HYDRAULIC EXCAVATOR

MAINTENANCE SPECIFICATIONS
SHOP SK330-8
MANUAL model SK350LC-8

INDEX
1 SPECIFICATIONS SECTION

SYSTEM
2 MAINTENANCE SECTION
3 SYSTEM SECTION
4 DISASSEMBLY SECTION

DISASSEMBLING
5 TROUBLESHOOTING
6 ENGINE SECTION
7 PROCEDURE E / G TROUBLESHOOTING
OF INSTALLING
OPTIONS SECTION OPT.

Book Code No.S5LC0011E02

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

2) WARNING- Indicates a potentially hazardous

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

0-2
SAFETY PRECAUTIONS
The proper and safe lubrication and maintenance
for this machine, recommended by Manufacturer,
are outlined in the OPERATOR’S MANUAL for the
machine.
Improper performance of lubrication or mainte-
nance procedures are dangerous and could result
in injury or death. Read and understand the MAN-
UAL before performing any lubrication or mainte-
nance.
The serviceman or mechanic may be unfamiliar with
many of the systems on this machine. This makes it
important to use caution when performing service work.
A knowledge of the system and or components is im-
portant before the removal or disassembly of any com-
ponent.
Because of the size of some of the machine compo-
nents, the serviceman or mechanic should check the
weights noted in this manual. Use proper lifting proce-
dures when removing any components. Weight of com-
ponents table is shown in the section ;
SPECIFICATIONS.
The following is a list of basic precautions that must al-
ways be observed.
(1) Read and understand all Warning plates and decal
on the machine before Operating, Maintaining or
Repairing this machine.
(2) Always wear protective glasses and protective
shoes when working around machines. In particu-
lar, wear protective glasses when using hammers,
punches or drifts on any part of the machine or at-
tachments. Use welders gloves, hood/goggles,
apron and the protective clothing appropriate to the
welding job being performed. Do not wear loose fit-
ting or torn clothing. Remove all rings from fingers,
loose jewelry, confine long hair and loose clothing
before working on this machinery.
(3) Disconnect the battery and hang a "Do Not Oper-
ate" tag in the Operators Compartment. Remove ig-
nition keys.
(4) If possible, make all repairs with the machine
parked on a firm level surface. Block the machine
so it does not roll while working on or under the ma-
chine. Hang a "Do Not Operate" tag in the Opera-
tors Compartment.
(5) Do not work on any machine that is supported only
by lift, jacks or a hoist. Always use blocks or jack
0-3
stands, capable of supporting the machine, before
performing any disassembly.
Do not operate this machine unless you have
read and understand the instructions in the OP-
ERATOR’S MANUAL. Improper machine opera-
tion is dangerous and could result in injury or
death.
(6) Relieve all pressure in air, oil or water systems be-
fore any lines, fittings or related items are discon-
nected or removed. Always make sure all raised
components are blocked correctly and be alert for
possible pressure when disconnecting any device
from a system that utilizes pressure.
(7) Lower the bucket, dozer, or other attachments to
the ground before performing any work on the ma-
chine. If this cannot be done, make sure the bucket,
dozer, ripper or other attachment is blocked correct-
ly to prevent it from dropping unexpectedly.
(8) Use steps and grab handles when mounting or dis-
mounting a machine. Clean any mud or debris from
steps, walkways or work platforms before using.
Always face to the machine when using steps, lad-
ders and walkways. When it is not possible to use
the designed access system, provide ladders, scaf-
folds, or work platforms to perform safe repair oper-
ations.
(9) To avoid back injury, use a hoist when lifting com-
ponents which weigh 20kg (45lbs) or more. Make
sure all chains, hooks, slings, etc., are in good con-
dition and are the correct capacity. Be sure hooks
are positioned correctly. Lifting eyes are not to be
side loaded during a lifting operation.
(10)To avoid burns, be alert for hot parts on machines
which have just been stopped and hot fluids in
lines, tubes and compartments.
(11)Be careful when removing cover plates. Gradually
back off the last two capscrews or nuts located at
opposite ends of the cover or device and carefully
pry cover loose to relieve any spring or other pres-
sure, before removing the last two capscrews or
nuts completely.
(12)Be careful when removing filler caps, breathers and
plugs on the machine. Hold a rag over the cap or
plug to prevent being sprayed or splashed by liq-
uids under pressure. The danger is even greater if
the machine has just been stopped because fluids
can be hot.
(13)Always use the proper tools that are in good condi- (21)Do not operate a machine if any rotating part is
tion and that are suited for the job at hand. Be sure damaged or contacts any other part during opera-
you understand how to use them before performing tion. Any high speed rotating component that has
any service work. been damaged or altered should be checked for
(14)Reinstall all fasteners with the same part number. balance before reusing.
Do not use a lesser quality fastener if replacements (22)Be careful when servicing or separating the tracks
are necessary. (crawlers). Chips can fly when removing or install-
(15)Repairs which require welding should be per- ing a track (crawlers) pin. Wear safety glasses and
formed only with the benefit of the appropriate ref- long sleeve protective clothing. Tracks (crawlers)
erence information and by personnel adequately can unroll very quickly when separated. Keep away
trained and knowledgeable in welding procedures. from front and rear of machine. The machine can
Determine type of metal being welded and select move unexpectedly when both tracks (crawlers)
correct welding procedure and electrodes, rods or are disengaged from the sprockets. Block the ma-
wire to provide a weld metal strength equivalent at chine to prevent it from moving.
least to that of the parent metal. Make sure to dis-
connect battery before any welding procedures are
attempted.
(16)Do not damage wiring during removal operations.
Reinstall the wiring so it is not damaged nor will be
damaged in operation of the machine by contacting
sharp corners, or by rubbing against some object or
hot surface. Do not connect wiring to a line contain-
ing fluid.
(17)Be sure all protective devices including guards and
shields are properly installed and functioning cor-
rectly before starting a repair. If a guard or shield
must be removed to perform the repair work, use
extra caution and replace the guard or shield after
repair is completed.
(18)The maintenance and repair work while holding the
bucket raised is dangerous due to the possibility of
a falling attachment. Don’t fail to lower the attach-
ment and place the bucket to the ground before
starting the work.
(19)Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not bend
or strike high pressure lines or install ones which
have been bent or damaged. Inspect lines, tubes
and hoses carefully. Do not check for leaks with
your hands. Very small (pinhole) leaks can result in
a high velocity oil stream that will be invisible close
to the hose. This oil can penetrate the skin and
cause personal injury. Use card-board or paper to
locate pinhole leaks.
(20)Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are in-
stalled correctly to avoid excessive heat, vibration
or rubbing against other parts during operation.
Shields that protect against oil spray onto hot ex-
haust components in event of a line, tube or seal
failure must be installed correctly.

0-4
 INDEX SK330-8/SK350LC-8
Book Code No. Index
Title
Distribution Year–Month No.

MAINTENANCE SPECIFICATIONS
S5YN0118E01
2006-7
OUTLINE 1
S5LC0211E01
2006-7
SPECIFICATIONS 2
S5LC0311E02
ATTACHMENT DIMENSIONS 3
2007-2
S5LC1111E01
TOOLS 11
2006-7
S5LC1211E01 STANDARD MAINTENANCE
2006-7
12
TIME SCHEDULE
S5LC1311E02 MAINTENANCE STANDARDS
2007-2
13
AND TEST PROCEDURES
S5LC2111E02 MECHATRO CONTROL
2007-2
21
SYSTEM
S5LC2211E02
2007-2
HYDRAULIC SYSTEM 22
S5LC2311E02

SYSTEM
2007-2
ELECTRICAL SYSTEM 23
S5LC2411E02
2007-2
COMPONENTS SYSTEM 24
S5LC2511E02
2007-2
AIR-CONDITIONER SYSTEM 25
_

S5YN3118E01 DISASSEMBLING
DISASSEMBLING

2006-7 & ASSEMBLING

31
S5LC3211E01
ATTACHMENTS 32
2006-7
S5LC3311E02
2007-2
UPPER STRUCTURE 33
S5LC3411E02
2007-2
TRAVEL SYSTEM 34
E / G TROUBLESHOOTING

S5YN4618E02
2007-2
BY ERROR CODES 46
S5LC4711E02
2007-2
BY TROUBLE 47
S5YN4818E01
2006-7
TROUBLE DIAGNOSIS MODE 48
_

S5LC5111E02
ENGINE 51
2007-2
_

LC10-07001~
YC10-03501~ APPLICABLE MACHINES

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

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

0-6
 1

1. OUTLINE
TABLE OF CONTENTS

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

1.1.1 PREPARATION BEFORE DISASSEMBLING..........................................................1-3
1.1.2 SAFETY WHEN DISASSEMBLING AND ASSEMBLING ........................................1-3
1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT .......................1-3
1.1.4 ELECTRICAL EQUIPMENT .....................................................................................1-4
1.1.5 HYDRAULIC PARTS ................................................................................................1-5
1.1.6 WELD REPAIR .........................................................................................................1-5
1.1.7 ENVIRONMENTAL ISSUES.....................................................................................1-5
1.2 INTERNATIONAL UNIT SYSTEM .....................................................................................1-6

Book Code No. S5YN0118E01

1-1
1. OUTLINE

Issue Date of Issue Applicable Machines Remarks

SK330-8 : LC10-07001~ S5YN0118E01
First edition July, 2006 K
SK350LC-8 : YC10-03501~ (ASIA, OCE)
SK200-8 : YN11-45001~ ↑
↑ August, 2006 K
SK210LC-8 : YQ11-06001~ (ASIA, OCE)
SK250-8: LQ12-06001~ ↑
↑ October, 2006 K
SK260LC–8 : LL12-05001~ (ASIA, OCE)
↑ December, 2006 SK850LC: LY01-00101~ ↑ K
E235BSR : YF05-02001~ ↑
↑ February, 2007 K
E235BSR(N)LC : YU05-02001~ (NHK)

1-2
 1. OUTLINE

1.1 GENERAL PRECAUTIONS FOR 2) Attach "Don’t operate" tag to control lever, and
begin a meeting before starting the work.
MAKING REPAIRS
3) Before starting inspection and maintenance
1.1.1 PREPARATION BEFORE stop the engine.
DISASSEMBLING
4) Confirm the position of first-aid kit and fire
extinguisher, and also where to make contact
Read Operator's Manual
for emergency measure and ambulance to
before disassembling

prepare for accidents and fire.

(1) Knowledge of operating procedure
Read Operator’s Manual carefully to understand
the operating procedure.
(2) Cleaning machines
Clean machines of soil, mud, and dust before
carrying into the service shop.
Carrying a soiled machine into the service shop,
causes making less efficient work and damage of
parts.
(3) Inspecting machines
Confirm the disassembling section before starting
work, determine the disassembly procedure taking
the conditions in work shop into account, and
request to procure necessary parts in advance.
(4) Recording
Record the following items to keep contact and
prevent malfunction from recurring.
1) Inspecting date, place
2) Model name, Serial number and Record on
hour meter
3) Trouble condition, place, cause
5) Choose a hard, lever and safe place, and put
attachment on the ground without fail.
6) Use hoist, etc. to remove parts of heavy weight
(23kg [50 lb] or more).
7) Use proper tools, and change or repair
defective tools.
8) Machine and attachment required to work in the
lifting condition should be supported with
supports or blocks securely.
1.1.3 DISASSEMBLING AND ASSEMBLING
HYDRAULIC EQUIPMENT
(1) Removing hydraulic equipment assy
1) Before removing pipes, release the pressure of
hydraulic oil tank, or open the cover on the
return side to tank, and take out the filter.
2) Drain the oil in the removed pipes into pan to
prevent the oil from spilling on the ground.

4) Visible oil leak, water leak and damage
5) Clogging of filters, oil level, oil quality, oil
contamination and looseness.
6) Examine the problems on the basis of monthly
operation rate with the last inspection date and
records on hour meter.
(2) Disassembling hydraulic equipment
(5) Arrangement and cleaning in service shop
1) Tools required for repair work.
2) Prepare the places to put the disassembled
parts.
3) Prepare oil pans for leaking oil, etc.
1.1.2 SAFETY WHEN DISASSEMBLING AND
ASSEMBLING
WARNING
(1) Safety
1) Wear appropriate clothing, safety shoes, safety
helmet, goggles, and clothes with long sleeves.
3) Pipes with plugs or caps to prevent oil leaking,
entry of dust, etc.
4) Clean the outside surface of equipment, etc.
before disassembling, and drain hydraulic oil
and gear oil before putting them on working
bench.
1) Since performance and function of hydraulic
equipment after disassembly and assembly
results in immunity from responsibility on the
manufacture’s side, disassembly, assembly
and modification without permission are strictly
prohibited.
2) If it is unavoidably necessary to disassemble
and modify, it should be carried out by experts
or personnel qualified through service training.
3) Make match mark on parts for reassembling.
4) Before disassembling, read Disassembling
Instruction in advance, and determine if the
disassembly and assembly are permitted or
not.

1-3
1. OUTLINE

5) For parts which are required to use jig and

tools, don’t fail to use the specified jig and tools.
6) For parts which can not be removed in the
specified procedure, never force removal. First
check for the cause.
7) The removed parts should be put in order and
tagged so as to install on proper places without
confusion.
8) For common parts, pay attention to the quantity
and places.
(3) Inspecting parts
1) Check that the disassembled parts are free
from adherence, interference and uneven
working face.
2) Measure the wear of parts and clearance, and
record the measured values.
3) If an abnormality is detected, repair or replace
the parts.
(4) Reassembling hydraulic equipment
1) During the parts cleaning, ventilate the room.
2) Before assembly, clean parts roughly first, and
then completely.
3) Remove adhering oil by compressed air, and
apply hydraulic oil or gear oil, and then
assemble them.
4) Replace the removed O-ring, back-up rings and
oil seal with new ones, and apply grease oil on
them before assembling.

