New Holland E200sr Excavator Service Repair Manual PDF

Copyright New Holland
INTRODUCTION
E200SR
WORKSHOP MANUAL
ENGLISH
Print No. 604.13.431
Edition: 03/2005
English - Printed in Italy
Printed by Studio ti - 20105
0-1
INTRODUCTION
TO THE READER
This manual has been written for a skilled technician, - For any question or comment, or in case you
in order to give him the information necessary to notice a mistake in this manual content, please
repair this machine.
contact:
- Read this manual carefully for correct
information about repair procedures. NEW HOLLAND KOBELCO CONSTRUCTION
MACHINERY S.p.A.
Strada di Settimo, 323
San Mauro Torinese (TO)
10099 ITALIA
PRODUCT SUPPORT
Fax. ++39 011 0077357
ADDITIONAL REFERENCE MANUALS
In addition to this Workshop Manual, refer also to

the following:
- Operation and maintenance instruction

manual
- Spare parts catalog
DESCRIPTION OF THE COMPLETE

WORKSHOP MANUAL
The complete repair manual consists of two volumes: equipment, information on maintenance standards,
remove and install procedures, disassembly and
- E200SR Workshop Manual "Excavator" assembly procedures.
The complete Workshop Manual for the excavator

"Excavator" and "Engine" Workshop Manuals model E200SR consists of the following volumes
contain the technical information necessary for identified by print number as shown herebelow:
machine/engine service and repair, service
VOLUME MACHINE TYPE PRINT No.

Workshop Manual - "Excavator" E200SR 604.13.431
0-3
INTRODUCTION
AVOID ACCIDENTS
Most accidents, whether they occur in industry, on the farm, at home or on

the highway, are caused by the failure of some individuals to follow simple and
fundamental safety rules or precautions. For this reason MOST ACCIDENTS
CAN BE PREVENTED by recognising the real cause and doing something
about it before the accident occurs.
Regardless of the care used in the design and construction of any type of
equipment there are conditions that cannot be completely safeguarded
against without interfering with reasonable accessibility and efficient operation.
Carefully read indications, cautions and safety warning quoted in the
SAFETY RULES section.
A careful operator is the best insurance against an accident.
The complete observance of one simple rule would prevent many thousand
serious injuries each year.
That rule is:
Never attempt to clean, oil or adjust a machine while it is in motion.
S ATTENTION
On machines having hydraulically, mechanically and/or cable controlled
equipment (such as showels, loaders, dozers, scrapers etc.) be certain
the equipment is lowered to the ground before servicing, adjusting and/
or repairing.
If it is necessary to have the equipment partially or fully raised to gain
access to certain items, be sure the equipment is suitably supported by
means other than the hydraulic lift cylinders, cable and/or mechanical
device used for controlling the equipment.
COPYRIGHT BY NEW HOLLAND KOBELCO CONSTRUCTION

MACHINERY S.p.A.
Product Support - Documentation Centre
Strada di Settimo, 323 - 10099 - S. Mauro T.SE (TO) ITALY
All rights reserved. Reproduction of text and illustrations in whole or in part, is

strictly prohibited.
0-4
INDEX
INDEX
SPECIFICATIONS
Section 1 - Outline
Section 2 - Specification
Section 3 - Attachment dimension
MAINTENANCE
Section 11 - Tools
Section 12 - Standard maintenance time schedule
Section 13 - Maintenance standard and test procedure
SYSTEM
Section 21 - Mechatro control system

Section 22 - Hydraulic system
Section 23 - Electric system
Section 24 - Components system
Section 25 - Air-conditioner system
DISASSEMBLING
Section 31 - Disassembling and assembling

Section 32 - Attachment
Section 33 - Upper structure
Section 34 - Travel system
TROUBLESHOOTING
Section 41 - Troubleshooting (mechatro control)

Section 42 - Troubleshooting (Hydraulic)
Section 43 - Troubleshooting (Electric)
Section 44 - Troubleshooting (Engine)
ENGINE
Section 51 - Engine
OPT
Section 63 - Mounting the breaker and nibbler & breaker
0-5
SAFETY PRECAUTIONS
SAFETY PRECAUTIONS 5. Do not work on any machine that is supported

only by lift, jacks or a hoist. Always use blocks or
YY S WARNING YY jack stands, capable of supporting the machine,
before performing any disassembly.
The proper and safe lubrication and maintenance for
this machine, recommended by Distributor, are
outlined in the OPERATORS MANUAL for the
machine.
YY S WARNING YY
Improper performance of lubrication or maintenance Do not operate this machine unless you have read
procedures are dangerous and could result in injury and understand the instructions in the OPERATORS
or death. Read and understand the MANUAL before MANUAL. Improper machine operation is dangerous
performing any lubrication or maintenance. and could result in injury or death.
The serviceman or mechanic may be unfamiliar with

6. Relieve all pressure in air, oil or water systems
many of the systems on this machine. This makes it before any lines, fittings or related items are
important to use caution when performing service disconnected or removed. Always make sure all
work. A knowledge of the system and or components raised components are blocked correctly and be
is important before the removal or disassembly of any alert for possible pressure when disconnecting
component. any device from a system that utilizes pressure.
7. Lower the bucket, dozer, or other attachments to

Because of the size of some of the machine the ground before performing any work on the
components, the serviceman or mechanic should machine. If this cannot be done, make sure the
check the weights noted in this manual. Use proper bucket, dozer, ripper or other attachment is
lifting procedures when removing any components. blocked correctly to prevent it from dropping
Weight of components table is shown in the section; unexpectedly.
SPECIFICATIONS.
8. Use steps and grab handles when mounting or
dismounting a machine. Clean any mud or debris
The following is a list of basic precautions that must from steps, walkways or work platforms before
always be observed. using. Always face to the machine when using
steps, ladders and walkways. When it is not
1. Read and understand all Warning plates and possible to use the designed access system,
decal on the machine before Operating, provide ladders, scaffolds, or work platforms to
Maintaining or Repairing this machine. perform safe repair operations.
2. Always wear protective glasses and protective 9. To avoid back injury, use a hoist when lifting
shoes when working around machines. In components which weigh 20 kg (45 lbs) or more.
particular, wear protective glasses when using Make sure all chains, hooks, slings, etc., are in
hammers, punches or drifts on any part of the good condition and are the correct capacity. Be
machine or attachments. Use welders gloves, sure hooks are positioned correctly. Lifting eyes
hood/goggles, apron and the protective clothing are not to be side loaded during a lifting operation.
appropriate to the welding job being performed.
Do not wear loose fitting or torn clothing. Remove 10. To avoid burns, be alert for hot parts on machines
all rings from fingers, loose jewelry, confine long which have just been stopped and hot fluids in
hair and loose clothing before working on this lines, tubes and compartments.
machinery.
11. Be careful when removing cover plates. Gradually
3. Disconnect the battery and hang a Do Not back off the last two capscrews or nuts located at
Operate tag in the Operators Compartment. opposite ends of the cover or device and carefully
Remove ignition keys. pry cover loose to relieve any spring or other
pressure, before removing the last two capscrews
4. If possible, make all repairs with the machine or nuts completely.
parked on a level, hard surface. Block the machine
so it does not roll while working on or under the 12. Be careful when removing filler caps, breathers
machine. Hang a Do Not Operate tag in the and plugs on the machine. Hold a rag over the cap
Operators Compartment. or plug to prevent being sprayed or splashed by
liquids under pressure. The danger is even
0-6
SAFETY PRECAUTIONS
greater if the machine has just been stopped Shields that protect against oil spray onto hot
because fluids can be hot. exhaust components in event of a line, tube or seal
failure must be installed correctly.
13. Always use the proper tools that are in good
condition and that are suited for the job at hand. 21. Do not operate a machine if any rotating part is
Be sure you understand how to use them before damaged or contacts any other part during
performing any service work. operation. Any high speed rotating component
that has been damaged or altered should be
14. Reinstall all fasteners with the same part number. checked for balance before reusing.
Do not use a lesser quality fastener if replacements
are necessary. 22. Be careful when servicing or separating the
tracks (crawlers). Chips can fly when removing or
15. Repairs which require welding should be installing a track (crawlers) pin. Wear safety
performed only with the benefit of the appropriate glasses and long sleeve protective clothing. Tracks
reference information and by personnel (crawlers) can unroll very quickly when separated.
adequately trained and knowledgeable in welding Keep away from front and rear of machine. The
procedures. Determine type of metal being machine can move unexpectedly when both tracks
welded and select correct welding procedure and (crawlers) are disengaged from the sprockets.
electrodes, rods or wire to provide a weld metal Block the machine to prevent it from moving.
strength equivalent at least to that of the parent
metal. Make sure to disconnect battery before
any welding procedures are attempted.
16. Do not damage wiring during removal operations.

Reinstall the wiring so it is not damaged nor will be
damaged in operation of the machine by contacting
sharp corners, or by rubbing against some object
or hot surface. Do not connect wiring to a line
containing fluid.
17. Be sure all protective devices including guards

and shields are properly installed and functioning
correctly 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. Dont fail to lower the
attachment 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
installed correctly to avoid excessive heat, vibration
or rubbing against other parts during operation.
0-7
SAFETY PRECAUTIONS
NOTE
0-8
E200SR
SECTION 1 OUTLINE
TABLE OF CONTENTS
1. GENERAL PRECAUTIONS FOR MAKING REPAIRS ................................................ 1
2. INTERNATIONAL UNIT CONVERSION SYSTEM...................................................... 4

1. GENERAL PRECAUTIONS FOR MAKING REPAIRS

1.1 PREPARATION BEFORE 4) Confirm the position of first-aid box and fire
DISASSEMBLING extinguisher, and also where to make contact
(1) Knowledge of operating procedure for emergency measure and ambulance to
Read Operators Manual carefully to prepare for accidents and fire.
understand the operating procedure. 5) Choose a hard, flat and safe place, and put
(2) Cleaning machines attachment on the ground without fail.
Clean machines of soil, mud, and dust before 6) Use crane, etc. to remove parts of heavy
carrying into the repair shop. weight (20kg [44 lbs] or more).
Carrying a soiled machine into the repair 7) Use proper tools, and change or repair
shop, causes making less efficient work and defective tools.
damage of parts, and interferes with rust 8) Machine and attachment required to work in
prevention and dust protection while the lifting condition should be supported with
reassembling. supports or blocks securely.
(3) Inspecting machines
Confirm the disassembling section before 1.3 DISASSEMBLING AND
starting work, determine the disassembly ASSEMBLING HYDRAULIC
procedure taking the conditions in repair EQUIPMENT
shop into account, and request to procure (1) Removing hydraulic equipment assy
necessary parts in advance. 1) Before removing pipes, release the pressure
(4) Recording of hydraulic oil tank, or open the cover on the
Record the following items to keep contact return side to tank, and take out the filter.
and prevent malfunction from recurring. 2) Put the oil in the removed pipes in reservoir
1) Inspecting date, place taking care it is not spilled on the ground.
2) Model name, Applicable machine No., 3) Pipes with plugs or caps to prevent oil
Records on hour meter leaking, entry of dust, etc.
3) Trouble condition, place, cause 4) Clean the outside surface of equipment, etc.
4) Visible oil leakage, water leakage and before disassembling, and drain hydraulic oil
damage and gear oil before putting them on working
5) Clogging of filters, etc., oil level, oil quality, bench.
oil contamination and looseness which can be (2) Disassembling hydraulic equipment
inspected. 1) Since performance and function of hydraulic
6) Examine the problems on the basis of equipment after disassembly and assembly
operation rate with the last inspection date results in immunity from responsibility on
and records on hour meter. the manufactures side, disassembly,
(5) Arrangement and cleaning in repair shop assembly and conversion without permission
1) Tools required for repair work. are strictly prohibited.
2) Specify places to put the disassembled parts 2) If it is unavoidably necessary to disassemble
on in advance. and convert, it should be carried out by
3) Prepare oil pans for leaking oil, etc. experts or personnel authorized through
service training.
1.2 SAFETY WHEN 3) Make match mark on parts for reassembling.
DISASSEMBLING AND 4) Before disassembling, read Disassembling
ASSEMBLING Instruction supplied with equipment in
(1) Safety advance, and determine if the disassembly
1) Wear appropriate clothing, safety shoes, and assembly are permitted or not.
safety helmet, goggles, and clothes with long 5) For parts which are required to use jig and
sleeves. tools, dont fail to use the specified jig and
2) Suspend warning tag Dont operate from tools.
lever, and begin preliminaries before getting 6) For parts which can not be removed in the
down to work. specified produre, never force removal. First
check for the cause.
3) Before starting inspection and maintenance
which contain the danger of being caught in
machine, stop the engine.
1
7) The removed parts should be put in order and 3) For air bleed of hydraulic pump and swing
tagged so as to install on proper places motor, loosen drain plug on the upper part,
without confusion. start engine, and run in low idling, then
8) For common parts, pay attention to the bleed air until hydraulic oil is oozed out.
quantity and places. After completion of air bleed, tighten plug
(3) Inspecting parts securely.
1) Check that the disassembled parts are free 4) For air bleed of travel motor and hydraulic
from adherence, interference and cylinder, starts engine and operate it for 10
non-uniform working face. minutes or more at no-load and low speed.
2) Measure the wear of parts and clearance, and
record the measured values. For cylinder, dont move it to the stroke
3) If an abnormality is detected, repair or end at beginning.
replace the parts.
5) Air in pilot circuit can be bled out by only
(4) Reassembling hydraulic equipment operating digging, swing and traveling
1) Before cleaning, turn the fun on or open doors motions thoroughly.
to ventilate air. 6) Check hydraulic oil level.
2) Before assembly, clean parts roughly first, Move attachments to hydraulic oil check
and then completely. position, and check hydraulic oil level of tank.
3) Remove with oil by compressed air, and apply Refill oil if the oil level is lower than the
hydraulic oil or gear oil, and then assemble minimum level.
them. Important Information
4) Replace the removed O ring, back-up rings
LEVEL GAUGE
and oil seal with new ones, and apply grease Oil level of hydraulic oil tank.
oil on them before assembling. If the indicator is within level
5) Removes stain and water on the surface on marks, the oil quantity is
allowable.
which liquid sealant are applied, decrease
them, and apply liquid sealant on them. How to check oil level of hydraulic oil tank
6) Before assembling, remove rust preventives
on new parts.
7) Use special tools to fit bearings, bushing and
oil seal. 1.4 ELECTRICAL EQUIPMENT
8) Assemble parts matching to the marks. (1) The disassembly of electrical equipment is
9) After completion, check that there is no not allowed.
omission of parts. (2) Handle equipment with care so as not to drop
it or bump it.
(5) Installing hydraulic equipment (3) Connector should be removed by unlocking
1) Confirm hydraulic oil and lubrication oil. while holding the connector.
2) Air release is required in the following cases ; Never stress in tension to the caulked section
a. Change of hydraulic oil by pulling wire.
b. Replacement of parts on suction pipe (4) Check that connector is connected and locked
side completely.
c. Removing and attaching hydraulic pump (5) Switch starter key off before removing and
d. Removing and attaching swing motor connecting connector
e. Removing and attaching travel motor (6) Switch starter key off before touching
f. Removing and attaching hydraulic cylinder terminals of starter and alternator.
(7) Remove battery grounding terminal before
If hydraulic oil and lubricating oil are beginning work close to battery and battery
not filled and also air bleed is not relay with tools.
performed, the hydraulic equipment (8) Wash machine with care so as not to splash
may be damaged. water on electrical equipment and connector.
2
(9) When water has entered in the waterproofed Tighten it to the specified torque,
connector, the removing of water is not easy. and check that it is free from
So check the removed waterproofed connector distortion, over tension, interference,
with care to protect it from entry of water. If and oil leakage.
moisture adheres on it, dry it completely
before connecting. 1.6 WELD REPAIR
(1) The weld repair should be carried out by
Battery electrolyte is dangerous. authorized personnel in the specified
The battery electrolyte is dilute procedure after disconnecting the grounding
sulfuric acid, and causes scald and loss cable of battery. If the grounding cable is not
of eyesight by adhering on eyes, skin disconnected, the electrical equipment may
and clothes. When the electrolyte has be damaged.
adhered on them, take an emergency (2) Remove parts which may cause flame due to
measure immediately and see a doctor the entry of spark beforehand.
for medical advice. (3) Repair attachments which are damaged,
When it has adhered on skin ; giving particular attention to the plated
Wash with soap and water. section of piston rod to protect it from sparks,
When it has got in eyes ; and don't fail to cover the section with fire
Wash in water for 10 minutes or clothes.
more immediately.
When it has spilled out in large 1.7 ENVIRONMENTAL ISSUES
quantity ; (1) Engine should be started and operated in the
Use sodium bicarbonate to place where air can be sufficiently ventilated.
neutralize, or wash away with (2) Industrial waste disposal
water. The following parts follows the regulation.
When it was swallowed ; Waste oil, waste container
Drink milk or water. Battery
When it has adhered on clothes ; (3) Precautions for handling hydraulic oil
Wash it immediately. Hydraulic oil may cause inflammation of
eyes.
Wear goggles to protect eyes on handling it.
1.5 HYDRAULIC PARTS When it has got in eyes ;
1) O ring Wash eyes with water until the
Check that O ring is free from flaw stimulus is gone.
and has elasticity before fitting. When it was swallowed ;
Even if the size of O ring is equal, Immediately see a doctor for
the usage differs, for example in medical advice.
dynamic and static sections, the When it has adhered on skin ;
rubber hardness also differs Wash with soap and water.
according to the pressure force, and (4) Others
also the quality differs depending on For spare parts, grease and oil, use
the materials to be seated. So, choose Distributor genuine ones.
proper O ring.
Fit O ring so as to be free from
distortion and bend.

Floating seal should be put in pairs.
2) Flexible hose (F hose)

Even if the connector and length of
hose are the same, the parts differ

according to the withstanding
pressure. Use proper parts.
3
2. INTERNATIONAL UNIT CONVERSION SYSTEM

Introduction (4) Derived Units bearing Peculiar Designations
Although this manual uses the JIS unit system. Table 2-4
If you need SI unit, refer to following QUANTITIES DESIGNATION SIGN DERIVED UNIT
international system of units. Frequency Hertz Hz 1Hz=1s-1
Given hereinunder are an excerpt of the units Force Newton N 1N=1kgfym/s2
that are related to this manual : Pressure, Pascal Pa 1Pa=1N/m2
Stress
1. Etymology of SI Units Energy Joule J 1J=1Nym
French : Le Systme International d Units Work,
English : International System of Units Quantity of
heat
2. Construction of SI Unit System
Power Watt W 1W=1J/s
Motive power,
Electric power
Basic units
Charge, Coulomb C 1C=1As
Table 2-1
Quantity of
Supplement- Derived units of
electricity
SI units ary units basic units Potential Volt V 1V=1J/C
SI unit Voltage, (1W/A)
Table 2-2 Table 2-3
system Electromotive
Derived Derived units force
units bearing peculiar Quantity of Farad F 1F=1C/V
designations static
Table 2-4 electricity
Capacitance
Prefixes of SI Electric Ohm 1=1V/A
(n-th power of 10, where n is an integral) resistance
Table 2- 5
Celcius Celcius degree
temperature or degree
(1) Basic Units Illuminance lux X 1 X=1 m/m2
Table 2-1
QUANTITIES DESIGNATION SIGN (5) Prefixes of SI
Length Meter m Table 2-5
Mass Kilogram kg PREFIX POWER
Time Second s DESIGNATION SIGN
Current Ampere A Giga- G 109
Thermodynamic Kelvin K Mega- M 106
temperature Kilo- k 103
Gram molecule Mol mol Hecto- h 102
Luminous intensity Candela cd Deca- da 10
Deci- d 101
(2) Supplementary Units Centi- c 102
Table 2-2 Milli- m 103
Micro- 106
QUANTITIES DESIGNATION SIGN
Nano- n 109
Plane angle Radian rad Pico- p 1012
Solid angle Steradian sr
(6) Unit Conversion Table
(3) Derived Units of Basic Units Table 2-6
Table 2-3 QUANTITIES JIS SI REMARKS
QUANTITIES DESIGNATION SIGN Mass kg kg
Area Square meter m2 Force kgf N 1kgf=9.807N
Volume Cubic meter m3 Torque kgfym Nym kgfym=9.807Nym
Velocity Meter per second m/s Pressure kgf/cm2 MPa 1kgf/cm2=0.098MPa
Acceleration Meter per second / second m/s2 Motive power PS kW 1PS=0.7355kW
Density Kilogram per cubic meter kg/m3 Revolution rpm min1 r/min 1
1 Units that are allowed to use

4
E200SR
SECTION 2 SPECIFICATIONS
TABLE OF CONTENTS
1. NAME OF COMPONENTS ....................................................................................... 1
2. GENERAL DIMENSION ............................................................................................ 2
3. WEIGHT OF COMPONENTS ................................................................................... 3
4. TRANSPORTATION DIMENSION AND WEIGHT ..................................................... 4
5. SPECIFICATIONS AND PERFORMANCE ................................................................ 6
6. TYPE OF CRAWLER ............................................................................................... 7
7. TYPE OF BUCKET ................................................................................................... 8
8. COMBINATIONS OF ATTACHMENT ........................................................................ 9
9. ENGINE SPECIFICATION ...................................................................................... 10

1. NAME OF COMPONENTS
1
2. GENERAL DIMENSION
NOTE :
Dimensions marked * do not include the height of
the shoe lug.
2.1 5.05m (167) Boom+2.60m (86) Arm+0.75m3 (0.98cu yd) Bucket

Unit : mm (ft-in)
E200SR
E200SRLC
Unit : mm (ft-in)
2
3. WEIGHT OF COMPONENTS
Unit : kg (lb)
Model
Item
E200SR (600mm Shoe
2.6m Arm )
E200SR (
LC
600mm Shoe
2.6m Arm )
Machine complete 19,900 (43,870) 20,400 (44,970)
1. Upper frame assy (including the following :) 9,880 (21,780)
1.1 Upper frame 2,110 (4,650)
1.2 Counterweight 4,620 (10,900)
1.3 Counterweight (ADD-on)
1.4 Cab 200 (440)
1.5 Engine 370 (815)
*
1.6 Hydraulic oil tank 125 (280)
*
1.7 Fuel tank 125 (280)
*
1.8 Slewing motor (including reduction unit) 220 (485)
1.9 Control valve 130 (290)
1.10 Boom cylinder 170 (370)
*
1.11 Pin (for mounting boom) 40 (90)
1.12 Pump 90 (200)
1.13 Radiator & oil color 99 (220)
2. Lower frame assy (including the following :) 7,130 (15,720) 7,630 (16,820)
2.1 Lower frame 2,450 (5,400) 2,650 (5,840)
2.2 Slewing bearing 245 (540)
2.3 Travel motor (including reduction unit) 250 (550)X2
2.4 Upper roller 22 (48)X4
2.5 Lower roller 35 (77)X14 35 (77)X16
2.6 Front idler 106 (230)X2
2.7 Idler adjuster 150 (330)X2
2.8 Sprocket 54 (120)X2
2.9 Swivel joint 30 (66)
2.10 Track link with 600mm (24in) shoe assy 1,260 (2,780)X2 1,420 (3,130)X2
Track link with 700mm (28in) shoe assy 1,360 (3,000)X2
2.11 Track link assy 510 (1,120)X2 540 (1,190)X2
3. Attachment (including the following) 2,890 (6,370)
3.1 Bucket assy (Japanese standard bucket) 640 (1,410)
3.2 Arm assy (including the following :) 890 (1,960)
3.2.1 Arm 550 (1,210)
*
3.2.2 Bucket cylinder 125 (280)
3.2.3 Idler link 20 (44)X2
3.2.4 Bucket link 80 (180)
3.2.5 Pin (2pcs. for mounting bucket cylinder/2pcs. for mounting bucket) 70 (150)
3.3 Boom assy 1,390 (3,060)
3.3.1 Boom 1,100 (2,430)
3.3.2 Arm cylinder 195 (430)
*
3.3.3 Pin (Mounting armMounting arm cylinde 40 (88)
4. Lubricant and water (including the following :) 440 (970)
4.1 Hydraulic oil 185 (410)
4.2 Engine oil 11 (24)
4.3 Fuel 225 (500)
4.4 Water 19 (40)
NOTE : Numerical values marked * indicate the dry weight.
3
4. TRANSPORTATION DIMENSION AND WEIGHT
4.1
OVERALL DIMENSIONS OF A COMPLETE MACHINE ON A TRAILER
[ 5.05m (16ft-7in) Boom+2.60m (8ft-6in) Arm+0.75m3 (0.9cuyd) Bucket ]
NOTE :
This illistration is for demonstration purposes only.
Always, make sure to check actual dimensions
after machine is loaded on trailer.

#

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OVERALL DIMENSIONS OF BOOM

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4
OVERALL DIMENSIONS OF ARM AND BUCKET

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OVERALL DIMENSIONS OF ARM

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OVERALL DIMENSIONS OF BUCKET

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Hoe bucket
H
5
5. SPECIFICATIONS AND PERFORMANCE
SPEED AND CLIMBING CAPABILITY

DESCRIPTION SPECIFICATIONS
Swing speed 11 rpm
Travel speed (1-speed/2-speed) km/h 3.5 / 5.0 (2.2 / 3.1)

(mile/h)
Gradeability %(degree) 70 (35)
ENGINE
Enging model ISUZU AA-4BG1 TC
Type Water-cooled, 4-cycle direct injection type engine

with turbo charger & inter cooler
Number of cylinders - Bore X Stroke 4 - 105mm X 125mm (4.13in X 4.92in)
Total displacement 4,329cc (264cuin)
Rated output / Rotation speed 91.9kW (125PS) / 2,200rpm
Maximum torque / Rotation speed 42.5kgfm (308lbfft) / 1,800rpm
Starter 24V/ 4.5kW
Alternator 24V / 40A
HYDRAULIC COMPONENTS
Hydraulic pump Variable displacement axial piston + gear pump
Hydraulic motor (swing) Axial piston motor
Hydraulic motor (travel) 2-speed axial piston motor
Control valve 6-spool control valve
Cylinder Double action cylinder

(Boom, Arm, Bucket)
Oil cooler Air -cooled type
Unit : kg (lb)
WEIGHT E200SR (600mm

2.6m Arm )
Shoe
E200SR (
LC
2.6m Arm )
600mm Shoe
E200SRLC (800mm
3.0m Arm )
Shoe
Fully equipped weight 19,900 (43,870) 20,400 (44,970) 22,000 (48,500)
Upper structure 9,880 (21,780) 10,500 (23,150)
Lower machinery 7,130 (15,720) 7,630 (16,820) 8,200 (18,100)
Attachment 2,890 (6,370) 3,300 (7,280)

(Boom + Arm + Bucket)
6
6. TYPE OF CRAWLER

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$"" % '("" ()!* ",#" -,!!
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!"" # '%"" ()* ",#! !,-
NOTE :
Use 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.)
damage.
7
7. TYPE OF BUCKET
,

.
,
/ 01+,+
*

1+ * +,
!" %$ '$ $$ 23 !&
!" &7"8 &7%8 "-"!
% '& #$ ' ! 23 !
%" 78 &8""8 "-
$ & !& "-' ' ! 23 %
%' 7%8 78 "-
() !% "-"& "-& ! 23 %#
$! ' $ 7'8 7#8 "-#"
' " ! "-"% "-% ! 23 %!
$$ 7"8 7%8 "-#
+ * , * 4 '*

"-% +,
6 1+ 1+,+
8
8. COMBINATIONS OF ATTACHMENT
% 3# ' 4('(

2

!" #$
0
10
$ ' 0
0 0
00
($ #*+ ' /-/
, - . 0 - 0
% )$
&''( )$
NOTE :
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 the Manufacturer. Reinforcement of arm allows to use it as
nibbler and breaker.
The trouble due to the use in the condition Use not allowed described in the above table is not in-
cluded in our responsibility
When bucket marked by has been attached or nibbler has been attached on long arm, the specified
stability may not be obtained. So attach add-on type counterweight (1,000kg : 2,200lb) in as required.
If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to
the arm and bucket may occur.
9
9. ENGINE SPECIFICATION
9.1 SPECIFICATIONS
Model E200SR(LC)
Engine model ISUZU AA-4BG1 TC
Type Diesel, 4-cycle water-cooled, in-line,

direct injection, turbo charged & inter cooled
Number of cylinder X mm (in) 4 X 105 X 125 (4.13 X 4.92)
Bore X Stroke
Total displacement cc (cuin) 4,329 (264)
Compression ratio 18.0
Rated out put PS (kW) at rpm 125 (91.9) at 2,200

Maximum kgfm (lbfft) at rpm 42.5 (308) at 1,800
torque
High idling rpm 2,420 30
Low idling rpm 1,000 25

Injection valve kgf/cm2 (psi) 185 (2,630)
opening pressure
Thermostat action C (F) 82 / 95 (180 / 203)
Start/Full open
Firing order 1-3-4-2
Compression kgf/cm2 (psi) 31 (440)
pressure
Lubrication kgf/cm2 (psi) at rpm
oil pressure
Fuel injection timing 9 before top dead point
Valve clearance Open Close
Valve clearance Intake valve 0.4mm (0.016") 19 before 47 after

in cold condition top dead point bottom dead point
Exhaust valve 0.4mm (0.016") 57 before 15 after

in cold condition bottom dead point top dead point
Starter capacity V X kW 24 X 4.5

Thermostat action VXA 24 X 40
Start/Full open
Cooling fan drive method 550 (21.7") suction type 8 fans, V-belt drive,
pulley ratio Crank / Fan= 1.01
Engine oil quantity l (gal) Full level 13 (3.4)
Low level sensor actuation 11 (2.9)
Dry weight kg (lb) 370 (820)
Fuel consumption ratio g/PSh 174 10
Allowable inclination Front / Rear and Right / Left : 35
Dimension (L X W X H) mm (in) 894 X 746 X 861 (35.2 X 29.4 X 33.9)
Rotating direction Counterclockwise seeing from flywheel side
10
9.2 ENGINE CHARACTERISTIC CURVE (ISUZU AA-4GB1 TC)

Condition to be measured : With fan, generator and
without air cleaner and muffler

# $%%&'( )*+

,- $%%&'(-&%.

/-/0-#
)*+
,0-&%.

0)*+
,0&%.

!"

#0
)*+
,#0&%.

1" 2 )*+ 3&%4
567 8'*95%:)'* ;'756

567 8'*95%:)'* &$:6
< = = '$> $8:'& , .
- =
# ? :$*>$&> 7'$> $8:'&
< - = = = ,-#A-.
< 567 8'*95%:)'* )* &657$& '%6&$:)'*

,7'$> $8:'& ? -#A-.
-A-
11 1
E200SR
SECTION 3 ATTACHMENT DIMENSIONS
TABLE OF CONTENTS
1. BOOM
1.1 Boom dimensional drawing ................................................................................................... 1
1.2 Boom maintenance standard ................................................................................................ 2
2. ARM
2.1 Arm dimensional drawing ...................................................................................................... 4
2.2 Arm maintenance standard .................................................................................................... 5
3. BUCKET
3.1 Bucket dimensional drawing ................................................................................................. 7
3.2 Bucket dimensional table ...................................................................................................... 7
3.3 Detail dimensional drawing of lug section ............................................................................. 8
3.4 Detail dimensional drawing of boss section ........................................................................... 9
1. BOOM
1.1 BOOM DIMENSIONAL DRAWING
SECTION B-B
Fig. 1-1 Boom dimensional drawing
Table 1-1 Unit : mm (ft-in)

5.05M (16ft-7in) BOOM
Code NAME DIMENSION
A Boom length 5,050 (167 )
B Boom foot width 612 (24.1 )
C Boom end inner width 287 (11.3 )
D Boom end outer width 421 (16.6 )
E Height of boom cylinder rod pin 1,023 (34 )
F Height of arm cylinder (head side) pin 1,132 (39 )
G Distance between pins of boss R 2,344.5 (78 )
H Distance between pins of bracket R 2,435 (712 )
I Arm cylinder (head side) inner width 122 (4.8 )
J Outer width of bracket on the boom cylinder 426 (16.8 )
d1 Boom foot pin dia. 90 (3.54 )
d2 Boom cylinder (rod side) pin dia. 85 (3.35 )
d3 Pin dia. of boom end. 80 (3.15 )
d4 Arm cylinder (head side) pin dia. 80 (3.15 )
1
1.2 BOOM MAINTENANCE STANDARD

(1) Clearance of pin and bushing
Fig. 1-2 Clearance of pin and bushing
Table 1-2 Unit : mm (in)
Standard value Clearance

Code Item
Pin dia. Bushing ID Standard Repairable Service Remedy
Pin dia. tolerance tolerance value level limit
+0.204 +0.224
fl90 (+0.0080) (+0.0088)
A Boom foot (3.5433) +0.020 +0.073 +0.053
(+0.0008) (+0.0029) (+0.0021)
Boom cylinder -0.020
B (-0.0008) +0.210 +0.230 More than Replace
(Head side) fl85 (+0.0083) (+0.0091) 2.0 2.5
+0.057 +0.037 (0.1) bushing
Boom cylinder (3.34645) (0.08) or pin
C (Rod side) (+0.0022) (+0.0015)
-0.050 +0.180 +0.290
D Arm cylinder fl80 (-0.0020) (+0.0071) (+0.0114)
(Head side) (3.1496) -0.110 +0.100 +0.150
(-0.0043) (+0.0039) (+0.0059)
2
(2) Clearance in thrust direction
SECTION C-C
SECTION A-A
SECTION D-D SECTION B-B
Fig. 1-3 Clearance in thrust direction

Basic size Shim adjusting clearance Length under
Sec- (Total of both sides) pin neck
Item Remedy
tion Sym- Size Standard Repairable Service
bol value level limit No. Length
Boom 612 (24.1) 0.5 (0.02) 768
A-A Boom foot L1 1 (30.2)
Upper frame 614 (24.2) or less
2.0 2.5
Boom cylinder 105 (4.13) (0.08) (0.10) 217
B-B Boom cylinder L2 0.6~1.0
(0.02~0.04) 2 (8.54)
(Head side) Upper frame 107 (4.21) Shim
adjustment
Boom cylinder L3 105 (4.13) 0.6~2.0 3.0 4.0
C-C Boom cylinder 3 690
(Rod side) Boom L3 426 (16.8) (0.02~0.08) (0.12) (0.16) (27.2)
Arm cylinder Arm cylinder 120 (4.72) 0.6~1.0 2.0 2.5 249
D-D (Head side) L4 (0.08) 4 (9.8)
Arm 122 (4.8) (0.02~0.04) (0.10)
3
2. ARM
2.1-1 ARM DIMENSIONAL DRAWING
F G
D H
R
D1 D2 O
d5 d3
L
K
d1 d2
SECTION A-A VEIW I
D4 d4
SECTION B-B
Fig. 2-1 Arm dimensional drawing
Table 2-1

" .;. " .;.
;<"" " ;<"" "
"# $%& 0122 3415 9 '' +& 31 / 5
'() *+ ,' 6 ! 3/75 9#()- # +& /35
* '' ( *#()-
./ * '' 87! /65 9#()- # +& 2 /25
./ * '' 83! / !5 .$# $- ' 12 5
./ * '' 87! /65 9:)- $- ' 122 /15
'() *+ ,' 0 6 64 %& *+ ,' ! / 35
* '' ( *#()- * '' ( )#
'() *+ ,' 2 1/!5 (/ 832 /!5
* '' ( * ''
%& *+ ,' 1 /15 (/ 862 /615
* '' ( *#()-
%& *+ ,' 1! 2/5 (/ 832 /!5
* '' ( *#()-
"# , * '' +& ! /35 (/ 832 /!5
"# $- ') * '' +& 2 /15 ! (/ 832 /!5
4
2.2 ARM MAINTENANCE STANDARD

(1) Clearance of pin and bushing
Standard value Clearance

Code Item
Pin dia. Bushing ID Standard Repairable Service Remedy
Pin dia. tolerance tolerance value level limit
+0.226 +0.286
Arm point (+0.0089) (+0.0113)
A -0.020 +0.153 +0.173
80 (-0.0008) (+0.0060) (+0.0068)
(3.1496) -0.060 +0.231 +0.291
(-0.0024)
Bucket link (+0.0091) (+0.0115)
B (Bucket connection) +0.161 +0.181
(+0.0063) (+0.0071)
+0.240 +0.300
Idler link 70 (+0.0094) (+0.0118)
C (Arm connection) (2.7559) +0.174 +0.174
(+0.0069) (+0.0069)
+0.000 +0.287
Bucket link (+0.0000) (+0.0113)
D (Idler link connection) -0.060 +0.155
(-0.0024) +0.227 (+0.0061)
(+0.0089)
+0.155 +0.287
Bucket cylinder (+0.0061) (+0.0113)
D (Rod side) +0.155
(+0.0061) 2.0 2.5 Replace
(0.08) (0.1) bushing
+0.020 +0.250 or pin
(+0.0008) (+0.0098)
-0.020 +0.230 +0.130
Bucket cylinder (-0.0008) (+0.0091) (+0.0051)
E (Head side) +0.150
+0.030 +0.260
80 (+0.0012) (+0.0059) (+0.0102)
(3.1496) -0.030 +0.120
(-0.0012) (+0.0047)
-0.050 +0.180 +0.290
Arm cylinder (-0.0020) (+0.0071) (+0.0114)
F (Rod side) -0.110 +0.100 +0.150
(-0.0043) (+0.0039) (+0.0059)
+0.020 +0.244 +0.264
(+0.0008) (+0.0096) (+0.0104)
G Arm foot -0.020 +0.174 +0.154
(-0.0008) (+0.0069) (+0.0061)
5
(2) Clearance in thrust direction
SECTION F-F
SECTION A-A SECTION C-C
SECTION E-E
SECTION B-B
SECTION D-D,D-D SECTION G-G
Table 2-4 4 5 $$

'$ ()* + &, + ' *(,
- & . % ' ( 1 2

6 $
#$

(,( 01,%&
,/ 3 + ' 0$(#
%& /&* &/& &$
,$ 1 ,$ "7
8
*2 8
*2 &2 2 ( "7 8 87
" 8"
*2
6(&, &2 ,$ , &
,$ 2 (
9
*2 &2 0( ( 9 7
6(&, &2 2 (
'$

0( ( 7 8 8 ()* $
*2
0( (
&2
*2 &2 (
*2 #&(, :( ( !
7
:( ( ,$ 7
78
,$ #&(, 0( ( !
"

0( ( ,$ 8 8
,$ . ,$ 8 , & 7
$ " 8" " 7
6
3. BUCKET
3.1 BUCKET DIMENSIONAL DRAWING

(1) Hoe bucket
Fig. 3-1 Hoe bucket dimensional drawing
Table 3-1
No. NAME No. NAME
A Distance between pin and bracket G Outer width of bucket bottom
B Distance between bucket pin and tooth end H Bucket outer width of front side
C Inner width of bucket top end I Pitch between teeth
D Inner width of lug I0 Pitch between teeth
E Inner width of bracket d1 Outer dia. of bushing
F Outer width of side cutter d2 Pin dia.
3.2 BUCKET DIMENSIONAL TABLE

Hoe bucket
Type [STD]
Capacity 0.75m3 (0.98cuyd) 0.63m3 (0.82cuyd)
A 445 (17.5 )
B R1,440 (49 )
C 964 (38 ) 830 (32.7 )
D 399 (15.7 )
E 327 (12.9 )
F 1,122 (38 ) 989 (389 )
G 826 (32.5 ) 693 (27.3 )
H 1,020 (34 ) 887 (34.9 )
I 214 (8.43 ) 180.5 (7.11 )
I0 213.5 (8.41 ) 180.5 (7.11 )
d1 95 (3.74 )
d2 80 (3.15 )
7
3.3 DETAIL DIMENSIONAL DRAWING OF LUG SECTION
VIEW II
Boss X
Boss Y
DETAIL I
Fig. 3-2 Dimension of lug section
Table 3-3
Unit : mm (ft-in)
Lug plate thickness
Screw hole P.C.D

Boss outer dia.
Boss outer dia.

Bushing length
Capacity
Spring pin dia.
Type of
Pin hole dia.
of bucket
Boss width.
Boss width.
bucket
Screw dia.
m3 (cuyd)
Hole dia.
A B C D E F G H J M N
[STD]
Hoe bucket 0.75 (0.98) 80 25 67 95 13 180
M16
25 170 36 140
(3.15) (0.984) (2.64) (3.74) (0.512) (7.09) (0.984) (6.69) (1.42) (5.51)
0.63 (0.82)
8
3.4 DETAIL DIMENSIONAL DRAWING OF BOSS SECTION
G H 5 (0.2 )
D
C
B
A
15 (0.59 )
DETAIL K
E
Fig. 3-3 Dimension of boss section

Capacity
Type of of bucket A B C D E F G H I
bucket m3 (cuyd)
[STD] 114.3 84 105.5 111.5 27 42 17 13 3.0

0.75 (0.98) (4.50) (3.31) (4.15) (4.39) (1.06) (1.65) (0.669) (0.512) (0.118)
Hoe bucket
23 38
0.63 (0.82) (0.91) (1.50)
9
10
E200SR
SECTION 11 TOOLS
TABLE OF CONTENTS
1.TIGHTENING TORQUES FOR CAPSCREWS AND NUTS ......................................... 1
2. SCREW SIZE ............................................................................................................ 2
3. TIGHTENING TORQUES FOR NUTS AND SLEEVES .............................................. 3
4. PLUG ......................................................................................................................... 4
5. SPECIAL SPANNER FOR TUBE ............................................................................... 7
6. SPECIAL TOOLS ...................................................................................................... 8
7. APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND ..... 10
8. SUCTION STOPPER ................................................................................................ 11
9. COUNTER WEIGHT LIFTING JIG ........................................................................... 12
10. UPPER FRAME LIFTING JIG ............................................................................... 13
11. ENGINE MOUNTING PEDESTAL .......................................................................... 14
12. TRACK SPRING SET JIG ..................................................................................... 14

1. TIGHTENING TORQUES FOR CAPSCREWS AND NUTS

Tables 1-1 and 1-2 indicate tightening torques Insufficient tightening may lead to a loosening or
applicable to cases where no special note is given. loss of bolts. Always tighten bolts to proper
Overtightening of bolts may result in a twist-off torques.
and a fracture under load.
Table 1-1 Tightening torque for coarse thread metric screws (not plated) unit : kgfym (lbfyft)
Strength
grade 4.8T 7T 10.9T
Size Use No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
0.450.05 0.380.04 0.980.1 0.830.08 1.770.18 1.50.15
M6 P=1
(3.30.4 ) (2.70.3) (7.10.7) (6.00.6) (131) (111)
1.090.11 0.920.09 2.40.2 2.00.2 4.30.4 3.60.4
M8 P=1.25
(7.90.8) (6.70.7) (171) (141) (323) (263)
2.20.2 1.830.18 4.70.5 4.00.4 8.50.9 7.20.7
M10 P=1.5 (161) (131) (344) (293) (617) (525)
M12 3.70.4 3.20.3 8.10.8 6.80.7 14.61.5 12.31.2
P=1.75 (273) (232) (596) (495) (11011) (899)
5.90.6 5.00.5 12.81.3 10.81.1 232 19.51.9
M14 P=2 (434) (364) (939) (788) (17014) (14014)
9.00.9 7.60.7 19.52.0 16.41.6 354 293
M16 P=2
(657) (555) (14014) (12012) (25029) (21022)
12.41.2 10.51.0 273 232 495 414
M18 P=2.5
(909) (767) (20022) (17014) (35036) (30029)
17.51.7 14.71.4 384 323 687 576
M20 P=2.5
(13012) (11010) (27029) (23022) (49051) (41043)
232 19.62.0 515 434 929 778
M22 P=2.5
(17014) (14014) (37036) (31029) (67065) (56058)
303 243 657 535 11812 9610
M24 P=3 (22022) (17022) (47051) (38036) (85087) (69072)
444 364 9610 788 17317 14014
M27 P=3 (32029) (26029) (69072) (56058) (1300120) (1000100)
606 505 13113 11011 23524 19820
M30 P=3.5 (43043) (36036) (95094) (80080) (1700170) (1400140)
818 687 17618 14815 31732 26627
M33 P=3.5
(59058) (49051) (1300130) (1100110) (2300230) (1900200)
10510 889 22723 19019 40941 34334
M36 P=4
(76072) (64065) (1600170) (1400140) (3000300) (2500250)
Table 1-2 Tightening torques for fine threads metric screws (not plated) unit : kgfym (lbfyft)
Strength
grade 4.8T 7T 10.9T
Size Use No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
1.150.11 0.970.1 2.50.2 2.10.2 4.50.4 3.80.4
M8 P=1
(8.30.8) (7.00.7) (181) (151) (333) (273)
M10 2.30.2 1.910.19 4.90.5 4.20.4 8.90.9 7.50.7
P=1.25 (171) (141) (354) (303) (647) (545)
M12 4.00.4 3.40.3 8.70.9 7.30.7 15.71.6 13.21.3
P=1.25 (293) (252) (637) (535) (11012) (959)
9.40.9 7.90.8 202 17.21.7 374 313
M16 P=1.5 (687) (576) (14014) (12012) (27029) (22022)
191.9 15.81.6 414 343 747 626
M20 P=1.5 (14014) (11012) (30029) (25022) (54051) (45043)
323 273 707 586 12612 10510
M24 P=2
(23022) (20022) (51051) (42043) (91087) (76072)
656 545 14214 11812 25526 21221
M30 P=2
(47043) (39036) (1000100) (85087) (1800190) (1500150)
879 727 19019 15816 34134 28428
M33 P=2
(63065) (52051) (1400140) (1100120) (2500250) (2100200)
10911 919 23823 19820 42843 35736
M36 P=3
(79080) (66065) (1700170) (1400140) (3100310) (2600260)
1
2. SCREW SIZE
(1) Capscrew (2) Socket bolt

d d
B
B
Table 2-1 Table 2-2 Table 2-3

Nominal B mm Nominal B mm Nominal B mm
screw size screw size screw size
Tool Unified Tool Tool
(d) size (d) size
size (screw threads)
M6 10 1/4-20UNC 11 M6 5
M8 13 5/16-18UNC 13 M8 6
M10 17 3/8-16UNC 14 M10 8
M12 19 7/16-14UNC 16 M12 10
(M14) (22) 1/2-13UNC 19 M14 12
M16 24 5/8-11UNC 24 M16 14
(M18) (27) 3/4-10UNC 29 (M18) 14
M20 30 7/8-9UNC 33 M20 17
(M22) 32 1-8UNC 38 M24 19
M24 36 1 1/8-7UN 43 M30 22
(M27) (41) 1 1/4-7UN 48 M36 27
M30 46 1 1/2-6UN 57 M42 32
M36 55 M48 36
M42 65 M52 36
M45 70
M48 75
(3) Set screw Table 2-4
M56 85
Nominal B mm
(M60) 90
screw size
M64 95 Tool
(d) size
(M68) 100
M72 105 d M2.5 1.27
M76 110 M3 1.5
M80 115 M4 2
M5 2.5
M6 3
B M8 4
M10 5
M12 6
M16 8
M20 10
2
3. TIGHTENING TORQUES FOR NUTS AND SLEEVES

Table 3 indicates standard tightening torques sleeves in flareless joint may develop oil leaks
applicable to cases where no particular note is through pipe connections.
given. Always tighten nuts and sleeves to proper
Overtightening or undertightening of nuts and torques.
Table 3-1
Working pressure Tube size Opposing Tightening torque
Manufacturers name OD thickness
kgf / cm (psi)
2
mm (in) flats (HEX) kgfm (lbfft)
10 1.5 19 5 1
(0.394 0.059) (36 7)
15 2.0 27 12 1.2
(0.591 0.079) (87 9)
300 18 2.5 15 1.5
Nippon A.M.C. 32
(4270) (0.709 0.098) (108 11)
22 3.0 36 22 2.2
(0.866 0.118) (159 16)
28 4.0 41 28 2.8
(1.10 0.157) (200 20)
300 35 5.0 45 4.5
Ihara Koatu 55
(4270) (1.38 0.197) (330 33)
Table 3-2
SLEEVE NUT
B
d d
Parts No. Opposing Parts No.

Tube size Tube size
flats (HEX)
d Ihara Koatu Nippon A.M.C. d B Ihara Koatu Nippon A.M.C.
6 6 14
8 8 17
10 10 19
12 12 22
15 15 27
18 18 32
22 22 36
28 28 41
32 32 50
35 35 55
38 38 60
3
4. PLUG
(1) Plug for hydraulic pipe joint
Table 4-1
1) Cap nut (Plug for joint)
Applicable Opposing flat
pipe Cap nut parts No. T screw
O. D : A H1 H
6 M12 1.5 14 14
8 M14 1.5 17 17
10 M16 1.5 17 19
12 M18 1.5 19 22
15 M22 1.5 24 27
18 M26 1.5 27 32
H1 T screw H 22 M30 1.5 32 36
28 M36 1.5 38 41
Table 4-2
2) Plug (Plug for tube)
Applicable
pipe Plug parts No.
O. D : A
6
8
10
12
15
Flareless 18
joint body Nut 22
28
3) Nut Table 4-3

HEX
Applicable Opposing
pipe Nut parts No. D screw
O. D : A flat
D screw 6 M12 1.5 14
8 M14 1.5 17
10 M16 1.5 19
12 M18 1.5 22
15 M22 1.5 27
18 M26 1.5 32
22 M30 1.5 36
28 M36 1.5 41
32 M42 1.5 50
35 M45 1.5 55
38 M48 1.5 60
4
(2) Plug for hydraulic equipment

1) PF(G) screw
B Table 4-4
O ring PF (G) O ring parts Norminal
screw Plug parts No. B mm No. O ring
PF 1/4 19 1B P11
PF 3/8 22 1B P14
PF 1/2 27 1B P18
PF 3/4 36 1B P24
PF screw PF 1 41 1B P29
2) PT(R) screw
Table 4-5
PT(R) Plug parts No. B mm
B screw
PT(R) screw
PT 1/8 5
PT 1/4 6
PT 3/8 8
PT 1/2 10
PT 3/4 14
PT 1 17
PT 1 1/4 22
PT 1 1/2 22
(3) Plug for (F) flare hose

Table 4-6
PF(G) screw
PF(G) Plug parts No. B mm
screw
PF 1/4 14
PF 3/8 17
PF 1/2 22
Opposing
flat B PF 3/4 27
PF 1 36
Table 4-7
PF (G) Plug parts No. E mm F mm
screw
PF 1/4 14 19
PF(G) PF 3/8 17 22
screw
PF 1/2 23 27
Opposing Opposing PF 3/4 27 36
flat F flat E PF 1 36 41
PF 1 1/4 40 50
5
(4) Plug for ORS joints

Male
O RING
Table 4-8
Applicable O ring parts Norminal
Opposing
Screw size A hose Plug parts No.
O.D flats(HEX) No. O ring
A 1-14UNS 21.7 27 1B A16
1 3/16-12UN 27.2 36 1B A18
1 7/16-12UN 34.0 41 1B A21
HEX
Female Table 4-9

Applicable
Opposing
Screw size A tube Plug parts No.
O.D flats(HEX)
A 1-14UNS 21.7 32
1 3/16-12UN 27.2 36
1 7/16-12UN 34.0 41
HEX
6
5. SPECIAL SPANNER FOR TUBE

Table 5-1
Applicable tube diameter HEX
Part No. Shape mm (in)
mm (in) mm
70 (2.76)
8(0.315)
15 16
27 (0.630) PART-No. 22(0.866)
(0.591)
HEX27 40(1.57)
12.7
0.3
0.1 ( 0.500 0.012
0.004 )
70 (2.76)
42(1.65)
18 19 22(0.866)
32 (0.748) PART-No.
(0.709)
22(0.866)
HEX32 12.7 0.3
0.1 ( 0.500 0.012
0.004 )
70 (2.76)
40(1.57)
22 19
PART-No. 22(0.866)
30 (0.748)
(0.866)
22(0.866)
HEX30 12.7 0.3
0.1 ( 0.500 0.012
0.004 )
48 (1.89) 70 (2.76)
11.5 (0.453)
22 23
36 PART-No. 22(0.866)
(0.866) (0.906)
HEX36 12.7 0.3

0.1 ( 0.500 0.012
0.004 )
60 (2.36) 109 (4.29)
14.5 (0.571)
28 29
41 PART-No. 22(0.866)
(1.10) (1.14)
HEX41
12.7
0.3
0.1 ( 0.500 0.012
0.004 )
80 (3.15) 109 (4.29)
28 31
PART-No. 35(1.38)
46 (1.22)
(1.10)
HEX46 19.05
0.5
0.1 ( 0.750 0.020
0.004 )
80 (3.15) 109 (4.29)
32 33 PART-No. 35(1.38)
50 (1.30)
(1.26)
HEX50
19.05 0.5
0.1 ( 0.750 0.020
0.004 )
7
6. SPECIAL TOOLS
Table 6-1
No. Tools name Tools No. Shape Use
Allen wrench Pump

1
Nominal B : 10 suction
Commercial tool length (L1) cut length = Required

length

40(1.57 ) 10(0.39 ) = 30(1.18 )
Allen wrench Pump

2
Nominal B : 14 install
Commercial tool length (L1) cut length = Required

length

56(2.20 ) 11(0.43 ) = 45(1.77 )
Cut
Swing
Spanner
3 motor
Nominal S : 32
A,B port
Commercial tool outer width (D) cut length = Required length

73(2.87 ) 13(0.51 ) = 65(2.56 )
Additional M10 22 For

Plug threading slinging
4 for M10 eye bolt
PF3/4 the swing
motor
PF3/4 O ring
For
Eye bolt slinging
M10 18 the swing
5
motor
&
M10 Flare hose
8
Table 6-2
No. Tools name Tools No. Shape Use

M8 Eye bolt
Plug
(Nominal
tube dia. 22 )
Nut Flare hose
6 (Reference)
Eye bolt
Nut M8 18
Additional
threading for
M8 Eye bolt
M8 Eye bolt
M8 18
Additional
Plug threading
Nominal
7 Flare hose
1-14UNS
Eye bolt
M8 Eye bolt
M8 18
Additional
threading
Plug
Nominal
8 Flare hose
1 3/16-12UN
Eye bolt
For slinging the

Eye bolt swing motor
9
M8 15 &
Flare hose
M8
M8 20
Plug Additional For slinging the
10
PF1/2 threading for
swivel joint
M8 Eye bolt
O RING
PF1/2
9
7. APPLICATION OF SCREW LOCKING

COMPOUND AND SEALING COMPOUND
(1) For general use
Table 7-1
Manufacturer
Use Features
Locktite Three-Bond
#242 1360K Low strength

Application of
screw locking #262 1374 Middle strength
compound
#271 1305 High strength
Sealing
compound #515 1215 Sealing
(2) For specific location

Table 7-2
Use Manufacturer Name Equivalent Location
(Manufacture ; Locktite)
#1901 Anti-seizure Cylinder
#1215 gray #5699 Swing motor

Three-Bond
#1211 white #5301J Swing motor
#1303B #211 Main pump
(Manufacturer ; Three-Bond)
Sealing
compound #222 #1344N Main pump
& Locktite
adhesive #277 #1307N Pilot valve
(Manufacture ; Three-Bond)
Locktite Parmatex 98D #1121 Hydraulic oil tank : Hose

Sumitomo Locktite #515
Chemical Cyano Bond P01 For swing bearing : Seal
Co., Ltd. Three-Bond #1215
Showa-Shell Shell Alvania EP2 New Molyknock Grease 2 Swing bearing grease
petroleum bath
10
8. SUCTION STOPPER
8.1 COMPONENTS

No. NAME PARTS No. Q TY
SUCTION STOPPER ASSY
1 ROD 1
1 Rod
2 NUT 1
3 COVER 1
4 O RING 1
2 Nut
3 Cover
4 O ring
8.2 DIMENSION
50
(1.97 ) Fig. 8-1 Components of suction stopper
113 (4.45 )
2
M8 NUT
9(0.354 )
M8 100 +0.5
0
(3.94 +0.0197
0 )
108
(4.25 )
ROD COVER
fig. 8-2 Dimension of suction stopper
11
9. COUNTER WEIGHT LIFTING JIG

(1) Use these jigs for the standard counter
weight lifting tools.
QTY : R.H. and L.H. as pairs
Fig. Counter weight lifting jig
(2) Use two commercial eye bolts M24 for the

lifting tools for the additional weight
(knapsack type).
M24
12
10. UPPER FRAME LIFTING JIG
SECTION AA
Q'ty : 2set
Fig. 10-1 Upper frame lifting jig
13
11. ENGINE MOUNTING PEDESTAL

Note) Hold the oil pan
section of engine.
Material : Plywood or wooden plate

Fig. 11-1 Engine stand
12. TRACK SPRING SET JIG
M30
Retainer nut
Retainer plate
Stand
Hydraulic jack
Base
Fig. 12-1 Track spring set jig
14
E200SR
SECTION 12 STANDARD MAINTENANCE TIME SCHEDULE
TABLE OF CONTENTS
1. STANDARD MAINTENANCE TIME SCHEDULE FOR EXCAVATOR ....................... 1-1

01. Attachment ......................................................................................................................... 1-1
02. Cab & Guard ...................................................................................................................... 1-2
03. Swing frame ....................................................................................................................... 1-3
04. Travel system .................................................................................................................... 1-6
06. Electric equipment ............................................................................................................. 1-7
2. STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF ENGINE ...... 2-1
1. STANDARD MAINTENANCE TIME SCHEDULE FOR EXCAVATOR

(1) Standard maintenance time schedule (2) Classification of working code
1) Units of working time : 6 minutes=0.1 hour
No. Group Remarks
2) Calculating method of standard maintenance
01 Attachment Indicates installing,
time : 02 Cab & Guard
03 Swing frame removing, replacement
Maintenance time=Working time
04 Travel system and overhaul.
the number of workers
06 Electric Indicates the installing,
(Working time=Maintenance time equipments removing and
the number of workers) replacement of single
3) When more than one operation is going on : items.
Add each standard service time. 09 E/G relation Indicates overhaul of the
single engine.
A pure time (readily started) is given except (Materials prepared by
covers easily removed by hand. Assy works manufacturer )
include the following works marked with
black dot . (3) Conditions for standard service time of the
4)O/H : Basically the installing and removing engine
operations are not included. 1) Tools designated by E/G maker are used
5) Abbreviations in the table. 2) Genuine parts are changed
A/C ; Air conditioner F hose ; Flexible hose 3) Correct working procedures are observed.
ASSY ; Assembly O/H ; Over haul The time required for works specified
ATT ; Attachment SOL ; Solenoid in this Chapter shows the total time
BRG ; Bearing SW ; Switch for maintenance.
C/V ; Control valve V ; Valve
Cyl ; Cylinder
E/G ; Engine Unit : Hour
Work to be E200SR
Group Location Unit Remark
done E200SRLC
00 Bucket relation 2. Reference for bucket
01 Bucket ASSY Detach/attach 1 pc. Include adjustment. 0.6
02 Bucket attaching and detaching position Preparation 1 pc. 0.1
03 Bucket attaching pin Detach/attach 1 Include lock pin. 0.1
04 Bucket drive pin Detach/attach 1 0.1
05 Bucket sling and movement Preparation 1 pc. 0.2
06 Bucket (single) O/H 1 pc. Not include attaching and detaching. 2.4
07 Tooth Replace 1 pc. 0.6
08 Side cutter Replace 1 pc. 1.2
09 Bushing Replace 1 pc. 0.6
01 Attachment
10 Arm relation 3. Reference for arm

11 Arm ASSY Detach/attach 1 pc. 1.2
Bucket cylinder attaching and detaching
12 position and piping Preparation 1 pc. 0.4
13 Bucket cylinder rod pin Detach/attach 1 pc. Include lock pin. 0.1
14 Bucket cylinder head pin Detach/attach 1 pc. Include lock pin. 0.1
15 Bucket cylinder assy Detach/attach 1 pc. 0.1
16 Arm cylinder rod pin Detach/attach 1 pc. Include lock pin. 0.1
17 Boom top pin Detach/attach 1 pc. Include detent of pin. 0.1
18 Arm sling and movement Detach/attach 1 pc. 0.2
30 Boom relation 4. Reference for boom

31 Boom ASSY Detach/attach 1 pc. 1.4
32 Boom attaching and detaching position Preparation 1 pc. 0.1
33 Boom cylinder temporary slinging Preparation 2 pcs. 0.2
34 Boom cylinder rod pin Detach/attach 2 pcs. Include lock two pins. 0.2
11
Unit : Hour
Group Location Work to be Unit Remark E200SR

done E200SRLC
35 Boom cylinder piping Detach/attach 2 pc. 0.2
36 Arm & bucket piping Detach/attach 1 pc. 0.2
37 Boom assy temporary slinging Detach/attach 1 pc. 0.1
38 Boom foot pin Detach/attach 1 Include lock pin. 0.2
39 Boom assy slinging Detach/attach 1 pc. 0.2
40 Arm cylinder attaching and detaching Detach/attach 1 pc. 0.4
41 Arm cylinder piping Detach/attach 1 pc. 0.2
01 Attachment
42 Arm cylinder head pin Detach/attach 1 Include lock pin. 0.1

43 Arm cylinder slinging Detach/attach 1 pc. 0.1
50 Boom cylinder attaching and detaching Detach/attach 2 pcs. 0.7
51 Boom cylinder piping Detach/attach 2 0.3
52 Boom cylinder head pin Detach/attach 2 pcs. Include lock two pins. 0.2
53 Boom cylinder slinging Detach/attach 2 0.2
60 Bucket cylinder O/H 1 3.6
61 Pin bushing Replace 1 Include seal. 1.2
70 Arm cylinder O/H 1 3.6
71 Pin bushing Replace 1 set Include seal. 1.2
80 Boom cylinder O/H 2 7.0
81 Pin bushing Replace 1 set Include seal. 1.2
10 Cab relation 1. Reference for cab

11 Cab ASSY Detach/attach 1 pc. 1.2
1 pc.
12 Front lower glass, floor mat Detach/attach each 0.1
13 Rear cover mounting bolts Detach/attach 5 places 0.2
14 Seat rear cover Detach/attach 1 pc. 0.2
15 Air-con duct Detach/attach 2 0.2
16 Coupler for gauge cluster (electric) Detach/attach 1 0.1
17 Cab slinging Detach/attach 3 places 0.4
20 Guard relation 4. Reference for guard

21 Box (1-1) Detach/attach 1 pc. 0.2
22 Box (1-2) Detach/attach 1 pc. 0.2
02 Cab & Guard
23 Panel assy (2) Detach/attach 1 pc. 0.2

24 Panel assy (3) Detach/attach 1 pc. 0.2
25 Cover (4) Detach/attach 1 pc. 0.1
26 Cover assy (5) Detach/attach 1 pc. 0.1
30 Bonnet (9) Detach/attach 1 pc. 0.2
31 Bonnet assy (10) Detach/attach 1 pc. 0.3
36 Bracket (16) Detach/attach 1 pc. 0.2
37 Bracket assy (17) Detach/attach 1 pc 0.3
38 Cover assy (18) Detach/attach 1 pc 0.2
39 Bracket (19) Detach/attach 1 pc. 0.2
41 Bracket assy (21) Detach/attach 1 pc. 0.1
43 Bracket assy (45) Detach/attach 1 pc. 0.2
1-2
Unit : Hour
Work to be E200SR
done E200SRLC
44 Guard assy (47) Detach/attach 1 pc. 0.2
45 Stay (49) Detach/attach 1 pc. 0.2
02 Cab & Guard
47 Cover (53) Detach/attach 1 pc 0.1

52 Cover relation 5. Reference for under cover

60 Counter weight relation 11. Reference for counter weight

61 Counter weight ASSY Detach/attach 1 pc. 0.6
62 Counter weight lifting jig Detach/attach 1 set 0.1
63 Counter weight temporary slinging Preparation 1 pc. 0.2
64 Counter weight mounting bolt Detach/attach 1 pc. 0.2
65 Counter weight slinging Detach/attach 1 pc. 0.1
00 Control relation
01 E/G control ASSY Detach/attach 1 pc. Include adjustment. 0.2
02 Emergency stop knob (control) cable Replace 1 pc. 0.2
10 Intake relation 9. Reference for Air cleaner

03 Swing frame
11 Air cleaner ASSY Detach/attach 1 pc. 0.4

12 Hose (3) Detach/attach 1 0.1
13 Hose (4) Detach/attach 1 0.1
14 Element Replace 1 0.1
20 Exhaust relation 10. Reference for muffler

21 Muffler ASSY Detach/attach 1 pc. 0.4
22 U bolt Detach/attach 1 pc. 0.1
23 Clamp ASSY Detach/attach 1 pc. 0.1
24 Gasket Replace 1 pc. 0.1
30 Radiator relation (Indlude inter cooler) 12. Reference for Radiator

31 Radiator ASSY Detach/attach 1 pc. 5.0
32 Coolant (LLC) Replace 1 pc. 0.2
33 Concentration of coolant Measuring 1 pc. 0.2
34 A/C condenser Detach/attach 1 pc. 0.2
35 Stay Detach/attach 1 pc. 0.1
36 Bracket Detach/attach 1 0.3
37 Sub tank Detach/attach 1 pc. 0.1
38 Fan guard Detach/attach 1 pc. 0.2
39 Water hose (radiator E/G) Detach/attach 1 0.2
40 Radiator mounting bolts removing Detach/attach 1 pc. 0.2
41 Under cover Detach/attach 1 pc. 0.1
42 Hydraulic oil tank suction stopper Attach/detach 1 pc. 0.2
Note : The numbers in the parentheses like cover(1) match the
guard numbers YB33 Upper Structure.
1-3
Unit : Hour
Work to be E200SR
done E200SRLC
43 Hydraulic oil piping coupling Detach/attach 1 pc. 1.0
44 Hydraulic oil piping Detach/attach 1 pc. 0.2
45 Water hose (E/G radiator) Detach/attach 1 0.2
46 Radiator lifting or hoisting Detach/attach 1 pc. 0.2
47 Radiator core Cleaning 1 pc 1.0
48 Inter cooler air leak Check 1 pc. 0.5
50 Fuel relation 6. Reference for fuel tank

51 Fuel tank ASSY Detach/attach 1 pc 1.8
52 Fuel Replace 1 pc. 0.3
53 Hose (water separator side) Detach/attach 2 0.1
54 Water separator Detach/attach 1 pc. 0.1
55 Tube (tank side) Detach/attach 1 0.1
57 Fuel tank installing bolts Detach/attach 1 pc. 0.3
58 Tank slinging Detach/attach 1 pc. 0.3
Other necessary works Detach/attach 1 pc. Removing and installing guard 0.4
Removing and installing battery 0.2
60 Hydraulic oil tank relation 7. Reference for hydraulic oil tank

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

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

81 Pump ASSY Detach/attach 1 pc. 2.3
82 Hydraulic oil tank cover Detach/attach 1 pc. 0.3
83 Strainer & stopper Detach/attach 1 pc. 0.3
84 Piping Detach/attach 1 set 0.8
85 Guard Detach/attach 2 pcs 0.4
86 Pump slinging Detach/attach 1 pc. 0.4
87 Cleaning Cleaning 1 pc. 0.1
88 Vent air Adjust 1 pc. 0.1
89 Pump ASSY O/H 1 pc. 3.0
Other necessary works Detach/attach 1 set Counter weight 0.6
90 Swing motor unit relation 19. Reference for swing motor unit
91 Swing motor ASSY Detach/attach 1 pc. 2.7
93 Drain hose clamp Detach/attach 1 0.3
95 Unit slinging Detach/attach 1 pc. 0.5
96 Cleaning and sealant Cleaning 1 set 0.2
97 Swing motor O/H 1 pc. 3.6
98 Swing reduction gear O/H 1 pc. 4.2
1 4
Unit : Hour
Work to be E200SR
done E200SRLC
100 Swivel joint relation 20. Reference for swivel joint
101 Swivel joint ASSY Detach/attach 1 2.6
102 Piping (Top part only) Detach/attach 1 set 0.5
103 Whirl stop bolt Detach/attach 1 0.2
104 Cover Detach/attach 1 0.4
105 Joint & elbow Detach/attach 1 set 0.4
106 Mounting bolt Detach/attach 1 set 0.4
107 Swivel joint slinging Detach/attach 1 0.4
108 Cleaning Cleaning 1 set 0.3
109 Swivel joint O/H 1 set Removing and installing guard 3.6
Other necessary works Detach/attach 1 set Lower piping 0.6
120 Main control valve 16. Reference for control valve

121 Main control valve ASSY Detach/attach 1 pc. 1.5
122 Attach tag to port name of pipe Preparation 1 pc. 0.5
124 Bracket mounting bolt Detach/attach 1 pc. 0.1
125 Valve slinging Detach/attach 1 pc. 0.1
126 Main control valve ASSY O/H 1 set 5.0
03 Swing frame
Other necessary works Detach/attach 1 set Guard 0.7
130 Valve relation

131 Solenoid valve ASSY Detach/attach 1 1.0
132 Attach tag to port name of pipe Preparation 1 set 0.2
140 Engine (E/G) mounting relation 13. Reference for engine

141 Engine ASSY Detach/attach 1 pc. After removing pump & radiator 1.6
142 Harness connector & grounding & cable connection Detach/attach 1 pc. 0.2
143 Fuel hose Detach/attach 1 pc. 0.1
144 Others Detach/attach 1 set 0.4
146 Engine slinging Detach/attach 1 set 0.2
148 Engine O/H 1 set Reference for engine
Other necessary works Detach/attach 1 set Removing and installing guard 0.7
Detach/attach 1 set Removing and installing counter weight 0.6
Detach/attach 1 set Removing and installing pump 2.3
Detach/attach 1 set Removing and installing air cleaner 0.4
Detach/attach 1 set Removing and installing muffler 0.4
Detach/attach 1 set Removing and installing radiator 5.0
1 5
Unit : Hour
Group Work to be E200SR
Location Unit Remark
done E200SRLC
150 Upper frame 21. Reference for upper frame
151 Upper frame ASSY Detach/attach 1 pc. After removing swivel joint 1.3
Swing frame
153 Upper frame slinging Detach/attach 1 pc. 0.4

155 Sealant Apply 1 pc. 0.2
Other necessary works Detach/attach 1 set Cab 1.2
Detach/attach 1 set Guard 0.7
03
Detach/attach 1 set Counter weight 0.6

Detach/attach 1 set Boom 1.4
00 Travel relation 2. Reference for crawler

One
01 Track link ASSY Detach/attach side Include adjustment of tension. 1.5
One
02 Track link attaching and detaching position Preparation side 0.1
One
03 Master pin Detach/attach side 0.5
One
04 Track link extending and winding Detach/attach side 0.5
05 Shoe plate Replace 1 pc. 0.4
10 Upper roller relation 3. Reference for upper roller

11 Upper roller ASSY Detach/attach 1 After removing track link 0.2
12 Upper roller O/H 1 1.0
20 Lower roller relation 4. Reference for lower roller

21 Lower roller ASSY Detach/attach 1 0.2
22 Lower roller O/H 1 1.5
30 Front idler relation 5. Reference for front idler

One
31 Front idler ASSY Detach/attach side After removing track link 0.6
Travel system
One
32 Front idler ASSY slinging Detach/attach side 0.3
One
33 Front idler ASSY Detaching side 0.3
One
34 Idler ASSY O/H side 1.0
One
35 Idler adjuster ASSY O/H side Replace spring 2.4
One
36 Grease cylinder O/H side 0.6
04
40 Sprocket 6. Reference for sprocket

One
41 Sprocket Replace side After removing track link 0.6
50 Travel motor relation 7. Reference for travel motor

One
51 Travel motor ASSY Detach/attach side After removing track link 1.7
One
52 Motor cover Detach/attach side 0.1
One
53 Hydraulic piping Detach/attach side 0.9
One
54 Motor mounting bolt Detach/attach side 0.5
One
55 Motor slinging Detach/attach side 0.1
One
56 Motor cleaning Cleaning side 0.1
One
57 Travel motor O/H side 3.6
One
58 Travel reduction gear O/H side 3.6
60 Swivel joint relation

Include bonnet assy removing and
61 Pipe on swivel joint travel side Detach/attach 1 pc. installing. 0.6
62 Swivel joint O/H 1 pc. Refer to Upper structure on page 1-5 3.6
16
Unit : Hour
Work to be E200SR
done E200SRLC
70 Swing bearing 8. Refer for Swing bearing
04 Travel system
71 Swing bearing ASSY Detach/attach 1pc. After removing upper frame 0.7
72 Swing bearing mounting bolt Detach/attach 1pc. 0.5
73 Swing bearing slinging Detach/attach 1pc. 0.3
Controller
C-1 Controller (KPSS) Replace 1 0.2
C-2 Gauge cluster Replace 1 0.2
C-4 Air conditioner Amplifier Replace 1 0.2
C-5 Air conditioner switch (panel) Replace 1 0.2
C-6 Power window controller (OPT) Replace 1 0.2
Diode
D-1 Diode Replace 1 0.2
Electric equipments
Include C1 controller removing and
E-1 Fuse box Replace 1 installing. 0.3
E-2 Alternator Replace 1 1.0
E-3 Hour meter Replace 1 0.2
Electric equipments
E-4 Horn (low) Replace 1 0.2

E-5 Horn (high) Replace 1 0.2
E-6 Cigar lighter Replace 1 0.2
E-7 Tuner AM & FM(OPT) Replace 1 0.2
E-7 Tuner AM(OPT) Replace 1 0.2
E-8 Speaker left (OPT) Replace 1 0.2
E-9 Speaker right Replace 1 0.2
E-10 Receiver dryer Replace 1 Include gas sealing. 0.3
06
Include counter weight removing and

E-11 Air compressor Replace 1 installing. 0.5
Light
L-1 Boom work light left Replace 1 Bulb 0.2
L-2 Work light right Replace 1 0.2
L-3 Room light Replace 1 0.2
L-4 CAB work light Replace 1 0.2
L-5 CAB work light (OPT) Replace 1 0.2
Motor
M-1 Starter motor Replace 1 installing. 1.0
M-2 Governor motor Replace 1 installing. 0.5
M-3 Wiper motor (Non rise up) Replace 1 0.2
M-4 Washer motor Replace 1 0.2
M-5 Cable assy (P/W motor OPT) Replace 1 0.5
M-6 Power window lock motor (OPT) Replace 1 0.2
M-7 Power window lock motor (OPT) Replace 1 0.2
M-8 Skylight wiper motor (OPT) Replace 1 0.2
17
Unit : Hour
Work to be E200SR
Group Location done Unit Remark
E200SRLC
Proportional valve
Include proportional valve removing and
PSV-A Arm re-circulation confulx proportional valve Replace 1 installing. 2.0
PSV-B P2 by-pass cut proportional valve Replace 1 installing. 2.0
PSV-C Travel straight proportional valve Replace 1 installing. 2.0
PSV-D P1 bypass cut proportional valve Replace 1 installing. 2.0
Relay
R-1 Battery relay Replace 1 0.2
R-3 Glow relay Replace 1 0.2
R-4 Safety relay Replace 1 Include guard removing and installing 0.4
Include C1 controller removing and
R-5 Wiper motor relay Replace 1 installing 0.3
R-6 Washer motor relay Replace 1 0.3
R-7 Horn relay Replace 1 0.3
R-8 Work light relay Replace 1 0.3
Sensor
Include removing and installing guard on
SE-1 Pressure sensor (low pressure ; bucket digging) Replace 1 cab lower side. 0.4
SE-2 Pressure sensor (low pressure ; bucket dump) Replace 1 0.2
SE-3 Pressure sensor (low pressure ; boom up) Replace 1 0.2
SE-4 Pressure sensor (low pressure ; boom down) Replace 1 0.2
SE-5 Pressure sensor (low pressure ; swing) Replace 1 0.2
SE-7 Pressure sensor (low pressure ; arm in) Replace 1 0.2
Electric equipments

SE-8 Pressure sensor (low pressure ; arm out) Replace 1 cab lower side. 0.4
SE-9 Pressure sensor (low pressure ; travel right) Replace 1 cab lower side. 0.4
SE-10 Pressure sensor (low pressure ; travel left) Replace 1 cab lower side. 0.4
SE-13 Engine speed sensor Replace 1 Include guard removing and installing. 0.5
SE-14 Engine water temperature sensor Replace 1 0.2
SE-15 Fuel sensor Replace 1 Include guard removing and installing. 0.3
SE-16 Accel potentio Replace 1 0.2
SE-22 P1 pump pressure sensor Replace 1
06
0.2
SE-23 P2 pump pressure sensor Replace 1 0.2
Solenoid
SV-1 Swing parking SOL Replace 1 installing. 2.0
SV-2 ATT boost pressure SOL Replace 1 installing. 2.0
SV-3 2-speed travel SOL Replace 1 installing. 2.0
SV-4 Lever lock SOL Replace 1 installing. 2.0
Switch
SW-1 Key switch Replace 1 0.2
SW-2 Switch Replace 1 0.2
SW-3 2-speed travel switch Replace 1 0.2
SW-4 Swing parking release switch Replace 1 0.2
SW-5 KPSS release switch Replace 1 0.2
SW-6 Engine water temperature switch Replace 1 0.2
SW-7 Engine oil pressure switch Replace 1 0.2
SW-8 Clogged air filter switch Replace 1 0.1
SW-10 Horn switch Replace 1 0.2
SW-11 Lever lock switch Replace 1 0.3
SW-12 Heater switch (OPT) Replace 1 0.2
SW-13 Air conditioner switch Replace 1 0.2
18
2. STANDARD WORKING TIME TABLE

FOR THE MAINTENANCE OF ENGINE
Introduction 2. Special equipments not listed in this table
This standard working time table provides time may be used for operation.
required for maintenance (if the work is carefully
carried out) under the following condition : If such operations are performed, fill out reasons
Tools designated by us are used.

in the Claim Application Sheet in detail and
Genuine parts are prepared.

submit it to us.
Correct working procedures are observed.

(Note 1) Unit of maintenance time
The engine is mounted correctly to the

The maintenance time is given in
machine. 6 minutes=0.1 hour in the decimal system.
1. The working hours given in this table can not (Note 2) Applicable models :
be applied because of special machine A-4BG1T ........... SK115SRDZ, SK135SR(LC)
construction. AA-4BG1TC ...... SK200SR(LC)
A-4BG1 ............. SK115SR
Work Mainte- Work Mainte-

to be nance to be nance
Location of work done time Location of work done time
Engine body Valve timing mechanism
Detach & Detach &
Flywheel assy attach 0.9 Rocker arm & shaft assy attach 0.6
Including replacing of ring gear, etc. Incl. overhauling locker arm
Engine cushion rubber (both sides) Replace 0.4 Tappet Replace 5.4
Replace 0.1 Detach &
Drain plug Tappet chamber cover attach 0.4
Detach &
Engine assy 21.6 Valve rocker stand Replace 0.4
attach
Detach &
Incl. overhaul of engine and cylinder body Timing gear casing cover attach 1.2
Sealing plug Replace 0.2 Incl. replacement of gear
Detach &
Cylinder block drain cock assy Replace 0.1 Cam shaft 11.6
attach
Detach &
Piston & conn rod (2 cycle) attach 11.8 Incl. replacement of bearing and tappet
Incl. replacing parts (4 cycle) 11.4 Intake, exhaust system
Crank shaft rear oil seal Replace 0.2 Air intake hose Replace 0.3
Detach &
Crank shaft pulley 0.8 Manifold fastening bolts Retighten 0.3
attach
Detach &
Incl. replacement of front oil seal Inlet manifold attach 1.1
Detach &
Oil pan Retighten 0.3 Exhaust manifold attach 0.7
Detach & Detach &
Oil pan attach 0.9 Throttle valve assy attach 0.8
Incl. overhaul of oil pump Incl. overhaul of throttle valve
Detach &
Crank casing & oil pan attach 2.5 Intake shutter spring Replace 0.1
Incl. overhaul of oil pump and replacement Detach &
of other parts Intake shutter attach 0.5
Oil pan level gauge guide tube Replace 0.1 Incl. overhaul of intake shutter
Detach &
Cylinder head Turbo charger assy (If equipped) attach 1.8
Valve clearance Adjust 0.5 Incl. overhaul of turbo charger
Detach & Detach &
Cylinder head cover attach 0.5 Turbo charger oil pipe (1 pc.) attach 0.1
Detach &
Incl. retightening cylinder head Turbo charger oil pipe (2 pcs.) attach 0.2
Detach & Detach &
Cylinder head assy attach 9.6 Inlet pipe assy attach 0.2
Overhaul of cylinder head, replacement of valve guide, Detach &
Exhaust pipe adapt assy attach 0.2
etc.
21
Work Mainte- Work Mainte-

Location of work to be nance Location of work to be nance
done time done time
Detach &
Lubricating system Fuel filter assy attach 0.6
Detach & Detach &
Oil filter element cover attach 0.5 Fuel filter overflow valve attach 0.4
Incl. replacement of relief valve Fuel pump (feed pump filter) Replace 0.4
Oil filter element (cartridge) Replace 0.2 Fuel pipe (Filter injection) Replace 0.4
Detach &
Oil filter assy attach 0.6 Fuel return pipe Replace 0.4
Incl. overhaul of oil filter Fuel hose Replace 0.2
Detach &
Oil filter oil pipe attach 0.3 Cooling system
Detach &
Oil cooler assy (incl. replacement of one hose) attach 0.7 Fan belt Adjust 0.1
Detach &
Oil cooler assy (2 hoses) attach 0.9 Fan belt Replace 0.1
Detach &
Oil cooler water hose Replace 0.1 Cooling fan attach 0.3
Detach &
Oil relief valve Replace 0.2 Water pump assy attach 1.2
Fuel system Incl. overthaul of pump
Detach &
Injection time Adjust 0.3 Water pipe and hose attach 1.0
Detach &
Injection pump assy attach 3.8 Incl. replacement of pipe and packings
Detach &
Incl. replacement of governor, feed pump, etc. Thermostat attach 0.6
Injection pump overflow valve Replace 0.3 Incl. performance test
Injection pump diaphragm Replace 0.3 Electrical equipments of engine
Detach & Detach &
Fuel feed pump assy attach 1.2 Starter assy attach 0.8
Incl. overhaul of pump and replacement of
check valve Generator pulley Replace 0.6
Detach & Detach &
Feed pump strainer attach 0.3 Generator assy attach 1.3
Incl. cleaning strainer Generator drive belt Replace 0.1
Detach &
Injection pipe (2 pcs.) attach 0.1 Voltage regulator Adjust 0.5
Injection pipe (4 pcs.) 0.2 Voltage regulator Replace 0.1
Injection pipe clip Replace 0.1 Glow plug (2 pcs.) Replace 0.3
Nozzle leakoff pipe Replace 0.3 Glow plug (4 pcs.) Replace 0.4
Primimg pump Replace 0.4 Glow plug relay Replace 0.1
Injection pump Vent air 0.1 Switch, unit, relay
Fuel cut solenoid Replace 0.1 Ignition & starter switch Replace 0.2
Detach &
Nozzle holder assy (1 pc.) attach 0.7 Oil pressure unit Replace 0.1
Detach &
Incl. replacement of nozzel (2 pcs.) attach 1.2 Oil pressure switch Replace 0.1
Detach &
Incl. replacement of nozzel (4 pcs.) attach 1.7 Thermo unit Replace 0.2
Fuel filter (cartridge) Replace 0.1 Control resistor Replace 0.2
Detach & Detach &
Fuel filter element attach 0.2 Auto stop motor assy attach 0.2
22
E200SR
SECTION 13 MAINTENANCE STANDARD

AND TEST PROCEDURE
TABLE OF CONTENTS
1. HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE

EXERCISED .............................................................................................................. 1
2. PERFORMANCE INSPECTION STANDARD TABLE ................................................. 2
3. MEASUREMENT OF ENGINE SPEED ...................................................................... 4
4. MEASUREMENT OF HYDRAULIC PRESSURE ........................................................ 5
5. MEASURING TRAVEL PERFORMANCES ................................................................ 9
6. MEASURING SWING PERFORMANCES ............................................................... 11
7. MEASURING ATTACHMENT OPERATING PERFORMANCES ............................... 13
8. MEASURING PERFORMANCES OF SWING BEARING ........................................ 14
9. MECHATRO CONTROLLERAADJUSTMENT ........................................................ 15

1. HOW TO USE THE MAINTENANCE STANDARD

AND CAUTIONS TO BE EXERCISED
(1) Application (3) Cautions to be Exercised at Judgment

1) When the machine is new ; 1) Evaluation of measured data ;
Confirm that the performances are in Disagreement of measuring conditions,
accordance with standard specifications as variations of data peculiar to a new machine,
compared to the performance standards. and measuring errors are to be evaluated.
Determine generally at what levels measured
2) At specific self inspection ; (Rule by country) values are located, instead of determining
Use the data for the criterion, for the purpose whether or not values fall within or run out
of correction, adjustment and replacement. of the reference values.
3) When performances are deteriorated ; 2) Determining correction, adjustment or

Determine whether it is caused by a fault or replacement ;
end of service life after long hours of Machine performances deteriorate with time
operation, to be used for safety and as parts wear and some deteriorated
economical considerations. performances may be restored to new levels.
Therefore, determine correction, adjustment
4) When main components are replaced ; or replacement, depending upon the
For example, use data to restore operating hours, kind of work and
performances of pumps and others. circumstances in which the machine is
placed, and condition the machine
(2) Terminology performances to its most desirable levels.
1) Standard values ;
Values to be used to condition or assemble a (4) Other Cautions to be Exercised
new machine. Where special notes are not 1) Parts liable to degrade ;
given, these values represent standard Rubber products, such as, hydraulic hoses,
specifications (machine with standard O rings, and oil seals deteriorate with time ;
attachments and standard shoes). replace them at regular intervals or at
overhauls.
2) Repairable level;
Values at which readjustment is required. In 2) Parts requiring regular replacement ;
order to ensure performance and safety it is Out of critical hoses that are necessary to
strictly prohibited to use the machine over secure safety, we designate Very Important
the specified values. Parts (V.I.P) and recommend that they
should be replaced regularly.
3) Service limit ;
This is the limit value at which 3) Inspection and replacement of oils and greases ;
reconditioning is impossible without In performing maintenance, it is necessary
replacement of parts. If the value is expected for the user to familiarize himself with how to
to exceed the service limit before next handle the machine safely, cautions to be
inspection and correction are performed, exercised and inspection/lubrication
replace the parts immediately. The operation procedures. Refer to the operators manuals
over the specified values causes increase of as well.
damage and requires the down time of
machine, and also causes safety problems.
1
2. PERFORMANCE INSPECTION STANDARD TABLE

Table 1 (1/2)
Note ; The mode is already S mode when power is thrown.
Unless otherwise specified, measure it on H mode.
Measuring Position Standard Adjusting Measuring

Inspection Item Hi Lo Unit Point condition
Position Size Port value
Cleanliness of hydraulic oil Hydraulic oil in tank NAS 8 +1 1 Class Sampling
Measuring condition
50 +5 5
Hydraulic oil temperature Tank surface (122) (41) (23) Ambient temp.
75 +15 5010
Coolant temperature Radiator surface 15 (
F) (122
F14 F)
(167) (59) (5)
Lo idle 1000 +25 25 LOW throttle
Engine speed
FULL throttle
Hi idle Selector switch on 2420 +30 30 (HI idle)
Adjustment
S mode the gauge cluster
rpm not required Perform all
Standard
2300 +30 30
screen
(Injection pipe) measurement with
FC mode 1800 +30 30 the air-conditioner
Decel 1050
OFF .
+50 50
51 +3 3
Pilot primary pressure circuit G pump a4 PR1 HI idle
(725) (40) (40)
RH and LH
ATT P1 a1 350 +5 Simultaneous
Valve pressure
0 MR1
Travel
Main relief
Main (4980) (70) Operation or

P2 a2 Boom up
pump ATT boost
Boost P1 a1 385 +10 5
pressure (5470) (140) (70)
MR1 pressure SW. ON
P2 a2 Boom up

H 405 55
(5760)
0
(780)
OR3 Boom up
Boom a1
R 385 35
(5470)
0
(500)
OR4 Boom down
High pressure circuit
H 405 55
(5760)
0
(780)
OR1 Bucket digging
Bucket a1
Over load relief valve pressure
R 385 35
(5470)
0
(500)
OR2 Bucket dump
RH
Forward PF1/4 a1 350 +15
0
OT1 Simultaneous
Travel
Main pump
Reverse (4980) (210) OT2 Operation of

LH
Forward
a2 350 +15
0
OT3 travel
Reverse (4980) (210) OT4 RH and LH
285 +55 +10
LH (4050) (780) (140)
OR5 Swing LH
Swing a2
RH 285 +55 +10 kgf/cm2
(4050) (780) (140) (psi)
OR6 Swing RH
385 35
H (5470)
0
(500)
OR7 Arm in
Arm a2
R 405 55
(5760)
0
(780)
OR8 Arm out

Performs proportional
B 21
Service diagnosis screen No.
P2 cut valve calculation from actual

Pressure circuit
Indicated
current reading on
Proportional Valve block
Travel 6.9 current value

straight valve
C 22 (100) +1.5 0.5 (mA)
display No. Values
which are calculated
Gauge cluster
by converting pressure
C2 Multi display
P1 cut valve D 20 (20) (7) 3505 values in the left figure

to current
values are shown.
Arm variable 25
recirculation
A 23 (300)
642 E/G Hi, Lever on neutral
position
Secondary pilot
25
P2 cut valve B 21 (300)
642
E/G Hi
Travel 28.6 The max. value is
straight valve
C 22 (410) +2 1.5
700 displayed as the
25 (30) (20) full lever strokes
P1 cut valve D 20 (300)
642 differ with types of
Arm variable 425 operations.
recirculation
A 23 (60360)
303642
2
Table 1 (2/2)
Measuring Posision Stand- Adjusting Measuring
Inspection Item ard Hi Lo Unit
Position Screen code value Point condition
Secondary pilot pressure circuit
Service diagnosis screen No.

Indicated E/G Hi
No.24
6 +0.5 0.5 Current value Lever on
&
P1 pump
Gauge cluster
(90) (7) (7) (mA) neutral
Multi display
No.25
proportional valve MIN 350 position
& kgf/cm2
(psi)
P2 pump
proportional valve No.24 E/G Hi
30 +1.5 1.5
C2
& MAX 750 Lever on

(430) (20) (20)
No.25 full
Inspection item Standard value Unit

1-speed 26.629.4
H mode
Sprocket revolution 2-speed 39.043.2
rpm
(RH,LH) S mode 2-speed 37.841.8
FC mode 2-speed 29.432.6
Raise 2.73.3
Boom
Lower 3.03.6
In 3.13.7
Operating speed
Arm
Out 2.32.9
Operating time of
Digging 2.93.5
cylinder Bucket sec
Dumping 1.72.3
(At no load)

Variable speed
Swing speed sec/1 rev
STD speed 5.05.6
Rubber
1-speed
Iron 20.622.8
Travel speed sec/20m
Rubber
2-speed
Iron 14.115.7
Amount of travel mm / 20m
deviation 2-speed 0240
Parking brake drift 15Gradient 0 mm / 5min
Performance of Newtral position after degree
Swing brake 180full speed swing 5575
Performance
Performance of mm (in)
Swing parking brake 15Gradient 0
Tip of the bucket tooth 96
ATT amount of Boom cylinder 3
mm/5min (At no load)
drift Arm cylinder 6
Dozer cylinder
5070 mm (in)
Amount of horizontal play at the bucket tooth
(1.972.76)
The port relief valves No.OR1OR8 on the control section are adjusted to the following
operation numbers in advance.

Bucket digging Bucket dumping Boom raise
Boom lower Swing left Swing right
Arm in Arm out

LH RH
CONTROL LEVER
3
3. MEASUREMENT OF ENGINE SPEED
3.1 MEASUREMENT OF ENGINE SPEED

(1) Warming up of engine
Start engine to raise the coolant temperature of engine
to 40to 80_. (104to 176F)
Engine coolant MONITOR
The E/G coolant tem-perature gauge 2250RPM
temperature gauge SYSTEM OK
is used to measure. The range in white
color shows the temperature of
approx. 40to 100_ (104to 212F), so 256 Hr AFT
confirm that the measured value in- E/G OIL CH
dicates the temperature within the
Example of screen change
range of white color.
(2) Actual measurement of engine revolution by the
screen select switch
After the engine starts, the following BUZZER STOP
SCREEN SWITCH
items are displayed in that order each SELECT SW (RETURNS)
time the screen change switch is (ADVANCES)
pressed. WORK MODE
z Engine s p e e d SELECT SW
(At this time, each mode is
chosen and engine speed is
measured.)
z Hours after the engine oil was
replaced Fig. 1 Gauge cluster
(3) Engine speed measured value through service
diagnosis No.2
1) Turn "ON" the starter switch with the buzzer stop E/G SET 2205 No load set rpm
switch pressed. MEAS 2201 Actual rpm
2) A program No. and an actual engine revolution are E/G PRS. LIVE LIVE/DEAD indication
displayed as the No.2 Item. KPSS SW H H/S/FC indication
3) At the "H" mode, if work mode select switch is
pressed after pressing buzzer stop switch and Fig. 2 Engine speed measuring service diagnosis
returning a display screen, the engine speed in "H"
mode is displayed.
4) Press a work mode select switch in "S" and "FC" mode, PICK UP
select each mode, and the engine speed in each mode is
displayed.
5) The screen advances like No.2, No.3....each time the
screen select switch is pushed.
6) The screen returns like No.40, No.39....each time the SPEED METER
buzzer stop switch is pressed.
7) The display does not disappear unless the starter
switch is turned to "OFF".
(4) Measuring with diesel engine speed meter
1) Install diesel engine speed meter pickup on and of
injection pipes on which the pickup can be easily
installed. (See Fig. 3.)
2) Check E/G speed shown in Table 1 in idling speed.
Fig. 3 Measurement of E/G speed
4
4. MEASUREMENT OF HYDRAULIC PRESSURE

4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE
(1) Hydraulic equipment
70kgf/cm2 (1000psi) pressure gauge ..... 1 unit
400500kgf/cm2 (57007100psi)
pressure gauge .............................................. 3 unit
Pressure measuring equipment and
instrument for analysis ............................... 1 set
A3
(2) Measuring cleanliness of hydraulic oil
After releasing air in the hydraulic oil
tank, open the cover and sample oil in
the hydraulic tank, and measure with
the instrument for analysis. If the
measured value is higher than the
reference value, replace the return
filter or change the hydraulic oil.
a2(a1)
Fig. 3 Gauge port on main pump
4.2 PLACE TO INSTALL PRESSURE GAUGE a3

(1) Main circuit
Replace plugs PF1/4 of main pump gauge
ports a1,a2 with plugs for pressure A3
measurement, and attach pressure gauge
500kgf/cm2 (7100psi).
PUMP
(2) Pilot circuit
Replace pilot gauge plug a3 with plug PF1/4
for pressure measurement, and attach
pressure gauge 70kgf/cm2 (1000psi).
a2
a1
Fig. 4 Location of plugs for pressure
mesurement
5
4.3 PRESSURE ADJUSTMENT POSITION

(1) Main control valve
MAIN RELIEF
VALVE
MR1
BUCKET
DUMPING
OR2
ARM IN
OR7
BOOM
UP
OR3
OPTION
OR12
View from the top of the machine
OPTION
OR11
ARM OUT
OR8
BOOM DOWN
OR4
BUCKET
DIGGING
OR1
View from the bottom of the machine
Fig.5 Relief valve position on main control valve

(2) Pilot relief valve A3

The pilot relief valve PR1 is located on the
gear pump that is attached to the main
pump.
a3
Dr4
B3
PR1 ADJUST SCREW
FOR PILOT RELIEF
Fig.6 Pilot relif valve position
SWING LEFT SWING RIGHT

(3) Swing over load relief OVER LOAD RELIEF OVER LOAD RELIEF
The swing motor is equipped with plugs OR5 OR6
PA,PB for pressure measurement, but the
measurement is carried out using gauge ports
a1 and a2 . (See Fig. 4)
PB
PA
Fig. 7 Swing over load relief position
4.4 PROCEDURE FOR ADJUSTING RELIEF

VALVE
(1) Pilot relief valve
Adjust it with adjust screw (311).
: 24mm Tightening torque :
3.0kgfym (22 lbfyft)
: 6mm
Table 2
Pressure change
No. of turns of adjust screw kgf/cm2(psi)
1 turn Approx. 21 (300) LOCK NUT HEX24
311
Fig. 8 Pilot relief valve
7
(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 HEX32 HEX19
adjustment on the boosting side. 1 2
Then, loosen nut (3), adjust the pressure on
the normal side with adjusting screw (4) and
tighten nut (3) after completion of the
adjustment.
2.8~3.2kgfym (20~23 lbfyft)
: 22mm Tightening torque : 4 3
2.8~3.2kgfym (20~23 lbfyft) HEX22
: 19mm Adjust screw
: 6mm Fig. 9 Main relief valve
Table 3 (Travel section, ATT common section)
Pressure change
No. of turns of adjust screw kgf/cm2 (psi)
Boosting side 1 turn Approx. 180 (2560)
Normal side 1 turn Approx. 180 (2560)
(3) Over load relief valve
(Boom, bucket, arm sections)
Loosen lock nut (1) and adjust it with adjust
screw (2).
2.8~3.2kgfym (20~23 lbfyft)
: 6mm
2 1
Table 4
HEX22
Pressure change
No. of turns of adjust screw kgf/cm2(psi) Fig. 10 Over load relief valve
1 turn Approx. 180 (2560) (Boom, bucket, arm sections)
(4) Over load relief valve (Swing)
HEX38 HEX30
When the adjustment of pressure is required,
1 2
loosen lock nut (1) and adjust the pressure
with cap (2).
: 30,38mm Tightening torque :
12kgfym (87 lbfyft)
: 12mm
Table 5 3
Pressure change
No. of turns of adjust screw kgf/cm2 (psi)
Fig. 11 Swing over load relief valve
1 turn Approx. 102 (1450)
5) Travel over load relief valve

The adjustment is done by manufacturer
before shipment. When adjustment is
required, loosen nut (1) and adjust the
pressure with adjusting screw (2). 2
: 19mm
1
: 6mm
Fig. 12 Travel over load relief valve
8
5. MEASURING TRAVEL PERFORMANCES

5.1 TRAVEL SPEED
(1) Purposes
Measure the travel sprocket revolution and
confirm the performances between the
hydraulic pump and the travel motor of the
travel drive system.
(2) Conditions
Operating oil temperature ; 4555(113131
4555 F)
Crawler on the right and left sides are Fig. 13 One side lifted position
tensioned evenly.
(3) Preparation
Install the reflection panel with a magnet to REFLECTION
PANEL
the travel motor cover.
Swing the swing frame through 90as shown
in Fig.13 and make the crawler on one side
take off the ground, using the attachment.
(4) Measurement YN-B74
Engine speed ; Hi idle Fig. 14 Adhering position of reflection panel

2-speed travel switch ; 1-speed and 2-speed
Measuring points ; Right and left Sprocket revolution Table 6 Unit : rpm
Method, example 1 ; Measurement Standard
Repairable level Service limit
item value
Measure revolution with a stroboscope.
H1 26.629.4 20.722.9 18.8
Method, example 2 ; RH
& H2 39.043.2 30.433.7 27.5
Measure the revolutions per minute
visually. LH S2 37.841.8 29.532.6 26.7
FC2 29.432.6 22.925.4 20.8
5.2 DEVIATION OF TRAVEL

(1) Purpose
Measure the amount of deviation at 20m
(22yard) travel and confirm the horizontal
balance between the hydraulic pump and the
travel motor of the travel drive system.
(2) Condition (Approx. 1ft)
3040cm
Hydraulic oil temperature ; 4555(113131
4555C F)
RH and LH crawler are tensioned evenly. Fig. 15 Travel position
Plain, level and solid ground
Engine speed ; Hi idle
(3) Preparation
1) Straight course more than 30m (33yard)
2) Travel position in which the bottom of the A
bucket is lifted by about 30cm (1ft). 20m (22yard)
(4) Measurement
1) Measure the max. deviation distance of the Fig. 16 Measuring method
circular arc in the 20m (22yard) length,
excluding the preliminary run of 35m (3.3 Travel deviation Table 7 Unit : mm/20m
5.5yard). Measuring
position Standard value Repairable level Service limit
2) Operate the both travel levers at the same
A 240 (9.5 ) or less 480 (17 ) 720 (24 )
time.
9
5.3 PERFORMANCES OF PARKING BRAKE

(1) Purpose
Confirm that the parking brake holds a
stopped condition of the machine in a no-load (1ft)
travel position and on a 15deg. slope. 30cm
(2) Condition 15deg.

A slope with 15deg. gradient and a stopped
condition in a no-load travel position Fig. 17 Parking brake operating position
(3) Preparation
Place an angle meter on the shoe plate and
confirm that it makes an angle more than
15deg..
Hang a perpendicular in parallel with the
guide frame rib on the track frame and put a C ANGLE METER
GUIDE FRAME
mark (matching mark) on the shoe plate. Fig. 18 Method of measurement
Parking brake Table 8 Unit : mm/5 min.

(4) Measurement
Five minutes after the engine stops, measure Measuring Service
position Standard value Repairable level
limit
the movement distance of the matching
mark. C 0 1 (0.04in) 2 (0.08in)
22 PIPE
5.4 DRAIN RATE OF TRAVEL MOTOR FORWARD (0.866 ) 90 10
(1) Purpose (3.54 ) (0.394 )
To measure the drain rate of the travel motor 40
(1.57 )
and to confirm the performances of the travel
motor. RIBA 130
STOPPER (5.11 )
B
(2) Conditions
Hydraulic oil temperature ; 45~55 C(113~131F )
70
Engine speed ; Hi idle (2.76 )
ROTARY DIRECTION
(3) Preparation Fig. 19 Location of stopper applied to travel sprocket

1) Place a stopper under the RH and LH travel
sprockets.
2) Stop the engine and vent pressure from the
hydraulic circuit.
3) Connect a hose with the drain port of the
travel motor and take drain in a container.
(4) Measurement ; at Travel Lock
Unless you observe the rotary force direction

at travel lock (See Fig. 19), rib A may be
broken by stopperBin some cases. Fig. 20 Method of measuring
the drain rate of travel motor
1) Start the engine and relieve pressure at the Drain rate of Table 9 Unit : /30sec
travel motor
full stroke of the travel lever. Measuring
2) Measure the drain rate for 30 seconds of
relieving. Drain rate 7 (1.85 gal) 14 (3.7 gal) 21 (5.55 gal)
10
6. MEASURING SWING PERFORMANCES

6.1 SWING SPEED
(1) Purpose
Measure the swing time and confirm the
performances between the hydraulic pump
and the swing motor of the swing drive
system.
(2) Conditions
Hydraulic oil temperature ;4 4555(113131 F) Fig. 21 Swing speed measuring position
Plain, level, and solid ground (at the max. reach)
Engine speed ;Hi idle (H mode)
(3) Preparation
Bucket empty, arm cylinder fully retracted
(Max. reach), or arm cylinder fully extended
(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
preliminary run and calculate the time
required for one turn. Fig. 22 Swing speed measuring position
(at the min. reach)
6.2 PERFORMANCE OF SWING BRAKE Swing speed Table 10 Unit : sec / rev
(1) Purpose
Measuring
Confirm the braking torque performances by position Standard value Repairable level Service limit
the swing relief valve. max.
5.05.6 6.47.2 8.0
Swing reach
(2) Conditions speed min.
4555(113131
Hydraulic oil temperature ;4555C F) reach 5.05.6 6.47.2 8.0
Plain, level and solid ground
Engine speed ;Hi idle (H mode)
(3) Preparation
1) A height of 1.5m (5ft) at which the bottom of
the bucket matches the tip of the tooth on
condition that the bucket is empty, the arm
cylinder is most retracted and the bucket is 1.5m (5ft)
used for digging.
2) Put a matching mark on the outer circumference Fig. 23 Swing brake performance measuring position
of the swing bearing of the upper frame side
and of the track frame side. Erect two poles Measuring the length of the arc over the
outer circumference of outer race
(flags ) at the front and back of the extended
line of the matching mark. Matching marks
(4) Measurement on outer race
B
1) When operating in regular swing speed, by
shifting lever to neutral position at pole
position the swing operation stops.
2) Calculate the swing drift angle by the
following equation, after the upper swing
body stops, using the amount of deflection
Matching marks on inner race
(m) of the matching marks on the swing race
and the length (m) of the circumference of the Fig. 24 Measuring position of swing brake performances
swing race :
Swing brake
Amount of deflection of performance Table 11 Unit : degree
Swing drift matching marks [m (ft-in)]
Measuring
angle ()= 360 position Standard value Repairable level Service limit
Circumferential length of
swing race [m (ft-in)] Swing 180 Less than 75 85 90
11
6.3 PERFORMANCE OF SWING PARKING BRAKE

(1) Purpose
To confirm the mechanical performances of
the swing parking brake that is fitted to the
inside of the swing motor.
(2) Conditions
On a slope with 15deg. gradient. 15
Stop the machine at right angles with the
slope at the height of 1.5m (5ft) at which the
bottom of the bucket matches the tip of the Fig. 25 Swing parking brake
tooth on condition that the bucket is empty, performance measuring position
the arm cylinder is most retracted and the
Measuring the length of the arc over the
bucket is operated for digging. outer circumference of outer race
(3) Preparation Matching marks
Put the angle meter on the shoe plate and on outer race C
make sure that the angle is more than
15deg..
Put a matching mark on the outer race side
and on the inner race side.
(4) Measurement
When five minutes has passed after the Matching marks on inner race
engine stops, measure the length of the
Fig. 26 Measuring position
movement of the matching marks. of swing brake performances
6.4 DRAIN RATE OF SWING MOTOR

Performance of swing
(1) Purpose parking brake Table 12 Unit : mm/5 min
Measure the drain rate of the swing motor Measuring
and confirm the performances of the swing
motor. C 0 1 (0.04in) 2 (0.08in)
(2) Conditions 4555(113131 F)
Hydraulic oil temperature;4555 C
Engine speed ;Hi idle
(3) Preparation
1) Stop the engine.
2) Release pressure from inside the hydraulic
circuit.
3) Disconnect the swing motor drain hose from
its end returning to the hydraulic oil tank
and take oil in a container.
4) Put a plug to the tank side.
(4) Measurement ; at Swing Lock
1) Start the engine and put the side faces of
bucket against the inside of the right or left
shoe plates.
2) Relieve the swing motor at full stroke of the
swing motion.
3) Receive in a container the amount of drain Fig. 27
accumulated in 30 seconds of relieving. Drain rate of
swing motor Table 13 Unit : /30sec
Measuring
item Standard value Repairable level Service limit
Drain rate 2.0 (0.53gal) 5.0 (1.3gal) 6.0 (1.6gal)
12
7. MEASURING ATTACHMENT OPERATING

7.1 OPERATING TIME OF CYLINDERS
(1) Purpose
Measure the operating time of the boom, arm
and bucket and confirm the performances
(1ft)
between the hydraulic pump and the cylinder
30cm
of the attachment drive system.
(2) Condition Fig. 28 Measuring position for bucket digging
and dump
4555(113131
Hydraulic oil temperature ;4555C F)
Engine speed ;Hi idle
Operating time excluding the cushion stroke
(3) Preparation
Plain, level and solid ground and bucket is
empty
(4) Measurement 1 ; Boom up and down
With the boom operating lever at full stroke, Fig. 29 Measuring position for boom up
measure the required operating time of the and down motions
bucket between the ground surface and its
highest position.
When lowering the boom, allow the

bucket onto a soft ground or cushioning
such as rubber tires ; never hit the
(1ft)
bucket against concrete or other solid 30cm
material. Fig. 30 Measuring position for arm in
and out motions
Measurement 2 ; Arm in and out, bucket
digging and dump Cylinder Operating time Table 14 Unit :
In a position in which the tooth of the bucket Measuring
Standard Repairable level Service limit
rises to a level of about 30cm (1ft) above position
value
ground, measure the full stroke operating
2.93.5 3.74.5 4.8
time required with the arm and bucket
operating levers at full stroke. 1.72.3 2.42.9 3.0
2.73.3 3.44.2 4.5
7.2 OIL TIGHTNESS OF CYLINDERS 3.03.6 3.84.6 5.0
(1) Purpose 3.13.7 4.04.7 5.1
Confirm that the cylinder oil tight by 2.32.9 3.03.7 3.9
checking the moving length of the cylinder B
rods. C
(2) Condition
A
4555(113131
Hydraulic oil temperature ;4555C F)
Plain, level and solid ground Falling distance D
from 1.5m(5ft)
Immediately after cylinders are replaced, height
bleed off air from the cylinders, before
checking for oil tightness. Fig. 31
(3) Preparation
Oil tightness of
Keep the tip of the bucket at 1.5m (5ft) cylinder Table 15 Unit : mm/5min
height, with the bucket empty and the arm Measuring
cylinder is most retracted. (but not in stroke
end.) A 3 (0.12in) 4.5 (0.18in) 6 (0.24in)
(4) Measurement B 6 (0.24in) 9 (0.35in) 12 (0.47in)
Measure the items five minutes after the C
engine is turned off. D 96 (3.8in) 150 (5.9in) 200 (7.9in)
13
8. MEASURING PERFORMANCES OF SWING BEARING

LOCATION OF BEARING
(1) Purpose
ATTACHING CAPSCREWS
Measure the gap between the lower frame
and the bottom face of the swing bearing and
SWING BEARING
estimate the degree of wear of the swing
A
bearing.
DIAL INDICATOR
(2) Condition
Plain, level and solid ground LOWER FRAME
The swing bearing mounting bolts are not
loosened. Fig. 32 How to measure the axial play
The swing bearing is lubricated well, not of swing bearing
making abnormal sound during turning.
(3) Preparation
1) Install a dial indicator to the magnetic base 90110
and fix it to the lower frame.

2) Direct the upper swing body and the lower
(1ft)
frame toward the travel direction, bring the 30cm
probe of the dial indicator in contact with the
bottom surface of the outer race on the swing Fig. 33 Measuring position
body side and set the reading at zero.
(4) Measurement 1 (Measuring position and

)
1) Measure the travel of the outer race in the
axial direction in position[The arm at 90
110 and the crawler front lifted about
30cm (1ft)] and in position , using a dial 1.5m (5ft)
indicator.
2) Take measurement three times on the right Fig. 34 Measuring position
and the left respectively, and make the mean
Axial play of
value a measured value. swing bearing Table 16 Unit : mm (in)
Measuring
0.81.8 2.33.3 3.6

A (0.030.07) (0.090.13) (0.14)
(5) Measurement 2 (Measuring position )

1) With the arm cylinder most retracted and the
bucket dump, lift the tip of the tooth of the
bucket about 10mm (0.4in) and swing the tip
of the bucket to the right and the left by man
power. 10mm
(0.4in)
But in this case, the gap of the attachment is Fig. 35 Measuring position
included. Right and left
movement of
the tip of bucket Table 17 Unit : mm (in)
Measuring Standard
position value Repairable level Service limit
Bucket
tiptoe 60 (2.36) 120 (4.72) 180 (7.09)
14
9. MECHATRO CONTROLLERAADJUSTMENT
9.1 ENGINE CONTROL INPUT/OUTPUT
C-1 MECHATRO CONTROLLER
GAUGE CLUSTER
GOVERNOR
MOTOR
ENGINE
ACCEL DIAL PUMP
STARTER SWITCH
E/G SPEED SENSOR

Fig. 36
9.2 ENGINE CONTROL INSTALLATION
E/G EMERGENCY
STOP KNOB
(1.77_)
DETAIL OF
E/G STOP KNOB Fig. 37(1/2)
15
Tightening torque1.1kgfym (8.0 lbfyft)

Apply Locktite #262 or equivalent.
Tightening torque
4.0kgfym (29 lbfyft) ADJUST BOLT
Tightening torque Fasten it with the mounting plate
2.0kgfym (14 lbfyft) for the engine lifting hook
Apply Locktite
#242 or equivalent. Tightening torque
1.1kgfym (8.0 lbfyft)
GOVERNOR Tightening torque

MOTOR 0.1kgfym (0.74 lbfyft)
Tightening torque
Apply Locktite
#262 or equivalent.
E/G EMERGENCY
STOP CABLE
NORMAL USE
Center of crank shaft
VIEW
Fig. 37 (2/2)
16
9.3 E/G CONTROL EQUIPMENT REDUCTION GEAR SECTION

(1) Governor motor and C1 controller OIL SEAL
MOTOR SECTION
1) By operating accel dial, the input voltage OUTPUT SHAFT
change is sensed by CN1132 pins of C1
controller.
2) The C 1 controller computes the input
voltage, and outputs command current to CAM
governor motor (M2), and incline governor
LIMIT
lever of engine to the swing angle SWITCH
corresponding to accel dial set value.
3) The limit switch in governor motor is set to a
angle from motor rotation OFF to ON
position (Starting point).
Fig. 38
(2) Speed sensor
1) Installing place Opposing flat 19 SIGNAL(Yellow)
M161.5 Opposing flat 17
Engine flywheel housing
2) Sensor attaching procedure

Apply Locktite #262 on pick-up thread GND(Black)
section. Fig. 39
Tighten thread until it contacts flywheel ring
gear, and turn it back one and half times.
After turning it back one and half, check that
the tightening torque of nut is 2.53.5kgym
(1825 lbfyft).
After installation, check that the Engine
speed meter measured value corresponds to
the engine speed in service diagnostics while
operating engine.
Output voltage at 2,420rpm 20V(AC) or more
at 1,000rpm 40V(AC) or less
(3) Work mode select switch

Press work mode select switch, and the
WORK MODE
operation signal is sent to C1 controller, SELECT SW
and when ever switch is pressed, work mode BUZZER STOP
SWITCH
changes in turn.
(4) Buzzer stop switch

When the error is detected by self-diagnosis,
the C1 controller sends alarm by sounding
buzzer. And press buzzer stop switch to stop Fig. 40
buzzer sounding. Also, when engine coolant
temperature has risen or the engine oil
pressure has lowered, buzzer sounds. But in
this case the buzzer sounding does not stop.
17
9.4 A
AADJUTMENT OF MECHATRO CONTROL
(1) When adjustment of mechatro control is
required; GROMMET
Case Aadjustment
Replace mechatronic controller.
Replace governor motor.

CPU ROM DATA FAILURE To be adjusted
on display.
CPU ROM DATA FAILURE and C1 MECHATRO CONTROLLER
CPU MECHATRO SET ERROR
are shown by turns. Fig. 41
(2) Preparation
1) Warm up engine.
2) Turn A/C switch OFF.
3) Turn starter switch OFF to stop engine.
4) Pull up the safety lock lever and pull up the
left control box upwards.
5) Pull operator seat forward fully and incline MULTI DISPLAY
seat back forward.
6) Remove resin cover on the rear side, then
mechatro controller appears. (Remove 5 SCREEN
atta-ching bolts from resin cover with driver CHANGE SWITCH
,).
Note : Check to be sure that the engine
emergency stop lever knob is fully
pressed down. If mechatro controller is
adjusted in the condition where the knob
is pulled out, the engine speed can not be Fig. 42
set properly. Table 18 (1/2)
(3) Adjustment
Procedure Multi display Movement of governor motor
Remove grommet on upper surface of
STOP
mechatro controller, and switch internal FULL
adjustment JP switch from RUN to
TEST .
LEVER
In normal
RUN position LEVER
During
TEST adjustment
GOVERNOR
MOTOR
Turn starter switch ON .

