminal using a megger tester. That the
injector will be damaged.

SAPH30ZCE0500063 10M: or more

Standard value
(Use 1,000V
(normal temperature)
megger tester)

(2) Measure the resistance between the each terminals using

Circuit tester a circuit tester.

Standard value
Upper body 0.47r0.1:
(at 20qC {68qF})

(3) If resistance of the step (1)(2) exceed standard value

replace the injector.

SAPH30ZCE0500064

2. Cleaning of the injector

(1) Use a shop towel to remove any sludge sticking to the
terminal part and its surroundings.

! CAUTION • When removing sludge, use dry cloth.

• Do not use cleaning fluids. (If cleaning fluids
are used, there is a possibility that a electrical
malfunction will occur.)

3. Cleaning inside the nozzle seat

Cylinder head (1) If sludge has accumulated inside the nozzle seat, spray it
with cleaning fluid, remove it by wiping with a shop towel,
Nozzle seat and then wash it again with cleaning fluid.

NOTICE • If the sludge has hardened, use a brush and

cleaning fluid for cleaning.
• Red lead can be used to check for contact.

(2) Confirm that the inside of the nozzle seat is free of sludge
SAPH30ZCE0500065
and foreign matter.
5–36 FUEL SYSTEM

Installation of the injector

! CAUTION • Take care that no dirt or water get into the

system during the work.
• Before assembly, make sure that there is no
dirt the seating surface of the parts.
• As air enters into the fuel piping during the
work, air bleeding must be performed after
completion of the work.

1. Installation of the injectors and injection pipes

(1) Apply the engine oil at a new O-ring and install it to the
injector, install the injector clamp and the injector
Mounting bolt Injector
temporarily.

! CAUTION • Apply engine oil to the O-ring and insert the

Injection pipe
O-ring so that it is not caught.
• Please use care as a damaged O-ring can
cause fuel leakage and starting the engine
may become impossible.
• Do not tighten the injector clamp until the
injection pipe has been installed
Plate Bolt
provisionally.
Injector clamp Injection pipe
oil seal (2) It covers the injector with a new injection pipe oil seal,
O-ring install the plate with bolts (2pcs.).

! CAUTION • Install the injection pipe oil seal so to the

injection nozzle that no unreasonable force is
applied. (When the positions of the injection
SAPH30ZCE0500066 pipe oil seal and the injection nozzle are not
matched, oil leakage or faulty installation of
the injection pipe may be caused.)

(3) Install the injection pipes (6pcs.) to the injectors and

common rail temporarily.

! CAUTION • Always replace the pressure feed pipe by a

new one because the injection pipe is
subjected to high pressure; reusing the same
pipe may result in a fuel leak.
• Always follow the procedure exactly, because
a fuel leakage can be the result when the
SAPH30ZCE0500060 injection pipe is not installed correctly.
• Fuel leakage causes engine damage.
 FUEL SYSTEM 5–37

• Install so that the injector and the injection

Injection pipe pipe are in a straight line.
Injector clamp

Injector

SAPH30ZCE0500067

NOTICE • Install so that the markings of the tightening

nuts for the flared parts of the injection pipes
are arranged in the indicated order.

Mark
Mark

Mark

Mark Mark Mark

SAPH30ZCE0500099
(4) Tighten the mounting bolt of the injector clamp.

Mouting bolt Tightening torque : 25 N˜m {250 kgf˜cm, 18 lbf˜ft}

! CAUTION • An insufficient tightening torque can cause

gas leakage, nozzle seizure, etc.

Injector

Injector clamp

SAPH30ZCE0500069

(5) Tighten the injection pipes at standard torque.

Tightening torque : 44 N˜m {450 kgf˜cm, 32.5 lbf˜ft}

SAPH30ZCE0500060
5–38 FUEL SYSTEM

(6) Fix the injection pipes with the clips by nuts (6pcs.).

SAPH30ZCE0500059

2. Entry of injector correction value to the engine ECU (entry

using Hino DX and QR code reader)
QR code

! CAUTION • When the injector is replaced, it is necessary

to enter the injector correction value (QR
code) described on the new injector to the
engine ECU. Incorrect entry of the correction
Injector
value may result in faulty engine.
• Incorrect entry of the correction value may
SAPH30ZCE0500070 result in faulty engine.

NOTICE • Available entry methods of the injector

correction value are the PC tool and the QR
code reader.
• The work flow is described below. For detailed
procedures, refer to the Hino DX operation
manual.

(1) Read the injector QR code with the scanner of the QR

code reader and prepare the correction data file.
 FUEL SYSTEM 5–39

(2) Enter the injector correction value directly from the Hino
DX to the engine ECU.

PC

QR code reader

Hino-Bowie
(Special interface)
Engine type code
(QR code)

Connector
New injector

ECU

SAPH30ZCE0500071

3. Installation of the injector harness

Injector (1) Install the injector harness together with the injector
harness Connector
bracket bracket by bolts (7pcs.).

Injector (2) Connect the connectors of the injector harness.

harness Nut
! CAUTION • Before connecting the connector, confirm that
the terminal shows no signs of sparking.

SAPH30ZCE0500100

NOTICE • Installation becomes easier when the

Connector connector part of the camshaft housing is
connected first.

Injector Camshaft
harness housing

SAPH30ZCE0500058
5–40 FUEL SYSTEM

4. Installation of the leakage pipe

Union bolts Union bolts (1) Remove dirt and foreign matter around the mounting
surface.

(2) Use the union bolts (7 bolts) with new gaskets to install
the leakage pipes to the injector and the camshaft
housing.

! CAUTION • Do not reuse the gasket.

Leakage pipe
• The leakage pipe is twisted easily, be careful
SAPH30ZCE0500056 for handling.
• It is noted that the union bolt (6pcs.) of the
A:Injector side (M8 x 1.0) injector and the union bolt (1pc) of the
B:Camshaft housing side (M8 x 1.25)
camshaft housing are different bolt pitch.

Leakage pipe

SAPH30ZCE0500072

• There is the "X" mark at the union bolt of the

camshaft housing.
Camshaft housing side
union bolt

SAPH30ZCE0500073

5. Installation of the head cover

(1) Install the head cover.
Refer to the “9 ENGINE MECHANICAL, Cylinder
head”.

6. Air bleeding of the fuel system

Please use the machine side priming pump. (1) Move the priming pump to discharge the air from the fuel
system.

Refer to "Fuel filter (Machine side), Water draining“

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åšä²óvóÃçÄñe

Do not use this priming pump.

SAPH30ZCE0500087
 FUEL SYSTEM 5–41

Common rail
Part layout
JP30ZCE050704011

SAPH30ZCE0500074

23280 Pressure limiter 23810 Common rail assembly

23290 Flow damper 89458 Common rail pressure sensor

Tightening torque
SH552-10860 28.5N˜m {290 kgf˜cm, 21 lbf˜ft}
5–42 FUEL SYSTEM

Inspection of the common rail

JP30ZCE050704007

1. Inspection of the flow damper

(1) Start the engine, accelerate the engine from idling to full
throttle, check the DTC code "flow damper operated"
using the Hino DX.
(2) If detect DTC code "flow damper operated", replace the
corresponded injector and recheck.
(3) If same DTC code are detected that corresponded injector
was replaced, replace the common rail assembly with the
flow damper.

2. Inspection of the pressure limiter

(1) Remove the union bolt from the pressure limiter.
Block pipe ends
(2) Block pipe ends at return pipe No.1 side by a bolt to
prevent fuel leak.

Pressure limiter

Union bolt

SAPH30ZCE0500075

(3) Install the union bolt to the pressure limiter, and set the
vinyl hose to the union bolt.

(4) Put a container under the vinyl hose.

Pressure (5) Start the engine. If the fuel flows continuously, replace the
limiter
Union bolt
common rail assembly with the pressure limiter.

Vinyl hose

Container

SAPH30ZCE0500076

3. Inspection of the common rail pressure sensor

  
(1) Measure the resistance between the terminals with a
circuit tester. If the value exceeds the standard value,
replace the common rail assembly.

Standard value (k:)

Measurement terminal when engine stopped
at 20qC {68qF}
  
1-2
SAPH30ZCE0500077
1.05 - 3.55
5-6

2-3
6.7 - 18.7
4-5
 FUEL SYSTEM 5–43

êÆî óvóÃ

Replacement
JP30ZCE050704008

Removal of the common rail

! CAUTION • Take care that no dirt or water get into the

system during the work.

1. Disconnection of the harness

(1) Disconnect the connector at common rail pressure
sensor.

SAPH30ZCE0500078

! CAUTION • Pull out the female connector from the male

Common rail side
Male connector connector during pushing the spring lock at
the female connector.

Harness side

Female connector
Spring lock
SAPH30ZCE0500101

2. Disconnection of the fuel pipe

(1) Disconnect the union bolt, and remove the return pipe
No.1 from the pressure limiter.

NOTICE • Prepare a container and waste cloth under the

fuel pipe.

Pressure
3. Removal of the injection pipe
limiter (1) Remove the injection pipe from the common rail.
Refer to “Injector, Replacement“
SAPH30ZCE0500102

4. Removal of the pressure feed pipe

(1) Remove the pressure feed pipe from the common rail and
the supply pump.
Refer to “Supply pump, Replacement of the supply
pump“
5–44 FUEL SYSTEM

5. Removal of the common rail

(1) Remove the bolts (2pcs.) and remove the common rail
Common rail and the bracket from the intake manifold.
pressure sensor

! CAUTION • Put a vinyl cover to prevent entry dirt inside

Bracket
the common rail.
• Remove dirt from around each parts before
remove the common rail.
• Remove the common rail together with the
Flow damper
flow damper, the common rail pressure
Pressure
limitter sensor, and the pressure limiter.

Bolt NOTICE • Prepare a container and a waste cloth

removing the common rail.

Common rail

SAPH30ZCE0500082
 FUEL SYSTEM 5–45

Installation of the common rail

! CAUTION • Take care that no dirt or water get into the

system during the work.
• Before assembly, make sure that there is no
dirt the seating surface of the parts.
• As air enters into the fuel piping during the
work, air bleeding must be performed after
completion of the work.

1. Installation of the common rail

(1) Install the common rail and the bracket to the intake
Common rail manifold with bolts (2pcs.).
pressure sensor
Tightening torque :
Bracket
28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

2. Installation of the pressure feed pipe

(1) Install a new pressure feed pipe.
Refer to “Supply pump, Replacement of supply
Flow damper
pump“.
Pressure
limitter

Bolt

Common rail

SAPH30ZCE0500082

3. Installation of the injection pipes

(1) Install new injection pipes (6pcs.) to the injector and the
common rail.
Refer to “Injector, Replacement“.

SAPH30ZCE0500103
5–46 FUEL SYSTEM

4. Installation of the fuel pipes

(1) Replace the gaskets by new ones and install the return
pipe No.1 to the pressure limiter with union bolts (2pcs.).
Refer to the “Supply pump, Replacement”.

Pressure
limitter
SAPH30ZCE0500084

5. Connecting of the harness

(1) Connect the connector to the common rail pressure
sensor.

SAPH30ZCE0500104

! CAUTION • Push the male connector to the female

Male connector
connector until the "CLICK" sounds are
Female connector heard.
Common
rail side
• Before connecting the connector, confirm that
the terminal shows no signs of sparking.

Spring lock

Harness side
SAPH30ZCE0500086

6. Air bleeding of the fuel system

Please use the machine side priming pump. (1) Move the priming pump to discharge the air from the fuel
system.

Refer to "Fuel filter (Machine side), Water draining“.

Do not use this priming pump.

SAPH30ZCE0500087
 EMISSION CONTROL 6–1

ENGINE

6 EMISSION CONTROL
Setup layout
Layout

EGR.............................................................................. 6-2
Part layout ............................................................... 6-2
Overhaul of the EGR valve and EGR cooler........... 6-3
Ventilator ..................................................................... 6-9
Part layout ............................................................... 6-9

6
6–2 EMISSION CONTROL

EGR
Part layout
JP30ZCE060402001

SAPH30ZCE0600001

17104B Gasket* 25620 EGR valve

17104C Gasket* 25627 Gasket*
17104D Gasket* Z4661 Clamp
17283 Stay Z4662A Clamp
21576 Clamp Z9203A Coolant hose
25601 EGR pipe A Z9203B Coolant hose
25601A EGR pipe B Z9203C Coolant hose
25601B EGR pipe C Z9203F Coolant hose
25608 EGR cooler

*Parts not to be reused.

Tightening torque
SH552-11025 55N˜m{560kgf˜cm, 41 lbf˜ft} Z1050A 36N˜m{367kgf˜cm, 26 lbf˜ft}
SH552-11060 55N˜m{560kgf˜cm, 41 lbf˜ft} Z1051 68.5N˜m{700kgf˜cm, 51 lbf˜ft}
Z1050 36N˜m{367kgf˜cm, 26 lbf˜ft}
Service procedure
Replacement procedure item
 EMISSION CONTROL 6–3

Overhaul of the EGR valve and EGR cooler

JP30ZCE060704001

1. Removal of the EGR pipes

Gasket
(1) Remove the bolts (7pcs.) and remove the EGR pipe A
from the EGR cooler and the EGR valve.

EGR pipe A

Gasket

EGR cooler EGR valve

SAPH30ZCE0600002

(2) Remove the bolts (5pcs.), and remove the EGR pipe B
EGR pipe B EGR cooler
and the gaskets (2pcs.) from the EGR cooler and the
Gasket
exhaust manifold.

(3) Remove the bolts (5pcs.), and remove the EGR pipe C
and the gaskets (2pcs.) from the EGR cooler and the
exhaust manifold.
EGR pipe C
')4ࡄࠗࡊ%
Gasket Gasket Exhaust
manifold
SAPH30ZCE0600003
6–4 EMISSION CONTROL

2. Disconnecting the coolant hoses

(1) Remove the clamp and remove the coolant hose from the
EGR cooler.
Clamp

Coolant
hose

EGR cooler
SAPH30ZCE0600004

(2) Remove the clamps (2pcs.) and remove the coolant hose
Water Coolant hose from the EGR cooler and water outlet block.
outlet block

Clamp EGR cooler

SAPH30ZCE0600005

(3) Remove the clamps (2pcs.) and remove the coolant hoses
Clamp
(2pcs.) from the EGR cooler.

Clamp
Coolant hose

SAPH30ZCE0600006

3. Removal the EGR cooler

(1) Remove the bolts (4pcs.) and remove the EGR cooler
Shell area EGR cooler from the thermostat case.

! CAUTION • Do not hold the shell area when attaching or

removing the EGR.
This can cause deformation, damage, or other
problems.
Thermostat
case
SAPH30ZCE0600007

4. Removal the intake pipe (intake side)

(1) Remove the intake pipe (intake side).
Refer to “8 INTAKE, Intake Manifold, Replacement“
 EMISSION CONTROL 6–5

5. Removal the EGR valve

(1) Remove the EGR valve and gaskets from the intake pipe.
Gasket
EGR valve (2) Remove the nuts and remove the stay from the EGR
valve.
Intake pipe
Stay ! CAUTION • Do not step onto the EGR valve at the time of
engine maintenance.
• Do not loosen or remove bolts, nuts, and/or
snap rings of the EGR valve component parts.
SAPH30ZCE0600008 Removal or loosening can cause performance
problems.
If disassembly with removal of bolts, nuts,
and/or snap rings has been performed, do not
try to reassemble, but replace the valve by a
new unit.
• Do not hold the link part when replacing the
EGR valve assembly. Holding the link part can
bend the link and can cause a malfunction.

Do not remove these bolts

Do not remove these nuts
Do not remove these snap rings
A

Link

A Section A - A

SAPH30ZCE0600009

INSPECTION OF THE COMPONENTS

1. Inspection of the EGR cooler

(1) Check visually for crack or clogging of the unit gas
channel. If a faulty item is found, replace the EGR cooler
unit.
6–6 EMISSION CONTROL

Installing of the EGR valve and the EGR cooler

1. Installation of the EGR cooler

(1) Install the stay to the EGR valve with the nuts.
Gasket
EGR valve (2) Replace the gasket by a new one and provisionally secure
the EGR valve at the intake pipe.
Intake pipe
Stay

SAPH30ZCE0600008

2. Installation of the intake pipe (intake side)

(1) Install the intake pipe (intake side).
Refer to “8 INTAKE, Intake Manifold, Replacement“

3. Installation of the EGR cooler

(1) Install the EGR cooler to the thermostat case with the
Shell area EGR cooler bolts (4pcs.).

Tightening torque :
36 N˜m {367 kgf˜cm, 26 lbf˜ft}

! CAUTION • Do not hold the shell area when attaching or

removing the EGR.
Thermostat
case This can cause deformation, damage, or other
SAPH30ZCE0600007 problems.
 EMISSION CONTROL 6–7

4. Connecting of the coolant hoses

Clamp
(1) Connect the coolant hoses (2pcs.) to the EGR cooler with
the clamps (2pcs.).

Clamp
Coolant hose

SAPH30ZCE0600006

(2) Connect the coolant hose to the EGR cooler and water
outlet block with the clamps (2pcs.).
Water Coolant hose
outlet block

EGR cooler
Clamp
SAPH30ZCE0600010

(3) Connect the coolant hose to the EGR cooler with the
clamp.

Clamp

Coolant
hose

EGR cooler
SAPH30ZCE0600004
6–8 EMISSION CONTROL

5. Installation of the EGR pipes

EGR pipe B EGR cooler
(1) Replace the gaskets by new ones (2pcs.) install the EGR
Gasket
pipe C to the EGR cooler and the exhaust manifold with
the bolts (5psc.).

Tightening torque : 68.5 N˜m {700 kgf˜cm, 51 lbf˜ft}

(2) Replace the gaskets by new ones (2pcs.) and install the
EGR pipe C
')4ࡄࠗࡊ% EGR pipe B to the EGR cooler and the exhaust manifold
Gasket Gasket Exhaust with the bolts (5psc.).
manifold
Tightening torque : 68.5 N˜m {700 kgf˜cm, 51 lbf˜ft}
SAPH30ZCE0600003

(3) Replace the gaskets by new ones (2pcs.) and install the
Gasket
EGR pipe A with the bolts (7psc.).

Tightening torque : 55 N˜m {560 kgf˜cm, 41 lbf˜ft}

EGR pipe A

Gasket

EGR cooler EGR valve

SAPH30ZCE0600002

6. Inspection of the EGR cooler

(1) Check visually for crack or clogging of the unit gas
channel and the sub-coolant pipe.
If a faulty item is found, replace the EGR cooler unit.

7. Inspection of EGR (Inspection with Hino DX)

(1) Inspect operation of the EGR valve on the vehicle using
Hino DX. (Refer to the “Hino DX operation manual”.)
 EMISSION CONTROL 6–9

Ventilator
Setup layout
Layout

Part layout
JP30ZCE060402002

NOTICE • This ventilator is maintenance free.

SAPH30ZCE0600011

12270 Ventilator SN711-00293 O-ring*

15609 Braket Z0104 O-ring*
17130 Ventilator pipe Z0104B O-ring*

*Parts not to be reused.

 ELECTRICAL 7–1

ENGINE

7 ELECTRICAL
Setup layout
Layout

Electrical System........................................................ 7-2

Part layout ............................................................... 7-2
Layout of components............................................. 7-5
Inspection of components....................................... 7-8
Installation of component ...................................... 7-10
Installation of starter ............................................. 7-11
Removal and installation of the alternator............. 7-12
Replacement of the Engine ECU .......................... 7-14
Replacement of back pressure sensor ................. 7-19 7
7–2 ELECTRICAL

Electrical System
Part layout
JP30ZCE070402001

SAPH30ZCE0700001

82051 Injector harness 89411 Engine main revolution sensor

83420 Water temperature sender gauge 89421 Boost pressure sensor
83530 Oil pressure warning switch Z4301 Gasket*
89390 Back pressure sensor Z4301A Gasket*
89410 Engine sub-revolution sensor
*Parts not to be reused.
 ELECTRICAL 7–3

SAPH30ZCE0700002

12511 Alternator bracket 28100 Starter assembly

27060 Alternator 88594 V –belt

Tightening torque
SH122-06440 83N˜m{850kgf˜cm, 61 lbf˜ft} SL150-40414 154N˜m{1,570kgf˜cm, 114 lbf˜ft}
SL150-41010 51N˜m{520kgf˜cm, 38 lbf˜ft} Z1051 154N˜m{1,570kgf˜cm, 114 lbf˜ft}
7–4 ELECTRICAL

SAPH30ZCE0700003

89661 Engine ECU

Tightening torque
SH552-10820 28.5N˜m{290kgf˜cm, 21 lbf˜ft}
 ELECTRICAL 7–5

Layout of components
JP30ZCE070402002

DPR back pressure senser

Boost pressure senser
EGR valve

Intake throttle
valve Engine main
revolution senser

Engine ECU

Starter
Suction control valve
Fuel temperature senser

SAPH30ZCE0700004
7–6 ELECTRICAL

Water temperature sender gauge

V-belt
Variable turbo actuator

Oil pressure warning switch Alternator

SAPH30ZCE0700005
 ELECTRICAL 7–7

Engine sub revolution senser

Common rail pressure senser

SAPH30ZCE0700006
Service procedure
Overhaul item
7–8 ELECTRICAL

Inspection of components
JP30ZCE070702001

1. Inspection of oil pressure warning switch

(Laid out on the oil filter)

(1) Apply pressure with air or oil and check continuity

between terminals using a circuit tester. If it is faulty,
replace it.

At no load or less than 39 kPa

With continuity
{0.4 kgf/cm2 ,5.6565 lbf/in.2}

At 39 kPa
SAPH30ZCE0700007
{0.4 kgf/cm2 , 5.6565lbf/in.2} Without continuity
or more

Oil pressure warning switch

39.2 - 58.8kPa
2 2
{0.4 - 0.6kgf/cm ,5.7 - 8.5 lbf/in } ON
2
2.9kPa{0.3kgf/cm ,
2
4.7lbf/in }
Within
OFF Toward pressure increase

SAPH30ZCE0700008

2. Inspection of coolant temperature sender gauge

Coolant temperature sender gauge
(Installation on thermostat case)

Connector color: Dark (1) Heat the coolant temperature sender gauge using hot
water.
A (2) Measure the resistance between terminals using a circuit
tester. If it is faulty, replace the gauge.
Between A and C
C
B Resistance value
Temperature (qC{qF})
SAPH30ZCE0700009
(:)

-20{-68} 13.84 - 16.33

20{68} 2.32 - 2.59

80{176} 0.31 - 0.326

110{230} 0.1399 - 0.1435

Between B and body

Resistance value
Temperature (qC{qF})
(:)

75{167} 79 - 92
100{212} 35.5 - 42.5
 ELECTRICAL 7–9

3. Inspection of glow plug

(1) Measure continuity between the body and the terminal

using a circuit tester. If it is faulty, replace the glow plug.

Standard value

Resistance value : :
(Normal temperature 2.7 - 3.5
20qC{68qF})

SAPH30ZCE0700010

4. Inspection of suction control valve SCV and fuel

Fuel temperature sensor temperature sensor

(1) For inspection of the suction control valve (SCV) and the
Suction control valve fuel temperature sensor, refer to the chapter of "5 FUEL
SYSTEM".
Refer to “5 FUEL SYSTEM, Supply pump, Inspection
of supply pump”

SAPH30ZCE0700011

5. Inspection of common rail pressure sensor

(1) For inspection of the common rail pressure sensor, refer

to the chapter of "5 FUEL SYSTEM".
Refer to “5 FUEL SYSTEM, Common rail, Inspection”

SAPH30ZCE0700012

6. Inspection of injector
(1) For inspection and replacement of the injector, refer to
the chapter of "5 FUEL SYSTEM".
Refer to “5 FUEL SYSTEM, Common rail, Inspection”
7–10 ELECTRICAL

Installation of component
JP30ZCE070702002

Installation of engine main revolution sensor

1. Installation of the engine main revolution sensor

Engine main revolution sensor
(1) Make sure that the sensor has the O-ring. Install the
sensor on the flywheel housing and the cam housing.

Tightening torque : 10 N˜m {102 kgf˜cm, 7.4 lbf˜ft}

! CAUTION • If the O-ring will be reused, make sure that the

o-ring is no sticking a foreign matter, no
damage, no deformation.
O-ring
NOTICE • This sensor is a flange type, gap does not
SAPH30ZCE0700013
have to be adjusted.
• This O-ring can be used again.

2. Connection of the harness

Connector
(1) Connect the connector to the engine main revolution
sensor.

! CAUTION • Before connecting the connector, confirm that

there are no signs of sparking on the terminal.

Flywheel housing

SAPH30ZCE0700014
 ELECTRICAL 7–11

Installation of the engine sub revolution sensor

1. Installation of the engine sub revolution sensor

Engine sub (1) Make sure that the sensor has the O-ring. Install the
revolution sensor
sensor to the cam housing upper side.
O-ring
Tightening torque : 4 - 6 N˜m {41 - 61 kgf˜cm, 3 - 4.4
lbf˜ft}

! CAUTION • If the O-ring will be reused, make sure that the

o-ring is no sticking a foreign matter, no
Cam housing
damage, no deformation.
SAPH30ZCE0700015
NOTICE • This sensor is a flange type, gap does not
have to be adjusted.
• This O-ring can be used again.

2. Connection of the harness

Connector (1) Connect the connector to the engine sub revolution
sensor.

! CAUTION • Before connecting the connector, confirm that

Cam housing
there are no signs of sparking on the terminal.

SAPH30ZCE0700016

Installation of starter
JP30ZCE070702003

1. Install the starter with bolts and nuts.

Tightening torque : 154 N˜m {1,570 kgf˜cm, 114 lbf˜ft}

SAPH30ZCE0700017
7–12 ELECTRICAL

Removal and installation of the alternator

JP30ZCE070702004

1. Removal of the alternator.

(1) Remove the adjustment bolt.

Adjustment
bolt Brace (2) Remove the fixing nut(s) on the side of the brace.
(3) Remove the through bolt while supporting the alternator,
Brace side
fixing nut and remove the alternator.

! CAUTION • When the through bolt is removed, the

alternator falls. The alternator must be firmly
Through bolt
supported during the through bolt removal.
SAPH30ZCE0700018

2. Installation of the alternator.

(A)
(1) Fasten the alternator provisionally with the through bolt
and the fixing nut on the side of the brace.
(2) Use the special tool and adjust the adjustment bolt so that
the V-belt is within the reference value at the measuring
position (A).

Measuring item Standard value

3 - 5mm
SAPH30ZCE0700019 Deflection
{0.1182 - 0.1968in.}
1,372 N
Tension
{140 kgf, 308 lbf}

Special tool : S0944-41210 (09444-1210)

Compression gauge (used at the time
of measuring the deflection amount)
[ Reference push force
98N {10kgf, 22lbf} ]
MITSUBOSHI BELTING LTD.; Belt
Tension Meter (DOCTOR TENSION£
TYPE-III) (used at the time of
measuring the tension force)

! CAUTION • When the V-belt has been replaced by a new

one, the V-belt will become loose because of
initial run-in, so that the V-belt tension should
be adjusted again after running the engine for
3 to 5 minutes.

NOTICE • At the time of inspection, the new V-belt has

reached the value after complete initial
stretching. A new V-belt completes initial
stretching after running the engine for
approximately two hours.
 ELECTRICAL 7–13

(3) After the adjustment, tighten all nuts and bolts securely.
Tightening torque :
83 N˜m {850 kgf˜cm, 61 lbf˜ft} (Through bolt)
51 N˜m {520 kgf˜cm, 38 lbf˜ft} (Fixing nuts at brace)
5.9 N˜m {60 kgf˜cm, 4 lbf˜ft} (Adjustment bolt)

! CAUTION • After the adjustment bolt has been tightened,

confirm that it is locked.
• When a tire lever is placed, do not place it
beyond the shaded area shown in the
alternator figure.

Alternator

SAPH30ZCE0700020
7–14 ELECTRICAL

Replacement of the Engine ECU

JP30ZCE070702005

Removing the engine ECU connector

! CAUTION • Before replacement, wait until the engine

cools down as you may get burned. (Turn the
starter key to the "OFF" position and leave it
for more than 30 minutes to cool.)

1. Cleaning the engine ECU connector

Engine ECU (1) Check that the engine ECU connector is completely
connected to the engine ECU.

(2) Directly spray water around the engine ECU connector by

using a small spray bottle.

! CAUTION • Do not remove the connector while at work.

Connector NOTICE • If it is much dirty, squirt water at the

connector sliding portion and connector
SAPH30ZCE0700021
surface.

(3) Blow air around the engine ECU connector and engine
ECU surface to remove dirt and foreign matter.

! CAUTION • Do not remove the connector while at work.

• Blow off water with air as much as possible
for drying.

(4) Using a small brush, carefully remove dirt and foreign

matter remaining at the sliding portion.

! CAUTION • Do not remove the connector while at work.

(5) Using a waste cloth, wipe off around the engine ECU
connector and engine ECU surface.

! CAUTION • Do not remove the connector while at work.

Sliding portion • Wipe up water thoroughly.
Lever
SAPH30ZCE0700022 (6) If you feel the movement of the lever unsmooth, repeat
steps (1), (2), (3), (4) and (5).
(7) Disconnect the engine ECU connector and check it for
deposition of dirt and foreign matter.
a. Set the hook of the connector in the direction of the
arrow to release the lock.

Hook

SAPH30ZCE0700023
 ELECTRICAL 7–15

b. While pushing the primary latch of the connector, move

the lever in the direction of the arrow as shown in the
figure until a “click” is heard and then detach the
connector.

Primary latch
Lever

SAPH30ZCE0700024

c. Pull out the connector straight.

! CAUTION • Do not insert and remove the connector more

than necessary.
• Do not give shocks to the engine ECU.
• Never detach the harness by holding and
pulling or prying as it may result in wire or
terminal deformation.
• Never insert a test lead from the rear of the
SAPH30ZCE0700025
connector.
• Do not paint or apply grease or oil to the
connector to maintain its function and
durability.

NOTICE • If it cannot be pulled out with a light force,

check if the lever is fully open.

(8) If the side of the harness side connector is found dirty,

wipe it off with a moistened waste cloth while being careful
Wipe off not allowing dirt and foreign matter to drop.
Do not wipe

! CAUTION • Use a thoroughly wrung waste cloth.

• Do not wipe off the terminal opening.
Harness side • Do not directly spray water.
connector

SAPH30ZCE0700026

(9) If the engine ECU side connector is found dirty, wipe off its
side with a moistened waste cloth.
Wipe off

Do not wipe ! CAUTION • Use a thoroughly wrung waste cloth.

• Do not wipe off the terminal opening.
• Do not directly spray water.
Engine ECU (10) Blow air on the terminal part inside the engine ECU side
side connector
connector to remove dirt and foreign matter.

SAPH30ZCE0700027
7–16 ELECTRICAL

Removal of the engine ECU

1. Removal of the engine ECU

Cylinder block (1) Remove the bolts (4pcs.) and remove the engine ECU
Rubber
and the rubber from the cylinder block.

! CAUTION • Protect the connector of the engine ECU with

a vinyl cover or similar to prevent the entry of
dirt or foreign matter.
• Do not subject the ECU to impacts.
Engine ECU • Do not use an engine ECU which has been
SAPH30ZCE0700028 dropped.
• Do not touch the connector terminals with
bare hands.
• The engine ECU cannot be disassembled.
• Do not apply paint, oil, or fat to the surface of
the ECU and the connector part in order to
maintain the functions and the durability.

Installation of the engine ECU

1. Installation of the engine ECU

Cylinder block (1) Install the engine ECU and the rubber with the bolts (4pcs.)
Rubber
to the cylinder block. Tighten the bolts in diagonal order.

Tightening torque : 28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

! CAUTION • Protect the connector of the engine ECU with

a vinyl cover or similar to prevent the entry of
dirt or foreign matter.
Engine ECU • Do not subject the ECU to impacts.
SAPH30ZCE0700028
• Do not use an engine ECU which has been
dropped.
• Do not touch the connector terminals with
bare hands.
• The engine ECU cannot be disassembled.
• Do not apply paint, oil, or fat to the surface of
the ECU and the connector part in order to
maintain the functions and the durability.
• Check that there is no dirt on the bosses (4
locations) on the rear of the engine ECU.

• Confirm that the filter (resin housing) on the

rear of the engine ECU is not broken or
Filter contaminated by oil.
(resin housing)

Boss

SAPH30ZCE0700029
 ELECTRICAL 7–17

Mounting the engine ECU connector

1. Attaching the engine ECU connector

(1) Check that the harness side connector lever is fully open
and place it straight on the engine ECU side connector.
Lever
! CAUTION • At this time, check that the lever is fully open.

SAPH30ZCE0700030

NOTICE • Check that it is inserted along the wrong

fitting prevention keyway.

Wrong fitting prevention keyway

SAPH30ZCE0700031

(2) Press the upper part of the harness side connector and
insert the connector uniformly.

Lever

SAPH30ZCE0700032
7–18 ELECTRICAL

(3) Move the lever in the direction of the arrow as shown in

the figure until a “click” is heard and attach the connector.

! CAUTION • If the lever cannot move smoothly, repeat

steps (1) and (2). Also drop a few drops of
water to the sliding portion to make it smooth.

Sliding portion Lever

SAPH30ZCE0700033

(4) Move the hook in the direction of the arrow as shown in

the figure until a “click” is heard in order to lock the
connector.

Hook
SAPH30ZCE0700034
 ELECTRICAL 7–19

Replacement of back pressure sensor

JP30ZCE070702006

Removal
NOTICE • DPR: Diesel Particulate active Reduction
system

1. Removal of the back pressure sensor

(1) Removal of the back pressure sensor.
Refer to the “10 EXHAUST, DPR cleaner, Overhaul”

Unit check

1. Resistance check
(1) Measure the resistance of the back pressure sensor with
a circuit tester. If the value exceeds the standard value,
replace it.

Measurement item Standard value (k:)

%

$
A to B 15
Back pressure sensor # B to C 15
SAPH30ZCE0700035

Installation of the back pressure sensor

1. Installation of the back pressure sensor

(1) Install the back pressure sensor.
Refer to the “10 EXHAUST, DPR cleaner, Overhaul”
 INTAKE 8–1

ENGINE

8 INTAKE
Setup layout
Layout

Intake Manifold ........................................................... 8-2

Part layout ............................................................... 8-2
Replacement........................................................... 8-3
Intake throttle valve .................................................... 8-5
Part layout ............................................................... 8-5
Inspection ............................................................... 8-6
Replacement........................................................... 8-6

8
8–2 INTAKE

Intake Manifold
Part layout
JP30ZCE080402001

SAPH30ZCE0800001

17103 Intake pipe 17171 Gasket*

17111 Intake manifold 17171A Gasket*

*Parts not to be reused.

Tightening torque
SH552-10855 28.5N˜m {290kgf˜cm, 21 lbf˜ft} SL150-10808 28N˜m {290kgf˜cm, 21 lbf˜ft}
SH552-11000 55N˜m {560kgf˜cm, 41 lbf˜ft}
Service procedure
Replacement procedure item
 INTAKE 8–3

Replacement
JP30ZCE080704001

1. Removal of intake manifold

(1) Remove bolts and nuts and remove the intake manifold.

2. Installation of intake manifold

(1) Clean inside of the intake manifold and the cylinder head.

(2) Assemble a new gasket.

! CAUTION • Install the gasket so that the protrusion may

come at the rear end stud bolt of the cylinder
head.

Protrusion
SAPH30ZCE0800002

(3) Install the intake manifold and tighten it with bolts and
nuts.

Tightening torque : 28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

SAPH30ZCE0800003

3. Installation of the intake pipe

EGR valve
(1) Install the stay to the EGR valve with the nut.
Gasket
Link (2) Replace the gaskets by new ones and provisionally install
the EGR valve to the intake pipe.
Intake pipe
Stay ! CAUTION • Do not hold the link part when replacing the
EGR valve assembly. Holding the link part can
bend the link and can cause a malfunction.

SAPH30ZCE0800004

(3) Remove dust from the joint surfaces and apply liquid
gasket {Threebond TB1207B (black) or equivalent} to the
Intake manifold
joint surface.

! CAUTION • Apply it continuously.

• Apply the liquid gasket at the width of 1.5 to
2.5 mm{0.0591 to 0.0984 in.}.
• Install that within 20 minutes after application
Liquid gasket of the liquid gasket.
SAPH30ZCE0800005
8–4 INTAKE

(4) Install the intake pipe to the intake manifold with the bolts
(3pcs.), nuts (2pcs.) and the EGR valve.
Intake manifold
Tightening torque : 55 N˜m {560 kgf˜cm, 41 lbf˜ft}
Intake pipe
! CAUTION • Provisionally secure the EGR valve with bolts
so as not to drop the EGR valve.
After installing the intake pipe and remove the
temporary tightened bolts.
EGR valve

SAPH30ZCE0800006

(5) Install the bracket to the cylinder block and the inlet pipe
with the bolts (4pcs.)

Tightening torque : 55 N˜m {560 kgf˜cm, 41 lbf˜ft}

Intake pipe

Bracket
Cylinder block
SAPH30ZCE0800007
 INTAKE 8–5

Intake throttle valve

Setup layout
Layout

Part layout
JP30ZCE080402002

SAPH30ZCE0800008

17113 Intake pipe 26100 Intake throttle valve

17171A Gasket*
*Parts not to be reused.
Tightening torque
SH552-10860 28.5N˜m {290kgf˜cm, 21 lbf˜ft}
Service procedure
Replacement procedure item
8–6 INTAKE

Inspection
JP30ZCE080704002

1. Inspection of the intake throttle valve

(1) Inspect the intake throttle valve using Hino DX.
Refer to the Hino DX manual
Service procedure
Replacement procedure item

Replacement
JP30ZCE080704003

Removal of the intake throttle valve

1. Removal of the inter cooler hose (outlet hose)

(1) Remove the inter cooler hose (outlet hose).

2. Removal of the harness

(1) Disconnect the connector from the intake throttle valve.

3. Removal of the intake throttle valve

Bolt (1) Remove the bolts (4pcs.) and remove the intake throttle
Intake throttle valve
valve and gasket from the intake pipe.

Intake pipe
SAPH30ZCE0800009

Installation of the intake throttle valve

1. Install the intake throttle valve to the intake pipe

Bolt temporarily with a new gasket.
Intake throttle valve
(1) Replace the gasket by new one, install the intake throttle
valve to the intake pipe temporarily, and tighten the bolts
in diagonal order.

Tightening torque : 28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

! CAUTION • Take care to install so that the valve is not

Intake pipe subjected to impact at the time of installation.
SAPH30ZCE0800009 Do not use the valve when it has been
subjected to impact.
• Remove any remaining gasket traces from the
intake throttle valve mounting surface of the
intake pipe before installation.

2. Connecting of the harness

(1) Connect the connector to the intake throttle valve.

3. Connecting of the inter cooler hose (outlet hose)

(1) Connect the inter cooler hose (outlet hose).
 ENGINE MECHANICAL 9–1

ENGINE

9 ENGINE MECHANICAL
Setup layout
Layout

Cylinder Head ............................................................. 9-2

Part layout ............................................................... 9-2
Replacement of cylinder head ................................ 9-4
Replacement of camshaft housing ......................... 9-7
Liquid gasket application procedure for cylinder plug
(only when cylinder plug is removed)...................... 9-8
Replacement of head cover .................................... 9-9
Overhaul of cylinder head ..................................... 9-10
Cylinder Block .......................................................... 9-13
Part layout ............................................................. 9-13
Overhaul ............................................................... 9-14
Timing Gear Cover and Flywheel Housing............. 9-18
Part layout ............................................................. 9-18
Replacement of flywheel housing ......................... 9-20
9
Replacement of rear end plate ............................. 9-21
Replacement of crankshaft front oil seal............... 9-22
Replacement of crankshaft rear oil seal................ 9-24
Main Moving Parts.................................................... 9-26
Part layout ............................................................. 9-26
Replacement of piston and connecting rod .......... 9-28
Inspection of piston and connecting rod ............... 9-32
Replacement of connecting rod bushing............... 9-34
Replacement of crankshaft ................................... 9-36
Inspection of crankshaft ........................................ 9-38
Replacement of crankshaft pulley......................... 9-41
Replacement of flywheel ...................................... 9-41
Camshaft and Idle Gear ........................................... 9-44
Part layout ............................................................. 9-44
Removal of camshaft ............................................ 9-46
Disassembly of camshaft ...................................... 9-46
Inspection of camshaft and camshaft bearing ...... 9-47
Assembly of camshaft........................................... 9-48
Installation of camshaft ......................................... 9-49
Gear train layout ................................................... 9-50
Removal of timing gear ........................................ 9-51
Inspection of timing gear components .................. 9-52
Installation of timing gear ...................................... 9-52
Overhaul of sub-idle gear (bearing case side) ...... 9-55
Inspection of installation status for each gear ...... 9-57
Valve System............................................................. 9-61
Part layout ............................................................. 9-61
Overhaul of valve system...................................... 9-62
Adjustment of valve clearance .............................. 9-67
9–2 ENGINE MECHANICAL

Cylinder Head
Part layout
JP30ZCE090402001

SAPH30ZCE0900001

11101 Cylinder head assembly 11135 Exhaust valve seat

11122 Valve guide 11176 Nozzle seat
11131 Intake valve seat Z9101 Gasket*

*Parts not to be reused.

 ENGINE MECHANICAL 9–3

SAPH30ZCE0900002

11101 Cylinder head assembly 11188A Cylinder plug

11103 Camshaft assembly 11210 Cylinder head cover
11115 Cylinder head gasket* 11213 Head cover gasket*
11118 Camshaft housing gasket* 12180 Oil filler cap
11188 Cylinder plug 23745 Pipe oil seal

*Parts not to be reused.

Tightening torque
11185 59N˜m{600kgf˜cm, 44 lbf˜ft}+90q+90q Z1050A 23N˜m{230kgf˜cm, 17 lbf˜ft}
SH512-21085 59N˜m{600kgf˜cm, 44 lbf˜ft} Z1050B 23N˜m{230kgf˜cm, 17 lbf˜ft}
SH521-20800 31N˜m{320kgf˜cm, 23 lbf˜ft} Z1050D 28.5N˜m{290kgf˜cm, 21 lbf˜ft}
SH521-20855 31N˜m{320kgf˜cm, 23 lbf˜ft} Z1070 6N˜m{60kgf˜cm, 4 lbf˜ft}
Z1050 23N˜m{230kgf˜cm, 17 lbf˜ft} Z1070A 6N˜m{60kgf˜cm, 4 lbf˜ft}
Service procedure
Replacement procedure item
9–4 ENGINE MECHANICAL

Replacement of cylinder head

JP30ZCE090704001

1. Removal of cylinder head and head gasket

(1) Loosen the head bolts from outside to inside gradually (1/
4 turn for each) as shown in the order of the figure and
remove them.

SAPH30ZCE0900003
(2) Remove the cylinder head using a special tool and hoist.
Figure is an Special tool : S0943–31070(09433–1070) Eye bolt
example of work.

NOTICE • If it is difficult to remove the cylinder head,

insert a chisel between the cylinder head and
the cylinder block, and move the chisel
vertically so that the contact surface may not
be damaged. Then, separate the cylinder
head.
SAPH30ZCE0900004

2. Inspection of head bolt length

(1) Measure the underhead length of the head bolt (M12 only)
using vernier calipers. If it is beyond the service limit,
replace it with a new one.

Standard value (mm{in.}) Service limit (mm{in.})

Underhead length
126{4.9606 in.} 126.5{4.9803 in.}

SAPH30ZCE0900005
 ENGINE MECHANICAL 9–5

3. Installation of head gasket and liquid gasket application procedure

(1) Cut the rear end plate gasket to be flush with the surface
of the cylinder block upper surface using a scraper.
(2) Install the head gasket on the cylinder block and the
flywheel housing.

! CAUTION • Remove dirt, water or oil from the mounting surfaces

of the cylinder head and the cylinder block before work.
• Never reuse the gasket. Otherwise, it may
damage the engine.
• The water hole seal ring of the head gasket is
susceptible to damage. Avoid contact with
hand or object.
Water hole seal ring
• Before installation of the head gasket, make
sure that there is no fall of or damage to the
seal ring.

SAPH30ZCE0900006

(3) Apply appropriate amount of liquid gasket [Threebond

Application area of liquid gasket TB1211 (white) or equivalent] to the head gasket hole at
the joint surface between the cylinder block and the
The arrow
shape flywheel housing.
area is
different
from the ! CAUTION • Apply the liquid gasket so that the surface of
actual
shape. the liquid gasket may be raised on the head
gasket.

Application area of • Install the oil cooler within 20 minutes after

liquid gasket
application of the liquid gasket.
Liquid gasket
Cylinder head

Cylinder Flywheel Small

block housing

Rear end plate

Clearance

Too small

Clearance Clearance

Raised from upper

Section A - A surface

SAPH30ZCE0900007
9–6 ENGINE MECHANICAL

4. Installation of cylinder head

Figure is an (1) Clean the head bolt seat at the cylinder head upper
example of work. surface and the cylinder head lower surface.
(2) Apply engine oil to the head bolt seat and the bolt thread.
(3) Align the dowel pins of the cylinder block using a special
tool and hoist and mount the cylinder head.