 
5) Removes dirt and water on the surface on
which liquid sealant are applied, decrease
them, and apply liquid sealant on them.
6) Before assembling, remove rust preventives on
new parts.
7) Use special tools to fit bearings, bushing and oil
seal.
8) Assemble parts matching to the marks.
9) After completion, check that there is no
omission of parts.
(5) Installing hydraulic equipment
1) Confirm hydraulic oil and lubrication oil.
2) Air release is required in the following cases ;
1. Change of hydraulic oil
2. Replacement of parts on suction pipe side
3. Removing and attaching hydraulic pump
4. Removing and attaching swing motor
5. Removing and attaching travel motor
6. Removing and attaching hydraulic cylinder
If hydraulic oil and lubricating oil are not
filled and also air bleed is not performed,
the hydraulic equipment may be damaged.
3) For air bleed of hydraulic pump and swing
motor, loosen drain plug on the upper part, start
engine, and run in low idling, then bleed air until
hydraulic oil is comes out. After completion of
comes, tighten plug securely.
4) For air bleed of travel motor and hydraulic
cylinder, starts engine and operate it for 10
minutes or more at no-load and low speed.
For cylinder, don’t move it to the stroke end
at beginning.
5) Air in pilot circuit can be bleed out by only
operating digging, swing and traveling motions
thoroughly.
6) Check hydraulic oil level.
Move attachments to hydraulic oil check
position, and check hydraulic oil level of tank.
Refill oil if the oil level is lower than the specified
level.
How to check oil level of hydraulic oil tank



LEVEL GAUGE
Oil level of hydraulic oil tank.
If the indicator is within
level marks, the oil quantity
is acceptable.
1.1.4 ELECTRICAL EQUIPMENT
(1) The disassembly of electrical equipment is not
allowed.
(2) Handle equipment with care so as not to drop it or
bump it.
(3) Connector should be removed by unlocking while
holding the connector.
Never stress in tension to the caulked section by
pulling wire.
(4) Check that connector is connected and locked
completely.
(5) Engine key off before removing and connecting
connector.

1-4

(6) Engine key off before touching terminals of starter
and alternator.
(7) Remove battery grounding terminal before
beginning work close to battery and battery relay
with tools.
(8) Wash machine with care so as not to splash water
on electrical equipment and connector.
(9) When water has entered in the waterproofed
connector, the removing of water is not easy. So
check the removed waterproofed connector with
care to protect it from entry of water. If moisture
adheres on it, dry it completely before connecting.
Battery fluid is dangerous.
The battery fluid is dilute sulfuric acid, and causes
scald and loss of eyesight by adhering on eyes,
skin and clothes. When the fluid has adhered on
them, take an emergency measure immediately and
see a doctor for medical advice.
• When it has adhered on skin ;
Wash with soap and water.
• When it has got in eyes ;
Wash in water for 10 minutes or more
immediately.
• When it has spilled out in large quantity ;
Use sodium bicarbonate to neutralize, or wash
away with water.
• When it was swallowed ;
Drink milk or water.
• When it has adhered on clothes ;
Wash it immediately.
1.1.5 HYDRAULIC PARTS
(1) O-ring
• Check that O-ring is free from flaw and has
elasticity before fitting.
• Even if the size of O-ring is equal, the usage
differs, for example in dynamic and static
sections, the rubber hardness also differs
according to the pressure force, and also the
quality differs depending on the materials to be
seated. So, choose proper O-ring.
• Fit O-ring so as to be free from distortion and
bend.
• Floating seal should be put in pairs.
1-5
1. OUTLINE
(2) Flexible hose (F hose)
• Even if the connector and length of hose are the
same, the parts differ according to the
withstanding pressure. Use proper parts.
• Tighten it to the specified torque, and check that
it is free from twist, over tension, interference,
and oil leak.
1.1.6 WELD REPAIR
(1) The weld repair should be carried out by qualified
personnel in the specified procedure after
disconnecting the grounding cable of battery. If the
grounding cable is not disconnected, the electrical
equipment may be damaged.
(2) Remove parts which may cause fire due to the
entry of spark beforehand.
(3) Repair attachments which are damaged, giving
particular attention to the plated section of piston
rod to protect it from sparks, and don’t fail to cover
the section with flame-proof clothes.
1.1.7 ENVIRONMENTAL ISSUES
(1) Engine should be started and operated in the place
where air can be sufficiently ventilated.
(2) Waste disposal
The following parts follows the regulation.
Waste oil, waste container and battery
(3) Precautions for handling hydraulic oil
Hydraulic oil may cause inflammation of eyes.
Wear goggles to protect eyes on handling it.
• When it has got in eyes ;
Wash eyes with water until the stimulus is gone.
• When it was swallowed ;
Don’t force him to vomit it, but immediately
receive medical treatment.
• When it has adhered on skin ;
Wash with soap and water.
(4) Others
For spare parts, grease and oil, use KOBELCO
genuine ones.
1. OUTLINE

1.2 INTERNATIONAL UNIT SYSTEM (4) Derived Units bearing Peculiar Designations
Introduction Table1-4
Although this manual uses the SI units system. Outline QUANTITY UNIT SYMBOL FORMULA
of SI units system is described here. Frequency hertz Hz 1Hz=1/s
Given hereinunder are an excerpt of the units that are Force newton N kg • m/s 2
related to this manual : Pressure and
pascal Pa N/m2
1. Etymology of SI Units Stress
English : International System of units Energy, Work
2. Construction of SI Unit System and Quantity of joule J N•m
heat
Base units Power watt W J/s
Table 1-1
Derived units Quantity of
coulomb C A•s
Supplemen of base units electricity
SI units tary units Table 1-3
SI unit Table 1-2 Electric
system Derived units potential
Derived bearing peculiar
designations difference,
units volt V W/A
Table 1-4 Voltage, and
Electromotive
Prefixes of SI
(n-th power of 10, where n is an integer) force
Table 1- 5 Quantity of
static electricity
(1) Basic Units farad F C/V
and Electric
Table1-1 capacitance
Electric
QUANTITIES DESIGNATION SIGN ohm V/A
resistance
Length Meter m
celcius
Mass Kilogram kg Celcius
degree or C
° (t+273.15)K
Time Second s temperature
degree
Current Ampere A
Thermodynamic Kelvin K Illuminance lux lx l m/m2
temperature
(5) Prefixes of SI
Gram molecule Mol mol
Luminous intensity Candela cd Table1-5
PREFIX
(2) Supplementary Units POWER
DESIGNATION SIGN
Table1-2 Giga G 109
QUANTITIES DESIGNATION SIGN Mega M 106
Plain angle Radian rad Kilo k 103
Solid angle Steradian sr Hecto h 102
Deca da 10
(3) Derived Units of Basic Units
Deci d 10–1
Table1-3 Centi c 10–2
QUANTITIES DESIGNATION SIGN Milli m 10–3
Area Square meter m2 Micro µ 10–6
Volume Cubic meter m3 Nano n 10–9
Velocity Meter per second m/s Pico p 10–12
Acceleration Meter per second / second m/s2
Density Kilogram per cubic meter kg/m3

1-6
 1. OUTLINE

(6) Unit Conversion Table

QUANTITIES JIS SI REMARKS

Mass kg kg
Force kgf N 1kgf=9.807N
Torque kgf•m N•m 1kgf•m=9.807N•m
Pressure kgf/cm2 MPa 1kgf/cm2=0.098MPa
Motive power PS kW 1PS=0.7355kW
Revolution r.p.m min –1 1r.p.m=1min–1

1-7
1. OUTLINE

[MEMO]

1-8
 2

2. SPECIFICATIONS
TABLE OF CONTENTS

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

2.2 GENERAL DIMENSIONS ..................................................................................................2-4
2.2.1 SK330–8/SK350LC–8 [6.50m (21ft-4in) Boom+3.30m (10ft-10in) Standard Arm+1.40m3 (1.83cu•yd) Bucket] ..........2-4

2.2.2 SK330–8/SK350LC–8 [6.50m (21ft-4in) Boom+2.60m (8ft-6in) Short Arm+1.60m3 (2.09cu•yd) Bucket] .................2-5

2.2.3 SK330–8/SK350LC–8 [6.50m (21ft-4in) Boom+4.15m (13ft-7in) Long Arm+1.20m3 (1.57cu•yd) Bucket] ................2-5
2.3 WEIGHT OF COMPONENTS............................................................................................2-6
2.4 TRANSPOTATION ............................................................................................................2-8
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER ........................................2-8
2.4.2 DIMENSIONS OF ATTACHMENT ...........................................................................2-9
2.5 SPECIFICATIONS AND PERFORMANCE .......................................................................2-11
2.5.1 SPEED AND CLIMBING CAPABILITY.....................................................................2-11
2.5.2 ENGINE ....................................................................................................................2-11
2.5.3 HYDRAULIC COMPONENTS ..................................................................................2-11
2.5.4 WEIGHT ...................................................................................................................2-11
2.6 TYPE OF CRAWLER.........................................................................................................2-12
2.6.1 SK330-8....................................................................................................................2-12
2.6.2 SK350LC-8 ...............................................................................................................2-12
2.7 TYPE OF BUCKET ............................................................................................................2-13
2.8 COMBINATIONS OF ATTACHMENT................................................................................2-14
2.9 ENGINE SPECIFICATIONS ..............................................................................................2-15
2.9.1 SPECIFICATIONS....................................................................................................2-15
2.9.2 ENGINE CHARACTERISTIC CURVE (HINO J08E-TM) ..........................................2-16

Book Code No. S5LC0211E01

2-1
2. SPECIFICATIONS

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC0211E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)

2-2
 2. SPECIFICATIONS

2.1 NAME OF COMPONENTS

ARM
ARM CYLINDER

BOOM

BOOM CYLINDER
BUCKET
CYLINDER
CAB

SLEWING BEARING

IDLER LINK
SLEWING MOTOR

FUEL TANK

CONTROL VALVE
BUCKET LINK
HYDRAULIC TANK

HYDRAULIC
PUMP

BUCKET GUARD
MONITOR PANEL

SHOE

FRONT IDLER

IDLER ADJUST

UPPER ROLLER ENGINE

AIR CLEANER
COUNTER WEIGHT

LOWER ROLLER
RADIATOR AND OIL COOLER
BATTERY
TRAVEL MOTOR

2-3
2. SPECIFICATIONS

2.2 GENERAL DIMENSIONS

2.2.1 SK330–8/SK350LC–8 [6.50m (21ft-4in) Boom+3.30m (10ft-10in) Standard Arm+1.40m3 (1.83cu•yd)
Bucket]

1500(4'11") 1450(4'9")

2950(9'8")
50(2")

R35
00(1
1'6"
)

11200(36'9")
3500(11'6")
3420(11'3")

3160(10'4")
1190*
(3'11")

(19.7")
500*
Q'TY OF LOWER ROLLER:7SETS[9SETS]
4650 (15'3") [4980(16'4")] (23.6") 600 3200(10'6")
5830 (19'2") [5990(19'8")]

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

[ ] include LC specifications.

2-4
 2. SPECIFICATIONS

2.2.2 SK330–8/SK350LC–8 [6.50m (21ft-4in) Boom+2.60m (8ft-6in) Short Arm+1.60m3 (2.09cu•yd)

Bucket]

11280(37')
4750(15'7")
3500(11'6")
3640(11'11")

1190*
(3'11")
Q'TY OF LOWER ROLLER:7SETS[9SETS] 4650(15'3") [4980(16'4"))

5830(19'2") [5990(19'8")]

2.2.3 SK330–8/SK350LC–8 [6.50m (21ft-4in) Boom+4.15m (13ft-7in) Long Arm+1.20m3 (1.57cu•yd)

Bucket]
11230(36'10")

4750(15'7")

3500(11'6")
3590(11'9")

1190*
(3'11")

Q'TY OF LOWER ROLLER:7SETS[9SETS]

4650(15'3") [4980(16'4"))
5830(19'2") [5990(19'8")]

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

[ ] include LC specifications.

2-5
2. SPECIFICATIONS

2.3 WEIGHT OF COMPONENTS

Unit ; kg (lb)
Model
SK330 - 8 SK350LC - 8
Item
Machine complete 33,800 (74,500) 34,600 (76,300)
1. Upper frame assy (Assembly of following :) 15,800 (34,840) ←
1.1 Upper frame 2,950 (6,500) ←
1.2 Counter weight
Counter weight (Semi-weighted) 8,130 (17,920) ←
Counter weight (weighted) 9,700 (21,380) ←
1.3 Cab 235 (520) ←
1.4 Engine *699 (1,540) ←
1.5 Hydraulic oil tank *189 (420) ←
1.6 Fuel tank *199 (440) ←
1.7 Slewing motor (including reduction unit) *456 (1,000) ←
1.8 Control valve *231 (510) ←
1.9 Boom cylinder *266 (590) × 2 ←
1.10 Pin (for mounting boom) 83 (180) ←
1.11 Pump *155 (340) ←
1.12 Radiator (including intercooler) *206 (450) ←
2. Lower frame assy (Assembly of following :) 11,300 (24,900) 12,000 (26,460)
2.1 Lower frame 4,070 (8,970) 4,300 (9,480)
2.2 Slewing bearing 545 (1,200) ←
2.3 Travel motor (including reduction unit) 397 (880) × 2 ←
2.4 Upper roller 40 (90) × 2 ←
2.5 Lower roller 57 (125) × 14 57 (125) × 18
2.6 Front idler 176 (390) × 2 ←
2.7 Idler adjuster 186 (410) × 2 ←
2.8 Sprocket 75 (165) × 2 ←
2.9 Swivel joint *24 (50) ←
2.10 Track guide 39 (86) × 2 39 (86) × 6
2.11 Track link with 600mm (23.6in) shoes assy 1,870 (4,120) × 2 2,000 (4,410) × 2
Track link with 800mm (31.5in) shoes assy 2,450 (5,400) × 2 2,610 (5,760) × 2
2.11.1 Track link assy 840 (1,850) × 2 900 (1,980) × 2
3. Attachment (Assembly of following / STD :) 6,590 (14,530) ←
{6.50m (21ft-4in) Boom + 3.30m (10ft-10in) Arm + 1.40m (1.83cu•yd)
3

Bucket}
3.1 Bucket assy (STD) 1,080 (2,380) ←
3.2 STD Arm assy (Assembly of following :) 1,900 (4,190) ←
3.2.1 STD Arm 1,250 (2,760) ←
3.2.2 Bucket cylinder *266 (590) ←
3.2.3 Idler link 33 (73) × 2 ←
3.2.4 Bucket link 142 (313) ←
3.2.5 Pin (2pcs. for mounting bucket cylinder / 2pcs. for mounting bucket) 102 (225) ←
3.3 Boom assy (Assembly of following :) 3,610 (7,960) ←
3.3.1 Boom 2,670 (5,890) ←
3.3.2 Arm cylinder *539 (1,190) ←
3.3.3 Pin (Mounting arm • Mounting arm cylinder) 75 (165) ←

2-6
 2. SPECIFICATIONS

Unit ; kg (lb)
Model
SK330 - 8 SK350LC - 8
Item
4. Lubricant and water (Assembly of following :) 862 (1,900) ←
4.1 Hydraulic oil 310 (684) ←
4.2 Engine oil 28 (62) ←
4.3 Fuel 484 (1,070) ←
4.4 Water 44 (97) ←

Marks * show dry weight.