A
Turn the accel dial to a certain position.
MONITOR
SYSTEM OK
Stop at the position set by accel dial.
18
Table 18 (2/2)
Procedure Multi display Movement of governor motor
Keep the buzzer stop switch pressed and
when it is let free after 5 to 10 seconds, A
S
STEP 1 is displayed on the multi display.
Then let your hand free and wait till the
display changes to STEP 2.
Self-traveled to the engine stop

position (S).
After confirming the STEP 2 display,
S
move to the engine room and adjust the
rod assy to its standard length
250mm(9.84in) so the clearance between
the governor lever and the engine stop set
bolt becomes0.1mm(0.004in).
Then if the governor motor is replaced, Stop at the position
insert the rod assy after the STEP 2 Tools
Spanner 13mm2pcs
indication.
Spanner 6mm
Thickness gauge
Press the buzzer stop switch once, and wait

until the STEP 3 indication is provided. S A
Automatically run to the engine

available position(A).
When STEP 3 comes up, start the engine. A
On that occasion, the accel dial may be in
any position.
Stop at the A position

If the buzzer stop switch is pressed once
time, STEP 4 comes up. The controller Lo A Hi
reads revolution from the A position of
governor motor to LOW IDLE and then to
HI IDLE. (The required time is approx 3
minutes.)
Move from A position to Lo
idling position, and self-travels
from Lo position to high idling
(Hi) position.
Wait till the indication on the multi display Hi
changes to "FINISH" after reading is
completed.
When the indication on the display changes,
the engine revolution returns automatically
to an initial position of the accel dial.
(Approx. A Hi
After a while, it switches "SYSTEM OK".
Note: If "FINISH" is not indicated, it means 5 seconds)
MONITOR
that the adjustment has failed. Then turn SYSTEM OK
OFF the starter switch and readjust it.
19
(4) After completion of adjustment

1) Turn starter switch OFF to stop engine.
2) Return the inner adjust switch to RUN from TEST, attach the grommet, push the screen change
switch on the gauge cluster one time, and get an engine rpm indication.
3) Auto accel release switch is switched and turn the mode to HIGH IDLE after the engine starts.
4) Make sure that the engine speed is changed on multi-display by switching the mode select switch of
gauge cluster.
5) Return accel dial to low position and stop the engine. Press the auto-accel switch to actuate
auto-accel function, and start the engine.
6) Set accel dial to high idling, and check engine speed when running in auto accel position.
7) Get "MONITOR SYSTEM OK" by pushing the screen change switch on the gauge cluster two times.
8) Attach resin cover as it was, and slide operator seat backward to move the seatback backward.
Then, check connector of speaker for disconnection.
9) Turn the left control box forward, bring down the safety lock lever, and start the engine again. Then
make sure that the actual engine revolution under the service diagnosis No.2 matches the measured
value on the diesel revolution meter. This completes the operation.
(5) Releasing auto accel (For checking the High Idling)

1) Auto accel release switch position
AUTO ACCEL RELEASE SWITCH (SW-16)
GAUGE CLUSTER
Fig. 43
20
E200SR
SECTION 21 MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS
1. SUMMARY OF MECHATRO CONTROL SYSTEM

1.1 Mechatro Control System in General ..................................................................................... 1
1.2 Boom Raise Conflux ............................................................................................................. 2
1.3 Swing Cut Valve Control ....................................................................................................... 2
1.4 Arm in Recirculation & Sequence Conflux ............................................................................. 3
1.5 Arm in Anti-cavitation Control ................................................................................................ 4
1.6 Arm Out Conflux .................................................................................................................... 4
1.7 Travel Straight ...................................................................................................................... 5
1.8 Swing Priority Control ........................................................................................................... 6
1.9 Pressure Draining (Releasing) Control ................................................................................. 7
1.10 Pump Control ...................................................................................................................... 8
1.11 Standby flow Constant Control ............................................................................................ 9
1.12 FC Mode Control ............................................................................................................... 10
2. MECHATRO CONTROLLER
2.1 Summary of Mechatro Controller.......................................................................................... 11
2.2 Self Diagnosis Display Function .......................................................................................... 11
2.3 Service Diagnosis ................................................................................................................ 13
2.4 Trouble History Diagnosis .................................................................................................... 14
2.5 How to Correct the E/G Oil Supply Cumulative Time ........................................................... 14
2.6 Engine starting frequency dispay function ............................................................................ 15
2.7 Mechatro Control Equipment ............................................................................................... 17
1. SUMMARY OF MECHATRO CONTROL SYSTEM
1.1 MECHATRO CONTROL SYSTEM IN GENERAL
System summary Furtures Purpose
P1, P2 pump is P1 pump is controlled by A) The power curve shall be an

1
controlled by proportional valve. ideal curve.
proportional valve.
P2 pump is controlled by B) Supply an optimum flow for
2
proportional valve. each operation.
Part of the control The travel straight valve is

3 z Make the changeover soft.
valve is controlled by proportional valve.
controlled by the
The bypass cut valve is controlled
proportional 4 z Make the changeover soft.
by proportional valve.
valve.
: GOVERNOR MOTOR The arm variable recirculation z Control the arm speed as
The main spool is 5 valve is controlled by proportional
valve. you desire.
controlled
: ENGINE SPEED SENSOR
hydraulically. The swing action is controlled by
: HIGH PRESSURE SENSOR
6 P2 bypass cut z Make the controllability soft.
valve(=proportional valve.)
The open and close actions of the
: LOW PRESSURE SENSOR swing P/B are controlled by
7
solenoid valve.
: ACCEL DIAL POTENTIOMETER
1
1.2 BOOM RAISE CONFLUX 1.3 SWING CUT VALVE CONTROL
(1) Boom raise conflux (1) Swing cut valve control

1) Start boom raise operation, and the boom raise operation pilot pressure switches boom spool and boom 1) Start swing operation, and the swing pilot secondary pressure switches swing spool, and is input into
conflux spool, and inputs into low pressure sensor. low pressure sensor.
2) The voltage output by low pressure sensor is input into mechatro controller, and the controller processes 2) The output voltage of the low pressure sensor is put into the mechatro controller which processes the
the pilot signal and outputs the command corresponding to input voltage to P1,P2 pump and P2 bypass pilot signal. A command value is then put out to the P2 bypass cut proportional valve.
cut valve. 3) The P2 pump and the P2 bypass cut proportional valve put out secondary pilot pressure according to a
3) Each proportional valve puts out the secondary pressure for the pilot proportional valve according to command value of the mechatro controller.
command values from the mechatro controller, changes the delivery rates of the P1, P2 pump and This changes the delivery rate of the P2 pump and switches the P2 bypass cut valve.
switches the P2 bypass cut valve. 4) The pure hydraulic command switches the swing main spool. Then a mechatro command switches the
4) A pure hydraulic command switches the boom main spool and the boom conflux valve. A mechatro P2 pump and the P2 bypass cut valve.
command switches the P1, P2 pumps and the P2 bypass cut valve. This causes the oil delivered by the If the amount of change is controlled, the swing motion is controlled softly.
P1 pump to combine with that by the P2 pump at boom raise operation.
2
1.4 ARM IN RECIRCULATION & SEQUENCE CONFLUX (1) Recirculation cut control
2
1) If load increases and the load pressure of the pump rises above 200kgf/cm (2840psi) during arm in
operation, the output voltage of the high pressure sensor (SE-23) is put into the mechatro controller.
The mechatro controller processes pilot signals and puts out a command current that cuts off the
variable recirculation, to the variable recirculation proportional valve.
2) The variable recirculation proportional valve puts out secondary pilot pressure according a command
current of the mechatro controller, brings back the variable recirculation valve to the recirculation cut
position and blocks the recirculation passage.
(2) Sequence conflux control
2
1) If load increases and the load pressure rises above 220kgf/cm (3130psi) during arm in operation, the
mechatro controller processes a pilot signal and puts out a command current to the travel straight
proportional valve and the P1 bypass cut proportional valve according to the secondary operating pilot
pressure.
2) The travel straight proportional valve and the P1 bypass cut proportional valve put out the secondary
pilot pressure according to a command current of the mechatro controller and switches the travel straight
valve and the P1 bypass cut valve.
3) When the travel straight valve is changed over, the parallel passage on the P1 side connects with the
parallel passage on the P2 side.
When the P1 bypass cut valve and the P2 bypass cut valve are changed over, the oil delivered by the P1
pump is combined with that by the P2 pump by arm operation.
Note: If sequence conflux control operates during slope finishing work, the oil is combined in the parallel
passage. The operability is deteriorated as the oil for the bucket operation is combined together. If a
signal is put into the low pressure sensor on the bucket dump side, the sequence conflux control does
not operate.
(3) Recirculation control
1) Start arm in operation simultaneously, and arm operation pilot secondary pressure switches arm spool,
and is input into low pressure sensor.
2) The output voltage of the low pressure sensor is put into the mechatro controller. The mechatro
controller processes the pilot signal and puts out a command current according to the input voltage to
the P2 pump proportional valve, the P2 bypass cut proportional valve and the variable recirculation
proportional valve.
3) Each proportional valve puts out secondary pilot pressure according to a command current from the
mechatro controller and switches the delivery rate of the P2 pump. At the same time it switches the P2
bypass cut valve and the variable recirculation valve of the control valve.
4) The pure hydraulic command switches the arm main spool. Then a command from the mechatro
controller switches the P2 pump, the P2 bypass cut valve and the variable recirculation valve. This
causes the returned oil of the arm cylinder rod side to be recirculated to the oil delivered by the P2 pump.
3
1.5 ARM IN ANTI- CAVITATION CONTROL 1.6 ARM OUT CONFLUX
(1) Arm in anti- cavitation control

1) If the arm in is performed, the secondary pilot pressure for arm operation switches the arm spool and is
put into the low pressure sensor. (1) Arm out conflux
2) An engine speed command put out from the acceleration potentiometer is put into he mechatro 1) Start arm out operation simultaneously, and arm operation pilot pressure switches arm spool, arm conflux
controller. spool and is input into low pressure sensor.
3) The output voltage from the low pressure sensor is put into the mechatro controller, and processes the 2) The output voltage of the low pressure sensor is put into the mechatro controller. The mechatro controller
pilot signal and puts out a command current according to the input voltage to the P2 pump proportional processes pilot signals and puts out command current according to the input voltage to the P1, P2 pump
valve and the P2 bypass cut proportional valve. proportional valves and the P1 cut proportional valve.
4) Also, the mechatro controller puts out a command current to the variable recirculation proportional valve 3) Each proportional valve puts out a secondary pilot pressure according to a command current from the
according to the input voltage from the accel potentiometer. mechatro controller, changes the delivery rate of the P1 and P2 pumps and switches the P1 bypass cut
5) Each proportional valve puts out a secondary pilot pressure according to a command current from the valve of the control valve.
mechatro controller. This controls the variable recirculation valve to provide a spool stroke according to 4) A pure hydraulic command switches the arm main spool. A mechatro command switches the P1, P2
the engine speed and changes the recirculation ratio. This holds down cavitation when the engine speed pumps and the P1 bypass cut valve. This causes the oil delivered by the P1 pump to combine with the oil
is low and the delivery rate of the pumps is low. delivered by the P2 pump during arm operation.
4
1.7 TRAVEL STRAIGHT TRAVEL STRAIGHT
1) Start ATTs work operations (boom, arm, bucket, swing) in travel operation (right and left), and the pilot
pressure switches respective spools, and is input into respective low pressure sensors.
Note: Boom raise operation is explained here.
2) If mechatro controller receives the input satisfying the following combination shown in Table, the
controller determines it as travel straight, and the travel straight signal turns on.
3) After the travel straight signal has turned on, the signal is input to respective proportional valve
corresponding to the following commands.
Travel straight proportional valve command

Outputs switching command corresponding to boom raise pilot pressure
(Selection of the higher ATT pilot pressure in operation)
P1 bypass cut valve command
The P1 bypass cut valve does not operate if the boom raise operation is performed. During the arm and
swing operation, the higher of the remote control pressures is selected to put out a select pressure.
P2 bypass cut valve command
Outputs switching command corresponding to boom raise pilot pressure (Selection of the higher ATT pilot
pressures from C/V on P1 side during operation) and the pressure selected by travel right pilot pressure
as high priority.
(Reference) Operating condition where travel straight signal turns on

ATT operation Boom Bucket Arm Swing
In travel right operation(P1)
In travel left operation(P2)
5
1.8 SWING PRIORITY CONTROL (1) Swing priority control at Arm in (The forced recirculation position)
1) If swing operation is performed during arm in (or arm in is performed during swing), the secondary pilot
pressure for arm operation switches arm spool and swing spool. Respective pressure is simultaneously
put into each low-pressure sensor (SE-7, SE-5).
2) The output voltage of the low pressure sensor is put into the mechatro controller.
The mechatro controller processes pilot signals. The command currents according to the input voltage
are put out to the ,P1 pump proportional valve(PSV-P1), P2 pump proportional valve (PSV-P2), travel
straight proportional valve (PSV-C), P1 bypass cut proportional valve (PSV-D), P2 bypass cut
proportional valve (PSV-B) and the arm variable recirculation valve (PSV-A).
3) Each proportional valve puts out a secondary pilot pressure according to a command current from the
mechatro controller and switches the delivery rate of the P1&P2 pumps. At the same time, the pressure
moves the P1&P2 bypass cut spool to full stroke position, and switches the arm variable recirculation
valve to the forced recirculation position.
4) If arm in and swing operations are performed simultaneously, the secondary pilot pressure moves
sub-spool of arm spool and consequently passage in arm cylinder head is restricted. The arm variable
recirculation spool is shifted to forced recirculation position, the return oil from rod side is recirculated at
head side while restricton. The operation pressure of arm cylinder is risen by restriction of arm cylinder
circuit.
5) Delivery oil of P2 pump flows into swing and arm sections of P2 side, but it flows preferentially into swing
side because the operation pressure of arm cylinder is higher than swing side pressure.
6) On the other hand, as travel straight spool is shifted to travel straight position and P1 bypass cut spool is
switched, delivery oil of P1 pump flows into parallel circuit of P2 side and confluxes with swing circuit, and
swing priority is available.
7) By this operation the operating pressure of arm cylinder is risen, delivery oil of P2 pump preferentially
flows into swing side which pressure is lower than arm.
Arm working speed keeps minimum loss because recirculation oil is used to arm cylinder, and as P1
pump delivery oil confluxes with swing circuit, swing priority control is more available.
8) If arm in and swing operation are performed, energized signal from mechatro controller to swing parking
brake solenoid valve (SV-1) is cut, and swing parking brake is released.
6
1.9 PRESSURE DRAINING (RELEASING) CONTROL (1) Pressure draining (releasing) control
1) Simultaneously the screen select switch and the buzzer stop switch of gauge cluster are kept pressed for
more than five seconds, the mechatro controller judges it as Pressure Releasing Control.
2) If the mechatro controller judges it pressure releasing control, the mechatro controller performs the
following regardless of input signals (From operation pilot valve, accel potentiometer, etc.):
a. Puts out a minimum tilting angle command to the pump proportional valve.
b. Puts out a command current for pressure releasing control revolution to the governor motor.
c. Puts out a command current for the pressure position switch to the travel straight proportional valve.
d. Puts out a standby command current to the P1 bypass cut valve and the P2 bypass cut proportional
valve.
3) A command current from the mechatro controller causes the following to occur:
a. The pump proportional valve puts out a secondary pilot pressure to the pump to minimize the tilting
angle of the pump.
b. The governor motor controls the engine revolution to a pressure releasing control revolution.
c. The travel straight proportional valve puts out a secondary pilot pressure to switch the travel straight
valve to the pressure releasing position.
d. The P1 bypass cut valve and the P2 bypass cut proportional valve put out a secondary pilot pressure
to hold the P1 bypass cut valve and the P2 bypass cut valve in their standby position.
4) The mechatro controller senses the output voltage of the high pressure sensor of the main pump, judges
it as pump pressure and displays DRAINING HYD. PRESS or FAIL DRAIN HYD. PRESS on the
gauge cluster.
5) Since the travel straight valve is in the pressure releasing position, the oil delivered by each pump is
unloaded to the tank passage.
If the operating levers are operated and the spools switched, the pressure remaining in the actuators may
be discharged.
7
(1) Positive control
1.10 PUMP CONTROL (POSITIVE CONTROL & P_Q CONTROL) 1) If any operation performed, the secondary pilot pressure switches the spools and is put into the low
pressure sensors.
2) The output voltage of the low pressure sensor is put into the mechatro controller which processes pilot
signals and puts out command current to the proportional valve of each pump according to the input
voltage.
3) The proportional valve of each pump puts out a secondary pilot pressure according to a command current
from the mechatro controller, switches the tilting angle of the pump and controls the delivery rate of the
pump.
4) This causes the delivery rate according to a lever stroke to be supplied to the actuator, thus an operating
speed according to a lever stroke is achieved.
(2) P-Q control
1) The output voltage of the high pressure sensor attached to each pump piping is put into the mechatro
controller, which processes pilot signals and computes command current according to input voltage (load
pressure).
2) The lower of the command current computed by positive control and the command value (1) computed by
P-Q control is selected and put out to the proportional valve of each pump as a command current.
3) The proportional valve of each pump puts out a secondary pilot pressure according to a command current
of the mechatro controller, switches the tilting angle of the pump and controls the delivery rate of the
hydraulic pressure.
4) This increases the load of the actuator, enabling the engine to keep running even if the pump is highly
loaded.
8
1.11 STANDBY FLOW CONSTANT CONTROL (1) Standby flow constant control
1) An engine rotation command put out of the accel potentiometer is put into the mechatro controller.
2) The mechatro controller processes pilot signals and puts out a command current to the proportional valve of
each pump so as to make the delivery rate of the pump constant when the engine speed is below an
intermediate rpm between the FC mode and the Decel revolutions.
3) The proportional valve of each pump puts out a secondary pilot pressure according to a command current of
the mechatro controller, changes the tilting angle of the pump till the engine speed arrives at an intermediate
rpm between the FC mode and the Decel revolutions.
4) If the engine speed increases an intermediate rpm between the FC mode and the Decel revolutions, command
current from the mechatro controller become constant, with the result that the delivery rate of each pump rises
linearly as the engine speed increases.
5) The result is that the motion of the lever at the start of each operation becomes the same as that when a
standby flow is available. Also, if the engine revolution is increased, the operating feeling according to each
revolution is available.
9
1.12 FC MODE CONTROL (1) FC mode control
1) If the FC mode is selected by the work mode selector switch on the gauge cluster, FC mode signal is put
into the mechatro controller.
2) Upon receipt of the FC mode signal, the mechatro controller;
a. Judges it as FC mode.
b. Puts out a FC mode rpm command to the governor motor.
3) The governor motor controls the engine speed to a level that matches a command current from the
mechatro controller. During operation it puts out, to each proportional valve, a command current in the FC
mode according to the input voltage from the low pressure sensor.
(2) Peculiar control of proportional valve at FC mode
1) If arm in action is performed at FC mode, the secondary pilot pressure for arm in operation switches the
arm spool and is put into the lower pressure sensor.
2) The output voltage of the low pressure sensor is put into the mechatro controller. The mechatro controller
processes pilot signals and puts out command current according to the input voltage to the P2 pump
proportional valve and the P2 bypass cut proportional valve.
3) In that case, a peculiar control command current at the FC mode is put out to the variable recirculation
proportional valve. (the recirculation ratio higher than normal recirculation operation)
4) This combines the speed drop of the ATTs as the engine speed decreases with the fine arm operation at
the FC mode, in order to improve the delicate controllability of the entire working.
10
2. MECHATRO CONTROLLER
The functions displayed on the multidisplay are classified roughly into the following 7 types.
2.1 SUMMARY OF MECHATRO CONTROLLER * 1. CPU error display............................................. Display the error of the mechatro controller, etc.
Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster. However, the * 2. Self-diagnosis display ...................................... Displays the failure of the I/O system of the mechatro controller such
mechatro display and the cumulative engine oil lubrication time may be changed over if the screen change as the low and high pressure sensors, governor motor, proportional
switch is pressed.
valve, solenoid valve, etc. (31 items)
3. Service diagnosis display................................. Displays the information output by the mechatro controller such as the
pressure sensor detection, proportional valve, solenoid valve, etc.
(23 items)
RIGHT HAND 4. Trouble history display ................................... Stores and displays the contents of the troubles detected through the
OPERATOR
CONTROL LEVER mechatro self diagnosis.
5. Mechatro A adjustment display........................ Displays it by procedure during the mechatro A adjustment.
CIGARETTE LIGHTER 6. E/G oil supply cumulative (integrated) time ... Displays the E/G oil supply cumulative time and E/G speed (rpm) list.
7. Warning displays ........................................... When the machine is normal after self-diagnosis ( ) but the actual
PLUG operation fails, the occurence of any of the following items is indicated
(Opt.switch)
every time.
NO.1
MAIN CONT. P/N
AUTO IDLE STOP STARTER CHG
SELECT SWITCH PROGRAM VER
VER 3.00
When the number of starting up of

ACCEL DIAL
starter reaches set value, and each
time the starter key is truned on, this
No.1 display is always flashed for 10
STARTER SWITCH
seconds.
Note 1. The buzzer sounds on display
No. 2,3,5,6,7,32 and 33.
FUSE BOX
Note 2. The buzzer does not stop by
the buzzer stop switch,
exept No.7.
MECHATRO
CONTROLLER SWING PARKING BRAKE RELEASE SWITCH
GAUGE CLUSTER KPSS WORK MODE RELEASE SWITCH
2.2 SELF DIAGNOSIS DISPLAY FUNCTION
(1) Summary
It performs self diagnosis of control inputs and outputs of pressure sensors and proportional valves
while the machine is in operation. Errors coming out of the self diagnosis are displayed on the multi
display of the gauge cluster. Regarding the connector numbers and the pin numbers, refer to the C-1
Mechatro Controller which described later. Wire numbers and colors may be confirmed on the
The work mode selector switch contains the following functions. electric circuit diagram or on the harnesses.
- Display item roll forwarded in trouble history operation (2) I/O configuration
- Time display roll forwarded when correcting E/G oil
supply cumulative time
INPUT
- Number of engine starting up is increased. SERIAL COMMUNICATION
Pressure sensor
Gauge cluster
Proportional valve
Control
Buzzer stop switch contains the following functions.
(Buzzer alarm)
- Stops the warning sounding Selector valve (SOL)
- Display item rollbacked in service diagnosis operation Governor motor
- Display item rollbacked in trouble history operation
- Time display rollbacked when correcting E/G oil supply Battery relay
SCREEN SELECT MULTI DISPLAY LCD
SWITCH cumulative time
- Number of engine starting up is decreased.
11
(3) Self diagnosis Connector
No. Contents Display of monitor No. Wire No. Wire color
Indication item -Pin No.
Connector Arm variable recirculation CN1510 757 BrG
19
No. Contents Display of monitor No. Wire No. Wire color propo-valve fail CN1511 758 YV
-Pin No.
Mechatro controller Pump P1 CN1517 760 VR
1 20 Proportional valve fail CN1518 759 BrG
fail
Pump P2 CN1519 764 VW
CN1425 21
2 ROM data 600 R Proportional valve fail CN1520 763 GY
When the E/G Travel two-speed
speed is not in 22 solenoid valve fail CN1521 702 LgB
3 Mechatro set error the range from
300rpm~3000rpm
CN113 Swing parking
Boom raising
902 WV 23 CN1522 700 VR
4 CN112 502 LgY solenoid valve fail
pressure sensor fail
CN111 952 BR
CN114 ATT boost pressure
Boom lowering
903 OB 24 solenoid valve fail CN1523 703 P
5 CN115 503 LO
pressure sensor fail CN116 953 BrW CN151 851 G
CN119 904 OL Governor motor CN152 852 B
6 Arm in CN118 504 PW 25 current fail CN1515 853 R
pressure sensor fail CN1516
CN117 954 BrY 854 W
CN1110 905 OW Governor motor
CN1134 560 V
Arm out
7 CN1111 505 PL 26 starting point indexing
pressure sensor fail CN1112 955 Gr fail
CN1115 900 RB CN1133 930 WR
8 Bucket digging CN1114 500 LgR 27 Accel potentio meter CN1132 530 P
pressure sensor fail fail CN1131
CN1113 950 BrR 970 BW
CN1116 901 RL Gauge clusterMechatro
CN1426 601 W
Bucket dump
9 CN1117 501 LgW 28 controller communication CN1427 602 B
pressure sensor fail CN1118 951 BL failure
CN1121 906 YB
10 Swing CN1120 506 V 29 Battery relay fail CN1524 805 WG
CN1119 956 GrL
Travel right CN1127 908 YL Draining
12 CN1126 508 VY 30 hyd. pressure
pressure sensor fail CN1125 958 BY
Travel left CN1128 909 YR Fail drain
13 CN1129 509 Sb 31
hyd. pressure

pressure sensor fail CN1130 959 BG
Pump P1 CN123 941 YL
14 CN122 514 VY
pressure sensor fail CN121 964 BrB
Pump P2 CN124 915 YR
15 CN125 515 Sb
pressure sensor fail CN126 965 BrL
P1 bypass cut CN154 755 BP
16 propo-valve fail CN155 756 PW
P2 bypass cut CN156 751 BO

17 propo-valve fail CN157 752 GrR
18 Travel priority CN158 753 BG

propo-valve fail CN159 754 GrB
12
2.3 SERVICE DIAGNOSIS No. DISPLAY REMARKS No. DISPLAY REMARKS
No.11 No.22
The result of the service diagnosis at the present time is displayed in 23 categories depending on the PRESS. SENSOR PROPO-VALVE
data output by the mechatro controller. B5 BUCKET DIG Sensor voltage / D3 S-TRAVEL Command current /
11 3.5V 37k Pressure converted value 22 COMP. 600mA 45k Pressure converted value
How to display B6 BUCKET DUNP Sensor voltage / MEAS. 600mA 45k Feedback current /
1) Turn the starter key switch on, keeping the buzzer stop switch depressed, and place the attachment 3.5V 37k Pressure converted value Pressure converted value
to the travel position while operating in the low idling condition after the engine starts. No.12 No.23
2) The mechatro controller P/NO and the program version in the 1st item are displayed. PRESS. SENSOR PROPO-VALVE
B7 SWING (R) Sensor voltage / D6 A-RECIRCULAT Command current /
GAUGE CLUSTER B8 SWING (L) Sensor voltage / MEAS. 600mA 45k Feedback current /
0.5V 0k Pressure converted value Pressure converted value
No.1
No.13 No.24
MAIN CONTROLLER PRESS. SENSOR PROPO-VALVE
PROGRAM VERSION B9 TRAVEL (R) Sensor voltage / E1 P1 PUMP Command current /
VER 5.60
Screen select switch Buzzer stop switch 13 3.5V 39k Pressure converted value 24 COMP. 600mA 45k Pressure converted value
Advances the screen Returns the screen B10 TRAVEL (L) Sensor voltage / MEAS. 600mA 45k Feedback current /
(As an example) 3.5V 39k Pressure converted value POWER SHIFT 100mA Pressure converted value
No.14 No.25
3) By pressing the screen select switch, goes to No.2,No.3 in order. PRESS. SENSOR PROPO-VALVE
4) By pressing the buzzer stop switch, returns from No.13, No.12 in order. C1 PUMP P1 Sensor voltage / E2 P2 PUMP Command current /
5) Turn the starter switch off, and the display also goes off. C2 PUMP P2 Sensor voltage / MEAS. 600mA 45k Feedback current /
3.5V 350k Pressure converted value POWER SHIFT 100mA Pressure converted value
No.15 No.39
PRESS. SENSOR MECHATRO ADJT.
No. DISPLAY REMARKS No. DISPLAY REMARKS B16 P1 OPT. Sensor voltage / CONT. SW TEST RUN/TEST indication
No.1 15 3.5V 36k Pressure converted value 39 CONT. VOL 100% Inner trimmer
B17 P2 OPT.
No.6
Service diagnosis
MAIN CONT. display Sensor voltage / PROG. SW OFF ON/OFF indication
SOL. VALVE
F3 1/2-TRAVEL
PROGRAM VER 3.5V 36k Pressure converted value
1 VER 5.60 P/No. indication 6 COMP. OFF ON/OFF indication
Version indication MEAS. OFF ON/OFF indication No.20 No.40
SWITCH OFF ON/OFF indication PROPO-VALVE RELEASE SW
D1 P1 BYPASS Command current / KPSS OFF ON/OFF indication
No.2 No.7 20 COMP. 600mA 45k Pressure converted value 40 SWING BRAKE OFF ON/OFF indication
E/G SET 2420 No load set rpm SOLENOID VALVE MEAS. 600mA 45k Feedback current /
MEAS 2420 Actual rpm F1 POWER UP Pressure converted value
2 E/G PRS. LIVE LIVE/DEAD indication 7 COMP. OFF ON/OFF indication
KPSS SW H H / S / FC indication MEAS. OFF ON/OFF indication No.21
KEY SWITCH OFF ON/OFF indication PROPO-VALVE
D2 P2 BYPASS Command current /
No.3 No.8 21 COMP. 600mA 45k Pressure converted value
H1 RELAY MEAS. 600mA 45k Feedback current /
ACCEL VOLT. 4.2V Potentio voltage I2 BAT. RELAY Pressure converted value
3 POS. 100% Voltage position 8 COMP. OFF ON/OFF indication
MOTOR STEP 440 No of motor steps MEAS. OFF ON/OFF indication
POS. 100% Step position KEY SWITCH OFF ON/OFF indication
No.4 No.9
GOVERNOR MOTOR PRESS. SENSOR
G1 COIL A 1.0A A phase current B1 BOOM RAISE Sensor voltage /
4 G1 COIL B 1.0A B phase current 9 3.5V 35k Pressure converted value Note:
G2 LIMIT OFF ON/OFF indication B2 BOOM LOWER Sensor voltage /
3.5V 35k Pressure converted value Service diagnosis and trouble history can be displyed with the screen select switch and the buzzer stop
switch. Note that the displays do not come out in some cases if the switches are pressed too quickly.
No.5 No.10
SOL. VALVE PRESS. SENSOR (This is not a fault.) Give one second or more before pressing next switch.
F2 SWING-BRAKE B3 ARM OUT Sensor voltage /
5 COMP. OFF ON/OFF indication 10 3.5V 36k Pressure converted value
MEAS. OFF ON/OFF indication B4 ARM IN Sensor voltage /
RELEASE SW OFF ON/OFF indication 3.5V 36k Pressure converted value
13
2.4 TROUBLE HISTORY DIAGNOSIS 4) To scroll the page, use the work mode selector 2.5 HOW TO CORRECT THE E/G OIL SUPPLY CUMULATIVE TIME
The error item detected by the self-diagnosis is switch and the buzzer stop switch. (1) LCD display
stored in the mechatro controller as a history and z Press the work mode selector switch, page up.
LCD display Operating procedure Buzzer sound
is displayed on the multidisplay. z Press the buzzer stop switch, page down.
Note :
(1) How to display
1) Turn the starter switch on.
All the error items are stored by hour meter, when
the hour meter is differed, press the work mode
O K 1515 RPM
2) Press the buzzer stop switch 5 times in selector switch and the buzzer stop switch, and
sequence for 10 seconds. displays all items and make sure that they are Normal
(Example) right. 256Hr. have passed None
display after E/G oil was
CONTENTS DISPLAY
5) Turn the starter switch off, and the display is
No errors NO ERROR Supplementary explanation :
disappeared.
00025H If the screen change switch is pressed, the above three
Error detected in the B-1 BOOM RAISE (2) How to cancel the contents of the trouble screen may be changed over.
past D-1 P1 BYPASS CUT history
F-3 TRAVEL 1.2-SPEED 1) Display the trouble history mode.
2) Press the work mode selector switch and the
3) Transmits the error data (one or many) and buzzer stop switch for 10 seconds or more
hour meter to the gauge cluster. concurrently.
z Hour meter and 3 error data are displayed 3) When the deletion is completed, the NO
on the screen. ERROR is displayed.
z If three error data or more exist, display the 4) Turn the starter switch off.
data three by three in order for every 5 (2) How to correct
seconds. Note : Proce-d
ure
Operating procedure Display on multidisplay
All the stored items are erased. (Normal)
It is impossible to erase data partially. MONITOR
A Turn the starter switch ON. is displayed.
SYSTEM OK
E/G speed is displayed
Press the gauge cluster screen change switch Press once
B MONITOR
2250RPM
once, and the E/G speed (rpm) is displayed. SYSTEM OK
(3) Contents of the trouble history
Symbol Display Symbol Display Press once more, and the engine oil supply E/G speed is displayed 100Hr AFT
C Press once more
cumulative time screen is displayed. 2250RPM E/G OIL CH
A 1 ROM DATA FAILURE D 1 P1 BYPASS CUT
A Controller relation
A 2 MECHATRO SET ERROR Proportional valve D 2 P2 BYPASS CUT
D D 3 TRAVEL PRIORITY Press the screen change switch for 3 to 10
(Control valve)
B 1 BOOM RAISING D 6 ARM VARIABLE D seconds and release the hand, it returns to 100Hr AFT MONITOR
100Hr AFT
B 2 BOOM LOWERING RECIRCULATION E/G OIL CH SYSTEM OK E/G OIL CH
Portional valve E 1 the correction mode.
B 3 ARM OUT E
PUMP P1 PORPO- VALV
B 4 ARM IN (Hydraulic pump) E 2 PUMP P2 PORPO- VALV
Low pressure Press the work mode selector switch, and the 100Hr AFT Cumulative time 101Hr AFT
B B 5 BUCKET DIGGING F 1 POWER UP E
sensor F Solenoid valve F 2 SWING PARKING cumulative time increases. (once 1Hr) E/G OIL CH increases E/G OIL CH
B 6 BUCKET DUMP
B 7 SWING RIGHT F 3 TRAVEL 1,2-SPEED
G 1 STEP MOTOR Press the buzzer stop switch, the cumulative 100Hr AFT The cumulative 99Hr AFT
B 9 TRAVEL RIGHT CURRENT-NG F
time decreases. (once 1Hr) E/G OIL CH time decreases E/G OIL CH
B 10 TRAVEL LEFT G E/G Accessory G 2 STEP MOTOR S/PT.
ERROR
High pressure Press the gauge cluster screen change switch
C 1 PUMP P1 G 3 E/G REV. SENSOR (Normal)
C sensor
C 2 PUMP P1 H Potentio relation H 1 ACCELERATR once the correcting time is stored, and exits 99Hr AFT Complete the MONITOR
(Hydraulic pump) POTENTIO G
E/G OIL CH correction SYSTEM OK
I 1 RECEIVE ERROR from the correction mode and OK symbol is
I
I 2 BAT. RELAY displayed to complete the correction.
MONITOR SYSTEM OK
Note :
Press the screen change switch once after the procedure D, and the condition is stored and the correction is
14 completed.
2.6 ENGINE STARTING FREQUENCY DISPLAY FUNCTION

Since it is supposed that the engine starting frequency increases because of adoption of auto idling stop
function, the engine starting frequency can be indicated on multidisplay as a guide for maintenance of
starter motor.
(1) How to display engine-starting frequency
1) Switch auto idling stop selector switch on.
2) While keeping buzzer stop switch pressed, switch starter switch on.
(Display service diagnosis.)
3) Press screen change switch in the condition the initial main controller parts number is displayed,
and the following screen is displayed.
(Ex.)
No.1
Starting frequency 12345 times
MAIN CONT. P/N
START 12345
Replacing reminder frequency 30,000 times
PROGRAM VER
(Differ with machine model)
VER 3.00
(2) How to correct the value of engine starting frequency

Set starting frequency to zero when starter was replaced, and reset starter frequency to the value
set before replacing controller.
In the engine condition shown in Item (1)-3).

4) Press screen change switch for 5 seconds or more and release it, and "Reset" mode is displayed.
5) Press work mode selector switch, and starting frequency increases. (By 100 times. By 1000 times
while keeping it pressed)
6) Press buzzer stop switch, and starting frequency decreases. (By 100 times. By 1000 times while
keeping it pressed)
7) Press screen change switch after setting starting frequency to the desired value, and the desired
value is memorized (stored).
(3) Warning contents when starting frequency was reached to the replacing reminder frequency.
Each time starter switch is switched on; the following screen is displayed and flickers on cluster
gauge for 10 seconds.
In this case, overhaul or replace the starter.
(Ex.)
No.1
MAIN CONT. P/N
STARTER CHG
Replacing reminder frequency 30,000 times
PROGRAM VER
(Differ with machine model)
VER 3.00
15
This page is left blank for editing convenience
16
2.7 MECHATRO CONTROL EQUIPMENT
(1) C1 Mechatro controller Connec- Pin Port
Specification In/out
Signal level
Connec- Pin Port
Specification In/out
Signal level
2 1 6 2 1 4 2 18 2 1 tor No. No. name put tor No. No. name put
1) Outside view 10 Engine coolant high temp. LS
IN GND / OPEN 1 D7
16 1 B8 High/Normal
Engine oil pressure low LS 2 D7
26 2 B9 Without/With IN GND / OPEN
3 D8
Air filter clogged LS
34 3 B10 Clogged/Normal IN GND / OPEN 4 D8
4 B11 Double single select SW. opt IN GND / OPEN 5 D9
GROMMET
27 22 18 16 12 28 22 5 B12 ATT boost pressure SW. IN GND / OPEN 6 D9
FOR CN11 CN12 CN13 CN14 7 D10
6 B13
ADJUST
13 2 18 2 1 11 2 1 7 B14 Travel alarm SW. IN GND / OPEN 8 D10
CN16
Fuel level thermistor 9 D11
ROM REWRITE COUPLER 8 B15 Low/Normal IN 670/1140
10 D11
9 B16 Wiper motor rise up(stop) IN GND / OPEN
11 D12
10 B17 Wiper motor rise up(reverse) IN 24V / OPEN
12 D12
11 B18 Connector for flat control IN
13 H1
26 14 16 9 22 12 12 C1 Wiper motor (rise up) OUT +24V / OPEN
CN15 CN16 CN17 ADJUSTMENT SWITCH 14 H1
13 Wiper motor (not rise
C2 OUT 15 B26
up)
Connec- Pin Port In/out CN14 16 C22
tor No. No. name Specification put Signal level 14 C3 Wiper motor (rise up) OUT +24V / OPEN
15 C4 Washer motor relay Out/Stop OUT GND / OPEN 1 C15 Rotating N&B relay right OUT GND / OPEN
1 G
2 C16 Rotating N&B relay left OUT GND / OPEN
2 A12 P1 pump pressure sensor IN 0.5~4.5V 16 C5 Front working light relay ON/OFF OUT GND / OPEN
2) List of connectors 17 C6 Extra dis-press. SW. OPT. IN GND / OPEN 3 C17 (Swing flasher & working light unit) OUT GND / OPEN
3 +5V
18 +5V 4 C18 (Swing flasher & working light unit) OUT GND / OPEN
Connec- Pin Port In/out 4 +5V
tor No. No. name Specification put Signal level 5 C19
5 A13 P2 pump pressure sensor IN 0.5~4.5V 19 B19
1 G 20 C7 6 C20 Travel alarm relay OUT GND / OPEN
6 G
2 A1 Boom raise pressure sensor IN 0.5~4.5V 21 C8 7 C21 Power window controller OUT GND / OPEN
7 G
3 +5V 8 B20 Auto decel releasing switch IN GND / OPEN
8 A14 Opt. 2 pressure sensor IN 0.5~4.5V 22 C9
4 +5V 23 C10 9 B21 Rotating N&B switch right OUT GND / OPEN
Boom lower pressure 9 +5V
5 A2 sensor IN 0.5~4.5V 24 G 10 B22 (Swing flasher select switch) IN GND / OPEN
10 +5V
6 G 25 TXD1 IN/OUT
11 B23 Lever lock switch IN GND / OPEN
11 A15 Extra press. CN17
7 G 26 RXD1 Gauge cluster IN/OUT
12 B24 Rotating N&B switch left OUT GND / OPEN
CN12 12 G
8 A3 Arm in pressure senor IN 0.5~4.5V 13 B25 Power window controller IN GND / OPEN
13 A16 Alternator voltage IN 0~36V 27 G
9 +5V 28 SHG Shield ground 14 TXD2
Auto idle stop select
10 +5V 14 A17 switch IN GND / OPEN 15 RXD2
1 F1 OUT
11 A4 Arm out pressure sensor IN 0.5~4.5V 15 B2 Key switch(ON) ON/OFF IN +24V / OPEN
2 F1
Governor motor A phase
OUT
16 G
12 G 16 B3 Key switch(GLOW) ON/OFF IN +24V / OPEN 17 SHG
3 SHG Shield ground
17 B4 IN GND / OPEN
0~800mA
13 G Travel 1.2 speed switch ON/OFF 18 +5V
Bucket digging pressure 4 D1 P1 bypass cut OUT
0.5~4.5V
Swing parking release switch
0~800mA
14 A5 IN 18 B5 IN 17/ OPEN proportional valve D 19 A23
sensor Release/Normal 5 D1 OUT
0~800mA
15 +5V 20 A24
19 B6
KPSS rerease switch
Release/Normal IN ~12V / 12V~ 6 D2 P2 bypass cut OUT
0~800mA
16 +5V proportional valve B 21 A25
Bucket extend pressure 20 E1 IN 3.0~20Vp-p 7 D2 OUT
17 A6 sensor IN 0.5~4.5V Engine revolution sensor
8 D3 OUT 0~800mA
22 G
CN11 21 E1 Travel straight
18 G
22 SHG Shield ground 9 D3 proportional valve C OUT 0~800mA 1 DL IN/OUT
0~800mA
19 G 2 TXD3 IN/OUT
1 G 10 D4 Arm variable recirculation OUT CN18 Handy checker
Swing pressure sensor 0.5~4.5V
0~800mA
20 A7 IN proportional valve A 3 RXD3
2 A18 Opt. 1 Pressure sensor IN 0.5~4.5V 11 D4 OUT IN/OUT
21 +5V 12 +24V 4 G
3 +5V Power supply + 24V
22 +5V 13 +24V
4 +5V
23 A8 CN15 14 +24V Battery back up
5 A19
24 G 15 F2
6 G Governor motor B phase
25 G
7 G 16 F2
26 A9 Travel right pressure sensor IN 0.5~4.5V
8 A20 Angle sensor (Boom) IN 0.5~4.5V 17 D5 P1 pump proportional OUT 0 800mA
27 +5V CN13 18 D5 valve OUT 0 800mA
9 +5V
28 +5V 19 D6 OUT 0 800mA
10 +5V P2 pump proportional
29 A10 Travel left pressure sensor IN 0.5~4.5V D6 valve
11 A21 Angle sensor (Arm) IN 0.5~4.5V 20 OUT 0 800mA
30 G Travel 1,2-speed selector valve
12 G 21 C11 2 speed/1 speed OUT +24V / OPEN
31 G
13 G Swing parking selector valve
32 A11 Accel potentio IN 0~5.0V 22 C12 ,P /Release OUT +24V / OPEN
14 A22 ATT boost pressure solenoid
33 +5V 23 C13 valve OUT +24V / OPEN
Governor motor starting point 15 +5V
34 B1 indexing LS starting Point/Reguler IN GND / OPEN 24 C14 Battery relay Operation/Stop OUT +24V / OPEN
16 B7 Over load SW ON/OFF IN GND / OPEN
25 G
Power supply (GND) 17
26 G
(2) Gauge cluster (symbol C-2) (3) Governor motor(Symbol M 2)
1) General view NAME PLATE
Gauge and
Display lamp
Multi display LCD MATED SIDE

(Liquid crystal display) AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
Screen select VIEW
switch etc.
CONNECTION DIAGRAM MOTOR CONNECTOR

No. Item name No. Item name LIMIT SWITCH CONNETOR
BROWN RED
1 Fuel sensor 5 GND
(A) (B) LIMIT SWITCH MOTION RANGE
2 Engine water temp. sensor 6 Sourse (+24V)
3 RXD (Serial communication) 7 GND
ORANGE YELLOW
4 TXD (Serial communication) 8 (None) (A) (B)
LIMIT SWITCH CONNECTOR WIRE TABLE MOTOR CONNECTOR WIRE TABLE
5 6 1 2 No. Lead color Connection

No. Lead color Connection 1 Brown A
5 White COM 2 Orange A
6 Red NO 3 Red B
3) Function 7 7 Yellow NC 4 Yellow B
3 4
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.
It puts out coolant temperature signals, fuel level signals and panel switch signals to the mechatro
controller through the communication port.
Screen Select SW: Scroll forward (See Page 11.), and displays of the E/G revolution and the cumulative
hours after changing engine oil (See Page 14.).
Other functions
MODE SW. : The display changes S, H, FC, S, in that order each time the switch is pressed.
After the key is turned OFF, the display begins with S.
Adjusting the engine : Perform mechatronic adjustment in a conventional way, using the Buzzer
Stop SW.
(See the Maintenance)
Service diagnosis : This is displayed if the key is turned ON with the Buzzer Stop SW pressed.
This is the same as before.
Trouble history : Turn ON the key and press the Buzzer Stop SW five times
continuously in ten seconds. (See Page 14.)
Pressure release control : Press both the Screen Select SW and the Buzzer Stop SW. at the same
time and hold it for more than five seconds.
18
E200SR
SECTION 22 HYDRAULIC SYSTEM
TABLE OF CONTENTS
1. SUMMARY ................................................................................................................ 1
2. HYDRAULIC CIRCUITS AND COMPONENT ............................................................. 2

2.1 STD Model ........................................................................................................................... 3
2.2 Boom & Arm Safety ............................................................................................................... 4
2.3 EXTRA .................................................................................................................................. 5
3. OPERTATION EXPLANATION OF HYDRAULIC CIRCUITS ...................................... 6

3.1 Color Coding Standard for Hydraulic Circuits ......................................................................... 6
3.2 Neutral Circuit ........................................................................................................................ 6
3.3 Travel Circuit ......................................................................................................................... 8
3.4 Bucket Circuit ..................................................................................................................... 10
3.5 Boom Circuit ....................................................................................................................... 12
3.6 Swing Circuit ....................................................................................................................... 16
3.7 Arm Circuit .......................................................................................................................... 18
3.8 Combined Circuit ................................................................................................................ 24
3.9 Pressure Draining (Releasing) Circuit ................................................................................. 28
4. PILOT PIPING ......................................................................................................... 30
5. MAIN PIPING .......................................................................................................... 40

1. SUMMARY
The hydraulic circuits are built up with the following functions and features in order to achieve easy operability,
safety, mass volume handling and low fuel consumption.
Table. 1
Perfor- Device Function Features
mance
Travel straight Travel straight at combined operation
Travel 2 speed change & Auto 1st (low) 2 speed changeover of travel speed.
speed return
Travel
Auto parking brake Automatic braking when parking

Motor overrun protection Prevents overrunning of travel motor on
the slope.
Travel pilot operation Prevents hunting by the built in travel
shockless mechanism
Reverse rotation protective function Easy positioning to protect it from
(Swing shockless function) swinging back when stops swinging.
Modification of swings on stop of swing action Prevention of swings on stop of swing
Easy operability and safety
Swing
action by means of by-pass valve.

Swing priority circuit Easy operation of stable swing speed,
(simultaneous operation of arm arm slanted leveling, swing press
digging and swing motions) digging
Automatic swing parking brake Protect it from swing drift on the slope.
Hydraulic pilot control system Delicate operability
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.
Pressurized hydraulic oil tank To prevent hydraulic oil from being
contaminated 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
Others
malfunctioning
Return circuit To prevent hydraulic oil from fouling
Cooling hydraulic oil by oil cooler To prevent hydraulic oil from being
deteriorated.
Pressure drain (release) circuit To release the main circuit pressure
for piping repair work
Variable displacement pump of electric Pump delivery rate control by a
Mass handling capability
flow control type current command to the solenoid

Pump
proportional valve of the variable

displacement pump
Attachment
Boom raise conflux circuit Speed up of boom raise operation

Arm conflux circuit Speed up of arm operation
consumption
Auto accel Reduce fuel consumption and noise by

computer
Low fuel
Micro
lowering engine speed when control

lever is in neutral position.
1
2. HYDRAULIC CIRCUITS AND COMPONENTS
No. NAME Maker's code
1 HYD. PUMP ASSY (WITH GP) K5V80DTP100R
2 CONTROL VALVE (MAIN) KMX13YC/B33046
3 SWING MOTOR UNIT M2X120B-CHB-10A
4 TRAVEL MOTOR UNIT M4V 150/100-RG3.5B
5 BOOM CYL. (RH) 115-80-1200
6 BOOM CYL. (LH) 115-80-1200
7 ARM CYL. 125-90-1290
8 BUCKET CYL. 105-75-1055
9 SWIVEL JOINT
10 PILOT VALVE (ATT) PV48K2005
11 PILOT VALVE (TRAVEL) 07291-00000
12 INLINE FILTER YTD9257
13 SUCTION STRAINER SB281JOA0004A
14 SOLENOID VALVE 8KWE5G-30/G24WR-814
17 RETURN FILTER
18 AIR BREATHER AB0210GA001A
19 BOOST CHECK VALVE E2005A001A
20 BY-PASS CHECK VALVE VA1000SA001A
21 SLOW RETURN CHECK VALVE 07579-00000
24 SHUTTLE VALVE
25 HYD. VALVE ASSY
26 HYD. VALVE ASSY
27 CONTROL VALVE ASSY KADV22Y / S10102
(Note) . The Part numbers and serial numbers of machine may be changed due to modifacation, so use only the
numbers for reference.
2
2.1 KCME STD Model
D MB MB D
SE-22 SE-23
1 P P
4
4
PSV1 PH1 A1 a1 Dr1 a2 A2 PH2 PSV2
a3 a4 SWING
VB VA PB M
B DB
VA VB
3
12
Pcr Pcr
M A3
5200~
5400psi
P MA MA P 5200~
5400psi
4060psi
B1 A Pi2 Pi1 PA PG
a5 TRAVEL RIGHT B DE E F F A C TRAVEL LEFT
PUMP ASSY 9 26
Dr3
725psi B3
BUCKET DIS. A T
BUCKET DIG.
18 B
17
2 20
71psi
36psi ARM OUT
19 BOOM RAI.
13 MAIN CONTROL VALVE P2 P1 T ARM IN
BOOM LOW.
SWING R
CMR1 SWING L
SE-1 SE-8
HYD. TANK 4980psi CMR2 P P
PL1
PTb REV. PBI 24 RELAY
BLOCK
TRAVEL TRAVEL
LEFT FOR. PAI 1 2 3 4 5 6 7 8
PRIORITY
REV. AI
Drb
CT2 CP2 FOR. BI 22
LCs
RIGHT PBS SE-5
PBr REV. PBS2
TRAVEL CT1 SWING P ATT.
Pss PILOT VALVE
PAr FOR. RIGHT LEFT PAS
Br FOR.
CP1
LEFT AS
25 PB3 PA3 PA4 PB4 PB1 PA1 PA2 PB2
BOOM
Ar REV.
Dra LCc CONFLUENCE RIGHT BS 10 10
PBc DIG.
BUCKET PB1
PAc DIS.
SE-2 P Bc DIG. 23
SE-7 P T P T
Ac DIS.
5470psi CCb PLc2 P BOOM ARM
5760psi & BUCKET & SWING
Drd
OUT PBa 21
LCb Pisc TRAVEL
21 SE-3
P
PBb LOW.
Drc BOOM
LCa ARM
IN PAa
PILOT VALVE P T
PAb RAI.
Bb LOW. IN Aa
PLc1
CRb
5470psi
5760psi
CAr
CRa
7 11
P
SE-4 5470psi 2 5 1 4 6 3
Ab RAI. OUT Ba
5760psi X1 P P
SE-9 SE-10
ARM
CONFLUENCE
PCb Pis
SOL/V BLOCK P1 ARM VARIABLE PCa
P1
BY-PASS
CUT D
14 PA1
BY-PASS CCa P2
BY-PASS CUT RECIRCULATION
LEVER (P4)
4 LOCK
TRAVEL
STRAIGHT C PBo2 LCo2 PAo2
TRAVEL
P2 1/2SPEED
BY-PASS
CUT B
3 CHANGEOVER
27 5480psi 5480psi Bo2
ATT Ao2
ARM VARIABLE 2 BOOSTING Po
RECIRCULATION A 6
SWING
1 P/B 5
PT
8
3
2.2 Boom & Arm safety KCME
Boom & Arm Safety Spec.

NO. NAME
50 HOLDING VALVE
51 HOLDING VALVE
52 HOLDING VALVE
Note:This hydraulic circuit is used to add following circuit

M
for completion.
PUMP
REMARKS
E200SR(LC)-1S KCME
MAIN CONTROL VALVE P2 P1 T
HYD. TANK
BOOM(LH)
A B1
DR
51
5760psi
PL C B
SW
SE-7
PLc2 P
Drd
OUT PBa C B
Pisc PL
PBb DOWN LCa ARM
IN PAa ARM IN
Drc BOOM 5760psi
PAb UP
IN Aa
Bb DOWN
CRa DR
A B1
50
PLc1 CAr
ARM
P 5470psi
OUT Ba
SE-4 BOOM(RH)
Ab UP
A B1
DR
52
5760psi
PL C B
4
2.3 EXTRA KCME Extra Spec.
NO. NAME
50 HYD.PUMP ASSY
51 PILOT VALVE
52 CONTROL VALVE
53 HYD. VALVE ASSY
M 50 54 SOLENOID VALVE
B4
A4
Note:This hydraulic circuit is used to add following circuit
PUMP
for completion.
REMARKS
E200SR(LC)-1S KCME
MAIN CONTROL VALVE P2 P1 T
HYD. TANK
EXTRA 52
VALVE TO EXTRA HYD.
A1 B1
3300psi
(R.H)
PA1
PB1
3000psi
P T 51
GAUGE PORT
53 T
P
A T
B B C1 C2 A
54 P SE11
T P
SOL/V BLOCK
LEVER
4 LOCK
P T
5
3. OPERATON EXPLANATION OF HYDRAULIC CIRCUITS
3.1 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS 3.2 NEUTRAL CIRCUIT rections and stop where the spool-sleeve open-
Blue ................................ Feed, drain, tank circuit This section describes the following. ing is closed.
less than 2.5kgf/cm2 (36psi) 1) Safety lock lever and pilot circuit 2) Flow reducing action
Green ............................. Return, make up circuit, 2) Pump control If the command current I of the mechatro control-
Negative control circuit ler decreases, the secondary pressure of the so-
2.5~6kgf/cm2 (36~85psi) (1) SAFETY LOCK LEVER AND PILOT CIRCUIT lenoid proportional valve decreases. This causes
Purple ............................. Secondary pilot pressure, Purpose: the pilot spring (646) to move the spool (652) to
6~50kgf/cm2 (85~710psi) To protect attachment from unexpected operation the left. If the spool is shifted, the discharge pres-
Red ................................ Primary pilot pressure, for safety. sure P1 is flowed to the larger diameter chamber
35~50kgf/cm2 (500~710psi) Principle: of the servo piston by way of the spool.
Orange ........................... Main pump drive pressure, Cut pressure source of pilot valve for operation. The discharge pressure P1 is there at the smaller
50~350kgf/cm2 (710~4980psi) Operation: diameter of the servo piston at all times, but be-
When power boosting After engine starts, push down the safety lock le- cause of the difference in the area causes the
385kgf/cm2 (5470psi) ver (red), and the limit switch (SW-11) is turned servo piston to move to the right and to decrease
Blue tone ........................ At valve operation on, the pilot operation circuit is changed to standby the tilting angle. If the servo piston moves to the
Red valve ....................... At solenoid proportional valve condition. right the same way as above, the sleeve moves
(reducing) is operating. to the left by the feedback lever, till the opening of
Red solenoid .................. In active and exciting (2) PUMP CONTROL the spool-sleeve is closed.
Displaying the flow circuit and standby circuit Type: Regarding the detail of the pump functions, refer
when operating. Variable displacement pump of electric flow con- to the Component system I-1.
Regrarding the electrical symbols in this manual, trol type.
refer to the electric circuit diagram. Principle:
Controls the tilting angle of the pump (delivery rate)
by changing the command current I to the sole-
noid proportional reducing valve.
Operation:
1) Flow increase function (for example; P1 pump):
This is a positive control type that increases the
command current I of the mechatro controller. If
each attachment, the swing and travel is oper-
ated, the secondary pilot operating pressure is put
in each low pressure sensor. The output voltage
of the low pressure sensor is put into the mechatro
controller. The mechatro controller processes pi-
lot signals and put out a current command ac-
cording to the input voltage. If the secondary pres-
sure of the solenoid proportional valve increases,
the spool (652) is pushed to the right via the pilot
piston (643) and stops where it balances the ac-
tion of the pilot spring (646).
The larger diameter of the servo piston (532)
opens to the tank port, moves to the left by the
discharge pressure P1 of the smaller diameter of
it and increases the tilting angle ().
The servo piston and the sleeve are linked to-
gether by the feedback lever (611). A pin is pro-
vided at point A of the feedback lever. Since the
feedback lever turns on the fulcrum, the servo pis-
ton and the sleeve (651) move in the opposite di-
6
D MB MB D
SE-22 SE-23
1 P P
4
4
a3 a4 SWING
VB VA PB M
B DB
VA VB
3
12
Pcr Pcr
M A3
5200~
5400psi
P MA MA P 5200~
5400psi
4060psi
B1 A Pi2 Pi1 PA PG
26
PUMP ASSY
Dr3 9 A T
725psi B3
BUCKET DIS.
BUCKET DIG.
B
18
17
71psi
2 20
36psi ARM OUT
19 BOOM RAI.
BOOM LOW.
SWING R
CMR1 SWING L
SE-1 SE-8
PL1
BLOCK
TRAVEL TRAVEL
LEFT FOR. PAI 1 2 3 4 5 6 7 8
PRIORITY
CT2 REV. AI
Drb
CP2 FOR. BI 22
LCs
RIGHT PBS SE-5
PBr REV. PBS2
Pss PILOT VALVE
Br FOR.
CP1
LEFT AS
Ar REV. BOOM
PBc DIG.
BUCKET PB1
PAc DIS.
SE-2 P Bc DIG. 23
SE-7 P T P T
Ac DIS.
Drd
OUT PBa 21
LCb Pisc TRAVEL
21 SE-3 PBb LOW. LCa ARM PILOT VALVE P
Drc T
P BOOM IN PAa
PAb RAI.
Bb LOW. IN Aa
PLc1
CRb
5470psi
5760psi
CAr
CRa
7 11
P
SE-4 5470psi 2 5 1 4 6 3
Ab RAI. OUT Ba
5760psi X1 ARM(O125/O90/1290) P P
SE-9 SE-10
ARM
CONFLUENCE
PCb Pis
P1 P2
BY-PASS
CUT D
14 PA1
BY-PASS CCa
LEVER
4 LOCK
(P4) (P3)
6
TRAVEL
STRAIGHT C TRAVEL
1/2SPEED
5
P2
BY-PASS 3 CHANGEOVER
CUT B BOOM(O115/O80/1200)
ATT
2 BOOSTING
8
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
NEUTRAL CIRCUIT:SAFETY LOCK LEVER ON

7
3.3 TRAVEL CIRCUIT speed tiling rotation with self pressure.
This section describes the following. Provided if the main circuit pressure exceeds
1) Travel forward pilot simultaneous operation cir- 280kgf/cm2 (3980psi), the self pressure pushes
cuit back the 2 speed select piston to select 1st speed.
2) 2 speed travel solenoid command circuit and
auto 1st.-speed return function (3) TRAVEL MAIN CIRCUIT
3) Travel main circuit Operation:
4) Travel motor function If the travel spool is changed by the travel pilot
action, the oil discharged from port A2, A1 of the
(1) TRAVEL FORWARD PILOT SIMULTANEOUS main pump enters ports Ar, Al of the travel motor
OPERATION CIRCUIT (4) by way of the VB, VA port of C/V and the D,C
Purpose: ports of the swivel joint (9) and performs the fol-
Light operating force and shockless operation lowing functions in the travel motor.
Operation: (Refer to the travel motor functions.)
1) If the travel lever with damping mechanism is op-
erated for travel right, left and forward motions, (4) TRAVEL MOTOR FUNCTION
the secondary pilot proportional pressure comes Function:
out of the 2, 4 ports of P/V (11). The higher of the 1) Prevents overrunning of travel motor on down
pressures is selected, comes out of the 5, 6 ports hill slope.
and acts upon the low pressure sensors (SE9), 2) Hydraulic motor cavitation protective check
(SE10). valve.
2) Pilot secondary pressure flows into PAr, PAl ports 3) Shockless relief valve and anticavitation valve
of control valve (2), acts on travel spool, and when stopping it with the force of inertia.
switches main circuit. 4) High/Low 2 step change mechanism and auto
3) The output voltage of the low pressure sensor is 1st speed return at high load.
put into the mechatro controller. The mechatro 5) Travel parking brake.
controller processes signals and puts out a flow
increase current to the P1 pump proportional valve
(PSV-1) and the P2 pump proportional valve (PSV-
2).
(2) 2 SPEED TRAVEL SOLENOID COMMAND

CIRCUIT AND AUTO 1st SPEED RETURN
FUNCTION
Purpose:
Change travel motor speed with switch.
Principle:
If the switch is turned, an electric signal is issued.
It excites the 2-speed travel solenoid which in turn
converts the primary pilot pressure and the self
pressure to a tilting angle of the variable displace-
ment motor.
Operation:
Press switches with rabbit and turtle marks on
travel lever grips, and the solenoid (SV-3) of pro-
portional valve block (15) is excited and is
switched, and solenoid command is output by port
3 and sends to P port of travel motor (4), opens
oil passage to 2 speed piton, and switches it to 2
8
D MB MB D
SE-22 SE-23
1 P P
4
4
a3 a4 SWING
VB VA PB M
B DB
VA VB
3
12
Pcr Pcr
M A3
5200~
5400psi
P MA MA P 5200~
5400psi
4060psi
B1 A Pi2 Pi1 PA PG
26
PUMP ASSY
Dr3 9 A T
725psi B3
BUCKET DIS.
BUCKET DIG.
B
18
17
71psi
2 20
36psi ARM OUT
19 BOOM RAI.
BOOM LOW.
SWING R
CMR1 SWING L
SE-1 SE-8
PL1
BLOCK
TRAVEL TRAVEL
LEFT FOR. PAI 1 2 3 4 5 6 7 8
PRIORITY
CT2 REV. AI
Drb
CP2 FOR. BI 22
LCs
RIGHT PBS SE-5
PBr REV. PBS2
Pss PILOT VALVE
Br FOR.
CP1
LEFT AS
Ar REV. BOOM
PBc DIG.
BUCKET PB1
PAc DIS.
SE-2 P Bc DIG. 23
SE-7 P T P T
Ac DIS.
Drd
OUT PBa 21
LCb Pisc TRAVEL
Drc T
P BOOM IN PAa
PAb RAI.
Bb LOW. IN Aa
PLc1
CRb
5470psi
5760psi
CAr
CRa
7 11
P
SE-4 5470psi 2 5 1 4 6 3
Ab RAI. OUT Ba
5760psi X1 ARM(O125/O90/1290) P P
SE-9 SE-10
ARM
CONFLUENCE
PCb Pis
P1 P2
BY-PASS
CUT D
14 PA1
BY-PASS CCa
LEVER
4 LOCK
(P4) (P3)
6
TRAVEL
STRAIGHT C TRAVEL
1/2SPEED
5
P2
ATT
2 BOOSTING
8
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
TRAVEL CIRCUIT:TRAVEL 2nd SPEED OPERATION

9
3.4 BUCKET CIRCUIT Even if the engine revolution of the accel potenti-
This section describes the following. ometer is set in Lo rpm, the pump delivers a dis-
1) Bucket digging pilot circuit charge rate equal to the intermediate revolution
2) Auto accel operation between the above decel and the FC mode. For
3) Constant flow control for standby this reason, the actuator operates faster than the
4) Bucket digging main circuit moving of the operating lever when load is light.
(1) BUCKET DIGGING PILOT CIRCUIT (4) BUCKET DIGGING MAIN CIRCUIT
Operation: Operation:
1) If bucket digging action is performed, the second- With pilot operation, the pressure oil switches
ary pilot pressure comes out of port 1 of the right bucket spool, and is fed into bucket cylinder H
pilot valve (10), enters port PBc of C/V (2) and side through C/V (2) BC port. And the return oil
acts upon the low pressure sensor (SE-1). At the from cylinder R side flows into tank circuit while
same time, the pressure changes the bucket being restricted by bucket spool through C/V (2)
spool. AC port.
2) The output voltage of the low pressure sensor is
put into the mechatro controller. The controller pro-
cesses signals and puts out a command current
for pump flow increase to the solenoid proportional
valve (PSV-1) on the P1 pump. The relation be-
tween the low pressure sensor and the pump flow
increase is the same as above; the explanation
of it is deleted hereafter.
(2) AUTO ACCEL OPERATION

Principle:
Start operating with signal output by low pressure
sensor.
Operation: <Lever in neutral position>
When the signal is not input to low pressure sen-
sor for 4 seconds or more after turning accel dial
to Max. position, become engine speed to
1050rpm automatically.
<Lever in operation position>
If a pressure signal of 5.7kgf/cm2 (81psi) or over
enters the low pressure sensor of the machine
with standard specifications (travel, bucket, boom,
swing and arm), a proportional voltage signal from
the low pressure sensor enters the mechatro con-
troller and brings the engine revolution back to
the accel dial setting according to the lever strokes.
(3) CONSTANT FLOW CONTROL FOR STANDBY
Principle:
At pressures below the intermediate revolution
between the decel and the FC mode, a command
current is put out so as to make the delivery rate
of the pump constant.
Operation:
10
D MB MB D
SE-22 SE-23
1 P P
4
4
a3 a4 SWING
VB VA PB M
B DB
VA VB
3
12
Pcr Pcr
M A3
5200~
5400psi
P MA MA P 5200~
5400psi
4060psi
B1 A Pi2 Pi1 PA PG
26
PUMP ASSY
Dr3 9 A T
725psi B3
BUCKET DIS.
BUCKET DIG.
B
18
17
71psi
2 20
36psi ARM OUT
19 BOOM RAI.
BOOM LOW.
SWING R
CMR1 SWING L
SE-1 SE-8
PL1
BLOCK
TRAVEL TRAVEL
LEFT FOR. PAI 1 2 3 4 5 6 7 8
PRIORITY
CT2 REV. AI
Drb
CP2 FOR. BI 22
LCs
RIGHT PBS SE-5
PBr REV. PBS2
Pss PILOT VALVE
Br FOR.
CP1
LEFT AS
Ar REV. BOOM
PBc DIG.
BUCKET PB1
PAc DIS.
SE-2 P Bc DIG. 23
SE-7 P T P T
Ac DIS.
Drd
OUT PBa 21
LCb Pisc TRAVEL
Drc T
P BOOM IN PAa
PAb RAI.
Bb LOW. IN Aa
PLc1
CRb
5470psi
5760psi
CAr
CRa
7 11
P
SE-4 5470psi 2 5 1 4 6 3
Ab RAI. OUT Ba
5760psi X1 ARM(O125/O90/1290) P P
SE-9 SE-10
ARM
CONFLUENCE
PCb Pis
P1 P2
BY-PASS
CUT D
14 PA1
BY-PASS CCa
LEVER
4 LOCK
(P4) (P3)
6
TRAVEL
STRAIGHT C TRAVEL
1/2SPEED
5
P2
ATT
2 BOOSTING
8
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
BUCKET CIRCUIT:BUCKET DIGGING OPERATION

11
3.5 BOOM CIRCUIT 3) Meanwhile, the oil delivered from the A2 port of
This section describes the boom raise conflux opera- the P2 pump enters the P2 port of C/V (2) and is
tion. branched to the bypass circuit and the parallel cir-
1) Boom raise pilot circuit cuit. If the P2 bypass cut valve is changed over,
2) Boom raise 2 pumps conflux main circuit in C/V the center bypass circuit is closed. The oil then
passes through the parallel circuit and via the
(1) BOOM RAISE PILOT CIRCUIT restrictor on the circumference of the boom
Operation: conflux spool, pushes the load check valve open
1) If the boom raise action is performed, the sec- from the boom conflux circuit, and combines the
ondary pilot pressure from the right pilot valve (10) oil delivered by the P1 pump internally.
comes out of port 3 and acts upon the low pres- 4) The return oil from boom cylinder R side flows
sure sensor (SE3). At the same time, the pres- into tank circuit through boom spool from C/V (2)
sure acts upon the PAb port and the PB1 port of Bb port.
C/V (2).
2) The voltage output by low pressure sensor is pro-
cessed by mechatro controller and outputs com-
mand current to P2 bypass cut valve (PSV-B) and
solenoid valve outputs proportional secondary
pressure and the pressure acts on C/V (2) PCa
port.
3) Then, the secondary pressure fed into C/V (2) PAb
port switches boom conflux spool. And the sole-
noid proportional secondary pressure fed into PCa
port switches P2 bypass cut valve.
(2) BOOM RAISE 2 PUMPS CONFLUX MAIN CIR-

CUIT IN C/V
Purpose: Boom raise speed up
Principle: Confluxing oil from 2 pumps
Operation:
1) The oil delivered through A1 port of P1 pump flows
into C/V (2) P1 port, and branches into bypass
circuit and parallel circuit. However since the boom
spool is moved and bypass circuit is closed, the
oil opens load check valve through parallel circuit
and flows into boom spool.
2) Then the oil passes through boom spool, opens
lock valve of boom lock valve, and is led into H
side of boom cylinder through C/V (2) Ab port.
12
D MB MB D
SE-22 SE-23
1 P P
4
4
a3 a4 SWING
VB VA PB M
B DB
VA VB
3
12
Pcr Pcr
M A3
5200~
5400psi
P MA MA P 5200~
5400psi
4060psi
B1 A Pi2 Pi1 PA PG
26
PUMP ASSY
Dr3 9 A T
725psi B3
BUCKET DIS.
BUCKET DIG.
B
18
17
71psi
2 20
36psi ARM OUT
19 BOOM RAI.
BOOM LOW.
SWING R
CMR1 SWING L
SE-1 SE-8
PL1
BLOCK
TRAVEL TRAVEL
LEFT FOR. PAI 1 2 3 4 5 6 7 8
PRIORITY
CT2 REV. AI
Drb
CP2 FOR. BI 22
LCs
RIGHT PBS SE-5
PBr REV. PBS2
Pss PILOT VALVE
Br FOR.
CP1
LEFT AS
Ar REV. BOOM
PBc DIG.
BUCKET PB1
PAc DIS.
SE-2 P Bc DIG. 23
SE-7 P T P T
Ac DIS.
Drd
OUT PBa 21
LCb Pisc TRAVEL
Drc T
P BOOM IN PAa
PAb RAI.
Bb LOW. IN Aa
PLc1
CRb
5470psi
5760psi
CAr
CRa
7 11
P
SE-4 5470psi 2 5 1 4 6 3
Ab RAI. OUT Ba
5760psi X1 ARM(O125/O90/1290) P P
SE-9 SE-10
ARM
CONFLUENCE
PCb Pis
P1 P2
BY-PASS
CUT D
14 PA1
BY-PASS CCa
LEVER
4 LOCK
(P4) (P3)
6
TRAVEL
STRAIGHT C TRAVEL
1/2SPEED
5
P2
ATT
2 BOOSTING
8
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
BOOM CIRCUIT:BOOM UP OPERATION,CONFLUX FUNCTION

13
This section describes boom lower operation. (5) FIXED RECIRCULATION FUNCTION OF BOOM
1) Boom lower pilot circuit LOWER MAIN CIRCUIT
2) Prevention of natural fall by lock valve and actua- Purpose:
tion at lowering Prevention of cavitation during boom
3) Fixed recirculation function of boom lower main lowering motion.
circuit Principle:
The oil returning from the boom cylinder head (H)
(3) BOOM LOWER PILOT CIRCUIT is recirculated to the rod (R).
Operation: Operation:
1) Start boom lower operation, and the pilot second- When the oil is supplied to the boom cylinder rod
ary pressure is output through port 4 of pilot valve (R) side during boom lower operation, the boom
(10), and acts on low pressure sensor (SE4), at moves faster than it should do in some cases by
the same time branches into two circuits, then acts the self weight of the attachment. On that occa-
C/V (2) PBb and PLC1 ports. sion, the circuit pressure on the rod (R) side is on
2) The voltage output by low pressure sensor (SE4) the negative side. The oil supplied to the boom
is input into mechatro controller. cylinder rod (R) flows into the A1 port of the P1
3) Then, the secondary pressure fed into C/V (2) PBb pump and the P1 port of C/V. The oil then passes
port switches boom spool. And the secondary through the boom spool and goes out of the Bb
pressure flowed into C/V (2) PLC1 port releases port. On that occasion, the oil returning from the
boom lock valve. head (H) goes through the recirculation path in
the boom spool, pushes the check valve in the
(4) PREVENTION OF NATURAL FALL BY LOCK spool open, is recirculated to the Bb port and is
VALVE AND ACTUATION AT LOWERING supplied to the rod (R). When the (R) pressure is
Purpose: larger than the (H) pressure, the check valve
Prevention of natural fall when the lever is neutral closes. Thereupon, the recirculation is stopped.
Principle:
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
Operation:
During the boom lowering, the boom spool shifts
to change the selector valve of the lock valve lo-
cated at the end of the spool. Then the poppet
spring chamber of the lock valve connects with
the drain line (Drc), with the result that the lock
valve poppet is moved to an open state. When
the boom spool is neutral, the drain line on the
lock valve poppet spring chamber side is closed.
Since the poppet is closed, the oil returning to
the boom spool from the boom cylinder head (H)
is held. This prevents oil leaks from the boom
spool, thereby preventing the boom cylinder from
making a natural fall.
14
D MB MB D
SE-22 SE-23
1 P P
4
4
a3 a4 SWING
VB VA PB M
B DB
VA VB
3
12
Pcr Pcr
M A3
5200~
5400psi
P MA MA P 5200~
5400psi
4060psi
B1 A Pi2 Pi1 PA PG
26
PUMP ASSY
Dr3 9 A T
725psi B3
BUCKET DIS.
BUCKET DIG.
B
18
17
71psi
2 20
36psi ARM OUT
19 BOOM RAI.
BOOM LOW.
SWING R
CMR1 SWING L
SE-1 SE-8
PL1
BLOCK
TRAVEL TRAVEL
LEFT FOR. PAI 1 2 3 4 5 6 7 8
PRIORITY
CT2 REV. AI
Drb
CP2 FOR. BI 22
LCs
RIGHT PBS SE-5
PBr REV. PBS2
Pss PILOT VALVE
Br FOR.
CP1
LEFT AS
Ar REV. BOOM
PBc DIG.
BUCKET PB1
PAc DIS.
SE-2 P Bc DIG. 23
SE-7 P T P T
Ac DIS.
Drd
OUT PBa 21
LCb Pisc TRAVEL
Drc T
P BOOM IN PAa
PAb RAI.
Bb LOW. IN Aa
PLc1
CRb
5470psi
5760psi
CAr
CRa
7 11
P
SE-4 5470psi 2 5 1 4 6 3
Ab RAI. OUT Ba
5760psi X1 ARM(O125/O90/1290) P P
SE-9 SE-10
ARM
CONFLUENCE
PCb Pis
P1 P2
BY-PASS
CUT D
14 PA1
BY-PASS CCa
LEVER
4 LOCK
(P4) (P3)
6
TRAVEL
STRAIGHT C TRAVEL
1/2SPEED
5
P2
ATT
2 BOOSTING
8
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
SWING
1 P/B
PT
BOOM CIRCUIT:BOOM LOWER(DOWN) OPERATION

15
3.6 SWING CIRCUIT
This section describes the following operations. In the case of arm digging operation, the swing
1) Swing left pilot circuit parking solenoid (SV-1) is excited the moment the
2) Swing auto parking brake pressure of the arm digging low pressure sensor
3) Prevention of swings on stop of swing action by (SE7) is reduced to zero. This causes the me-
means of by-pass valve. chanical brake to operate.
4) Swing main circuit
5) Swing motor function (3) PREVENTION OF SWINGS ON STOP OF SWING
ACTION BY MEANS OF BY-PASS VALVE
(1) SWING LEFT PILOT CIRCUIT Purpose:
Operation: Prevention of swings on stop of swing action
1) If the swing left action is performed, the second- Principle:
ary pilot pressure goes out of port 5 of left pilot Reducing pressure surges of main circuit on stop
valve (10) and acts upon the PAS port of C/V (2). of swing action
At the same time, high-pressure selection is car- Operation:
ried out, and the pressure acts upon the low pres- 1) At the start of swing action and during continuous
sure sensor (SE5). operation, the swing pilot pressure comes out of
2) The low pressure sensor output voltage enters in the PSS port of C/V (2) and acts upon both the
the mechatro controller, and after signal process- Pi1 and pi2 ports of the swing motor. Therefore,
ing the mechatro controller outputs the command the ports A and B are shut off by spring action.
current to P2 bypass cut solenoid proportional 2) If the swing lever is brought back to neutral, the
valve (PSV-B), and the proportionl valve second- pressure drop on the slow return valve (25) side
ary pressure is discharged from this the solenoid is delayed. As the result, the pressure pushes the
valve and acts on PCa port of the C/V (2). valve leftward against the spring action of the by-
3) Then, the secondary pressure entered into PAS pass valve and causes ports A and B to be con-
port of the C/V (2) switches the slewing spool. nected together.
And the solenoid proportionl valve secondary pres-
sure entered in PCa port switches the P2 bypass (4) SWING MAIN CIRCUIT
cut valve together with the slewing conflux valve. Operation:
The delivery oil through A2 port of P2 pump flows
(2) SWING AUTO PARKING BRAKE into P2 port of the C/V (2) and is branched into
Purpose: the bypass circuit and parallel circuit, but the by-
Swing lock and parking in neutral position pass circuit is closed with the movement of the
Principle: slewing spool, the pressure opens load check
Release mechanical brake only when required to valve through the parallel circuit, flows into B port
operate of the slewing motor through AS port of the C/V
Operation: (2) and rotates the slewing motor counterclock-
1) The swing parking function operates usually when wise. However, when starting slewing operation,
the key switch is ON condition and the mechani- the confluxed oil flows out in the tank circuit
cal brake is actuated. through P2 bypass cut valve from the bleed off
2) The mechanical brake is released if the swing passage of the slewing spool. The P2 bypass cut
parking solenoid is de-excited only when the sec- valve closes in late and consequently the slewing
ondary operating pressure in the swing and arm hunting due to the control of the slewing flow rate
digging actions acts upon any of the low pressure is prevented.
sensors (SE-5,7).
3) The swing parking solenoid (SV-1) is excited five (5) SWING MOTOR FUNCTION
seconds after the pressure of the swing low pres- 1) Anticavitation circuit when reducing swing speed.
sure sensors (SE-5) is reduced to zero. 2) Shockless relief to protect it from reverse rota-
tion.
16
D MB MB D
SE-22 SE-23
1 P P
4
4
a3 a4 SWING
VB VA PB M
B DB
VA VB
3
12
M A3 P MA MA P 4060psi
B1 A Pi2 Pi1 PA PG
a5 TRAVEL RIGHT B DE E F F A C
26
PUMP ASSY
Dr3 9 A T
725psi B3
BUCKET DIS.
BUCKET DIG.
B
18
17
71psi
2 20
36psi ARM OUT
19 BOOM RAI.
BOOM LOW.
SWING R
CMR1 SWING L
SE-1 SE-8
PL1
PTb REV. PBI 24
FOR. PAI 1 2 3 4 5 6 7 8
CT2 REV. AI
Drb
CP2 FOR. BI 22
LCs
RIGHT PBS SE-5
PBr REV. PBS2
CT1 SWING P
Pss
PAr FOR. LEFT PAS
Br FOR.
CP1
LEFT AS
Ar REV. BOOM
PBc DIG.
BUCKET PB1
PAc DIS.
SE-2 P Bc DIG. 23
SE-7 P T P T
Ac DIS.
5470psi CCb PLc2 P
5760psi
Drd
OUT PBa 21
LCb Pisc
21 SE-3 PBb LOW. LCa ARM
Drc P T
P BOOM IN PAa
PAb RAI.
Bb LOW. IN Aa
PLc1
CRb
5470psi
5760psi
CAr
CRa
7 11
P
SE-4 5470psi 2 5 1 4 6 3
Ab RAI. OUT Ba
5760psi X1 ARM(O125/O90/1290) P P
SE-9 SE-10
ARM
CONFLUENCE
PCb Pis
SOL/V BLOCK P1 PCa
P1 P2
BY-PASS
CUT D
14 PA1
BY-PASS CCa
BY-PASS CUT
LEVER
4 LOCK
(P4) (P3)
6
TRAVEL
STRAIGHT C
5
P2
BY-PASS 3
ATT
2 BOOSTING
8
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
1
PT
SWING CIRCUIT:SWING OPERATION

17
3.7 ARM CIRCUIT (2) ARM DIGGING,LIGHTDUTY VARIABLE NOR-
This section describes the following operations. MAL RECIRCULATION MAIN CIRCUIT
1) Arm digging, light-duty operating pilot circuit Operation:
2) Arm digging, light-duty variable normal recircula- 1) The oil returning from the arm cylinder (R) side
tion main circuit opens the arm lock valve and flows into the arm
variable recirculation spool through the arm spool.
(1) ARM DIGGING, LIGHTDUTY OPERATING PI- 2) Since the passage to the tank is blocked by the
LOT CIRCUIT arm variable recirculation spool, the oil returning
Purpose: from the arm cylinder (R) side flows into the load
Speed-up and Anticavitation when the arm is at check valve.
light duty. 3) Since the R side pressure of the cylinder is higher
Principle: than the H side pressure of it when working load
The oil returning from the arm cylinder rod (R) is light, the pressure pushes the load check valve
side is recirculated to the head of C/V. open and is recirculated to the (H) side so as to
Operation: speed up the light-duty digging operation.
1) If the arm digging operation is performed, the sec- 4) If the FC mode is selected, the command current
ondary pilot pressure gets out of port 7 of the left to the arm variable recirculation solenoid propor-
pilot valve (10) and acts upon the low pressure tional valve decreases. This reduces the second-
sensor (SE-7). ary pressure of the solenoid proportional valve.
At the same time, the pressure is branched off to The result is that the arm variable recirculation
two flows, acts upon the PAa port and the PLC2 valve is turned to the normal recirculation, thereby
port, changes over the arm spool and the arm causing the arm variable recirculation function to
lock valve selector. prevent cavitation.
2) The output voltage of the low pressure sensor is
put into the mechatro controller and processes
pilot signals. It is then put out to the P2 pump pro-
portional valve (PSV-2) of the arm variable recir-
culation proportional valve (PSV-A).
3) The P2 pump proportional valve (PSV-2) acts on
the P2 pump in proportion to the secondary pilot
pressure. However, in the case of the arm vari-
able displacement proportional valve, the second-
ary pressure of the solenoid proportional valve
operates in reverse proportion to the secondary
pilot pressure. This causes the secondary pres-
sure of the solenoid proportional valve to be re-
duced by the secondary pilot pressure in light duty
arm in operation. This change over the machine
mode from the forced recirculation to the normal
recirculation mode.
18
D MB MB D
SE-22 SE-23
1 P P
4
4
a3 a4 SWING
VB VA PB M
B DB
VA VB
3
12
B1 A Pi2 Pi1 PA PG
26
PUMP ASSY
Dr3 9 A T
725psi B3
BUCKET DIS.
BUCKET DIG.
B
18
17
71psi
2 20
36psi ARM OUT
19 BOOM RAI.
BOOM LOW.
SWING R
CMR1 SWING L
SE-1 SE-8
PL1
PTb REV. PBI 24
FOR. PAI 1 2 3 4 5 6 7 8
CT2 REV. AI
Drb
CP2 FOR. BI 22
LCs
RIGHT PBS SE-5
PBr REV. PBS2
CT1 SWING P
Pss
PAr FOR. LEFT PAS
Br FOR.
CP1
LEFT AS
Ar REV. BOOM
PBc DIG.
BUCKET PB1
PAc DIS.
SE-2 P Bc DIG. 23
SE-7 P T P T
Ac DIS.
5470psi CCb PLc2 P
5760psi
Drd
OUT PBa 21
LCb Pisc
Drc P T
P BOOM IN PAa
PAb RAI.
Bb LOW. IN Aa
PLc1
CRb
5470psi
5760psi
CAr
CRa
7 11
P
SE-4 5470psi 2 5 1 4 6 3
Ab RAI. OUT Ba
5760psi X1 ARM(O125/O90/1290) P P
SE-9 SE-10
ARM
CONFLUENCE
PCb Pis
SOL/V BLOCK P1 PCa
P1 P2
BY-PASS
CUT D
14 PA1
BY-PASS CCa
BY-PASS CUT
LEVER
4 LOCK
(P4) (P3)
6
TRAVEL
STRAIGHT C
5
P2
BY-PASS 3
ATT
2 BOOSTING
8
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
1
PT
ARM CIRCUIT:ARM IN (DIGGING)LIGHT LOAD OPERATION,RECIRCULATION FUNCTION

19
This section describes the following operations.
3) Arm digging, heavy duty operating pilot circuit (re-
circulation cut)
4) Arm digging, heavy-duty sequence confluxed main
circuit
(3) ARM DIGGING, HEAVY DUTY OPERATING PI-

LOT CIRCUIT
Operation :
1) If the arm is at heavy duty [(more than 160 kgf/
cm2 (2280psi)] of the pump pressure during arm
digging operation, the current of the arm variable
recirculation solenoid proportional valve is reduced
to a minimum, and the arm variable recirculation
function is cut off.
2) The moment the arm variable recirculation cut is
performed, the travel straight proportional valve
and the P1 bypass cut valve change to sequence
conflux circuit.
(4) SEQUENCE CONFLUX CIRCUIT AT HEAVY-

DUTY ARM DIGGING
Purpose: Arm in speed up.
Principle: Confluxing oil from 2 pumps in C/V (2).
Operation:
1) The oil delivered by the P2 pump flows into the
travel left section from the P2 port of C/V (2). The
oil is then branched to the bypass circuit and the
parallel circuit. The pressure then pushes the load
check valve via the parallel circuit and flows into
the arm spool.
2) Meanwhile, the oil delivered by the P1 pump en-
ters the P1 port of C/V (2) and then the travel
straight section, confluxed with the oil from the
load check valve of the P2 parallel line, and en-
ters the arm spool.
3) Then, the confluxed oil is fed into arm cylinder H
side through C/V (2) Aa port from arm spool.
4) In addition, the return oil from arm cylinder (R)
side flows into arm lock valve through Ba port,
but since the arm lock valve is open, it flows into
arm spool.
5) Then, the oil passes though orifices on arm spool
and returns into tank while restricting.
20
D MB MB D
SE-22 SE-23
1 P P
4
4
a3 a4 SWING
VB VA PB M
B DB
VA VB
3
12
B1 A Pi2 Pi1 PA PG
26
PUMP ASSY
Dr3 9 A T
725psi B3
BUCKET DIS.
BUCKET DIG.
B
18
17
71psi
2 20
36psi ARM OUT
19 BOOM RAI.
BOOM LOW.
SWING R
CMR1 SWING L
SE-1 SE-8
PL1
PTb REV. PBI 24
FOR. PAI 1 2 3 4 5 6 7 8
CT2 REV. AI
Drb
CP2 FOR. BI 22
LCs
RIGHT PBS SE-5
PBr REV. PBS2
CT1 SWING P
Pss
PAr FOR. LEFT PAS
Br FOR.
CP1
LEFT AS
Ar REV. BOOM
PBc DIG.
BUCKET PB1
PAc DIS.
SE-2 P Bc DIG. 23
SE-7 P T P T
Ac DIS.
5470psi CCb PLc2 P
5760psi
Drd
OUT PBa 21
LCb Pisc
Drc P T
P BOOM IN PAa
PAb RAI.
Bb LOW. IN Aa
PLc1
CRb
5470psi
5760psi
CAr
CRa
7 11
P
SE-4 5470psi 2 5 1 4 6 3
Ab RAI. OUT Ba
5760psi X1 P P
SE-9 SE-10
ARM
CONFLUENCE
PCb Pis
SOL/V BLOCK P1 PCa
P1 P2
BY-PASS
CUT D
14 PA1
BY-PASS CCa
BY-PASS CUT
LEVER
4 LOCK
(P4) (P3)
6
TRAVEL
STRAIGHT C
5
P2
BY-PASS 3
CUT B
ATT
2 BOOSTING
8
ARM VARIABLE
RECIRCULATION A
1
PT
ARM CIRCUIT:ARM IN (DIGGING)OPERATION,CONFLUX FUNCTION

21
This section describes the following operations. (7) NATURAL DROP PROTECTION WITH ARM
5) Arm out pilot circuit LOCK VALVE
6) Arm out 2 pumps conflux main circuit Purpose :
7) Natural fall protection with arm lock valve To prevent the arm from falling naturally by the
weight of the arm & bucket.
(5) ARM OUT PILOT CIRCUIT Principle :
Operation : Complete seat of the return circuit against the arm
1) If arm out operation is performed, the secondary spool of the arm cylinder (R) side circuit.
pilot pressure comes out of port j of the left pilot Operation :
valve (10) and acts upon the low pressure sensor 1) If the secondary pressure for arm operation dis-
(SE8). At the same time, the pressure is branched appears and the arm cylinder stops, the pressure
to two circuits and acts upon the PA1, PBa ports on the rod (R) side passes through the selector of
of C/V (2). the lock valve from the Ba port of C/V (2), acts the
2) The output voltage of the low pressure sensor back pressure on the lock valve and seats the
(SE8) puts in the mechatro controller which pro- lock valve.
cesses signals. The controller puts out a current 2) Since the oil flow from the lock valve to the arm
command to the P1 bypass cut solenoid propor- spool is blocked completely, the arm is prevented
tional valve (PSV-D). The secondary pressure from falling naturally due to oil leaks through the
comes out of the solenoid valve, acts upon the arm spool.
PCb port of C/V (2) and switches the spool of P1
bypass cut valve.
3) Then, the pilot secondary pressure fed into C/V

(2) PBa port switches arm spool.
(6) ARM OUT 2 PUMPS CONFLUX MAIN CIRCUIT

Purpose : Arm out operation speed up.
Principle :
The oil delivered by the P1 pump is combined with
that delivered by the P2 pump in C/V (2).
Operation :
1) The action is the same as the arm digging till the
oil delivered by the P2 pump enters the arm spool.
In the arm out action, the oil runs freely through
the arm lock valve from the arm spool and is sup-
plied to the arm R side from the Ba port of the
control valve (2).
2) The oil delivered by the P1 pump passes through
the arm conflux valve and is combined with the oil
of the arm cylinder (R) side.
3) And, the return oil from arm cylinder (H) side flows
into Aa port, passes through arm spool, and re-
turns into tank circuit.
22
D MB MB D
SE-22 SE-23
1 P P
4
4
a3 a4 SWING
VB VA PB M
B DB
VA VB
3
12
B1 A Pi2 Pi1 PA PG
26
PUMP ASSY
Dr3 9 A T
725psi B3
BUCKET DIS.
BUCKET DIG.
B
18
17
71psi
2 20
36psi ARM OUT
19 BOOM RAI.
BOOM LOW.
SWING R
CMR1 SWING L
SE-1 SE-8
PL1
PTb REV. PBI 24
FOR. PAI 1 2 3 4 5 6 7 8
CT2 REV. AI
Drb
CP2 FOR. BI 22
LCs
RIGHT PBS SE-5
PBr REV. PBS2
CT1 SWING P
Pss
PAr FOR. LEFT PAS
Br FOR.
CP1
LEFT AS
Ar REV. BOOM
PBc DIG.
BUCKET PB1
PAc DIS.
SE-2 P Bc DIG. 23
SE-7 P T P T
Ac DIS.
5470psi CCb PLc2 P
5760psi
Drd
OUT PBa 21
LCb Pisc
Drc P T
P BOOM IN PAa
PAb RAI.
Bb LOW. IN Aa
PLc1
CRb
5470psi
5760psi
CAr
CRa
7 11
P
SE-4 5470psi 2 5 1 4 6 3
Ab RAI. OUT Ba
5760psi X1 ARM(O125/O90/1290) P P
SE-9 SE-10
ARM
CONFLUENCE
PCb Pis
SOL/V BLOCK P1 PCa
P1 P2
BY-PASS
CUT D
14 PA1
BY-PASS CCa
BY-PASS CUT
LEVER
4 LOCK
(P4) (P3)
6
TRAVEL
STRAIGHT C
5
P2
BY-PASS 3
ATT
2 BOOSTING
8
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
1
PT
ARM CIRCUIT:ARM OUT(EXTEND)OPERATION,CONFLUX FUNCTION

23
3.8 COMBINED CIRCUIT 3) However, a part of flow is connected at the notched
This section describes only the difference in combined orifice of the travel straight spool. When the at-
operation. tachment is operated during running, a part of the
1) Boom raise/travel, pilot circuit pressure oil on the attachment side flows in and
2) Boom raise/travel, main circuit changes the travel speed reducing the travelling
shock.
(1) BOOM RAISE/TRAVEL, PILOT CIRCUIT
Operation :
<Points which are differed from the independent op-
eration>
1) With signal processing of mechatro controller, the
controller outputs command current to travel
straight valve (PSV-C) and P2 bypass cut valve
(PSV-B) and this solenoid valve outputs second-
ary pressure, then acts on C/V (2) PTb and PCa
ports.
2) Next, the PTb port pressure changes the travel
straight valve by one step. The solenoid propor-
tional secondary pressure which flows into the PCa
port of C/V (2) changes over the P2 bypass cut
valve.
(2) BOOM RAISE/TRAVEL, MAIN CIRCUIT

Purpose:
Trevel straight operation is available even if the
attachment is operated during travel operation.
Principle:
The travel motion and attachment operations are
performed by respective pump.
Operation:
1) The P1 pump and P2 pump delivery oil flows into
travel straight section through P1 and P2 ports of
the C/V (2). But the P2 pump delivery oil is
branched into P1 and P2 bypass circuits because
of travel straight spool is shifted.On the other hand,
the P1 pump delivery oil is branched into P1 and
P2 parallel circuits.
2) And, both travel operations are performed bypass
circuit, then is performed by the oil delivered by
P2 pump.
Since boom spool and other spool are operated
through paralel circuit, so oil delivered by P1 pump
is available.
24
D MB MB D
SE-22 SE-23
1 P P
4 4
a3 a4 SWING
VB VA PB M
B DB
VA VB
3
12
B1 A Pi2 Pi1 PA PG
26
PUMP ASSY
Dr3 9 A T
725psi B3
BUCKET DIS.
BUCKET DIG.
B
18
17
71psi
2 20
36psi ARM OUT
19 BOOM RAI.
BOOM LOW.
SWING R
CMR1 SWING L
SE-1 SE-8
PL1
PTb REV. PBI 24
FOR. PAI 1 2 3 4 5 6 7 8
CT2 REV. AI
Drb
CP2 FOR. BI 22
LCs
RIGHT PBS SE-5
PBr REV. PBS2
CT1 SWING P
Pss
PAr FOR. LEFT PAS
Br FOR.
CP1
LEFT AS
Ar REV. BOOM
PBc DIG.
BUCKET PB1
PAc DIS.
SE-2 P Bc DIG. 23
SE-7 P T P T
Ac DIS.
5470psi CCb PLc2 P
5760psi
Drd
OUT PBa 21
LCb Pisc
Drc P T
P BOOM IN PAa
PAb RAI.
Bb LOW. IN Aa
PLc1
CRb
5470psi
5760psi
CAr
CRa
7 11
P
SE-4 5470psi 2 5 1 4 6 3
Ab RAI. OUT Ba
5760psi X1 ARM(O125/O90/1290) P P
SE-9 SE-10
ARM
CONFLUENCE
PCb Pis
SOL/V BLOCK P1 PCa
P1 P2
BY-PASS
CUT D
14 PA1
BY-PASS CCa
BY-PASS CUT
LEVER
4 LOCK
(P4) (P3)
6
TRAVEL
STRAIGHT C
5
P2
BY-PASS 3
ATT
2 BOOSTING
8
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
1
PT
COMBIEND OPERATION:BOOM RAISE/TRAVEL LHRH FORWARD 1st-SPEED TRAVEL

25
This section describes difference in combined opera- (4) SWING/ARM IN, SWING PRIORITY MAIN CIR-
tion from single operation. CUIT
3) Swing/Arm in, pilot circuit Purpose :
4) Swing/Arm in, swing priority main circuit Stabilization in the swing speed
Principle :
(3) SWING/ARM IN, PILOT CIRCUIT The supplied oil to swing motor is used to have
Operation : the P1 pump flow rate confluxed to P2 pump flow
1) When swing and arm in operations are concur- rate.
rently carried out, with signal processing of Operation ;
mechstro controller, the controller outputs com- Swing main circuit is actuated by P2 pump flow,
mands current to travel straight valve(PSV-C) & but when the operation of swing and arm in are
P1 bypass cut valve(PSV-D) & P2 bypass cut valve operated simultaneously, the secondary pressure
(PSV-B) and this solenoid valve outputs second- of travel straight valve switches its spool and the
ary pressure, then acts on C/V (2) PTb & PCb & secondary pressure of P1 cut proportional valve
Pca ports. closes P1 cut valve and oil of P1 pump confluxes
(These operations are the same as that of the consequently with P2 pump circuit. The oil flows
combined respective independent operation.) into swing and arm circuits in the same time be-
2) The arm variable recirculation valve operates the cause both circuits are paralleled.
same as usual, but the spool moves toward the Return oil pressure rises and also arm cylinder
forcible recirculation side according to the pilot head (H) pressure rises because of following two
pressure for the swing action. reason.
Arm variable recirculation spool returns to forced
recirculation side according to swing pilot pres-
sure. Return oil from arm cylinder rod (R) side is
restricted in arm variable recirculation valve.
And swing pilot pressure is led from Pisc port to
sub-spool in arm spool, the pressure of arm cylin-
der head (H) rises higher by restricting opening of
arm spool circuit according to swing pilot pres-
sure, as a result the oil P2 pump flows preferen-
tially into swing circuit.
This is so-called. swing priority control.
26
D MB MB D
SE-22 SE-23
1 P P
4
4
a3 a4 SWING
VB VA PB M
B DB
VA VB
3
12
B1 A Pi2 Pi1 PA PG
26
PUMP ASSY
Dr3 9 A T
725psi B3
BUCKET DIS.
BUCKET DIG.
B
18
17
71psi
2 20
36psi ARM OUT
19 BOOM RAI.
BOOM LOW.
SWING R
CMR1 SWING L
SE-1 SE-8
PL1
PTb REV. PBI 24
FOR. PAI 1 2 3 4 5 6 7 8
CT2 REV. AI
Drb
CP2 FOR. BI 22
LCs
RIGHT PBS SE-5
PBr REV. PBS2
CT1 SWING P
Pss
PAr FOR. LEFT PAS
Br FOR.
CP1
LEFT AS
Ar REV. BOOM
PBc DIG.
BUCKET PB1
PAc DIS.
SE-2 P Bc DIG. 23
SE-7 P T P T
Ac DIS.
5470psi CCb PLc2 P
5760psi
Drd
OUT PBa 21
LCb Pisc
Drc P T
P BOOM IN PAa
PAb RAI.
Bb LOW. IN Aa
PLc1
CRb
5470psi
5760psi
CAr
CRa
7 11
P
SE-4 5470psi 2 5 1 4 6 3
Ab RAI. OUT Ba
5760psi X1 ARM(O125/O90/1290) P P
SE-9 SE-10
ARM
CONFLUENCE
PCb Pis
SOL/V BLOCK P1 PCa
P1 P2
BY-PASS
CUT D
14 PA1
BY-PASS CCa
BY-PASS CUT
LEVER
4 LOCK
(P4) (P3)
6
TRAVEL
STRAIGHT C
5
P2
BY-PASS 3
ATT
2 BOOSTING
8
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
1
PT
COMBINED OPERATION:SWING/ARM(DIGGING),SWING PRIORITY

27
3.9 PRESSURE DRAINING (RELEASING) CIRCUIT and right and left four to five times to their full
This section describes the following operations. stroke, pressure may be relieved. If the pump
1) Pressure drain (releasing) pilot circuit pressure is determined to be more than 5 kgf/cm2
2) Pressure drain (releasing) main circuit (70psi) by the output value of the high pressure
sensor or the high pressure sensors (SE22, 23)
(1) PRESSURE RELEASE PILOT CIRCUIT are broken, the buzzer sounds continuously. In
Purpose: that case, the buzzer is not stopped unless the
To release the main circuit pressure for piping re- engine key is turned to OFF.Repeat the pressure
pair work. releasing procedure once again.
Principle: Operation:
If the SCREEN SELECT switch & BUZZER STOP If the travel straight valve is turned to the pres-
switch are kept pressed for more than five sec- sure release position, the oil delivered by each
onds simultaneously, the mechatro controller pump is unloaded to the tank passage. If the
judges it a pressure release control and puts out spools are switched by pilot operation, the remain-
the following commands. ing pressure from the actuators may be relieved
1) Puts out the minimum tilting command value to to the tank circuit, i.e. the main circuit pressure
the pump proportional valve (PSV-1, PSV-2). may be released.
2) Puts out a pressure release control revolution
command value to the governor motor. (electric
system).
3) Travel straight solenoid proportional valve (PSV-
C) outputs the command value to change the pres-
sure release position to the travel straight valve.
4) Puts out a standby command value to the P1, P2
bypass cut proportional valves. (a command that
does not put out the secondary pressure of the
P1, P2 bypass proportional valves).
Operation:
1) The pump proportional valve minimizes the deliv-
ery rates of the P1, P2 pumps.
2) The secondary pilot pressure for the travel straight
valve pressure release position selection comes
out of the travel straight proportional valve (PSV-
C), flows into the PTb port of C/V (2) and switches
the travel straight valve to its pressure release po-
sition.
(2) PRESSURE RELEASE MAIN CIRCUIT

Operation:
If the operating lever is shifted to neutral during
engine running and the SCREEN SELECT switch
& BUZZER STOP switch are kept pressed for
more than five seconds simultaneously, DRAIN-
ING HYD. PRESS is displayed on the gauge
cluster and the intermittent buzzer sounds for five
seconds and is stopped. If the operating levers
of the right and left are operated back and forth
28
D MB MB D
SE-22 SE-23
1 P P
4
4
a3 a4 SWING
VB VA PB M
B DB
VA VB
3
12
B1 A Pi2 Pi1 PA PG
26
PUMP ASSY
Dr3 9 A T
725psi B3
BUCKET DIS.
BUCKET DIG.
B
18
17
71psi
2 20
36psi ARM OUT
19 BOOM RAI.
BOOM LOW.
SWING R
CMR1 SWING L
SE-1 SE-8
PL1
PTb REV. PBI 24
FOR. PAI 1 2 3 4 5 6 7 8
CT2 REV. AI
Drb
CP2 FOR. BI 22
LCs
RIGHT PBS SE-5
PBr REV. PBS2
CT1 SWING P
Pss
PAr FOR. LEFT PAS
Br FOR.
CP1
LEFT AS
Ar REV. BOOM
PBc DIG.
BUCKET PB1
PAc DIS.
SE-2 P Bc DIG. 23
SE-7 P T P T
Ac DIS.
5470psi CCb PLc2 P
5760psi
Drd
OUT PBa 21
LCb Pisc
Drc P T
P BOOM IN PAa
PAb RAI.
Bb LOW. IN Aa
PLc1
CRb
5470psi
5760psi
CAr
CRa
7 11
P
SE-4 5470psi 2 5 1 4 6 3
Ab RAI. OUT Ba
5760psi X1 ARM(O125/O90/1290) P P
SE-9 SE-10
ARM
CONFLUENCE
PCb Pis
SOL/V BLOCK P1 PCa
P1 P2
BY-PASS
CUT D
14 PA1
BY-PASS CCa
BY-PASS CUT
LEVER
4 LOCK
(P4) (P3)
6
TRAVEL
STRAIGHT C
5
P2
BY-PASS 3
ATT
2 BOOSTING
8
ARM VARIABLE
RECIRCULATION A
BUCKET(O105/O75/1055)
1
PT
PRESSURE DRAIN (RELEASE) CIRCUIT