! CAUTION • Before mounting the cylinder head, make

sure that there is no foreign matter in the
SAPH30ZCE0900004
cylinder.
• When the cylinder head is mounted, be
careful for engagement between the cam idle
gear and the sub-idle gear. (Contact of gear
teeth with undue force may cause impact
mark or chipping, resulting in abnormal noise
or missing tooth.)

NOTICE • Mounting of the cylinder head with guide bolt

can prevent displacement of the liquid gasket.

Special tool : S0943–31070(09433–1070) Eye bolt

(4) Tighten head bolts M12 only in the order from the center
to outside.
Tightening torque : 59 N˜m {600 kgf˜cm, 44 lbf˜ft}

(5) After tightening M12 bolt, tighten the bolts again from the
center to outside.
Tightening torque : 59 N˜m {600 kgf˜cm, 44 lbf˜ft}

No. 1 to No. 26: M12 bolt

No. 27 to No. 29: M10 bolt
SAPH30ZCE0900008

(6) Mark the heads of the head bolts (M12 only) using paint.
(7) Retighten the 90 deg head bolts (M12 only) in the same
order in (5).
(8) Retighten the 90 deg head bolts (M12 only) in the same
order.
(9) Make sure that all marks face the same direction.
Paint mark
! CAUTION • If a bolt is turned excessively in retightening,
do not loosen it.

SAPH30ZCE0900009
 ENGINE MECHANICAL 9–7

(10) Tighten remaining head bolts (M10) in the order in the

figure.

Tightening torque : 59 N˜m {600 kgf˜cm, 44 lbf˜ft}

SAPH30ZCE0900010

Replacement of camshaft housing

JP30ZCE090704002

1. Removal of camshaft housing

(1) Remove bolts and remove the camshaft housing.

SAPH30ZCE0900011

2. Installation of camshaft housing

(1) Install new gasket and camshaft housing.

Tightening torque : 23 N˜m {230 kgf˜cm, 17 lbf˜ft}

! CAUTION • Refer to the figure for the mounting bolt

position.

SAPH30ZCE0900012
9–8 ENGINE MECHANICAL

Liquid gasket application procedure for

cylinder plug (only when cylinder plug is
removed) JP30ZCE090704003

1. Advance preparation
(1) Remove liquid gasket from the cylinder plug and the
camshaft housing.

2. Installation of the cylinder plug

(1) Apply the liquid gasket [Threebond TB1207B (black) or
equivalent] to the semi-circular areas at the front/rear
ends of the camshaft housing and install the cylinder plug.

{0.2362in.} Liquid gasket

SAPH30ZCE0900013

(2) Tighten the Torx bolt.

Tightening torque : 6 N˜m {60 kgf˜cm, 4 lbf˜ft}

SAPH30ZCE0900014

! CAUTION • Be sure to wipe protruding liquid gasket.

Area not applied with Cylinder plug
liquid gasket
• Make sure that the cylinder plug is seated
without inclination to the front or back.

Wipe Faulty Good

SAPH30ZCE0900015
 ENGINE MECHANICAL 9–9

Replacement of head cover

JP30ZCE090704004

1. Installation of head cover

(1) Remove liquid gasket near the side of the cylinder plug at
the front/rear ends of the camshaft housing, using a
scraper.

! CAUTION • If there is oil leak from the cylinder plug, do

not remove the cylinder plug.

SAPH30ZCE0900016

(2) Wipe dirt (including liquid gasket) and oil on the joint
surfaces of the head cover and the camshaft housing.
Install a new gasket on the head cover.

Head cover shape is a representative model.

SAPH30ZCE0900017

(3) Apply the liquid gasket [Threebond TB1207B(black) or

equivalent] near the side of the cylinder plug immediately
before installation of the head cover.

! CAUTION • Apply the liquid gasket at the width of 1.5 to

2.5 mm{0.0591 to 0.0984 in.}
• Install the oil cooler within 20 minutes after
application of the liquid gasket.
• Never apply the liquid gasket to the upper
SAPH30ZCE0900018 semi-circle of the cylinder plug.

(4) Put the head cover on the camshaft housing and tighten
Head cover Bolt bolts.
Silent block
Tightening torque : 28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

NOTICE • Silent block the rubber is attached to the

Head cover
spacer
gasket Head cover lower Overhaul item

surface

Camshaft housing
SAPH30ZCE0900019
9–10 ENGINE MECHANICAL

Overhaul of cylinder head

JP30ZCE090702001

1. Cleaning of cylinder head

(1) Remove carbon or other deposit using a scraper.

(2) Clean the cylinder head.

! CAUTION • To remove carbon or other deposit, do not

damage the lower surface of the cylinder
head.

SAPH30ZCE0900020

2. Replacement of valve guide

Intake Exhaust
(1) Remove the valve stem seal.
(2) Remove the valve guide using a brass bar or press.
(3) When a new valve guide is assembled, do not pry the end
in assembly and press fit using a special tool.
Special tool : S0947–11520(09471–1520) Guide

! CAUTION • In press fit, be careful not to damage the

Lower surface of cylinder head
valve stem at the upper/lower ends of the
SAPH30ZCE0900021
guide.
• In press fit, be sure to apply engine oil to the
circumference of the valve guide.

3. Replacement of valve seat

! CAUTION • The valve seat replacement procedure below

may damage the cylinder head depending on
the case. It is recommended that a request for
replacement be made to a machining vendor.

(1) If the valve seat is replaced, use an out-of-use valve.

Backing Valve seat After cutting three pieces from the valve circumference,
metal
weld them to the valve seat.

! CAUTION • Apply grease to protect the cylinder head

lower surface from welding spatter before
Electric welding
Valve work.
Cut three areas
from here. (2) Put a backup metal (e.g. brass bar) at the valve stem
head and pull out the valve seat using a press.
SAPH30ZCE0900022
(3) Remove welding spatter or dirt on the valve seat surface.
 ENGINE MECHANICAL 9–11

(4) Heat the cylinder head to approx. 80 to 100 qC {176 to 212

qF} and strike the cooled valve seat into the mounting area
of the cylinder head.

SAPH30ZCE0900023

(5) Apply small amount of lapping compound to the contact

surface between the valve and the valve seat.

(6) Strike gently while turning the valve using a special tool
for adjustment.
Special tool : S0943–11020(09431–1020)
Valve lapping tool

SAPH30ZCE0900024

4. Replacement of nozzle seat

(1) Tap the nozzle seat from the cylinder head lower part.
Then, put an appropriate bolt inside.
(2) Hit the bolt head using a hammer and pull out the nozzle
seat toward the the cylinder head upper part.
(3) Remove the O-ring from the cylinder head.

! CAUTION • After pulling out the nozzle seat, be sure to

remove deposit such as remaining liquid
SAPH30ZCE0900025 gasket or dirt.

(4) After attaching a new O-ring into the nozzle seat hole of
Cylinder head the cylinder head, apply the liquid gasket [Threebond
O-ring
TB1211 (white) or equivalent] at the lower part of a new
nozzle seat and assemble it on the cylinder head.

Nozzle sheet ! CAUTION • Be sure to replace the O-ring with a new part.
Reuse may cause water leak or gas leak,
resulting in overheat or crack of the cylinder
head.
SAPH30ZCE0900026
9–12 ENGINE MECHANICAL

(5) Clamp the nozzle seat using a special tool.

Bar Nozzle seat
Special tool : S0947-21210 (09472–1210) Bar
9800–06100 Steel ball

Cylinder
Head

Steel ball

Stamp out and clamp

SAPH30ZCE0900027

5. Inspection of cylinder head

(1) Inspection of cylinder head distortion

a. Measure distortion of the cylinder head lower surface
and the manifold mounting surface using a ruler.

Standard value (mm{in.}) Service limit (mm{in.})

Longitudinal direction
0.2{0.0079}
0.06{0.0024}
Lateral direction
0.2{0.0079}
0.03{0.0012}

b. If the measurement value is beyond the service limit,

replace it.

! CAUTION • Repair of the lower surface by grinding can

change backlash of the timing gear. Do not
grind it.

SAPH30ZCE0900028

(2) Inspection of cylinder head crack

a. With dye penetrant test method (red check), make sure
that there is no crack or damage in the cylinder head.
Setup layout
Layout
 ENGINE MECHANICAL 9–13

Cylinder Block
Part layout
JP30ZCE090402002

SAPH30ZCE0900029

11401 Cylinder block assembly 11463 Cylinder liner

11418 Cooling jet 11464 Cylinder liner
11462 Cylinder liner

Tightening torque
11521 69N˜m{700kgf˜cm, 51 lbf˜ft}+90q+45q 15605 22N˜m{220kgf˜cm, 16 lbf˜ft}
Service procedure
Overhaul item
9–14 ENGINE MECHANICAL

Overhaul
JP30ZCE090702002

1. Replacement of cylinder liner

(1) Put match marks on the flange surfaces of the cylinder

block and the cylinder liner using a oil based marker.

! CAUTION • Store removed cylinder liners for each

Match mark cylinder number.
• Never provide match marks with a punch.

SAPH30ZCE0900030

(2) Pull out the cylinder liner toward the cylinder block upper
part using a special tool.

Special tool : S0942-02100(09420-2100)

Cylinder liner puller

! CAUTION • Be careful for handling of the cylinder liner.

Do not reuse the cylinder liner which has
been dropped.

SAPH30ZCE0900031
• Do not touch the cooling jet during work.

(3) Apply engine oil to the inner bore of the cylinder block.

(4) Align the match mark of the cylinder liner with that of the
cylinder block. Install the cylinder liner using a special tool.
Special tool : S0947–11490(09471–1490) Guide

SAPH30ZCE0900032

! CAUTION • When a new cylinder liner is installed, install

Liner identification mark
the cylinder liner with the same identification
mark (A, B, C) stamped on the cylinder block.
• The example in the figure shows that the #1
cylinder is a liner of B.

Engine type stamp Example:

Front of engine
SAPH30ZCE0900033
 ENGINE MECHANICAL 9–15

$
#$%˴
OCTMKPIRQUKVKQP

SAPH30ZCE0900034

2. Inspection of protrusion at cylinder liner flange

(1) Fix the cylinder liner using a special tool.

Tightening torque : 9.8 N˜m {100 kgf˜cm, 7 lbf˜ft}
(2) Measure protrusion of the flange using a dial gauge.
Special tool : S0942–02100(09420–2100) Cylinder
liner puller

0.01 - 0.08
Standard value (mm{in.})
SAPH30ZCE0900035 {0.0004 - 0.0031}

3. Inspection and adjustment of cooling jet

Check bolt
(1) Remove the standard oil check valve and install the
cooling jet on the cylinder block using a special tool.
Special tool : SZ910–24098(9001–24262) Check bolt

Cooling jet

SAPH30ZCE0900184

(2) Connect the injection test oil hose from the lower part of
the cylinder block to the special tool check bolt.

! CAUTION • Use new engine oil for injection of oil.

Check bolt

Oil hose

SAPH30ZCE0900037
9–16 ENGINE MECHANICAL

(3) Set a special tool on the cylinder block.

SST Special tool : 09219-E4010 Gauge

Cylinder block

SAPH30ZCE0900038

(4) Inject oil from the nozzle of the cooling jet at the hydraulic
Oil injection unit (example)
Pressure pressure of 196kPa{2kgf/cm2, 28lbf/in.2}.
Regulator
Oil
Hose NOTICE • Refer to the drawing for the oil injection unit.
Air tank
(Oil tank) Compressed
Air gauge air

Air hose

To cooling jet Valve

SAPH30ZCE0900039

(5) When the injection center hits within the specified line of
the gauge, it is considered normal.
Injection Gauge target circle
! CAUTION • Oil is susceptible to combustion due to
spread. Do not use fire near around.
• Work at well ventilated place.

Faulty Faulty Normal Normal

(6) Make sure that the jet position check gauge hole at the
tool assembly.
(7) If injection does not hit the target circle, replace a new
SAPH30ZCE0900040
cooling jet for reinspection.
(8) Remove the check bolt and install the cooling jet on the
cylinder block using the genuine oil check valve.
Tightening torque : 22 N˜m {220 kgf˜cm, 16 lbf˜ft}
(9) After assembly of the piston, make sure that the cooling
jet does not interfere with the piston at the piston bottom
dead center.
 ENGINE MECHANICAL 9–17

4. Inspection of cylinder block

(1) Inspection of cylinder block distortion

a. Measure distortion on the cylinder block using a ruler.

Standard value (mm{in.}) Service limit (mm{in.})

Longitudinal direction
0.2{0.0079}
0.06{0.0024}
Lateral direction
0.2{0.0079}
0.03{0.0012}

b. If the measurement value is beyond the service limit,

replace it.

! CAUTION • Repair of the upper surace by grinding can

change backlash of the timing gear. Do not
grind it.

SAPH30ZCE0900042

(2) Inspection of cylinder block crack

a. With dye penetrant test method (red check), make sure
that there is no crack or damage in the cylinder block.
Setup layout
Layout
9–18 ENGINE MECHANICAL

Timing Gear Cover and Flywheel Housing

Part layout
JP30ZCE090402003

SAPH30ZCE0900043

11351 Flywheel housing 11359 Flywheel housing stay

11357 Gasket* 11390 End plate
11357A Gasket* Z3110 Rear oil seal*

*Parts not to be reused.

Tightening torque
SH552-11020 55N˜m{560kgf˜cm, 41 lbf˜ft} Z1101 55N˜m{560kgf˜cm, 41 lbf˜ft}
SH552-11075 55N˜m{560kgf˜cm, 41 lbf˜ft} Z1191 196N˜m{2,000kgf˜cm, 145 lbf˜ft}
SH552-11290 97N˜m{990kgf˜cm, 72 lbf˜ft} Z9102 196N˜m{2,000kgf˜cm, 145 lbf˜ft}
SH552-16085 55N˜m{560kgf˜cm, 41 lbf˜ft} Z9102A 196N˜m{2,000kgf˜cm, 145 lbf˜ft}
SL150-41010 55N˜m{560kgf˜cm, 41 lbf˜ft} Z9012B 36N˜m{370kgf˜cm, 27 lbf˜ft}
Z1051 171.5N˜m{1,750kgf˜cm, 127 lbf˜ft}
 ENGINE MECHANICAL 9–19

SAPH30ZCE0900044

11309 Oil seal retainer Z3117 Front oil seal*

*Parts not to be reused.

9–20 ENGINE MECHANICAL

Service procedure
Overhaul item

Replacement of flywheel housing

JP30ZCE090702003

1. Removal of flywheel housing

(1) Remove bolts and remove the flywheel housing.

! CAUTION • Remove bolts fixing the flywheel housing

from the cylinder block.

SAPH30ZCE0900045

2. Installation of flywheel housing

Liquid gasket
(1) Remove contamination from the joint surfaces of the
flywheel housing and the rear end plate using a scraper.
liquid
Gasket (2) Apply the liquid gasket [Threebond TB1207D (silver) or
equivalent] to the flywheel housing as shown in the figure.

! CAUTION • Apply it continuously.

• Apply the liquid gasket at the width of 1.5 to
2.5 mm{0.0591 to 0.0984 in.}.
SAPH30ZCE0900046
• Install the oil cooler within 20 minutes after
application of the liquid gasket.

(3) Install the flywheel housing on the cylinder block with

B bolts.
A A
B C Tightening torque :
196 N˜m {2,000 kgf˜cm, 145 lbf˜ft} (Area A)
C
C 36 N˜m {370 kgf˜cm, 27 lbf˜ft} (Area B)
C
A A 55 N˜m {560 kgf˜cm, 41 lbf˜ft} (Area C)
A
A ! CAUTION • Tighten bolts fixing the flywheel housing from
the cylinder block.
SAPH30ZCE0900047
 ENGINE MECHANICAL 9–21

Replacement of rear end plate

JP30ZCE090702004

1. Removal of rear end plate

(1) Remove bolts.

(2) Remove the Torx bolt using a special tool.
Special tool : S0941–11300(09411–1300)
Socket wrench

SAPH30ZCE0900048

2. Installation of rear end plate

(1) Install the rear end plate and a new gasket with bolts.

! CAUTION • Make sure that there is no dirt or foreign

matter on the installation surface of the
cylinder block and the screw holes.

(2) Apply sealant (Super 5M or equivalent) to the thread of

the Torx bolt.
(3) Install the Torx bolt using a special tool.
Special tool : S0941–11300(09411–1300)
Socket wrench

Tightening torque : 55 N˜m {560 kgf˜cm, 41 lbf˜ft}

SAPH30ZCE0900048

(4) Cut the rear end plate gasket with a scraper to be flush to
Gasket the upper/lower surfaces of the cylinder block.
Cylinder block Rear end plate

Flywheel housing

SAPH30ZCE0900049

Replacement procedure item

9–22 ENGINE MECHANICAL

Replacement of crankshaft front oil seal

JP30ZCE090704005

1. Removal of crankshaft front oil seal

(1) Install the plate of the special tool oil seal puller on the
crankshaft using two crankshaft damper mounting bolts.

Special tool : S0942–01731(09420–1731)

Oil seal puller

SAPH30ZCE0900050

(2) Hook the special tool oil seal puller with the tab of the
crankshaft front oil seal and install the hook on the plate of
the special tool oil seal puller with accompanying bolts.

SAPH30ZCE0900051

(3) Remove two bolts which installed the plate of the special
tool oil seal puller on the crankshaft.

(4) Attach the accompanying center bolt to the special tool oil
seal puller and tighten it. Pull out the crankshaft front oil
seal.

SAPH30ZCE0900052

2. Installation of crankshaft front oil seal

Guide
(1) Insert a new crankshaft oil seal into the guide of the oil
seal press.
Special tool : S0940–71030(09407–1030)
Oil seal press

! CAUTION • Be careful for front/rear directions of the

Oil seal crankshaft front oil seal. (The felt surface is at
the crankshaft damper side.)
SAPH30ZCE0900053
 ENGINE MECHANICAL 9–23

(2) Remove contamination from the joint surface of the

crankshaft front oil seal and the cylinder block.

(3) Apply small amount of engine oil to the seal area of the
crankshaft front oil seal.
(4) Install the oil seal press guide inserting a new crankshaft
front oil seal with accompanying guide bolts on the
crankshaft.

SAPH30ZCE0900054

(5) Align the oil seal press hole to the guide bolt and insert
the oil seal press.

(6) Attach the accompanying center bolt to the oil seal press
and tighten it until stop. Press fit the crankshaft front oil
seal.

SAPH30ZCE0900055
9–24 ENGINE MECHANICAL

Replacement of crankshaft rear oil seal

JP30ZCE090704006

1. Removal of crankshaft rear oil seal

(1) Install the plate of the special tool oil seal puller on the
crankshaft using two flywheel assembly mounting bolts.
Special tool : S0942–01742 (09420–1742)
Oil seal puller

! CAUTION • Align the large hole of the plate with the collar
dowel of the crankshaft.

SAPH30ZCE0900056

(2) Hook the oil seal puller with the tab of the crankshaft rear
oil seal and install the hook on the plate of the oil seal
puller with accompanying bolts.

(3) Remove two bolts which installed the plate of the oil seal
puller on the crankshaft.

SAPH30ZCE0900057

(4) Attach the accompanying center bolt to the oil seal puller
and tighten it. Pull out the crankshaft rear oil seal.

SAPH30ZCE0900058

2. Installation of crankshaft rear oil seal

Guide of oil seal press (1) Insert a new crankshaft rear oil seal into the guide of the
oil seal press.
Special tool : S0940–71040 (09407–1040)
Oil seal press

! CAUTION • Be careful for front/rear directions of the

Rear oil seal crankshaft rear oil seal. (The felt surface is at
the flywheel side.)
SAPH30ZCE0900059
 ENGINE MECHANICAL 9–25

(2) Remove contamination from the joint surface of the

crankshaft rear oil seal and the flywheel housing

(3) Apply small amount of engine oil to the seal area of the
crankshaft rear oil seal.
(4) Install the oil seal press guide inserting a new crankshaft
rear oil seal with accompanying guide bolts on the
crankshaft.

! CAUTION • Align the large hole of the guide with the

SAPH30ZCE0900060 collar dowel of the crankshaft.

(5) Align the oil seal press hole to the guide bolt and insert
the oil seal press.

SAPH30ZCE0900061

(6) Attach the accompanying center bolt to the oil seal press
and tighten it until stop. Press fit the crankshaft rear oil
seal.
Setup layout
Layout

SAPH30ZCE0900062
9–26 ENGINE MECHANICAL

Main Moving Parts

Part layout
JP30ZCE090402004

SAPH30ZCE0900063

11011 Thrust bearing 13450 Flywheel assembly

11701 Main bearing 13453 Ring gear
13041 Connecting rod Bearing 13521 Crankshaft gear
13260 Connecting rod assembly S130B Piston and piston ring set
13411 Crankshaft Z5203 Retainer ring*
*Parts not to be reused.
Tightening torque
13265 69N˜m{700kgf˜cm, 51 lbf˜ft}+90q+45q
 ENGINE MECHANICAL 9–27

SAPH30ZCE0900064

13407 Crankshaft damper 13471 Crankshaft pulley

*Parts not to be reused.

Tightening torque
13455 186N˜m{1,900kgf˜cm, 137 lbf˜ft} Z9102 108N˜m{1,100kgf˜cm, 80 lbf˜ft}
9–28 ENGINE MECHANICAL

Service procedure
Overhaul item

Replacement of piston and connecting rod

JP30ZCE090702005

1. Removal of piston
Figure is an
example of work. (1) Remove bolts and remove the connecting rod cap.

! CAUTION • Insert a large flat tip screwdriver into the

flywheel gear from the flywheel housing
inspection hole to prevent turning of the
crankshaft.
• Store removed connecting rod cap for each
cylinder number so that combinations of the
SAPH30ZCE0900065 connecting rod and the connecting rod cap
may not be changed.

(2) Remove carbon on the cylinder liner inner surface with a

scraper or a sand paper (No. 150 or so) in the
circumferential direction.

! CAUTION • Do not damage parts lower than the carbon

deposit area.

(3) Fix the cylinder liner with bolts and a plate.

SAPH30ZCE0900066

(4) Hit the connecting rod from underneath the engine using
a handle of a hammer. Remove the piston together with
the connecting rod.

! CAUTION • Store removed pistons and connecting rods

for each cylinder number.
• Be careful not to touch the cooling jet.

SAPH30ZCE0900067

NOTICE • In removing the piston, rotate the connecting

Cooling jet
rod as shown in the figure. Do not bend the
cooling jet.

SAPH30ZCE0900068
 ENGINE MECHANICAL 9–29

2. Disassembly of piston and connecting rod

(1) Remove the retainer ring using snap ring pliers.

(2) Remove the piston pin using the brass bar and disconnect
the piston from the connecting rod.

SAPH30ZCE0900069

(3) Remove the piston ring using a special tool.

Special tool : S0944–21011(09442–1011)

Piston ring expander

! CAUTION • Since the piston ring is susceptible to

damage, be careful for handling.
• Store piston rings for each cylinder number.
• Store the piston rings so that the upper and
SAPH30ZCE0900070 lower surfaces may be identified.

3. Assembly of piston and connecting rod

"0" mark position Piston
(1) Install the piston on the connecting rod so that the "0"
mark on the piston may be opposite to the match mark
Exhaust side Intake side
stamp on the connecting rod
(2) Install a new retainer ring using a snap ring pliers.
Oil hole
! CAUTION • Make sure that there is no backlash in the
Match mark retainer ring.
stamp

SAPH30ZCE0900071
9–30 ENGINE MECHANICAL

(3) Face the side with the piston ring identification print
upward and install in the order of the oil ring, second ring
and top ring using a special tool.

NOTICE • The identification print is present only on the

secondary ring and the top and bottom of the
top ring and the oil ring are not identified.
Top ring Second ring Oil ring
Upper surface
Special tool : S0944–21011(09442–1011)
Piston ring expander
Lower surface
(4) Connect the joint of the coil expander and fit the oil ring
Oil ring joint Clearance
inside the ring. Offset the coil expander joint with the ring
joint by 180 deg for installation.
(5) Allocate the joints of the piston ring with uniform intervals
Coil expander Ring
as shown in the figure.
Second ring

Oil ring Top ring

SAPH30ZCE0900072

4. Installation of piston and connecting rod

Oil hole
Concave shape (1) Allocate the joints of the piston ring with uniform intervals
as shown in the figure.
Oil hole
(2) Install the connecting rod bearing to suit concave shape of
Bearing
the connecting rod.

! CAUTION • Make sure that the oil hole of the connecting

rod bearing is aligned with the oil hole of the
Connecting rod
connecting rod.
SAPH30ZCE0900073

(3) Apply engine oil to the piston, cylinder liner and

connecting rod bearing and compress the piston ring
using a special tool.

Special tool : S0944–11370(09441–1370)

Piston ring holder

! CAUTION • Make sure that there is no deformation or

damage to the special tool piston ring holder.

SAPH30ZCE0900074
 ENGINE MECHANICAL 9–31

(4) Insert the piston carefully so that the connecting rod may
not come in contact with the cooling jet.

! CAUTION • Face the "0" mark on the piston toward the

exhaust side for insertion.
• Set the crankshaft of the cylinder as the top
dead center for assembly.
• Do not damage the cylinder liner, crankshaft
and cooling jet during work.
SAPH30ZCE0900075

(5) Install the connecting rod bearing to suit concave shape of

the connecting rod cap.
Cap

Bearing

SAPH30ZCE0900076

(6) Align the match mark of the connecting rod cap with that
of the connecting rod and fix it with a dowel pin.
Match mark
Stamp ! CAUTION • Do not change the combination between the
connecting rod and the connecting rod cap.
1234 1234

SAPH30ZCE0900077

(7) Measure the underhead length of the connecting rod bolt

using a vernier calipers. If it is out of the service limit,
replace it with a new one.

Standard value (mm{in.}) Service limit (mm{in.})

Underhead length
67.0{2.6378} or less 68.0{2.6772} or less

(8) Apply engine oil to the connecting rod bolt thread and the
seat and install it on the connecting rod.
SAPH30ZCE0900078
9–32 ENGINE MECHANICAL

(9) Tighten the connecting rod bolt and mark the bolt head in
Paint mark the same direction with paint.

Connecting rod cap Tightening torque : 69 N˜m {700 kgf˜cm, 51 lbf˜ft}

(10) Retighten the connecting rod bolt 90 q.
(11) Retighten the connecting rod bolt further 45 q.
45°
90° (12) Make sure that all marks are in the same direction.

! CAUTION • If a bolt is turned excessively in retightening,

do not loosen it.
SAPH30ZCE0900079

Inspection procedure item

Inspection of piston and connecting rod

JP30ZCE090703001

1. Inspection of piston clearance

(1) Measure the inner diameter of the cylinder liner sliding

surface using a cylinder gauge.

Standard value (mm{in.}) Service limit (mm{in.})

112{4.4094} 112.15{4.4154}

SAPH30ZCE0900080

(2) Measure the piston outer diameter using a micrometer.

! CAUTION • The measuring position is 23 mm{0.9055 in.}

above the piston lower end and square to the
pin hole.

Standard value (mm{in.}) 111.9r0.008{4.4055r0.0003}

(3) Calculate the difference between the inner diameter of the

SAPH30ZCE0900081
cylinder liner and the outer diameter of the piston. If it is beyond
the standard value, replace the cylinder liner and the piston.

Standard value (mm{in.}) 0.053 - 0.077{0.0021 - 0.0030}}

2. Inspection of clearance between piston ring and ring

groove

(1) Measure the piston ring width (B width) using a

micrometer. If it is beyond the service limit, replace the
piston ring.

Measuring Standard value Service limit

item (mm{in.}) (mm{in.})

Top ring 2.948{0.1161} 2.848{0.1121}

SAPH30ZCE0900082

Second ring 2{0.0787} 1.9{0.0748}

Oil ring 4{0.1574} 3.9{0.1535}

 ENGINE MECHANICAL 9–33

(2) Measure the piston ring groove using a thickness gauge.

If it is out of the service limit, replace the piston.

Measuring Standard value Service limit

item (mm{in.}) (mm{in.})

Top ring groove Tapered shape —

Second ring groove 2.0{0.0787} 2.2{0.0866}

Oil ring groove 4.0{0.1574} 4.1{0.1614}

SAPH30ZCE0900083

3. Inspection of piston ring joint clearance

Cylinder liner
(1) Insert the piston ring into the cylinder liner by 80 mm
horizontally using piston.
(2) Measure the piston ring joint clearance using a thickness
gauge. If it is out of the service limit, replace the piston
Piston Ring ring.

Measuring Service limit

Standard value (mm{in.})
item (mm{in.})
SAPH30ZCE0900084
0.30 - 0.40
Top ring 1.5{0.0591}
{0.0118 - 0.0157}

Second ring 0.75 - 0.90 {0.0295 - 0.0354} 1.5{0.0591}

0.15 - 0.30
Oil ring 1.2{0.0472}
{0.0059 - 0.0118}

4. Inspection of piston pin

(1) Measure the outer diameter of the contact area of the

piston pin with the piston boss using a micrometer.

Standard value (mm{in.}) Service limit (mm{in.})

37 {1.4567} 36.96{1.4551}

SAPH30ZCE0900085

(2) Measure the piston boss inner diameter using a cylinder gauge.

Standard value (mm{in.}) Service limit (mm{in.})

37 {1.4567} 37.05{1.4587}

(3) Calculate the difference between the outer diameter of the

piston pin contact area with the piston boss and the inner
diameter of the piston boss. If it is out of the service limit,
replace the piston pin or piston.
SAPH30ZCE0900086

Standard value (mm{in.}) Service limit (mm{in.})

0.011 - 0.032
0.05{0.0020}
{0.0005 - 0.0012}
9–34 ENGINE MECHANICAL

Replacement procedure item

Replacement of connecting rod bushing

JP30ZCE090704007

1. Removal of connecting rod bushing

Press (1) Put the special tool press sub-assembly together with the
Sub-assembly
Wing nut special tool guide nut and fix them using the special tool
wing nut.
Guide
Special tool : S0948–11130 (09481–1130) Guide
S0940–21530 (09402–1530)
Press sub-assembly
SL271–01036 (9233-10360) Wing nut

SAPH30ZCE0900087
! CAUTION • Face "H" mark of the guide upward for
assembly.
• Assemble it on a level table and make sure
that the lower end of the guide and the press
sub-assembly is flat.

(2) With the large end bearing removed, assemble the

connecting rod and put it on the assembled special tool.

SAPH30ZCE0900088

(3) Install the special tool spindle on the bushing of the

connecting rod.

Groove
Spindle
Special tool : S0940–21540(09402–1540) Spindle

Connecting rod ! CAUTION • Align the press sub-assembly groove with the
special tool spindle groove for installation.
Press
Sub-assembly

SAPH30ZCE0900089

(4) Remove the bushing of the connecting rod using a press.

! CAUTION • Move the press slowly.

SAPH30ZCE0900090
 ENGINE MECHANICAL 9–35

(5) Chamfer one side of the connecting rod small end

uniformly according to the figure.
Chamfer
! CAUTION • Remove burr completely.
• After chamfering, remove dirt from the inner
surface at the small end and from the oil hole.

SAPH30ZCE0900091

2. Installation of connecting rod bushing

(1) Install a new bushing on the special tool spindle and
Groove install the special tool guide and the special tool bolt.
Spindle
Special tool : S0940–21540 (09402–1540) Spindle
S0948–11540 (09481–1540) Guide
Bushing
SH691–20825 (9191–08252) Bolt
Guide
Tightening torque :
Bolt
5 - 6 N˜m {50 - 70 kgf˜cm, 3.5 - 4 lbf˜ft}
SAPH30ZCE0900092
! CAUTION • Align grooves of the special tool guide and
the special tool spindle for installation.
• Make sure that the edge of the special tool
spindle and the special tool guide is in close
contact.

(2) Align the connecting rod oil hole with the bushing oil hole
assembled on the special tool. Make sure that the groove
of the special tool spindle is in alignment with the groove
of the special tool press sub-assembly.
Groove
Oil hole ! CAUTION • Place the connecting rod so that the chamfer
side of the connecting rod small end inner
diameter may be the bushing side
• Apply engine oil to the inner diameter surface
SAPH30ZCE0900093 of the connecting rod.

(3) Install the bushing on the connecting rod using a press.

(4) Insert a rod with the diameter of 6 mm from the oil hole at
the connecting rod large end and make sure that it goes
through the oil hole at the small end.

NOTICE • Displacement of oil holes may cause

insufficient lubrication, resulting in seizure.

(5) Insert a new piston pin and check if there is no drag or

backlash.

SAPH30ZCE0900094
9–36 ENGINE MECHANICAL

Replacement of crankshaft
JP30ZCE090704008

1. Removal of crankshaft

(1) Remove the main bearing cap and the crankshaft bearing.
Remove the crankshaft using a hoist.

! CAUTION • Since the part is heavy, be careful for

handling.
• Store removed main bearing caps and
crankshaft bearings for each cylinder number.

SAPH30ZCE0900095

2. Installation of crankshaft

(1) Face the groove side (front) of the thrust bearing toward
the crankarm and the part number side (back) toward the
main bearing cap or the cylinder block. Install it on the
cylinder block and the main bearing cap.

! CAUTION • To prevent falling in assembly, apply engine

oil or grease to the back of the thrust bearing.

(2) Install the main bearing on the cylinder block and each
bearing cap.

! CAUTION • Assemble the bearing with oil hole on the

cylinder block and assemble the bearing
without oil hole on the cap.
• Apply new engine oil to the sliding surfaces of
each bearing.

(3) Align the crankshaft with the cylinder block.

SAPH30ZCE0900096

(4) Align the main bearing cap which has the thrust bearing
Stamp number and the main bearing with the cylinder block.
Front of engine

! CAUTION • The pentagon mark on the main bearing cap

should face the front of the vehicle. Align in
1 2 3 4 5 6 7 the order of 1, 2, 3, 4, 5, 6 and 7 from the
front.
• Check the stamp number of each main
Stamp number bearing cap with the stamp number of the
SAPH30ZCE0900097 cylinder block.
 ENGINE MECHANICAL 9–37

(5) Measure the underhead length of the bearing cap bolt

using a vernier calipers. If it is out of the service limit,
replace it with a new one.

Standard value (mm{in.}) Service limit (mm{in.})

Underhead length
106.8{4.2047} 108{4.2520}

SAPH30ZCE0900078

(6) Apply engine oil to the bolt seat and the bolt thread of the
bearing cap bolt.

(7) Tighten the bearing cap bolt according to the sequence in

2 4 6 8 10 12 14 the figure.
Tightening torque : 69 N˜m {700 kgf˜cm, 51 lbf˜ft}
1 3 5 7 9 11 13
(8) Loosen the bearing cap fixing the thrust bearing and hit
the crankshaft gently at the front/rear end using a plastic
Front of engine hammer.
(9) Loosen all bearing cap bolts.
SAPH30ZCE0900098
(10) Tighten the bearing cap bolt as in (7).
Tightening torque : 69 N˜m {700 kgf˜cm, 51 lbf˜ft}
(11) Mark bearing cap bolt heads in the same direction with
paint.
(12) Tighten 90 deg (1/4 turn) with the same order as in (7).
(13) Retighten 45 deg (1/8 turn) as in (7).
Paint mark
(14) Make sure that all paint marks are in the same direction.

! CAUTION • If it is excessively retightened, do not loosen

it.
45ࠑ
90ࠑ
(15) After tightening, hit the front/rear ends of the crankshaft
gently with a plastic hammer for initial fit.

SAPH30ZCE0900099 ! CAUTION • Make sure that the crankshaft turns smoothly.

• Measure the end play of the crankshaft and
make sure that it is within the standard value.

Standard value Repair limit Service limit

(mm{in.}) (mm{in.}) (mm{in.})

0.05 - 0.270
0.5{0.0197} 1.270{0.0500}
{0.0020 - 0.0106}

Inspection procedure item

9–38 ENGINE MECHANICAL

Inspection of crankshaft
JP30ZCE090703002

1. Inspection of end play

(1) Measure the end play of the crankshaft using a dial
gauge. If it is beyond the repair limit, replace the thrust
bearing. If it is beyond the service limit, replace the
crankshaft.

Standard value Repair limit Service limit

(mm{in.}) (mm{in.}) (mm{in.})

0.05 - 0.270
SAPH30ZCE0900100 0.5{0.0197} 1.270{0.0500}
{0.0020 - 0.0106}

NOTICE • Standard width of thrust

bearing2.5mm{0.0984in.}

2. Inspection of rotation runout

Figure is an
example of work. (1) Measure the crankshaft rotation runout using a dial
gauge. If it is beyond the repair limit, replace the
crankshaft.

Standard value (mm{in.}) Repair limit (mm{in.})

0 - 0.1{0 - 0.0039} 0.15{0.0059}

SAPH30ZCE0900101

3. Inspection of journal wear

Measure two (1) Measure the outer diameter of the crankshaft journal
places. using a micrometer. If it is faulty, replace the crankshaft.
90ࠑ

Standard value (mm{in.}) Service limit (mm{in.})

80.0{3.1496} 79.3{3.1221}

SAPH30ZCE0900102

(2) Measure the crankshaft center journal width using a

Figure is an vernier calipers. If it is out of the service limit, replace the
example of work.
crankshaft.

Standard value (mm{in.}) Service limit (mm{in.})

36{1.4173} 37.0{1.4567}

SAPH30ZCE0900103
 ENGINE MECHANICAL 9–39

4. Inspection of crankshaft oil clearance

(1) Measure the outer diameter of the crankshaft journal

using a micrometer.
90

Standard value (mm{in.}) 80{3.1496}

SAPH30ZCE0900104

(2) Do not install the crankshaft. Install the crankshaft bearing

and the main bearing cap on the cylinder block.

(3) Measure the crankshaft bearing inner diameter using a

cylinder gauge.
(4) Calculate the difference between the outer diameter of the
crankshaft journal and the inner diameter of the
crankshaft bearing. If it is beyond the repair limit, grind the
crankshaft or replace the crankshaft.

SAPH30ZCE0900105
Standard value (mm{in.}) Repair limit (mm{in.})

0.051 - 0.102
0.2{0.0079}
{0.0020 - 0.0040}

(5) If grinding the crankshaft, adjust the dimension of fillet “R”

as shown below.
Radius is
incomplete. Radius is Crank pin
small. Step Step
R
2.5 to 3.0mm {0.0984 to 0.1181 in.}
Journal
2.5 to 3.0mm {0.0984 to 0.1181 in.}
Good Poor

SAPH30ZCE0900106

5. Inspection of crack and damage on crankshaft and of oil

Figure is an hole
example of work.
(1) Check for crack or damage using dye penetrant. If a faulty
condition is found, replace the crankshaft.

SAPH30ZCE0900107
9–40 ENGINE MECHANICAL

(2) Check for clogging of the crankshaft oil hole. If faulty

Figure is an condition is found, replace the crankshaft.
example of work.

SAPH30ZCE0900108

6. Inspection of pin wear

(1) Measure the outer diameter of the crankshaft crank pin

90°Measurement
at 2 places using a micrometer. If it is faulty, replace the crankshaft.

Standard value (mm{in.}) Service limit (mm{in.})

65{2.5590} 64.3{2.5315}

SAPH30ZCE0900109

(2) If grinding the crankshaft, adjust the dimension of fillet “R”

as shown below.
Radius is
incomplete. Radius is Crank pin
small. Step Step
R
2.5 to 3.0mm {0.0984 to 0.1181 in.}
Journal
2.5 to 3.0mm {0.0984 to 0.1181 in.}
Good Poor

SAPH30ZCE0900106
 ENGINE MECHANICAL 9–41

Replacement procedure item

Replacement of crankshaft pulley

JP30ZCE090704009

1. Removal of crankshaft pulley

(1) Remove bolts and remove the crankshaft pulley.

NOTICE • Insert a large flat tip screwdriver into the

flywheel gear from the flywheel housing
inspection hole to prevent turning of the
crankshaft.

SAPH30ZCE0900110

2. Installation of crankshaft pulley

(1) Apply engine oil to the bolt seat and the bolt thread of the
1 crankshaft pulley mounting bolt.
6 3 (2) Install the crankshaft pulley on the crankshaft and tighten
it according to the figure.
4 5 Tightening torque : 118 N˜m {1,200 kgf˜cm, 87 lbf˜ft}
2
NOTICE • Insert a large flat tip screwdriver into the
flywheel gear from the flywheel housing
SAPH30ZCE0900111 inspection hole to prevent turning of the
crankshaft.

Replacement of flywheel
JP30ZCE090704010

1. Removal of flywheel
Engine revolution sensor
Flywheel
(1) Remove the engine revolution sensor.
Mounting bolt (2) Remove bolts fixing the flywheel.

NOTICE • Insert a large flat tip screwdriver into the

flywheel gear from the flywheel housing
inspection hole to prevent turning of the
crankshaft.

SAPH30ZCE0900112

(3) Install a special tool into the bolt hole of the crankshaft to
remove the flywheel.

Special tool : S0948–11340(09481–1340) Guide

! CAUTION • Since the flywheel is heavy, be careful for

handling.
• Do not give impact to the special tool during
work.
SAPH30ZCE0900113
9–42 ENGINE MECHANICAL

2. Removal of ring gear

(1) Heat the entire ring gear circumference with a burner until
it is about 200 qC {392qF}.

! CAUTION • Do not touch the ring gear and the flywheel

with bare hand while they are hot.

SAPH30ZCE0900114

(2) Hit the circumference of the ring gear gently using a

backing rod to remove the ring gear from the flywheel.

! CAUTION • Do not touch the ring gear and the flywheel

with bare hand while they are hot.

SAPH30ZCE0900115

3. Installation of ring gear

(1) Heat the entire ring gear circumference with a burner until
it is about 200 qC {392qF}.

! CAUTION • Do not touch the ring gear and the flywheel

with bare hand while they are hot.

SAPH30ZCE0900116

(2) Face the chamfered side toward the flywheel and install it
on the flywheel quickly.

! CAUTION • Do not touch the ring gear and the flywheel

with bare hand while they are hot.

SAPH30ZCE0900117
 ENGINE MECHANICAL 9–43

4. Installation of flywheel

(1) Make sure that there is no burr or dirt on the joint surface
of the crankshaft and the flywheel and the screw hole.
(2) Install the special tool into the bolt hole of the crankshaft.
Special tool : S0948–11340(09481–1340) Guide

NOTICE • Install one special tool on the collar dowel

and the other at the opposite side of the collar
dowel.
SAPH30ZCE0900118

(3) Insert the flywheel until it comes in contact with the collar
dowel of the crankshaft and adjust the position.

! CAUTION • Since the flywheel is heavy, be careful for

handling.
• Do not give impact to the special tool during
work.

(4) Insert the flywheel until it comes in contact with the

crankshaft.

(5) Apply engine oil to the bolt seat and the bolt thread of the
flywheel mounting bolt.

SAPH30ZCE0900119

(6) Tighten 6 bolts by 2 to 3 threads temporarily with hand in

the bolt holes without installation of the special tool.

(7) Tighten 6 bolts gradually and tighten temporarily.

(8) Remove the special tool and tighten remaining two bolts
temporarily as in (6) and (7).

SAPH30ZCE0900120

(9) Tighten the flywheel according to the order in the figure.

Tightening torque : 186 N˜m {1,900 kgf˜cm, 137 lbf˜ft}

1 NOTICE • Insert a large flat tip screwdriver into the
5 8
flywheel gear from the flywheel housing
3 4
inspection hole to prevent turning of the
7 6
2 crankshaft.

(10) Loosen all bolts.

(11) Tighten the bolts again.
SAPH30ZCE0900121
Tightening torque : 186 N˜m {1,900 kgf˜cm, 137 lbf˜ft}
(12) Install the engine revolution sensor.
Setup layout
Layout
9–44 ENGINE MECHANICAL

Camshaft and Idle Gear

Part layout
JP30ZCE090402005

SAPH30ZCE0900122

13501 Camshaft assembly 13572 Thrust plate

13505 Sub-idle gear 13572A Thrust plate
13508 Main idle gear 13581 Idle gear shaft
13050 Camshaft gear 13581A Idle gear shaft

Tightening torque
Z9102A 59N˜m{600kgf˜cm, 44 lbf˜ft}+90q Z9102B 172N˜m{1,750kgf˜cm, 127 lbf˜ft}
 ENGINE MECHANICAL 9–45

SAPH30ZCE0900123

13508 Cam idle gear 13581 Idle gear shaft

13572 Thrust plate

Tightening torque
Z9102 108N˜m{1,100kgf˜cm, 80 lbf˜ft}
9–46 ENGINE MECHANICAL

Service procedure
Overhaul item

Removal of camshaft
JP30ZCE090702006

1. Removal of rocker arm and camshaft assembly

(1) Loosen the lock nut and turn the adjusting screw
completely.
Rock nut

! CAUTION • Removal without turning the adjusting screw

may bend the rocker shaft.