2-7
2. SPECIFICATIONS

2.4 TRANSPOTATION
2.4.1 OVERALL DIMENSIONS OF MACHINE ON A TRAILER
(1) 6.50m (21ft-4in) Boom+3.30m (10ft-10in) Arm+1.40m3 (1.83cu•yd) Bucket

Model
SK330-8 SK350LC-8
Item
Width 600mm (23.6in) shoes 3,200 (10ft-6in) 3,200 (10ft-6in)
Weight 33,800kg (74,500 lbs) 34,200kg (75,400 lbs)

6")
.7(4.
116

(16.5")
420.1

SECTION AA

11218(36'10") 1800(5'11")

219.5(8.6")

4179(13'9")
660 1020(3'4")
100
(4")

(26")
528
(21")

2-8
 2. SPECIFICATIONS

2.4.2 DIMENSIONS OF ATTACHMENT

(1) BOOM

Type
6.50m (21ft-4in) Boom
Item
Length×Height×Width 6.75 × 1.84 × 0.83
m (ft-in)
L×H×W (22'2"× 6'0"× 2'9")
Weight kg (lbs) 3,290 (7,250)

H
L

(2) ARM AND BUCKET

Type 2.6m (8ft-6in) Arm + 3.30m (10ft-10in) Arm + 4.15m (13ft-7in) Arm +
1.6m 3(2.09cu•yd) Bucket 1.40m 3 (1.83cu•yd) Bucket 1.20m 3 (1.57cu•yd) Bucket
Item
Length×Height×Width 5.41 × 1.13 × 1.57 6.07 × 1.12 ×1.42 6.94 × 1.10 × 1.24
m (ft-in)
L×H×W (17'9"×3'8"×5'2") (19'11"×3'8"×4'8") (22'9"×3'7"×4'1")
Weight kg (lbs) 2,870 (6,330) 2,960 (6,530) —
H

(3) Arm

Type
2.6 m (8ft-6in) Arm 3.30 m (10ft-10in) Arm 4.15 m (13ft-7in) Arm
Item
Length×Height×Width 3.82 × 1.09 × 0.62 4.48 × 0.97 × 0.62 5.35 × 0.99 × 0.63
m (ft-in)
L×H×W (12'6"×3'7"×2'2") (14'8"×3'2"×2'2") (17'7"×3'3"×2'1")
Weight kg (lbs) 1,660 (3,660) 1,830 (4,040) —
H

2-9
2. SPECIFICATIONS

(4) Bucket

Type Hoe bucket

Length×Height×Width 1.64 × 1.46× 1.24 1.62 × 1.47× 1.42 1.62 × 1.42× 1.57 1.67 × 1.46× 1.68
m (ft-in)
L×H×W (5'5"×4'9"×4'1") (5'4"×4'10"×4'8") (5'4"×4'8"×5'2") (5'6"×4'9"×5'6")
Weight kg (lbs) 930 (2,050) 1070 (2,360) 1140 (2,510) 1170 (2,580)
m3
Bucket capacity 1.2 (1.57) 1.40 (1.83) STD 1.60 (2.09) 1.80 (2.35)
(cu•yd)

HOE BUCKET

L H

2-10
 2. SPECIFICATIONS

2.5 SPECIFICATIONS AND PERFORMANCE

2.5.1 SPEED AND CLIMBING CAPABILITY

Area & Model

SK330-8 SK350LC-8
Item
Swing speed min-1 {rpm} 10.0 {10.0}
Travel speed (1-speed/2-
km/h (mile/h) 3.3 / 5.6 (2.05 / 3.5)
speed)
Gradeability % (degree) 70 (35)

2.5.2 ENGINE

Engine model HINO J08E-TM

Water-cooled, 4-cycle direct injection type engine
Type
with inter cooler turbo charger
6 -ø112 mm × 130 mm
Number of cylinders—Bore×Stroke
(4.41 in × 5.12 in)
Total displacement 7.684 L (468.9 cu•in)
Rated output / Engine speed 197 kW (268 PS) / 2,100 min-1
Maximum torque / Engine speed 998 N•m (736 lbf•ft)/ 1,600 min-1
Starter 24 V / 5.0kW
Alternator 24 V / 60A

2.5.3 HYDRAULIC COMPONENTS

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

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

2.5.4 WEIGHT

Unit : kg (lbs)
SK330-8 SK350LC-8
Fully equipped weight 33,800 (74,500) 34,600 (76,300)
Upper structure 15,800 (34,840) ←
Lower machinery 11,300 (24,900) 12,000 (26,460)
Attachment
6.50m (21ft-4in) Boom+3.30m (10ft-10in) Arm 6,590 (14,530) ←
+1.40m3 (1.83cu•yd) Bucket

2-11
2. SPECIFICATIONS

2.6 TYPE OF CRAWLER

2.6.1 SK330-8

Overall width of crawler Ground pressure kPa

Shape Shoe width mm (in)
mm (ft-in) (psi)
Grouser shoe
600 (23.6) 3,200 (10'6") 68 (9.86)

800 (31.5) 3,400 (11'2") 53 (7.69)

45 LINKS

2.6.2 SK350LC-8

Overall width of crawler Ground pressure kPa

Shape Shoe width mm (in)
mm (ft-in) (psi)
Grouser shoe
600 (23.6) 3,200 (10'6") 64 (9.28)

800 (31.5) 3,400 (11'2") 50 (7.25)

48 LINKS

Use 600mm (23.6in) grouser shoes on rough ground (areas covered with rocks and gravel). If you drive or excavate
with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, etc.)

2-12
 2. SPECIFICATIONS

2.7 TYPE OF BUCKET

Heaped Outer width mm (ft-in) Availability
Struck Number W or W/O Weight
Hoe bucket capacity With side Without side of face
m3(cu•yd) of tooth side cutter kg (lbs)
m3(cu•yd) cutter cutter shovel
0.84 930
1.20 (1.57) 1,240 (4'1") 1,110 (3'8") 4 W YES
(1.10) (2,050)
1.40 (1.83) 1.00 1,070
1,420 (4'8") 1,300 (4'3") 5 W YES
STD (1.31) (2,360)
1.20 1,140
1.60 (2.09) 1,565 (5'2") 1,450 (4'9") 5 W YES
(1.57) (2,510)
1.40 1,170
1.80 (2.35) — 1,670 (5'6") 5 W/O YES
(1.83) (2,580)

2-13
2. SPECIFICATIONS

2.8 COMBINATIONS OF ATTACHMENT

Bucket Available Arm
Heaped capacity Struck 3.3m (10ft-10in) Arm 4.15m (13ft-7in) 2.6m (8ft-6in) Arm
Type
m3 (cu•yd) m3 (cu•yd) (STD) Arm (Long) +Arm (Short)
1.20 (1.57) 0.84 (1.10)
1.40 (1.83) STD 1.00 (1.31)
Hoe bucket
1.60 (2.09) 1.02 (1.57)
1.80 (2.35) 1.40 (1.83)
Breaker — —
Nibbler — —

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

• Use the attachments recommended by KOBELCO.

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

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

2-14
 2. SPECIFICATIONS

2.9 ENGINE SPECIFICATIONS

2.9.1 SPECIFICATIONS

Applicable machine SK330-8, SK350LC-8

Engine model HINO J08E-TM
Water-cooled, 4 cycle 6 cylinder direct injection type
Type
diesel engine with intercooler turbo-charger
Number of cylinder×Bore×Stroke mm (in) 6 × 112 × 130 (4.41 × 5.12)
Total displacement cc (cu•in) 7,684 (469)
Compression ratio 18.0
Rated output kW (PS) at min -1
197 (268) at 2,100
N•m (lb•ft) at
Maximum torque 998 (736) at 1,600
min-1
High idling min-1 2,310 ± 30
Low idling min -1
1,000 ± 30
Injection starting pressure MPa (psi) 3.2 (464)
Start/Full open
Thermostat action 350 (170) / 363 (194)
K (°F)
Firing order 1-4-2-6-3-5
Compression pressure MPa (psi)at min -1 3.4~3.7 (493~537) at 280
Fuel injection timing 0° before top dead point
Valve clearance Open Close
14° before top 30° after bottom
Intake valve 0.3 mm at cool
Valve clearance dead point dead point
54° before bottom 13° after top dead
Exhaust valve 0.45 mm at cool
dead point point
Starter capacity V × kW 24 × 5.0
Generator capacity (Alternator) V×A 24 × 60
ø850 (33.5") × suction type 6 fans, V-belt drive,
Cooling fan drive method
pulley ratio Crank / Fan= 0.80
Full level 26.0 (6.87)
Engine oil quantity L (gal) Low level 20.0 (5.28)
Total 28.5 (7.53)
Dry weight kg (lbs) 680 (1,500)
Fuel consumption ratio g/kW•h (g/ps•h) 225 (165)
Allowable inclination
Front / Rear and Right / Left : 35°
(Limited by E/G lubrication)
Dimension (L×W×H) {without fan} mm (in) 1,294 × 868 × 987 (4ft-2.95in × 34.2in × 38.9in)
Rotating direction Counterclockwise seeing from flywheel side

2-15
2. SPECIFICATIONS

2.9.2 ENGINE CHARACTERISTIC CURVE (HINO J08E-TM)

Condition to be measured: The net value is indicated, measuring it without cooling fan.
marks show the rated point

SHAFT TORQUE
SHAFT OUTPUT

FUEL CONSUMPTION RATE

ENGINE SPEED (min-1)

Fuel consumption volume

Fuel consumption rate X kW X Load factor ( )
0.835 X 1000
225g/kW.h
X 209kW X
0.835 X 1000 : Standard load factor
. L/h (0.70~0.80)
56.3
Fuel consumption in regular operation
(load factor 0.70~0.80)
39.4 L/h~45.1 L/h

2-16
 3
3. ATTACHMENT DIMENSION
TABLE OF CONTENTS

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

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

Book Code No. S5LC0311E02

3-1
3. ATTACHMENT DIMENSION

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC0311E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)
S5LC0311E02
Revision February, 2007 ↑ K
(ASIA, OCE)

3-2
 3. ATTACHMENT DIMENSION

3.1 BOOM
3.1.1 BOOM DIMENSIONAL DRAWING

d4
J

I
d3 K
d1

D C
H G B

E
F
K

A
J

d2

SECTION K-K

Fig. 3-1 Boom dimensional drawing

Unit : mm (ft-in)
STD
6.50M (21ft-4in) BOOM
LC02B00164F1
No NAME DIMENSION
A Boom length 6,500 (21'4")
B Boom foot width 826 (32.5")
C Boom end inner width 405.8 (16.0")
D Boom end outer width 577 (22.7")
E Height of boom cylinder rod pin 1,115 (3'8")
F Height of arm cylinder (head side) pin 1,460.8 (4'9.5")
G Distance between pins of boss R2,955 (9'8")
H Distance between pins of bracket R3,390.5 (11'1.5")
I Arm cylinder (head side) inner width 146 (5.75")
J Outer width of bracket on the boom cylinder (rod side) mounting 564 (22.2")
d1 Boom foot pin dia. ø 125 (4.92")
d2 Boom cylinder (rod side) pin dia. ø 110 (4.33")
d3 Pin dia. of boom end. ø 110 (4.33")
d4 Arm cylinder (head side) pin dia. ø 110 (4.33")

3-3
3. ATTACHMENT DIMENSION

3.1.2 BOOM MAINTENANCE STANDARD

(1) Clearance of pin and bushing on boom section ASIA, OCEANIA

A
C

Fig. 3-2 Clearance of pin and bushing on boom section

ASIA Unit : mm (in)

Standard value Clearance
Sym- Bushing Repaira
Item Pin part No. Pin dia. Standard Service Remedy
bol Pin dia. i.d. ble
tolerance value limit
tolerance level
+ 0.020 + 0.226 + 0.246
ø 110 (+0.0008) (+0.0089) (+0.0097)
A Boom foot LC02B01373P1
(4.331) - 0.020 + 0.098 + 0.078
(-0.0008) (+0.0039) (+0.0031)
+ 0.222 + 0.262
0
Boom cylinder ø 100 - 0.040
(+0.087) (0.0103)
B LC02B01344P1
(Head side) (3.937) + 0.105 + 0.0105 More
(-0.0016) Replace
(+0.0041) (+0.0041) than 3.0
bushing
+ 0.020 + 0.230 + 0.250 2.5 (0.12)
or pin
Boom cylinder (+0.0008) (+0.0091) (+0.0098) (0.10)
C LC02B01345P1
(Rod side) - 0.020 + 0.105 + 0.085
ø 110 (-0.0008) (+0.0041) (+0.0033)
(4.331) + 0.030 + 0.250 + 0.280
Arm cylinder (+0.0012) (+0.0098) (+0.0110)
D LC02B01444P1
(Head side) - 0.030 + 0.050 + 0.020
(-0.0012) (+0.0020) (+0.0008)

3-4
 3. ATTACHMENT DIMENSION

OCEANIA Unit : mm (in)

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

3-5
3. ATTACHMENT DIMENSION

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

D
D C

A
L3 L3' X3

B A

PL3
X1 L1
SECTION C-C
X4

L4 PL4
PL2 PL2

PL1

SECTION D-D SECTION A-A

X2 L2 L2 X2

SECTION B-B
Fig. 3-3 Clearance in thrust direction on the boom cylinder installation section