29
4. PILOT PIPING
No. NAME QTY REMARKS No. NAME QTY REMARKS No. NAME QTY REMARKS No. NAME QTY REMARKS No. NAME QTY REMARKS
(1) Pump delivery 36 CONNECTOR 1 PF3/8-PF1/4 10 CONNECTOR 2 2 PF3/8 With olifice L=23 27 TUBE 1 L=650
37 TEE 1 PF1/4 11 ELBOW 6 4 PF1/4 28 TEE 1 PF3/8
1 INLINE FILTER 1 38 CONNECTOR 1 PF1/4 12 ELBOW 4 4 PF1/4-PF3/8 29 TEE 1 PF3/8
2 CONNECTOR 1 PF3/8 40 HYD. VALVE ASSY 1 13 ELBOW 6 3 PF3/8 31 HOSE GUARD 1 L=500
3 TEE 1 PF1/4 41 TEE 1 PF1/4 (4) Block Control valve. Multiless 3 14 ELBOW 4 4 PF3/8 32 HOSE GUARD 1 L=600
Bucket dump secondary, Boom up secondary,
4 ELBOW 3 PF3/8 42 SHUTTLE VALVE 1 1 HOSEPF3/8 L=3700 2 Arm in secondary 15 TEE 2 1 PF1/4 33 HOSE GUARD 1 L=550
5 ELBOW 2 PF3/4 43 CAPSCREW 1 M8x50 2 HOSEPF3/8 L=2650 1 Boom down secondary, Swing right secondary 16 TEE 10 7 PF3/8 34 ELBOW 1 PF3/8
6 ELBOW 1 PF1/4 44 WASHER 1 3 BRACKET 1 17 TEE 2 2 PF1/4 35 HOSE GUARD 1 L=650
45 CONNECTOR 1 PF1/4-PF3/8 4 BRACKET 2 18 TEE 1 1 2-PF1/4-PF3/8 36 CONNECTOR 1 PF1/4 L=38
7 CONNECTOR 1 PF1/4L=23 46 HOSE ; PF3/8 L=2300 1 5 PRESSURE SENSOR ; PF1/4 1 19 PRESSURE SENSORPF1/4 5 5 37 HOSE GUARD 1 L=450
8 ELBOW 1 PF1/4 With mesh filter 47 HOSE ; PF3/8 L=1700 1 6 RUBBER 1 L=370 20 HOSEPF1/4 L=300 1 1 Arm conflux select command 38 TEE 1 PF1/4
9 TEE 2 PF3/8 48 HOSE ; PF1/4 L=400 1 7 GROMMET 1 21 HOSEPF1/4 L=760 1 1 Boom conflux select command 39 ELBOW 1 PF1/4
10 HOSEPF1/4 L=400 1 P2 S/V primary 49 HOSE ; PF1/4 L=1600 1 8 RUBBER 6 L=370 22 HOSEPF1/4 L=300 1 1 Drain 40 CONNECTOR 2 PF1/4 With filter L=23
11 HOSEPF3/8 L=500 1 Pilot pump delivery 50 HOSE ; PF3/8 L=900 1 9 PLUG 15 PF1/4 23 HOSEPF1/4 L=600 3 3 Drain 41 CHECK VALVE 1 PF3/8 With olifice L=28
12 HOSEPF1/4 L=540 1 P1 S/V primary 51 HOSE GUARD 1 L=600 10 ELBOW 1 PF3/8 24 HOSEPF1/4 L=700 1 1 Arm lock valve release command 42 CONNECTOR 1 PF3/8-PF1/4
13 HOSEPF3/4 L=400 1 Pilot pump suction 52 CLIP 2 11 BLOCK 1 25 HOSEPF1/4 L=660 1 1 Boom lock valve release command 43 HOSEPF1/4 L=550 1
14 CONNECTOR 1 PF1/4-PF3/8 L=23 53 ELBOW 1 PF1/4 12 ELBOW 4 PF3/8 26 ELBOW 1 1 PF1/4 44 VALVE ASSY 2 PF3/8
15 CAPSCREW 2 M10x20 54 TUBE 2 L=500 13 CAPSCREW 6 M8x20 27 TUBE 1 1 L=650 45 CONNECTOR 2 PF3/8
16 WASHER 2 WASHER 2 29 PLUG 1 1 PF3/8 46 CONEECTOR 1 PF1/4 L=60
17 CONNECTOR 1 PF1/4 With mesh filter L=23 (3) Remote control (ATT) CAPSCREW 1 M8x55 30 HOSE GUARD 1 1 L=500
18 PLUG 1 PF1/4 1 HOSEPF1/4 L=1450 1 Pilot primary 16 HOSEPF3/8 L=2700 1 31 HOSE GUARD 1 1 L=600 (7) Remote Control lines for Travel
19 CONNECTOR 1 PF1/4-PF3/8 2 HOSEPF1/4 L=1750 1 Pilot primary 17 HOSEPF3/8 L=2900 1 Bucket digging secondary 32 HOSE GUARD 1 1 L=550 1 PILOT VALVE 1
20 ELBOW 1 PF3/8 3 HOSEPF3/8 L=1400 1 Drain 18 HOSEPF3/8 L=3500 1 Swing left secondary 33 ELBOW 1 1 PF3/8 2 PRESSURE SENSORPF1/4 2
21 HOSEPF3/8 L=2000 1 Drain 4 HOSEPF3/8 L=1750 1 Drain 19 CUSHION RUBBER 1 L=325 34 TEE - 1 PF3/8 3 CONNECTOR 1 PF3/8
22 HOSE GUARD 1 L=250 5 HOSEPF3/8 L=2600 1 Drain 20 CHECK VALVE PF3/8 With orifice 35 HOSE GUARD 1 1 L=650 4 WASHER 4
23 HOSE GUARD 1 L=400 6 HOSEPF3/8 L=1850 RED 1 Bucket digging secondary 36 CONNECTOR 1 - PF1/4 L=38 5 CONNECTOR 1 PF1/4 With filter
24 HOSE GUARD 1 L=1900 7 HOSEPF3/8 L=1850 BLUE 1 Bucket dump secondary (4a) Multi control piping 2 37 HOSE GUARD 1 - L=450 6 ELBOW 4 PF3/8
28 PLUG 2 PF1/4 L=23 8 HOSEPF3/8 L=1850 GREEN 1 Boom up secondary 2 PRESSURE SENSOR ; PF1/4 1 38 TEE 1 - PF1/4 7 HOSEPF1/4 L=300 1 Pilot primary
29 TEE 1 PF3/4-PF1/4 9 HOSEPF3/8 L=1900 GRAY 1 Boom down secondary 3 BRACKET 1 40 CONNECTOR 2 - PF1/4 With filter L=23 8 HOSEPF3/8 L=380 1 Drain
30 CONNECTOR 1 PF1/4 With olifice 10 HOSEPF3/8 L=1600 RED 1 Swing right secondary 4 BRACKET 1 41 CHECK VALVE 1 - PF1/4 With olifice L=28 9 HOSEPF3/8 L=3000 2 1.Travel RH R. 3.Travel LH R.
31 CONNECTOR 1 PF1/4 11 HOSEPF3/8 L=1600 BLUE 1 Arm in secondary 5 BRACKET 1 42 CONNECTOR 1 - PF3/8-PF1/4 10 CAPSCREW 4 M10x30
12 HOSEPF3/8 L=1600 GREEN 1 Arm out secondary 6 RUBBER 5 L=370 43 HOSEPF1/4 L=550 1 - 11 HOSEPF3/8 L=3800 2 1.Travel RH F. 3.Travel LH F.
(2) Proportional valve block lines 13 HOSEPF3/8 L=1800 GRAY 1 Swing left secondary 7 ELBOW 1 PF1/4 44 VALVE ASSY 2 - PF3/8
14 HOSE 2 8 CUSHION RUBBER 1 L=325 45 CONNECTOR 2 - PF3/8 (8) Boom ,Arm safety control
1 SOLENOID VALVE ASSY 1 15 PILOT VALVE 2 9 RUBBER 12 L=300 46 CONEECTOR 1 - PF1/4 L=60 1 HOSEPF3/8 L=2600 1 Arm in command
2 CONNECTOR 3 PF1/4 16 WASHER 8 10 CAPSCREW 12 M8x20 47 ELBOW 1 - PF1/4 2 HOSEPF3/8 L=2600 1 Arm H/V drain
3 CONNECTOR 2 PF3/8 17 CONNECTOR 11 PF3/8 11 WASHER 1 3 HOSEPF3/8 L=1900 1 Boom RH H/V drain
Control Valve piping
4 ELBOW 9 PF1/4 18 CONNECTOR 2 PF1/4 With mesh filter 12 GROMMET 7 (6) (with boom,arm safety) 4 HOSEPF3/8 L=2100 1 Boom RH down command
5 ELBOW 1 PF3/8 With mesh filter 19 BOOT 2 13 PLUG 1 PF1/4 1 CONNECTOR 1 PF1/4 5 HOSEPF3/8 L=2100 1 Boom LH H/V drain
6 GUIDE 2 20 CLIP 4 14 CONTROL VALVE 2 2 CONNECTOR 6 PF1/4-PF3/8 6 HOSEPF3/8 L=2300 1 Boom LH down command
7 CLIP 2 21 CAPSCREW 8 15 CONNECTOR 4 PF1/4 L=38 3 CONNECTOR 9 PF3/8 7 CONNECTOR 2 PF3/8
8 CAPSCREW 4 M10x20 22 GROMMET 1 16 CONNECTOR 10 PF1/4 L=17 4 CONNECTOR 1 PF1/4 L=23 8 HOSE GUARD 2
9 CAPSCREW 3 M10x75 17 ELBOW 6 PF3/8-PF1/4 5 CONNECTOR 3 PF1/4-PF3/8 L=23 9 CLIP 16
10 WASHER 8 18 ELBOW 2 PF3/8-PF1/4 6 CONNECTOR 2 PF3/8 L=46
Boom down secondary,
11 WASHER 3 19 HOSEPF3/8 L=2650 3 Swing right secondary 7 CHECK VALVE 2 PF3/8 With olifice (9) Block control lines
Boom up secondary, Bucket dump secondary
12 HOSEPF1/4 L=600 1 Travel straight 20 HOSEPF3/8 L=3700 1 Arm in secondary 8 HOSE 1 PF3/8 L=760 1 BLOCK 1
13 HOSEPF1/4 L=700 1 P2 bypass cut secondary 21 HOSEPF3/8 L=3100 1 Bucket digging secondary 9 CONNECTOR 1 PF3/8 With olifice L=23 2 CONNECTOR 1 PF1/4 L=23
14 HOSEPF1/4 L=850 1 ATT power boost command primary 22 HOSEPF3/8 L=3500 1 Swing left secondary 10 CONNECTOR 2 PF3/8 With olifice L=23 3 CONNECTOR 1 PF3/8 L=23
15 HOSEPF1/4 L=1250 1 Travel 1,2 speed primary 23 HOSEPF3/8 L=2700 1 Arm out secondary 11 ELBOW 6 PF1/4 4 ELBOW 2 PF1/4
16 HOSEPF1/4 L=1350 2 P1 bypass cut secondary, Swing P/B primary 26 TEE 3 PF1/4 12 ELBOW 4 PF1/4-PF3/8 5 ELBOW 3 PF3/8
17 HOSEPF1/4 L=1400 1 Arm variable recirculation secondary 29 CHECK VALVE 2 13 ELBOW 8 PF3/8 6 ELBOW 1 PF1/4
18 HOSEPF3/8 L=2000 1 P/V block pressure supply 30 CONNECTOR PF1/4-PF3/8 14 ELBOW 3 PF3/8 7 ELBOW 2 PF3/8
19 HOSEPF3/8 L=2700 1 Lever lock primary 15 TEE 2 PF1/4 8 PLUG 1 PF1/4
20 HOSEPF3/8 L=300 1 Drain (5) Control Valve piping 16 TEE 13 PF3/8 9 CAPSCREW 2 M8 x 40
21 HOSE GUARD 1 L=1900 17 TEE 2 PF1/4 10 WASHER 2
22 BRACKET 1 1 CONNECTOR 1 1 PF1/4 18 TEE 1 2-PF1/4-PF3/8 14 PLUG 1 PF3/8
23 CAPSCREW 1 M10x25 2 CONNECTOR 6 6 PF1/4-PF3/8 19 PRESSURE SENSORPF1/4 5
24 ELBOW 2 PF3/8 3 CONNECTOR 6 7 PF3/8 20 HOSEPF1/4 L=300 1 Arm conflux select command
25 GROMMET 1 4 CONNECTOR 1 1 PF1/4 L=23 21 HOSEPF1/4 L=760 1 Boom conflux select command
26 CLIP 10 5 CONNECTOR 3 3 PF1/4-PF3/8 L=23 22 HOSEPF1/4 L=300 1 Drain
31 HOSE GUARD 1 L=450 6 CONNECTOR 2 2 PF3/8 L=46 23 HOSEPF1/4 L=600 3 Drain
32 ELBOW 3 PF1/4-PF3/8 7 CHECK VALVE 2 1 PF3/8 With olifice 24 HOSEPF1/4 L=700 1 Arm lock valve release command
33 CONNECTOR 1 PF1/4 L=38 8 HOSE 1 1 PF3/8 L=760 25 HOSEPF1/4 L=660 1 Boom lock valve release command
34 HOSE ; PF3/8 L=1500 1 S/M bypass V command 1 9 CONNECTOR 1 1 PF3/8 With olifice L=23 26 ELBOW 1 PF1/4
30
31
(1) Pump delivery;
(2) Proportional valve block lines;
32
(3) Remote control (ATT);
33
(4) Block Control valve;
34
(5) Control valve piping;
35
(6) Control valve piping; (With boom, arm safety)
36
(7) Remote control lines for travel;
37
(8) Boom,arm safety control;
38
(9) Block control lines
39
5. MAIN PIPING
No. NAME QTY REMARKS No. NAME QTY REMARKS No. NAME QTY REMARKS No. NAME QTY REMARKS No. NAME QTY REMARKS
(1) Pump delivery 8 HOSE ; PF1 L=1900 1 L=1600 (5) Travel system hyd. piping (9) Arm hyd. piping 26 O RING 4
1 TUBE 1 Suction 9 COUPLING 3 42.7 1 TUBE 1 27 O RING 4 1B P14
2 TUBE 1 Suction 10 COUPLING 2 48.6 2 TUBE 1 1 HOSE ; L=1200 2 Arm (H&R) 28 CAPSCREW 2 M10 x 65
3 HOSE 2 Suction 11 COUPLING 1 50.8 3 TUBE 1 2 HOSE ; L=1200 Arm (H&R) 29 CAPSCREW 2 M8 x 35
4 HOSE ; L=1110 1-3/16-12UN 1 P1 Pump delivery 12 CHECK VALVE 1 245 KPa 4 TUBE 1 30 CAPSCREW 8 M10 x 65
5 HOSE ; L=1040 1-3/16-12UN 1 P2 Pump delivery 13 CHECK VALVE 1 500 KPa 5 TUBE 1 (10) Boom cyl. Piping 31 CAPSCREW 8 M10 x 30
6 O RING 1 1A G75 14 SUPPORT 3 6 TUBE 1 marked parts have different 32 WASHER 2
parts number between KCME,
7 O RING 2 1B P26 15 SUPPORT 1 7 HOSE 2 Travel 2-speed command KCMA and OCE. 33 LOCK WASHER 2
8 HALF CLAMP 4 3/4 16 SUPPORT 2 8 HOSE 4 L=300 1 TUBE 1 Left boom cyl. (H) 34 LOCK WASHER 2
9 CAPSCREW 8 M10x35 17 SUPPORT 1 9 CLIP 10 2 TUBE 1 Right boom cyl. (H) 35 LOCK WASHER 16
10 CAPSCREW 4 M12x30 18 CLAMP 3 42.7 P85 10 CLAMP 2 3 TUBE 1 Left boom cyl. (R) 36 GREASE NIPPLE 2 PT1/8
11 U-BOLT 2 19 CLAMP 2 42.7 P85 11 CLAMP 2 4 TUBE 1 Right boom cyl. (R) 37 CLIP 4 48 L=188
12 WASHER 4 20 CLAMP 3 42.7 12 SPACER 4 h=17.5 5 HOSE 2 Boom cyl. (H) 38 BLOCK 2
13 LOCK WASHER 8 21 CLAMP 1 50.8 13 CAPSCREW 4 M8 X 40 6 HOSE 2 Boom cyl. (R) 39 CAPSCREW 8 M10 x 45
14 LOCK WASHER 4 22 O-RING 1 1A G45 14 WASHER 4 7 CLAMP 2 40 PLUG 2
15 NUT 8 23 CONNECTOR 1 PF3/4 - PF1 15 LOCK WASHER 4 8 CAPSCREW 2 M12 x 50 42 TEE 1
16 CLIP 8 24 CONNECTOR 1 PF3/4 9 CAPSCREW 16 M10 x 30 43 CONNECTOR 1
17 PRESSURE SENSOR : PF3/8 2 25 CONNECTOR 1 PF3/4 (5a) Travel system hyd. piping 10 CONNECTOR 1 PF1/4 44 OIL PRESSURE SWITCH 1
18 ELBOW 1 PF1/2 26 ELBOW 1 PF1/2 1 TUBE 1 11 GREASE NIPPLE 2 45 CLAMP 1
19 GROMMET 2 27 ELBOW 1 PF3/4 - PF1 2 TUBE 1 12 O RING 2 46 CLAMP 1
20 CLIP 2 28 TEE 1 PF1/2-PF1/2-PF3/8 3 TUBE 1 13 O RING 2 47 PLATE 1
29 TEE 1 PF1/2-PF1/2-PF3/4 4 TUBE 1 14 O RING 4 48 BRACKET 1
(2) Control valve piping 30 SPACER 3 L=22.5 5 TUBE 1 15 LOCK WASHER 2 49 ELBOW 1
1 TUBE 27.2 1 Boom (H) 31 CLIP 1 6 TUBE 1 16 PLUG 1 50 CONNECTOR 1
2 TUBE 27.2 1 Boom (R) 32 CLIP 1 7 TUBE 1 51 CAPSCREW 2 M5 x 40
3 TUBE 34 1 Arm (H) 33 TUBE 1 L=1000 8 TUBE 1 (11) Arm cyl. hyd. piping 52 CAPSCREW 2 M8 x 25
4 TUBE 27.2 1 Arm (R) 34 BUSHING 1 9 TUBE 1 1 TUBE 1 53 CAPSCREW 2 M12 x 65
5 TUBE 27.2 1 Bucket (H) 35 HOSE GUARD 1 L=1000 10 TUBE 1 2 HOSE ; L=860 1 Arm (R) 54 WASHER 2
6 TUBE 27.2 1 Bucket (R) 36 CAPSCREW 1 M10 x 25 11 TUBE 1 3 HOSE ; L=860 1 Arm (H) 55 WASHER 2
7 HOSE ; 1 3/16-12UN L=1250 1 Travel right 37 CAPSCREW 1 M10 x 30 12 TUBE 1 Travel 2-speed command 4 CLAMP 1 56 LOCK WASHER 2
8 CAPSCREW 2 M12 x 70 38 CAPSCREW 3 M10 x 55 13 HOSE 2 L=300 5 CONNECTOR 1 57 O RING 1
9 HOSE ; 1 3/16-12UN L=1400 1 Travel right 39 CAPSCREW 4 M10 x 90 14 HOSE 4 6 HALF CLAMP 2
10 HOSE ; 1 3/16-12UN L=1500 2 Swing motor 40 CAPSCREW 3 M12 x 25 15 CLIP 10 7 GREASE NIPPLE 1 PT1/8 (14) Arm cyl. piping for arm safety
11 CAPSCREW 2 M12 x 55 41 CAPSCREW 12 M12 x 30 16 CONNECTOR 4 8 CAPSCREW 8 M10 x 35 1 HOLDING VALVE 1
12 HOSE ; 1 3/16-12UN L=1600 1 Travel left 42 CAPSCREW 2 M12 x 35 17 CONNECTOR 2 9 CAPSCREW 1 M12 x 55 2 TUBE 1 27.2
13 PLATE 1 43 CAPSCREW 4 M12 x 65 18 CLAMP 2 10 O RING 2 1B P26 3 HOSE ; L=860 1 Arm (R)
14 O RING 2 1-14UNS 44 WASHER 12 19 CLAMP 2 h=17.5 11 O RING 1 4 HOSE ; L=860 1 Arm (H)
15 O RING 22 1"3/16-12UN 45 WASHER 25 20 SPACER 4 M8 X 40 12 LOCK WASHER 4 5 HOSE ; L=4000 1 18- 18
16 O RING 2 1"7/16-12UN 46 NUT 2 21 CAPSCREW 4 13 LOCK WASHER 1 6 HOSE ; L=3900 1 15- 15
17 CONNECTOR 3 1"3/16-12UN - PF3/4 47 NUT 4 22 WASHER 4 7 HALF CLAMP 2
18 CONNECTOR 5 1"3/16-12UN - PF3/4 48 CLIP 1 23 LOCK WASHER 4 (12) Bucket cyl. hyd. piping 8 CLAMP 1
19 CONNECTOR 1 1"3/16-12UN - PF3/4 49 TUBE 1 L=1100 1 TUBE 1 27.2 x t3.2 9 ELBOW 1 PF3/4 1"3/16-12UNS
20 CONNECTOR 2 1"3/16-12UN - PF3/4 50 PLUG 1 PF1 (6) Travel motor hyd. piping 2 TUBE 1 27.2 x t3.2 10 ELBOW 1
21 CONNECTOR 1 1"7/16-12UN - PF3/4 51 TUBE 1 L=750 1 CONNECTOR 4 PF1- 28 3 CLAMP 1 11 CONNECTOR 1
22 HOSE ; 1 3/16-12UN L=1450 1 Travel left 52 CLIP 1 2 CONNECTOR 2 PF1/2- 18 4 CAPSCREW 1 M10 x 55 12 CONNECTOR 1 PT1/4-PF1/4
23 ELBOW 4 1-3/16-12UN - PF3/4 53 GROMMET 1 3 CONNECTOR 2 PF1/4 5 CAPSCREW 4 M10 x 55 13 GREASE NIPPLE 1 PT1/8
24 CONNECTOR 1 PF3/4 L=60 54 CLIP 1 4 O RING 4 1B P29 6 CAPSCREW 4 M10 x 35 14 O RING 1 1B P26
26 NUT 3 62 SUPPORT 1 5 O RING 2 1B P18 7 O RING 2 1B P26 15 O RING 2 1B P18
27 CLAMP 1 63 U BOLT 1 44 8 O RING 2 16 CLIP 15
28 CLAMP 4 64 NUT 4 (7) Swivel hyd. piping 9 GREASE NIPPLE 1 PT1/8 17 PLUG 1
29 WASHER 12 65 WASHER 2 1 CONNECTOR 4 PF1- 28 10 GREASE NIPPLE 1 PT1/8 18 CAPSCREW 1 M12 x 55
30 CAPSCREW 2 M12 x 25 2 CONNECTOR 2 PF1/4 11 LOCK WASHER 1 19 CAPSCREW 4 M10 x 65
31 SUPPORT 1 3 CONNECTOR 2 PF1/2- 18 20 CAPSCREW 4 M10 x 35
32 SUPPORT 1 4 O RING 4 1B P29 (13) Boom cyl. Piping for boom safety 21 LOCK WASHER 1
33 GROMMET 1 5 O RING 2 1B P18 1 TUBE 1 21.7 22 LOCK WASHER 8
34 HOSE ; 1 3/16-12UN L=1300 2 Boom (R) 2 TUBE 1 21.7
35 GROMMET 2 (8) Boom hyd. piping 3 TUBE 1 27.2
36 CLIP 4 1 TUBE 1 4 TUBE 1 27.2
37 CAPSCREW 2 M12 x 30 2 TUBE 1 5 TUBE 1 15
38 CONNECTOR 2 PF3/4 L=75 3 TUBE 1 6 TUBE 1 15
39 CAPSCREW 1 M12 x 75 4 TUBE 1 7 TUBE 1 15
40 TUBE 1 L = 22.0 5 HOSE 1 Arm (R) 8 TUBE 1 15
41 TUBE 1 L = 26.0 6 HOSE 2 Bucket (H&R) 9 TAPPED BLOCK 2
7 O RING 7 10 HOSE ; L=860 2 Arm (R)
(3) Swivel joint hyd. Piping 8 CLAMP 2 11 HOSE ; L=860 2 Arm (H)
1 CONNECTOR 1 PF1/2 9 CLAMP 2 12 HOSE ; L=1300 1 Equalizer
2 CONNECTOR 4 1"3/16-12UN - PF1 10 CLAMP 4 13 CONNECTOR 4
3 TUBE 2 1"3/16-12UN - PF1 11 CAPSCREW 6 M12 x 55 14 HOLDING VALVE 1
4 TUBE 2 1"3/16-12UN - PF1 12 LOCK WASHER 6 15 HOLDING VALVE 1
5 O RING 8 1"3/16-12UN - PF1 13 CLIP 4 16 CLAMP 2 28- 22
14 O RING 1 17 CLAMP 2 15- 15
(4) Return piping 15 HOSE ; L=1430 1 Arm (H) 18 ELBOW 2
1 TUBE 1 16 CAPSCREW 2 M12 x 60 19 ELBOW 2
2 TUBE 1 17 GUARD 1 20 CONNECTOR 1
3 TUBE 1 18 GUARD 1 21 CONNECTOR 2
4 TUBE 1 22 CONNECTOR 2
5 HOSE ; PF1/2 L=940 1 PF1/2 23 CONNECTOR 2
6 HOSE ; PF1/2 L=2100 1 PF3/4 24 O RING 4 1B P26
40 7 HOSE ; PF1/2 L=2700 1 PF1 25 O RING 4
41
(1) Pump delivery;
(2) Control valve piping (1/2);
42
Control valve piping (2/2);
43
(3) Swivel joint hyd. piping; (4) Return piping (1/2);
44
45
Return piping (2/2);
(5) Travel system hyd. piping;
(6-2) Connector installing

procedure (RH MOTOR)
(6-1) Connector installing procedure (LH MOTOR);

(7) Connector installing procedure (S/J);
46
(5a) Travel system hyd. piping;
47
(8) Boom hyd. piping;
(12) Bucket cyl. piping;
(9) Arm hyd. piping;
(10) Boom cyl. piping;
(11)Arm cyl. piping;
48
(13) Boom cyl. piping for boom safety;
49
(14) Arm cyl. piping for arm safety;
50
E200SR
SECTION 23 ELECTRIC SYSTEM
TABLE OF CONTENTS
1. ELECTRIC CIRCUIT DIAGRAM ................................................................................ 1
2. ELECTRICAL EQUIPMENT LIST .............................................................................. 5

2.1 Specification ......................................................................................................................... 5
3. HARNESS
3.1 Harness list ........................................................................................................................... 6
3.2 Harness Connection Drawing ............................................................................................... 7
3.3 Controller Assy ...................................................................................................................... 8
3.4 Instrument Panel Assy ......................................................................................................... 12
3.5 Upper Electric Assy ............................................................................................................. 13
3.6 Upper Harness Assy ........................................................................................................... 14
3.7 Engine Harness Assy .......................................................................................................... 20
3.8 Upper Harness Assy (Floor Plate) ....................................................................................... 22
3.9 Cab Harness Assy .............................................................................................................. 24
3.10 Cab Assy ........................................................................................................................... 27
3.11 Boom Harness Assy .......................................................................................................... 29
3.12 Installing Light ................................................................................................................... 31
3.13 Fuel Pump Assy Install ...................................................................................................... 34
3.14 Name plate install (electric component for auto idle stop) ................................................. 35
4 TUNER DC-DC
1B CONTROLLER
WIPER/WASHER
CONVERTER.
1. ELECTRIC CIRCUIT DIAGRAM
MECHATRO
FUEL SUPPLY
CONTROLLER
9 CONVERTER
CIGARETTE
MECHATRO
KEY SW.
3 LIGHTER
7 BACK UP
5 HORN
930 WR (5V)
DC-DC
2 RELAY
8 PUMP
11-33 C-1:MECHATRO CONTROLLER
530 P 11-32
SE-16:ACCEL POTENTIO
970 BW (GND) 11-31
1A
WV 10
RY
WG
WR
WY
PRESS. SENSOR(LOW) 900 RB (5V)
YG
1.25
RY
OL
YB
RL
E-1:FUSE BOX 11-15
SE-1:BUCKET DIGGING 500 LgR 11-14
20A
10A
10A
10A
10A
10A
10A
20A
BrR(GND)
20A
950
11-13
51 2W 52 5R 901 RL (5V) 11-16 851 GREEN A
15-1
50 1.25L 501 LgW 852 BLACK
53 5Y SE-2:BUCKET DUMP 11-17 15-2
951 BL (GND) 11-18 853 RED B M M-2:GOVERNER MOTOR
RW 20A
15-15
RL 10A
20A
10A
10A
RB 20A
WB 10A
WL 10A
WG 20A
WR 20A
C-1:MECHA
TRO CONT- 902 WV (5V) 15-16 854 WHITE
11-3 SHIELD
ROLLER C-1 502 LgY
WORK LIGHT 16 1.25

15-3
CAB WORKING LIGHT 11 1.25
1.25
HEATER 18 1.25
1.25
11-2
TRAVEL ALARM, 12 RG
4 3 SE-3:BOOM RAISING
W
R
952 BR (GND) 11-1 11-34 560 V B
GAUGE CLUSTER 13
WIPER,WASHER 14
SOLENOID 15
RESISTOR 17
AIR CON. 19
RESERVE 20
903 OB (5V) 11-4
FUEL PUMP
SWING FLASHER
AIR CON.
503 LO N L E
SE-4:BOOM LOWERING 11-5 TIO A AS
953 BrW(GND) SI RM LE
PO NO RE
TERMINAL
11-6
904 OL (5V) SW-4:SWING PARKING RELEASE SW.
11-9
504 PW 11-8
SE-7:ARM IN 561 Lg
954 BrY(GND) 11-7 12-18 3
701 PB B SV-1:SWING PARKING BRAKE SOL.
2
51A G 60A 60A 905 OW (5V) 11-10 700 VR
15-22 1
EA B BATTERY BATTERY 505 PL 11-11
SE-8:ARM OUT
51B R 60B 60B 60B 955 Gr (GND) 11-12
W 702 LgB B
EB B 906 YB (5V) 11-21 15-21 SV-3:TWO-SPEED SELECT SOL.
SHIELD 506 V 11-20
SE-5:SWING B
956 GrL(GND) 11-19 15-23 703 P SV-2:POWER BOOST SOL.
SW-1: 908 YL (5V) 11-27 751 BO
STARTER KEY SW. R-28: R-1: 15-6
AUTO IDLE STOP RELAY 1 R-3:GLOW RELAY 508 VY 752 GrR PSV-B:P2 BY-PASS CUT
ION ATING BATTERY RELAY SE-9:TRAVEL RIGHT 11-26 15-7
POSIT
PREHE PROPORTIONAL SOL.
TERMINAL
GLOW 958 BY (GND)

64 GW 53 5Y 66 5W 11-25

60 GrL 70 YW 753 GB
B 909 YR (5V)

11-28 15-8
D-3 B 71 YL 509 Sb 754 GrB PSV-C:TRAVEL PRIORITY
D-1 SE-10:TRAVEL LEFT 11-29 15-9 PROPORTIONAL SOL.
10 1.25WV 60B
D-7
10 D-4 959 BG (GND) 11-30

15-4 755 BP
D-2 756 PW PSV-D:P1 BY-PASS CUT
61 BrY M-1:STARTER MOTOR OPTION 910 RL (5V) 13-3 15-5 PROPORTIONAL SOL.
1
62 GrB SE-11:OPT.1 510 GO
2 M 13-2
B E 960 BL (GND) 757 BrG
63 WY M 13-1 15-10
758 YV PSV-A:ARM VALUABLE RECIRCULATION
S 912 RB (5V) 15-11 PROPORTIONAL SOL.
12-9
512 LgR
SE-20:OPT.2 12-8
65 5L
S 962 BO (GND) 12-7
R E-2:ALTERNATOR
R-4: 5B
SAFETY RELAY B E
PRESS.SENSOR(HIGH) 914 YL (5V) 12-3
65 L 514 VY 12-2
R SE-22:PUMP P1
651 WR L 964 BrB(GND) 12-1
D-5
915 YR (5V) N
12-4 IO AL SE
E-3:HOUR METER 515 Sb SIT RM EA
SE-23:PUMP P2 12-5 PO NO REL
TERMINAL
C-2:GAUGE CLUSTER B 965 BrL(GND) 650 Sb SW-5:K.P.S.S MODE RELEASE SW.
HM 12-6 12-19
13 W 21-6 R-29: E-14:RESISTOR
13 1 B
ENG. WATER TEMP AUTO IDLE STOP RELAY 2 1
SE-14: INDICATOR 17 WL 650 Sb
537 YR 21-2 17
2 761 G
COOLANT THERMO 805 WG RY
SENSOR C-1:MECHA 759 GrG 3
553 BrB B 730 YR 15-18
5 TRO CONT- 15-24 4
760 VR 762 L
SE-15:FUEL SENSOR
B 536 BrB ROLLER 21-1 FUEL METER 15-17 5 PSV-P1:PUMP P1
CHARGE 651 WR 6 PROPORTIONAL SOL.
12-13 B
KEY ON 60 GrL 7
12-15 8 765 GB
GLOW 61 BrY 9
BACK LIGHT 12-16 763 GY
15-20 10
B 559 PL 764 VW 11 766 LB
SW-3:TWO-SPEED SELECT SW. 12-17 15-19
12 PSV-P2:PUMP P2
B SW-34:POWER BOOST SW.
B 567 GR 14-5 PROPORTIONAL SOL.
H S FC 21-7
534 B 12-20
SE-13:ENG.SPEED SENSOR 535 W
LCD 12-21
SHIELD
12-22
21-3 600 0.5R 14-25
21-4 601 0.5W 14-26
21-5 602 0.5B 14-27
SHIELD
14-28
1A RY 15-12
1A
1B RY 15-13
1B
DISPLAY BUZZER MODE WASHER
SELECT SW. STOP
LED EA B 15-25
3
EA W 15-26 TO 2/3
4
WORKING WIPER 7 YG
LIGHT 7 15-14
Fig.1 (1/3) 1
C-1:MECHATRO CONTOLLER
FROM 1/3
550 O 14 RB
SW-7:ENG.OIL PRESS.SW. 14-2
R-5:
B 551 BrL WIPER MOTOR RELAY 80 LY
SW-8:AIR FILTER RESTRICTION SW. 14-3
552 GB 14 1.25RB 81 BrB M

B M-3:
SW-6:ENG. WATER TEMP. SW. 14-1 14 E-10:
2 WY WIPER MOTOR
2 RECEIVER DRIER E-11:
330 AIR COMMPRESSOR CLUTCH
E-1:FUSE BOX 1 RY R-8: C-4
1 85 WB 92 BP 93 LW
WORK LIGHT 10
RELAY
SE-15:FUEL SENSOR 553 BrB 14-8 SW-23:WIPER INTERLOCK SW.
5
FUEL WARNING
B 800 GB 800 GB 180 OL 18 1.25WG
555 LB 17-8
14-13
18
SW-16:AUTO ACCEL RELEASE SW. 1.25B
AIR
19 RL CONDITIONER
558 YV 19
FLOW CONTROLLER CONECTOR 14-11 AMP.
R-6:WINDOW WASHER MOTOR RELAY 181 R
24V 24V
14 RB 82 GO B M-4:WINDOW WASHER MOTOR TXD 608 G SW-13:
14 M
2 WY RXD 609 W TXD AIR CONDITIONER SW.
2
COOLING 184 B GND
801 GrL UNIT
B 563 PL 14-4 14-15
SW-22:DOUBLE SINGLE SELECT SW.
OPTION
R-8:WORK LIGHT RELAY
16 1.25RW 16 85 1.25WB 85
16 L-1:BOOM WORKING LIGHT LEFT
16 85
L-9:BOOM WORKING LIGHT RIGHT
85 B L-2:WORKING LIGHT RIGHT
14-16 802 BrY
WORKING
LIGHT ON 85
10 C-4:AIR CONDITIONER AMP.
B 583 VW 971 VR 13-16
SW-39:OVERLOAD SW.
SW-32:OVERLOAD INDICATE SW.
SWING FLASHER UNIT

FKOPT B 590 PB
SW-52:AUTO IDLE STOP SELECT SW. 12-14
KCMESTD CONTACT AT RELEASE
R-19:FLASHER RELAY
L-11:SWING FLASHER RIGHT

RG
12 25W
209 LY B
865 GL L-12:SWING FLASHER LEFT

17-3
17-4 866 GrR 25W
210 Lg B
17-10 557 Gr B SW-17:SWING FLASHER SELECT SW.

OPT
SV-4:
OPERATING
R-20:TIMER RELAY LEVER LOCK SOL.
15 WB 87 WL E D 86 OW B R-17:EXTRA DIS-PRESS RELAY
15
WB 200 OB B SV-5:
SW-11:LEVER LOCK SW. 15 EXTRA DIS-PRESS SOL
WY
2
A B
TIMER
17-11 14-17 566 VR

918 RG (5V)
12-10
12-11 518 WY SE-24:EXTRA PRESS
12-12 968 BG (GND)
OPT.
EXTRA DIS-PRESS
2 Fig.1 (2/3)
L-3:ROOM LIGHT
9 YB
9
E-16:DC-DC CONVERTER E-7:TUNER AM&FM

ANT.
88 LR
OL 207 PB E-17:SOCKET 2(+)
4 IGN 12V 89 OB E-9:SPEAKER RIGHT
6(-)
YB MEM 208 PW FM/AM 3 RL B
9 24V B 3 E-6:
1(+) 90 LW CIGARETTE LIGHTER
B 91 Br E-8:SPEAKER LEFT
5(-)
207 PB 3 B
7
208 PW 8 6
11 R B
11 M
M-9:FUEL PUMP
OPTION
R-10:CAB WORK LIGHT RELAY 1
11 1.25R 11 179 1.25L L-4:CAB WORKING LIGHT(FRONT 1)
11
11 185 LY B L-5:CAB WORKING LIGHT(FRONT 2)
SW-21: M-11:FUEL SUPPLY PUMP
WORK LIGHT SW.
L-6:CAB WORKING LIGHT(FRONT 3)
10A
WR B
20 1.25WR 178 WY L-7:CAB WORKING LIGHT(FRONT 4) 8 M
20
B L-10:CAB WORKING LIGHT(BACK)
R-11:CAB WORK LIGHT RELAY 2
176 LO B
L-15:ROTARY LIGHT
SW-30:ROTARY LIGHT SW. EXAMPLE OF WIRE COLOR
W L
Stripe color (Blue)
SW-42: L-8: Ground color (White)

ENG.ROOM LIGHT SW. ENG.ROOM LIGHT
YB B
9
WIRE COLOR CODING TABLE

Sign Color Sign Color Sign Color Sign Color
B Black W White Br Brown V Violet

R-7:HORN RELAY
5 WG 5 83 WL B Y Lg Light Green
5 E-5:HORN HIGH G Green Yellow
5 84 WB B
SW-10:HORN SW.(LEFT) B E-4:HORN LOW L Blue P Pink Gr Gray
84 WB B
SW-20:HORN SW.(RIGHT) R Red O Orange Sb Sky Blue
OPTION
Fig.1 (3/3) 3
4
2. ELECTRICAL EQUIPMENT LIST
2.1 SPECIFICATION
Group Code NAME Group Code NAME Group Code NAME
B1 Battery M1 Starter motor SV1 Swing parking SOL
POWER
M2 Governor motor SV2 ATT boost pressure SOL

M3 Wiper motor SV3 Travel 1-2 speed SOL
M4 Washer motor SV4 Safety lock lever SOL
MOTOR
C1 Mechatro controller M5
SOLENOID
CONTROLLER
C2 Gauge cluster M8
M9 Fuel pump (OPT.)
C4 Air conditioner amplifier
M11 Fuel supply pump
C6 IT controller (ORBCOMM) (OPT.)
PSVA Arm variable recirculation proportional valve
PROPORTIONAL
PSVB P2 bypass cut proportional valve
D1 Diode PSVC Travel straight proportional valve
VALVE
D2 Diode PSVD P1 bypass cut proportional valve
D3 Diode SW1 Key switch
DIODE
D4 Diode PSVP1 P1 pump proportional valve

D5 Diode PSVP2 P2 pump proportional valve SW3 Travel 1-2 speed switch
D6 Diode SW4 Swing parking release switch
R1 Battery relay SW5 KPSS release switch
E1 Fuse box R3 Glow relay SW6 Engine water temperature switch
E2 Alternator R4 Safety relay SW7 Engine oil pressure switch
E3 Hour meter R5 Wiper motor relay SW8 Air filter clogging switch
E4 Horn (Low) R6 Washer motor relay
E5 Horn (High) R7 Horn relay SW10 Horn switch (LH)
E6 Cigarette lighter R10 Cab work light relay 1 SW11 Safety lock lever switch
RELAY
ELECTRIC EQUIPMENTS
E7 Tuner AM&FM R11 Cab work light relay 2

E8 Speaker LH R19 Flusher relay (OPT.) SW13 Air conditioner switch
E9 Speaker RH R20 Timer relay
E10 Receiver dryer R28 Auto idle stop relay 1
E11 A/C compressor R29 Auto idle stop relay 2 SW16 Auto accel release switch
SW17 Swing flusher select switch (OPT.)
SWITCH
E14 Resistor SW20 Horn switch (RH) (OPT.)
SE1 Press. Sensor (LOW) : bucket digging SW21 Work light switch
E16 Converter (DC24V12V) SE2 Press. Sensor (LOW) : bucket dump SW22 Single/Conflux select switch (OPT.)
E17 Socket SE3 Press. Sensor (LOW) : boom raising SW23 Wiper inter lock switch
SE4 Press. Sensor (LOW) : boom lowering
SE5 Press. Sensor (LOW) : swing SW30 Rotary light switch
E23 Antenna (OPT.) SE6
E24 GPS Antenna (OPT.) SE7 Press. Sensor (LOW) : arm in SW32 Overload indicate switch
SE8 Press. Sensor (LOW) : arm out
L1 Boom work light LH SE9 Press. Sensor (LOW) : travel right SW34 Power boost switch
L2 Deck light RH SE10 Press. Sensor (LOW) : travel left
SENSOR
L3 Room light SE11 Press. Sensor (LOW) : opt. 1

L4 Cab work light (Front 1)
L5 Cab work light (Front 2) SE13 Engine speed sensor
L6 Cab work light (Front 3) SE14 Engine water thermo sensor SW39 Overload switch
L7 Cab work light (Front 4) SE15 Fuel sensor
LIGHT
L8 Engine room light SE16 Accel potentiometer

L9 Boom work light RH SW42 Engine room light switch
L10 Cab work light (Rear)
SW52 Auto idle stop select switch
L15 Rotary light SE20 Press. Sensor (LOW) : opt. 2
SE22 Press. Sensor (HIGH) : P1 pump

SE23 Press. Sensor (HIGH) : P2 pump
Note : z The part numbers and serial numbers of machine may be changed due to
modification, so use only the numbers for references.
5
3. HARNESS
3.1 HARNESS LIST
Table 1
INDEX No. EQUIPMENT HARNESS
DEVICE ITEM NAME ITEM NAME
25 Cab harness
3.3 Controller assy
254 Instrument panel harness
3.4 Instrument panel assy
3.5 Upper electric assy
1 Starter cable
2 Battery relay cable
3 Battery cable
4 Battery ground cable
3.6 Upper harness assy
5B Main harness
6 Frame ground cable
UPPER 15 E/G room light harness
16 Over load switch harness
FRAME
3.7 Engine harness 1 Engine sub harness
Upper harness assy 2 Ground cable
3.8
(Floor plate) 7 Harness
3 Cab right front harness (STD)
3.9 Cab harness assy 2B RH instrument panel harness
1B LH instrument panel harness
237 Wiper harness
61 Curl code harness
Cab assy
3.10 64 Cab wiper motor harness
Cab install
65 Antenna
189 Room lamp harness
3.11 Boom harness assy 1 Harness
1. Boom
UPPER 3.12
Light instal 2. Deck
FRAME
3. Cab 1 Harness
& BOOM 3.14 Fuel pump assy install
3.15 Name plate install

(Electric component for AIS)
(Note : AIS=Auto idle stop)
Note : z The part numbers and serial numbers of machine may be changed due to
modification, so use only the numbers for references.
6
3.2 HARNESS CONNECTION DRAWING SOL. BLOCK
3.6.2 BATTERY RELAY CABLE 3.5.1 BATTERY CONTROL VALVE
GROUNDING POSITION
MECHATRO CONTROLLER LEVER LOCK SOL.
FUEL SENSOR SWING PARKING SOL. HYDRAULIC PUMP
FUEL PUMP (AUTO AIR BLEED ) FUEL SUPPLY PUMP
AIR FILTER CLOGGING SWITCH TRAVEL ALARM
WASHER MOTOR SWING FLSHER RH
GLOW RELAY SWING FLSHER LH L P-1
BATTERY RELAY (POWER SUPPLY) DECK LIGHT B
HORN (HIGH) 3.6.3 BATTERY CABLE B2
HORN (LOW) A
DECK LIGHT
GOVERNOR MOTOR
3.6.4
ATT POWER BOOST SOL. BATTERY GROUND CABLE
OVER LOAD DETECT SWITCH
2-SPEED TRAVEL SOL. CN-150F
CN-152M
GLOW RELAY TO E/G ROOM LIGHT

3.6.1 STARTER CABLE
BATTERY GROUND STARTER MOTOR
P2 CN-158F
E/G GROUND
KCME 3.11.1 BOOM HARNESS
CN-165F
3.11.1-A
HORN (H) CN-352F CN-318M
CB-104 CN-110M CN-157F
CN-166F
CN-352M CN-318F
CB-104 OVER LOAD SWITCH
HORN (L)
3.6.16 OVER LOAD DETECT SWITCH 2PAM-HW CN234F S
B
GROUNDING POSITION 3.9.2 C
GAUGE CLUSTER B M
2-SPEED TRAVEL SWITCH HOUR METER 3.9.2B INSTRUMENT PANEL
3.9.2A RH HARNESS CN-4F SAFETY RELAY
BOOM WORKING LIGHT STARTER
3.6.6 ACCESSORY
FRAME GROUND CABLE CN-4M CN-351M F-32
INPANE RIGHT GOVERNOR MOTOR
1PAM CN-76F
1PAF CN-77F
3.8.2 UNDER FLOOR GROUND CABLE CN-76M CONTROLLER
M-32
GROUNDING POSITION 3.6.5A
ROOM LAMP WARM UP SWITCH CN-34F 3.6.5B MAIN HARNESS 3.7.1
3.9.10 3.6.5C
WIPER MOTOR RELAY HEAVY LIFT SWITCH E/G SUB HARNESS
3.9.3 CAB FRONT HARNESS
AIR CONDITIONER SWITCH ENGINE ROOM LIGHT P1 3.9.3A
CAB WORK LIGHT AUTO ACCEL RELEASE SWITCH
DC-DC CONVERTER HAND CONTROL CN-350F
3.3.25-4 P-36 ALTERNATOR
TIMER RELAY HYD. OIL TEMP SWITCH GROUND
3.3.28-3 INSTRUMENT PANEL HARNESS P-37
ROTARY LIGHT CIGARETIE LIGHTER TO WASHER MOTOR
3.3.6-3 FUEL SENSOR B P-31
MAIN HARNESS AUTO IDLE STOP RELAY 1
RECEIVER DRIER
TUNER AUTO IDLE STOP RELAY 2
FUEL SUPPLY PUMP
GAUGE CLUSTER AUTO IDLE STOP SELECT SWITCH
CN-252F P1
HORN SWITCH
CN-30F
POWER RESERVE
CN-251F (GROUND CONNECTOR)
MAINTENANCE CONNECTOR
KPPS. MODE RELEASE SWITCH E
3.8.1 P-35
DIODE (GLOW RELAY) CN-251M
3.8.7 UNDER FLOOR HARNESS
HOUR METER 3.8.8 CN-3M
ATT POWER BOOST SWITCH ALTERNATOR
CAB WORK LIGHT SWITCH CN-10F CN-10M
INPANE LEFT TO AIR CONDITIONER
SINGLE/CONFLUX SELECT SWITCH
3.9.1 CN-11F
12V SOCKET
3.9.1B INSTRUMENT PANEL LH HARNESS
FLASHER RELAY 3.9.1A CN-3F CN-70M
SWING FLASHER SELECT SWITCH
Fig.2 Harness connection drawing
7
3.3 CONTROLLER ASSY
Fig.3 Controller harness assy
CONTROLLER ASSY
ITEM PART NAME REMARKS

4 SWITCH ASSY 1 For swing parking release
5 RELAY 7
6 CAB HARNESS ASSY Not shown
6-3 HARNESS Inst-panel harness
13 SWITCH ASSY 1 KPSS release SW.
16 RESISTOR 1
23 TIMER 1
25 CAB HARNESS ASSY 1 Not shown
25-4 HARNESS 1 Inst-panel harness
26 FUSE ASSY 1
27 CONTROLLER
28 CAB HARNESS ASSY Not shown
28-3 HARNESS Inst-panel harness
29 FUSE ASSY
30 RELAY ASSY
32 RELAY 1 Auto idle stop relay 1
37 CONTROLLER 1
38 FUSE ASSY
39 RELAY 1 Auto idle stop relay 2
40 CONTROLLER
8
3.3.25-4 INSTRUMENT PANEL HARNESS
Fig. 4 (1/2) Instrument panel harness 9

Fig. 4 (2/2) Instrument panel harness
10
11
3.4 INSTRUMENT PANEL ASSY
INSTRUMENT PANEL ASSY
ITEM PART NAME QTY REMARKS

1 PANEL ASSY 1 RH
1-2 POTENTIO METER 1
1-3 KEY SWITCH 1
2 GAUGE CLUSTER 1
11 SPEAKER 2
17 GAUGE CLUSTER
21 SWITCH 1 Auto accel release
21A TUNER
21B TUNER AM/FM
22 GAUGE CLUSTER
24 SWITCH Auto accel release
26 CONVERTER 1 DC-DC
38 SOCKET 1 12V power source
40 ANTENNA
40A SWITCH 1 Over load indication
41 SWITCH 1 Rotary light
43 SWITCH
46 HOUR METER 1
Fig.5 Instrument panel assy

12
3.5 UPPER ELECTRIC ASSY
UPPER ELECTRIC ASSY BATTERY RELAY

1
Tighten from the forward
1 BATTERY RELAY 1 TIGHTENING TORQUE :
2 HORN 1 High 1.09kgfym {7.9 lbfyft}
3 HORN 1 Low
8 LIGHT ASSY 1 For E/G room
TORQUE :
1.09kgfym {7.9 lbfyft} 3 DETAIL OF HORN
5Y(YELLOW) B
5W(WHITE) (R-3)
GLOW RELAY
1PAF
WL
2PAF
Connect as shown so
as to avoid short
Fix the circuit power source
connector with clip. To right work light id
VIEW I VIEW II
(R-1)
BATTERY RELAY
STARTER
TORQUE :
CABLE
DETAIL OF E/G ROOM LIGHT 0.45kgfym {3.25 lbfyft} Fix the rubber
with this hole.
TORQUE :
1.09kgfym Case of fix rubber
{7.9 lbfyft} (R-3)
8 GLOW RELAY
SECTION A A UPPER
HARNESS
Cover the rubber as shown in drawing,

and fix the battery relay with sems bolt.
BATTERY Then fit the cable (harness).
RELAY CABLE DETAIL OF FIXING THE RUBBER
DETAIL OF BATTERY RELAY
Fig. 6 Upper electric assy
13
3.6 UPPER HARNESS ASSY
UPPER HARNESS ASSY

1 CABLE 1 Starter
2 CABLE 1 Battery relay
3 CABLE 1 Battery
4 CABLE 1 Ground
5A HARNESS 1 Main harness
5B HARNESS Main harness
5C HARNESS Main Harness
6 CABLE 1 Frame ground
15 HARNESS E/G room light
16 HARNESS Over load SW.
NOTE :
1. Torque for battery terminal is 0.34kgfym {2.46 lbfyft}.
2. Unspecified torque for grounding is 2.4kgfym {17.3 lbfyft}.
Fig. 7 (1/3) Upper harness assy
14
(SE5)
PRESS. SENSOR :
SWING LEFT
(PSV-P1) (PSV-P2)
(SE2)
PROPO. VALVE : P1 PUMP PROPO. VALVE : P2 PUMP
PRESS. SENSOR : Fix the harness at
BUCKET DUMP white taping portion. Connect with governor
motor harness. (M2)
GOVERNOR MOTOR
CLIP CLIP CLIP
CLIP
(L-11) CLIP
SWING FLASHER RIGHT
(SE7)
PRESS. SENSOR :
(SE4) (SE13)
ARM IN
PRESS. SENSOR : E/G SPEED SENSOR
BOOM DOWN
(SE3)
PRESS. SENSOR : (SE22) (SE23) VIEW III CONNECTION WITH ENGINE HARNESS
BOOM UP PRESS. SENSOR : PRESS. SENSOR :
P1 PUMP P2 PUMP
Fix the harness at
DETAIL OF CONTROL VALVE white taping portion.
YAZAKI
VIEW I DETAIL OF PUMP 1 PAM-58Y E/G SUB HARNESS
(PSV-C)
(PSV-B) TRAVEL
(PSV-A) P2 BYPASS CUT
ARM VARIABLE STRAIGHT
PROPO. VALVE (PSV-D) TORQUE :
RECIRCULATION PROPO. VALVE
P1 BYPASS CUT 0.08kgfym {0.58 lbfyft} Fix the
PROPO. VALVE PROPO. VALVE connector with clip. To right work light
CLIP
(R-1)
BATTERY RELAY MAIN SUMITOMO
STARTER
HARNESS 8 PAF-HW
CABLE
1
VIEW IV CONNECTION WITH ENGINE HARNESS
MAIN (R-3) 5Y(YELLOW)

(R-3)
(SW-37) GLOW RELAY 5W(WHITE)
HARNESS GLOW RELAY
HYD. FLUID TEMP. SW 1PAF
5
(SV1)
2PAF
(SV2) (SV3) (SV4)
SWING PARKING SOL ATT BOOST SOL TRAVEL LEVER LOCK SOL
1,2 SPEED SOL
DETAIL OF PROPORTIONAL VALVE BLOCK BATTERY VIEW V DETAIL OF GLOW RELAY

RELAY CABLE 2
VIEW II DETAIL OF BATTERY RELAY
Fig. 7 (2/3) Upper harness assy

15
Fig.7 (3/3) Upper harness assy
16
3.6.1 STARTER CABLE 3.6.4 BATTERY GROUND CABLE 3.6.6 FRAME GROUND CABLE
4000 (131)
300 (11.8)
(0.787)
[20] 450 TERMINAL
TERMINAL 100 (3.94)
100 60sq INSTALL (17.7) 100 BA710 LA308 5B 5B
60-8 CORRUGATE TUBE
(3.94) (3.94) 1PAM
YAZAKI 7122-3010
INSTALL Fig. 12
WHITE TAPING CORRUGATE 150
CAP TUBE CAP
(5.91) YAZAKI 7034-1283 AV60B TERMINAL
YAZAKI 7034-1283 TAPING A TERMINAL 60-8
DOUBLE-
50 BC816 WOUND TAPING
(1.97) TERMINAL
1PAF-58Y LA310
[20] AVX5sq
(0.787) Fig. 11
Bundle two connectors back to
back with vinyl tape and put a cap.
3.6.15 E/G ROOM LIGHT HARNESS
DETAIL OF A PORTION
SW-42 :
E/G ROOM LIGHT SW
CONNECTORS SELECTION TABLE CB104
CONNECTOR PART. NUMBER

NAME MANUFUC.
(PIN NUM.) HOUSING TERMINAL HARNESS SEAL
1PAF-58Y YAZAKI 7123-4210-40 7116-3250 7157-3580-60
Fig. 8
2PAM-MK LA105
L-8 :
TO UPPER HARNESS
E/G ROOM LIGHT
3.6.2 BATTERY RELAY CAB
800 (31.5)
CAP TERMINAL
YAZAKI 7034-1283 60-8 AV60B TERMINAL CAP
BC818 BTC-135-R(RED)
Fig. 9
Fig. 13
3.6.3 BATTERY C
3.6.16 OVER LOAD SWITCH HARNESS
250 (9.84)
AV60B
CAP LEFT CAP RIGHT
TERMINAL LEFT TERMINAL RIGHT
INSTALL CORRUGATE TUBE
Fig. 10
Fig. 14
17
3.6.5 MAIN HARNESS
Fig. 14 Main harness

18
19
3.7 E/G HARNESS ASSY CONNECTOR FOR
E/G SPEED SENSOR
E/G HARNESS ASSY BRACKET
ITEM NAME QTY REMARKS Fit this clip directing

as shown.
1 HARNESS 1 E/G SUB CLIP
Fix harness using

this hole as shown.
This harness not to be

contacted with the pulley.
VIEW II
UPPER
DETAIL B
FRAME HARNESS
STARTER MOTOR(M-1) GND (E/G ACCESSORY) Fix the harness at

Clamp with grounding bolt. white taping portion.
YAZAKI
GOVERNOR MOTOR(M-2) 1PAM-58Y E/G SUB HARNESS
CLIP
Fix connector Clamp this clip
of harness. with level gauge. E/G SUB HARNESS CLIP
SAFETY RELAY
(R-4)
GLOW E/G OIL

PRESS.SW
(SW-7)
1
SUMITOMO DETAIL OF
MAIN
8PAF-HW
HARNESS STARTER MOTOR
E/G COOLANT
TEMP. SW A AIR-CON DETAIL OF GOVERNOR
B COMPRESSOR
MOTOR BRACKET
E/G COOLANT Tighten ground terminal to
TEMP.SENSOR Fix the harness free from ALTERNATOR(E-2) A/C compressor bracket.
(SE-14) contacting with engine.
C
GLOW Tighten to fuel filter using

existing capscrew. NUT
TORQUE : 6.6kgfym {47.7 lbfyft} E/G
LOCK ACCESSORY
CLIP WASHER
Tighten to lifting lug using

exsisting capscrew.
TORQUE : 6.6kgfym {47.7 lbfyft} BRACKET HARNESS
WASHER
CLIP Insert this portion into
clip of connector.
CLIP
DETAIL C
DETAIL OF ALTERNATOR
E/G SPEED SENSOR
DETAIL A CONNECTOR INSTALLATION
VIEW I
Fig. 15 E/G harness
20
3.7.1 ENGINE SUB HARNESS
SW-7 :
E/G OIL SW GND
LA104 LA310
P-32 P-31
CONNECTORS SELECTION TABLE

CONNECTOR PART. NUMBER
NAME MANUFUC.
2FY-SWP
1MY-58Y CN-350F
(PIN NUM.) HOUSING TERMINAL
CN-351M GLOW
M-1 : 2FY-SWP YAZAKI 7123-1424-40 7116-1471
CAP : YAZAKI 7034-1279
STARTER MOTOR LA305
LA304 1MY-58Y YAZAKI 7222-4210-40 7114-3250
PLUG P-38 P-35
CB104 E-2 : STRAIGHT
LA306 ALTERNATOR TERMINAL YAZAKI 7120-3011 7116-2270
E-11 : F-31
P-37
CB104 CA104 AIR-CON COMPRESSOR
8FS-HW090 SUMITOMO 6189-0134 1500-0106
F-32 M-32 CAP :
R-4 : SAFETY RELAY YAZAKI 7034-1279 CA104 YAZAKI 7120-8012 7113-1020-02
LA306
8FS-HW090 P-36 CB104 YAZAKI 7120-1010 7115-1050-02
CN-318F
WITH TAPING
STRAIGHT
1MY-58Y FEMALE
CN-352M F-33 LA104 SW-6 :
P-34 E/G COOLANT TEMP.SW
TO MAIN HARNESS SE-14 :
E/G COOLANT TEMP. SENSOR
Fig. 16 Engine sub harness
21
3.8 UPPER HARNESS ASSY (FLOOR PLATE)
UPPER HARNESS ASSY

(FLOOR PLATE)

2 CABLE 1 GROUND
7 HARNESS 1 UNDER FLOOR
Fig. 17 Upper harness assy (Floor plate)
22
3.8.7 UNDER FLOOR HARNESS
Fig. 18 Under floor harness 23

3.9 CAB HARNESS ASSY
CAB HARNESS ASSY

3 HARNESS 1 Cab front
1B HARNESS 1 Inst LH
2B HARNESS 1 Inst RH
Fig. 19 Cab harness assy

24
3.9.9 INSTRUMENT PANEL LH HARNESS
Fig. 20 Instrument panel LH harness

25
3.9.2A INSTRUMENT PANEL RH HARNESS
Fig. 21 Instrument panel RH harness

26
3.10 CAB ASSY
CAB ASSY

2 FRONT WINDOW ASSY 1 M/W
2-8 WIPER ASSY 1

2-37 HARNESS 1
25 SWITCH 1 Door
61 HARNESS 1 Curl code
64 HARNESS 1 M/W
65 ANTENNA 1
68 ROOM LIGHT 1
189 HARNESS 1 M/W, Room lamp
195 STOPPER ASSY 1 Wiper control
195-3 INTER ROCK SWITCH 1
CAB INSTALL
4 WATER TANK ASSY 1
4-1 ELEC MOTOR ASSY 1
Fig. 22 Cab install Fig. 23 Cab assy

27
3.10.2-37 WIPER HARNESS 3.10.61 CURL CODE HARNESS 3.10.64 CAB WIPER MOTOR HARNESS
Fig. 24 Fig. 25
Fig. 26
3.10.65 ANTENNA
3.10.189 ROOM LAMP HARNESS 3.10.4 WINDOW WASHER TANK & MOTOR
Fig. 27 Antenna
Fig. 29 Wind washer pump
Fig.28 Room lamp harness
28
3.11 BOOM HARNESS ASSY
BOOM HARNESS ASSY

1 HARNESS 1 Boom harness
Fig. 30 Boom harness assy
29
3.11.1 BOOM HARNESS
Fig. 31 Boom harness
30
3.12 INSTALLING LIGHT
3.12.1 INSTALLING BOOM LIGHT 3.12.2 INSTALLING DECK LIGHT
INSTALLING BOOM LIGHT INSTALLING DECK LIGHT
ITEM PART NAME QTY REMARKS ITEM PART NAME QTY REMARKS
Install two lights 1 LIGHT 1
1 LIGHT 2 symmetrically
1
To bucket bottom center

Direct the light beam to the bottom
of bucket, when arm is completely
extended (Arm out) and bucket is
fully closed.
NUT(LIGHT ACCESSORY)
TORQUE ;
1 1.75kgfym {12.7 lbfyft}
BRACKET
TORQUE ; INSTALLING PROCEDURE OF RIGHTSIDE DECK LIGHT

1.90kgfym {13.7 lbfyft}
SECTION A-A
Fig. 32 Boom light installing Fig. 33 Deck light installing
31
3.12.3 CAB LIGHT INSTALL
CAB LIGHT INSTALL

18 HARNESS 1
Fig. 34 Cab light install
32
3.12.3.18 CAB LIGHT HARNESS 3.12.4 SWING FLASHER LAMP INSTALL
SWING FLASHER LAMP INSTALL

1 LAMP 2
6 SWITCH 1
Fig. 35 Cab light harness Fig. 36 Swing flasher lamp
33
3.13 FUEL PUMP ASSY INSTALL
FUEL PUMP ASSY INSTALL

1 FUEL PUMP ASSY 1
Fig. 37 Fuel pump assy
34
3.14 NAME PLATE INSTALL (ELECTRIC COMPONENT FOR AUTO IDLE STOP)
NAME PLATE INSTALL

1 SWITCH 1
Fig. 38 Switch install
35
36
E200SR
SECTION 24 COMPONENTS SYSTEM
TABLE OF CONTENTS
I. HYDRAULIC COMPONENTS
1. Hydraulic Pump_Regulator ............................................................................................... H1-1
2. Pilot Valve (ATT) ............................................................................................................... H2-1
3. Pilot Valve (Travel) ............................................................................................................ H3-1
4. Control Valve .................................................................................................................... H4-1
5. Swing Motor Unit .............................................................................................................. H5-1
6. Travel Motor ..................................................................................................................... H6-1
7. Swivel Joint ....................................................................................................................... H7-1
8. Hydraulic Cylinder............................................................................................................. H8-1
II. ELECTRIC EQUIPMENT

1. List of Electric Equipments .................................................................................. E1-1
2. Specification of Electric Equipments .................................................................... E1-3
1. HYDRAULIC PUMP REGULATOR
1.1 SUMMARY
(1) Outside view and hydraulic port
a3 PSV1 5 a5,Dr3
A3
3 No. NAME
1 MAIN PUMP ASSY
B3 2 REGULATOR ASSY
Dr1
3 GEAR PUMP ASSY(FOR PILOT)
5 PTO GEAR CASE ASSY
SOLENOID PROPORTIONAL
6 REDUCING VALVE
PSV2 a4
6 a3 6
a4 2 PSV1
2 A3
a5
Dr3
B3
Dr1 A1 A2 B1 PH2 a2 A2
Table 1-1 Hydraulic ports
Code Ports name Size

A1,2 Delivery port 3/4
B1 Suction port 2 1/2
Dr1 Drain port PF1/2
PSV1,2 Servo assist port PF1/4
PH1,2 Pressure sensor port PF3/8
a15 Gauge port PF1/4
A3 Delivery port of gear pump(for pilot) PF3/8
B3 Suction port of gear pump(for pilot) PF3/4
Dr3 Drain port of gear pump(for pilot) PF3/8
Fig. 1-1 Hydraulic pump y regulator
H11
(2) Hydraulic circuit diagram
Solenoid Solenoid
proportional proportional
reducing valve reducing valve
Regulator
Regulator
Engine
Main pump
PTO Gear case Gear pump for pilot
(3) Specification
Table 1-2
Item Main pump Gear pump for pilot

Max.displacement
capacity cm3 /rev 802 10
Rated revolution rpm 2,200(clockwise as seen from shaft end)
Working pressure kgf/cm2(psi) 350(4,980) 51(725)
Max. flow /min(gal/min) 176(46)2 22(5.8)
Max. input horsepower PS 125 (Gear pump only : 4.3)
Max. input torque kgfym (lbfyft) 40.7(290) [Gear pump only :1.5 (11)]
Model KR380E02
Regulator Control function Positive electric flow control
With solenoid proportional reducing
Others valve(KDRDE5K)
Relief set pressure kgf/cm2(psi) 350(4980) 51(725)
H12
1.2 HYDRAULIC PUMP

1.2.1 CONSTRUCTION
(1) Main pump
535 789 732 212 156 532 214 531,548 534 702 792 724 954 124 901 116 711 312 719 151 152 113 252
953
808
251
886
406
261 717
406
111 123
824
774
127
710
262
401
490
271 211 153 467,728 157 313 466,725 885 886 314 141 468,728
Fig. 1-2 Construction of main pump
Table 1-3
No. NAME QTY No. NAME QTY No. NAME QTY
111 SHAFT(F) 1 262 SEAL COVER(R) 1 711 O RING : 1B G95 1
113 SHAFT(R) 1 271 PUMP CASING 2 717 O RING : 1B G120 2
116 1st GEAR 1 312 VALVE BLOCK 1 719 O RING : 1B G115 2
123 ROLLER BEARING 2 313 VALVE PLATE (For clockwise) 1 724 O RING : 1B P8 18
314 VALVE PLATE 1
124 NEEDLE BEARING 2 (For counter clockwise) 725 O RING : 1B P11 2
127 BEARING SPACER 4 401 SOCKET BOLT : M16175 8 728 O RING : 1B P18 4
141 CYLINDER BLOCK 2 406 SOCKET BOLT : M616 8 732 O RING : 1B P16 2
151 PISTON 18 466 VP PLUG : PF1/4 2 774 OIL SEAL 1
152 SHOE 18 467 VP PLUG : PF1/2 3 789 BACKUP RING 2
153 RETAINER PLATE 2 468 VP PLUG : PF1/2 1 792 BACKUP RING 2
156 SPHERICAL BUSHING 2 490 PLUG : NPTF1/16 15 808 HEX. NUT : M16 4
157 CYLINDER SPRING 18 531 TILTING PIN 2 824 SNAP RING 2
211 SHOE PLATE 2 532 SERVO PISTON 2 885 VALVE PLATE PIN 2
212 SWASH PLATE 2 534 STOPPER : L 2 886 SPRING PIN 4
214 TILTING BUSHING 2 535 STOPPER : S 2 901 EYE BOLT : M10 2
251 SWASH PLATE SUPPORT(F) 1 548 FEED BACK PIN 2 953 SET SCREW : M16 2
252 SWASH PLATE SUPPORT(R) 1 702 O RING : 1B G30 2 954 SET SCREW : M16 2
261 SEAL COVER(F) 1 710 O RING : 1B G85 2
H13
(2) Gear pump(for pilot)
433
700 354 351
434
728
435
312
311
732 850 467
710 361 353 307 310 308 309 434 466 355
725
Fig.1-3 Construction of gear pump(for pilot)
Table 1-4
No. NAME QTY No. NAME QTY

307 POPPET 1 433 FLANGE SOCKET : M840 2
308 SEAT 1 434 FLANGE SOCKET : M855 2
309 SPRING SEAT 1 435 FLANGE SOCKET : M1035 2
310 SPRING 1 466 VP PLUG : PF1/4 1
311 ADJUST SCREW 1 467 ADAPTER : PF1/2-PF3/8 1
312 LOCK NUT : M14 1 700 RING 1
351 GEAR CASE 1 710 O RING : 1B G80 1
353 DRIVE GEAR 1 725 O RING : 1B P11 1
354 DRIVEN GEAR 1 728 O RING : 1B P18 1
355 FILTER 1 732 O RING : 1B P16 1
361 FRONT CASE 1 850 SNAP RING 1
H14
(3) PTO gear case
GEAR PUMP
326 118 125 825 (for pilot) 728 468
117
126
128
435
886
827
115
826
FRONT SIDE REAR SIDE
Fig.1-4 Construction of PTO gear
Table 1-5
115 IDLE SHAFT 1 435 FLANGE SOCKET : M1020 4

117 2nd GEAR 1 468 VP PLUG : PF3/4 1
118 3rd GEAR 1 728 O RING : 1B P24 1
125 BALL BEARING 2 825 SNAP RING 1
126 ROLLER BEARING 1 826 SNAP RING 1
128 BEARING SPACER 2 827 SNAP RING 1
326 GEAR CASE 1 886 PIN 2
H15
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 REGULATOR
engine rotation is transmitted to front shaft(111)
that drives the two pumps and, at the same time,
drives the pilot gear pump arranged on a different
axis. 116
The pump assy consists largely of the rotary
group, the main part of the pump that makes
rotary on; the swash plate group that changes the 111
delivery rate; the valve block group that selects
between oil suction and delivery ; and the PTO
group that transmits the drive power to the gear
pump.
(1) Rotary group PTO

The rotary group consists of shaft(111), GEAR
cylinder block(141), piston(151), shoe(152), GEAR PUMP CASE
(FOR PILOT)
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 Fig. 1-5 Construction of hydraulic pump
and relieves it of thrust force that is
generated by load pressure.
Further, the piston is provided with a pocket
so it moves lightly on shoe plate(211), taking
hydraulic balance.
The sub group of the piston-shoe is pressed
against the shoe plate by the cylinder spring,
via the retainer plate and the spherical
bushing, so that it moves smoothly over the
shoe plate. The cylinder block(141) is also
pressed against valve plate(314) by the
action of cylinder spring(157).
313
124
312
111
116
314124
141
157
151 156
153
152
211
Fig. 1-6 Rotary group
H16
(2) Swash plate group 532

The swash plate group consists of swash
plate(212), shoe plate(211),swash plate
support(251), tilting bushing(214), tilting 531 214
pin(531),and servo piston(532). The swash 211
plate is the cylindrical part that is formed on 212
the opposite side of the shoe sliding surface
and is supported by the swash plate
support. 251
The hydraulic force controlled by the
regulator flows into the hydraulic chamber
that is provided on both sides of the servo
piston. This moves the servo piston to the
right and left. The result is that the swash
plate swings on the swash plate support via
the spherical part of the tilting pin and
changes the tilting angle(). Fig. 1-7 Swash plate group
(3) Valve block group

The valve block group consists of valve 313
block(312), valve plates(313),(314), and valve 312
plate pin(885). The valve plates having two
crescent-shaped ports are installed to valve
block(312) to feed oil and recycle it from 116
cylinder block(141). The oil switched over by 111
the valve plate is connected with the 141 314
885
external pipe by way of the valve block.
(4) PTO group

The PTO group is composed of 1st gear(116),
2nd gear(117) and 3rd gear(118). The 2nd
and the 3rd gear are supported by Fig. 1-8 Valve block group
bearings(125) and (126) respectively and
installed to the valve block. 117
Now, if the shaft is driven by the engine, the
cylinder block rotates together by the spline 126
linkage. If the swash plate is inclined, the
pistons arranged in the cylinder block make
reciprocating motion with respect to the
cylinder while rotating with the cylinder
block. If we keep an eye on a single piston,
it makes a motion away from the valve
plate(oil suction process)in the first 180 and
118
a motion toward the valve plate(oil delivery
125
process) in the remaining 180. If the swash
plate is not inclined(zero tilting angle), the
piston does not stroke i.e. delivers no oil.
At the same time, the shaft rotation is taken 125
up by the 1st gear(116) and transmitted to
the 2nd gear(117) and the 3rd gear(118), in
that order, to drive the gear pump that is Fig. 1-9 PTO group
linked to the 3rd gear.
H17
1.3 REGULATOR Table1-7

1.3.1 CONSTRUCTION
No. NAME Q'TY
418 SOLENOID PROPORTIONAL

079 REDUCING VALVE 1
325 VALVE CASING 1
402 SOCKET BOLT : M616 4
415 415 SOCKET BOLT : M845 6
601 466 VP PLUG : PF1/4 1
897
496 PLUG 9
496 755 541 SEAT 2
543 STOPPER 2
543 614 545 BALL 2
601 CASING 1
545 611 FEED BACK LEVER 1
614 FULCRUM PLUG : PF1/4 1
541 624 SPRING SEAT 1
756 708 627 PLUNGER 1
631 SLEEVE 1
643 PISTON 1
611 646 SPRING 1
651 SLEEVE 1
652 SPOOL 1
656 COVER 1
SECTION AA 658 PLUG : NPTF1/16 1
708 O RING : 1B G75 1
724 O RING : 1B P8 5
731 O RING : 1B P25 1
733 O RING : 1B P18 2
755 O RING : 1B P11 2
756 O RING : 1B P12.5 2
801 HEX NUT : M8 1
887 PIN 1
897 PIN 1
325 496 079 924 SET SCREW 1
624 646 627 733 656 402
643 A 801
466 924

755
407
724
A
631 887
731 Fig. 1-10 Construction of regulator

651 733 652 658
H18
1.3.2 OPERATION
(1) Summary
Regulator KR38-0E02 for the inline axial
piston pump K5V series is of electric flow
control type that regulates the tilting angle
(delivery rate) of the pump as the command
current I to the solenoid proportional
reducing valve is varied.
This regulator is of positive flow control type
that increases the delivery flow Q as the
command current I increases.
If an electric current is put in by this control
according to the flow needed for the
operation, the pump delivers at a flow rate
that is only required by the pump,
consequently holding down unwanted power
consumption.
(2) Positive control.
As shown in the figure on the right, the
regulator regulates the delivery rate of the
pump by command current I. DELIVERY RATE Q
1) Flow increasing action
As the command current I rises, the
secondary pressure of solenoid proportional
reducing valve (079) increases. This causes
spool (652) to move via pilot piston (643) and
stops where the hydraulic pressure pushing
the spool rightwards balances with the action COMMAND CURRENT I
of pilot spring (646).
If the spool (652) moves, port C opens to the
Fig.1-11 Positive flow control
tank port. This causes the pressure of the
large diameter part of servo piston (532) to go
away. This causes the servo piston (532) to
the left by delivery pressure P1 of the small
diameter part, resulting in an increase in the
tilting angle .
643 652 651 611 624 627 646 801 924
532
808
808
954 953
A
TILTING MAX. TILTING MIN.
Fig. 1-12 Functions of regulator
H19
Feedback lever(611) is linked with the servo

piston and sleeve(651). As the servo piston
moves to the left, the feedback lever rotates
on point A which causes the sleeve to the
right. As the servo piston moves to the right,
the feedback lever rotates on point A to move SOLENOID PROPORTIONAL
the sleeve to the right. The result is that the REDUCING VALVE REGULATOR
opening of the spool sleeve begins to close
gradually and the servo piston settles down
when the opening of the spool sleeve closes
completely.
646
(2) Flow decrease function
As the command current decreases, the 652
secondary pressure of the solenoid
proportional valve decreases. This causes the
spool to move to the left.
When the spool(652) has moved, delivery MAIN
pressure P1 reaches port C via spool and is PUMP
admitted to the large diameter chamber of
the servo piston. Delivery pressure P1 is 643
admitted to the small diameter part of the
servo piston at all times. The servo piston 651
moves rightward by areal difference to C PORT 532 POINT 611
decrease tilting angle ( ). As the servo A
Fig. 1-13 Regulator hydraulic circuit
piston moves to the right, the feedback lever
rotates on point A to move the sleeve to the
left. The sleeve keeps moving till the opening
of the spool sleeve closes and settles down
when the spool sleeve closes completely.
H110
1.3.3 ADJUSTING REGULATOR

The maximum flow, minimum flow and flow
control characteristics of the regulator may be
controlled by the adjust screw of the
regulator.(Amounts of adjustment are shown in
table 1-8.)
However, the adjustment may change

the flow characteristics. Therefore, do
not tamper with the adjust screws
unless there is special reason.
Table1-8 Amounts of change by the adjustment of regulator
Solenoid proportional valve model KR380E02

Pump revolution 2200rpm-1
Adjust screw(954)1/4turn
Max. flow
Flow rate Q=3.5 /min (0.87gal/min)
Min. flow
Flow control characteristics Current I=24.5mA
(1) Adjusting the maximum flow

For adjustment, loosen the hex nut (808) and
DELIVERY RATE Q
tighten (or loosen) the set screw (954) on the

large diameter part of the servo piston.
Tightening it decreases the flow and
loosening it increases the flow.
Only the maximum flow changes with other
control characteristics unchanged.
COMMAND CURRENT I
Fig. 1-14 Adjusting the max. delivery rate

(2) Adjusting the minimum flow
For adjustment, loosen hex nut (808) and
tighten (or loosen) the set screw (953) on the
small diameter part of the servo piston.
Tightening it increases the flow and
DELIVERY RATE Q
loosening it decreases the flow.

Other characteristics do not change the same
way as the adjustment of the maximum flow.
Note that if the set screw is tightened too
much, the power requirement at the
maximum delivery pressure (at relieving)
increases in some cases.
COMMAND CURRENT I
Fig. 1-15 Adjusting the min. delivery rate
H111
(3) Adjusting the flow control characteristics

For adjustment, loosen hex nut (801) and tighten
(loosen) the set screw (924). If the set screw is
tightened, the control curve moves rightwards, as
DELIVERY RATE Q
shown in Fig.1-16.
COMMAND CURRENT
Fig. 1-16 Flow control characteristics

1.3.4 CAUSES OF FAULT RESULTING FROM
REGULATOR
(1) Engine is overloaded
Load each of the pumps and check which of the
pumps, front or rear is faulty. In case both are faulty,
check the following and : If only one of the
pumps is faulty, start with .
Check that the command current of the solenoid
proportional reducing valve is normal.
The secondary pressure Check amplifier
of solenoid proportional dither.
reducing valve is high. Replace solenoid
proportional
reducing valve.
Spool (652) and Disassemble and

Sleeve (651) are clean.
stuck.
Pilot piston (643) Disassemble and

is stuck clean.
(2) Max. delivery rate can not be attained

Confirm that the secondary pressure of the solenoid
proportional reducing valve is normal.
Pilot piston (643) Disassemble and clean.

is stuck.
Spool (652) and Disassemble and clean.

sleeve (651) are
stuck.
H1 12
1.4 CONTROL CURVE OF PUMP E200SR

(1) At H mode
1
Input rotation_2200min_ {rpm}
200 2
(52.8) Independent loading (P2=5.1kgf/cm (72.5psi),Qmin)
(Travel_ATT) 83.6kw (113PS)
/min (gal/min)
150
(39.6)
Delivery flow rate_Q
100
(26.4)
Simultaneous loading
83.6kw (113PS)
50
(13.2) Min. flow rate
0 2
0 50 100 150 200 250 300 350 kgf/cm
0 711 1422 2133 2844 3555 4266 4977 (psi)
Delivery pressure Pd
(2) At S mode
1
200
(52.8) (Travel) Independent loading
2
(Travel_ATT) (P2=5.1kgf/cm (72.5psi),Qmin) 79.8kw (108PS)
/min (gal/min)
150 (ATT) Independent loading

2
(39.6) (P2=5.1kgf/cm (72.5psi),Qmin)
78kw (106PS)
(Travel)
100 Simultaneous loading

(26.4) 79.8kw (108PS)
(ATT) Simultaneous loading
78kw (106PS)
50
(13.2) Min. flow rate
0 2
0 50 100 150 200 250 300 350 kgf/cm
0 711 1422 2133 2844 3555 4266 4977 (psi)
H1-13
(3) At FC mode
1
200
(52.8)
/min (gal/min)
Independent loading
2
150 (P2=5.1kgf/cm (72.5psi),Qmin)
(39.6) (Travel_ATT) 53.1kw (72.2PS)
100
(26.4)
50 Simultaneous loading
(13.2) 53.1kw (72.2PS)
Min. flow rate
0 2
0 50 100 150 200 250 300 350 kgf/cm
0 711 1422 2133 2844 3555 4266 4977 (psi)
H1-14
2. PILOT VALVE (ATT)

2.1 OUTLINE
(1) Outside view (2) Specification
SINGLE SINGLE
Table 2-1
OPERATION OPERATION
ANGLE ANGLE Item Specification
The adjust nut (PORT 2,4) (PORT 1,3)
(opposing flats : 22) : Model PV48K2005
Fix adjust nut Operating torque Refer to the curve below
(opposing flats : 22)
when the lever is installed by Max. primary pressure 70kgf/cm2 (995psi)
means of spanner or the like.
Primary pressure 51kgf/cm2 (725psi)
Then tighten the mating lock
nut to 4.20.3kgfym Rated flow 20 /min (5.3gal/min)
(302.2 lbfyft).
Weight Approx. 1.9kg (4.2 lbs)
(3) Performance characteristics
5-PF3/8
T=50.5(363.6)
PF1/4
T=30.2(221.4)
T=Tightening torque : kgfym (lbfyft)
Hydraulic simbol
Fig. 2-1
H21
2.2 CONSTRUCTION,FUNCTION AND OPERATION

(1) Cross section view
312
302
Apply grease
on rotating and
501 sliding sections.
301 Be careful the
assembling
direction
Apply grease on
top section
212 213
151 246
218-2 211
214
218-1
216-2 216-1
241-2 241-1
201-2
201-1
217
Secondary
pressure 101 221
adjusting shim
Designed value
t=0.4 (0.016 ),
1 pc.
PORT 2,4 PORT 1,3

Fig. 2-2 Pilot valve (ATT)
Apply Loctite #277 to areas marked

Tightening torque Tightening torque
kgfym (lbfyft) No. NAME QTY kgfym (lbfyft) No. NAME QTY
101 CASING 1 218-1 SEAT 2
151 PLATE 1 218-2 SEAT 2
201-1 SPOOL 2 221 SPRING 4
201-2 SPOOL 2 241-1 SPRING 2
211 PLUG 4 241-2 SPRING 2
212 PUSH ROD 4 246 SPRING 4
213 SEAL 4 4.8 (35) 301 JOINT : M14 1
214 O RING : 1B P20 4 302 CIRCULAR PLATE 1
216-1 SPRING SEAT 1 2 7 (51) 312 ADJUST NUT : M14 1
216-2 SPRING SEAT 1 2 501 BOOTS 1
217 WASHER 2 (SHIM) 4
Note) The parts marked may not be equipped depending on value type.
H22
(2) Construction
The pilot valve is constructed as shown in the
cross-sectional view (Fig.2-2). The casing has
a vertical shaft hole in which a reducing
valve is assembled.
The reducing valve consists of spool (201),
spring (241) (for secondary pressure setting),
spring (221) (for return), spring seat (216),
and washer (217). The spring (241) (for
secondary pressure setting) is so set as to
achieve the secondary pressure conversion
5~10kgf/cm2 (71~140psi) (varies with the
model.). The spool (201) is pressed against
push rod (212) by spring (221) (for return).
If push rod (212) is pushed down by tilting
the control part of the handle, the spring seat
(216) falls at the same time and changes a set
pressure of spring (241) (for secondary
pressure setting).
The casing (101) and the port plate (111) are
provided with an oil inlet (primary pressure)
port P and an outlet (tank) port T. They are
further provided with ports 1, 2, 3, 4 from
which secondary pressure is discharged.
(3) Function
1) Basic functions 2) Main functions
The pilot valve controls the stroke and the The function of spool (201) is to receive the
direction of the control valve spool. This is supply pressure of the hydraulic pump by
achieved by applying the output pressure of port P and admit the hydraulic pressure at
the pilot valve to the end of the control valve port P to output ports (1, 2, 3, 4) or admit the
spool. hydraulic pressure at the output ports to port
In order to satisfy the functions, the pilot T. Spring (241) (for secondary pressure
valve is constructed with the following setting) acts upon spool (201) and determines
elements : the output pressure.
Inlet port (P) to which the oil of the Push rod (212) that changes the deflection of
hydraulic pump is supplied. spring (241) (for secondary pressure setting)
Multiple output ports (1, 2, 3, 4) that is inserted in plug (211) so as to enable
exert the supply pressure from the input smooth movement.
port upon the end of the spool of the Spring (011) (for return) acts upon casing
control valve. (101) and spring seat (216) and brings push
Tank port (T) to control the above rod (212) toward zero displacement
mentioned output pressure. regardless of output pressure, in order to
Spool that connects the output port with positively bring spool (201) back to neutral.
the inlet port or the tank port. The spring also acts as a reactive force that
The mechanical means including springs gives the operator a proper operating feeling.
that act upon the above- mentioned
spool, in order to control the output
pressure.
H23
(4) Function
Now, let us explain the function of the pilot
valve, using the hydraulic diagram (the
figure on the right) and the functional
explanation drawing (Fig.2-3 to 2-5).
1 3
P T
cPilot valve dPilot pump
Lever in neutral
1) Handle in neutral (See Fig.2-3.)

The action of spring (241) (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 1
(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
241
221
201
PORT(2,4)
Fig. 2-3 Handle in neutral
H24
2) When the pilot lever is tilted (See Fig. 2-4 )

When the lever is tilted and the push rod
(212) strokes, the spool (201) spring seat
(216) moves down-ward 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 212
2 ,4 to produce a pressure.
216
201
PORT(2,4)
3) Handle held (See Fig.2-5.) Fig. 2-4 When the lever is tilted
When the pressure at ports (2,4) rises to a
level equivalent to the action of spring (241)
that is set by tilting the handle, the hydraulic
pressure balances the spring action. When
the pressure of ports (2,4) rises above a set
value, ports (2,4) and the P port close while
ports (2,4) and the T port open. When the
pressure at ports (2,4) falls below a set value,
ports (2,4) and the P port open while ports
(2,4) and the T port close. Thus the secondary
pressure is kept constant.
241
T PORT
P PORT
PORT (2,4)
Fig. 2-5 When the handle is held

(When the secondary pressure is higher than a set value)
4) Operation in the area where the tilting angle the bottom of the bore of the push rod
of the handle is large. (varies with the model) contacts the spring if the handle is turned
If the handle is inclined beyond a certain beyond a certain angle. This causes the
angle on certain models, the top end of the secondary pressure gradient to change by the
spool contacts the bottom of the bore of the spring action. Thereafter, the bottom of the
push rod. This keeps the output pressure bore of the push rod contacts the top end of
connected with the P port pressure. the spring seat, keeping the output pressure
Furthermore, on a model in which a spring connected with the P port.
seat and a spring are built in the push rod,
H25
H26
3. PILOT VALVE (TRAVEL)

3.1 OUTLINE
(1) Outside view
VIEW FROM MACHINE REAR SIDE
Tightening 4-11
Port torque Port
size kgfym (ftylbs) name
Function Through
1 RH travel reverse port

2 RH travel forward port MACHINE FRONT
7.50.5
PF3/8 3 LH travel reverse port
(543.6)
4 LH travel forward port
T Tank port
5 Travel pressure sensor
6 port
3.70.2
PF1/4 P Travel pressure sensor
(271.4) Fig. 3-1 Out side view of travel pilot valve
port
(2) Specification Pilot primary pressure port
(3) Performance characteristics
Item Specification
Type 07291-00000
Primary pressure 51kgf/cm2 (725psi)
Secondary pressure 5.524kgf/cm2 (78340psi)
Rated flow 10 /min (2.6gal/min)
Weight Approx. 11kg (24 lbs)
LEFT RIGHT
Hydraulic simbol Control diagram
H31
3.2 CONSTRUCTION AND OPERATION

Z
33 2 36 33
13 12 28 RORT5
36 14
PORT
5
42
19
37 26 25
1,3 30
20
34 25
22 15
20 21 42
20
39 PORT
PORT66
32 17
44,16 33 36 33
40
6 7 SECTION AA
18 8
24 25,42
41
27
4 10,11 35
9 31 5 29
38
4-M10
T=4.30.4(3129)
SECTION BB
24,41 VIEW Z Fig. 3-2 Construction of travel pilot valve
Apply Locktite #262 to areas marked .
Tightening Tightening
torque No. NAME QTY torque No. NAME QTY
kgfym (lbfyft) kgfym (lbfyft)
1 ORIFICE(SHIM) 4 22 SPRING 4
1.5(11) 2 SEAT 2 1.0(7.2) 24 PLUG : PF1/8 3
3 ORIFICE(SHIM) 4 2.5(18) 25 PLUG : PF1/4 3
4 SPOOL 4 6.0(43) 26 SOCKET BOLT : M1060 2
5 BODY 1 0.5(3.6) 27 FLANGE BOLT 4
6 STOPPER 4 1.5(11) 28 SETSCREW : M8 4
7 SPRING 4 29 WASHER 4
9 NAME PLATE 1 31 RIVET 2
10 SHIM t=0.2 4 32 PIN : 5 4
11 SHIM t=0.1 4 33 BALL 6
12 CAM 2 34 BALL 4
13 BOOTS 2 35 BALL 4
14 PIN 2 36 BALL 6
15 COVER 2 37 U PACKING 4
16 PISTON 4 38 O RING : 1A P5 4
17 GUIDE 4 39 O RING : 1A P24 4
18 SLEEVE 4 40 O RING : 1A P26 4
19 HOLDER 4 41 O RING : 1B P8 3
20 RING 12 42 O RING : 1B P11 3
21 ORIFICE(SHIM) 4 44 PISTON ASSY 4
H32
3.3 OPERATION
(1) Construction z If the cam operates during travel operation,
The valve consists of the following parts in the oil in the damper chamber is kept from
terms of hydraulic function: flowing back by the check valve. Thus the oil
flows to part E oly from the orifice. Damper
A : Damper section
action operates by the resistance that is built
B : Reducing valve section
up as the oil passes through the orifice.
C : Shuttle section Let us explain the profile of the piston (See
(2) Operation Fig. 3-4.)
1) Damper section The upper part of the piston has a diameter
z If the primary pressure is supplied by P, it is of 12mm(0.472in), while the lower part of it
flowed to the damper chamber by way of has a diameter of 11mm(0.433in). This
circuits D and E. results in an areal difference, with the result
The pressure is then filled up in the damper that the piston is constantly subject to a
vertical force.
chamber via the orifice and the check valve.
For this reason, the orifice rises by the pressure
In that case, the air present in the damper
caused by the areal difference between the
chamber is pushed out to the T port from operating part of the cam and the piston on the
circuits F and G, in order to prevent the opposite side i.e. the piston follows the cam.
damper characteristics from fluctuating by That is to say, constant damper action
air mixture. operates wherever the cam is located.
Since the larger diameter of the piston, the
cover, the 11mm diameter part of the piston
and the guide are manufactured with
minimal clearance, only a little leakage
occurs. Consequently, the damper
CAM
performance is not affected at all.
F
PISTON G
COVER CHECK
E VALVE
GUIDE
ORIFICE
SPRING FOR DAMPER

SECONDARY CHAMBER
PRESSURE T
D
SPOOL P P
H
SECONDARY PRESSURE PORT
BODY
Fig. 3-3
H3 3
2) Reducing valve section If the pressure at the secondary pressure port

z At neutral rises above the action of the secondary
The primary pressure supplied by P is shut off pressure spring, the spool is pushed up by the
by the seal between the circumference of the pressure. The result is that the notch J
spool and the body hole. enters the hole of the body, shuts off the
The secondary pressure port is connected circuit from the primary pressure port to the
with the T port through the vertical hole H secondary pressure port, and causes the
and the horizontal hole I in the center of the horizontal hole I to connect with the T port to
spool. This causes the pressure to be reduced let the pressure of the secondary pressure
to zero. port out to the T port.
z At operation If the above-mentioned action is repeated, the
If the cam tilts toward the operating pressure at the secondary pressure port
direction, the piston goes down. The spool sub becomes a level that balances the
assy moves down. compressive load of the secondary pressure
If the notch J on the circumference of the spring proportional to the cam stroke.
spool connects with the secondary pressure The return spring provides proper repulsive
port, the primary pressure supplied by P force and positively brings the spool of the
enters the secondary pressure port. reducing valve back to its neutral position.
In that case, the horizontal hole I enters the
hole of the body and seals it. As the result,
the circuit from the secondary pressure port
to the T port is shut off.
12
(0.472 )
11
(0.433 )
RETURN
SPRING
T T
I
J
P P
H
SECONDARY Fig. 3-4
PRESSURE PORT
H3 4
3) Shuttle section
z If pressure is built up at port 1 or 3, the ball
is pressed against the seat by the pressure.
The pressure goes through from port 1 to port
5(or from port 3 to port 6).
Only a little leakage occurs from port 2 or 4
as the ball is sealed metallically by the seat.
If pressure occurs at port 2 or 4, the ball is
pressed against the body by the pressure. The
result is that the pressure connects with port
5 from port 2(with port 6 from port 4).
Only a little leakage occurs at port 1 or 3 as
the ball is sealed metallically against the
body.
PORT 5
PORT 2 PORT 1
SEAT BALL
BODY
PORT 4 PORT 3
PORT 6
Fig. 3-5 Shuttle section
H35
H36
Table 4-1(1/2) Table 4-1(2/2)
2-M10-20/27 (FOR LIFTING)
4. CONTROL VALVE 4-M10 SCREW DEPTH 13 Port
Tightening
Port Port
Tightening
Port
torque Description torque Description
size name size name
4.1 SPECIFICATION P1 (P3)
Pump P1 port 10~12 Option port
(This shows the valve with OPT2.) P2 Pump P2 port PF1/2 (72~87) (P4) Option port
Ab Boom up port PAa Arm in pilot port
Bb Boom down port PBa Arm out pilot port
Ac Bucket dump port PAb Boom up pilot port
Bc Bucket digging port PBb Boom down pilot port
Ar Travel right port (forward)
(1) General view and hydraulic ports Br
PAc Bucket dump pilot port
15~18 Travel right port (reverse) PBc Bucket digging pilot port
PF3/4 (110~130) AL Travel left port (forward) PAr Travel right pilot port (forward)
BL Travel left port (reverse) PBr Travel right pilot port (reverse)
Aa Arm in port PAL Travel left pilot port (forward)
Ba Arm out port PBL Travel left pilot port (reverse)
As Swing port (right) 7~8
PF3/8 PAs Swing right pilot port
Bs Swing port (left) (51~58)
PBs1 Swing left pilot port 1
Ao2 Option 2 port (A) PBs2 Swing left pilot port 2
Bo2 Option 2 port (B) Pis Arm recirculation port
PA1 Arm conflux pilot port
PB1 Boom conflux pilot port
3-M10-20/27 (FOR LIFTING) P1
T PTb Travel straight pilot port
PCa P2 bypass pilot port
PCb P1 bypass pilot port
TRAVEL TRAVEL PAo2 Option 2 pilot port (A)
PTb TRAVEL
STRAIGHT STRAIGHT TRAVEL LEFT PBL PBo2 Option 2 pilot port (B)
PAL LEFT
Dra,Drb PL1 Att power boost port
TRAVEL
PBr PAr SWING Dra Drain port
RIGHT TRAVEL SWING PBs1
PAs Drb Drain port
BUCKET RIGHT
Pss 3.5~3.9 Drc Drain port
PBc PAc BOOM BOOM PF1/4 Drd Drain port
B BUCKET PB1 (25~28)
CONFLUX CONFLUX Pss Swing pilot press. sensor port
BOOM
PLc2 Pisc Swing priority pilot port
PBb PAb ARM PLc1
BOOM ARM Boom lock valve release pilot port
PAa Drd PLc2 Arm lock valve release pilot port
P1 CUT
ARM 5~6.6
PA1 CONFLUX PCb ARM
M10 T Tank port
P1 CUT ARM Pis RECIRCU-LAT PCa (36~48)
RECIRCULATION ION
(P4) PA02 PB02
(P3)
A
(2) Machine specification

Table 4-2
ARM CUT Item STD VALVE OPT VALVE

CONFLUX
(CUT) Model KMX13YC/B33046
BOOM 174 /min
ARM Max flow (46gal/min)2
350(4980) at 120 /min
BUCKET BOOM CONFLUX Main relief valve set pressure (32gal/min)
386(5490) at 110 /min
Power boost pressure (29gal/min)
TRAVEL SWING
RIGHT
Over load relief valve set pressure
TRAVEL 405(5760) at 30 /min
STRAIGHT TRAVEL LEFT
Boom H, Bucket H, Arm R (7.9gal/min)
386(5490) at 30 /min
Boom R, Bucket R, Arm H (7.9gal/min)
386(5490) at 30 /min
OPT1, OPT2 H&R (7.9gal/min)
P2
VIEW B VIEW A
Fig. 4-1-1 Control valve outside view and hydraulic
H41
4.2 CONSTRUCTION 155 164 101
T
B A
273
PBL PAL
H H PAs
TRAVEL
STRAIGHT TRAVEL
C LEFT C PBs1 PBs2
TRAVEL Pss
RIGHT SWING PB1
D D
BOOM
BUCKET
PBa PAa
E CONFLUX E
BOOM ARM Pis

PCa
F F
ARM
RECIRCULATION
G CUT G
(ARM PBo2 PAo2
(CUT)
CONFLUX)
OPTION 2
H B H
162 164 155 162

A SECTION A
166 156 102

(974) 974 973
162 P2 P1
973
562 562
552 552
PTb
CT1 CT2 973
522 522
PBr PAr
512 512
162 168 158 973
PAc
(973)
PBc
SECTION JJ
973 PBb
PAb
SECTION HH
PA1 PCb
973 973
162 164 155 162
H42 Fig. 4-2 (1/3) Construction of control valve SECTION B

201 166 156 201
201 156 166 201
333
333 333
333
332 PAc
332 332
PAL 332
337 337 337
326 338
328 326
325 327 602
325
332 325 329 332
262 332 332
262
262 262
512
162 162 Ac CCB
(ROD SIDE) 522
601 AL 512
512 552
513 522 LCc 562
522 CP2 522
CMR1 552 552 552
552
562
562 562 562 Bc
BL
562 CMR2 162 (HEAD
163
SIDE)
552 162
306
522 304
513 265
265 305
162 206 603
PBc PB1
265
307
PTb PBL 206 (BUCKET) (BOOM CONFLUX) 206
265 (TRAVEL (TRAVEL
STRAIGHT) LEFT)
206
SECTION C SECTION E
PBs2 201 201
201 333 333
202 332 332 PLc1 Drc
333 (PLc2) (Drd)
Pss 333 337
PAb PAa
337
332 PAr 324
PAs 332 324
338 329 329
337
332 602
327 324
262 332 SECTION K
325
211 262
332 329 162
Drb 332 562 162
262 262 512
163 556 (HEAD
512 Ar As 512 524 CRb

SIDE)
Aa 522
522 522 514 552
CP1 LCs 552 562 LCb LCa 562
552 552 562
562
562 522 556
Br Bb CRa
Bs
163 303 512 (ROD SIDE)
524
Pisc
162 514
Dra
265
301
302
306 206 265
211
265 PBr PBs1 602 PBb PBa
(BOOM) (ARM)
265
206 (TRAVEL RIGHT) (SWING) 206
206 H43
SECTION D Fig. 4-2 (2/3) Construction of control SECTION F
204 204 Table 4-3 Apply Loctite #262 to areas marked .
333 333
332 (CUT) (ARM RECIRCULATION)
332 Tightening torque Tightening torque
PCb Pis No. NAME Q'TY No. NAME Q'TY
337 337
326 PAL 101 CASING A 1
326
325 102 CASING B 1 308 ARM CONFLUX SPOOL 1
325
332 11~13 (80~94) 155 PLUG ; PF1/2 3 309 BYPASS CUT SPOOL 2
332
262 262 7~8 (51~58) 156 PLUG ; PF3/8 3 310 ARM RECIRCULATION SPOOL ASSY 1
603 1.3~1.7 (9.4~12) 158 PLUG ; PF1/8 1 324 SPRING(BOOM, ARM,SWING INNER) 3
512
309 162 O RING ; 1B G30 17 325 SPRING (TRAVEL,CUT,ARM CONFLUX, 8
562
Ab 552 163 O RING ; 1B P15 3 BOOM CONFLUX,TRAVEL)
(HEAD SIDE) CAa 164 O RING ; 1B P18 3 326 SPRING (CUT,ARM CONFLUX, 6
308 522
166 O RING ; 1B P14 3 BOOM CONFLUX, TRAVEL)
310
512 168 O RING ; 1B P8 1 327 SPRING(TRAVEL INNER) 2
522 162 201 SPRING COVER 7 328 SPRING(BUCKET INNER) 1
552 CCa (ROD SIDE)
202 SPRING COVER 1 329 SPRING(ARM,BOOM, BUCKET,SWING OUTER) 4
Ba 309
562 204 SPRING COVER 4 332 SPRING SEAT 24
262 262
332 206 SPOOL COVER 8 1.6~1.8 (12~13) 333 SPACER BOLT ; M8 12
332
325 211 LOCK VALVE SELECTOR SUB ASSY 2 337 STOPPER(OTHER THAN TRAVEL) 10
325
326 213 CONTROL VALVE FOR OPTION 1 338 STOPPER(TRAVEL) 2
326
603 214 PLATE 2 512 POPPET 11
337 337 262 O RING 12 513 POPPET 2
332 332 265 O RING ; 1B G35 8 514 POPPET(LOCK VALVE) 2
333 PA1 PCa 333 10~12 (72~87) 271 SOCKET BOLT M1225 4 522 SPRING 13
(ARM CONFLUX) (CUT) 204
204 10~12 (72~87) 272 SOCKET BOLT M1290 4 524 SPRING(LOCK VALVE POPPET) 2
SECTION GG 2.6~3.5 (19~25) 273 SOCKET BOLT M825 40 13~15 (94~110) 552 PLUG M22 14
301 BOOM SPOOL ASSY 1 13~15 (94~110) 556 PLUG M22 2
PAo2
302 ARM SPOOL ASSY 1 562 O RING ; 1B P20 16
272 303 SWING SPOOL 1 7~8 (51~58) 601 RELIEF VALVE(MAIN) 1
304 BUCKET SPOOL 1 7~8 (51~58) 602 RELIEF VALVE(OVER LOAD) 3
271
305 BOOM CONFLUX SPOOL 1 7~8 (51~58) 603 RELIEF VALVE(PORT) 3
306 TRAVEL SPOOL 2 14~18 (100~130) 973 SOCKET BOLT M14110 7
307 TRAVEL STRAIGHT SPOOL 1 14~18 (100~130) 974 SOCKET BOLT M1475 1
Note : *marked parts differ according to specifications.

Ao2
214 213
Bo2
PBo2
271 272
SECTION HH
Fig. 4-2 (3/3) Construction of control valve
H44
(2) Main relief valve (601) (3) Over load relief valve (602) ,(603)
123 124 125 561 562 611 104 103 614 661 613 301 564 563 521 124 561 611 621 661 612
123 125 562
512 541 521 121 122 621 663 163 664 673 652 671 511 522 161 541 101 162 102 651 671
Fig. 4-3 Fig. 4-5
Tightening Tightening torque No. NAME Q'TY torque No. NAME Q'TY
torque No. NAME Q'TY torque No. NAME Q'TY kgfym (lbfyft) kgfym (lbfyft)
78 (5158) 101 BODY M27 (HEX 32) 1 541 SEAT 1
78 (5158) 103 PLUG M27 1 562 BACKUP RING 1 78 (5158) 102 PLUG M27 (HEX 30) 1 561 O RING ; 1A, P16 1
104 ADJUST SCREW 1 611 POPPET 1 123 SNAP RING 1 562 BACKUP RING 1
121 C RING 1 613 STOPPER 1 124 FILTER STOPPER 1 563 O RING ; 1A, P10 1
122 SPACER 1 614 PISTON 1 125 FILTER 1 564 BACKUP RING 1
123 C RING 1 621 SPRING 1
161 O RING ; 1B, P24 1 611 POPPET 1
124 FILTER STOPPER 1 652 ADJUST SCREW 1 162 O RING ; 1B, P22.4 1 612 SPRING SEAT 1
125 FILTER 1 661 O RING 1 301 PISTON 1 621 SPRING 1
163 O RING 1 663 O RING 1 511 PLUNGER 1 651 ADJUST SCREW 1
512 PLUNGER 1 664 O RING 1 521 SPRING 1 661 O RING ; 1B, P8 1
521 SPRING 1 2.83.2 (2023) 671 LOCK NUT ; M14 1
522 SPRING 1 2.83.2 (2023) 671 LOCK NUT M14 (HEX 1
541 SEAT 1 2.83.2 (2023) 673 LOCK NUT ; M24 1 22)
561 O RING 1 (5) Boom spool (301)
353 315 316 301 317 340 352
(4) Arm spool (302)
320 330
Fig. 4-6
359 302 torque No. NAME Q'TY torque No. NAME Q'TY
301 SPOOL 1 330 SPRING B2 1
Fig. 4-4
315 PLUNGER 1 1 340 SPRING B3 1
Tightening 316 PLUNGER 2 1 56 (3643) 352 PLUG 1 M16 1
torque No. NAME Q'TY 317 PLUNGER 3 1 56 (3643) 353 PLUG 2 M16 1
kgfym (lbfyft)
320 SPRING B1 1
302 SPOOL 1
H45
56 (3643) 359 PLUG 1
(6) Control valve for option (213) (7) Lock valve selector sub assy (211)
S202 A
PAo
S334
S337
S333 L101
S323 L541
S603
S324
L162
S271
S337 L163
TA S261 S512
Ao
S101 S522
S162 S301 S561
S551 L171
Po
L511
B B
Bo L512
L161
TB
L201
S262
PBo S603
S204 A
SECTION AA Fig. 4-8
(Po)
torque No. NAME Q'TY torque No. NAME Q'TY
L101 CASING 1 7~8 (51~58) L201 PLUG (M27 ; HEX 22) 1
Po L161 O RING 1 L511 SPOOL 1
SECTION BB L162 O RING 3 L512 SPRING 1
L163 O RING 2 L541 BUSHING 1
1~1.4 (7.2~10) L171 CAPSCREW ; M645 4
Fig. 4-7
torque No. NAME Q'TY torque No. NAME Q'TY
S101 CASING 1 S333 STOPPER 1
S162 O RING 3 1.6~1.8 (12~13) S334 BOLT M8 1
S202 SPRING COVER 1 S337 SPRING SEAT 2
S204 SPOOL COVER 1 S512 POPPET 1
S261 O RING 1 S522 SPRING 1
S262 O RING 1 12~14 (87~100) S551 PLUG (M24 ; HEX 12) 1
2.5~3.5 (18~25) S271 SOCKET BOLT ; M825 4 S561 O RING 1
S301 SPOOL 1 7~8 (51~58) S603 RELIEF VALVE Over
load 2
S323 SPRING (INNER) 1 S991 NAME PLATE 1
S324 SPRING (OUTER) 1 S992 RIVET 2
H46
4.3 HYDRAULIC CIRCUIT
Table 4-4
No. NAME
51 Main passage (P1 side)

601 513 307 54 306
52 Bypass circuit (P1 side)
53 Parallel circuit (P1 side)
54 Main passage (P2 side)
TRAVEL 55 Bypass circuit (P2 side)

STRAIGHT 512 TRAVEL LEFT
306 56 Parallel circuit (P2 side)
51 303
211 Lock valve selector A sub
512 301 Boom spool
TRAVEL 56
RIGHT
SWING 302 Arm spool
53
303 Swing spool
304 52 512 304 Bucket spool
512 305
55 BOOM CONFLUX 305 Boom conflux spool
BUCKET
306 Travel spool
301 302 307 Travel straight spool
308 Arm conflux spool

602 602
512
ARM 309 P1,P2 bypass cut valve
BOOM
310 Arm recirculation spool
512 Poppet D=20

602
513 Poppet
CUT (CUT)
514 Lock valve poppet
(ARM CONFLUX) ARM RECIRCULATION
601 Main relief valve
514
602 Over load relief valve
310 S301 Spool for option valve

OPTION 2
211 309 514 308 211 S603 Over load relief valve for option valve
309
S603
512
S603 S301
Fig. 4-9 Hydraulic circuit diagram
H47
This page is left blank for editing convenience.
H48
4.4 OPERATION
(1) Control valve in neutral
The oil delivered by hydraulic pump P1 The oil delivered by hydraulic pump P2 also
enters port P1 of the control valve and passes goes past the main passage (54), passes
through the travel straight spool (307) and through the bypass circuit (55) that goes
the main passage (51). It then passes through through the left travel, swing, boom conflux
the bypass circuit (52) that passes the right and arm circuits and then the P2 bypass cut
travel bucket and boom circuits and then the spool (309) and is brought back to the
P1 bypass cut spool (309) and is brought back hydraulic tank via the tank port (T).
to the hydraulic tank via the tank port (T).
309
P1
P2
307
(54) (55) 309 (51) (52)

SECTION AA SECTION BB
Flow of hydraulic oil from hydraulic pump P2 Flow of hydraulic oil from hydraulic pump P1
Fig. 4-10 Functions at neutral
H49
(2) Functions for travel action

1) At independent travel
If travel operation (forward) is performed, the Meanwhile, the oil which has returned from
secondary pilot pressure from ports (2) and the right travel A side and the left travel A
(4) of the travel pilot valve acts upon ports side passes between the outer circumference
PBr and PBL of the control valve and moves of the left travel spool (306) and the casing
the right and left travel spools (306). and returns to the hydraulic tank via the
The pressurized oil delivered by pump (P1) tank port (T) of the low pressure circuit (D).
flows to the main passage (51) past the travel At backward travel action (when the
straight spool (307), passes between the outer secondary pilot pressure acts upon ports PAr
circumference of the right travel spool (306) and PAL of the control valve), the pressurized
and the casing and is supplied to the right oil works the same way as in the forward
travel motor B by way of port Br. travel action.
In the meantime, the pressurized oil
delivered by pump (P2) passes between the
outer circumference of the left travel straight
spool (306) and the casing, runs to port BL
and is supplied to the left travel motor A side,
the same way as the pressure oil by pump
(P1).
RIGHT TRAVEL MOTOR
B A
Br Ar
306
PILOT PORT
PBr PAr
51 52 51
SECTION DD (Travel right)
Fig. 4-11 At right travel forward (when PBr is pressurized)
H410
2) At travel straight motion

If an actuator except the one for travel action The pressure oil delivered by pump P2 flows,
is actuated with the travel system in most amount of oil, in the CD direction
i n and the main passage (54), becomes the oil
position [ ], the secondary pressure of the pressure for the right travel and the left
electromagnetic proportional valve [C] acts travel motions and realizes simultaneous
upon port PTb of the control valve and moves operation of the actuator and travel action.
the travel straight spool (307) right in order (travel straight function)
to take position []. The secondary pressure of the solenoid
The result is that the pressurized oil proportional valve [C] is applied additionally
delivered by pump P1 flows from A to B in and shifts the travel straight spool (307) to
most amount of oil and becomes the pressure the right to take the position . All of A to D
for the actuators except one for travel action. ports connect with the T-port in order to
P1
unload the pressure of the circuits as a
P2 CMR2 CMR1 whole.(unload function)
307 CA
T
PTb
DB
T C D A B T Position []
CA
T
DB
At travel straight action

Position []
CA
T
DB
At unload action
SECTION CC Position []
Fig. 4-12 Functions at travel straight action
H411
(3) Bucket
1) When the bucket is digging
When the bucket is digging, secondary pilot the bucket spool (304) and the casing by way
pressure coming from port (1) of the pilot of the U-shaped passage and is supplied to
valve enters port PBc of the control valve and the bucket cylinder head (H) via port (Bc).
moves the bucket spool (304) to the right. In the meantime, the oil which has returned
The pressure oil delivered by pump (P1) flows from the bucket cylinder rod side goes
to the bypass circuit (52) past the main between the outer circumference of the
passage (51), but since it is blocked by the bucket spool (304) and the casing through the
bucket spool (304) that has shifted, it pushes port (Ac) and returns to the hydraulic oil
the check valve open, enters the parallel tank by way of the low pressure circuit (D)
circuit (53), pushes the load check valve (512) and the tank port (T).
open, goes between the outer circumference of
D (52) 304
PILOT PORT
PAC PBC
AC BC
(53)
U-SHAPED PASSAGE
512
R H
BUCKET CYLINDER
SECTION EE (Bucket)
Fig. 4-13 When bucket is digging
H412
2) When the bucket is dumped

When the bucket is dumped, secondary pilot outer circumference of the bucket spool (304)
pressure from port (2) of the pilot valve and the casing via the U-shaped passage and
enters port PAC of the control valve and supplied to the bucket cylinder rod (R) via
moves the bucket spool (304) to the right. port (AC).
The pressure oil delivered by the pump P1 In the meantime, the oil which has returned
flows to the bypass circuit (52) through the from the bucket cylinder head goes between the
main passage (51), but since it is blocked by outer circumference of the bucket spool (304)
the bucket spool (304), it pushes the check and the casing through the port (Bc) and is
valve open, enters the parallel circuit (53) the supplied to the hydraulic oil tank by way of the
load check valve (512) open, goes between the low pressure circuit (D) and the tank port (T).
(52) (53) D 304
PAC
PBC
AC BC
U-SHAPED PASSAGE
512
R H
BUCKET CYLINDER
SECTION EE
Fig. 4-14 When bucket is dumped
H413
(4) Boom
1) When the boom is up
When the boom is up, secondary pilot The pressure oil then passes through the
pressure from port (3) of the pilot valve U-shaped passage, Pushes the boost check
enters port PAb of the control valve and valve open via chamber E of the boom spool
moves the boom spool (301) to the right. It (301), enters chamber BH.
also acts upon port PB1 (Refer to next page) Or the pressure oil enters chamber BH,
and change over the boom conflux spool (305). passing between the outer circumference of
At the same time the secondary pressure of the boom spool (301) and the casing, pushes
the electromagnetic valve [B] acts upon port the lock valve poppet (514) open, flows into
PCa of the control valve and change over the port (Ab) and is supplied to the boom
the P2 bypass cut spool (309). cylinder head (H).
The pressurized oil delivered by the pump P1 Meanwhile, the oil port (Bb) which returns
flows into the bypass circuit (52) through the from the boom cylinder rod (R) goes between
main passage (51), but since it is blocked by the outer circumference of the boom spool
the boom spool (301), it pushes the check (301) and the casing, flows into the tank port
valve open, enters the parallel circuit (53) (T) via the low pressure circuit (D) and
and pushes the load check valve (512) open. returns to the hydraulic tank.
INSIDE CONFLUX PASSAGE E (53) 301 D
PAb PBb
(CRb) Ab Bb U-SHAPED PASSAGE

CHAMBER BH 514 512
R R
SECTION F
H H
BOOM CYLINDER
Fig. 4-15 When boom is up (Boom spool)
H414
2) Conflux for boom up

The oil delivered by the pump P2 flows into The oil then pushes the load check valve
the main passage (54), but since the bypass (512) open, passes between the outer
circuit (55) and the parallel circuit (56) are circumference of the boom conflux spool (305)
closed by the P2 bypass cut spool (309) which and the casing via the A side of the U-shaped
has shifted as explained in 1) above (Refer to passage, enters port Ab through the conflux
Fig. 4-16), the oil enters the parallel circuit passage in the casing and combines with the
(56) from travel spool. (Refer to Fig. 4-17) pressure on the pump P1 side.
PCa
P2 BYPASS CUT SPOOL (309)

SECTION GG
Fig. 4-16 P2 cut valve
CONFLUX CHECK VALVE (512) (56)
U-SHAPED PASSAGE
BOOM CONFLUX
PB1
305 TO PORT Ab THROUGH THE CONFLUX PASSAGE IN CASING
SECTION EE (Boom conflux)
Fig. 4-17 When boom is up (Boom conflux spool)
H415
3) When the boom is down (in H or S mode)

When the work mode selector switch on the conjunction of the boom spool whereupon the
instrument panel is set to the H (heavy back pressure of lock valve poppet (514)
digging) mode or S (save energy) mode, connects with DrC.
operation is as follows. The returned oil then enters chamber BH and
If the boom down action is performed, the runs into the boom spool (301) through the
secondary pilot pressure from port (4) of the circular notch of the boom spool (301). Since
pilot valve acts upon port PBb of the control the returned oil has sufficient pressure by the
valve and lock valve selector port PBb and weight of the boom, arm, etc. , it pushes the
shifts the boom spool (301) to the left, it also poppet on the right of the illustration through
change over the lock valve. in the spool, passes through its outer
The pressure oil delivered by the pump (P1) circumference and is supplied to the boom
flows into the bypass circuit (52) through the cylinder rod side as the hydraulic oil for boom
main passage (51), but since it is blocked by down motion. (Boom fixed recirculation
the boom spool (301), it pushes the check function).
valve open, enters the parallel circuit (53), Some of the return oil from the head end of the
pushes the load check valve (512) open, boom cylinders forces open the boost check
enters the U-shaped passage, goes between valve, and flows through the low pressure
the outer circumference of the boom spool circuit D to the tank port T, and back to the
(301) and the casing and is supplied to the hydraulic oil tank. The purpose is to allow
boom cylinder rod side via port (Bb). excess return oil to escape to the tank. This
In the meantime, the oil which returns from excess oil is caused by the fact that the area of
the boom cylinder head enters the control the piston at the head end is larger than the
valve by way of port (Ab). Lock valve poppet area of the piston at the rod end.
(514) is located in front of boom spool (301), The boost check valve acts on oil flowing to
but the lock valve is pushed open as the the tank to secure an adequate amount of
lock valve selector spool is changed over in recirculating oil.
CONFLUX
LOCK VALVE PASSAGE IN CASING
SELECTOR SPOOL BOOST CHECK 301 (52) (53)
D
PBb
PLC1 PAb
Drc
LOCK VALVE
SELECTOR
(CRb) Ab Bb
CHAMBER BH 514 512 U-SHAPED PASSAGE
R R
SECTION FF
H H
BOOM CYLINDER
Fig. 4-18 When boom is down (in H or S mode)
H416
(5) Arm
1) Arm out operation
If arm out operation is performed, the spool (302), it pushes the check valve open,
secondary pilot pressure from port (8) of the flows into the parallel circuit (56), pushes the
pilot valve acts upon ports PBa and PA1 of load check valve (512) open, goes between the
the control valve. (refer to next page) outer circumference of the arm spool and the
The pressure oil which enters port PBa shifts casing by way of the U-shaped passage, runs
the arm spool (302) leftwards. The pressure into chamber AR, pushes the lock valve
oil which enters port PA1 changes over the poppet (514) open and is supplied to the arm
arm conflux valve. cylinder rod side via port (Ba).
The secondary pressure of the electromagnetic In the meantime, the oil which returns from
proportional valve [D] acts upon port PCb of the arm cylinder bottom side passes between
the control valve and changes over the P1 the outer circumference of the arm spool
bypass cut valve (309). (302) and the casing by way of the port (Aa),
The pressure oil delivered by pump P2 flows flows into the tank port (T) from the low
into the bypass circuit (55) by way of the main pressure circuit (D) and returns to the
passage (54), but since it is blocked by the arm hydraulic oil tank.
ARM CYLINDER
H R
512 514
302 (Ba) CHAMBER AR
Aa
PBa
PAa
D (55) (56)
U-SHAPED PASSAGE
SECTION FF
Fig. 4-19 At arm out operation (Arm spool)
H417
2) Arm out conflux

In operation 1), the oil delivered by pump P1 Part of the delivered oil passes through the
flows into the bypass circuit (52) through the parallel circuit (53) and the restrictor,
main passage (51), but since the bypass combines with the pressure oil of the bypass
circuit (52) and the low pressure circuit (D) circuit (52), pushes the conflux check poppet
are blocked by the bypass cut spool (309), it (512) open, enters port Ba by way of the
does not run into the low pressure circuit (D). conflux circuit in the casing and finally
Meanwhile, since the arm conflux spool (308) combines with the pressure oil on the pump
has now been changed over, the pressure oil P2 side.
of the bypass circuit (52) goes between the
outer circumference of the arm conflux spool
(308) and the casing.
To port Ba through the conflux

P1 BYPASS CUT SPOOL passage in the casing
309 D (52) 308
PCb PA1
(53) 512
ORIFICE
SECTION
SECTION GG (Arm conflux)
Fig. 4-20 At arm out operation (Bypass cut spool and arm conflux spool)
H418
3) When the arm is digging (under light load) Meanwhile, the oil which has returned from
If the arm digging operation is performed, the the arm cylinder rod (R) enters the control
secondary pilot pressure coming out of port(7) valve through the port (Ba).
of the pilot valve acts upon the PAa port of Lock valve poppet (514) is located before arm
the control valve and the PLc2 port of the spool (302). Since the lock valve selector spool
lock valve selector. This causes the arm is changed over, the lock valve poppet (514) is
spool(302) to move to the right and changes pushed open and the oil enters the AR
the lock valve. The secondary pressure of the chamber. Since the return oil has sufficient
solenoid proportional valve [A] acts on the Pis pressure by the weight of the arm, it flows
port of the control valve and changes the arm into the arm spool, passes through the inside
recirculation spool(310) to position []. of the arm spool, the notch of the arm spool
The pressure oil delivered by the pump P2 and the recirculation passage (60), and flows
flows into the bypass circuit (55) past the into arm recirculation spool (310).
main passage (54), but since the bypass Since the arm recirculation spool is at
circuit (55) is blocked by the arm spool (302), position [], the pressurized oil thus flowed
the oil pressure pushes the check valve open, enters passage (61) through the inside of arm
flows into the parallel circuit (56), pushes the recirculation spool (310), pushes arm
load check valve (512) open, goes between the recirculation check valve poppet (512) open,
outer circumference of the arm spool and is supplied again to the arm cylinder
(302) and the casing through the U-shaped head (H) as the hydraulic oil for arm digging.
passage and is supplied to the arm cylinder (arm recirculation function)
head (H) side via port (Aa).
ARM CYLINDER
D (60) LOCK VALVE
SELECTOR SPOOL
H R CHAMBER AR LOCK VALVE PLc2

302
514 SELECTOR Drd
(61)
Aa
Position []
PAa
SECTION FF
522 (61) (60) (56) (55)
310 Ba
Pis
SECTION GG
D
Fig. 4-21 When arm is digging (under light load)
H419
4) When the arm is digging (under heavy load)

The arm oil recirculation function is effective Then, the hydraulic oil flowed into arm
when operating the arm cylinder quickly recirculation spool (310) does not flow to the
under a light load, but under a heavy load arm cylinder head [H] that is heavily loaded,
(when heavy duty is required), this function but flows to tank port (T) from low pressure
wastes power. circuit(D) and returns to the hydraulic oil
The control valve switches automatically tank. (recirculation cut)
between oil recirculation under light load
conditions and no recirculation under heavy Sequenced conflux :
load conditions by detecting pump pressure. If the arm cylinder head (H) is loaded
This is called the variable recirculation heavily, the solenoid proportional valves [C],
function. When the arm is under a heavy [D] operate in addition to the
load, that is, when no recirculation occurs, above-mentioned recirculation cut action. As
the oil supply passage to the arm cylinder is the result, each secondary pressure acts upon
the same as during recirculation described the PTb and PCb ports of the control valve,
above, but the return oil passage is different. changes the travel straight spool (307) to
The system detects the pump pressure at position [ ] [Refer to the above 4.4.(2).2).]
heavy load condition [more than 200kgf/cm2 and changes the P1 bypass cut spool (309).
(2840psi) of pump pressure]. This causes the As the result, the oil flow from the pumps P1
secondary pressure of solenoid proportional and P2 are confluxed in the parallel circuit
valve [A] to operate and changes the arm (56) of the control valve and are supplied to
recirculation spool (310) to position [I]. the arm cylinder head (H).
ARM CYLINDER
D (60) LOCK VALVE
SELECTOR SPOOL
CHAMBER AR
H R
LOCK VALVE PLc2
302 SELECTOR
514 Drd
(61)
Aa
Position []
PAa
522 (61) (60) (56) (55) SECTION FF

310
Ba
Pis
D
SECTION GG
Fig. 4-22 When arm is digging (under heavy duty)
H420
5) Simultaneous operation of swing and arm

digging
If the swing and arm digging actions are In the above condition, the system detects the
performed at the same time, the hydraulic oil pilot pressure that actuates the swing spool.
from pump P2 which is confluxed with P1 The secondary pressure of the solenoid
pump by switching travel straight valve and proportional valve (A) acts upon the Pis port
closing P1 cut valve passes through the of the control valve and changes the arm
parallel circuit (56) and flows into the swing recirculation spool (310) to position [].
motor and the arm cylinder at the same time. The result is that the hydraulic oil flowed
However, since the swing system is more into arm recirculation spool (310) is higher on
heavily loaded than the arm system at the the arm cylinder rod (R) because the passage
start of swing action and during arm digging to the arm cylinder head (H) are restricted.
(at light load), most of the hydraulic oil flow The result is that the pressure on the arm
to the arm cylinder that is lighter loaded. cylinder head side (H) rises which in turn
This causes the simultaneous operation to increases the operating pressure for the arm
deteriorate. digging operation.
In order to improve such a condition, the load And swing pilot pressure is led from Pisc
on the arm digging side is increased port to sub-spool in arm spool, the pressure of
intentionally so the simultaneous operation arm cylinder head (H) rises higher by
of swing and arm digging motions is restricting opening of arm spool circuit
performed easily.(swing priority) according to swing pilot pressure, as result
the oil P2 pump flows preferentially into
swing circuit.
ARM CYLINDER
LOCK VALVE
D (60)
SELECTOR SPOOL
CHAMBER AR
H R LOCK VALVE PLc2
302 Drd
514 SELECTOR
(61) Aa Pisc
Position []
PAa
(56) (55) SECTION FF