(2) Loosen the rocker arm support bolts gradually from the
center and remove the rocker arm and the rocker arm
shaft.
SAPH30ZCE0900124

Disassembly of camshaft
JP30ZCE090702007

1. Disassembly of camshaft
(1) Fix the camshaft gear using a vice to disassemble the
camshaft.

! CAUTION • Prevent faulty conditions on the gear such as

deformation, impact, scratch, etc.

SAPH30ZCE0900125
 ENGINE MECHANICAL 9–47

Inspection of camshaft and camshaft

bearing
JP30ZCE090702008

1. Inspection of cam height on camshaft

(1) Measure the cam height using a micrometer. If it is
beyond the service limit, replace the camshaft.

Measuring Standard value Service limit

item (mm{in.}) (mm{in.})

Cam IN 50.067{1.9711} 49.987{1.9680}

height EX 52.104{2.0513} 52.024{2.0482}

SAPH30ZCE0900126 IN 8.067{0.3176} (7.987{0.3144})

Cam lift
EX 10.104{0.3978} (10.024{0.3946})

2. Inspection of camshaft runout

(1) Put the journal at both ends of the camshaft on the V

Camshaft runout measuring area
block.
(2) Put a dial gauge to each journal of the camshaft and
measure runout of the camshaft. If it is beyond the service
limit, replace the camshaft.

Standard value (mm{in.}) Service limit (mm{in.})

0.04{0.0016} 0.1{0.0039}
SAPH30ZCE0900127

3. Inspection of camshaft bearing oil clearance

(1) Measure the outer diameter of the camshaft journal using
a micrometer.

Standard value (mm{in.}) Service limit (mm{in.})

40{1.5748} 39.85{1.5689}

(2) Measure the camshaft bearing inner diameter using a

cylinder gauge.
SAPH30ZCE0900128

Standard value (mm{in.}) Service limit (mm{in.})

40{1.5748} 40.15{1.5807}

(3) Calculate the difference of the camshaft journal bearing

inner diameter. If it is beyond the standard value, replace
the camshaft or the camshaft bearing.

0.020 - 0.063
Standard value (mm{in.})
{0.0008 - 0.0025}
9–48 ENGINE MECHANICAL

Assembly of camshaft
JP30ZCE090702009

1. Measuring of the camshaft gear mounting bolt

(1) Measure the camshaft mounting bolt using a vernier
calipers. If it is out of the service limit, replace it with a
new one.

Standard value (mm{in.}) Service limit (mm{in.})

Underhead length 30.0{1.1811} 30.5{1.2010}

SAPH30ZCE0900129

2. Assembly of the camshaft

(1) Fix the camshaft gear using a vice. Apply engine oil to the
seat and the bolt thread of the camshaft gear mounting
bolt.

(2) Set the dowel pin to the camshaft and the camshaft gear
and tighten the camshaft gear mounting bolt.
Tightening torque : 59 N˜m {600 kgf˜cm, 44 lbf˜ft}
(3) Retighten 90 deg (1/4 turn).

SAPH30ZCE0900130 ! CAUTION • If it is excessively retightened, do not loosen

it.
• Prevent faulty conditions on the gear such as
deformation, impact, scratch, etc.
 ENGINE MECHANICAL 9–49

Installation of camshaft
JP30ZCE090702010

1. Advance preparation
(1) Align the No. 1 cylinder to the compression top dead
center.

2. Installation of camshaft
Timing judgment drill hole
(1) Place the camshaft so that two holes at 180 degrees from
the three drilled holes of the camshaft gear may be
horizontal to the upper surface of the camshaft housing.

! CAUTION • Place a transparent plastic ruler or an edged

ruler on the upper surface of the camshaft
Ruler, etc. housing and the side of the camshaft gear.
Drilled hole to prevent incorrect assembly Make sure that the position of the foolproof
SAPH30ZCE0900131 drilled hole is above the ruler.

(2) Coat the bearing parts with engine oil and then install the
camshaft bearing caps in numerical order 1-2-3-4-5 from
the front of the engine, making sure the three-sided mark
on the cap points forward.
1

(3) Make sure the crosshead is correctly laid across each

valve.

! CAUTION • To make sure the crosshead is correctly in

place, move it to the left and right by hand and
SAPH30ZCE0900132 make sure it clicks against the valves.
• If the crosshead is not sitting properly on the
valves, it will push the upper seat and cause
the valve to drop out.

(4) Make sure the rocker arm is correctly assembled on the

rocker arm shaft.
(5) Fully unscrew the adjust screw on the end of the rocker
arm.

NOTICE • Securing the rocker arm and nozzle clamp

together with a string will facilitate installation
work.

(6) Apply engine oil to the cam threads and set the rocker
arm in position, making sure it is correctly laid on the
crosshead. Then, tighten the bolts in the sequence
shown in the figure, making several passes and gradually
tightening them each time.
Tightening torque : 28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

! CAUTION • After the bolts are tightened, make sure the

rocker arm moves smoothly.
Setup layout
Layout
9–50 ENGINE MECHANICAL

Gear train layout

JP30ZCE090402006

Camshaft gear

Main idle gear

Cam idle gear

Pump drive idle gear

Sub-idle gear

Oil pump gear

Crankshaft gear

Air compressor
drive gear
(supply pump
drive gear)

Match mark Match mark Match mark

SAPH30ZCE0900133
 ENGINE MECHANICAL 9–51

Service procedure
Overhaul item

Removal of timing gear

JP30ZCE090702011

1. Removal of main idle gear

(1) Remove the idle gear shaft mounting bolt and pull out the
main idle gear assembly using a special tool.

Special tool : S0942–01100(09420–1100)

Sliding hammer

(2) Remove the idle gear thrust plate.

(3) Remove the idle gear shaft from the main idle gear.

SAPH30ZCE0900134

2. Removal of sub-idle gear

(1) Remove the idle gear shaft mounting bolt and the idle
gear thrust plate and pull out the sub-idle gear assembly
using a special tool.

Special tool : S0942–01100(09420–1100)

Sliding hammer

(2) Remove the idle gear thrust plate.

(3) Remove the idle gear shaft from the sub-idle gear.
SAPH30ZCE0900135
9–52 ENGINE MECHANICAL

Inspection of timing gear components

JP30ZCE090702012

1. Inspection of clearance between idle gear shaft and idle

gear bushing
(1) Measure the idle gear shaft outer diameter using a
micrometer and the idle gear bushing inner diameter
using a cylinder gauge.

Standard value
Measuring item
(mm{in.})

Main idle Shaft outer diameter 57{2.2441}

gear shaft Bushing inner diameter 57{2.2441}

Sub-idle Shaft outer diameter 50{1.9685}

gear shaft Bushing inner diameter 50{1.9685}

Cam idle Shaft outer diameter 34{1.3386}

gear Bushing inner diameter 34{1.3386}

(2) Calculate the difference between the idle gear bushing

inner diameter and the idle gear shaft outer diameter. If it
SAPH30ZCE0900136 is beyond the service limit, replace the idle gear shaft and
the idle gear bush.

Measuring Standard value Service limit

item (mm{in.}) (mm{in.})

Main idle gear 0.030 - 0.090

0.20{0.0079}
shaft {0.0012 - 0.0035}

Sub-idle gear 0.025 - 0.075

0.20{0.0079}
shaft {0.0010 - 0.0030}

0.025 - 0.075
Cam idle gear 0.20{0.0079}
{0.0010 - 0.0030}

Installation of timing gear

JP30ZCE090702013

1. Installation of sub-idle gear

(1) Install the idle gear shaft on the sub-idle gear.
Thrust plate
(2) Install the idle gear thrust plate.
(3) Provide the lubricating hole of the idle gear shaft in the
Idle gear thrust vertical direction.
plate
(4) Install the idle gear thrust plate on the idle gear shaft.
Lubricating
hole
Cylinder block

SAPH30ZCE0900137
 ENGINE MECHANICAL 9–53

(5) Apply engine oil to the bolt seat and the bolt thread of the
idle gear shaft mounting bolt.
(6) Install the idle gear shaft mounting bolt.
Tightening torque : 108 N˜m {1,100 kgf˜cm, 80 lbf˜ft}

SAPH30ZCE0900138

2. Installation of main idle gear

Idle gear thrust plate (1) Install the idle gear shaft on the main idle gear.
(2) Install the idle gear thrust plate.

Lubricating
hole
Cylinder
Block

SAPH30ZCE0900139

(3) Face the lubricating hole of the idle gear shaft toward the
oil pan (downward). Install A in the figure by adjusting the
Sub-idle gear timing of the crankshaft gear and the main idle gear as in
the detailed drawing.

Oil pump
gear

A
Main idle gear

Crankshaft gear

Arrange drilled holes in line.

Detail

SAPH30ZCE0900140
9–54 ENGINE MECHANICAL

(4) Apply engine oil to the bolt seat and the bolt thread of the
idle gear shaft mounting bolt.

(5) Install the idle gear shaft mounting bolt.

Tightening torque : 172 N˜m {1,750 kgf˜cm, 127 lbf˜ft}
(6) Measure backlash and end play of each idle gear. Make
sure that it is within the standard value.

SAPH30ZCE0900141
 ENGINE MECHANICAL 9–55

Overhaul of sub-idle gear (bearing case side)

JP30ZCE090702014

1. Removal of bearing case assembly

(1) Remove the supply pump drive.
Refer to “5 FUEL SYSTEM, Supply pump,
Replacement of supply pump”
(2) Remove 5 bolts and remove the bearing case assembly.

! CAUTION • One bolt is tightened from the timing gear

case.

SAPH30ZCE0900142

(3) Fix the bearing case with a vice.

SAPH30ZCE0900143

(4) Remove the sub-idle gear shaft mounting bolt and pull out
the idle gear shaft using a sliding hammer.

SAPH30ZCE0900144

(5) Remove the sub-idle gear.

(6) Remove the idle gear thrust plate.

SAPH30ZCE0900145
9–56 ENGINE MECHANICAL

2. Inspection of clearance between sub-idle gear shaft and

sub-idle gear bushing

(1) Measure the outer diameter of the idle gear shaft.

SAPH30ZCE0900146

(2) Measure the inner diameter of the sub-idle gear.

(3) Calculate the clearance. If it is beyond the service limit

value, replace the shaft and the bushing.

Standard value (mm{in.}) Service limit (mm{in.})

0.025 - 0.057 0.010

{0.0010 - 0.0022} {0.0039}

SAPH30ZCE0900147

3. Installation of bearing case assembly

(1) Install the idle gear thrust plate.

(2) Install the gear shaft on the sub-idle gear.
(3) Face the lubricating hole of the gear shaft downward and
install it on the bearing case.
(4) Install the sub-idle gear shaft mounting bolt.
Tightening torque : 108 N˜m {1,100 kgf˜cm, 80 lbf˜ft}

SAPH30ZCE0900148

(5) Align two pins of the bearing case assembly with the
concave area of the flywheel housing for installation.

Tightening torque : 28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

! CAUTION • Be careful for fall of the O-ring

Inspection procedure item

SAPH30ZCE0900149
 ENGINE MECHANICAL 9–57

Inspection of installation status for each

gear
JP30ZCE090703003

1. Inspection of backlash between camshaft gear and cam

idle gear

(1) Insert a large flat tip screwdriver into the cam idle gear
from the side of the camshaft gear of the camshaft
housing to prevent turning of the cam idle gear.

SAPH30ZCE0900150

(2) Measure backlash between the camshaft gear and the

cam idle gear using a dial gauge. If it is beyond the
service limit, replace each gear.

Standard value (mm{in.}) Service limit (mm{in.})

0.030 - 0.253
0.30{0.0118}
{0.0012 - 0.0100}

SAPH30ZCE0900151

2. Inspection of camshaft end play

(1) Measure the end play of the camshaft using a thickness

gauge. If it is beyond the standard value, replace the
camshaft.

0.100 - 0.178
Standard value (mm)
{0.0039 - 0.0070}

SAPH30ZCE0900152

3. Inspection of backlash between main idle gear and pump

drive idle gear

(1) Remove the supply pump drive at the bearing case.

Refer to “5 FUEL SYSTEM, Supply pump,
Replacement of supply pump”
(2) Insert a large flat tip screwdriver into the main idle gear
from the timing gear dust cover of the flywheel housing to
prevent turning of the main idle gear.

SAPH30ZCE0900153
9–58 ENGINE MECHANICAL

(3) Measure backlash between the main idle gear and the
pump drive idle gear using a dial gauge and a magnet
stand. If it is beyond the service limit, replace each gear.

NOTICE • If the magnet stand is not stable, provide a

steel plate for measurement using bolt holes
of the cylinder block.

Standard value (mm{in.}) Service limit (mm{in.})

SAPH30ZCE0900154
0.032 - 0.096
0.30{0.0118}
{0.0013 - 0.0038}

4. Inspection of backlash between idle gear at bearing case

and supply pump drive gear
(1) Remove the supply pump drive.
Refer to “5 FUEL SYSTEM, Supply pump,
Replacement of supply pump”
(2) Remove the bearing case assembly.
(3) Fix the supply pump drive with a vice and install the
bearing case assembly.

(4) Measure backlash between the idle gear and the supply
pump drive gear using a dial gauge and a magnet stand. If
it is beyond the service limit, replace each gear.

Standard value (mm{in.}) Service limit (mm{in.})

0.020 - 0.083
0.10{0.0039}
{0.0008 - 0.0033}
SAPH30ZCE0900155

5. Inspection of backlash between main idle gear and sub-

idle gear

(1) Insert a large flat tip screwdriver into the main idle gear
from the timing gear dust cover of the flywheel housing to
prevent turning of the main idle gear.

SAPH30ZCE0900156

(2) Measure backlash between the main idle gear and the
sub-idle gear using a dial gauge and a magnet stand. If it
is beyond the service limit, replace each gear.

Standard value (mm{in.}) Service limit (mm{in.})

0.030 - 0.113
0.30{0.0118}
{0.0012 - 0.0044}

SAPH30ZCE0900157
 ENGINE MECHANICAL 9–59

6. Inspection of backlash between sub-idle gear at cam idle

gear and oil pump gear

(1) Insert a large flat tip screwdriver into the sub-idle gear to
prevent turning of the sub-idle gear.

SAPH30ZCE0900158

(2) Measure backlash between the sub-idle gear and the oil
pump gear using a dial gauge and a magnet stand. If it is
beyond the service limit, replace each gear.

Standard value (mm{in.}) Service limit (mm{in.})

0.030 - 0.131
0.30{0.0118}
{0.0012 - 0.0052}

SAPH30ZCE0900159

7. Inspection of idle gear end play

(1) Measure the end play of each gear using a thickness

gauge. If it is beyond the service limit, replace each gear
or shaft.

Standard value Service limit

Measuring item
(mm{in.}) (mm{in.})

0.114 - 0.160
Main idle gear {0.0045 - 0.30{0.0118}
SAPH30ZCE0900160
0.0063}

0.040 - 0.120
Sub-idle gear {0.0016 - 0.30{0.0118}
0.0047}

0.040 - 0.120
Cam idle gear {0.0016 - 0.30{0.0118}
0.0047}

8. Inspection of backlash between cam idle gear and sub-idle

gear
(1) Insert a large flat tip screwdriver into the sub-idle gear
from the side of the cam idle gear of the cylinder head to
prevent turning of the sub-idle gear.

SAPH30ZCE0900161
9–60 ENGINE MECHANICAL

(2) Measure backlash between the cam idle gear and the
sub-idle gear using a dial gauge. If it is beyond the service
limit, replace each gear.

Standard value (mm{in.}) Service limit (mm{in.})

0.030 - 0.218
0.30{0.0118}
{0.0012 - 0.0086}

Setup layout
Layout

SAPH30ZCE0900162
 ENGINE MECHANICAL 9–61

Valve System
Part layout
JP30ZCE090402007

SAPH30ZCE0900163

13706 Crosshead assembly 13735 Valve seat upper

13709 Adjusting screw 13801 Rocker arm (intake)
13711 Intake valve 13802 Rocker arm (exhaust)
13715 Exhaust valve 13901 Rocker shaft
13731 Outer spring 13951 Rocker support
13732 Inner spring Z9102 Valve stem seal*
13734 Valve seat lower

*Parts not to be reused.

Tightening torque
13788 25N˜m{250kgf˜cm, 18 lbf˜ft}
9–62 ENGINE MECHANICAL

Service procedure
Overhaul item

Overhaul of valve system

JP30ZCE090702015

1. Removal of rocker arm and rocker arm shaft

(1) Loosen the lock nut and turn the adjusting screw
completely.
Lock nut
! CAUTION • Removal without turning the adjusting screw
may bend the rocker arm shaft.

SAPH30ZCE0900164

(2) Loosen the rocker arm support bolts gradually from the
center and remove the rocker arm and the rocker arm
shaft.
ԝ ԛ ԙ Ԙ Ԛ Ԝ Ԟ

Rocker arm support

SAPH30ZCE0900165

2. Installation of rocker arm and rocker arm shaft

(1) Make sure that the crosshead is correctly (covering) on

each valve.

! CAUTION • To ensure that the crosshead is correctly on

the valve, move the crosshead to left or right
with hand and confirm "clicking" sound.
• If the crosshead is offset from the valve in
assembly, the upper seat may be pressed,
SAPH30ZCE0900166 resulting in fall of the valve.

(2) Make sure that the rocker arm is correctly assembled into
the rocker arm shaft.
(3) Turn the adjusting screw at the end of the rocker arm
Rocker arm
completely.

NOTICE • Bundling the rocker arm with a rubber band

eases installation.

Adjusting ! CAUTION • After installation, apply engine oil to the cam.

screw

Rubber band
SAPH30ZCE0900167
 ENGINE MECHANICAL 9–63

(4) Place the rocker arm and the rocker arm shaft on the
camshaft housing and make sure that the rocker arm is
correctly on the crosshead. Tighten the rocker arm
support bolts gradually several times.

Tightening torque : 59 N˜m {600 kgf˜cm, 44 lbf˜ft}

! CAUTION • After tightening, make sure that the rocker

arm moves smoothly.
• Make sure that there is no undue force on the
SAPH30ZCE0900168 injection pipe oil seal.
(Otherwise, oil leak or poor assembly of
injection pipe may occur.)

3. Inspection of rocker arm oil clearance

(1) Measure the outer diameter of the rocker shaft using a

micrometer.

Standard value (mm{in.}) Service limit (mm{in.})

22{0.8661} 21.92{0.8630}

(2) Measure the rocker arm bushing inner diameter using a

cylinder gauge.
SAPH30ZCE0900169

Standard value (mm{in.}) Service limit (mm{in.})

22{0.8661} 22.08{0.8693}

(3) Calculate the difference between the outer diameter of the

rocker shaft and the inner diameter of the rocker arm
bushing. If it is beyond the standard value, replace the
rocker shaft or the rocker arm bushing.

Standard value (mm{in.}) Service limit (mm{in.})

0.030 - 0.101
0.15{0.0059}
{0.0012 - 0.0039}

4. Removal of valve spring

(1) Compress the valve spring using a special tool and

remove the valve spring retainer.
Special tool : S0947–01170(09470–1170)
Valve spring press

SAPH30ZCE0900170
9–64 ENGINE MECHANICAL

(2) Remove the intake and exhaust valves.

! CAUTION • Attach a tag with the applicable cylinder

number to the valve so that combinations of
the valve and the cylinder head may not be
mixed.

SAPH30ZCE0900171

5. Replacement of valve stem seal

Stem seal Special tool (1) After removing the valve stem seal, assemble the valve
Valve spring spring lower seat. Apply engine oil to the lip and the inner
lower seat surface of the stem seal. Strike the valve guide using a
special tool until the special tool comes in contact with the
valve spring lower sea
Special tool : S0947–22100(09472–2100) Bar

! CAUTION • After assembly of the stem seal, make sure

that there is no deformation, crack or
inclination of the rubber.
Oil application
Rubber

SAPH30ZCE0900172

(2) After striking, check the height.

22.5 - 23.0
Standard value (mm{in.})
+0.1{0.0039in.}
{0.8858 - 0.9055}
22.9mm{0.9022in.}
-0.4{0.0157in.}

SAPH30ZCE0900173
 ENGINE MECHANICAL 9–65

6. Installation of valve spring

(1) Install the valve spring upper seat on the valve spring.
(2) Compress the valve spring using a special tool and install
the valve spring retainer.
Special tool : S0947–01170(09470–1170)
Valve spring press

! CAUTION • Apply engine oil to the contact surface of

each part before assembly.
SAPH30ZCE0900174
• Be sure to assemble each valve at the original
cylinder position.
• When the valve spring is compressed, avoid
contact of the valve spring upper seat with the
valve stem seal.
• Since the valve spring has equal spacing,
vertical direction is not specified for
assembly.
• Check for scratch on the valve stem seal
when the valve is reused.

7. Inspection of valve spring

Clearance A
(1) Measure squareness of the valve spring using a square or
a thickness gauge. If it is beyond the service limit
(clearance A), replace the valve spring.

Clearance A (mm{in.}) 2.0{0.0787}

SAPH30ZCE0900175

(2) Measure the free length of the valve spring using a vernier
calipers. If it is out of the service limit, replace the valve
spring.

Standard
Service limit
Measuring item value
(mm{in.})
(mm{in.})
Inner valve spring (64.6{2.5433}) 61.6{2.4252}

SAPH30ZCE0900176 Outer valve spring (75.7{2.9803}) 72.7{2.8622}

The value in [ ] is the reference value.

9–66 ENGINE MECHANICAL

8. Inspection of oil clearance between valve guide and valve

stem

(1) Measure the outer diameter of the valve stem using a

micrometer.

Standard value
Measuring item
(mm{in.})

Intake valve stem 7{0.2756}

SAPH30ZCE0900177 Exhaust valve stem 7{0.2756}

(2) Measure the valve guide inner diameter using a cylinder

gauge.

Standard value
Measuring item
(mm{in.})

Intake valve guide 7{0.2756}

Exhaust valve guide 7{0.2756}

(3) Calculate the difference between the valve system outer

SAPH30ZCE0900178
diameter and the valve system inner diameter. If it is
beyond the standard value, replace the valve or the valve
guide.

Standard value
Measuring item
(mm{in.})

0.023 - 0.058
Intake valve oil clearance
{0.0009 - 0.0023}

Exhaust valve oil 0.050 - 0.083

clearance {0.0020 - 0.0033}

Attachment procedure item

 ENGINE MECHANICAL 9–67

Adjustment of valve clearance

JP30ZCE090706001

1. Precautions before adjustment

! CAUTION • Before adjustment, make sure that bolts of

the cylinder head, rocker arm support,
nozzle clamp, camshaft housing and
camshaft bearing cap are tightened to the
specified torque.

2. Adjustment of valve clearance

(1) Make sure that there is no dirt between the crosshead and
the valve stem
(2) Turn the crankshaft in the forward direction and adjust the
cylinder to the compression top dead center.

! CAUTION • Make sure that there is a roller on the cam

base circle.

(3) Loosen the adjusting screw and the lock nut of the
Adjusting screw of rocker arm
Roller crosshead completely.
Cam base
circle Lock nut
Adjusting screw of
crosshead ! CAUTION • Provide the adjusting screw protrusion of 10
10 mm or more
mm or more from the top surface of the
crosshead. If the adjusting screw is not
completely separated from the valve stem,
Clearance correct adjustment is not allowed.
Close contact

Nut
SAPH30ZCE0900179

(4) Insert a thickness gauge between the rocker arm and the
Rocker arm Thickness gauge crosshead and adjust the clearance with the adjusting
screw of the rocker arm. Tighten the lock nut.

Standard value IN 0.30mm{0.0118 in.}

(cold engine) EX 0.45mm{0.0177 in.}

Close contact Tightening torque : 25 N˜m {250 kgf˜cm, 18 lbf˜ft}

Crosshead
SAPH30ZCE0900180

(5) Loosen the adjusting screw of the crosshead with the

Start thickness gauge inserted. Make sure that feel on the
Feel of thickness gauge

thickness gauge is not lighter.

(No move) Nut fixing position

! CAUTION • If it becomes lighter, make adjustments again

(Appropriate from the beginning.
contact)

Feel remains the same.

Loosening of adjusting screw Large

SAPH30ZCE0900181
9–68 ENGINE MECHANICAL

(6) Tighten the adjusting screw of the crosshead until the

thickness gauge does not move.

Close contact
Close contact

SAPH30ZCE0900182

(7) While loosening the adjusting screw of the crosshead

Start gradually, tighten the lock nut of the crosshead at the
Feel of thickness gauge

position where feel on the thickness gauge is appropriate.

(No move) Nut fixing position
Tightening torque : 25 N˜m {250 kgf˜cm, 18 lbf˜ft}

(Appropriate ! CAUTION • Do not over-loosen the adjusting screw. Over-

contact)
loosening of the adjusting screw reproduces
Feel remains the same. the original status. Although feel on the
Loosening of adjusting screw Large thickness gauge is appropriate, there is
SAPH30ZCE0900183 clearance between the adjusting screw and
the valve of the crosshead. Correct
adjustment is not allowed.
 EXHAUST 10–1

ENGINE

10 EXHAUST
Setup layout
Layout

Exhaust Manifold...................................................... 10-2

Part layout ............................................................. 10-2
Replacement......................................................... 10-3
DPR cleaner .............................................................. 10-4
Part layout ............................................................. 10-4
Overhaul ............................................................... 10-6
Inspection ........................................................... 10-14
Replacement of DPR filter .................................. 10-25

10
10–2 EXHAUST

Exhaust Manifold
Part layout
JP30ZCE100402001

SAPH30ZCE1000001

17104 Gasket* 17104A Exhaust manifold

*Parts not to be reused.

Tightening torque
Z1701 53N˜m{540kgf˜cm, 40 lbf˜ft}
Service procedure
Replacement procedure item
 EXHAUST 10–3

Replacement
JP30ZCE100704001

1. Removal of exhaust manifold

(1) Remove nuts and remove the exhaust manifold.

2. Replacement of stud bolt

(1) Remove dirt (e.g. sealant) at the female thread of the
cylinder head and clean the thread again with tap (M10 x
1.5).
(2) Use the Torx wrench to tighten a new stud bolt.
Tightening torque : 30 N˜m {300 kgf˜cm, 22 lbf˜ft}

! CAUTION • Excessive tightening with over torque may

cause crack in the cylinder head.

3. Installation of exhaust manifold

(1) Assemble a new gasket.

! CAUTION • Since a gasket has front and back, install the

black side on the exhaust manifold.

Black side
SAPH30ZCE1000002

(2) Tighten the mounting nut of the exhaust manifold

according to the order in the figure.

New exhaust manifold installation case Tightening torque : 53 N˜m {540 kgf˜cm, 40 lbf˜ft}
18 17 16 15 14 13 12 11 10 9 8 7
! CAUTION • When nuts are tightened, prevent each spacer
from riding on the counterbore area of the
1 2 5 6 manifold flange.
3 4
• The tightening sequence of the exhaust
manifold varies between use of a new part
Exhaust manifold reuse installation case and reuse.
14 15 8 9 2 3 6 5 11 12 17 18
(3) Tighten the same nuts again according to the order in the
figure.
13 7 10 16 Tightening torque : 53 N˜m {540 kgf˜cm, 40 lbf˜ft}
1 4

! CAUTION • Be sure to retighten it.

Spacer
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SAPH30ZCE1000003
10–4 EXHAUST

DPR cleaner
Part layout
JP30ZCE100402002

SAPH30ZCE1000004

17041 Heat insulator S1803 Exhaust rear pipe

17104 Gasket* S1805 Exhaust front pipe
17435 Heat insulator S1850 DPR cleaner

*Parts not to be reused.

Tightening torque
Z1780 35r5 N˜m{360r50kgf˜cm, 26r3 lbf˜ft}

NOTICE • DPR : Diesel Particulate active Reduction system

 EXHAUST 10–5

SAPH30ZCE1000005

S1701 DPR cleaner bracket S170J Rubber

*Parts not to be reused.

10–6 EXHAUST

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Overhaul
JP30ZCE100704002

Removal of the DPR cleaner

1. Removal of the DPR cleaner

! CAUTION • Please handle the catalyst in the DPR cleaner carefully, because it is made of ceramic and
can break when subjected to strong impact.
• As the DPR cleaner is heavy, removal should be done by two persons for reasons of safety.

(1) Remove the clips and disconnect the hoses for the back pressure sensor from the pipes.
(2) Disconnect the connectors (2pcs.) and disconnect the harness (2pcs.) of the DPR exhaust temperature
sensor from the engine harness.

DPR exhaust temperature

sensor connectors

DPR back pressure

sensor hose

Clip

SAPH30ZCE1000006
(3) Remove the bolts (4pcs.) and disconnect the DPR
Bolt cleaner.

DPR cleaner Turbocharger outlet pipe

SAPH30ZCE1000007

(4) Remove the nuts (4pcs.) and remove the DPR cleaner
DPR cleaner
bracket assembly from the DPR cleaner bracket.

Nut
SAPH30ZCE1000008
 EXHAUST 10–7

Installation of the DPR cleaner

1. Installation of the DPR cleaner

NOTICE • If a removal has been necessary, re-install according to the following instructions.

! CAUTION • Do not touch the sensor pin of the DPR exhaust temperature sensor.
• Do not bend the sensor pin of the DPR exhaust temperature sensor. (Do not reuse it if it has
been dropped.)

Sensor pin

DPR exhaust temperature sensor

SAPH30ZCE1000009

(1) Always apply anti-seize (NEVER-SEEZ Nickel Special Grade, BOSTIC FINDLEY(U.S.A.)) to the DPR
exhaust temperature sensor when re-installing.
(2) Install the DPR exhaust temperature sensor to the boss of the DPR cleaner for the sensor.
Tightening torque : 30 N˜m {306 kgf˜cm, lbf˜ft, 22 lbf˜ft}

HARNESS ROUTING FIGURE

DPR exhaust temperature sensor

DPR exhaust
temperature sensor

SAPH30ZCE1000010
10–8 EXHAUST

(3) Adjust the clip between the white markings of the harness
Harness White marking (width approximately 24mm {0.9449in.}) and secure the
harness of the DPR exhaust temperature sensor to the
DPR cleaner with the nuts.

Tightening torque : 22 N˜m {224 kgf˜cm, 16 lbf˜ft}

Clip
SAPH30ZCE1000011
 EXHAUST 10–9

2. Connect the hoses of the back pressure sensor

NOTICE • If a removal has been necessary, re-install according to the following instructions.

(1) Mark the match mark to the back pressure hose and the DPR back pressure sensor before removing.
(2) Insert the hose of the DPR back pressure sensor into the port on the rear of the engine (flywheel housing
side) and push it in securely until there is contact.
(3) Secure the painted part of the hoses to the engine body, using a clip.
28.5 N˜m {291 kgf˜cm, 21 lbf˜ft}

Push in until there is contact

DPR back pressure sensor with the sensor body
Hose inserting side

Open atmospheric side

Hose
Clip

SAPH30ZCE1000012
10–10 EXHAUST

3. Installation of the DPR cleaner

! CAUTION • Please handle the catalyst in the DPR cleaner

carefully, because it is made of ceramic and
can break when subjected to strong impact.
• As the DPR cleaner is heavy, removal should
be done by two persons for reasons of safety.

(1) Lower the DPR cleaner at the DPR cleaner bracket upper
face level.

DPR cleaner assembly Flange part

Floating mounting

SAPH30ZCE1000013

! CAUTION • Make sure that the flange part of the DPR

cleaner does not hit the exhaust manifold
during handling.
 EXHAUST 10–11

(2) Match the bolts for securing the DPR cleaner with the
bracket bolt holes while moving the DPR cleaner to the
front of the engine (fan side). When the positions are
matched, lower the DPR cleaner onto the DPR cleaner
bracket.
(3) Engage the projecting part of the rubber with the bolt hole
of the DPR cleaner bracket.

(4) Tighten provisionally with the nuts on the lower side of the
DPR cleaner bracket until the rubber and the spacer are in
Rubber close contact. (4 locations)

Spacer

Nut Section of the floating

mounting

DPR cleaner
bracket

Always engage the projecting

part to the bolt hole

SAPH30ZCE1000014

(5) Measure the deviation between the flange on the engine

side and the flange on the DPR side and confirm that the
Flexible pipe DPR cleaner assembly is installed within the
specifications shown in the following table. When the
dimensions of the table have been exceeded, adjust the
{0.1968in.}

mounting position of the DPR cleaner assembly by

Within 5mm

correcting the flexion of the flexible part etc.

Mark for 207 4mm
aiming {8.1496 0.1575in.} Unit: mm(in.)
Measuring item Standard value
SAPH30ZCE1000015
Axial deviation in left/
Within r 5 (0.1968)
right direction
Length of the flexible
207(8.1496) r 4 (0.1575)
pipe

(6) Replace the gasket by a new one and provisionally secure

the flange part with bolts (the 2 upper ones) to the engine
body.

! CAUTION • In order to minimize flexible pipe deformation,

keep the provisional tightening within
approximately two or three threads.

Bolt
SAPH30ZCE1000016
10–12 EXHAUST

(7) Securely tighten the nuts (4pcs.) on the lower side of the
DPR cleaner
bracket DPR cleaner bracket from the exhaust inlet side as
shown.

Tightening torque : 51 N˜m {520 kgf˜cm, 38 lbf˜ft}

! CAUTION • Rotate the nuts one by one for 1 to 1.5 turns

so that the projecting part of the rubber does
not get disengaged, and perform final
Nut tightening after tightening the entire body in
SAPH30ZCE1000008 several steps.

• After tightening, confirm that the rubber is in

Section of the floating mounting close contact with the bracket.

Confirm that the rubber

is in close contact

SAPH30ZCE1000017

(8) After provisionally tightening the bolt on the lower side of

the flange, tighten it well, together with the bolts (2pcs.)
previously tightened securely.

Tightening torque : 68.5 N˜m {699 kgf˜cm, 44 lbf˜ft}

Bolt
SAPH30ZCE1000018
 EXHAUST 10–13

(9) Install the DPR back pressure hose to the pipe and secure it using the clips.
(10) Connect the connector of the DPR exhaust gas temperature sensor in the shown orientation. (The
opposite orientation is not possible.)

DPR exhaust temperature

sensor connectors

DPR back pressure

sensor hose

Clip

SAPH30ZCE1000006
10–14 EXHAUST

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Inspection
JP30ZCE100702001

Standard maintenance
1. Check the DPR backpressure every 4,500 Hour and determine
whether maintenance is required or not.

NOTICE • When except for HINO genuine oil and

irregular fuel is used, it is not warrantable at
the maintenance interval.

Inspection of the DPR

1. Routine inspection items

(1) Confirm that there is no abnormal increase of the engine
oil in the oil pan.

NOTICE • If the engine oil quantity has increased

abnormally, it is possible that there is a
malfunction in the injection system or that
unburned fuel has leaked through the gap
between the piston rings and the cylinder
liner into the oil pan.

(2) Check the exhaust system tightening portions (exhaust

pipe, main unit flange) for looseness or exhaust leakage.
(3) Check external appearance of the harness of the exhaust
temperature sensor for trouble (crack in coating or missing
clip).
(4) Inspect the hose of the differential pressure sensor and
check the hose for deterioration or cracks. Replace a hose
which has been used for 3 years or more with new one.
(5) Check clogging in the backpressure hose and pipe.
 EXHAUST 10–15

Inspection procedure (Regular situation)

NORMAL OPERATION

RECEIVING
FOR SAFETY CHECK

CONNECT HINO DX <Checking a fault code against HINO DX>

PAST FAULT CHECK

1.CHECKING THE CURRENT CONDITION
DPR STATE MONITOR CHECK

(If the engine has a past fault history,

2.DIAGNOSIS ENGINE INSPECTION
inspect the esngine before inspecting DPR.)

<Forced regeneration by way of HINO DX>

3.FORCED REGENERATION
Execution of manual regeneration

4.FORCED REGENERATION
COMPLETION
<See "7 EXHAUST, Inspection,
Example of the Hino DX check screen">
(Regeneration is not complete)
5.DIAGNOSIS CHECK DPR SYSTEM

<Check the backpressure sensor value by way of Hino DX while raising

6.MEASUREMENT OF the engine revolution up to the decided constant speed.>
BACKPRESSURE Monitor the backpressure value of the backpressure sensor.
Monitor the engine revolution.

(Predetermined backpressure tolerance is exceeded)

7.DIAGNOSIS FILTER CLEANING

SAPH30ZCE1000019
10–16 EXHAUST

Inspection by way of Hino DX

1. Routine inspection items

(1) Select the "DPR Reset confirmation" in the "Check
function" menu of Hino DX.
(2) Confirm Data View of the "DPR Status" display (monitor),
if the status for all the items are "OFF", DPR functions
normally.
Then "Forced regeneration" and "DPR backpressure
check" can be done.
(3) In case "ON" is displayed in Data View of the "DPR
Status" display (monitor), check according to the
procedure on "Determination by way of DPR state
determination monitor of HINO DX".

2. Forced regeneration
(1) Forced regeneration is done by the "Forced regeneration"
screen.

! CAUTION • Confirm safety of the surrounding area, then

press DPR regeneration switch inside the
cabin to execute the regeneration.

(2) When the "manual regeneration failure flag" status is ON,

inspection of engine and oil pressure load and wash or
replace the filter.
When the status is OFF, DPR functions normally.

3. DPR backpressure check

(1) Confirm that the exhaust temperature fell on 200qC
{392qF} or less, check the DPR backpressure through the
"DPR Status" display.
(2) Engine revolution will rise automatically, then record the
indicated maximum DPR backpressure, then "Stop" the
DPR backpressure check.
(3) In case the central value of the recorded DPR
backpressure value exceeds the specific value, clean or
replace the filter.

Specific value

Backpressure inspection
Engine Engine speed standard value
(kPa {kgf/cm2, lbf/in.2})

J08E 2,000 rpm 10.0 {0.1, 1.5}

EXHAUST 10–17

(4) When the backpressure is unchanged check the following.

If the following are normal, the backpressure sensor
should be replaced.
a. Confirm backpressure hose for cracks or hole openings.
b. Confirm that the hose clamp i neither loose nor
disconnected.
c. Confirm whether there is clogging in the backpressure
pipe (DPR cleaner side).
Use compressed air from one end of the pipe to check
for clogging. If the air passes to the other side easily, it
is clear.
d. Check the back pressure sensor.
10–18 EXHAUST

Inspection procedure followed when DTC code is indicated (abnormal)

When any DTC codes are indicated, record the report of the Hino DX and
DTC indicated check as shown below.

When engine DTC codes are indicated, check the engine DTC code first.
Connect Hino DX When DPR system DTC codes are indicated, check the engine DTC code
first and check the status of the DPR using Hino DX.
Step
1. Check injection quantity (At idling, at machine side loaded)
2. Check fuel system (Fuel filter clogging)
Engine Inspection 3. Check intake system (Air element clogging, inspection of air flow meter)
4. Check EGR (Foced drive, check opening traceability)
5. Check VNT (Foced drive, check opening traceability)

Check the "DPR status monitor"

[Indication] [Cause] [Inspection and repair]
DPR missing substrate DPR is damaged or back pressure -Disassembly DPR and check
flag ON or OFF system malfunction -Black smoke at engine side and oil leak
(P244A) -Check fuel leakage
-Check back pressure sensor

DPR over temp flag by rear exh "DPR filter heated up excessively" -Disassembly DPR and check
gas temp. ON or OFF detect -Black smoke at engine side and oil leak
(P200C) -Check fuel leakage
-Check temperature sensor

DPR excessive backpressure "DPR back pressure abnormal" -Disassembly DPR filter and clean
flag ON or OFF detect -Black smoke at engine side, injection
(P244B) quantity
-Check EGR system
-Check back pressure sensor pipe
DPR clogged danger level Abnormal pilling up of soot at
flag ON or OFF DPR filter
(P2463 or P224B)

DPR clogged warning level It does not operate "DPR manual -Check whether DPR regeneration
flag ON or OFF regeneration" or switch switch are operated or are not
system malfunction -Check DPR regeneration switch system
(P2463) (breaking wire, short circut)

DPR manual regeneration failure "DPR manual regeneration" is not -Disassembly DPR filter and clean
flag ON or OFF finished. -Check engine system
(P2458) -Check injection quantity, machine side
oil load,
-EGR system
DPR active regeneration failure "DPR acrive regeneration is not -Disassembly DPR filter and clean
flag ON or OFF finished" history are detected -Check engine system
(P2458) -Check injection quantity, EGR system

Total quantity of regeneration additive "DPR manual regeneration" operating -Confirm operation of DPR regeneration
fuel final limit flag ON or OFF are interrupted frequently switch
(P24A2)

SAPH30ZCE1000020
 EXHAUST 10–19

Determination by way of DPR state determination

monitor or Hino DX

1. Check that the DTC code comes on.

2. Connect Hino DX.

3. Check past faults.

(1) Check past faults by way of Hino DX. In case a general
engine fault such as a trouble of an exhaust control
system is displayed, inspect and repair the pertinent
section.
(2) Inspect and repair general engine faults and check past
faults again. In case a code indicating a sensor system
trouble is displayed, inspect and replace the sensor
circuit.

Inspection item DTC code

Front DPR exhaust temperature

P0545, P0546
sensor trouble

Rear DPR exhaust temperature

P2032, P2033
sensor trouble

DPR backpressure sensor

P1427, P1428
trouble

(3) Check past faults. In case DPR trouble (DTC code:

P200C, P244A, P2463, P244B, P2458, P24A2) is
displayed, check the DPR state monitor.

Checking the DPR state

1. Check the DPR state monitor.

(1) Refer to "Inspection by way of Hino DX" and check the
DPR state monitor. Perform inspection as per the
procedure under "Inspection by way of Hino DX".
10–20 EXHAUST

Example of the Hino DX check screen

1. DPR Reset Confirmation.

(1) Monitoring/ Check/ Forced regeneration of DPR status can be performed.

DPR Reset Confirmation window

SAPH30ZCE1000021
 EXHAUST 10–21

2. Forced regeneration
(1) Select the “DPR Reset confirmation” in the “Check function” menu of HinoDX after system fix is made.
Menu:[Check function]-[DPR Reset Confirmation]

Select

SAPH30ZCE1000022

(2) Forced regeneration is done by the “Forced regeneration” screen.

If you click the “Manual regeneration” Button, DPR Manual regeneration switch will be shown.

DPR Reset Confirmation window

Manual regeneration Button

SAPH30ZCE1000023
10–22 EXHAUST

(3) Click the “Start” Button.

Manual regeneration window

Start Button

SAPH30ZCE1000024

(4) If you press the “DPR manual regeneration switch” in the cabin, manual regeneration will start.

SAPH30ZCE1000025
 EXHAUST 10–23

(5) When manual regeneration is completed, carry out Backpressure Check.

! CAUTION • Never park the unit near any flammable material, including high grass or leaves, during
manual regeneration.
• Extreme heat from the exhaust outlet could cause a fire resulting in personal injury and
property damage.
• Always keep all flammable materials away from the DPR cleaner, exhaust pipe and tail
pipes.
• Never touch the DPR cleaner, exhaust pipe or tail pipe during regeneration. Severe burns
and/or other personal injuries could occur.

NOTICE • Manual regeneration is carried out when the DPR clogged warning level flag is ON in the
"DPR Reset Confirmation Window"
• When the DPR clogged danger level flag is ON, remove the DPR from the unit and clean it
with Hino's recommended cleaner or replace it.
10–24 EXHAUST

3. DPR back pressure check

(1) If you click the “Backpressure Check” button, you can measure the soot clogging status of the DPR as it’s
differential pressure and whether it is necessary to do maintenance or not can be checked.

Back pressure check button

SAPH30ZCE1000026

DPR back pressure check window

SAPH30ZCE1000027
a. If you click “Backpressure Check” button, DPR back pressure check window will be shown.
b. Click the “Start” button.
c. Engine rotation will go up automatically to maximum and DPR differential pressure will be recorded.
d. Click the “Stop” Button and you are finished measuring.

NOTICE • Every time you click the "Start" and "Stop" button, the display will change "Start" and
"Stop" alternately.

Switch indicate item

Click

SAPH30ZCE1000028
 EXHAUST 10–25

Replacement of DPR filter

JP30ZCE100702002

Replacement of DPR filter

1. Remove the DPR cleaner.

(1) Remove the DPR cleaner from the engine.
Refer to “DPR cleaner, Overhaul”
(2) Mark the match marks to the mufflers and the filter.
(3) Remove the filter mounting nuts and remove the front/rear
Front Filter Rear muffler pipe.
muffler muffler

! CAUTION • The catalyst in the DPR cleaner is made of

ceramic; it could break if a strong impact is
applied. Handle it with care.
Match mark Match mark (4) When cleaning the filter, refer to "DPR cleaner, Overhaul".

SAPH30ZCE1000029

2. Install the DPR cleaner.

(1) Align the front and rear mufflers by match mark then
replace the bolts by new ones and install into the filter.
(2) After that, follow the reverse order of removing to install
Front Rear
muffler Filter muffler the DPR cleaner.

NOTICE • Diagonally tighten the nuts.

• Always replace the bolts but the nuts is
reusable.