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

3-6
 3. ATTACHMENT DIMENSION

3.2 ARM
3.2.1 ARM DIMENSIONAL DRAWING

VIEW J

SECTION X-X

SECTION Y-Y SECTION Z-Z

Fig. 3-4 ARM DIMENSIONAL DRAWING

3.30m (10ft-10in) LC12B00457F1 (ASIA)

ARM LC12B00383F1 (OCE) Unit : mm (ft-in)
Code NAME DIMENSION Code NAME DIMENSION
C Arm length 3,300 (10'10") N Bracket inner width 146 (5.75")
Distance between pins of boss
D R1,010 (3'4") O Bracket inner width 136 (5.35")
and bracket
D1 I.D of boss ø120 (4.72") P Idler link dimension 696 (27.4")
D2 I.D of boss ø95 (3.74") Q Bucket link dimension 686 (27.0")
Height between pins of boss and
D4 I.D of boss ø125 (4.92") R 44 (1.73")
center
Distance between pins of boss
E R2,429.5 (7'12") d1 Pin dia. ø90 (3.54")
and bracket
Distance between pins of boss
F R515 (20.3") d2 Pin dia. ø80 (3.15")
and boss
Height between pins of boss and
G 735.5 (29.0") d3 Pin dia. ø110 (4.38")
bracket
Height between pins of boss and
H 280 (11.0") d4 Pin dia. ø110 (4.33")
bracket
K Arm top end boss width 368 (14.5") d5 Pin dia. ø90 (3.54")
L Arm link section boss width 390 (15.4")
M Boss width 400 (15.75")

3-7
3. ATTACHMENT DIMENSION

3.2.2 ARM MAINTENANCE STANDARD

(1) Clearance of pin and bushing ASIA, OCEANIA

E F
D, D'
B

C
G

Fig. 3-5 Clearance of pin and bushing on arm section

ASIA Unit : mm (in)

Standard dimensions Clearance
No. Item Pin part No. Pin dia. Bushing i.d. Standard Repairable Service Remedy
Pin dia.
tolerance tolerance value level limit
+0.272 +0.332
(+0.0107) (+0.0131)
A Arm point
–0.020 +0.095 +0.115
ø90 (-0.0008) (+0.0037) (+0.0045)
LC12B01783P1
(3.5433) –0.060 +0.298 +0.358
Bucket link (-0.0024) (+0.0117) (+0.0141)
B
(Bucket side) +0.168 +0.188
(+0.0066) (+0.0074)
0 +0.229 +0.269
Idler link
ø80 (0) (+0.0090) (+0.0106)
C (Connected part LC12B01784P1
(3.1496) –0.040 +0.158 +0.158
of arm) (+0.0062) (+0.0062)
(-0.0016)
+0.299 +0.359
Bucket link (+0.0118) (+0.0141) Replace
D 2.5 3.0
(Idler link side) 0 +0.170 +0.170 bushing
(0.10) (0.01)
(0) (+0.0067) (+0.0067) or pin
LC12B01789P1
ø90 –0.060 +0.310
Bucket cylinder (3.5433) (-0.0024) (+0.0122)
D'
(Rod side) +0.250 +0.050
(+0.0098) (+0.0020)
Bucket cylinder +0.030 +0.050 +0.280
E LC12B01790P1
(Head side) (+0.0012) (+0.002) (+0.0110)
Arm cylinder –0.030 +0.020
F LC02B01444P1 (+0.0008)
(Rod side) (-0.0012)
ø110 +0.020 +0.288 +0.308
Arm foot
(4.331) (+0.0008) (+0.0113) (+0.0121)
G (Connected part LC12B01468P1
–0.020 +0.190 +0.170
of boom)
(-0.0008) (+0.0075) (+0.0067)

3-8
 3. ATTACHMENT DIMENSION

OCEANIA Unit : mm (in)

Standard dimensions Clearance
No. Item Pin part No. Pin dia. Bushing i.d. Standard Repairable Service Remedy
Pin dia.
tolerance tolerance value level limit
+0.272 +0.332
(+0.0107) (+0.0131)
A Arm point
–0.020 +0.095 +0.115
ø90 (-0.0008) (+0.0037) (+0.0045)
LC12B01657P2
(3.5433) –0.060 +0.217 +0.277
Bucket link (-0.0024) (+0.0085) (+0.0109)
B
(Bucket side) +0.071 +0.091
(+0.0028) (+0.0036)
+0.222 +0.262
Idler link
ø80 (+0.0087) (+0.0103)
C (Connected part LC12B01613P1
(3.1496) +0.079 +0.079
of arm) (+0.0031) (+0.0031)
0 +0.219 +0.259
Bucket link (0) (+0.0086) (+0.0102)
D
(Idler link side) –0.040 +0.034 +0.034
Replace
(-0.0016) (+0.0013) (+0.0013) 2.5 3.0
LC12B01614P1 bushing
+0.235 +0.275 (0.10) (0.01)
or pin
Bucket cylinder ø90 (+0.0093) (+0.0108)
D'
(Rod side) (3.5433) +0.074 +0.074
(+0.0029) (+0.0029)
+0.238 +0.258
Bucket cylinder (+0.0094) (+0.0102)
E LC12B01461P1
(Head side) +0.077 +0.057
(+0.0030) (+0.0022)
+0.020 +0.226 +0.246
Arm cylinder (+0.0008) (+0.0089) (+0.0097)
F LC02B01337P1
(Rod side) –0.020 +0.098 +0.078
ø110 (-0.0008) (+0.0039) (+0.0031)
(4.331) +0.200 +0.220
Arm foot
(+0.0079) (+0.0087)
G (Connected part LC12B01468P1
+0.099 +0.079
of boom)
(+0.0039) (+0.0031)

3-9
3. ATTACHMENT DIMENSION

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

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

C G
G
L3
L1 X3
X1
X5

L5 PL5
X6 L6

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

L2 X4 L4
X2
PL6

SECTION F-F

PL2 X7 L7
X4' L4'
SECTION B-B PL4 PL7
SECTION D-D,D'-D' SECTION G-G
Fig. 3-6 Clearance of arm and cylinder installing sections in thrust direction

3-10
 3. ATTACHMENT DIMENSION

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

3-11
3. ATTACHMENT DIMENSION

3.3 BUCKET
3.3.1 BUCKET DIMENSIONAL DRAWING
(1) Hoe bucket

 




 
 


 
 



Fig. 3-7 Bucket dimensional drawing

No. NAME No. NAME

A Distance between pin and bracket G 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 Io Pitch between teeth
E Inner width of bracket d1 Outer dia. of bushing
F Outer width of side cutter d2 Pin dia.

3.3.2 BUCKET DIMENSIONAL TABLE

Unit : mm (ft-in)
Type GD bucket (General Duty)
[STD]
1.20 m3 1.60 m3 1.80 m3
Capacity 1.40 m3
(1.57 cu•yd)) (2.09 cu•yd)) (2.35 cu•yd))
(1.83 cu•yd)
Part No. LC61B00115F1 LC61B00052F1 LC61B00118F1 LC61B00057F1
A R517 (20.4") ← ← ←
B R1,690 (5'7") ← ← ←
C 1,238 (4'1") 1,060 (3'6") 1,388 (4'7") 1,620 (5'4")
D 444 (17.5") ← ← ←
E 382 (15.0") ← ← ←
F 1,415 (4'8") 1,240 (4'1") 1,565 (5'2") 1,683 (5'6")
G 1,122 (3'8") 936 (36.9") 1,272 (4'2") 1,496 (4'11")
H 1,238 (4'1") 1,060 (3'6") 1,388 (4'7") 1,620 (5'4")
I 280.5 (11") 316 (12.4") 318 (12.5") 377 (14.8")
IO 280.5 (11") 315 (12.4") 318 (12.5") 376 (14.8")
d1 ø 105 (4.13") ← ← ←
d2 ø 90 (3.54") ← ← ←

3-12
 3. ATTACHMENT DIMENSION

3.3.3 LUG SECTION DIMENSIONAL DRAWING

LS12B01054P1

28 (1.10")

19
(0.748")

VIEW I

SHIM t=1
(Five shims are installed
at shipping) Insert this pin flush with surface

SECTION AA
Fig. 3-8 Dimension of lug section

Unit : mm (ft-in)
Lug plate thickness

Screw hole P.C.D

Boss outer radius

Plate thickness

Boss outer dia.

Spring pin dia.
Pin hole dia.

Boss width.
Screw dia.

Capacity of
Hole dia.

Type of Part No. of

bucket
bucket bucket
m3 (cu.yd)

A B D E F G H J M N
1.40 (1.83) LC61B00115F1
1.20 (1.57) LC61B00052F1 90 28 105 16 105 19 190 12 150
GD bucket M20
1.60 (2.09) LC61B00118F1 (3.54") (1.10") (4.13") (0.63") (4.13") (0.748") (7.48") (0.472") (5.91")

1.80 (2.35) LC61B00057F1

3-13
3. ATTACHMENT DIMENSION

3.3.4 BOSS SECTION DIMENSIONAL DRAWING

)
gh
ou
thr
rill
(D
G

Fig. 3-9 Dimension of boss section

Unit : mm (ft-in)
Capacity of
Type of Part No. of Part No.
bucket øA øB E F øG
bucket bucket of boss
m3 (cu•yd)
1.40 (1.83) LC61B00115F1
1.20 (1.57) LC61B00052F1 139.8 103.8 15 40 21
GD bucket LS12B01054P1
1.60 (2.09) LC61B00118F1 (5.50") (4.09") (0.591") (1.58") (0.827")
1.80 (2.35) LC61B00057F1

3-14
 11. TOOLS
11
TABLE OF CONTENTS

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

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

Book Code No. S5LC1111E01

11-1
11. TOOLS

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC1111E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)

11-2
 11. TOOLS

11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS

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

11-3
11. TOOLS

Table11-2 Tightening torques for metric fine threads (not plated)

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

11-4
 11. TOOLS

11.2 SCREW SIZE

11.2.1 CAPSCREW (BOLT)

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

11.2.2 CAPSCREW (SOCKET BOLT)

Nominal B mm Nominal B mm
screw size screw size
Tool size Tool size
(d) (d)
(M3) 2.5 M20 17
(M4) 3 (M22) 17 @
(M5) 5 M24 19
M6 5 (M27) 19
M8 6 M30 22
M10 8 M36 27
*
M12 10 M42 32
M14 12 (M45) 32
M16 14 M48 36
(M18) 14 M52 36

11.2.3 SOCKET SET SCREW

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

11-5
11. TOOLS

11.3 TIGHTENING TORQUE FOR HOSE AND FITTING

11.3.1 JOINT (O-RING TYPE)

Size Wrench Tightening torque

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

11.3.2 HYDRAULIC HOSE (30° FLARE TYPE)

Size Tightening torque

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

11.3.3 JOINT (ORS TYPE)

Tightening Torque CONNECTOR O-RING FITTING

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

11.3.4 SPLIT FLANGE

Tightening torque N•m (lbf•ft)

 

 

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

11-6
 11. TOOLS

11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES

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

SLEEVE NUT
B

d
d

Tube size Parts No. Tube size Opposing Parts No.

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

11-7
11. TOOLS

11.5 PLUG
11.5.1 PLUG FOR HYDRAULIC PIPE JOINT
(1) Cap nut (Joint plug)

Applicable Cap nut parts Opposing flats

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

(2) Plug (Tube plug)

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

6 ZF83P06000
8 ZF83P08000
10 ZF83P10000
12 ZF83P12000
Sleeve Nut
Type 15 ZF83P15000
joint body 18 ZF83P18000
22 ZF83P22000
28 ZF83P28000

(3) Nut

Applicable
A

d screw tube Nut parts No. d screw Opposing flats

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

11-8
 11. TOOLS

11.5.2 PLUG FOR HYDRAULIC EQUIPMENT

(1) PF screw

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

(2) PT screw

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

(3) Plug for (F) flare hose

PF screw

PF screw Plug parts No. B mm

PF1/4 2444Z2728D1 14
60

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

PF screw Plug parts No. E mm F mm

PF PF1/4 2444Z2729D1 14 19
60

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

11-9
11. TOOLS

(4) Plug for ORS joints

Male


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

Female

 

 

$

   
  % &"'()
  !" 
   !"# 
   !" 

(5) Plug for half clamp

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

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

ZE12Q16000 52.37 39.75~ ZD12P03400

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

For high pressure : 41.2 MPa (5970 psi)

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

11-10
 11. TOOLS

11.6 SPECIAL SPANNER FOR TUBE

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

70(2.76)

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

40(1.57) 12.7 (0.500 )

70(2.76)
42(1.65)

19 22
18 (0.709) 2421T138 32 (0.748) (0.866)

12.7 (0.500 )
22(0.866)

70(2.76)
48(1.89) 11.5(0.453)

23 22
22 (0.866) 2421T130 36 (0.906) (0.866)

12.7 (0.500 )

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

12.7 (0.500 )

 
  







28 (1.10) 2421T231 46    


   

 

  






  
32 (1.26) 2421T232 50    


  

81(3.19) 90(3.54)
20.5(0.807)

35 (1.38) 2421T314 55 41 PART-No. 45

(1.61) (1.77)

HEX55 19.05 (0.750 )

11-11
11. TOOLS

11.7 SPECIAL TOOLS

Table11-4
No. Tools name Tools No. Shape Applicable
Spanner or
Pump
1 socket ZT22A17000 General tools
install
Nominal B : 17
CUT

Spanner ZT12A36000 Swing motor

2
Nominal S : 36 A,B port

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

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

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

O-ring
PF1

M12 Eye bolt

ZS91C01200 For slinging the

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

M12

M8 Eye bolt

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

M8 Eye bolt

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

Eye bolt ZS91C00800

1-14UNS

11-12
 11. TOOLS

Table11-4

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

Eye bolt ZS91C00800

1 3/16-12UN

M12 Eye nut

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

PF 1/2

TORX driver 5.49

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

11-13
11. TOOLS

11.8 APPLICATION OF SCREW LOCKING COMPOUND AND

SEALING COMPOUND
(1) For general use

Manufacturer
Service Features
Loctite Three-Bond
Low
#242 1360K
strength
Screw locking Middle
#262 1374
compound strength
High
#271 1305
strength
Sealing
#515 1215 Sealing
compound

(2) For specific location

No. Use Manufacturer Name Equivalent Applicable

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

11-14
 11. TOOLS

11.9 SUCTION STOPPER

11.9.1 COMPONENTS

No. NAME PARTS No. Q'TY

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

2 Nut
3 Cover

4 O-ring

Fig. 11-1 Components of suction stopper

11.9.2 DIMENSION

50
(1.97")

R8
O113 (4.45")
2
M8 NUT

O8 (1.315")
600 (23.6")

M8 O100 +0.5
0
(0.787")

(3.94 +0.0197
0 )
O108
20

(4.25")
ROD COVER
Fig. 11-2 Dimension of suction stopper

11.9.3 APPLICABLE MODEL

SK200-6ES

Applicable
SK115SR

SK135SR

SK235SR

SK200-6E
SK100-2

SK120-2

SK100-3

SK120-3

SK200-6

SK200-8

SK330-8

model
SK100

SK120

Part No.