522 (61) (60)
310
Ba
Pis
D
SECTION GG
Fig. 4-23 Simultaneous operation of swing and arm digging
H421
(6) Swing action

If swing action is performed, the secondary Then the pressurized oil which has entered
pilot pressure from port (5) or (6) of the pilot the U-shaped passage of the swing spool
valve acts upon port PAS or PBS1 of the (303) passes between the outer circumference
control valve and shifts the swing spool (303) of the swing spool (303) and the casing and is
rightward or leftward. supplied to the A or B side of the swing motor
The pressurized oil delivered by the pump through port AS or BS.
P2 enters the bypass circuit (55) through the In the meantime, the oil which has returned
main passage (54), but since it is blocked by from the B or A side of the swing motor
the swing spool (303), it pushes the check passes between the outer circumference of
valve (512) open and enters the parallel the swing spool (303) and the casing through
circuit (56). the port (BS) or (AS), flows from the low
Then the pressure oil pushes open the load pressure circuit (D) to the tank port (T) and
check valve (512) for swing action, flow into returns to the hydraulic oil tank.
U-shaped passage of the swing spool (303).
PARALLEL CIRCUIT (56) P2 SIDE

A B
SWING MOTOR
U-SHAPED PASSAGE
FOR SWING MOTION 512
AS BS
303
Pss PAs
PBs2
PBS1
(55)
SECTION DD
Fig. 4-24 Swing left action (When PBS1 is
H422
(7) Action of option valve (for P2 pump) :

If such an attachment as the dozer that uses pushes the check valve open, flows into
an option valve, the secondary pilot pressure parallel circuit (56), pushes the load check
from port (P) of the pilot valve acts upon the valve open, passes through the clearance
PAo2 or PBo2 port of the control valve and between the outer circumference of the option
shifts the option spool to the right or the left. spool and the casing and is supplied to each
At the same time, the secondary pressure of attachment from port (Ao2) or (Bo2).
solenoid proportional valve [B] acts upon the In the meantime, the oil returned from the
PCa port of the control valve and changes the attachment enters the control valve from port
P2 pilot bypass cut spool (309). (Bo2) or (Ao2), passes through the clearance
The hydraulic oil delivered by pump P2 runs between the outer circumference of the option
into bypass circuit (55) through the main spool and the casing and returns to the
passage (54), but since it is cut off by P2 hydraulic oil tank from the low pressure
bypass cut spool (309) that has shifted, the oil circuit (D) and the tank port (T).
LOAD CHECK VALVE (LCo2)

Ao2 Bo2
PAo2
PBo2
(56) D
Sectional view of option valve
PCa
(55) 309
SECTION GG
Fig. 4-25 Action of option valve
H423
(8) Functions of lock valve

Lock valve(514) is located between arm In this position, the holding pressure from
cylinder rod side(R) and arm spool(302) of the boom cylinder head(H) side passes through
control valve to decrease the leakage due to passage Sa, passage(a) of bushing(L541) and
the holding pressure from the cylinder. around spool(L511), and connects to (b), then
Similarly, lock valve(514) is located between flows through passage Sb, consequently
arm cylinder head side(H) and boom poppet(514) of the lock valve is pressed down
spool(301) of the control valve to decrease the maintaining the seated condition, and the
leakage due to the holding pressure from the leakage results in minimal quantity.
cylinder.
1) When the Main spool is Neutral ;

The boom spool (301) will be explained
hereinunder. The arm spool (302) will be
explained also.
When boom spool (301) is in neutral position,
it is held in the position shown in Fig. 4-26.
That is to say, lock valve selector sub spool
(L511) is pressed against bushing (L541) by
the action of spring (L512).
BOOM CYLINDER
HEAD (H) SIDE
L511 L512
CHAMBER RH
PLc1 Drc
514
Sb
Sa
(a) (b) L541
(301)
Fig. 4-26 Functions of lock valve (when the main spool is neutral)
H424
2) At boom lower action :

The secondary pilot pressure from port (4) of This causes the orifice (b) of the bushing
the pilot valve acts upon the PBb port of the (L541) to connect with the passage Sb, the
control valve and the PLc1 port of the lock spring chamber of the lock valve poppet (514)
valve selector and shifts the boom spool (301) and the low pressure circuit. The lock valve
to the right. At the same time, the pressure poppet (514) is received by the ring-shaped
shifts the spool (L511) of the lock valve pressure bearing area that consists of the
selector to the right. guide diameter and the seat diameter of the
As the spool (L511) is shifted, the orifice (a) lock valve poppet (514), so that the lock valve
in the bushing (L541) closes. This shuts off poppet is pushed open upwards to release the
the continuity from passage Sa to passage Sb lock function.
in the lock valve selector B sub (212) and the
hold pressure received from the boom Note : The action in the above takes place
cylinder head (H) side ceases to act upon the before the opening (meter-out opening) that
spring chamber (RH) of the lock valve poppet brings the oil returning from the boom
(514). cylinder head (H) of the boom spool (301)
As the spool (L511) moves, continuity is during boom lower action, back to the
established from the orifice (b) of the bushing hydraulic oil tank; the action operates before
(L541) to the drain port (Drc) through the the boom spool strokes from its neutral
inside of the bushing (L541). position. Therefore, the action does not affect
the controlability of the boom lower motion.
BOOM CYLINDER
HEAD (H) SIDE L511 L512
CHAMBER RH
PLc1 Drc
514
Sb
Sa
Pressurized (a) (b) L541

part of poppet
(514)
PBb
PAa
301
Fig. 4-27 Functions of lock valve (at boom lower)
H425
(9) Operation of main relief valve

The main relief valve is built in casing and
operates as follows :
1) The pressure oil is filled up in chamber A

through the orifice (B) of the plunger (512) B A
and seats the plunger (512) securely against
the body (541). R
PL
541 512
Fig. 4-28
2) When the hydraulic pressure of (P) reaches a
set pressure of the spring (621), it pushes B D
open the poppet (611) through the orifice (B)
and flows through the hole (D) to (R). R
611 PL 621
Fig. 4-29
3) When the poppet (611) opens, the pressure in

chamber A falls, which causes the plunger
A
(512) to open and the pressure oil of port (P)
to flow directly to (R). R
611 PL
512
Fig. 4-30
4) Press the boost

Press the boost button, and the pilot pressure
enters in PL port. The pilot pressure pushes
piston (614) leftward, the spring (621) force is
raised, and finally the relief pressure is R
raised.
P
z The numbers of the parts of the PL

main relief valve in this section 621 614
correspond to those in Fig.4-3. Fig. 4-31
H426
(10) Operation of over load relief valve

The over load relief valve is located between
the cylinder port and the low pressure
passage, functions as both a relief valve and
an anti cavitation check valve, as mentioned
below :
301 A B
1) Operation as a relief valve

1. The pressurized oil enters the hole A through
the clearance between piston (301) and
plunger (511) and fills up chamber B. Thus P
plunger (511) is seated tightly against seat
(541). R
511 541
Fig. 4-32
2. When the hydraulic pressure of the port (P)
arrives at a set pressure of the spring (621), it C
pushes the poppet (611) open, flows on the
circumference of the poppet (611) and passes
through the hole (C) to (R).
3. When the poppet (611) opens, the hydraulic 611 621

pressure in chamber B falls which causes the Fig. 4-33
plunger (511) to open and allows the
hydraulic pressure of port (P) to flow directly 511 B
to (R).
2) Operation of anti cavitation check valve R

The check valve supplies oil from port (R)
611
when a negative pressure is built up at port
(P). When the pressure at (R) gets higher Fig. 4-34
than that of port (P), the push-up force of
circuit (R) gets stronger than the pressing
force of chamber B.
This causes seat (541) to move to the right.
Then the oil passes through the clearance of P
seat (541) and enters port (P) in sufficient
quantity to fill up the vacancy.
R
z The numbers of the parts of the over
load relief valve in this section 541
correspond to those in Fig.4-5. Fig. 4-35
H427
H428
5. SWING MOTOR UNIT
5.1 SPECIFICATIONS
(1) General view
Tightening THREAD FOR EYE
Port torque
Port Port name size kgfym (lbfyft) BOLT 2-M12
M L DEPTH 24
PB
A,B Main port PF3/4 17 (120) RELIEF VALVE
B
DB Drain port PF3/8 7.5 (54) (B PORT SIDE)
M Make-up port PF3/4 17 (120)

PA,PB Pressure measuring port PF1/4 3.7 (27)
PG Parking brake release port PF1/4 3.7 (27)
IP
Pi1,Pi2 Pilot ports PF1/4 3.7 (27) PG
L Gear oil level Gauge PT1/2 6.6 (48) RELIEF VALVE
(A PORT SIDE)
IP Gear oil filling port PT3/4 10 (72) A
DB
PA
SWING SHOCKLESS
PB PA VALVE BLOCK
Pi2
Pi1 M
DB
A,(B)
IP
FILLING PORT
PG PT3/4
DB
PB REDUCTION UNIT
PA Pi2 DRAIN OIL HOSE
Pi1
A B
Hydraulic diagram
Fig. 5 -1 General view of swing motor unit
H5-1
(2) Specification
Swing motor unit
Type M2X120BCHB10A58/285
Displacement cm3 (in3) 121.6 (7.54)
Working pressure kgf/cm2 (psi) 285 (4050)

Hydraulic motor
Max. flow /min (gal/min) 179 (47)
Braking torque kgfym (lbfyft) 63.5 (460)

Release pressure
(Stroke end) kgf/cm2 (psi) 29 (410)
Relief set pressure kgf/cm2 (psi) 285 (4050)
Weight kg (lbs) 54 (119)
Speed reduction type Planetary 2-stage
Reduction ratio 15.38
Lublicate oil Gear oil SAE90 (API class GL4 grade)

Reduction unit
Lublicate oil volume (gal) 7.5 (1.98)
Grease Extreme pressure multi-purpose grease
Grease volume A small amount
Weight kg (lbs) 154 (339)
Total weight kg (lbs) 208 (458)
H52
5.2 CONSTRUCTION
(1) Swing motor
488 469 992
355 401
ANTI CAVITATION
PLUNGER
351 051 RELIEF VALVE
051-1
391 390
VALVE CASING SECTION
SWING SHOCKLESS
VALVE BLOCK
161,
052 171 152 162 163 V162
053
(400-1)
303 981 111 984 131 451
444 (400-2)
052
981 485
438 464 400
472 706 SECTION AA

712 743
V981
707 742 V162 V163 V252
121 V164 V262
980 113 V154
122
702 123
(053)
114
118 V301
116
V101 V154
117
V164
301 443 491 305 101 437 124 994

V261V251 V981 V324
SECTION BB
Fig. 5-2 Swing motor
H53
TIGHTENING TIGHTENING
TORQUE No. PARTS QTY TORQUE No. PARTS QTY
18 (130) 051 RELIEF VALVE ; M33-P1.5 2 443 ROLLER BEARING 1

051-1 O RING ; 1B G30 2 444 ROLLER BEARING 1
SWING SHOCKLESS VALVE
052 SUB ASSY 1 451 PIN 2
BYPASS VALVE BLOCK SUB
053 ASSY 1 3.7(27) 464 VP PLUG ; PF1/4 1
CASING FOR SHOCKLESS
100 VALVE 1 34 (250) 469 ROMH PLUG ; M30-P1.5 2
101 DRIVE SHAFT 1 472 O RING 1
111 CYLINDER 1 485 O RING ; 1B P11 1
113 SPHERICAL BUSHING 1 488 O RING ; 1B P28 2
114 CYLINDER SPRING 1 491 OIL SEAL 1
116 PUSH ROD 12 702 BRAKE SPRING 1
117 SPACER F 1 706 O RING 1
118 SPACER 2 707 O RING 1
121 PISTON 9 712 BRAKE SPRING 24
122 SHOE 9 742 FRICTION PLATE 3
123 SET PLATE 1 743 SEPARATOR PLATE 4
124 SHOE PLATE 1 0.09 (0.65) 980 PLUG ; PF1/4 1
131 VALVE PLATE 1 0.45 (3.3) 981 PLUG ; PF3/4 3
3.7 (27) 152 PLUG 2 0.17 (1.2) 984 PLUG ; PF3/8 1
161 O RING ; 1B P11 2 6.6 (48) 992 PLUG ; PT1/2 1
162 O RING ; 1B P12 2 10 (72) 994 PLUG ; PT3/4 1
163 O RING ; 1B P6 2 V101 CASING FOR BYPASS VALVE 1
301 CASING 1 3.7 (27) V154 PLUG 2
303 VALVE CASING 1 V162 O RING 2
305 SEAL COVER 1 V163 O RING 2
351 PLUNGER 2 V164 O RING 2
355 SPRING 2 3.0 (22) V171 SOCKET BOLT ; M890 4
390 NAME PLATE 1 17 (120) V251 PLUG 1 1
391 RIVET 2 11 (80) V252 PLUG 2 1
SWING SHOCKLESS VALVE ;
7 (51) 400 M22-P1.5 2 V261 O RING 1
400-1 O RING ; 1B P20 2 V262 O RING 1
400-2 BACKUP RING 2 V301 SPOOL 1
44 (320) 401 SOCKET BOLT ; M2045 4 V304 SPRING 1
437 SNAP RING 1 0.09 (0.65) V981 PLUG 2
438 SNAP RING 1
H54
(2) Swing reduction unit
33 29 28 27 26
19 25
18 22
17 23
16 24
14 22
20
15
21
13 10
12
11
34
37
36 35
9
8
7
5
6
2
1
Fig. 5-3 Cross-sectional view of swing reduction unit
Tightening
torque No. PARTS QTY No. PARTS QTY
kgfym (lbfyft)
1 PINION SHAFT 1 19 #.1 SUN GEAR 1
2 SLEEVE 1 20 SPRING PIN 4
4 PLUG (Not shown) 1 21 SHAFT 4
5 O RING 1 22 THRUST WASHER 8
6 OIL SEAL 1 23 #.2 PINION 4
7 RETAINER 1 24 NEEDLE BEARING 4
3.4 (25) 8 SOCKET BOLT ; M825 12 25 THRUST WASHER 3
9 BEARING 1 26 #.1 PINION 3
10 HOUSING 1 27 ROLLER 102
11 SPACER 1 28 THRUST WASHER 3
12 BEARING 1 29 SNAP RING 3
13 SNAP RING 1 33 SNAP RING 1
14 #.2 SPIDER 1 34 SET SCREW ; M2020 2
15 #.2 SUN GEAR 1 35 CONNECTOR 1
16 RING GEAR 1 36 HOSE 1
17 #.1 SPIDER ASSY 1 37 PLUG 1
18.5 (130) 18 SOCKET BOLT ; M14130 10
z Apply Three-Bond #1360K
H55
5.3 OPERATION
CYLINDER BLOCK(111)
5.3.1 OPERATION OF HYDRAULIC MOTOR
If the high pressure oil flows into the cilynder F2
through the inlet port (a) of valve plate (131), as F1
shown on the right figure, the hydraulic pressure

F
acts upon piston (121) and generates force F in
the axial direction.
The force F may be divided into force F1 vertical
DRIVE SHAFT(101)
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.
VALVE
The cylinder block (111) has nine pistons equally
PLATE
arranged. Rotating torque is transmitted to drive (131)
shaft by turns by pistons connected to inlet port of SHOE SHOE PISTON
PLATE (122) (121)
high pressure oil.
(124)
If the oil supply and discharge directions are
reversed, the drive shaft rotates in the opposite (LOW PRESSURE OIL) (HIGH PRESSURE OIL)
direction.
Theoretical output torque T can be given by the

OUTLET INLET (a)
following equation.
pq
T=
2
p : Effective differential pressure kgf/cm2
q : Displacement per revolution c.c. /rev
Fig. 5-4 Operation of hydraulic motor
5.3.2 VALVE CASING SECTION 351

(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 dificient oil, in order to prevent cavitation
from occurring due to oil deficiency.
Fig. 5-5 Operation of anti-cavitation check plunger
H56
(2) Operation of relief valve CHAMBER h

1) Consider where the P port is pressurized ORIFICE m SPRING(321) PISTON 1(302)
from the tank pressure.
The pressure at the P, R ports is equal to the
tank pressure at the beginning, as shown in
Fig.5-6-(1).
The relief valve begins to operates when the P
hydraulic pressure that is determined by
the product of the pressure-receiving area A1 R
of plunger(301) and the pressure P balances PRESSURE-
CHAMBER g
A3 A2 ORIFICE n A4
the hydraulic pressure that is determined by RECEIVING
PLUNGER (301)
the product of the pressure-receiving area A2 AREA A1

of the plunger(301) and the pressure Pg of Fig. 5-6-(1)
chamber g.
Thereafter, the pressure of chamber g rises CHAMBER h
and the piston 1 (302) begins to stroke. The ORIFICE m SPRING(321)
PIN(303) PISTON 1(302)
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. P
This process is explained in the following in
the relationships between the movements of
the components shown in (2) to (4) of Fig. R
5-6 and the relief pressure : PLUNGER (301)
ORIFICE n
CHAMBER g
1. Condition shown in Fig. 5-6. (2)
If the P port of the relief valve is pressurized, Fig. 5-6-(2)
pressure is built up in chamber g via the
restrictor m of plunger (301). CHAMBER h
The hydraulic pressure acting on plunger ORIFICE m SPRING(321) PIN(303) PISTON 1(302)
(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 :
P1A1FSP1Pg1A2 P
where Fsp1:
primary set load value of spring (321) R
2. Condition shown in Fig.5-6. (3)
The pressure of chamber g acts upon the PLUNGER (301)
ORIFICE n
CHAMBER g
pressure-receiving area A3-A4 of piston 1
(302). When the hydraulic pressure rises Fig. 5-6-(3)
above the load of spring (321), the piston 1
begins to move to the left.
On that occasion, since the machine turns to ORIFICE m SPRING(321) PIN(303) PISTON 1(302)
the left while discharging the oil of chamber
h arranged between piston 1 and adjust plug
(401) into chamber g via restrictor n provided
in piston 1 (302), chamber h serves as a
dumping chamber. P
The load of the spring increases slowly till
piston 1 reaches the end of the adjust plug.
The relief pressure P rises smoothly. R
3. Condition shown in Fig.5-6. (4) ORIFICE n
The machine does not travel to the left PLUNGER (301) CHAMBER g
further when piston 1 (302) arrives at the end Fig. 5-6-(4)

of adjust plug (401). Therefore, the relief Fig. 5-6 Functional explanation of relief valve
valve keeps its normal relieving action
whereby the relief pressure is held at P2.
In the processes 1 to 3 above, the relief
pressure changes as shown in Fig.5-7.
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 Fig. 5-7 Pressure boost characteristics
condition of Fig.5-6 (1).
H57
(3) Operation of swing shockless valve
Fig. 5-8 Hydraulic circuit diagram for

1) Neutral condition : swing shockless valve.
Fig.5-8 illustrates the relationship between
the neutral condition of the swing shockless
valve and the hydraulic circuits. Now, let us
consider a braking condition in which brake
pressure generates on the AM port side.
2) When brake pressure occurs :
If pressure (P) generates at the AM port, it k
passes through the passage l, the hole on the 322 313 321 311
shaft of seat (313) and the passage m of
plunger (311) and is admitted to the n Fig. 5-9(1) Neutral condition
chamber. m n
When the pressure P rises above a value (Ps)
set by spring (321), plunger (311) compresses
P=PS
spring (321) and shifts it to the left.
Seat (313) compresses weak spring (322) as
pushed by plunger (311) and moves to the
left.
3) At swing shockless action 322 313 321 311
When inertia load stops moving (point Y, Fig. 5-9(2) When brake pressure occurs
Fig.5-10), brake pressure (P) tries to fall. p t
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 P<PS
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. k
Consequently, seat t opens. This makes a 322 313 g r 321 311
passage connecting the AM port and BM Fig. 5-9(3) At swing shockless action
ports or both ports of the hydraulic motor by Fig. 5-9 Operation of swing shockless valve
way of 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 Fig.5-10. This prevents the hydraulic
motor from swing shock by the closing
pressure of the AM port.
Fig. 5-10 Pressure change diagram of swing

shockless operation
H58
(4) Operation of bypass valve

1) Neutral condition : SPOOL
In the case where pilot pressure Pi1 is not CASING
inputted, the spool is pushed rightward with
the spring (324). A and B port are not
connected in this state.
Pi2 Pi1
2) Operation state :
If pilot pressure Pi1 is inputted and the
hydraulic pressure is became higher than the
PLUG (1)
set load of spring, the spool moves leftward SPRING (324)
and A and B port are connected.
If pilot pressure is lowered, the spool will
PLUG (2)
return according to spring power again, and a
connecting circuit will be blocked. Fig. 5-11 Operation of bypass valve
5.3.3 OPERATION OF BRAKE SECTION

The cylinder (111) is jointed by drive shaft (101) 111
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
702
circumference of the cylinder is pressed against
712 743
casing (301) via separator plate (743) and brake
piston (702) by the action of brake spring (712),
742
frictional force is generated between friction plate
(742) and casing (301) and between separator
702
plate (743) and brake piston (702). The frictional 301
force bounds the drive shaft to brake the motor. 743 742 301 101
In the meantime, when brake release pressure
applied to the oil chamber formed between brake Fig. 5-12 Operation of swing brake
piston (702) and casing (301) overcomes the
spring force, the brake is released as brake piston
(702) moves till friction plate (742) is detached
from casing (301).
H59
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 effort (torque).
This swing speed reduction unit is equipped with
planetary speed reducing mechanism.
The planetary mechanism is made up of sun gear, RING GEAR (FIXED) PLANETARY SHAFT
planetary pinion, planetary shaft, spider and ring
gear, as shown in Fig. 5-12.
For the operation of the 1st stage planetary, the
hydraulic motor rotates #1 sun gear (19). Sun SPIDER
gear (19) is engaged with planetary pinion (26)
and rotates, but since ring gear (16) is fixed,
planetary pinion (26) revolves about sun gear (19) SUN
GEAR
with the planetary shaft and spider (17).
The role of spider is to hold the planetary pinion

and planetary shaft and transmits the power from
the planetary pinion to the spider through the
planetary shaft.
The #1 spider (17) is linked with #2 sun gear(15) PLANETARY PINION
by the involute spline, and transmits the power to Fig. 5-12 Planetary mechanism
the 2nd stage planetary mechanism.
For the operation of the 2nd stage planetary, the
power is transmitted to sun gear (15)planetary
pinion (23)spider(14) similarly to the 1st stage.
SWING MOTOR
The #2 spider (14) is linked with pinion shaft (1)
by the involute spline, and pinion shaft(1) is 26 19
engaged with the swing gear fixed on the
16
undercarriage (lower frame) and rotates.
17
15
14
10
23
12
9 1
Fig. 5-13 Function of reduction unit
H510
6. TRAVEL MOTOR (2) Specifications
Travel motor unit M4V150/100-RG3.5B

6.1 SPECIFICATIONS Motor Type M4V150/100Z
(1) General view Reduction
SPROCKET CENTER Reduction ratio 41.46
Number of reduction stages 2
22-M18 Reduction unit
OVERLOAD RELIEF VALVE Lube oil capacity (gal) 5.5 (1.5)
M27 Lube oil capacity specification Gear oil SAE#90 (GL-4)
T=11 (80) P T=5.5 (40)
T=5.5 (40) Max. displacement cc/rev (cuyin/rev) 154.4 (41)
Min. displacement cc/rev (cuyin/rev) 103.7 (27)
8-M12
T=10 (72) Relief valve set pressure kgf/cm2 (psi) 350 (4,980)
2 speed changeover
Travel motor pilot pressure kgf/cm2 (psi) 51 (725)
Parking brake torque kgfym (lbfyft) More than 4570 (330510)
Y Parking brake release
pressure kgf/cm2 (psi) Less than 16 (230)
MB MA
Working 2.0 (28)
Allowable drain pressure kgf/cm2 (psi)
Surge 10.0 (140)
VA,VB Unit Weight (With oil) kg (lbs) Motor 82 (181)Reduction 156 (344)=238 (525)
Dr
PT3/4 17-M20
FILLING PORT 8-M16
OIL LEVEL CHECK PORT T=23.5 (170)
T=10 (72)
GEAR OIL LEVEL

FILL
LEVEL
15-M10
T=8 (58)
LOCKTITE#242
DRAIN
PT3/4
DRAIN PORT
VIEW Y T=10 (72)
Fig. 6-1 Travel motor
Rotation direction
Oil inlet Oil outlet Rotation direction Tightening
port port (Viewed from valve side) Port name Port size torque Function
kgfym(lbfyft)
VA VB Right (Clockwise)
P PF1/4 5.5 (40) Pilot (2 speed changeover) port
VB VA Left (Counterclockwise)
Dr PF1/2 11.0 (80) Drain port
VA,VB PF1 26.0 (190) Motor drive port
H61
MA,MB PF1/4 3.0 (22) Pressure measurement
6.2 CONSTRUCTION No. NAME QTY No. NAME QTY No. NAME QTY
6.2.1 TRAVEL MOTOR
35 37 12 13 3 7 5 6 40 24 28 36 1 CASING 1 21 BALL 1 41 O RING1B P11 4
2 REAR COVER 1 22 PIVOT 2 42 O RING1B P14 2
20 33 3 CYLINDER BLOCK 1 23 PISTON SEAL 1 43 O RING190.172.62 1
21 4 SHOE RETAINER 1 24 M6 RESTRICTOR (0.6) 2 44 OVERLOAD RELIFE VALVE 2
23 5 FRICTION PLATE 3 25 OIL SEAL 1 45 SPOOL 1
29 32 6 BRAKE PISTON 1 26 SPRING 3 46 PLUGPF3/8 1
17
7 SEPARATOR PLATE 4 27 SPRING (CYLINDER) 9 47 SPRING RETAINER 1
18 26
8 VALVE PLATE 1 28 SPRING (BRAKE) 12 48 PIN 1
38
9 40 9 SHAFT 1 29 BEARING 1 49 SPRING 1
Z 10 COUPLING 1 30 BEARING 1 50 CONNECTOR 1
39
41 11 SHOE PLATE 1 31 SOCKET BOLTM1645 8 51 SPOOL ASSY 1
10 12 BALL JOINT 1 32 SHIM 12 52 COVER 2
13 SPRING RETAINER 1 33 PARALLEL PIN612 1 53 SPRING 2
19 2
14 PISTON ASSY 9 54 SPRING RETAINER 2
15 D RING (SMALL) 1 35 PLUGNPT1/16 1 55 RESTRICTOR VALVE 2
30
16 D RING (LARGE) 1 36 PLUGNPT1/16(Meck : TB) 10 56 SPRING 2
8 17 CHECK VALVE 3 37 PLUG 1 57 PLUG 2
25
18 SNAP RING 1 38 PLUGPF1/8 3 58 O RING42.522.62 2
22 1 11 4 27 15 16 43 14
19 SNAP RING 1 39 PLUGPF1/4 2 59 O RING1B P9 2
44 50 42 45 48 47 49 42 46
20 TILTING PISTON 1 40 O RING1B P8 5 60 SOCKET BOLTM1235 8
58
54
60
53
52
57
41
31 51 59 55 56
VIEW Z (Sectional view is shown partially)
H62
Fig. 6-2 Travel motor
6.2.2 REDUCTION UNIT
24 15 16 14 13 12 18 25
5
20
10
Clearance :
6 0.08 to + 0.02mm
(0.0031 to + 0.0008in)
Adjust it with one shim.
9
8 Store it so the shaft center is

1 level with regard to the ground.
11
26
17 21 22 19 23
Fig6-3 Reduction unit
1 COVER 1 10 SUN GEAR 2 1 19 BEARING 2

2 CARRIER 1 1 11 CARRIER 2 1 20 SHIM 1
3 CARRIER PIN 1 3 12 CARRIER PIN 2 3 21 LOCK WASHER 2
4 NEEDLE BEARING 3 13 NEEDLE BEARING 3 22 SUPPORT RING 1
5 THRUST WASHER 1 6 14 PLANETARY GEAR 2 3 23 FLOATING SEAL 1
6 PLANETARY GEAR 1 3 15 SPRING PIN; 840 3 24 SOCKET BOLT M1025 15
7 SPRING PIN; 532 3 16 THRUST WASHER 2 6 25 SOCKET BOLT M1680 19
8 THRUST PLATE 1 17 RING GEAR 1 26 SOCKET PLUG PT3/4 2
9 SUN GEAR 1 1 18 HOUSING 1
H63
6.3 MAKEUP OF TRAVEL MOTOR (3) Variable displacement mechanism

The travel motor consists mainly of the rotary The variable displacement mechanism
group that generates rotating power, the negative consists of pivot (22) supporting shoe plate
brake that prevents the machine from moving by (11) that is put in two semispherical concaves
itself while it is parked, the variable displacement provided in shoe plate tilting piston (20) that
mechanism that switches over the motor capacity tilts shoe plate on pivot (22) tilting stopper
to the large or small mode, the overload relief (1-1) supporting the piston at a certain
valve that is built in the rear cover, and the brake position; the pilot valve that admits the
valve (counterbalance valve) that controls the pressurized oil to the tilting piston (20) by an
hydraulic circuits. external command; and three check valves
(17) that take out the highest of the external
(1) Rotary group command activated pilot pressure, the motor
Cylinder block (3) is inserted in the gear inlet pressure and the motor outlet pressure
tooth grooves of the spline of shaft (9) that is and that sends it to the pilot valve.
supported by bearings (29, 30) at it both ends.
The cylinder block (3) is pressed against rear (4) Overload relief valve
cover (2) with valve plate (8) by the action of The overload relief valve consists of socket
spring (27). (44-1) that has valve seat (44-3) metallically
9 piston assy (14) slide over shoe plate (11), seating rear cover (2) of the motor and
while stroking in cylinder block (3). screwed up in rear cover (2) valve (44-2)
A bearing retainer is arranged at the end face engaged with socket (44-1) that is tangential
of piston assy (14) to reduce the sliding in contact with valve seat (44-3) by the action
resistance. The action of spring (27) is of adjust spring (44-9) connecting piston
transmitted to spring retainer (13), ball joint (44-4) that is inserted in valve (44-2) and
(12), and shoe retainer (4) and presses the serves also as an oil path to pilot body (44-6)
end face of piston assy (14) against shoe plate piston (44-7) that is put in pilot body (44-6)
(11) so the piston assy moves close to the and pressed against plug (44-5) and shim
surface of shoe plate (27). (44-8).
44-2 44-9 44-12 44-9 44-12 44-11 44-7

(2) Negative brake 44-3 44-13 44-8 44-10 44-6
44-1 44-5
Four separator plates (7) and three friction
plates (5) are inserted by turns in the spline
grooves in the outer surface of cylinder block
(3) and are pressed against casing (1) by the
action of 2 springs (28) via brake piston (6).
Fig. 6-4 Construction of overload relief valve
No. NAME No. NAME

44-1 SOCKET 44-8 SHIM
44-2 VALVE 44-9 SPRING
44-3 VALVE SEAT 44-10 O RING1B P7
44-4 CONNECTING PISTON 44-11 BACKUP RING
44-5 PLUG 44-12 O RING1B G25
44-6 PILOT BODY 44-13 BACKUP RING
44-7 PISTON
H64
(5) Brake valve

1) Spool 2) Check valve (built in the spool)
If the spool (51) is shifted, the oil discharged It is the oil feeding passage to the hydraulic
from the hydraulic motor is shut off and motor and locks the exhaust oil. Therefore,
throttled automatically. The hydraulic motor the check valve serves as the suction valve
performs holding, acceleration, stop and and the holding valve for the hydraulic
counterbalance actions. motor.
Spool select pressure 6.110.2kgf/cm2 (87150psi)

Check valve cracking pressure 0.1kgf/cm2 (1.4psi)
53 54 58 60 52
57 41 56 55 59 51
Fig. 6-5 Brake valve
H65
6.4 FUNCTIONS OF TRAVEL MOTOR

(1) Functions of motor
The high pressure hydraulic oil delivered by
the hydraulic pump enters from the inlets
(VA, VB), passes through the brake valve,
rear cover (2) and valve plate (8), and is
admitted into cylinder block (3).
The high pressure oil acts upon each of the
pistons arranged in 180bordering on the
line Y-Y that connects the upper dead point
with the lower dead point of the piston, as
shown in Fig.6-6 (a).
And the high pressure oil generates ;
Force F1=P A (P; Pressure, A; Sectional
area of piston).
This force F1 becomes thrust component F2
and radial components F31-F34 (or F35) by
Fig. 6-6 (a) Fig. 6-6 (b)
shoe plate (11) having a tilting angle .
[See Fig.6-6 (b).] These radial components act
upon the Y-Y axis as rotating force, and
T=r1yF31+r2yF32+r3yF33+r4yF34
(If high pressure acts upon five pistons, add
r5yF35.) is produced.
This torque is transmitted to the spline via
cylinder block (3) and then to shaft (9).
(2) Functions of negative brake

The negative brake is released when
preferentially selected high pressure from the
counterbalance built in rear cover (2) acts
upon brake piston (6) and is generating
braking torque when there is no pressure.
The braking torque is produced by frictional
force that is generated by separator plate (7)
linked to casing (1) with the spline and 7 5 28 2
friction plate (5) linked to cylinder block with
the spline.
When pressure is not acting upon the brake
piston, brake piston (6) is pushed by the
action of spring (28). Friction plate (5) and
separator plate (7) are sandwiched between
brake piston (6) and casing (1).
This sandwiching force generates frictional 9
force between friction plate (5) and separator
plate (7) and acts as braking torque that
binds cylinder block (3) or shaft (9). 1 3 6
Fig. 6-7 Negative brake
H66
(3) Functions of variable displacement

mechanism The point on which the sum of the forces act
Fig.6-8 shows a modeled variable is nearly the center of shoe plate (11) as
displacement mechanism. shown in Fig. 6-8. Since pivot (22) is located
When pressure overcoming spring (49) enters away from the center by distance S, the
the high speed travel command line PA, rotating force resulting from S multiplied by
spring (49) is compressed. Then spool (45) the pressing force of the piston is generated.
moves to the right which connects port P with The pistons return to their original position
port C. The highest of motor pressures A, B and the motor changes to the low speed.
and the high speed travel command line In case the engine power lacks in climbing up
pressure is selected in check valve (17) and a steep slope at high speed or during
presses tilting piston (20). For that reason, steering, the motor speed is changed to low
shoe plate (11) tilts along the broken line speed automatically to prevent engine stop.
with the line L connecting two pivots (22) as The mechanism is as below :
the axis center, stops tilting when it hits The hydraulic pump pressure is admitted to
tilting stopper (H), and keeps that condition. the PB port as in Fig.6-8.
This decreases the stroke of piston (14) and This pressure acts upon pin (48). When the
makes the motor displacement smaller. The pressure exceeds a specified level, spool (45)
motor is capable of rotating at high speed is brought back to the left by the reaction of
without increasing the oil flow from the main pin (48). Then the pressure which has been
pump. The speed is approx. 1.5 times on this pressing tilting piston (20) is released to the
machine. tank. Shoe plate (11) tilts which makes a
Inversely, if the high speed travel command larger displacement motor to take up low
line pressure PA disappears, spool (45) is speed.
brought back to the left by the action of When the pressure falls below a specified
spring (49). The result is that the hydraulic level, spool (45) moves to the right and the
pressure pressing tilting piston (20) is motor changes to high speed.
released to the tank and makes the pressing
force zero.
The motor has nine pistons that are arranged
evenly over shoe plate (11) and presses shoe
plate (11).
TO CONTROL VALVE
A B
HIGH SPEED TRAVEL COMMAND LINE
17 17 17
21 20 H 14
S
L
22 22 11
45 48 49
PB P C
Fig. 6-8 Function of variable displacement mechanism
H67
(4) Function of overload relief valve If the A port pressure of the overload relief
Two overload relief valves are arranged in valve rises at the start of the hydraulic
the crossover and operate as below : motor, it acts upon the effective
1) To stop the hydraulic motor, the system circumference on which valve seat (44-3) of
keeps the braking pressure generating on the valve (44-2) is seated and upon connecting
motor discharge side at a certain level to stop piston (44-4) in the valve (44-2) through the
inertia load. small holes of it. The valve (44-2) causes the
2) At start, the hydraulic motor is driven at a pressure to rise to a set pressure by standing
specified set pressure to make sharp against adjust spring (44-9) by the areal
acceleration. At stop, generated pressure is difference between the effective
held low for a short time to dampen shocks by circumference of the valve seat and the
braking the motor. circumference of the connecting piston.
Further, the circuit pressure is held at a set When the hydraulic motor is braked, piston
pressure so the reduction and travel crawler (44-7) at the back of the valve is on its left by
sprockets are engaged smoothly. the drive pressure. As the A port pressure
In short, boost pressure cushioning action is rises, it acts upon piston (44-7) through the
performed. small hole in the valve. The piston moves to
the right till the piston hits plug (44-5).
During this period, valve (44-2) holds the A
port pressure relatively low, counteracting
adjust spring (44-9) and discharges the oil to
the B port side.
After piston (44-7) strikes plug (44-5), the
valve operates the same way as at the start of
the motor.
PLUG
CONNECTING PISTON (44-5)
B port (44-4)
VALVE SEAT
(44-3)
A port
Small hole VALVE ADJUST SPRING PISTON

(44-2) (44-9) (44-7)
Fig. 6-9 Function of overload relief valve
H68
(5) Function of brake valve

1) Hold condition (See Fig. 6-10) If an external force acts upon the hydraulic
When the selector valve is at neutral, the VA motor, the motor is kept normally from
and VB ports are connected with the tank. turning by the negative brake. Suppose the
Spool (51) is held in its center position by the negative brake is released, pressure is built
action of springs located at its both ends. up at the MA or MB port. Since the hydraulic
Since the VAMA passage and the VBMB motor turns a little as the high pressure of
passage are closed, the MA and MB ports the closed circuit escapes due to internal
that are connected with both sides of the leaks of the hydraulic motor, cavitation is
hydraulic motor are closed. about to be built up on the low pressure side
Furthermore, since the parking brake of the closed circuit. The check valve built in
passage is connected with the tank, the feed the spool operates to prevent cavitation it
pressure for the brake cylinder of the allows the VAMA or VBMB passage to be
negative brake mechanism is equal to the formed and makes up an amount of oil equal
tank pressure. This makes the brake in to the leakage to the closed circuit from the
operating condition and prevents the tank.
hydraulic motor from turning mechanically.
Fig. 6-10 Hold condition
H69
2) At acceleration (See Fig. 6-11)

If the selector valve is shifted, the VA port is If the inertia load of the hydraulic motor is
connected with the main pump and the VB large, the pressure required for acceleration
port with the tank, the hydraulic oil from the reaches a set pressure of the relief valve.
hydraulic pump pushes up the check valve in Then the hydraulic motor increases
the spool via the VA port. Then hydraulic oil revolution, while relieving the pressurized
is fed to the hydraulic motor from the MA oil. As the hydraulic motor increases speed,
port to turn it. the amount of relieving oil falls and the
The result is that the oil delivered by the motor arrives at a constant speed.
pump rises and releases the brake in the
negative brake mechanism. Meanwhile, since
the pressure in the pilot chamber rises, the
spool overcomes the spring action in the pilot
chamber of the VB port side and moves to the
left. Then the return passage MB VB is
formed which makes the hydraulic motor to
rotate.
Fig. 6-11 At acceleration
H610
3) At stop operation (See Fig. 6-12)

If the selector valve is brought back to The release pressure for the negative brake
neutral while the hydraulic motor is rotating falls slowly by the restrictor. The brake falls
to cut off the oil supply and the VA and VB into an operating condition which causes the
ports are connected with the tank, the hydraulic motor to stop mechanically.
pressures of the pilot chamber at both ends of
the spool are equalized. Then the spool
returns to neutral position by the spring
action. This closes the MB VB passage.
However, since the hydraulic motor tries to
rotate by inertia load, the hydraulic motor
makes pumping action to discharge the
hydraulic oil to the MB port. Since the
passage is shut off, the pressure rises, the
relief valve operates and the hydraulic motor
is decelerated gradually to a complete stop.
Fig. 6-12 At stop operation
H611
4) Counterbalance function (See Fig. 6-13)

If the hydraulic motor is decelerated which is Then the pressure in the pilot chamber on the
rotating by inertia force, counterbalance VB port side rises. The result is that the
action is required. Now if the hydraulic oil spool moves to the right which makes the MA
supplied to the VB port of the hydraulic VA passage area larger and decreases the
pump decreases gradually, the hydraulic braking action. The revolution of the
motor tries to rotate by inertia beyond the oil hydraulic motor is at last controlled to a level
feed rate. equal to the oil feed rate.
Then the pressure in the pilot chamber of the A restrictor that gives damping effect to the
VB side falls. The spool is pushed to the left spool is built in the pilot chambers at its both
by spring action and moves toward neutral ends to make the counterbalance action
position. Then the area of the MA VA stable.
passage decreases and the passage resistance The negative brake is released while the
increases. The pressure on the MA side rises. spool is regulating the pressure.
The hydraulic motor is braked and
decelerated below a revolution equal to the oil
feed rate.
Fig. 6-13 At counterbalance action
H612
6.5 FUNCTIONAL PRINCIPLE OF REDUCTION

GEAR
The reduction gear reduces the revolution
transmitted from the hydraulic motor and
converts it to powerful rotating power.
The reduction gear employs a planetary FIXED RING GEAR
2-stage reduction method.
The planetary mechanism consists of a sun PLANETARY CARRIER (k)
gear, a planetary gear, a (planetary) carrier, PINION
and a ring gear. (b)
If the sun gear (s) on the input side is rotated,
INPUT OUTPUT
the planetary gear (b) revolves meshed with
the fixed ring gear (a) while rotating by itself. SUN GEAR (s)
This revolution is transmitted to the carrier
(k) to convey torque.
This is the planetary gear mechanism.
RING GEAR (a)
CARRIER (k)
SUN GEAR (s)
PLANETARY PINION
(b)
Fig. 6-14 Planetary gear mechanism
In Fig.6-15, if the sun gear S1 on the input

side rotates, planetary motion occurs between a
gear S1, a and b. The revolution of gear b
conveys the input of carrier K1 to the No.2 b d
sun gear S2 to cause planetary motion to
occur between gear S2, a and d.
S1 S2
On that occasion, since carrier K2 is fixed to
the frame body, gear d transmits the power to
the ring gear and makes ring gear a rotate. K1 K2
Fig. 6-15 2-stage reduction mechanism
H613
H614
7. SWIVEL JOINT
7.1 OUTSIDE VIEW
Y
VIEW Y
VIEW Z
Z
Fig. 7-1 Outside view of swivel joint
7.2 SPECIFICATIONS
Table 7-1
Item Spec.
Working pressure 350kgf/cm2(4980psi)
High pressure ports
Max. impact pressure 525kgf/cm2(7470psi)
A,B,C,D
Rated flow 255 /min(67gal/min)
Low pressure ports Working pressure 5kgf/cm2(71psi)
E Rated flow 50 /min(13gal/min)
Low pressure ports Working pressure 50kgf/cm2(710psi)
F Rated flow 30 /min(8gal/min)
Revolution 15rpm
A,B,C,D PF1
Ports size E PF1/2
F PF1/4
Length (height) 355mm(14)
Weight 27.4kg(60.4 lbs)
H71
7.3 CONSTRUCTION
Y
X C
2
6
X
1 A E
D
B
D
C
VIEW Y
VIEW Y
B
12
A
5
F
7
3
13 E E 9
Tightening torque
8
Tightening torque
SECTION XX
Fig. 7-2 Construction
Table 7-2
1 BODY 1 7 O RING 1
2 STEM 1 8 SOCKET BOLT; M820 2
3 THRUST PLATE 1 9 SOCKET BOLT; M830 4
5 COVER 5 12 PLUG 1
6 SEAL ASSY 2 13 COVER 1
7.4 OPERATION
The swivel joint consists mainly of body (1) and The body (1) and the stem (2) rotate mutually.
stem(2) that rotate mutually, thrust plate (3) The oil flowing in from body (1) or stem (2) keeps
preventing both components from falling off, on flowing to stem (2) or body (1) past the
cover(13) closing one side of body (1), seal (5) that circumferential groove between body (1) and stem
partitions off the circuits and O rings(6) and (7) (2); the oil flow is never shut off because of
that prevent external leaks. rotation. Further, an oil groove for lubrication
Four ports for the travel main circuits are that connects with the drain port is provided, in
provided on body (1) and stem (2). Further, four order to prevent the body (1) from seizure with
oil passing grooves are arranged in the inner the stem (2).
surface of body (1), with seal (5) fixed above and This construction keeps on connecting the circuits
below the circumferential groove. between the swing bodies by means of a swivel joint.
H72
8. CYLINDER
8.1 SPECIFICATIONS
(1) General view
Part No. and Manufacturing No.

Stamp position
Fig. 8-1 General view of cylinder
(2) Specifications
Center distance Dry

Cylinder bore / of pins
Use Rod Dia. Stroke Full extend B / Cushion weight
Full retract A kg (lbs)
115 / 80 1,200 2,970 / 1,770 With cushion
Boom 160 (353)
(4.53 / 3.15 ) (41) (974 / 58 ) on rod side
125 / 90 1,290 3,060 / 1,770 With cushion
Arm
(4.92 / 3.54 ) (411) (10 / 58) on both sides 190 (419)
105 / 75 1,055 2,630 / 1,575 With cushion
Bucket 120 (264)
(4.13/ 2.95) (346) (862 / 516 ) on rod side
H81
8.2 CONSTRUCTION T=Tightening torque ; kgfym (lbfyft)

(1) Boom cylinder
(4.13-0.0197 )
(4.13-0.0197 )
0
660 (26.0) B
0
105 -0.5
105-0.5
0
0
M121.75 (Through)
24 25 25 24
27
SLIT
26
BLACK 28,2
GREEN
T=3.2(23)
With hole DETAIL B VIEW Z
(1 place)
DETAIL C
T=27.2(200) T=421(3000) T=5.8(42)
9 8 7 6 3 4 5 12 10,11 2 1 13 14 15 16 17 18 19 20 21 22,23
SLIT
Fig. 8-2 Construction of boom cylinder

(The figure shows the right-hand cylinder.)

1 CYLINDER TUBE 1 11 BACK-UP RING 1 21 NUT 1
2 PISTON ROD 1 12 SOCKET BOLT 10 22 SET SCREW 1
3 CYLINDER HEAD 1 13 CUSHION BEARING 1 23 STEEL BALL 1
4 BUSHING 1 14 CUSHION SEAL 1 24 PIN BUSHING 2
5 SNAP RING 1 15 PISTON 1 25 WIPER RING 4
6 BUFFER RING 1 16 SEAL RING 1 26 BAND 1
7 U RING 1 17 BACK-UP RING 2 27 BAND 1
8 BACK-UP RING 1 18 SLIDE RING 2 28 BOLT 2
9 WIPER RING 1 19 SLIDE RING 2 29 WASHER 2
10 O RING 1 20 SHIM 1
H82
(2) Arm cylinder T=Tightening torque ; kgfym (lbfyft)

200 (7.87)
28 27
(4.72 -0.0197 )
B
0
(4.72 -0.0197 )
120 -0.5
Z
0
120 -0.5
0
0
27 28 T=3.2(23)
29
31,32
30
SLIT
BLACK
GREEN

(1 place)
DETAIL C
T=27.2(200) T=836.5(6100) T=5.8(42)
7,8 6 4 5 3 12 10,11 2 1 13 14 20 15 17 16 18 19 21,22 26 24 23 25

9
SLIT
SLIT
Fig. 8-3 Construction of arm cylinder

1 CYLINDER TUBE 1 12 SOCKET BOLT 12 23 CUSHION BEARING 1
2 PISTON ROD 1 13 CUSHION BEARING 1 24 CUSHION SEAL 1
3 CYLINDER HEAD 1 14 CUSHION SEAL 1 25 STOPPER 2
4 BUSHING 1 15 PISTON 1 26 SNAP RING 1
5 SNAP RING 1 16 SEAL RING 1 27 PIN BUSHING 2
6 BUFFER RING 1 17 BACK-UP RING 2 28 WIPER RING 4
7 U RING 1 18 SLIDE RING 2 29 BAND 1
8 BACK-UP RING 1 19 SLIDE RING 2 30 BAND 1
9 WIPER RING 1 20 SHIM 1 31 BOLT 2
10 O RING 1 21 SET SCREW 1 32 WASHER 2
11 BACK-UP RING 1 22 STEEL BALL 1
H83
(3) Bucket cylinder T=Tightening torque ; kgfym (lbfyft)
(3.94 -0.0197 )
(3.94 -0.0197 )
0
B
0
100 -0.5
0
Z
100 -0.5
0
210 (8.27)
24 25 25 24
T=3.2(23)
27 28,29
SLIT
BLACK
GREEN
With hole DETAIL B

26
(1 place)
VIEW Z
DETAIL C
T=17.4(130) T=491(3600) T=5.8(42)
8 7 6 3 4 5 12 10,11 2 1 13 14 15 16 17 18 19 20 21 22,23
9
C
SLIT
Fig. 8-4 Construction of bucket cylinder

H84
Hydraulic cylinder construction

(See Fig. 8-2, 8-3, 8-4)
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
CUSHION RING(13) CHAMBER A PATH B
tube assy (1) and cylinder head (3).
TANK
PISTON(15)
8.2.2 OPERATION ROD(2)
If pressurized oil is fed alternatively to the oil
ROD SIDE
inlet and outlet provided in the cylinder, force HEAD
SIDE
acts on the piston which in turn causes the piston
rod (2) to extend and retract.
CYLINDER HEAD(3)
CUSHION STROKE
(1) Operation of cylinder with cushion
(Cushion on rod side) Fig. 8-5 Cushion mechanism on the rod side
The cushion mechanism is provided to
prevent the generation of shock when the
moving speed of piston (15) is not reduced TANK
and strikes cylinder head (3). CLEARANCE D
An oil in chamber "A" returns to the tank by
passing through paths "B" at a fixed flow rate
in a intermediate stroke state (Fig. 8-5) of MOUTH GAP C
pressing bottom side. Next, in a state of just
before stroke end (Fig. 8-6), cushion ring (13)
plunges into path "B".
At this time, an oil in chamber "A" passes
clearance "D" and mouth gap "C", an oil flow
volume returning to tank suddenly drops and Fig. 8-6 Cushioning action on the rod side
the piston part movement slows down.
H85
(Cushion on head side)

This construction is similar to the one of CUSHION SEAL (25)
PATH B
cushion on rod side. In a state of intermediate TANK CUSHION BEARING (24)
stroke pressing rod side, an oil in chamber
"A" returns to tank by passing through paths
"B" at a fixed flow rate.
Next, in a state of just before stroke end,
cushion bearing (24) plunges into path "B".
At this time, an oil in chamber "A" path
clearance "D" and cushion seal (25) are
mouth gap "C", an oil flow volume returning CHAMBER A CLEARANCE D
to tank suddenly drops and the piston part
movement slows down GAP "C"
CUSHION SEAL (25)
Fig. 8-7 Cushion mechanism on the head side
H86
II. ELECTRICAL EQUIPMENT
1. LIST OF ELECTRICAL EQUIPMENTS
1.1 SPECIFICATION
Group Code NAME Group Code NAME Group Code NAME
(B) B-1 Battery (P) PSV-A Arm variable recirculation proportional valve (SW) SW-1 Key switch
PSV-B P2 bypass cut proportional valve
PROPORTIONAL
(C) C-1 Mechatro controller PSV-C Travel straight proportional valve SW-3 Travel1-2 speed switch
C-2 Gauge cluster PSV-D P1 bypass cut proportional valve SW-4 Swing parking release switch
VALVE
CONTROLLER
SW-5 KPSS release switch

C-4 Air conditioner amplifier PSV-P1 P1 Pump proportional valve SW-6 Engine water temperature switch
PSV-P2 P2 Pump proportional valve SW-7 Engine oil pressure switch
C-6 IT controller (ORBCOMM) (OPT.) SW-8 Air filter clogging switch
(R) R-1 Battery relay
SW-10 Horn switch (LH)
(D) D-1 Diode R-3 Glow relay SW-11 Safety lock lever switch
D-2 Diode R-4 Safety relay
D-3 Diode R-5 Wiper motor relay SW-13 Air conditioner switch
DIODE
D-4 Diode R-6 Washer motor relay
SWITCH
D-5 Diode R-7 Horn relay SW-16 Auto accel pressure switch
D-6 Diode R-8 Work light relay SW-17 Swing flusher select switch (OPT.)
RELAY
(E) E-1 Fuse box R-10 Cab work light relay 1 SW-20 Horn switch (RH) (OPT.)
E-2 Alternator R-11 Cab work light relay 2 SW-21 Work light switch
E-3 Hour meter SW-22 Single / Conflux select switch (OPT.)
E-4 Horn (Low) R-19 Flusher relay (OPT.) SW-23 Wiper inter lock switch
E-5 Horn (High) R-20 Timer relay
E-6 Cigarette lighter SW-30 Rotary light switcfh
ELECTRIC EQUIPMENTS
E-7 Tuner AM & FM R-28 Auto idle stop relay 1

E-8 Speaker LH R-29 Auto idle stop relay 2 SW-32 Overload indicate switch
E-9 Speaker RH
E-10 Receiver dryer (SE) SE-1 Press. sensor (LOW) : Bucket digging SW-34 Power boost switch
E-11 A/C compressor SE-2 Press. sensor (LOW) : Bucket dump
SE-3 Press. sensor (LOW) : Boom raising SW-39 Overload switch
E-14 Resister SE-4 Press. sensor (LOW) : Boom lowering
SE-5 Press. sensor (LOW) : Swing SW-42 Engine room light switch
E-16 Converter (DC24V12V) SE-6
E-17 Socket SE-7 Press. sensor (LOW) : Arm in SW-52 Auto idle stop select switch
ELECTRIC SENSOR
SE-8 Press. sensor (LOW) : Arm out

E-23 Antenna (OPT.) SE-9 Press. sensor (LOW) : Travel right
E-24 GPS Antenna (OPT.) SE-10 Press. sensor (LOW) : Travel left
SE-11 Press. sensor (LOW) : OPT. 1
(L) L-1 Boom work light LH
L-2 Deck light RH SE-13 Engine speed sensor
L-3 Room light SE-14 Engine water thermo sensor
L-4 Cab work light (Front 1) SE-15 Fuel sensor
L-5 Cab work light (Front 2) SE-16 Accel potentiometer
LIGHT
L-6 Cab work light (Front 3)

L-7 Cab work light (Front 4) SE-20 Press. sensor (LOW) : OPT. 2
L-8 Engine room light
L-9 Boom work light RH SE-22 Press. sensor (HIGH) : P1 pump
L-10 Cab work light (Rear) SE-23 Press. sensor (HIGH) : P2 pump
L-15 Rotatry light

(SV) SV-1 Swing parking SOL
(M) M-1 Starter motor SV-2 ATT boost pressure SOL
M-2 Governor motor SV-3 Travel 1-2 speed SOL
SOLENOID
M-3 Wiper motor SV-4 Safety lock lever SOL

MOTOR
M-4 Washer motor

M-5
M-8
M-9
M-11
Fuel pump (OPT.)
Fuel supply pump

(Note) . The Part numbers and serial numbers of machine may be changed
due to modifacation, so use only the numbers for reference.
E1 1
E1 2
2.2. SPECIFICATION OF ELECTRIC EQIUPMENTS

File No.
Name of part
Specification Description
Use
B-1 Type 130E41R 115E41R

Voltage 12V 12V
Battery Capacity 5HR 92Ah 88Ah 1 3 0E4 1 R
130E41R
OR 11
115E41R
5E4 1 R
Weight 30kg (66 lbs) 28kg (62 lbs)
Power
Terminal Terminal
C-1 Maker SHINKO ELECTRIC

Rated voltage DC 24V
Controller
Window for adjust 4-7 Attaching hole
Mechatro controller
C-2 Maker KANSEI

Rated voltage DC24V
Controller More than 3M at
Insulation resistance
500Vmegger
LCD
Gauge cluster
E13
File No.
Name of part
Use
C-4 Maker's part No. TKS-C215AO

Rated voltage DC 20~30V
CONTROLLER
Controller
Air-con controller
D-1,2,3,5,6 Maker's part No. 7321-9822-30

Peak reverse voltage 400V
Diode
Mean output current 3A
Surge current 200A
Key switch relay

Battery relay
Gauge cluster
D-4 Part No. 7321-9332-60

Rated current 2.5A
Diode
Glow relay
E14
File No.
Name of part
Use
E-1
Fuse box Fuse capacity and circuit name

Capacity Name of circuit
18PAF-HD
1 20A Mechatro controller SUMITOMO
2 10A Wiper / washer relay HOUSING : 6098-0257
TERMINAL : 8240-4422
Fuse 3 10A Cigarette lighter
4 10A DC-DC Converter, Tuner
5 10A Horn
6 - Blank
7 10A Mechatro controller back-up I 18PAF-HD
8 20A Fuel supply pump
9 10A Tuner back-up, room lamp
10 20A Key switch
11 20A Fuel pump, cab work light
12 20A Travel alarm,swing flasher
II 7PAM-HD
13 10A Gauge cluster
14 20A Wiper, Washer
15 10A Solenoid valve
16 20A Work light
17 10A Resistor
7PAM-HD
18 20A Air conditioner, Heater SUMITOMO
19 10A Air conditioner HOUSING : 6950-1030
TERMINAL : 8230-4050
20 20A Spare (24V) : 8232-4238
E-2 Rated output 24X40A

M5 X 0.8
TERMINAL E 12.5
Alternator R L
VIEW A
Generator
M6 X 1.0
TERMINAL B
M5 X 0.8
E-3 Movement Quartz

GM TERMINAL P No. : 2962447
Hour meter GM CONNECTOR P No. : 2962448
Service meter
E15
File No.
Name of part
Use
LOWER
E-4,5 Type
Rated voltage DC24V STAMP
Horn
Operating voltage range DC 20~30V
Sound level 1135 dB
42020Hz high sound
Basic frequency 35020Hz low sound
Warning sound
More than 3M /
DC500V
8.5
E-6 Model 409112-0000

Cigar lighter
Max. current 5A PLUG COMPLETE
KNOB
Return time Less than 18sec
More than 3M /
Insulation resistance 500V megger
Cigar lighter
180C~250C
Fusing temp. JIS CA104
(356F~482F) CASE
SOCKET COMPLETE
E-7 Rated voltage DC24V
Tuner
1 L SPEAKER(+)
2 R SPEAKER(+)
3 ACC(+B)
4 OPEN
Radio (AM & FM) 5 L SPEAKER(-)
6 R SPEAKER(-)
7 GND(-)
8 BACK UP (+)
9 OPEN
E-8,9 Model SX-M1024K

Rated input 8W
Speaker
Impedance 4
Freguency 33.3Hz
Radio
E16
File No.
Name of part
Use
E-10 Maker's part No. 56640-A0450
Receiver dryer
CAULK
Air conditioner
2-M6 X 1.0
E-11 Maker's part No. 7351-6000

Air compressor
Max. revolution 4000rpm
V belt Type B
1
Refrigerant R-134a
Air conditioner Oil SP-20 : 135cc
Cover (clutch)
CP3.96MA
YAZAKI 7120-8019
AVX1.25 (BLACK)
AVX1.25 (GREEN)
CONNECTOR YAZAKI 2PAM

E-14 Rated power consumption 40W HOUSING 7122-2128
TERMINAL 7114-2020
Resistance value 16
Resistor
DC500V /
Insulation resistance FURUKAWA DENKO
More than 20M Viewmex ER400 or equivalent
SILICONE GLASS
Braided wire heat resistant tube
(NISSEI DENKI) 5X20mm (0.197" X0.787")
P1,P2 pump NS-GE 1.25sq
Hot soldering treatment
proportional valve [melting point 240C (464F)]
Sumi-tube K
-55C+175C
(-67F~+347F)
20mm (0.787")
-4.70.3
(0.185"0.012")
E17
File No.
Name of part
Use
E-15 Rated voltage DC 12V36V

Rated current 0.2A at 24V
Alarm
Travel
E-16 Input voltage DC 24V

Output voltage DC 12V
Converter Output current 2.5A Max
Ground Negative
YV
WG YB
OL
Power socket Fix the wire with tape B
HOUSING YAZAKI 7122-2262

TERMINAL YAZAKI 7114-2020
VIEW A
E-17 Power supply For 12V
Socket
Power socket
L-1,9 Type BL84-130

Bulb 24V,70W
Light (halogen)
Boom work light (left)

CA104
Boom work light (right)
M14X1.5
E18
File No.
Name of part
Use
L-2 Type BL84-200

Bulb DC 24V,70W
Light (halogen)
Effective area of lens 71cm2
Deck work light(right)
CA104 R
CB104 W
L-3 Bulb 24V,5W

Note) Equivalent to 2456Z322F1 BODY
Light LENS
Z
Room light
BULE
BULB
OFF ON
View Z
L-8 A
Maker's part No. 3509-KB
Bulb 12V,10W
Light
E/G room light
SECTION A-A A
E19
File No.
Name of part
Use
M-1 Rated output DC 24V,4.5kW

ISUZU 897029-8634 M10 TERMINAL (B)
Motor
Starter motor
TERMINAL (R)
TERMINAL (S)
SAFETY RELAY
REDUCTION GEAR SECTION

M-2 Drive voltage DC 24V OUTPUT OIL SEAL
SHAFT MOTOR SECTION
Rated voltage DC 8.5V (INVOLUTE)
Motor
Rated current 1.5A / phase
Number of phases 2 phase Z
Excitation method 2 Excitation

Governor motor Step angle 1.8 CAM
Insulation resistance More than 100M
(500V megger) LIMIT
SWITCH
Excitation sequence
Step
Brown(A) Red(B) 1 2 3 4
Lead
A - + + -
MOTOR LIMIT SWITCH
B - - + +
Orange(A) Yellow(B) CONNECTOR CONNECTOR
A + - - +
B + + - -
Limit switch connector Motor connector
Lead Connec-
No. Lead Connec- 1 2 No. color tion
6 color tion
1 Blown A
1 White COM
2 Orange A
5 2 Red NO
7 4 3 Red B LIMIT
3 Yellow NC 3
SWITCH
4 Yellow B
MOTION
HOUSING : 6181-0072 (SUMITOMO DENSO) HOUSING : 6181-0073 (SUMITOMO DENSO) RANGE
VIEW Z
TERMINAL : 1500-0134 (SUMITOMO DENSO) TERMINAL : 1500-0105 (SUMITOMO DENSO)
RETAINER : 6918-0327 (SUMITOMO DENSO) RETAINER : 6918-0329 (SUMITOMO DENSO)
WATER WATER
RESISTANCE : 7165-0118 (SUMITOMO DENSO) RESISTANCE : 7165-0118 (SUMITOMO DENSO)
E1 10
File No.
Name of part
Use
M-3 DENSO Part No. 5-159200-377

Rated voltage 24V
Motor
Wipe-out angle 106
Insulation resistance 1MMIN/500V megger
Wiper
M-4 Rated voltage DC 24V (+) (-)
Injection pressure More than 780cc / min

Motor(tank) Tank capacity 1.5L (0.4gal)
Time rated Max. continuous 20sec
Injection nozzle 1 X 2 pcs.
Window washer
PUMP
M-9 Maker's part No. 375-01016

Rated voltage DC24V
Motor (pump)
Current Less than 1.5A
Operating fluid Light oil HEX24
Discharge rate
(open circuit) More than 200cc/min
Fuel pump (OPT.) IN
OUT
Z
GROMMET M6X1
BLACK / RED
WATERPROOF
CONNECTOR (MALE)
VINYL TUBE (WHITE) YAZAKI 7322-9021
L=100 (3.94 )
BLACK
VIEW Z
E1 11
File No.
Name of part
Use
M-11 Flow rate More than 30L/min

Voltage 24V
Pump
Current Less than 14A
Fuse 15A
Fuel supply pump
R-1 Rated voltage / At start 24V2000A (0.1sec.)

current At charge 28V120A (continuous)
Relay Exciting current Less than 0.4A / 24V TERMINAL A
More than TERMINAL FLW2.0
Contact force 3.5kgf (7.7 lbs) B
FLW2.0
Closed circuit voltage Less than 16V F HOUSING :
SUMITOMO
Battery relay Open circuit voltage Less than 7V 7123-4220-30
F TERMINAL :
SUMITOMO
More than 3M / 7116-3251
Insulation resistance 500V megger REAR HOLDER :
SUMITOMO
7157-6801-30
MODEL WATER
NUMBER STAMPING RESISTANCE :
SUMITOMO
POSITION IN A 7157-3580-60
PRODUCTION PROCESS
Z
FLOWING DIRECTION OF AVS1.25B AVS1.25G AVS1.25L

MAIN CURRENT EARTH
TERMINAL
TERMINAL A TERMINAL B
HOUSING SUMITOMO
6181-0072
RETAINER SUMITOMO
TERMINAL A1 LOCK SECTION L TERMINAL
6918-0327
TERMINAL SUMITOMO
1500-0105
WIRE SEAL SUMITOMO
7165-0119
B
TERMINAL B1 TERMINAL EARTH TERMINAL
BLACK VIEW I VIEW Z
EARTH
CIRCUIT DIAGRAM
E1 12
File No.
Name of part
. Specification Description
Use
R-3 ISUZU part No. 894258-0140

Rated voltage DC24V
Relay In-rush current 130A
Rated load Breaking current 30A
Operating voltage Less than DC16V
Release voltage More than DC2V
Glow relay Exciting current Less than 1A
1 3
1 2
3 4
INTERNAL CONNECTION DIAGRAM 2 4

CONNECTOR ON CONNECTOR ON
MATED SIDE. MATED SIDE.
YAZAKI 7323-3010 YAZAKI 7323-2228
VIEW Z
R-4 ISUZU part No. 897129-9360

Relay
M10 TERMINAL (B)
Safety relay
TERMINAL (R)
TERMINAL (S)
SAFETY RELAY
TO ALTERNATOR
TO STARTER SWITCH (C)
SAFETY RELAY STARTER
E1 13
File No.
Name of part
Use
R-5,6,7,8,10,11,18 Rated voltage DC 24V

Coil resistance 360 10%
Relay
Insulation resistance 20M (500V megger)
Wiper motor,
Washer motor,
Horn relay, Applicable connector
Work light relay, VCF41003 (P&B)
Travel alarm relay,
CONNECTION DIAGRAM
R-19
Relay
Flasher relay (OPT.)
R-20 Rated voltage DC 24V

Delay time 1 sec.
Relay
Operation ON : 10 sec, OFF : 5 sec
Timer relay
R-28,29 Maker MITSUBA

Relay
Insulation resistance More than 1M (500V megger)
Auto idle stop relay 1,2
with bracket
without bracket
CIRCUIT
E1 14
File No.
Name of part
Use
SE-1~5,7~11,20 Pressure range 0~30kgf/cm2(0~430psi)

Pressure sensor Rated voltage 5 0.5V DC
(low pressure) More than 100M /
Insulation resistance Vcc
DC50V megger GND
Vout
Bucket digging, dump, AMP HQS-TYPE

Boom up, down, 3-poles (TYPE-B)
Swing
Arm in, out
Travel R, L (HEX) 19
Option 1, 2
PF1/4
TIGHTENING TORQUE 3.7kgfm (26.8 lbfft)
SE-13 Rated
Output voltage More than 2.5V
Revolution sensor
Clearance 1.0mm (0.04in)
CONNECTOR
YAZAKI 7322-1424
M16 X 1.5
TORQUE2.5~3.5kgfm HEX 19 HEX 17 SIGNAL (YELLOW)
E/G speed sensor
(18~25 lbfft)
GND (BLACK)
Z
SE-14 Maker part No. 71400-KW0300
Water temperature
sensor Resistance characteristics
50C(122F) 80 M16 X 1.5
TORQUE
60C(140F) 56.3 2.5 kgfm
E/G Water (18ftlbs)
temperature 80C(176F) 29.5
100C(212F) 16.5
106C(222.8F) 14.3 VIEW Z
120C(248F) 10
E1 15
File No.
Name of part
Use
SE-15 Float operating standard

Float Resistance value FLOAT
+0.1 FULL
Fuel sensor FULL 10-0.5
3/4 (19)
3/4
1/2 32 3
1/4 (49.5)
Fuel sending
EMPTY 80+12 1/2 110
+2 A
1/4
FUEL LEVEL
FUEL METER WARNING LAMP POSITION
EMPTY SENSOR SWITCH

G
24V3W FLU E
DC
24V
FLOAT SUMITOMO CONNECTOR

PART 6187-3231
VIEW A
SE-16 Total resistance value 2K

Effective electric angle 120
Potentio meter 3MA-JM II + AMP
Number of notches 10
HOUSING : 174359-2
Source voltage 5V TERMINAL : 171661-1
RETAINER : 1-174360-1
NOTCH PART HARNESS SEAL : 172888-2
Accel dial
DIAL
POTENTIO
BRACKET
SE-22,23 AMP HQS-TYPE 3-poles (TYPE-B)

Pressure range 0~500kgf/cm2(0~7110psi) HOUSING : 2-967642-1
Max. allowable press 750kgf/cm2(10700psi) TERMINAL (GOLD PLATING) : 965906-5
Pressure sensor HARNESS SEAL : 967067-1
(High pressure) Operating source voltage 5 0.5V DC
TERMINAL No. CONNECTION

P1 pump, P2 pump 1 COMMON
2 OUTPUT (+)
3 POWER SUPPLY (+)
22 x 25.4 HEX
PF3/8
E1 16
File No.
Name of part
Use
SV-1,2,3,4 Rated press. 51kgf/cm2 (710psi)

Directional valve Rated voltage DC24V
Solenoid valve assy
Dither 100Hz, 300mA P-P
Proportional valve
(8-SPOOLS) Coil resistance 17.51 (at 20)
Equivalent to AMP econoseal J series
connectors MARK II (+W)
Refer to HYD. SYMBOL CAP HOUSING
Specifications of connector CAP HOUSING
174354-2 or Equivalent
TERMINAL
173706-1 or Equivalent
PORT P,T,4 PF3/8

PORT A,B,C,D,1,2,3 PF1/4
PSV-A,B,C,D
Solenoid valve assy
(8-SPOOLS)
Refer to HYD. SYMBOL
SECTION A-01-02-A
E1 17
File No.
Name of part
Use
PSV-P1,P2 Type KDRDE-5K

Rated feed press 50kgf/cm2 (710psi)
Solenoid 10kgf/cm2 (140psi)
Allowable back press
Control pressure range 0~30kgf/cm2 (0~430psi)
Rated voltage DC24V
Proportional valve for
pumps P1,P2
AMP MARK II 2P
HOUSING 174354-2 or equivalent
TERMINAL 173706-1 or equivalent
O RING HEX 10
1B P20 Tightening torque
0.5kgfm (3.6 lbfft)
E1 18
File No.
Name of part
Use
SW-1 AUTO RETURN
Switch T
P B G1 G2 ACC M ST
H AUTO RETURN
OFF
Starter switch
ACC VIEW A
ON K250 STAMPED
START
A
TERMINAL
ARRANGEMENT
MARKS ON SWITCH PORTION

SW-3 Type Buried in right travel lever
Switch
(Right travel grip)
Travel 1,2-speed
CA103
E1 19
File No.
Name of part
Use
SW-4 Single-pole double-throw

Type INSULATION TAPE
(alternate)
R B W
Switch Rated DC 30V,10A
VINYL TUBE
YAZAKI
Swing parking release 7122-2237
Contact RED (2)
T No
construction 1 2 3 7114-2020
Position
Swing parking release ON 1
Normal ON 2 WHITE (3) BLUE (1)
SW-5 Type ST-425N M12P1
Switch (2)
(2)
(3)
(4)
(5) KEY WAY
(6)
KPSS release
~ (7)
(8)
(9)
(10)
(11)
(12) 12PAM-HD
SUMITOMO 6098-0252
TERMINAL 8230-4282
SW-6 Rated voltage WDC24V, DC12V, Z

M4 X 0.7
Operating
Switch temperature ON 105 2 C
Contact type A
(500V megger) HEX 21
E/G water
temperature switch
[105C (221F)]
VIEW Z
PT 3/8
SW-7 ISUZU Part No. 182410-0082

Engine oil Rated voltage DC24V
pressure switch More than 0.3kgf/cm2
Operating pressure (4psi)
Contact type Normally closed
Engine oil pressure
PT 1/8 M4 X 0.7
E1 20
File No.
Name of part
Use
SW-8 Rated output 24X40A

CA104 CB104
CLOGGING SWITCH
Switch
Air filter
clogging switch
SW-10,20,34 Type Buried in left grip Buried in right grip

Grip assy (with switch) YT03M01102F2 YN03M01367F1
Switch
Use Horn Power boost (Horn)
Rated switch 125V X 3A
More than 100M /
Horn DC500Vmegger
power boost
SUMITOMO DENSO HOUSING ITEM No. : 6090-1031 (2P MALE)

SUMITOMO DENSO TERMINAL ITEM No. : 8230-4282
SW-11 Roller plunger type

Type
D4MC-5020
Switch
HEX 17
CONNECTION TABLE
Safety lock lever 1

NO
2PAM
2
COM NC
1
YAZAKI HOUSING 7122-2228
2
TERMINAL 7114-2020
E1 21
File No.
Name of part
Use
SW-13 Maker's part No. TAP-151N40

Operating voltage range DC 20V~30V
Switch
Air conditioner
operation panel
SW-16 Maker's part No. RS-31700

Single-pole single-throw
Switch Type (Alternate)
Rated voltage DC 24V CONNECTOR (WITH LOCK) (R)
EQUIVALENT YAZAKI 7122-2228 RED
Insulation resistance More than 1M /
500V megger
Auto accel release SW. TERMINAL CONNECTOR
~
Terminal
R RW RED / WHITE
Position
(RW)
OFF
ON
SW-17 Single-pole single-throw

Type
(Alternate)
Switch Rated voltage DC 24V
Insulation resistance More than 1M / CONNECTOR (WITH LOCK) (R)
500V megger EQUIVALENT YAZAKI 7122-2228 RED
Swing flasher select SW. TERMINAL CONNECTOR

(OPT.)
Terminal
R RW
Position
RED / WHITE
OFF (RW)
ON

Type
(Alternate)
Work light TERMINAL CONNECTOR

~ Terminal
R RW
Position
RED / WHITE
OFF (RW)
ON
E1 22
File No.
Name of part
Use
SW-22 Rated voltage DC 24V

Switch Type (Alternate)
Conflux/single select TERMINAL CONNECTOR

(OPT.)
Terminal
R RW
Position
RED / WHITE
OFF (RW)
ON
SW-23 Maker's part No. DS-431

Contact components ON- (OFF) momently
Switch
More than 100M /
Insulation resistance 8.7
500V megger
14
BLACK CB104
Wiper interlock switch
RED CA104

Type
(Alternate)
Rotary light TERMINAL CONNECTOR

Terminal
R RW
Position
RED / WHITE
OFF (RW)
ON

Type
(Alternate)
Overload indicator TERMINAL CONNECTOR

Terminal
R RW
Position
RED / WHITE
OFF (RW)
ON
E1 23
File No.
Name of part
Use
SW-42
Switch CA-104 LA103 M3

TERMINAL YAZAKI : 7113-1020-02 (R)
CAP YAZAKI : 7120-8012 RED
Engine room
light switch CB-104
TERMINAL YAZAKI : 7115-1050-02
CAP YAZAKI : 7120-1010
BLACK
(B)
E1 24
E200SR
SECTION 25 AIR-CONDITIONER SYSTEM
TABLE OF CONTENTS
1. CONSTRUCTION AND PIPING

1.1 Construction ......................................................................................................................... 1
1.2 Piping ................................................................................................................................... 2
2. CONSTRUCTION OF MAIN COMPONENTS

2.1 Intake Unit ............................................................................................................................. 4
2.2 Air-Conditioner Unit ............................................................................................................... 5
2.3 Receiver Dryer ...................................................................................................................... 6
3. FUNCTION
3.1 Mechanism of Cooling Circuit ............................................................................................... 7
3.2 Cooling Circuit ...................................................................................................................... 8
3.3 Component Parts .................................................................................................................. 9
4. DISASSEMBLY AND ASSEMBLY

4.1 Precautions to be Exercised in Operation ........................................................................... 13
4.2 Removal and Installation of Unit .......................................................................................... 14
5. CHARGING REFRIGERANT
5.1 Precautions to be Exercised in Operation ........................................................................... 18
5.2 Operating Procedure .......................................................................................................... 19
5.3 Charging Procedure ............................................................................................................ 20
6. ELECTRIC CIRCUIT
6.1 Wiring Diagram and Connectors ......................................................................................... 24
6.2 Inspecting Functional Parts ................................................................................................. 25
7. TROUBLESHOOTING ............................................................................................. 27
1. CONSTRUCTION AND PIPING

1.1 CONSTRUCTION
1
3 5
B 1-1
C
1-3
4
F
1-4
1-5
6 2
2-7
D
TO CONDENSER
D
2-3 C
TO 2-8
COMPRESSOR
E
TO CONDENSER 2-6
E 2-4 2-5
2-1 B
TO COMPRESSOR
F
TO AIR CONDITIONER
2-2
A
TO AIR CONDITIONER
Fig. 1 Air-conditioner group

1 AIR-CONDITIONER ASSY 1 2 AIR DRYER ASSY 1 3 COMPRESSOR ASSY 1
1-1 AIR-CONDITIONER UNIT 1 2-1 RECEIVER DRYER 1 4 PANEL ASSY 1
1-3 SENSOR 1 2-2 BRACKET 1 5 FILTER ASSY 1
1-4 PLATE 1 2-3 L HOSE ASSY 1 6 CONDENSER 1
1-5 MACHINE SCREW 1 2-4 D HOSE ASSY 1
2-5 S HOSE ASSY 1
2-6 L HOSE ASSY 1
2-7 D TUBE ASSY 1
2-8 S TUBE ASSY 1
1
1.2 PIPING
T : Tightening torque kgfym (lbfyft)
28
19
T=6.6 (48)
5
28 21
T=6.6 (48) 18 24
15
27 1
T=1.1 (8.0)
T=4.6 (33)
26 Nut for tension pully
AC
OUT HEATER
IN
10
4
4
10 10 11
6
11
T=2.3 (17)
11
T=4.0 (29)
2
T=1.0 (7.2)
21
14 25
12 28
3
28 12
T=1.0 25
(7.2)
20
23 7
16
8
20
17 11
T=4.0 (29)
T=1.0 (7.2) 20
23 9
16
T=0.45 (3.3)
Fig. 2(1/2) Installing air conditioner and heater
2
HEATER CIRCUIT
AIR CONDITIONER UNIT

ENGINE OUT
IN OUT
IN
AIR CONDITIONER CIRCUIT

AIR CONDITIONER UNIT
L HOSE
S HOSE
D HOSE
COMPRESSOR
CONDENSER
L TUBE (HOSE)
RECEIVER DRYER
Fig. 2(2/2) Installing air conditioner and heater
Note) Apply Locktite #262 to mark.

torque No. NAME QTY torque No. NAME QTY
kgfym (ftylbs) kgfym (ftylbs)
1 BRACKET 1 0.45 (3.3) 16 CAPSCREWM650 6
2 SUPPORT 1 17 CAPSCREWM620 2
3 SUPPORT 1 6.6 (48) 18 CAPSCREWM1050 2
4 HOSEL=4150 2 6.6 (48) 19 CAPSCREWM1060 2
5 SPACER 2 20 WASHER 8
6 TUBEL=3800 2 21 WASHER 6
7 TUBEL=2800 1 23 LOCK WASHER 6
8 TUBEL=1900 1 24 LOCK WASHER 4
9 TUBEL=3200 1 25 NUT 2
10 CLIP 4 26 GROMMET 1
11 CLIP 4 27 V BELTB42 1
12 CLIP 2 28 WASHER 6
4.0 (29) 14 CAPSCREWM816 2
1.1 (8.0) 15 CAPSCREWM8100 4
3
2. CONSTRUCTION OF MAIN COMPONENTS

2.1 INTAKE UNIT
51 64
1 62
61 50
64 61
62
52 62
61 61
48
53
62 62
43 49
62
62
62
57
61
45 62
61 44
45
47
42
61 46
55
63
63 60
63
Fig. 3 Intake unit
4
2.2 AIR-CONDITIONER UNIT
39
36
40
61 27
7 5
37 61 20
64
9 21
62
64
1
62 62 65 26 22
31
14
36 62
60 62
60 4
19
30
62
18 17 62
10 29 32
24 4
23 34
25 67
24 35
67
62
33
11 62
24 23 16
62
12 15
67
67
8 56
23 2
59
58 62 64
20
28 62
1 62
3 41
6 5 64
13 6
56
54
Fig. 4 Air-conditioner unit
5

1 ACTUATOR 3 24 LEVER 3 47 BLOWER MOTOR 1
2 VALVE 1 25 CAM 1 48 CASING 1
3 THERMISTOR 1 26 ROD 1 49 CASING 1
4 CLAMP 2 27 ROD 1 50 FILTER 1
5 ROD HOLDER 2 28 ROD 1 51 LEVER 1
6 SENSOR HOLDER 2 29 DAMPER 1 52 LEVER 1
7 CLAMP 1 30 DAMPER 1 53 DAMPER 1
8 EVAPORATOR 1 31 DAMPER 1 54 FLANGE PLATE 1
9 CASING 1 32 DAMPER 1 55 SENSOR 1
10 CASING 1 33 DAMPER 1 56 SEMS BOLT 1
11 CASING 1 34 DAMPER 1 57 GASKET 1
12 THERMAL INSULATION 1 35 HEATER CORE 1 58 O RING 1
13 THERMAL INSULATION 1 36 CONTROLLER 1 59 O RING 1
14 PACKING 1 37 RELAY 1 60 TAPPING SCREW 6
15 PACKING 1 38 CLAMP 1 61 TAPPING SCREW 13
16 PACKING 1 39 BAND 1 62 SCREW 30
17 BRACKET 1 40 DUCT HOSE 1 63 SEMS BOLT 3
18 CLAMP 1 41 HARNESS 1 64 TAPPING SCREW 9
19 PLATE 1 42 RESISTOR 1 65 SCREW 1
20 LEVER 2 43 CASING 1 66 CAPSCREW 2
21 LEVER 1 44 CASING 1 67 TAPPING SCREW 4
22 LEVER 1 45 BRACKET 1
23 LEVER 3 46 HOSE 1
2.3 RECEIVER DRYER

REFRIGERANT 2
INLET
REFRIGERANT No. NAME QTY
OUTLET
1 PRESSURE SWITCH 1
2 SIGHT GLASS 1
2-M6 3 DESICCANT 1
4 SUCTION PIPE 1
1
5 FILTER 1
6 RECEIVER TANK 1
3
4
Fig. 5 Receiver dryer
6
3. FUNCTION
3.1 MECHANISM OF COOLING CIRCUIT
(1) Mechanism of Cooling
In the cooling process, the refrigerant that Table 1
flows through the cooling circuit changes its
phases from liquid to gas and vice versa Item HFC-134a (R134a)
during which process heat is transferred from Chemical formula CH2FCF3
the low temperature part (compartment) to Molecular weight 102.03
the high temperature part (outside of the
Boiling point 26.19 (15.14 F)
vehicle).
1) Kind of Refrigerant Critical temperature 101.14 (214.05 F)
Many kinds of refrigerants that change in Critical pressure 4.065MPa (41.45kgf/cm2 1)
that way are available, but the following
Critical density 511kg/m3 (31.9 lb/ft3)
requirements are needed for use in such
applications: Density of saturated 1206kg/m3 (75.3 lb/ft3)
z Latent heat of vaporization (heat of liquid [25 (77.0 F)]
vaporization) is large. Specific volume of 0.0310m3/kg (0.496ft3/lb)
z It is easy to liquefy (condense). (It dose not saturated vapor
require very high pressure for condensation.) [25 (77 F)]
z It is easy to gasify (evaporate). (It evaporates Latent heat of 197.5KJ/kg {47.19kcal/kg}
sufficiently at not too low pressure, i.e. cools vaporization
down an object.) [0 (32 F )]
z It has small specific heat. (Since the
refrigerant itself is cooled by the expansion Flammability Nonflammable
valve, the loss resulting from it must be held Ozone destruction 0
down to a minimum.) coefficient
z It has a high critical temperature and a low
1 : 1MPa (mega pascal) equals 10.1972kgf/cm2
solidification point.
z It is stable chemically and does not corrode (145psi)
and permeate into the circuit parts.
z It is free from toxicity, objectionable odor,
flammability and explosiveness and excels in
thermal conductivity and electric insulation.
z It has small specific volume.
z 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 PRESSURE
designated refrigerant for the cooling unit. MPa(kgf/cm2)
Table 1 shows the principal characteristics of R134a
the R134a refrigerant that is used in this 4 (40.8)
machine.
3 (30.6)
(2) Characteristics of Refrigerant (See Fig.6.) LIQUID
In general, the fluid (general term of gas and
liquid) has the following qualities: 2 (20.4)
1) As a gas under certain pressure is cooled
down, it begins to condensate at a certain
1 (10.2) GAS
temperature to take a liquid state. The
temperature at which condensation begins is (5.2)
TEMPERATURE
unique to each substance (fluid) at a given
pressure. The temperature determined by a 0 0 15 18 35 50 100 [ (
F)]
(32) (59)(64) (95) (122) (212.0)
given pressure is called saturation
Fig. 6 Pressure-temperature characteristics of R134a
temperature.
7
2) Inversely to 1) above, the pressure at which a

gas condenses for a temperature is
determined. This pressure is called
saturation pressure.
Fig.6 illustrates the relationships between
the saturation temperature and the
saturation pressure in the case of refrigerant
R134a used in the air-conditioner. At the
temperature and the pressure on the lower
righthand side of the curve in Fig.6, the
refrigerant take a gaseous state, while at the
temperature and the pressure on the upper
lefthand side of the curve, the refrigerant
takes a liquid state.
Let us think of a case where an
air-conditioner is operated in the midst of
summer. As the refrigerant evaporates, it
absorbs evaporation heat from the air of the
compartment. In order to cool the inside of
the compartment down to 25 (77 F), the
refrigerant must transform (evaporate) from
a liquid to a gaseous state at a lower
temperature. It can be seen from Fig.6 that
R134a under a pressure above the
atmospheric pressure is capable of cooling the
inside of the compartment sufficiently. (If a
refrigerant that requires a pressure below the
atmospheric pressure to cool it to a required
temperature is used, air is mixed into the
circuits, thereby deteriorating the
performance of the cooling unit.) In the
process in which gaseous refrigerant is
brought back to a liquid state, the refrigerant
is cooled and condensed by the outer air
exceeding 35 (95 F).
Accordingly the refrigerant is capable of
condensing at a pressure exceeding
10.2kgf/cm2 (145psi), as seen from Fig.6.
3.2 COOLING CIRCUIT
Fig.7 illustrates the cooling circuit of the car
air-conditioner.
In this circuit diagram, the portion that cools
the air of the compartment is the evaporator.
The object air is cooled off by utilizing the INSIDE OF COMPARTMENT (CAB)
fact that the refrigerant takes heat off the
surrounding area as evaporation heat as it
evaporates in the cooling circuit. Since the
part at which vaporization of the refrigerant
takes place is the evaporator, cooled air is EVAPORATOR EXPANSION
constantly delivered to the circumference of BLOWER
VALVE
the evaporator by the blower fan. In the

meantime, liquid refrigerant (slightly wet
vaporized refrigerant) is fed into the INSIDE OF ENGINE
evaporator, when cooling effect is attained. S D ROOM
For instance, in order to cool the air to 15
(59 F), the refrigerant can not absorb COMPRESSOR COOLING FAN
evaporation heat from the air unless it
evaporates at a temperature lower that 15
(59F). For that purpose, it can be seen from
Fig.6 that the pressure of the refrigerant in RECEIVER
the evaporator must be less than 5.2kgf/cm2 DRYER
(74psi).
Furthermore, the cooling effect deteriorates CONDENSER
unless the feed rate of the refrigerant is
controlled so that all of the refrigerant Fig. 7 Construction of cooling circuit
supplied to the evaporator vaporizes and
turns into dry vapor.
8
Consequently, the cooling circuit is so

constructed that the evaporator can cool
down an object (air in this case) sufficiently
(i.e. so as to decrease the pressure in the
evaporator) and that an adequate amount of
refrigerant can be fed to the evaporator.
The feed rate of the refrigerant is controlled
by the expansion valve, but the pressure in
the evaporator is held low by the throttling
action of the expansion valve and the suction
action of the compressor. The compressor acts
as a pump that allows the refrigerant to
circulate. The compressive action of the
compressor and the heat exchange (heat
radiation) action of the condenser transform
the refrigerant in a dry vapor state back to a
liquid state.
3.3 COMPONENT PARTS

(1) Evaporator (See Fig.8.)
The evaporator is an important heat
exchanger that absorbs the heat of the
compartment air (object) by the utilization of
the latent vaporization heat of the
low-temperature, low-pressure liquid-state
refrigerant. Therefore, it is necessary that EVAPORATOR
satisfactory heat transfer between the object
and the refrigerant take place in the
evaporator.
To that end, the evaporator is equipped with O RING
fins on the air side in order to increase the EXPANSION
heat transfer area of the air side and thereby VALVE
perform excellent thermal transfer between
the refrigerant and the air. SOCKET
The humidity in the air condenses as the air BOLT
cools down and adheres to the outside of the M540
evaporator as water drops. The cooling effect EVAPORATION (2 PCS.)
deteriorates if the water drops freeze. SENSOR
Therefore, how to discharge water is an
important point. Fig. 8 Evaporator
The amount of refrigerant supplied to the
evaporator is controlled by the expansion
valve which is described in the following. In
order to attain proper control, it is necessary
to reduce the pressure drop of the refrigerant
of the evaporator. Accordingly, reducing the
pressure drop is one element that makes the
evaporator attain its full performances.
(2) Expansion Valve
In order for the evaporator to fulfill its
performances, a proper amount of
low-pressure low-temperature liquid
refrigerant must be fed to the evaporator.
If the feed rate is too low, the refrigerant
completes vaporization early in the
evaporator which results in deterioration of
the cooling effect. If the feed rate is too high,
unvaporized liquid refrigerant returns to the
compressor (liquid back). This not only
deteriorates the cooling effect, but also
damages the compressor valves.
9
The expansion valve feeds the flowing

high-pressure high-temperature liquid
refrigerant to the evaporator as low-pressure DIAPHRAGM
low-temperature liquid refrigerant (damp
vapor of low dryness). The expansion valve
controls the feed rate of the refrigerant at the
same time.
Fig.9 shows how the block type expansion REFRIGERANT
valve is constructed. The temperature OUTLET
sensing part is provided in the shaft of the EVAPORATOR
expansion valve to directly detect the SIDE SHAFT
refrigerant temperature at the outlet of the
evaporator.
The diaphragm contains R134 a in saturated
state. The pressure in the diaphragm changes
according to the temperature detected by the
sensor. The change in the pressure causes the REFRIGERANT
force acting upon the diaphragm to vary BALL
INLET
accordingly. VALVE
The high-pressure high-temperature liquid
SPRING
refrigerant that is fed from the receiver side
reduces the pressure abruptly as it passes
through the valve (throttling action). On that Fig. 9 Block type expansion valve
occasion, part of the refrigerant evaporates
by the very heat of the refrigerant and cooled
off. The result is that low-pressure
low-temperature damp refrigerant vapor is
fed to the evaporator.
The opening of the valve is determined by the
equilibrium between the pressure (low) of the
evaporator side, the action of the adjust
spring and the pressing force of the
diaphragm (the temperature of the
refrigerant at the outlet of the evaporator to
be sensed by the thermowell). The feed rate is
controlled automatically so that under the
pressure in the evaporator, the refrigerant is
properly overheated (3 ~ 8 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.
Fig. 10 Expansion valve outside view
10
(3) Compressor (See Fig.11)

D HOSE
The compressor performs the following three
functions in the cooling circuit:
1) Suction action
2) Pumping action S HOSE
3) Compressive action
1) The suction action, as combined with the
throttling action, works to decrease the
refrigerant pressure in the evaporator. This
permits the refrigerant to vaporize at low
temperature in order to perform cooling
effect.
2) The pumping action serves to cause all the
refrigerant to circulate in the cooling circuit.
This enables enables continuous cooling.
3) The compressive action, as combined with the
action of the condenser which is mentioned Fig. 11 Compressor
hereunder, transforms vaporized refrigerant
back to a liquid state again.
The saturation temperature gets higher as
the pressure increases. For instance, it
becomes possible to cool down the refrigerant
by the use of an outer air of 35 (95 F) and
liquefy it. The compressive action of the
compressor works to turn low pressure
vaporized refrigerant to high pressure vapor
refrigerant. The condenser then serves to cool
down the refrigerant. However, since the
compressive action takes place only for a
short period, the refrigerant hardly
exchanges heat with outer air. That is to say,
it takes a near form of thermally insulated
compression, so that the refrigerant
discharged by the compressor turns into
high-temperature high-pressure vapor and is
delivered to the condenser.
(4) Condenser (See Fig. 12)

This is a heat exchanger that cools the
vaporized refrigerant at high temperature
and high pressure by the use of outer air and
condenses the refrigerant. The direction in
which heat moves is from the refrigerant to
air, the opposite to the case of the evaporator.
Fins are equipped on the outer air side to
improve thermal transfer. If the refrigerant
is not cooled well by the condenser, the air in
the compartment can not be cooled
sufficiently by the evaporator. For that
purpose, it is necessary to secure ventilation
required for the cooling of the refrigerant. Fig. 12 Condenser
11
(5) Receiver Dryer (See Fig.13)

1) Receiver Tank REFRIGERANT SIGHT GLASS
On the air-conditioner, the revolution of the INLET
compressor varies greatly which causes the REFRIGERANT
proper flow of refrigerant in the cooling OUTLET
circuit to vary. It is the receiver tank that
receives the variations. When the cooling
circuit does not need much refrigerant, the
receiver tank stores extra refrigerant
temporarily and supplies it when the cooling
circuit needs much refrigerant. The receiver
tank also stores an extra amount of PRESSURE SWITCH
refrigerant to be used for filling balance and
supplement small amounts of leakage of the
refrigerant through penetration into rubber
hoses.
2) Dryer
If water is mixed in the cooling circuit, it
deteriorates the compressor valves and oil,
corrodes the metallic parts of the circuit or DESICCANT
clogs the circuit as the water freezes in the
expansion valve. It is desirable that the
SUCTION PIPE
amount of water mixed in the refrigerant
should be held below a concentration of
30ppm. The air-conditioner uses a molecular
sieve as desiccant suited for the circuit, in
FILTER
order to absorb water content that intrudes
into the circuit when the dryer is installed or
when refrigerant is charged.
3) Sight Glass
This is a inspection window with which the
refrigerant level in the circuit is determined,
the only means of confirming the inside of the RECEIVER TANK
circuit visually.
4) Filter
5) Pressure Switch
This machine employs pressure switches of
high/low pressure type.
The pressure switch protects the circuit by
cutting off the power supply to the
compressor when high pressure increases Fig. 13 Receiver dryer
abnormally high [more than 32kgf/cm2
(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 2kgf/cm2 (28psi).
12
4. DISASSEMBLY AND ASSEMBLY

4.1 PRECAUTIONS TO BE EXERCISED IN
OPERATION
(1) Special Refrigerator Oil
This air-conditioner uses special refrigerator Table 2 Unit : kgfycm (lbfyft)
oil SP20 for use with new refrigerant R134a.
Oils other than SP20 may not be used. Since Pipe Fastening Part Tightening Torque
SP20 tends to absorb moisture and may D hose and compressor
200 ~ 250 (14 ~ 18)
corrode paint and resin, the following points (M8 bolt)
must be noted: D hose and condenser 200 ~ 250 (14 ~ 18)
1) Keep open all pipe connections on a new L hose and condenser 120 ~ 150 (8.7~11)
compressor and the component parts of the L hose and receiver dryer
80~120 (5.8~8.7)
installed refrigeration circuit (M6 bolt)
(Remove valves and caps at the pipe openings L hose and air-conditioner unit 120~150 (8.7~11)
of the compressor, just before connecting S hose and air-conditioner unit 300~350 (22~25)
pipes. If you have removed a pipe joint for Inlet of expansion valve 120~150 (8.7~11)
repair, put a cap to both ports immediately.) Outlet of expansion valve 200~250 (14~18)
2) Use care so SP20 does not adhere to the Pressure sensing part of
expansion valve 70~90 (5.1~6.5)
painted surface and resin parts. In case SP20
has adhered to such surfaces, wipe it off Table 3 Unit : kgfycm (lbfyft)
immediately.
Screw Size Tightening Torque
(2) The receiver dryer is filled with desiccant to
absorb moisture in the circuit. Therefore, N4, T4 machine screw, M4 8~12 (0.58~0.87)
remove the valve at the pipe port N5, T5 machine screw, M5 20~25 (1.4~1.8)
immediately before connecting pipes. M6 (mounting part of
80~120 (5.8~8.7)
L hose joint)
(3) Tightening Torque
M6 (except mounting part of
1) Pipe Joints (See Table 2.) 100~120 (7.2~8.7)
L hose joint)
When connecting pipe joints, coat the O ring M8 (mounting parts of S, D
200~250 (14~18)
with special oil (SP20) and fasten to the hose joints)
tightening torque indicated in the table, M8 (mounting part of A/C unit) 100~120 (7.2~8.7)
using a double spanner. M8 (other than those
120~160 (8.7~12)
2) Screws and Bolts (See Table 3.) mentioned above)
(4) Amount of Oil for Compressor (See Table 4.) M10 400~550 (29~40)
The compressor SD7H (HD type) is filled with
135cc (8 cuyin) of oil. If the oil volume is Table 4
small, seizure at high revolution and
Replaced parts Amount to be filled in
shortening of service life will occur. If the oil
volume is large, the cooling ability will be Evaporator 40cc (2.4cuyin)
deteriorated. Condenser 40cc (2.4cuyin)
Once the air-conditioner is operated, part of Compressor Drain out the volume of oil
the oil is dispersed in the refrigeration left in the compressor to be
circuit. Therefore, when replacing the parts replaced, from the new
compressor.
in Table 4, adjust the oil level to that of table.
(5) Before performing operation, stop the engine
and turn off all power supplies to the
equipment related to the air-conditioner.
(6) After the operation is over, confirm that all
faults have been repaired completely, by
operating the air-conditioner.
13
4.2 REMOVAL AND INSTALLATION OF THE UNIT

(1) Removing the blower unit INNER / OUTER
AIR MOTOR
1) Remove the connectors connected to the ACTUATOR
inner/outer air select motor actuator, the CONNECTOR
blower motor and the blower controller. Also
remove the harness from the blower casing.
HARNESS
EVAPORATOR
SENSOR BLOWER
CONNECTOR CONTROLLER BLOWER MOTOR
CONNECTOR CONNECTOR
Fig. 14
2) Draw out the inner air filter from the intake
casing. Remove four cross-recessed screws INNER AIR FILTER INTAKE
T514 (T1) from the top of the intake casing, CASING
MOUNTING
using a screwdriver. Then remove the intake SCREWS
casing. (4 PCS.)
INTAKE
CASING
3) Remove three cross-recessed screws T514 BLOWER
(T1) fastening the blower casing with the unit CASING
MOUNTING
casing. Then separate the blower unit from SCREWS
the air-conditioner unit. (3 PCS.)
UNIT BLOWER
(2) Replacing the blower motor CASING
1) Disconnect the cooling hose that is connected
between the blower motor and the blower Fig. 15
casing.
2) Remove three cross-recessed screws N516 BLOWER CASING

(W) fixed from the bottom of the blower unit
casing. Then draw out the blower motor.
z Do not separate the fan from the

blower motor.
BLOWER
MOTOR
3) Assembly is the reverse order of disassembly. BLOWER
CONTROLLER
(3) Replacing the blower controller COOLING
1) Remove two cross-recessed screws T4 14 HOSE
(T1) fixed from the bottom of the blower unit
casing and draw out the blower controller. BLOWER MOTOR
BLOWER MOUNTING
2) Install a new blower controller in the reverse CONTROLLER SCREWS (3 PCS.)
MOUNTING
order of removal. SCREWS (2 PCS.)
Fig. 16
z Do not disassemble the blower
controller in any circumstances.
14
(4) Removing the heater core

1) After discharging the cooling water,
disconnect the heater hose from heater core.
HEATER CORE
2) Remove one cross-recessed screw N516 (T2)
each for the AHC bracket fixing the heater PIPE CLAMP
core to the unit and for the pipe clamp. Then
remove the AHC bracket and the pipe clamp PIPE CLAMP
and draw out the heater core from the unit MOUNTING
casing. SCREW
(1 PC.)
AHC BRACKET AHC MOUNTING
3) Assembly is the reverse order of disassembly. SCREW (1 PC.)
Fig. 17
(5) Removing the upper and lower parts of the
air-conditioner unit casing
1) Draw out the connectors for the mode motor
actuator and the evaporation sensor.
2) Separate the rod 120 from the rod holder that ROD 120
REAR OF
is fixed to the lever MAL1 on the mode motor UNIT CASING
ROD HOLDER
actuator.
MOUNTING SCREW
LEVER MAL1
3) Remove three cross-recessed screws N422
(T2) fastening the mode motor actuator that MOUNTING BOTTOM OF
UNIT CASING
install the bottom of the unit casing to the SCREW
back of the unit casing. Then separate the MOUNTING MODE MOTOR
mode motor actuator. SCREW ACTUATOR
4) Remove eleven cross-recessed screws N516 Fig. 18

(T2) that install the bottom of the unit casing
to the top of the unit casing.
Draw out the top of the unit casing upwards,
using care so the evaporator sensor cord is TOP OF UNIT
not arrested by the casing. CASING
z On that occasion, do the work with

the heater core off the unit casing. EVAPORATOR ASSY
EXPANSION
VALVE
EVAPORATION
SENSOR
BOTTOM OF
UNIT CASING
TOP / BOTTOM
UNIT CASING
MOUNTING
SCREWS (11 PCS.)
Fig. 19
15
(6) Replacing the evaporator and the expansion

valve
1) Remove the evaporator assy from the bottom EVAPORATOR
of the casing, together with the casing
insulator and the expansion valve.
2) Remove the upper and lower casing O RING

EXPANSION
VALVE
insulators from the evaporator assy and draw
out the evaporator sensor with the sensor SOCKET HEAD
holder. CAPSCREW
M5 x 40 (2 pcs.)
3) Remove the socket head cap screws M5 x 40
(2 pcs.) from the evaporator. Then separate
the expansion valve from the evaporator. EVAPORATION SENSOR
: 4mm
Fig. 20
4) Attach O rings (NFO ring 5/8 and 1/2, one
piece each) to a new evaporator. Then install
the expansion valve to it.
: 4mm,
Tightening torque 0.7kgfym (5.1 lbfyft)
z When attaching O rings, use care so

the O rings are not caught.
3rd row
(7) Installing the evaporator sensor

Install the evaporation sensor as shown in 5th and 6th rows
Fig.21.
z When installing the casing, exercise 13th and 14th rows

care so the sensor cord is not caught
EVAPORATION SENSOR
by the casing.
(8) Replacing the motor actuator Fig. 21 Installing the evaporator sensor
1) Replacing the mode motor actuator
Remove the connector fixed to the motor
actuator.
Remove the rod 120 linking the motor
actuator with the mode cam, from the rod
holder.
Remove three cross-recessed screws T4 x 14
(T1) fixing the motor actuator. Separate the ROD 120
REAR OF
motor actuator from the unit, together with UNIT CASING
ROD HOLDER
the rod holder and the lever MAL1. Remove
MOUNTING
the rod holder and the lever MAL1 from the
SCREW
motor actuator and install them to a new LEVER MAL1
motor actuator. Assembly is the reverse order MOUNTING BOTTOM OF
of disassembly. SCREW UNIT CASING
MOUNTING MODE MOTOR
SCREW ACTUATOR
Fig. 22
16
2) Replacing the air mix motor actuator

Disconnect the connector connected with the
motor actuator.
Separate the rod 67 linking the motor
LEVER AM ROD 67
actuator with the lever AM, from the rod
ROD HOLDER
holder.
LEVER MAL1
Remove three cross-recessed screws T414
AIR MIX MOTOR
(T1) fastening the motor actuator. Then ACTUATOR
remove the motor actuator with the rod
holder and the lever MAL1, from the unit.
Remove the rod holder and the lever MAL1
from the motor actuator and install them to a
new motor actuator. Assembly is the reverse
order of disassembly.
Fig. 23
3) Replacing the inner/outer air select motor
actuator
Disconnect the connector connected with the
motor actuator.
Separate the motor actuator with lever MAL2
from the unit. LEVER MAL2
Remove the lever MAL2 from the motor
actuator and install it to a new motor
actuator, in the reverse order of disassembly.
INNER / OUTER AIR

MOTOR ACTUATOR
Fig. 24
17
5. CHARGING REFRIGERANT
5.1 PRECAUTIONS TO BE EXERCISED IN (3) Charging
OPERATION 1) When warming the can in which refrigerant
(1) Always assign a person in charge of handling is charged, do not fail to open the service can
refrigerant. valve and the low pressure valve of the gauge
Refrigerant charge operation involves manifold and warm the can in warm water of
dangers as it handles high pressure gas.
40 (104 F) or below (to an extent that you
Always assign a person familiar with how
do not feel hot when you put your hand in the
work is done for handling refrigerant.
water.) If the can is put in hot water or
z Always wear protective goggles. (You
may lose your sight if the refrigerant heated by a direct fire, the pressure of the
gets in your eyes.) can may rise sharply, thereby blowing off the
z The refrigerant in liquid state is at can.
very low temperature [approx. 26 2) When charging refrigerant while running the
(15 F)]. Therefore, handle it with engine, do not open the high pressure valve
care. (You may get a frostbite if the (HI) of the gauge manifold in any case.
refrigerant is sprayed over your (4) Others
skin.) Re-use of service cans is prohibited by law;
(2) Storage and Transportation never use them again. Do not allow foreign
1) Keep the service can (hereinafter called can) matter to enter the air-conditioner circuit.
less than 40 (104 F). Since high pressure
Air, water and dust are detrimental to the
gas of R134a is filled in the can in a
refrigeration cycle. Install the components of
saturated liguefied state, the pressure in the
the air-conditioner correctly and speedily.
can increases sharply as temperature rises.
The can may blast as the result. Pay full attention to the entry of water and
It is for this reason why the can temperature dust.
must be kept below 40 (104 F).
2) For storage, choose a cold dark place not z Be careful about overcharge of gas.
exposed to direct sunlight. z Fasten pipes to a specified torque.
3) If the can is placed near a fire source, it is
subject to radiation heat and gets hot. This
causes the inside pressure to rise and may
cause the can to blow out. Therefore, never
bring the can close to a fire.
4) The inside of the closed compartment gets
very hot as the radiation heat of the sunlight
enters the compartment. The areas of the
compartment which are exposed to direct
sunlight may rise to a dangerous
temperature level. Therefore, do not bring the
can into the compartment. Also, the inside of
the trunk room may rise to a dangerous
temperature level even in the summer time.
Use sufficient care, therefore, taking the
above into account.
5) Note that if the can has scratches, marks and
distortion, the strength of the can will
deteriorate.
1. Do not drop or knock on the can.
2. When transporting, loading or unloading
cans and packages containing cans, do
not throw or drop them.
6) Store cans beyond the reach of children.
18
5.2 OPERATING PROCEDURE

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

30 min. for five minutes.
Begin vacuum Stop vacuum Check Fill in Check for Fill in
making making air-tightness refrigerant gas leak refrigerant
Lower than
750mmHg Gauge
indicates
b li Charge refrigerant gas to a gauge
Check and correct joints pressure of 1kgf/cm2 (14 psi)
(3) Tools
Table 5 unit : mm
No. Name of Part Q
TY Sketch Service No. Name of Part Q
TY Sketch Service
1 Gauge 1 4 Quick joint 1 Low
23.5 pressure
manifold side
5 T joint 1 For service
can valve
2 Charging 3 Red : high 6 Service can 2 For service

pressure can
hose side valve
Blue : low
pressure
side
Yellow :
vacuum
pump
side
3 Quick joint 1 High 7 Vacuum 1 For
pressure vacuum
27.5 side pump adapter pump
19
5.3 CHARGING PROCEDURE

5.3.1 VACUUM MAKING OPERATION Note) DIS : Discharge
(1) Connecting Gauge Manifold (See Fig.25.) SUC : Suction
1) Close the high pressure valve (HI) and the
HIGH
low pressure valve (LO) of the gauge PRESSURE GAUGE
LOW PRESSURE
manifold. GAUGE GAUGE MANIFOLD
2) Connect the charging hoses (red and blue) (CLOSED) LOW HIGH PRESSURE
with the service valves of the compressor. PRESSURE VALVE
VALVE (CLOSED)
Red hose : High pressure side (HI) of the BLUE RED
gauge manifold high pressure
HIGH
side (DIS) of compressor PRESSURE YELLOW
Blue hose : Low pressure side (LO) of gauge SIDE
DIS
manifold low pressure side LOW
(SUC) of compressor PRESSURE
SIDE
SUC
z Do not mistake the high pressure
hose for the low pressure hose in any VACUUM PUMP
COMPRESSOR
circumstances when connecting (STOP)
them. Put the hose in firmly till a Fig. 25 Connecting gauge manifold
clicking sound is heard.
z Connect the end bent like L of the
charging hose with the service valve
of the compressor. If the charging
hose is connected the opposite way, BLUE
the mini core valve of the compressor RED
does not open. (See Fig.26.)
CHARGING
HOSE
3) Connect the center valve of the gauge
(MINI CORE VALVE)
manifold with the charging hose of the
vacuum pump. Fig. 26 Connecting piping with compressor
Some kinds of gauge manifolds are not LOW PRESSURE VALVE (OPEN) (CLOSE)
equipped with an open/close valve in HIGH PRESSURE VALVE (OPEN) (CLOSE)
the center. More than 30 min
(2) Vacuum Making (See Fig.27.) GAUGE MANIFOLD

1) Open the high pressure valve (HI) and the
low pressure valve (LO) of the gauge
manifold.
2) Turn on the switch of the vacuum pump and
make vacuum for more than 30 minutes. DIS
3) When vacuum making for a specified
duration is over (degree of vacuum : less than
750mmHg), close the high pressure valve
and the low pressure valve of the gauge SUC
manifold.
4) Then turn off the vacuum pump. Fig. 27 Vacuum making operation
20
(3) Air-tightness Check

Close the high pressure valve and the low
pressure valve of the gauge manifold, leave it
as it is for more than five minutes and make
sure that the gauge indication does not
return toward O.
If the gauge indication swings toward

O, there is somewhere that is leaking.
Retighten pipe joints, make vacuum
again and make sure of no leakage.
5.3.2 GAS CHARGING OPERATION

(1) Charging from High Pressure Side
(See Fig.28.)
1) After making vacuum repeatedly, change the
AIR PURGE
charging hose (yellow) of the gauge manifold
CLOSE
from the vacuum pump to the service can.
RED
2) Air purge
Open the service can valve. (However, close OPEN SERVICE CAN VALVE
the high and low pressure valves of the gauge SCREWDRIVER
manifold.) Then push the mini core valve of

BLUE YELLOW
the side service port on the low pressure side
of the gauge manifold, using a screwdriver, in
order to let out the air in the charging hose
by the pressure of the refrigerant. (See Fig. 28 Gas charging operation
Fig.28.) (The operation ends when a hissing
sound is heard.)
3) Open the high pressure valve of the gauge
manifold and charge in refrigerant. [Charge
in gaseous refrigerant to a gauge pressure of
1kgf/cm2 (14psi).]
After charging, close the high pressure valve
LOW PRESSURE HIGH PRESSURE VALVE
of the gauge manifold and the service and
VALVE (CLOSE) (OPEN) (CLOSE)
valve. (See Fig.29.) RED
FILL IN 11.5 CANS
BLUE
OF REFRIGERANT
Do not run the compressor in any case,
DIS YELLOW
(Otherwise the refrigerant flow in
reverse direction which causes the SERVICE CAN
VALVE
service can and the hoses to rupture.
(OPEN) (CLOSE)
This is very dangerous.)
CHARGE
SUC
(2) Checking for Gas Leakage
Check for gas leakage in the cycle, using a
gas leak detector (electric type). Retighten Fig. 29 Gas charging operation
and correct leaking points. (High pressure side)
Always use the leak tester for R134a.