Match mark Match mark Tightening torque :

35r5 N˜m {360r50 kgf˜cm, 26r3lbf˜ft}
(Filter mounting nuts)

Tightening order

SAPH30ZCE1000030
10–26 EXHAUST

Cleaning of DPR filter

1. Cleaning method
(1) Use a dedicated cleaning machine to perform filter
cleaning. Never clean the filter elsewhere. For the
cleaning method, refer to the cleaning machine handling
manual.
 COOLING 11–1

ENGINE

11 COOLING
System drawing

Cooling System ........................................................ 11-2

Cooling system drawing........................................ 11-2
Part layout ............................................................. 11-3
Replacement of thermostat case .......................... 11-4
Adjustment of the fan belt tension......................... 11-7
Replacement of coolant pump .............................. 11-8

11
11–2 COOLING

Cooling System
Cooling system drawing
JP30ZCE110803001

Reserver tank

Radiator cap

EGR cooler

Thermostat
Radiator

cover (Outlet) Heater

Coolant
temperature
gauge
Thermostat
case Cylinder head

Thermostat
cover (Inlet) Thermostat Turbocharger

Cylinder block

Drain cock

Coolant pump
Oil cooler
For engine cooling
Cooling except
for engine Drain cock
Air bleeding
EGR
valve

SAPH30ZCE1100001
Setup layout
Layout
 COOLING 11–3

Part layout
JP30ZCE110402001

SAPH30ZCE1100002

16100 Coolant pump 16321 Thermostat case cover

16303 Thermostat case 16325 Gasket*
16304 Thermostat case cover SZ301 O-ring*

*Parts not to be reused.

Service procedure
Replacement procedure item
11–4 COOLING

Replacement of thermostat case

JP30ZCE110704001

1. Removal of the thermostat case

Cylinder
head (1) Remove the bolts (7pcs.), and remove the thermostat
case and the O-ring from the cylinder head and the
coolant pump.
O-ring
NOTICE • Prepare a container and a waste cloth for
spilling coolant at removing the thermostat
Coolant
case.
Thermostat case pump

SAPH30ZCE1100003

2. Inspection of the thermostat

Wire Thermometer (1) Warm up the thermostat as shown figure.

! CAUTION • Support the thermostat at center of the

container by wire for keep at a distance from
the heat source.
• Mix it to even up the temperature.
Thermostat Valve lift

Heat source
SAPH30ZCE1100004

(2) Measure the temperature at valve opening temperature

T1 : Valve opening temperature (start of valve opening) (T1).
T2: Full open lift inspection temperature

OO Thermostat valve

74.5 - 78.5qC
opening standard
Valve lift

{166.1 - 177.3qF}
temperature:T1

0°C{32°F} T1°C{°F} T2°C{°F} Temperature

SAPH30ZCE1100005

NOTICE • The thermostat valve opening temperature

Jiggle valve
(T1) is stamped into the thermostat seat.

Opening
temperature

SAPH30ZCE1100016
 COOLING 11–5

(3) Warm up the thermostat at fully open temperature (T2) of

the valve, measure the lift of the thermostat valve.

Thermostat valve full

open standard Valve lift : L
L1 At cold open
L2 :Temperature at (T2)°C{°F} temperature:T2
L : Valve lift
㧸 13mm {0.5118in.}
㧸 90qC {194qF}
㧸 or more

SAPH30ZCE1100007
(4) Immerse the opened thermostat in water at normal
temperature. If it completely closes within 5 minutes, it is
satisfactory.
(5) If a faulty item is found, replace the thermostat.

3. Installation of the thermostat case

(1) Use a scraper to remove dirt from the connection surfaces
Thermostat case
of the thermostat case and the cylinder head.
(2) Apply liquid gasket (Three Bond TB1207B: Black or
equivalent) to the thermostat case.

! CAUTION • Apply without breaks.

• Apply liquid gasket with a width of 1.5 to 2.5
Liquid gasket
mm.
SAPH30ZCE1100008 • Install within 20 minutes of applying liquid
gasket.

(3) Install a new O-ring in the groove at the top of the coolant
Bolt 2 Cylinder
head pump.
Bolt 1 (4) Insert the thermostat case mounting bolts 1 (4 bolts) in
advance into the thermostat case.
O-ring (5) Match the thermostat case to the mounting position and
provisionally tighten the mounting bolts 1 (4 bolts) to the
Coolant cylinder head.
6JGTOQUVCVECUG pump
(6) Provisionally tighten the mounting bolts 2 (3 bolts) to the
coolant pump.
SAPH30ZCE1100009
(7) Securely tighten the mounting bolts 1 (4 bolts) to the
cylinder head and the mounting bolts 2 (3 bolts) to the
coolant pump in this order.

4. Installing of the thermostat

Thremostat (1) Replace the gasket with new ones, and install the
Gasket thermostat and the coolant pipe to the thermostat case.

Thremostat case

Coolant pipe

SAPH30ZCE1100010
11–6 COOLING

! CAUTION • As a wrong gasket installation can cause

Flange
water leakage, make sure during assembly
Thermostat
that it is clamped to the flange part of the
thermostat.

Gasket
SAPH30ZCE1100011

• Install the thermostat with the jiggle valve at

TOP the top.
Jiggle valve

SAPH30ZCE1100017
 COOLING 11–7

Adjustment of the fan belt tension

JP30ZCE110705001

1. Adjustment of the fan belt tension.

(A)
(1) Use the special tool and check the fan belt tension at the
measuring position (A).

Measuring item Standard value

3 - 5mm
Deflection
{0.1182 - 0.1968in.}

1,372 N
Tension
SAPH30ZCE1100013 {140 kgf, 308 lbf}

Special tool : S0944-41210 (09444-1210)

Compression gauge (used at the time
of measuring the deflection amount)
[ Reference push force
98N {10kgf, 22lbf} ]
MITSUBOSHI BELTING LTD.; Belt
Tension Meter (DOCTOR TENSION£
TYPE-III) (used at the time of
measuring the tension force)

! CAUTION • When the fan belt has been replaced by a new

one, the fan belt will become loose because of
initial run-in, so that the fan belt tension
should be adjusted again after running the
engine for 3 to 5 minutes.

NOTICE • At the time of inspection, the new fan belt has

reached the value after complete initial
stretching. A new fan belt completes initial
stretching after running the engine for
approximately two hours.

(2) If the tension is not within the standard value, adjust with
the adjustment bolt (M8) or replace the fan belt.

NOTICE • When the adjustment bolt is tightened, the

tension pulley moves in tensioning direction.
Replacement procedure item
11–8 COOLING

Replacement of coolant pump

JP30ZCE110704002

1. Removal of coolant pump

(1) Remove bolts and remove the coolant pump.

SAPH30ZCE1100014

2. Installation of coolant pump

Coolant pump
(1) Remove contamination on the joint surface between the
coolant pump and the cylinder block using a scraper and
degrease the surface.
(2) Apply the liquid gasket [Threebond TB1207B (black) or
equivalent] to the coolant pump as shown in the figure.

! CAUTION • Apply it continuously.

Liquid gasket
• Apply the liquid gasket at the width of 2 to
SAPH30ZCE1100015 3mm{0.0787 to 0.1181in.}.
• Install the oil cooler within 20 minutes after
application of the liquid gasket.
• Fill the groove on the water pump flange with
the liquid gasket.

(3) Install the coolant pump to the dowel pin of the cylinder
block.

NOTICE • When the coolant pump is installed using a

guide bolt, displacement of the liquid gasket
does not occur.

SAPH30ZCE1100014
 LUBRICATION 12–1

ENGINE

12 LUBRICATION
System drawing

Oil Cooler, Oil Filter and Oil Pump.......................... 12-2

System drawing .................................................... 12-2
Part layout ............................................................. 12-3
Replacement of oil cooler ..................................... 12-5
Overhaul of oil cooler ............................................ 12-6
Replacement of oil pump ...................................... 12-9
Overhaul of oil pump........................................... 12-10
Replacement of oil strainer ................................. 12-13
Oil Pan ..................................................................... 12-14
Part layout ........................................................... 12-14
Replacement....................................................... 12-15
Inspection of lubrication status ........................... 12-16

12
12–2 LUBRICATION

Oil Cooler, Oil Filter and Oil Pump

System drawing
JP30ZCE120805001

Roller pin

Cam Roller

Adjusting
Valve Crosshead Rocker arm Rocker arm shaft
screw

Camshaft
Oil pan

Cam idle
gear shaft

Sub-idle
gear shaft

Turbocharger
Strainer

Main
Oil pump Oil cooler Oil filter oil hole

Connecting
Piston pin rod Crankshaft

Cooling jet Sub-oil

(Check valve) hole

Main idle
gear shaft

Air compressor
idle gear shaft
: Lubrication
: Return
SAPH30ZCE1200001
Setup layout
Layout
 LUBRICATION 12–3

Part layout
JP30ZCE120402001

SAPH30ZCE1200002

15110 Oil pump assembly 15135 Relief valve

15104 Oil strainer 15710 Oil cooler
15119 Gasket* SM381-04040 Cotter pin*
15132 Spring Z3012A O-ring*
*Parts not to be reused.
Tightening torque
SH552-10820 28.5N˜m {290kgf˜cm, 21 lbf˜ft} SH552-10860 24.5r4.9N˜m {250r50kgf˜cm, 18r4 lbf˜ft}
SH552-10825 31N˜m {320kgf˜cm, 23 lbf˜ft} SH552-10890 31N˜m {320kgf˜cm, 23 lbf˜ft}
SH552-10832 24.5r4.9N˜m {250r50kgf˜cm, 18r4 lbf˜ft} SH552-15810 24.5r4.9N˜m {250r50kgf˜cm, 18r4 lbf˜ft}
SH552-10855 28.5N˜m {290kgf˜cm, 21 lbf˜ft}
12–4 LUBRICATION

JP30ZCE120402002

SAPH30ZCE1200003

15662 Drain plug 15720 Oil cooler case assembly

15675 Safety valve Z3011 O-ring*
15701 Oil cooler case Z3011A O-ring*
15710 Oil cooler Z3012B O-ring*
15712 Oil cooler element Z3012C O-ring*
15717 Gasket* Z3012D O-ring*
*Parts not to be reused.
Tightening torque
15662 44.1r4.9N˜m {450r50kgf˜cm, 33r4 lbf˜ft}
Service procedure
Replacement procedure item
 LUBRICATION 12–5

Replacement of oil cooler

JP30ZCE120704001

1. Removal of oil cooler

(1) Remove bolts and remove the oil cooler.

SAPH30ZCE1200004

(2) If it is difficult to remove the oil cooler due to liquid gasket

Figure is an sticking to the cylinder block, put a flat tip screwdriver at
example of work.
the protrusion in the figure for removal.

SAPH30ZCE1200005

2. Installation of oil cooler

D-Ring (1) Assemble the new D-ring into the D-ring groove of the oil
Block
Oil cooler cooler.

! CAUTION • Face the D-ring flat area toward the oil cooler.

Flat area

SAPH30ZCE1200006

(2) Remove contamination on the joint surface between the

oil cooler and the cylinder block using a scraper. Apply the
Liquid gasket
liquid gasket [Threebond TB1207 (silver) or equivalent] to
the oil cooler as shown in the figure.

! CAUTION • Apply it continuously.

• Apply the liquid gasket at the width of 1.5 to
2.5 mm{0.0590 to 0.0984 in.}.
• Install the oil cooler within 20 minutes after
SAPH30ZCE1200007 application of the liquid gasket.
12–6 LUBRICATION

(3) Insert the positioning stud into the screw hole of the
cylinder block and install the oil cooler.

(4) After temporary tightening with bolts, remove the

positioning stud and tighten bolts.
Tightening torque :
24.5r4.9 N˜m {250r50 kgf˜cm, 18r4 lbf˜ft}

! CAUTION • Tighten together with the alternator ground.

• Be sure to connect the turbocharger
SAPH30ZCE1200008 lubricating oil hose.

(5) Install the drain plug.

Tightening torque :
44.1r4.9 N˜m {450r50 kgf˜cm, 33r4 lbf˜ft}

SAPH30ZCE1200009

Overhaul item

Overhaul of oil cooler

JP30ZCE120702001

1. Removal of oil cooler element

(1) Remove nuts and remove the oil cooler element.

2. Inspection of oil cooler element

(1) Wash water and oil channels with kerosene oil or washing
fluid.
(2) Check for crack or deformation on the stud bolt mounting
area and element visually.
(3) Blow air of approx. 49kPa {0.5kgf/cm2 7.1 lbf/in2} into the
SAPH30ZCE1200010 oil channel to check for leak from parts. If crack, leak or
deformation is found, replace it with a new part.

3. Disassembly of oil cooler case

! CAUTION • Disassembly immediately after stop of the

engine may cause blowout of engine oil.

(1) Remove valve spring plugs and safety valves using a

hexagonal wrench.

SAPH30ZCE1200011
 LUBRICATION 12–7

(2) Remove the oil pressure warning switch.

Soft washer

Hydraulic pressure
warning switch

SAPH30ZCE1200012

4. Inspection of safety valve wear and damage

(1) If wear or damage is found, replace it.

SAPH30ZCE1200013

5. Inspection of oil pressure warning switch

(1) For inspection of oil pressure warning switch,
Refer to "7 ELECTRICAL, Electrical System,
Inspection of components".

6. Assembly of oil cooler case

(1) Install a new O-ring and install valve spring plugs and
safety valves using a hexagonal wrench.

Tightening torque :
24.5r4.9 N˜m {250r50 kgf˜cm, 18r4 lbf˜ft} (M14, M20)
29.4r4.9 N˜m {300r50 kgf˜cm, 22r4 lbf˜ft} (M22)
34.3r4.9 N˜m {350r50 kgf˜cm, 25r4 lbf˜ft} (M24)

SAPH30ZCE1200011

(2) Apply the liquid gasket [Threebond TB1211 (white) or

equivalent] to the sealing surface of a new soft washer.

(3) Install the soft washer in (2) and the hydraulic pressure
Soft washer warning switch.

Hydraulic pressure
warning switch

SAPH30ZCE1200012
12–8 LUBRICATION

7. Installation of oil cooler element

(1) Assemble new gasket and new O-ring and assemble the
oil cooler element with nuts.

Tightening torque :
24.5r4.9 N˜m {250r50 kgf˜cm, 18r4 lbf˜ft}

! CAUTION • In handling the oil cooler element, be careful

not to give damage to it.

SAPH30ZCE1200010 Replacement procedure item

 LUBRICATION 12–9

Replacement of oil pump

JP30ZCE120704002

1. Removal of oil pump

(1) Dismount the engine from the vehicle.
(2) Remove the flywheel.
(3) Remove the flywheel housing.
(4) Remove the timing gear.
(5) Remove the oil pump.

2. Installation of oil pump

(1) Apply engine oil to the pump case and the bearing
(shaded area) of the cylinder block.

! CAUTION • Without application of engine oil, poor oil

suction may occur at the initial start,
Application of engine oil resulting in seizure or abnormal wear.
(Shaded area)

SAPH30ZCE1200014

(2) To prevent bolt hole offset of the gasket, apply engine oil
to the cylinder block in advance and place and fix the
gasket.

! CAUTION • Assembly with offset gasket may cause faulty

sealing. Oil in the oil pump may be completely
discharged when the engine stops. Faulty
sealing may cause insufficient suction of oil
at initial revolution of engine restart,
resulting in seizure or abnormal wear.

(3) Tighten the oil pump according to the order in the figure.
Tightening torque : 28.5 N˜m {290 kgf˜cm, 21 lbf˜ft}

! CAUTION • If the tightening order is not observed, the oil

Gasket
pump may be damaged.
Oil pump • After tightening, make sure that the gear can
be turned with hand.
Overhaul item

SAPH30ZCE1200015
12–10 LUBRICATION

Overhaul of oil pump

JP30ZCE120702002

1. Remove the driven gear.

SAPH30ZCE1200016

2. Remove the cotter pin and remove seat 2, seat 1, relief

valve spring and safety valve.

! CAUTION • When the cotter pin is removed, seat 2 and

the relief valve spring may eject out.

SAPH30ZCE1200017

3. Inspection of clearance between drive gear and cylinder

block

(1) Measure the outer diameter of the drive gear and the
inner diameter of the pump chamber at cylinder block.

Standard value
Measuring area
(mm{in.})

Outer diameter of drive gear 54{2.1260}

SAPH30ZCE1200018 Inner diameter of pump chamber

54{2.1260}
at cylinder block

(2) Calculate the difference between the outer diameter of the

drive gear and the inner diameter of the pump chamber at
the cylinder block. If it is beyond the service limit, replace
the oil pump assembly.

Standard value (mm{in.}) Service limit (mm{in.})

0.093 - 0.252
0.30{0.0118}
{0.0037 -0.0099}

SAPH30ZCE1200019
 LUBRICATION 12–11

4. End play inspection between drive gear and cylinder block

(1) Measure the drive gear width and the pump chamber
depth at the cylinder block using a depth gauge.

Standard value
Measuring area
(mm{in.})

Width of drive gear 43{1.6929}

Depth of pump chamber at
43{1.6929}
SAPH30ZCE1200020 cylinder block

(2) Calculate the difference between the depth of the drive

gear and the pump chamber depth at the cylinder block. If
it is beyond the service limit, replace the oil pump
assembly.

Service limit
Standard value (mm{in.})
(mm{in.})

0.047 - 0.15
Gasket use 0.15{0.0059}
{0.0019 - 0.0059}
SAPH30ZCE1200021

-0.013 - 0.05
No gasket —
{-0.0005 - 0.0020}

5. Inspection of clearance between outer diameter of drive

gear shaft and cylinder block hole diameter

(1) Measure the outer diameter of the drive gear shaft using a
micrometer and measure the cylinder block hole diameter
using a cylinder gauge.

Standard value
Measuring area
(mm{in.})

Outer diameter of drive gear shaft 18{0.7087}

SAPH30ZCE1200022

Cylinder block hole diameter 18{0.7087}

(2) Calculate the difference between the outer diameter of the

drive gear and the cylinder block hole diameter. If it is
beyond the service limit, replace the oil pump assembly.

0.040 - 0.099
Standard value (mm{in.})
{0.0016 - 0.0039}

SAPH30ZCE1200023
12–12 LUBRICATION

6. Inspection of clearance betweeen outer diameter of driven

gear shaft and inner diameter of driven gear bushing

(1) Measure the outer diameter of the driven gear shaft using
a micrometer and measure the inner diameter of the
driven gear bushing using a cylinder gauge.

Standard value
Measuring area
(mm{in.})

Outer diameter of driven gear

SAPH30ZCE1200024 18{0.7087}
shaft

Cylinder block hole diameter 18{0.7087}

(2) Calculate the difference between the outer diameter of the

driven gear and the cylinder block hole diameter. If it is
beyond the service limit, replace the oil pump assembly.

0.030 - 0.075
Standard value (mm{in.})
{0.0012 - 0.0030}

SAPH30ZCE1200025

7. Inspection of clearance betweeen outer diameter of driven

gear shaft and inner diameter of driven gear bushing

(1) Measure the outer diameter of the driven gear shaft using
a micrometer and measure the inner diameter of the
driven gear bushing using a cylinder gauge.

Standard value
Measuring area
(mm{in.})

Outer diameter of driven gear

SAPH30ZCE1200024 18{0.7087}
shaft

Inner diameter of driven gear

18{0.7087}
bushing

(2) Calculate the difference between the outer diameter of the

driven gear shaft and the inner diameter of the driven gear
bushing. If it is beyond the service limit, replace the oil
pump assembly or the driven gear bushing.

Standard value (mm{in.}) Service limit (mm{in.})

0.040 - 0.083
0.15{0.0059}
{0.0016 - 0.0033}

SAPH30ZCE1200026
 LUBRICATION 12–13

8. Inspection of drive gear backlash

(1) Fix the oil pump assembly with a vice.

(2) Measure backlash between the drive gear and the driven
gear using a dial gauge. If it is beyond the service limit,
replace the oil pump assembly.

Standard value (mm{in.}) Service limit (mm{in.})

0.073 - 0.207
0.30{0.0118}
{0.0029 - 0.0082}
SAPH30ZCE1200027

9. Assembly of oil pump

(1) Install the safety valve, relief valve, seat 1 and seat 2 on
the oil pump cover assembly with new cotter pins.

SAPH30ZCE1200017

(2) Install the driven gear.

SAPH30ZCE1200016

Replacement procedure item

Replacement of oil strainer

JP30ZCE120704003

1. Removal of oil strainer

(1) Remove bolts and remove the oil strainer.

2. Installation of oil strainer

(1) Install the oil strainer.
Tightening torque : 31 N˜m {320 kgf˜cm, 23 lbf˜ft}
Setup layout
Layout

SAPH30ZCE1200028
12–14 LUBRICATION

Oil Pan
Part layout
JP30ZCE120402003

SAPH30ZCE1200029

12111 Oil pan assembly 12149 Drain valve

12151 Oil pan gasket* Z4301 Gasket*

*Parts not to be reused.

Tightening torque
12149 41N˜m {420kgf˜cm, 30 lbf˜ft} Z1190 30N˜m {300kgf˜cm, 22 lbf˜ft}
Service procedure
Replacement procedure item
 LUBRICATION 12–15

Replacement
JP30ZCE120704004

1. Installation of oil pan

Bolt tightening direction (1) Cut the gasket of the rear end plate to be flush to the
cylinder block lower surface using a scraper.
(2) Make sure that there is no deformation, dirt or oil on the
joint surface between the cylinder block and the oil pan.
Apply liquid gasket [Threebond TB1207D (silver) or
equivalent] to the front rear end of the cylinder block lower
Rear surface.
(3) Insert several stud bolts (70 mm{2.7559 in.} or larger) for
Protrusion
positioning into the cylinder block screw hole.
Front (4) Position the gasket protrusion at the intake side and the
flywheel housing (printed seal surface at cylinder block).
Align the new gasket and oil pan to the cylinder block
lower surface and tighten bolts in the arrow order of the
figure.
Tightening torque :
19.6 - 24.5 N˜m {200 - 250 kgf˜cm, 14 - 18 lbf˜ft}
Liquid gasket applying position (5) Remove positioning stud bolts and install the correct bolts.
(6) Tighten bolts in the arrow order of the figure.
SAPH30ZCE1200030
Tightening torque : 30 N˜m {300 kgf˜cm, 22 lbf˜ft}

! CAUTION • Check if the washer is not riding on the

flange.
• Make sure that the printed seal is not peeled
or damaged before installation of the gasket.
Inspection procedure item
12–16 LUBRICATION

Inspection of lubrication status

JP30ZCE120703001

1. Inspection of valve system

! CAUTION • Perform inspection with the water

temperature at 60 qC{140qF}.

(1) Remove the head cover.

! CAUTION • To prevent spread of engine oil, attach a jig

which cuts a head cover in half. Cut it to the
degree that the camshaft is covered.

(2) Adjust the engine revolution to the standard idling

revolution [1,000r/min{rpm}].
(3) After start of the engine, make sure that oil is supplied to
the areas below of all rocker arms within about 10
seconds.
• Roller and cam surface
• Cross head and spring upper seat surface through
adjusting screw

! CAUTION • If time until lubrication is long or if lubrication

is not performed, the oil pressure may be low
SAPH30ZCE1200031
or the oil channel may be clogged. Seizure,
abnormal wear or abnormal noise may occur
due to insufficient lubrication.
 STARTING AND CHARGING 13–1

ENGINE

13 STARTING AND CHARGING

Setup layout
Layout

Starter........................................................................ 13-2
Part layout ............................................................. 13-2
Disassembly.......................................................... 13-3
Inspection of components..................................... 13-9
Assembly ............................................................ 13-14
Alternator (60A) ...................................................... 13-21
Part layout (60A) ................................................. 13-21
Circuit drawing (60A) .......................................... 13-22
Disassembly (60A).............................................. 13-23
Inspection of components (60A) ......................... 13-26
Assembly (60A)................................................... 13-28
Inspection after assembly (60A) ......................... 13-32

13
13–2 STARTING AND CHARGING

Starter
Part layout
JP30ZCE130402001

SAPH30ZCE1300001

28011 Clutch sub-assembly 28138 Packing*

28100 Starter 28140 Brush holder assembly
28111 Bushing 28142 Brush
28111A Bushing 28143 Spring
28113 Lever 28150 Center bracket
28115 Start drive housing 28160 Armature assembly
28117 Packing* 28168A Retainer clip*
28117A Packing* 28199 Dust protector
28118 Plate 28251 Pinion
28118A Plate 28252D Bearing*
28118B Plate 28255 Shaft assembly
28118D Cover 28253 Planetary gear
28120 Yoke assembly 28253A Internal gear
28133 Commutator end frame

*Parts not to be reused.

Tightening torque
28112 3.6-4.9N˜m{37-49kgf˜cm, 3-4 lbf˜ft} 28112 14-16N˜m{140-160kgf˜cm, 10-12 lbf˜ft}
28112A 15.7-17.6N˜m
{160-179kgf˜cm, 12-13 lbf˜ft}
Service procedure
Overhaul item
 STARTING AND CHARGING 13–3

Disassembly
JP30ZCE130702001

NOTICE • Fix the starter on the working table to ease

accessibility.

1. MRemoval of lead wire

M lead wire
(1) Remove the cap of the M terminal.
M terminal
(2) Remove nuts and remove the M lead wire.

SAPH30ZCE1300002

2. Removal of commutator end frame

Through bolt (1) Loosen and remove two through bolts.

Commutator end
frame

SAPH30ZCE1300003

(2) Remove two set bolts and remove the commutator end
frame.
Set bolt
! CAUTION • Hold the M lead wire and remove the
commutator end frame by lifting.

SAPH30ZCE1300004
13–4 STARTING AND CHARGING

3. Removal of brush holder assembly

Brush holder
Assembly (1) Lift the spring using a flat tip screwdriver or pliers.
Remove four brushes from the brush holder assembly.

! CAUTION • Do not cut the brush lead fixing clamp.

(2) Remove the brush holder assembly from the armature

assembly.
Spring
Brush

Brush lead
Clamp

SAPH30ZCE1300005

4. Removal of yoke assembly

M lead wire (1) Remove the yoke assembly from the center bracket
Yoke assembly
assembly.

! CAUTION • Do not hold the M lead wire and hold the yoke
assembly outer diameter for removal.

Center bracket
assembly

SAPH30ZCE1300006

5. Removal of packing
Yoke assembly (1) Remove the packing from the centering parts at both ends
of the yoke assembly.

! CAUTION • Damaged packing must not be resued.

Replace it with a new part.

Packing Packing

SAPH30ZCE1300007
 STARTING AND CHARGING 13–5

6. Removal of armature assembly

(1) Remove the armature assembly by lifting.
Armature
assembly • When the armature assembly is removed, the
! CAUTION
washer at the end of the gear may be dropped
and lost. Be careful for handling.
Center bracket
assembly

SAPH30ZCE1300008

7. Removal of rear bearing

(1) Pull out the bearing of the armature assembly using a
Rear bearing puller or press.

! CAUTION • Removed bearing must not be reused.

Replace it with a new one.

Puller

SAPH30ZCE1300009

8. Removal of cover
Packing Cover (1) Remove the cover from the center bracket assembly.
(2) Remove the packing.

! CAUTION • Damaged packing must not be resued.

Replace it with a new part.

SAPH30ZCE1300010

9. Removal of planetary gear

(1) Remove the planetary gear from the carrier pin.

Planetary gear ! CAUTION • Make sure that the gear is not damaged or
chipped.
Carrier pin

SAPH30ZCE1300011
13–6 STARTING AND CHARGING

10. Removal of internal gear

(1) Remove the internal gear from the center bracket.

! CAUTION • Make sure that the gear is not damaged or

chipped.
Internal gear

Center bracket

SAPH30ZCE1300012

11. Removal of shim washer

(1) Remove the shim washer from the center bracket.

Shim

SAPH30ZCE1300013

12. Removal of pinion

(1) Remove the retainer clip using a tool such as snap ring
pliers.

Retainer clip ! CAUTION • Retainer clip must not be reused. Replace it

Pinion stopper
with a new one.

NOTICE • Push upward or pull out the chipped part of

the clip mouth.
Pinion
SAPH30ZCE1300014

(2) Remove the pinion stopper.

(3) Remove the pinion.
Pinion stopper
! CAUTION • Make sure that the gear is not damaged or
Pinion chipped.

SAPH30ZCE1300015
 STARTING AND CHARGING 13–7

13. Removal of center bracket

Center bracket
(1) Remove two set bolts at the switch using a box
screwdriver or offset wrench.
(2) Lift and remove the center bracket.
Clutch
assembly

SAPH30ZCE1300016

14. Removal of lever

(1) Hold the lever holder and press the entire lever to the
Plunger clutch. Remove the link with the plunger.

Holder

Lever assembly

SAPH30ZCE1300017

(2) Turn and pull out the lever assembly using the clutch as
the axis.

Lever assembly

SAPH30ZCE1300018

15. Removal of brake plate

(1) Hold the clutch case outer diameter and slide the clutch
assembly upward. Pinch the clip end fixing the brake plate
and remove it by bending.

SAPH30ZCE1300019
13–8 STARTING AND CHARGING

(2) Remove the brake plate.

Brake plate

SAPH30ZCE1300020

16. Removal of clutch assembly

(1) While pressing the clutch assembly to the center bracket
Clutch assembly
assembly, offset the helical spline by one tooth.
Pull out the clutch assembly upward from the offset
Center bracket position and remove it.
assembly

SAPH30ZCE1300021

17. Removal of shaft assembly

Washer
(1) Turn the center bracket assembly upside down. Hold the
carrier plate and pull out the shaft assembly.

! CAUTION • Washers are available at the upper and lower

parts of the carrier plate. Be careful for loss of
the washers.
Shaft assembly

SAPH30ZCE1300022

18. Removal of packing

(1) Turn the center bracket upside down again and remove
the packing.

! CAUTION • Packing must not be reused.

Packing

SAPH30ZCE1300023

Inspection procedure item

 STARTING AND CHARGING 13–9

Inspection of components
JP30ZCE130703001

1. Inspection of yoke assembly

(1) Make sure that the coil lead wire has electric continuity
using a circuit tester.
(2) Make sure that there is no discoloration at the coil.

SAPH30ZCE1300024

(3) Measure the resistance between the coil lead wire and the
Tester rod yoke with a circuit tester and check insulation.
When the value is below the service limit, replace it.
Feed coil
Service limit 1k: or less

! CAUTION • After cleaning and drying, take

Yoke assembly measurements.

SAPH30ZCE1300025

(4) Measure the brush length using vernier calipers.

When the value is below the service limit, replace it.

Standard value (mm{in.}) Service limit (mm{in.})

18{0.7087} 13{0.5118} or less

SAPH30ZCE1300026

2. Inspection of armature assembly

Piece of steel
(1) Turn the armature assembly using a commercially
available growler tester and put a piece of steel on the
armature assembly. Make sure that the steel piece is not
vibrating on the core circumference.

Growler tester

SAPH30ZCE1300027
13–10 STARTING AND CHARGING

(2) Make sure that adjacent segments of the commutator

have electric continuity using a circuit tester.
(3) Make sure that there is no discoloration at the coil.

SAPH30ZCE1300028

(4) Measure the resistance between the commutator and the

Megger tester core using a circuit tester and check insulation.
When the value is below the service limit, replace it.
Core
Standard value Service limit

1k: or less
1M: or more
(Use 500V megger tester)

Commutator ! CAUTION • After cleaning and drying, take

SAPH30ZCE1300029 measurements.

(5) Measure the commutator outer diameter using vernier

calipers.
When the value is below the service limit, replace it.

! CAUTION • After removing roughness on the surface

(after polishing), take measurements.

Commutator outer diameter

Standard value (mm{in.}) Service limit (mm{in.})

Commutator
SAPH30ZCE1300030 36{1.4173} 34{1.3386} or less

(6) Measure the undercut depth between segments. If the

undercut depth is beyond the service limit, repair it.

Standard value (mm{in.}) Service limit (mm{in.})

Undercut length:
0.5 to 0.8 mm 0.5 - 0.8{0.0197 - 0.0315} 0.2{0.0079} or less
Segment {0.0197 - 0.0315}

! CAUTION • In repair, do not leave insulation material at

the end of the segment.
Insulating material
SAPH30ZCE1300031
 STARTING AND CHARGING 13–11

(7) Measure the shaft outer diameter using a micrometer. If it

is beyond the service limit, replace the shaft.

A Standard value Service limit

Measuring area
(mm{in.}) (mm{in.})
B 11.98{0.4717} or
Area A 12{0.4724}
less
8.98{0.3535} or
Area B 9{0.3543}
SAPH30ZCE1300032 less

3. Inspection of brush holder assembly

(1) Measure the resistance between the holder (plus) and the
plate using a circuit tester and check insulation.
When the value is below the service limit, replace it.

Service limit 1k: or less

! CAUTION • After cleaning and drying, take

measurements.
SAPH30ZCE1300033

(2) Measure the brush length using vernier calipers.

Brush Spring When the value is below the service limit, replace it.

Standard value (mm{in.}) Service limit (mm{in.})

18{0.7087} 13{0.5118} or less

(3) Make sure that the spring has pressure.

Brush

SAPH30ZCE1300034

4. Inspection of shaft assembly

(1) Measure the outer diameter of the shaft using a
micrometer
If it is beyond the service limit, replace the shaft.
B A
Standard value Service limit
Measuring area
(mm{in.}) (mm{in.})

25.90{1.0197} or
Area A 26{1.0236}
less
SAPH30ZCE1300035

12.04{0.4740} or
Area B 12.1{0.4764}
less
13–12 STARTING AND CHARGING

5. Inspection of clutch assembly

(1) Measure the outer diameter of the inner sleeve using a
micrometer.
If it is beyond the service limit, replace the clutch
assembly.

Standard value (mm{in.}) Service limit (mm{in.})

25{0.9843} 24.9{0.9803} or less

SAPH30ZCE1300036

6. Inspection of bearing
(1) Measure the bearing metal inner diameter (1 in the figure)
of the pinion case using a cylinder gauge. If it is beyond
the service limit, replace the bushing.

1
Standard value (mm{in.}) Service limit (mm{in.})

25{0.9843} 25.2{0.9921} or more

SAPH30ZCE1300037

(2) Measure the bearing metal inner diameter (2 in the figure)

of the center bracket using a cylinder gauge. If it is beyond
the service limit, replace the center bracket.

Standard value (mm{in.}) Service limit (mm{in.})

2 26{1.0236} 26.2{1.0315}

SAPH30ZCE1300038

(3) Measure the bearing metal inner diameter (3 in the figure)

3 4 of the shaft assembly using a cylinder gauge. If it is
beyond the service limit, replace the shaft assembly.

Standard value (mm{in.}) Service limit (mm{in.})

9{0.3543} 9.2{0.3622}

(4) Measure the bearing housing inner diameter (4 in the

figure) of the commutator end frame using a cylinder
SAPH30ZCE1300039
gauge. If it is beyond the service limit, replace the
commutator end frame.

Standard value (mm{in.}) Service limit (mm{in.})

28{1.1024} 28.1{1.1063} or more

 STARTING AND CHARGING 13–13

7. Inspection of start magnet switch assembly (resistance of

C terminal
P coil)
M terminal (1) Measure the P coil resistance between the C terminal and
the M terminal using a circuit tester.
If it is beyond the service limit, replace the start magnet
switch.

Standard value ( : ) 0.12 - 0.14

SAPH30ZCE1300040

8. Inspection of start magnet switch assembly (resistance of

H coil)
(1) Measure the H coil resistance between the C terminal and
C terminal the body using a circuit tester.
If it is beyond the service limit, replace the start magnet
switch.

Body
Standard value( : ) 1.13 - 1.25

SAPH30ZCE1300041

9. Inspection of start magnet switch assembly (electric

continuity inspection)
M terminal (1) Check electric continuity between the B terminal and the
M terminal using a circuit tester, and make sure that there
is no electric continuity.

B terminal

SAPH30ZCE1300042

(2) Push the end of the start magnet switch assembly (close
the internal contact) and make sure that there is electric
continuity between the B terminal and the M terminal
using a circuit tester.

SAPH30ZCE1300043

Overhaul item
13–14 STARTING AND CHARGING

Assembly
JP30ZCE130702002

1. Installation of packing
(1) Install a new packing on the center bracket assembly.

Packing

SAPH30ZCE1300023

2. Installation of shaft assembly

Washer
(1) Turn the center bracket assembly upside down and hold
the carrier plate. Lubricate parts (refer to the lubrication
point drawing and the lubrication list) and install the shaft
assembly.

! CAUTION • Washers are available at the upper and lower

Shaft assembly parts of the carrier plate. Be careful for loss of
the washers.
SAPH30ZCE1300022

3. Installation of clutch assembly

(1) Lubricate parts (refer to the lubrication point drawing and
Clutch assembly
the lubrication list) and insert the clutch assembly into the
center bracket assembly.
Center bracket
assembly

SAPH30ZCE1300044

4. Installation of brake plate

(1) Lubricate parts (refer to the lubrication point drawing and
the lubrication list) and install the brake plate.

Brake plate

SAPH30ZCE1300045
 STARTING AND CHARGING 13–15

5. Installation of lever
(1) Lubricate parts (refer to the lubrication point drawing and
the lubrication list). Turn and install the lever assembly
using the clutch as the axis.

Lever assembly

SAPH30ZCE1300018

6. Installation of pinion case

Center bracket
(1) Install two set bolts at the switch using a box screwdriver
or offset wrench.
Tightening torque :
Clutch 14 - 16 N˜m {140 - 160 kgf˜cm, 10 - 12 lbf˜ft}
assembly

SAPH30ZCE1300016

7. Installation of pinion
(1) Lubricate parts (refer to the lubrication point drawing and
Pinion stopper the lubrication list) and install the pinion and the pinion
stopper.
Pinion

SAPH30ZCE1300015

(2) Install the retainer clip using a tool such as snap ring
pliers.

Retainer clip

Pinion stopper

Pinion
SAPH30ZCE1300014
13–16 STARTING AND CHARGING

8. Installation of shim washer

(1) Lubricate parts (refer to the lubrication point drawing and
the lubrication list) and install the shim washer on the
center bracket.
Shim

SAPH30ZCE1300013

9. Removal of internal gear

(1) Lubricate parts (refer to the lubrication point drawing and
the lubrication list) and install the internal gear on the
center bracket.

Internal gear

Center bracket

SAPH30ZCE1300012

10. Installation of planetary gear

(1) Lubricate parts (refer to the lubrication point drawing and
the lubrication list) and install the planetary gear on the
Planetary gear carrier pin.
Carrier pin

SAPH30ZCE1300011

11. Installation of cover

Packing Cover (1) Install a new packing.
(2) Install the cover on the center bracket assembly.

SAPH30ZCE1300010

12. Installation of rear bearing

(1) Install the bearing on the armature assembly using a
press.

! CAUTION • When the bearing is removed, replace it with

a new one.
 STARTING AND CHARGING 13–17

13. Installation of armature assembly

(1) Install the armature assembly.
Armature
assembly • When the armature assembly is installed, the
! CAUTION
washer at the end of the gear may be dropped
and lost. Be careful for handling.
Center bracket
assembly

SAPH30ZCE1300008

14. Installation of packing

Yoke assembly (1) Install a new packing on the centering location at both
ends of the yoke assembly.

! CAUTION • Damaged packing must not be resued.

Replace it with a new part.

Packing Packing

SAPH30ZCE1300007

15. Installation of yoke assembly

M lead wire (1) Install the yoke assembly on the center bracket assembly.
Yoke assembly

Center bracket
assembly

SAPH30ZCE1300006
13–18 STARTING AND CHARGING

16. Installation of brush holder assembly

Brush holder
Assembly (1) Lift the spring using a flat tip screwdriver, long-nose pliers
or pliers. Install four brushes on the brush holder
assembly.

Spring
Brush

Brush lead
Clamp

SAPH30ZCE1300005

17. Installation of commutator end frame

Through bolt (1) Tighten the through bolt of the commutator end frame.

Tightening torque :
15.7 - 17.6 N˜m {160 - 179 kgf˜cm, 12 - 13 lbf˜ft}

Commutator end
frame

SAPH30ZCE1300003

(2) Tighten two set bolts.

Tightening torque :
Set bolt
3.6 - 4.9 N˜m {37 - 49 kgf˜cm, 3 - 4 lbf˜ft}

! CAUTION • Hold the M lead wire and remove the

commutator end frame by lifting.

SAPH30ZCE1300004
 STARTING AND CHARGING 13–19

18. Installation of lead wire

M lead wire
(1) Install the M lead wire.
M terminal

SAPH30ZCE1300002

19. Lubrication
Refer to the following figure and table for lubricant to be applied.

! CAUTION • There shall be no lubricant on the commutator surface, brush and contact.

Figure of lubricating locations

SAPH30ZCE1300046
13–20 STARTING AND CHARGING

Table of lubricant

Amount Lubricant
Code Lubricating point Lubricant used Remark
(g{oz}) manufacturer

Pinion case metal 0.8 - 1.5

1 Multemp AC-N Kyodo Yushi
and grease reservoir {0.03 - 0.05}

Bracket center metal 0.5 - 1.5

2 Multemp AC-N Kyodo Yushi
and grease reservoir {0.03 - 0.05}

0.2 - 0.5 Applied to both sides

3 Shim washer Multemp AC-N Kyodo Yushi
{0.01 - 0.02} of washer.

0.5 - 1
4 Armature front metal Multemp AC-N Kyodo Yushi
{0.02 - 0.04}

0.2 - 0.5 Applied to both sides

5 Shim washer Multemp AC-N Kyodo Yushi
{0.01 - 0.02} of washer.

Internal gear
7 -11
6 Armature gear Multemp AC-N Kyodo Yushi
{0.25 - 0.39}
Planetary gear
Pinion straight 0.5 - 1
7 Multemp AC-N Kyodo Yushi
Spline {0.02 - 0.04}

0.3 - 0.6
8 Inner sleeve metal Multemp AC-N Kyodo Yushi
{0.01 - 0.02}

0.5 - 1
9 Helical spline Multemp AC-N Kyodo Yushi
{0.02 - 0.04}

Clutch case lever 1-2 Nippon Oil

10 Pyroknock No.2
shifter {0.04 - 0.07} Corporation

Bracket rear bearing 0.2 - 0.5 Nippon Oil

11 Pyroknock No.2
housing {0.01 - 0.02} Corporation

1-2
12 Planetary gear metal Multemp AC-N Kyodo Yushi
{0.04 - 0.07}

0.4 - 0.8
13 Lever holder Multemp AC-N Kyodo Yushi
{0.01 - 0.03}

Assemble the roller

after application of
0.2 - 0.5 Nippon Oil
14 Lever roller rod Pyroknock No.2 grease to prevent fall
{0.01 - 0.02} Corporation
of the roller in
assembly.

Setup layout
Layout
 STARTING AND CHARGING 13–21

Alternator (60A)
Part layout (60A)
JP30ZCE130402002

SAPH30ZCE1300047

27017 Field coil 27383A Insulator

27060 Alternator 27389 Insulator
27310 Drive end frame assembly 27392 Cover
27311 Drive end frame 27410 Stator coil
27312 Bearing cover 27412 Collar
27330 Rotor assembly 27431 Pulley
27350 End frame assembly 27441 Fan
27353 Rectifier cathode 27700 Regulator
27356 Rectifier anode 28252 Front bearing
27359 End frame 28252A Rear bearing
27383 Insulator

Tightening torque
27317 1.9 - 2.5N˜m 27391A 4.9 - 5.9N˜m
{20 - 25kgf˜cm, 1.4 - 1.8 lbf˜ft} {50 - 60kgf˜cm, 3.6 - 4.3 lbf˜ft}
(Internal nut)
27317B 1.9 - 2.5N˜m (1) 127 - 157N˜m
{20 - 25kgf˜cm, 1.4 - 1.8 lbf˜ft} {1,300 - 1,600kgf˜cm, 94- 116 lbf˜ft}
27317C 2.9 - 3.9N˜m {30 - 39kgf˜cm, 2 - 3 lbf˜ft} (2) 7.8 - 9.8N˜m
{80 - 100kgf˜cm, 6 - 7 lbf˜ft}
System drawing
13–22 STARTING AND CHARGING

Circuit drawing (60A)

JP30ZCE130803001

Diode
B Fuse Load

L Lamp㧔1.4 to 3W㧕

Feild coil R
Starter switch
Regulator C

Stator coil Battery

24V

E
Alternator

SAPH30ZCE1300048
Service procedure
Overhaul item
 STARTING AND CHARGING 13–23

Disassembly (60A)
JP30ZCE130702003

1. Disconnection of the drive end frame from the end frame

Cover Tab Drive end
frame ! CAUTION • Place a rubber mat and perform work on the
mat.

(1) Remove the bolts and remove the cover from the drive
end frame.

! CAUTION • Be careful not to break the tab with excessive

force when pressing the tabs of the cover for
Bolt Tab
removal.
SAPH30ZCE1300049
• Do not push the tabs by screwdriver.

(2) Remove 3 through bolts and disconnect the drive end

End frame side frame from the end frame.