24100P978F2

11-15
11. TOOLS

11.10 UPPER FRAME LIFTING JIG

No. NAME Q'TY TYPE

1 MASTER LINK L 1 KITO HL050

2 HIGH COUPLING HC 9 KITO HC020

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

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

5 GRAB HOOK H 1 KITO HH020

6 HOOK 2 KITO HJ050

Fig. 11-3 Upper frame lifting jig

11-16
 11. TOOLS

11.11 ENGINE MOUNTING PEDESTAL

Material : Wood
Unit : mm(inch)

5
1
6

3
2

6 6

4
6
6

1X1 set

5X1 set

4X1 set 2X1 set

3X1 set

6X5 sets

Fig. 11-4 Engine stand

11-17
11. TOOLS

[MEMO]

11-18
 12. STANDARD MAINTENANCE
TIME TABLE
12
TABLE OF CONTENTS

12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ...12-4
12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST
(TEMPORARY EDITION) ................................................................................................12-15
12.2.1 MEASURING METHOD .........................................................................................12-15
12.2.2 WORKING CONDITION .........................................................................................12-15
12.2.3 STANDARD TIME CONSTITUENT ........................................................................12-15
12.2.4 MEANING OF WORDS IN USE .............................................................................12-17

Book Code No. S5LC1211E01

12-1
12. STANDARD MAINTENANCE TIME TABLE

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC1211E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)

12-2
 12. STANDARD MAINTENANCE TIME TABLE

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

12-3
12. STANDARD MAINTENANCE TIME TABLE

12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF

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

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

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

(2) Classification of working code

No. Group Remarks

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

(3) Conditions for standard service time of the engine

1) Tools designated by E/G maker are used
2) Genuine parts are changed
3) Correct working procedures are observed.
• The time required for works specified in this Chapter shows the total time for maintenance.

12-4
 12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
00 Bucket relation See 32.1.2
01 Bucket ASSY Detach/attach 1 pc. Include adjustment. 0.9
02 • Bucket attaching and detaching position Preparation 1 pc. 0.1
03 • Bucket attaching pin Detach/attach 1 Include stopper pin. 0.2
04 • Bucket drive pin Detach/attach 1 0.2
05 • Bucket sling and movement Preparation 1 pc. 0.3
06 Bucket (single) O/H 1 pc. Not include attaching and detaching 3.6
07 • Tooth Replace 1 pc. 0.9
08 • Side cutter Replace 1 pc. 1.8
09 • Bushing Replace 1 pc. 0.9

10 Arm relation See 32.1.3

11 Arm ASSY Detach/attach 1 pc. 1.9
12 • Bucket cylinder attaching and Preparation 1 pc. 0.6
detaching position and piping
13 • Bucket cylinder rod pin Detach/attach 1 pc. Include stopper pin 0.2
14 • Bucket cylinder head pin Detach/attach 1 pc. Include stopper pin 0.2
15 • Bucket cylinder assy Detach/attach 1 pc. 0.2
16 • Arm cylinder rod pin Detach/attach 1 pc. Include stopper pin 0.2
17 • Boom top pin Detach/attach 1 pc. Include wire stop pin. 0.2
01 Attachment

18 • Arm sling and movement Detach/attach 1 pc. 0.3

30 Boom relation See 32.1.4

31 Boom ASSY Detach/attach 1 pc. 2.1
32 • Boom attaching and detaching position Preparation 1 pc. 0.1
33 • Boom cylinder temporary slinging Preparation 2 pcs. 0.3
34 • Boom cylinder rod pin Detach/attach 2 Include two stopper pins. 0.3
35 • Boom cylinder piping Detach/attach 2 pc. 0.3
36 • Arm & bucket piping Detach/attach 1 pc. 0.3
37 • Boom assy temporary slinging Detach/attach 1 pc. 0.1
38 • Boom foot pin Detach/attach 1 Include stopper pin. 0.3
39 • Boom assy slinging Detach/attach 1 pc. 0.2
40 Arm cylinder attaching and detaching Detach/attach 1 pc. 0.7
41 • Arm cylinder piping Detach/attach 1 pc. 0.3
42 • Arm cylinder head pin Detach/attach 1 pc. Include stopper pin. 0.2
43 • Arm cylinder slinging Detach/attach 1 pc. 0.2
50 Boom cylinder attaching and detaching Detach/attach 2 pcs. 1.0
51 • Boom cylinder piping Detach/attach 2 0.4
52 • Boom cylinder head pin Detach/attach 2 pcs. 0.3
53 • Boom cylinder slinging Detach/attach 2 0.3
60 Bucket cylinder O/H 1 4.0
61 • Pin bushing Replace 1 Include seal. 1.5
70 Arm cylinder O/H 1 4.0

12-5
12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
71 • Pin bushing Replace 1 set Include seal. 1.5
80 Boom cylinder O/H 2 8.0
01

81 • Pin bushing Replace 1 set Include seal. 1.5

10 Cab relation See 33.1.2

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

20 Guard relation See 33.1.4

21 Bonnet assy (11) Detach/attach 1 pc. 0.3
22 Guard (7) Detach/attach 1 pc. 0.2
23 Guard (8) Detach/attach 1 pc. 0.2
24 Guard assy (5) Detach/attach 1 pc. 0.2
25 Stay (3) Detach/attach 1 pc. 0.2
02 Cab & Guard

26 Guard (2) Detach/attach 1 pc. 0.2

27 Panel assy (21) Detach/attach 1 pc. 0.2
28 Panel assy (23) Detach/attach 1 pc. 0.2
29 Panel assy (22) Detach/attach 1 pc. 0.2
30 Guard (15) Detach/attach 1 pc. 0.2
31 Guard assy (17) Detach/attach 1 pc. 0.2
32 Guard (16) Detach/attach 1 pc. 0.2
33 Beam (11) Detach/attach 1 pc. 0.2
34 Pillar (10) Detach/attach 1 pc. 0.2
35 Panel (4) Detach/attach 1 pc. 0.2
36 Beam (6) Detach/attach 1 pc. 0.2
37 Pillar (9) Detach/attach 1 pc. 0.2
38 Pillar (12) Detach/attach 1 pc. 0.2
39 Plate (49) Detach/attach 1 pc. 0.2
40 Guard assy (13) Detach/attach 1 pc. 0.2
41 Cover assy (2) Detach/attach 1 pc. 0.2
42 Guard assy (1) Detach/attach 1 pc. 0.2
43 Guard assy (4) Detach/attach 1 pc. 0.2
44 Guard (3) Detach/attach 1 pc. 0.2
45 Plate (18) Detach/attach 1 pc. 0.2
46 Cover assy (1) Detach/attach 1 pc. 0.2
Note: The numbers in the parenthesis like guard (14) match the guard numbers on the upper structure.

12-6
 12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
50 Under cover relation See 33.1.5
51 Cover (1) Detach/attach 1 pc. 0.1
52 Cover (2) Detach/attach 1 pc. 0.1
53 Cover (3) Detach/attach 1 pc. 0.1
54 Cover (4) Detach/attach 1 pc. 0.1
55 Cover (5) Detach/attach 1 pc. 0.1
02 Cab & Guard

56 Cover (6) Detach/attach 1 pc. 0.1

57 Cover (7) Detach/attach 1 pc. 0.1
58 Cover (8) Detach/attach 1 pc. 0.1

60 Counterweight relation See 33.1.11

61 Counterweight ASSY Detach/attach 1 pc. 0.9
62 • Counterweight temporary slinging Preparation 1 pc. 0.3
63 • Counterweight mounting bolt Detach/attach 1 pc. 0.3
64 • Counterweight slinging Detach/attach 1 pc. 0.2

10 Intake relation See 33.1.9

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

20 Exhaust relation See 33.1.10

21 Muffler ASSY Detach/attach 1 pc. 0.5
22 • U bolt Detach/attach 1 pc. 0.2
23 • Clamp ASSY Detach/attach 1 pc. 0.2
03 Swing frame

30 Radiator relation See 33.1.12

31 Radiator ASSY Detach/attach 1 pc. 5.0
32 • Coolant (LLC) Replace 1 pc. 0.3
33 • • Concentration of coolant Measuring 1 pc. 0.2
34 • A/C condenser Detach/attach 1 pc. 0.3
35 • Stay Detach/attach 1 pc. 0.1
36 • Bracket Detach/attach 1 0.3
37 • Sub tank hose Detach/attach 1 pc. 0.1
38 • Fan guard Detach/attach 1 pc. 0.3
39 • Water hose (radiator ~ E/G) Detach/attach 2 0.6
40 • Radiator mounting bolts removing Detach/attach 1 set 0.2
41 • Under cover Detach/attach 1 pc. 0.1
42 • Hydraulic oil tank suction stopper Detach/attach 1 pc. 0.2
43 • Hydraulic oil piping Detach/attach 1 pc. 0.6
Note: The numbers in the parenthesis like cover (2) match the guard numbers on the upper structure.

12-7
12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
44 • Inter cooler hose & tube Detach/attach 2 pcs. 0.5
(E/G to inter cooler)
45 • Radiator lifting or hoisting Detach/attach 1 pc. 0.2
46 • Radiator inter cooler core & oil cooler Cleaning 1 pc. 1.0

50 Fuel relation See 33.1.6

51 Fuel tank ASSY Detach/attach 1 pc. 1.8
52 • Fuel Replace 1 pc. 0.4
53 • Hose (water separator side) Detach/attach 2 0.1
54 • Tube (tank side) Detach/attach 1 0.1
55 • Fuel tank installing bolts Detach/attach 1 pc. 0.3
56 • Tank slinging Detach/attach 1 pc. 0.3
Other necessary works Detach/attach 1 pc. Removing and installing guard 0.4

60 Hydraulic oil tank relation See 33.1.7

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

66 • Hydraulic oil Replace 1 pc. 0.6

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

80 Pump relation See 33.1.8

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

90 Swing motor unit relation See 33.1.19

91 Swing motor ASSY Detach/attach 1 pc. 2.4
92 • Piping Detach/attach 1 set 1.0
93 • Mounting bolt Detach/attach 1 pc. 0.7
94 • Unit slinging Detach/attach 1 pc. 0.5
95 • Cleaning and sealant Cleaning 1 set 0.2

12-8
 12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
96 Swing motor O/H 1 pc. 4.0
97 Swing reduction gear O/H 1 pc. 5.0

100 Swivel joint relation See 33.1.20

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

110 Multi control valve (For Oceania) See 33.1.15

111 • Multi C/V ASSY Detach/attach 1 After removing guard 1.7
112 Write hose name on multi C/V connecting hose Detach/attach 1 set 0.3
03 Swing frame

113 • Piping Detach/attach 1 set 0.5

114 • Mounting bolt Detach/attach 1 set 0.3
115 • Cleaning Cleaning 1 set 0.2
Other necessary works Detach/attach 1 set Guard 0.4

120 Main control valve See 33.1.16

121 Main control valve ASSY Detach/attach 1 pc. 2.5
122 • Attach tag to port name of pipe Preparation 1 pc. 0.6
123 • Piping Detach/attach 1 set 1.7
124 • Bracket mounting bolt Detach/attach 1 pc. 0.1
125 • Valve slinging Detach/attach 1 pc. 0.1
126 Main control valve ASSY Detach/attach 1 set 6.0
Other necessary works Detach/attach 1 set Guard 0.4

130 Valve relation OPT

131 Solenoid valve ASSY Detach/attach 1 1.0
132 • Attach tag to port name of pipe Preparation 1 0.2
133 • Piping Detach/attach 1 set 0.5
134 • Mounting bolt Detach/attach 1 0.3

140 Engine (E/G) mounting relation See 33.1.13

141 Engine ASSY Detach/attach 1 pc. After removing pump & radiator 2.0
142 • Harness connector & grounding & Detach/attach 1 pc. 0.3
cable connection
143 • Fuel hose Detach/attach 1 pc. 0.1

12-9
12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
144 • Others Detach/attach 1 set 0.5
145 • Mounting bolt Detach/attach 1 pc. 0.5
146 • Engine slinging Detach/attach 1 set 0.3
147 • Cleaning Cleaning 1 pc. 0.5
148 Engine O/H 1 set Reference for engine (Chapter 51)
Other necessary works Detach/attach 1 set Removing and installing guard 0.6
Detach/attach 1 set Removing and installing counterweight 0.9
Detach/attach 1 set Removing and installing pump 3.2
Detach/attach 1 set Removing and installing air cleaner 0.4
1 set Removing and installing muffler 0.4
03 Swing frame

Detach/attach

Detach/attach 1 set Removing and installing radiator 4.0

150 Upper frame See 33.1.21

151 Upper frame ASSY Detach/attach 1 pc. After removing swivel joint 1.3
152 • Mounting bolt Detach/attach 1 set 0.4
153 • Upper frame slinging Detach/attach 1 pc. 0.4
154 • Cleaning Cleaning 1 pc. 0.3
155 • Sealant Apply 1 pc. 0.2
Other necessary works Detach/attach 1 set Cab 1.4
Detach/attach 1 set Guard 0.4
Detach/attach 1 set Counterweight 0.9
Detach/attach 1 set Boom 2.1

00 Travel relation See 34.1.2

01 Track link ASSY Detach/attach One side Include adjustment of tension 2.0
02 • Track link attaching and detaching position Preparation One side 0.1
03 • Master pin Detach/attach One side 0.7
04 • Track link extending and winding Detach/attach One side 0.7
05 Shoe plate Replace 1 pc. 0.4
04 Travel system