(Do not use one for flon gas service as it
provides poor sensitivity.)
21
(3) Charging from Low Pressure Side

(See Fig.30.)
1) Make sure that the high-pressure and
HIGH PRESSURE
low-pressure valves of the gauge manifold VALVE (CLOSE)
LOW PRESSURE
and the service can valve are closed. VALVE
(MUST BE CLOSED
2) Start the engine and run the revolution to POSITIVELY)
OPEN CLOSE
1500100rpm and fully open the cab door WHEN AIR
BUBBLES IN THE
RED
and the windows. SIGHT GLASS
DISAPPEAR
3) Turn on the air-conditioner switch, set the BLUE
YELLOW
DIS
fan switch to Max and the temperature
control switch to cool Max.
SERVICE CAN
4) When charging gas, set the discharge VALVE (OPEN)
pressure of the compressor to 1416kgf/cm2 SUC
(200230psi).
5) Open the low pressure valve of the gauge COMPRESSOR SERVICE CAN
OPERATION (DO NOT TURN IT OVER)
manifold and the service can valve and fill in
refrigerant till air bubbles of the sight glass Fig. 30 Gas charging operation
of the receiver go away. (See Fig.30.) (Low pressure side)
[Total amount of gas to be charged :
1000g100g (2.20.22 lbs )]
SIGHT GLASS
6) When refrigerant charge is over, close the low
pressure valve of the gauge manifold and the
service can valve.
z Do not open the high pressure valve

of the gauge manifold in any
circumstances.
z Never place the service can upside
down. (The compressor valve may be
scored because the refrigerant is
sucked in a liquid state.)
Fig. 31 Receiver dryer
22
(4) Criterion for Checking the Amount of

Refrigerant Filled in
Judgment of refrigerant level through the sight glass of receiver dryer
Proper level After A/C is turned on,

only a little bubbles are
seen and thereafter light
milky white is seen.
Overcharge After A/C is turned on,
no air bubbles are seen.
Undercharge After A/C is turned on,

continuous air bubbles
are seen.
z If the air-conditioner is run with

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

When the refrigerant level has been checked,
disconnect the charging hoses from the
compressor in the following manner :
1) Press the L shape metal fitting of the
charging hose (blue) on the low pressure side
against the service valve of the compressor so
the refrigerant does not leak out and loosen
the nut. As soon as the nut has been
removed, disconnect the charging hose from
the service valve.
2) Leave the high pressure side as it is till the
high pressure gauge reading falls. [below
10kg/cm2 (140psi)].
3) Disconnect the charge hose (red) on the high
pressure side the same way as on the low
pressure side.
23

6. ELECTRIC CIRCUIT
6.1 WIRING DIAGRAM AND CONNECTORS
Fig. 32 Electric diagram 24

6.2INSPECTING FUNCTIONAL PARTS

3 1
(1)Relay (244PE)
1)Coil resistance : 320 (across 1 and 2) 4 2
2)Operating voltage : DC2030V
3)The coil of the relay has polarity : Care is As viewed from A
needed.
A
4) Turn on and off the power to the blower
motor by controlling the controller.
5) Check: Check conductance across 3 and 4 in
the following condition :
Apply 2030V across terminals 1 and 2 :
continue
No voltage applied across terminals 1 and 2 : Fig. 33 Relay
not continue
(2) Inner air sensor (C44)

Resistance across terminals :
at 0 (32F) : 7.2K
at 25 (77F) : 2.2K
The inner air temperature sensor is installed
to the sensor bracket under the operator's
seat. The temperature in the cab is sensed by
the thermistor. Changes in the resistance
according to temperature variations are
transmitted to the controller.
Fig. 34 Inner air temperature sensor
(3) Blower controller

The blower controller changes output
voltages for the motor according to signals
emitted by the controller.
Fig. 35 Blower controller
(4) Motor actuator

1) Operating voltage : DC2030V
2) Operating temperature range :
30(22 F) to +75 (167
F)
The motor is controlled by signals (pulses)
put out by the controller.
CONNECTOR
PIN NUMBER
Fig. 36 Motor actuator
25
(4) Pressure Switch (Attached to Receiver PRESSURE SWITCH

Dryer)
1) Contents of checking (specification)
Low pressure side OFF pressure :
2.00.2kgf/cm2 (283psi)
Low pressure side return pressure :
OFF pressure +0.3kgf/cm2 (4.3psi) or below
High pressure side OFF pressure :
322kgf/cm2 (45528psi)
High pressure side return pressure :
OFF pressure62kgf/cm2 (8528psi)
Fig. 37 Pressure switch
LOW PRESSURE RETURN HIGH PRESSURE RETURN

(26) (30) (31) (36) (310) (430) (480)
1.8 2.1 2.2 2.5 22 30 34 kgf/cm2 (psi)
LOW PRESSURE OFF HIGH PRESSURE OFF
2) Performance
Low pressure side : To prevent actuation of
the compressor clutch
where refrigerant is
deficient
High pressure side : To prevent actuation of
the compressor clutch
where pressure rises
abnormally because of
the clogging of the
refrigeration circuit, etc.
(5) Thermistor (C19)

1) Contents of checking (specification)
Resistance across terminals
at 0 (32 F) : 7.2k
at 25 (77 F) : 2.2k
Note :
Normally check that there is no shortcircuit
or disconnection.
2) Performance
In order to prevent freezing of the evaporator,
the blowoff air temperature of the evaporator Fig. 38 Thermistor
is controlled by turning the compressor clutch
ON and OFF. The thermistor operates as the
sensor of the control.
26
7. TROUBLESHOOTING
Temperature does not fall. Note) M/A : Motor actuator
If A/C switch is pushed, HL.E is indicated on the set temp. display of the panel.
NO YES
HL. is shown on the set temp. display of the panel. Connector for air mix M/A is
Note) is any of the disconnected or in poor contact.
NO YES numbers 0 9. M/A is broken.
E on display. Main harness shows poor conductance.
A snow mark on the A snow mark ( ) on panel is flashing.
panel is flashing. Inspect and correct or replace parts.
NO YES NO YES
Inner air sensor or harness Both inner air sensor

is disconnected or shorted. and
Inner air sensor connector is evaporation sensor are
disconnected or in poor contact. disconnected or shorted.
Inspect and correct or replace parts.

A
B
Blowout temp. falls if temp. is set
at 18.0 (64.4F) (COOLMAX) and the Evaporation sensor connector
blowout mode is changed to vent mode. is disconnected or in poor contact.
Evaporation sensor is
NO YES disconnected or shorted.
1 Air mix damper is Chilly air flowing Inspect and correct or replace parts.
in COOLMAX. into inner air sensor
NO YES NO YES
If M/A is at stop Turn compressor clutch Controller is faulty Inspect duct or

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

M/A failed or controller
M/A lever link.
is out of order.
After cleaning lever link,
apply grease.
Replace.
27
Temperature does not rise.
HL.E is shown on the set temp. display of panel.
NO YES
HL. is shown on the set temp display the panel. Note) is any of the numbers 09
NO YES
Blowout temp. rises at blowout z Inner air sensor or harness

mode if temp. is set at is disconnected or shorted.
HOTMAX 32.0 (89.6 F). z Inner air sensor connector
is off or in poor contact.
Inspect and correct or replace parts.
NO YES Inspect and correct

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

replace M/A lever link. is out of order.
2 : HOT-MAX
z Clean lever link and apply grease.
operating condition.
Replace.
28
Blower motor does not run.
At air flow HI, battery voltage acts across Note) Measure with
both terminals (+) and () of blower motor. connector set.
NO YES
Battery voltage acts across red Blower motor fails.

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

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

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

or replace controller.
Blower motor speed does not change.
HL. is shown on the set temp. display of panel. Note) is any of the
numbers 09.
NO YES
Air flow rate is constant regardless of readings. z Inner air sensor and harness
are disconnected or shorted.
z Inner sensor connector is
disconnected or in poor contact.
Replace blower
amplifier or controller. Inspect and correct or replace parts.
29
Magnet clutch does not engage.
Snow mark ( ) lights if A/C switch is
NO YES
Snow mark flickers and E is Voltage acts upon clutch.

shown on panel display.
NO YES
To B On page 27. Terminal voltage present across Clutch faulty.

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

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

and machine connector. harness. No fault.
Also clutch fuses.
NO YES
Replace harness. Replace controller.
Inner air and outer air do not change over.
Inner / outer air mode display on

operation panel is flickering.
NO YES
M/A lever includes Connector of inner/outer air M/A is

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

and replace parts.
Replace
30
Modes do not change.
Mode display (Mark of person)

on operating panel is flickering.
NO YES
M/A rod does not disengage. Mode M/A connector is disconnected or

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

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

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

z Clean cam and apply new grease.
31
Trouble with refrigeration cycle.
Both high and low pressures are lower. Low pressure is higher.
Air bubbles are seen in sight glass. Air bubbles are High pressure
seen in sight glass. is lower.
NO YES
Cooling does not work Oil oozes out from Compressor Hot air Compressor
if run at high speed. piping and parts. cylinder does comes out of cylinder gets
not get hot. heater unit. very hot.
NO YES NO YES
Expansion Expansion Natural Gas leaks Expansion Water cock Compressor

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

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

High pressure is lower. it does not cool down or air flow decreases.
Frost deposits.
Air bubbles are seen in sight glass.
NO YES
Thermistor does
High pressure gets Condenser is not cool off.
lower slowly. fouled or clogged.
NO YES
YES
NO Thermostat is Thermistor position

High pressure
circuit before Air bubbles are hard to not turned off. is normal.
receiver is go out even if water
clogged up. is poured on condenser. NO YES NO YES
Functions and Thermistor Thermistor Air

Remove Clean Air is mixed. performances is faulty or position is leaks
clogging condenser Make vacuum are normal. cord is faulty. out of
or replace and refill Familiarize disconnected. Correct casing.
parts. refrigerant. the user with position.
how to use it.
32
E200SR
SECTION 31 DISASSEMBLING AND ASSEMBLING
TABLE OF CONTENTS
1. EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY ....................... 1

1. EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY
1.1 FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY

This chapter is consist of 3-Section as follows.
(1) ATTACHMENTS .......................................................................................................... Code No.:32

Part I; Removing and Installing
Part II; Disassembling and Assembling
1) Cylinder
(2) UPPER SLEWING STRUCTURE ............................................................................... Code No.:33

1) Hydraulic pump 2) Control Valve 3) Pilot Valve (ATT)
4) Pilot Valve (Travel) 5) Slewing Motor 6) Swivel Joint
(3) TRAVEL SYSTEM ....................................................................................................... Code No.:34

1) Travel Motor
1.2 INDICATION OF TIGHTENING TORQUE

Tightening torque is indicated as follows, for example;
T=10kgfym (72 lbfyft)
Tolerance is 10% unless specified.
z Refer Code No. 11 TOOLS for standard tightening torque.
1
E200SR
SECTION 32 ATTACHMENT
TABLE OF CONTENTS
[Part I. Removing and Installing Assy]

1. ATTACHMENT ASSY AND NAME ............................................................................ I-1
2. BUCKET .................................................................................................................. I-1
3. ARM ........................................................................................................................ I-4
4. BOOM ..................................................................................................................... I-7
[Part II. Disassembling and assembling equipment]

1. CYLINDER ............................................................................................................. II-1
1. ATTACHMENT ASSY AND NAME
(D) ARM CYLINDER HEAD PIN

(C) BOOM CYLINDER ROD PIN
ARM CYLINDER
(A) BOOM FOOT PIN
4. BOOM
(F) BOOM TOP PIN
(E) ARM CYLINDER

ROD PIN
3. ARM
(G) BUCKET CYLINDER
(I) IDLER LINK PIN (J) BUCKET DRIVE PIN
HEAD PIN
IDLER LINK BUCKET LINK (B) BOOM CYLINDER
BUCKET CYLINDER
HEAD PIN
(H) BUCKET CYLINDER ROD (K) BUCKET ATTACHING PIN
Fig. 1-1 Front attachment name and position
2. BUCKET
2.1 REMOVING BUCKET

(1) Put the machine in position to remove
bucket.
Fig. 2-1 Position to remove bucket
BOSS
DRIVER
(2) Removing lock pin (2)
Expand slit of ring (1) with driver, and
1 2
remove it. Push out the pin (2) with driver
().
BOSS SECTION
Fig. 2-2 Removing pin (2)
I1
(3) Removing bucket attaching pin (K).

Lift up bucket, position it so that bucket
attaching pin (K) is not loaded, adjust bucket K
link, and pull out bucket attaching pin (K).
Fig. 2-3 Removing bucket attaching pin

(4) Removing bucket drive pin (J)
Put bucket on the ground, position it so that
the bucket drive pin (J) is not loaded, adjust
bucket link, and pull out pin (J).
J
Fig. 2-4 Removing bucket drive pin

2.2 ATTACHING BUCKET
(1) Attaching bucket drive pin (J)
Attach bucket drive pin (J) first, then
CROWBAR
continue in the reverse procedure of the
pulling out. J
z When aligning the pin holes, do not

put your finger in the pin holes in
any circumstances, but align them
visually.
z Check that the seals are not scored
and replace a faulty one if necessary.
zWhen inserting the pin, coat the shaft
with grease.
Fig. 2-5 Attaching bucket
2
2.3 PROCEDURE FOR ADJUSTING CLEARANCE

Adjustment of clearance between bucket and
arm
(1) Shift O ring (3) toward the bucket boss, using BUCKET
a spatula. (ab)
12
3
(2) When adjusting clearance (B), bring the
non-adjusting side of the bucket in contact
with the arm. 10 (b)
(a)
(3) Measure clearance (B) and check that it is
within 1.2mm (0.05in). ARM
(4) Adjust clearance (B) where it is more than

1.2mm (0.05in). BUCKET ATTACHING PIN (K)
(5) An average of 5 shims (12) of 1mm (0.04in)

thickness are set in the plate (13) fixed by the 8
three capscrews M1650 (10). The clearance
can be adjusted by 1mm (0.04in) if one shim
is removed in the fixed plate. 13 B
9
: 24mm
(6) After adjustment, tighten the capscrews Fig. 2-6 Adjusting clearance between
evenly. bucket and arm
z The gap exceeding the specified
dimension causes a premature wear.
(7) Operate the bucket and confirm that the total

sum of both clearance is within 1.2mm
(0.05in)
(8) Refit O ring (3) to its original position.
z When shifting O ring (3) by means of

a spatula, use care so as not to score
O ring (3).
z Remove shims (12), push out
bushing (8) rightwards by means of
three capscrews (10) and adjust
clearance (B) so it falls within the
standard value evenly all round.
z Check the clearance at 120 hours
intervals in normal operation.
Shorten these intervals in heavy
digging. Adjust the intervals as
necessary.
3
3. ARM
3.1 REMOVING ARM
(1) Put the machine in position to remove arm.
Extend the arm cylinder, retract the bucket
cylinder to a maximum and bring the arm
down on the ground.
Fig. 3-1 Position to remove arm

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

ORS plug : 4-(4)
When the removal of bucket cylinder is not

required, skip to procedure (6).
Fig. 3-2 Disconnecting piping of bucket cylinder
(3) Removing bucket cylinder rod pin (H)
1) Loosen nut (9), remove capscrew M16140
After adjustment of shim,
(8), and push out pin (H). the total gap should be
within 0.61.0mm (0.02
0.04in).
: 24mm H
8
2) Retract cylinder rod.

SECTION 9
Fig. 3-3 Detail of bucket cylinder rod pin (H)
(4) Removing cylinder head pin (G)
Loosen nut (3), remove capscrew M16140
After adjustment of shim,
(2), and push out pin (G). the total gap should be
within 0.61.0mm (0.02
0.04in).
: 24mm
G 2
SECTION
Fig. 3-4 Detail of bucket cylinder head pin (G)
4
(5) Removing bucket cylinder

Sling tube of bucket cylinder with nylon
sling, and remove it.
Bucket cylinder weight : 125kg (276 lbs)
Fig. 3-5 Slinging bucket cylinder

(6) Removing arm cylinder rod pin (E)
Put a wooden block between the arm cylinder 4
and the boom.

(4), and push out arm cylinder rod pin (E).
: 24mm
Retract arm cylinder rod, and return pin (E) 6

to the original position (hole).
SHIM
After adjustment of shim, the
total gap should be within
E 0.62.0mm (0.020.08in).
BLOCK
SECTION
Fig. 3-6 Detail of arm cylinder rod pin (E)
After adjustment of shim, the total

(7) Removing boom top pin (F)
gap should be within 0.5mm (0.02in).
Loosen capscrew M1225 (5), remove plate
(3) and pull out boom top pin (F).
: 19mm F
Insert pin (F) into the original hole.

5
SECTION
Fig. 3-7 Detail of boom top pin (F)
5
(8) Slinging arm assy

Sling arm with nylon sling and remove it.
Arm weight
Standard spec ; 550kg (1170 lbs)
Fig. 3-8 Slinging arm assy

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 in any circumstances,
but align them visually.
2) Check that the dust seals is not scored and
replace a faulty one if necessary.
3) When inserting the pin, coat the shaft with
grease.
4) Apply Locktite #242 to the pin-securing
capscrews and nuts and fasten them.
Pin lock nut handling procedure
5) When installing the arm and the cylinder,

inspect the clearance in the thrust direction
of the mounts and decide the thickness of
shims by referring to the Maintenance
Standard.
6) Tightening torque Tightening torque
Classification Size
kgfym lbfyft
M12 11.7 85
M-threads
M16 28.5 210
PF,PT
1/8 1.7 12
threads
I6
4. BOOM
4.1 PREPARATION FOR REMOVING AND
ATTACHING BOOM
When removing and attaching boom in the
position shown in Fig.4-1, to remove and
attach boom foot pin (A), removing and
attaching of cab and guard are required.
4.2 REMOVING BOOM

(1) Put the machine in position to remove boom.
Place top end of boom down on block, etc.
giving attention for arm cylinder rod not to be
extended.
BLOCK
Fig. 4-1 Position to remove boom

(2) Lifting up boom cylinder temporarily
Remove the right and left boom cylinders one
side by one side according to the following
procedure:
Lift up boom cylinder temporarily to prevent
it from dropping.
A
STAND
Fig. 4-2 Lifting up boom cylinder temporarily
(3) Removing boom cylinder rod pin (C)

(3), boss (4) and push out pin (C).
After adjustment of shim, the total gap
should be within 0.62.0mm (0.020.08in).
: 24mm
SHIM
3
C 4
(4) Preparing for disconnecting cylinder pipes

Retract boom cylinder rod, and place one side
of cylinder on block. (See Fig.4-2.) 5
SECTION AA
Fig. 4-3 Detail of boom cylinder rod pin (C)
7
(5) Disconnecting piping of arm cylinder and bucket

cylinder
Release pressure in hydraulic tank, and disconnect
pipe at section AA.
: 36mm 18kgfym (130 lbfyft)
41mm 21kgfym (150 lbfyft)
After disconnection of pipe, plug every pipe.
ORS plug : 4-(4)
TO CLAMP
After connecting the

hoses to the body,
clamp them at a point
450mm (17.7in) from
the ARM (R) hose.
Fig. 4-4_Boom piping disconnection

SECTION_AA
VIEW__
(6) Lifting up boom assy temporarily

Lift up boom cylinder with nylon sling so that boom
foot pin (A) is not loaded. Weight of single boom
Standard spec. : 1000kg (2200 lbs)
Fig. 4-5_Boom assy temporary lift up procedure
(7) Removing boom foot pin (A)

After adjustment of shim, the total gap
1) Remove pin (3) and pull out lock pin (2). should be within 0.5mm (0.02in).
2) Draw out pin (A). SHIM
DUST SEAL 2
A
Apply molybdenum added grease

3
in the inner surface of the bushing.
SECTION_AA
Fig. 4-6_Details of boom foot pin (A) section
I-8
(8) Slinging boom assy

Sling and remove boom assy.
Weight of single boom

Standard spec. : 1000kg (2200 lbs)
Fig. 4-7 Boom assy slinging procedure
(9) Completion of removal of front attachments

When the removing and attaching of cylinder A
are not required, the work is finished.
(10) Removing arm cylinder

1) Disconnect hose at A section, and plug both
ends. After adjustment of shim, the
total gap should be within 0.6
ORS plug 4-(4) 1.0mm (0.02 0.04in).
SHIM
: 36mm,
Tightening torque ; 18kgfym (130 lbfyft)
D 2
2) Removing arm cylinder head pin (D)

Loosen nut (3), remove capscrew M16140 (2)
and pull out pin (D).
3
: 24mm
3) Remove arm cylinder.
Fig. 4-8 Removing arm cylinder
(11) Removing boom cylinder

1) Disconnect hose at B section. and plug both B
ends.
ORS plug 4-(4)
: 32mm,
Tightening torque ; 14kgfym (100
lbfyft)
: 36mm,
Tightening torque ; 18kgfym (130
Fig. 4-9 Removing boom cylinder
lbfyft)
I9
2) Removing boom cylinder foot pin (B) After adjustment of shim, the
total gap should be within
(See Fig. 4-10) 0.6~1.0mm (0.02~0.04in).
Loosen capscrew M16 30 (6) and plate (7) SHIM
and pull out pin (B).
: 24mm
B
3) Remove boom cylinder (02).
4) Remove other boom cylinder in the same way. B
6,7
SECTION BB
Fig. 4-10 Removing boom cylinder head pin (B)
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.
B
z When aligning the pin holes, do not
put your finger in the pin holes in B
any circumstances, but align them
B
visually.
z Check that the dust seals is not Fig. 4-11 Boom foot pin (A),
scored and replace a faulty one if boom cylinder head pin (B)
necessary.
z When inserting the pin, coat the
shaft with grease.
z M16 Tightening torque : 28.5kgfym
(210 lbfyft)
z Pin lock nut handling procedure
I10
1. CYLINDER
1.1 PREPARATION BEFORE DISASSEMBLY (2) Work bench
Before assembly, secure a dustfree workshop and The work bench must have strength and
necessary equipment and facilities. rigi-dity capable of accommodating the total
length of the cylinder in its most retracted
1.1.1 WORK AREA condition and of withstanding the repulsive
The following working area is required for force of the tightening torques of the cylinder
disassembly: head and the piston nut. Since a vise is
(1) Ample space attached to the bench, the width of the work
For the disassembly of the hydraulic cylinder, bench must be sufficiently large.
the cylinder tube and the piston rod must be (3) Support stand
drawn out. For this reason, the first condition If the clevis part of the piston rod is fully
is that the working area is long enough for extended in a free condition, the bushing and
the work. In terms of width, it is also the seals may be damaged as the rod bushing
necessary to keep sufficient space so and the piston are twisted due to the weight
disassembly, cleaning and measuring of the rod. A stand is required to support the
equipment are placed and the work can be rod to prevent such.
performed. (4) Hydraulic source
(2) Suitable working environment A Hydraulic source is required for
The hydraulic cylinder is a disassembly and assembly of the cylinder
precision-machined product that uses seals head and piston nut and for oil leak tests
and packings made of rubber and plastic after completion of assembly.
materials. For this reason full care should be (5) Jet air source
exercised so the hydraulic cylinder is free It is used for drying after oil draining and
from dust, dirt, and in particular, such hard cleaning of the cylinder.
particles as sand, metal chips, and weld slag (6) Cleaning bath, cleaning oil and detergent
(spatter). If the hydraulic cylinder is (7) Oil pan and oil reservoir
assembled with hard particles adhered on An oil pan is necessary to contain oil drained
such components as the cylinder tube and the from the cylinder and oil spilt during work.
piston rod, the tube inner surface and the rod An oil reservoir is required to collect oil spilt
surface are scratched as the cylinder on the floor and waste oil.
operates, consequently disabling it in worst (8) Others
cases. Damage to the piston seals and the rod Oil extracting hoses, wooden skids, rag and
seals will result in oil leaks. For this reason, sawdust in which oil soaked are also
grinding and welding operation should not be necessary.
performed in the neighborhood of the working
area to keep it clean
1.1.2 APPARATUS
The following equipment are required for
disassembly:
(1) Hoist or crane
The hoist or crane must be capable of
carrying the cylinder in an assembled
condition. It must also be capable of marking
level and liner movement under load for
retracting and extending the piston rod and
the tube.
11
1.1.3 NECESSARY TOOLS

Tools and jigs vary with types of cylinder, but it is
necessary to prepare the tools in Table 1-1 as a
guideline.
Table 1-1 List of Tools and Jigs
Tool / Jig Remarks Tool / Jig Remarks

Hammer 1. Steel hammer Spatula Metallic one with smooth
2. Wooden or plastic mallet corners.
Screwdriver A few types of large and small sizes Jig 1. For fitting piston seals C
Chisel Flat chisel 2. For hodling in slipper seals D
Vise One having an operation wide 3. For inserting piston rod bushing
enough to hold cylinder head O.D. A
and tube mounting pins (clevis) 4. For pressing in dust seal E
Wrench 1. Hook wrench 5. For pressing piston seal G
2. Allen wrench Rust remover
3. Extension pipe for wrenches
Measuring 1. Slide calipers
Gimlet A sharp-point tool may be used in instruments 2. Micrometer
place of a gimlet. 3. Cylinder gauge (Fig. 1-1)
4. V-block
z For the details of special tools and

jigs, refer to the end pages of this
article.
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 Fig. 1-1 Cylinder gauge
soil and contamination from the cylinder with
water and steam before bringing it into the WOODEN
workshop. BLOCK
z The following describes the

PORT B
construction of boom cylinder (with V BLOCK
cushions on both sides). When
disassembling and servicing the
cylinder, confirm the construction of
cylinder referring to Parts Manual.
1.1.5 DISCHARGING OIL

Place a wooden-block on the work bench and PORT A
mount the cylinder on it to prevent it from AIR
rotating. Charge air into ports A and B
alternately to actuate the piston rod till the
OIL PAN
hydraulic oil in the cylinder is drained out. At this
time, connect a suitable hose to each port so that Fig. 1-2 Discharging oil
the hydraulic oil may not gush out.
12
1.2 CONSTRUCTION OF CYLINDER (AN EXAMPLE OF BOOM CYLINDER)

T=Tightening torque ; kgfym (lbfyft)
(4.13-0.0197)
(4.13 -0.0197 )
0
660 (26.0) B
0
105 -0.5
105-0.5
0
0
M12 x1.75 (Through)

24 25 25 24
27
SLIT
26
BLACK 28,2
GREEN
T=3.2(23)
(1 place)
DETAIL C
T=27.2(200) T=421(3000) T=5.8(42)
9 8 7 6 3 4 5 12 10,11 2 1 13 14 15 16 17 18 19 20 21 22,23
SLIT
Fig. 1-3 Construction of boom cylinder

(The figure shows the right-hand cylinder.)

II13
1.3 DISASSEMBLY
z When disassembling and servicing

the cylinder, check the construction
and the availability of service parts
as well as necessary tools and jigs on
separate Parts Manual.
z The figures in parentheses after part
names correspond to those in
Fig.1-3.
z The explanations and quantities
below are for a boom cylinder. Apply
the same to other cylinder as well.
1.3.1 REMOVING CYLINDER HEAD AND PISTON

ROD
1) Hold the clevis section of the tube in a vise.
Use mouth pieces so as not to damage

the machined surface of the cylinder
tube. Do not make use of the outside
piping as a locking means.
2) Pull out piston rod (2) about 200mm (8in).

Because the piston rod (2) is heavy, finish
extending it with air pressure after the
above-mentioned oil draining operation.
2
3) Loosen and remove socket bolts (12) of the Fig. 1-4

cylinder head in sequence.
ALLEN WRENCH 12
: 14mm
Cover the extended piston rod (2) with rag

to prevent it from being accidentally Turn counterclockwise
damaged during operation.
4) Strike the corner of the cylinder head flange 3

by means of a plastic mallet till cylinder head Cover here with rag.
2
(3) comes off.
Fig. 1-5
14
z At this time, the weight of piston rod

KNOCK THIS EDGE
(2) is loaded on cylinder head (3). WITH A PLASTIC
LIFT HERE.
Therefore, lift the top end of the MALLET.
piston rod with a crane or something
to the extent that only the rod
weight may be held.
1
5) Draw out the piston rod assy (2) from

cylinder tube (1). 3
2
Fig. 1-6 Drawing out piston rod assy (2).
Since the piston rod assy is heavy in
this case, lift the tip of the piston rod
LIFT HERE. 1
(2) with a crane or some means and
draw it out. However, when piston rod PULL
STRAIGHT
(2) has been drawing out to SIDEWAYS
approximately two thirds of its length, HORIZONTALLY
lift it in its center to draw it
completely. However, since the plated
surface of piston rod (2) is lifted, do not
use a wire rope or something which OIL PAN
may score the surface, but use a strong Fig. 1-7 Method of drawing out the piston rod
cloth, a belt or a rope. assy
6) Place the removed piston rod assy on a

wooden V-block that is set level.
PISTON ROD ASSY
z Cover a V-block with rag.

WOODEN V-BLOCK
(PLACE RAG.)
Fig. 1-8 Method of placing the piston rod

7) Remove slide ring (18),(19) and back-up ring 15
(17) from piston (15).
TAKE IT OFF BY WIDENING
THE SLIT TOWARD
THE ARROW
17
18,19
Fig. 1-9 Remove slide ring (18),(19) and

back-up ring (17)
II15
1.3.2 REMOVING PISTON ASSY 3 WOODEN

1) Fix piston rod (2) by holding its clevis section 2 PIECE
in a vise. Fix the piston rod (2) rigidly as 15
piston nut (21) is tightened to a high torque.
21
z 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.
z It is also necessary to place a
suitable supporting block near the
piston (15). In case a V-block is used,
WOODEN V-BLOCK
put rag or something over the rod to (PLACE RAG.)
prevent it from being scored
Fig. 1-10 How to loosen piston nut (21)
2) Scrape off the caulked part of setscrew (22) of
piston nut (21) by means of a hand drill and
22 DRILL
loosen and remove setscrew (22).
: 6mm
21
23
Fig. 1-11 Removing setscrew (22), ball (23)

3) Loosen and remove piston nut (21).
Since piston nut (21) is strongly

tightened, use a ring spanner most
suitable with the outside diameter of
piston nut (21) and also use a power TURN
wrench equipped with hydraulic jack COUNTER
CLOCKWISE.
and hydraulic cylinder. 15
HOOK
WRENCH 21
Fig. 1-12 How to loosen piston nut (21)

4) Strike it lightly with plastic hammer and
remove it while supporting piston (15).
2 15
Fig. 1-13 Removing piston (15)
16
5) After removing cushion bearing (13), remove

LIFT WITH A CRANE.
cushion seal (14) and remove cylinder head STRIKE WITH
(3) from piston rod (2). If it is difficult to slide A PLASTIC MALLET.
PULL STRAIGHT.
it, strike the flange section of cylinder head
(3) with plastic hammer and slide it. And NOTE:
then hang cylinder head (3) with crane and DO NOT
DAMAGE
pull it out horizontally. PISTON ROD
SURFACE.
Take care so bushing (4) and the lip of
pistons (6), (7), (8), (9) may not be
damaged by screw the piston rod (2). 3 4 6 8,7 9 2
Fig. 1-14 Removing cylinder head (3)
1.3.3 DISASSEMBLING PISTON ASSY

1) Remove seal ring (16) and buck-up ring (17). HAMMER
Cut the seal ring (16) by tapping it

SCREWDRIVER (OR CHISEL)
with a screwdriver or a chisel. Take
care not to strike it too hard, otherwise
the groove may be damaged. BACK-UP RING
17 SEAL RING
16
15 USE CARE NOT O RING

TO DAMAGE
THE GROOVE.
Fig. 1-15 Removing seal ring (16) and back-up

ring (17)
II17
1.3.4 DISASSEMBLING CYLINDER HEAD ASSY SPATULA

1) Remove O ring (10) and back-up ring (11)
extending them with a spatula like an 10
earpick.
11
Fig. 1-16 Removing the outer circumferential

2) Remove buffer ring (6), U ring (7) and seal of cylinder head (3)
back-up ring (8). Each seal is fixed in the GIMLET
groove on the bore and removing in flawless
is impossible.
Stab each seal with a gimlet and pull it out of 8
the groove. 3 7
Take care in this operation not to 6

damage the grooves.
Fig. 1-17 Removing the inner circumferential

seal of cylinder head (3)
HAMMER 3
3) Remove wiper ring (9). When taking out
SCREWDRIVER
wiper ring (9), fix cylinder head (3) in a vise.
WOOD PIECE
WOOD PIECE
VISE
Fig. 1-18 Removing wiper ring (9)
5 4
4) Remove snap ring (5) and bushing (4). After
taking out snap ring (5) in the same way as 3
mentioned above, remove rod bushing (4).
Bushing (4) is impossible to remove as it is
press fitted in cylinder head (3). Machine the
bushing thin on a lathe, insert a steel
WOOD PIECE WOOD PIECE
spatula hard into the gap at the chamfered
edge of the remaining bushing and pry it up. VISE
Center the work on a lathe sufficiently

so the bushing may be shave on a lathe
as thin as possible. Fig. 1-19 Removing rod bushing (4)
18
1.3.5 REMOVING PIN BUSHING PUSH WITH A PRESS.

Cylinder tube (1) is pressed hard in the pin
METAL PIECE
bushing (24) of piston rod (2). When (JIG A)
disassembling them, use the jig A and push the

rod with a press.
24
BASE
Fig. 1-20 Drawing out pin bushing (24)
1.4 CLEANING
1) When the cylinder has been disassembled,
wash all parts with a suitable commercial
detergent.
Do not use volatile agents (gasoline

and thinner) as they deteriorate
rubber.
2) Do not reuse the once-removed oil seals, O

rings and back-up rings even though they
have found reusable on inspection.
3) After cleaning, dry all parts with jet air and
place them on a clean work bench so that
they may not be damaged.
1.5 ASSEMBLY
Start assembly with the subassemblies listed
below:
Cylinder tube assy
Piston assy
Cylinder head assy
PUSH WITH A PRESS
2
1.5.1 INSTALLING PIN BUSHING 24
Press fit pin bushing (24) into cylinder tube (1)
and piston rod (2), using a press.
OIL HOLE LOCATION
Fig. 1-21 Pressing fit pin bushing (24)
19
1.5.2 ASSEMBLING PISTON ASSY PRESS HERE

1) A special jig shown in Fig. 1-22 is required to METAL
fit seal ring (16). Push seal ring (16) in by
means of a press and using the pressing jig
that is shown in the figure.
(Fit O ring of seal ring (16) and back up ring
HOLDING
(17) on one side in advance.)
JIGD
The slipper seal softens if heated, but

do not heat it above 100 (212.0 F) in
any circumstance.
JIGC
2) Fit back-up ring (17) on other side. After

fitting, press it for 2 or 3 minutes with 15
pressure jig G as shown in Fig. 1-23.
16
z After fitting the seal ring (16), wind 17
vinyl tape a few turns around the
slipper seal and do not take it off Fig. 1-22 Installing seal ring (16)
immediately before piston (15) is set
HOLDING JIG G
in cylinder tube (1). for piston seal.
z Attach slide ring (18), (19) when
inserting piston (15) into cylinder
tube (1).
HANDLE
Fig. 1-23 Installing seal ring (16)

1.5.3 ASSEMBLING CYLINDER HEAD ASSY
PRESS HERE. (STRAIGHT DOWN)
1) Press bushing (4) into cylinder head (3) using
METAL
a metal ring. There after fix snap ring (5) into (MAKE O.D.SMALLER
4
the groove. Before pressing in the bushing, THAN ROD
coat the inner face of cylinder head (3) with BUSHING O. D.)
hydraulic oil. GROOVE FOR
FIXING SNAP RING (5)
Snap ring (5) can be pushed in by

hand, but it can not be set in place PRESS BUSHING TILL
unless bushing (4) is press fitted full to BUSHING COMES IN
3 CONTACT WITH
the stop surface. THIS FACE.
2) Apply grease to wiper ring (9) or the hole of Fig. 1-24 Pressing in bushing (4)
cylinder head (3), and fit wiper ring (9) to the PRESS HERE. (STRAIGHT DOWN)
bottom of the hole. At this moment, press the
metal ring of wiper ring (9) with a jig E. PRESSING PRESS METAL
JIGE RING.
METAL RING RUBBER

LIP
Fig. 1-24 Pressing in wiper ring
110
3) Fit buffer ring (6), back-up ring (8) and U PUT IN GROOVE FROM THIS SIDE.
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.
Fig. 1-26 Inserting a seal into the inner

circumference of cylinder head.
PUSH BAR
z U ring (7) is harder than other
(WOOD OR PLASTIC)
packing and it would be difficult to
deform them in a heart shape. In 10
such a case, put a rod packing in the 11
groove obliquely by hand as deep as
3
possible and push in the last part
with a push bar till it is set with a
click.
z Buffer ring (6) have directions in
which they should be fixed.
Therefore check their fitting
directions.
z If U ring (7) is set upside down, the
lip may be damaged. Check that it is
6
positioned correctly Fig. 1-27.
z Attach backup ring (11) on the open 7
air side of O ring (10). 8
Open air side
9
Fig. 1-27 How to fit U ring (7)
1.5.4 INSERTING CYLINDER HEAD ASSY TO
PISTON ROD
Inserting the cylinder head (3) to the piston rod
assy as follows:
1) Fix the piston rod assy into the work bench.
111
2) Apply hydraulic oil or grease to the O. D. of 3 LIFT WITH A CRANE

piston rod (2), the bore of packings (6,7,8,9)
and bushing (4). Hold the cylinder head CYLINDER HEAD
PRESS IN.
carefully and slide it over piston rod (2),
taking care not to damage the lip of dust
wiper ring (9). It may be difficult in some
cases to slide the cylinder head over the
TURN
piston rod (2) because of the resistance of U CLOCKWISE.
ring (7), buckup ring (8) and buffer ring (6).
In such a case, force it in, using a suitable
plate and piston nut (21), (See Fig. 1-28.) In
this operation, hold the cylinder head
horizontally with a crane. 21 AUXILIARY PLATE 4 6 7,8 9 2
3) After lifting cylinder head (3) to the level FOR PUSHING
where it is pressed by piston nut (21), remove Fig. 1-28 Inserting cylinder head
piston nut (21) and the plate. Press in the
cylinder head about 300mm (12in) further. In
some cases, the cylinder head must be
pressed into piston rod (2) by striking the
flanged part of cylinder head (3) with a
wooden or plastic mallet.
During the above operation, use care so

not to allow the cylinder head to turn
with respect to piston rod (2).
1.5.5 ASSEMBLING PISTON ASSY TO PISTON

ROD
1) Fit cushion seal (14), insert cushion bearing
(13), and install the piston assy on piston rod
(2). 14 13 2
2) Apply hydraulic oil or grease to the inside of

the piston assy and to the piston mounting
part of piston rod (2). Then install the piston
assy as shown in Fig. 1-29.
TURN
CLOCKWISE. V-BLOCK
PISTON ASSY HOLD THE POINT AS

CLOSE TO THE PISTON
AS POSSIBLE.
Fig. 1-29 Tightening piston assy
112
3) Place shim (20) in, screw piston nut (21) in,

and tighten it. Always tighten the piston nut
(21) to a specified torque (Refer to-1-16.)
21
Always correct the threads of the HOOK WRENCH

tapped hole in piston nut (21) before
fixing piston nut, using a tap.
TURN CLOCKWISE.
4) Place steel ball (23) in and screw set screw Fig. 1-30 Tightening piston nut (21)
(22) in.
22 ANTI-LOOSENING CAULKING
20 2
: 6mm 23
5) After tightening the setscrew to a specified

torque of 5.8 1.1kgfym (42 7.9 lbfyft),
caulk the two places of the thread of the
piston nut side to secure the setscrew.
6) Fit slide rings (18), (19). Remove vinyl tape V-BLOCK

around piston (15), apply quality grease (or 13
vaseline) on slide rings (18), (19) and wind Fig. 1-31 Attaching setscrew (22)
and fit it around the groove. 22 18 19
Shift it 90 degree in order that the slits are 2
not on the same axis.
21 V-BLOCK
Fig. 1-32 Attaching slide ring (18)

1.5.6 OVERALL ASSEMBLY
1) Place a V-block on a rigid work bench (A
wooden V-block is preferable.). Place the
cylinder tube assy (1) on it and fix the assy by
passing a bar through the clevis pin hole to
1
lock the assy.
2) Insert the piston rod assy into the cylinder
tube assy, while lifting and moving the piston LIFT
rod assy with a crane. 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 STRAIGHT FIX IT WITH A BAR
of the piston rod assy with the center of the (A WOODEN ONE
cylinder tube assy and put it in straight PREFERABLE)
OR IN A VISE.
forward.
When inserting, make sure that slide ring Fig. 1-33 Inserting piston rod assy
(18), (19) on the perimeter of the piston is
not out on the groove.
113
3) Turn up socket bolt (12). Match the bolt holes

of the cylinder head flange to the tapped
holes in the cylinder assy, and screw in
socket bolts (12) one by one. Tighten the bolts
to a specified torque, taking care so the bolts 12
may not be tightened unevenly.
PLACE RAG.
:14mm,
Tightening torque :
Take care so as not to damage the rod

surface by accidentally slip a wrench.
Covering the rod surface with rag is
recommended to prevent damage to it. TORQUE WRENCH
For the tightening torques, refer to TURN
(-1-16). CLOCKWISE.
Fig. 1-34 Tightening socket bolts (12)

1.6 INSPECTION AFTER ASSEMBLY
(1) No-load functional test
Place the cylinder level at no load, operate DIRECTIONAL VALVE
the piston rod 5 to 6 strokes by the PUMP
directional valve and make certain that it
operates without fault.
z Do not raise the hydraulic pressure H R

above the maximum pressure of
385kg/cm2 (5470psi) for the cylinder
of the machine.
z Grease coated on the O rings and the HYDRAULIC CYLINDER
seals of the cylinder head may ooze Fig. 1-35 External leak test
out. Wipe it off and retest the
cylinder head in such a case.
(2) Leak test (See Fig. 1-36) MEASURE THE

1) Apply a test pressure to the retracting and INTERNAL LEAK.
extending sides of the cylinder for three
minutes independently, and check that the
rod section and the welds have external leaks
and permanent deformation. For an internal
leak test, connect the cylinder with a test
unit . FROM DIRECTIONAL VALVE
Fig. 1-36 Internal leak test
2) After completing the test, apply a plug to
CYLINDER ASSY
each port and store it (Fig. 1-37).
For storage, place the cylinder on

wooden V-blocks and bring the cylinder
to the most retracted condition.
PLUG PLUG
Fig. 1-37 How to store the cylinder
114
1.7 MAINTENANCE STANDARDS

1.7.1 INSPECTION AFTER DISASSEMBLY
Visually inspect all parts after cleaning to see
that excessive wear, crack and other faults that
are detrimental to use are not present.
(1) Inspection Item

Table 1-2
Part Name Inspecting Section Inspection Item Remedy
Piston rod 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
5. Bend Measure degree of bend Refer to Table 1-3.
(See Fig. 1-38.)
6. Plated surface Check that:
1) Plating is not worn off 1) Replace or replate
to base metal
2) Rust is not present on 2) Replace or replate
plating.
3) Scratches are not 3) Recondition, replate or
present. replace.
7. Rod Wear of O. D. Recondition, replate or replace.
8. Bushing at mounting Wear of I. D. Replace.
part
Cylinder 1. Weld on bottom Presence of crack Replace.
tube 2. Weld on head Presence of crack Replace.
3. Weld on hub Presence of crack Replace.
4. Tube interior Presence of faults Replace if oil leak is seen.
5. Bushing at mounting Wear on inner surface Replace.
part
Cylinder 1. Bushing 1) Wear on inner surface 1) See para. 1.7.2.
head 2) Flaw on inner surface 2) Replace if flaw is deeper than
coating.
(2) Repair method

Check all seals and parts to see that they do z Always regrind after replating. The
not show excessive damage and wear. For thickness of the plating must be
co-rrection of faults on the piston rod, observe maximum 0.1mm (0.004in).
the following procedure: z In case plating is removed to the
1) Correct very fine longitudinal scratches with base metal during reconditioning
an oilstone. Replace the piston rod if the with an oilstone, do not fail to
scratch is so deep as may be caught by your replate the surface.
nail.
2) In case of a smooth indention, recondition by
removing the sharp area around the
inden-tion with an oilstone. If the flaw or the
in-dention is excessive, replace or replate the
faulty part.
115
1.7.2 LIMIT OF SERVICEABILITY 1.7.3 TIGHTENING TORQUE

Serviceability limits represent the limits of wear
A B
on the sliding surfaces of the cylinder tube and
the rod that have no such faults as may degrade
the sealing effect.
(1) Clearance between piston rod and rod
bushing
Replace the bushing if the clearance between Fig. 1-39
the piston rod and the rod bushing exceeds
0.25mm (0.01in). Table 1-4 Unit : kgfym (lbfyft)
(2) Bend of piston rod A B
Cylinder
The allowable bend of the rod is maximum Piston nut Socket bolt
1mm / 1m (0.04/33). For measurement, 421 27.2
support both ends of the parallel section of Boom
(3050) (200)
the piston rod with V-blocks, set a dial
indicator in the middle between the two 837 27.2
Arm
V-block turn the piston rod, and read the (6050) (200)
difference between the maximum and
minimum oscillations on the dial indicator. 491 17.4
Bucket
(3550) (130)
1.7.4 VOLUME OF OIL LEAKAGE

The oil leak rates as mentioned in 1.6 (2) of
Ins-pection after Assembly are as shown in Table
Middle of rod
1-5.
Table 1-5
Fig. 1-38 Measuring Method
Cylinder Volume of Internal Oil Leakage
Table 1-3 shows an example of measurement.
Boom 1 cc (0.06 cuyin) or below / 3min
Arm 1 cc (0.06 cuyin) or below / 3min

Table 1-3 Example of Measurement
Oscillation of the dial Bucket 1 cc (0.06 cuyin) or below / 3min

Distance
between indicator in the middle
Remedy
V-blocks of the rod.
m (in) mm (in)
1 (33) 1 (0.04) Replace
Even if the bend is within the above

limit, the cylinder may not operate
smoothly because of localized bend.
Beware of it during function test after
assembly. Replace the rod if the
cylinder makes a squeaking noise or
dose not operate smoothly.
116
1.8 TROUBLESHOOTING Table 1-6

Trouble Faulty Part Cause Remedy
1. Oil leakage through 1. Rod packing 1. Foreign matter is 1. Remove foreign matter.
sliding surface of piston included in the bore of
rod oil ring is formed on rod packing
piston rod, and the ring 2. Lips on outer and inner 2. Replace rod packing.
grows up to oil drops, diameter surfaces of rod
and they drip. packing are scored.
3. Other rod packing are 3. Replace rod packing.
faulty.
2. Buffer seal 1. Foreign matter is caught 1. Remove foreign matter.
in the bore of buffer seal.
2. Flaw is present on the 2. Replace buffer seal.
bore of buffer seal.
OIL LEAKS FROM HERE. 3. Other buffer seals are 3. Replace buffer seal.
faulty.
3. Dust seal 1. Foreign matter is include 1. Remove foreign matter.
in the bore of dust seal.
2. Lip on the bore of dust 2. Replace dust seal.
seal is scored.
3. Other dust seals are 3. Replace dust seal.
faulty
4. Piston rod 1. Flaw is present on the 1. Smooth out the sliding
sliding surface of piston surface with an oilstone.
rod. 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 leakage will not stop by
that treatment, replace
piston rod.
2. Hard chromium plating 2. Replate.
has peeled off
2. Oil leaks from the 1. O ring 1. O ring is damaged. 1. Replace O ring.
perimeter of cylinder 2. Back-up ring 1. Backup ring is damaged. 1. Replace backup ring.
head
OIL LEAKS FROM HERE.

3. Oil leaks from welds. 1. Cylinder 1. Welds of cylinder are 1. Replace cylinder tube.
tube fractured.
WELDS
4. Cylinder falls by it-self. 1. Piston seal 1. Foreign matter is caught 1. Remove foreign matter.
[When the rod is loaded on the sliding surface of
with a static load equal slipper seal
to the maximum 2. Flaw is present on the 2. Replace slipper seal.
working pressure sliding surface of slipper
multiplied by the area seal.
of the cylinder bore, the 3. Other back rings are 3. Replace back ring.
maximum movement of faulty.
the piston is more 2. Wear ring 1. Sliding surface of wear 1. Replace wear ring.
than 0.5mm (0.02) in rings is scored.
ten minutes.] 3. O ring 1. O ring is scored. 2. Replace O ring.
117
1.9 TOOLS AND JIGS LIST

The tool and jig list provides the materials and
the dimensions of tools and jigs so that they may
be utilized in manufacturing in a service shop.
Follow the directions given below in selecting,
manufacturing and using the tools and jigs.
1) For the cylinder head, piston nut and others

that require large tightening torques, use eye
wrenches (symbol FS) as much as possible.
The tools and the jigs are so designed
dimensionally that they can withstand the
maximum tightening torques even if material
SS400 (JIS) is used. However, the hook of the
tool (symbol PS) may be distorted if struck
with a hammer. If such occurs, apply
reinforcement weld and finish it by grinding.
1.9.1 ALLEN WRENCH (AW)

(For cylinder head socket bolt)
(For nut setscrew)
B
A MATERIAL : SNCM 6 OR SCM 3
SURFACE TREATMENT : PARKERIZING
C
Fig. 1-40
Table 1-7 Unit : mm (inch)

Cylinder Used A B C Socket Bolt
Boom, Arm 140 (5.51) 56 (2.20) 14 (0.55) M16
Bucket 125 (4.92) 45 (1.77) 10 (0.39) M12
Boom, Arm, Bucket 90 (3.54) 32 (1.26) 6 (0.24) M12 (setscrew)
1.9.2 DUST SEAL PRESSING JIG [SYMBOL E]

(For cylinder head)
D
E
A MATERIAL : SS41
SURFACE TREATMENT : PARKERIZING
B
15 C
Fig. 1-41
Cylinder Used A B C D E
77.5 88
Bucket (3.05) (3.47)
50~70 82.5 93 20~30 8
Boom (1.97~2.76) (3.25) (3.66) (0.787~1.18) (0.315)
92.5 103
Arm (3.64) (4.06)
II118
1.9.3 WRENCH FOR PISTON NUT
B Cylinder used
95 (3.74) Arm
85 (3.35) Boom
80 (3.15) Bucket
B
Fig. 1-43 Wrench for piston nut
119
1.9.4 BUSHING EXTRACTION JIG (SYMBOL A)

(For clevis)
Fig. 1-43

Cylinder Used d D
Bucket
80 (3.15) 89 (3.50)
Arm
Boom 85 (3.35) 100 (3.94)
1.9.5 PISTON (SLIPPER) SEAL FIXING JIG

(SYMBOL C)
Fig. 1-44
Cylinder Used d D1 D2 Q L
Bucket 104.6 (4.12) 106 (4.17) 80 (3.15) 23 (0.906)
Boom 114.6 (4.51) 116 (4.57) 90 (3.54) 24 (0.945) 65 (2.56)
Arm 124.6 (4.91) 126 (4.96) 100 (3.94) 26 (1.02)
II120
1.9.6 SLIPPER SEAL HOLDING-DOWN JIG MATERIAL : NYLON

(SYMBOL D)
O RING
Fig. 1-45
Cylinder Used D O ring

Bucket 105 (4.13) 1B P105
Boom 115 (4.53) 1B P115
Arm 125 (4.92) 1B P125
1.9.7 SLIPPER SEAL HOLDING-DOWN JIG

(SYMBOL G)
HARD CHROMIUM PLATING
MATERIAL : SS41
Weld it before
d lathed
Fig. 1-46
Cylinder Used d D L
Bucket 105 (4.13) 120 (4.72)
40 (1.58)
Boom 115 (4.53) 130 (5.12)
Arm 125 (4.92) 140 (5.51) 50 (1.97)
II121
E200SR
SECTION 33 UPPER STRUCTURE
TABLE OF CONTENTS
[Part I. Removing and Installing Assy]

1. CAB .......................................................................................................................... I-1
2. OPERATOR SEAT .................................................................................................... I-2
3. BATTERY ................................................................................................................. I-3
4. GUARD..................................................................................................................... I-4
5. UNDER COVER ....................................................................................................... I-9
6. FUEL TANK ............................................................................................................. I-10
7. HYDRAULIC TANK ................................................................................................. I-11
8. HYDRAULIC PUMP ................................................................................................ I-14
9. AIR CLEANER ........................................................................................................ I-18
10. MUFFLER ............................................................................................................. I-19
11. COUNTERWEIGHT .............................................................................................. I-20
12. RADIATOR & OIL COOLER ................................................................................. I-21
13. ENGINE ................................................................................................................ I-25
14. INSTRUMENT PANEL ........................................................................................... I-27
15. CONTROL VALVE ................................................................................................ I-28
16. PILOT VALVE (FOR ATT) ..................................................................................... I-30
17. PILOT VALVE (FOR TRAVEL) ............................................................................. I-31
18. SWING MOTOR UNIT .......................................................................................... I-32
19. SWIVEL JOINT ..................................................................................................... I-34
20. UPPER FRAME .................................................................................................... I-37

1. PUMP ...................................................................................................................... II-1
2. CONTROL VALVE ...................................................................................................II-2
3. PILOT VALVE (FOR ATT) ........................................................................................II-3
4. PILOT VALVE (FOR TRAVEL) ................................................................................ II-4
5. SWING MOTOR UNIT ............................................................................................. II-5
6. SWIVEL JOINT........................................................................................................ II-6
1. CAB Rotate 90 degrees to remove.
GROMMET BOLT (25-9)

COVER
1.1 REMOVAL 24
(1) Remove floor mat
(2) Remove the following parts for air-con cover. 14 CATCH (24)
BRACKET
1) Five bolts (25-9) for catch (24)

2) Cover (25-14) assy 25-14
GRILLE
3) Grille under front seat
4) Duct from duct (14) to under right duct on
cab inside.
: Cross recessed screw driver FLOOR MAT
: 13mm
Fig. 1-1 Detaching and attaching air conditioner cover
(3) Remove the following parts for harness and
connector.
1) Antenna cable from back side of tuner HARNESS FOR ROOM LAMP HARNESS
HARENSESS
2) Harness for room lamp FOR
GROMMET
3) Harness on cab front right side WINDOW
WASHER
4) Harness for gauge cluster
DOOR SW.
(4) Remove window washer tube ANTENNA
(5) Remove the following parts for cab mounting

bolt
GROMMET
1) Five capscrews (A1)M10 (Fig. 1-2 Mark U) To instrument panel
2) Four nuts M16 (Fig. 1-2 Mark c) CONNECTOR

HAND RAIL
: 17mm, 24mm FOR TUNER GROMMET
B2
(6) Slinging cab A1
M105pcs TUBE
Remove washer
1) Remove two plastic plugs on front side of cab tube at connector
ceiling, and attach eye bolts M10, and hook TUBE
wire three places, two bolts and lifting eye, on
rear left side.
2) Then lift up slowly avoiding interference with NUT
surroundings. M164 pcs.
Wire with hook ;
Length 1.5m (4ft 11in) Dia. 8mm (0.315in) Fig. 1-2 Removing and attaching harness
3pcs. connector and cab mounting bolts
Weight of cab ; Approx. 180kg (400 lbs)
1.2 INSTALLATION
M10 EYE BOLT
Mount it in reverse procedure of Dismounting
according to the Tightening Torque Table.
Tightening torque
Tightening position Tool kgfym (lbfyft) A1
Nut M16 24 19.5 (140)
Capscrew (A1) 17 4.7 (34)
Fig. 1-3 Slinging cab

I 1
2. OPERATOR SEAT
2.1 REMOVAL
(1) Remove seat. (Include upper rail.)
1) Remove four M8 capscrews (15) in the upper
rail.
2) Remove seat
[Approx.15kg (33 lbs) with upper rail]
: 6mm
(2) Remove slide on lower rail of seat.

M816 SEAT
1) Remove four capscrews (15)M8.
15
2) Remove support (4).
4) Remove lower rail (3).
: 6mm
(3) Remove seat stand (1)

2) Remove seat stand (1).
4 UPPER RAIL
: 8mm
Weight of seat stand ; 17kg (37 lbs)
2.2 INSTALLATION 15
Install it in reverse procedure of removing
LOWER RAIL
3 M816
according to the tightening torque table.
Allen Tightening torque

Tightening position wrench kgfym (lbfyft)
HEX
Capscrew (9) 8 4.7 (34) M825
M830 18
Capscrew (15) 6 2.4 (17) M816 13
15
PLATE
Reference : Movement on rail 9 (STOPPER)
M1025 1
Upper rail Fixed on lower surface of seat
(Forward 80, backward 80)
Lower rail Fixed on seat stand.
Height adjustment lever (L.H)
Seat raise 23mm (0.91inch)
Seat lower 37mm (1.5inch)
Floor plate
Fig. 2-1 Dismounting and mounting seat
2
3. BATTERY
3.1 REMOVE
RIGHT COVER
(1) Open right cover.
1) Open it with starter key.
2) Open cover.
3) Fix it with stay.
4) Remove rubber (A7). (See Fig.3-3)
(2) Remove right front deck cover (See Fig.4-8)

1) Remove seven sems bolts (36) M12.
2) Remove deck cover.
: 19mm
(3) Remove battery cable RIGHT FRONT DECK COVER

1) Remove M8 nut (7). Then disconnect cable (4) Fig. 3-1 Preparation for removing battery
across ground and battery (). (Always remove
() terminal first and install it at last.)
2) Cable (3) (between battery (+) and ())
3) Cable (2) (between battery (+) and battery relay) 2
: 13mm 4 BATTERY RELAY
7 3
Follow the battery removal order.
Start removing battery from grounding
side, and finish attaching to grounding
GND
side. If this order is missed,
short-circuits may occur.
(4) Remove battery (B1)

1) Remove four capscrews (A3) M10.
: 17mm Fig. 3-2 Remove battery cable
2) Remove supports (A1), (A2). A3
3) Remove battery (B1). A7
A1
3.2 INSTALL A2
(1) Install the battery in the reverse procedure of
removing.
B1
Battery attaching capscrew (A3)
: 17mm,
Tightening torque : 1.1kgfym (8.0 lbfyft)
(2) Installing grounding cable

Install grounding cable last. Especially care
must be taken that the grounding face is free
from painting, rust, etc.
: 13mm
Fig. 3-3 Removing battery
3
4. GUARD
4.1 PREPARATION FOR REMOVAL 11 2,3
(1) Remove guard in the following procedure. 1-2 18
1-1
When removing the components remove only
the guards that are required for removal. The
4
order of removal of the engine : (4), (5), (9), 52,83
and (10) 14,25,53,54
9
8
(2) All the locked cover, open them using starter
key. 17
7
91 10
5
Fig. 4-1 Arrangement of guard assy

4.2 REMOVE GUARD (The figures represent the item numbers)
(1) Remove cover assy (11)
1) Unlock cover assy (11) and lift it up
2) Remove stay for stopper. 11
36
3) Remove gas spring.
4) Remove two sems bolts (36) M1230.
5) Remove cover assy (11).
: 19mm
Weight : 18kg (39 lbs)
HINGE
Fig. 4-2 Removing cover assy (11)
(2) Remove panel assy (2), (3)
1) Remove two sems bolts (37) M1025 and 37
open the panel assembly.
2
: 17mm 3
80
2) Remove two nuts (70) M12.
3) Remove panel assy (2).
: 19mm
4) Remove three sems bolts (36) M12 30, a
capscrew (80) M1230 and panel assy (3). 36
: 19mm 36
Weight : 15kg (33 lbs) 70
Fig. 4-3 Removing panel assy (2), (3)
4
(3) Remove bonnet assy (10)

1) Remove snap pin (27) and gas spring (41).
2) Remove four sems bolts (36) M1230.
3) Lift up bonnet assy (10) with nylon sling.
: 19mm
35
9
51
10
(4) Remove bonnet assy (9)

1) Remove two sems bolts (35) M1225. 28 27
2) Remove capscrew (51) M1025.
41 27
: 19mm, 17mm
3) Remove bonnet sssy (9).
28
36
Fig. 4-4 Removing bonnet assy (9), (10)

(5) Remove cover (4)
1) Remove four capscrews (37) M10 25 and
cover (4).
: 17mm 37

1) Unlock it with the key.
: 19mm
5 35 4
Fig. 4-5 Removing cover (4), (5)

1) Remove two sems bolts (36) M1220. 8
2) Remove cover (8).
36
: 19mm
Fig. 4-6 Removing cover (8)
5
(8) Remove cover (1-2)

1) Unlock cover (1-2) and remove snap pin (1-5) 1-2
and stay (1-3). 1-6
2) Remove two sems bolts (1-6) M1225. 1-3
: 19mm
3) Remove cover (1-2).
1-5 36
1-1
36
Fig. 4-7 Removing box (1)
(9)Remove cover assy (52), (83)
1)Remove five sems bolts (36) M1230.
2)Remove two capscrews (61) M1245.
3)Remove cover assy (52). 52
: 19mm 83
: 19mm 36 61
61
(10) Remove box (1-1)
1) Remove five sems bolts (36) M1230. Fig. 4-8 Removing cover assy (32), (52)
: 19mm
2) Remove box (1-1).
49
(11) Remove stay (49)
1) Remove five capscrews (78) M1265 and two
capscrews (62) M1270. 62
: 19mm
(12) Remove bracket (21)

: 19mm
2) Remove bracket (21). 36
21
Fig. 4-9 Removing stay (49) and bracket (21)
6

: 19mm
2) Remove cover assy (12). 19
(14) Remove cover assy (18) 35

1) Remove six sems bolts(35) M1235. 36
: 19mm
2) Remove cover assy (18) . 18

35
35 12
(15) Remove bracket (19) 35
1) Remove three sems bolts (36) M1230.
: 19mm 35
2) Remove brackets (19). Fig. 4-10 Removing cover assy (12),(13),(18),(19)

64 14
(16) Remove cover assy (14), (25), (53) and (54) 35 56
located under the boom. 54
1) Remove all attaching bolts.
: 19mm
53
2) Remove covers (14), (25), (53) and (54), in

that order.
35
35
25
Fig. 4-11 Removing cover assy (14), (25), (53),
(17) Remove guard assy (47) (54)
64
1) Remove two capscrews (64) M1225.
: 19mm
47
2) Remove guard assy (47).

: 19mm
36
15
Fig. 4-12 Removing cover assy (15)
and guard assy (47)
I 7

35 17
1) Remove four sems bolts (69)M820.
: 13mm
2) Remove cover (68). 36
69
35
(20) Remove cover (16) 68
: 19mm
35
(21) Remove bracket assy (17)
16
: 19mm Fig. 4-13 Removing cover (16), (68)
2) Lift up bracket assy (17) with nylon sling. and bracket assy (17)
35
1) Remove seven sems bolts (35) M1225.
: 19mm
2) Remove cover assy (20)
20
(23) Remove bracket assy (45) Fig. 4-14 Removing cover assy (20)
1) Remove three sems bolts (36) M1230. 45
2) Remove two capscrews (64) M1225.
: 19mm
3) Remove bracket assy (45).

1) Remove six sems bolts (36) M1230. 64
: 19mm
Fig. 4-15 Removing bracket assy (45)
36
1) Open cover (91-1). 36
2) Remove six sems bolts (36) M1230.
: 19mm
7
91-1
4.3 INSTALLATION
(1) Installing is done in the reverse order of 36 91-2
removing.
(2) Tightening torque Fig. 4-16 Removing cover assy (7), (91)
: 19mm M12 8.1kgfym (59 lbfyft)
: 17mm M10 6.7kgfym (48 lbfyft)
8
5. UNDER COVER
5.1 REMOVAL
(1) Remove under cover (1, 2, 3, 4, 5, 6)
1) Remove sems bolts (7) M1225.
2) Remove covers.
: 19mm
1
7
2
7
6
7
3 5
7
7
4
7
5.2 INSTALLATION Fig. 5-1 Under cover assy
(1) Install under cover (1, 2, 3, 4, 5, 6)
: 19mm
Tightening torque : 8.1kgfym (59 lbfyft)
9
6. FUEL TANK
6.1 PREPARATION FOR REMOVAL
A2
(1) Draining fuel.
1) Unlock cap (A2) with a starter key and open it.
2) Loosen cock (B8) under the tank.
(Refer to Fig.6-2)
3) Draining fuel
RETURN
Capacity of tank : 270 (71gal)
5,9,12
(2) Open bonnet (10) and cover (5) and remove

covers (8), (15) and guard assy (47). (Refer to
Fig.4-4, 4-5, 4-6, 4-12.) SUCTION
(3) Remove the connector for level sensor (B4).

(See Fig. 6-2)
(4) Remove cab assy (Refer to 1. CAB.). 6,11,12
(5) Remove guard tube (9), (11) and hose (5), (6)
1) Loosen the clip (12) in the tank return
position and in the tank suction position, and Fig. 6-1 Removing fuel hose (5), (6)
draw out the hose.
2) Put in plugs that match the hose bore. A2
6.2 REMOVAL A1
B20
(1) Remove bracket (B17) and stay (B18) that
connect the tank with the upper frame.
1) Remove two sems bolts (B19) M1230.
2) Remove bracket (B17).
B18
: 19mm B17 B19
3) Remove four sems bolts (B20) M12 25 and

separate stay (B18). B20
: 19mm
(2) Remove fuel tank assy (A1)

1) Remove four capscrews (B1) M16 45 and
B4 B1
three shims (B3).
B6 B3
: 24mm
2) Hook the wire to the lifting eye on the fuel

tank assy and remove the fuel tank. Fig. 6-2 Removing fuel tank
Weight : 120kg (264 lbs) B8
6.3 INSTALLATION (2) Tightening torque

(1) Installing is done in the reverse order of Tightening torque
removing. No. NAME kgfym (lbfyft)
Tank attaching bolt (B1) M1645 B1 CAPSCREW 22 (160)
: 24mm, Apply Loctite #262
B6 MACHINE SCREW 0.2 (1.4)
Tightening torque : 22.0kgfym
(160 lbryft) B8 COCK 0.5 (3.6)
B19, 20 SEMS BOLT 8.1 (59)
I10
7. HYDRAULIC TANK
11 2,3
(1) Remove cover assy (11), panel assy (2), (3)
and other guards necessary to remove the
hydraulic oil tank. (Refer to 4. GUARDS.)
Fig. 7-1 Remove guard

(2) Bleeding the tank internal pressure
Push the boot of the cap on breather assy Push
(A9) by your finger tip, to vent the internal
pressure. A9
Keep pressing until the hissing stops.
Fig. 7-2 Bleeding internal air of tank

(3) Remove cover (A7).
1) Remove six capscrews (A13) M1020.
: 17mm
2) Remove cover (A7). A13
A8
3) Remove suction strainer (A2). A13
A14
A7
A6
(4) Remove cover (A8).
1) Remove six capscrews (A13) M1020. B
: 17mm
2) Remove cover (A8). C
A2
3) Remove filter element (A23). A10 A23 D

A11
(5) Disassembling filter element E
A9 F
Turn the handle of element assy (B), and
disassemble the removed filter element (A23).
Disassembling parts : (B), (C), (D), (E), (F)
Fig. 7-3 Remove cover (A7), (A8)
I11
(6) Draining hydraulic oil

Place pump in tank and draw up hydraulic
oil.
Capacity of tank : 115 (30gal)
7.2 REMOVAL
(1) Draw out the suction hose (3)
1) Remove two clips (16) of the tank side. PLATE
FOR PILOT
2) Pulling out hose (3). RETURN
LIFTING
: Flat-blade screwdriver HOSE
SECTION
(2) Disconnecting the main pipe return hose
3
1) Remove hose (7).
: 22, 27mm B3
2) Remove hose (6).
16
: 22, 27mm B1
Fig. 7-4 Draining hydraulic oil and

(3) Remove radiator return tube (2) drawing out the suction hose
1) Remove coupling (11) M8 nut.
: 13mm
2) Separate tube (2).
(4) Disconnecting pilot return hose

1) Remove pilot hose (A21). 11
: 19, 22mm
2) Remove pilot hose (B5). 6 2
: 19, 22mm
3) Remove pilot hose (C20).
: 19, 22mm 7
4) Remove two pilot hoses (D23).
: 17, 19mm Fig. 7-5 Removing main piping return hose
(5) Remove hydraulic tank attaching bolt HYDRAULIC TANK

A21
Remove four capscrews (B1) M1640, and a
shim (B3).
: 24mm
B5
Record the shim locations.
(6) Slinging hydraulic oil tank

Place a wire sling in the lifting plate of the D23
tank.
Tank weight : Approx : 125kg (276 lbs)
D23
C20
Fig. 7-6 Remove pilot drain hose
12
7.3 INSTALLATION
(1) Cleaning hydraulic oil tank
(2) Cleaning suction hose
(3) Cleaning mount of tank.

Installing is done in the reverse order of
removing.
(4) Install four attaching capscrews (B1) M1640

with Locktite #262. (See Fig. 7-4)
: 24mm
Tightening torque : 22kgfym (160 lbfyft)
If there is any clearance (gap) more

than 1mm (0.04in) between the tank
mount and the frame, adjust shim (B3)
thickness and fasten them together.
(5) Connection of suction hose (3)

Apply PERMATEX on pipe side of hose
connection and insert it.
1) Put the hose with clip (16).
Tightening torque : 0.55kgfym (4.0 lbfyft) O RING
(6) Assembling return element

Assemble filter element by the use of element
kit (B-2). (See Fig. 7-3, 7-7)
C
1. Two elements (D) are used as one
set.
2. Replace O ring (C) and packing (F)
with new ones respectively. D
(7) Install return element (A23).

SUCTION
STRAINER F
(8) Installing suction strainer (A2)
FILTER ELEMENT KIT (B-2)
(9) Install tank cover (A7, A8) attaching capscrews
(A13), M1020.
M10 Tightening torque : 4.7kgfym (34 lbfyft)
Fig. 7-7 Strainer & filter
Replace O ring fitted on the backside of
tank cover (A8) with new one.
I13
8. HYDRAULIC PUMP
8.1 PREPARATION FOR REMOVAL A13
(1) Remove bonnet and counterweight.
(2) Release pressure in hydraulic oil tank. A7

(See item Hydraulic Tank.)
SUCTION
(3) Remove six capscrews (A13) M10. STOPPER
(4) Remove cover (A7) SUCTION

: 17mm STRAINER
(5) Take out suction strainer.
(6) Install suction stopper.

For suction stopper, see item Chapter YB 11
Tools.
Note : Pump can be removed even when
counterweight is not removed. But
HYDRAULIC TANK
removal of counterweight facilitates
working, and the working time is also Fig. 12-1 Suction stopper installing
reduced.
(7) Remove cover (16), (68).

: 19mm 35
68
2) Remove cover (16), (68).
(8) Disconnect drain down pipe installed under

engine muffler. 35
16
Fig. 12-2 Removing guard (18), (19)

HYDRAULIC PUMP
8.2 REMOVAL HYDRAULIC

TANK
(1) Loosen half clamp (8) on hoses (4), (5) and
capscrews (9) M10 35 and disconnect two
hoses on the delivery side.
: 17mm 8
5
9
(2) Remove suction tube 4
1) Remove four capscrews (10) M1230.
: Special service tool No.6-1 of

opposing flats 10mm
40mm
(1.57in) 10
2) Remove suction tube (1) from pump.
Fig. 12-3 Removing hose (4), (5)
and suction tube (1) 1
I14
(3) Removing other hoses

1) Disconnect hoses of the following ports.
(See Fig. 8-4.)
Connected
Port Size Tool to Remarks
Dr1 PF1/2 27 Tank Drain

A3
Proportional For control Dr3
Psv1,2 PF1/4 19 valve block valve
Psv1
Gear pump
A3 PF3/8 22 Line filter delivery port
for pilot
Suction port
B3 PF3/4 36 Tank
for pilot Psv2
Drain port
Dr3 PF3/8 22 Tank
for pilot
B1
Dr1
A4 A2
A1
B3
2) Attach tags to hoses to identify. Fig. 8-4 Pump port
(4) Remove main pump
1) Place a wire rope and tension it a little by

utilizing the eye bolt (M10) at the top of the
hydraulic pump. Temporarily loosen
capscrew (4) and remove capscrew (3).
: 14mm, weight : 95kg (209 lbs)
: 17mm
2) Draw out the power take-off assy from the

flywheel housing slowly, adjusting the
tension of the wire rope. 0
On that occasion, the coupling rubber (2-1)
comes out with the hydraulic pump.
4
3) Remove capscrew (2-4) fastening coupling

rubber (2-1) and remove coupling rubber
3
(2-1).
: 14mm 1
4) Remove hub (2-2)

If you loosen two set screws (2-5), hub (2-2)
comes off from the spline shaft of the pump. 2-3
: 8mm 2-4
2-1
5) Remove bracket (1)
2-6
If you loosen and remove capscrew (4), 2-2
bracket (1) comes off the pump. 2
2-5
: 14mm
Fig. 8-5 Removing pump
15

8.3 INSTALLATION Do not use Loctite. (The
T=Tightening torque
Installing is done in the reverse order of attached bolts are coated
with micro capsule coating.) T=19.5kgfym (140 lbfyft)
removing. 1 4
2-4
(1) Installing bracket (1)
Install bracket (1) to the pump and
temporarily fasten them together by means of
socket bolts (4). 2
: 14mm
(2) Installing hub (2-2)
Insert hub (2-2) into the spline of the pump A
till the end face of the spline enters 4mm
(0.16in) inward (Refer to the Detail A.) and 2-5
attach two setscrews (2-5). T=11kgfym
(80 lbfyft)
: 8mm T=6.6kgfym(48 lbfyft)
Tightening torque : 11kgfym (80 lbfyft) 2-3 3 Apply Loctite #262
T=22kgfym(160 lbfyft) equivalent
(3) Installing coupling rubber (2-1) Do not use Loctite. (The
Insert coupling rubber (2-1) into hub (2-2) attached bolts are coated
with micro capsule coating.)
and attach socket bolts (2-4).
BRACKET 6
On that occasion, do not coat socket bolts
(2-4) with Loctite. (Socket bolts (2-4) are with 2-1
micro capsule coating.) 2-2
: 14mm 2-4
(4) Installing the pump
Lift the pump with bracket level and dock it (0.157) 2-5 3
in so bolts (2-3) enter the holes in coupling DETAIL A
rubber (2-1).
VIEW
Re-fit nine cap screws (3) and two cap screws
(6) where they were. Fig. 8-6 Installing Hydraulic pump
: 17mm
(5) Tighten socket bolts (4) regularly. HYDRAULIC PUMP
: 14mm HYDRAULIC TANK
Tightening torque : 19.5kgfym
(140 lbfyft)
(6) Attach hoses (4), (5) of the delivery side with
half clamp capscrews (9).
: 17mm 8
Tightening torque : 5.8kgfym 5
9
(42 lbfyft) 4
(7) Install the suction tube (1) attaching socket
bolts (10) M12 (4pcs.)
: 10mm, ( Special service tool No.6-1)
(8) Installing the hose Tool Tightening torque 10
Tightening position kgfym (lbfyft)
Cap nut Dr1 27 8.0 (58)
Cap nut Psv1, 2 19 3.0 (22) 1
Cap nut A3 22 5.0 (36) Fig. 8-7 Installing delivery hose (4),(5)
Cap nut B3 36 12.0 (87) and suction tube (1)
Cap nut Dr3 22 5.0 (36)
I16
(9) Remove suction stopper
(10) Installing suction strainer
(11) To bleed air in pump, loosen plugs on

pressure measuring ports a1, a2.
(12) Check hydraulic oil level.
(13) Start engine and check it for oil leakage and

noise.
(14) Attach drain down pipe under engine muffler.

a1 a2
(15) Install guards (16), (68)
Tightening torque Fig. 12-8 Bleed air in pump
Tightening position Tool kgfym (lbfyft)
Sems bolt (35) 19 8.1 (59)
After replacing pump, be sure to fill

hydraulic oil to 1 (0.26gal) or more.
35
68
35
16
Fig. 12-9 Installing guard (16),(68)
17
9. AIR CLEANER

(1) Opening bonnet assy (10)
9
(2) Opening cover assy (5)
(3) Unplug terminals on indicator lines (1-5)
9.2 REMOVAL
(1) Pulling out hose (5). 10
5
1) Loosen clips (7) on both sides of hose (5).
Fig. 9-1 Preparation for removal
2) Pulling out hose (5)
: Flat-blade screw driver
(2) Pulling out hose (2).
1) Loosen clips (7) on both sides of hose (2).
2) Pulling out hose (2)
(3) Removing hoses (3), (4) and intake tube (6) 1
1) Loosen clips (8), (9) on both ends of hoses (3), 1-6
(4). 1-2
2) Loosen nut (12) and remove U bolt (11).
3) Separate hoses (3), (4) and intake tube (6). 7
: 13mm 1-5
10
12
(4) Remove air cleaner assy (1)
2 7
1) Remove four sems bolts (10) M1025
7 7
: 17mm
2) Remove air cleaner assy (1) from guard 5
bracket. 3 8
6
9.3 INSTALLATION 8 8
(1) Installing is the reverse order of removing
with attention paid to the following items: 11
9
1) The insertion depth of air hose (2) shall be 4
30mm (1.2in).
Fig. 9-2 Removing air cleaner

2) The insertion depth at both ends of air hoses
(3), (4), (5) shall be 40mm (1.6in), provided
that the depth on the turbo side shall be
25mm (1.0in). (2) Replacing parts
3) Tightening torque :
Tightening Torque
No. NAME kgfym (lbfyft)
1-5 INDICATOR 0.4 (2.9)
10 SEMS BOLT 4.0 (29) Apply Locktite #262
FILTER ELEMENT (1-2) O RING (1-6)
I18
10. MUFFLER
10
10.1 PREPARATION FOR REMOVAL 9
16
(1) Remove bonnet assy (9) and open (10).
(2) Remove cover (4).
4
(3) Remove sems bolt (69) and remove cover (68).
10.2 REMOVAL
(1) Remove U bolt (3).
1) Remove four nuts (5) M8.
2) Remove two U bolts (3).
: 13mm
(2) Remove clamp assy (10) Fig. 10-1 Preparation for removal
1) Remove two capscrews (8) M1035 69 SPACE
2) Separate clamp assy (10) from muffler (1).
: 17mm 68
(3) Removing other parts
Remove exhaust tube (7) and brackets (2), (17),
where necessary.
: 13mm, 17mm B
A C
10.3 INSTALLATION 16
PROCEDURE OF
Installing is the reverse order of removing with attention FASTENING U BOLT
paid to the following items:
(1) Procedure of fastening U bolt (3) Fig. 10-2 Removing cover (68)
1) Tighten four nuts (A) till there is no space and make
sure that the dimension C is even all around.
5
2) Tighten nuts (A) to specified torque and confirm the 3
C dimensions on the right and left once again.
3) Tighten nuts (B) to specified torque and make sure 12 1
that U bolts (3) are not inclined. 16
4) Tightening torque
Nut A : 0.9kgfym(6.5 lbfyft)
Nut B : 1.1kgfym(8.0 lbfyft) 5
19
Procedure of fastening the nuts :
Fasten (5-1) for the flange of exhaust tube (7) 2 18
and (5) for U bolt (3). Then fasten (11) for 5-1 8
clamp assy (10).
(2) Tightening torque : 17

10
18
7 11
Tightening
No. NAME torque REMARK
kgfym (lbf yft)
4
5-1 NUT ; M8 2.9 (21) Tightening exhaust tube (7)
8 CAPSCREW ; M10 7.2 (52)
12 CAPSCREW ; M10 6.6 (48) Apply Locktite #262
16 CLIP 0.3 (2.2)
(3)19 Replacing parts
CAPSCREW ; M10 6.0 (43) Apply Locktite #262 Fig. 10-3 Removing muffler
NAME
MUFFLER (1)
GASKET (4)
I-19
11. COUNTERWEIGHT
11.1 PREPARATION FOR REMOVAL BONNET
(1) Removing bonnet assy.
Remove bonnet on engine. (See Fig. 4-4.)
(2) Remove cover (4), (5) (See GUARD Fig. 4-5.)
(3) Preparing slinging jig 3
Remove plug (B5) and install the counterweight
lifting jig (Refer to Chapter YB 11 Tools.)
(Use bolt : M48120)
: 75mm
For an additional weight, use two eye bolts
M24.
4
Fig. 11-1 Lifting up counter weight
11.2 REMOVAL 7 8 4 10
(1) Lifting up counter weight temporarily 6
Hook wire rope to slinging jig, and lift it and
9
stretch wire rope to the degree where it is B5
providing no slack temporarily. 5
A1 2 C5
Weight of counterweight ;
Approx. 4,600kg (10,100 lbs) B6
Wire more than 16 (0.63) ;
1.5m (4ft 11in)2 pcs. C5
B7
(2) Removing counterweight
B2
1) Remove two capscrews (B1) M30 140 and C1
(B7) M30190. C4
: 46mm B3 C3
2) Remove shim (B3), (B4). B4
3) Remove counterweight (A1).
(3) Removing counterweight (Add-on) C4

1) Attach two eye bolts M24 to the add-on C2
counterweight and lift it up temporarily.
Weight of counterweight ;
COUNTERWEIGHT
Approx. 1,000kg (2,205 lbs)
(ADD-ON)
2) Remove 3 capscrews M24 (C2,C3) and add-on
counterweight (C1).
B2
11.3 INSTALLATION B1
(1) Install counterweight in the reverse Fig. 11-2 Removing counterweight
procedure of removing.
(2) Install shim (B3), (B4) as it was.
(3) Slinging counterweight
Check that the attaching bolts can be B3,B4
screwed in by hand.
(4) Apply Loctite #242 on capscrews (B1), (B7),
and tighten them with washers (B2).
: 46mm,
Tightening torque : 170kgfym (1,200 lbfyft)
(5) Remove slinging tools, and attach plugs (B5).
(6) Mounting add-on counterweight
1) Apply Loctite #262 on capscrews M24 (C2,C3)
and tighten them with washers (C4). B1,B2
Fig. 11-3 Installing counterweight rear section
: 36mm and tightening capscrew
Tightening torque : (C3) 89kgfym (643 lbfyft)
: (C2) 96kgfym (694 lbfyft)
2) Remove eye bolt, and attach plugs (C5).
I20
12. RADIATOR & OIL COOLER

(1) Bleed air from the hydraulic tank and install
the suction stopper.
7
(2) Remove counterweight 7
(See 11. COUNTERWEIGHT) 5
Fig. 12-1 Removing air cleaner hose
(3) Remove air cleaner hose

1) Loosen clips (7). Refer to
2) Pulling out hose (5). 9. AIR CLEANER
: Flat-blade screwdriver
(4) Removing under cover installed on lower side

of radiator.
1) Remove eight sems bolts (7) M12 25.
2) Remove cover (3). 3
: 19mm 7
Fig. 12-2 Removing under cover (3)
(5) Drain down of radiator
Put container 18 (5gal) under drain cock
hose for draining water.
[Water capacity of radiator : 9.5 (2.5gal)]
A4
(6) Remove washer tank (A4)
1) Pulling out hose.
2) Move washer tank.
Fig. 12-3 Removing washer tank (A4)

(7) Remove sub tank (B2) for radiator
1) Loosen clip (B15) on one side of hose (B8) and B8
B15
pull out hose.
2) Remove four capscrews (B17) M8 25 and
separate sub tank (B2) from bracket assy. B15 B2
: 13mm
B17
T 1.1kgfm
(8 lbfft))
Fig. 12-4 Removing sub tank (B2)
21
(8) Removing inter-cooler (B1)

1) Loosen clip (B13) on inter-cooler hoses (B5), B5
B13
(B6).
2) Remove hose (B5), (B6).
B6
3) Remove three capscrews (B18) M1040 and B13
one capscrew (B22) M1240. B18
: 17mm, 19mm
4) Remove inter cooler (B1).
B22 B1
Do not loosen the joints of the hoses
related to the air-conditioner. Otherwise
the refrigerant leaks. Fig. 12-5 Removing inter cooler
CONDENSER
(9) Move air-conditioner condensers.
14
1) Remove six capscrews (16) M650.
2) Move A/C condenser
: 10mm RECEIVER TANK
(10) Move receiver tank

1) Remove two capscrews (14) M816 which
are used to install receiver tank with bracket. 16
2) Move receiver tank. 16
: 13mm
ig. 12-6 Moving condensers and receiver tank
B14 B3
B14
12.2 REMOVAL
(1) Remove radiator stay (A1), (A2) B14
1) Remove four sems bolts (A4) M1230.
: 19mm B4
A4
2) Remove stay (A1), (A2). B14
(2) Remove water hose (B3) A1

1) Loosen the clip (B14) for water hose (B3).
2) Remove hose (B3).
3) Loosen the clip (B14) for water hose (B4). A4
: Flat-blade screwdriver A4
4) Remove hose (B4).
A2
Fig. 12-7 Removing radiator assy
22
(3) Remove wire net (26) 27 26

1) Remove three capscrews (27) M820.
2) Remove guard (26).
: 13mm
(4) Disconnecting hydraulic oil tube (3), (4) Fig. 12-8 Removing wire net
Place an oil pan under the tube joint. Remove
the coupling (9) that connects tubes (3), (4).
(5) Remove radiator body (C1)

Remove four capscrews (A3) M1245.
: 19mm
: 19mm
C1
(6) Disconnecting hydraulic oil pipe

1) Shift the radiator outwards so the engine fan
A3
do not interfere with it when lifted up. 4
2) Stop up pipe ends with clean cloth, etc.
9
(7) Removing radiator
Place a wire sling in the lifting metals of the
radiator assy and remove the assy by crane. 3
Weight : Radiator approx. 30kg (66 lbs)
Oil cooler approx. 16kg (35 lbs) Fig. 12-9 Removing hydraulic hose (3), (4)
23
12.3 INSTALLATION
(1) Installing is done in the reverse order of
removing.
C1
(2) Install radiator assy

Place a wire sling in the lifting metals of the
radiator, match the openings of the hydraulic
pipes, match the mounting positions of the
radiator and assemble it temporarily.
A3
Water hose insert allowance 40mm (1.6in)
(3) Radiator attaching bolt

Apply Locktite #262 on four capscrews (A3) Tightening torque
M12 45, and tighten it with washer 12.3kgfym
respectively. (89 lbfyft)
Apply Locktite
: 19mm
#262
Tightening torque ; 12.3kgfym (89 lbfyft)
Fig. 12-10 Installing radiator
(4) Adjust the clearance between the fan and the Adjust the engine fan so its rear end sticks
out 36mm (1.42in) from the radiator shroud.
radiator shroud all around the circumference,
as below : (1.42in)
Circumferential direction:
205mm (0.8in0.2in)
Longitudinal direction :
365mm (1.4in0.2in)
(5) Clean the plastering area of the insulation

thoroughly before plastering it.
(6) Making up hydraulic oil and LLC (Long Life

Coolant)
After completion of other installation, make Fig. 12-11 Back-and-forth
up hydraulic oil and water. adjusting position of radiator
Cooling water volume of engine body

8.5 (2.2gal)
Water capacity of radiator 9.5 (2.5gal)
24
13. ENGINE
13.1 PREPARATION FOR REMOVING
(1) Remove battery ground (See 3. BATTERY) (7) If necessary, remove pump, muffler and
radiator.
(2) Remove bonnet and cover (See 4. GUARD)
(8) Remove harness connector
(3) Remove air cleaner hose 1) Remove E/G ground cable
(See 9. AIR CLEANER) 2) Starter cable Starter B terminal
3) Remove the connector that connects the main
(4) Remove counterweight harness with the engine.
(See 11. COUNTERWEIGHT) -CN-318E/G sub harness
MAIN HARNESS -CN-165
(5) Remove radiator hose and inter cooler hose Govenor motor
(See YB23 -CN-166
(See 12. RADIATOR) ELECTRIC -CN-170 Pump
SYSTEM) -CN-171 proportional valve
(6) Remove fuel hose and heater hose, and if
-CN-167E/ G speed sensor
necessary air-con hose.
Prepare a stand, which withstands the
weight of the engine assy and can place
the removed engine firmly.
(Refer to YB11 Tools on Page 13.)
THERMOSTAT SPEED SENSOR
FUEL FILTER
TURBO CHARGER
STARTER MOTOR
WATER TEMP. SENSOR
THERMO SWITCH
OIL PRESSURE SWITCH
OIL FILTER ELEMENT (BYPASS)
ALTERNATOR
OIL FILTER ELEMENT (FULL FLOW)
ISUZU 4BG1TCY(WITH TURBO CHARGER)

Fig. 13-1 General view of engine
I25
13.2 REMOVAL T=Tightening torque

5
4
8
6 CAPSCREW
Apply Loctite #271
8 WASHER
10 TEMP.SENSOR
4 CAPSCREW
T=23kgfym(170 lbfyft)
Apply Loctite #271
1
9 PLATE
9 2 RUBBER MOUNT
RUBBER MOUNT 1
2 15 SHIM
16 SHIM
3 RUBBER MOUNT
7 NUT
15,16 1,2
+1.0 + 0.039
15 1 0 (0.039 0 )
15 3 +1.0
Adjust to 1 0
16 15 +0.04
(0.04 0 )
3 16 16 using shims
7 3 3 No.15, 16.
7 7
Clearance Adjustment of Engine Mount
(1) Removing attaching bolt to frame 13.3 INSTALLATION

1) Remove four nuts (7) M18. (1) Installing is done in the reverse order of
2) Remove rubber mount (3) and shim (15), (16). removing.
3) Remove four capscrews (4), (5), (6) M1890. 1) Clearance adjustment of engine mount
: 27mm Adjust the clearance between the lower
mounting surface of the engine and rubber
4) Remove two washers (8). Mount (3) to 1.0mm (0.04in), using shims
5) Remove two plates (9). (15), (16).
6) Remove two rubber mounts (1), (2). 2) Refer to the above figure for the tightening
(2) Slinging engine body torques and Loctites (Adhesive).
1) Sling engine hooking wire to lifting lugs on
the front and rear sides.
Wire : 6 (0.24)1m (3ft 3in) 2pcs.
(3) Position engine on the mount stably.
I26
14. INSTRUMENT PANEL

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

rear side of left instrument panel
1 8P for air-con panel
2 9P for tuner Fig. 14-1 Around of instrument panel
LH instrument panel RH instrument panel

CAP 12
4) Remove connectors on rear side of right panel
12 M516
1 6P for key switch
2 3P for accel dial 12 12
3 2P for switch
BRACKET
ANTENNA CABLE
(2) Remove control box TUNER
1) Remove four sems bolts (19) M8 on right and Fig. 14-2 Removing instrument panel
left sides.
PILOT VALVE
2) Separate control box from support.
: 13mm SUPPORT
Weight : Left control box 8.5kg (19 lbs) and PILOT
VALVE 19
right control box 7kg (15 lbs) including M825
pilot valve
37
M616
Remove hose referring to Page 1-32.
SUPPORT
14.3 INSTALLATION
Install it in reverse procedure of removing
SEAT STAND
according to the tightening torque table.
Fig. 14-3 Removing control box
Tightening Tightening torque
Tool
position kgfym (lbfyft)
Sems bolt (19) 13 2.4 (17)
Sems bolt (12) cross recessed 0.27 (2.0)

screw driver
I27
15. CONTROL VALVE

(1) Remove cover assy (11) (See Fig. 4-2.)
(2) Remove panel assy (2), (3) (See Fig. 4-3.)
(3) Release air in hydraulic oil tank, open cover

of suction element of hydraulic oil, and lower
the level. (See Fig.8-1.)
15.2 REMOVAL
(1) Removing hoses for each piping
Attach tag on hose, and write port name in it,
then remove hoses.
Ports Functions Ports on upper sides (on machine) Ports Functions

FRONT SIDE RIGHT SIDE REAR SIDE
PAr PAL Travel left forward

PAL
PAr Travel right forward PAc

PAc Bucket dump
PLc1 PAa
PLc1 Boom down lock release
PAb
PAb Boom up Pis PAa Arm in
Drc Drain Drc
PAo2
Pis Arm recirculation
Pcb P1 side cut Pcb
PAo2 Option valve
Ports Functions Ports on front sides (on machine) Ports Functions

LOWER SIDE RIGHT SIDE UPPER SIDE
Dra Drain PL1 Attach boost pressure
Br Travel right reverse Ar Travel right forward
Bc Bucket digging Drb Drain
Bb Boom down Ac Bucket dump
Ab Boom up
I28
Ports Functions Ports on rear sides (on machine) Ports Functions

UPPER SIDE RIGHT SIDE LOWER SIDE
Travel left
AL BL Travel left reverse
forward
As Bs Swing (right)
Swing (left)
PAs
Swing (left)
Aa Ba Arm out
Arm in
Ao2 Bo2 Option valve

Option valve
Ports Functions Ports on lower sides (on machine) Ports Functions

FRONT REAR
SIDE SIDE
PBo2 Option valve
Arm conflux Pca P2 side cut

PA1
Drd Drain
Boom dowm
PBb PBa Arm out
Bucket digging Arm in
PBc PLc2 Lock release
Travel right
PB1 Boom conflux
PBr
reverse PBs Swing (right)
PTb
Travel straight PBL Travel left reverse
RIGHT SIDE
(2) Remove control valve MACHINE FRONT 4

1) Remove four capscrews (3) M12 40 from
upper frame.
2) Remove bracket (1), (2) together with control
valve. A1
3) Remove three capscrews (4) M12 65 from
bracket.
: 19mm
4) Weight : 220kg (490 lbs) (include bracket) 2
1
3
15.3 INSTALLATION
3
remove.
: 19mm,
Tightening torque : 12.3kgfym(89 lbfyft)
(2) Make certain that attachment moves
normally in operation.
(3) Check oil level and that it is free from oil
leakage. Fig. 15-1 Removing main control valve
I29
16. PILOT VALVE (FOR ATT)

PANEL ASSY
The removing procedure for right and left is the
same, so the preparation for left side is described
29
here. 28
(1) Put attachment on ground, stop engine and
release pressure in tank.
(2) Remove panel assy referring to Section 4.

Instrument Panel.
(3) Remove one sems bolt (12) M5 from lower

side of control box.
: cross recessed screw driver 12
Fig. 16-1 Removing instrument-panel cover
(4) Remove cover on outer surface.
BOOTS
(5) Remove sems bolt (28) and rubber sheet (29)

securing cover and control box on inner A1
surface.
PILOT VALVE
(6) Remove cover on inner surface.
PF3/8
(7) Remove harness connector for horn. VALVE SIDE Opposing
PF1/4
Opposing
Flats 22 Flats 19
(8) Attach tag to hoses for identification.
MARK F
16.2 REMOVAL
(1) Remove hoses from your side to far side in PF3/8
PF1/4
order. P PORT CONNECTOR
: 19mm, 22mm HOSE SIDE (WITH FILTER)
1~4,5~6,T PORT CONNECTOR
(2) Shift boots. Fig. 16-2 Pilot valve connector
(3) Remove four socket bolts (A1) M6. FRONT OF THE MACHINE
: 5mm
T 8 ARM(R) 4 BOOM(R)
2
(GREEN) T (GRAY)
BUCKET
(4) Remove pilot valve.
6 (R)
SWING (BLUE)
(5) Plug hose ends. Plug PF1/4 (R)
(RED)
5 SWING(L)
16.3 INSTALLATION (GRAY)
1
Install it in the reverse order of removal and P
P BUCKET(H)
tighten it to the below tightening torque. 7 ARM(H) (RED)
(BLUE)
: 5mm T=1.1kgfym (8 lbfyft) 3 BOOM(H)
(GREEN)
: 19mm T=3.0kgfym (22 lbfyft)
LEFT SIDE RIGHT SIDE
Fig. 16-3 Port position (Seeing from upper side)
I30
17. PILOT VALVE (FOR TRAVEL)

(1) Release pressure in hydraulic oil tank
(2) Remove under cover (1) (See 5. UNDER COVER) TRAVEL

2 SPEED
(3) Remove floor mat SWITCH
17.2 REMOVAL 4
(1) Separate pressure sensors (B2) at two places
of the harnesses under the floor.
(2) Remove two pressure sensors (B2).
CA103 7
: 19mm
(3) Separate the lead wires CA103 for the travel

1, 2 speeds, at two places, from the harnesses
B10 25 24
of the main body, at two places.
B2
(4) Attach tag, and disconnect connectors and

hoses (B7), (B8), (B9), (B11). B1 B8
: 19mm (P port) B2
: 22mm (T port, 1~4 port)
CONNECTOR
SECTION B7B9
(5) Plug hose ends
Plug PF1/4, PF3/8
B11
B9
(6) Remove four sems bolts (7) M1020.
B11
(7) Remove right and left levers (4).
(8) Remove four socket bolts (B10) M1030. Opposing

: 8mm PF3/8 flats 22
PF3/8
(9) Remove four sems bolts (25) M1025 and

remove plate (24). VALVE HOSE
SIDE SIDE
: 17mm
T port connector
(10) Remove pilot valve lifting it upward. Opposing

VALVE SIDE flats 19 MARK F
(11) Stop up holes with plugs PF1/4, 3/8. PF3/8 PF1/4 PF1/4
Opposing
17.3 INSTALLATION flats 22
Install it in the reverse order of removal and PF3/8
tighten it to the below tightening torque. P port connector
Hose HOSE SIDE

: 19mm T=3.0kgfym (22 lbfyft) 1~4 port connector
: 8mm T=4.7kgfym (34 lbfyft) Fig. 17-1 Attaching and detaching pilot V
Pressure sensor
I31
18. SWING
19. MOTOR UNIT
(1) Park machine on flat and solid ground and
put attachment on ground. 6
(2) Remove the under-cover under the engine.

8 5
(3) Stop engine and release pressure in circuit
operating swing control lever.
(4) Remove the air cleaner at the top of the

swing motor.
B10
(5) Bleed air from the hydraulic oil tank and
attach to each hose a tag showing port name B10
and other information.
(6) Remove guard as necessary to make work

easier. (Refer to 4. GUARD.)
A16
18.2 REMOVAL Fig. 18-1 Removing swing unit piping

(1) Remove hose.
1) Remove hose (8) from the Tee in the makeup
port M.
: 36mm
2) Remove hose (5), (6) from the Tee in the drain M PORT
port Dr.
: 27mm
B1
3) Remove one hose (A16) from the elbow of the
PG port (for swing parking brake).
: 19mm
4) Remove two hoses (B10) from the elbows of B20

the A, B port. B19
: 36mm
Put in plugs 1" 3/16-12UN, PF1/2, and PF1/4

into the removed ports.
Fig. 18-2 Removing swing unit
I32
(2) Loosen one nut (B20) M10 from upper side of

upper frame and remove drain hose clip (B19)
for reduction unit.
: 17mm
(3) Removing the swing motor unit

1) Remove twelve capscrews (B1) M2055.
: 30mm
2) Fit an eye bolt to the M port, place a wire

sling on it and remove the swing motor unit.
Weight of swing motor unit ;
Approx. 235kg (520 lbs) (include reduction unit)
18.3 PREPARATION FOR INSTALL

(1) Clean mating surfaces of swing motor unit
and upper frame.
Tools : spatula, wash oil
(2) Apply Locktite #515 on entire mounting

surface of swing motor unit.
18.4 INSTALLATION
Install the swing motor unit in the reverse order
of disassembly, confirming the orientation of the
Coat all the mounting surface
swing motor unit..
of the swing motor with
1) Tighten capscrews (B1).
Locktite #515 or equivalent.
: 30mm
Apply Loctite #262
2) Fill inside from motor drain port to casing

with hydraulic oil before piping for drain. Swing motor unit mount
18.5 PREPARATION FOR DRIVE Apply Loctite #262 or equivalent.

(1) Before starting operation, check that gear oil Tightening torque 55kgfym (400 lbfyft)
#90 (API grade GL-4) level of swing reduction
is sufficient.
Amount of charge : 7.5 (2gal)
(2) When starting operation, operate motor in

low idling and at low speed for several
minutes, and check it for possible oil leakage
and noise.
Fig. 18-3 Installing swing motor unit
I33
20. SWIVEL JOINT

20.1 PREPARATION FOR REMOVE 20.2 REMOVAL
1) Remove boom piping hose (1) Remove travel motor hose and tube
[Refer to Travel section under HYDRAULIC
SYSTEM YN22 (8)]
1) Remove tube (A5), (A6). (E port : PF1/2)
: 32mm
Tightening torque :
2) Remove tubes (A1), (A2). (C, D port : PF1)
: 41mm
Tightening torque :
3) Remove tubes (A3), (A4). (A, B port : PF1)
: 41mm
Tightening torque :
4) Remove two hoses (A7). (F port : PF1/4)
: 19mm
A2
A4
SWIVEL JOINT
A7
B2
A7
A3
A1
A6
A5
Fig. 20-1 Removing piping (lower side)
I34
(2) Disconnecting the hoses on the top part of

swivel joint A7
[Refer to Swivel Joint under, HYDRAULIC A9
SYSTEM 22 (3), (4).] A22
1) Remove drain hose (5). (E port : PF1/2)
5 A12
: 27mm
2) Remove hoses (A9), (A12).
(C, D port : 1-3/16-12UN)
: 36mm
Tightening torque :
3) Remove hoses (A7), (A22).
(A, B port : 1-3/16-12UN)
: 36mm
Tightening torque :
4) Remove hose (15).
(1, 2-speed select port : PF1/4) 15
: 19mm 4
Tightening torque : 3.0kgfym (22 lbfyft) Fig. 19-2 Disconnecting the hoses
on the top part of swivel joint
(3) Remove whirl-stop of swivel joint. C5 C3 T=16kgfym

1) Loosen the nut (C5) M16. (120 lbfyft)
2) Remove a capscrew (C3)M16110.
: 24mm
Fig. 19-3 Removing whirl-stop nut & the capscrew
(4) Remove joint for piping

(Refer to Fig.20-1, 20-2)
1) Remove two connectors (B2). (F port)
2) Remove elbow (4) for travel 2-speed change T=0.69kgfym (5 lbfyft) B9
over. (PF1/4)
: 19mm T=1.5kgfym (11 lbfyft) B8
(5) Remove seal (B4)

1) Remove six capscrews (B8) M1020.
PLATE
: 17mm
2) Remove clip (B9).