Drive end
frame side
SAPH30ZCE1300050

2. Disassembly of drive end frame

Fan
(1) Remove the nuts and remove the pulley, fan and collar.

Pulley ! CAUTION • Tie around a general V –belt in the pulley

groove and fix the pulley with a vice.
8-belt
• Do not reuse if outer frame of the pulley was
damaged.

SAPH30ZCE1300051

(2) Remove the rotor assembly from the drive end frame
using a press.

! CAUTION • Do not damage the end of the thread.

• Support the rotor assembly to prevent fall of
the rotor assembly.

SAPH30ZCE1300052
13–24 STARTING AND CHARGING

(3) Remove the screws (3pcs.) and remove the bearing cover
from the drive end frame.
Bearing cover

SAPH30ZCE1300053

(4) Remove the front bearing from the drive end frame using
a press or jig C.

! CAUTION • Place jig C at the inner race of the front

bearing.
• Removed bearing must not be reused.

SAPH30ZCE1300054

3. Disassembly of end frame

(1) Remove solder of the lead wire connecting the stator coil
and the diode using a soldering bit and suction line or a
solder suction device.

! CAUTION • At solder of the stator coil and the diode, the

end of the diode is clamped. Do not damage
the diode by prying. Deformed diode must not
Solder
be reused.
SAPH30ZCE1300055 • Perform soldering in a short time (within 5
seconds).

(2) Remove the stator coil from the end frame.

! CAUTION • Do not damage the stator coil.

End frame

Stator coil

SAPH30ZCE1300056
 STARTING AND CHARGING 13–25

(3) Remove the regulator connecting bolts (3pcs.) and the

Regulator regulator fixing bolts (2pcs.), and remove the regulator.

! CAUTION • As Screw-lock has been applied to the two

regulator fixing bolts, the torque required to
loosen the bolts is high; care must be taken
not to strip the bolt thread.

SAPH30ZCE1300057

(4) Loosen the nut at the B terminal.

! CAUTION • Loosen the nut to some extent and do not

remove it from the B terminal.

Nut

SAPH30ZCE1300058

(5) Remove the bolts (4pcs.) and remove the rectifier anode
and rectifier cathode.

! CAUTION • As Screw-lock has been applied, the torque

required to loosen the bolts is high; care must
be taken not to strip the bolt thread.

Rectifier

SAPH30ZCE1300059

(6) Remove the bolts (3pcs.) and remove the field coil from
the end frame.

Field coil
End frame

SAPH30ZCE1300060
13–26 STARTING AND CHARGING

(7) Remove the rear bearing from the end frame using a
press and jig A.
Jig A
! CAUTION • When the inner surface of the bearing hole of
the end frame etc. has been damaged when
pulling the bearing, the end frame cannot be
reused.
• Removed bearing must not be reused.

SAPH30ZCE1300061

Inspection procedure item

Inspection of components (60A)

JP30ZCE130703002

1. Inspection of stator coil and field coil

㨃
! CAUTION • Place a rubber mat and perform work on the
mat.

㨂 㨁 (1) Measure the resistance between the U - V, V - W, W - U

terminals of the stator coil using a circuit tester, if the
Wiring diagram
value exceeds the standard value, replace it.

Stator coil Standard value (:) 0.15 - 0.17

SAPH30ZCE1300062

(2) Measure the resistance between the terminal of the stator

Megger tester
coil core and each terminals using a 500V megger tester,
if the value exceeds the standard value, replace it.
Stator coil

1 or more
Standard value (M:)
(Use 500V megger tester)

! CAUTION • Do not reuse if the coil was damaged.

• Do not damage the circumferential surface of
SAPH30ZCE1300063
the coil.
• Damaged coil circumference must not be
reused.
• Do not use an organic solvent at the coil
cleaning, the coil may be damaged.
• Do not measure between the terminal to other
terminal, stator coil may be damaged.
 STARTING AND CHARGING 13–27

(3) Measure the resistance at the field coil using a circuit

tester, if the value exceed the standard value, replace it.

Standard value (:) 6.2 - 6.8

! CAUTION • Do not reuse if the coil was damaged.

Field coil • Do not damage the circumferential surface of

the coil.
SAPH30ZCE1300064
• Damaged coil circumference must not be
reused.
• Do not use an organic solvent at the coil
cleaning, the coil may be damaged.

(4) Measure the resistance between the field coil core and
the coil using a megger tester, if the value exceed the
Megger tester standard value, replace it.

1 or more
Standard value (M:)
(Use 500V megger tester)

! CAUTION • Do not measure between the coils, the field

Field coil
coil may be damaged.
SAPH30ZCE1300065

2. Inspection of rotor assembly

(1) Measure the outer diameter of the shaft of the front
bearing insertion portion of the rotor assembly using a
micrometer, if value exceed the service limit, replace it.

Standard value (mm{in.}) Service limit (mm{in.})

25.0{0.9843} 24.98{0.9835}
Micrometer

SAPH30ZCE1300066

(2) Measure the outer diameter of the shaft of the rear

bearing insertion portion of the rotor assembly using a
micrometer, if value exceed the service limit, replace it.

Standard value (mm{in.}) Service limit (mm{in.})

17.0{0.6693} 16.98{0.6685}

Micrometer

SAPH30ZCE1300067
13–28 STARTING AND CHARGING

3. Inspection of the diode and the regulator

(1) Measure the resistance between the cathode of the diode
and rectifier holder portion using a circuit tester, if value
exceed the standard value, replace it.

Measuring direction Standard value

Forward resistance value Approx. 10 :

Rectifier Reverse resistance value Infinite
SAPH30ZCE1300068

! CAUTION • Do not use a digital tester.

(2) Measure the resistance between the terminals F - E of the

regulator using a circuit tester, if value exceed the
standard value, replace it.

Measuring direction Standard value

㧲 Forward resistance value Approx. 10 :

Back
view Reverse resistance value Infinite

SAPH30ZCE1300069 ! CAUTION • Do not use a digital tester.

Overhaul item

Assembly (60A)
JP30ZCE130702004

1. Assembly of the drive end frame

! CAUTION • Place a rubber mat and perform work on the

mat.

(1) Press fit a new front bearing into the drive end frame
using a press and jig C.

! CAUTION • Place jig C at the outer race of the front

bearing.

SAPH30ZCE1300070

(2) Install the bearing cover to the drive end frame by screws
Screw (3pcs.).

Tightening torque :
1.9 - 2.5 N˜m {20 - 25 kgf˜cm, 1.4 - 1.8 lbf˜ft}

Bearing cover

Drive end frame

SAPH30ZCE1300071
 STARTING AND CHARGING 13–29

(3) Press fit the rotor assembly to the drive end frame using a
press.

! CAUTION • Always fit the inner race part of the bearing

when press-fitting.
• Do not damage the shaft.

SAPH30ZCE1300072

(4) Tie around a general V-belt in the pulley groove and fix the
Fan
Rotor
pulley with a vice.
assembly (5) Install the collar, fan and pulley on the shaft of the rotor
Pulley
assembly.

Tightening torque :
V-belt
127 - 157 N˜m {1,300 - 1,600 kgf˜cm, 94 - 116 lbf˜ft}

! CAUTION • Do not reuse if outer frame of the pulley was

damaged.
SAPH30ZCE1300073

2. Assembly of the end frame

(1) Press fit a new rear bearing into the end frame using a
press, jig A and jig B.

! CAUTION • Press fit until jig A comes in contact with the

end frame.
• Reuse is not possible when the bearing case
is deformed at the time of press-fitting.

SAPH30ZCE1300074

(2) Install the field coil on the end frame.

Tightening torque :
2.9 - 3.9 N˜m {30 - 39 kgf˜cm, 2 - 3 lbf˜ft}

! CAUTION • Tighten bolts finally after temporary

tightening. Tighten them evenly.

Field coil
End frame
SAPH30ZCE1300075
13–30 STARTING AND CHARGING

(3) Assemble the stator coil on the end frame temporarily.

! CAUTION • Do not damage the stator coil during work.

End frame

Stator coil

SAPH30ZCE1300076

(4) Apply screw lock (Three bond TB1344) to the end of the
rectifier mounting bolts, and install the rectifier to the end
frame.

Tightening torque :
1.9 - 2.5 N˜m {20 - 25 kgf˜cm, 1.4 - 1.8 lbf˜ft}

Rectifier

SAPH30ZCE1300077

(5) Apply screw lock (Three bond TB1344) to the end of the
Regulator regulator mounting bolts, and install the regulator to the
end frame.

Tightening torque :
1.6 - 2.3 N˜m {16 - 23 kgf˜cm, 1.2 - 1.6 lbf˜ft}
(Regulator fix)
1.0 - 1.4 N˜m {10 - 14 kgf˜cm, 0.8 - 1.0 lbf˜ft}
(Coil lead wire connecting)
1.0 - 1.4 N˜m {10 - 14 kgf˜cm, 0.8 - 1.0 lbf˜ft}
SAPH30ZCE1300078
(Heat sink connecting)
(6) Solder the lead wire connecting the stator coil and the
diode using a solder bit.

! CAUTION • Perform soldering after tightening of bolts.

• Insert the lead wire of the stator coil into the
end of the diode, and bend and fix the end of
the diode, before soldering it.

Solder
• Perform soldering in a short time (within 5
seconds).
SAPH30ZCE1300079
 STARTING AND CHARGING 13–31

(7) Tighten the nut inside the B terminal.

Tightening torque :
4.9 - 5.9 N˜m {50 - 60 kgf˜cm, 3.6 - 4.3 lbf˜ft}

NOTICE • After installation of the alternator, connect the

wire and tighten the outside nut.

Nut

SAPH30ZCE1300080

3. Joint of the drive end frame and the end frame

End frame side (1) Joint the drive end frame and the end frame by through
bolts (3pcs.).

Tightening torque :
7.8 - 9.8 N˜m {80 - 100 kgf˜cm, 6 - 7 lbf˜ft}

! CAUTION • Tighten bolts evenly.

Drive end
frame side

SAPH30ZCE1300081

(2) Match the position of the tab, and install the cover to the
Cover Tab
Drive end dive end frame, fix the cover with the bolt.
frame
Tightening torque :
3.3 - 4.4 N˜m {34 - 44 kgf˜cm, 2 - 3 lbf˜ft}

! CAUTION • Do not hit the cover, the tab may be broken.

Bolt Tab
SAPH30ZCE1300082
13–32 STARTING AND CHARGING

Inspection procedure item

Inspection after assembly (60A)

JP30ZCE130703003

1. Inspection of rotation

! CAUTION • Place a rubber mat and perform work on the

mat.

(1) Turn the pulley with hand to check if there is no

interference with internal parts and if rotation is smooth.

Pulley

SAPH30ZCE1300083

(2) Measure the resistance between B - E terminals and

between P - E terminals using a circuit tester, if it is
exceeds the standard value (e.g. 0:), disassemble it
again and reassemble the unit correctly.

Circuit tester lead

Standard value
(+) (-)

B E Approx. 20 :
SAPH30ZCE1300084
E B Infinite

P E Approx.7 :

E P Infinite

Connector lock

4 %

. 2

Connector details Connector lock

'
SAPH30ZCE1300085
 TURBOCHARGER 14–1

ENGINE

14 TURBOCHARGER
Setup layout
Layout

Turbocharger Assembly........................................... 14-2

Part layout ............................................................. 14-2
Inspection ............................................................. 14-5
Replacement......................................................... 14-6

14
14–2 TURBOCHARGER

Turbocharger Assembly
Part layout
JP30ZCE140402001

 $ #  #

#   
SAPH30ZCE1400001

1 Intake pipe stay 6 Turbine outlet elbow

2 Intake pipe 7 Oil outlet pipe
3 Air hose 8 Bracket
4 Clamp 9 Gasket*
5 Turbocharger assembly
*Parts not to be reused.
Tightening torque
A 28.5N˜m{291kgf˜cm, 21 lbf˜ft} B 60N˜m{612kgf˜cm, 44 lbf˜ft}
 TURBOCHARGER 14–3

# #  $

<

 #

View Z
SAPH30ZCE1400002

1 Coolant pipe 3 Gasket*

2 Oil inlet pipe

*Parts not to be reused.

Tightening torque
A 25N˜m{255kgf˜cm, 18 lbf˜ft} C 28.5N˜m{291kgf˜cm, 21 lbf˜ft}
B 60N˜m{612kgf˜cm, 44 lbf˜ft}
14–4 TURBOCHARGER

 $ #

$

<

View Z
SAPH30ZCE1400003

1 Coolant pipe 2 Gasket*

*Parts not to be reused.

Tightening torque
A 56N˜m{571kgf˜cm, 41 lbf˜ft} B 25N˜m{255kgf˜cm, 18 lbf˜ft}
 TURBOCHARGER 14–5

Maintenance
List of maintenance
inspection
inspection
(preventive service)

Inspection
JP30ZCE140501001

1. Inspection of turbine shaft axial play

(1) Inspect axial play of the turbine shaft at the exhaust side
using a special tool.

Special tool : S0944-41800(09444-1800)

Tool assembly

(2) If the measurement value is beyond the standard value,

ask the manufacturer to overhaul the unit.

SAPH30ZCE1400004 0.040 - 0.085

Standard value (mm{in.}) {0.0016 - 0.0033}
(Only axial play)

NOTICE • Since the assembly is replaced, disassembly

and inspection are not allowed.
Service procedure
Replacement procedure item
14–6 TURBOCHARGER

Replacement
JP30ZCE140704001

1. Removal
(1) Remove the boost pipe and U-turn pipe.
(2) Disconnect all pipes connected to the turbocharger.

! CAUTION • Loosen union bolt of the coolant pipe, drain

coolant and remove the pipe. Disconnect the
lower pipe similarly and remove the oil pipe.
• After removing pipes, be sure to seal oil
holes, water holes and cylinder block holes
to prevent entry of dirt.

(3) Remove the bolts fixing the exhaust pipe and the
turbocharger and remove the turbocharger.

! CAUTION • After removal, seal holes both at the exhaust

manifold and the exhaust pipe to prevent
entry of foreign matter.
• If a stud bolt is sticking, remove and replace
the stud bolt using a commercially available
stud remover.

2. Installation
(1) Before installation on the engine, pour new engine oil from
the oil inlet and turn the turbocharger with hand to
lubricate the journal bearing and the thrust bearing.
(2) Replace the o-ring by new ones, and assemble the
exhaust pipe and the turbocharger, and install the
turbocharger on the engine.
Tightening torque :
56 N˜m {570 kgf˜cm, 41 lbf˜ft}
(Turbocharger to exhaust manifold)

! CAUTION • Make sure that there is no dirt or foreign

matter in the exhaust pipe system.
• As heat-resistant steel is used for the bolts
and nuts, take care that they do not become
mixed up with standard bolts and nuts.

(3) Replace the gasket by new ones, install the coolant pipe
and the oil pipe to the turbocharger.

! CAUTION • Clean the pipes and confirm that they are not
crushed and that the inside of the pipes is
free of dirt and foreign matter.
• Do not use a sealing agent at the installation
surfaces of oil pipes and fuel pipes and at the
connection parts of coolant hoses and
coolant pipes; small particles can cause
clogging, loose connections, damage to
components, as well as other malfunctions.
TURBOCHARGER 14–7

(4) Install the boost pipe and the U turn pipe.

! CAUTION • Confirm that the inside of the intake system is

free of dirt and foreign matter.
Do not use a sealing agent at the air intake of
the air pipe; small particles can cause
clogging, loose connections, damage to
components, as well as other malfunctions.
• Install correctly to prevent leak of air from
intake pipe and air hose connections.
 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS 16–1

ENGINE

16 FAILURE DIAGNOSIS FOR EACH ENGINE

STATUS
Failure diagnosis list

FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

.................................................................................... 16-2
Engine mechanical ............................................... 16-2
Alternator .............................................................. 16-5
Starter ................................................................... 16-6
Turbocharger......................................................... 16-7
DPR filter .............................................................. 16-9

16
16–2 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

Engine mechanical
JP30002150601001

Status Cause Action

Engine overheat (coolant) Insufficient coolant Replenish coolant
Faulty thermostat Replace thermostat
Water leak from cooling system Correction
Faulty coolant pump Repair or replace
Faulty head gasket Replace head gasket
Engine overheat Clogging of radiator Cleaning of radiator
(radiator) Corrosion of cooling system Clean and repair cooling system
Clogging of radiator core front part Clean radiator
Faulty radiator cap Replace radiator cap
Engine overheat (lubrication Deterioration of engine oil Replace engine oil
unit) Faulty oil pump Replace oil pump
Insufficient engine oil Replenish engine oil
Large engine oil consumption Wear of piston ring and cylinder Replace piston ring and cylinder
(piston, cylinder liner and piston liner liner
ring) Damage to piston ring Replace piston ring and cylinder liner
Faulty fixing of piston ring Replace piston ring and cylinder liner
Faulty assembly of piston ring Replace piston ring and cylinder
liner
Faulty engine oil Replace engine oil
Faulty piston ring joint Reassemble piston ring
Large engine oil consumption Wear of valve stem Replace valve and valve guide
(valve and valve guide) Wear of valve guide Replace valve guide
Faulty assembly of valve stem seal Replace stem seal
Excessive oil lubrication to rocker Inspection of clearance between
arm rocker arm and rocker arm shaft
Large engine oil consumption Faulty oil level gauge Replace with correct level gauge
(others) Excessive filling of engine oil Fill with appropriate amount of oil.
Leak of engine oil Repair or replace the part of oil
leak.
Piston seizure (in operation) Sudden stop of engine Perform warm-up before stop of
engine
Piston seizure (lubrication unit) Insufficient engine oil Replenish engine oil
Deterioration of engine oil Replace engine oil
Incorrect engine oil Replace with correct engine oil.
Low oil pressure Inspection of lubrication unit
Faulty oil pump Replace oil pump
Piston seizure Abnormal combustion Refer to overheat section.
Piston seizure Cooling unit Refer to overheat section.
Insufficient engine power (air Clogging of air cleaner element Clean or replace air cleaner
cleaner) element
Insufficient engine power Overheat Refer to overheat section.
 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS 16–3

Status Cause Action

Insufficient engine power (fuel Faulty injection of injector Replace injector
unit) Faulty injector due to deposit of Replace injector
carbon
Entry of air into fuel system Air bleeding of fuel system
Faulty fuel filter Replace element
Faulty fuel Replace with correct fuel
Insufficient engine power Abnormal compression pressure Refer to overheat section.
Insufficient engine power Piston, cylinder liner and piston Refer to large engine oil
ring consumption section.
Faulty engine start (electric unit) Faulty battery Check battery
Faulty wiring of starter Replace starter wiring
Loose battery cable Tighten battery terminal connection
or replace cable
Faulty operation of starter Replace starter assembly
Faulty start assist unit Replace start assist unit
Faulty engine start (air cleaner) Clogging of air cleaner element Clean or replace air cleaner
element
Faulty engine start (fuel unit) Insufficient fuel Replenish fuel and bleed air from
fuel system
Clogging of fuel system Clean fuel system.
Air entering from connection of fuel Check sealing parts and replace
system
Clogging of fuel filter Replace fuel filter and air bleeding
of fuel system
Faulty fuel from fuel system Check and replace sealing parts
Fuel freezing Warm up fuel pipes by hot water
(60qC {140qF} below)
Water in fuel tank Discharge water
Water in fuel filter Discharge water
Faulty engine start (lubrication Excessive viscosity of engine oil Replace with engine oil with correct
unit) viscosity
Faulty engine start (others) Piston seizure Replace piston, piston ring and
cylinder liner
Bearing seizure Replace bearing and crankshaft

Low compression pressure Overhaul engine

Damage to ring gear Replace ring gear and replace
starter pinion gear.
16–4 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

Status Cause Action

Faulty idling (fuel system) Insufficient fuel Replenish fuel and bleed air from
fuel system
Clogging of fuel system Clean fuel system.
Air entering from connection of fuel Check sealing parts and replace
system
Clogging of fuel filter Replace fuel filter and air bleeding
of fuel system
Faulty fuel from fuel system Check and replace sealing parts
Fuel freezing Warm up fuel pipes by hot water
(60qC {140qF} below)
Water in fuel tank Discharge water
Water in fuel filter Discharge water
Faulty idling (engine) Faulty valve clearance Adjustment of valve clearance
Faulty contact of valve seat Adjust or replace valve and valve
seat.
Low coolant temperature Perform warm-up.
Large variation of compression Overhaul engine
pressure between cylinders
Training of engine difference not Perform training of engine
performed after exchange of the difference after exchange of the
engine ECU engine ECU
Gas leak (head gasket) Reuse Replace gasket.
Damage Replace gasket.
Replace gasket. Replace gasket.
Gas leak (head bolt) Loose head bolt Tighten bolt.
Incorrect tightening sequence or Tighten bolt to correct torque
incorrect tightening torque according to the correct tightening
sequence.
Extension of head bolt Replace bolt.
Gas leak (cylinder block) Crack Replace cylinder block.
Distortion of cylinder block upper Repair or replace cylinder block.
surface
Depression of cylinder liner insertion Replace cylinder liner or block.
(insufficient protrusion of cylinder liner)
Gas leak (cylinder head) Crack of cylinder head Replace cylinder head.
Distortion of cylinder head lower Repair or replace cylinder head.
surface
Gas leak (cylinder liner) Crack of cylinder liner Replace cylinder liner.
Corrosion of cylinder liner Replace cylinder liner.
Insufficient protrusion of cylinder Replace cylinder liner or block.
liner
 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS 16–5

Alternator
JP30002150601002

Status Cause Action

Lamp is ON. o Charge current Faulty regulator (open PTr) Replace regulator.
does not run (alternator). Faulty stator coil (disconnection, Replace stator coil.
rare shorting)
Fault feed coil (disconnection, rare Replace feed coil.
shorting)
Faulty diode (open, shorting) Replace rectifier.
Disconnection or poor contact of Repair or replace lead wire.
lead wire (plate, support, etc.)
Lamp is ON. o Charge current Disconnection of wire (fuse) Replace wire (fuse).
does not run (wiring).
Lamp is ON. o Voltmeter Faulty regulator (shorting of PTr) Replace regulator.
indicates 29V or more Faulty tightening of voltage Repair, replace voltage detection
(alternator). detection circuit (e.g. support) circuit or replace regulator.
Lamp is ON. o Charge current is Faulty regulator (open Tr) Replace regulator.
correctly running (alternator).
Lamp is OFF. o Charge current Faulty stator coil (disconnection of 1 Replace stator coil.
is always limited. o Battery goes phase, rare shorting)
flat (alternator). Faulty diode (open, shorting) Replace rectifier.
Disconnection or poor contact of Repair or replace lead wire.
lead wire (plate, support, etc.)
Lamp is OFF. o Charge current Operation load is large (Load Reduce load
is always limited. o Battery goes balance is poor).
flat (operation load).
Lamp is OFF. o Charge current Faulty regulator (shorting of PTr) Replace regulator.
is always large. o Battery fluid Faulty tightening of voltage Repair or replace voltage detection
runs short in a short period of detection circuit (e.g. support) circuit.
time (alternator).
Lamp is OFF. o Charge current Battery is close to the service life. Replace battery.
is always large. o Battery fluid
runs short in a short period of
time (battery).
Others o Abnormal noise Faulty stator coil (rare shorting, Replace stator coil.
(alternator) grounding)
Contact of inner surface (faulty Repair or replace bearing.
bearing, wear of bracket)
Others o Abnormal noise (V belt) Faulty tension of V belt (belt slip) Correction
16–6 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

Starter
JP30002150601003

Status Cause Action

Starter does not turn. Turning is Faulty connection of starter key Repair connecting area.
low. Flat battery Charge or replace.
Disconnection, loosening or After cleaning, tighten.
corrosion of battery terminal
Grounding wire is disconnected. Be sure to connect it.
Use of incorrect engine oil Replace with correct oil.
Faulty contact of start magnet Replace start magnet switch
switch assembly. assembly
Faulty contact or failure of starter Replace starter relay.
relay
Wear of starter brush Replace brush
Seizure of commutator Repair commutator.
Wear of commutator Undercut
Shorting of armature Replace armature assembly
Insufficient tension of brush spring Replace brush spring.
Faulty operation of clutch Clean or replace.
 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS 16–7

Turbocharger
JP30002150601004

Status Cause Action

Oil is quickly reduced Seal ring is excessively worn or damaged Disassemble and repair
due to excessive wear of the bearing. turbocharger.
Engine oil enters into exhaust gas Check and service engine parts.
before the turbocharger.
Clogged or damaged of oil return Repair or replace oil pipes.
pipe, then engine oil is entering to
blower side or turbine side.
Blower Impeller back side vacuum Check or replace oil pipes, replace
is excessive incease, then engine or cleaning air cleaner element.
oil is entering to blower side.
Low engine output Gas leak from exhaust system Check and repair faulty areas.
parts
Clogging of air inlet Repair air inlet.
Gas leak from exhaust system Check and repair faulty areas.
parts
Clogging or damaging of exhaust Repair exhaust system.
system, then revolution of the turbo-
charger doesn't increase
Air leak from the blower side Repair blower side.
Contamination of or damage to Replace turbocharger.
turbocharger
Operation defect of VG assembly Check using Hino DX.
Seizure of bearing (lack lubrication Check lubrication system and
or clogging of oil pipe) repair, replace engine oil and
turbocharger.
Seizure of bearing (Too hot oil Check lubrication system and
temperature) repair, replace engine oil and
turbocharger.
Seizure of bearing (Turbine is Check lubrication system and
eccentricity) repair, replace engine oil and
turbocharger.
Seizure of bearing (Rapid stop from Drive correctly, according to the
high load condition) attention of the driver's manual,
replace turbocharger.
16–8 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS

Status Cause Action

Acceleration (follow-up of Carbon deposit at the turbine (disc Replace engine oil and
turbocharger) is poor (slow). sealing area) makes revolution of turbocharger.
the turbine heavy.
Air and gas leak from intake/ Check and repair faulty areas.
exhaust system parts
Lack of fuel. Check fuel system and be good
condition.
Operation defect of VG assembly Check using Hino DX.
Seizure of bearing (lack lubrication Check lubrication system and
or clogging of oil pipe) repair, replace engine oil and
turbocharger.
Seizure of bearing (Too hot oil Check lubrication system and
temperature) repair, replace engine oil and
turbocharger.
Abnormal noise If the gas passage is extremely Replace turbocharger.
narrowed due to clogging at the
turbine case nozzle or if acceleration
is performed, reverse flow (usually
called surging) occurs due to clogging
of blower discharge air.
Revolving part is in contact. Replace turbocharger.
Operation defect of VG assembly Check using Hino DX.
Air and gas leak from intake/ Check and repair faulty areas.
exhaust system parts
Vibration Loosening between turbocharger Check the turbocharger mounting
and intake/exhaust pipe and status and repair faulty areas.
between oil pipe and mounting area
Failure of metal, contact between Replace turbocharger. Remove
revolving part and peripheral parts, foreign matter completely, if any.
or damage to the blower impeller of
the turbine rotor due to entry of
foreign matter is found.
Balance of revolving body is poor. Replace revolving body.
 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS 16–9

DPR filter

Status Cause Action

DPR damaged or melted DPR filter was cracked Replace DPR filter
DPR filter was melted Replace DPR filter
 ENGINE DIAGNOSIS CODE 17–1

ENGINE

17 ENGINE DIAGNOSIS CODE

General information

Engine ECU ............................................................... 17-3 DTC code P0201 [61]

Precautions........................................................... 17-3 DTC code P0202 [62]
System block diagram........................................... 17-4 DTC code P0203 [63]
Inspection ............................................................. 17-5 DTC code P0204 [64]
Table of failure code .............................................. 17-7 DTC code P0205 [65]
Signal check harness.......................................... 17-11 DTC code P0206 [66]
Computer pin arrangement ................................. 17-13 ............................................................................ 17-69
Check the ECU power supply voltage DTC code P0217 [6]
............................................................................ 17-21 ............................................................................ 17-73
Check the ground DTC code P0219 [7]
............................................................................ 17-22 ............................................................................ 17-74
DTC code P0016 [13] DTC code P0234 [34]
............................................................................ 17-23 ............................................................................ 17-75
DTC code P0045 [35] DTC code P0237 [25]
DTC code P00AF [35] ............................................................................ 17-77
............................................................................ 17-24 DTC code P0263 [61]
DTC code P0087 [76] DTC code P0266 [62]
DTC code P0088 [76] DTC code P0269 [63]
DTC code P2635 [76] DTC code P0272 [64]
............................................................................ 17-26 DTC code P0275 [65]
DTC code P0088 [69] DTC code P0278 [66]
............................................................................ 17-35 ............................................................................ 17-81
DTC code P0104 [17] DTC code P0335 [13]
............................................................................ 17-36 ............................................................................ 17-83
DTC code P0108 [25] DTC code P0336 [13]
............................................................................ 17-37 ............................................................................ 17-85
DTC code P0112 [17] DTC code P0340 [12]
DTC code P0113 [17] ............................................................................ 17-88
............................................................................ 17-41 DTC code P0341 [12]
DTC code P0117 [11] ............................................................................ 17-89
DTC code P0118 [11] DTC code P0540 [53]
............................................................................ 17-44 ............................................................................ 17-91
DTC code P0122 [32] DTC code P0545 [27] 17
............................................................................ 17-47 ............................................................................ 17-93
DTC code P0123 [32] DTC code P0546 [27]
............................................................................ 17-51 ............................................................................ 17-96
DTC code P0182 [14] DTC code P0617 [45]
DTC code P0183 [14] ............................................................................ 17-99
............................................................................ 17-55 DTC code P0628 [73]
DTC code P0192 [74] DTC code P0629 [75]
............................................................................ 17-58 .......................................................................... 17-100
DTC code P0193 [74] DTC code P0642 [5]
............................................................................ 17-63 .......................................................................... 17-102
DTC code P0200 [71] DTC code P0643 [5]
DTC code P0611 [71] .......................................................................... 17-103
DTC code P0605 [3] DTC code P0652 [5]
DTC code P0606 [3] .......................................................................... 17-104
DTC code P0607 [3] DTC code P0653 [5]
............................................................................ 17-68 .......................................................................... 17-105
 17–2 ENGINE DIAGNOSIS CODE

DTC code P0686 [51] DTC code P244A [91]

..........................................................................17-106 ..........................................................................17-171
DTC code P06D3 [5] DTC code P244B [92]
..........................................................................17-107 ..........................................................................17-172
DTC code P06D4 [5] DTC code P2458 [93]
..........................................................................17-109 DTC code P24A2 [93]
DTC code P1133 [23] ..........................................................................17-177
..........................................................................17-110 DTC code P2463 [92]
DTC code P1197 [74] ..........................................................................17-182
..........................................................................17-113 DTC code U0073 [8]
DTC code P1198 [74] ..........................................................................17-187
..........................................................................17-118 DTC code U1001 [9]
DTC code P119F [74] ..........................................................................17-188
..........................................................................17-123 DTC code U110A [9]
DTC code P1211 [68] ..........................................................................17-189
..........................................................................17-125 DTC code U1122 [8]
DTC code P1212 [68] ..........................................................................17-190
..........................................................................17-127 DTC code U1123 [8]
DTC code P1214 [68] ..........................................................................17-192
..........................................................................17-129
DTC code P1215 [68]
..........................................................................17-131
DTC code P1427 [28]
..........................................................................17-133
DTC code P1428 [28]
..........................................................................17-137
DTC code P1458 [81]
..........................................................................17-142
DTC code P1459 [81]
.........................................................................17-144
DTC code P1601 [2]
.........................................................................17-145
DTC code P200C [91]
..........................................................................17-147
DTC code P2032 [27]
..........................................................................17-152
DTC code P2033 [27]
..........................................................................17-156
DTC code P2100 [31]
DTC code P2103 [31]

17
..........................................................................17-160
DTC code P2101 [31]
..........................................................................17-162
DTC code P2120 [22]
..........................................................................17-163
DTC code P2121 [22]
DTC code P2126 [22]
..........................................................................17-164
DTC code P2122 [22]
DTC code P2123 [22]
..........................................................................17-166
DTC code P2127 [22]
DTC code P2128 [22]
..........................................................................17-168
DTC code P2228 [15]
DTC code P2229 [15]
..........................................................................17-170
 ENGINE DIAGNOSIS CODE 17–3

Engine ECU
Precautions
JP31ZCE170102001

! CAUTION • Make sure that each connector is connected

before inspection.
• Do not place a tester rod on the connecting
surface of the connector. Otherwise,
terminals are damaged or short-circuited.
• Delete the past failure memory after
recording. Perform failure diagnosis again to
check current failure.
• After failure analysis, delete the past failure
memory. If the past failure memory is not
deleted, the failure indicator lamp remains
ON.
• All connector drawings are viewed from the
connecting surface. Place the tester rod from
the back.
System drawing

SAPH31ZCE1700001
17–4 ENGINE DIAGNOSIS CODE

System block diagram

JP31ZCE170803001

ACT Relay FUSE

Each Sensor Power
Main relay
Key switch signal FUSE
Starter signal

Battery
Accelerator signal 1, 2

Check engine lamp

Glow relay
Clutch switch (Hi fixing) DPR indicator lamp

O
Neutral switch U
T
P
DPR regeneration switch
U
T
Volume for Supply pump
emergency accelerator
Supply pump control valve drive signal

Injector drive signal T

I CAN communication 250K

N (Variable geometry Turbocharger/Linear EGR)
P
Intake throttle valve drive signal
U
CAN communication 500K Outside
T O send and receive
t communication
h CAN communication 500K
e
PC Diagnosis
r
s

Back pressure sensor

Diagnosis tool

Exhaust gas temperature sensor Fuel temperature sensor (Supply pump)

(DPR inlet)
Intake throttle valve position sensor
Engine speed main sensor
Engine speed sub sensor Exhaust gas temperature sensor (DPR outlet)
Boost pressure sensor Air flow sensor
(frequency system)
Fuel rail
pressure sensor1
Fuel rail
pressure sensor2
Intake air
temperature
temperature

P sensor
(Air flow meter
Intake throttle valve
sensor

built-in)
Water

Fuel rail System

T DC Motor
Air flow Intake throttle valve
P T meter
G
Engine
N
DPR Cleaner
EGR System VNT System
Turbocharger T P T
EGR
Variable geometry DC Motor
DC Motor actuator

SAPH31ZCE1700003
Service procedure
Inspection procedure item
 ENGINE DIAGNOSIS CODE 17–5

Inspection
JP31ZCE170703001

1. Pre-inspection
(1) If an error occurs on the system, The DTC code is
indicated in the console panel.
(2) Reading of failure code
a. Connection of HinoDX
1. Remove the maintenance cover on the rear cover
Maintenance cover behind the operator seat by pushing down the tab at
the top (at one location).

NOTICE • The engine fault diagnosis connector (16 P) is

on the inside.

SAPH31ZCE1700004

2. Connect the engine failure diagnosis connector to

the PC which installed HinoDX through the interface
Mechatronic contoroller box.

Engine failure
diagnostic connector

SAPH31ZCE1700005

3. Set the starter key to "ON" and start HinoDX.

Failure diagnosis connector
Special tool : 09993-E9070 Hino-Bowie
(Interface box)
09042-1220 Connecting cable
CD-ROM HinoDX
Hino-Bowie

Connect to the failure diagnosis Connecting cable

connector at the vehicle side.
SAPH31ZCE1700007
17–6 ENGINE DIAGNOSIS CODE

2. Deletion method of past failure

(1) To delete past failures of the engine ECU, use HinoDX on
the PC. (Refer to "HinoDX operation manual".)

SAPH31ZCE1700008

3. List of failure diagnosis tools

Part name Part No. External shape General description and function

• Software and CD-ROM

NOTICE

Hino Diagnostic • Install the software of the Hino

eXplorer — Diagnostic eXplorer (HinoDX)
(HinoDX) in the PC. For the installation
method, refer to the
instruction manual
accompanying the CD.

• PC interface

! CAUTION
09993 - E9070
• It is necessary to update
hardware.

Hino-Bowie • The cable between the personal

computer and the Hino-Bowie is
bundled to the Hino-Bowie.
— • Please use either RS-232C or USB.

Cable bundled
to the Hino-Bowie

Cable for machine side diagnosis

connector.
Cable between
S0904-21220
machine and Hino-
(09042-1220)
Bowie
Cable between
machine
and Hino-Bowie
 ENGINE DIAGNOSIS CODE 17–7

Failure
List of failure
diagnosis
diagnosis

Table of failure code

JP31ZCE170601001

NOTICE • The P0000 of "P0000 [00]" in this text indicates an SAE code, and [00] indicates a 2-digit
code of TCCS.
• "Fuel rail" in this text indicates "common rail".

SAE TCCS 2-DIGT TROUBLE

CODE CODE (Estimated failure cause)

Crankshaft position sensor and Camshaft position sensor -

P0016 13
rationality
Nozzle position sensor failure
DC motor open circuit
DC motor short circuit
P0045 35
Nozzle stuck
Nozzle operating range failure
Initialization failure

P0087 76 Fuel system pressure control - low

P0088 76 Fuel system pressure control - high

P0088 69 Excessive common rail pressure

VNT controller CAN communication (ECM)

P00AF 35 Power supply failure
EEPROM failure

P0104 17 Air flow sensor - out of range

P0108 25 Boost pressure sensor - out of range (Out of range high)

Intake air temperature sensor (air flow sensor built-in) - out of range
P0112 17
(Out of range low)

Intake air temperature sensor (air flow sensor built-in) - out of range
P0113 17
(Out of range high)

Engine coolant temperature sensor - out of range

P0117 11
(Out of range low)
Engine coolant temperature sensor - out of range
P0118 11
(Out of range high)

Intake throttle valve-opening sensor 1 out of range

P0122 32
(Out of range low)

Intake throttle valve position sensor 1 out of range

P0123 32
(Out of range high)
P0182 14 Fuel temperature sensor Low

P0183 14 Fuel temperature sensor High

P0192 74 Fuel rail pressure sensor (main) - out of range (Out of range low)
P0193 74 Fuel rail pressure sensor (main) - out of range (Out of range high)

P0200 71 Fuel injector driver charge circuit - circuit (circuit high)

P0201 61 Fuel injector - disconnection (#1cyl)

17–8 ENGINE DIAGNOSIS CODE

SAE TCCS 2-DIGT TROUBLE

CODE CODE (Estimated failure cause)

P0202 62 Fuel injector - disconnection (#2cyl)

P0203 63 Fuel injector - disconnection (#3cyl)

P0204 64 Fuel injector - disconnection (#4cyl)

P0205 65 Fuel injector - disconnection (#5cyl)

P0206 66 Fuel injector - disconnection (#6cyl)

P0217 6 Engine coolant over temperature condition

P0219 7 Engine overspeed condition

P0234 34 Overboost

P0237 25 Boost pressure sensor - out of range (Out of range low)

P0263 61 Injection quantity and timing (#1cyl)

P0266 62 Injection quantity and timing (#2cyl)

P0269 63 Injection quantity and timing (#3cyl)

P0272 64 Injection quantity and timing (#4cyl)

P0275 65 Injection quantity and timing (#5cyl)

P0278 66 Injection quantity and timing (#6cyl)

P0335 13 Crankshaft position sensor - disconnection

P0336 13 Crankshaft position sensor - rationality

P0340 12 Camshaft position sensor - disconnection

P0341 12 Camshaft position sensor - rationality

P0540 53 Air intake heater circuit malfunction

Exhaust gas temperature sensor (DPR inlet)-out of range

P0545 27
(Out of range low)

Exhaust gas temperature sensor (DPR inlet)-out of range

P0546 27
(Out of range high)

P0605 3 Flash ROM error

P0606 3 Control module processor

P0607 3 Control module performance

P0611 71 Fuel injector driver charge circuit - circuit (circuit low)

P0617 45 Starter switch - rationality

P0628 73 Suction control valve for fuel supply pump - circuit (Circuit low)

P0629 75 Suction control valve for fuel supply pump - circuit (Circuit high)

P0642 5 ECU sensor supply 1 failure (low)

P0643 5 ECU sensor supply 1 failure (high)

P0652 5 ECU sensor supply 2 failure (low)

P0653 5 ECU sensor supply 2 failure (high)

P0686 51 ECM/PCM Power relay control circuit high

 ENGINE DIAGNOSIS CODE 17–9

SAE TCCS 2-DIGT TROUBLE

CODE CODE (Estimated failure cause)

P06D3 5 Air flow sensor power supply failure Short to GND

P06D4 5 Air flow sensor power supply failure (high)

P1133 23 P.T.O. accelerator sensor (Hi)

P1197 74 Fuel rail pressure sensor (sub) - out of range (Out of range low)

P1198 74 Fuel rail pressure sensor (sub) - out of range (Out of range high)

P119F 74 Fuel rail pressure sensor - rationality

P1211 68 Fuel injector driver circuit 1 - circuit (Circuit low)

P1212 68 Fuel injector driver circuit 1 - circuit (Circuit high)

P1214 68 Fuel injector driver circuit 2 - circuit (Circuit low)

P1215 68 Fuel injector driver circuit 2 - circuit (Circuit high)

P1427 28 Differential pressure sensor - out of range (Out of range low)

P1428 28 Differential pressure sensor - out of range (Out of range high)

Valve position control failure - DC motor out of range, functional
P1458 81 Valve link failure
Low battery voltage

P1459 81 EGR actuator malfunction 2

P1601 2 Fuel injector adjustment data error

P200C 91 DPF over temperature

Exhaust gas temperature sensor (DPR outlet) - out of range

P2032 27
(Out of range low)

Exhaust gas temperature sensor (DPR outlet) - out of range

P2033 27
(Out of range high)

DC motor for intake throttle valve - circuit

P2100 31
[Open circuit (circuit low)]

P2101 31 Intake throttle valve - functional

DC motor for intake throttle valve - circuit

P2103 31
[Short circuit (circuit high)]
P2120 22 Throttle/Pedal Position Sensor / Switch "D" Circuit

P2121 22 Accelerator sensor 1 malfunction

Accelerator pedal position sensor 1 - out of range

P2122 22
(Out of range low)
Accelerator pedal position sensor 1 - out of range
P2123 22
(Out of range high)

P2126 22 Accelerator sensor 2 malfunction

Accelerator pedal position sensor 2 - out of range

P2127 22
(Out of range low)

Accelerator pedal position sensor 2 - out of range

P2128 22
(Out of range high)
17–10 ENGINE DIAGNOSIS CODE

SAE TCCS 2-DIGT TROUBLE

CODE CODE (Estimated failure cause)

P2228 15 Barometric pressure sensor - out of range (out of range low)

P2229 15 Barometric pressure sensor - out of range (out of range high)

P244A 91 Filtering performance (missing substrate)

P244B 92 Incomplete regeneration

P2458 93 DPR regeneration duration

P2463 92 DPF clogged

P24A2 93 DPR regeneration incomplete by fuel consumption over

P2635 76 Fuel Pump "A" Low Flow/Performance

Engine ECU CAN communication bus for Emission control system -

U0073 8
bus off
U1001 9 Engine ECU CAN communication bus for vehicle control bus off

U110A 9 Engine ECU CAN communication (Vehicle control ECU)

U1122 8 Engine ECU CAN communication (EGR valve controller)

U1123 8 Engine ECU CAN communication (VNT controller)

 ENGINE DIAGNOSIS CODE 17–11

Function, movement
Description of function
and operation

Signal check harness

JP31ZCE170301001

1. Signal check harness

! CAUTION • When measuring terminal of the engine ECU,

connect the signal check harness to prevent
damage to the connector. Place the tester rod
on the contact box of the signal check
harness for measurement.

NOTICE • Terminal numbers in the text and the

illustrations correspond as shown below in
the "Computer pin arrangement".

COMPUTER (ECU) TERMINAL SIGNAL

COMPUTER (ECU) TERMINAL No.
V
Main/
Power supply 1 Glow
Starter cut relay Actuator power - P.T.O. cut relay -
(+BF) (indic
relay 1

V1 +BF1 V2 STCR V3 MRL1 V4 - V5 ARL1 V6 - V7

Vehicle speed Glow pulg CAN CA

Neutral switch Starter signal Starter switch 1 communication commu
pulse converter (Signal)
line lin
V11 NUSW V12 ST V13 SSWS V14 VS V15 GCUS V16 CA1L V17

Main/
Power supply 2
- Actuator power - - - Diagno
(+BF)
relay 2

V21 +BF2 V22 - V23 MRL2 V24 - V25 - V26 - V27

Engine stop Glow pulg CAN CA

P.T.O switch 1 Starter switch 2 - (Signal) communication commu
switch
line lin
V31 PTO V32 STOP V33 SWSS V34 - V35 GCUD V36 CA1H V37

EXAMPLE: V23 TERMINAL

V
V (1 to 40)
SIGNAL CHECK
HARNESS
(CONTACT BOX) 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
V23

SAPH31ZCE1700009
17–12 ENGINE DIAGNOSIS CODE

2. Connection of signal check harness

(1) Set the starter key to "OFF" and disconnect the connector
from the engine ECU.
(2) Connect the signal check harness to the engine ECU and
the unit side harness.