10 Upper roller relation See 34.1.3

11 Upper roller ASSY Detach/attach 1 After removing track link 0.3
12 Upper roller O/H 1 1.0

20 Lower roller relation See 34.1.4

21 Lower roller ASSY Detach/attach 1 0.3
22 Lower roller O/H 1 1.5

30 Front idler relation See 34.1.5

31 Front idler ASSY Detach/attach One side After removing track link 0.8
32 Front idler ASSY slinging Detach/attach One side 0.3
33 Front idler ASSY Detaching One side 0.5
34 Idler ASSY O/H One side 1.5

12-10
 12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
40 Sprocket See 34.1.6
41 Sprocket Replace One side After removing track link 0.9

50 Travel motor relation See 34.1.7

51 Travel motor ASSY Detach/attach One side After removing track link 2.4
52 • Motor cover Detach/attach One side 0.1
53 • Hydraulic piping Detach/attach One side 1.3
54 • Motor mounting bolt Detach/attach One side 0.6
04 Travel system

55 • Motor slinging Detach/attach One side 0.2

56 Motor cleaning Cleaning One side 0.2
57 Travel motor O/H One side 4.0
58 Travel reduction gear O/H One side 4.0

60 Swivel joint relation

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

70 Swing bearing See 34.1.8

71 Swing bearing ASSY Detach/attach 1 pc. After removing upper frame 0.8
72 Swing bearing mounting bolt Detach/attach 1 pc. 0.6
73 Swing bearing slinging Detach/attach 1 pc. 0.4

Controller
C-1 Controller (KPSS) Replace 1 0.5
C-2 Gauge cluster Replace 1 1.0
C-4 Air conditioner Amplifier Replace 1 2.0

Diode
D-4 Diode Replace 1 0.3
D-5 Diode Replace 1 0.3
06 Electric equipments

D-6 Diode Replace 1 0.3

D-9 Diode Replace 1 0.3
D-10 Diode Replace 1 0.3
D-12 Diode Replace 1 0.3
D-13 Diode Replace 1 0.3
D-14 Diode Replace 1 0.3
D-15 Diode Replace 1 0.3
D-16 Diode Replace 1 0.3
D-17 Diode Replace 1 0.3
Electric equipments
E-1 Fuse & relay box Replace 1 0.3
E-2 Alternator Replace 1 1.0
E-3 Hour meter Replace 1 0.3

12-11
12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
E-5 Horn (High) Replace 1 0.3
E-6 Horn (Low) Replace 1 0.3
E-7 Tuner AM & FM (OPT) Replace 1 0.3
E-8 Speaker left Replace 1 0.3
E-9 Speaker right Replace 1 0.3
E-10 Receiver dryer Replace 1 Include gas sealing. 1.0
E-11 Air compressor Replace 1 Include counterweight removing and installing. 1.0
E-12 Battery Replace 2 0.4
E-13 Travel alarm (OPT) Replace 1 0.3
E-14 Cigarette lighter Replace 1 0.3
E-15 Fusible link Replace 1 0.2
E-27 Accel emergency mode volume Replace 1 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 Swing flusher & work light (left) Replace 1 0.2
L-4 Swing flusher & work light (right) Replace 1 0.2
L-5 Room light Replace 1 0.2
06 Electric equipments

L-6 Boom cylinder work light (right) Replace 1 0.2

Motor
M-1 Starter motor Replace 1 Include counterweight removing and installing. 1.2
M-3 Wiper motor Replace 1 0.5
M-4 Washer motor Replace 1 0.5
M-8 Grease motor (OPT) Replace 1 0.5
M-9 Skylight wiper motor (OPT) Replace 1 0.5

Proportional valve
PSV-A Arm variable recirculation proportional valve Replace 1 0.5
PSV-B P2 bypass cut proportional valve Replace 1 Include proportional valve block removing and installing. 0.5
PSV-C Travel straight proportional valve Replace 1 0.5
PSV-D P1 bypass cut proportional valve Replace 1 0.5
PSV-P1 P1 pump proportional valve Replace 1 0.5
PSV-P2 P2 pump proportional valve Replace 1 0.5

Relay
R-1 Battery relay Replace 1 0.3
R-2 Starter relay Replace 1 0.3
R-3 Glow relay Replace 1 0.3
R-4 Safety relay Replace 1 0.1
R-5 Horn relay Replace 1 0.1
R-6 Work light relay Replace 1 0.1

12-12
 12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
R-23 Auto idle stop relay 1 Replace 1 0.1
R-24 Auto idle stop relay 2 Replace 1 0.1
R-25 E/G emergency stop relay Replace 1 0.1
R-26 Safety lock lever relay Replace 1 0.1
R-28 Alternator relay Replace 1 0.1
R-29 Wiper motor relay (Normal rotation) Replace 1 0.1
R-30 Wiper motor relay (Reverse rotation) Replace 1 0.1
R-31 Wiper motor relay arc prevention relay Replace 1 0.1
R-32 Washer motor relay Replace 1 0.1

Sensor
SE-1 Pressure sensor : Bucket digging
SE-2 Pressure sensor : Bucket dump
SE-3 Pressure sensor : Boom up
SE-4 Pressure sensor : Boom down
SE-5 Pressure sensor : Swing
SE-7 Pressure sensor : Arm in
SE-8 Pressure sensor : Arm out
06 Electric equipments
Replace 1 0.3
Replace 1 0.3
Replace 1 0.3
Replace 1 0.3
Replace 1 0.3
Replace 1 0.3
Replace 1 0.3

SE-9 Pressure sensor : Travel right Replace 1 Include under cover removing and installing 0.5
SE-10 Pressure sensor : Travel left Replace 1 Include under cover removing and installing 0.5
SE-11 Pressure sensor : P2 side OPT. Replace 1 Include under cover removing and installing 0.5
SE-13 Engine speed sensor Replace 1 Include under cover removing and installing 0.5
SE-15 Fuel sensor Replace 1 Include guard removing and installing 0.5
SE-16 Accel potentio Replace 1 0.5
SE-20 Pressure sensor : P1 side : P1 side (OPT.) Replace 1 Include under cover removing and installing 0.5
SE-22 Pressure sensor : P1 pump Replace 1 0.5
SE-23 Pressure sensor : P2 pump Replace 1 0.5

Solenoid
SV-1 Swing parking SOL Replace 1 Include proportional valve block removing and installing. 0.5
SV-2 Attachment boost pressure SOL Replace 1 Include proportional valve block removing and installing. 0.5
SV-3 2-speed travel SOL Replace 1 Include proportional valve block removing and installing. 0.5
SV-4 Safety lever lock SOL Replace 1 Include proportional valve block removing and installing. 0.5

Switch
SW-1 Key switch Replace 1 0.3
SW-4 Swing parking release switch Replace 1 0.3
SW-7 Engine oil pressure switch Replace 1 0.3
SW-8 Clogged air filter switch Replace 1 0.3
SW-10 Horn switch (left) Replace 1 0.3
SW-11 Safety lever lock switch Replace 1 0.3
SW-19 Wiper interlock switch Replace 1 0.3

12-13
12. STANDARD MAINTENANCE TIME TABLE

Work to be Unit :
Group Location Unit Remarks
done Hour
SW-20 Attachment power boost switch (right) Replace 1 0.3
06

SW-27 Engine cooling coolant level switch Replace 1 0.3

12-14
 12. STANDARD MAINTENANCE TIME TABLE

12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST

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

12.2.1 MEASURING METHOD

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

12.2.2 WORKING CONDITION

12.2.2.1 TOOLS, INSTRUMENT

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

12.2.2.2 WORKING PROCEDURE

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

12.2.2.3 STANDARD WORKMAN QUALIFICATION

Workmen shall basically acquire 2~3 years of maintenance experience of HINO

12.2.3 STANDARD TIME CONSTITUENT

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

12-15
12. STANDARD MAINTENANCE TIME TABLE

12.2.3.2 ALLOWANCE RATE, STANDARD PREPARATION TIME

12.2.3.2.1 HINO allowance rate (0.15~0.75)

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

12.2.3.2.2 STANDARD WORKING TIME

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

12-16
 12. STANDARD MAINTENANCE TIME TABLE

12.2.4 MEANING OF WORDS IN USE

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

12-17
12. STANDARD MAINTENANCE TIME TABLE

SK200-8 SK330-8

Work No. Work Work unit Works Q'ty

Adding hour 1 Adding hour
1
by 1 each by 1 each

Completed Timing adjustment

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

12-18
 12. STANDARD MAINTENANCE TIME TABLE

SK200-8 SK330-8

Work No. Work Work unit Works Q'ty

Adding hour 1 Adding hour
1
by 1 each by 1 each

Include; Valve lapping

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

12-19
12. STANDARD MAINTENANCE TIME TABLE

SK200-8 SK330-8

Work No. Work Work unit Works Q'ty

Adding hour 1 Adding hour
1
by 1 each by 1 each

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

Completed Include; Replacing stud bolt with new

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

12-20
 12. STANDARD MAINTENANCE TIME TABLE

SK200-8 SK330-8

Work No. Work Work unit Works Q'ty

Adding hour 1 Adding hour
1
by 1 each by 1 each

From timing gear cover is removed

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

12-21
12. STANDARD MAINTENANCE TIME TABLE

SK200-8 SK330-8

Work No. Work Work unit Works Q'ty

Adding hour 1 Adding hour
1
by 1 each by 1 each

Include; Checking for temperature at

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

Completed Include; Function check and

443 01806 Replacing injector assembly 3.4 4.0
machine reprogramming
Removal and installing injector
444 01807 One set Include; Function check 1.9 0.2 1.9 0.2
assembly
Include; Function check and
445 01808 Replacing injector assembly One set 2.4 0.2 2.4 0.2
reprogramming
Removal and installing injector sub
446 01809 One set Include; Function check 1.9 1.9
harness assembly
Replace injector sub harness
447 01810 One set Include; Function check 1.9 1.9
assembly
448 01811 Removal and installing flow dumper One set Include; Function check 1.2 0.3 1.2 0.3
449 01812 Replacing flow dumper One set Include; Function check 1.2 0.3 1.2 0.3
Removal and installing pressure
450 01813 One set Include; Function check 1.2 1.2
limiter
451 01814 Replacing pressure limiter One set Include; Function check 1.2 1.2
Replacing common rail pressure
452 01815 One set Include; Function check 1.2 1.2
sensor
453 01816 Replacing main engine speed sensor One set Include; Function check 1.2 1.2
454 01817 Replacing sub engine speed sensor One set Include; Function check 1.2 1.2
Replacing coolant temperature
455 01818 One set Include; Function check 1.2 1.2
sensor
456 01819 Replacing fuel temperature sensor One set Include; Function check 1.2 1.2
457 01820 Replacing accel sensor One set Include; Function check 1.5 1.5
Removal and installing pressure
460 01823 1 Include; Function check 0.3 0.3
sensor
Removal and installing pressure
461 01824 1 Include; Function check 0.3 0.3
limiter
463 01826 Replacing injection pipe One set Include; Function check 1.2 0.1 1.2 0.1
Replacing fuel pipe
464 01827 One set Include; Function check 1.2 0.1 1.2 0.1
(common rail to supply pump)
465 01828 Replacing fuel leakage pipe One set Include; Function check 1.7 1.7
469 01840 Checking leakage of pressurized fuel One set Include; Function check 1.2 1.2

12-22
 12. STANDARD MAINTENANCE TIME TABLE

SK200-8 SK330-8

Work No. Work Work unit Works Q'ty

Adding hour 1 Adding hour
1
by 1 each by 1 each

471 01901 Replacing main engine speed sensor One set Include; Function check 1.2 1.2
472 01902 Replacing sub engine speed sensor One set Include; Function check 1.2 1.2
Replacing coolant temperature
473 01903 One set Include; Function check 1.2 1.2
sensor
474 01904 Replacing accel sensor One set Include; Function check 1.5 1.5
475 01908 Removal and installing EGR valve One set Include; Function check 2.1 2.5
476 01909 Replacing EGR valve One set Include; Function check 2.1 2.5
479 01916 Removal and installing EGR cooler One set 1.8 1.8
480 01917 Replacing EGR cooler One set 1.8 1.8
Removal and installing closed
481 01918 One set 0.3 0.3
ventilator
482 01919 Replacing closed ventilator One set 0.3 0.3

12-23
12. STANDARD MAINTENANCE TIME TABLE

[MEMO]

12-24
13. MAINTENANCE STANDARD AND
TEST PROCEDURE
TABLE OF CONTENTS 13
13.1 HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED ..........13-3
13.2 PERFORMANCE INSPECTION STANDARD TABLE.....................................................13-4
13.3 MEASUREMENT OF ENGINE SPEED ...........................................................................13-6
13.3.1 MEASUREMENT OF ENGINE SPEED..................................................................13-6
13.4 MEASUREMENT OF HYDRAULIC PRESSURE ............................................................13-7
13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE .......................................13-7
13.4.2 PLACE TO INSTALL PRESSURE GAUGE............................................................13-7
13.4.3 PRESSURE ADJUSTMENT POSITION.................................................................13-8
13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE.................................................13-10
13.5 MEASURING TRAVEL PERFORMANCES.....................................................................13-12
13.5.1 TRAVEL SPEED.....................................................................................................13-12
13.5.2 DEVIATION OF TRAVEL .......................................................................................13-12
13.5.3 PERFORMANCES OF PARKING BRAKE .............................................................13-13
13.5.4 DRAIN RATE OF TRAVEL MOTOR.......................................................................13-14
13.6 MEASURING SWING PERFORMANCES.......................................................................13-15
13.6.1 SWING SPEED ......................................................................................................13-15
13.6.2 PERFORMANCE OF SWING BRAKE ...................................................................13-15
13.6.3 PERFORMANCE OF SWING PARKING BRAKE ..................................................13-16
13.6.4 DRAIN RATE OF SWING MOTOR ........................................................................13-17
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES ....................................13-18
13.7.1 OPERATING TIME OF CYLINDERS .....................................................................13-18
13.7.2 OIL TIGHTNESS OF CYLINDERS.........................................................................13-19
13.8 MEASURING PERFORMANCES OF SWING BEARING ...............................................13-20
13.9 MECHATRO CONTROLLER...........................................................................................13-21
13.9.1 ENGINE CONTROL INPUT / OUTPUT ..................................................................13-21
13.9.2 ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT)..........13-21
13.9.3 OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO
CONTROLLER .......................................................................................................13-27

Book Code No. S5LC1311E02

13-1
13. MAINTENANCE STANDARD AND TEST PROCEDURE

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC1311E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)
S5LC1311E02
Revision February, 2007 ↑ K
(ASIA, OCE)

13-2
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.1 HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE

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

13-3
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.2 PERFORMANCE INSPECTION STANDARD TABLE

The mode is already "S" mode when power is thrown.