Before mounting the seal B4
: Flat-blade screw driver (B4), apply adhesive to
3) Remove seal (B4). the adhering surface of
S/J and the upper frame.
Fig. 19-4 Removing seal (B4)
I35
(6) Remove capscrew for installation

Attach eye bolt, lift it up temporarily, and
remove three capscrews (2) M1225.
: 19mm
(See YB11 Tools No.610)
EYE BOLT
LOWER FRAME
2
CAPSCREW
M1225
Loctite #262
T=11kgfym(80 lbfyft) 1
SWIVEL JOINT
Fig. 19-5 Removing capscrew for installation
(7) Slinging the swivel joint

Weight : Approx.26kg (57 lbs)
19.3 INSTALLATION
removing.
Piping tightening torque
Tool Tightening torque kgfym(lbfyft)

Size
HEX O ring type joint Hydraulic hose
PF1/4 19 3.7(27) 3.0(22)
PF3/8 22 7.5(54) 5.0(36)
PF1/2 27 11.0(80) 8.0(58)
PF3/4 36 16.5(120) 12.0(87)
PF1 41 26.0(180) 14.0(100)
1-3/16-12UN 36 18.0(130)
(2) Check for oil leakage and the hydraulic oil

level.
(3) Check for operating.
I36
20. UPPER FRAME

(1) Remove attachment
WIRE ROPE
(Refer to Chapter 32 : ATTACHMENT) 162.5m
(0.630) (8ft 2in)
(2) Remove cab (Refer to 1. CAB.)
CHAIN HOISTS
(3) Remove guard (Refer to 4. GUARD)
(4) Remove counterweight

(Refer to 11. COUNTERWEIGHT)
(5) Remove swivel joint

(Perform the steps (1) thru (7) of 20. SWIVEL
JOINT)
20.2 REMOVAL
(1) Lifting up upper frame temporarily LIFTING JIG No.13 FOR
Install two upper swing body lifting jigs UPPER FRAME
(Refer to 11 Tool two in the holes into which Fig. 20-1 Temporarily lift upper frame
the counterweight is placed. Mount two chain
hoists to the boom foot and lift the upper
frame at four points. MATCH
MARK
Wire rope ; 16 (0.630)2.5m(8ft 2in), 2pcs.
16 (0.630)1.5m(4ft 11in), 2pcs.
Chain hoists ; For 1,000kg (2,200 lbs) 2pcs.
(2) Marking match marks on swing bearing

Mark match marks on upper frame and
swing bearing.
(3) Removing upper frame attaching bolts Fig. 20-2 Matching mark on swing bearing
Remove thirty capscrews M20105 and three and upper frame
reamer bolts used to install swing bearing
and upper frame.
: 30mm
(4) Slinging upper frame

Sling according to Fig.20-1, and remove
upper frame and put it on a stand.
Weight : Approx. 5,100kg (11,200lbs)
Fig. 20-3 Removing upper frame attaching bolts
I37
20.3 INSTALLATION
21.3
removing. Apply Locktite #515 to the race surface over the whole
circumference (hatched) on the inside of capscrew.
(2) Cleaning mating surfaces of upper frame and
swing bearing.
(3) Apply Locktite #515 to the inside of the

capscrews on the contact surface. Apply Locktite #262
equivalent.
(4) Slinging upper frame T=40kgfym (290 lbfyft)
Match marks and install it with three reamer 13,14

bolts (14) temporarily.
Fig. 20-4
21-4 Bearing mount
Confirm the reamer bolt positions referring to
Fig. 20-5.
21-5. OUTER (S) ZONE POSITION
: 30mm, Tightening torque :

Tightening40kgf
torque : 40kgfylbs)
ym (290ft ym (290 lbfyft)
Apply Locktite
Apply#262
Locktite #262
(5) Install swing bearing

Install thirty capscrews (13) M20105.
: 30mm,
30mm Tightening torque :
Tightening40kgf
torque
ym: (290ft
40kgfyylbs)
m (290 lbfyft))
Apply Locktite
Apply#262
Locktite #262
Fig. 20-5
21-5 Reamer bolt position (K)
( )
Apply Locktite on section specified
by slanting lines
I38
1. HYDRAULIC PUMP REGULATOR Table 1-1
TIGHTENING
1.1 HYDRAULIC PUMP REGULATOR TORQUE No. NAME QTY
kgfym (lbfyft)
1.1.1 STRUCTURAL EXPLODED VIEW
(1) Main pump 111 SHAFT (F) 1
113 SHAFT (R) 1
116 1st GEAR 1
534 406
792 261 123 ROLLER BEARING 2
531,548 702 124 NEEDLE BEARING 2
532 774
732 710 127 BEARING SPACER 4
789
535 ENGINE 141 CYLINDER BLOCK 2
886
SIDE 151 PISTON 18
953
808 152 SHOE 18
153 PLATE 2
(RETAINER PLATE)
724
728 156 SPHERICAL BUSHING 2
719
113 467 313 157 CYLINDER SPRING 18
808 124 211 SHOE PLATE 2
127 954
123 212 SWASH PLATE 2
127 214 TILTING BUSHING 2
824 271 901
710 251 SWASH PLATE SUPPORT 1
(F)
262 312
717 252 SWASH PLATE SUPPORT 1
406 490 490 111 (R)
251 885 261 SEAL COVER (F) 1
719
262 SEAL COVER (R) 1
401 116 886 271 PUMP CASING 2
124
312 VALVE BLOCK 1
314
313 VALVE PLATE 1
141 GEAR PUMP (for CW rotation)
(FOR DOZER)
157 314 VALVE PLATE 1
711 (for CCW rotation)
156 24 (170) 401 SOCKET BOLT ; M16_175 8
886
153 885 1.2 (8.7) 406 SOCKET BOLT : M6_16 8
725
466 TIGHTENING
151,152 TORQUE No. NAME QTY 3.7 (27) 466 VP PLUG ; PF1/4 2
05
kgfym (lbfyft) 11 (80) 467 VP PLUG ; PF1/2 3
211
725 O RING : 1B_P11 2 468 VP PLUG ; PF1/2 1
214 Refer to Fig.1-34
212 728 O RING : 1B_P18 4 0.9 (6.5) 490 PLUG ; NPTF1/16 15
732 O RING : 1B_P16 2 24 (170) 531 TILT PIN; M20_1.5 2
774 OIL SEAL 1 24 (170) 532 SERVO PISTON ; M20_1.5 2
GEAR PUMP
(FOR PILOT) 789 BACKUP RING 2 534 STOPPER ( L) 2
792 BACKUP RING 2 535 STOPPER (S) 2
Refer to Fig.1-2 13 (94) 808 HEX. NUT ; M16 4 548 FEED BACK PIN 2
824 SNAP RING 2 702 O RING ; 1B_G30 2
885 VALVE PLATE PIN 2
886 SPRING PIN 4 711 O RING : 1B_G95 1
901 EYE BOLT ; M10 2 717 O RING ; 1B_G120 2
953 SET SCREW 2 719 O RING ; 1B_G115 2
954 SET SCREW 2 724 O RING ; 1B P8 18
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Fig. 1-1 Structural exploded view of main pump
II-1-1
12
(2) Gear pump (for pilot)
433
700 354 351
434
728
435
312
311
732 850 467
710 361 353 307 310 308 309 434 466 355
725
Fig. 1-2 Structural of gear pump (for pilot)
Table 1-2
TORQUE No. NAME QTY TORQUE No. NAME QTY
307 POPPET 1 1.7 (12) 433 FLANGE SOCKET ; M840 2
308 SEAT 1 1.7 (12) 434 FLANGE SOCKET ; M855 2
309 SPRING SEAT 1 3.4 (25) 435 FLANGE SOCKET ; M1035 2
310 SPRING 1 1.6 (12) 466 VP PLUG ; PF1/4 1
311 ADJUSTING SCREW 1 5.4 (39) 467 ADAPTER ; PF1/2-PF3/8 1
3 (22) 312 LOCK NUT ; M14 1 700 RING 1
351 GEAR CASE 1 710 O RING ; 1B G80 1
353 DRIVE GEAR 1 725 O RING ; 1B P11 1
354 DRIVEN GEAR 1 728 O RING ; 1B P18 1
355 FILTER 1 732 O RING ; 1B P16 1
361 FRONT CASE 1 850 SNAP RING 1
II13
1.1.2 DISASSEMBLY AND ASSEMBLY OF MAIN

PUMP
(1) Tools Table 1-3
The following list shows the tools required for Tool name Dimension
remove and install.
Allen wrench Opposing flats 4,5,6,8,14mm
Eye wrench
Socket wrench
Wrench with double Opposing flats 19, 27mm
heads (single head)
Adjust wrench Medium size 1pc.
Screw driver Flat-bladed screw driver 1pc.
Hammer Plastic hammer 1pc.
Plier For snap ring

Steel bar for key
Steel bar Approx.108200mm
(0.400.310.79)
One that may be fastened to
(2) Disassembling procedure Torque wrench specified torque
1) Selecting a place for disassembly.
z Choose a clean place.

z 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 (467), (468).
: 27mm
z Drain out oil from the plug of the REGULATOR

front pump and the rear pump.
4) Removing regulator and PTO gear casing

Remove the socket bolts [415 (See Fig.1-20),
435 (See Fig.1-34.)]. Then remove the
regulator and the PTO gear casing.
: 6mm, 8mm
z Regarding the disassembly of the

regulator, refer to article of
Regulator. Fig. 1-3 Removing regulator
z Regarding the disassembly of the
PTO gear casing, refer to article of
PTO Gear Casing.
14
5) Remove socket bolt (401)

Loosen socket bolts (401) that fasten swash
plate support (251), pump casing (271) and
valve block (312).
: 14mm
6) Disassembling the pump casing and the valve

block
Place the pump level on a work bench with
its mounting surface of the regulator facing
312 271
down. Then separate pump casing (271) and
valve block (312).
z When facing the mounting surface of

the regulator down, place a rubber
board on a work bench so as not to
score the mounting surface.
z When the pump casing has been
separated from the valve block, draw
out the 1st gear at the same time.
Fig. 1-4 Disassembling the pump casing (271)
and the valve block (312)
7) Drawing out the cylinder assy
Draw out cylinder (141) out of pump casing
(271) in parallel to shaft (111). At the same 271
time draw out piston (151), plate (153),
141(151)
spherical bushing (156) and cylinder spring
(157). 153
156
z Use care so as not to score the
sliding surface of the cylinder,
spherical bushing, shoe and the
swash plate .
Fig. 1-5 Drawing out the cylinder assy
15
8) Remove seal cover (F) 406

Remove socket bolt (406) and seal cover F
(261). 261
: 5mm
z 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).
z An oil seal is fitted to seal cover (F).
Therefore, use care so as not to score
the oil seal. Fig. 1-6 Removing seal cover F (261)
271
9) Remove seal cover (R)
Remove socket bolt (406) and seal cover R
(262). 251
: 5mm
10) Separating the swash plate support and the

pump casing
Knock lightly on the mounting flange of
swash plate support (251) from the pump
casing (271) side and separate the swash
plate support from the pump casing.
Fig. 1-7 Separating the swash plate (251)
support and the pump casing (271)
11) Remove shoe and swash plate
Draw out shoe plate (211) and swash plate 271
(212) from pump casing (271).
212 (211)
Fig. 1-8 Removing shoe (211)

and swash plate (212)
12) Drawing out the shaft
251
Tap lightly the shaft end (111, 113) by means
of a plastic hammer and draw out the shaft
from the swash plate support.
113
Fig. 1-9 Drawing out the shaft (111), (113)
16
13) Remove valve plate

Remove valve plate (313, 314) from valve
block (312).
z The valve plate may come off during

the operation under 6). 312
314
(313:OPPOSITE SIDE)
Fig. 1-10 Removing valve plates (313), (314)
14) Remove other parts

If necessary, remove stopper (L) (534), 531
stopper (S) (535), servo piston (532) and
tilting pin (531) from pump casing (271), and
remove needle bearing (124) from valve block
535 534
(312). 808
532
z When removing the tilting pin, use

care so as not to score the head of
the tilting pin, using a jig. 808
z It is hard to separate the tilting pin
from the servo piston in some cases 124
312
as Locktite is coated on the mating 271
part between them. Use care so as
not to score the servo piston by
251
applying unreasonable force.
z Do not draw out needle bearings
except when their service life has
ended.
z Do not loosen hex nuts (808) of valve
block (312) and swash plate support
Fig. 1-11 Removing other parts
(251). A set flow rate changes.
17
(3) Installing procedure

1) Precautions to be exercised in installation
Assembly is a reverse order of disassembly,
but notice the following.
1. Repair scored parts at disassembly. Get
replacements ready beforehand.
2. Wash parts sufficiently in cleaning oil and
dry them with jet air.
3. Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
4. In principle, replace sealing parts such as O
rings and oil seals.
5. Tighten socket bolts and plugs to specified
torques in this manual, using a torque
wrench.
6. Do not mix up front pump parts with rear
pump parts.
2) Installing swash plate support

Attach swash plate support (251) to pump
271
casing (271) by tapping the swash plate
support lightly with a plastic hammer.
z When the servo piston, the tilting

pin, the stopper (L) and the stopper
(S) have been removed, install them
to the pump casing beforehand.
z When tightening servo piston and
tilting pin, use a jig so as not to
damage the head of the tilting pin
251
and feedback pin.
Coat the screwed part with Locktite
#262.
Fig. 1-12 Installing swash plate support (251)
3) Installing swash plate 251
Place the pump casing with its mounting 271(531)
surface of the regulator facing down, insert
the tilting bushing of the swash plate into
tilting pin (531), and fit swash plate (212) to
swash plate support (251) properly.
z Confirm by the fingers of your both

hands that swash plate moves 212
smoothly.
z The shaft be installed easily if grease
is applied to the sliding parts of
swash plate and swash plate
support.
Fig. 1-13 Installing swash plate (212)
18
4) Installing shaft
Install shaft (111) fitted with bearing (123),
bearing spacer (127) and snap ring (824), to
swash plate support (251). 251
z Do not knock on the shaft with a

hammer or something. 123
z Fix the bearing by lightly tapping
127,824
the outer race of it by means of a
plastic hammer and set it exactly to
the end by using a steel rod and
others.
111
Fig. 1-14 Installing shaft (111)
5) Installing seal cover

Assemble seal cover (F) (261) to pump casing
(271) and fix it with socket bolts (406). 271
: 5mm,
Tightening torque : 1.2kgfym (8.8 lbfyft) 261
z Coat the oil seal in seal cover (F) 406

with a thin film of grease.
z Handle the oil seal with sufficient
care so it is not scored.
z Fit seal cover (R) (262) the same way
as above.
Fig. 1-15 Installing seal cover F (261)
6) Inserting piston cylinder sub

Assemble the piston cylinder sub [cylinder
141(151,152)
block (141), piston (151), shoe (152), plate
(153), spherical bushing (156) and cylinder 156
spring (157)].
Align the spherical bushing with the cylinder 153
spline and insert them into the pump casing.
Fig. 1-16 Inserting piston cylinder sub
II19
7) Installing valve plate

Install valve plate (313), (314) to valve block
(312) by aligning pin.
z Do not mistake the suction and 312

delivery sides of the valve plate.
8) Installing valve block 314

Install valve block (312) to pump casing (271) (313:OPPOSITE SIDE)
and fasten them together with socket bolts
(401).
: 14mm,
Tightening torque : 24kgfym (170 lbfyft) Fig. 1-17 Installing valve plates (313), (314)
z Work will be promoted if assembly is

started from the rear pump. 271
401
z Exercise care so as not to mistake
the direction of the valve block (312).
(Install it so the regulator comes up
as seen from the front side and the
suction flange comes on the right.)
z Insert the 1st gear into the valve
block beforehand and connect it with
the spline of the shaft.
Fig. 1-18 Installing valve block (312)

9) Installing regulator and PTO gear casing
Pinch feedback pin of tilting pin in feedback
lever of the regulator and PTO gear casing,
REGULATOR
install the regulator and fasten socket bolt.
Refer to [415 (See Fig.1-20.), 435[See
Fig.1-34.)].
Socket bolt (415) ........... For regulator

: 6mm,
Socket bolt (435) ........... For PTO gear casing
: 8mm,
Fig. 1-19 Installing regulator and PTO gear
z Do not mistake the front regulator casing
for the rear regulator.
10) Installing drain port plug

The work is complete when drain port VP
plugs (467), (468) have been set.
: 27mm,
110
1.1.3 MAINTENANCE STANDARDS

(1) Replacement standards for abrasive parts However, always replace such parts that
Replace or readjust parts that exceed the show excessive damage on appearance.
following standards of wear.
Unit: mm (in)
Standard Recommended
Part name and inspection item value for Remedy
dimension replacement
Clearance between piston and 0.028 0.056
Replace piston or cylinder.
cylinder bore (Dd) (0.0011) (0.0022)
Gap between piston and caulked part 00.1 0.3

Replace piston shoe assy.
of shoe () (0.004) (0.012)
3.9 3.7
Thickness of shoe (t) Replace piston shoe assy.
(0.154) (0.146)
31.3 30.2
Free height of cylinder spring (L) Replace cylinder spring .
(1.23) (1.19)
Combined height of retainer plate and 10.5 9.8 Replace a set of spherical
spherical bushing (Hh) (0.413) (0.386) bushing or retainer plate.
d H
h
Combination of retainer plate and spherical

Clearance between piston and bushing Height=H-h
cylinder bore: Dd
L
Gap between piston and shoe :
thickness of shoe: t Free height of cylinder spring: L
(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face)
Valve plate (sliding section) Surface roughness requiring correction 3Z
Swash plate (shoe plate face)
Cylinder (sliding section) Standard surface roughness
(correction value) Less than 0.4Z (lapping)
Roughness of each surface
111
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 3) When two pumps are used
Inspect the filter element to check for In case two single pumps or motors are used
abnormal contaminations. Some metallic or when a double pump is used. change pump
particles will be deposited on it as the shoe pipelines. This will make clear that the
and the cylinder wear off. In case metallic pumps are faulty or the circuit after the
particles are found in large quantity, the pumps is faulty.
elements may be damaged. In that case check
the drain oil in the pump casing as well. 4) Pressure measurements
If the problem is related to control functions,
2) Checking for abnormal vibration and sound avoid disassembling the pumps carelessly,
Check that the pump does not vibrate and but look for causes by measuring pressures.
make an abnormal sound.
Check that the hunting of the regulator and
the attached valves relief valve are of regular
frequency. In case vibration and sound are
abnormal, the pump may be making a
cavitation or internally broken.
(2) Troubleshooting
1) Overloading to engine
Cause Remedy Remarks

1. Revolution and pressure are 1) Set pressure to specified
higher than set values. value.
2. Regulator torque is set higher 2) Readjust regulator. 2) Refer to Regulator Manual.
than normal.
3. Pumps internal parts are 3) Replace damaged parts. 3) Check filter and drain oil to see if
seized or broken. abnormal wear particles are
present.
4. Regulator is piped incorrectly. 4) Pipe regulator correctly.
112
(2) Pumps oil flow rate is extremely low and delivery pressure is not available.
Cause Remedy Remark

1. Regulator is out of order 1) Repair regulator. 1) Refer to Regulator Manual.
2. Pumps internal parts are 2) Replace damaged parts. 2) Check filter and drain oil.
seized 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, Valve.
seat and spring.
5. Regulator is piped incorrectly. 5) Pipe correctly.
(3) Abnormal Sound and Vibration
Cause Remedy Remark

1. Cavitation 1) Prevent cavitation. 1-1) The boost pressure is low.
Check that hydraulic oil 1-2) The attached pump is in trouble.
is not clouded. 1-3) The suction pipe is inhaling air.
1-4) The suction resistance is high.
2. Caulked part of shoe is broken. 2) Replace piston shoe and
shoe plate.
3. Cylinder is cracked 3) Replace cylinder.
4. Pump is installed improperly. 4) Correct installation.
5. Regulator is hunting. 5) Repair regulator, 5) See Regulator Manual.
6. Relief valve in attached valve 6) Repair attached valve. 6) See the Manual for Attached
is hunting. Valve.
113

1.2 REGULATOR
656 402
733
627
646
624
496 601
801
924
415
543
545
541
079 756
755
614
733
887
658
724
325 418 708
496 652
897
Table 1-4
651
643 611 TORQUE No. NAME Q
TY TORQUE No. NAME Q
TY
631
079 SOLENOID PROPORTIONAL
REDUCING VALVE
1 643 PISTON 1
731
325 VALVE CASING 1 646 SPRING 1
1.2 (8.7) 402 SOCKET BOLT ; M616 4 651 SLEEVE 1
1.2 (8.7) 407 SOCKET BOLT ; M630 4 652 SPOOL 1
755
407 466 3.0 (22) 415 SOCKET BOLT ; M845 6 656 COVER 1
0.7 (5.1) 418 SOCKET BOLT ; M512 2 0.9 (6.5) 658 PLUG ; NPTF1/16 1
1.6 (12) 466 VP PLUG ; PF1/4 1 708 O RING ; 1B G75 1
0.9 (6.5) 496 PLUG 9 724 O RING ; 1B P8 5
541 SEAT 2 731 O RING ; 1B P25 1
543 STOPPER 2 733 O RING ; 1B P18 2
545 BALL 2 755 O RING ; 1B P11 2
601 CASING 1 756 O RING ; 1B P12.5 2
611 FEEDBACK LEVER 1 1.6 (12) 801 HEX. NUT ; M8 1
3.7 (27) 614 FULCRUM PLUG ; PF1/4 1 887 PIN 1
624 SPRING SEAT 1 897 PIN 1
627 PLUNGER 1 924 SET SCREW 1
631 SLEEVE 1
114
Fig. 1-20 Structural exploded view of regulator
1.2.2 DISASSEMBLY AND ASSEMBLY

(1) Tools
The right list shows the tools required for Table 1-5
remove and install.
Tool name Dimension
(2) Disassembling procedure Allen wrench Opposing flats 4,5,6,8mm

1) Selecting a place for disassembly. Eye wrench
Socket wrench
Wrench with double Opposing flats 19mm
z Choose a clean place. heads (single head)
z Spread rubber sheet or cloth on work
bench to protect parts from Adjust wrench Medium size 1pc.
damaging.
Screw driver Flat-bladed screw driver 1pc.
Plunger (627),
Socket bolt for drawing out (M4)
2) Cleaning
One that may be fastened to
Remove dust and rust, etc. on regulator Torque wrench specified torque
surface with wash oil.
3) Remove regulator
REGULATOR
Remove socket bolts (415) and separate the
regulator from the pump body.
: 6mm
z Exercise care so as not to lose O

rings and check valve sub (541),
(543), and (545).
Fig. 1-21 Removing regulator
4) Remove valve casing

Remove socket bolts (407) and remove valve
casing (325) with solenoid proportional
reducing valve (079).
: 5mm
325 (079)
407
Fig. 1-22 Removing valve casing (325)
115
5) Remove cover
Remove socket bolt (402) and cover (656).
: 5mm
l The cover is assembled with set

screw (924) and hex nut (801), but do
not loosen them. If they are 801
loosened, the pressure settings
change.
402 924 656

Fig. 1-23 Removing cover (656)
6) Remove sleeve and pilot piston

Draw out sleeve (631) and pilot piston (643)
from the regulator body.
631(643)
Fig. 1-24 Removing sleeve (631)
and pilot piston (643)
7) Remove feedback lever

Remove fulcrum plug (614) and feedback 611
lever (611).
: 19mm
8) Drawing out the spool and the sleeve

Draw out spool (652) and sleeve (651) from
the sleeve hole of the regulator casing.
HOLE FOR FULCRUM PLUG (614)

Fig. 1-25 Removing feedback lever (611)
9) Remove plunger, pilot spring and spring seat

Draw out plunger (627). Then take out pilot 627(624,646)
spring (646) and spring (624).
l The plunger comes off easily if an

M4 bolt is used.
Fig. 1-26 Removing plunger (627)
1 16
10) Drawing out the check valve 541

The disassembly is complete when the check
valve [seat (541), ball (545), and stopper
(543)] have been drawn out.
543 (545)
z The check valves are placed on two
places; the mating surface of the
pump casing and on the matching
surface of the valve casing.
601
Fig. 1-27 Drawing out the check valve.
1. Do not fail to correct parts damaged during
disassembly and get replacement parts ready
beforehand.
2. Entry of foreign matter causes faulty
functions; clean parts thoroughly, dry them
with jet air and work in a clean place.
3. Tighten bolts and plugs to specified torques.
4. Do not fail to coat the sliding parts with clean
hydraulic oil, before proceeding to assembly.
5. In principle, replace seals such as O rings
with new ones.
1) Placing the check valve 541

Fit the check valve to casing (601).
z Assemble the check valve into the

matching surface of the pump casing 543 (545)
and the matching surface of the
valve casing.
601
Fig. 1-28 Placing the check valve.
2) Fitting the sleeve and the spool
Place sleeve (651) and spool (652) into the
sleeve hole of casing (601). 601
z Make sure that the spool and the

sleeve slide smoothly in the casing
without interference.
z Beware of the direction of the spool.
651(652)
Fig. 1-29 Fitting the sleeve (651)
and the spool (652).
117
3) Installing feedback lever 611(897)

Insert pin (897) of feedback lever (611) into
the pin hole of the sleeve and fix the feedback
lever with fulcrum plug (614).
: 19mm,
z Operate the feedback lever and

make sure that it does not have
much looseness and that it operates 614
without catching. Fig. 1-30 Installing feedback lever (611)
4) Installing spring seat, pilot spring and 646(627)

plunger
Place spring seat (624), pilot spring (646) and
plunger (627) into the hole in the sleeve.
Fig. 1-31 Installing spring seat (624),

pilot spring (646) and plunger (627)
5) Installing cover
Attach cover (656) to casing (601) and fasten
them together with socket bolts (402).
: 5mm,
z The cover is fitted with set screw

(924) and hex nut (801).
601
656 402
Fig. 1-32 Installing cover (656)
6) Assembling the sleeve and the pilot piston
Assemble sleeve (631) and pilot piston (643)
into casing (601).
7) Installing valve casing

Attach valve casing (325) fitted with solenoid
proportional reducing valve (079) to casing
(601) and fasten them together with socket
bolts (407).
: 5mm, 631
643
Fig. 1-33 Assembling the sleeve (631)

This completes assembly.
and the pilot piston (643).
118
1.3 PTO GEAR CASING

414
117 128
126 435
826 886 711
326
128
414
115
827 886 262
728
125 468
118
125
825
435
435
Fig. 1-34 Structural exploded view of PTO gear casing
Table 1-6
TORQUE No. NAME Q
TY TORQUE No. NAME Q
TY
115 IDLE SHAFT 1 3.4 (25) 435 FLANGE SOCKET ; M1020 4
117 2nd GEAR 1 7.5 (54) 468 VP PLUG ; PF3/4 1
118 3rd GEAR 1 711 O RING ; 1B G85 1
125 BALL BEARING 2 728 O RING ; 1B P24 1
126 ROLLER BEARING 1 825 SNAP RING 1
128 BEARING SPACER 2 826 SNAP RING 1
262 COVER 1 827 SNAP RING 1
326 GEAR CASING 1 886 PIN 2
3.4 (25) 414 SOCKET BOLT ; M1020 2
119

(1) Tools
The right list shows the tools required for Table 1-7
remove and install.
Tool name Dimension
(2) Disassembling procedure Allen wrench Opposing flats 8mm

1) Selecting a place for disassembly. Eye wrench
Socket wrench
Wrench with double Opposing flats 27mm
z Choose a clean place. heads (single head)
z Spread rubber sheet or cloth on work For snap ring RR-20
bench to protect parts from Plier For snap ring RR-72
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 (467), (468).
FLANGE SOCKET (M10)
: 27mm
TIGHTENING TORQUE : 3.4kgfym (25ftylbs)
z Drain out the oil from the plugs of

the front pump and the rear pump.
4) Remove gear pump and cover

Remove the flange socket and the socket
bolts. Then remove the gear pump and the
cover. GEAR PUMP
: 8mm (FOR DOZER)
COVER
PTO GEAR CASING
435
GEAR PUMP
Fig. 1-35 Removing gear pump
5) Remove PTO gear casing
Remove flange socket (435) and PTO gear
casing.
: 8mm HOLE FOR FLANGE
SOCKET (435)
PTO
GEAR CASING
Fig. 1-36 Removing PTO gear casing
120
6) Removing the 2nd gear, the roller bearing HOLE FOR

IDLE SHAFT (115)
and the bearing spacer
Remove snap ring (827) and idle shaft (115).
Then draw out 2nd gear (117), roller bearing
(126) and bearing spacer (128). 117(126,128)
z Roller bearing (126) can not be

separated from 2nd gear (117).
Fig. 1-37 Removing 2nd gear (117)

7) Removing the 3rd gear and the ball bearing
Remove snap ring (825) and draw out 3rd
gear (118) and ball bearing (125).
z Ball bearing (125) can not be 125

separated from 3rd gear (118).
118
Fig. 1-38 Removing 3rd gear (118)

and ball bearing (125)

1. Repair scored parts at disassembly. Get
replacements ready beforehand.
2. Wash parts sufficiently in cleaning oil and
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.
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.
121
122
2. CONTROL VALVE
2.1 GENERAL PRECAUTIONS 2.3 DISASSEMBLY
1) As all the hydraulic components are precisely Regarding the construction of the control valve,
machined, it is essential to carry out refer to 4.2 Construction, 4. Control Valve under
disassembly and reassembly in an especially YB24 Components System.
clean location. The figures in parentheses after part names in
2) When handling the control valve, take special the contents represent those in the
care to prevent the entry of foreign matter, above-mentioned Fig.4 structural exploded view
such as dust or sand. on YB24, 4 Control valve.
3) Cap each port of the control valve before
removing the valve from the machine. Before Place the control valve on the workbench with the
disassembly, confirm that each cap is in place ports facing upward.
and then clean the exterior of the assembly.
Use an appropriate workbench. Lay a clean Disassemble the valve in a clean
sheet of paper, rubber mat, or the like over location, and be careful not to damage
the workbench. flange surfaces or plate mounting
4) When carrying or moving the control valve, surfaces.
hold the body, and never put pressure on a
lever, an exposed spool, or the end cover.
Handle the valve with care.
5) Tests(for relief characteristics, leaks,
overload valve setting, flow resistance, etc.)
that are desired after disassembly and
reassembly require hydraulic testing
apparatus.
For this reason, do not disassemble hydraulic
units that you are capable of disassembling
but cannot test or adjust.
Prepare beforehand washing fluid, hydraulic
oil, grease, etc. .
Fig. 2-1 Preparation for disassembly
(valve upper side)
2.2 TOOLS
Prepare the following tools before disassembling
the control valve.
No. Name Table

QTY2-1 Remarks
a Vise 1
b Box end wrench 1 of each 8,22,24,27,30,32mm
size
c Allen wrench 1 of each 4,5,6,8,10,12,14,22mm
size
e Locktite #262 1
f Spatula 1
g Tweezers 1
h Adjust wrench 1 (valve lower side)
21
(1) Remove option valve block (Section H-H) 214

1) Loosen the socket bolts (272) and remove the 213(272)
plate (214) and the option valve (213).
: 10mm
Regarding the disassembly of the

optional valve block, refer to the
Disassembling option valve under (20).
Fig. 2-3 Removing option valve

(2) Remove plate
271
1) Loosen the socket bolts (271) and remove the
plate (214). 214
: 10mm
Fig. 2-4 Removing plate (214)

(3) Disassembling arm recirculation spool
273 204(262)
(Section G-G)
spring cover (204) and the O ring (262) for
arm recirculation.
: 6mm
Fig. 2-5 Removing arm recirculation

spool spring cover (204)
2) Draw out, from casing A (101), the assy of
310
arm recirculation spool (310), spring seat
(332), springs (325), (326), stopper (337) and
bolt (333).
When drawing out the spool assy, use

care so as not to score casing A (101).
Fig. 2-6 Drawing out arm recirculation spool
II22
3) Fix the arm recirculation spool assy with vise

via a protective plate (aluminum plate, etc.)
and remove bolt (333). Then separate spring
seat (332), springs (325), (326) and stopper 333
(337) from arm recirculation spool (310).
332
326(337)
325
310
Fig. 2-7 Disassembling arm recirculation

(4) Disassembling cut spool (Section G-G) spool assy
1) Loosen socket bolt (273) and separate spring 273 204(262)
cover (204) and O ring (262) from the cut
spool.
: 6mm
Fig. 2-8 Removing cut spool spring cover (204)

2) Draw out the assy of cut spool (309), spring 309
seat (332), springs (325), (326), stopper (337)
and bolt (333) from casing A (101) or casing B
(102).
When drawing out the spool assy, take

care so as not to score casing A (101) or
casing B (102).
Fig. 2-9 Drawing out cut spool assy

3) Fix the cut spool assy with vise via a
protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring seat
(332), springs (325), (326) and stopper (337) 333
from cut spool (309).
332
326(337)
325
309
Fig. 2-10 Disassembling cut spool assy
23
273
(5) Disassembling the arm spool (Section F-F)
1) Loosen socket bolts (273) and remove spring 201(262)
cover (201) for arm and O ring (262).
: 6mm
Fig. 2-11 Removing arm spool spring cover (201)

2) Draw out the assy of arm spool (302), spring
302
and bolt (333) from casing A (101).

Fig. 2-12 Drawing out arm spool assy

3) Fix the arm spool assy with vise via a
333
(332), springs (324), (329) and stopper (337)
from arm spool (302). 332
: 6mm 324(337)
329
4) Do not disassemble the arm spool (302)
further unless there is any problem. 302
(See Fig. 4-5)
Take care so as not to distort arm spool

(302) by overtightening it in the vise. Fig. 2-13 Disassembling arm spool assy
273
(6) Disassembling the boom spool (Section F-F) 201(262)
1) Loosen socket bolts (273) and remove spring
cover (201) for boom and O ring (262).
: 6mm
Fig. 2-14 Removing boom spool spring cover
24
2) Draw out the assy of boom spool (301), spring 301

and bolt (333) from casing B (102).

care so as not to score casing B (102).
Fig. 2-15 Drawing out boom spool assy

3) Fix the boom spool assy with vise via a
from boom spool (301). 332
324(337)
329
301
Fig. 2-16 Disassembling boom spool assy

4) Do not disassemble the boom spool (301) 301(352,353)
further unless there is any problem.
(See Fig. 4-6)
Take care so as not to distort boom

spool (301) by overtightening it in the
vise.
Fig. 2-17 Disassembling boom spool (301)

(7) Disassembling the boom conflux spool
(Section E-E)
201(262)
cover (201) for boom conflux and O ring (262).
: 6mm
273
Fig. 2-18 Removing boom conflux
spool spring cover (201)
25
2) Draw out the assy of boom conflux spool

(305), spring seat (332), springs (325), (326), 305
stopper (337) and bolt (333) from casing A
(101).

Fig. 2-19 Drawing out boom conflux spool assy
3) Fix the boom conflux spool with vise via a

from boom conflux spool (305).
332
326(337)
325
305
Fig. 2-20 Disassembling boom conflux spool assy
(8) Disassembling bucket spool (Section E-E) 273

1) Loosen socket bolts (273) and remove bucket
spring cover (201) and O ring (262). 201(262)
: 6mm
Fig. 2-21 Removing bucket spool spring cover
2) Draw out the assy of bucket spool (304), 304

spring seat (332), springs (328), (329), stopper
(337) and bolt (333) from casing B (102).

Fig. 2-22 Drawing out bucket spool assy
2 6
3) Fix the bucket spool assy with vise via a

from bucket spool (304).
332
328(337)
329
304
Fig. 2-23 Disassembling bucket spool assy

(9) Disassembling the swing spool (Section D-D)
cover (202) and O ring (262).
: 6mm
273 202(262)
Fig. 2-24 Removing swing spool spring cover
2) Draw out the assy of swing spool (303), spring
and bolt (333) from casing A (101).
303
care so as not to score casing A (101) or
casing B (102).
Fig. 2-25 Drawing out swing spool assy

3) Fix the swing spool assy with vise via a
from swing spool (303). 333
332
324(337)
329
303
Fig. 2-26 Disassembling swing spool assy
27
(10) Disassembling the travel spool (left travel

and right travel) (Section C-C, D-D)
travel.
: 6mm
273 201(262)
Fig. 2-27 Removing travel (right)

spool spring cover
2) Draw out the assy of travel spool (306),
spring seat (332), springs (325), (327), stopper
(338) and bolt (333) from casing A (101) or 306
casing B (102).

care so as not to score the casing A
(101) or the casing B (102).
Fig. 2-28 Drawing out travel (right) spool assy

3) Fix the travel spool assy with vise via a
protective plate (aluminum plate, etc.).
Remove bolt (333) and separate spring seat
333
from travel spool (306).
332
327(338)
325
306
Fig. 2-29 Disassembling travel (right) spool

(11) Disassembling travel straight spool (306)
(Section C-C)
travel straight.
: 6mm
273 201(262)
Fig. 2-30 Removing travel straight

l i
28
2) Draw out the assy of travel straight spool

(307), spring seat (332), springs (325), (326),
stopper (337) and bolt (333) from casing B 307
(102).

care so as not to score the casing B
(102).
Fig. 2-31 Drawing out travel straight spool assy

3) Fix the travel straight spool assy with vise
via a protective plate (aluminum plate, etc.).
Remove bolt (333) and separate spring seat
(332), springs (325), (326) or (322),(323) and
333
stopper (337) or (339) from travel spool (307).
332
326(337)
325
307
Fig. 2-32 Disassembling travel straight spool

assy
(12) Remove lock valve selector sub (Section F-F)
Loosen socket bolts (L171) and remove lock L171
valve selector (211). 211
: 5mm
Do not disassemble the lock valve

selector sub assy.
Fig. 2-33 Removing lock valve selector sub assy

273
(13) Disassembling the arm conflux spool 204(262)
(Section G-G)
cover (204) and O ring (262) for arm conflux.
: 6mm
Fig. 2-34 Removing arm conflux

spool spring cover
II29
2) Draw out the assy of arm conflux spool (308), 308

spring seat (332), spring (325), (326), stopper
(337) and bolt (333) from casing B (102).

Fig. 2-35 Drawing out arm conflux spool assy

3) Fix the arm conflux spool assy (308) with vise
via a protective plate (aluminum plate, etc.)
and remove bolt (333). Then separate spring
seat (332), springs (325), (326) and stopper
(337) from arm conflux spool (308). 333
332
326(337)
325
308
Fig. 2-36 Disassembling arm conflux spool assy

(14) Removing spool cover
273
Loosen the socket bolts (273) for the travel,
206(265)
arm, boom, bucket, swing, travel straight and
boom conflux sections. Then remove spool
cover (206) and O ring (265).
: 6mm
Fig. 2-37 Removing spool covers (206)
(15) Removing relief valve

Remove the main relief valve (601) and over
load relief valve (602) from the casing.
Regarding the disassembly of the relief valve,
refer to the disassembling Main and Port
relief valve. Refer to (18) and (19).
: 30mm
601
Fig. 2-38 Removing main relief valve(601)
210
602
Fig. 2-39 Removing over load relief valve (602)

552
(16) Remove check valve (Section G-G)
1) Arm recirculation check valve (CAr)
Loosen plug (552) and remove poppet (512)
and spring (522).
Remove the load check valve the same way.
(CT2,CP2,LCs,CCb,LCa)
(CP1,LCc,LCb,CCa)

check valve plug (552)
512(522)

check valve poppet (512)
2) Check valve in the lock valve section.
(Arm ; CRa, Boom ; CRb) (Section F-F) 556
Loosen plug (556) and remove poppet (514)

and spring (524).
Exercise care so as not to mistake parts

as they all differ in kind from 1) above.
Fig. 2-42 Removing arm lock valve plug (556)
211
514
524
Fig. 2-43 Removing arm lock valve poppet (514)
3) Check valve in the travel straight section
(CT1)
Remove plug (552). Then remove poppets
552
(512) and spring (522).
: 10mm CT1
522
512
SECTION H -H
Fig. 2-44 Removing check valve
in the travel straight section
4) Check valve in the main relief valve section
(CMR1,CMR2)
513
Remove plug (552) and remove poppet (513)
522
and spring (522). CMR1
: 10mm 552
CMR2
552
Those plugs that are not mentioned in
the foregoing disassembly procedure 522
are blind for extra holes and cast-on 513
holes; do not remove them unless SECTION C-C
necessary. Fig. 2-45 Removing check valve
in the main relief valve section
973
(17) Disassembling casing
1) Loosen socket bolts (973), (974) and separate
casing A (101) and casing B (102).
: 12mm
Fig. 2-46 Disassembling casing
II212
(18) Disassembling main relief valve (See Fig.4-3.)

1) Remove plug (103) and seat (541) by pulling
them by hand as C ring (121) is fixed.
2) Draw out spring (521) and plunger (512) from
inside seat (541).
3) Remove locknut (671) and adjust screw (651).
Remove spring plate (612), spring (621) and
poppet (611).
4) Separate C ring (121), spacer (122), O ring
(561) and backup ring (562) from plug (103).
541 121 103
Filter (125) and filter stopper (124) are
assembled with plug (103) by means of Fig. 2-47 Disassembling main relief valve
C ring (123).
Therefore, it can not be disassembled
any further.
(19) Disassembling port relief valve (See Fig.4-4.)

1) Loosen plug (102), remove springs (521),
(522) and seat (541) out of body (101) and
draw out piston (301) and plunger (511) out
of seat (541).
: 30mm
102
2) Separate locknut (671) and adjust screw (651)
from plug (102) and remove spring seat (612),
spring (621) and poppet (611).
Filter (125) and filter stopper (124) are

101
assembled with plug (103) by means of
snap ring (123). Fig. 2-48 Disassembling over load relief valve
Therefore, it can not be disassembled
any further.
213
(20) Disassembling option valve (See Fig.4-7 on 24

H4-6 (6)).
1) Loosen the socket bolts (S271) and remove
the spring cover (S202) and the O ring (S261)
for option.
: 6mm
2) Draw out the assy of option spool (S301),

spring seat (S337), springs (S323), (S324),
stopper (S333) and bolt (S334) from casing
(S101).

care so as not to score the casing
(S101).
3) Fix the option spool assy with vise via a

protective plate (aluminum plate, etc.).
Remove bolt (S334) and separate spring seat
(S337), springs (S323), (S324) and stopper
(S333) from option spool (S301).
: 6mm
4) Loosen the socket bolts (S271) and remove

the spool cover (S204) and the O ring (S262)
for option.
: 6mm
5) Remove the over load relief valve (S603) from

the casing (S101).
Regarding the disassembly of the relief valve,
refer to the disassembling main and over load
relief valve. Refer to (18) and (19).
6) Loosen the plug (S551) and remove the

poppet (S512) and spring (S522).
: 12mm
7) Remove the plug (S552).

: 10mm
II214
2.4 INSPECTION AFTER DISASSEMBLY 7) Remove any slight defects found during the
Thoroughly clean all disassembled parts with above inspection by lapping.
wash oil, and dry them with jet air. Place each 8) If any abnormal part is found, replace the
part on a clean sheet of paper or cloth for relief valve as an assy.
inspection.
(1) Control valve 2.5 REASSEMBLY

1) Inspect the entire surface of each part for 1) Here, only the reassembly procedures are
burrs, scratches, cuts, and other defects. described. Regarding drawings, refer to the
2) Confirm that the O ring groove surface of the disassembly procedures.
casing or the block is free from foreign
matter, dents or rust. 2) The figures in parentheses after part names
3) If the check valve seat of the casing or the in the contents represent those in 4. Control
block has dents or damage on its surface, Valve under 24 Components System.
smooth it by lapping.
3) Precautions on reassembling O ring
Take care not leave lapping compound 1. Confirm that O rings are free from defects
behind in the casing or block. caused by poor handling.
2. Apply thin coat of grease or hydraulic oil to O
4) Confirm that O ring or the outer rings and their mating parts.
circumference of the sliding part of a manual 3. Do not stretch O rings to the extent that they
spool is free from scratches, dents, and the become permanently set.
like. Remove any small defects with an oil 4. When installing O rings, do not roll them into
stone or lapping compound. place. Twisted O rings do not easily untwist
5) Manually confirm that all sliding and fitted by themselves after installation, and can
parts move smoothly. Confirm that all cause oil leaks.
grooves and passages are free from foreign 5. Use a torque wrench to tighten each
matter. attaching bolt. Tighten to the torque in
6) Replace any broken or deformed spring with Maintenance Standards.
new one.
7) If a relief valve malfunctions, repair it by (1) Casing
following the relief valve disassembly and 1) Fix O rings (162,163) to casing B (102). Then
reassembly procedures. fasten socket bolts (973,974) against casing A
8) Replace all O ring with new ones. (101) to the specified torque.
(2) Relief valve Confirm that the mating surface is free

1) Confirm that the seating face of each poppet from foreign matter such as dust, and
and each seat edge is free from defects and is that each O ring is securely installed in
a uniform contact surface. its groove.
2) Manually confirm that the main poppet slides
smoothly onto and off the seat. (2) Assembling check valve
3) Confirm that the outer circumference of the 1) Load check valve, conflux check valve, etc.
main poppet and the inner circumference of Fit poppet (512) and spring (522), put O ring
its seat are free from defects such as (562) in plug (552) and fasten it to the
scratches. specified torque. (10 places)
4) Confirm that each spring is free from
breakage, deformation, and excessive wear. 2) Lock valve (CRa, CRb)
5) Confirm that the orifices of the main poppet Fix poppet (514) and spring (524), put O ring
and its seat are not clogged. (562) in plug (556) and fasten it to the
6) Replace all O rings with new ones. specified torque. (2 places)
II215
Plugs (552) and (556) look similar; use (5) Assembling travel straight spool
care of the parts combination and 1) Put a mouthpiece (aluminum plate, etc.) in
assembling position. the vise and hold the center of travel straight
spool (307) in it. Set spring seat (332), springs
3) Travel straight sections (CT1) (325), (326) or (322), (323) and stopper (337)
Fit poppets (512) and spring (522), put O ring or (339) and tighten bolts (333) to the
(562) in plug (552) and fasten it to the specified torque.
specified torque.
z When tightening bolts (333), coat
4) Main relief valve sections (CMR1, CMR2) them with Loctite #262.
Fit poppets (513) and spring (522), put O ring z Be careful so as not to distort travel
(562) in plug (552) and fasten it to the straight spool (307) by
specified torque. over-tightening it in the vise.
(3) Installing relief valve 2) Assemble the travel straight spool assy in 1)
1) Tighten main relief valve (601) and over load into casing B (102).
relief valves (602) to the specified torques in
correct positions. When assembling the travel straight
spool assy into casings B (102), do it
Regarding the reassembly of the relief slowly and carefully ; never force it in.
valve, refer to the (15), (16) assembling
main and over load relief valve. 3) Fit O ring (262) to the spring side of the
travel straight spool assy. Then attach spring
(4) Assembling arm conflux spool cover (201) to the assy and tighten socket
1) Put a mouthpiece (aluminum plate, etc.) to a bolts (273) to the specified torque.
vise. Hold the center of arm conflux spool
(308) in the vise, set spring seat (332), (6) Assembling travel spool
springs (325), (326) and stopper (337) and 1) Put a mouthpiece (aluminum plate, etc.) in
tighten bolts (333) to the specified torque. the vise and hold the center of travel spool
(306) in it. Set spring seat (332), springs
z Before tightening bolts (333), coat (325), (327) and stopper (338) and tighten
them with Loctite #262. bolts (333) to the specified torque.
z Be careful so as not to distort arm
conflux spool (308) by overtightening z When tightening bolts (333), coat
it in the vise. them with Loctite #262.
z Be careful so as not to distort travel
2) Fix the arm conflux spool assy in 1) into spool (306) by overtightening it in
casing B (102). the vise.
Fix the arm conflux spool assy into 2) Assemble the travel spool assy in 1) into
casing B (102) slowly and carefully and casing A (101), B (102).
never force it in.
When assembling the travel spool assy
3) Attach spring cover (204) with O ring (262) to into casings A (101), B (102), do it
the spring side of the arm conflux spool assy. slowly and carefully ; never force it in.
Then fasten socket bolts (273) to the specified
torque. 3) Fit O ring (262) to the spring side of the
travel spool assy. Then attach spring cover
(201) to the assy and tighten socket bolts
(273) to the specified torque.
II216
(7) Assembling swing spool (9) Assembling boom conflux spool

1) Put a mouthpiece (aluminum plate, etc.) to 1) Put a mouthpiece (aluminum plate, etc.) and
the vise and hold the center of swing spool hold the center of boom conflux spool (305) in
(303). Set spring seat (332), springs (324), the vise. Set spring seat (332), springs (325),
(329) and stopper (337) and tighten bolts (326) and stopper (337) and tighten bolts
(333) to the specified torque. (333) to the specified torque.
z When tightening bolts (333), coat z When tightening bolts (333), coat
them with Locktite #262. them with Locktite #262.
z Be careful so as not to distort swing z Use care so as not to distort boom
spool (303) by overtightening it in conflux spool (305) by overtightening
the vise. it in the vise.
2) Assemble the swing spool assy in 1) into 2) Fix the boom conflux spool assy in 1) into
casing A (101). casing A (101).
When assembling the swing spool assy When assembling the boom conflux
into casing A (101), do it slowly and spool assy into casing A (101), do it
carefully ; never force it in. slowly and carefully ; never force it in.
3) Put O ring (262) to the spring side of the 3) Fit O ring (262) to the spring side of the boom
swing spool assy and attach spring cover conflux spool assy and attach spring cover
(202) to the assy. Then tighten socket bolts (201) to the assy. Then tighten socket bolts
(273) to the specified torque. (273) to the specified torque.
(8) Assembling bucket spool (10) Assembling boom spool

1) Put a mouthpiece (aluminum plate, etc.) to 1) Assemble plunger 1 (315), plunger 2 (316),
the vise and hold the center of bucket spool plunger 3 (317), spring B1 (320), spring B2
(304) in it. Set spring seat (332), spring (328), (330) and spring B3 (340) in boom spool (301).
(329) and stopper (337) and tighten bolts Then tighten plugs (352), (353) to the
(333) to the specified torque. specified torque.
z When tightening bolts (333), coat Use care so parts are assembled in
them with Locktite #262. correct positions and make sure that
z Be careful so as not to distort bucket each plunger slides lightly in boom
spool (304) by overtightening it in spool (301).
the vise.
2) Put a mouthpiece (aluminum plate, etc.) in a
2) Assemble the bucket spool assy in 1) into vise and hold the center of boom spool (301)
casing B (102). in the vise. Set spring seat (332), springs
(324), (329) and stopper (337) and tighten
When assembling the bucket spool assy bolts (333) to the specified torque.
into casing B (102), do it carefully and
slowly ; never force it in. z When tightening bolts (333), coat
them with Locktite #262.
3) Fit O ring (262) to the spring side of the z Be careful so as not to distort boom
bucket spool assy and attach spring cover spool (301) by overtightening it in
(201) to the assy. Then tighten socket bolts the vise.
(273) to the specified torque.
3) Install the boom spool assembly reassembled
in Article 2) above in casing B (102).
217
When assembling the boom spool assy 3) Attach spring cover (204) with O ring (262) to
into casing B (102), do it slowly and the spring side of the cut spool assy. Then
carefully ; never force it in. fasten socket bolts (273) to the specified
torque.
4) Attach O rings (262) to the spring side of the
boom spool assy. Then fit spring cover (201) (13) Assembling arm recirculation spool
to the assy and tighten socket bolts (273) to 1) Put a mouthpiece (aluminum plate) in the
the specified torque. vise and hold the center of arm recirculation
spool (310) in the vise. Set spring seat (332),
(11) Assembling arm spool springs (325), (326) and stopper (337) and
1) Put a mouthpiece (aluminum plate) in the tighten bolts (333) to the specified torque.
vise and hold the center of arm spool (302) in
the vise. Set spring seat (332), springs (324), z When tightening bolts (333), coat
(329) and stopper (337) and tighten bolts them with Locktite #262.
(333) to the specified torque. z Take care so as not to distort arm
recirculation spool (310) by
z When tightening bolts (333), coat over-tightening it in the vise.
them with Locktite #262.
z Take care so as not to distort arm 2) Fit the arm recirculation spool assy in 1) to
spool (302) by overtightening it in casing A (101).
the vise.
When assembling the arm recirculation
2) Fit the arm spool assy in 1) to casing A (101). spool assy into casing A (101), do it
slowly and carefully ; never force it in.
When assembling the arm spool assy
into casing A (101), do it slowly and 3) Attach spring cover (204) with O ring (262) to
carefully ; never force it in. the spring side of the arm recirculation spool
assy. Then tighten socket bolts (273) to the
3) Attach spring cover (201) with O ring (262) to specified torque.
the spring side of the arm spool assy. Then
tighten socket bolts (273) to the specified (14) Assembling spring covers
torque. 1) Travel, boom, bucket, swing and arm.
Fit O ring (265) to spool cover (206) and
(12) Assembling cut spool tighten socket bolts (273) to the specified
1) Put a mouthpiece (aluminum plate, etc.) in a torque.
vise and hold the center of cut spool (309) in
the vise. Set spring seat (332), springs (325), 2) Travel straight and boom conflux
(326) and stopper (337) and fasten bolts (333) Fit O ring (265) to spool cover (206) and
to the specified torque. tighten socket bolts (273) to the specified
torque.
z Before tightening bolts (333), coat
them with Locktite #262. (15) Assembling main relief valve (See Fig.4-3.)
z Use care so as not to distort cut spool 1) Fit spacer (122), C ring (121), O rings (163),
(309) by overtightening it in the vise. (561) and backup ring (562) to plug (103).
2) Fix poppet (611) and spring (621) to plug
2) Fit the cut spool assy in 1) into casing A (101) (103) in 1) above. Then fix spring seat (612)
and casing B (102). in 2) fitted with O rings (661).
When assembling the cut spool assy Make sure that poppet (611) is snugly
into casing A (101), B (102), do it slowly placed in the seat of plug (103).
with care ; never force it in.
218
3) Temporarily assemble adjust screw (651) and (17) Assembling option valve
lock nut (671) to plug (103). 1) Tighten plug (S552) with O ring (S562) to
casing (S101) and fasten it to the specified
4) Assemble plunger (512) and spring (521) into torque.
seat (541). 2) Assemble poppet (S512) and spring (S522) to
casing (S101) and fasten plug (S551) with O
5) Assemble the seat in 4) to the plug (103) assy ring (S561) to the specified torque.
under 3) and fix it with snap ring (121). 3) Put a mouthpiece (aluminum plate, etc.) in
the vise and hold the center of option spool
6) Pressure adjustment is performed in accor- (S301) in it. Set spring seat (S337), springs
dance with Maintenance Standard and Test (S323), (S324) and stopper (S333) and tighten
Procedure. Leave adjust screw (651) tempo- bolts (S334) to the specified torque.
rarily assembled.
z When tightening bolts (S334), coat
(16) Assembling Over load Relief Valve them with Locktite #262.
(See Fig.4-4.) z Be careful so as not to distort option
1) Assemble spring seat (612) with poppet (611), spool (S301) by overtightening it in
spring (621) and O ring (661), into plug (102) the vise.
that is fitted with O rings (162), (561) and
backup ring (562). Then temporarily assem- 4) Assemble the option spool assy in 3) into
ble adjust screw (651) and locknut (671). casing (S101).
Make certain that poppet (611) is When assembling the option spool assy
snugly fitted in the seat of plug (102). into casing B (102), do it carefully and
slowly ; never force it in.
2) Fit O ring (563) and backup ring (564) to seat
(541) and attach the seat to plunger (511) and 5) Put O ring (S261) to the spring side of the
assemble piston (301) and springs (521), option spool assy, attach spring cover (S202)
(522). to the assy and tighten socket bolts (S271) to
the specified torque.
3) Assemble the seat (541) assy in 2) into body
(101) and tighten the plug (102) assy in 1) to 6) Install spool cover (S204) with O ring (S262)
the specified torque. and fasten socket bolt (S271) to the specified
torque.
Confirm that springs (521), (522) are
guided properly. 7) Install over load relief valve (S603) to casing
(S101) and fasten it to the specified torque.
4) Pressure adjustment is performed in accor-
dance with Maintenance Standard and Test
Procedure and adjust screw (651) is left tem-
porarily assembled.
219

(1) Inspection of components
Part name Inspection item Criterion and remedy

Casing 1) Look for scratches, rusting and 1) If any of the following parts are
corrosion. damaged, replace the casing.
z Sliding part of casing hole and spool,
particularly the land, to which holding
pressure is applied.
z Part of sealing pocket through which
spool is inserted.
z Area of sealing part that is in contact
with O ring.
z Sealing and seating part of main or over
load relief valve.
z Defects of other parts that seem to
prevent normal function.
Spool 1) Look for scratches, galling, rusting 1) If a defect detectable with your
and corrosion. fingernail is found on the sliding part of
the outer circumference, replace the
spool.
2) Inspect ends that are sealed with an 2) If the sliding part is damaged, replace
O ring. the spool.
3) Insert the spool in the casing bore, 3) If the spool damages the O ring or does
and move it while turning it. not move smoothly, repair or replace
the spool.
Poppet 1) Look for damage on the poppet and 1) If sealing is incomplete, correct or
the spring. replace the seal.
2) Insert the poppet in the casing, and 2) If the poppet moves lightly without
move it. catching, it is normal.
Spring and 1) Look for rust, corrosion, deformation, 1) If damaged heavily, replace.
related parts and breakage of the spring, spring
seat, plug and cover.
Spool seal and 1) Look for external oil leak. 1) Repair or replace.
related parts 2) Look for rust, corrosion and deformation 2) Repair or replace.
of sealing plate.
Main relief valve 1) Look for rust and damage on outer 1) Replace.
Over load relief surface.
valve 2) Inspect the contact face of the valve 2) If damaged, replace.
seat.
3) Inspect the contact face of the poppet. 3) If damaged, replace.
4) Look for spring abnormality. 4) Replace.
5) Inspect the O ring, backup ring, and 5) As a general rule, replace all parts with
seal. new ones.
220
2.7 TROUBLESHOOTING
1) If an abnormal condition is noticed, check to If any part of the system is to be
see if the problem is with the control valve disassembled, take dust protection measures
itself, one of the main pumps, the gear pump, beforehand.
or a circuit. To this end, you will need to 3) Moving parts must be handled with care. If
measure pilot pressure, pump delivery they are damaged, smooth the damage using
pressure, load pressure, etc. If any part of the an oil stone or the like.
system is to be disassembled for inspection, 4) Take care not to damage the contact face of
follow the disassembly and reassembly O rings. A damaged contact face will
procedures in this manual. certainly cause oil leaks.
2) Dust is the enemy of hydraulic components.
Pay strict attention to protection from dust.
(1) Control valve
Trouble Cause Remedy

1. Travel does not 1) Malfunctioning main relief valve. 1) Measure travel relief valve pressure
occur. z Foreign matter between main z Disassemble and clean. If damaged
Slow to start up poppet and seat. heavily, replace the assy as a unit.
(or poor power). z Foreign matter between poppet z Same as above.
Slow response. and seat.
z Sticking main poppet. z Smooth sticking part with oil stone.
z Broken or deformed spring. z Replace spring.
z Clogged main poppet throttle. z Remove foreign matter.
z Loosened adjusting screw. z Readjust, and tighten lock nut to
specified torque.
2. Machine does not 1) Malfunctioning travel straight 1) Measure pilot pressure.
travel straight valve.
during z Sticking spool. z Smooth sticking part with oil stone.
simultane-ous z Broken or deformed spring. z Replace spring.
travel and operate z Clogged small hole in spool. z Remove foreign matter.
attachment. 2) Malfunctioning right or left 2) Measure pilot pressure.
neutral cut valve.
z Sticking spool. z Smooth sticking part with oil stone.
z Excessive clearance between right z Replace spool.
or left casing and spool.
z Clogged small hole in spool. z Remove foreign matter.
3) Malfunctioning main relief valve. 3) Replace main relief valve.
See item 1. 1) above.
221

3. Excessive natural 1) Excessive clearance between 1) Replace spool.
falls of attachment casing and spool.
under its own
2) Spool is not completely in 2) Measure secondary pilot pressure.
weight when spool
neutral position.
is in neutral.
z Foreign matter between casing z Disassemble, clean and smooth sticking
and spool, or sticking spool. part with oil stone.
z Clogged pilot circuit. z Remove foreign matter.
3) Malfunctioning port relief valve. 3) Measure over load relief valve pressure.
Refer to item 1. 1) above. Refer to item 1. 1) above.
4) Malfunctioning anti-cavitation 4) Checking the over load relief valve

check valve.
z Foreign matter between poppet z Disassemble and clean.
and casing.
5) Lock valve function is faulty. 5)

z Foreign matter between poppet z Disassemble and clean. In case
and casing. scratches are excessive, replace casing.
z Poppet is stuck. z Correct stuck part with oil stone.
z Selector spool is stuck. z Replace lock valve selector sub assy.
z Dirt is included between selector z Replace lock valve selector sub assy.
spool and bushing.
z O ring in bushing is worn out. z Replace lock valve selector sub assy.
4. When raising 1) Malfunctioning load check valve. 1)
attachment, at z Foreign matter between poppet z Disassemble and clean. If heavily
first it drops. and casing. damaged, replace control valve.
z Sticking poppet. z Smooth sticking part with oil stone.
5. Bucket, boom, arm 1) Malfunctioning main spool. 1) Measure secondary pilot pressure.
or swing does not z Excessive clearance between z Replace spool.
operate. casing and spool.
z Foreign matter between casing z Disassemble and clean.
Slow to start up
and spool.
(or poor power).
z Sticking spool. z Smooth stuck part with oil stone.
Slow response.
z Broken or deformed return z Replace spring.
spring.
z Clogged pilot circuit. z Remove foreign matter.
2) Malfunctioning main relief 2) Measure main relief valve pressure.

valve. Refer to item 1. 1) above. Refer to item 1. 1) above.
3) Malfunctioning over load relief 3) Measure over load relief valve pressure.
valve. Refer to item 1. 1) above. Refer to item 1. 1) above.
4) Malfunctioning pilot valve. 4) Refer to Pilot valve section.
Refer to Pilot valve section.
222

6. Swing priority 1) Operating fault of arm recirculation 1) The same way as 5.1).
function does not spool [the same way as 5.1) below].
operate.
7. Boom or arm 1) Malfunctioning conflux valve. 1) Measure pilot pressure.

conflux does not Refer to item 5.1) above. Refer to item 5.1) above.
operate.
(2) Relief valve

1. No pressure rise. Main or pilot poppet of relief valve is z Check for foreign matter on each
sticking and valve is open, or there is poppet.
foreign matter on valve seat. z Confirm that each component slides
smoothly.
z Clean all components thoroughly.
2. Unstable relief Damaged pilot poppet seat of relief z Replace damaged component.
pressure. valve. Pilot piston sticks against main z Clean all components thoroughly.
poppet. z Smooth surface damage.
3. Irregular relief 1) Wear due to foreign matter. 1) Disassemble and clean.

pressure.
2) Loosened lock nut or adjusting 2) Adjust pressure.
screw.
4. Oil leak. 1) Damaged seat. 1) Replace damaged or worn
Worn out O ring. component. Confirm that each
component operates smoothly before
reassembling.
2) Sticking component due to foreign 2) Confirm that there are no scratches,
matter. scores, or foreign matter present
before reassembling.
223
224
4. PILOT VALVE (FOR TRAVEL)

Z 33 2 36 33
4.1 CONSTRUCTION 13 12 28
(1) Sectional view 36 14 42
19
37 25
26
1,3 30
20
34 25
22 15
21 42
20
39 20
32 17
33 36 33
44,16 40
6 7 SECTION AA
18 8
24
25,42
41
27
4 10,11 35
9 31 5 29
4-M10
T=4.30.4 38
(312.9)
24,41
SECTION BB
VIEW Z
Fig. 4-1 Sectional view of pilot valve (for travel)
Apply Locktite #262
TORQUE NO. NAME QTY TORQUE NO. NAME QTY
1 ORIFICE (SHIM) 4 22 SPRING 4
1.5 (11) 2 SEAT 2 1.0 (7.2) 24 PLUG ; PF1/8 3
3 ORIFICE (SHIM) 4 2.5 (18) 25 PLUG ; PF1/4 3
4 SPOOL 4 6.0 (43) 26 SOCKET BOLT ; M1060 2
5 BODY 1 0.5 (3.6) 27 FLANGE BOLT 4
6 STOPPER 4 1.5 (11) 28 SET SCREW ; M8 4
9 NAME PLATE 1 31 RIVET 2
10 SHIM t=0.2 4 32 PIN ; 5 4
11 SHIM t=0.1 4 33 BALL 6
12 CAM 2 34 BALL 4
13 BOOTS 2 35 BALL 4
14 PIN 2 36 BALL 6
15 COVER 2 37 U PACKING 4
16 PISTON 4 38 O RING ; 1A P5 4
17 GUIDE 4 39 O RING ; 1A P24 4
18 SLEEVE 4 40 O RING ; 1A P26 4
19 HOLDER 4 41 O RING ; 1B P8 3
20 RING 12 42 O RING ; 1B P11 3
21 ORIFICE (SHIM) 4 44 PISTON ASSY 4
41
(2) Explosion view
13
26
30
28
12 LIP DETAIL
37 14
15
6
27
18
36
DAMPER SECTION
19
8
1,3
10,11,29
REDUCING VALVE SECTION
16,44
20 21
4
34
22
20 7
20
39 40
17 32
38
24
41 5
Fig. 4-2 Explosion view of travel pilot valve
42
1. Tools used 3. Disassembling the damper (See Fig.4-3.)

Tool name Use (1) Draw out piston assy (44) and guide (17) from
For fixing the valve cover (15).
Vise
body z The damper is drawn out easily if it is pushed
Small vise from the ball side (36).
For disassembling the
(Place a copper plate on
reducing valve spool (2) Draw out four balls (36), holders (19) and
the mouthpiece.)
orifices (1), (3) from piston assy (44).
Allen wrench 3, 4, 5, 6, 8mm
z On that occasion, align the hole in the cover,
Scriber the piston assy and the guide as a set as each
For disassembling the
(or a sharp point rod of
U-packing part is shop fitted. Therefore, if parts for
the same shape)
Hex rod for torque different locations are assembled, functional
3, 4, 5, 6, 8mm
wrench faults may occur in some cases.
Torque wrench z Ring (20), orifice (21), spring (22) and ball
For picking up ball (36) (34) can not be separated from the piston
Magnet bar assy as they are assembled with ring (20)
and holder (19)
pressed in.
z Disassembly and assembly procedures
It is usual that disassembly and assembly are
executed at the makers factory, but in
unusual cases, do the work at a service shop
where skilled technicians are available.
Hydraulic parts are precision products of 37
small clearance. Therefore, disassembly and 15
assembly work shall be performed in a clean
place where there is little dust in the
following manner:
Never knock on precision parts in case they
do not operate smoothly.
Replace seal parts such as O rings and U 36
packings with new ones. 19
1,3
2. Disassembly 44,16
(1) Put a plug into each port (P,T,1,2,3,4,5,6) of 20
the valve and clean the outside. 21
(2) Fix the valve after cleaning it in a vise. 34
(3) Remove two boots (13). 22
(4) Loosen 22 places of socket head set screws 20
20
(28) and remove them from cam (12). 39
: 4mm 17
(5) Draw out two pins (14) from cover (15). On

that occasion, the pins may be drawn out Fig. 4-3 Disassembling the damper
with ease if the pins are pushed out of the
inside by the use of an allen wrench 4mm.
(6) Remove two cams (12).
(7) Loosen socket bolts (26) and remove two of
them with washers (30).
: 8mm
(8) Remove two dampers from the reducing

valve.
43
(3) Separate four O rings (39) from guide (17). (3) Draw out two balls (36) from body (5) by
(4) Remove four U packings (37) from cover (15), attracting the balls to a magnet.
using a scriber. z Balls (33), (35) are for circuit plugs and press
fitted to body (5). Therefore, they are not
4. Disassembling the reducing valve section separable.
(See Fig.4-4.)
(1) Separate three socket plugs (24) from body
REDUCING VALVE SPOOL ASSY

(5).
: 5mm 6
(2) Separate O ring (41) from socket plug (24).

(3) Remove four reducing valve spool assemblies
from body (5).
(4) Remove stopper (6) from the reducing valve
spool assy.
(5) Remove four springs (7); parallel pins (32), O 7
rings (38), (40) from body (5). 40
32
5. Disassembling the reducing valve spool assy
(See Fig.4-5.) 38
z The outer diameter of reducing valve spool (4) 24
is finished with a small clearance against the
hole of body (5). Therefore, put a copper plate 5
41
on the mouthpiece of the vise at disassembly
so as not to score the outer diameter.
Note that the spool is deformed if the vise is Fig. 4-4 Disassembling the reducing valve
tightened too much.
(1) Fix spool (4) in a vise (Put a copper plate
against the mouthpiece.) and loosen four 27
socket flange bolts (27). 18
: 3mm
(2) Draw out socket flange bolt (27), sleeve (18), 8

spring (8), shims (10), (11) and washer (29) 10,11,29
from spool (4), in that order.
z On that occasion, mate the disassembled
parts with mating parts as sets. 4
6. Disassembling the shuttle (See Fig.4-6.) Fig. 4-5 Disassembling the reducing spool assy
z The shuttle is unseparable basically as seat
(2) is fixed with adhesive agent (Locktite 33 33
#262.). 36 36
(1) Remove two socket plugs (25) from body (5). 2 2
: 6mm
33 33
(2) Remove two seats (2) from body (5).
: 5mm
z On that occasion, the Locktite comes off. 42 42

Remove it including that adhered to the 25 25
neighboring area of the screw. Fig. 4-6 Disassembling the shuttle
44
7. Assembly 11. Assembling the damper (See Fig.4-3.)

z Clean and degrease parts before assembly. In (1) Fit four U packings (37) to cover (15).
particular, clean the body with a nylon brush z On that occasion, place the cover so the lip of
or something. the U packing faces down (damper chamber
Foreign matter intruded into the valve causes side).
functional faults to occur. (2) Insert four piston assemblies (44) into cover
z Prepare new seals (O rings and U packings) (15).
and coat the surface with hydraulic oil or a z In that case, make sure that each piston is
thin film of grease. set in the same hole where it was before
disassembly.
8. Assembling the shuttle. (See Fig.4-7.) The performances of the piston are not
(1) Put two balls (36) into body (5). affected at all if it is placed in any direction
(2) Coat the screwed part of seat (2) with on the circumference.
Locktite#262 and fit two of them to body (5). (3) Fit O ring (39) to guide (17). Install four
: 5mm, Tightening torque : guides to cover (15).
1.50.1kgfym(110.7 lbfyft) z Fix the guide in the same hole where it was
set before disassembly.
(3) Set O rings (42) to socket plugs (25) and
fasten two plugs to body (5).
2.50.2kgfym (181.4 lbfyft) 33 33
36 36
2 2
9. Assembling the reducing valve spool assy
(See Fig. 4-5.) 33 33
(1) Fix spool (4) in a vise. (Put copper plates
against the mouthpiece.) Set washer (29),
shims (10), (11), spring (8) and sleeve (18), in
that order, and tighten them with four socket
flange bolts (27). 42 42
: 3mm, Tightening torque : 25 25
0.50.1 kgfym (3.60.7 lbfyft) Fig. 4-7 Assembling the shuttle
z On that occasion, pair parts with the 6

REDUCING VALVE
disassembled parts as sets, before performing

assembly work. Incorrect pairing may change
SPOOL ASSY
the secondary pressure.
10. Assembling the reducing valve (See Fig.4-8.)

(1) Fit four O rings (38), (40), parallel pins (32)
7
and springs (7) to body (5).
40
(2) Fit four reducing valve spool assemblies and
stoppers (6). On that occasion, use care as 32
stopper (6) has a direction in which it should
38
be installed; Place it so the concave surface of
it faces down (reducing valve spool side). 24
(3) Set O rings (41) to socket plugs (24). Fasten
three plugs to body (5). 5
41
10.1 kgfym (7.20.7 lbfyft)
Fig. 4-8 Assembling the reducing valve
45
(4) Set orifices (1), (3) to piston assy (44) that is In case such scratches and burrs can not be
set in the cover. corrected with ease, replace the parts with
l The orifices absorbs rattles that are made new ones in pairs.
when cam (12) is in neutral: either orifice (3) If you feel the moving parts of the reducing
may be at the top or at the bottom. valve, body (5) and spool (4) unsmooth,
l In case the cam rattles very much because correct them to be free from scratches and
the cam and the pin are worn out after long burrs, using #1000 emery paper. If it is
hours of use, increase the number of orifices. difficult to correct, replace the parts with new
However, if many orifices are set when there ones in pairs.
is no gap, the reducing valve spool is actuated (4) If you feel the moving parts of the cam
at neutral and pressure is built up in the assembly such as, cam (12), pin (14) and
secondary pressure port. When there is no cover (15), correct them to be free from
gap on the cam at neutral, do not increase the scratch and burr, using #1000 emery paper. If
orifices. it is hard to correct, replace the parts with
(5) Set four holders (19) and balls (36) to piston new ones.
13
assembly (44). 28
36 12
(6) Install two dampers on the reducing valve 14
19
and fasten them with socket bolts (26) with 37 15 35
washers (30). 16,44
In that case, parallel pin (32) set in body (5) 20
34 26
is placed in the hole of cover (15) to position 22
20 39 30
the reducing valve and the damper in place. 17 32
: 8mm, Tightening torque : 40 6 1,3
6 0.5kgfm (43 3.6 lbfft) 18 27 21 38
(7) Set cam (12) to cover (15) and insert pin (14). 24
41 20
On that occasion, check the gap of the cam 8
7 25,42
and if the gap is large, increase orifices (1),
4 10,11,29
(3) according to item (4) above.
l Ball (36) and holder (19) can be drawn out 5
easily by magnet bar. If a magnet bar is not

available, place the valve on its side and give 13 Fig. 4-9
vibration to it.
(8) When the gap adjustment of the cam has
been finished, apply grease to the moving 28
parts of cam (12), pin (14), cover (15) and ball
(36). 12
(9) Attach 2 2 pcs. set screws to cam (12) and 26
30
tighten them.
1.5 0.1kgfm (11 0.7 lbfft) 14
(10) Fit two boots (13).
DAMPER
12. Standard for the judgement of serviceability

of parts
(1) Replace seals with new ones at disassembly
and reassembly.
REDUCING
(2) If you feel the moving parts of the damper,

cover (15), piston assy (44) and guide (17)
VALVE
unsmooth, correct the sliding surfaces and

corners to be free from scratches and burrs,
using #1000 emery paper.
4 6
5. SWING MOTOR UNIT

5.1 CONSTRUCTION
(1) Swing motor 488 992
469
355 401
ANTI CAVITATION
PLUNGER
351 051 RELIEF VALVE
051-1
391 390
VALVE CASING SECTION
SWING SHOCKLESS
VALVE BLOCK 161,
052 V171 152 162 163 V162
053
(400-1)
303 981 111 984 131 451
444 (400-2)
052
981 485
438 464 400
472 706 SECTION_A_A

712 743
V981
707 742 V162 V163 V252
121 V164 V262
980 113 V154
122
702 123
(053)
114
118 V301
116
V101 V154
117
V164
301 443 491 305 101 437 124 994

V261 V251 V981 V324
SECTION_B_B
Fig. 5-1 Swing motor
II-5-1
TORQUE
No. PARTS QTY TORQUE
No. PARTS QTY
18 (130) 051 RELIEF VALVE ; M33-P1.5 2 438 SNAP RING 1

051-1 O RING ; 1B G30 2 443 ROLLER BEARING 1
052 SWING SHOCKLESS VALVE SUB ASSY 1 444 ROLLER BEARING 1
053 BYPASS VALVE BLOCK SUB ASSY 1 451 PIN 2
100 CASING FOR SHOCKLESS VALVE 1 3.7(27) 464 VP PLUG ; PF1/4 1
101 DRIVE SHAFT 1 34 (250) 469 ROMH PLUG ; M30-P1.5 2
111 CYLINDER 1 472 O RING 1
113 SPHERICAL BUSHING 1 485 O RING ; 1B P11 1
114 CYLINDER SPRING 1 488 O RING ; 1B P28 2
116 PUSH ROD 12 491 OIL SEAL 1
117 SPACER F 1 702 BRAKE SPRING 1
118 SPACER 2 706 O RING 1
121 PISTON 9 707 O RING 1
122 SHOE 9 712 BRAKE SPRING 24
123 SET PLATE 1 742 FRICTION PLATE 3
124 SHOE PLATE 1 743 SEPARATOR PLATE 4
131 VALVE PLATE 1 0.09 (0.65) 980 PLUG ; PF1/4 1
3.7 (27) 152 PLUG 2 0.45 (3.3) 981 PLUG ; PF3/4 3
161 O RING ; 1B P11 2 0.17 (1.2) 984 PLUG ; PF3/8 1
162 O RING ; 1B P12 2 6.6 (48) 992 PLUG ; PT1/2 1
163 O RING ; 1B P6 2 10 (72) 994 PLUG ; PT3/4 1
3.0 (22) 171 SOCKET BOLT ; M855 V101 CASING FOR BYPASS VALVE 1
301 CASING 1 3.7 (27) V154 PLUG 2
303 VALVE CASING 1 V162 O RING 2
305 SEAL COVER 1 V163 O RING 2
351 PLUNGER 2 V164 O RING 2
355 SPRING 2 3.0 (22) V171 SOCKET BOLT ; M890 4
390 NAME PLATE 1 17 (120) V251 PLUG 1 1
391 RIVET 2 11 (80) V252 PLUG 2 1
7 (51) 400 SWING SHOCKLESS VALVE ; M22-P1.5 2 V261 O RING 1
400-1 O RING ; 1B P20 2 V262 O RING 1
400-2 BACKUP RING 2 V301 SPOOL 1
44 (320) 401 SOCKET BOLT ; M2045 4 V304 SPRING 1
437 SNAP RING 1 0.09 (0.65) V981 PLUG 2
II52
(2) Swing reduction unit
33 29 28 27 26
19 25
18 22
17 23
16 24
14 22
20
15
21
13 10
12
11
34
37
36 35
9
8
7
5
6
2
1
Fig. 5-2 Cross-sectional view of swing reduction unit

TIGHTENING
TORQUE No. NAME QTY No. NAME QTY
kgfym (lbfyft)
1 PINION SHAFT 1 19 #1 SUN GEAR 1

2 SLEEVE 1 20 SPRING PIN 4
4 PLUG (Not shown) 1 21 SHAFT 4
5 O RING 1 22 THRUST WASHER 8
6 OIL SEAL 1 23 #2 PINION 4
7 RETAINER 1 24 NEEDLE BEARING 4
3.4 (25) 8 SOCKET BOLT; M825 12 25 THRUST WASHER 3
9 BEARING 1 26 #1 PINION 3
10 HOUSING 1 27 ROLLER 102
11 SPACER 1 28 THRUST WASHER 3
12 BEARING 1 29 SNAP RING 3
13 SNAP RING 1 33 SNAP RING 1
14 #2 SPIDER 1 34 SET SCREW; M2020 2
15 #2 SUN GEAR 1 35 CONNECTOR 1
16 RING GEAR 1 36 HOSE 1
17 #1 SPIDER ASSY 1 37 PLUG 1
18.5 (130) 18 SOCKET BOLT ; M14130 10
Apply Three-Bond #1360K
II53
5.2 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR

5.2.1 TOOL
Tools Remarks
Socket
VP plug PF1/4 19mm
wrench
Allen
M8,M14,M20,M20(Set screw) 6,10,12,17mm
wrench
Plier For bearing fixing locking rings Snap ring for hole 60, 52
Screwdriver Flat-bladed type, medium size 2 pcs.
108200 (0.390.317.87 )
Steel bar
(key material) 1 pc.
Hammer Plastic hammer 1 pc.
1.04.5 (7.233)
Torque wrench kgfym(lbfyft) 4.018 (29130)
1248 (87350)
Slide hammer bearing puller
(1.57)
40
40 (1.57)
100(4)
250(10)
Brake piston drawing tool (0.433 )

(Bolt M875 2pcs.) BORE DIA.11
M8
10 (0.4)
M10
(0.2)
150(5.91)
5
175.5(6.91) Place this

200(7.87) claw in the
groove of
brake piston.
54
5.2.2 DISASSEMBLY
(1) General cautions
1) Hydraulic components are precision products
and have small clearance. Therefore,
assemble and disassemble in a less dusty
clean place. Use clean tools and cleaning oil
and handle components with full care.
2) If a component is removed from the main
body, clean the area around the ports
thoroughly and plug them up so no dust and
water do not enter. When fitting them back to
the body, do not remove the plugs till piping
is completed.
3) Study the structural drawing before the work
begins and prepare necessary parts according
to your purpose and the scope of work. Seals
and O rings once removed can not be used
again.
Some parts can not be supplied as single
parts and available only in sub assy. Prepare
such parts according to the parts manual.
4) The piston and the cylinder block are shop
fitted when new. If you intend to reuse them,
put a matching mark on the piston and the
cylinder block.
(2) Disassembly procedure
The figures in parentheses after part names
in this manual represent those item numbers
in Fig. 5-1.
1) Draining oil
Remove the drain plug and drain hydraulic
oil from casing (301).
2) Preparation for removing the valve casing
Fix the motor on a work bench so the drive
shaft (101) end comes down. On that
052
occasion, put a matching mark on the mating 053
parts of casing (301) and valve casing (303). 051
303
z Choose a clean place, and lay with a
rubber sheet or a cloth on a work
712
bench. Handle the valve casing with
702
care so parts do not have dents.
301
101
Fig.5-3 Removing valve casing (303)
55
3) Loosen relief valve (051) and separate it from 052 351 355
valve casing (303).
: 41mm
4) Loosen swing shockless valve sub assy (052) 303

& bypass valve block sub assy (053) and
separate it from valve casing (303). 469
: 6mm
5) Separate RO plug (469) from valve casing

(303) and draw out spring (355) and plunger
(351).
: 14mm 401
051
6) Loosen socket bolt (401) and separate valve Fig. 5-4 Removing relief valve (651), swing
casing (303) from casing (301). If the socket shockless valve (052), anti-cavitation
bolt (401) are loosened, the valve casing floats plunger (351) and valve casing (303)
off casing (301) by the force of brake spring
BRAKE PISTON
(712). DRAWING JIG
Then separate valve plate (131) from valve
casing (303). 131
: 17mm
7) Draw out brake spring (712) from brake

piston (702).
8) Put the claw of the brake piston removing jig

in the concaved part of brake piston (702).
702
Hold the cylindrical part of the jig and pull it
straight up at once by reaction. 301
Draw out the brake piston with the jig, from Fig. 5-5 Removing brake piston (702)
the casing.
117
9) Lay the motor on its side again and draw out
cylinder block (111) from drive shaft (101).
Then draw out piston (121), retainer plate
(123), spherical bushing (113), spacer F (117)
and shoe plate (124).
Handle the parts with care so as not to

score the sliding surfaces of cylinder
block (111), spherical bushing (113)
101
and shoe (122).
124
122 121 743

301 123 113 742 111
Fig. 5-6 Drawing cylider block (111), piston sub
assy, friction plate (742) and separator plate
56
10) Draw out friction plate (742) and separator

plate (743) from casing (301).
301
11) Draw out drive shaft (101) from casing (301),

while lightly tapping the side face of valve
casing (303) in drive shaft (101), using a
plastic mallet.
PLASTIC
MALLET
101 443
Fig. 5-7 Removing drive shaft (101)

z Do the following work as required.
PRESS
1. Drawing the inner race of roller bearing (443)
101
from drive shaft (101), using a press.
z Do not reuse the removed bearing.
443
2. Remove snap ring (437) with pliers. Then
draw out seal cover (305) from casing (301).
Put a bolt in the screwed hole (M40.7) of oil
seal (491). Then draw out oil seal (491) from
casing (301). Put the inner race
on the press bench.
3. Drawing out the outer race of roller bearing Fig. 5-8 Removing inner race of roller
(443) from casing (301), by lightly tapping the bearing (443)
steel rod from the oil seal (491) housing side.
(Do not reuse the bearing.)
4. Separate the outer race of roller bearing (444)

from valve casing (303), using a slide
hammer bearing puller.
57
5.2.3 ASSEMBLY
(1) General cautions
1) Repair those parts damaged after
disassembly and prepare replacement parts
beforehands.
2) Clean all parts thoroughly in cleaning oil and

3) Always coat the moving parts with clean

hydraulic oil, before assembly.
4) Replace such seals as O ring and oil seal in OUTPUT SHAFT SIDE
principle. 444
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 Fig. 5-1.
1) Preparation for assembly

443
Place casing (301) on a work bench so its
valve casing (303) side faces upward.
101
z This operation is necessary only
when the roller bearing is removed. Fig.5.9 Assembling the inner race of
bearings (443), (444)
2) Shrinkage fit the inner race of roller bearing
(443) into drive shaft (101).
3) Shrinkage fit the inner race of roller bearing

(444) to drive shaft (101).
z This operation is necessary only

when the oil seal is removed.
Fit snap ring (437) to casing (301),
put in seal cover (305) and fix oil seal
(491) by the use of the jig. On that
occasion, coat the lip of the oil seal
with grease and check the direction
of it, before fixing it.
4) Assemble the outer race of roller bearing

(443) into casing (301), by lightly tapping the 301
steel rod. 443 437 305 101 491
Fig.5.10 Fitting snap ring (437), seal cover (305),
5) Attach drive shaft (101) to casing (301). oil seal (491), outer race of roller
bearing (443), and drive shaft (101)
58
6) Place casing (301) as shown in Fig. 5-11 and

insert shoe plate (124).
On that occasion, the shoe plate does not
come off if it is coated with grease.
The larger
chamfer side 124
301
443
Fig. 5-11 Inserting shoe plate (124)

7) Fix spacer (118) and spring to cylinder (111),
fit snap ring (438) to it and insert push rod
(116) into cylinder (111).
Then mount the spherical bushing (113) with
spacer F (117) on the cylinder.
8) Place piston sub assy (121, 122) on retainer

plate (123). 117
123 116
9) Assemble piston sub assy (121, 122) fixed in 118
122
retainer plate (123) into cylinder (111). Match
it to the spline of drive shaft (101) and insert 113
it in place. 114
On that occasion, drive shaft (101) is easy to 121
be inserted if the phase of spherical bushing
(113) is aligned with that of the spline of
cylinder (111).
111
101
438
Fig. 5.12 Inserting cylinder assy

10) Replace casing (301) with seal cover facing
downward and assemble separator plate
(743) and friction plate (742) into casing
(301), in that order.
Assemble four separator plates and three
friction plates.
Assemble the same phases of four slits

in the gears of friction plate (742).
Assemble four slits in the four claws of
separator plate (743) in the position of
Fig.5-13.
PG PORT
Fig. 5-13 Mounting position of separator plate
59
11) Fit O rings (706), (707) to casing (301). In that case, 702
if the O rings are coated with grease, they are hard to
tear off when brake piston (702) is inserted.
12) Assemble brake piston (702) into casing (301).
13) Assemble brake spring (712) into brake piston (702).

In that case, make sure that a spring is placed
correctly in the spot faced part of the brake piston.
SLIT (OPPOSITE SIDE)

l This operation is necessary only where
roller bearing (444) is removed. PG PORT
14) Insert the outer race of roller bearing (444) into Fig. 5-14 Assembling brake piston
valve casing (303), while lightly tapping the steel
rod placed on the outer race, using a hammer.
15) Assemble valve plate (131) into valve casing (303)

and fit O ring (472) in it.
16) Install valve casing (303) to casing (301) and fasten

them with socket bolts (401).
: 17mm,
Tightening torque : 44kgfm (320 lbfft)
17) Fit plunger (351) and spring (355) to valve casing

(303). Then tighten RO plug (469) fitted with O ring
(488) against valve casing (303).
: 14mm,
18) Fit relief valve (051) to valve casing (303).

: 41mm,
19) Fit swing shockless valve (052) & bypass valve

block sub assy (053) to valve casing (303).
: 6mm,
20) Fit O ring (485) to plug (464) and fasten the plug
against casing (301).
: 19mm,
Tightening torque : 3.7kgfm (27 lbfft)
5 10
5.3 DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT

5.3.1 TOOLS
Code Tool name Remarks
Material : SS41
10mm
(0.394)
50mm
(1.97)
Jig
a
(for press fitting bearing )
910.5mm
(3.5830.020)
1400.5mm
(5.5120.020)
b Snap ring plier For shaft
Material : SS41 140mm

(5.51)
(0.591)
15mm
c Oil seal fitting jig

0
208 0.5 mm
0
(8.189 0.020 )
d Torque wrench Class 14kgfym (100 lbfyft)
e Plastic hammer (Wooden hammer)
f Press Class 10ton (22000 lbs )
h Flat screwdriver
20mm
(0.787)
i Metal bar 3 pcs. 155mm

(6.10)
j General tools Allen key wrench and steel rod
Screw lock compound Three-Bond 1360K

k
Sealing compound Locktite #515
5.3.2 DISASSEMBLY
The figures in parentheses correspond to the ones
in construction drawings (Fig. 5-2).
3) Disconnect the drain hose.
(1) Preparation
1) Before disassembly, clean the outside of the 4) Matching Mark
reduction unit thoroughly and check for no To facilitate the reassembly of the unit, put
damage and scoring. matching mark on the maiting parts of the
2) Drain gear oil from the reduction unit. housing before disassembly.
511
(2) Separating swing motor from reduction unit

1) Preparation for disassembly SWING MOTOR
Place the reduction unit assy on a stable
work bench as shown in Fig.5-15, remove
plug (32), drain out oil put a matching mark 18
on the matching surface of the figure on the 32 h
right.
2) Removing swing motor assy MATCHING

MARK
Loosen all socket bolt (18) (M14). Attach eye
bolts (M12 1.75) in the lifting bolt holes in
the top surface of the swing motor and lift the 160 290
assy by crane. (6 (12)
If it is hard to remove the swing motor assy )
Fig. 5-15 Removing swing motor assy
from the reduction unit, float it by inserting a 17
flat-blade screwdriver (h) in the groove of the 19
flange.
: 12mm
16
(3) Disassembling reduction unit
1) Remove #1 sun gear (19).
2) Removing #1 spider assy (17).

The spider assy (17) [consisting of thrust 10
washer (28), #1 pinion (26), needle bearing
(27) and snap ring (29)] can be removed from Fig. 5-16 Removing #1 sun gear and
the spline easily if it is lifted up in that #1 spider assy
condition.
3) Removing ring gear (16) #2 SPIDER ASSY

Attach eye bolts (M14) to the top surface of
ring gear (16) and lift the ring gear lightly by
a wire sling. 16
Put a flat-blade screwdriver (h) into the h
matching surface of ring gear (16) and
housing (10) and remove ring gear (16) by
lightly tapping the outer circumference of the 10
ring gear with a plastic mallet.
4) Remove #2 sun gear and separate the #2 Fig. 5-17 Removing ring gear (16)
spider assy. #2 SPIDER ASSY
Draw out #2 sun gear (15) and separate the
15
#2 spider assy.
Regarding the disassembly of the #2 assy,
refer to par. (4) which will come up later.
Fig. 5-18 Removing #2 spider assy
5 12
5) Turn over the housing so gear side of pinion

1
shaft faces up, as shown in Fig. 5-19.
180 (7 )
35010(140.4)
Fig. 5-19 Turning over housing

6) Remove all socket bolts (8).
: 6mm
8
Fig. 5-20 Removing socket bolts (8)
7) Remove retainer (7) with oil seal (6).
Fig. 5-21 Removing retainer (7)
513
8) Removing pinion shaft assy M10

Attach an M10 eye bolt to the end of the
pinion and lift it upright : The pinion shaft 1
assy (1,2,5,9,11,12,13) can be lifted up easily. 5
2
9
11
12
13
Fig.5-22 Removing the pinion shaft assy

(4) Disassembling spider assy
1) Disassembling #1 spider assy
1. Remove snap ring (29) with a plier (b).
2. Remove thrust washers (25,28), pinion (26) 17 26 29 27 28
and roller (27).
z The shaft attached to spider assy 25

(17) is caulked. When replacing
parts, replace the spider assy as a Fig.5-23 Disassembling #1 spider assy
whole.
z The pinion can not be replaced as a
piece. For replacement, do it in a set
of three.
2) Disassembling #2 spider assy

1. Draw out spring pin (20).
2. Draw out shaft (21) from spider (14) and
remove thrust washer (22), pinion (23) and 21 22
needle bearing (24).
24
z Pinions (23) can not be replaced
singly. Replace them in a set of four. 23
22
14 20
Fig.5-24 Disassembling #2 spider assy
514
(5) Disassembling pinion shaft assy

1) Remove snap ring (13), using pliers (b).
13
Fig. 5-25 Removing snap ring

2) Removing pinion shaft (1)
Erect three supporting metal bars (i) at equal
intervals in the grooves in the teeth of pinion
shaft (1), place sleeve (2) on them and draw
down the pinion shaft by press in Fig. 5-26.
Pressing force : about 1011 tons
(2200024000 lbs)
Bind the supporting metal bars (i)

around their outside with a steel wire
when performing press operation.
Fig. 5-26 Removing pinion shaft (1)

3) Draw out the pinion shaft (1) and
remove
7
O ring (5) from sleeve (2). Then the pinion
shaft is disassemlbed into the parts in Fig.
5-27. 12 5
2
11
9 1
Fig. 5-27 Disassembling pinion shaft assy
515
5.3.3 ASSEMBLY
(1) Preparation
1) Clean parts thoroughly in cleaning oil and
2) Check that parts are not faulty.
(2) Assembling pinion shaft assy

1) Apply grease 5
Apply a thin film of grease over O ring (5)
and the O ring seat of pinion shaft (1).
2
2) Insert sleeve 1
Heat sleeve (2) to 100120 (212248 F),
fit O ring (5) and fix it into pinion shaft (1).
Fig. 5-28 Inserting sleeve to pinion shaft
3) Coat the outer surface of the sleeve with a
thin film of grease.
4) Coat the gear oil

a
Coat the outer circumference of pinion shaft
(1) with a thin film of gear oil to prevent
13
seizure.
12
5). Fill grease in the groove of the oil seal lip in
contact with the oil seal till about 1/3 of the
19
groove is filled with grease.
9
6) Assembling bearing
Heat bearings (9,12) to 100120 (212
248F), fit the bearings with spacer (19) into 1
pinion shaft (1). Push them in, using jig (a) OIL SEAL
and fix snap ring (13).
Pressing force : 1112ton Fig. 5-29 Assembling pinion shaft assy
(2400026500 lbs)
516
(3) Assembling spider assy

1) Assembling #1 Spider Assy
1. Coat the bore surface of pinion (26) with
grease. Put pinion (26) on thrust washer (25) 17 26 29 27 28
and assemble roller (27) into the bore surface.
2. Fit thrust washers (25,28) and pinion (26) as

in Fig. 5-30, 5-31 and fit snap ring (29) by 25
means of pliers (b).
Fig. 5-30 Assembling #1 spider assy
Fix the snap ring with the sharp edge
on the motor side (top side in the
position of Fig.5-31 ).
b
MOTOR SIDE
SNAP RING (29)
25, 28
17
29 26
Fig. 5-31 Fixing snap ring

2) Assembling #2 Spider Assy
GEAR SIDE
1. Coat the bore surface of pinion (23) with
grease. Put pinion (23) on thrust washer (22) CAULK TWO
POINTS WITH
and fit needle bearing (24) to the bore
A PUNCH.
surface.
2. Fit thrust washer (22) and pinion (23) as in

Fig. 5-32, insert shaft (21) into spider (14)
and fix spring pin (20).
67mm 67mm
(0.240.28in) (0.240.28in)
z Make sure that the oil hole (A in
Fig. 5-32) in shaft (21) faces the VIEW
outside as shown in the figure.
z Insert shaft (21) into spider (14) so
A 21 22
spring pin hole (20) is aligned.
24
23

22
14 20
Fig. 5-32 Assembling #2 spider assy
517
(4) Assembling reduction unit assy

1) Mounting pinion assy 1
Place housing (10) on a work bench. Lift the
pinion assy and lower it slowly into the
housing till it is set in place.
9
z Take care on this step so that outer
race of bearing (9) is installed
straight along the inner face of
housing (10).
z Outer races of bearings (9,12) can
normally be installed in the housing
(10) easily as enough clearance is 12
provided between the two parts. If
10
they cannot be inserted easily, check
to see whether or not the outer race
of bearings (9,12) are positioned Fig. 5-33 Installing pinion assy
correctly and if there is any damage
to housing (10). Pressing them in
with undue force may damage these
parts.
2) Attaching retainer
1. Fit the oil seal to retainer (7), making sure of
its direction and set it in place by using oil
seal fixing jig (c).
M825
2. Apply sealing compound (Locktite #515) to 8
the retainer (7) with oil seal and the 10 7
matching surface of housing (10). Then fit it Fig. 5-34 Assembling retainer (7)
to sleeve (2).
#2 SPIDER ASSY
Use care when assembling so as not to
score the oil seal by the gear teeth of
pinion (1)
3. Tighten socket bolt (8)

: 6mm,
Tightening torque 3.4kgfym (25 lbfyft)
3) Turning over housing (10) Fig. 5-35 Installing #2 spider assy

Place pinion shaft (1) on a stable work bench,
with its spline facing up. 19
4) Attaching #2 spider Assy

Insert the #2 spider assy into the spline shaft
of pinion shaft (1).
5) Attaching #2 sun gear (19)

Install #2 sun gear (19) with its spline facing
up.
Fig. 5-36 Installing #2 sun gear (19)
518
6) Installing ring gear (16)

Apply a thin film of sealing compound
(Locktite #515) to the matching surface of #2 SPIDER ASSY
housing (10) and ring gear (16) and assemble
16
them, aligning the gear teeth and according ALIGN
MATCHING MARKS.
to the matching marks given.
10
Fig. 5-37 Installing ring gear (16)

7) Installing #1 spider assy
1. Mesh the #1 spider assy with ring gear (16)
and set them in place.
2. Mesh #1 sun gear (19) with #1 pinion (26)
and set them in place. 19
#1 SPIDER ASSY
8) Fit drain hose (36) and plug (37). 16

: 12mm
26
9) Filling Lube Oil
Fill in 7.5 (2.0gal) of Extreme pressure gear
oil SAE90 (API Service Grade GL4).
10
Fig.5-38 Installing #1 spider assy

10) Installing swing motor assy
Attach eye bolts (M121.75) in the tapped
holes of the swing motor and put a wire sling
in them.
SWING MOTOR
Coat the matching surface of ring gear (16)
with sealing compound (Locktite #515), insert
M14130
the spline joint of the swing motor and match
18
the matching marks.
Coat socket bolts (18) with screw lock
compound (Three-Bond 1360K) and fasten
them.
: 12mm, MATCHING
MARKS
Tightening torque 18.5kgfym (130 lbfyft)
160 290
(6) (12)
Fig. 5-39 Installing swing motor assy
519

5.4.1 SWING MOTOR
(1) Replacement standards for parts
The following are the standards to determine disassembly, it is most important to
whether or not parts may be reused from determine which parts should be replaced,
values taken at disassembly. These are only depending upon the purpose of disassembly
general standards and in case the motor and the remaining service life of the motor
displays poor performance or parts shows that the user expects.
extreme damage and discoloration
before
Standard Recommended
Item Dimension Value for Remedy
mm (in) Replacement
mm (in)
Clearance between piston and
cylinder bore (D-d)
0.027 0.052
Replace piston or cylinder.
d D (0.00160) (0.00205)
Gap between piston and caulked

part of shoe ()
0.3
0 Replace piston and shoe assy.
(0.0112)
Thickness of shoe (t)
5.5 5.3
Replace piston and shoe assy.
t (0.217) (0.209)
Assembled height of retainer plate

and retainer (H-h)
5.5 5.0 Replace a spherical bushing and a

(0.217) (0.197) retainer plate as a pair.
H
h
Thickness of friction plate
1.8 1.6
t Replace.
(0.0709) (0.0630)
520
(2) Standard for correcting sliding surfaces

If the surface roughness of the sliding surface
of parts exceeds the following standard,
correct it or replace the parts.
Standard for correcting sliding surfaces

Standard surface Surface roughness
Parts roughness requiring correction
0.8Z (Ra=0.2)
Shoe 3Z (Ra=0.8)
(lapping)
0.4Z (Ra=0.1)
Shoe plate 3Z (Ra=0.8)
(lapping)
1.6Z (Ra=0.4)
Cylinder 12.5Z (Ra=3.2)
(lapping)
0.8Z (Ra=0.2)
Valve plate 6.3Z (Ra=1.6)
(lapping)
z Lap each sliding surface to a z If the sliding surface of the cylinder

standard roughness level or finer. block, valve plate, retaining plate or
spherical bushing is roughened,
replace parts in set.
521
5.4.2 SWING REDUCTION GEAR

(1) Inspection at disassembly (2) Inspection after assembly
1) Spacer and thrust washer 1) Function
1. Inspect that the parts are not seized or worn Check to see that #1 sun gear (19) is not
abnormally or unevenly. faulty when turned by hand.
2. Inspect and measure the parts to see that the
wear does not exceed the allowable values. 2) Checking for oil leakage and oil quality
Check for oil leakage.
2) Gears Check the oil level by level gauge and confirm
1. Inspect that the gear teeth do not show that the oil is not dirty. If the oil is short,
pitching and seizure. replenish gear oil SAE90 (API Service Grade
2. Inspect by dye penetrant examination that GL-4).
the bottom of the teeth does not show cracks.
3) Bearing
Turn the bearing and check that it does not
develop abnormal sound, catching and other
faults.
4) O rings and oil seals

Do not reuse O rings and oil seals; always
replace them with new ones at reassembly.
522
(3) Maintenance standards
(H) A
LUBE OIL LEVEL

D
APPLY LOCKTITE #515.
G
APPLY LOCKTITE #515.
Unit : mm (in)
Serviceability
Code Item Standard Value Remedy
Limit
0.021
39.45 0.032 Replace entire
A Wear in #1 planetary shaft 0.00083
(1.55315 0.00126 ) spider assy.
0
No flaking
29 0.009 Replace four
B Wear in #2 planetary shaft 0
(1.14173 0.00035 ) shafts as a set.
There should be no pitching
Condition of tooth face exceeding 1.6mm (0.0630in) dia, Replace
abnormal wear or seizure. (Planetary pinion
C Gears
should be replaced
Condition of tooth flank There should be no cracks. in a set of four.)
2.00.1 1.8
D Thickness of thrust washer Replace
(0.0790.004) (0.0709 )
0
Wear in sleeve (Diameter of part coming 160 0.063 159.5
F 0 Replace
in contact with oil seal ) (6.29920 0.00248 ) (6.28)
Apply Three-Bond
G M83.4 kgfym(25 lbfyft)
Capscrew tightening torque 1360K and tighten
(H) M1418.5 kgfym(130 lbfyft)
to specified torque.
Lube Extreme pressure gear oil Replenish or
I 7.5 (2.0gal)
oil SAE90(API Service Grade GL4) replace.
II523
5.5 TROUBLESHOOTING
5.5.1 SWING MOTOR
(1) Hydraulic motor does not rotate.

Pressure does not 1. Relief valve pressure in circuit is not 1. Set to correct value.
rise. adjusted correctly.
2. Malfunction of relief valve. 2.
2-1. Sticking plunger. 2-1. Correct the stuck areas or
replace the plunger.
2-2. Orifice on plunger is clogged. 2-2. Disassemble and clean.
3. Plunger seat is faulty. 3. Check the seat surface and
replace the plunger if scored.
4. Swing shockless valve seat is faulty. 4. Replace the swing shockless
valve cartridge or block.
5. Bypass valve seat is faulty, 5. Replace
malfunction.
Pressure rises. 1. Overload. 1. Reduce the load.
2. Moving parts are seized. 2. Inspect and repair piston, shoe
and cylinder valve plate.
3. Brake release pressure is not 3. Check circuit and correct it.
working on the motor
4 Brake piston is stuck. 4. Disassemble and check.
5. Friction plate is seized. 5. Disassemble, check and repair.
Replace one that is seized.
(2) Rotating direction is opposite.

Rotating direction 1. Motors assembling direction is reversed. 1. Assemble correctly.
is opposite. 2. Piping inlets and outlets are reversed. 2. Pipe correctly.
524
(3) Revolution does not rise to set value.

Revolution does not 1. Oil inflow is deficient. 1. Check pumps delivery rate and
rise to set value circuits to motor.
2. Oil leaks are excessive due to high 2. Lower oil temperature.
temperature.
3. Sliding surfaces are worn or broken. 3. Replace.
4. Malfunction of bypass valve. 4. Replace.
(4) Brake torque is insufficient.

Brake torque is 1. Friction plate is worn. 1. Disassemble and check. Replace if
insufficient. wear is beyond standard value.
2. Brake piston is stuck. 2. Disassemble and check.
3. Brake release pressure is not 3. Check and correct circuit.
released. 4. Disassemble and check.
4. Spline of friction plate is broken. Replace broken part.
(5) The swing motor drifts much.

Check the drain rate of the hydraulic motor.
If it is less than 200cc/min(12cuyin/min), you
should think that the motor is not faulty.

The swing motor 1. Relief valve malfunctions. 1.
drifts much when it is Same as (1). Same as (1).
actuated by external 2. Plunger seat is faulty. 2. Replace.
torques. (e.g. Machine 3. Seat of the swing shockless valve is 3. Replace the swing shockless valve
is on a slope.) no good. cartridge or block.
4. Bypass valve seat is faulty, 4. Replace.
malfunction.
525
(6) Oil leaks

1) Oil leak from oil seal

Oil leaks from oil 1. Lip of seal contains dirt and 1. Replace oil seal.
seal damaged. 2. Shift the lip and shaft positions or
2. Shaft is damaged or worn. replace oil seal.
3. Repair drain piping if clogged up.
3. Casing inner pressure has risen
abnormally high, with the result that
lip of oil seal has turned up. 4. Disassemble and correct.
4. Shaft is rusted.
2) Oil leak from matching surface

Oil leak from 1. O ring is missing. 1. Set O ring correctly and assemble
matching surface it.
2. O ring has a scratch. 2. Replace.
3. Seal surface has a scratch. 3. Disassemble and correct.
4. Bolt is loose or broken. 4. Tighten to specified torque or
replace.
526
5.5.2 REDUCTION UNIT
1)Reduction unit does not rotate.
Hydraulic motor inlet pressure has risen. Overloaded Reduce the load of
Reduction unit is broken. Replace reduction unit.
Parking brake of the Inspect the release

hydraulic motor is not pressure and the brake.
released.
Check the release

Hydraulic motor inlet pressure has not
command pressure.
Rotating sound is heard from Motor shaft is broken. Replace hydraulic motor.
hydraulic motor.
Reduction unit is broken. Replace reduction unit.
Pump and valve are out of Check for fault and

Rotating sound is not heard
order. correct.
from hydraulic motor.
2) Oil leakage
Oil leaks through matching surface. Liquid packing is not applied. Disassemble and apply
liquid packing.
Bolts are not fastened tight. Disassemble, apply

The matching surface is liquid packing and
slipping because of loosening. reassemble as specified.
The matching surface is

Replace faulty parts.
scored.
Oil leaks from shaft. Oil seal is damaged. Disassemble reduction

unit and replace oil
3) Temperature is high.
Temperature of reduction unit casing The gear oil is not filled up or Check oil level and fill oil
is high. the oil level is low. up to a specified level.
The amount of grease is small. Fill up grease.
Gear and bearing are

damaged. Replace reduction unit.
527
528
6. SWIVEL JOINT
6.1 CONSTRUCTION VIEW
Y
E
D
B
C
2 E
6 X
1 A
X
D
VIEW Y
C
12
F
B
F
5
7 SECTION XX
3
9
13
E E
8
Tble 6-1
No. PART NAME QTY No. PART NAME QTY
1 BODY 1 7 O RING ; 1A G95 1
2 STEM 1 8 SOCKET BOLT ; M820 2
3 THRUST PLATE 1 9 SOCKET BOLT ; M830 4
5 SEAL ASSY 5 12 PLUG 1
6 SEAL ASSY 2 13 COVER 1
Fig.6-1 Construction of swivel joint
61
6.2 DISASSEMBLY AND ASSEMBLY

6.2.1 TOOLS Table 6-2
Code Tool Name Used for Remarks
1. Steel hammer
a Hammer
2. Wooden or plastic mallet
b Rubber mat 750mm (30in) square or more
1. Allen wrench
c Wrench 2. Double-ended and single-ended wrench
3. Extension pipe
d Torque wrench Assembly 10kgfym (72 lbfyft)

Grind the tip ofa nailto shape
as a screwdriver.
e Pin Disassembly
Made from a hack-saw blade
Disassembly Approx. 120mm (4.72 in)

f Spatula
Assembly
Vinyl tape Remove the edge completely

and make corner round smooth.
Disassembly
g Vise Vise movable over 150mm (6in)
Assembly
h Locktite #242
i Lubricating oil Hydraulic oil or vaseline
j Cleaning oil
6.2.2 APPARATUS 6.2.3 CLEANING OUTSIDE

(1) Hoist or crane Clean the swivel joint to be free from dirt and
The lifting device should be capable of lifting dust, using steam and cleaning oil.
the swivel joint assy.
(2) Work bench z Keep all ports plugged up while
The work bench should have an area of 1.2m cleaning.
1.5m (4ft5ft).
(3) Others
Also prepare waste cloth, wooden block and
oil pan.
62
6.2.4 DISASSEMBLY 2
1
The part numbers used in this disassembly
13
procedure correspond to those of a construction 9
drawing in Fig.6-1.
(1) Removing cover

1) Mark cover (13) and body (1) with matching
marks for convenient reassembly.
ALLEN
2) Place a V-block on a work bench, place a WRENCH
V-BLOCK PIPE
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 Fig. 6-2 Removing cover (13)
fixed by holding stem (2) in a vise.
: 6mm
7
3) Remove cover (4) from body (1) and draw out

13
O ring (7) from cover (13).
Fig. 6-3 Removing O ring (7)
1 BODY
(2) Removing thrust plate 3 THRUST PLATE
Loosen socket bolt (8) fastening thrust plate 8 SOCKET BOLT
(3), in the same manner as the removing of
the above-mentioned cover.
z When removing thrust plate (3) by

fixing body (1), support stem (2) so it PIPE
may not fall down.
: 6mm
(3) Removing stem

Place body (1) on a Vblock. Put a wooden 2
STEM
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 Fig. 6-4 Removing thrust plate (3)
the body, it can be easily pulled out by hand. WOODEN BLOCK Secure
FOR PROTECTOR with hands. 1
Stem weight ; 12kg(26 lb) 2
WORK BENCH V-BLOCK

Fig. 6-5 Drawing out stem (2)
63
BACK-UP RING
(4) Removing sealing parts
1) Pierce slipper ring of seal assemblies (6) and
(5) with pin (e) and remove them from the
seal groove. Fig. 6-6 shows only one pin, but
use two pins to remove it securely. SLIPPER RING
Pay attention to the body (1) not to be DETAIL(5), (6)

damaged by pin (e).
1 BODY
PIN(e)
6
SEAL ASSY
GROOVES
FOR HYD. OIL
5
SEAL ASSY
Fig. 6-6 Removing out seal assy (5)(6)

2) Remove backup rings of seal assemblies (6)
and (5) with spatula (f).
Pay attention to the body (1) not to be SPATULA(f)
damaged by the top edge of spatula (f).
Fig. 6-7 Removing back-up ring
6.2.5 ASSEMBLY
Prior to assembly, clean each parts (excluding the
O ring and slipper ring), and arrange in the
sequence of assembly. SLIPPER RING
(1) Assembling seals to body

1) Make sure that oiliness, such as hydraulic oil
and grease, has been completely removed.
2) Apply grease on the groove of seal to be
installed on seal assemblies (6).
3) Slipper ring is assembled, after first inserting
the backup ring, by slightly-distorting the
shape as shown in Fig.6-8. Also after
inserting all of the seals, be certain that these
are installed in the seal groove by use of the Fig. 6-8 Inserting seal assy (5),
spatula. and slipper ring(6)
64
(2) Assembling stem

Lightly coat the outer circumference of stem Press in by applying your weight
(2) and the inner surface of body (1) with by your both hands.
grease or vaseline and slowly insert stem (2)
into body (1).
2 STEM
If stem (2) is pressed in too fast, the
seal may be damaged. Do it slowly.
The clearance between body (1) and
stem (2) is about 0.1mm (0.004in). SEAL 6
Push stem straight along the shaft
1 BODY
center.
5
SEAL ASSY
WORK BENCH
Fig. 6-9 Inserting stem (2)
(3) Assembling thrust plate

1) While holding stem (2) and body (1), match 8 3 2
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 Locktite #242
and tighten to stem (2).
: 6mm,
Fig. 6-10 Tightening socket bolt (8)
1
(4) Assembling cover
MATCHING MARK
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 9
Locktite #242 and tighten it which will then 4
complete assembly.
: 6mm,
ALLEN
WRENCH
PIPE
Fig. 6-11 Tightening socket bolt (9)
6 5

6.3.1 INSPECTION PROCEDURE AND REMEDY
Table 6-3
Interval Check Item Checking Procedure Remedy
2,000Hrs. Seal for oil Check oil leakage outside Replace O ring or dust seal , if any oil
leakage outside leakage can be found.
4,000Hrs. All sealing Replace all sealing parts such as slipper
In principle, parts seal with back-up ring and O ring.
disassemble
and check All sliding parts Check abnormal wear, scoring Repair or replace referring to their limit
re-gardless of or corrosion caused by foreign of service.
oil leakage or matters or seizure.
not.
When All parts Check them for seizure, foreign Repair or replace referring to their limit
disassembled matters, abnormal wear, and of service.
for repair defect of seals. O rings and dust seal should be
replaced.
6.3.2 SERVICE LIMIT OF THE PARTS
Table 6-4
Parts Maintenance Standards Remedy
Sliding surface with

Plating worn or peeled due to seizure or contamination. Replace
sealing sections
Sliding surface 1) Worn abnormally or damaged more than 0.1mm Replace
between body and (0.004in) in depth due to seizure or contamination.
stem other than
Body, Smooth with
sealing sections 2) Damaged less than 0.1mm (0.004in) in depth.
Stem oilstone.
1) Worn more than 0.5mm (0.02in) or abnormality. Replace
Sliding surface 2) Worn less than 0.5mm (0.02in). Smooth

with thrust plate 3) Damage due to seizure or contamination repairable Smooth
within wear limit 0.5mm (0.02in).
1) Worn more than 0.5mm (0.02in) or abnormality. Replace
Sliding surface 2) Worn less than 0.5mm (0.02in). Smooth
Cover
with thrust plate 3) Damage due to seizure or contamination repairable Smooth
within wear limit 0.5mm (0.02in).
66
Parts Maintenance Standards Remedy
1) Protruded excessively from seal groove.

Replace
PROTRUSION (With
back-up
ring)
BACK-UP RING
2) Slipper ring 1.5mm (0.06in) narrower than seal

groove, or narrower than back-up ring. Replace
(With
Slipper ring
back-up
ring)
1.5mm (max.)
(0.06in)
BACK-UP RING
3) Worn unevenly more than 0.5mm (0.02in)

0.5mm (max.) Replace
(0.02in) (With
back-up
ring)
67
6.6.3 INSPECTION AFTER ASSEMBLY

After completion of assembly, inspection for oil 1
leakage, pressure resistance, etc., using a device
as shown in the figure right.
9
(1) High pressure port (A,B,C,D port) Connect to
Install a directional valve and pressure gauge body side
to the stem side port and body side port
2
respectively, and while watching the pressure
gauge (for high pressure) installed on the Connect to
stem side
body side and also by regulating high
pressure relief valve (7), gradually increase
3
the pressure and when the pressure has
reached 1.5 times the maximum working 8
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 7
at this time.
Check that it is free from looseness,
deformation, breakage, etc. under three
minutes pressurizing.
And, the oil leakage must be checked for the
first 1 minute, and if there be a pressure drop
for any reason, the pressure drop should be in
Hydraulic 6 5
10% of the trapped pressure. source
This checking must be carried out for every
circuit. Fig. 6-12 Hydraulic circuit for inspection equipment
(2) Low pressure port

(Drain port, return port : E,F port.)
Similar to the high pressure port, install a
directional valve and pressure gauge on each
port of the stem side and body side.
Table 6-5
Open stop valve (6) on the side of low
pres-sure relief valve (5) and while watching Item Description Remarks
the pressure gauge (for low pressure) High and Low Pressures
1 Pressure Gauge
connected to the body side and also by are required.
regulating low pressure relief valve (5), 2 Swivel Joint
gradually increase the pressure and check for
outside leakage with a color check at a 3 Stop Valve
pressure of 5 kgf/cm2 (71psi). Relief Valve for Setting Pressure :
5
low pressure 5kgf/cm2 (71psi)
6 Stop Valve
Relief Valve for Setting Pressure
7
high pressure (Working pressure1.5times)
8 Directional Valve
9 Piping, etc.
68
6.4 TROUBLESHOOTING
Table 6-6

1. External leakage of Defective O ring & seal Replace all seals.
hydraulic oil
2. Internal leakage of 1) Defective slipper seal 1) Replace all seals.
hydraulic oil 2) Sliding face worn 2) Replace assy.
excessively
1) Stem and body 1) Grind and hone.
seized Replace assy, if stem and body
are too loose and causing oil
3. Swivel stem seized leakage.
2) Inappropriate swivel 2) Reinstall
stopper bracket Secure 2 3mm (0.08 0.12in)
allowance for bolt stopper.
4. Loose swivel stem and Socket bolt tightened Retighten.
cover insufficiently.
69
610
E200SR
SECTION 34 TRAVEL SYSTEM
TABLE OF CONTENTS
[Part I. Removing and Installing]
1. TRAVEL SYSTEM .................................................................................................... I-1
2. CRAWLER
2.1 Removing crawler ................................................................................................................ I-1
2.2 Installing ............................................................................................................................... I-2
2.3 Construction ........................................................................................................................ I-3
2.4 Maintenance standard ......................................................................................................... I-4
2.5 Tools and jigs ....................................................................................................................... I-4
3.UPPER ROLLER
3.1 Upper roller assy.................................................................................................................. I-5
3.2 Removing ............................................................................................................................. I-5
3.3 Installing ............................................................................................................................... I-5
3.4 Construction ........................................................................................................................ I-6
3.5 Disassembly and Assembly .................................................................................................. I-6
3.6 Maintenance standard ......................................................................................................... I-9
3.7 Tools and jigs ....................................................................................................................... I-9
4. LOWER ROLLER (TRACK ROLLER)

4.1 Lower roller assy................................................................................................................ I-11
4.2 Removal ............................................................................................................................ I-11
4.3 Installation .......................................................................................................................... I-11
4.4 Construction ...................................................................................................................... I-12
4.5 Disassembly and Assembly ................................................................................................ I-12
4.6 Maintenance standard ....................................................................................................... I-16
4.7 Tools and jigs ..................................................................................................................... I-17
INDEX
5. FRONT IDLER
5.1 Front idler assy ..................................................................................................... I-18
5.2 Removing .............................................................................................................. I-18
5.3 Idler assy .............................................................................................................. I-19
5.4 Idler adjuster assy ................................................................................................ I-23
6. SPROCKET
6.1 Removing ............................................................................................................. I-27
6.2 Installing............................................................................................................... I-27
6.3 Maintenance standard ......................................................................................... I-28
6.4 Sprocket tooth profile gauge ................................................................................ I-28
7. TRAVEL REDUCTION UNIT

7.1 Travel motor ........................................................................................................ I-30
7.2 Removing ............................................................................................................. I-30
7.3 Installing............................................................................................................... I-31
8. SWING BEARING
8.1 Swing bearing assy ............................................................................................. I-32
8.2 Removing ............................................................................................................. I-32
8.3 Installing............................................................................................................... I-33
8.4 Construction ......................................................................................................... I-33
8.5 Disassembly and Assembly ................................................................................. I-33
8.6 Maintenance Standard ......................................................................................... I-34
1. TRAVEL MOTOR ................................................................................................... II-1

[Part ; Removing and Installing]

1. TRAVEL SYSTEM
8. SWING BEARING
2. CRAWLER
7. TRAVEL MOTOR
5. FRONT IDLER 6. SPROCKET
GUARD
LOWER FRAME
GREASE NIPPLE OF THE 3. UPPER ROLLER
TRACK SPRING ADJUSTER
4. LOWER ROLLER
Fig. 1-1 Designation and location of undercarriage
2. CRAWLER
2.1 REMOVING CRAWLER

(1) Position the machine to remove crawler.
(2) Pushing out master pin.

1) Find the master pin and place it in its
removing/fixing position in Fig.2.2.
2) Loosen the grease nipple and slacken crawler.
: 19mm
z When loosening the grease nipple of

the adjuster, do not loosen it more
than one turn. Fig. 2-1 Crawler removing position
z Where grease does not come out
well, travel the machine back and
forth. The over loosening of grease
nipple may cause it to jump out
incurring danger of injury. So be
careful not to over loosen the grease
nipple.
3) Pushing out master pin
Apply jig on master pin and strike it out with
a mallet.
(Refer to Fig.2-6 Fixing the master pin.)
z When using a big hammer, wear Removing/fixing
protective goggles and a long-sleeved position of master pin
uniform so you do not injure yourself
by flying objects. Fig. 2-2 Removing/fixing position of master pin
1
(3) Removing crawler

Removing
Put attachment on ground so that weight is
master pin
not loaded to the lower frame, and remove
track link assy by means of rotating sprocket.
Crawler end section may fall on the

ground just before extending it on the
ground incurring danger of injury.
Please keep well away from the
equipment.
Fig. 2-3 Removing crawler
2.2 INSTALLING
removing.
(1) Checking crawler installation direction. Front
idler side
Place the track links on the ground so they
converge, facing the front idler, as shown in
the figure on the right.
(2) Installing crawler

1) Preparation for installation
Treat paint flaking protection with care not
to damage lower flame. Fig. 2-4 Installing direction of crawler
2) Winding crawler
Insert a crowbar into the master pin hole, lift
the lower frame 1 to 2cm above the ground
level by holding it by hand so the machine
body weight is not exerted on the shoe.
Reverse the sprocket to help push the back
winding of the crawler.
(3) Preparation for press fitting master pin

1) Preparing for installation
Put square wood under the shoe plate.
2) Aligning master pin holes Fig. 2-5 Winding crawler

Aligning master pin holes through fine
adjustment turning sprocket.
z 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.
z Coat the master pin with
molybdenum disulfide grease, before
pressing it in.
Press fitting jig
on master pin
(4) Press fitting of master pin
Apply press fitting jig on master pin, and Fig. 2-6 Press fitting of master pin
strike it with a mallet to press fit.
2
(5) Adjusting crawler tension(See Fig. 2-8)

After installing, adjust tension of crawler.
: 19mm
Standard dimension
A
Dimension of iron crawler in 320350mm
a max. slackened condition (12.613.8in)
Fig. 2-8 Adjusting crawler tension

2.3 CONSTRUCTION 1-6
1-1
STD LC
No. PARTS 1-8
QTY QTY
1-4
1 LINK ASSY 1 1
1-3
1-1 TRACK LINK R 46 49 1-8
1-2 TRACK LINK L 46 49
1-3 BUSHING 45 48 1-7
1-4 PIN 45 48
1-5 MASTER BUSHING 1 1
1-6 MASTER PIN 1 1
1-1
1-7 COLLAR 2 2 4
1-8 SEAL 90 96 1-5
1-7
2 SHOE 600mm 46 49 1-2 1-2
3 BOLT 2420Z1292 184 196 Fig. 2-9 Track link assy
4 NUT 2420Z1293 184 196
Fig.2-10 Shoe plate
3
2.4 MAINTENANCE STANDARD
Fig. 2-10
Table 1-1 Unitmm(in)
REPAIRABLE
No. ITEM STANDARD VALUE
LEVEL
SERVICE LIMIT REMEDY
A Link pitch 1900.1 (7.48030.0039) 194 (7.64) 198 (7.80) Replace the link
assy if the
B O.D. of bushing 58.780.05 (2.31420.0020) 55 (2.17) 54 (2.13)
service limit is
C Height of link 1060.3 (4.17320.0118) 100 (3.94) 98 (3.86) exceeded
Basic
Interference Tolerance Fit Fit
dimension
D between bushing
58.78 0.05 Interference Interference
and link
(2.3142) Shaft (0.0020) 0.05 (0.0020) 0 Replace
Interference 36.63 Interference Interference
E between track pin 0.05
Shaft
(1.4421) (0.0020) 0.05 (0.0020) 0
and link
0.03
Interference 36.50 Interference Interference Replace
F between master Shaft
0.088
(1.43701) 0.00118 0.05 (0.0020) 0 Link
pin and link
0.00315
Clearance between 1.5 (0.06) 8 (0.32) 10 (0.39)
G links (both side) (both side) (both side) Replace
Tightening torque
H 87kgfym (630 lbfyft) Retighten
of shoe bolt
2.5 TOOLS AND JIGS

(1) Tightening tools (2) Jig
Unit : mm
NAME OPPOSING FLATS NAME SHAPE

Socket 30
Master pin
fixing jig
for iron
crawler
4
3. UPPER ROLLER
3.1 UPPER ROLLER ASSY
UPPER ROLLER ASSY No.

ITEM NAME QTY
1 ROLLER ASSY 4
2 CAPSCREW 4
3 NUT 4
4 WASHER 8 3 4
4
2
3.2 REMOVING
(1) Preparation for removal 1
Remove crawler (Above mentioned).
(2) Removing upper roller (1)

1) Remove nuts on support tightening section,
and also remove capscrew (2) M20120.
: 30mm
Fig. 3-1 Removing upper roller
3.3 INSTALLING
removing.
(1) Inspection
Before reassembling, check it that it rotates
smooth manually and for leakage.
Countersinking
(2) Installing upper roller (1)
1) To install the upper roller, turn up socket
bolts (2) toward the center of machine.
2) Insert it until collar comes in contact with VIEW

support.
3) Fit it directing the countersinking mark of

shaft end upward.
4) Apply Locktite #262 on capscrew M20120,

Center of machine
and tighten it to the specified torque.
: 30mm,
2,4 1 3,4
Fig. 3-2 Installing upper roller
5
3.4 CONSTRUCTION 2 3 7 6 4 8 11
1 ROLLER 1 7 FLOATING SEAL 1

2 SHAFT 1 8 O RING : 1A P65 1
3 COLLAR 1 9 SOCKET BOLT 2
4 PLATE 1 10 PLUG 1
5 COVER 1 11 SNAP RING 1
6 BUSHING 1
10
1 9 5
Fig. 3-3 Construction of upper roller
3.5 DISASSEMBLY AND ASSEMBLY 9 11
(1) Disassembly 4 10
1) Draining out oil
Remove plug (10) and drain out oil. 8
: 6mm 5
1
2) Removing snap ring (11)
Mount the upper roller (1) on stand jig (f) and
separate snap ring (11), using snap ring
pliers. f
3) Removing cover (5)

Take off cover (5) upwards, utilizing the
screwed hole for the plug.

4) Removing O ring (8)
Separate O ring (8) from cover (5). Push with press
5) Removing plate (4)

h
Loosen two socket bolts (9) and draw out
plate (4) from roller (1).
: 8mm 2
7
6) Removing shaft (2)
3
Put the extrusion jig (h) against the end face
of shaft (2) and push shaft (2) with collar (3)
for floating seal (7), using a press or hammer.
f
Fig. 3-5 Extruding shaft
6
7) Removing floating seal (7). 7

Take out floating seal (7) from roller (1).
8) Removing floating seal (7). Fig. 3-6 Removing out floating seal
Remove from collar (3), floating seal (7) that
is located on the side from which shaft (2) g
was disparted.
2 6
Collar (3) is press fitted into shaft (2).
Therefore do not disassemble it. 7 1
3
9) Removing bushing (6)
Since the bushing is thin, machine it on a
f
lathe or scrape it off, exercise care so as not
to damage the bore of roller (1).
Fig. 3-7 Removing
If the bushing is not worn much, mount floating seal
upper roller (1) on jig (f), insert jig (g) into the
end face of bushing (6) and push it out with a
press. Fig. 3-8 Extruding bushing
Push with press (e)

(2) Assembly
Assembly of the upper roller is done in the i
reverse order of disassembly.
6
1) Place upper roller (1) on the top end face of
jig ( f ) , with its floating seal setting side
1
facing down.
2) Confirm that the outer surface of bushing (6)
is not seized and coat the outer surface of the
inserting side of the bushing, with f
molybdenum disulfide grease.
3) Put jig (i) into bushing (6) and press it in,
using the bore of the bushing and the bore of
the roller as guides.
Fig. 3-9 Pushing in bushing
If you fail in this operation by pressing
2
the bushing unevenly, the bushing is
distorted and gets unserviceable. In 7
that case, do not re-use the bushing as
7
it may develop malfunctioning after 1
assembly.
3
Fig. 3-10 Fixing floating seal
7
4) Installing floating seals (7). Push with press

Two floating seals (7) make a pair. Attach one
floating seal to retainer fixed in shaft (2), and
another to the inside of upper roller (1). 2
z Prior to placing floating seal (7) in,

apply engine oil lightly to seal
surface.
1
5) Inserting shaft (2).

Coat shaft (2) with a thin film of oil and
insert it into upper roller (1).
Fig. 3-11 Inserting shaft
6) Installing plate (4). 11
Mount upper roller (1) on the stand jig ( f ) 9
8
and attach plate (4) to the end face of the
5
shaft with bolt (9).
4
: 8mm,
1
Tightening torque : 11.7kgfym (85
lbfyft)
7) Installing O ring (8).

Fit O ring (8) to the groove of cover (5).
z Apply grease to O ring.
8) Installing cover (5). f

Attach cover (5) to upper roller (1). Use a
press in this operation as a press fit is used.
9) Installing snap ring (11).