COMPUTER (ENGINE ECU)

CONNECTOR CONNECTOR
(ENGINE ECU SIDE) (ENGINE ECU SIDE)

ENGINE UNIT
SIDE SIDE

CONNECTOR
CONNECTOR
(ENGINE SUB
(ENGINE SUB
HARNESS SIDE)
HARNESS SIDE)

RED WHITE

E ENGINE SUB HARNESS

V

TERMINAL TERMINAL
E01-E40 V01-V40

BLUE E V

BLACK
TERMINAL TERMINAL
TEST LEAD
E41-E80 V41-V80

SIGNAL CHECK SIGNAL CHECK

HARNESS HARNESS
(ENGINE SIDE) (UNIT SIDE)

09843-E4030 CONTACT BOX 09843-E4020

SIGNAL CHECK HARNESS ASSEMBLY

09843-E4010
SAPH31ZCE1700010

Special tool : Signal check harness (09843-E4010)

 V
Power supply 1 Main/ Check engine
- Actuator power - - - - DPR refresh light warning light -
(+BF)
relay 1

V1 +BF1 V2 - V3 MRL1 V4 - V5 - V6 - V7 - V8 DPF V9 CE/G V10 -

Wiring

CAN
Specification
diagram

Power supply 1
Neutral switch Starter signal Starter switch 1 - - communication - (+B) - -
(performance)

line

V11 NUSW V12 ST V13 SSWS V14 - V15 - V16 CA1L V17 - V18 VB1 V19 - V20 -

Power supply 2 Main/

Glow -
(+BF) - Actuator power - - - -
relay 2 Relay

V21 +BF2 V22 - V23 MRL2 V24 GRY1 V25 V26 - V27 - V28 - V29 - V30 -
ENGINE DIAGNOSIS CODE

CAN
Power supply 2
- - Starter switch 2 - - communication - Power ground 1 Signal ground 1
(+B)
line

V31 - V32 - V33 SWSS V34 - V35 - V36 CA1H V37 - V38 VB2 V39 PGD1 V40 CGD1
Computer pin arrangement

SAPH31ZCE1700011
17–13

JP31ZCE170201001
17–14 ENGINE DIAGNOSIS CODE

TERMINAL TERMINAL TERMINAL TERMINAL

SIGNAL SIGNAL
No. SIGNAL No. SIGNAL
V1 +BF1 Power supply 1 (+BF) V21 +BF2 Power supply 2 (+BF)

V2 – – V22 – –

Main / Actuator power Main / Actuator power

V3 MRL1 V23 MRL2
relay 1 relay 2

V4 – – V24 GRY1 Glow Relay

V5 – – V25 – –

V6 – – V26 – –
V7 – – V27 – –

V8 DPF DPR refresh light V28 – –

Check engine warning

V9 CE/G V29 – –
light

V10 – – V30 – –

V11 NUSW Neutral switch V31 – –

V12 ST Starter signal V32 – –

V13 SSWS Starter switch 1 V33 SWSS Starter switch 2

V14 – – V34 – –

V15 – – V35 – –

CAN communication line CAN communication line

V16 CA1L V36 CA1H
Low High

V17 – – V37 – –

V18 VB1 Power supply 1 (+B) V38 VB2 Power supply 2 (+B)

V19 – – V39 PGD1 Power ground 1

V20 – – V40 CGD1 Signal ground 1

 V
Accelerator
- - - - Sensor ground 7 Sensor ground 9 - - -
sensor 1

V41 - V42 - V43 - V44 - V45 ADG7 V46 ADG9 V47 ACS1 V48 - V49 - V50 -

Exhaust gas
Clucth DPR refresh temperature sensor
Power supply 3
- - - - Power ground 2 Signal ground 2
switch switch (DPR outlet) (+B)

V51 - V52 - V53 - V54 - V55 CLSW V56 DPSW V57 ET4+ V58 VB3 V59 PGD2 V60 CGD2

P.T.O. Exhaust gas DPR differential

Accelerator
- - - - Sensor ground 8 - acceclerator temperature sensor
sensor 2 pressure sensor
sensor (DPR intlet)

V61 - V62 - V63 - V64 - V65 ADG8 V66 - V67 ACS2 V68 ASCS V69 ET3+ V70 EXPS
ENGINE DIAGNOSIS CODE

Sensor power Power supply 4

- - - - - - Power ground 3 Power ground 4
supply 5 (+B)

V71 AVC5 V72 - V73 - V74 - V75 - V76 - V77 - V78 VB4 V79 PGD3 V80 PGD4

SAPH31ZCE1700012
17–15
17–16 ENGINE DIAGNOSIS CODE

TERMINAL TERMINAL TERMINAL TERMINAL

SIGNAL SIGNAL
No. SIGNAL No. SIGNAL

V41 – – V61 – –

V42 – – V62 – –

V43 – – V63 – –

V44 – – V64 – –

Sensor ground 7
Sensor ground 8
V45 ADG7 (Accelerator sensor 1, V65 ADG8
(Accelerator sensor 2)
P.T.O. accelerator sensor)

Sensor ground 9
(Exhaust gas temperature
V46 ADG9 V66 – –
sensor, DPR differential
pressure sensor)

Accelerator sensor signal Accelerator sensor signal

V47 ACS1 V67 ACS2
1 2

P.T.O. accelerator sensor

V48 – – V68 ASCS
signal
Exhaust gas temperature
V49 – – V69 ET3+
sensor (DPR inlet)

DPR differential pressure

V50 – – V70 EXPS
sensor

Sensor power supply 5

(P.T.O. accelerator
V51 – – V71 AVC5
sensor, DPR differential
pressure sensor)

V52 – – V72 – –

V53 – – V73 – –

V54 – – V74 – –

V55 CLSW Clutch switch V75 – –

V56 DPSW DPR refresh switch V76 – –

Exhaust gas temperature

V57 ET4+ V77 – –
sensor (DPR outlet)

V58 VB3 Power supply 3 (+B) V78 VB4 Power supply 4 (+B)

V59 PGD2 Power ground 2 V79 PGD3 Power ground 3

V60 CGD2 Signal ground V80 PGD4 Power ground 4

 E
Intake throttle Suction control Suction control
valve motor (+) - - - - - - - valve (Main) valve (Main)

E1 MOT+ E2 - E3 - E4 - E5 - E6 - E7 - E8 - E9 SPV1 E10 SPV2

No.1, No.2, No.3 No.1 Fuel injector No.2 Fuel injector No.3 Fuel injector No.4, No.5, No.6 No.4 Fuel injector No.6 Fuel injector
Air flow sensor Sensor power Fuel injector Fuel injector
- drive signal drive signal drive signal drive signal drive signal
(Power) supply 1 power supply power supply
(Main) (Main) (Main) (Main) (Main) (Main) (Main)

E11 - E12 AFVB E13 AVC1 E14 IJ1+ E15 INJ1 E16 INJ3 E17 INJ5 E18 IJ2+ E19 INJ2 E20 INJ4

Intake throttle Suction control Suction control

valve motor (-) - - - - - - - valve (Sub) valve (Sub)

E21 MOT- E22 - E23 - E24 - E25 - E26 - E27 - E28 - E29 SP1S E30 SP2S
ENGINE DIAGNOSIS CODE

No.1, No.2, No.3 No.1 Fuel injector No.2 Fuel injector No.3 Fuel injector No.4, No.5, No.6 No.4 Fuel injector No.6 Fuel injector
Sensor power Fuel injector Fuel injector
- - power supply drive signal drive signal drive signal drive signal drive signal
supply 2 power supply
(Sub) (Sub) (Sub) (Sub) (Sub) (Sub) (Sub)

E31 - E32 - E33 AVC2 E34 I1+S E35 IJ01 E36 IJ03 E37 IJ05 E38 I2+S E39 IJ02 E40 IJ04

SAPH31ZCE1700013
17–17
17–18 ENGINE DIAGNOSIS CODE

TERMINAL TERMINAL TERMINAL TERMINAL

SIGNAL SIGNAL
No. SIGNAL No. SIGNAL

Intake throttle valve Intake throttle valve

E1 MOT+ E21 MOT-
motor (+) motor (-)

E2 – – E22 – –
E3 – – E23 – –

E4 – – E24 – –

E5 – – E25 – –
E6 – – E26 – –

E7 – – E27 – –

E8 – – E28 – –

Suction control valve Suction control valve

E9 SPV1 E29 SP1S
(Main) (Sub)

Suction control valve Suction control valve

E10 SPV2 E30 SP2S
(Main) (Sub)

E11 – – E31 – –

E12 AFVB Air flow sensor (Power) E32 – –

Sensor power supply 2

(for Boost pressure
Sensor power supply 1
sensor, Intake throttle
E13 AVC1 (for Fuel rail pressure E33 AVC2
valve position sensor,
sensor 1)
Fuel rail pressure sensor
2)

No.1, 2, 3 Fuel injector No.1, 2, 3 Fuel injector

E14 IJ1+ E34 I1+S
power supply (Main) power supply (Sub)
No.1 Fuel injector drive No.1 Fuel injector drive
E15 INJ1 E35 IJ01
signal (Main) signal (Sub)

No.2 Fuel injector drive No.2 Fuel injector drive

E16 INJ3 E36 IJ03
signal (Main) signal (Sub)

No.3 Fuel injector drive No.3 Fuel injector drive

E17 INJ5 E37 IJ05
signal (Main) signal (Sub)
No.4, 5, 6 Fuel injector No.4, 5, 6 Fuel injector
E18 IN2+ E38 I2+S
power supply (Main) power supply (Sub)

No.4 Fuel injector drive No.4 Fuel injector drive

E19 INJ2 E39 IJ02
signal (Main) signal (Sub)

No.6 Fuel injector drive No.6 Fuel injector drive

E20 INJ4 E40 IJ04
signal (Main) signal (Sub)
 E
Intake air
temperature sensor Fuel temperature Fuel rail pressure
- - - - - -
(Air flow sensor sensor 1 (Main) -
sensor built-in)
E41 - E42 - E43 - E44 - E45 - E46 - E47 THA+ E48 THF+ E49 PCR1 E50 -

G sensor G sensor CAN No.5 Fuel injector

- Ne sensor (+) - Sensor ground 1 Sensor ground 3 Sensor ground 5 communication drive signal
(Supply) (ground)
line (Main)

E51 - E52 NE1+ E53 GVCC E54 GGND E55 - E56 AGD1 E57 AGD3 E58 AGD5 E59 CA3H E60 INJ6

Intake throttle Coolant Boost pressure Fuel rail pressure

Fuel rail pressure Fuel rail pressure
- valve position - temperature sensor - -
sensor 2 (Main) sensor 2 (Sub) sensor 1 (Sub)
sensor 1 sensor

E61 - E62 DTS1 E63 - E64 PCR3 E65 PCR4 E66 THW+ E67 PIM E68 PCR2 E69 - E70 -
ENGINE DIAGNOSIS CODE

CAN No.5 Fuel injector

NE sensor (-) G sensor Air flow sensor NE sensor (SLD) Sensor ground 2 Sensor ground 4 Sensor ground 6
- communication drive signal
(signal) (signal)
line (Sub)
E71 - E72 NE1- E73 G3+ E74 AFSI E75 NESD E76 AGD2 E77 AGD4 E78 AGD6 E79 CA3L E80 IJ06

SAPH31ZCE1700014
17–19
17–20 ENGINE DIAGNOSIS CODE

TERMINAL TERMINAL TERMINAL TERMINAL

SIGNAL SIGNAL
No. SIGNAL No. SIGNAL

E41 – – E61 – –

Intake throttle valve

E42 – – E62 DTS1
position sensor 1

E43 – – E63 – –

Fuel rail pressure sensor

E44 – – E64 PCR3
2 (Main)

Fuel rail pressure sensor

E45 – – E65 PCR4
2 (Sub)

Coolant temperature
E46 – – E66 THW+
sensor

Intake air temperature

E47 THA+ sensor E67 PIM Boost pressure sensor
(Air flow sensor built-in)

Fuel rail pressure sensor

E48 THF+ Fuel temperature sensor E68 PCR2
1 (Sub)

Fuel rail pressure sensor

E49 PCR1 E69 – –
1 (Main)

E50 – – E70 – –

E51 – – E71 – –

E52 NE1+ NE sensor (+) E72 NE1- NE sensor (-)

E53 GVCC G sensor (Supply) E73 G3+ G sensor signal

E54 GGND G sensor (ground) E74 AFSI Air flow sensor signal

E55 – – E75 NESD NE sensor (SLD)

Sensor ground 2
Sensor ground 1
(for Fuel temperature
E56 AGD1 (for Fuel rail pressure E76 AGD2
sensor, Fuel rail pressure
sensor 1)
sensor 2)

Sensor ground 3 Sensor ground 4

E57 AGD3 (for Intake throttle valve E77 AGD4 (for Boost pressure
position sensor) sensor)
Sensor ground 5
Sensor ground 6
(for Coolant temperature
E58 AGD5 E78 AGD6 (for Air flow sensor
sensor, Intake air
signal)
temperature sensor)

CAN communication line CAN communication line

E59 CA3H (EGR valve drive, VNT E79 CA3L (EGR valve drive, VNT
drive) drive)

No.5 Fuel injector drive No.5 Fuel injector drive

E60 INJ6 E80 IJ06
signal (Main) signal (Sub)

Failure diagnosis list

 ENGINE DIAGNOSIS CODE 17–21

Check the ECU power supply voltage

JP31ZCE170601002

1 MEASUREMENT OF VOLTAGE BETWEEN TERMINALS

1. Set the starter key to "OFF" and connect the signal check
harness to the engine ECU.
2. Turn the starter key "ON" and measure voltage between
㨂 V18 㨂 terminals .
V58,V59

Terminal to measure the voltage

V38,39 V78,79,80 + Side - Side
V18, V38, V58, V78 V39, V59, V79, V80

Standard value : 20 V or more

SAPH31ZCE1700015

NG • 0 V : Blown fuse, harness failure, ground failure,

etc.
• 20 V or less : Battery deterioration, ground
failure, etc.

OK

Normal
17–22 ENGINE DIAGNOSIS CODE

Check the ground

JP31ZCE170601003

1 MEASUREMENT OF RESISTANCE BETWEEN TERMINALS

1. Set the starter key to "OFF" and connect the signal check
harness.
2. Disconnect the ECU side connector of the signal check
㨂 㨂 harness and measure the resistance between terminals V39,
V59
V59, V79, V80 and the terminal (-) of the battery.
V79,80
Standard value : 1 : or less
V39

Frame
SAPH31ZCE1700016

NG Disconnection of ground harness, contact failure,

etc.

OK

Normal
 ENGINE DIAGNOSIS CODE 17–23

DTC code P0016 [13]

/Crankshaft position sensor and Camshaft position sensor - rationality
JP31ZCE170601004

1 CHECK THAT THE CAM GEAR IS PROPERLY ASSEMBLED

NG Assemble the cam gear normally

OK

2 CHECK THAT THE FLYWHEEL IS ASSEMBLED

NG Assemble the flywheel normally

OK

3 CHECK THAT CRANKSHAFT POSITION SENSOR AND CAMSHAFT POSITION SENSOR ARE
INSTALLED IN PROPER LOCATIONS RESPECTIVELY

NG Install the NE sensor and G sensor in proper

locations respectively

OK

Delete the DTC and reload

17–24 ENGINE DIAGNOSIS CODE

DTC code P0045 [35]

/Nozzle position sensor failure
/DC motor open circuit
/DC motor short circuit
/Nozzle stuck
/Nozzle operating range failure
/Initialization failure
DTC code P00AF [35]
/VNT controller CAN communication (ECM)
/Power supply failure
/EEPROM failure
JP31ZCE170601005

1 CHECK THE VNT

1. Connect the PC DIAGNOSIS TOOL (HinoDX).

SAPH31ZCE1700017

2. Set the starter switch "ON" position.

3. Select the "VNT" menu and check the VNT.

Standard: Max. 2 sec. delay in opening

NG Fault in turbocharger

OK
 ENGINE DIAGNOSIS CODE 17–25

2 CHECK CONNECTION OF THE CONNECTOR

1. Check connection of the VNT controller connector and the VNT

actuator connector.

2. Set the starter switch to "LOCK" position and then to "ON"

position again.

3. Check that no malfunction codes exist.

NG Proceed to 3

OK

Normal

3 MEASURING VOLTAGE BETWEEN SENSOR TERMINALS

1. Set the starter switch "LOCK" position.

2. Disconnect the connectors of VNT controller.

3. Set the starter switch "ON" position.

4. Measure the voltage between 24V and GND terminal of VNT
controller connector (engine sub harness side).
GND +24V Standard value: 19V or more

SAPH31ZCE1700018

NG Fault in harness

OK

Fault in turbocharger
17–26 ENGINE DIAGNOSIS CODE

DTC code P0087 [76]

/Fuel system pressure control - low
DTC code P0088 [76]
/Fuel system pressure control - high
DTC code P2635 [76]
/Fuel pump "A" low flow / performance
JP31ZCE170601006

1 CHECK THE FUEL

1. Check that suitable fuel at region temperature is used.

NG Replace to suitable fuel

OK

2 CHECK THE FUEL FILTER AND FUEL PIPE FOR FUEL LEAKAGE

1. Check the fuel filter and fuel pipe for fuel oozing and leakage.

NG • Defective fuel filter

• Defective fuel pipe

OK

3 CHECK THE FUEL TANK FOR CLOGGING OF THE AIR HOLE AND THE REMAINING AMOUNT

1. Check the air hole for clogging.

2. Check if fuel is sufficiently supplied.

NG • Clogging of the air hole

• Insufficient fuel supply

OK

4 CHECK THE SUPPLY PUMP FOR FUEL LEAKAGE

1. Check the supply pump for fuel oozing and leakage.

NG Faulty supply pump

OK
 ENGINE DIAGNOSIS CODE 17–27

5 MEASURING RESISTANCE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness on the engine side.

3. Disconnect the connector on the engine ECU side.

4. Measure the resistance between the terminals.
E9
㧱 E10
Terminals to measure the resistance
SPV1 (E9) l SP2S (E30)
E30 SPV1 (E9) l SPV2 (E10)
E29
SP1S (E29) l SP2S (E30)
SP1S (E29) l SPV2 (E10)

Standard value: 7.65 - 8.15 : (20qC {68qF})

SAPH31ZCE1700019

NG Faulty SCV

OK

6 CHECK THE DTC

1. Check that no other DTC exist.

NG Check with other diagnosis codes

OK
17–28 ENGINE DIAGNOSIS CODE

7 USING THE HinoDX, CHECK THE ACTUAL INJECTION PRESSURE AT THE ENGINE START
WHILE MONITORING

1. Connect the PC DIAGNOSIS TOOL (HinoDX).

2. Start the engine while monitoring the actual injection pressure.
Actual injection pressure
Specified injection pressure
Injection pressure

Standard:
222MP䌡
The peak of the actual injection pressure is 222 MPa
The pressure limiter is
open reducing the pressure. or under

Idling

Starter 䌏䌎 (Engine starting) Hour

SAPH31ZCE1700020

NG Proceed to 13

OK
 ENGINE DIAGNOSIS CODE 17–29

8 USING THE HinoDX, CHECK THE ACTUAL INJECTION PRESSURE DURING DRIVING WHILE
MONITORING

1. Check the actual injection pressure while depressing the

accelerator pedal.

2. Check that there are no characteristics shown in Fig.1, Fig.2,

Fig.3 and Fig.4.

Actual injection pressure

Specified injection pressure
Injection pressure

Depress the Depress the Depress the Depress the

accelerator pedal. accelerator pedal. accelerator pedal. accelerator pedal.

Idling Idling
Release the Idling
Release the Release the accelerator pedal.
Release the
accelerator pedal. accelerator pedal. accelerator pedal.
Hour
[Fig. 1] [Fig. 2]

222MPa 222MPa
After start, extremely high
actual injection pressure
than the specified injection Not start
pressure is directed not Slow start
hard vacuum. Actual injection pressure remains low even if start.

Idling Idling

Starter ON (Engine starting) Starter ON (Engine starting)

[Fig. 3] [Fig. 4]
SAPH31ZCE1700021

NG Restudy the supply pump

(If there is no improvement after restudying, proceed
to 9)

OK
17–30 ENGINE DIAGNOSIS CODE

9 USING THE HinoDX, CHECK THE LEAKAGE OF FUEL

1. Lower the pressure while monitoring the actual injection

pressure.
2. Check that the pressure is reduced when the actual injection
Actual injection pressure
Specified injection pressure pressure exceeds 222 MPa.
Injection pressure

222MPᵞ
Depress the
accelerqtor pedal.

Release the
accelerator pedal.

Hour
SAPH31ZCE1700022

NG • If the pressure is reduced without the actual.

injection pressure exceeding 222 MPa, proceed to
11.
• If the actual injection pressure does not rise to 200
MPa, hold the pressure limiter pipe and check for
flow of fuel.
a. The pressure limiter is defective if there is flow
of fuel.
b. If there is no flow of fuel, proceed to 11.

OK

10 CHECK THE INJECTOR LEAK PIPE FOR CLOGGING

NG Defective leak pipe

OK
 ENGINE DIAGNOSIS CODE 17–31

11 USING THE HinoDX, CHECK THE SPECIFIED INJECTION PRESSURE AND ACTUAL
INJECTION PRESSURE WHILE MONITORING

1. While monitoring the injection pressure, gradually increase the

engine speed from idle to wide open throttle.

2. Check if the specified injection pressure corresponds to the

actual injection pressure.

Actual injection pressure

Specified injection pressure
Injection pressure

Gradually increase the engine Gradually increase the engine

engine speed
speed while depressing the speed while depressing the engine speed
WOT
accelerator pedal. accelerator pedal. WOT

engine speed
The actual injection pressure engine speed
1,000rpm
become unstable from specific 1,000rpm
Low actual injection pressure
rotation and fails to follow the The differential is larger on the
specified injection pressure. high speed side.

Hour
SAPH31ZCE1700023

NG • The specified injection pressure does not

correspond to the actual injection pressure at high
speed.
• The specified injection pressure does not
correspond to the actual injection pressure in the
full range.
a. The actual injection pressure is lower than the
specified injection pressure in the full range.
o Faulty supply pump
b. The SCV is defective for other than a.

OK

12 CHECK THE SCV HARNESS FOR DISCONNECTION

1. Shake the harness between the SCV and ECU and check that
the specified injection quantity and actual injection quantity are
unaffected.

NG Faulty harness

OK

Faulty SCV
17–32 ENGINE DIAGNOSIS CODE

13 USING THE HinoDX, CHECK THE ACTUAL INJECTION PRESSURE DURING DRIVING WHILE
MONITORING

1. Check if the specified injection pressure corresponds to the

Actual injection pressure
Specified injection pressure actual injection pressure while depressing the accelerator
Injection pressure

Depress the
pedal.
Depress the
accelerator pedal. accelerator pedal.

Release the
Idling accelerator pedal. Release the
accelerator pedal.

Hour
SAPH31ZCE1700024

NG Faulty SCV

OK
 ENGINE DIAGNOSIS CODE 17–33

14 CHECK THE VOLTAGE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position and connect the

signal check harness.

2. Start the engine.

3. Perform warm-up until the coolant temperature gauge moves.

4. At engine speed idling. The target pressure (P FIN) =

APPROX. 35 MPa {357 kgf/cm2, 5076 lbf/in2} (APPROX. 1.5 V)
5. Measure the voltage between PCR1 (E49), PCR2 (E68) and
AGD1 (E56) terminals.
E68
E56 㧱 E49
Standard value: less than 1.56 V

SAPH31ZCE1700025

6. Measure the voltage between PCR3 (E64), PCR4 (E65) and

E64 E65 AGD2 (E76) terminals.
E
E76 Standard value: less than 1.56 V

SAPH31ZCE1700026

NG Faulty fuel rail pressure sensor

OK

Faulty SCV
17–34 ENGINE DIAGNOSIS CODE

15 CHECK THE FUEL FILTER AND FUEL PIPE FOR CLOGGING

NG • Faulty fuel filter

• Faulty fuel pipe

OK

Faulty supply pump

 ENGINE DIAGNOSIS CODE 17–35

DTC code P0088 [69]

/Excessive common rail pressure
JP31ZCE170601007

1 MEASURING VOLTAGE BETWEEN TERMINALS

1. Set the starter switch "LOCK" position.

2. Connect the signal check harness on the engine ECU.

3. Set the starter switch "ON" position.

4. Measure voltage between the terminals PCR3 (E64), PCR4
E64 E65 (E65) and AGD 2(E76).
E
E76 Standard value: 0.75-0.95 V

SAPH31ZCE1700026

5. Measure voltage between the terminals PCR2 (E68), PCR1

(E49) and AGD1 (E56).
E68
E56 㧱 E49
Standard value: 1.25-1.45 V

SAPH31ZCE1700025

NG • Bad contact of harness or connectors

• Fault in engine ECU

OK

Faulty fuel rail pressure sensor

17–36 ENGINE DIAGNOSIS CODE

DTC code P0104 [17]

/Air flow sensor - out of range
JP31ZCE170601008

1 CHECK INSTALLATION OF THE CONNECTOR

1. Check that the air flow sensor connector is properly installed.

NG Faulty connector

OK

2 CHECK A DTC CODE

1. Make sure that air flow sensor power supply failure code
(P06D3 [5], P06D4 [5]) is not output.

NG Proceed to air flow sensor power supply failure

diagnosis method (P06D3 [5], P06D4 [5])
P06D3 [5] : Refer to 17-107
P06D4 [5] : Refer to 17-109

OK

3 MEASURING FREQUENCY BETWEEN TERMINALS

1. Set the starter switch "LOCK" position.

2. Connect the signal check harness on the engine side.

3. Measure frequency between the terminals AFSI (E74) and
E74 E78 AGD6 (E78) while idling.
E

Standard value

Idling revolution Frequency

(r/min) (kHz)

800 5-6

SAPH31ZCE1700027

NG Fault in air flow sensor

OK

Fault in engine ECU

 ENGINE DIAGNOSIS CODE 17–37

DTC code P0108 [25]

/Boost pressure sensor - out of range (Out of range high)
JP31ZCE170601009

1 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Set the starter switch "LOCK" position.

2. Disconnect the connector of boost pressure sensor.

3. Measure the resistance between VCC and SIG terminal of the
boost pressure sensor connector.

NOTICE • If it is difficult to check only the sensor,

proceed to Step 5.

Standard value: 2-15 k:

SAPH31ZCE1700028

NG Fault in boost pressure sensor

OK

2 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Measure resistance between the terminals SIG and GND of the

boost pressure sensor connector (engine sub harness side).

Standard value: 209-231 k:

SAPH31ZCE1700029

NG • Fault in harness
• Irregular contact of connectors

OK
17–38 ENGINE DIAGNOSIS CODE

3 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Measure resistance between the terminals VCC and SIG of the

boost pressure sensor connector (engine sub harness side).

Standard value: f :

SAPH31ZCE1700030

NG Fault in harness

OK

4 MEASURING RESISTANCE BETWEEN TERMINALS

1. Connect the signal check harness on the engine side.

2. Disconnect the connector on the engine sub harness side.

3. Measure resistance between the terminals AVC2 (E33) and
PIM (E67).
㧱 E67 㧱
E33 Standard value: f :

SAPH31ZCE1700031

NG Fault in engine harness

OK
 ENGINE DIAGNOSIS CODE 17–39

5 MEASURING RESISTANCE BETWEEN TERMINALS

1. Connect the boost pressure sensor connector.

2. Connect the signal check harness on the engine side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals AVC2 (E33) and
PIM (E67).
㧱 E67 㧱
E33 Standard value: 2-15 k:

SAPH31ZCE1700032

NG • Fault in harness
• Fault in boost pressure sensor

OK

6 MEASURING RESISTANCE BETWEEN TERMINALS

1. Measure resistance between the terminals AGD4 (E77) and

PIM (E67).
㧱 E67
E77 Standard value: 2-15 k:

SAPH31ZCE1700033

NG • Fault in harness
• Irregular contact of connectors

OK
17–40 ENGINE DIAGNOSIS CODE

7 CHECK A MALFUNCTION CODE

1. Connect the connector on the engine ECU side.

2. Set the starter switch "ON" position.

3. Make sure that the malfunction code P0237 is present.

NG Fault in engine ECU

OK

Clear and recheck the DTC

 ENGINE DIAGNOSIS CODE 17–41

DTC code P0112 [17]

/Intake air temperature sensor (air flow sensor built-in) - out of range
(Out of range low)
DTC code P0113 [17]
/Intake air temperature sensor (air flow sensor built-in) - out of range
(Out of range high)
JP31ZCE170601010

1 CHECK THE INTAKE AIR TEMPERATURE SENSOR

1. Set the starter switch to "LOCK" position.

2. Disconnect the connector of intake air temperature sensor (air

flow sensor built-in).
3. Measure the resistance between AFT+ and AFT- terminal of
the intake air temperature sensor (air flow sensor built-in).

NOTICE • If it is difficult to check only the sensor,

proceed to Step 3.

Standard value

Outside air temperature

Resistance
(qC{qF})
SAPH31ZCE1700034
2.202 k: 50 {122}

508.1 : 100 {212}

160.4 : 150 {302}

NG Fault in intake air temperature sensor

(air flow sensor built-in)

OK
17–42 ENGINE DIAGNOSIS CODE

2 MEASURING VOLTAGE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "ON" position.

2. Measure the voltage between IAT+ and IAT- terminal of the
intake air temperature sensor (air flow sensor built-in) (engine
sub harness side).

Standard value: 4.5-5.5 V

SAPH31ZCE1700035

NG Proceed to 3

OK

Bad contact of connectors

3 MEASURING RESISTANCE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness on the engine side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals THA+ (E47) and
AGD5 (E58).
E47 㧱 E58

Standard value

Outside air temperature

Resistance
(qC{qF})

2.202 k: 50 {122}
508.1 : 100 {212}
SAPH31ZCE1700036

160.4 : 150 {302}

NG Fault in intake air temperature sensor

(air flow sensor built-in)

OK
 ENGINE DIAGNOSIS CODE 17–43

4 MEASURING VOLTAGE BETWEEN TERMINALS

1. Connect the connector on the engine ECU side.

2. Disconnect the connector on the engine sub harness side.

3. Set the starter switch to "ON" position.

4. Measure voltage between the terminals THA+ (E47) and AGD5
(E58).
E47 㧱 E58
Standard value: 4.5-5.5 V

SAPH31ZCE1700037

NG • Fault in engine ECU

• Faulty ECU connector

OK

Bad contact of connectors

17–44 ENGINE DIAGNOSIS CODE

DTC code P0117 [11]

/Engine coolant temperature sensor - out of range (Out of range low)
DTC code P0118 [11]
/Engine coolant temperature sensor - out of range (Out of range high)
JP31ZCE170601011

1 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "LOCK" position.

2. Disconnect the coolant temperature sensor connector.

3. Measure resistance between the terminals WTM+ and WTM-
of the engine coolant temperature sensor.

NOTICE • If it is difficult to check only the sensor,

proceed to Step 3.

Standard value

Water temperature
Resistance
(qC{qF})
SAPH31ZCE1700038
2.45 k: 20 {68}

1.15 k: 40 {104}

584 : 60 {140}

318 : 80 {176}

NG Fault in engine coolant temperature sensor

OK
 ENGINE DIAGNOSIS CODE 17–45

2 MEASURING VOLTAGE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals WT+ and WT- of the
engine coolant temperature sensor connector (engine sub
harness side).

Standard value: 4.5-5.5 V

SAPH31ZCE1700039

NG Proceed to 3

OK

Bad contact of connectors

3 MEASURING RESISTANCE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness on the engine side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals THW+ (E66) and
AGD5 (E58).
E66 㧱 E58

Standard value

Water temperature
Resistance
(qC{qF})

2.45 k: 20 {68}
1.15 k: 40 {104}
SAPH31ZCE1700040

584 : 60 {140}

318 : 80 {176}

NG • Fault in engine coolant temperature sensor

• Fault in harness

OK
17–46 ENGINE DIAGNOSIS CODE

4 MEASURING VOLTAGE BETWEEN TERMINALS

1. Connect the connector on the engine ECU side.

2. Disconnect the connector on the engine sub harness side.

3. Set the starter switch to "ON" position.

4. Measure voltage between the terminals THW+ (E66) and
AGD5 (E58).
E66 㧱 E58
Standard value: 4.5-5.5 V

SAPH31ZCE1700041

NG • Fault in engine ECU

• Faulty ECU connector

OK

Bad contact of connectors

 ENGINE DIAGNOSIS CODE 17–47

DTC code P0122 [32]

/Intake throttle valve position sensor 1 - out of range (Out of range low)
JP31ZCE170601012

1 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "LOCK" position.

2. Disconnect the connector of the intake throttle valve position

sensor 1 connector.
3. Check continuity between the terminals VCC and DTS1 of the
DTS1 VCC intake throttle valve position sensor 1 connector.

NOTICE • If it is difficult to check only the sensor,

proceed to Step 4.

Standard value: Approx. 180 :

SAPH31ZCE1700042

4. Check continuity between the terminals VCC and GND of the

VCC GND intake throttle valve position sensor 1 connector.

Standard value: Approx. 3 k:

SAPH31ZCE1700043

5. Check continuity between the terminals DTS1 and GND of the

DTS1 GND intake throttle valve position sensor 1 connector.

Standard value: Approx. 3 k:

SAPH31ZCE1700044

NG Fault in intake throttle valve position sensor 1

OK
17–48 ENGINE DIAGNOSIS CODE

2 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Measure resistance between the terminals SIG1 and GND of

GND SIG1
the intake throttle valve position sensor 1 connector (engine
sub harness side).

Standard value: Approx. 25-35 k:

SAPH31ZCE1700045

NG • Fault in harness
• Irregular contact of connectors

OK

3 MEASURING VOLTAGE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals VCC and GND of the
intake throttle valve position sensor 1 connector (engine sub
GND
harness side).
VCC

Standard value: 4.5-5.5 V

SAPH31ZCE1700046

NG • Fault in harness
• Irregular contact of connectors

OK

Bad contact of connectors

 ENGINE DIAGNOSIS CODE 17–49

4 MEASURING RESISTANCE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness on the engine side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals AVC2 (E33) and
DTS1 (E62).
㧱 㧱 E62
E33 Standard value: 2 : or more

SAPH31ZCE1700047

5. Measure resistance between the terminals AVC2 (E33) and

AGD3 (E57).
㧱 㧱 E57
E33 Standard value: Approx. 3 k:

SAPH31ZCE1700048

6. Measure resistance between the terminals DTS1 (E62) and

AGD3 (E57).
㧱 E57
E62
Standard value: f :

SAPH31ZCE1700049

NG • Fault in harness
• Fault in intake throttle valve position sensor 1

OK
17–50 ENGINE DIAGNOSIS CODE

5 MEASURING VOLTAGE BETWEEN TERMINALS

1. Connect the connectors on the engine ECU side.

2. Disconnect the connector on the engine sub harness side.

3. Set the starter switch to "ON" position.

4. Measure voltage between the terminals AVC2 (E33) and AGD3
(E57).
㧱 㧱 E57
Standard value: 4.5-5.5 V
E33

SAPH31ZCE1700050

NG • Fault in engine ECU

• Faulty ECU connector

OK

6 MEASURING RESISTANCE BETWEEN TERMINALS

1. Measure resistance between the terminals DTS1 (E62) and

AGD3 (E57).
㧱 E57
E62
Standard value: Approx. 25-35 k:

SAPH31ZCE1700051

NG • Fault in engine ECU

• Faulty ECU connector

OK

Bad contact of connectors

 ENGINE DIAGNOSIS CODE 17–51

DTC code P0123 [32]

/Intake throttle valve position sensor 1 - out of range (Out of range high)
JP31ZCE170601013

1 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Set the starter switch "LOCK" position.

2. Disconnect the connector of the intake throttle valve position

sensor 1.
3. Measure resistance between the terminals VCC and DTS1 of
DTS1 VCC the intake throttle valve position sensor 1 connector.

NOTICE • If it is difficult to check only the sensor,

proceed to Step 5.

Standard value: Approx. 180 :

SAPH31ZCE1700042

4. Check continuity between the terminals VCC and GND of the

VCC GND intake throttle valve position sensor 1 connector.

Standard value: Approx. 3 k:

SAPH31ZCE1700043

5. Check continuity between the terminals DTS1 and GND of the

DTS1 GND intake throttle valve position sensor 1 connector.

Standard value: Approx. 3 k:

SAPH31ZCE1700044

NG Fault in intake throttle valve position sensor 1

OK
17–52 ENGINE DIAGNOSIS CODE

2 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Measure resistance between the terminals SIG1 and GND of

GND SIG1
the intake throttle valve position sensor 1 connector (engine
sub harness side).

Standard value: Approx. 25-35 k:

SAPH31ZCE1700045

NG • Fault in harness
• Irregular contact of connectors

OK

3 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Measure resistance between the terminals VCC and SIG1 of

VCC SIG1 the intake throttle valve position sensor 1 connector (engine
sub harness side).

Standard value: f :

SAPH31ZCE1700052

NG Fault in harness

OK
 ENGINE DIAGNOSIS CODE 17–53

4 MEASURING RESISTANCE BETWEEN TERMINALS

1. Connect the signal check harness on the engine side.

2. Disconnect the connector on the engine sub harness side.

3. Measure resistance between the terminals AVC2 (E33) and
DTS1 (E62).
㧱 㧱
E33 E62 Standard value: f :

SAPH31ZCE1700053

NG Fault in engine ECU

OK

5 MEASURING RESISTANCE BETWEEN TERMINALS

1. Connect the intake throttle valve position sensor 1.

2. Connect the signal check harness on the engine side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals AVC2 (E33) and
DTS1 (E62).
㧱 㧱
E33 E62 Standard value: 2 : or more

SAPH31ZCE1700054

NG • Fault in harness
• Fault in intake throttle valve position sensor 1

OK
17–54 ENGINE DIAGNOSIS CODE

6 MEASURING RESISTANCE BETWEEN TERMINALS

1. Measure resistance between the terminals AGD3 (E57) and

㧱 E57 DTS1 (E62).
E62
Standard value: Approx. 3 k:

SAPH31ZCE1700055

NG • Fault in harness
• Irregular contact of connectors

OK

7 CHECK A MALFUNCTION CODE

1. Connect the connector on the engine ECU side.

2. Set the starter switch "ON" position.

3. Make sure that the malfunction code P0122 is present.

NG Fault in engine ECU

OK

Clear and recheck the DTC

 ENGINE DIAGNOSIS CODE 17–55

DTC code P0182 [14]

/Fuel temperature sensor Low
DTC code P0183 [14]
/Fuel temperature sensor High
JP31ZCE170601014

1 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "LOCK" position.

2. Disconnect the fuel temperature sensor connector.

3. Measure resistance between the terminals THF+ and THF- of
the fuel temperature sensor connector.
THF- THF+

NOTICE • If it is difficult to check only the sensor,

proceed to Step 3.

Standard value

Resistance Fuel temperature (qC{qF})

SAPH31ZCE1700056
15 k: -20 {-4}

2.45 k: 20 {68}
580 : 60 {140}

NG Fault in fuel temperature sensor

OK
17–56 ENGINE DIAGNOSIS CODE

2 MEASURING VOLTAGE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals FT2+ and FT2- of the
FT2+ FT2- fuel temperature sensor connector (engine sub harness side).

Standard value: 4.5-5.5 V

SAPH31ZCE1700057

NG Proceed to 3

OK

Bad contact of connectors

3 MEASURING RESISTANCE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness on the engine side.

3. Disconnect the connector on the engine ECU side.

4. Set the starter switch to "ON" position.

5. Measure resistance between the terminals THF+ (E48) and
AGD2 (E76).
E76 E E48

Standard value

Resistance Fuel temperature (qC{qF})

15 k: -20 {-4}
2.45 k: 20 {68}

SAPH31ZCE1700058 580 : 60 {140}

NG • Fault in fuel temperature sensor

• Fault in harness

OK
 ENGINE DIAGNOSIS CODE 17–57

4 MEASURING VOLTAGE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the connector on the engine ECU side.

3. Disconnect the connector on the engine sub harness side.

4. Set the starter switch to "ON" position.

5. Measure voltage between the terminals THF+ (E48) and AGD2
E E48 (E76).
E76
Standard value: 4.5-5.5 V

SAPH31ZCE1700059

NG • Fault in engine ECU

• Faulty ECU connector

OK

Bad connect of connectors

17–58 ENGINE DIAGNOSIS CODE

DTC code P0192 [74]

/Fuel rail pressure sensor (main) - out of range (Out of range low)
JP31ZCE170601015

1 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "LOCK" position.

2. Disconnect the fuel rail pressure sensor connector.

3. Check continuity between the terminals PCR+ and PCR of the
fuel rail pressure sensor (main) connector.
PCR- PCR PCR+
(main) (main) (main) Standard value: 1.05-3.55 k:
PCR+ PCR PCR-
(sub) (sub) (sub)

SAPH31ZCE1700060

4. Check continuity between the terminals PCR and PCR- of the

fuel rail pressure sensor (main) connector.
PCR- PCR PCR+
(main) (main) (main) Standard value: 6.7-18.7 k:
PCR+ PCR PCR-
(sub) (sub) (sub)

SAPH31ZCE1700061

NG Fault in fuel rail pressure sensor

OK
 ENGINE DIAGNOSIS CODE 17–59

2 CHECK THE CONTINUITY OF HARNESS

1. Disconnect the engine ECU connector.

2. Check continuity between the terminals ECU GND and VCC of
VCC the fuel rail pressure sensor (main) connector on the engine
GROUND
sub harness side.

NOTICE • If it is difficult to check only the sensor,

proceed to Step 3.

Standard value: f :

SAPH31ZCE1700062

3. Check continuity between the terminals ECU GND and SIG of

SIG the fuel rail pressure sensor (main) connector on the harness
GROUND
side.

Standard value: f :

SAPH31ZCE1700063

NG Fault in harness

OK
17–60 ENGINE DIAGNOSIS CODE

3 MEASURING RESISTANCE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness on the engine side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals AVC2 (E33) and
E ECU GND.
GROUND E33
Standard value: f :

SAPH31ZCE1700064

5. Measure resistance between the terminals PCR3 (E64), PCR4

E64 E (E65) and ECU GND.
E65
GROUND
Standard value: f :

SAPH31ZCE1700065

NG Fault in harness

OK
 ENGINE DIAGNOSIS CODE 17–61

4 MEASURING RESISTANCE BETWEEN TERMINALS

1. Connect the signal check harness on the engine side.

2. Disconnect the connector on the engine ECU side.

3. Measure resistance between the terminals AVC2 (E33) and
E E AGD2 (E76).
E33 E76
Standard value: 2 : or more

SAPH31ZCE1700066

4. Measure resistance between the terminals PCR3 (E64), PCR4

(E65) and AGD2 (E76).
E65 E
E64 E76
Standard value: 2 : or more

SAPH31ZCE1700067

NG Faulty fuel rail pressure sensor

OK
17–62 ENGINE DIAGNOSIS CODE

5 MEASURING RESISTANCE BETWEEN TERMINALS

1. Connect the signal check harness on the engine ECU side.

2. Measure resistance between the terminals AVC2 (E33), PCR3
E E (E64) and PCR4 (E65).
E65
E33 E64
Standard value: 200-250 k:

SAPH31ZCE1700068

NG Fault in engine ECU (ECU connector)

OK

6 MEASURING VOLTAGE BETWEEN TERMINALS

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals AVC2 (E33) and AGD2
E E (E76).
E33 E76
Standard value: 4.5-5.5 V

SAPH31ZCE1700069

NG Fault in engine ECU (ECU connector)

OK

Replace the engine ECU

 ENGINE DIAGNOSIS CODE 17–63

DTC code P0193 [74]

/Fuel rail pressure sensor (main) - out of range (Out of range high)
JP31ZCE170601016

1 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "LOCK" position.

2. Disconnect the fuel rail pressure sensor connector.

3. Check continuity between the terminals PCR+ and PCR of the
fuel rail pressure sensor (main) connector.
PCR- PCR PCR+
(main) (main) (main)
Standard value: 1.05-3.55 k:
PCR+ PCR PCR-
(sub) (sub) (sub)

SAPH31ZCE1700070

4. Check continuity between the terminals PCR and PCR- of the

fuel rail pressure sensor (main) connector.
PCR- PCR PCR+
(main) (main) (main) Standard value: 6.7-18.7 k:
PCR+ PCR PCR-
(sub) (sub) (sub)

SAPH31ZCE1700071

NG Fault in fuel rail pressure sensor

OK
17–64 ENGINE DIAGNOSIS CODE

2 MEASURING VOLTAGE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "ON" position.

2. Check voltage between the terminals VCC and GND of the fuel
GND rail pressure sensor (main) connector on the engine sub
VCC
harness side.

Standard value: 4.5-5.5 V

SAPH31ZCE1700072

3. Check voltage between the terminals SIG and GND of the fuel
SIG GND rail pressure sensor (main) connector on the engine sub
harness side.