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

Table13-1
Measuring Position Standard Tolerance Adjusting Measuring
Inspection Item Unit
Position Size Port value Hi Lo Point condition

Class
NAS 9
Cleanliness of hydraulic oil Hydraulic oil in tank — — — Sampling
Standard Measuring condition

or less
Hydraulic oil temperature Tank surface 50 (122) + 5 (41) - 5 (23) °
C — Atmospheric temp
Water temperature Radiator surface 75 (167) + 15 (59) - 15 (5) (°F) — 50°C~-10°C (122°F~14°F)

H mode Lo idle 1000 + 25 - 25 LOW throttle

Engine speed

H mode Hi idle 2100 + 30 - 70 Full throttle (HI idle)

not required
Adjustment
Measure the engine
B mode Hi idle 2100 + 30 - 70 Perform all
speed at multi display on min-1
A mode Hi idle 2100 + 30 - 70 measurement with
the gauge cluster.
Decel 1050 + 25 - 25 the air-conditioner
S mode Hi idle 1900 + 30 - 70 "OFF".
Pilot primary pressure circuit G pump a4 5.0 (725) + 0.5 (+73) 0 PR1 HI idle
valve pressure

P1 a1
Main relief

ATT 34.3 (4970) + 0.7 (+100) - 0.5 (-73) MR1 Boom up

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

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

Over load relief valve pressure

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

Main pump

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

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

13-4
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

Standard
Inspection item Unit
value
1st speed 34.3 ~ 31.1
Track link revolution STD
2nd speed 20.4 ~ 18.4
(RH,LH) sec / 3 rev
1st speed 36.4 ~ 33.2
(H mode) LC
2nd speed 21.7 ~ 19.9
Up 2.7 ~ 3.3
Boom
Operating speed

Down 2.1 ~ 2.7

Operating time of
In 3.4 ~ 4.0
cylinder Arm sec (At no load)
Out 2.9 ~ 3.5
(At no load)
Digging 2.7 ~ 3.3
Bucket
Dumping 1.9 ~ 2.5
RH
Swing speed 17.1 ~ 19.1 sec / 3 rev
LH
1st speed Iron shoe 19.6 ~ 24.6
Travel speed sec / 20 m
2nd speed Iron shoe 12.3 ~ 14.3
Amount of travel
2nd speed 0 ~ 240 mm / 20 m
deviation
Parking brake drift 15 degree gradient 0 mm / 5 min
Performance of Swing Neutral position after
Performance

58 ~ 98 degree
brake 180° full speed swing
Performance of Swing
15 degree gradient 0 mm
parking brake
Tip of the bucket tooth 120
ATT amount of drift Boom cylinder 4.2 mm / 5min (At no load)
Arm cylinder 6
Amount of horizontal play at the bucket tooth 27 ~ 53 mm

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

 
   
 
 


 

13-5
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.3 MEASUREMENT OF ENGINE SPEED

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

(2) Engine speed measured value through service


 

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

 
4) The screen returns like No.45, No.44....each 

time the "Washer switch" is pushed.
5) The display does not disappear unless the
  

starter switch is turned to"OFF".
   

Fig. 13-1 Switch for E/G speed indication

NO.2 ENG
G-3 SPEED SET 2205
MEAS 1 2201
MEAS 2 2201
G-5 ENG OIL PRS. LIVE
WATER TEMP. 100 OF
F
MODE HM
H-1 ACCEL. VOLT. 4.2V
POS 100%
ECU OUTPUT 0.5V

Fig. 13-2 Service diagnosis for E/G speed

measuring (Example)

13-6
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.4 MEASUREMENT OF HYDRAULIC PRESSURE

13.4.1 PREPARING TO MEASURE HYDRAULIC PRESSURE
(1) Hydraulic equipment
6.9 MPa (1000psi) pressure gauge : 1unit
49 MPa (7100psi) pressure gauge : 2 units A3 a5
Pressure measuring equipment and instrument for
analysis : 1 set A2
PSV2 (A1)
(2) Measuring cleanliness of hydraulic oil (PSV1)
Dr3
B3

B1
After releasing air in the hydraulic oil tank, open the
cover and sample oil in the hydraulic tank, and a1 a2
measure with the instrument for analysis. If the
Fig. 13-3 Gauge port on main pump
measured value is higher than the standard value,
replace the return filter or change the hydraulic oil.

13.4.2 PLACE TO INSTALL PRESSURE GAUGE

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

13-7
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.4.3 PRESSURE ADJUSTMENT POSITION

(1) Main control valve

PLUG FOR
OR8 : ARM (R) OPTIONAL RELIEF

MACHINE
FRONT

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

(ATT & TRAVEL)

VIEW FROM THE TOP OF THE MACHINE

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

MACHINE
FRONT

OR7 : ARM (H) PLUG FOR OPTIONAL RELIEF

VIEW FROM THE BOTTOM OF THE MACHINE

Fig. 13-4 Relief valve position on main control valve

13-8
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

(2) Pilot relief valve

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

A3

a5

Dr3

B3
PR1 ADJUST SCREW
FOR PILOT RELIEF

Fig. 13-5 Pilot relif valve position

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

  








 







  





 


 
Fig. 13-6 Swing over load relief position

13-9
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.4.4 PROCEDURE FOR ADJUSTING RELIEF VALVE

(1) Pilot relief valve
Adjust it with adjust screw (311).

: 24 mm,
Tightening torque : 29.4 N•m (22 lbf•ft)

: 6 mm

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

LOCK NUT HEX24
1 turn Approx. 2.1 (305) 311
Fig. 13-7 Pilot relief valve
(2) 2-stage main relief valve
(Commom for travel and ATT sections) 0-:! 0-:'
Start from the boosting side, first. Loosen nut (1),

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

: 22 mm,
Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft)

: 19 mm, Adjust screw

: 6 mm

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

Boosting side 1 turn Approx. 17.6 (2560)
STD side 1 turn Approx. 17.6 (2560)

(3) Over load relief valve

(Boom, bucket, arm sections)
Loosen lock nut (1) and adjust it with adjust screw
(2).

: 22 mm,
Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft)

: 6 mm 0-:
Fig. 13-9 Over load relief valve
No. of turns of adjust screw Pressure change MPa (psi) (Boom, bucket, arm sections)

1 turn Approx. 17.7 (2560)

13-10
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

(4) Over load relief valve (Swing) 0-:!& 0-:!

When the adjustment of pressure is required, 
loosen lock nut (1) and adjust the pressure with cap
(2).

: 30, 38 mm,
Tightening torque : 118 N•m (87 lbf•ft)
4 !
: 12 mm Fig. 13-10 Swing over load relief valve

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

1 turn Approx. 10 (1450)

(5) Travel over load relief valve

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

Fig. 13-11 Travel over load relief valve

13-11
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.5 MEASURING TRAVEL PERFORMANCES

13.5.1 TRAVEL SPEED
(1) Purposes
Measure the track link revolution and confirm the
performances between the hydraulic pump and the
travel motor of the travel drive system.
(2) Conditions
Hydraulic oil temperature ;
45~55°C (113~131°F)
Crawler on the right and left sides are tensioned
evenly.
(3) Preparation
Attach the reflection panel shoe plate. Fig. 13-12 One side lifted position
Swing the swing frame through 90°as shown in Fig.
13-12 and make the crawler on one side take off the
ground, using the attachment. REFLECTION
PANEL
(4) Measurement
Engine revolution; Hi idle
2-speed travel switch; 1st-speed and 2nd-speed
Measuring points ; Right and left
Method, example
Measure the revolutions visually.

Fig. 13-13 Adhering position of reflection panel

Track link revolution Unit : sec / 3 rev

Measurement item Standard Reference value Service
value for remedy limit
H mode 1st speed 31.1~34.3 39.8~43.9 49.1~
STD
H mode 2nd speed 18.4~20.4 23.6~26.1 29.1~
H mode 1st speed 33.2~36.4 42.5~46.6 57.2~
LC
H mode 2nd speed 19.7~21.7 25.2~27.8 31.1~

13.5.2 DEVIATION OF TRAVEL

(1) Purpose
Measure the amount of deviation at 20m (66ft) BOOM FOOT PIN
travel and confirm the horizontal balance between
the hydraulic pump and the travel motor of the
travel drive system.
(2) Condition
Hydraulic oil temperature ; ARM TOP PIN
45~55°C (113~131°F)
RH and LH crawler are tensioned evenly.
Firm, level ground Fig. 13-14 Travel position
Engine revolution; Hi idle

13-12
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

(3) Preparation
1) Straight course more than 30m (108ft)
2) Travel position in which the bottom of the bucket
is lifted by about 30cm (1ft). A
(4) Measurement 20m (66ft)
1) Measure the max. deviation distance of the
circular arc in the 20m (66ft) length, excluding
Fig. 13-15 Measuring method
the preliminary run of 3~5m (10~16ft).
2) Operate the travel lever at the same time. Travel deviation Unit : mm (in) / 20m (66ft)
Measuring Reference value
position Standard value for remedy Service limit
A 240 (9.45") or less 480 (18.9") 720 (28.4")

13.5.3 PERFORMANCES OF PARKING BRAKE

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

C
GUIDE FRAME
Fig. 13-17 Method of measurement

Parking brake Unit : mm/5min

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

13-13
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.5.4 DRAIN RATE OF TRAVEL MOTOR

(1) Purpose FORWARD 90 o 10
To measure the drain rate of the travel motor and to (3.54") (0.394")

confirm the performances of the travel motor. o 22 PIPE 40

(0.866") (1.57")
(2) Conditions
Hydraulic oil temperature ; RIB "A" STOPPER
150
(5.91")
45~55°C(113~131°F) "B"
Engine revolution; Hi idle
(3) Preparation o 90
(3.54")
ROTARY DIRECTION
1) Place a stopper under the RH and LH travel
sprockets. Fig. 13-18 Location of stopper applied to travel
2) Stop the engine and release pressure from the sprocket
hydraulic circuit.
3) Connect a hose with the drain port of the travel
motor and take drain in a container.
(4) Measurement ; at Travel Lock

Unless you observe the rotary force direction at

travel lock, rib "A" may be broken by stopper "B" in
some cases. (See Fig. 13-18)

1) Start the engine and relieve pressure at the full

stroke of the travel lever. Fig. 13-19 Method of measuring the drain rate of
2) Measure the drain rate for 30 seconds of travel motor
relieving.
Travel deviation Unit : L/30sec
Measuring Reference value
position Standard value for remedy Service limit
Drain rate 7.0 (1.8 gal) 14.0 (3.7 gal) 21.0 (5.5 gal)

13-14
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.6 MEASURING SWING PERFORMANCES

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

13.6.2 PERFORMANCE OF SWING BRAKE

(1) Purpose $ 

  ! 
"# 

Confirm the braking torque performances by the
 





swing relief valve.

  

 

 


    
(2) Conditions
Hydraulic oil temperature ;

   
45 ± 55°C (113±131°F)
Firm, level ground
Engine revolution; Hi idle
(3) Preparation
1) Put the bucket empty, retract the arm cylinder
1.5m (4'11")
fully and extend the bucket cylinders fully. And
move the boom so that the arm top pin is Fig. 13-21 Swing brake performance measuring
positioned at same height with boom foot pin. position
2) Put a matching mark on the outer circumference
of the swing bearing of the upper frame side and
of the track frame side. Place two poles (flags)
on the front and back of the extended line of the
matching mark.

13-15
13. MAINTENANCE STANDARD AND TEST PROCEDURE

(4) Measurement MEASURING THE LENGTH OF THE ARC OVER

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

   
  Fig. 13-22 Measuring position of swing brake
 

 
 performances

   
  

   
   
 Swing brake performance Unit : degree
Measuring Reference value
position Standard value for remedy Service limit
Swing 180 98 or less 108 118

13.6.3 PERFORMANCE OF SWING PARKING BRAKE

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

Fig. 13-24 Measuring position of swing parking

brake performances

Performance of swing parking brake Unit : mm/5min

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

13-16
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.6.4 DRAIN RATE OF SWING MOTOR

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

3) Collect the amount of drained oil in a container

for 30 seconds.

13-17
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES

13.7.1 OPERATING TIME OF CYLINDERS
(1) Purpose
Measure the operating time of the boom, arm and
bucket and confirm the performances between the
hydraulic pump and the cylinder of the attachment
drive system.
(2) Condition 30cm (1ft)
Hydraulic oil temperature ; 45~55°C(113~131°F) Fig. 13-26 Measuring position for bucket digging
Engine revolution; Hi idle and dump
Operating time excluding the cushion stroke


 
(3) Preparation 
 

  
  

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

When lowering the boom, allow the bucket onto a

soft ground or cushioning such as rubber tires ;
never put the bucket against concrete or other
solid material.
30cm (1ft)
Measurement 2 ; Arm in and out, bucket digging
and dump Fig. 13-28 Measuring position for arm in and out
In a position in which the tooth of the bucket rises to motions
a level of about 30cm (1ft) above ground, measure
Cylinder Operating time Unit : sec
the full stroke operating time required with the arm
Measuring Reference value
and bucket operating levers at full stroke. position Standard value for remedy Service limit
2.7~3.3 3.5~4.2 4.5~
1.9~2.5 2.4~3.2 3.3~
2.7~3.3 3.5~4.2 4.5~
2.1~2.7 2.7~3.5 3.6~
3.4~4.0 4.4~5.1 5.6~
2.9~3.5 3.7~4.5 4.8~

13-18
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.7.2 OIL TIGHTNESS OF CYLINDERS

(1) Purpose
Confirm that the cylinder oil tight by checking the   

moving length of the cylinder rods.