Fix snap ring (11) into upper roller (1), using
snap ring pliers.
Fig. 3-12 Installing cover
10) Filling oil

5
Fill in 30cc (1.83cuyin) of engine oil API grade
CD#30 through the plug hole in cover (4).
11) Installing plug (10). 1

Wind seal tape around plug (10) and screw it
into the plug hole of cover (4).
: 6mm,
z After assembling the upper roller, f

confirm that oil is not leaking from it
and that it rotates smoothly by hand.
Fig. 3-13 Filling oil

8
E
F
A
D D

REPAIRABLE
No. ITEM STANDARD VALUE LEVEL SERVICE LIMIT REMEDY
A Dia. 160 (6.30)

B Width 150 (5.91)
Replace
C Tread dia. 140 (5.51) 130 (5.12) 128 (5.04)
D Tread width 33 (1.30)
Basic
dimension
Tolerance Fit Fit
Clearance 0.025
E between shaft and 50 Clearance Clearance
0.050
bushing Shaft
(1.96850) 0.00098 0.7 (0.028) 1.0 (0.039)
0.00197 Replace bushing.
0.030
Interference 55 0 Interference Clearance
F between roller Hole
and bushing (2.16535) 0.00118 0 0.01 (0.0004)
0
Tightening torque
G of socket bolt 11.7kgfym(85 lbfyft)
Oil Engine oil API grade CD #30, 30cc (1.83cuyin) Refill
Roller rotation Roller rotates smoothly by hand. Reassembly
9
3.7 TOOLS AND JIGS

(1) Tightening tools
Unit : mm
NAME OPPOSING FLATS

Socket 30
Allen wrench 6,8
(2) Jigs
Unit : mm (in)
No. NAME SHAPE

140 (5.51 )
100 (3.94 )
160 (6.30 )
f Stand jig
52.5 (2.07 )
For
(0.71 )
g extruding
18
bushing
49 (1.93 )
For
(1.18 )
h extruding
30
shaft
(1.93 +0.004 )
+0.1
(2.36 )
0
49
Bushing
i
fixing jig
20 50
(0.79 ) (1.97 )
70
(2.76 )
10
4. LOWER ROLLER (TRACK ROLLER)

4.1 LOWER ROLLER ASSY
4 Apply Locktite #262
STD LC T=40.5kgfym (290 lbfyft)
ITEM NAME REMARKS
Q
TY
1 LOW ROLLER 14 16
2 CAPSCREW 56 64 M1880(P=1.5)
3 TRACK GUIDE 2 2
4 CAPSCREW 8 8 M1840(P=1.5)
2 3
Apply Locktite #262
T=40.5kgfym (290 lbfyft) 1
Fig. 4-1 Lower roller assy and track guide
4.2 REMOVAL
(1) Preparation for removal
1) Loosen the tension of the crawler, lift up the
lower frame by the front attachment and stop
the engine in that condition.
2) Place a safety block (wooden) at the front and
back of the lower frame.
(2) Removing track guide SAFETY BLOCK

Remove capscrews (4) and remove track guide. (Square timbers)
: 27mm
Weight of track guide : Approx.24kg (52 lbs) Fig. 4-2 Preparation for removal
(3) Remove lower roller

Remove capscrews (2) and remove lower roller
(1).
: 27mm
Weight of lower roller : Approx.35kg (77 lbs)
4.3 INSTALLATION
(1) Installation of lower roller
Coat mounting capscrews (2) with Locktite #262
and fasten all four capscrews temporarily. Then
tighten them to a specified torque.
: 27mm
Tightening torque : 40.5kgfym(290 lbfyft) Fig. 4-3 Installing lower roller
(2) Installation of track guide

Capscrews (4) with Locktite #262 and fasten all GREASE NIPPLE
four capscrews temporarily. Then tighten them
to a specified torque.
: 27mm
Tightening torque : 40.5kgfym(290 lbfyft)
(3) Adjusting tension of crawler.

Tighten grease nipple and fill it with grease.
: 19mm,
Tightening torque : 6kgfym(43 lbfyft)
Fig. 4-4 Adjusting tension of crawler
11
4.4 CONSTRUCTION
No. NAME QTY REMARKS 4 1 6 2 7 5

8
1 ROLLER 1
2 COLLAR 2
3 SHAFT 1
4 BUSHING 2
5 PIN 2
FLOATING
6 SEAL
2
7 O RING 2 1A,G60 3
8 PLUG 2 PT1/4
Fig. 4-5 Construction of lower roller
4.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
1) Drain oil
Remove plug (8) and drain out oil.
: 6mm
2
2) Removing pin (5)
Put both ends of lower roller assy on the
V-shaped blocks (K), apply push-out bar ( ) 5
on upper end face of pin (5), and push pin (5)
out striking with mallet.
3) Removing collar (2), O ring (7) Fig. 4-6 Pushing out collar fixing pin (5)
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) JIG P
separate from collar (2) with press or mallet,
and take out collar (2) and O ring (7). 7 2
4) Removing shaft (3) 1

In addition, push out and remove shaft (3)
together with the lower collar (2) and O ring 3
(7).
JIG m
The shaft (3) extrusion operation may
cause the remaining lube oil to flow
out. Prepare an oil container
beforehand.
Fig. 4-7 Removing shaft (3), collar (2), O ring (7)
12
5) Removing collar (2), O ring (7)

Remove O ring (7) from shaft (3) that was
drawn out in the previous par.(1).
6
6) Removing floating seal (6)
Remove floating seal (6) from collar (2).
2
7) Removing floating seal (6)
Remove floating seal (6) from roller (1).
Fig. 4-8 Removing floating seal (6)
Fig. 4-9 Removing floating seal (6)

Since thickness of bushing (4) is thin
[thickness is 2.0mm (0.079in)], remove it
through lathe or strip it with care not
damage inner hole of roller. When the wear of n
bushing is not large, place upper roller (1) on
jig (m) for repair stand and apply the end of 1
push-out jig on the end face of bushing (4)
end, and push it out striking it with mallet.
4
Hammer the inside surface of roller
lightly so as not to damage the surface.
Put the extrusion jig (n) uniformly over JIG m
the circumference of bushing (4) and
extrude it perpendicularly little by
little. Fig. 4-10 Extruding bushing (4)
13
(2) Installing
7 3
1) Attach O ring (7) to one side
Install O ring (7) to groove on shaft.
z Grease O ring.
z Replace O ring with new one without
fail at reassembling.
Fig. 4-11 Attach O ring (7) to one side
2) Press fitting bushing (4)
Align inner hole of roller (1) and bushing (4)
and press fit it vertically in capacity of press
JIG Q
fit load, 5ton (11000 lbs), in the condition that
bushing push-in jig (Q) is inserted into
bushing (4). 4
z Apply molybdenum disulfide grease

on press-fit section of bushing, and
press fit it in ordinary temperature.
z Bushing which fails to press-fit

because of the uneven pressing Fig. 4-12 Press fitting bushing (4)
should not be fitted.
3) Press fitting collar (2)

Fit O ring (7) to the one side of shaft (3)
6
mating pin hole of collar (2) on which floating 5
seal (6) is fit with pin hole of shaft (3) in
advance. Use the press of capacity 17 ton
(37500 lbs) or more. 3
z Care should be taken not to damage

O ring (7) while press-fitting collar
(2) to shaft (3). 2
7
Fig. 4-13 Inserting pin (5)
4) Inserting pin (5)

Press-fit pin (5) to pin hole on aligning pin
holes of shaft (3) and collar (2).
5) Attach floating seal (6) to roller side

Fit floating seal (6) to inner holes on both
ends of roller (1).
z Check that the seal surface is free
from flaws, rusts, etc. before reusing 6
the floating seal.
6) Inserting roller (1) 3

Insert roller (1) from the side where collar (2),
2
O ring (7) is not press-fitted to the shaft (3). 7
Fig. 4-14 Inserting roller (1)
14
7) Installing O ring (7) Press

Install O ring (7) to groove on shaft.
z Grease O ring. Pin hole

z Replace O ring with new one without 2
fail at reassembling.
8) Press fitting collar (2) 7

Press-fit collar (2) to shaft (3).
z Press-fit collar (2) on aligning pin (5)

3
hole.
9) Inserting pin (5)

Press-fit pin (5) in to the pin hole mating pin
hole of collar (2) with pin hole on the end side
of shaft (3).
Fig. 4-15 Installing O ring (7), collar (2)

10) Filling oil
Remove plug (8) and fill in 160cc (9.8cuyin) of
engine oil API grade CD#30.
11) Check it for leakage

Before tightening plug (8), check it for
leakage in the condition of air pressure
2.0kgf/cm2 (28psi). 8
Tightening
torque
12) Installing plug (8) 2.4kgfym
Apply oil resistant sealant on plug (8), and (17 lbfyft)
tighten it in the plug hole on the collar (2)
end face. 2
: 6mm,
After assembling the lower roller, Fig. 4-16 Installing filling oil plug (8)
confirm that oil is not leaking and that
the roller rotates smoothly by hand.
15
C C
A
B
D
E
Fig. 4-17 Lower roller (Track roller)

No. ITEM STANDARD VALUE REPAIRABLE LEVEL SERVICE LIMIT REMEDY
A O.D. of flange 185 (7.28) Reinforcement

B Tread dia. 150 (5.91) 134 (5.28) 128 (5.04) weld, repair or
replace
C Flange width 23.5 (0.925) 18 (0.709) 16.5 (0.65)
Basic
Tolerance Fit Fit
dimension
Clearance between
0.060
D shaft and bushing
65 0.090 Clearance Clearance
(Wrapped bushing) Shaft
(2.55905) 0.00236 0.7 (0.276) 1.0 (0.394) Replace
0.00354 bushing.
0.030
Interference
69 0.020 Interference Clearance
E between roller and Hole
(2.71653) 0.00118 0 0.01 (0.0004)
bushing
0.00079
F Oil Engine oil API grade CD #30, 160cc (9.8cuyin) Refill
H Plug (8) Execute air leak test at 2.0kgf/cm2 (28psi) before tightening the plug.
Roller rotation Rotates smoothly by hand. Reassembly
16
4.7 TOOLS AND JIGS

Unit : mm
NAME OPPOSING FLATS

Socket 19,27
Allen wrench 6
(2) Jigs
Unit : mm (in)
No. NAME SHAPE
k V-block
(0.55 )
100 (3.94 )
Pin (5)
14
extrusion
rod
(0.63 )
Bushing 200
16
n extrusion
rod
290
m Stand jig
(4.92 )
(6.30 )
160
125
270
Shaft
p extrusion
(1.18 ) (2.52 )
64
jig
86
30
(3.72 )
94.5
(2.54 )
Bushing
64.5
q
fixing jig
+0.1
64.6 0
(2.54 +0.004
0
)
17
5. FRONT IDLER (IDLER ADJUSTER ASSY)

5.1 FRONT IDLER ASSY
Apply Loctite#262 or equivalent
No. NAME Q
TY REMARKS T=28.5kgfym (210 lbfyft)
1 4 2
1 IDLER ASSY 2
2 IDLER ADJUSTER ASSY 2
3 GREASE NIPPLE 2
4 CAPSCREW 4 M1645
Fig. 5-1 Front idler assy
5.2 REMOVING
Remove crawler. (Above mentioned)
CROWBAR
(2) Removing idler assy
Sling idler assy, and push it forward with
crowbar.
Weight of crawleridler assy : 420kg (926 lbs)
(Sum total of both sides.)
Keep away from the front side of front
idler.
(3) Installing
removing.
Fig. 5-2 Removing and installation the front
idler
1
(4) Where idling assy (1) has to be separated
Loosen capscrew (4), and separate idler assy
(1) from idler adjuster assy (2).
: 24mm
Weight of idler assy : 107kg (236 lbs)
Weight of idler adjuster assy : 103kg (227 lbs) 2
z The separated idler assy should be

placed on square timbers.
4 3
Fig. 5-3 Separating idler assy (1)

from idler adjuster
18
5.3 IDLER ASSY

5.3.1 CONSTRUCTION
No. NAME Q
TY 1
1 IDLER 1 2
3
2 BUSHING 2 7
3 COLLAR 2
4 FLOATING SEAL 2 8
6
5 PIN 2 5
6 SHAFT 1 4
7 O RING 2
8 PLUG 2
Fig. 5-4 Idler assy
5
R
5.3.2 REMOVING AND INSTALLING
(1) Removing
1) Drain oil
Remove plug (8) on the side of collar (3) to
drain.
: 5mm
2) Removing pin (5) Fig. 5-5 Removing pin (5)

Apply pin push bar (jig R) to the top of pin,
Push with press
and push out striking bar (jig R) lightly by
hammer.
S
6
3) Removing collar (3)
3
Put idler (1) on repair stand (U), apply 1
push-out jig (S) on shaft (6), push out shaft
(6) with collar (3), then remove collar (3).
U
3
Fig. 5-6 Removing collar (3)

Push with press
4) Removing collar (3) from shaft (6)
If removal of collar (3) on the opposite side is S
required, turn over front idler and proceed
6 3
with the procedure described in Par. 3).
Fig. 5-7 Removing collar (3)
19

With idler (1) mounted on the stand, tap
bushing (2) lightly by hammer, while placing
the bushing drawing rod (T) against the end
face of bushing (2) evenly all round, till it
comes out.
T 2
1
6) Removing floating seals (4)
Take out floating seals (4) from idler (1),
collar (3). If you intend to re-use floating
seals (4), confirm that there is no scoring and
rusting on the contact surface and store the
floating seals in pairs by placing card board
between the sealing faces.
U
7) Removing O ring (7)
Separate O ring (7) from shaft (6).
Fig. 5-8 Removing bushing (2)
(2) Assembly
1) Pressing in bushing (2)
Align inner hole of idler (1) and bushing (2) 2 Push with press V
and press fit it vertically with press so that 1
jig (V) for bushing press-fitting is inserted
into bushing (2).
2) Installing O ring (7)

Fit O ring (7) to groove on shaft (6).
z Apply grease to O ring Fig. 5-9 Pressing in bushing (2)
3) Installing collar (3) (See Fig. 5-10) Pressing

Press fit the O ring (7) installed side of shaft
(6) into collar (3), and drive pin (5). 6
4) Installing floating seal (4)

Fit the half of floating seal (4) on each side of 3
5
collar (3) and idler (1).
5) Inserting idler (1)

Insert floating seal (4) fitted side of idler (1) Fig. 5-10 Installing collar (3), shaft (6)
into shaft (6).
6
4
6) Installing floating seal (4)
Fit floating seal (4) on the other side of idler
1
(1).
Fig. 5-11 Inserting idler (1) and installing

floating seal (4)
20
7) Installing collar (3)

Fit the half of floating seal (4) on the other
collar (3), press fit it in shaft (6), and drive 8
pin (5) in with hummer. 3
5
8) Filling oilInspection
Fill in 200cc (12.2cuyin) of engine oil API 1
grade CD #30 through the plug hole of collar
(3), wind seal tape and tighten plug (8).
: 5mm
Fig. 5-12 Installing collar (3) and filling oil
z After installing the idler assy to the
idler adjuster assy, make certain 160 (6.30)
that no oil leaks from floating seal C
and plug (8) and that idler (1)
rotates smoothly.
5.3.3 MAINTENANCE STANDARD F

A
B
Fig. 5-13 Front idler

No. ITEM STANDARD VALUE REPAIRABLE LEVEL SERVICE LIMIT REMEDY
Dia. of idler
A projection 535 (21.1)
B Tread dia. 497 (19.6) 490 (19.3) 487 (19.2) Replace
C Flange width 840.5 (3.3070.020) 78 (3.07) 76 (2.99)

Basic
dimension
Tolerance Fit Fit
Clearance 0.030
D between shaft 75
and bushing Shaft
0.060 Clearance Clearance
(2.95275) 0.00118 1.5 (0.059) 2.0 (0.079) Replace
0.00236 bushing.
0.036
Interference 83 0 Interference Clearance
E between idler Hole
and bushing (3.26771) 0.00142 0 0.01 (0.0004)
0
F Oil Engine oil API grade CD#30, 200cc (12.2cuyin) Refill
Idler rotation Rotates smoothly by hand. Reassemble
21
5.3.4 TOOLS AND JIGS

Unit : mm
NAME OPPOSING FLATS
Socket 24
Allen wrench 5
(2) Jigs
Unit : mm (in)
No. NAME SHAPE No. NAME SHAPE
(0.59 )
15
105 (4.13 )
(1.18 )
30
Pin
R
(0.79 )
striking jig
20
105 15
Bushing
(3.54 )
V Press fitting
90
(4.13 ) (0.59 )
(2.76 )
jig
70
(2.91 )
340 (13.4 )
74
+0.
Shaft 74.61
S (2.94 +0.004 )
push out jig 0
(1.18 )
103 (4.06 )
30
Collar Press
(0.63 )
300 (11.8 )
W
16
Bushing fitting jig

T
drawing rod
About. 150 (5.91 )

About. 600
(23.6 )
U Stand
About.
400
(15.7 )
2 pcs.
22
5.4 IDLER ADJUSTER ASSY

5.4.1 CONSTRUCTION
2 4 3 7 1 5 9 8 6
No. NAME Q
TY REMARKS
1 GREASE CYLINDER 1
2 BRACKET 1
3 NUT 1
4 SPRING PIN 1 880
5 SPRING 1
6 PISTON 1
7 COLLAR 1 11 10
8 O RING 1 1B G80
9 OIL SEAL 1
10 PIN 2 Fig. 5-14 Idler adjuster assy
11 COVER 1

(1) Disassembly
1) Spring set special jig M30
Holding-down nut
Before disassembling and assembling the
idler adjuster assy, prepare spring setting jig Retainer plate
(V).
Capacity of hydraulic jack : more than 20

tons (44000 lbs) V
: 46mm
Hydraulic jack
Large power is needed to set the

spring. Prepare a special jig before
disassembly and assembly. BASE
Fig. 5-15 Spring set special jig (V)
2) Preparation for working
Place a hydraulic jack between the jig base
and the stand.
Loosen the holding-down nuts of the jig and
draw out the retainer plate upward.
: 46mm
3) Draw out grease cylinder (See Fig. 5-14)
Draw out piston (6) from grease cylinder (1)
of the idler adjuster assy.
4) Removing oil seal (9), O ring (8)
(See Fig. 5-14)
Taken out oil seal (9) and O ring (8) from
5
grease cylinder (1).
5) Slinging work idler adjuster

Set the idler adjuster assy on the stand of
the jig, with its bracket side facing up. V
Fig. 5-16 Slinging idler adjuster
23
6) Fixing idler adjuster assy

Fit retainer plate to bracket (2), tighten
holding-down nuts alternately, and secure
idler adjuster assy.
Holding-down nut
: 46mm
3,4 Retainer plate
Fig. 5-17 Fixing idler adjuster assy

7) Compression of spring (5)
Remove spring pin (4), press spring (5) lifting
it with jack so that nut (3) can be turned 5
freely, and remove nut (3).
: 46mm
: 75mm
Fig. 5-18 Compression of spring (5)
8) Removing bracket (2)

Allow the hydraulic jack to retract slowly till
the spring is extended to its free length.
Retainer plate
Remove the retainer plate and take off
bracket (2), cover (11).
The free length of the spring :
About 531.1mm(20.9in)
2
: 46mm 11
Fig. 5-19 Removing retainer plate, bracket (2)

9) Removing spring (5), grease cylinder (1)
Hook lifting eye nut (W) to screw M48P2 on W
grease cylinder (1) top end and hoist it. Then, 1
remove the set of grease cylinder (1) and
spring (5) using crane from the jig.
Remove spring (5), collar (7), grease cylinder 5
(1), in that order.
Fig. 5-20 Removing spring (5), grease cylinder (1)
24
(2) Assembly W
Assembly is done in the reverse order of
disassembly. 1
1) Installing spring (5), grease cylinder (1)
Insert grease cylinder (1), collar (7) into
spring (5) and attach lifting eye nut (W) to
5
screw M48 P2 at the tip of the grease
cylinder. Lift the grease cylinder by crane
and erect it in the center of the jig stand
upright.
2) Fixing idler adjuster assy Fig. 5-21 Attach spring (5) and grease
Install bracket (2), cover (11) on top of spring cylinder (1) to the jig
(5). Center the rod of grease cylinder (1) and
Holding-down nut
the holes in bracket (2). Attach the retainer
plate and four holding-down nuts. Fasten the Retainer plate
nuts evenly all round and fix the idler
adjuster assy to the jig body.
: 46mm 2
4
3) Compressing spring (5) and installing nut (3) 3
Extend the hydraulic jack, compress spring 7
11
(5) to a set length and screw in nut (3) to the
screwed part at the tip of grease cylinder (1). 1
5
Set length of the spring : 429mm (16.9in)
4) Installing spring pin (4) Fig. 5-22 Compression of spring (5), and
Tighten nut (3) till the holes for locking attaching nut (3) and spring pin (4)
spring pins (4) are aligned. Then fit spring
pin (4).
: 46mm
: 75mm
5) Removing idler adjuster assy

Remove idler adjuster assy from jig.
Fig. 5-23 Removing idler adjuster assy
25
6) Installing oil seal (9), O ring (8)

Fit oil seal (9) and O ring (8) to grease
cylinder (1).
z Grease oil seal (9) and O ring (8). 1 9 8 6
7) Filling grease cylinder(1) with grease.

Fill up grease in cylinder (1), remove the
grease nipple from piston (6) to discharge the
inside air, and press in the piston by hand.
z Direct grease nipple hole downward

to make air discharge easier. Grease Nipple
Fig. 5-24 Grease cylinder (1)
8) Installing grease nipple
Tighten grease nipple to piston (6).
: 19mm,
5.4.3 MAINTENANCE STANDARD

STANDARD
No. ITEM
VALUE
A Installed length of spring 429mm (16.9in)
About. 531.1mm
B Free length of spring (20.9in)
C Stroke 50mm (1.97in)
D Set length 630mm (24.8in)

Nor scoring
E Outside view of piston and rusting
Tightening torque of 6kgfym
F grease nipple (43 lbfyft)
F
A, B
D
26
6. SPROCKET
6.1 REMOVING
Remove crawler referring to Section 2.
"Crawler", lift up crawler frame with
attachment, and put it on square timbers to
float and stabilize.
Fig. 6-1 Preparation for removal

(2) Removing sprocket
Loosen twenty two capscrews (2) M1850,
for the attaching of the sprocket, and remove
the sprocket (1).
Weight of sprocket : 57kg (126 lbs)
: 27mm
1
Fig. 6-2 Removing sprocket
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) Securing sprocket temporarily

Coat the sprocket attaching capscrews with
Locktite #262 and fasten the sprocket
temporarily.
(3) Securing sprocket completely

Remove the wooden blocks under the track
frame, bring the machine down on the ground
and tighten the sprocket.
: 27mm,
Fig. 6-3 Securing sprocket temporarily
27

Table 6-1
96.07mm NUMBER
PITCH 21
(3.78in) OF TEETH
SPECIFICATION
ROLLER 58.72 PITCH 644.602
DIA. (2.31in) DIA. (25.333in)
A C
Fig. 6-4 Sprocket
Table 6-2 Unit:mm(in)

No. NAME STANDARD VALUE REPAIRABLE LEVEL SERVICE LIMIT REMEDY
664 656 654 Reinforcement weld,

A O.D. of sprocket (26.1) (25.8) (25.7) repair or replace.
Width of 0 0
B 704 (2.7510.157 ) 64 (2.52) 62 (2.44) Replace.
sprocket teeth
O.D. of sprocket Reinforcement weld,
C bottom 586 (23.1) 578 (22.8) 576 (22.7) repair or replace.
6.4 TOOLS AND JIGS

Unit : mm
NAME OPPOSING FLATS
Socket 27
28
(2) Sprocket tooth profile gauge : W
Unit : mm (in)
Fig. 6-5 Tooth profile gauge (Full scale)
29
7. TRAVEL MOTOR
Apply Loctite #262
7.1 TRAVEL MOTOR or equivalent
T=40.5kgfym (290 lbfyft)
No. NAME Q
TY REMARKS 2
0 TRAVEL MOTOR ASSY 2
1 SPROCKET 2
2 CAPSCREW 44 M1855 3
3 CAPSCREW 34 M2060 Apply Loctite #262
or equivalent
1
0
Fig. 7-1 Installing travel motor
7.2 REMOVING
Remove crawler, lift up crawler frame using
attachment, and put it on square timbers to
float and stabilize.
7
(2) Removing cover (1)
1
Remove sems bolt (7) M12 25 and also
remove covers (1).
: 19mm Fig. 7-2 Removing and installing cover (1)
(3) Preparation of oil pan
(4) Removing hydraulic pipe

Bleed air in hydraulic oil tank, remove all
pipes connecting to travel motor. Then plug
up all pipes and joint section to protect them
from entry of dust.
: 19mm, 27mm, 32mm, 41mm

Refer to tool 4.plug (1).
Hydraulic pipe plug 4-1
ORS plug 4-1 11 See tools Fig. 7-3 Removing and installing hydraulic pipe
30
(5) Removing sprocket

Removing forty four (both side) capscrews (2)
M1850.
: 27mm
Fig. 7-4 Removing and installing sprocket

(6) Loosening travel motor attaching bolts (3)
Apply match marks on travel motor and Remove pipes.(Disconnect)
lower frame, and remove thirty four (both
side) capscrews (3) M2060.
: 30mm
Fig. 7-5 Removing and installing travel motor

(7) Slinging travel motor assy attaching bolts
Sling travel motor with nylon sling applied on
the side close to sprocket installing section
and remove the motor.
Weight of motor : About. 240kg (529 lbs)
7.3 INSTALLING
Installing of the travel motor piping is performed
in the reverse order of removal.
1) Cleaning
Check that contact surface of travel motor Fig. 7-6 Slinging travel motor
and lower frame is free from burr and stain.
Tightening
Tools RE-MA
2) Tightening torque NAME SIZE No. Torque
HEX RKS
kgfym(lbfyft)
Tighten capscrew and hydraulic pipes to the Sems bolt M12 19 7 8.5 (61) Apply
torque specified in "Tightening Torque".
M18 27 2 40.5 (290) Loctite
Capscrew #262
M20 30 3 55 (400)
3) Fill inside from motor drain port to casing with
Flareless
hydraulic oil before piping for drain. When nut for 101.5 19 5 (36)
pipes, 182.5 32 15 (110)
starting operation, operate motor in low idling 28 41 28 (200)
sleeve
and at low speed for several minutes, and check PF1/4 19 3.7 (27)
it for possible oil leakage and noise. Connector PF1/2 27 11 (80)
PF1 41 26 (190)
31
8. SWING BEARING
8.1 SWING BEARING ASSY
No. NAME QTY REMARKS

1 SWING BEARING 1
2 CAPSCREW 36 M20P1.565
FRONT
2 Inner S zone position of

swing bearing
SECTION AA
Fig. 8-1 Swing bearing assy
8.2 REMOVING
(1) Matchmarks
Remove upper structure, apply matchmarks Swing bearing
on inner race of swing bearing and lower
Outer race
frame.
(2) Remove thirty six capscrews (2) M2065 for Inner race
installation inner race.
: 30mm
Matchmarks
(3) Drawing out grease

Remove grease in grease bath.
Fig. 8-2 Matchmarks
(4) Removing swing bearing
Attach eyebolt on swing bearing and sling it.
Weight of swing bearing : 220kg (485 lbs)

Swing bearing
Eye bolt
Grease bath
Fig. 8-3 Removing and installing swing bearing
32
8.3 INSTALLING
(1) Cleaning
Clean it completely so that installing surfaces
of swing bearing and lower frame are free
from dust and stain.
FRONT
(2) Installing
Install swing bearing on lower frame meeting
the matchmarks and positioning the S mark
on inner race as shown in the figure.
(3) Temporary fastening of inner race

Coat the threads of the capscrews (2) with Inner S zone position of
Locktite #262 and tighten all the capscrews swing bearing
(2) temporarily. Fig. 8-4 Location of S mark on swing bearing
: 30mm
(4) Regular tightening of inner race

Tighten the capscrews (2) at 180 degrees
intervals alternately to a specified torque.
:30mm, 1
Tightening torque :
2 Locktite #262 or equivalent
to be applied
(5) Filling grease. T=57.4kgfym (420 lbfyft)
SECTION AA
Fill grease bath with 8.3kg (18 lbs) of grease
NLGI-2 (containing molybdenum disulfide) or Fig. 8-5 Removing and installing capscrew (2)
equivalent.
8.4 CONSTRUCTION
No. NAME QTY No. NAME QTY 6
1 OUTER RACE 1 6 SEAL 1 1 8
2 INNER RACE 1 7 TAPER PIN 1 9
3 BALL 104 8 PLUG 1
7
4 RETAINER 104 9 GREASE NIPPLE 1 3,4
5 SEAL 1 (PT1/8)
5
2
8.5 DISASSEMBLY AND ASSEMBLY Fig. 8-6 Cross-sectional view of swing bearing
(1) Disassembly
1) Take out seal (5) fitted in the groove in the EYE BOLT
6 2
outer circumference under inner race (2) and
7
seal (6) fitted in the groove in the inner
circumference on top of outer race (1) and 1
place them level on a square wooden block or Square wooden
something. block
2) Draw out taper pin (7), using a hammer and
an extrusion rod.
8
3) Draw out plug (8), utilizing an pull bolt
inserted in the screwed hole (M10) in the 5
center of the plug and using a puller. Fig. 8-7 Removing swing bearing
33
4) While rotating outer race (1) little by little, 1

take out ball (3) and retainer (4) through plug
hole, in that order.
2
4
3
Fig. 8-8 Removing balls (3) and retainers (4)
(2) Installing
1) Thoroughly degrease the groove for seal (6)
located on the inner surface of outer race (1)
and the groove for seal (5) located on the
outer surface of inner race (2). Coat the
grooves with adhesive Cyano Bond PX-3000
or equivalent, fit seal (5) and place it on a 1
surface plate. Push rod 6
2) Lower outer race (1) to the position where
2
upper surface of inner race (2) and lower
portion of seal groove is mated, put adjusting 3
5
washer under outer race (1) so that outer Square
wooden block
raceway surface of ball (3) aligns with inner
raceway, and support it. Fig. 8-9 Fitting balls (3)
3) Insert ball (3) and retainer (4), on which
grease is applied, through plug (8) hole on Eye bolt
outer race (1), alternately.
To insert ball (3) and retainer (4), use a

push rod, etc., to protect persons from Hooked rod
injury from inserting fingers into plug
hole.
4) Fit plug (8) to outer race (1) while checking it 4

for direction and position of taper pin hole.
5) Coat seal (6) with adhesive Cyano Bond Square
wooden block
PX-3000 equivalent and fit it in the groove of
outer race (1). Fig. 8-10 Fitting retainer (4)
6) Check that grease nipple (7) is properly
fitted, and fill it with grease. Then, check
bearing for smooth rotation and flaws on seal
lip portion.
z Shell Alvania EP#2 ; 160cc (9.8cuyin)

Maintenance standard concerning wear of swing
bearing is described in the section Maintenance
Standard and Test Procedure in the separate
volume.
34
1. REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT * : Apply Locktite #242
1.1 CONSTRUCTION OF TRAVEL MOTOR Tightening Opposing Tightening Opposing
torque flats No. NAME QTY torque flats No. NAME QTY
35 37 12 13 3 7 5 6 40 24 28 36 kgfym(lbfyft) mm kgfym(lbfyft) mm
1 CASING 1 23.5 (170) 14 31 SOCKET BOLT ; M1645 8
2 REAR COVER 1 32 SHIM 1~2
20 33 3 CYLINDER BLOCK 1 33 PARALLEL PIN ; 612 1
21 4 SHOE RETAINER 1 _ ___ _
5 FRICTION PLATE 3 35 PLUG ; NPT1/16 1
23
6 BRAKE PISTON 1 36 PLUG ; NPT1/16(Meck : TB) 10
29 32 7 SEPARATOR PLATE 4 1.4 (10)* 37 PLUG 1
17 8 VALVE PLATE 1 1.5 (11) 5 38 PLUG ; PF1/8 3
9 SHAFT 1 3.0 (22) 6 39 PLUG ; PF1/4 2
9 26 10 COUPLING 1 40 ORING ; 1B P8 5
38 11 SHOE PLATE 1 41 ORING ; 1B P11 4
18
40 12 BALL JOINT 1 42 ORING ; 1B P14 2
13 SPRING RETAINER 1 43 ORING ; 190.172.62 1
39 _Z 14 PISTON ASSY 9 11 (80) 32 44 OVER LOAD RELIEF VALVE_M27 2
41 15 D RING (SMALL) 1 45 SPOOL 1
16 D RING (LARGE) 1 5.5 (40) 22 46 PLUG ; PF3/8 1
10 17 CHECK VALVE 3 47 SPRING RETAINER 1
18 SNAP RING 1 48 PIN 1
19 2 19 SNAP RING 1 49 SPRING 1
20 TILTING PISTON 1 5.5 (40) 50 CONNECTOR 1
21 BALL 1 51 SPOOL ASSY 1
30 22 PIVOT 2 52 COVER 2
23 PISTON SEAL 1 53 SPRING 2
8 24 M6 ORIFICE_0.6 2 54 SPRING RETAINER 2
25 25 OIL SEAL 1 55 RESTRICTOR VALVE 2
22 1 11 4 27 15 16 43 14 26 SPRING 3 56 SPRING 2
27 SPRING(CYLINDER) 9 2.8 (20) 57 PLUG 2
44 50 42 45 48 47 49 42 46 28 SPRING(BRAKE) 2 58 ORING ; 42.522.62 2
29 BEARING 1 59 ORING ; 1B P9 2
30 BEARING 1 10 (72) 10 60 SOCKET BOLT ; M1235 8
58
54 44-3 44-2 44-1 44-4 44-12 44-13 44-9 44-8 44-12 44-10 44-11 44-6 44-7 44-5
60
53
52
57
Note) Quantities are worth one overload relief valve.

41
Tightening Opposing Tightening Opposing
kgfym(lbfyft) mm kgfym(lbfyft) mm
11 (80) 32 44-1 SOCKET 1 44-8 SHIM 1
59 44-2 VALVE 1 44-9 ADJUSTMENT SPRING 1
31 51 55 56
44-3 VALVE SEAT 1 44-10 O RING ; 1BP7 1
VIEW_Z (Shows part of the cross-sectional view) 44-4 CONNECTING PISTON 1 44-11 BACK UP RING 2
16 (120) 35 44-5 PLUG 1 44-12 O RING ; 1BG25 2
Fig.1-1 Construction of travel motor 44-6 PILOT BODY 1 44-13 BACK UP RING 1
44-7 PISTON 1
II - 1
1.2 CONSTRUCTION OF REDUCTION UNIT
24 15 16 14 13 12 18 25 20
5
10 Clearance:0.08 to0.02mm (0.0031 to0.0008in)
6 Adjust it with only one shim.
9 1.1mm
0.42.4mm (0.043 )
(0.016 0.094 )
8 Storage this unit in condition
that the axis is horizon.
1
11
26
17 21 22 19 23
Fig.1-2 Construction of reduction unit

Apply Locktite #242
Tightening Opposing Tightening Opposing
kgfym(lbfyft) mm kgfym(lbfyft) mm
1 COVER 1 14 PLANETARY GEAR 2 3

2 CARRIER 1 1 15 SPRING PIN840 3
3 CARRIER PIN 1 3 16 THRUST WASHER 2 6
4 NEEDLE BEARING 3 17 RING GEAR 1
5 THRUST WASHER 1 6 18 HOUSING 1
6 PLANETARY GEAR 1 3 19 BEARING 2
7 SPRING PIN532 3 20 SHIM 1
8 THRUST PLATE 1 21 LOCK WASHER 2
9 SUN GEAR 1 1 22 SUPPORT RING 1
10 SUN GEAR 2 1 23 FLOATING SEAL 1
11 CARRIER 2 1 8.0 (58) 8 24 SOCKET BOLTM1025 15
12 CARRIER PIN 2 3 28.0 (200) 14 25 SOCKET BOLTM1680 19
13 NEEDLE BEARING 3 1.0 (7.2) SEAL
TAPE 14 26 SOCKET PLUGPT3/4 2
2
1.3 TRAVEL MOTOR DISASSEMBLY

1.3.1 TOOLS
Table 1-1 Unitmm

TOOLS SPECIFICATION
Allen wrench Opposing flats 5, 6, 10, 14
Spanner Opposing flats 19, 27, 32, 35
Plier for snapring For shaft 45
Plier for snapring For hole 3280
Plastic hammer
Screw driver Flat-bladed (), Medium size 2pc.
Torque wrench 23.5kgfym (170 lbfyft) max.
Gear (Bearing) puller Effective opening dimension: diameter 75 width 45
Holding-down metal fitting Ex. L160 (6.3)W70 (2.76)H37 (1.46),
20 (0.79)100 (3.94) oval hole:
2 tools are needed.
L
W
(0.79 )
20
100
(3.94 ) H
Oil seal fitting jig 90

(0.39 )
(3.54 )
10
(0.39 )
10
52
(2.05 )
Brake piston fitting jig

PCD220
(0.39 )
(0.87 )
(8.66 )
DRILL THROUGH 2-18 (0.71)
10
22
Others
Seal tape
Cleaning oil (Kerosene) 170
(6.69 )
Grease
190
Hydraulic oil (7.48 )
Rag 250
(9.84 )
Compressed air
3
1.3.2 DISASSEMBLY
(1) General cautions Separate spring (53), spring retainer (54) and
1) In general, the hydraulic components are spool assembly (51).
made to precision and have very little
clearance. For this reason, disassemble and Put a matching mark on spool
assemble them in a less dusty clean place. assembly (51) and rear cover (2) so
Use clean tools and cleaning oil and handle they are reassembled in correct
them with care. directions. (Right and left directions)
Since the screw threads of spool
2) When the motor has been separated from the assembly (51) is coated with
machine , clean the ports and the neighboring adhesive, further disassembly is not
areas thoroughly and put plugs into ports so possible.
no dirt, water and other foreign matter enter
the motor. Draw out plug (57), O ring (41), spring (56)
and restrictor valve (55).
3) Study the assembly drawing before starting
the work and prepare necessary parts Remove overload relief valve (44).
according to the purpose and the scope of : 32mm
disassembly. Seals and O rings once
disassembled can not be used again. Some Remove coupling (10).
parts cannot be supplied singly, but must be
supplied as sub-assemblies. Prepare such
parts beforehand according to the parts
manual.
4) Pistons and cylinders do not have specific

combinations when new. If you expect to use 2
disassembled pistons again, put a matching
mark on each piston and cylinder so they are
reassembled where they were. 10
5) Use care so you do not pinch your finger

between parts and drop parts on your foot.
(2) Disassembly procedure

1) Removing the attached valves. 44
Remove the attached valves before
disassembling the motor.
58
60
Do not remove such valves that are
not supposed to be taken off because
of the purpose of disassembly.
However, you can not disassemble
the motor without removing the 52
53
brake valve.
54
Loosen socket bolts (60) and take off O rings

(58), (59).
: 10mm 57 41 56 55 59 51
Fig. 1-3 Removing the attached valves
4
2) Disassembling the motor

Place the motor shaft level and remove all
bolts (31) except two vertically diagonal ones. AIR SUPPLY 28
2
: 14mm
Loosen two remaining bolts slowly at the

same time.
Remove rear cover (2) and spring (28), taking

care so cylinder block (3) does not come off
with rear cover (2).
3 8 30 43 31
In that case, do not drop valve plate
(8), brake spring (28) or O ring (43).
Fig.1-4 Removing the rear cover
Remove valve plate (8) so cylinder block (3)
does come off together.
Put a matching mark on valve plate

(8) and rear cover (2) so they are
reassembled correctly. (so the face
and the back are not reversed.)
Push in cylinder block (3), using removed bolt

(31) in the holding-down metal so the
cylinder block is not damaged, till the inner
race of rear bearing (30) sticks out.
Remove the inner race of rear bearing (30) by

putting the gear (bearing) puller in the inner
race.
30
Fig.1-5 Removing the rear bearing
5
Hold down brake piston (6) by hand and

press it out by blowing air through the brake AIR SUPPLY
releasing oil hole.
7 5 13
Use care as the brake piston pops up

3
by air pressure.
Put such a bar (marked) that does not score

cylinder block (3) (such as a coiled paper
shaped like a pipe) into the hole of piston (14) 14
and give a matching mark on the outer
surface of cylinder block (3).
Remove cylinder block (3), spring retainer
(13) and spring (27). MARK
Remove separator plate (7) and friction plate MATCHING MARK
(5).
Take off nine piston assy (14), shoe retainer 12 4 27 6
(4) and ball joint(12) at the same time.
With piston assy (14) and shoe

retainer (4) removed, match the Fig.1-6 Removing the cylinder block
mark with the matching mark and
put them into the cylinder block.
This operation is to insure that the
pistons are reassembled where they
were.
Take care so as not to score the

moving surfaces. Scored ones can not
be used again.
The piston and the shoe are caulked

together and can not be separated.
(Reference)
The above-mentioned explanations are associated
with a single motor, but the motor with a
reduction gear may be separated the same way.
The motor with a reduction gear may be
disassembled more easily in some cases as the
shaft does not swing too much.
6
Remove shoe plate (11).
Do not remove tilting piston (20). In case it

must be removed for unavoidable reason, AIR SUPPLY
hold down tilting piston (20) by hand and
push it out by blowing air through the hole in 19 25 29 1 20 11
the figure.
Shaft (9) comes off.
Take off snap ring (19) and oil seal (25).
When replacing the bearing, remove the

inner race and the outer race with a bearing 9
puller and replace them as an assembly.
Shim (32) is placed under the outer

22
race of bearing (30). Put it in as it is
at reassembly.
When replacing such parts that are Fig.1-7 Removing the shoe plate
related with the fastening allowance
of the bearing such as bearings (29,
30), shaft (9), casing (1) and rear
cover (2), the thickness of shim (32)
needs adjustment.
Measure the shim clearance
correctly when the shim is placed
lightly, replace it with a proper one
and adjust the clearance of the
bearing to 0 to 0.1mm.
A special jig is required to determine
the shim thickness.
Do not take off pivot (22). In case it

must be taken off for indispensable
reason, put a matching mark on shoe
plate (11).
Do not take off oil seal (25). Replace

it with a new one in case it was
taken off.
7
Determining the shim thickness for taper

roller bearing
This operation is necessary when
any of casing (1), rear cover (2), shaft
(9) and bearings (29), (30) has been
replaced. E S
9
1. Measure the dimension E in the 30

as-assembled condition in Fig.1-8. 2
Make sure that shaft (9) is

perpendicularly positioned.
(Not tilted).
2. Measure the dimension F on the rear cover

side.
Measure four diagonal points on the

circumference and make a mean
F
value.
1
3. Suppose the thickness of shim (32) to be used Fig.1-8 Determining the shim thickness
is "S", the clearance "Y" is as below:
YF(ES)
4. Choose one or two shims that make the

clearance "Y" 00.1mm (00.004 ).
3) Disassembling the overload valve

Remove the overload valve as an assembly,
utilizing the opposing faces of the hexagon of
socket (44-1).
In principle, the overload valve is handled as
an assembly, but in case it must be
disassembled for unavoidable reason, remove
plug (44-5) from socket (44-1) and pull out the
internal parts.
44-3 44-2 44-1 44-4 44-12 44-13 44-9 44-8 44-12 44-10 44-11 44-6 44-7 44-5
Fig.1-9 Disassembling the overload relief
8
1.4 ASSEMBLING THE TRAVEL MOTOR

1.4.1 GENERAL PRECAUTIONS TO BE EXERCISED
(1) Clean the parts in cleaning oil and blow them
with jet air.
(2) Coat the moving parts with clean hydraulic
oil before proceeding to assembly.
(3) Take care so you do not pinch your hand
between parts and you do not drop parts on
your foot.
1.4.2 ASSEMBLY PROCEDURE

(1) Coat the outer surface of oil seal (25) and the
inner surface of casing(1) with grease. Insert
oil seal (25) into casing (1) by lightly tapping 25
it so it does not tilt, using the fixing jig.
(2) Fix oil seal (25) with snap ring (19).
(3) Put the outer race of bearing (29) into casing
(1) (clearance fit) and press the inner race
1
into shaft (9). (interference fit).
The inner race is set more easily if it Fixing jig of oil seal
is heated below 100.
(4) Put shaft (9) in casing (1). In that case, coat

the contact surface of oil seal with grease. Fig.1-10 Oil seal fixing
(5) Put in tilting piston (20).
(6) Fit pivot (22).
z In that case, put it on the side on

which the matching marks of the
shoe plate are aligned. If the motor
is run for a long time, put the shoe
plate where the traces on the
spherical part match the contact
marks of shoe plate (11). 19 25 29 1 20 11
22
Fig.1-11 Installing the shoe plate
9
(7) Coat the three spherical areas of shoe plate

(11) with a thick film of grease.
(8) Assemble piston assy (14), shoe retainer (4),

ball joint (12), spring retainer (13) and
cylinder spring (27) into cylinder block (3), as
shown in the figure. Then put the whole
assembly into shaft (9). 4 14 13 3
Do not fail to bring back each piston

assy (14) into the hole in which the
assy was set.
(9) Install the inner race of bearing (30) to the

end of shaft (9) by lightly tapping it with a
mallet.
(10) Assemble separator plate (7) and friction 9 1 12 27

plate (5) by turns till all of them are put
together. The first and the last are separator
plates (7).
Fig.1-12 Assembling the piston assy
(11) Fit brake piston (6) with D rings (15, 16) to

casing (1), using a fixing jig.
The brake piston is equipped with

two D rings (15, 16), large and small. 1 14 7 5 15 16 31
The larger D ring (16) enters the
hole first and the small D ring (15)
enter the hole later.
You can not check visually that the
smaller D ring (15) is entering.
In some cases, the D ring is scraped
off by the hole of casing (1). 30
BRAKE
PISTON
6 FIXING JIG
Fig.1-13 Assembling the brake piston
10
(12) Put valve plate (8) into rear cover (2)

according to the matching marks left at
disassembly. Fit brake spring (28) and O ring
(43) to the rear cover, insert rear cover (2)
into casing (1), and fasten them together with
socket bolts (31).
: 14mm,
Tightening torque: 23.5kgfym (170 lbfyft)
In case the outer race of bearing (30)

was removed, do not forget to fit 1 15 16
shim (32). 6
18 10 28
(13) Attach coupling (10). 8
(14) Install overload relief valve (44).

30 32
(15) Put restrictor valve (55) and spring (56) in
cover (52). Then fix the cover with plug (57)
that is fitted with O ring (41). 42 2 31
: 22mm,
Tightening torque: 2.8kgfym (20 lbfyft) Fig.1-14 Assembling the rear cover
(16) Fit O rings (58), (59) to cover (52).
(17) Put spool assy (51) into rear cover (2)

according to the matching marks left at
disassembly. Then assemble spring retainer
(54) and spring (53).
Exercise care of the orientation of

spool assy (51).
(18) Install cover (52) with socket bolts (60). 44

: 10mm,
Tightening torque: 10kgfym (72 lbfyft) 52 60 58 54 54 60 52
51 53
57 41 56 5559 53
Fig.1-15 Assembling the brake valve
11
1.5 TRAVEL MOTOR

1.5.1 PARTS MAINTENANCE STANDARDS
The following are reference values by which
serviceability of the disassembled parts are
determined. These are general values and the
extent of disassembly should be determined
depending upon the performances, extreme
external damage and discoloration, the purpose of
disassembly and the expected service life.
Table 1-2
Inspection Item / Method Criterion and Remedy
Standard Surface Allowable surface
(1) Sliding surface of cylinder Inspection item Remedy
roughness roughness
block, valve plate and swash
plate Cylinder block
Replace
valve plate
Measure the surface roughness 0.4-Z max. 3.0Z max. or
surface roughness
of the sliding surface of the correct.
of shoe plate
cylinder, valve plate and
swash plate, using a surface
roughness meter. To correct the surface roughness of the cylinder block and the
valve plate,lap them together. (lapping powder # 1200 )
Allowable hardness
Inspection item Standard hardness requiring Remedy
Measure the hardness of the replacement
sliding surface of the valve

Higher than
plate and swash plate, using a Shoe plate HS74 Replace.
HS78
hardness meter.
(2) Piston and cylinder block Inspection item Standard Allowable value Remedy
clearance
Piston O.D. dd1 0.01mm(0.0004 ) 0.05(0.0020 )
Replace
Measure the outside diameter
piston or
of pistons and the bore of the Cylinder bore DD1 0.01mm(0.0004 ) 0.022(0.00087 )
cylinder
cylinders at least three Clearance Dd 0.0350.045mm 0.065(0.0026 )
(0.00140.0018 ) block.
locations longitudinally by
means of a micrometer, and let
the maximum O.D. value be d, When any piston is to be replaced, replace nine pistons
the minimum O.D. value be d1, altogether.
the maximun bore value be D,
and the minimum bore value
be D1.
12
Inspection Item/Method Criterion and Remedy
(3) Gap of piston shoe Part name and Standard Allowable

Remedy
inspection item dimension value
Gap of caulked part
Hold down the shoe to the
between piston and
surface plate by means of jig,
shoe
draw out the piston upward 00.1mm 0.3mm
Replace piston
and measure the gap between (00.004 ) (0.012 )
the piston and the shoe.
DIAL INDICATOR
PISTON
JIG
MAGNET SHOE
SURFACE
PLATE
40
(1.58
Fig.1-16 Measure 27+0.2
+0.1
(1.06 +0.008
+0.004 )
(2.76 )
70
Fig.1-17 Gap of caulked part Fig.1-18 Jig
(4) Negative brake force Standard Allowable

Inspection item Remedy
value value
After the end of assembly, place
a torque wrench in the end of Replace all of
the output shaft, apply torque separator
50kgfym 41kgfym
to it and measure the torque Brake torque plate, friction
(360 lbfyft) (300 lbfyft)
reading when the motor begins plate and
to turn. spring.
13
Inspection Item/Method Criterion and Remedy

(5) Shaft Allowable stepped wear is up to 0.05mm (0.002in).
Measure the wear of the shaft

When the shaft is to be replaced. replace the oil seal (25)
seal by means of a roughness
at the same time.
meter.
When replacing the shaft, the thickness of shims (32)
must be adjusted.
(6) Bearing Replace bearing (29) and bearing (30) within 10,000
hours on the hour meter.
Replace bearing
When replacing the bearings, replace the inner race and

the outer race at the same time.
When the bearings have been replaced, the thickness of
shims (32) must be adjusted.
(7) Spline Serviceable stepped wear is up to 0.3mm (0.012in) on the

contact surface.
Replace spline if it is worn
beyond its allowable limit.
(8) Overload relief valve section Replace the sub assembly every 10,000 hours on the
hour meter.
This is the overload relief
valve section. Pressure can
not be checked and regulated
without a special test bench.
14
1.6 TRAVEL MOTOR TROUBLESHOOTING

The following are corrective actions to be taken in
case the motor is in trouble.
1.6.1 GENERAL PRECAUTIONS (3) Handling parts

(1) Cautions to be exercised before work Handle parts with due care, particularly the
Before proceeding to work, determine the moving portions, so as not to damage the
kind of abnormality and think if a similar moving parts.
symptom occurred before.
Think once again if the fault really comes (4) Handle O rings so as not to score the seat
from the motor. surfaces.
At removal, replacing O rings with new ones
(2) Beware of dust. is recommended.
Many faults are caused by dust. Therefore,
take dustproofing measures at disassembly.
1.6.2 TROUBLESHOOTING
(1) Motor does not start.
Symptom Cause Remedy
Pressure does not
Built-in relief valve is out of order. Repair or replace relief valve.
rise.
Pressure rises. 1. Negative brake is not released. 1. Check if orifice is not clogged.
(Orifice in release pressure path is Clean or replace orifice.
clogged.)
2. Negative brake is not released. 2. Assemble the spool in correct
(The spool is assembled the other orientation.
way in terms of right and left.)
3. Friction plate or separator plate in 3. Replace friction plate and separator
Negative brake is stuck. plate.
4. Negative brake piston in mechanical 4. Recondition O. D. of brake piston of
brake section is stuck. replace brake piston.
5. Sliding area is seized. 5. Repair or replace piston, shoe, shoe
plate, cylinder block and valve plate.
6. Spool malfunctions 6. Correct or replace
(Spool is stuck.)
(The hole in the restrictor valve is
clogged.)
(2) Motor does not start powerfully.

A set pressure is Spool malfunctions Correct or replace
normal, but brake (Spool is stuck.)
release lags behind.
15

Negative brake is The viscosity of hydraulic oil is too high. Raise the oil temperature.
released but the
motor is late to
start.
Negative brake is 1. Negative brake is not released 1. Investigate to see if orifice is not
released but the completely. clogged.
motor starts feebly. (The orifice in the release pressure
path is clogged with dirt.)
2. Dirt is included in relief valve. 2. Clean relief valve.
Inspect seat surface or replace relief
valve.
3. Sliding surfaces are seized. 3. Inspect and repair sliding surface or
replace relief valve.
(3) Revolution does not reach a set value.

Pressure does not 1. Oil flow is insufficient. 1. Inspect pump, delivery rate and the
reach a set value. oil path to motor.
2. Shoe, cylinder block and valve plate 2. Inspect and repair faulty parts or
are worn off or scratched much. replace faulty parts.
(4) Brake does not work.

Brake does not Negative brake malfunctions. Inspect and repair or replace brake
work. piston, friction plate and spring.
1. Friction plate is worn off.
2. Spring is broken.
Reverse brake Spool malfunctions Correct or replace

works.
1. Spool and the body are stuck
together.
2. Check valve is stuck or includes dirt.
3. The hole in the restrictor valve is
clogged.
(5) Oil leaks.

Oil leaks. 1. Bolts and plugs are loosen. 1. Tighten bolts or plugs to a specified
torque.
2. O rings are galled. 2. Replace O ring.
3. Oil is leaking into gear casing. 3. Replace oil seal.
16
(6) The motor speed does not change from high to low.

Motor does not Spool of pilot valve is stuck. Check and repair pilot valve.
change from high to
low speed.
(7) Abnormal sound occurs.

Intense vibration Spool malfunctions. Bleed air.
and sound occur Air remains in circuit and valve.
when brake is
operated slowly or Spool is stuck. Correct or replace.
with other circuits.
(8) Hunting occurs when machine goes down a slope.

Hunting is intense Spool malfunctions. Correct or replace.
during inching. Spool and body are stuck.
Seat of restrictor valve is poor.
Interference with negative brake Correct or replace.

Spring at end of spool is fatigued or
broken.
17
1.7 REDUCTION UNIT DISASSEMBLY

1.7.1 TOOLS
Before removal and installation, prepare tools,
jigs and measuring instruments.
No. Tools Application

1 Torque wrench 0 50kgfm (0 360 lbfft)
2 Allen wrench Opposing flats 8mm, 14mm
3 Stand More than 420 (16.5 )
(7.09 )
340
180
(13.4 )
t=16 (0.63 )
4 Micro depth meter 0 15mm
5 Caliper 0 150mm
6 Eye bolt M10 M18 3pcs. each
7 Pin Spring pin 3.5 75, 5 55
8 Press machine It is used to insert the angular bearing and fix the lock
washer.
Capacity 3 tons (6610 lbs)
9 Others Cleaning oil, Detergent, Gear oil, Grease,
Locktite#242, #515, Seal tape, rag and others
1.7.2 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) Leaving matching marks

Put a matching mark on the outside of each
matching surface so it may be installed where
it was.
l The numbers in the parentheses after

part names correspond to those in the
assembly drawing on page II-2.
18
(2) Mounting the travel unit to the stand. COVER MATCHING MARK
1) Remove three M10 socket bolts (24) in cover
(1) at equal spacings. Put eye bolts and lift it.
Then install the travel unit so the cover
comes up and the motor faces down.
: 8mm
Take care so you do not pinch your

hand between parts and drop parts.
(3) Removing the cover Fig.1-19

1) Take off the remaining M10 socket bolts (24).
: 8mm
2) The contact surfaces of cover (1) and ring

gear (17) are coated with sealing compound.
Therefore, remove cover (1) by placing a 24
wooden piece on the area of the cover
1
protruded from ring gear (17) and knocking it
with a hammer.
Fig.1-20
17
Fig.1-21
19
(4) Removing Carrier 1 Assy

1) Remove thrust plate (8).
2) Remove sun gear 1 (9). 2
3) Place three M10 eye bolt in carrier 1 (2) and 6

remove carrier 1 assy (2, 3, 4, 5, 6, 7). (3,4,5,7)
Fig.1-22
(5) Removing carrier 2 assy
1) Remove sun gear 2 (10).
11
2) Place three M10 eye bolt in carrier 2 (11) and
remove carrier 2 assy (11, 12, 13, 14, 15, 16).
14
(12,13,15,16)
Fig.1-23
(6) Removing housing assy
1) Remove support ring (22).
2) Remove lock washer (21) by hammering on 22

something like a screwdriver that is placed in
the split.
3) Place an eye bolt in each of the three M10

threaded holes in ring gear (17). Then remove
housing assy [ring gear (17), housing (18),
bearing (19), and floating seal (23)].
Fig.1-24
21
Fig.1-25
20
(7) Removing housing assy

1) Place the housing assy with ring gear (17) facing
downward and housing (18) upward. Leave a
matching mark on the outer surface of the housing
19 25 18
and the ring gear.
2) Separate floating seal (23) from housing (18).
3) Take off all M16 socket bolts (25), except two in
diagonal directions.
300 (11.8_) or more

: 14mm
4) With the remaining two loosened, knock the head of 17
them with a hammer. Then ring gear (17) comes off
from housing (18) easily.
Use care so as not to score the moving

surface of the floating seal (23) and the O
ring. Fig.1-26_Three stands of same height
The outer circumference of the bearing

(19) is engaged with the bore diameter of
the housing (18) by a very close fit. Do not
remove them except when necessary.
When the bearing has been separated from
the housing, do not use it again, but
replace it with a new one.
(8) Removing the floating seal

1) Remove the floating seal (23) on the motor side.
23
When reusing a carrier pin 1 (3), store it

Fig.1-27_Removing floating seal (23)
by putting a mark in the carrier 1 (2) hole
and the carrier pin 1 (3) so they are
assembled the same way before they were 3
removed.
Fig.1-28_Carrier 1 assy
II-21
1) Drive in spring pin (7) into carrier pin 1 (3).

2) Remove carrier pin 1 (3) from carrier 1 (2).
3) Separate thrust washer 1 (5), planetary gear
1 (6), and needle bearing (4). 7
4) Remove spring pin (7) from carrier pin 1 (3).
3
When replacing the carrier pin 1 (3)
or the planetary gear 1 (6), always 2
replace a set of three at one time.
2
Fig.1-29 Removing carrier 1 assy
6 4
6
When reusing a carrier pin 2 (12),

store it by putting a mark in the
carrier 2 (14) hole and the carrier
pin 2 (12) so they are assembled the
same way before they were removed. 15
12
1) Drive in spring pin (15) into carrier pin 2
11 11
(12).
2) Remove carrier pin 2 (12) from carrier 2 (11).
3) Separate thrust washer 2 (16), planetary gear
2 (14), and needle bearing (13).
4) Remove spring pin (15) from carrier pin 2 Fig.1-31 Removing carrier 2 assy
(12).
When replacing the carrier pin 2 (12)

or the planetary gear 2 (14), always 11 14
replace a set of three at one time.
16
13
22
1.8 INSTALLATION
(1) General precautions
1) Clean parts thoroughly in cleaning oil and
dry it up by jet air. Degrease areas to coated
with Locktite, using thinner or something. 11
2) Check that parts are free from fault.
3) Coat socket bolt with Locktite #242, before
tightening them. 14(13,16)
4) Coat the parts with a thin film of gear oil,
before proceeding to assembly operation.
5) Use care so you do not pinch your hand
between parts and you do not drop parts.
(2) Installing carrier 2 assy Fig.1-33 Installing carrier assy

1) Install planetary gear 2 (14), needle bearing
(13), and thrust washer 2 (16) into carrier 2
(11).
2) Insert carrier pin 2 (12) into carrier 2 (11),
14(13,16)
matching the carrier pin in the direction of
the spring pin hole.
3) Drive spring pin(15) into carrier 2 (11) and
carrier pin 2 (12).
15
[Drive in the spring pin 1 to 2mm (0.04
0.08in) below the surface into which it is 11
placed.]
4) Caulk two places 180diagonally located.
Fig.1-34 Install spring pin
(3) Installing carrier 1 assy
(See carrier 2 in the figure.)
1) Install planetary gear 1 (6), needle bearing
(4), and thrust washer 1 (5) into carrier 1 (2).
2) Insert carrier pin 1 (3) into carrier 1 (2),
matching the carrier pin in the direction of
the spring pin hole.
3) Drive spring pin (7) into carrier 1 (2) and
carrier pin 1 (3).
[Drive in the spring pin 1 to 2mm (0.04
CAULKING
0.08in) below the surface into which it is POSITION
placed.]
4) Caulk two places 180diagonally located.
15
Fig.1-35 Caulking the spring pin
23
(4) Installing floating seal

1) Install floating seal (23) on the motor side. 23
Fig.1-36 Installing floating seal (23)

(5) Installing housing assy
1) Apply Locktite #515 to the matching surface
of housing (18) and ring gear (17).
2) Attach three eye bolt M18 in housing (18), lift 18

it with a wire sling, align the matching
marks, and install the housing to ring gear
(17).
3) Apply Locktite #242 to nineteen socket bolts

M1680 (25) and tighten them up. LOCKTITE #515
: 14mm,
Fig.1-37 Installing housing assy

4) Install floating seal (23) to the housing side.
HOUSING SIDE 23 25 18
Clean the floating seal to be free
from oil, dirt, paint and other foreign
matter.
17
Coat the moving part of the floating
seal (23) with a thin film of gear oil.
Fix the O ring so it is not twisted.
Confirm that the floating seal (23) is GOOD

fixed parallel to the housing (18) and
the motor, as illustrated.
BAD
BAD
Fig.1-38 Install floating seal (23)
24
(6) Deciding the shim thickness for angular

bearing
z This operation is needed when the

motor (casing), housing (18),
bearing(18), bearing (19) or lock
washer (21) is replaced. If any of the
above parts was not replaced, use
the original shim (20) as it is.
1) Press the inner races of two bearings (19)

evenly and measure the assembled width (A)
of the inner races.
2) Measure the width (B) of the assembled part
of the motor bearing.
3) Measure the width (C) of groove on the
motor. D A
4) Measure the thickness (D) of lock washer B
C
(21).
In the above measurements,

measure four diagonally intersecting 17 21 22 19 18 20
points on the circumference and get
a mean value.
5) Suppose the thickness of shim (20) being used

is (S), the clearance (X) is as follows :
X(BC)(ADS)
6) For this unit, choose one shim that makes the
clearance X;0.08mm to0.02mm
(0.00310.0008in).
(A plus value is a clearance fit and a minus
value is a interference fit.) Fig.1-39 Deciding a shim thickness
(7) Pressing fit the motor

1) Place the motor on a level stand with its shaft
facing up. Then place shims (20) selected
under 6) above, on the end face in which
21 22
motor bearing is inserted.
2) Attach three M10 eye bolts to ring gear (17)
and lift it up, bring it down slowly vertically
matching it to the center of the motor and
insert bearing (19) fixed in the bore of
housing (18) into the motor. Press the inner
race of the bearing (19) to full depth, using a
press.
3) Fix lock washer (21) into the groove, pressing
the flange of housing (18).
4) Fix support ring (22) in the outside of lock
washer (21).
Fig.1-40 Pressing fit the motor
25
(8) Installing carrier 2 assy PLANETARY GEAR 2

1) Place the carrier 2 assy in ring gear (17) and engage
it with the motor spline so that three planetary gears
2 (14) are placed in the illustrated position Fig.1-41. BRAKE VALVE
2) Insert sun gear 2 (10).
The reason why the carrier 2 assy is

assembled in the illustrated position is to
promote oil lubrication; do not fail to observe
it.
Fig.1-41
11
(9) Installing carrier 1 assy

1) Put the carrier 1 assy into ring gear (17). Turn the
planetary gear (6) by hand to correct position and SUN GEAR 2(10)
engage it with sun gear 2 (10). Fig.1-42 Assembling carrier 2
2) Insert sun gear 1 (9).
3) Put thrust plate (8) into carrier 1 (2).
2
(10) Installing cover

1) Apply Locktite #515 to the matching surface
between cover (1) and ring gear (17). Then install
cover (1) to ring gear (17).
2) Apply Locktite #242 to fifteen socket
bolts
SUN GEAR 1(9)
(24) and tighten them up. 2
: 8mm,
Tightening torque 8kgfm (58 lbfft) 8
(11) Filling gear oil

1) Fill in gear oil (SAE90, API Grade GL-4, 5.5 lit.)
through the socket plug PT3/4 (26), place seal tape Fig.1-43 Assembling carrier 1
on the plug and attach it to cover (1).
: 14mm,
1
LOCKTITE #515
17
26
Fig.1-44 Installing cover (1)
26

1.9.1 INSPECTION BEFORE REASSEMBLY
(1) Thrust washer (3) Bearing
1) Check to see that there is no seizure, Turn it by hand and check to see that it turns
abnormal wear and uneven wear. without unusual sound and resistance.
2) Check that the wear does not exceed an
allowable value. (4) Floating seal
Inspect that the moving parts and O rings
(2) Gears are not scored.
1) There is no pitching and seizure on the gear
tooth surface.
2) Inspect that the root of gears is not cracked
by liquid penetrant examination technique.
1.9.2 SERVICING PARTS

The following are reference values by which the D E C
serviceability of used parts is determined. Since
these serve as general reference, it is
recommended that the extent of disassembly be
decided depending upon performances, excessive
damage or discoloration of components, the
purpose of disassembly and remaining service life
that is expected.
Fig.1-45
Maintenance Standard
Code Item Reference value Allowable value Remedy
A Planetary shaft is worn. To be smooth, no abnormal Replace 3 shafts as
wear and seizure. a set.
B Tooth face and root To be smooth, no abnormal No pitching over Replace3 planetary
condition wear and seizure. 1.6mm (0.063) and no gears as a set.
crack at root of gear.
C Thrust clearance of angular 0.08mm (0.0032 ) [Interferance] Replace shims.

bearing inner race to0.02mm (0.0008) [Clearance] [See.1.8 (6)]
D Thickness of thrust washer 1 1.80.2mm Wear 0.1mm Replace
(0.0710.008 ) (0.004 )
E Thickness of thrust washer 2 0.70.06mm Wear 0.1mm Replace
(0.0280.002 ) (0.004 )
27
1.9.3 TIGHTENING TORQUE

Fasten with a torque wrench.
No. Part name Size Tightening torque

24 Socket bolt M10_25 8kgfym (58 lbfyft) [Apply Locktite #242]
25 Socket bolt M16_80 28kgfym (200 lbfyft) [Apply Locktite #242]
26 Socket plug PT3/4 10kgfym (72 lbfyft) [Coil seal tape.]
1.9.4 INSPECTION AFTER ASSEMBLY

(1) Checking the oil level
After assembling the travel unit, place the shaft level
and direct the drain port of the cover downward.
Loosen the level plug and check that gear oil comes
out.
(2) Rotation test

Install the assembled travel unit on a hydraulic test
bench and run it at no load. On this occasion, check
that there is no abnormal sound and oil leakage. You
may carry out this checkup by installing the travel
unit on the machine, bringing the attachment down
on the ground and lifting up the crawler.
II-28
E200SR
SECTION 41 TROUBLESHOOTING (MECHATRO CONTROL)
TABLE OF CONTENTS
1. OUTLINE ................................................................................................................... 1
2. TABLE OF ACTUATOR FOR TROUBLESHOOTING ................................................. 3
3. TROUBLESHOOTING OUTLINE ............................................................................... 4
4. CHECK POINT FOR MECHATRO SYSTEM ............................................................. 5

1. OUTLINE
Troubleshooting provides process locating for the

cause of trouble in the order that trouble
occurred. This manual describes how to solve the
specific phenomenon systematically as early as
possible. For troubleshooting concerning the
inside of equipment, refer to troubleshooting for
each manual of equipment.
1.1 JUDGMENT OF ACTUAL THING AT SITE

(1) Get to the site as quickly as possible.
Verify model, serial number, situation of
trouble and field, and notify person of arrival
time.
(2) Verify background of trouble occurred

1) Model name and serial number
YR-B76
2) Kind of attachment Attending the field to verify actual thing.
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 modification.
(3)How to diagnose trouble

1)Verify defective part
2)Make the condition of trouble again
3)Where defective parts can not be verified, YR-B76
surmise causes systematically. Verifying background of trouble occurred.

4) Verify reasons for surmise
5) Report methods, procedure, and period for
repairing to user.
(4) Explanation of the cause of trouble

1) Explain the cause of trouble to clients. For
example, oil leak through piston is caused by
flaws on the piston rod. And the method of
using the machines should be explained so YT-B87
that the same kind of trouble does not Confirm the symptoms of the trouble.
reoccur.
2) Treatment of damaged parts
The damaged parts to be claimed and
returned are evidence so they should be
handled with care. Protect them from entry of
water, soils, etc. into port of hydraulic unit,
etc. and return them. And also use care not to
flaw and damage those surfaces. YR-B76
Diagnosing fail by means troubleshooting.
1
2
2. TABLE OF ACTUATOR FOR TROUBLESHOOTING ; MECHATRO CONTROL
Electric Hydraulic
Arm variable recirculation

Control valve Motor Cylinder Other
Hi pressure sensor (P1)
Hi pressure sensor (P2)
P2 Pump proportional
P1 Pump proportional
Swing parking brake
Low pressure sensor
proportional valve
Proportional valve
proportional valve
proportional valve
Actuator
Safety lock lever

Travel 1-2speed
Arm variable recirculation

Travel straight
Solenoid valve
Solenoid valve
Solenoid valve
P1 bypass cut
P2 bypass cut
Travel straight valve

P2 bypass cut valve
P1 bypass cut valve
Boom conflux valve
Travel right motor

Arm conflux valve
valve
valve
Travel left motor
Boom lock valve
Arm lock valve

Swing motor
S S P P P P S S S P P
Travel right
Travel left
E E S S S S V V V S S
V V V V V V
Bucket

Bucket
Swing
Boom
Boom
Operating condition
valve

Arm
22 23 1 3 4
Arm
A B C D 1 2
Boom raising slight lever

operation
Boom raising full lever operation
Boom lowering operation
Arm out slight lever operation

Independent operation
Arm out full lever operation
Arm in slight lever operation
Arm in full lever operation

Heavy duty arm in full lever
operation
Bucket digging
Bucket dump
Swing operation
Travel LH / RH operation
(1st. speed)
Travel LH / RH operation
(2nd speed)
3
3. TROUBLESHOOTING OUTLINE ; MECHATRO CONTROL
Pilot secondary pressure Pressure sensor Pump proportional valve Proportional valve
Location
Arm variable recirculation valve
High pressure Low pressure P2 bypass cut proportional valve
Lever position Att Travel P1 P2
(Pump) (Pilot) Travel straight proportional valve
Operation P1 bypass cut proportional valve
ATT Arm variable recirculation proportional valve
Bucket digging Neutral ; 642mA
Bucket dump Max Max Min ; 303mA
Control lever at More than More than
Approx 35kgf/cm2 Approx 24kgf/cm2 Max 750 mA Max 750 mA
Boom raise full stroke 2.9V 3.7V P2 bypass cut proportional valve
(500psi) (340psi)
Boom lower Neutral ; approx 350mA
Swing left Max ; 642mA
Swing right Travel straight proportional valve
Arm in Neutral ; approx 350mA
Arm out Neutral Neutral Max ; 700mA (When releasing pressure)

Approx (513mA Except when releasing pressure)
Approx6.0kgf/cm2 Less than Less than (Hi idle) (Hi idle)
TRAVEL Lever at neutral 6.0kgf/cm2
(85psi) or less 0.5V 0.5V
(85psi) or less P1 bypass cut proportional valve
Forward 350mA 350mA
Neutral ; approx 350mA
Reverse
Max ; 642mA
4
4. CHECK POINTS FOR MECHATRO SYSTEM

4.1 ATTACHING POSITION OF SENSOR AND ELECTRIC EQUIPMENTS
(1) Location of under floor harness and low pressure sensor
GROUND TRAVEL TWO SPEED SW
PRESSURE SENSOR
(OPTION 1) (SE-11) PRESSURE SENSOR
(BUCKET DIGGING) (SE-1)
PRESSURE SENSOR
(TRAVEL RIGHT) (SE-9)
PRESSURE SENSOR
(TRAVEL LEFT) (SE-10)
PRESSURE SENSOR
(OPTION 2) (SE-20)
PRESSURE SENSOR Under floor harness To the front side of floor plate
(ARM OUT) (SE-8)
Fig. 1 Location of under floor harness and low pressure sensor

(View from the front of floor plate)
(2) Location
P of high pressure sensor and pump proportional valve
PRESSURE SENSOR(P1 PUMP)(SE-22)
PRESSURE SENSOR (P2 PUMP)(SE-23)

PROPORTIONAL
VALVE (P1 PUMP)
(PSV-P1) PROPORTIONAL VALVE
(P2 PUMP)(PSV-P2)
Fig. 2 Location of high pressure sensor and pump proportional
5
(3) Location of low pressure sensor
(SE-5)
PRESSURE SENSOR
(SE-2) (SWING)
PRESSURE SENSOR
(BUCKET DUMP)
(SE-7)
PRESSURE
SENSOR
(ARM PULL)
(SE-4)
PRESSURE SENSOR
(BOOM DOWN)
(SE-3)
PRESSURE SENSOR
(BOOM UP)
Fig. 3 Location of low pressure sensor on C/V and multi C/V
(4) Location of solenoid valve block

SOLENOID VALVE BLOCK
CONTROL VALVE
Fig.4 Location of solenoid valve block
6
4.2 EQUIPMENT
(1) Solenoid proportional valve block
HYDRAULIC SYMBOLS
Fig. 5 Proportional valve block
(2) Low pressure sensor (3) High pressure sensor

A A
AMP MQS-TYPE 3P (B-TYPE)
OTHER PARTY CONNECTOR(FEMAIL)
HOUSING2-967642-1
TERMINAL (GOLD PLATING)965906-5
CONNECTER TERMINAL
ARRANGEMENT
TERMINAL NO.
1-COMMON
2-OUT PUT(+)
3-POWER SUPPLY(+)
VIEW A
1921.9 HEX
HEX 22
O RING P11 O RING P14

PF1/4 PF3/8
DETAIL OF SENSOR
7
E200SR
SECTION 42 TROUBLESHOOTING (HYDRAULIC)
TABLE OF CONTENTS
1. TROUBLE DIAGNOSIS TABLE ................................................................................ 1
2. TROUBLESHOOTING .............................................................................................. 3
1.1 HYDRAULIC SYSTEM 1. TROUBLE DIAGNOSIS
Oil pressure
Swing
Pump Control valve motor Travel motor Cylinder Other valve Proportional valve block
P2 bypass cut proportional valve

Travel straight proportional valve

Counter balance check valve
Pilot valve (1-2speed select)
Safety lock lever sol. valve

Check valve of relief valve
Travel 1-2speed sol. valve

Component
Boost pressure sol. valve

Swing parking sol. valve
Counter balance valve
Travel straight spool
P2 bypass cut valve

P1 bypass cut valve
Boom conflux valve
Pilot valve (travel)

Arm conflux valve
Pilot valve (ATT)

Load check valve
Pilot relief valve
Reduction parts
Bucket cylinder
E/G revolution
Parking brake
Parking brake
Boom cylinder
Arm cylinder
Bucket spool
Swing motor
Travel spool
Swing spool
Swivel joint
Boom spool
Pilot pump
Classification
Lock valve
Arm spool
P1 pump
P2 pump
Group No.
Motor
Trouble Device No. 2 3 4 5 6 7 8 9 10 11
No operation is possible.
(1) Machine operates unexpectedly
even though lever is in neutral.
All actions

Speed is low.
Bucket digging and dump
Raise
(2) Boom
Attachment operation
Lower
Arm in
Arm out
All motions
Power lacks
Bucket digging
(3)
Boom Raise
Hydraulic systems
Arm in
Bucket digging and dump
Fine operation
impossible.
Boom Raise
(4)
Swing
Arm in and out
Travel 1, 2 speed change
(5) impossible
Travel operation
(6) Travel speed is low.

(7) Travel power is low.
Machine cannot travel straight
(8) or deviates in one direction or
zigzags.

Machine does not stop still on a
(9) slope.
(10) Swing motion does not work.
Swing operation
(11) Swing speed is low.

Swing power is poor.
(12)
Swing motion drifts very large.
Abnormal sound is heard during
(13) swing motion.
1
2. TROUBLESHOOTING
(1)-1
No operation is possible. Note: (1)-1 matches the Groupe No. on page 1.
24V is alive across white/blue and black terminals of connector NO To electric

(CN-253F) of safety lock lever solenoid (SV-4). troubleshooting
YES
Is the main relief valve pressure
Only the hydraulic pilot system NO within a standard value? NO Pilot relief valve NO Replace relief
(ATT and travel motion) not pressure is about
P1,P2 ; 350kgf/cm2(4980psi) valve.
operative? 50kgf/cm2 (710psi).
(OPT)-P4 ; 250kgf/cm2(3550psi)
YES YES Inspect or replace pump.
YES Also inspect pump
coupling.
Inspect if there is any other cause.
Machine does not operate if

Travel straight valve port PTb NO connector(CN-258F) for travel NO
To electric troubleshooting
pressure is about 7kgf/cm2(100psi). straight proportional valve(PSV-C) is
disconnected 7kgf/cm2(100psi).
YES
YES Replace proportional valve NG Replace proportional valve
for travel straight. block.
NO
The primary pressure of pilot pump is about 50kgf/cm2 (710psi). Inspect or replace pilot pump and pilot relief valve.
YES
NO
The pilot valve P port inlet pressure is approx. 50kgf/cm2 (710psi). Inspect or replace safety lock lever solenoid valve.
YES
NO
The secondary pressure of pilot valve is approx. 50kgf/cm2 Inspect or replace pilot valve.
3
(1)-2
Machine moves unexpectedly with levers in neutral.
Machine stops moving unexpectedly if the connector (CN-257F,CN-259F) YES

for proportional valve P1,P2 bypass cut is disconnected. To electrical troubleshooting
NO
Pump NO The secondary pilot pressure of the system YES Inspect or replace pilot
delivery that is moving unexpectedly is generated
pressure in when the lever is in neutral. valve.
unloaded
NO
condition is
approx. The spool returning spring of the circuit that YES Inspect or replace spool
is moving unexpectedly is broken. assy and pilot cover.
5kgf/cm2
(71psi) or NO
lower. The spool of the system that is operating NO The outer YES
circumference of Replace spool assy.
YES unexpectedly moves smoothly by hand.
(Remove pilot cover.) spool is scratched.
NG
YES NO
Replace control valve.
Pilot pressure at ports PCa, PCb (P1, P2 YES Inspect or replace the proportional valve for bypass cut
bypass cut valve) is approx. 7kgf/cm2 valve that is defective.
(100psi).
NG
NO
Inspect or replace proportional valve block.
Return spring of bypass cut valve spool is YES Inspect or replace bypass cut valve spool assy and pilot
broken. cover.
NO
Bypass cut valve spool moves smoothly by NO Spool is scored on YES Replace bypass cut valve
hand. (together with P1 and P2 bypass cut inspection. spool assy.
valves)
NO NG
YES
Boom or YES When the lock valve, body seat and selector YES Replace lock valve and correct body seat or replace
parts were inspected, faults such as scratch
arm? body or replace selector.
were discovered.
NO NO
Faults such as scratch are discovered in load YES
check valve and seats in conflux passage and Replace check valve, correct body seat or replace body.
recirculation passage.(CCb,CCa, CAr)
NO
YES
Spool of the circuit that operates unexpectedly is scored on inspection. Replace spool assy.
NO Inspect or replace NG Inspect the cylinder of the circuit that NG Inspect or replace control
overload relief valve. operates unexpectedly and replace if faulty. valve.
(Inside leak)
4
(2)-1
All attachment motions are slow.
(Service diagnosis 24,25)

Command current readings of pump NO The sum of pump NO To electric
proportional valve are at standerd levels(below) pressures(P1+P2)during check
during operation. troubleshooting.
operation is
P1 ; approx. 750mA by bucket operation. 460kgf/cm2 (6540psi).
P2 ; approx. 750mA by swing operation.
YES Inspect or replace boost
YES check, bypass check piping.
Do motions get normal if the coupler(PSV-C) for YES
travel straight proportional valve is To electric troubleshooting.
disconnected?
NO
NO Inspect or replace pilot pump
Primary pilot pressure is 50kgf/cm2 (710psi).
and pilot relief valve.
YES
Secondary pilot pressure at PTb port (travel YES Inspect or replace travel
straight) is approx. 5.7kgf/cm2 (81psi). straight proportional valve.
NO NG
Inspect or replace
proportional valve block.
NO Inspect or replace travel

Return spring of travel straight spool is broken. straight spool assy and pilot
cover.
YES
NO Outside of travel straight YES Replace travel straight spool
Travel straight spool moves smoothly by hand.
spool is scored.
(Remove the pilot cover.) assy.
YES NO NG
Main relief pressure lies within standard level NO Inspect or replace main relief NG Replace control valve or
P1,P2 ; 350kgf/cm2 (4980psi). valve. pump.
YES
5
(2)-2
Only the bucket motion is slow.
Is the motion normal if connector (CN-257F) for P2 YES

bypass cut proportional valve is disconnected? To electrical troubleshooting.
NO
Secondary pilot pressure at PBc, PAc ports (bucket NO
digging and dump ports) is 50kgf/cm2 (710psi). Inspect or replace pilot valve.
YES
(Service diagnosis 24) Pump pressure during check operation lies
Command current readings of pump NO within standard value(below). YES To electrical
proportional valve are within standard P1 ; digging approx 80kgf/cm2(1140psi)
troubleshooting.
levels(below) during full lever operation. dump approx 200kgf/cm2(4980psi)
Bucket digging / dumping operation : 750mA P2 ; approx 5kgf/cm2(71psi)
YES
NO Inspect or replace boost NG
Inspect or replace control valve.
check, bypass check piping.
Relief pressure lies within standard levels(below) Inspect overload relief valve
NO Relief pressures for both YES
when bucket operation is changed. digging and dump operations on the faulty pressure side
Digging / dumping : 350kgf/cm2(4980psi). are abnormal. and replace valve if defective.
YES NO Confirm the check valve
before main relief valve for NG
control valve. Check the seat Replace control valve.
of it as well. (CMR1,CMR2)
YES
Return spring for bucket spool is broken. Replace bucket spool assy.
NO
Bucket spool moves smoothly by hand. (Remove NO Outside of bucket spool is YES
pilot cover.) Replace bucket spool assy.
scored.
YES NO NG
Is the motion slow if coupler for travel straight NO To electric troubleshooting.

proportional valve is disconnected? (toAll motions are slow.)
YES
Pilot pressure at port PTb (travel straight) is NO Inspect or replace travel
approx. 7kgf/cm2 (100psi). straight proportional valve.
YES NG
Inspect or replace
Return spring for travel straight spool is broken.
proportional valve block.
NO YES Inspect travel straight spool
assy and pilot cover and
replace them if faulty.
NO Outside of travel straight YES Replace travel straight spool

Travel straight spool moves smoothly by hand.
spool is scored. assy.
YES NO NG
Is the motion slow if pump delivery ports P1 and NO

P2 are exchanged. Inspect or replace pump.
YES
Inspect bucket cylinder for oil

tightness and replace if
defective.
6
(2)-3
Only the boom raise motion is slow.
(Service diagnosis 21)

Control current of P2 bypass cut proportional NO
valve is approx. 640mA when full lever To electric troubleshooting.
operation is performed for boom raise motion.
YES
Secondary pilot pressure at port PCa (P2 bypass NO Inspect or replace P2 bypass NG Inspect or replace
cut valve) is approx. 25kgf/cm2 (360psi). cut proportional valve. proportional valve block.
YES
Pilot pressure at PAb, PB1 ports (boom raise NO Inspect or replace ATT pilot
and boom conflux) is 50kgf/cm2 (710psi). valve.
YES
Does the pump delivery
(Diagnosis 24,25)
pressure lie at normal levels
Command current readings for pump NO during check operation? NO
To electric troubleshooting.
proportional valve lie within standard levels Normal values for P1 & P2 ;
(below) during the above operation. approx. 150kgf/cm2(2130psi).
P1 ; approx. 670mA YES
P2 ; approx. 670mA Hasn't the weight changed by NO Change ATT to normal one
YES the change of ATT's? and reconfirm.
YES
Inspect or replace boost NG Inspect or replace control
check, bypass check piping. valve.
Relief pressure lies within standard level

(below) when boom up lever is turned to the full. NO Adjust boom port relief NG Replace overload relief valve
350kgf/cm2(4980psi) pressure. at port Ab (boom head side).
YES
Return spring for P2 bypass cut valve spool is YES Inspect or replace P2 bypass
broken. cut spool assy and pilot cover.
NO
NO Outer circumference of P2 YES Replace P2 bypass cut spool
P2 bypass cut valve spool moves smoothly by
bypass cut valve spool is assy.
hand. (Remove pilot cover.)
scored.
YES NG
NO
Return spring of boom spool is broken. YES Inspect or replace boom spool
(Remove pilot cover.) assy and pilot cover.
NO
Boom spool moves smoothly by hand. NO Outer circumference of boom YES
Replace boom spool assy.
(Remove pilot cover.) spool is scored.
YES NO NG
YES Inspect or replace boom spool

Return spring for boom conflux spool is broken.
assy and Pilot cover.
NO
NO Outer circumference of boom YES Replace boom conflux spool
Boom conflux spool moves smoothly by hand. conflux spool is scored. assy.
YES NO NG
7
(2)-4
Only boom lower action is slow.
Control current for travel straight proportional
valve is approx. 350mA. NO
To electric troubleshooting
(Are the motions slow if coupler (PSV-C) for travel
straight proportional valve is disconnected?)
YES
Pilot pressure at port PTb (travel straight) is YES Inspect or replace travel NG Inspect or replace
approx. 7kgf/cm2(100psi). straight proportional valve. proportional valve block.
NO
Inspect or replace travel
YES
Return spring for travel straight spool is broken. straight spool assy and pilot
cover.
NO
Outside of travel straight YES
Travel straight spool moves smoothly by hand. NO Replace travel straight spool
spool is scored.
(Remove pilot cover.) assy.
YES NO

(2)-5
Only arm in action is slow.

Control current readings for arm recirculation NO
proportional valve are about 480mA when To electric troubleshooting
H-mode arm in lever is turned to the full.
YES
Inspect or replace arm
Pilot pressure at arm variable recirculation is NO NG Inspect or replace
variable recirculation
port Pis approx. 15kgf/cm2(210psi). proportional valve block.
proportional valve.
YES
Command current readings for pump Does the pump delivery pressure
proportional valve lie within standard levels NO lie at normal levels during check YES
(below) during the above operation. operation? To electric troubleshooting
P1 ; approx. 350mA Normal values for
P1 ; approx. 5kgf/cm2(71psi)
P2 ; approx. 750mA
P2 ; approx. 100kgf/cm2(1420psi)
YES
NO Inspect or replace boost
check, bypass check piping.
Secondary pilot pressure at PAa, PLC2 ports NO
(arm in, lock valve release) is approx. 50kgf/cm2 Inspect or replace pilot valve.
(710psi).
YES
Adjust or replace overload
Relief pressure lies within standard levels NO
relief valve on the arm head
when arm in is operated. (H) side.
350kgf/cm2(4980psi).
YES
Inspect or replace arm spool,
Arm spool or recirculation spool return spring is YES
recirculation spool and pilot
broken. cover.
NO
Arm spool or recirculation spool moves smoothly NO Outside of arm spool or YES Replace arm spool or
by hand. (Remove pilot cover.) recirculation spool is scored. recirculation spool assy.
YES NO NG
8
(2)-6
Only arm out operation is slow.
Command current for P1 bypass cut proportional NO
valve is approx. 640mA when arm out lever is To electrical troubleshooting
shifted to the full.
YES
Secondary pilot pressure at port Pcb NG
NO Inspect or replace P1 bypass Inspect or replace
(P1 bypass cut valve) is approx. 25kgf/cm2
cut proportional valve. proportional valve block.
(360psi).
YES
Secondary pilot pressure at port PBa (arm out) NO
Inspect or replace pilot valve.
is approx. 50kgf/cm2 (710psi) or over.
YES
(Service diagnosis 24,25)
Command current readings for pump
proportional valve lie within standard levels Pump delivery pressure lies
(below) during the above operation. NO within standard level during YES
the above operation. To electrical troubleshooting
P1 ; approx. 550mA
P2 ; approx. 550mA P1,P2 ; approx. 200kgf/cm2
(2840psi).
YES Inspect or replace boost
NO check, bypass check piping.
Relief pressure lies within standard level

NO Inspect or replace overload
(below) when arm out is turned to the full. relief valve at port Ba (arm
350kgf/cm2(4980psi) rod side).
YES
YES Inspect or replace arm spool
Arm spool return spring is broken. assy and pilot cover.
NO
Arm spool moves smoothly by hand. NO Outside of arm spool is YES
scored. Replace arm spool assy.
(Remove pilot cover.)
YES NO NG
Return spring of P1 bypass cut valve spool is NO Inspect or replace P1 bypass cut
broken. valve spool assy and pilot cover.
YES
P1 bypass cut valve spool moves smoothly by NO Outside of P1 bypass cut YES Replace P1 bypass cut valve
hand.(Remove pilot cover.) valve spool is scored. spool assy.
YES NO NG
Inspect or replace arm

NO conflux spool assy and pilot
Arm conflux spool return spring is broken.
cover.
YES
Arm conflux spool moves smoothly by hand. NO Outside of arm conflux spool YES Replace arm conflux spool
(Remove pilot cover.) is scored. assy.
YES NO NG
9
(3)-1
All ATT operating power is poor.
Each independent operating speed is within a NO Refer toAll motions are

standard value. slow..
YES
Relief pressure lies within standard level NO Adjust main relief pressure NG Replace the relief valve of
P1,P2 ; 350kgf/cm2(4980psi). of control valve. main control valve.
YES
Primary pilot pressure is approx. 50kgf/cm2 NO Replace pilot pump and relief
Adjust pilot relief pressure. valve.
(710psi).
YES Inspect or replace travel
YES
Travel straight spool return spring is broken. straight spool assy and pilot
cover.
NO
Travel straight spool moves smoothly by hand. NO Outside of travel straight YES Replace travel straight spool
(Remove pilot cover.) spool is scored. assy.
YES NO NG
Inspect or replace control

valve or pump.
(3)-2
Bucket digging power is poor.
No-load independent operating speed is within a NO Refer to Only bucket motion

standard value. is slow.
YES
Relief pressure lies within standard level NO Adjust overload relief valve NG Replace overload relief valve
(below) when bucket digging lever is turned to on bucket digging side. at port BC (bucket head side).
the full.
( )
YES
Secondary pilot pressure at port PBC (bucket NO

digging) is approx. 50kgf/cm2 (710psi).
YES
YES Inspect or replace bucket
Bucket spool return spring is broken. spool assy and pilot cover.
NO
Bucket spool moves smoothly by hand. (Remove NO Outside of bucket spool is YES
scored. Replace bucket spool assy.
pilot cover.)
YES NO NG
Replace control valve or

pump.
10
(3)-3
Boom raise operating power is poor.
No-load independent operating speed is within a NO Refer toOnly boom raise motion
standard value. is slow.
YES
Relief pressure lies within standard level NO Adjust or replace overload relief
Adjust main relief on control NG
(below) when boom up lever is turned to the full. valve at port Ab (boom head
P1, P2 ; 350kgf/cm2(4980psi). valve. side).
YES
Secondary pilot pressure at boom raise PAb port NO
and boom conflux PB1 port is 50kgf/cm2(710psi)
YES
Boom spool return spring is broken.
assy and pilot cover.
NO
NO Outside of boom spool is YES
Boom spool moves smoothly by hand. Replace boom spool assy.
scored.
YES NO NG

Boom conflux spool return spring is broken.
NO
NO Outside of boom conflux YES
Boom conflux spool moves smoothly by hand. Replace boom conflux spool
spool is scored.
YES NO NG
Inspect or replace control valve

or pump.
11
(3)-4
Arm in power is poor.
No-load independent operating speed is within a NO Refer toOnly arm in is

standard value. slow..
YES
Adjust or replace overload
Relief pressure during arm in for both P1 and NO Adjust main relief on control NG
relief valve at port Aa (on
P2 pumps lies within standard levels. valve. arm head side).
P1,P2 ; 350kgf/cm2(4980psi).
YES (Service diagnosis 23)
Control current readings for arm recirculation NO To electric trouble shooting.
proportional valve are about 480mA when
Refer toOnly arm in is
H-mode arm in lever is turned to the full.
YES
NO Inspect or replace arm NG Inspect or replace

Pilot pressure at arm variable recirculation port variable recirculation
Pis is about 15kgf/cm2(210psi) proportional valve block.
proportional valve.
YES
Secondaly pilot pressure at arm in port PAa and NO
arm lock valve release PLC2 port is Inspect or replace pilot valve.
50kgf/cm2(710psi)
YES
YES Inspect or replace arm spool
Arm spool return spring is broken. assy and pilot cover.
NO
Arm spool moves smoothly by hand. NO Outside of arm spool is YES
Replace arm spool assy.
(Remove pilot cover.) scored.
YES NO NG
Arm variable recirculation spool return spring is YES Inspect or replace arm spool
broken. assy and pilot cover.
NO
Arm variable recirculation spool moves smoothly NO Outside of arm variable YES Replace arm variable
by hand. (Remove pilot cover.) recirculation spool is scored. recirculation spool assy.
YES NO NG
Replace control valve or

pump.
12
(4)-1
Machine can not perform fine operation of bucket digging and dump.
Machine returns normal if connector of P1 bypass cut proportional YES

valve (PSV-D) is disconnected. To electric troubleshooting.
NO
Unload pressure of P1 NO No-load independent operating NO Refer toOnly bucket motion
pump is less than 5kgf/cm2 speed is within a standard
is slow..
(71psi) when bucket digging value.
lever is at neutral.
YES
YES Secondary pilot pressure at
port PCb (P1 bypass cut valve) YES Inspect or replace P1 NG Inspect or replace
bypass cut proportional
is approx. 7kgf/cm2 (100psi) proportional valve block.
valve.
when lever is at neutral.
NO
P1 bypass cut spool return YES Inspect or replace P1 bypass
spring is broken. cut spool assy and pilot cover.
NO
P1 bypass cut spool moves NO Outside of P1 bypass YES Replace P1 bypass cut
smoothly by hand. (remove cut spool is scored.
spool assy.
pilot cover.) NO
NG
YES
Secondary pressure of pilot Replace control valve.

valve is approx. 5.5kgf/cm2
(78psi) when bucket digging NO
lever is just shifted a little.
YES
Pilot spool return spring is YES Inspect or replace bucket
broken. spool assy or pilot cover.
NO
Bucket spool moves NO Outside of bucket spool is YES
smoothly by hand. (Remove Replace bucket spool assy.
scored.
pilot cover.) NG
NO
YES
13
(4)-2
Machine can not perform fine operation of boom raise and lower.
Machine gets normal if connector of P1 bypass cut proportional YES

To electrical troubleshooting.
valve (PSV-D) is disconnected.
NO
Unload pressure of P1
pump is less than 5kgf/cm2 NO Secondary pilot pressure at YES Inspect or replace NG Inspect or replace
port PCb (P1 bypass cut valve) proportional valve for
(71psi) when boom lever is proportional valve
is approx. 7kgf/cm2 (100psi). P1 bypass cut valve.
at neutral. block.
NO
YES
Return spring of P1 bypass cut YES Inspect or replace P1 bypass
spool is broken. cut spool assy and pilot cover.
NO
P1 bypass cut spool moves NO Outside of P1 bypass YES Replace P1 bypass
cut spool assy.
smoothly by hand. cut spool is scored.
YES NO NG
Secondary boom pilot pressure is approx. NO

5.5kgf/cm2 (78psi) when lever is just shifted.
YES
Return spring of boom spool is broken. assy and pilot cover.
NO
Boom spool moves smoothly NO YES
Outside of boom spool is scored. Replace boom spool assy.
by hand.
YES NO NG
Does boom lock valve move NO

smoothly by hand? Inspect or replace lock valve.
YES
14
(4)-3
Machine can not perform fine swing operation.
Machine gets normal if connector (CN-257F) for P2 bypass cut YES

proportional valve (PSV-B) is disconnected.
NO
Machine gets normal if connector (CN-254F) for swing parking YES
brake solenoid (SV-1) is disconnected. To electrical troubleshooting
NO
Secondary pressure of swing pilot valve is approx. 6kgf/cm2 YES Inspect or replace NG Inspect or replace
(85psi), while pilot pressure of parking brake solenoid valve is swing parking solenoid proportional valve
0kgf/cm2 (0psi).
block.
NO
Unload pressure of P2 Pilot pressure of port PCa (P2
pump is approx. 5kgf/cm2 NO bypass cut valve) is approx. YES Inspect or replace NG Inspect or replace
proportional valve for
(71psi) or less when swing 7kgf/cm2 (100psi) when swing proportional valve
P2 bypass cut valve.
lever is at neutral. lever is at neutral. block.
YES NO
Return spring for P2 bypass cut YES Inspect or replace P2 bypass
spool is broken. cut spool and pilot cover.
NO
smoothly by hand. (Remove
cut spool is scored. cut spool assy.
pilot cover.)
NO NG
YES
Secondary pilot pressure of parking brake solenoid valve is

NO Inspect or replace swing NG Inspect or replace
0kgf/cm2 (0psi) when secondary pressure of pilot valve is proportional valve
approx. 6kgf/cm2 (85psi). parking solenoid valve.
block.
YES
Secondary pressure of pilot

valve at startup is approx. NO
5.5kgf/cm2 (78psi).
YES
Return spring for swing YES
spool is broken. Replace swing spool assy.
NO
Swing spool moves NO YES
Outside of swing spool is Replace swing spool assy.
smoothly by hand.
YES NO NG
15
(4)-4
Machine can not perform fine operation of arm in and out.
Machine gets normal if connector (CN-257F) of P2 bypass cut YES

proportional valve (PSV-B) is disconnected. To electrical troubleshooting
NO
P2 pump unload pressure is NO Secondary pilot pressure at NO Inspect or replace NG Inspect or replace
less than 5kgf/cm2 (71psi) port PCa (P2 bypass cut valve) proportional valve for proportional valve
when arm lever is at is approx. 7kgf/cm2 (100psi). P2 bypass cut valve. block.
neutral.
YES
YES Return spring of P2 bypass cut YES Inspect or replace P2 bypass
spool is broken. cut spool assy and pilot cover.
NO
smoothly by hand.
cut spool is scored. cut spool assy.
(Remove pilot cover.)
NO NG
YES
Secondary pressure is Replace control valve.

approx. 5.5kgf/cm2 (78psi)
when arm lever is shifted a NO
little.
YES
Return spring of arm spool YES
is broken. Replace arm spool assy.
NO
Arm spool moves smoothly NO YES
Outside of arm spool is scored. Replace arm spool assy.
by hand.
YES NO NG
Arm lock valve moves NO

Inspect or replace lock valve.
smoothly by hand.
YES
(5)
Travel 1st and 2nd speeds can not be changed over.
24V is alive across light green/black and black NO

of connector (CN-255F) for travel 1-2 speed To electrical troubleshooting
solenoid (SV-3).
YES
Pilot pressure of travel 1-2 speed select solenoid NO Inspect or replace travel 1-2 NG Inspect or replace
(SV-3) is approx. 50kgf/cm2 (710psi). speed select solenoid valve. proportional valve block.
YES
Travel 1-2 speed select can not be done in heavy NO Inspect travel motor (throttle in passage to 1-2 select valve, inclusion of
duty condition on a slope or on a muddy land. foreign matter in shuttle valve, etc.) or replace it.
YES Since the delivery rate of pump is small at heavy duty, the difference
between 1st and 2nd speeds gets smaller. This makes you feel sometimes
that speed is not changed. But this is normal.
16
(6)
Travel independent speed is low.
Is the travel motion in both speeds slow

at no load? NO Refer to Travel independent
(H-mode, Hi idle, 1st-speed, sprocket deviates..
revolution ; approx. 28rpm)
YES
Since the pump delievery
Machine is slow on slopes and in muddy YES rate is decreased at high
fields? load, travel speed is
NO decreased, but it is normal.
Pump pressure
Current readings of pump proportional during travel idling
NO NO Inspect or replace NG Inspect or replace
valve lie within standard levels during is 50~70kgf/cm2 boost check, bypass
control valve.
both travel speeds. (710~1000psi). check piping.
P1,P2 ; approx. 750mA
YES
YES Secondary pressure for travel NO Inspect or replace pilot valve
pilot valve is approx. for travel.
24kgf/cm2 (340psi).
YES
(Service diagnosis 22) To electrical troubleshooting.
Control current of travel straight
proportional valve is approx. 350mA.
NO
Is the machine slow even if connector To electrical troubleshooting.
for travel straight proportional valve
is disconnected.
YES
Is the pivot turn possible? NO Secondary pilot pressure at YES Inspect or replace NG Inspect or replace
port PTb (travel straight valve) travel straight proportional valve
(in both directions)
is approx. 7kgf/cm2 (100psi). proportional valve. block.
YES
NO
Return spring of travel straight
straight spool assy and pilot
spool is broken.
cover.
NO
Travel straight spool moves NO Outside of travel YES Replace travel
smoothly by hand. straight spool is scored. straight spool assy.
YES NO NG
Return spring of travel YES Inspect or replace travel

spool is broken. spool assy and pilot cover.
NO
Travel spool moves NO Outside of travel spool is YES
smoothly by hand. scored. Replace travel spool assy.
YES NO NG
Relief pressure during both Replace control valve.

travel speeds lies within NO Inspect or replace travel
standard value.
motor relief valve.
; 350kgf/cm2 (4980psi)
motor.
17
(7)
Travel power is poor.
Both travel speeds are slow during idle

traveling. NO Refer to Travel independent
(H-mode, Hi idle, 1st-speed, sprocket is slow..
revolution ; approx. 28rpm)
YES
Command current for travel straight NO
proportional valve is approx. 350mA.
YES
YES Since the delivery rate of pump is small and travel speed is
Power lack is felt on a slope or in muddy
low in heavy duty condition, power lack is felt in some cases,
fields.
but it is normal.
NO
Is the secondary pilot NO Inspect or replace travel pilot
pressure for travel approx.
valve.
24kgf/cm2 (340psi)?
YES
Is a pivot turn possible? NO Pilot pressure at port PTb NO Inspect or replace NG Inspect or replace
(travel straight valve) is travel straight proportional valve
(in both directions)
approx. 7kgf/cm2 (100psi). proportional valve. block.
YES
YES
Return spring of travel straight
spool is broken.
cover.
NO
Travel straight spool moves NO Outside of travel YES Replace travel
smoothly by hand. straight spool is scored. straight spool assy.
YES NO NG
Return spring of travel YES Inspect or replace travel

spool is broken. straight spool and pilot cover.
NO
Travel spool moves NO Outside of travel spool is YES
smoothly by hand. scored. Replace travel spool assy.
YES NO NG
Relief pressure lies within
standard value in both NO Inspect or replace travel
travel speeds. motor relief valve.
; 350kgf/cm2 (4980psi)
YES
Inspect or replace travel
motor.
18
(8)-1
Machine does not travel straight.

Control current for travel NO
straight proportional valve To electrical troubleshooting
(PSV-C) is 515mA.
YES
Secondary pilot pressure at
port PTb (travel straight NO Secondary pressure of travel NO Inspect or replace travel pilot
pilot valve is approx. 24kgf/cm2
valve) is approx. 17kgf/cm2 valve.
(340psi).
(240psi).
YES Inspect or replace NG Inspect or replace
YES travel straight proportional valve block.
proportional valve.

Return spring of travel
straight spool is broken.
cover.
NO
Travel straight spool moves NO Outside of travel straight spool YES Replace travel straight spool
smoothly by hand. is scored. assy.
YES NO NG
(8)-2
Machine deviates in travel independent motion.
Does the machine deviates

In idle run, the right and the left crawlers rotate NO from former direction if NO Inspect or replace control
at different speeds. (H-mode, Hi idle, delivery ports are valve.
1st-speed) exchanged?
YES YES
Pump pressure for P1 and P2
Control current for travel straight proportional NO lies within NO Inspect or replace control
valve (PSV-C) is 515mA. 50~70kgf/cm2 (7101000psi) valve.
during travel idling.
YES
YES
Secondary pilot pressure for NO Inspect or replace travel pilot
travel is 24kgf/cm2 (340psi). valve.
YES
Relief pressure lies within

Machine deviates from former direction if the right NO standard value in both travel NO Inspect or replace travel
and left pipes between control valve and travel motor relief valve.
speeds.
motor are exchanged.
; 350kgf/cm2 (4980psi)
YES
motor.

Return spring of travel straight spool is broken. straight spool assy and pilot
cover.
NO
NO Outside of travel straight YES
Travel straight spool moves smoothly by hand. Replace travel straight spool
spool is scored.
YES NO NG
19
(9)
Machine drifts on a slope. (Machine can not be held on a slope.)
Machine can not be held on a slope when engine YES Inspect or replace travel
is off. motor.
NO
Secondary pilot pressure for travel is 0kgf/cm2 NO Inspect or replace remote
(0psi). control valve.
YES
YES Inspect or replace travel spool
Return spring of travel spool is broken. assy and pilot cover.
NO
NO Outside of travel spool is YES
Travel spool moves smoothly by hand. scored. Replace travel spool.
YES NO NG
20
(10)
Swing motion dose not work.
Machine moves if connector(CN-254F) of swing YES

To electrical troubleshooting
parking SOL(SV-1) is disconnected.
NO
Is the pilot pressure of parking SOL reduce to NO Inspect or replace swing NG
0kgf/cm2 (0psi)when the secondary pressure of Inspect or replace
pilot valve is 6kgf/cm2(85psi)? . parking solenoid. proportional valve block.
YES Reference
In case of a machine with a
multi control valve, check if
the condition returns normal
by changing swing lever back
& forth operation.
Secondary pressure of swing pilot valve is NO Dirt or something is stuck in YES Inspect or replace slow return
the restrictor of slow return valve.
50kgf/cm2(710psi) for both directions.
valve.
YES NO
YES Inspect or replace swing spool
Return spring of swing spool is broken.
NO
Swing spool moves smoothly by hand. NO Outside of swing spool is YES
Replace swing spool assy.
(Remove pilot cover.) scored.
YES NO NG
Return spring of P2 bypass cut spool is broken..

YES Inspect or replace P2 bypass cut
valve spool assy and pilot cover.
NO
P2 bypass cut spool moves smoothly by hand. NO Outside of P2 bypass cut YES
Replace P2 bypass cut assy.
(Remove pilot cover.) spool is scored.
YES NO NG
Swing relief pressure lies within standard level. NO Inspect or replace swing
285kgf/cm2(4050psi). motor relief.
YES NG
Machine can be held on a slope during swing NO Inspect or replace swing

motion. reduction unit and swing motor.
YES
Machine drifts largely when swing parking YES Inspect or replace swing
brake is released (arm in action) on a slope. motor.
NO Inspect or replace swing
reduction unit and swing motor.
21
(11)
Swing speed is slow.
Command current of P2 bypass cut proportional NO

valve (PSV-B) is 640mA when swing lever is To electrical troubleshooting
turned to the full.
Reference
YES In case of a machine with a multi
control valve, check if the condition
returns normal by changing swing
lever back & forth operation.
Secondary pilot pressure for swing motion is NO Dirt or something is stuck in YES
approx. 50kgf/cm2 (710psi) when lever is turned Inspect or replace slow return
the restrictor of slow return
to the full in either direction. valve.
valve.
YES NO NG
Secondary pilot pressure at PCa port (P2 bypass NO Inspect or replace P2 bypass NG Inspect or replace
cut valve) is approx. 25kgf/cm2 (360psi) when
swing lever is shifted to the full.
YES
YES Inspect or replace P2 bypass
Return spring of P2 bypass cut spool is broken. cut spool assy and pilot cover.
NO
NO Outside of P2 bypass cut YES Replace P2 bypass cut spool
P2 bypass cut spool moves smoothly by hand.
spool is scored. assy.
YES NO NG
; 285kgf/cm2(4050psi).
motor relief.
YES NG
is released (arm in action) on a slope. motor.
NO
NO
NO Outside of swing spool is YES
Swing spool moves smoothly by hand. Replace swing spool assy.
scored.
YES NO NG
22
(12)-1
Swing power is
Swing speed lies within standerd level NO Refer toSwing speed is

; (H-mode HI idle is approx. 11.3rpm or over.) slow..
YES
YES Inspect or replace P2 bypass
Return spring of P2 bypass cut spool is broken. cut spool assy and pilot cover.
NO
NO Outer circumference of P2 YES Replace P2 bypass cut spool
P2 bypass cut spool moves smoothly by hand. bypass cut spool is scored. assy.
YES NO NG
Reference Replace control valve.
In case of a machine with a
multi control valve, check if
the condition returns normal
by changing swing lever back
& forth operation.
Secondary pilot pressure for swing motion is NO Dirt or something is stuck in YES
approx. 50kgf/cm2 (710psi) when lever is turned Inspect or replace slow return
to the full in both directions. valve. valve.
YES NO
Inspect or replace pilot valve .
; 285kgf/cm2(4050psi) motor relief.
YES NG
NO
The pressure at the P/B (PG) port of swing NO Inspect or replace P2 bypass NG
motor is 50kgf/cm2(710psi) when swing lever is Inspect or replace
turned to the full or during arm in action.
YES
NO
(Remove pilot cover.) scored. Replace swing spool assy.
YES NO NG
23
(12)-2
Swing motion drifts very large.
; 285kgf/cm2(4050psi)
motor relief valve.
YES
Command voltage
Machine can be held on a NO of swing parking YES Replace the lining of swing NG
brake releasing To electrical troubleshooting
slope during swing motion. motor parking brake.
acts on swing
YES parking solenoid.
NO
Inspect or replace swing
motor and reduction unit.
NO Reference
In case of a machine with a multi
control valve, check if the condition
returns normal by changing swing
lever back & forth operation.
Secondary pilot pressure in swing motion NO Dirt or something is stuck in YES

decreases quickly when swing lever is brought Inspect or replace slow return
to neutral. valve.
valve.
YES NO
Inspect or replace pilot valve .

NO
(Remove pilot cover.) scored. Replace swing spool assy.
YES NO NG
24
(13)
Abnormal sound is heard
during swing motion.
Abnormal sound occurs during swing relief YES Inspect or replace swing
action. motor relief valve.
NO
YES Inspect or replace swing
Abnormal sound occurs when swing motion stops.
shockless valve.
NO
Swing relief pressure lies within standard level. Control current for P2
NO bypass cut proportional valve NO
; 285kgf/cm2(4050psi) To electrical troubleshooting
is approx. 640mA.
YES
YES
Pressure at P2 bypass cut port PCa
NO Inspect or replace NG Inspect or replace
is about 25kgf/cm2(360psi)during P2 bypass cut proprotional valve
swing operation. proprotional valve. block.
YES
Main relief pressure lies YES Inspect or replace NO Inspect or replace
within standard level. swing motor relief
swing motor.
; 350kgf/cm2(4980psi) valve.
NO
Outside of P2 cut valve spool YES Inspect or replaceP2 bypass
is scored. cut valve spool assy and pilot
cover.
NO
P2 bypass cut spool moves
smoothly by hand.
YES Inspect or replace main relief
(Remove pilot cover) valve.
NO
Outside of P2 bypass cut YES Replace P2 bypass cut valve
valve spool is scored. spool assy.
NO NG
NO
(Remove pilot cover) scored. Replace swing spool assy.
YES NO NG
Machine can be held on a slope during swing NO Inspect or replace swing

motion. motor or reduction unit.
Inspect or replace swing motor
YES
pinion gear, swing bearing race
and swing bearing gear.
25
E200SR
SECTION 43 TROUBLESHOOTING (ELECTRIC)
TABLE OF CONTENTS
1. TROUBLE DIAGNOSIS TABLE ................................................................................. 1
2. SELF DIAGNOSIS TABLE ......................................................................................... 4
3. SERVICE DIAGNOSIS TABLE .................................................................................. 4
4. TROUBLESHOOTING ............................................................................................... 5
1. TROUBLE DIAGNOSIS TABLE ; ELECTRIC
C1 mechatro controller
Low pressure sensor Power supply & other signal Switch & relay Governor motor & proportional & SOL
Arm variable recirculation proportional valve A

Accel motor start point indexing LS
P1 bypass cut proportional valve D
P2 bypass cut proportional valve B

Conflux / single select SW (OPT)
Bucket digging pressure sensor
Boom lowering pressure sensor
Bucket dump pressure sensor

Boom raising pressure sensor
Travel right pressure sensor
P1 pump proportional valve

Engine water temp high LS
Component
Engine oil pressure low LS

Travel left pressure sensor
Front working light relay

P1 pump pressure sensor
Option 2 pressure sensor
Option 1 pressure sensor
ATT boost pressure SOL

Arm out pressure sensor
Governor motor B phase
Power supply grounding

Auto idle stop select SW
Governor motor A phase

ATT boost pressure SW
Arm in pressure sensor
Swing pressure sensor
Swing P/B release SW
Fuel level thermister
Travel 1-2speed SOL

Air filter clogging LS
Engine speed sensor
Accelerator potentio
Travel 1-2speed SW
Washer motor relay
Swing parking SOL

Power supply +24V
Alternator voltage
Wiper motor relay

KPSS release SW
Shield grounding
Shield grounding
Shield grounding
Travel alarm SW
Key SW GLOW
Battery backup
Gauge cluster
Battery relay
Key SW ON
Group No
System
C
Connector
No. CN-11 CN-12 CN-13 CN-14 CN-15
1 4 7 10 13 16 19 25 28 31 34 1 4 7 13 14 15 16 17 18 19 20 22 1 1 2 3 4 5 7 8 13 15 16 25 28 1 3 4 6 8 10 12 14 15 17 19 21 22 23 24 25
Trouble
2 5
Pin No. 8 11 14 17 20 26 29 32 2 5 8 21 2 26 2 5 7 9 11 13 16 18 20 26

3 6 9 12 15 18 21 27 30 33 3 6 9 3 27
No motions operate.
(1) Machine moves freely when
All operate
Only bucket speed is
slow.
Speed is slow
Only boom raise speed is

slow.
(2)
Attachment operation
Motions are slow except

boom raise and arm out.
Only arm in motion is
slow.
Only arm out motion is
slow.
All operate
Power is poor
Bucket digging
(3)
Boom raising
Arm in
Bucket digging, dumping

Fine operation
impossible
Boom raising, lowering

Electric systems
(4)
Swing
Arm in, out
Travel 1-2 speeds can not be
(5) changed
(6)
Travel operation
(7) Travel power is poor
ATT travel combined and

operation with
(at combined
travel straight are

ATT swing)
impossible.
(8)
Travel deviates, zigzags.
Machine drifts on a downhill
(9) and does not stop still on a slope
(10) Swing motion does not work

Swing operation
(11) Swing speed is slow

(12) Swing power is poor
Swing leftright
(13)
Swing can not be held on a slope
(14) Auto idle stop is not actuated
Others
1
Electrical equipments
Proportioal valve Controller Diode Electrical equipments Light Motor Relay
Power window look motor (right, OPT)

Arm variable recirculation proportional valve
Power window look motor (left, OPT)

Cab working light relay (OPT)

Power window motor (OPT)
Wiper motor (rise up, OPT)

Component
Boom working light (left)

Air conditioner amplifier
Power window controller
Tuner AM&FM (OPT)
Working light (right)
Washer motor relay
Working light relay

Speaker left (OPT)
Wiper motor relay

Roof wiper motor
Wiper relay assy

Governor motor
Air compressor
Receiver dryer
Washer motor
Gauge cluster
Speaker right
Starter motor
Heater (OPT)
Battery relay
Wiper motor
Safety relay
Hourmeter
Room light
Horn relay
Fuel pump
Glow relay
Alternator
Tuner AM
Fuse box
Resistor
Battery
Group No
Diode
Horn
System
Trouble P P P P P P B C C C D D D D D E E E E E E E E E E E E L L L M M M M M M M M M M R R R R R R R R R
S S S S S S 1 2 4 5 1 2 3 4 5 1 2 3 4 7 7 8 9 10 11 12 14 1 2 3 1 2 3 4 5 6 7 8 9 10 1 3 4 5 6 7 8 9 10
Pin V V V V V V
No. E
A B C D P P 5
1 2
No motions operate.
All operate
slow.
Speed is slow

slow.
(2)
Attachment opration

slow.
slow.
All operate
Power is poor
Bucket digging
(3)
Boom raising
Arm in

Fine operation
impossible

Electric systems

(4)
Swing
Arm in, out

(5) changed
(6)
Travel operation

ATT travel combined
operation with
(at combined
ATT swing)
and travel straight are

impossible.
(8)
Travel deviates,
zigzags.