Standard value: 4.5-5.5 V

SAPH31ZCE1700073

NG Proceed to 3

OK

Improper connection of connector

 ENGINE DIAGNOSIS CODE 17–65

3 MEASURING RESISTANCE BETWEEN TERMINALS

1. Connect the signal check harness on the engine side (blue).

2. Disconnect the connector on the engine ECU side.

3. Measure resistance between the terminals AVC2 (E33), PCR3
E E (E64) and PCR4 (E65).
E65
E33 E64
Standard value: 2 : or more

SAPH31ZCE1700074

4. Measure resistance between the terminals AGD2 (E76), PCR3

E65 E (E64) and PCR4 (E65).
E64 E76
Standard value: 2 : or more

SAPH31ZCE1700075

NG • Improper connection of connector

• Fault in harness

OK
17–66 ENGINE DIAGNOSIS CODE

4 MEASURING RESISTANCE BETWEEN TERMINALS

1. Disconnect the connector on the engine sub harness side.

2. Connect the signal check harness on the engine ECU side.

3. Measure resistance between the terminals AVC2 (E33), PCR3
E E (E64) and PCR4 (E65).
E65
E33 E64
Standard value: 200-250 k:

SAPH31ZCE1700076

NG Fault in engine ECU

OK
 ENGINE DIAGNOSIS CODE 17–67

5 MEASURING VOLTAGE BETWEEN TERMINALS

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals AVC2 (E33) and AGD2
E E (E76).
E33 E76
Standard value: 4.5-5.5 V

SAPH31ZCE1700077

3. Measure voltage between the terminals PCR3 (E64), PCR4

E65 E (E65) and AGD2 (E76).
E64 E76
Standard value: 4.5-5.5 V

SAPH31ZCE1700078

NG • Fault in engine ECU

• Fault in engine ECU connector

OK

Replace the rail assembly and harness

17–68 ENGINE DIAGNOSIS CODE

DTC code P0200 [71]

/Fuel injector driver charge circuit - circuit (Circuit high)
DTC code P0611 [71]
/Fuel injector driver charge circuit - circuit (Circuit low)
DTC code P0605 [3]
/Flash ROM error
DTC code P0606 [3]
/Control Module Processor
DTC code P0607 [3]
/Control Module Performance
JP31ZCE170601017

1 CHECK A MALFUNCTION CODE

1. After the starter switch is positioned on the "LOCK" once, it

should be turned to "ON" position again.

2. After erasing the DTC, check that the same code is displayed
again.

NG Fault in engine ECU

OK

Normal (Temporary malfunction because of radio interference noise)

 ENGINE DIAGNOSIS CODE 17–69

DTC code P0201 [61]

/Fuel injector - disconnection (#1cyl)
DTC code P0202 [62]
/Fuel injector - disconnection (#2cyl)
DTC code P0203 [63]
/Fuel injector - disconnection (#3cyl)
DTC code P0204 [64]
/Fuel injector - disconnection (#4cyl)
DTC code P0205 [65]
/Fuel injector - disconnection (#5cyl)
DTC code P0206 [66]
/Fuel injector - disconnection (#6cyl)

JP31ZCE170601018

1 MEASUREMENT OF RESISTANCE BETWEEN TERMINALS

1. Set the starter key to "LOCK" and connect the signal check
harness.
17–70 ENGINE DIAGNOSIS CODE

2. Disconnect the ECU side connector of the signal check

㧱 㧱 harness and measure the resistance between terminals.

SAPH31ZCE1700079

P0201 P0202 P0203 P0204 P0205 P0206

DTC code
[61] [62] [63] [64] [65] [66]

Failure position (injector) #1 #2 #3 #4 #5 #6

E14 l E15 E14 l E16 E14 l E17 E18 l E19 E18 l E60 E18 l E20
Terminal to measure E15 l E34 E16 l E34 E17 l E34 E19 l E38 E38 l E60 E20 l E38
resistance E14 l E35 E14 l E36 E14 l E37 E18 l E39 E18 l E80 E18 l E40
E34 l E35 E34 l E36 E34 l E37 E38 l E39 E38 l E80 E38 l E40

Standard value : 2 : or less

NG [3] Go to measurement of resistance between

injector terminals

OK

2 CHECK OF DIAGNOSIS CODE

1. Set the starter key to "LOCK" and connect the ECU side
connector of the signal check harness.
2. Start the engine and delete the past failures with the failure
diagnosis tool (HinoDX) using PC.

SAPH31ZCE1700080

3. If the same failure code is output again, replace the engine

ECU. If the normal code is output, it is considered that a
temporary error has occurred.
 ENGINE DIAGNOSIS CODE 17–71

3 MEASUREMENT OF RESISTANCE BETWEEN INJECTOR TERMINALS

1. Disconnect the injector connector at the cylinder head.

2. Measure the resistance between terminals of the injector
clustered connector (male) at the cylinder head.

SAPH31ZCE1700081

P0201 P0202 P0203 P0204 P0205 P0206

DTC code
[61] [62] [63] [64] [65] [66]

Failure area (injector) #1 #2 #3 #4 #5 #6

Terminal to measure
9 l 10 11 l 12 7l8 5l6 1l2 3l4
resistance

Standard value : 2 : or less

NG [4] Go to measurement of resistance between

injector terminals

OK

Engine sub harness disconnection (Check the harness between the ECU and the injector clustered connector)
17–72 ENGINE DIAGNOSIS CODE

4 MEASUREMENT OF RESISTANCE BETWEEN INJECTOR TERMINALS

1. Remove the head cover and disconnect the injector connector

(injector side) of the cylinder indicated by the failure code.
2. Measure the resistance between the No. 1 terminal and the No.
2 terminal.

Standard value : 0.47 r 0.1 : (20qC{68 qF})

SAPH31ZCE1700082

NG [5] Go to measurement of resistance between

injector terminals

OK

Contact failure of harness or connector inside the head cover

(Check the connector or the harness in the head cover)

5 MEASUREMENT OF RESISTANCE BETWEEN INJECTOR TERMINALS

1. Remove the terminal cap of the injector of the cylinder

indicated by the failure code and measure the insulation
resistance between the terminal and the upper body.

Standard value : 10 M: or more

2. Measure the resistance between terminals.

Standard value : 0.47 r 0.1 : (20qC{68 qF})

SAPH31ZCE1700083

NG Injector TWV coil disconnection

(Replace the injector assembly)

OK

Injector harness disconnection

(Replace the injector harness)
 ENGINE DIAGNOSIS CODE 17–73

DTC code P0217 [6]

/Engine coolant over temperature condition
JP31ZCE170601019

1 CHECK THE COOLANT TEMPERATURE SENSOR

1. Set the starter switch to "LOCK".

2. Disconnect the connector of engine coolant temperature

sensor.
3. Measure the resistance between terminals.

NOTICE • Measure the resistance under any of the

following conditions.

Standard value

Water temperature
Resistance
(qC{qF})

SAPH31ZCE1700084
2.45 k: 20 {68}

1.15 k: 40 {104}

584 : 60 {140}

318 : 80 {176}

NG Fault in engine coolant temperature sensor

OK

Fault in engine cooling system

NOTICE • This code will be displayed when the coolant temperature sensor operates normally and
coolant temperature ascends over 115qC {239qF}. Also, while the DTC is being detected,
Max. volume of fuel injection will be limited and will return back to normal control volume
when it descends less than 80qC {176qF}.
17–74 ENGINE DIAGNOSIS CODE

DTC code P0219 [7]

/Engine overspeed condition
JP31ZCE170601020

1 INSPECTION ITEM

1. The DTC will be displayed, once detected over 3100 r/min. in

the engine revolution. Also, the fuel injection will be suspended
during the DTC to be detected and the fuel injection will be
resumed when Engine revolution goes down less than 2700 r/
min.

NOTICE • The DTC aim is not for detecting the engine

over-run under abnormal operation of the
system, but for storing in memory the high
revolution of the engine. (For detection of
wrong shifting, etc.) Also, there is a case in
which "over-run" will be detected by
misunderstanding the engine revolution, with
a noise to be generated by harness
malfunction and its modification.
 ENGINE DIAGNOSIS CODE 17–75

DTC code P0234 [34]

/Overboost
JP31ZCE170601021

1 USE THE HinoDX TO INSPECT THE VNT

1. Connect the PC DIAGNOSIS TOOL (HinoDX).

SAPH31ZCE1700085

2. Set the starter switch "ON" position.

3. Check that no other codes (P0045, P00AF, P0108, P0237 and

U1123) exist.
If a DTC code is issued, follow each diagnostic flow.

4. Inspect the VNT.

Standard: Max. 2 sec. delay in opening

NG • Faulty VNT controller

• Faulty turbocharger

OK

2 CHECK EXHAUST SYSTEM PARTS

1. Check that exhaust system parts are not modified or blocked.

NG Faulty exhaust system parts

OK

3 CHECK THE BOOST PRESSURE SENSOR HOSE

1. Check the boost pressure sensor hose for looseness or

damage.

NG Faulty boost pressure sensor hose

OK
17–76 ENGINE DIAGNOSIS CODE

4 USE THE HinoDX TO INSPECT THE EGR

1. Inspect the EGR.

Standard:
Actual opening must follow required opening

SAPH31ZCE1700085

NG Proceed to inspect the EGR valve

OK

Proceed to inspect the boost pressure sensor

 ENGINE DIAGNOSIS CODE 17–77

DTC code P0237 [25]

/Boost pressure sensor - out of range (Out of range low)
JP31ZCE170601022

1 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "LOCK" position.

2. Disconnect the connector boost pressure sensor.

3. Check continuity between the terminals VCC and SIG of the
boost pressure sensor connector.

NOTICE • If it is difficult to check only the sensor,

proceed to Step 4.

Standard value: 2-15 k:

SAPH31ZCE1700086

4. Check continuity between the terminals SIG and GND of the

boost pressure sensor connector.

Standard value: 2-15 k:

SAPH31ZCE1700087

NG Fault in boost pressure sensor

OK
17–78 ENGINE DIAGNOSIS CODE

2 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Measure resistance between the terminals SIG and GND of the

boost pressure sensor connector (engine sub harness side).

Standard value: 209-231 k:

SAPH31ZCE1700088

NG Proceed to 4

OK

3 MEASURING VOLTAGE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals VCC and GND of the
boost pressure sensor connector (engine sub harness side).

Standard value: 4.5-5.5 V

SAPH31ZCE1700089

NG Proceed to 4

OK

Bad contact of harness connector

 ENGINE DIAGNOSIS CODE 17–79

4 MEASURING RESISTANCE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness on the engine side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals AVC2 (E33) and
PIM (E67).
㧱 㧱 E67
Standard value: 2-15 k:
E33

SAPH31ZCE1700090

5. Measure resistance between the terminals AVC2 (E33) and

AGD4 (E77).
㧱 㧱
E77
E33
Standard value: 2-15 k:

SAPH31ZCE1700091

6. Measure resistance between the terminal PIM (E67) and AGD4

㧱 (E77).
E67
E77
Standard value: f :

SAPH31ZCE1700092

NG • Faulty harness
• Fault in boost pressure sensor

OK
17–80 ENGINE DIAGNOSIS CODE

5 MEASURING VOLTAGE BETWEEN TERMINALS

1. Connect the connectors on the engine ECU side.

2. Disconnect the connector on the harness side.

3. Set the starter switch to "ON" position.

4. Measure voltage between the terminals AVC2 (E33) and ADG4
(E77).
㧱 㧱 E77
E33 Standard value: 4.5-5.5 V

SAPH31ZCE1700093

NG Fault in engine ECU

OK

6 MEASURING RESISTANCE BETWEEN TERMINALS

1. Measure resistance between the terminals PIM (E67) and

AGD4 (E77).
㧱 E67
E77 Standard value: 209-231 k:

SAPH31ZCE1700094

NG Fault in engine ECU

OK

Bad contact of harness connector

 ENGINE DIAGNOSIS CODE 17–81

DTC code P0263 [61]

/Injection quantity and timing (#1cyl)
DTC code P0266 [62]
/Injection quantity and timing (#2cyl)
DTC code P0269 [63]
/Injection quantity and timing (#3cyl)
DTC code P0272 [64]
/Injection quantity and timing (#4cyl)
DTC code P0275 [65]
/Injection quantity and timing (#5cyl)
DTC code P0278 [66]
/Injection quantity and timing (#6cyl)

JP31ZCE170601023

1 CHECK THE FLOW DAMPER

1. Turn the starter switch to "LOCK" position. Stop the engine.

2. Wait for about 30 seconds and then start the engine.

SAPH31ZCE1700095

3. Perform warm-up until the coolant temperature becomes 60qC

{140qF} or higher. And erase the DTC.

4. If the same DTC is displayed again after erasing it, replace the
fuel rail.
17–82 ENGINE DIAGNOSIS CODE

2 RECHECK THE DTC

1. Check that the other DTC is not displayed.

• If the other DTC is displayed, repair the trouble.
• If the same DTC is displayed again, it is possibly from the
following problems.
a
b a. Excessive fuel flow will cause fuel leakage from injection
pipe (between flow damper and injector) by bending,
cracking and pipe connection looseness.
o Check leakage.
b. Excessive or shortage fuel flow will cause injector
operation malfunction.
o Check by replacing the injector.
c. Shortage fuel flow will cause clogging of the fuel supply
system.
o Check fuel filter.

SAPH31ZCE1700096

2. The above problems can be diagnosed using the "Data

Monitor" menu to determine the cylinder contribution quantity
and "Activation Test" menu to stop the injector.

(1) When there is a cylinder whose cylinder contribution is

larger than other cylinders (the engine behavior will not
change even if fuel injection is stopped by active test for
the cylinder), the cylinder will not contribute to the engine
rotation.
o Inspecting the injector harness (disconnection)
SAPH31ZCE1700097
o Checking the piston for compression leakage
(2) When there is a cylinder whose cylinder contribution is
smaller than other cylinders, the contribution of the
cylinder to the engine rotation is excessive.
o Inspecting the injector harness (+B short circuit)
 ENGINE DIAGNOSIS CODE 17–83

DTC code P0335 [13]

/Crankshaft position sensor - disconnection
JP31ZCE170601024

1 MEASURING RESISTANCE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" and connect the signal check
harness.

2. Disconnect the signal check harness connector on the engine

ECU side.
3. Measure the resistance between NE1+ (E52) and NE1- (E72)
㧱 terminals.
E52
E72 Standard value: 108.5-142.5 : at 20qC {68qF}

SAPH31ZCE1700098

NG Proceed to 3

OK

2 RECHECK THE DTC

1. Connect the signal check harness connector on the engine

ECU side.

2. Erase the DTC.

3. No DTC code must be output again.

NG • Bad contact of ECU connectors

• Fault in engine ECU
• Malfunction of harness (Short circuit)

OK

Clear and recheck the DTC

17–84 ENGINE DIAGNOSIS CODE

3 CHECK THE ENGINE SPEED MAIN SENSOR

1. Disconnect the connectors of engine speed main sensor.

2. Measure the resistance between terminals of engine speed
main sensor.

Standard value: 108.5-142.5 : at 20qC {68qF}

SAPH31ZCE1700099

NG Fault in engine speed main sensor

OK

Harness disconnection
Bad contact of connectors
 ENGINE DIAGNOSIS CODE 17–85

DTC code P0336 [13]

/Crankshaft position sensor - rationality
JP31ZCE170601025

1 CHECK THE INPUT PULSE GENERATION TO ENGINE ECU

1. Set the starter switch to "LOCK" and connect the signal check
harness.

2. Start the engine.

3. Measure the pulse generation between NE1+ (E52) and NE1-
㧱 (E72) terminals using an oscilloscope.
E52
E72 Standard: 56 pulse

SAPH31ZCE1700100

1 rotation

56 peaks (pulse)

0V

No pulse (No gear tooth)

SAPH31ZCE1700101

4. After measurement, stop the engine.

NG Proceed to 2

OK

Fault in engine ECU

Malfunction of ECU connectors
17–86 ENGINE DIAGNOSIS CODE

2 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Connector of engine speed main sensor remains connected.

2. Measure the resistance between NE- main sensor connector
(engine sub harness side) and signal check harness NE1-
NE+ (E72).
In same way, measure the resistance between NE+ main
NE- sensor connector (engine sub harness side) and signal check
E52
E E72
harness NE1+ (E52).

Standard value: Less than 2 :

SAPH31ZCE1700102

NG Fault in harness

OK
 ENGINE DIAGNOSIS CODE 17–87

3 CHECK THE OUTPUT PULSE GENERATION FROM SENSOR

1. Connector of engine speed main sensor remains connected.

2. Start the engine.

3. Measure the pulse generation between terminals using an
oscilloscope.

Standard: 56 pulse

SAPH31ZCE1700103

1 rotation

56 peaks (pulse)

0V

No pulse (No gear tooth)

SAPH31ZCE1700101

4. After measurement, stop the engine.

NG • Engine speed main senor malfunction

• Flywheel signal hole abnormal

OK

Bad contact of connector

17–88 ENGINE DIAGNOSIS CODE

DTC code P0340 [12]

/Camshaft position sensor - disconnection
JP31ZCE170601026

1 MEASURING VOLTAGE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness on the engine side.

3. Disconnect the connector on the engine sub harness side.

4. Set the starter switch to "ON" position.

5. Measure voltage between the terminals CGND (E54) and
GVCC (E53).
E53 㧱 Standard value: 4.5-5.5 V

E54

SAPH31ZCE1700104

NG • Bad contact of ECU connectors

• Fault in engine ECU

OK

Fault in engine speed sub sensor

 ENGINE DIAGNOSIS CODE 17–89

DTC code P0341 [12]

/Camshaft position sensor - rationality
JP31ZCE170601027

1 MEASURING THE INPUT WAVEFORM ON THE ENGINE ECU SIDE

1. Set the starter key to "OFF" and connect the signal check
harness.

2. Start the engine.

3. Measure the waveform between terminals E54 and E73 of the

E54 㧱 signal check harness.

E73 Standard
Seven pulses from excess tooth to excess tooth

SAPH31ZCE1700105

2 rotation

5V

0V

SAPH31ZCE1700106

4. Stop the engine after measuring.

NG Go to [2] Measuring the output waveform on the

sensor side

OK

Defective engine ECU, defective ECU connector

17–90 ENGINE DIAGNOSIS CODE

2 MEASURING THE OUTPUT WAVEFORM ON THE SENSOR SIDE

1. Leave the connector of the engine auxiliary rotation sensor

connected.

2. Start the engine.

3. Measure the waveform between terminal SIG of the engine
auxiliary rotation sensor connector (unit harness side) and
terminal GND.

! CAUTION • The connector of the engine auxiliary rotation

sensor is shown from the engagement side.

Standard
Seven pulses from excess tooth to excess tooth

SAPH31ZCE1700107

2 rotation

5V

0V

SAPH31ZCE1700106

4. Stop the engine after measuring.

NG Defective engine auxiliary rotations sensor or

defective pulser

OK

Defective connector contact

 ENGINE DIAGNOSIS CODE 17–91

DTC code P0540 [53]

/Air intake heater circuit malfunction
JP31ZCE170601028

1 MEASUREMENT OF RESISTANCE BETWEEN TERMINALS

1. Set the starter key to "OFF" and connect the signal check
harness.
2. Disconnect the ECU side connector of the signal check
㨂 V harness and measure the resistance between terminals.
V24 V59

Terminal to measure the resistance

V39 V79, + Side - Side
V80
V24 V39, V59, V79, V80

Standard value : 25 r 2.5 :

SAPH31ZCE1700108

Signal check harness

E
Heater relay C
U

SAPH31ZCE1700109

NG [2] Go to measurement of relay resistance

OK

Engine ECU failure, ECU connector failure

17–92 ENGINE DIAGNOSIS CODE

2 MEASUREMENT OF RELAY RESISTANCE

1. Remove the heater relay and measure the resistance between

terminals (parts side).

Standard value : 24.8 r 0.5 :

SAPH31ZCE1700110

NG Heater relay failure

OK

Harness failure, connector failure

 ENGINE DIAGNOSIS CODE 17–93

DTC code P0545 [27]

/Exhaust gas temperature sensor (DPR inlet) - out of range (Out of range low)
JP31ZCE170601029

1 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Set the starter to the "LOCK" position.

2. Disconnect the exhaust gas temperature sensor (DPR inlet)

connector.
3. Measure resistance between the terminals TEX3 and GND3 of
GND3 TEX3 the exhaust gas temperature sensor (DPR inlet).

NOTICE • If it is difficult to check only the sensor,

proceed to Step 3.

Standard value

Resistance Temperature (qC{qF})

SAPH31ZCE1700111
9.75 k: 50 {122}

3.77 k: 100 {212}

1.80 k: 150 {302}

NG Faulty exhaust gas temperature sensor (DPR inlet)

ok

2 MEASURING VOLTAGE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals LCY and LCZ of the
LCZ LCY exhaust gas temperature sensor (DPR inlet) connector (engine
sub harness side).
Standard value: 4.5-5.5 V

SAPH31ZCE1700112

NG Proceed to 4

OK

Bad contact of connectors

17–94 ENGINE DIAGNOSIS CODE

3 MEASURING RESISTANCE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness on the unit side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals ET3+ (V69) and
ADG9 (V46).
V46 V69
V
Standard value

Resistance Temperature (qC{qF})

9.75 k: 50 {122}

3.77 k: 100 {212}

1.80 k: 150 {302}
SAPH31ZCE1700113

NG • Faulty exhaust gas temperature sensor (DPR inlet)

• Faulty harness
• Faulty sensor connector

OK

Fault in engine ECU

 ENGINE DIAGNOSIS CODE 17–95

4 MEASURING VOLTAGE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness on the unit side.

3. Set the starter switch to "ON" position.

4. Measure voltage between the terminals ET3+ (V69) and ADG9
(V46).
V46
V69
V Standard value: 4.5-5.5 V

SAPH31ZCE1700114

NG • Fault in engine ECU

• Faulty ECU connector

OK

Fault in harness
17–96 ENGINE DIAGNOSIS CODE

DTC code P0546 [27]

/Exhaust gas temperature sensor (DPR inlet) - out of range
(Out of range high)
JP31ZCE170601030

1 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Set the starter to the "LOCK" position.

2. Disconnect the exhaust gas temperature sensor (DPR inlet)

connector.
3. Measure resistance between the terminals TEX3 and GND3 of
GND3 TEX3 the exhaust gas temperature sensor (DPR inlet).

NOTICE • If it is difficult to check only the sensor,

proceed to Step 3.

Standard value

Resistance Temperature (qC{qF})

SAPH31ZCE1700111
9.75 k: 50 {122}

3.77 k: 100 {212}

1.80 k: 150 {302}

NG Faulty exhaust gas temperature sensor (DPR inlet)

ok

2 MEASURING VOLTAGE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals LCY and LCZ of the
LCZ LCY exhaust gas temperature sensor (DPR inlet) connector (engine
sub harness side).
Standard value: 4.5-5.5 V

SAPH31ZCE1700112

NG Proceed to 4

OK

Bad contact of connectors

 ENGINE DIAGNOSIS CODE 17–97

3 MEASURING RESISTANCE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness on the unit side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals ET3+ (V69) and
ADG9 (V46).
V46 V69
V
Standard value

Resistance Temperature (qC{qF})

9.75 k: 50 {122}

3.77 k: 100 {212}

SAPH31ZCE1700113 1.80 k: 150 {302}

NG • Faulty exhaust gas temperature sensor (DPR inlet)

• Faulty harness
• Faulty sensor connector

OK

Fault in engine ECU

17–98 ENGINE DIAGNOSIS CODE

4 MEASURING VOLTAGE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness on the unit side.

3. Set the starter switch to "ON" position.

4. Measure voltage between the terminals ET3+ (V69) and ADG9
(V46).
V46
V69
V Standard value: 4.5-5.5 V

SAPH31ZCE1700114

NG • Fault in engine ECU

• Faulty ECU connector

OK

Fault in harness
 ENGINE DIAGNOSIS CODE 17–99

DTC code P0617 [45]

/Starter switch - rationality
JP31ZCE170601031

1 INSPECTION

1. Prior check and check to see that there is no abnormal.

2. Use HinoDX to call up the start switch on the data monitor, then
confirm that the switch is synchronized with the actual start
switch operation.

NG Repair the trouble

OK

2 CHECK THE STARTER SWITCH

1. Check the starter switch and check to see that there is no

abnormal.

NG • Trouble of connector
• Trouble of harness

OK

Clear and recheck the DTC

17–100 ENGINE DIAGNOSIS CODE

DTC code P0628 [73]

/Suction control valve for fuel supply pump - circuit (circuit low)
DTC code P0629 [75]
/Suction control valve for fuel supply pump - circuit (circuit high)

JP31ZCE170601032

1 MEASUREMENT OF RESISTANCE BETWEEN TERMINALS

1. Set the starter key to "OFF", connect the signal check harness
and disconnect the ECU side connector.
2. Measure the resistance between terminals of the signal check
E9
㧱 E10 harness.

Terminal to measure the resistance

E30 E9 (SPV1) l E30 (SP2S)
E29
E9 (SPV1) l E10 (SPV2)
E29 (SP1S) l E30 (SP2S)
E29 (SP1S) l E10 (SPV2)

SAPH31ZCE1700019 Standard value : 7.9 r 0.25 : (20 qC{68 qF})

NG [2] Go to measurement of resistance between

terminals

OK

[4] Go to measurement of voltage between terminals

2 MEASUREMENT OF RESISTANCE BETWEEN TERMINALS

1. Disconnect the SCV harness and measure the resistance

between terminals (parts side).

Standard value : 7.9 r 0.25 : (20 qC{68 qF})

SAPH31ZCE1700115

NG Failure of SCV

OK
 ENGINE DIAGNOSIS CODE 17–101

3 MEASUREMENT OF RESISTANCE BETWEEN TERMINALS

1. Measure the resistance between terminals of the signal check

SCVL harness and the SCV connector (at engine sub harness side).
㧱 E10

Terminal to measure the resistance

Signal check harness SCV
E30
E10 (SPV2)
No.1 (SCVL)
E30 (SP2S)
E9 (SPV1)
No.2 (SCVH)
E29 (SP1S)
SAPH31ZCE1700116

Standard value : 1 : or less

SCVH NG Harness disconnection, bad contact of harness

㧱 E9
connector

E29

SAPH31ZCE1700117

OK

4 MEASUREMENT OF VOLTAGE BETWEEN TERMINALS

1. Connect the signal check harness on the engine ECU side.

2. Turn "ON" the starter key.

3. Measure voltage between terminal V59 and terminals E10/E30
of the signal check harness.
㨂 V59 㧱 E10

! CAUTION • After turning "ON" the starter key, take

measurements within 40 seconds.
E30
Standard value : Pulse wave-shape by 24V l 0V

SAPH31ZCE1700118

4. Stop the engine after measuring.

NG Fault in engine ECU (ECU connector)

OK

Fault in engine ECU

17–102 ENGINE DIAGNOSIS CODE

DTC code P0642 [5]

/ECU sensor supply 1 failure (low)
JP31ZCE170601033

1 INSPECTION ITEM

1. Boost pressure sensor connector, Intake throttle valve position

sensor 1 connector, Fuel rail pressure sensor 1 connector,
Camshaft position sensor connector by removing each of one,
P0642 fault code disappears things check.

NOTICE • When sensor power supply 1 fails, the trouble

code of P0122, P0193, P0237, P0340 occurs
other than a trouble code of P0642.

NG Proceed to 2

OK

2 MEASURE THE CONTINUITY BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness.

3. Disconnect the connector on the engine sub harness side and

sensor side (Boost pressure sensor, Intake throttle valve
position sensor, Fuel rail pressure sensor (main), Camshaft
position sensor).
4. Measure the resistance between the terminals AVC2 (E33),
E53 E56 GVCC (E53), AVC4 (V51) and AGD1 (E56).
㨂 E33 㧱 㧱
V51
Terminal to measure the resistance
+ Side - Side
E33
E53 E56
V51

SAPH31ZCE1700119 Standard value: f :

NG Faulty harness

OK

Fault in engine ECU

 ENGINE DIAGNOSIS CODE 17–103

DTC code P0643 [5]

/ECU sensor supply 1 failure (high)
JP31ZCE170601034

1 MEASURE THE VOLTAGE

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness.

3. Set the starter switch to "ON" position.

4. Measure the voltage between the terminals AVC2 (E33),
E53 E56 GVCC (E53), AVC4 (V51) and AGD1 (E56).
㨂 E33 㧱 㧱
V51
Terminal to measure the voltage
+ Side - Side
E33
E53 E56
V51

SAPH31ZCE1700120 Standard value: 4.9-5.1 V

NG Faulty harness

OK

Fault in engine ECU

17–104 ENGINE DIAGNOSIS CODE

DTC code P0652 [5]

/ECU sensor supply 2 failure (low)
JP31ZCE170601035

1 INSPECTION ITEM

1. Fuel rail pressure sensor (sub) connector, Differential pressure

sensor connector, P.T.O. accelerator sensor connector by
removing each of one, P0652 fault code disappears things
check.

NOTICE • When sensor power supply 2 fails, the trouble

code of P1198, P1428 occurs other than a
trouble code of P0652.

NG Proceed to 2

OK

Faulty sensor fault code disappears when remove

2 MEASURE THE CONTINUITY BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness.

3. Disconnect the connector on the engine sub harness side.

4. Measure the resistance between the terminals AVC1 (E13),
V50 AVC3 (V50), AVC5 (V71) and AGD1 (E56).
㨂 㧱 E56 㧱

V71
Terminal to measure the resistance
+ Side - Side
E13
E33
V50 E56
V71

SAPH31ZCE1700121 Standard value: f :

NG Faulty harness

OK

Fault in engine ECU

 ENGINE DIAGNOSIS CODE 17–105

DTC code P0653 [5]

/ECU sensor supply 2 failure (high)
JP31ZCE170601036

1 MEASURE THE VOLTAGE

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness.

3. Set the starter switch to "ON" position.

4. Measure the voltage between the terminals AVC1 (E13), AVC3
V50 (V50), AVC5 (V71) and AGD1 (E56).
㨂 㧱 E56 㧱
Terminal to measure the voltage
V71
+ Side - Side
E13
E13
V50 E56
V71

SAPH31ZCE1700122 Standard value: 4.9-5.1 V

NG Faulty harness

OK

Fault in engine ECU

17–106 ENGINE DIAGNOSIS CODE

DTC code P0686 [51]

/ECM/PCM Power relay control circuit high
JP31ZCE170601037

1 MEASURING VOLTAGE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" and connect the signal check
harness.

2. Set the starter to "ON" position.

3. Measure the voltage between MRL1 (V3), MRL2 (V23)
terminals and Chassis GND.
V3 V
V23 Standard value: 19 V or more

SAPH31ZCE1700123

NG Fault in harness or mechatronic controller

OK

Fault in engine ECU

Malfunction of ECU connectors
 ENGINE DIAGNOSIS CODE 17–107

DTC code P06D3 [5]

/Air flow sensor power supply failure Short to GND
JP31ZCE170601038

1 CHECK A MALFUNCTION CODE

1. Set the starter switch to "LOCK" position.

2. Disconnect the air flow sensor connector.

3. Set the starter switch to "ON" position.

4. Check that P06D3 [5] is no longer present.

NG Proceed to 2

OK

Faulty air flow sensor

2 CHECK THE CONTINUITY IN HARNESS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness.

3. Measure the resistance between the terminals AFVB (E12)
and PGD4 (V80).
㧱 㨂
E12
V80 Standard value: f :

SAPH31ZCE1700124

NG Proceed to 3

OK

Faulty harness
17–108 ENGINE DIAGNOSIS CODE

3 MEASURE THE VOLTAGE BETWEEN TERMINALS

1. Set the starter switch to "ON" position.

2. Measure the voltage between the terminals AFVB (E12) and
PGD4 (V80).
㧱 㨂
E12
V80 Standard value: 11.5-13.5 V

SAPH31ZCE1700125

NG Fault in engine ECU

OK

Faulty ECU connector

Faulty harness
 ENGINE DIAGNOSIS CODE 17–109

DTC code P06D4 [5]

/Air flow sensor power supply failure (high)
JP31ZCE170601039

1 MEASURE THE VOLTAGE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness on the engine side.

3. Set the starter switch to "ON" position.

4. Measure the voltage between the terminals AFVB (E12) and
E56
AGD1 (E56).
㧱 㧱
E12
Standard value: 11.5-13.5 V

SAPH31ZCE1700126

NG Proceed to 2

OK

Fault in engine ECU

2 CHECK THE BATTERY

1. Check the battery voltage.

Standard value: 19 V or more

NG Check the battery

OK

Fault in engine ECU

17–110 ENGINE DIAGNOSIS CODE

DTC code P1133 [23]

/P.T.O accelerator sensor (Hi)
JP31ZCE170601040

1 MEASURING RESISTANCE BETWEEN VOLUME FOR EMERGENCY ACCELERATOR

TERMINALS

1. Set the starter switch to "LOCK" position.

2. Disconnect the volume for emergency accelerator connector.

3. Measure resistance between the terminals of volume for
5V emergency accelerator connector.

NOTICE • If it is difficult to check only the sensor,

proceed to Step 4.
GND
SIG Standard value

Resistance
Volume Terminals
value
SAPH31ZCE1700127
GND - SIG 0:
Lo
GND - 5 V 3.1 k:

GND - SIG 2 k:
Hi
SIG - 5 V 1.1 k:

NG Faulty volume for emergency accelerator

OK

2 MEASURING RESISTANCE BETWEEN TERMINALS

1. Measure resistance between the terminals SIG and GND of the

volume for emergency accelerator connector (engine sub
SIG GND
harness side).

NOTICE • If it is difficult to check only the sensor,

proceed to Step 5.

Standard value: 740-760 k:

SAPH31ZCE1700128

NG • Fault in harness
• Irregular contact of connectors

OK
 ENGINE DIAGNOSIS CODE 17–111

3 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Measure resistance between the terminals 5V and SIG of the

5V
volume for emergency accelerator connector (engine sub
SIG harness side).

Standard value: f :

SAPH31ZCE1700129

NG Faulty harness

OK

4 MEASURING RESISTANCE BETWEEN TERMINALS

1. Connect the signal check harness on the unit side.

2. Disconnect the connector on the engine ECU side.

3. Measure resistance between the terminals ASCS (V68) and
AVC5 (V71).
㨂
V68
V71 Standard value: f :

SAPH31ZCE1700130

NG Faulty harness

OK
17–112 ENGINE DIAGNOSIS CODE

5 MEASURING RESISTANCE BETWEEN TERMINALS

1. Connect the emergency accelerator volume and set [Lo]

position.
2. Measure resistance between the terminals ASCS (V68) and
AVC5 (V71).
㨂
V68
V71 Standard value: 1.1 k: or more

SAPH31ZCE1700130

NG Fault in emergency accelerator connector terminal

OK

6 MEASURING RESISTANCE BETWEEN TERMINALS

1. Measure resistance between the terminals ADG7 (V45) and

ASCS (V68).
V45 㨂 V68
Standard value: 2: less than

SAPH31ZCE1700131

NG • Faulty harness
• Irregular contact of connectors

OK

Fault in engine ECU

 ENGINE DIAGNOSIS CODE 17–113

DTC code P1197 [74]

/Fuel rail pressure sensor (sub) - out of range (Out of range low)
JP31ZCE170601041

1 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "LOCK" position.

2. Disconnect the fuel rail pressure sensor connector.

3. Check continuity between the terminals PCR+ and PCR of the
fuel rail pressure sensor (sub) connector.
PCR- PCR PCR+
(main) (main) (main)
Standard value: 1.05-3.55 k:
PCR+ PCR PCR-
(sub) (sub) (sub)

SAPH31ZCE1700132

4. Check continuity between the terminals PCR and PCR- of the

fuel rail pressure sensor (sub) connector.
PCR- PCR PCR+
(main) (main) (main)
Standard value: 6.7-18.7 k:
PCR+ PCR PCR-
(sub) (sub) (sub)

SAPH31ZCE1700133

NG Fault in fuel rail pressure sensor

OK
17–114 ENGINE DIAGNOSIS CODE

2 CHECK THE CONTINUITY OF HARNESS

1. Disconnect the engine ECU connector.

2. Check continuity between the terminals ECU GND and VCC of
the fuel rail pressure sensor (sub) connector on the harness
VCC
ECU GND
side.

NOTICE • If it is difficult to check only the sensor,

proceed to step 3.

Standard value: f :

SAPH31ZCE1700134

3. Check continuity between the terminals ECU GND and SIG of

SIG the fuel rail pressure sensor (sub) connector on the harness
ECU GND
side.

Standard value: f :

SAPH31ZCE1700135

NG Fault in harness

OK
 ENGINE DIAGNOSIS CODE 17–115

3 MEASURING RESISTANCE BETWEEN TERMINALS

1. Set the starter key to "LOCK" and connect the signal check
harness on the engine ECU.

2. Disconnect the signal check harness connector on the engine

ECU side.
3. Measure resistance between the terminals AVC1 (E13) and
ECU GND.
㧱
E13 ECU GND Standard value: f :

SAPH31ZCE1700136

4. Measure resistance between the terminals PCR1 (E49), PCR2

㧱 (E68) and ECU GND.
E49
E68 ECU GND Standard value: f :

SAPH31ZCE1700137

NG Fault in harness

OK
17–116 ENGINE DIAGNOSIS CODE

4 MEASURING RESISTANCE BETWEEN TERMINALS

1. Connect the signal check harness on the engine side.

2. Disconnect the connector on the engine ECU side.

3. Connect the fuel rail pressure sensor connector.

4. Measure resistance between the terminals AVC1 (E13) and
AGD1 (E56).
E13 㧱 㧱 E56
Standard value: 2 : or more

SAPH31ZCE1700138

5. Measure resistance between the terminals PCR1 (E49), PCR2

E49 (E68) and AGD1 (E56).
E56 㧱 E68
Standard value: 2 : or more

SAPH31ZCE1700139

NG Fault in fuel rail pressure sensor

OK
 ENGINE DIAGNOSIS CODE 17–117

5 MEASURING RESISTANCE BETWEEN TERMINALS

1. Connect the signal check harness on the engine ECU side.

2. Measure resistance between the terminals AVC1 (E13), PCR1
(E49) and PCR2 (E68).
㧱 㧱 E49
E13
E68 Standard value: 200-250 k:

SAPH31ZCE1700140

NG Fault in engine ECU (ECU connector)

OK

6 MEASURING VOLTAGE BETWEEN TERMINALS

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals AVC1 (E13) and AGD1
(E56).
E13
㧱 㧱 E56
Standard value: 4.5-5.5 V

SAPH31ZCE1700141

NG Fault in engine ECU (ECU connector)

OK

Replace the engine ECU

17–118 ENGINE DIAGNOSIS CODE

DTC code P1198 [74]

/Fuel rail pressure sensor (sub) - out of range (Out of range high)
JP31ZCE170601042

1 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "LOCK" position.

2. Disconnect the fuel rail pressure sensor connector.

3. Check continuity between the terminals PCR+ and PCR of the
fuel rail pressure sensor (sub) connector.
PCR- PCR PCR+
(main) (main) (main)
Standard value: 1.05-3.55 k:
PCR+ PCR PCR-
(sub) (sub) (sub)

SAPH31ZCE1700142

4. Check continuity between the terminals PCR- and PCR of the

fuel rail pressure sensor (sub) connector.
PCR- PCR PCR+
(main) (main) (main)
Standard value: 6.7-18.7 k:
PCR+ PCR PCR-
(sub) (sub) (sub)

SAPH31ZCE1700143

NG Fault in fuel rail pressure sensor

OK
 ENGINE DIAGNOSIS CODE 17–119

2 MEASURING VOLTAGE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "ON" position.

2. Check voltage between the terminals VCC and GND of the fuel
rail pressure sensor (sub) connector on the engine sub
GND VCC harness side.

Standard value: 4.5V-5.5 V

SAPH31ZCE1700144

3. Check voltage between the terminals SIG and GND of the fuel
rail pressure sensor (sub) connector on the engine sub
GND SIG harness side.

Standard value: 4.5V-5.5 V

SAPH31ZCE1700145

NG Proceed to 3

OK

Improper connection of connector

17–120 ENGINE DIAGNOSIS CODE

3 MEASURING RESISTANCE BETWEEN TERMINALS

1. Connect the signal check harness on the engine side.

2. Disconnect the connector on the engine ECU side.

3. Measure resistance between the terminals AVC1 (E13), PCR1

E13 㧱 㧱 E49
(E49) and PCR2 (E68).
E68
Standard value: 2 : or more

SAPH31ZCE1700146

4. Measure resistance between the terminals AGD1 (E56), PCR1

E56 E49 (E49) and PCR2 (E68).
㧱 E68
Standard value: 2 : or more

SAPH31ZCE1700147

NG • Improper connection of connector

• Fault in harness

OK
 ENGINE DIAGNOSIS CODE 17–121

4 MEASURING RESISTANCE BETWEEN TERMINALS

1. Connect the signal check harness connector on the engine

ECU side and disconnect the engine sub harness side
connector.
2. Measure resistance between the terminals AVC1 (E13) and
PCR1 (E49) PCR2 (E68).
㧱 E68 㧱 E49
E13
Standard value: 200-250 k:

SAPH31ZCE1700148

NG Fault in engine ECU

OK
17–122 ENGINE DIAGNOSIS CODE

5 MEASURING VOLTAGE BETWEEN TERMINALS

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals AVC1 (E13) and AGD1
(E56).
E13
㧱 㧱 E56
Standard value: 4.5-5.5 V

SAPH31ZCE1700149

3. Measure voltage between the terminals PCR2 (E68), PCR1

(E49) and AGD1 (E56).
E68
E56 㧱 E49
Standard value: 4.5-5.5 V

SAPH31ZCE1700150

NG Fault in engine ECU (ECU connector)

OK

Replace the rail assembly and harness

 ENGINE DIAGNOSIS CODE 17–123

DTC code P119F [74]

/Fuel rail pressure sensor - rationality
JP31ZCE170601043

1 MEASURING VOLTAGE BETWEEN TERMINALS

1. Check that no other malfunction codes (P0192, P0193, P1197

and P1193)exist.

2. Disconnect the Boost pressure sensor, Intake throttle position

sensor, Fuel temperature sensor, Intake manifold temperature
sensor connectors and observe that a trouble remains.

3. Set the starter switch to "LOCK" position.

4. Connect the signal check harness.

5. Set the starter switch to "ON" position.

6. Measure a difference in voltage between the terminals of signal
E E49 check harness.
E65
E64
Terminal to measure the voltage
+ Side - Side
PCR3 (E64)
PCR1 (E49)
PCR4 (E65)
PCR3 (E64)
PCR2 (E68)
PCR4 (E65)
SAPH31ZCE1700151

Standard value: 0.3-0.7 V

E E68
E65
E64

SAPH31ZCE1700152

NG Fault in fuel rail pressure sensor

OK
17–124 ENGINE DIAGNOSIS CODE

2 MEASURING VOLTAGE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Disconnect the common rail pressure sensor connector.

3. Set the starter switch to "ON" position.

4. Measure the voltage between the terminals of the signal check
E13 E harness.
E49
E56 E
Terminal to measure the voltage
+ Side - Side

E68
AVC1 (E13)
PCR1 (E49) AGD1 (E56)
PCR2 (E68)
AVC2 (E33)
SAPH31ZCE1700153
PCR3 (E64) AGD2 (E76)
PCR4 (E65)

Standard value: 4.5-5.5 V

E65
E33 E E64 E E76

SAPH31ZCE1700154

NG Fault in engine ECU (ECU connector)

OK

Replace the engine ECU

 ENGINE DIAGNOSIS CODE 17–125

DTC code P1211 [68]

/Fuel injector driver circuit 1 - circuit (Circuit low)
JP31ZCE170601044

1 MEASURING RESISTANCE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" and connect the signal check
harness.

2. Disconnect the signal check harness connector on the engine

ECU side.
3. Measure the resistance between the terminals of ECU
E14 㧱 connector.
E34

+ side - side

ECU CASE GND IJ1+ (E14)

(ECU MOUNTING BOLT) ECU case GND
I1+S (E34)

Standard value: f :

SAPH31ZCE1700155

NG Proceed to (3)

OK

2 CHECK OF FAILURE CODE

1. Turn the starter switch to "LOCK" position.

Reconnect all the connectors.
2. Start the engine and erase the DTC.

SAPH31ZCE1700156

3. If the same DTC is displayed, replace ECU. If no DTC is

displayed, a temporary failure would have occurred.
17–126 ENGINE DIAGNOSIS CODE

3 MEASUREMENT OF RESISTANCE BETWEEN INJECTOR TERMINALS

1. Turn the starter switch to "LOCK" position (with all connectors

of ECU disconnected).

2. Disconnect the injector connector that is located on the front

side of the cam housing.
3. Measure the resistance between the pins of injector connector
(engine sub harness side) and ECU case GND.

1 2 12 11 ! CAUTION • Measure the resistance of this connector from

7 8 6 5 the connector terminals (female).
3 4 10 9 • Do not damage the connector terminals.

A ARROW VIEW A Failure position

(JUDGMENT DIRECTION)
(breaking + side - side
SAPH31ZCE1700157 position)

9
No.1 injector
10

11
No.2 injector ECU case GND
12

7
No.3 injector
8

Standard value: f :

NG Fault in harness
(It is defective the harness which resistance value is
out of the standard)

OK

Check the harness in the head cover

(A short-circuit would occur between the harness in the head cover and the GND line)
 ENGINE DIAGNOSIS CODE 17–127

DTC code P1212 [68]

/Fuel injector driver circuit 1 - circuit (Circuit high)
JP31ZCE170601045

1 MEASURING VOLTAGE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" and connect the signal check
harness.

2. Turn "ON" the starter switch.

3. Measure the voltage between the terminals of ECU connector
E14 E and ECU case GND.
E34
! CAUTION • Make sure that failure code which is
concerned with engine ECU is not output.
ECU CASE GND
(ECU MOUNTING BOLT)
+ side - side

IJ1+ (E14)
ECU case GND
I1+S (E34)
SAPH31ZCE1700158

Standard value: Less than battery voltage x 3/4 V

NG Proceed to (3)

OK

2 CHECK OF FAILURE CODE

1. Turn the starter switch to "LOCK" position.

Reconnect all the connectors.
2. Start the engine and erase the DTC.

SAPH31ZCE1700156

3. If the same DTC is displayed, replace ECU. If no DTC is

displayed, a temporary failure would have occurred.
17–128 ENGINE DIAGNOSIS CODE

3 MEASUREMENT OF VOLTAGE BETWEEN INJECTOR TERMINALS

1. Turn the starter switch to "LOCK" position.

2. Disconnect the injector connector that is located on the front

side of the cam housing. Turn the starter switch to "ON"
position.
3. Measure the voltage between the pins of injector connector
(engine sub harness side) and ECU case GND.

1 2 12 11 ! CAUTION • Measure the voltage of this connector from

7 8 6 5 the connector terminals (female).
3 4 10 9 • Do not damage the connector terminals.
• Make sure that failure code which is
A ARROW VIEW A concerned with engine ECU is not output.
(JUDGMENT DIRECTION)

SAPH31ZCE1700159
Failure position
(breaking + side - side
position)

No.1 injector 10

No.2 injector 12 ECU case GND

No.3 injector 8

Standard value: Less than battery voltage x 3/4 V

NG Fault in harness
(It is defective the harness which voltage value is out
of the standard)

OK

Check the harness in the head cover

(A short-circuit would occur between the harness in the head cover and the power source line)
 ENGINE DIAGNOSIS CODE 17–129

DTC code P1214 [68]

/Fuel injector driver circuit 2 - circuit (Circuit low)
JP31ZCE170601046

1 MEASURING RESISTANCE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" and connect the signal check
harness.

2. Disconnect the signal check harness connector on the engine

ECU side.
3. Measure the resistance between the terminals of ECU
E E18 connector.
E38

+ side - side

ECU CASE GND IJ2+ (E18)

(ECU MOUNTING BOLT) ECU case GND
I2+S (E38)

Standard value: f :

SAPH31ZCE1700160

NG Proceed to (3)

OK

2 CHECK OF FAILURE CODE

1. Turn the starter switch to "LOCK" position.

Reconnect all the connectors.
2. Start the engine and erase the DTC.

SAPH31ZCE1700161

3. If the same DTC is displayed, replace ECU. If no DTC is

displayed, a temporary failure would have occurred.
17–130 ENGINE DIAGNOSIS CODE

3 MEASUREMENT OF RESISTANCE BETWEEN INJECTOR TERMINALS

1. Turn the starter switch to "LOCK" position (with all connectors

of ECU disconnected).

2. Disconnect the injector connector that is located on the front

side of the cam housing.
3. Measure the resistance between the pins of injector connector
(engine sub harness side) and ECU case GND.

1 2 12 11 ! CAUTION • Measure the resistance of this connector from

7 8 6 5 the connector terminals (female).
3 4 10 9 • Do not damage the connector terminals.

A ARROW VIEW A Failure position

(JUDGMENT DIRECTION)
(breaking + side - side
SAPH31ZCE1700162 position)

5
No.4 injector
6

1
No.5 injector ECU case GND
2

3
No.6 injector
4

Standard value: f :

NG Fault in harness
(It is defective the harness which resistance value is
out of the standard)

OK

Check the harness in the head cover

(A short-circuit would occur between the harness in the head cover and the GND line)
 ENGINE DIAGNOSIS CODE 17–131

DTC code P1215 [68]

/Fuel injector driver circuit 2 - circuit (Circuit high)
JP31ZCE170601047

1 MEASURING VOLTAGE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" and connect the signal check
harness.

2. Turn "ON" the starter switch.

3. Measure the voltage between the terminals of ECU connector
E E18 and ECU case GND.
E38
! CAUTION • Make sure that failure code which is
concerned with engine ECU is not output.
ECU CASE GND
(ECU MOUNTING BOLT)
+ side - side
IJ2+ (E18)
ECU case GND
I2+S (E38)
SAPH31ZCE1700163
Standard value: Less than battery voltage x 3/4 V

NG Proceed to (3)

OK

2 CHECK OF FAILURE CODE

1. Turn the starter switch to "LOCK" position.

Reconnect all the connectors.
2. Start the engine and erase the DTC.

SAPH31ZCE1700156

3. If the same DTC is displayed, replace ECU. If no DTC is

displayed, a temporary failure would have occurred.
17–132 ENGINE DIAGNOSIS CODE

3 MEASUREMENT OF VOLTAGE BETWEEN INJECTOR TERMINALS

1. Turn the starter switch to "LOCK" position.

2. Disconnect the injector connector that is located on the front

side of the cam housing. Turn the starter switch to "ON"
position.
3. Measure the voltage between the pins of injector connector
(engine sub harness side) and ECU case GND.

1 2 12 11 ! CAUTION • Measure the voltage of this connector from

7 8 6 5 the connector terminals (female).
3 4 10 9 • Do not damage the connector terminals.
• Make sure that failure code which is
A ARROW VIEW A concerned with engine ECU is not output.
(JUDGMENT DIRECTION)

SAPH31ZCE1700164 Failure position

(breaking + side - side
position)
No.4 injector 6
No.5 injector 2 ECU case GND
No.6 injector 4

Standard value: Less than battery voltage x 3/4 V

NG Fault in harness
(It is defective the harness which voltage value is out
of the standard)

OK

Check the harness in the head cover

(A short-circuit would occur between the harness in the head cover and the power source line)
 ENGINE DIAGNOSIS CODE 17–133

DTC code P1427 [28]

/Differential pressure sensor - out of range (Out of range low)
JP31ZCE170601048

1 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "LOCK" position.

2. Disconnect the differential pressure sensor connector.

3. Check continuity between the terminals VCC and GND of the
VCC GND differential pressure sensor connector.

Standard value: 2 - 15 k:

SAPH31ZCE1700165

4. Check continuity between the terminals VOUT and GND of the

VOUT GND differential pressure sensor connector.

Standard value: 2 - 15 k:

SAPH31ZCE1700166

NG Faulty differential pressure sensor

OK
17–134 ENGINE DIAGNOSIS CODE

2 CHECK THE CONTINUITY OF HARNESS

1. Disconnect the engine ECU connector.

2. Check continuity between the terminals ECU GND and VCC of
the differential pressure sensor connector on the engine sub
VCC
GROUND harness side.

Standard value: f :

SAPH31ZCE1700167

3. Check continuity between the terminals ECU GND and SIG of

SIG the differential pressure sensor connector on the engine sub
GROUND
harness side.

Standard value: f :

SAPH31ZCE1700168

NG Fault in harness

OK
 ENGINE DIAGNOSIS CODE 17–135

3 MEASURING RESISTANCE BETWEEN TERMINALS

1. Disconnect the connector on the engine ECU side.

2. Disconnect the differential pressure sensor.

3. Measure resistance between the terminals AVC5 (V71) and
㨂 V46 ADG9 (V46).

V71 Standard value: f :

SAPH31ZCE1700169

4. Measure resistance between the terminals EXPS (V70) and

AGD9 (V46).
㨂 V46
V70 Standard value: f :

SAPH31ZCE1700170

NG • Fault in harness
• Irregular contact of connector

OK
17–136 ENGINE DIAGNOSIS CODE

4 MEASURING RESISTANCE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Also connect the signal check harness on the engine ECU

side.

3. Disconnect the differential pressure sensor connector.

4. Measure resistance between the terminals AVC5 (V71) and
㨂 EXPS (V70).
V70
V71 Standard value: 200-250 k:

SAPH31ZCE1700171

NG Fault in engine ECU

OK

5 MEASURING VOLTAGE BETWEEN TERMINALS

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals AVC5 (V71) and AGD9
㨂 V46 (V46).

V71 Standard value: 4.5-5.5 V

SAPH31ZCE1700172

NG Fault in engine ECU

OK

Clear and recheck the DTC

 ENGINE DIAGNOSIS CODE 17–137

DTC code P1428 [28]

/Differential pressure sensor - out of range (Out of range high)
JP31ZCE170601049

1 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "LOCK" position.

2. Disconnect the differential pressure sensor connector.

3. Check continuity between the terminals VCC and GND of the
VCC GND differential pressure sensor connector.

Standard value: 2-15 k:

SAPH31ZCE1700165

4. Check continuity between the terminals VOUT and GND of the

VOUT GND differential pressure sensor connector.

Standard value: 2-15 k:

SAPH31ZCE1700166

NG Faulty differential pressure sensor

OK
17–138 ENGINE DIAGNOSIS CODE

2 MEASURING VOLTAGE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "ON" position.

2. Check voltage between the terminals VCC and GND of the
VCC GND differential sensor connector on the engine sub harness side.

Standard value: 4.5-5.5 V

SAPH31ZCE1700173

3. Check voltage between the terminals SIG and GND of the

SIG differential sensor connector on the engine sub harness side.
GND
Standard value: 4.5-5.5 V

SAPH31ZCE1700174

NG Proceed to 3

OK

Improper connection of connector

 ENGINE DIAGNOSIS CODE 17–139

3 MEASURING RESISTANCE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness on the unit side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals AVC5 (V71) and
㨂 EXPS (V70).
V70
V71 Standard value: f :

SAPH31ZCE1700175

5. Measure resistance between the terminals AGD9 (V46) and

EXPS (V70).
㨂 V46
V70 Standard value: f :

SAPH31ZCE1700176

NG • Improper connection of connector

• Fault in harness

OK
17–140 ENGINE DIAGNOSIS CODE

4 MEASURING RESISTANCE BETWEEN TERMINALS

1. Disconnect the connector on the engine sub harness side and

connect the engine ECU side.
2. Measure resistance between the terminals AVC5 (V71) and
㨂 EXPS (V70).
V70
V71 Standard value: 200-250 k:

SAPH31ZCE1700177

NG Fault in engine ECU

OK
 ENGINE DIAGNOSIS CODE 17–141

5 MEASURING VOLTAGE BETWEEN TERMINALS

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals AVC5 (V71) and AGD9
㨂 V46 (V46).

V71 Standard value: 4.5-5.5 V

SAPH31ZCE1700178

3. Measure voltage between the terminals EXPS (V70) and

AGD9 (V46).
㨂 V46
V70 Standard value: 4.5-5.5 V

SAPH31ZCE1700179

NG Fault in engine ECU

OK

Clear and recheck the DTC

17–142 ENGINE DIAGNOSIS CODE

DTC code P1458 [81]

/Valve position control failure - DC motor out of range, functional
/Valve link failure
/Low battery voltage
JP31ZCE170601050

1 CHECK THE EGR VALVE LINK

1. Remove the EGR valve and check for any foreign matters

NG • Remove foreign matters, if any

• Faulty EGR valve

OK

2 MEASURING VOLTAGE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "LOCK" position.

2. Disconnect the EGR valve connector.

3. Set the starter switch to "ON" position.

4. Measure voltage between the terminals EGRV and EGRG of
the EGR valve connector (engine sub harness side).
EGRV EGRG

NOTICE • If it is difficult to check only the sensor,

proceed to step 3.

Standard value: 19 V or more

SAPH31ZCE1700180

NG • Faulty harness
• Faulty battery

OK
 ENGINE DIAGNOSIS CODE 17–143

3 INSPECT THE EGR VALVE

1. Connect the PC DIAGNOSIS TOOL (HinoDX).

SAPH31ZCE1700017

2. Set the starter switch to "ON" position.

3. Functional check.

4. Inspect the EGR.

5. For the forcibly driven item, check the data monitor value to see
if the opening of the EGR valve is driven as indicated by the
specified value.

NG Faulty EGR valve

OK

Fault in harness
Fault in engine ECU
17–144 ENGINE DIAGNOSIS CODE

DTC code P1459 [81]

/EGR actuator malfunction 2
JP31ZCE170601051

1 USE THE HinoDX TO INSPECT THE EGR VALVE

1. Connect the PC DIAGNOSIS TOOL (HinoDX).

SAPH31ZCE1700017

2. Set the starter switch to "ON" position.

3. Functional check.

4. Inspect the EGR.

5. For the forcibly driven item, check the data monitor value to see
if the opening of the EGR valve is driven as indicated by the
specified value.

NG Faulty EGR valve

OK

Fault in harness
Fault in engine ECU
 ENGINE DIAGNOSIS CODE 17–145

DTC code P1601 [2]

/Fuel Injector adjustment data error
JP31ZCE170601052

1 CHECK INJECTOR REPLACED RECORD

1. Check injector replaced record.

Standard
No replace record : Go to OK
Replaced record was found, or not clear : Go to NG

NG Proceed to 3

OK

2 INSPECTION OF QR CODE

1. Re-input the registration QR code date of the service server.

2. Erase the DTC memory, and recheck DTC code. Confirm that
DTC code P1601 [2] is not displayed.
Standard
Not displayed

NG Proceed to 3

OK

Normal
17–146 ENGINE DIAGNOSIS CODE

3 INSPECTION OF QR CODE

1. Read the QR code date of the injectors using HinoDX, re-input

QR code date.

SAPH31ZCE1700181

2. Erase the DTC memory, and recheck DTC code. Confirm that
DTC code P1601 [2] is not displayed.
Standard
Not displayed

NG Replace engine ECU

OK

Normal
 ENGINE DIAGNOSIS CODE 17–147

DTC code P200C [91]

/DPF over temperature
JP31ZCE170601053

1 INSPECTION OF SOOT LEAK

1. Remove the DPR, and check the rear roller end face.
Standard: No soot

NG Replace the DPR

OK

2 INSPECTION OF THE DPR

1. Check that the exhaust gas is not large amount black smoke
with DPR detached.

NG Check the engine body

OK

3 INSPECTION OF THE EXHAUST GAS TEMPERATURE SENSOR (DPR OUTRET)

1. Check the resistance the exhaust gas temperature sensor.

NG Replace the exhaust gas temperature sensor

OK

4 BASIC INSPECTION OF THE ENGINE

1. Clean the DPR by compressed air or replace the DPR, and do

the basic inspection of the engine (Injector quantity check).

! CAUTION • Perform it after the engine warm-up.

Standard value

Engine revolution Quantity

(r/min) (q)
800 10 - 30

NG Check the injectors

OK
17–148 ENGINE DIAGNOSIS CODE

5 DPR FORCED REGENERATION

1. Do the DPR forced regeneration.

Standard: Regeneration was finished.

! CAUTION • Confirm safety of the surrounding area, then

press DPR regeneration switch inside the
cabin to execute the regeneration.

NOTICE • Manual regeneration time of the DPR is within

15 to 20 minutes approximately.

2. Select the "DPR Reset confirmation" in the "Check function"

menu of HinoDX after system fix is made.
Menu : [Check function]-[DPR Reset Confirmation]

Select

SAPH31ZCE1700182
 ENGINE DIAGNOSIS CODE 17–149

3. Forced regeneration is done by the "Forced regeneration"

screen.
If you click the "Manual regeneration" Button, DPR Manual
regeneration switch will be shown.

DPR Reset Confirmation window

Manual regeneration Button

SAPH31ZCE1700183
17–150 ENGINE DIAGNOSIS CODE

4. Click the "Start" Button.

Manual regeneration window

Start Button

SAPH31ZCE1700184

5. If you press the "DPR manual regeneration switch" in the cabin,

manual regeneration will start.

SAPH31ZCE1700185
 ENGINE DIAGNOSIS CODE 17–151

6. When manual regeneration is completed, carry out

Backpressure Check.

! CAUTION • Never park the unit near any flammable

material, including high grass or leaves,
during manual regeneration.
• Extreme heat from the exhaust outlet could
cause a fire resulting in personal injury and
property damage.
• Always keep all flammable materials away
from the DPR cleaner, exhaust pipe and tail
pipes.
• Never touch the DPR cleaner, exhaust pipe or
tail pipe during regeneration. Severe burns
and/or other personal injuries could occur.

NOTICE • Manual regeneration is carried out when the

DPR clogged warning level flag is ON in the
"DPR Reset Confirmation Window"
• When the DPR clogged danger level flag is
ON, remove the DPR from the unit and clean it
with Hino's recommended cleaner or replace
it.

NG Replace the DPR

OK

Diagnosis is finish
17–152 ENGINE DIAGNOSIS CODE

DTC code P2032 [27]

/Exhaust gas temperature sensor (DPR outlet) - out of range
(Out of range low)
JP31ZCE170601054

1 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Set the starter to the "LOCK" position.

2. Disconnect the exhaust gas temperature sensor (DPR outlet)

connector.
3. Measure resistance between the terminals TEX3 and GND3 of
GND3 TEX3 the exhaust gas temperature sensor (DPR outlet).

NOTICE • If it is difficult to check only the sensor,

proceed to Step 3.

Standard value

Resistance Temperature (qC{qF})

SAPH31ZCE1700186
9.75 k: 50 {122}

3.77 k: 100 {212}

1.80 k: 150 {302}

Exhaust gas temperature sensor characteristic

Resistance(Ω)

Temperature(C)
SAPH31ZCE1700187

NG Faulty exhaust gas temperature sensor (DPR outlet)

OK
 ENGINE DIAGNOSIS CODE 17–153

2 MEASURING VOLTAGE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals LCY and LCZ of the
LCZ LCY exhaust gas temperature sensor (DPR outlet) connector
(engine sub harness side).

Standard value: 4.5-5.5 V

SAPH31ZCE1700188

NG Proceed to 4

OK

Bad contact of connectors

17–154 ENGINE DIAGNOSIS CODE

3 MEASURING RESISTANCE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness on the unit side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals ET2+ (V49) and
ADG9 (V46).
V46 V49
V
Standard value

Resistance Temperature (qC{qF})

9.75 k: 50 {122}

3.77 k: 100 {212}

SAPH31ZCE1700189 1.80 k: 150 {302}

Exhaust gas temperature sensor characteristic

Resistance(Ω)

Temperature(C)
SAPH31ZCE1700187

NG • Faulty exhaust gas temperature sensor

(DPR outlet)
• Faulty harness
• Faulty sensor connector

OK

Fault in engine ECU

 ENGINE DIAGNOSIS CODE 17–155

4 MEASURING VOLTAGE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness on the unit side.

3. Set the starter switch to "ON" position.

4. Measure voltage between the terminals ET2+ (V49) and ADG9
(V46).
V46
V49
V Standard value: 4.5-5.5 V

SAPH31ZCE1700190

NG • Fault in engine ECU

• Faulty ECU connector

OK

Faulty harness
17–156 ENGINE DIAGNOSIS CODE

DTC code P2033 [27]

/Exhaust gas temperature sensor (DPR outlet) - out of range
(Out of range high)
JP31ZCE170601055

1 MEASURING RESISTANCE BETWEEN SENSOR TERMINALS

1. Set the starter to the "LOCK" position.

2. Disconnect the exhaust gas temperature sensor (DPR outlet)

connector.
3. Measure resistance between the terminals TEX3 and GND3 of
GND3 TEX3 the exhaust gas temperature sensor (DPR outlet).

NOTICE • If it is difficult to check only the sensor,

proceed to Step 3.

Standard value

Resistance Temperature (qC{qF})

SAPH31ZCE1700186
9.75 k: 50 {122}

3.77 k: 100 {212}

1.80 k: 150 {302}

Exhaust gas temperature sensor characteristic

Resistance(Ω)

Temperature(C)
SAPH31ZCE1700187

NG Faulty exhaust gas temperature sensor (DPR outlet)

OK
 ENGINE DIAGNOSIS CODE 17–157

2 MEASURING VOLTAGE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "ON" position.

2. Measure voltage between the terminals LCY and LCZ of the
LCZ LCY exhaust gas temperature sensor (DPR outlet) connector
(engine sub harness side).

Standard value: 4.5-5.5 V

SAPH31ZCE1700188

NG Proceed to 4

OK

Bad contact of connectors

17–158 ENGINE DIAGNOSIS CODE

3 MEASURING RESISTANCE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness on the unit side.

3. Disconnect the connector on the engine ECU side.

4. Measure resistance between the terminals ET2+ (V49) and
ADG9 (V46).
V46 V49
V
Standard value

Resistance Temperature (qC{qF})

9.75 k: 50 {122}

3.77 k: 100 {212}

SAPH31ZCE1700189 1.80 k: 150 {302}

Exhaust gas temperature sensor characteristic

Resistance(Ω)

Temperature(C)
SAPH31ZCE1700187

NG • Faulty exhaust gas temperature sensor

(DPR outlet)
• Faulty harness
• Faulty sensor connector

OK

Fault in engine ECU

 ENGINE DIAGNOSIS CODE 17–159

4 MEASURING VOLTAGE BETWEEN TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness on the unit side.

3. Set the starter switch to "ON" position.

4. Measure voltage between the terminals ET2+ (V49) and ADG9
(V46).
V46
V49
V Standard value: 4.5-5.5 V

SAPH31ZCE1700190

NG • Fault in engine ECU

• Faulty ECU connector

OK

Faulty harness
17–160 ENGINE DIAGNOSIS CODE

DTC code P2100 [31]

/DC motor for intake throttle valve - circuit [Open circuit (circuit low)]
DTC code P2103 [31]
/DC motor for intake throttle valve - circuit [Short circuit (circuit high)]
JP31ZCE170601056

1 MEASURING VOLTAGE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "LOCK" position.

2. Disconnect the connector of intake throttle valve.

3. Set the starter switch to "ON" position.

4. Measure voltage between the terminals MOT+ and MOT- of the
MOT+ intake throttle valve connector (engine sub harness side).
MOT-
Standard value: 19V or more

SAPH31ZCE1700191

NG Fault in harness

OK

2 CHECK THE INTAKE THROTTLE VALVE

1. Disconnect the intake throttle from the intercooler so that the

intake throttle valve will be visible.

2. Check the intake throttle valve for dragged foreign matters.

3. Remove all foreign matters if any.

4. Set the starter switch to "ON" position.

(The engine does not start running.)

5. Set the starter switch to "LOCK" position and check that the
intake throttle valve functions.

NG Proceed to 3

OK

Clear and recheck the DTC

 ENGINE DIAGNOSIS CODE 17–161

3 INSPECT THE INTAKE THROTTLE VALVE

1. Connect the PC DIAGNOSIS TOOL (HinoDX).

SAPH31ZCE1700017

2. Set the starter switch to "ON" position.

3. Inspect the intake throttle valve.

NG Faulty intake throttle valve

OK

Fault in harness
Fault in engine ECU
17–162 ENGINE DIAGNOSIS CODE

DTC code P2101 [31]

/Intake throttle valve - functional
JP31ZCE170601057

1 CHECK THE INTAKE THROTTLE VALVE

1. Remove intercooler hose above intake throttle so that the

intake throttle valve will be visible.

2. Check the intake throttle valve for dragged foreign matters.

3. Remove all foreign matters if any.

4. Set the starter switch to "ON" position.

(The engine does not start running.)

5. Set the starter switch to "LOCK" position and check that the
intake throttle valve functions.

NG Proceed to 2

OK

Clear and recheck the DTC

2 INSPECT THE INTAKE THROTTLE VALVE

1. Connect the PC DIAGNOSIS TOOL (HinoDX).

SAPH31ZCE1700017

2. Set the starter switch to "ON" position.

3. Inspect the intake throttle valve.

NG Faulty intake throttle valve

OK

Fault in harness
Fault in engine ECU
 ENGINE DIAGNOSIS CODE 17–163

DTC code P2120 [22]

/Throttle/Pedal Position Sensor / Switch "D" Circuit
JP31ZCE170601058

1 INSPECTION ITEM

1. Make sure to inspect it in accordance with the contents of DTC

P2120, P2122, P2123, P2127 and P2128.
17–164 ENGINE DIAGNOSIS CODE

DTC code P2121 [22]

/Accelerator sensor 1 malfunction
DTC code P2126 [22]
/Accelerator sensor 2 malfunction
JP31ZCE170601059

1 MEASURING VOLTAGE BETWEEN TERMINALS

1. Set the starter key to "LOCK" and connect the signal check
harness to the engine ECU.

2. Set the cluster mode to "H" and select the "Lo idle" position.
3. Set the starter key to "ON" and measure the voltage between
accelerator sensor 1 terminal V47 and V45, terminal V65 and V67 of the signal
V45 V V47 check harness.

SAPH31ZCE1700192

accelerator sensor 2

V65 V V67

SAPH31ZCE1700193

4. Confirm that the difference in voltage between accelerator

sensor 1 and accelerator sensor 2 is 0.5V less than.
Standard value: 0.5 V less than

NG Proceed to 2

OK

Fault in engine ECU

 ENGINE DIAGNOSIS CODE 17–165

2 MEASURING VOLTAGE AT THE OUTPUT PORT OF THE MECHATRONIC CONTROLLER

1. Disconnect the 28PIN connector of the mechatronic controller.

2. Measure the voltage between pin 28 (785) and pin 25 (781).

Standard value
785 781
Accelerator potentio Voltage (V)
Low idle Approx. 1.4
High idle Approx. 3.5

SAPH31ZCE1700194

NG Fault in mechatronic controller

OK

Disconnection of harness, short-circuit of harness

17–166 ENGINE DIAGNOSIS CODE

DTC code P2122 [22]

/Accelerator pedal position sensor 1 - out of range (Out of range low)
DTC code P2123 [22]
/Accelerator pedal position sensor 1 - out of range (Out of range high)
JP31ZCE170601060

1 MEASUREMENT OF VOLTAGE BETWEEN TERMINALS

1. Set the starter key to "OFF" and connect the signal check
harness.
2. Set the starter key to "ON" and measure the voltage between
terminal V47 and terminal V45 of the signal check harness.
V45 V V47

Standard value

Idling revolution Voltage

(r/min) (V)

800 0.7 - 1.5

SAPH31ZCE1700195

NG [3] Measuring voltage at the output port of the

mechatronic controller

OK

2 MEASUREMENT OF VOLTAGE BETWEEN TERMINALS

1. While increasing the throttle, measure the voltage between

terminal V47 and terminal V45 of the signal check harness.
V45 V V47

Standard value

Engine
Voltage
Measuring item revolution
(V)
(r/min)
Low idle 1,000 Approx. 1.4
SAPH31ZCE1700195
High idle 2,100 Approx. 3.5

NG Defective mechatronic controller

OK

Harness failure
 ENGINE DIAGNOSIS CODE 17–167

3 MEASURING VOLTAGE AT THE OUTPUT PORT OF THE MECHATRONIC CONTROLLER

1. With the starter key set to "ON", do not open the throttle and
measure the voltage between pin 25 (781) of the pin connector
V45 V
28 of the mechatronic controller and V45 of the signal check
781
harness.
When an abnormal value is detected, the mechatronic
controller becomes defective.

Abnormal value
: 0.3 V or less
SAPH31ZCE1700196 : 4.6 V or more

NG Engine ECU failure, ECU connector failure or

disconnection of harness, short-circuit of harness

OK

Defective mechatronic controller

17–168 ENGINE DIAGNOSIS CODE

DTC code P2127 [22]

/Accelerator pedal position sensor 2 - out of range (Out of range low)
DTC code P2128 [22]
/Accelerator pedal position sensor 2 - out of range (Out of range high)
JP31ZCE170601061

1 MEASUREMENT OF VOLTAGE BETWEEN TERMINALS

1. Set the starter key to "OFF" and connect the signal check
harness.
2. Set the starter key to "ON" and measure the voltage between
terminal V67 and terminal V65 of the signal check harness.
V65 V V67

Standard value

Idling revolution Voltage

(r/min) (V)

800 0.7 - 1.5

SAPH31ZCE1700197

NG [3] Measuring voltage at the output port of the

mechatronic controller

OK

2 MEASUREMENT OF VOLTAGE BETWEEN TERMINALS

1. While increasing the throttle, measure the voltage between

terminal V67 and terminal V65 of the signal check harness.
V65 V V67

Standard value

Engine
Voltage
Measuring item revolution
(V)
(r/min)
Low idle 1,000 Approx. 1.4
SAPH31ZCE1700197
High idle 2,100 Approx. 3.5

NG Defective mechatronic controller

OK

Harness failure
 ENGINE DIAGNOSIS CODE 17–169

3 MEASURING VOLTAGE AT THE OUTPUT PORT OF THE MECHATRONIC CONTROLLER

1. With the starter key set to "ON", do not open the throttle and
measure the voltage between pin 25 of the pin connector 28 of
V65 V
the mechatronic controller and V65 of the signal check
781
harness.
When an abnormal value is detected, the mechatronic
controller becomes defective.

Abnormal value
: 0.3 V or less
SAPH31ZCE1700198 : 4.6 V or more

NG Engine ECU failure, ECU connector failure or

disconnection of harness, short-circuit of harness

OK

Defective mechatronic controller

17–170 ENGINE DIAGNOSIS CODE

DTC code P2228 [15]

/Barometric pressure sensor - out of range (Out of range low)
DTC code P2229 [15]
/Barometric pressure sensor - out of range (Out of range high)
JP31ZCE170601062

1 CHECK OF DIAGNOSIS CODE

1. Check that no other diagnosis codes exist.

2. After the starter switch is positioned on the "LOCK" once, it

should be turned to "ON" position again.

3. After erasing the DTC, check that the same code is displayed
again.

NG Fault in engine ECU

OK

Normal
(Temporary malfunction because of radio interference noise)
 ENGINE DIAGNOSIS CODE 17–171

DTC code P244A [91]

/Filtering performance (missing substrate)
JP31ZCE170601063

1 CHECK THE DPR

1. Remove the DPR.

2. Check for soot leakage, damage and cracking.

NG Replace the DPR

OK

2 INSPECTION ITEM

1. Blow air against the DPR.

2. Perform a forced regeneration and check that regeneration is

completed.

NG Do the basic inspection of the engine

(injector quantity check)
Standard value : 10 - 30q (800r/min)

! CAUTION • Perform it after the engine

warm-up.

OK

3 INSPECT DIFFERENTIAL PRESSURE OF THE DPR

NG • Check the differential pressure sensor and

differential pressure pipe for clogging
• Check the hose for damage

OK

4 CHECK FOR EXHAUST GAS LEAKAGE

1. Check the muffler body and flange surface for gas leakage.

NG Inspection or replacement of the exhaust gas pipe

OK

Delete the error and see how it works

17–172 ENGINE DIAGNOSIS CODE

DTC code P244B [92]

/Incomplete regeneration
JP31ZCE170601064

1 INSPECTION OF THE DPR BACK PRESSURE PIPE

1. Check the back pressure pipe.

Standard: No clogged

NG Clean the pipe

OK

2 INSPECTION OF THE DPR

1. Remove the DPR, and check the rear roller end face.
Standard: No soot

NG Replace the DPR

OK

3 INSPECTION OF THE DPR

1. Remove the DPR front roller end face.

Standard: No clogged at front end of the catalyst

NG Replace the DPR

OK

4 INSPECTION OF THE DPR

1. Check that the exhaust gas is not large amount black smoke
with DPR detached.

NG Check the engine body

OK

5 INSPECTION OF THE DPR BACK PRESSURE SENSOR

1. Check of the DPR back pressure sensor.

NG Replace the DPR back pressure sensor

OK
 ENGINE DIAGNOSIS CODE 17–173

6 BASIC INSPECTION OF THE ENGINE

1. Clean the DPR by compressed air or replace the DPR, install

the muffler, and do the basic inspection of the engine (Injector
quantity check).

! CAUTION • Perform it after the engine warm-up.

Standard value

Engine revolution Quantity

(r/min) (q)
800 10 - 30

NG Adjust the injection quantity

OK

7 DPR FORCED REGENERATION

1. Do the DPR forced regeneration.

Standard: Regeneration was not finished.

! CAUTION • Confirm safety of the surrounding area, then

press DPR regeneration switch inside the
cabin to execute the regeneration.

NOTICE • Manual regeneration time of the DPR is within

15 to 20 minutes approximately.

2. Select the "DPR Reset confirmation" in the "Check function"

menu of HinoDX after system fix is made.
Menu : [Check function]-[DPR Reset Confirmation]

Select

SAPH31ZCE1700182
17–174 ENGINE DIAGNOSIS CODE

3. Forced regeneration is done by the "Forced regeneration"

screen.
If you click the "Manual regeneration" Button, DPR Manual
regeneration switch will be shown.

DPR Reset Confirmation window

Manual regeneration Button

SAPH31ZCE1700183
 ENGINE DIAGNOSIS CODE 17–175

4. Click the "Start" Button.

Manual regeneration window

Start Button

SAPH31ZCE1700184

5. If you press the "DPR manual regeneration switch" in the cabin,

manual regeneration will start.

SAPH31ZCE1700185
17–176 ENGINE DIAGNOSIS CODE

6. When manual regeneration is completed, carry out

Backpressure Check.

! CAUTION • Never park the unit near any flammable

material, including high grass or leaves,
during manual regeneration.
• Extreme heat from the exhaust outlet could
cause a fire resulting in personal injury and
property damage.
• Always keep all flammable materials away
from the DPR cleaner, exhaust pipe and tail
pipes.
• Never touch the DPR cleaner, exhaust pipe or
tail pipe during regeneration. Severe burns
and/or other personal injuries could occur.

NOTICE • Manual regeneration is carried out when the

DPR clogged warning level flag is ON in the
"DPR Reset Confirmation Window"
• When the DPR clogged danger level flag is
ON, remove the DPR from the unit and clean it
with Hino's recommended cleaner or replace
it.

NG Replace the DPR

OK

8 INSPECTION OF THE BACK PRESSURE

1. Check the back pressure.

NG Clean the DPR or replace the DPR

OK

Delete the DTC code. Diagnosis is finish.

 ENGINE DIAGNOSIS CODE 17–177

DTC code P2458 [93]

/DPR regeneration duration
DTC code P24A2 [93]
/DPR regeneration incomplete by fuel consumption over
JP31ZCE170601065

1 INSPECTION OF THE SOOT LEAK

1. Check inside of the tail pipe, and check the DPR rear roller end
face.
Standard: No soot

NG Replace the DPR

OK

2 BASIC INSPECTION OF THE ENGINE

1. Basic inspection of the engine (Injector quantity check).

Standard: Injector quantity is standard value.

NG Check the injection system, EGR system and VNT

system

OK

3 INSPECTION OF THE EXHAUST GAS TEMPERATURE SENSOR (DPR inlet)

1. Check the resistance the exhaust gas temperature sensor

(DPR inlet).

NG Replace the exhaust gas temperature sensor

OK

4 CHECK THE EXHAUST SYSTEM

1. Check the gas leak from the exhaust system.

Standard: No gas leak

NG Replace the gasket, retighten the tightening parts.

OK
17–178 ENGINE DIAGNOSIS CODE

5 DPR FORCED REGENERATION

1. Clean the DPR or replace the DPR, and do the DPR forced
regeneration.
Standard: Regeneration was finished.

! CAUTION • Confirm safety of the surrounding area, then

press DPR regeneration switch inside the
cabin to execute the regeneration.

NOTICE • Manual regeneration time of the DPR is within

15 to 20 minutes approximately.

2. Select the "DPR Reset confirmation" in the "Check function"

menu of HinoDX after system fix is made.
Menu : [Check function]-[DPR Reset Confirmation]

Select

SAPH31ZCE1700182
 ENGINE DIAGNOSIS CODE 17–179

3. Forced regeneration is done by the "Forced regeneration"

screen.
If you click the "Manual regeneration" Button, DPR Manual
regeneration switch will be shown.

DPR Reset Confirmation window

Manual regeneration Button

SAPH31ZCE1700183
17–180 ENGINE DIAGNOSIS CODE

4. Click the "Start" Button.

Manual regeneration window

Start Button

SAPH31ZCE1700184
 ENGINE DIAGNOSIS CODE 17–181

5. If you press the "DPR manual regeneration switch" in the cabin,

manual regeneration will start.

SAPH31ZCE1700185

6. When manual regeneration is completed, carry out

Backpressure Check.

! CAUTION • Never park the unit near any flammable

material, including high grass or leaves,
during manual regeneration.
• Extreme heat from the exhaust outlet could
cause a fire resulting in personal injury and
property damage.
• Always keep all flammable materials away
from the DPR cleaner, exhaust pipe and tail
pipes.
• Never touch the DPR cleaner, exhaust pipe or
tail pipe during regeneration. Severe burns
and/or other personal injuries could occur.

NOTICE • Manual regeneration is carried out when the

DPR clogged warning level flag is ON in the
"DPR Reset Confirmation Window"
• When the DPR clogged danger level flag is
ON, remove the DPR from the unit and clean it
with Hino's recommended cleaner or replace
it.

NG Replace the DPR

OK

Delete the DTC code. Diagnosis is finish.

NOTICE • Explain to the customer that frequent interruption of a DPR forced regeneration leads to an
incorrect evaluation.
17–182 ENGINE DIAGNOSIS CODE

DTC code P2463 [92]

/DPF clogged
JP31ZCE170601066

1 INSPECTION OF SOOT LEAK

1. Remove the DPR, and check the rear roller end face.
Standard: No soot

NG Replace the DPR

OK

2 DPR FORCED REGENERATION

1. Operated of the switch, and check the DPR regeneration.

Standard: Regeneration was finished

NG [3] Inspection item

OK

Diagnosis is finish

3 INSPECTION ITEM

1. Check the neutral signal circuit, and check the returning of the
emergency accelerator.

NG Check each item

OK
 ENGINE DIAGNOSIS CODE 17–183

4 DPR FORCED REGENERATION

1. Do the DPR forced regeneration.

Standard: Regeneration was finished

! CAUTION • Confirm safety of the surrounding area, then

press DPR regeneration switch inside the
cabin to execute the regeneration.

NOTICE • Manual regeneration time of the DPR is within

15 to 20 minutes approximately.

2. Select the "DPR Reset confirmation" in the "Check function"

menu of HinoDX after system fix is made.
Menu : [Check function]-[DPR Reset Confirmation]

Select

SAPH31ZCE1700182
17–184 ENGINE DIAGNOSIS CODE

3. Forced regeneration is done by the "Forced regeneration"

screen.
If you click the "Manual regeneration" Button, DPR Manual
regeneration switch will be shown.

DPR Reset Confirmation window

Manual regeneration Button

SAPH31ZCE1700183
 ENGINE DIAGNOSIS CODE 17–185

4. Click the "Start" Button.

Manual regeneration window

Start Button

SAPH31ZCE1700184

5. If you press the "DPR manual regeneration switch" in the cabin,

manual regeneration will start.

SAPH31ZCE1700185
17–186 ENGINE DIAGNOSIS CODE

6. When manual regeneration is completed, carry out

Backpressure Check.

! CAUTION • Never park the unit near any flammable

material, including high grass or leaves,
during manual regeneration.
• Extreme heat from the exhaust outlet could
cause a fire resulting in personal injury and
property damage.
• Always keep all flammable materials away
from the DPR cleaner, exhaust pipe and tail
pipes.
• Never touch the DPR cleaner, exhaust pipe or
tail pipe during regeneration. Severe burns
and/or other personal injuries could occur.

NOTICE • Manual regeneration is carried out when the

DPR clogged warning level flag is ON in the
"DPR Reset Confirmation Window"
• When the DPR clogged danger level flag is
ON, remove the DPR from the unit and clean it
with Hino's recommended cleaner or replace
it.

NG Replace the DPR

OK

There is possibility that the customer forgets to push the switch. Please explain the operation again.
 ENGINE DIAGNOSIS CODE 17–187

DTC code U0073 [8]

/Engine ECU CAN communication bus for Emission control system - bus off
JP31ZCE170601067

1 CHECK THE TERMINATION RESISTOR

1. Check that it is installed.

2. Check that the resistance is as much as 120: .

3. Check that the connectors have no poor contact.

NG Repair the trouble

OK

2 CHECKING EACH ECU

1. Remove the EGR, VNT and check the diagnosis of U0073 is

restored.

NOTICE • Before detaching the ECU, turn the key OFF.

NG Proceed to the communication blackout diagnostic

flow of each ECU.
If abnormalities are still not found, replace each
ECU.

OK

Replace the ECU

17–188 ENGINE DIAGNOSIS CODE

DTC code U1001 [9]

/Engine ECU CAN communication bus for Vehicle control - bus off
JP31ZCE170601068

1 CHECKING EACH ECU

1. Remove the unit side controller and check the diagnosis of

U1001 is restored.

NG Proceed to the communication blackout diagnostic

flow of each ECU.
If abnormalities are still not found, replace each
ECU.

OK

Replace the engine ECU

 ENGINE DIAGNOSIS CODE 17–189

DTC code U110A [9]

/Engine ECU CAN communication (vehicle control controller)
JP31ZCE170601069

1 INSPECTION OF THE FUSE POWER SUPPLY CIRCUIT OF THE UNIT SIDE CONTROLLER

1. Check the power supply circuit of the unit side controller.

NG Check the unit side controller main relay and fuse

power supply circuit.

OK

2 CHECK A MALFUNCTION CODE

1. Since the following actuators and switches are connected in

the downstream of the actuator power relay, more than one
malfunction code or functional failure can occur.
Check the supply circuit from the actuator power relay.

Sensor Case
EGR actuator U1122
VNT actuator U1123
Manual regeneration
DPR regeneration switch
failure of DPR

NG Check the CAN harness

OK

Replace the unit side controller

17–190 ENGINE DIAGNOSIS CODE

DTC code U1122 [8]

/Engine ECU CAN communication (EGR valve controller)
JP31ZCE170601070

1 CHECK THAT THE ACTUATOR RELAY HAS NO MALFUNCTION

1. Check that the actuator relay has no malfunction.

NG Check the actuator relay and fuse circuit

OK

2 CHECK A MALFUNCTION CODE

1. Since the following actuators and switches are connected in

the downstream of the actuator power relay, more than one
malfunction code or functional failure can occur.
Check the supply circuit from the actuator power relay.

Sensor Case
EGR actuator U1122
VNT actuator U1123
Manual regeneration
DPR regeneration switch
failure of DPR

NG Check the CAN harness

OK
 ENGINE DIAGNOSIS CODE 17–191

3 MEASURE VOLTAGE OF THE EGR ACTUATOR

1. Set the starter switch to "LOCK" position.

2. Disconnect the EGR actuator connector.

3. Measure voltage between the terminals EGRV and EGRG of
the EGR actuator connector (engine sub harness side).

Standard value: 19 V or more

SAPH31ZCE1700199

NG Fault in harness

OK

Faulty EGR actuator

17–192 ENGINE DIAGNOSIS CODE

DTC code U1123 [8]

/Engine ECU CAN communication (VNT controller)
JP31ZCE170601071

1 CHECK THAT THE ACTUATOR RELAY HAS NO MALFUNCTION

1. Check that the actuator relay has no malfunction.

NG Check the actuator relay and fuse circuit

OK

2 CHECK A MALFUNCTION CODE

1. Since the following actuators and switches are connected in

the downstream of the actuator power relay, more than one
malfunction code or functional failure can occur.
Check the supply circuit from the actuator power relay.

Sensor Case
EGR actuator U1122
VNT actuator U1123
Manual regeneration
DPR regeneration switch
failure of DPR

NG Check the CAN harness

OK
 ENGINE DIAGNOSIS CODE 17–193

3 MEASURING VOLTAGE BETWEEN SENSOR TERMINALS

1. Set the starter switch to "LOCK" position.

2. Connect the signal check harness.

3. Disconnect the VNT controller connector.

4. Set the starter switch to "ON" position.

5. Check voltage between the terminals +24V and GND of the
VNT controller connector.
GND +24V Standard value: 19 V or more

SAPH31ZCE1700018

NG Fault in harness

OK

4 CHECK THE CONTINUITY OF HARNESS

1. Check continuity between the terminals VNTH and VNTL of the

VNTH VNT controller connector and the terminals CA3H (E59) and
㧱 E59 CA3L (E79) of the signal check harness respectively.
VNTL
E79

Terminals to measure the resistance

VNT controller side Signal check harness side
VNTH CA3H
VNTL CA3L

SAPH31ZCE1700200 Standard value: 2 : or less

NG Fault in harness

OK

Fault VNT controller

 2011
All rights reserved. This manual may not be reproduced or copied in
whole or in part, without the written permission of Hino Motors, Ltd.
PRINTED IN JAPAN

Pub. No. KSS-Z4J8-001E Oct. 2010

KSS-Z4J8-002E Feb. 2011