Swing operation

Swing leftright
(13)
(14) Auto idle stop is not actuated

Others
2
Electrical equipments
Senser Solenooid Switch
Low pressure sensor Pressure
sensor
Engine water temperature sensor
Single/Conflux select SW (OPT)

Engine water temperature, oil pressure,
Component
ATT boost pressure SOL
Work light switch (OPT)
ATT boost pressure SW

Wiper inter lock switch
Swing P/B release SW
Safety lock lever SOL
Travel 1-2 speed SOL
Heater & A/C switch

KPSS release switch
Safety lock lever SW

Travel 1-2 speed SW
Engine speed sensor
Swing parking SOL
Horn switch (right)

Horn switch (left)
Bucket digging
Bucket dump
Travel right
Boom lower
Fuel sensor
Accelerator
Boom raise
Key switch
Travel left
filter clogging
Option 1
Option 2
Arm out
Arm in
Swing
Group No
System
S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S
Trouble E E E E E E E E E E E E E E E E E V V V V W W W W W W W W W W W W W
Pin 1 2 3 4 5 7 8 9 10 11 13 14 15 16 20 22 23 1 2 3 4 1 3 4 5 6 10 11 12 20 21 22 23 34
No.
7 13

8
No motions operate.
All operate
slow.
Speed is slow

slow.
(2)
Attachment opration

slow.
slow.
All operate
Power is poor
Bucket digging
(3)
Boom raising
Arm in

Fine operation
impossible

Electric systems

(4)
Swing
Arm in, out

(5) changed
(6)
Travel operation

ATT travel combined
operation with
(at combined
ATT swing)
and travel straight are

impossible.
(8)
Travel deviates, zigzags.

Swing operation

Swing leftright
(13)
(14) Auto idle stop is not actuated.
Others
Regarding the C-1 mechatro controller, refer to two pages back.
3
2. SELF DIAGNOSIS TABLE 3. SERVICE DIAGNOSIS TABLE
The self diagnosis detects errors in the control I/Os of the pressure sensors and the proportional valves The results of service diagnosis are displayed in up to 23 items according to data from the mechatro
while the machine is in operation and shows them on the multi display of the gauge cluster. controller.
Displaying procedure:
DISPLAY ITEM
1) TurnONthe starter switch with the buzzer stop switch pressed.
No. Contents Display of monitor No. Contents Display of monitor 2) A mechatro controller parts number and a program version are displayed as the No.1 item.
3) The diagnosis advances like No.2, No.3.... each time the display select switch is pressed.
P1 by-pass cut
1 Mechatro controller fail 16 4) The diagnosis returns like No.40, No.39... each time the buzzer stop switch is pressed.
propo-valve fail
5) The display does not disappear unless the starter switch is turnedOFF.
P2 by-pass cut
2 ROM data 17
propo-valve fail
No.1
Travel priority
3 Mechatro set error 18 PROGRAM VERSION
propo-valve fail
VER 5.60 Display select switch
Arm variable Advances the screen
Boom raising Buzzer stop switch
4 19 recircula-tion Returns the screen
propo-valve fail
Boom lowering Pump P1 pressure
5 20
pressure sensor fail sensor fail
Arm in pressure Pump P2 pressure SERVICE DIAGNOSIS DISPLAY

6 21
sensor fail sensor fail
Arm out pressure ATT boost pressure No. DISPLAY No. DISPLAY No. DISPLAY No. DISPLAY
7 22 No.1 No.7 No.13 No.23
sensor fail Solenoid valve fail
SOLENOID PRESS. SENSOR PROPO-VALVE
PROGRAM VER F1 POWER UP B9 TRAVEL (R) D6 A-RECIRCULAT
Bucket digging Travel two-speed 1 7 13 23
8 23 VER 5.60 COMP. OFF 3.5V 39k COMP. 600mA 45k
pressure sensor fail solenoid valve fail MEAS. OFF B10 TRAVEL (L) MEAS. 600mA 45k
SWITCH OFF 3.5V 39k
Bucket dump Swing parking solenoid No.2 No.8 No.14 No.24
9 24 E/G SET 2420 RELAY PRESS. SENSOR PROPO-VALVE
pressure sensor fail valve fail
MEAS 2420 I2 BAT. RELAY C1 PUMP P1 E1 P1 PUMP
Swing pressure Governor motor current 2 E/G PRS. LIVE 8 COMP. OFF 14 3.5V 42k 24 COMP. 600mA 45k
10 25 KPSS SW H MEAS. OFF C2 PUNP P2 MEAS. 600mA 45k
sensor fail fail KEY SWITCH OFF 3.5V 42k POWER SHIFT 100mA
Travel right pressure Governor motor starting No.3 No.9 No.15 No.25
12 26
sensor fail point indexing fail H1 PRESS. SENSOR PRESS. SENSOR PROPO-VALVE
ACCEL VOLT. 4.2V B1 BOOM RAISE B16 P1 OPT. E2 P2 PUMP
Travel left pressure 3 POS. 100% 9 3.5V 35k 15 3.5V 36k 25 COMP. 600mA 45k
13 27 Accel potentio meter fail MOTOR STEP 256 B2 BOOM LOWER B17 P2 OPT. MEAS. 600mA 45k
sensor fail POS. 100% 3.5V 35k 3.5V 36k POWER SHIFT 100mA
Gauge cluster
Pump P1 pressure No.4 No.10 No.20 No.39
14 28 Mechatro controller
sensor fail GOVERNOR MOTOR PRESS. SENSOR PROPO-VALVE MECHATRO ADJT.
communication failure G1 COIL A 0.9A B3 ARM OUT D1 P1 BYPASS CONT. SW TEST
4 G1 COIL B 1.0A 10 3.5V 36k 20 COMP. 600mA 45k 39 CONT. VOL 100%
Pump P2 pressure G2 LIMIT OFF B4 ARM IN MEAS. 600mA 45k PROG. SW OFF
15 29 Battery relay fail
sensor fail 3.5V 36k
No.5 No.11 No.21 No.40

30 Draining hyd. pressure SOL.VALVE PRESS. SENSOR PROPO-VALVE RELEASE SW
F2 SWING-BRAKE B5 BUCKET DIG D2 P2 BYPASS KPSS TEST
5 COMP. OFF 11 3.5V 37k 21 COMP. 600mA 45k 40 SWING BRAKE OFF
31 Fail drain hyd. pressure MEAS. OFF B6 BUCKET DUNP MEAS. 600mA 45k
RELEASE SW OFF 3.5V 37k
No.6 No.12 No.22

SOL.VALVE PRESS. SENSOR PROPO-VALVE
F3 1/2-TRAVEL B7 SWING (R) D3 S-TRAVEL
6 COMP. OFF 12 3.5V 38k 22 COMP. 600mA 45k
MEAS. OFF B8 SWING (L) MEAS. 600mA 45k
SWITCH OFF 3.5V 38k
4
4. TROUBLESHOOTING
(1)-1
Note: (1)-1 matches the Groupe No. on page

No motions operate.
1.
Lever stand down

24V is alive across
white/blue and black of YES To hydraulic
connector (CN-253F) for troubleshooting
safety lever lock solenoid.
NO
Harness between safety

24V is alive across white
lever lock switch (SW-11)
and blue of connector YES YES
and safety lever lock Inspect harness.
(CN-46F) for safety lever
solenoid (SV-4) is
lock switch (SW-11).
disconnected.
NO
Safety lever lock switch YES

Replace switch (SW-11).
(SW-11) is faulty.
24V is alive across white
and black of connector YES
(CN-46F) for safety lever
lock switch (SW-11).
Safety lever lock switch
NO YES
(SW-11) is attached Adjust and replace.
improperly.
Harness between fuse box

24V is alive across white YES YES
and safety lever lock
and black of connector Inspect harness.
switch (SW-11) is
(CN-38M) on fuse box.
disconnected.
NO
YES YES Inspect the shorted point

Fuse No.15 is blown. Harness shorted to frame.
of harness.
NO
Inspect if there is no
disconnection in fuse box.
5
(1)-2
Machine moves unexpectedly when lever is at neutral.
(P1 bypass cut proportional valveandP2 bypass cut

proportional valveare displayed on the gauge cluster.)
The machine operates unexpectedly if the YES To hydraulic

connector (CN-257F) for the P1 bypass
troubleshooting
cut proportional valve is removed.
NO
(Service diagnosis No.10)
Arm out operation pressure sensor Arm out operation
YES Trouble disappears if arm out operation YES pressure sensor (SE-8) is
(SE-8) shows more than 1.3V even
pressure sensor (SE-8) is replaced. faulty.
NO
NO Arm out pilot pressure is 6kgf/cm2 (85psi) YES
Inspect ATT pilot valve.
NO
C-1 controller is faulty.
Arm in operation pressure sensor YES YES Arm in operation
Trouble disappears if arm in operation
(SE-7) shows more than 1.3V when pressure sensor (SE-7) is
pressure sensor (SE-7) is replaced.
lever is at neutral. faulty.
NO
NO YES
Arm in pilot pressure is 6kgf/cm2 (85psi)
NO
The machine operates unexpectedly if the YES To hydraulic

connector(CN-257F) for the P2 bypass cut
troubleshooting.
proportional valve is removed.
NO
Boom raise operation pressure sensor Boom raise operation
(SE-3) shows more than 1.3V when
YES Trouble disappears when boom raise YES pressure sensor (SE-3) is
ope-ration pressure sensor (SE-3) is
lever is at neutral. faulty.
NO NO
Boom raise pilot pressure is more than YES
6kgf/cm2 (85psi) when lever is at neutral.
NO

Swing operation pressure sensor Swing operation
YES Trouble disappears when swing ope-ration YES pressure sensor (SE-5) is
(SE-5) shows more 1.3V when lever is
at neutral.
NO
NO YES
Swing pilot pressure is more than 6kgf/cm2
(85psi) when lever is at neutral.
NO
6
(2)-2
Only bucket motion is slow.

The bucket operating pressure sensor value YES To hydraulic
is more than 4.0V when the bucket
troubleshooting
operating lever is turned to the full.
NO
Bucket opration pressure
Trouble disappears if bucket operation YES sensor (SE-1,or SE-2) is
pressure sensor (SE-1,or SE-2)is changed.
faulty.
NO
If the harness for the bucket operation Harness between bucket
NO
pressure sensor is connected another opeeration pressure sensor
pressure sensor, the pressure sensor gets and controller is faulty.
out of order.
YES
Bucket pilot pressure is more than approx. YES
35kgf/cm2 (500psi) when lever is at full.
NO To hydraulic
(2)-3 troubleshooting
Only boom raise speed motion is slow.

The boom raise operation pressure sensor
(SE-3) value is more than 4.0V when the YES To hydraulic
boom raise operating lever is turned to the troubleshooting
full.
NO
Boom reise operation
Trouble disappears if boom raise operation YES
pressure sensor is replaced. pressure sensor (SE-3) is
fauly.
NO
If the harness for the boom raise operation
pressure sensor is connected another YES Inspect ATT pilot valve.
pressure sensor, the pressure sensor gets
out of order.
NO To hydraulic
Except for boom raise and arm out motions are slow.

Command current for travel straight
NO To hydraulic
proportional valve is approx. 350mA or over
troubleshooting
at boom raise or arm in motions.
YES (Service diagnosis No.13)

Travel right operation pressure sensor
YES Trouble disappears when travel right YES Travel right operation
(SE-9) shows more than 1.3V when travel operation pressure sensor (SE-9) is pressure sensor (SE-9) is
right lever is at neutral. replaced. faulty.
NO NO
Travel right pilot pressure is more than YES Inspect travel pilot valve.
6kgf/cm2 (85psi) when lever is at
NO Inspect harness between
travel right operation
pressure sensor (SE-9) and
controller.
Travel left operation pressure sensor
YES Trouble disappears if travel left YES Travel left operation
(SE-10) shows approx. 1.3V or over when pressure sensor (SE-10) is
opera-tion pressure sensor (SE-10) is
travel left lever is at neutral. faulty.
NO NO
Travel left pilot pressure is more than YES
Inspect travel pilot valve.
6kgf/cm2 (85psi) when lever is at
travel left operation
pressure sensor (SE-10)
and C-1 controller.
7
(2)-5
Only arm in motion is slow.

Arm in operation pressure sensor shows YES To hydraulic
4.0V or over when arm in lever is shifted to
troubleshooting
the full.
NO
Trouble disappears if arm in operation YES Arm in operation pressure
pressure sensor (SE-7) is replaced. sensor (SE-7) is faulty.
NO
Faulty symptom changes if the harness for Harness between arm in
YES
the arm in operation pressure sensor is operation pressure sensor
connected with another pressure sensor. and controller is faulty.
NO
Arm in pilot pressure is approx. 35kgf/cm2
YES
(500psi) or over when arm in lever is shifted Inspect ATT pilot valve.
to the full.
NO To hydraulic
Only arm out motion is slow.

Arm out operation pressure sensor shows
YES To hydraulic
4.0V or over when arm out lever is shifted to
troubleshooting
the full.
NO
Arm out operation
Trouble disappears if arm out operation YES pressure sensor (SE-8) is
NO
If the harness for the arm out operation Harness between arm out
YES
pressure sensor is connected another operation pressure sensor
pressure sensor, the pressure sensor gets and controller is faulty.
out of order.
NO
Arm out pilot pressure is approx. 35kgf/cm2
YES
(500psi) or over when arm out lever is Inspect ATT pilot valve.
NO To hydraulic
Fine operation of bucket digging and dump motions can not be performed.

Bucket digging (dump) Trouble gets normal if
operation pressure NO connector on P1 bypass NO To hydraulic
sensor shows cut proportional valve troubleshooting.
0.7V or over when (PSV-D) is disconnected.
YES Arm in operation pressure
Trouble disappears if arm
sensor (SE-7) shows YES in operation pressure YES Arm in operation pressure
approx. 1.3V or over when sensor (SE-7) is faulty.
sensor (SE-7) is replaced.
NO
NO
Arm in pilot pressure is
6kgf/cm2 (85psi) or over YES
arm in operation pressure
sensor (SE-7) and C-1
controller.
Continued on the P9. Continued on the P9.
8
Continued from P8. Continued from P8.
YES NO
Arm out operation pressure YES Trouble disappears if arm YES Arm out operation
sensor (SE-8) shows approx. out operation pressure pressure sensor (SE-8) is
1.3V or over when lever is at sensor (SE-8) is replaced. faulty.
neutral.
NO
NO Arm out pilot pressure is
YES
more than 6kgf/cm2 (85psi) Inspect ATT pilot valve.
Inspect harness between
NO arm out operation pressure
sensor (SE-8) and
C-1 controller.
Replace C-1 controller.

Trouble disappears if bucket digging
(dump) operation pressure sensor SE-1
YES Bucket digging (dump) operation pressure
sensor is faulty.
(SE-2) is changed.
NO
If the harness for the bucket digging Harness between bucket digging (dump)
operation pressure sensor is connected YES
operation pressure sensor and controller is
another pressure sensor, the pressure faulty.
sensor gets out of order.
NO
(4)-2 Replace C-1 controller.
Fine operation of boom raise and lower motions can not be performed.
(Service diagnosis No. 9) (

P1 bypass cut proportional valve is displayed on the gauge cluster.)
Boom raise (lower) Trouble gets normal if
operation pressure NO connector of P1 bypass cut NO To hydraulic
sensor shows 0.7V proportional valve troubleshooting
or over when lever (PSV-D) is disconnected.
is at neutral.
YES Arm in operation pressure
sensor (SE-7) shows YES Trouble disappears if arm in YES Arm in operation pressure
operation pressure sensor
(SE-7) is replaced.
NO
NO Arm in pilot pressure is
6kgf/cm2 (85psi) or over YES
Inspect ATT pilot.valve
sensor (SE-7) and
C-1 controller.
Arm out operation pressure
sensor (SE-8) shows YES Trouble disappears if arm YES Arm in operation pressure
out operation pressure
NO
NO
Arm out pilot pressure is YES
NO arm in operation pressure
sensor (SE-8) and
C-1 controller.
Trouble disappears if boom raise (lower) Replace C-1 controller.

operation pressure sensor SE-3 (SE-4) is
changed. YES Boom raise (lower) operation pressure sensor
SE-3 (SE-4) is faulty.
NO
The harness between bucket digging operation
If the harness for the bucket YES
pressure sensor SE-1 and the bucket dump
digging(dump) operation pressure sensor
operation pressure sensor SE-2 is faulty.
is connected to another pressure sensor,
the faulty symptom changes.
NO Replace C-1 controller.

9
(4)-3
Fine operation of swing motion can not be performed.

(P2 bypass cut proportional valve is displayed on the gauge cluster.)
Trouble gets Swing operation pressure Trouble is corrected if swing
normal if YES sensor (SE-5) shows approx. YES operation pressure sensor YES Swing operation pressure
sensor (SE-5) is faulty.
connector of P2 1.3V or over when lever is at (SE-5) is replaced.
bypass cut neutral.
proportional NO
valve (PSV-B) is
NO Swing pilot pressure is more YES
disconnected. than 6kgf/cm2 (85psi) when Inspect ATT pilot valve.
NO swing operation pressure
(Service diagnosis No.9) controller.
Boom raise operation
pressure sensor (SE-3) YES Trouble disappears if boom YES Boom raise operation
raise operation pressure
shows approx. 1.3V or over pressure sensor (SE-3) is
when lever is at neutral. faulty.
NO NO
Boom raise pilot pressure is YES
NO boom raise operation
(Service diagnosis No.10) C-1 controller.
Arm out operation pressure Trouble disappears if arm
sensor (SE-8) shows 1.3V or YES out operation pressure YES Swing operation pressure
over when lever is at sensor (SE-8) is replaced. sensor (SE-5) is faulty.
neutral.
NO NO
Arm out pilot pressure is
6kgf/cm2 (85psi) or over
YES
NO
Arm in operation pressure
sensor (SE-7) shows 1.3V or YES Trouble disappears if arm in YES Arm in operation pressure
over when lever is at operation pressure sensor sensor (SE-7) is faulty.
neutral. (SE-7) is replaced.
NO NO
Arm in pilot pressure is
YES
6kgf/cm2 (85psi) or over Inspect ATT pilot valve.
NO
Trouble gets normal if
connector of swing parking NO To hydraulic
solenoid (SV-1) is troubleshooting
disconnected.
YES
Swing operation pressure
Trouble disappears if swing
sensor (SE-5) shows approx. NO YES Swing operation pressure
operation pressure sensor
4.0V or over when lever is sensor (SE-5) is faulty.
(SE-5) is replaced.
NO
YES Inspect harness between
Swing pilot pressure is
approx. 35kgf/cm2 (500psi) YES swing operation pressure
or over when lever is shifted sensor (SE-5) and C-1
to the full. controller.
NO
10
(4)-4
Fine operation of arm in and out motions is not possible.
(Displays Service Diagnosis No21.)

Trouble gets normal if
connector of P2 bypass cut NO To hydraulic
proportional valve (PSV-B) is troubleshooting
disconnected.
Trouble gets normal if swing
sensor (SE-5) shows approx. YES YES Swing operation pressure
operation pressure sensor sensor (SE-5) is faulty.
1.3V or over when lever is at
(SE-5) is replaced.
neutral.
NO
NO
Swing pilot pressure is more YES
than 6kgf/cm2 (85psi) when Inspect ATT pilot valve.
swing sensor (SE-5) and
C-1 controller.
Boom raise sensor (SE-3) Trouble disappears if boom YES
YES Boom raise sensor (SE-3)
shows approx. 1.3V or over raise operation pressure
sensor (SE-3) is replaced. is faulty.
NO NO
Boom raise pilot pressure is
YES
boom raise operation
(Service diagnosis No.10) C1 controller.
Arm out operation pressure YES Trouble disappears if arm YES Arm out operation
sensor (SE-8) shows 1.3V or out operation pressure
pressure sensor (SE-8) is
over when lever is at neutral. sensor (SE-8) is replaced.
faulty.
NO NO
Arm out pilot pressure is YES
NO
Arm in operation pressure YES Trouble disappears if arm in YES Arm in operation pressure
sensor (SE-7) shows 1.3V or operation pressure sensor
over when lever is at neutral. (SE-7) is replaced.
NO NO
Arm in pilot pressure is more YES
than 6kgf/cm2 (85psi) when Inspect ATT pilot valve.
NO
11
(5)
Travel 1-2 speeds can not be changed.
24V is alive across light green/black

and black wires of connector YES To hydraulic
(CN-255F) for travel 1-2 speed select troubleshooting
solenoid (SV-3).
NO
If Switch travel 1-2 speed select Each time the switch turns ON
switch(SW-3) is pressed in the YES and OFF by turns in the service YES
service diagnosis No.6, ON is diagnosis No.6, the 2nd digit and 1st Replace C-1 controller.
displayed, and if the switch is not digit numbers turn to 1 and 0
pressed, OFF is displayed. alternately. Inspect harness (light
green and black) between
NO NO travel 1-2 speed select
If the plugs(two females) connecting solenoid (SV-3) and
the travel 1-2 speed select C-1 controller.
switch(SW-3) with the main harness YES Replace travel 1-2 speed
are connected together, the switch is
select switch (SW-3).
turned ON and if the plugs are
disconnected, the switch is
turned OFF .
NO
Harness (pink and blue) between
travel 1-2 speed select switch YES
Repair harness.
(SW-3) and C-1 controller is
disconnected.
NO
12
(6)

Command current of travel straight
NO To hydraulic
proportional (PSV-C) is more than
349mA during traveling. troubleshooting
YES
Bucket digging operation pressure Bucket digging operation
YES Trouble disappears if bucket digging YES pressure sensor (SE-1) is
sensor (SE-1) shows 1.3V when lever operation pressure sensor (SE-1) is
is at neutral. replaced. faulty.
NO NO
Bucket digging pilot pressure is YES
more than 6kgf/cm2 (85psi) when Inspect ATT pilot valve.
NO

Bucket dump operation pressure
YES Trouble disappears if bucket dump YES Bucket dump operation
sensor (SE-2) shows more than 1.3V operation pressure sensor (SE-2) is pressure sensor (SE-2) is
when lever is at neutral. replaced. faulty.
NO NO
Bucket dump pilot pressure is more YES
than 6kgf/cm2 (85psi) when lever is Inspect ATT pilot valve.
at neutral.
NO

Boom raise operation pressure YES Trouble disappears if boom raise YES Boom raise operation
sensor (SE-3) shows more than 1.3V operation pressure sensor (SE-3) is pressure sensor (SE-3) is
NO NO
Boom raise pilot pressure is more YES
at neutral.
NO
Boom lower operation pressure
sensor (SE-4) shows more than 1.3V
YES Trouble disappears if boom lower YES Boom lower operation
operation pressure sensor (SE-4) is pressure sensor (SE-4) is
NO NO
Boom lower pilot pressure is more YES
at neutral.
NO

Swing operation pressure sensor YES Trouble disappears if swing YES Swing operation pressure
(SE-5) shows more than 1.3V when operation pressure sensor (SE-5) is
replaced. sensor (SE-5) is faulty.
NO NO
Swing pilot pressure is more than YES
6kgf/cm2 (85psi) when lever is at Inspect ATT pilot valve.
neutral.
NO
Continued on the P14
13
Continued from P13
NO (Service diagnosis No.10)

Arm in operation pressure sensor Trouble disappears when arm in
(SE-7) shows more than 1.3V when
YES YES Arm in operation pressure
operation pressure sensor (SE-7) is
lever is at neutral. replaced.
NO NO
Arm in pilot pressure is more than YES
neutral.
NO
Arm out operation pressure sensor
YES Trouble disappears if arm out YES Arm out operation
(SE-8) shows more than 1.3V when operation pressure sensor (SE-8) is pressure sensor (SE-8) is
lever is at neutral. replaced. faulty.
NO NO
Arm out pilot pressure is more than
YES
neutral.
NO Replace C-1 controller.
(8)
Machine does not travel straight.
Command current of travel straight YES To hydraulic

proportional valve (PSV-C) is 650mA or troubleshooting
NO
Check harness (green / black and gray /
TRAVEL PROP-VALV is displayed on YES
black) between travel straight proportional
gauge cluster.
valve (PSV-C) and C-1 controller.
NO
Machine deviates YES sensor (SE-5) shows more NO Trouble disappears if swing YES Swing operation pressure
operation pressure sensor sensor (SE-5) is faulty.
to the left. than 4.0V when lever is
(SE-5) is replaced.
NO NO
YES
Swing pilot pressure is more Check harness between
than approx. 35kgf/cm2 YES swing operation pressure
(500psi) when lever is sensor (SE-5) and C-1
shifted to the full. controller.
NO
Arm out operation pressure
sensor (SE-8) shows more NO Trouble disappears if arm YES Arm out operation
out operation pressure pressure sensor (SE-8) is
than 4.0V when lever is
sensor (SE-8) is replaced. faulty.
NO
YES
Arm out pilot pressure is Inspect harness between
approx. 35kgf/cm2 (500psi) YES arm out operation pressure
or over when lever is shifted sensor (SE-8) and
to the full. C-1 controller.
NO
Continued on the P15 Continued on the P15 Inspect ATT pilot valve.
14
Continued from P14 Continued from P14
NO YES (Service diagnosis No.10)

Arm in operation pressure
Trouble disappears if arm
sensor (SE-7) shows more NO in operation pressure YES Arm in operation pressure
than 4.0V when lever is sensor (SE-7) is faulty.
NO
YES
Arm in pilot pressure is Inspect harness between
approx. 35kgf/cm2 (500psi) YES arm in operation pressure
or over when lever is shifted sensor (SE-7) and C-1
to the full. controller.
NO

Boom raise
Boom raise operation
operation pressure NO Trouble disappears if boom YES
sensor (SE-3) shows raise operation pressure pressure sensor (SE-3) is
more than 4.0V sensor (SE-3) is replaced. faulty.
when lever is shifted NO
to the full. Boom raise pilot pressure is Inspect harness between
YES approx. 35kgf/cm2 (500psi) YES boom raise operation
or over when lever is shifted pressure sensor (SE-3) and
NO

Boom lower NO Trouble disappears if boom YES Boom lower operation
operation pressure lower operation pressure pressure sensor (SE-4) is
sensor (SE-4) shows sensor (SE-4) is replaced. faulty.
approx. 4.0V or over
NO
when lever is shifted
Boom lower pilot pressure is Inspect harness between
to the full.
approx. 35kgf/cm2 (500psi) YES boom lower operation
YES or over when lever is shifted pressure sensor (SE-4) and
NO
Bucket digging Bucket digging operation
NO Trouble disappears if bucket YES
operation pressure digging operation pressure pressure sensor (SE-1) is
NO
Bucket digging pilot Inspect harness between
to the full.
pressure is YES bucket digging operation
YES approx.35kgf/cm2 (500psi) or pressure sensor (SE-1)
over when lever is shifted to and C-1 controller.
the full.
NO
Bucket dump
NO Trouble disappears if bucket YES Bucket dump operation
operation pressure dump operation pressure pressure sensor (SE-2) is
NO
to the full. Bucket dump pilot pressure Inspect harness between
is approx. 35kgf/cm2 YES bucket dump operation
YES (500psi) or over when lever pressure sensor (SE-2) and
is shifted to the full. C-1 controller.
NO
15
(10)
Swing motion does not work.
Swing motion works if connector

(CN-254F) of swing parking NO To hydraulic
solenoid (SV-1) is disconnected. troubleshooting
YES
Swing operation pressure sensor NO Trouble disappears if swing YES Swing operation pressure
(SE-5) shows approx. 1.3V or operation pressure sensor (SE-5) sensor (SE-5) is faulty.
over when lever is shifted to the is replaced.
full.
NO
YES Swing pilot pressure is approx. Inspect harness between
35kgf/cm2 (500psi) or over when YES swing operation pressure
lever is shifted to the full. sensor (SE-5) and C-1
controller.
NO
(11)
Swing speed is low.
Actual current readings of P2

pump proportional valve are YES To hydraulic
more than 619mA when the troubleshooting
swing lever is turned to the full.
NO
Command current of P2 pump
proportional valve are more than YES
619mA when the swing lever is Replace C-1 controller.
turned to the full.
NO
The swing operation pressure Trouble disappears if swing YES
sensor value is more than 4.0V
NO Swing operation pressure
operation pressure sensor (SE-5)
when the swing operation lever sensor is faulty.
is replaced.
is turned to the full.
NO
YES If the harness for the bucket
operating pressure sensor is put YES Harness between swing
into another pressure sensor, the operation pressure sensor
pressure sensor gets out of order. and controller is faulty.
NO
Swing pilot pressure is approx. YES Inspect or replace ATT
35kgf/cm2 (500psi) or over when
pilot valve
lever is shifted to the full.
NO
Check piping
P1 or P2 pump pressure sensor YES Trouble disappears if P1 or P2 YES P1 or P2 pump pressure

shows more than 0.7V when pump pressure sensor is
changed. sensor is faulty.
NO NO
Faulty symptom changes if the Harness between pressure
YES
harnesses for P1 and P2 pump sensor and controller is
pressure sensors are exchanged. faulty.
NO
Swing operating pressure is YES

normal.
NO To hydraulic
troubleshooting
16
(12)
Swing power is poor.
Actual current readings of P2

pump proportional valve are YES To hydraulic
more than 619mA when the troubleshooting
swing lever is turned to the full.
NO
Command current of P2 pump
proportional valve are more than YES
619mA when the swing lever is Replace C-1 controller.
turned to the full.
NO
The swing operation pressure Trouble disappears if swing YES
sensor valve is more than 4.0V
NO Swing operation pressure
operation pressure sensor is
when the swing operation lever sensor is faulty.
replaced.
is turned to the full.
NO
YES If the harness for the bucket
operating pressure sensor is put YES Harness between swing
into another pressure sensor, the operation pressure sensor
pressure sensor gets out of order. and controller is faulty.
NO
Swing pilot pressure is approx. YES Inspect or replace ATT
35kgf/cm2 (500psi) or over when
pilot valve
lever is shifted to the full.
NO
Check piping
P1 or P2 pump pressure sensor

YES Trouble disappears if P1 or P2 YES P1 or P2 pump pressure
shows more than 0.7V when pump pressure sensor is
changed. sensor is faulty.
NO NO
Faulty symptom changes if the YES Harness between pressure
harnesses for P1 and P2 pump sensor and controller is
pressure sensors are exchanged. faulty.
NO
Swing operating pressure is YES

normal.
NO To hydraulic
troubleshooting
17
(13)
Swing motion can not be held on a slope.
24V is alive across

pink/black and black wires YES
To hydraulic
of connector (CN-254F) for
troubleshooting
swing parking solenoid
(SV-1).
NO
Swing parking release NO
switch (SW-4) is at Turn to NORMAL.
NORMAL.
YES
sensor (SE-5) shows more YES Trouble gets normal if YES Swing operation pressure
swing operation pressure
than 1.3V when lever is at sensor (SE-5) is faulty.
neutral.
NO NO
Swing pilot pressure is more YES
than 6kgf/cm2 (85psi) is Inspect ATT pilot valve.
swing operation pressure
controller.
Arm in operation pressure Trouble gets normal if arm YES

sensor (SE-7) shows more YES in operation pressure sensor Arm in operation pressure
than 1.3V when lever is at (SE-7) is replaced. sensor (SE-7) is faulty.
neutral.
NO
NO Arm in pilot pressure is YES
NO
sensor (SE-7) and
C-1 controller.
Inspect that harness (pink

If swing right (or swing left,
YES and black) between swing
or arm in) lever is operated,
parking brake solenoid
SWINGBRAKE SOLENOID
(SV-1) and C-1 controller is
is indicated.
not disconnected.
NO
18
(14)
Auto idling stop (AIS) does not function. (E/G does not stop after an
elapse of 60 seconds after the lock lever was moved upward to locked
ii )
In auto warm-up (OPT)
operation, AIS does not
YES work. Switch warm-up SW
Is WARM-UP displayed?
off or check on it after
NO completion of warming up.
When overheating is
YES detected, AIS does not
Is E/G water temperature work to protect E/G.
warning indicated? Check on it in normal
NO operation condition.
When AIS selector SW is

YES off, it does not work.
Is AIS selector SW off? Switch AIS SW on and
check on it.
NO
Are mechatrocontroller NO Check the line between

12-14 pin and grounding grounding - AIS selector
connected? SW - controller.
YES
Is E/G speed indication on

E/G speed display or Check speed sensor gap, or
Service diagnosis display NO check between controller
normal. (About 2200 rpm and speed sensor for
in high idling, about 1000 continuity.
rpm in low idling)?
YES
Is ATT operation possible
even if the lock lever is YES Adjust or replace lock
moved upward to locked lever limit switch.
position ?
NO
Is 24 V loaded on mechatro
controller 17-11 when the Check the line between
YES
lock lever is moved lock lever limit switch and
downward to locked controller.
position?
NO
YES Replace fuse, or check the
Is fuse No.15 blown? line around the fuse.
NO
* Is set time (60 seconds) YES

until the AIS is tripped Replace controller.
correct?
NO
*Adjust set time.
NOTE :
1. AIS is Auto Idling Stop.
2. For checking and adjusting method of AIS set time shown by mark *,
contact KOBELCO Field Support Group.
19
E200SR
SECTION 44 TROUBLESHOOTING (ENGINE)
TABLE OF CONTENTS
1. TROUBLE DIAGNOSIS TABLE ................................................................................. 1
2. TROUBLESHOOTING ............................................................................................... 3
Engine
System
Other trouble Drop in output Rotation trouble Starting trouble
(9)
(8)
(7)
(6)
(5)
(4)
(3)
(2)
(1)
Group No.
(12)
(11)
(10)
start.
Over heat
revolution.
1.
Idling unsmooth
Exhaust gas is white

warming-up E/G
key is turned off.

Trouble
not work properly.

Does not reach max
Component
Exhaust gas is black

Starter does not run.
not disappear after idling.)

High speed unsmooth
Knocking occurs after

Medium speed hunting
E/G deficiency in output

Accel potentiometer does
Starter runs but does not
(In cold state, white smoke does
The key is turned to OFF,

Excessive oil consumption.
Engine does not stop when

if work modes are changed.
Revolution does not change
Max. revolution is too high.
Excessive fuel consumption.
but power does not shut off.

Fuel not filled up or leaking.

Oil cooler element clogged.
Fuel system trouble(Air or water entered.)

Oil filter clogged.

Air cleaner clogged.
Filters
Gauze filter clogged.
Fuel filter clogged.

V-belt slips.
Inspection

Breather hose bent.
Cooling water level

Fuel is of poor quality or leaking.

Specific gravity of battery fluid

Fluid
Viscosity of engine oil is not suited, engine oil is

TROUBLE DIAGNOSIS TABLE ; ENGINE

leaking, or the engine oil level not proper.
Poor quality fuel is used or heavy oil is

used.

Blowby gas is much.

Gas leaks from valve and gasket.

Engine oil is too much.
Gas / fluid
Visual check
Service man
Battery fluid level

Fuse

Starter key
Battery relay
Mechatoronic controller
Mechatoro A adjust.
Machine side
Governor motor
Electrical fittings
Accel potentiometer

Connector and electric wiring

Safety relay
Glow relay

Glow
Starter motor
Engine side
Starter relay
Electrical fittings
Alternator
Feed pump function

Check injection timing

Fuel
Inspect nozzle.
system
Stop

Injection pump
position

Valve clearance

Valve spring is fatigued.

system
Intake /
exhaust
Air cleaner & muffler

Check if engine oil level goes into combustion

chamber.

Check relief valve.

Oil strainer clogged.
system
Lubrication
Fuel is mixed.

Check thermostat.

Oil cooler element damaged.

Cooling
Compression pressure low.

Engine dealer
Control rack movement unsmooth.

Governor spring fatigued.

Crank shaft oil seal no good.
Piston liner worn.

Piston ring worn.

Valve spring fatigued.

Main structure
Internal parts stuck.

Check fuel feed.

Head gasket faulty.

Flywheel gear damaged.

1

2
2. TROUBLESHOOTING
(1)
Starter does not run.
NO Check battery fluid level

Check battery voltage. Charge or replace battery.
and specific gravity.
OK
The voltage at B1 NO
Check battery relay B1
terminal of battery is Replace fusible link 60A.
voltage.
24V ore more.
OK
The voltage at outlet
side of 20A fuse for NO
Check fuse box voltage. keyswitch is 24V or Replace fuse.
more.
OK OK
The voltage at inlet side YES Check electric wiring and
of 20A fuse for
connectors.
keyswitch is lower than
Measure the voltage at

L terminal of battery NO Check electric wiring
relay instead of M
and connector.
terminal of keyswitch to
check the voltage of the
Check key switch M terminal.
Check key switch.
voltage.
Measure the voltage at
S terminal of safety
relay on wire No.63 NO Check electric wiring
instead of ST terminal of and connector.
keyswitch to check the
NO
voltage at ST terminal.
Check electric wiring
OK and connector.
The voltage at L YES

Check voltage of battery
terminal of battery relay Replace battery relay.
relay.
is 24V or more.
OK
Check voltage of battery
relay A. Also check 24V is alive on A side,
but not on A1. Replace fusible link 60A.
voltage of battery relay
A1.
OK
Check voltage of starter 24V is alive on terminal
motor. B of starter motor.
OK OK
Replace starter motor.
Check voltage of starter 24V is alive on terminal

motor. S of starter motor.
OK
Check voltage of safety 24V is alive on terminal YES

relay. S of safety relay.
OK Replace safety relay.
The voltage across NO
Check voltage of safety safety relay and starter
relay. motor(across coil) is
Condition ; Check keyswitch in START position.

Emergency stop knob (for engine stop) is back in normal position.
3
(2)
Starter turns but engine is hard to start.
Check starter power is strong or WEAK Check battery fluid level and
Charge or replace battery.
weak. specific gravity.
OK
Check compression
Check engine itself. pressure and valve
clearance. Check that
valve spring is not
Check that air filter clogged
Check air intake system. fatigued, that piston
lamp lights.
liner is not worn, that
OK OK piston ring is not worn,
Check that air cleaner clogged that head gasket is not
sensor. faulty and that flywheel
gear is not damaged.
Also check radiator and
thermostat.
E/G side Check gauze filter. Check feed pump

OK performance, injection
Check fuel feed system. pump, injection nozzle
Check fuel gauge and water and injection timing.
Machine
separator. Check that poor
side
quality fuel is not used.
YES
Check electric system. E/G side 24V is alive on glow plug. Glow plug is faulty.
NO
Harness between glow
24V is alive on wire No. 66 (5W) YES relay and glow plug is
of CN-153F on glow relay (R-3). faulty.
NO
Harness between glow
24V is alive on wire No.53 (5Y) NO
relay and battery relay
of CN-154F on glow relay (R-3).
is faulty.
OK
24V is alive across wire No. 62 YES
of CN-155F on glow relay (R-3) Replace glow relay.
and earth.
NO Harness between key
NO
Ground connection is poor. switch and glow relay is
faulty.
Check E/G oil of viscosity if it is NO

Check viscosity of E/G oil. suited to ambient temperature. Replace engine oil.
Checking condition ; E/G starter key is in ON position.
CN-154F CN-153F

CN-155F CN-155F

Internal connection Fig.1 Glow relay terminals and connector
4
(3)
E/G revolution is faulty.
Check high pressure pipe

and injection nozzle. Check
that compression
Idling not smooth.
pressures in cylinder are
equal. Check injection
pump and thermostat.
Idling is faulty.
1
Idling revolution is too
high. Adjust mechatroA.
Medium revolution is Hunting occurs at medium Check control rack.

faulty. revolution. Change over governor
spring.
Check that air is not mixed YES

in fuel. Bleed air.
OK
Check that air cleaner is
Check air intake system. not clogged.
OK
Check fuel gauge, water
separator and gauze filter.
Check fuel feed system.
Check also that poor
OK quality fuel is not used.
High idling is faulty.
Check injection nozzle,

injection pump and
injection timing.
E/G does not reach max.

revolution. 1
Adjust mechatroA.
Max revolution is too high.
Checking condition ; E/G water temperature is 505 (1229

F).
1 ; Refer to Electric Troubleshooting.
5
Note ; (6) matches the group No. on page 1. The same is true on the following pages.
(6)
E/G output is insufficient.
Check that E/G water OK
temperature lamp is on and Check the contents of
Overheat
that buzzer sounds. excavating.
NO
Check E/G water
temperature switch, gauge
Inspect electric system.
cluster, electric wiring and
OK connectors.
Check cooling water level.

Check that fan belt does
Check cooling system.
not slip.
OK Check thermostat.
Also check that radiator.
Oil cooler is not clogged.
Check that poor quality

Check fuel system.
fuel is not used.
OK
Check E/G oil system. Check E/G oil filter.
Check air intake Check that air filter clogged OK Check that air cleaner is
system. display of warning not clogged.
OK
Check fuel feed Check that air is not mixed in
system. fuel. Bleed air.
OK OK
Check water separator and Check feed pump
gauze filter. Check also that performance, injection
poor quality fuel is not used. pump, injection nozzle and
injection timing.
Check E/G oil of viscosity if it

Check E/G oil. is suited to ambient Replace engine oil.
temperature.
OK
Check compression
Check that blowby gas is not pressure and valve
much, that gas does not leak clearance. Check that
Check engine
from gasket, and that engine valve spring is not
itself.
oil level does not go into fatigued. Check that
combustion chamber. control rack moves
smoothly. Check that
Checking condition ; High idling piston ring is not worn.
Check also that head
gasket is not faulty.
(7)
Knocking occurs after warming-up E/G.
OK
Check that poor quality fuel is
Check fuel system. not used. Replace fuel.
Check that engine oil goes into Judge it if oil is there on

Check E/G itself. combustion chamber. exhaust port.
OK
Check that blowby gas is not Check compression
much and that gas does not pressure, injection timing
leak from gasket. and injection nozzle.
Checking condition ; E/G water temperature is 505 (1229F).
6
(8)
Exhaust is abnormal.
Check that air cleaner is not

Exhaust gas is black. clogged. Replace air element.
OK
Check engine oil viscosity.
Check that engine oil is not too
much.
Check injection nozzle,
OK injection timing, injection
Check that gas is not leaking pump and valve clearance.
from head gasket. Check that valve spring is not
fatigued and that piston ring is
not faulty.
Check that water is not mixed

Exhaust gas is white. in fuel. Check water separator.
OK
Check that engine oil goes
into combustion chamber. Check compression pressure
Blowby gas is much. A lot of and injection timing.
gas leaks from gasket.
Checking condition ; Engine water temperature is 505 (1229

F).
(9)
Excessive oil consumption.
Check leakage by checking the

Check that engine oil is not Retighten.
ground under E/G or by placing
leaking. Replace packing and seal.
an oil pan under E/G.
(Check that engine oil is not
filled up too much.) OK
Check that breather hose is not
bent or clogged. Replace breather hose.
OK
not used. Advise to replace fuel.
OK
Check viscosity of engine oil. Advise to replace engine oil.
OK Check that; CR shaft oil seal is
Checking condition ; No engine oil leaks. Check that engine oil goes into not faulty, piston liner is not
combustion chamber. worn, or piston ring is not
worn.
(10)
Excessive fuel consumption.

Check fuel leakage. not used. Advise to replace fuel.
OK
Blowby gas is much.
Check that gas does not leak
Check nozzle function.
from gasket.
Check injection timing.
Checking condition ; Use proper fuel. Check compression pressure.
7
(11)
E/G does not stop Confirm governor Check if governor Check that governor
when starter key is lever stop bolt motor is not faulty motor link
turned off. position. mechanically. connecting bolts are
not loose.
OK
Wire number 60C of Check resistance
Check that terminal instrument panel NG across terminals M Replace starter key
M of starter key right harness and B on starter if resistance across
switch shows 0V. CN-43F shows 0V. key. M and B is 0.
See Fig.3.
OK
Check that battery Does resistance
relay terminal B2 Wire No.857 of main NG across C1 controller
measures 0V four harness CN-150F Check C1 controller. terminals 11-1 and
seconds after key is measures 0V. 14-22 measure 72
turned off. ?
(12) OK
When starter key is Does battery NG Replace battery Replace C1
Check that battery
turned off, power terminals A and B controller if
relay operates. relay.
does not shut off. measure 0? resistance measures
See Fig.2. 0.
Checking condition ; Starter key is off.

CN-152F
TERMINAL A1 LOCK
Flowing direction of
main current
TERMINAL A1 A B B1 TERMINAL
TERMINAL B1
FLW FLW
2.0sq 2.0sq TERMINAL A VIEW
FLW2.0sq
TERMINAL B
GW B2 FLW2.0sq
WG L P COIL
H COIL
BRACKET
TERMINAL B2
Circuit diagram
L TERMINAL GW
L TERMINAL
AVS1,25L GROUND
AVS1,25G B2 TERMINAL TERMINAL
GROUND CABLE
AVS1,25B WD
CN-150M
Fig. 2 Battery relay
Fig. 3 Key SW. terminal
8
E200SR
SECTION 51 ENGINE
TABLE OF CONTENTS
1. GENERAL INFORMATION .................................................................................... 1-1
2. MAINTENANCE ..................................................................................................... 2-1
3. DISASSEMBLY ..................................................................................................... 3-1
4. INSPECTION & REPAIR ....................................................................................... 4-1
5. REASSEMBLY ...................................................................................................... 5-1
6. LUBRICATING SYSTEM ....................................................................................... 6-1
7. COOLING SYSTEM .............................................................................................. 7-1
8. FUEL SYSTEM ...................................................................................................... 8-1
9. TURBOCHARGER ................................................................................................. 9-1
10. AIR COMPRESSOR ........................................................................................... 10-1
11. ENGINE ELECTRICALS ..................................................................................... 11-1
12. TROUBLESHOOTING ........................................................................................ 12-1
13. SPECIAL TOOL LIST ......................................................................................... 13-1
14. CONVERSION TABLE ........................................................................................ 14-1

E200SR
SECTION 63 MOUNTING THE BREAKER AND

NIBBLER & BREAKER
TABLE OF CONTENTS
1.LIST OF ADDITIONAL PARTS

1.1 Additional Parts for the Modification of the Nibbler & Breaker ............................................ 1-2
1.2 Additional Parts for the Modification of the Breaker ............................................................ 1-8
2. SUMMARY
2.1 General Precautions .......................................................................................................... 2-1
2.2 Basic Method to be taken when Mounting ......................................................................... 2-1
2.3 Outline of Modification ....................................................................................................... 2-2
3. HYDRAULIC CIRCUIT DIAGRAM

3.1 Hydraulic Circuit for Nibbler & Breaker .............................................................................. 3-1
3.2 Hydraulic Circuit for Breaker .............................................................................................. 3-3
3.3 Hydraulic Components ....................................................................................................... 3-4
4. ELECTRIC SYSTEM DIAGRAM FOR NIBBLER & BREAKER............................... 4-1
5. MODIFICATION PROCEDURE FOR NIBBLER & BREAKER

5.1 Modification Item ................................................................................................................ 5-1
5.2 Floor Mat (Nibbler & Breaker) ............................................................................................ 5-1
5.2a Modification of the Control Valve ...................................................................................... 5-1
5.2b Replacement of return filter of the Hydraulic Tank ............................................................ 5-2
5.3 Remote Control Piping ; P/V .............................................................................................. 5-3
5.4 Control Block Piping .......................................................................................................... 5-3
5.5 Main Remote Control Piping ; C/V ...................................................................................... 5-4
5.6 Upper Hydraulic Piping ...................................................................................................... 5-5
5.7 Modification of the Instrument Panel .................................................................................. 5-6
5.8 Install of the Name Plate .................................................................................................... 5-6
6. MODIFICATION PROCEDURE FOR BREAKER

6.1 Modification Item ................................................................................................................ 6-1
6.2 Floor Mat ........................................................................................................................... 6-1
6.2a Modification of the Control Valve (Same as N&B, See item 5.2a) ..................................... 6-2
6.2b Modification of the Hydraulic Tank (Same as N&B, See item 5.2b) .................................. 6-2
INDEX
6.3 Remote Control Piping ....................................................................................................... 6-3

6.4 Remote Control Block (Same as N&B, See item 5.4) ......................................................... 6-4
6.5 Main Remote Control Piping ; C/V...................................................................................... 6-4
6.6 Upper Hydraulic Piping ...................................................................................................... 6-5
6.7 Install of the Name Plate .................................................................................................... 6-6
7. MODIFICATION PROCEDURE FOR ATTACHMENT .............................................. 7-1
8. REMINDERS ON THE USE OF NIBBLER & BREAKER ......................................... 8-1
9. PRECAUTIONS TO BE EXERCISED ON BREAKERS OF DIFFERENT

MANUFACTURES................................................................................................... 9-1
10. REFERENCE ....................................................................................................... 10-1

1. LIST OF ADDITIONAL PARTS

How to utilize the list of additional modification parts
This manual describes the parts which are added and canceled on
the basis of Parts Manual for standard machines when the
machine is modified into the machines equipped with N&B or
breaker.
The manual is divided into five parts, 1. Upper structure, 2. Boom,
3. STD arm, 4. LONG arm, 5. Connector, each being assigned a kit
number. In the case of connector, select for ordering. But ( ) of
quantity are appropriate for the parts of standard machine.
COMPARISON TABLE FOR KIT AND ASSY NO. BY COUNTRY

Table 1
CLASSIFI-CAT
NAME
ION
Upper structure modification kit No.
Modification of the control valve
Modification of the hydraulic tank

UPPER STRUCTURE
Remote control piping (P/V)
Remote control block
HYDRAULIC Remote control piping (C/V)
(C/V) with Boom safety
(C/V) with B&A safety
Upper hydraulic piping
ELEC Modification of the instrument panel
LABEL Install of the name plate
Boom modification kit No.

BOOM
Modification of the 5.05M (16 7 ) boom

STD BOOM
5.05M (16 7 ) boom hydraulic piping
2.6M (8 6 ) Arm modification kit No.
Modification of the 2.6M (8 6 ) STD arm
STD ARM 2.6M (8 6 ) STD arm hydraulic piping
Reinforcing of the idler link

ARM
3.0M (9 10 ) Arm modification kit No.
Modification of the 3.0M (9 10 ) LONG arm

LONG
3.0M (9 10 ) LONG arm hydraulic piping
ARM
Reinforcing of the idler link
CONNECTOR
1 1
1.1 ADDITIONAL PARTS FOR THE MODIFICATION OF THE NIBBLER & BREAKER
(1) UPPER STRUCTURE N&B
Applicable
No. NAME QTY REMARK
Machines
,A Upper structure modification kit No. N&B
HYDRAULIC TANK ASSY

23-100 REPAIR KIT 1
REMOTE CONTROL PIPING (P/V)

1 PILOT VALVE 1
2 PRESSURE SENSOR 1
3 CONNECTOR 1
4 PLUG 1
5 ELBOW 3
6 ELBOW 1
7 WASHER 1
8 HOSE 1
9 HOSE 1
10 HOSE 1
11 HOSE 1
12 PIN 1
13 PEDAL 1
14 RUBBER 1
15 LOCK ASSY 1
16 CAPSCREW 2
17 CAPSCREW 2
18 CAPSCREW 2
19 LOCK WASHER 2
20 WASHER 4
21 NUT 1
CONTROL BLOCK PIPING

4 ELBOW 1
11 CONNECTOR 1
12 ELBOW 1
13 ELBOW 1
15 TEE 1
MAIN CONTROL PIPING (C/V)

2 CONNECTOR 1
12 ELBOW 1
UPPER HYDRAULIC PIPING

1 TUBE 1
2 TUBE 1
3 HOSE 1
4 HOSE 1
5 CONNECTOR 1
6 CONNECTOR 1
7 SELECTOR VALVE 1
8 ELBOW 1
9 O RING 3
10 HALF CLAMP 4
11 ELBOW 1
12 BRACKET 1
13 SUPPORT 1
14 CLAMP 1
15 CAPSCREW 4
12
(3) 2.6M (86) ARM NOTE) COMMON TO BREAKER N&B

Applicable
No. NAME QTY REMARK
Machines
(C) 2.6M (86) Arm modification kit No. N&B, BREAKER
2.6M(86) ARM ASSY

1 2.6M(8'6) ARM ASSY (1) With bushing
2 TAPPED BLOCK 2
3 TAPPED BLOCK 2
4 TAPPED BLOCK 2
5 PLATE 1
6 PLATE 1
7 PLATE 1
2.6M(86) ARM HYDRAULIC PIPING

1 TUBE 1
2 TUBE 1
3 HOSE 2
4 STOP VALVE 2
5 CONNECTOR 2
6 O RING 2
7 O RING 2
8 BRACKET 2
9 HALF CLAMP 4
10 CLAMP 8
11 BUSHING 4
12 CAPSCREW 4
13 CAPSCREW 8
14 CAPSCREW 8
15 CAPSCREW 8
16 LOCK WASHER 4
17 LOCK WASHER 8
18 WASHER 4
19 WASHER 8
20 WASHER 8
21 WASHER 8
IDLER LINK REINFORCEMENT

1 PLATE 2 RH, LH
(4) CONNECTOR ASSY N&B

Applicable
No. NAME QTY REMARK
Machines
Kit No. is not given because it is provided after selection.
CONNECTOR ASSY
1 CONNECTOR 1
2 PLUG 1
3 O RING 1
14
(3) 2.6M (86) ARM NOTE) COMMON TO BREAKER N&B

Applicable
No. NAME QTY REMARK
Machines
(C) 2.6M (86) Arm modification kit No. N&B, BREAKER
2.6M(86) ARM ASSY

1 2.6M(8'6) ARM ASSY (1) With bushing
2 TAPPED BLOCK 2
3 TAPPED BLOCK 2
4 TAPPED BLOCK 2
5 PLATE 1
6 PLATE 1
7 PLATE 1
2.6M(86) ARM HYDRAULIC PIPING

1 TUBE 1
2 TUBE 1
3 HOSE 2
4 STOP VALVE 2
5 CONNECTOR 2
6 O RING 2
7 O RING 2
8 BRACKET 2
9 HALF CLAMP 4
10 CLAMP 8
11 BUSHING 4
12 CAPSCREW 4
13 CAPSCREW 8
14 CAPSCREW 8
15 CAPSCREW 8
16 LOCK WASHER 4
17 LOCK WASHER 8
18 WASHER 4
19 WASHER 8
20 WASHER 8
21 WASHER 8

1 PLATE 2 RH, LH
(4) CONNECTOR ASSY N&B

Applicable
No. NAME QTY REMARK
Machines
CONNECTOR ASSY
1 CONNECTOR 1
2 PLUG 1
3 O RING 1
14
(5) UPPER STRUCTURE N&B

Applicable
No. NAME QTY REMARK
Machines
F Upper structure modification kit No. N&B
MODIFICATION OF THE CONTROL VALVE

1 OPTION VALVE 1
2 CAPSCREW 4
HYDRAULIC TANK ASSY

18-4 RETURN FILTER 1

1 PILOT VALVE 1
2 PRESSURE SENSOR 1
3 CONNECTOR 1
4 PLUG 1
5 ELBOW 3
6 ELBOW 1
7 WASHER 1
8 HOSE 1
9 HOSE 1
10 HOSE 1
11 HOSE 1
12 PIN 1
13 PEDAL 1
14 RUBBER 1
15 LOCK ASSY 1
16 CAPSCREW 2
17 CAPSCREW 2
18 CAPSCREW 2
19 LOCK WASHER 2
20 WASHER 4
21 NUT 1

4 ELBOW 1
11 CONNECTOR 1
12 ELBOW 1
13 ELBOW 1
15 TEE 1
REMOTE CONTROL PIPING (C/V)

2 CONNECTOR 1
12 ELBOW 1

1 TUBE 1
2 TUBE 1
3 HOSE 1
4 HOSE 1
5 CONNECTOR 1
6 CONNECTOR 1
7 SELECTOR VALVE 1
8 ELBOW 1
9 O RING 3
1 5
N&B
Applicable
No. NAME QTY REMARK
Machines
10 HALF CLAMP 4
11 ELBOW 1
12 BRACKET 1
13 SUPPORT 1
14 CLAMP 1
15 CAPSCREW 4
16 CAPSCREW 5
17 CAPSCREW 2
18 WASHER 4
19 WASHER 9
20 NUT 2
21 O RING 2
22 O RING 2
23 CAPSCREW 4
24 CAPSCREW 8
25 LOCK WASHER 12
INSTRUMENT PANEL ASSY

39 SWITCH 1
INSTAL OF THE NAME PLATE

20 LABEL 1
21 LABEL 1
22 LABEL 1
(6) BOOM NOTE) COMMON TO BREAKER N&B

Applicable
No. NAME QTY REMARK
Machines
H Boom modification kit No. N&B , BREAKER
5.05M(16 7 ) BOOM HYDRAULIC PIPING

1 TUBE 1
2 TUBE 1
3 TUBE 1
4 TUBE 1
5 PLUG 2
6 O RING 1
7 O RING 1
8 O RING 4
9 CLAMP 5
10 CLAMP 1
11 CLAMP 2
12 CAPSCREW 4
13 CAPSCREW 13
14 CAPSCREW 16
15 LOCK WASHER 17
16 LOCK WASHER 16
17 HALF CLAMP 8
18 HOSE 2
19 CLIP 1
20 CLAMP 1
1 6
1.2 ADDITIONAL PARTS FOR THE MODIFICATION OF THE BREAKER

(1) UPPER STRUCTURE
Applicable
No. NAME QTY REMARK
Machines
(I) Upper structure modification kit No. BREAKER
HYDRAULIC TANK ASSY

23-100 REPAIR KIT 1

1 HOSE 1
2 HOSE 1
3 HOSE 1
4 NUT 1
5 PIN 1
6 WASHER 3
7 CAPSCREW 2
8 WASHER 2
9 BRACKET 1
10 PIN 1
11 PIN 1
12 CONNECTOR 1
13 ELBOW 1
14 ELBOW 1
15 PILOT VALVE 1
16 CUSHION RUBBER 1
17 CAPSCREW 2
18 LOCK ASSY 1
19 PEDAL 1
20 COVER 1
21 WASHER 1
22 PLATE 2
23 PRESSURE SENSOR 1
24 CONNECTOR 1
25 TEE 1

4 ELBOW 1
11 CONNECTOR 1
12 ELBOW 1
13 ELBOW 1
15 TEE 1
MAIN CONTROL PIPING (C/V)

2 CONNECTOR 1
12 ELBOW 1
17 TEE 1
28 HOSE 1

1 TUBE 1
2 TUBE 1
4 HOSE 1
5 PLUG 1
6 CONNECTOR 1
7 BLOCK 1
9 O RING 2
10 HALF CLAMP 2
11 ELBOW 1
12 BRACKET 1
13 SUPPORT 1
17
Applicable
No. NAME QTY REMARK
Machines
14 CLAMP 1
15 CAPSCREW 4
16 CAPSCREW 5
17 CAPSCREW 2
18 WASHER 4
19 WASHER 9
20 NUT 2
21 O RING 1
22 O RING 2
23 CAPSCREW 4
24 CAPSCREW 4
25 LOCK WASHER 8
INSTAL OF THE NAME PLATE

20 LABEL 1
21 LABEL 1
22 LABEL 1
2) BOOM NOTE) COMMON TO NIBBLER & BREAKER BRAKER

Applicable
No. NAME QTY REMARK
Machines
(B) Boom modification kit No. N&B , BREAKER
5.05M(167) BOOM ASSY

1 5.05M(167) BOOM ASSY (1) With bushing
2 TAPPED BLOCK 2
3 TAPPED BLOCK 3
4 TAPPED BLOCK 1
5 TAPPED BLOCK 2
6 TAPPED BLOCK 1
5.05M(167) BOOM HYDRAULIC PIPING

1 TUBE 1
2 TUBE 1
3 TUBE 1
4 TUBE 1
5 PLUG 2
6 O RING 1
7 O RING 1
8 O RING 4
9 CLAMP 5
10 CLAMP 1
11 CLAMP 2
12 CAPSCREW 4
13 CAPSCREW 13
14 CAPSCREW 16
15 LOCK WASHER 17
16 LOCK WASHER 16
17 HALF CLAMP 8
18 HOSE 2
19 CLIP 1
20 CLAMP 1
18
(3) 3.0M (910) LONG ARM BREAKER

Applicable
No. NAME QTY REMARK
Machines
(J) 3.0M (910) Arm modification kit No. BREAKER
3.0M(910) LONG ARM ASSY

1 3.0M(910) LONG ARM ASSY (1) With bushing
2 TAPPED BLOCK 2
3 TAPPED BLOCK 2
4 TAPPED BLOCK 2
5 PLATE 1
6 PLATE 1
7 PLATE 1
3.0M(910) LONG ARM HYDRAULIC PIPING

1 TUBE 1
2 TUBE 1
3 HOSE 2
4 STOP VALVE 2
5 CONNECTOR 2
6 O RING 2
7 O RING 2
8 BRACKET 2
9 HALF CLAMP 4
10 CLAMP 8
11 BUSHING 4
12 CAPSCREW 4
13 CAPSCREW 8
14 CAPSCREW 8
15 CAPSCREW 8
16 LOCK WASHER 4
17 LOCK WASHER 8
18 WASHER 4
19 WASHER 8
20 WASHER 8
21 WASHER 8

1 PLATE 2 RH, LH
(4) CONNECTOR ASSY BREAKER

Applicable
No. NAME QTY REMARK
Machines
CONNECTOR ASSY
1 CONNECTOR 1
2 PLUG 1
3 O RING 1
CONNECTOR ASSY
1 CONNECTOR 1
2 PLUG 1
3 O RING 1
19
110
2. SUMMARY
2.1 GENERAL PRECAUTIONS (2) Functions of the option valve :
(1) Applications of Breaker or Nibbler & Breaker The option valve is equipped with spool which
Breaker piping ................... Applicable only when functions to send the pressure oil into nibbler
a breaker is mounted. and breaker, and also to switch the flow
Nibbler & breaker piping .. Applicable only when direction to the rod side or head side of the
a nibbler and a nibbler cylinder.
breaker are mounted.
(3) Action of the single / conflux flow switch :
(2) Modifying a Breaker and a Nibbler & The single/conflux flow select switch is
Breaker provided on the instrument panel and is
There are specific procedures to be followed connected to the harness to actuate the
when modifying a breaker and a nibbler & single/conflux flow select spool.
breaker. Therefore, when they are to be
modified at our service shop, contact the (4) Installing the operation pedal :
nearest breaker and nibbler manufacturers A pedal and a pilot valve are mounted to the
office, and obtain instructions, so that you floor plate and a remote control piping is
install the pipes and handle the machinery placed between the option valves and pedal,
correctly. in order to operate the breaker or the nibbler.
(3) Differences between a Breaker Piping and a (5) Installing the selector valve :
Nibbler & Breaker Piping For the machines equipped with nibbler and
z Breaker Piping breaker, the selector valve which functions to
There is a single oil flow from pump change the oil flow direction according to the
P2 to the breaker. The oil returns to use of breaker or nibbler is provided on the
the hydraulic tank directly. The flow main C/V in the inside of guard on the right
is single flow. side of slewing motor.
(6) Reinforcement of the attachment :

If the return oil from the breaker is fed back to the Reinforcement plates are welded to the
control valve, the pulsation of the breaker is standard arm (civil engineering services : for
transmitted to the oil cooler. This causes the general use) and to the idler links of the
machine to break down. nibbler & breaker attached machine.
z Nibbler Piping (7) Replace the return filter with new standard
The oil flows to the nibbler is conflux filter.
flow ; the oil flow is changed to the
rod and the head of the nibbler
cylinder.
2.2 BASIC METHOD TO BE TAKEN WHEN

MOUNTING
(1) For specifications for nibbler & breaker,
the modification of control valve is not
required.
21
2.3 OUTLINE OF MODIFICATION

(1) Nibbler & Breaker specification
ARM HYDRAULIC
PIPING HYDRAULIC PIPING FOR BOOM
SELECTOR VALVE
STOP RETURN HYDRAULIC PIPING
VALVE RETURN FILTER
ARM
BRACKET MAIN CONTROL
VALVE
HYDRAULIC ARM TOP

BREAKER PIPING
Replacing the OPTION VALVE
breaker with the (ADD-ON VALVE)
nibbler is possible.
OPERATING
PEDAL
FLOOR MAT REMOTE CONTROL PIPING
SINGLE / CONFLUX
FLOW SELECT SWITCH
Fig. 1 Outside view of Nibbler & Breaker-attached machine

(2) Breaker specification
ARM HYDRAULIC HYDRAULIC PIPING FOR BOOM

PIPING

RETURN HYDRAULIC PIPING
STOP RETURN FILTER

VALVE
ARM MAIN CONTROL

BRACKET VALVE
ARM TOP
HYDRAULIC PIPING OPTION VALVE
BREAKER
(ADD-ON VALVE)
OPERATING
PEDAL
FLOOR MAT
REMOTE CONTROL PIPING

Fig. 2 Outside view of Breaker-attached machine
22
3. HYDRAULIC CIRCUIT DIAGRAM NOTE :
1. Marking of selector valve (51.)
3.1 HYDRAULIC CIRCUIT DIAGRAM OF NIBBLER Stamped N : NIBBLER, Stamped B : BREAKER
& BREAKER (2 WAY P/V) 2. Selection condition and proportional valve command when any of nibbler single & conflux flow or
z Conflux / single select switch z 2 way P/V pedal breaker is in service.
Conflux / single Step on pedal COMMAND SIGNAL OF SOLENOID PROPORTIONAL VALVE
Spec. Mechatro function Trip condition CONDITIONS FOR SELECTION
select switch direction (W : , W/O : )
Refer to selection SINGLE/CONFLUX SELECTOR VALVE TRAVEL
Use of CONFLUX ON Toe step (Front step) Nibbler (catch) SELECT SWITCH (No.51)
P1 PUMP P2 PUMP P1 CUT P2 CUT
conditions and NIbbler STRAIGHT
nibbler
SINGLE OFF proportionality valve Heel step (Rear step) Nibbler (release) NIBBLER CONFLUX FLOW
N
instructions at the time CONFLUX FLOW (ON)
Use of of Nibbler conflux and Pedal neutrality Breaker stopping NIBBLER SINGLE CONFLUX FLOW
SINGLE OFF SINGLE Breaker N
breaker breaker use of notes Heel step (Rear step) Breaker impacting FLOW (OFF)
FLOW SIDE
2. CONFLUX FLOW
BREAKER
(OFF)
B
NIBBLER & BREAKER SPEC.
No. NAME
Select Conflux or single flow according to the nibbler type.
50 CONTROL VALVE ASSY
51 SELECTOR VALVE (1) Nibbler conflux circuit operation
52 STOP VALVE 1) Mechatro of switch operation and pedal operation
53 PILOT VALVE If the conflux/single select switch is turned to the Conflux of the nibbler and the nibbler &
HYDRALUIC 54 RETURN FILTER breaker pedal is stepped on, secondary pilot pressure enters the low-pressure sensor (SE-11).
PUMP The output voltage of the low-pressure sensor is put into the mechatronic controller. The
mechatronic controller processes the pilot signal and puts out command signals to the solenoid
proportional valves for the travel straight valve, the P2 bypass cut valve and the P1 bypass cut
valve, according to the input voltage levels. And the solenoid proportional valve secondary
54 pressure switches the travel straight valve of C/V, P1 bypass cut valve and P2 by-pass cut valve.
2) Pilot circuit
HYDRALUIC
OIL TANK 53 Depress N&B pilot valve (53), the pilot secondary pressure flows into PA02 port of C/V through B
TRAVEL port and switches the N&B spool.
STRAIGHT
VALVE 52 3) Main circuit
51 P1,P2 pump delivery oil is confluxed in the C/V, is discharged through A02 port and is fed into
NIBBLER nibbler head side, and consequently the nibbler starts the closing action.
The return oil from the nibbler rod side flows into the hydraulic tank through B02 port of C/V.
BREAKER NOTE : Single flow is selected when it is operated with the travel action.
(2) Nibbler single circuit operation

P1 BYPASS CUT P2 BYPASS CUT 1) Mechatro of switch operation and pedal operation
If the conflux/single select switch is turned to the Single of the nibbler and the nibbler &
breaker pedal is stepped on, secondary pilot pressure enters the low-pressure sensor (SE-11).
The output voltage of the low-pressure sensor is put into the mechatronic controller. The
50 mechatronic controller processes the pilot signal and puts out command signals to the solenoid
proportional valves for the P2 bypass cut valve according to the input voltage levels. And the
solenoid proportional valve secondary pressure switches the P2 by-pass cut valve.
2) Pilot circuit
NOTE :
1. This hydraulic circuit is used in combination with the standard circuit diagram. Depress N&B pilot valve (53), the pilot secondary pressure flows into PA02 port of C/V through B
port and switches the N&B spool.
2. Return filter of number 54 shows before modification. 3) Main circuit
After modification, the filter that is available for N&B is equipped as standard P2 pump delivery oil is confluxed in the C/V, is discharged through A02 port and is fed into
nibbler head side, and consequently the nibbler starts the closing action.
The return oil from the nibbler rod side flows into the hydraulic tank through B02 port of C/V.
Fig.1 Hydraulic circuit for Nibbler & Breaker (At nibbler operating)
31
(3) Breaker operation
1) Mechatro control with switches and pedals
N & B SPECIFICATION Impacting with the breaker is attained with
No. NAME the 2-way pedal. If the heel of the 2-way pedal
50 CONTROL VALVE ASSY is stepped on, the secondary pilot pressure
51 SELECTOR VALVE enters the low-pressure sensor (SE-11). A
52 STOP VALVE voltage output from the low-pressure sensor
53 PILOT VALVE enters the mechatronic controller. The
54 RETURN FILTER
controller processes the signal and puts out a
command to the solenoid proportionate valve
for the P2 bypass cut valve according to the
HYDRAULIC PUMP input voltage.
Then the secondary pressure of the solenoid
proportionate valve changes the P2 bypass
cut valve of the control valve.
2) Pilot circuit
54
If the heel of the 2-way pilot valve (53) is
stepped on, pressure comes out of the A-port,
HYDRAULIC TANK 53
enters the PB02 port of the control valve, and
TRAVEL changes the spool of the option valve.
STRAIGHT 52
3) Main circuit
VALVE 51 The oil discharged by the P2 pump comes out
of the B02 port of the control valve and is
BREAKER supplied to the breaker to give impact to the
breaker. The oil returned from the breaker
returned directly to the hydraulic tank via
the control valve because the selector valve
P1 P2 (51) is changed.
BYPASS CUT BYPASS CUT
50
NOTE :
1. This hydraulic circuit is used in combination with the standard circuit diagram.
2. Return filter of number 54 shows before modification.

After modification, the filter that is available for N&B is equipped as standard.
Fig. 2 Hydraulic circuit for Nibbler & Breaker (Breaker operation)
32
3.2 Hydraulic circuit for breaker (1way P/V) (1) Breaker impacting operation
1) Mechatro control with pedals
BREAKER SPECIFICATION Impacting with the breaker is attained with
the 1-way pedal. If the 1-way pedal is steeped
No. NAME
on, secondary pilot pressure enters the low
50 CONTROL VALVE ASSY
pressure sensor (SE-12) from which a voltage
51 STOP VALVE output is put into the mechatro controller.
52 PILOT VALVE The controller processes the signal, puts out a
53 RETURN FILTER command to the P2 bypass cut solenoid
proportionate valve according to the input
voltage, and changes the p2 bypass cut valve.
2) Pilot circuit
If the toe of the 1-way pilot valve (52) is
HYDRAULIC PUMP
stepped on, secondary pilot pressure enters
the PA02 port of the control valve and enters
the breaker spool.
3) Main circuit
The P2 pump delivery oil flows out through
53 A02 port of C/V and reaches to the breaker.
52 The return oil from the breaker flows into the
HYDRAULIC TANK tank directly.
In the breaker independent operation, the
51 delivery rate of the P2 pump rises only to a
value set in the breaker mode.
BREAKER
P2
BYPASS C/UT
50
NOTE :
1. This hydraulic circuit is used in combination with the standard circuit diagram.
2. Return filter of number 53 shows before modification.

After modification, the filter that is available for N&B is equipped as standard.
Fig. 3 Hydraulic circuit for breaker
33
3.3 HYDRAULIC COMPONENTS
(1) Control valve assy
Option valve (Breaker, Nibbler & Breaker)
STD With OPT. P2
BREAKER
N&B
3-M10-20/27 (FOR LIFTING)

P1 (P2)
T
TRAVEL TRAVEL
PTb TRAVEL
STRAIGHT
STRAIGHT TRAVEL LEFT PAL PBL
LEFT
TRAVEL Dra,Drb
PBr RIGHT PAr SWING
TRAVEL SWING PBs1
BUCKET RIGHT PAs
Pss
PBc PAc BOOM BOOM
BUCKET CONFLUX CONFLUX PB1
BOOM
PLc2
PBb PAb ARM
BOOM ARM
PAa Drd
P1 CUT
ARM
PA1 PCb ARM
CONFLUX ARM
P1 CUT Pis RECIRCU-L PCa
RECIRCULATION ATION
(P4) PA02 PB02

OPTION P2
(P3)
Fig.5 Control valve (Breaker, Nibbler & Breaker)
34
(2) Pilot valve

SECONDARY
PRESSURE OPERATING TORQUE
SECONDARY PRESSURE
OPERATING FORCE
CIRCUIT DIAGRAM STROKE
CONTROL DIAGRAM
Fig. 8 Pilot valve (Breaker)
(3) Pilot valve
CIRCUIT DIAGRAM
SECONDARY
PRESSURE OPERATING TORQUE
SECONDARY PRESSURE
OPERATING FORCE
4-PF1/4 OPERATING ANGLE

JISB2351 O
CONTROL DIAGRAM
2-11THROUGH
Fig. 9 Pilot valve (Nzibbler & Breaker)
35
4. ELECTRIC SYSTEM DIAGRAM FOR NIBBLER & BREAKER
Fig. 1 Single / Conflux flow select switch
4-1
5. MODIFICATION PROCEDURE FOR NIBBLER & BREAKER 5.2a MODIFICATION OF THE CONTROL VALVE
(BREAKER, NIBBLER & BREAKER)
5.1 MODIFICATION ITEM 5.2a.1 MODIFICATION PROCEDURE
The main items that are needed to modify the Install the additional parts listed in Table 1-2
standard machine into a nibbler & breaker to the control valve of the standard machine,
mounted machine are as follows : as shown in Fig. 1-2. On that occasion, some
parts become unnecessary.
Table 1-1
Modification items to Table 1-2
ITEM NAME be added and change MODIFICATION OF
THE CONTROL VALVE
FRAME
No. NAME QTY REMARK 1

5.2 Modification of the floor mat Floor mat
Standard
CONTROL VALVE (1) machine
5.2a Modification of the control valve Option valve, capscrew 1 OPTION VALVE 1
2
Replacement of return filter of the 2 CAPSCREW 4 M1290
5.2b hydraulic tank Replace return filter
HYDRAULIC
5.3 Remote control piping ; P/V Add on 2 way valve

Block, Elbow, Fig. 1-2 Modification of control valve
5.4 Remote control block Connector
Remote control piping ; C/V Connector
5.5
Remote control piping ; B&A safety Connector
5.6 Upper hydraulic piping Hose, Connector

LABEL ELEC
5.7 Modification of the instrument panel Add on the switch

5.2a.2 PARTS TO BE DISUSED
When the option valve is installed, the parts
5.8 Install of the name plate Label
shown in Table 1-3 and Fig. 1-3 are disused
Cautions to be exercised in modification 5.2 FLOOR MAT (NIBBLER & BREAKER) from the standard machine.
(1) General precautions Make slits to face of the standard floor mat
1) Before starting the modification work, check according to Fig. 1-1 and cut out the hatching. Table 1-3
parts according to the additional parts list. No. NAME QTY REMARK
2) When disconnecting and reconnecting pipes,
271 CAPSCREW 4 M1225
take care, so as not to allow dirt and foreign
matter to enter. CUT OUT
3) When the O ring type joint is removed, 271
always replace it with a new one.
4) At assembly, use care of O rings do not come
off.
5) Regarding the tightening torque of O ring
type joints, hydraulic hoses, refer to the
tightening torque table. Fig. 1-3 Parts to be disused
6) Apply Loctite #242 to the clamp mounting
bolts.
(2) Weld
1) Use weld symbol B welding rod (mild steel
50kg grade).
2) Seal the unwelded areas of the tapped block. Fig. 1-1 Modification of floor mat
51
5.2b REPLACEMENT OF RETURN FILTER OF
THE HYDRAULIC TANK
(BREAKER, NIBBLER & BREAKER) VALVE
When the standard machine is modified to nibbler
& Breaker machine, replace the return filter with
new one.
z Be sure to release the internal pressure

remaining in the hydraulic tank and hydraulic
oil circuit before inspection, maintenance and
repair.
Supplementary Explanation : Fig.1-4 Drain pressure for hydraulic tank

The internal pressure in the hydraulic tank can be
released by pushing the valve with the rubber cap
on the upper surface of the tank 5 or 6 times. CAPSCREW
WASHER
5.2b.1 REPLACING PROCEDURE
COVER
Remove the capscrew, on the hydraulic tank and
take out the spring, check valve and filter 8
element.
Replace them with return filters shown below SPRING
according to the procedure shown in table 1-4 and
Fig.1-5. Replace it by the reverse procedure of
disassembly. CHECK VALVE
Table 1-4 4
HYDRAULIC TANK ASSY

23-100 REPAIR KIT
4 O RING 1
PLATE
5 PACKING 1
5
7 FILTER ELEMENT 2
8 O RING 1
Fig.1-5
52
5.3 REMOTE CONTROL PIPING
(NIBBLER & BREAKER) (2) Parts to be disused
CONTROL
(1) Modification procedure Concerning the remote control piping, the 10
CONTROL VALVE
Assemble the additional parts listed in Table parts listed in table 3 and Fig. 3 are disused
BLOCK
2 to the remote control piping of the standard from the standard machine.
machine, as shown in Fig. 2. Table 3
A2 SUPPORT 1
A4 COVER 1
A8 SEMS BOLT 2
REMOTE CONTROL
PIPING Table 2 11
No. NAME QTY REMARK No. NAME QTY REMARK
9
1 PILOT VALVE 1 12 PIN 1

2 PRESSURE SENSOR 1 PF1/4 13 PEDAL 1
3 CONNECTOR 1 PF1/4 L=23 14 RUBBER 1
4 PLUG 1 PF1/4 15 LOCK ASSY 1
5 ELBOW 3 PF1/4 16 CAPSCREW 2 18
6 ELBOW 1 PF1/4 17 CAPSCREW 2
19
7 WASHER 3 18 CAPSCREW 2
20 14
8 HOSE 1 PF1/4 L=300 19 LOCK WASHER 2 12
9 HOSE 1 PF1/4 L=350 20 WASHER 4 8
7
10 HOSE 1 PF1/4 L=4100 21 NUT 1 21
16
11 HOSE 1 PF1/4 L=2650 13
7 17 CONTROL
4
20 BLOCK
5.4 CONTROL BLOCK PIPING 12 15
3 8
(NIBBLER & BREAKER) Establishied article
Re-use 2 1
(1) Modification procedure
Assemble the additional parts listed in Table 13
4 9
15
4 to the control block piping of the standard 5
machine, as shown in Fig. 4. 11 6
Table 4
CONTROL BLOCK PIPING 9
5 10
No. NAME QTY REMARK
4 ELBOW 1 PF1/4
5 10
11 CONNECTOR 1 PF3/8 A4
Fig. 4 Control block piping (Nibbler & Breaker)
12 ELBOW 1 PF1/4
PF3/8 - A8
13 ELBOW 1 C5 A2
PF1/4
C8 C2 Fig. 2 Remote control piping (Nibbler &
15 TEE 1 PF3/8
Breaker)
(2) Parts to be disused

Concerning the control block piping, the parts
listed in table 5 and Fig. 5 are disused from
the standard machine.
Table 5
No. NAME QTY REMARK
C2 CONNECTOR 1 PF1/4
C5 ELBOW 1 PF3/8
C8 PLUG 1 PF1/4 Fig. 5 Parts to be disused Fig. 3 Parts to be disused
53
5.5 MAIN REMOTE CONTROL PIPING
(NIBBLER & BREAKER) 12
(1) Modification Procedure
Assemble the additional parts listed in Table 6
to the main remote control piping of the
standard machine, as shown in Fig. 6.
MACHINE
Table 6 FRONT
MAIN REMOTE
CONTROL PPING

2 CONNECTOR 1 PF1/4-PF3/8
12 ELBOW 1 PF1/4-PF3/8
CONTROL
VALVE
2 OPTION VALVE
Fig.6 Remote control piping (Nibbler & Breaker)
(2) Parts to be disused 2

Concerning the remote control piping, the
parts listed in Table 7 and Fig. 7 are disused
from the standard machine.
Table 7
2 PLUG 2
2
54
Fig. 7 Parts to be disused
5.6 UPPER HYDRAULIC PIPING (NIBBLER & BREAKER)
(1-1) Modification Procedure
Tightening torque
Fit the additional parts in table 8-1, according
Hydraulic hose
to Fig. 8-1. (ORS Type)
Spanner Tightening torque
Thread size (mm) kgfym (lbfyft)
CHANGING OVER PROCEDURE OF THE SELECTOR VALVE
13/16-12UN 36 18 (130)
Hydraulic hose
TO TANK TO TANK O ring type coupling (30flare)
Thread size Spanner Tightening torque Tightening torque
TO TO kgfym (lbfyft) kgfym (lbfyft)
ATTACHMENT ATTACHMENT
(PF) (mm)
3/4 36 16.5 (119.3)
TO CONTROL TO CONTROL
VALVE VALVE 1 41 14 (101)
STAMP
Capscrew
Tightening torque
Thread size kgfym (lbfyft) 3
USE NIBBLER USE BREAKER
M10 7.2 (52.1)
2
M12 12.3 (89.0)
UPPER HYDRAULIC PIPING Table 8-1
1 TUBE 1 14 CLAMP 1
2 TUBE 1 15 CAPSCREW 4 M1030
3 HOSE 1 13/16-12UN 16 CAPSCREW 5 M1230
4 HOSE 1 PF1 17 CAPSCREW 2 M1285 5
5 CONNECTOR 1 PF3/4 18 WASHER 4 8
22
6 CONNECTOR 1 13/16-12UN 19 WASHER 9
22
7 SELECTOR VALVE 1 20 NUT 2
8 ELBOW 1 13/16-12UN 21 O RING 2
9 O RING 3 1 22 O RING 2 21 2
10 HALF CLAMP 4 1 23 CAPSCREW 4 M1270
6 17
11 ELBOW 1 PF1 24 CAPSCREW 8
21 3 19
12 BRACKET 1 25 LOCK WASHER 12 14
13 SUPPORT 1 1
(2) Parts to be disused 2

50
Concerning upper hydraulic piping, the parts
listed in table 9 and in Fig. 9 are disused
from the standard machine. 4 23 20
Table 9 25 13
RETURN HYDRAULIC PIPING 10
9 7 9 1
50 PLUG 1 Fig. 9 Parts to be disused
24
25 9
(3) Parts to be disused ; only 10
parts listed in table 10 and in Fig. 10 are 12
16
disused from the standard machine. 19 4
18 3
Table 10
REMOTE CONTROL PIPING 1 15 25
24
No. NAME QTY REMARK
1 PLUG 2
Fig. 8-1 Upper hydraulic piping (Nibbler & Breaker)
1
55
5.7 MODIFICATION OF THE INSTRUMENT PANEL 5.8 INSTALL OF THE NAME PLATE
(NIBBLER & BREAKER) (NIBBLER & BREAKER) 22
(1) Modification procedure Fit the label shown in table 13 to the cab of the
Install the additional parts listed in Table 11 standard machine, according to Fig. 13 & 14.
to the instrument panel assy of the standard
machine, as shown in Fig. 11. On that Table 13
occasion, some parts become unnecessary.
INSTALL OF THE NAME PLATE
Table 11 No. NAME QTY REMARK
INSTRUMENT PANEL ASSY 20 LABEL 1

21 LABEL 1
No. NAME QTY REMARK
For single / conflux 22 LABEL 1
39 SWITCH 1 switching
20
21
Fig. 13 Right hand view of cab interior
21
20
39
Fig. 11 Modification of instrument panel
Fig. 14 The cover left & rear side view

of operator seat
Concerning instrument panel, the parts listed
in table 12 and in Fig. 12 are disused from
the standard machine.
Table 12
No. NAME QTY REMARK

22
13 CAP 1
Attachment operation by foot pedal.

Always check the foot pedal control pattern
13 before operation.
Fig. 12 Parts to be disused Always read operators manual before
operating machine.
PY20T01062P1
56
6. MODIFICATION PROCEDURE FOR BREAKER

6.1 MODIFICATION ITEM
The main items that are needed to modify the
standard machine into a breaker-mounted
machine are as follows :
Table 1
Modification items to
ITEM NAME be added and change
FRAME
6.2 Modification of the floor mat Floor mat
6.2a Modification of the control valve Same as N&B (5.2a)

HYDRAULIC
6.2b Modification of the hydraulic tank Same as N&B (5.2b)
6.3 Remote control piping ; P/V Add on 1 way valve
6.4 Remote control block Same as N&B (5.4)
6.5 Remote control piping ; C/V

B&A safety
6.6 Upper hydraulic piping

LABEL
6.7 Install of the name plate Label
Cautions to be exercised in modification 6.2 FLOOR MAT (NIBBLER)

(1) General precautions Make slits to face of the standard floor mat
1) Before starting the modification work, check according to Fig. 1 and cut out the hatching.
parts according to the additional parts list.
2) When disconnecting and reconnecting pipes,
matter to enter. CUT OUT
3) When the O ring type joint is removed,
off.
tightening torque table.
bolts.
(2) Weld
1) Use weld symbol B welding rod (mild steel
50kg grade).
2) Seal the unwelded areas of the tapped block. Fig. 1 Modification of floor mat
61
6.2a MODIFICATION OF THE CONTROL VALVE

(SAME AS N&B, SEE ITEM 5.2a)
6.2b MODIFICATION OF THE HYDRALUIC TANK

(SAME AS N&B, SEE ITEM 5.2b)
62
6.3 REMOTE CONTROL PIPING (BREAKER) Tightening torque
(1) Modification procedure 19
Capscrew
Assemble the additional parts listed in Table Thread Spanner Tightening torque 20
2 to the remote control piping of the standard size (mm) kgfym (lbfyft)
machine, as shown in Fig. 2,3. On that 7
M8 13 3.6 (26) 5
11
occasion, some of the existing parts must be 21
used and some of them become unnecessary. 6
Hydraulic hose
O ring type coupling (30flare) 4 8
17
(PF) (mm) kgfym (lbfyft) kgfym (lbfyft)
6 9
1/4 19 3.7 (26.8) 3.0 (21.7) 22 3
REMOTE CONTROL 18
Table 2 16
PIPING 10
1 HOSE 1 PF1/4 14 ELBOW 1 PF1/4
14 15 CONTROL
2 HOSE 1 PF1/4 15 PILOT VALVE 1 BLOCK
3 HOSE 1 PF1/4 16 CUSHION RUBBER 1
12
4 NUT 1 17 CAPSCREW 2
PIN 13 3
5 1 18 LOCK ASSY 1 R.H
6 WASHER 3 19 PEDAL 1
7 CAPSCREW 2 20 COVER 1
2
8 WASHER 2 21 WASHER 1
9 BRACKET 1 22 PLATE 2
2 23 25 24 1
10 PIN 1 23 PRESSURE SENSOR 1 PF1/4
11 PIN 1 24 CONNECTOR 1 PF1/4
PF1/4
12 CONNECTOR 1 With filter 25 TEE 1 PF1/4
13 ELBOW 1 PF1/4
Fig. 3 Remote control piping (Breaker)

Concerning the remote control piping, the 4
parts listed in table 3 and in Fig.4 are
8
disused from the standard machine. 2
Table 3
CONTROL
No. NAME QTY REMARK
BLOCK
2 SUPPORT 1
4 COVER 1
8 SEMS BOLT 2
3 1
2
63
Fig. 2 Remote control piping (Breaker)
6.4 REMOTE CONTROL BLOCK (3) Parts to be disused
(SAME AS N&B, SEE ITEM 5.4) Concerning the remote control piping, the 2
parts listed in table 6 and in Fig. 7 are
17
6.5 MAIN REMOTE CONTROL PIPING ; disused from the standard machine.
C/V (BREAKER) 12
(1) Modification Procedure Table 6
28
Install the additional parts listed in Table 4
No. NAME QTY REMARK
to the remote control piping as shown in Fig.
5. MACHINE FRONT 2 PLUG 2
TableCONTROL
MAIN REMOTE 4 PIPING
No. NAME QTY REMARK

2 CONNECTOR 1 1 PF1/4-PF3/8
12 ELBOW 1 1 PF1/4-PF3/8
17 TEE 1 1 PF1/4
28 HOSE 1 1 PF1/4
CONTROL VALVE
OPTION VALVE
2
Fig. 5 Main remote control piping (Breaker) 2


parts listed in table 5 and in Fig. 6 are
disused.
C11
No. NAME Table 5

QTY REMARK
11 ELBOW 1 PF1/4
CONTROL VALVE

64
6.6 UPPER HYDRAULIC PIPING (BREAKER)
(1) Modification Procedure
Tightening torque
Fit the additional parts in table 7, according
Hydraulic hose
to Fig. 8. (ORS Type)
Spanner Tightening torque
Thread size (mm) kgfym (lbfyft)
4
13/16-12UN 36 18 (130) CONTROL VALVE
Hydraulic hose
O ring type coupling (30flare)
(PF) (mm) kgfym (lbfyft) kgfym (lbfyft)
3/4 36 16.5 (119.3)
1 41 14 (101)
Capscrew
Tightening torque
Thread size kgfym (lbfyft)
2
M10 7.2 (52.1)
M12 12.3 (89.0)
1
UPPER HYDRAULIC PIPING Table 7
No. NAME QTY REMARK No. NAME QTY REMARK 22
1 TUBE 1 15 CAPSCREW 4 M1030 22
2 TUBE 1 16 CAPSCREW 5 M1230
4 HOSE 1 PF1 17 CAPSCREW 2 M1285 CONTROL
2
VALVE
5 PLUG 1 PF3/4 18 WASHER 4
17
6 CONNECTOR 1 13/16-12UN 19 WASHER 9
19
7 BLOCK 1 20 NUT 2 5 14
9 O RING 2 1 21 O RING 1 1
10 HALF CLAMP 2 1 22 O RING 2
11 ELBOW 1 PF1 23 CAPSCREW 4 M1270
12 BRACKET 1 24 CAPSCREW 4 16
21
13 SUPPORT 1 25 LOCK WASHER 8 19
14 CLAMP 1
6 2 13
50 19 20
Concerning upper hydraulic piping, the parts 4
23
listed in table 8 and in Fig. 9 are disused. 25
Table 8 10 11
9 7 9
RETURN HYDRAULIC PIPING 1
No. NAME QTY REMARK

24
50 PLUG 1 25

12 4
parts listed in table 9 and in Fig. 10 are 16
disused from the standard machine. 19
Table 9 18
1
15
REMOTE CONTROL PIPING
No. NAME QTY REMARK

Fig. 8 Upper hydraulic piping (Breaker)
1 PLUG 2 1
65
6.7 INSTALL OF THE NAME PLATE
(BREAKER) 22
Fit the label shown in table 10 to the cab of the
standard machine, according to Fig. 11 & 12.
Table 10
INSTALL OF THE NAME PLATE
No. NAME QTY REMARK
20 LABEL 1
21 LABEL 1
22 LABEL 1
20
21
Fig. 11 Right hand view of cab interior
21
20
Fig. 12 The cover left & rear side view

of operator seat
22
Attachment operation by foot pedal.

Always check the foot pedal control pattern
before operation.
Always read operators manual before
operating machine.
66
7. MODIFICATION PROCEDURE FOR ATTACHMENT

7.1 MODIFICATION ITEM FOR NIBBLER & BREAKER, BREAKER ATTACHMENT
The main item that are needed to modify the standard boom and standard arm into a breaker and a
nibbler & breaker-mounted machine are as follows:
Table 1
Modification
ITEM Types of attachment Spec. item
7.2 Modification of the 5.05M (167) boom N&B B Tapped block

BOOM
7.3 5.05M (167) boom hydraulic piping N&B B Tube

7.4 Modification of the 2.6M (86) STD arm N&B Tapped block
7.5 Modification of the 3.0M (910) long arm B Tapped block
2.6M (86 ) STD arm hydraulic piping N&B Tube
7.6
3.0M (910) long arm hydraulic piping N&B B Tube
ARM
N&B
7.7 Connector assy Connector
B
7.8 Reinforcing of the idler link N&B B Plate
Cautions to be exercised in modification

(1) General precautions (2) Weld
1) Before starting the modification work, check 1) Use weld symbol B welding rod (mild steel
parts according to the additional parts list. 50kg grade).
2) When disconnecting and reconnecting pipes, 2) Seal the unwelded areas of the tapped block.
matter to enter.
3) When the O ring type joint is removed,
off.
tightening torque table.
bolts.
71
7.2 MODIFICATION OF THE 5.05M (16ft-7in) BOOM

(NIBBLER & BREAKER, BREAKER) Table 2
Weld the additional parts listed in Table 2 to 5.05M (167 )
the boom of the standard specification, BOOM ASSY
according to Fig. 1. No. NAME QTY REMARK
1 BOOM ASSY (1) STD

2 TAPPED BLOCK 2
3 TAPPED BLOCK 3
4 TAPPED BLOCK 1
5 TAPPED BLOCK 2
6 TAPPED BLOCK 1
2 2
SECTION AA
1
VIEW
SECTION DD
3 4 3
5
3 5
SECTION BB SECTION CC SECTION EE
Fig. 1 Modification of the 5.05M (16ft-7in) boom (Nibbler & Breaker, Breaker)
72
7.3 HYDRAULIC PIPING FOR 5.05M (16ft-7in) BOOM
(BREAKER, NIBBLER & BREAKER)
Install the additional parts listed in table 3 to the
5.05m (16ft-7in) boom modified according to Fig. 2.
9,13,15 9,13,15
HYDRAULIC PIPING FOR BOOM Table 3 11,12,15
No. NAME QTY REMARKS No. NAME QTY REMARKS
1 TUBE 1 11 CLAMP 2
13,15,20
2 TUBE 1 12 CAPSCREW 4
3 TUBE 1 13 CAPSCREW 13 SECTION AA 7
4 TUBE 1 14 CAPSCREW 16
8
5 PLUG 2 15 LOCK WASHER 17
9,13,15 9,13,15
6 O RING 1 16 LOCK WASHER 16
7 O RING 1 17 HALF CLAMP 8 SECTION DD
8 O RING 4 18 HOSE 2
9 CLAMP 5 19 CLIP 1
10 CLAMP 1 20 CLAMP 1 SECTION BB
3 8,14,16,17
z Tightening torque for M-threads
Thread size Tightening torque
M12 11.7kgfym (84.6 lbfyft)
M12 (Hexagon socket head) 8.5kgfym (61.5 lbfyft)
z Tightening torque for PF, PT-threads 1
PF,PT1 26kgfym (188 lbfyft) 8,14,16,17 4 8,14,16,17
z Tightening torque for ORS-joint nut
13/16-12UN 18kgfym (130 lbfyft)
17/16-12UN 21kgfym (152 lbfyft) 2
5
18
NOTE :
z Remove item 5 plug as necessary,
and install an accumulator
recommended by the breaker maker.
5
11,12,15
19
9,13,15
9,13,15
SECTION EE
SECTION CC
Fig.2 Hydraulic piping for 5.05M (16ft-7in) boom (Breaker, Nibbler & Breaker)
73
7.4 MODIFICATION OF THE 2.6M (8ft-6in) 7.5 MODIFICATION OF THE 3.0M (9ft-10in)
STANDARD ARM LONG ARM (BREAKER)
(NIBBLER & BREAKER, BREAKER) Finish by grinder MODIFICATION OF THE 3.0M (9ft-10in) ARM
MODIFICATION OF THE 2.6M (8ft-6in) ARM Weld the additional parts listed in Table 5 to the arm of
Weld the additional parts listed in Table 4 to the arm of the long specification, acording to Fig. 4.
the long specification, acording to Fig. 3. DETAIL E Table 5
Table 4 3.0M (9_10_) ARM ASSY
2.6M (8_6_) ARM ASSY No. NAME QTY REMARK
No. NAME QTY REMARK (1) ARM (1) STD
(1) ARM (1) STD 2 TAPPED BLOCK 2
2 TAPPED BLOCK 2 3 TAPPED BLOCK 2 Finish by grinder
SECTION_D_D
3 TAPPED BLOCK 2 4 TAPPED BLOCK 2
4 TAPPED BLOCK 2 5 PLATE 1
5 PLATE 1 6 PLATE 1
6 PLATE 1 7 PLATE 1
DETAIL E
7 PLATE 1 SECTION_D_D 4
5 2 3
5 2 3 4
6 2 3
6 2 3 4
4
(1) (1)
7
7
7
7
6 5
6 5
2 2
2 2
3 3 4 4 3 3 4 4
SECTION_A_A SECTION_B_B SECTION_C_C

SECTION_A_A SECTION_B_B SECTION_C_C
Fig. 3_Modification of the 2.6M (8ft-6in) standard arm (Nibbler & Breaker, Breaker)
Fig. 4_Modification of the 3.0M (9ft-10in) Long arm (Breaker)
7-4
7.6 ARM HYDRAULIC PIPING
(1) 2.6M (8ft-6in) Standard arm hydraulic piping
10 11 13,19
(Nibbler & Breaker, Breaker)
(2) 3.0M (9ft-10in) Long arm hydraulic piping
(breaker)
This hydraulic piping applies to both the nibbler
& breaker machine and the breaker machine.
Install the additional parts listed in Table 6 to the DETAIL OF CLAMP
arm body as shown in Fig. 5.
6 1 7,9,15,17 3
2.6M (8ft-6in)
ARM HYDRAULIC PIPING Table 6
3.0M (9ft-10in)
ARM HYDRAULIC PIPING
No. NAME QTY REMARKS No. NAME QTY REMARKS

1 TUBE 1 1 11 BUSHING 4 4
2 TUBE 1 1 12 CAPSCREW 4 4
3 HOSE 2 13 CAPSCREW 8 8
HOSE 2 14 CAPSCREW 8 8 2
6 7, 9,15,17 3
4 STOP VALVE 2 2 15 CAPSCREW 8 8
5 CONNECTOR 2 2 16 LOCK WASHER 4 4
6 O RING 2 2 17 LOCK WASHER 8 8
7 O RING 2 2 18 WASHER 4 4
8 BRACKET 2 2 19 WASHER 8 8
9 HALF CLAMP 4 4 20 WASHER 8 8
10 CLAMP 8 8
4
10,11 13,19 13,19 10,11
14,20
4 12,16,18
8
14,20
SECTION BB
12,16,1 8
SECTION AA
Fig. 5 2.6M (8ft-6in) STD arm, 3.0M (9ft-10in) long arm hydraulic piping
75
7.7 CONNECTOR ASSY 2 M451.5 1 3 7.8 RCING THE IDLER LINK
(1) For nibbler & breaker (BREAKER, NIBBLER & BREAKER)
PF1-1/4
When using the machine with a nibbler & When using the machine as a nibbler & breaker,
breaker, attach the below parts to the tip of breaker machine, the right and left idler links
the stop valve. need reinforcement. Reinforce them according to
Table 7 Table 10 and Fig. 9.
CONNECTOR
ASSY
No. NAME QTY REMARK
Table 10
1 CONNECTOR 1
IDLER LINK (R.H)
2 PLUG 1
3 O RING 1 1B P38 IDLER LINK (L.H) 1 0
No. NAME QTY REMARK IDLER LINK (L.H)
0 IDLER LINK (1) (LH) STD
Fig. 6 Connector assy (Nibbler & Breaker) 0 IDLER LINK (1) (RH) STD
1-5/16-UNF 1 PLATE 2 LH, RH

(2) For breaker
2 3 1
Select application from the breaker maker.
Table 8
CONNECTOR ASSY
FOR NPK
No. NAME QTY REMARK
1 CONNECTOR 1
NPK PF1-1 1/4
2 PLUG 1
3 O RING 1 1B P38
1 0
IDLER LINK (R.H)
Fig. 9 Reinforcing the idler link

Fig. 7 Connector assy (NPK)
2 PF1 1 3 PF1-1/4
Table 9
CONNECTOR ASSY
FOR TOKU, KRUPP
No. NAME QTY REMARK
1 CONNECTOR 1
2 PLUG 1
3 O RING 1 1B P38
TOKU, KRUPP
Fig. 8 Connector assy (TOKU, KRUPP)

76
8. REMINDERS ON THE USE OF NIBBLER & BREAKERS

8.1 CHANGING OVER THE SELECTOR VALVE N&B
A nibbler & breaker-attached machine is LOW PRESSUSE SIDE
(RETURN)
equipped with a selector valve in both the
operation circuit and the main circuit. When N&B
running the machine after completion of HIGH PRESSUSE
SIDE
modification, always set the selector valves
according to a nibbler or a breaker used.
NOTE : Incorrect setting of the selector valves not

only deteriorates operating efficiency and
decreases speed but also causes failure of
the machine. Therefore, confirm completion
of the modification and give proper advice
to the user.
z Tools used
For main circuit changeover
: 5mm
: 24mm
CHANGING OVER PROCEDURE OF THE SELECTOR VALVE
Changing over procedure of the selector valve TO TANK TO TANK
1) Remove socket bolt with allen wrench. TO TO

2) Turn the nibbler or the breaker to its ATTACHMENT ATTACHMENT
operating position, using a spanner. TO CONTROL

VALVE
TO CONTROL
VALVE
3) Stop it at a specified position and tighten the
setscrew. STAMP
ALLEN WRENCH (HEX 5mm)

USE NIBBLER USE BREAKER
SPANNER (HEX 24mm) Fig. 2 Changing over procedure of the selector

valve
Fig. 1 Changing over procedure of the selector

valve
81
8.2 FLUSHING METHOD

After completion of piping work, connect the high
pressure side and the low pressure side, as shown
in Fig. 3, open the stop valves on both sides and (ON) (OFF)
depress the operating pedal to perform flushing.
CONNECTOR(PF3/4)
z Before beginning flushing, run the
engine at low speed, depress the STOP VALVE
HOSE
breaker operating pedal and then
run the engine at high speed.
z Perform flushing operation for at
least 40 minutes, and during the
operation, make sure of no oil
leakage from each of the connections
of the newly attached breaker circuit An example of flushing time (23min.) in a single
and the nibbler & breaker circuits. process
8.3 REPLACING HYDRAULIC OIL AND RETURN

FILTER
Contamination and deterioration of hydraulic oil 5 min 1 min 5 min 1 min
may develop malfunctioning of the control valve, Flushing Stop Flushing Stop
early wear and seizure of the hydraulic pumps
and malfunctioning of the entire hydraulic 5 min 1 min 5 min
circuits : always replace hydraulic oil at regular Flushing Stop Flushing
intervals, based on table 1.
Fig. 3 Flushing method
Table 1
Inspection / Replacement intervals
Item
maintenance points First replacement 2nd replacement Regular replacement
Hydraulic oil Hydraulic oil tank Every 600h
Return filter Hydraulic oil tank 50h 250h Every 250h
8.4 OPERATING PROCEDURE

This machine is provided with breaker single
circuit and nibbler and breaker conflux (bi-flow)
circuit. To use breaker or nibbler, select circuit
appropriate to the specification through single /
conflux select switch on the left console.
(1) Switch operating

(Nibbler & breaker specification)
Specification Switch position Circuit
Breaker ( ) OFF Single flow
Nibbler ( ) ON Conflux flow
Never turn switch on (conflux) to operate

breaker. It may cause trouble of machine. NIBBLER & BREAKER SPECIFICATION
Fig.4
82
(2) Throttle potentiometer

When operating the machine with a
hydraulic breaker, do the following
operations :
Use the throttle potentiometer on the high
idle side. (Refer to Fig. 5.)
(3) Control pedal Fig. 5 Throttle potentiometer position

1) Hydraulic breaker single circuit
Release pedal lock on the right front side of
drivers seat to operate pedal.
Precaution for pedal operation

The operation varies in the specifications, so
before operating, read the Operator Manual
carefully.
Foot pedal
Operating condition.
depressing section
Depress toe section Breaker starts operation.
Pedal in neutral position. Breaker stops operation.
2) Nibbler and breaker conflux (bi-flow) circuit.

Release pedal lock on the right front side of
drivers seat to operate pedal.
l Hydraulic breaker PUSH LOCK ROD

FORWARD
Foot pedal TO RELEASE
depressing section Operating condition.
Depress heel section. Breaker starts operation.
Pedal in neutral position. Breaker stops operation. PULL LOCK ROD
BACKWARD
TO LOCK PEDAL
l Nibbler
DEPRESS PEDAL
Foot pedal WITH TOE TO
depressing section Operating condition.
ACTIVATE
Depress toe section Nibbler close
Depress heel section Nibbler open
8 3
84
9. PRECAUTIONS TO BE EXERCISED ON BREAKERS

OF DIFFERENT MANUFACTURERS
There are some differences between Low pressure : Measure the inlet pressure of the
manufac-turers as to the piping to breakers and side line filter on the breaker side by
the handling of breakers. For this reason, consult actuating the breaker at full
with the manufacturer when mounting a breaker engine revolution in the H mode,
in the field. The following is a summary of how and in case the maximum
2
breakers should be handled that is extracted from pressure exceeds 55kgf/cm (780
manu-facturers catalog use and operation psi), install a low pressure
manuals. accumulator.
2
NOTE : This is a general outline of how breakers Max. < 55kgf/cm (780 psi)
should be used and may differ with Regarding the capacity and the
excavator models. Always contact the charge pressure of accumulators,
breaker manufacturer before field contact the breaker manufacturer
mounting. before installation.
(1) Placing high and low pressure accumulators (2) Installation of a relief valve
NPK They must be placed basically NPK Installation is not necessary.
(depending upon models). (Contact the breaker manufacturer
as it is necessary depending upon
T O K U
Check the oscillation of the models.)
K R U P P pulsation of the breaker
pressure and if pulsation is Installation is necessary.
O K A D A T O K U
large, always install A relief valve is specified by
FURUKAWA accumu-lators. K R U P P each breaker manufacturer.
Since the method of pressure
Standard of judgment on the installation of O K A D A
setting of the relief valve
accumulators T A I S E I differs with breaker
Measure the pulse oscillation by manufac-turers, install a relief
pressure on the high pressure FURUKAWA
High valve according to the
side of the breaker at the
pressure : inspection port for the pumps manufac-turers instructions.
delivery pressure by actuating the NOTE : Only the B series TOKU machine requires
breaker at the full revolution of a relief valve to be installed.
the engine in mode H and set the
maximum pressure difference to N&B
within 20% of the excavators LOW PRESSUSE SIDE
(RETURN)
system pressure 350kgf/cm2
(4980psi). N&B
In case it exceeds 20%, install a HIGH PRESSUSE
high pressure accumulator. SIDE
NOTE : The pulse oscillation is 350 20%=
2
70kgf/cm (1000psi). Therefore, if it is more
than this level, an accumulator must be
installed.
Install accumulator referring to the
result of verification test.
max
ACCUMULATOR
min
Fig. 1 Accumulator mounting
9 1
6 (4) Changing over the breaker to high and low

4 speeds
N P K
2 These breakers are not so
T O K U
(PF1) 3 constructed as to be switched
TO TANK
T A I S E I over to high and low speed.
FURUKAWA
RETURN SIDE
5 1
KRUPP Breakers larger than MKB1200 are
constructed with a switching function.
It can be operated from inside the cab
by the installation of a solenoid valve.
TO BREAKER OIL SUPPLY SIDE For piping work, consult with the
breaker manufacturer.
1. HIGH PRESSURE HOSE 4. PLUG
2. NIPPLE 5. ELBOW NOTE : Piping work is not required in some cases if
3. ADAPTER 6. RELIEF VALVE a high-low changeover function is not
Fig. 2 necessary at users request.
On that occasion, it is necessary to fix the
(3) Restriction of engine speed changeover valve contained in the breaker
NPK Full engine speed may be used. to the low speed side beforehand. Consult
with the breaker manufacturer in that case.
T O K U There are restriction on the It is prohibited to use the high-low speed
K R U P P engine speed. Since a changeover valve without laying high-low
specified speed differs with speed piping and without fixing the high-low
O K A D A
breakers, follow the breaker speed changeover valve.
T A I S E I manufacturers instructions.
FURUKAWA
HIGH-LOW SPEED
CHANGEOVER VALVE
NOTE : In the case of a breaker for which the
engine revolution is limited, the breaker
does not increase impact power and cycles
even at full engine revolution.
Since extra hydraulic oil returns to the RELIEF VALVE HYDRAULIC
BREAKER
hydraulic oil via the relief valve, it causes
the hydraulic oil temperature to rise and the TO CONTROL VALVE
fuel consumption to increase. Plaster the
label (furnished by the breaker maker)
indicating the revolution (Check the engine TO TANK
revolution.), to the throttle potentiometer
position. Always observe the indicated
CHECK VALVE
revolution.
Fig. 3
92
10. REFERENCE
Typical combinations are quoted from breaker When fitting a breaker, read through reminders
manufacturers catalog use as below, but on the use of breakers and cautions instructed by
concerning applicable breaker models, decide it breaker manufacturers.
after consultation with the breaker manufacturer.
Table 1
Working press Oil volume Total weight Total length Bucket
Applicable
Manufacturer kgf/cm2 used /min kg mm capacity m3
breaker
(psi) (gal/min) (lbs) (in) (cuyd)
120140 160200 1,450 2,156
H-10XB
(1,7101,990) (42.252.8) (3,200) (84.9 )
N P K
130150 3560 410 1,644
H-4XE
(1,8502,130) (9.2415.8) (900) (64.7 )
100140 110140 1,000 0.550.70
TNB-10B
(1,4201,990) (29.037.0) (2,210) (0.720.92)
120140 140160 1,400 0.700.90
TNB-14B
(1,7101,990) (37.042.2) (3,100) (0.921.18)
100160 4580 391 1,476 0.250.35
T O K U TNB-6E
(1,4202,280) (11.921.1) (860) (58.1 ) (0.330.46)
120170 100140 997 1,850 0.550.70
TNB-10E
(1,7102,420) (26.437.0) (2,200) (72.8 ) (0.720.92)
130170 130170 1,550 2,190 0.700.90
TNB-14E
(1,8502,420) (34.344.9) (3,400) (86.2 ) (0.921.18)
150160 80110 1,1001,250 2,278 0.500.90
MKB1100
(2,1302,280) (21.129.0) (2,4302,760) (89.7 ) (0.651.18)
K R U P P
150180 90130 1,1201,200 0.551.00
MKB1200
(2,1302,560) (23.834.3) (2,4702,650) (0.721.31)
150180 110 1,450 2,240 0.70
UB 11
(2,1302,560) (29.0 ) (3,200) (88.2) (0.92 )
O K A DA
130160 110155 1,070 2,040 0.550.70
OUB 310
(1,8502,280) (29.040.9) (2,360) (80.3 ) (0.720.92)
150170 100120 1,330 1,596 0.600.90
T A I S ETF-150
(2,1302,420) (26.431.7) (2,930) (62.8 ) (0.781.18)
160180 125150 1,400 2,119
FURUKAWA HB20G
(2,2802,560) (33.039.6) (3,100) (83.4 )
[ ] Excludes chisels.
General precautions to be exercised on the installation of breakers by different manufacturers
Table 2
Installation of Installation of Restriction of
Manufacturer engine High-low speed changeover
accumulators a relief valve speed
NPK changeover type not available.
TOKU
changeover type not available.
Series B
TOKU
changeover type not available.
Series E
changeover type available for large
KRUPP
machines.
changeover type available on
OKADA
special request.
FURUKAWA changeover type not available.
TAISEI changeover type not available.

Adaptation test completed. One that must be adjusted at installation.
One that must be installed. Capacity 1 liter, pressure is 70kgf/cm2 (1,000psi)
One that does not need to be installed.
101

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Printed by Studio ti - 20105

ADDITIONAL REFERENCE MANUALS

In addition to this Workshop Manual, refer also to

- Operation and maintenance instruction

DESCRIPTION OF THE COMPLETE

The complete Workshop Manual for the excavator

VOLUME MACHINE TYPE PRINT No.

Most accidents, whether they occur in industry, on the farm, at home or on

COPYRIGHT BY NEW HOLLAND KOBELCO CONSTRUCTION

All rights reserved. Reproduction of text and illustrations in whole or in part, is

Section 21 - Mechatro control system

Section 31 - Disassembling and assembling

Section 41 - Troubleshooting (mechatro control)

Section 63 - Mounting the breaker and nibbler & breaker

SAFETY PRECAUTIONS 5. Do not work on any machine that is supported

The serviceman or mechanic may be unfamiliar with

7. Lower the bucket, dozer, or other attachments to

16. Do not damage wiring during removal operations.

17. Be sure all protective devices including guards

18. The maintenance and repair work while holding

19. Loose or damaged fuel, lubricant and hydraulic

20. Tighten connections to the correct torque. Make

1. GENERAL PRECAUTIONS FOR MAKING REPAIRS ................................................ 1

2. INTERNATIONAL UNIT CONVERSION SYSTEM...................................................... 4

1. GENERAL PRECAUTIONS FOR MAKING REPAIRS

distortion and bend.

2) Flexible hose (F hose)

hose are the same, the parts differ

2. INTERNATIONAL UNIT CONVERSION SYSTEM

1 Units that are allowed to use

1. NAME OF COMPONENTS ....................................................................................... 1

2. GENERAL DIMENSION ............................................................................................ 2

3. WEIGHT OF COMPONENTS ................................................................................... 3

4. TRANSPORTATION DIMENSION AND WEIGHT ..................................................... 4

5. SPECIFICATIONS AND PERFORMANCE ................................................................ 6

6. TYPE OF CRAWLER ............................................................................................... 7

7. TYPE OF BUCKET ................................................................................................... 8

8. COMBINATIONS OF ATTACHMENT ........................................................................ 9

9. ENGINE SPECIFICATION ...................................................................................... 10

2.1 5.05m (167) Boom+2.60m (86) Arm+0.75m3 (0.98cu yd) Bucket

NOTE : Numerical values marked * indicate the dry weight.

4. TRANSPORTATION DIMENSION AND WEIGHT

       

    ! "# ! "!

OVERALL DIMENSIONS OF BOOM

 ! "#   

OVERALL DIMENSIONS OF ARM AND BUCKET

   !  

OVERALL DIMENSIONS OF ARM

 ! "#   

OVERALL DIMENSIONS OF BUCKET

5. SPECIFICATIONS AND PERFORMANCE

SPEED AND CLIMBING CAPABILITY

Swing speed 11 rpm

Travel speed (1-speed/2-speed) km/h 3.5 / 5.0 (2.2 / 3.1)

Gradeability %(degree) 70 (35)

Type Water-cooled, 4-cycle direct injection type engine

Number of cylinders - Bore X Stroke 4 - 105mm X 125mm (4.13in X 4.92in)

Total displacement 4,329cc (264cuin)

Rated output / Rotation speed 91.9kW (125PS) / 2,200rpm

Maximum torque / Rotation speed 42.5kgfm (308lbfft) / 1,800rpm

Starter 24V/ 4.5kW

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! "#

!

! "#

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

!"" # '%"" ()* ",#! !,-

,

+ * , 4 '

% 3# ' 4('(

567 8'95%:)' ;'756

< 567 8'95%:)' )* &657$& '%6&$:)'*

Table 2-1

Table 2-4 4 5 $$

- & . % ' ( 1 2