(2) Condition 
Hydraulic oil temperature ; 45~55°C (113~131°F)
Firm, level ground   

After cylinders are replaced, bleed off air from the

cylinders, before checking for oil tightness. Fig. 13-29
Retract the arm cylinder rod 50mm (2in) from stroke
end so that the piston does not match a same range Oil tightness of cylinder Unit : mm/5min
of the cushioning mechanism. Measuring
Standard value
Reference value
Service limit
position for remedy
(3) Preparation A 4 (0.16 in) 5 (0.2 in) 7 (0.28 in)
Put the bucket empty. Extend the arm cylinder rod B 6 (0.24 in) 7.5 (0.3 in) 10 (0.4 in)
50mm (2in) from the most retracted position. And C - - -
extend the bucket cylinders fully. Then hold the D 120 (4.7 in) 150 (5.9 in) 200 (7.9 in)
boom so that the arm top pin is positioned at same
height with boom foot pin.
(4) Measurement
Measure the items five minutes after the engine is
turned off.

13-19
13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.8 MEASURING PERFORMANCES OF SWING BEARING

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

the reading at zero. Fig. 13-31 Measuring position 1

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

Fig. 13-32 Measuring position 2

Axial play of swing bearing Unit : mm (in)

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

(5) Measurement 2 (Measuring position 3)

1) With the arm cylinder most retracted and the ARM TOP BOOM FOOT
PIN PIN
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 the man power.
But in this case, the gap of the attachment is
included.

Fig. 13-33 Measuring position 3

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

Measuring Reference value
position Standard value for remedy Service limit
Bucket 30~50 (1.18~1.97) 100 (3.94) 120 (4.72)

13-20
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.9 MECHATRO CONTROLLER

13.9.1 ENGINE CONTROL INPUT / OUTPUT

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

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

ENGINE
ENGINE SPEED
SENSOR

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

Fig. 13-34 INPUT / OUTPUT

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

13.9.2.1 PURPOSE OF THE ADJUSTMENT

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

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

When the following parts are replaced or repaired, carry out the adjustment without fail.
(1) Mechatro controller
(2) Engine or engine controller
(3) Hydraulic pump or hydraulic pump proportional valve
(4) Unloading proportional valve, spool of unloading valve

13-21
13. MAINTENANCE STANDARD AND TEST PROCEDURE

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

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

13-22
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

13.9.2.4 ADJUSTING PROCEDURE

MULTI DISPLAY

BUZZER STOP SWITCH WORK MODE SELECT SWITCH

WASHER SWITCH

WIPER SWITCH
SELECTOR SWITCH

Fig. 13-35 Gauge cluster

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


2) Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release
it and the screen for selecting adjustment is displayed. When adjustment data
ADJUST
READY
is not entered in mechatro controller, "READY" is indicated. If the adjustment FEED
operation is once performed, "FIN" is indicated.
And the lever lock solenoid is automatically released, disabling all operations.
3) Press selector switch on gauge cluster to display "START ENG".
START ENG
"Engine SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration ENGINE SPEED
2000rpm
command voltage) are indicated. PUMP PRESSURE
C-1 00.0M C-2 00.0M
STEP
140

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



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





 
adjustment of engine is performed.





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

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

unloading adjustment required later are not performed, and default value is
written.)

13-23
13. MAINTENANCE STANDARD AND TEST PROCEDURE

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

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

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






unloading proportional valve and pump proportional valve actuate, accordingly   


   
the loading of pump is increased. 


 
 
The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 pump
"PROPO-VALVE" current (command value) are indicated.
2) After detection of the engine rated speed, the adjustment of pump is
FINISH PUMP
automatically completed. And "FINISH PUMP" is displayed. ENGINE SPEED
2000rpm
(Press the buzzer stop switch on gauge cluster while this display is appeared PUMP PRESSURE
C-1 35.0M C-2 35.0M
and the adjustment is completed. The unloading adjustment required later is PROPO-VALVE
E-1 300mA E-2 300mA

not performed, and default value is written.)

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

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

VALVE" voltage (command value) are indicated.

2) When the unloading valve operates to the specified value, the adjustment of


 

unloading proportional valve is automatically terminated. And "FINISH 
  


UNLOAD" is displayed.  
   
  
The speed is shifted to the speed corresponding to acceleration potentiometer.
 
 

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

unloading proportional valves. The adjusting range is usually 520~635mA.

Stop the engine. (The adjusted data is automatically stored.)

(4) Corrective actions taken when the adjustment can not be performed;
ERROR ENG.
1) In cases where the adjustment of engine can not be performed; And ERROR ENGINE SPEED
2000rpm
PUMP PRESSURE
ENG" is displayed. C-1 2.0M C-2 2.0M
STEP
Judging condition: The read engine speed is 50rpm lower than the last value. 400

It is conceived that the error is caused by the speed read error, pump load
applied to the engine and unusual acceleration command voltage applied to
the engine controller in the course of adjustment.
a. Checking speed sensor: Check that it is free from wrong reading of speed
due to engine vibration.
b. Checking load applied to pump: Check that it is free from abnormal
increase of pump pressure during adjustment of engine through
adjustment screen.
c. Checking acceleration command voltage: Measure the acceleration
command voltage output from mechatro controller to engine controller.
Check that signal is regularly input to the engine controller by actual
measurement of voltage or with failure diagnosis tool of engine controller.

13-24
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

2) In cases where the adjustment of pump can not be performed; And "ERROR
ERROR PUMP
PUMP" is displayed. ENGINE SPEED
2000rpm
Judging condition 1: PUMP PRESSURE
C-1 35.0M C-2 35.0M
PROPO-VALVE
P1 and P2 average pump pressure at the time when the adjustment is E-1 300mA E-2 300mA
completed is 25MPa or less.
Judging condition 2:
The adjustment does not complete although the pump proportional valve
current reaches to the specified value.

The P1 and P2 pump pressures usually increase to 33~38MPa

(4785~5510psi).
When the pressure does not increase;
a. Identify the reason why the pressure does not increase,
• Check that the relief valve operates normally.
• Check that the hydraulic circuit is free from leak of pressure.
• Check that the pressure sensor functions normally.
And so on.
b. Identify the reason why the actual flow rate does not increase,
• Check that the pump proportional valve operates normally.
• Check that the pump regulator operates normally.
And so on.
3) In cases where unloading valve can not be performed; And "ERROR
ERROR UNLOAD
UNLOAD" is displayed. ENGINE SPEED
2000rpm
Judging condition 1: PUMP PRESSURE
C-1 2.0M C-2 2.0M
PROPO-VALVE
The pump pressure does not increase up to the pressure in the range of the D-1 300mA D-2 300mA
specified adjustment. Or the increased pressure is held as it is.
Judging condition 2:
Pressure sensor of either P1 pump or P2 pump is failed.

Normally the pump pressures of P1 and p2 pumps gradually increase to

10~25MPa (1450~3625psi).
(It may be affected by operating oil temperature.)

When the pump pressure does not increase;

a. Identify the reason why the pressure does not increase,
• Check that the relief valve operates normally.
• Check that the hydraulic circuit is free from leak of pressure.
• Check that the pressure sensor functions normally.
And so on.
(5) Other precautions:
1) In the event of a failure, there is case where the adjustment may not be
performed normally.
First serve the machine, and perform the adjustment work.
2) In the condition where large load is constantly applied to engine, the
adjustment could not be performed normally.

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

13-25
13. MAINTENANCE STANDARD AND TEST PROCEDURE

(6) When the adjustment of unloading valve only is performed; ("C" adjustment)
In the event where only unloading valve and unloading proportional valve are
replaced, perform the adjustment of unloading valve only.
Procedure
1) Turn starter switch ON keeping the work mode selector switch on the gauge    
cluster pressed, and hold it for 5~10 seconds, and then release it.  
(If the engine is started, the following indication is not displayed. Therefore do
not start the engine.)


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

 

select "ADJUST UNLOAD". (See Fig. 13-35)


Like the output adjustment, when adjustment data is not entered in mechatro 

controller, "READY" is indicated. If the adjustment operation is once
performed, "FIN" is indicated.
4) Press selector switch on gauge cluster to display "START ENG".
START ENG
"ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration ENGINE SPEED
2000rpm
command voltage) are indicated. PUMP PRESSURE
C-1 00.0M C-2 00.0M
STEP
140

5) After starting engine, press selector switch on gauge cluster and "MEMORY
MEMORY UNLOAD
UNLOAD" is indicated, the engine speed is automatically increased and the ENGINE SPEED
2000rpm
adjustment of unloading valve is performed. PUMP PRESSURE
C-1 2.0M C-2 2.0M
"ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "PROPO-VALVE" PROPO-VALVE
D-1 300mA D-2 300mA

(acceleration command current) are indicated.

6) When the unloading proportional valve operates to the specified value, the


 

adjustment of unloading proportional valve automatically completes. "FINISH 
  


UNLOAD" is indicated.  
   
  
The speed is shifted to the speed corresponding to acceleration potentiometer.
 
 

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

P2 unloading proportional valves. The adjusting range is usually 520~635mA.

Stop the engine. (The adjusted data is automatically stored.)

13-26
 13. MAINTENANCE STANDARD AND TEST PROCEDURE

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

(1) Engine emergency mode
When the trouble occurs and the control of engine is impossible, the engine speed can be controlled by operating
emergency acceleration (E-27) provided on the seat rear side. (See Fig. 13-34)

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

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

(2) Pump emergency mode

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

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

13-27
13. MAINTENANCE STANDARD AND TEST PROCEDURE

[MEMO]

13-28
 21. MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS

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

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

Book Code No. S5LC2111E02

21-1
21. MECHATRO CONTROL SYSTEM

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC2111E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)
S5LC2111E02
Revision February, 2007 ↑ K
(ASIA, OCE)

21-2
 21. MECHATRO CONTROL SYSTEM

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

21-3
21. MECHATRO CONTROL SYSTEM

21.1 SUMMARY OF MECHATRO CONTROL SYSTEM

21.1.1 MECHATRO CONTROL SYSTEM IN GENERAL

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21-4
 21. MECHATRO CONTROL SYSTEM

MAIN CONTROL VALVE

L1

SE-29

ARM OUT DUMP DOWN FORWARD FORWARD LEFT ARM OUT

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

P1 UNLOAD

ATTACHMENT BOOST

SELECTOR VALVE
CONFLUX
BOOM UP
BOOM LOW SPEED

TRAVEL RIGHT
ARM 2 SPEED

ARM 1 SPEED
TRAVEL LEFT

N&B
BUCKET

P2 UNLOAD

OPTION
STRAIGHT

SWING
TRAVEL

PL1
SOL

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

L4

SWING MOTOR PARKING RELEASE

TRAVEL MOTOR 1,2 SPEED SELECT

BOOM CYLINDER
BOOM DOWN RECIRCULATION
BOOM CONFLUX
SWING PARKING BRAKE

SAFETY LOCK LEVER

ATTACHMENT BOOST

TRAVEL 1,2 SPEED

TRAVEL STRAIGHT
ARM IN 2 SPEED

L5
P1 UNLOAD

P2 UNLOAD

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

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

L7
PROPORTIONAL VALVE
SOLENOID VALVE ) BLOCK

21-5
21. MECHATRO CONTROL SYSTEM

21.1.2 UNLOAD VALVE CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

VALVE

SWING

BOOM
STRAIGHT
SOLENOID

TRAVEL
P2 UNLOAD
P2 P1

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

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

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

MECHATRO
PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE

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

21-6
 21. MECHATRO CONTROL SYSTEM

21.1.3 POSITIVE CONTROL & P-Q CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
P2 UNLOAD
SOLENOID

TRAVEL
OPTIONAL
PILOT VALVE
P2 P1

SE-23 SE-22

SE-11

(LEFT) (RIGHT) PILOT PILOT

VALVE VALVE

PILOT VALVE
FOR TRAVEL

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

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

PILOT SECONDARY PRESSURE

pi

pi

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

21-7
21. MECHATRO CONTROL SYSTEM

(1) Positive control

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

POSITIVE CONTROL P-Q CONTROL

PILOT SIGNAL PROCESS PILOT SIGNAL PROCESS

SECONDARY PRESSURE

SECONDARY PRESSURE
PUMP PROPORTIONAL

PUMP PROPORTIONAL

PILOT PRESSURE PUMP DELIVERY PRESSURE

21-8
 21. MECHATRO CONTROL SYSTEM

21.1.4 BOOM UP CONFLUX CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
PILOT P2 P1
VALVE

LOW
PRESSURE
SENSOR
SE-3

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

BOOM UP PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

BOOM UP PILOT SECONDARY PRESSURE

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

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

21-9
21. MECHATRO CONTROL SYSTEM

21.1.5 ARM IN RECIRCULATION & CONFLUX CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED

ARM 2 SPEED
N&B
SELECTOR

BUCKET
OPTION

SWING

BOOM
VALVE

STRAIGHT
P2 UNLOAD
SOLENOID

TRAVEL
PILOT
VALVE
P2 P1

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

CONTROL PROCESS
FOR 2 SPEED

pi PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

ARM IN PILOT SECONDARY PRESSURE

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

PILOT SECONDARY PRESSURE

PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

ARM IN PILOT SECONDARY PRESSURE

P1 UNLOAD
pi PROPORTIONAL
VALVE PSV-D

PILOT SECONDARY PRESSURE

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

P2 PUMP PRESSURE MECHATRO pi : PROPORTIONAL VALVE

CONTROLLER SECONDARY PRESSURE

21-10
 21. MECHATRO CONTROL SYSTEM

(1) Recirculation and conflux (Low loading)

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

21-11
21. MECHATRO CONTROL SYSTEM

21.1.6 ARM-IN ANTI-CAVITATION CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
PILOT
VALVE

P2 P1

LOW
PRESSURE ACCEL
SENSOR POTENTIO
SE-7

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

ARM IN PILOT SECONDARY PRESSURE

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

ARM IN PILOT SECONDARY PRESSURE

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

ENGINE SPEED (COMMAND VALUE) MECHATRO

CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE

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

21-12
 21. MECHATRO CONTROL SYSTEM

21.1.7 ARM-OUT CONFLUX CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
PILOT P2 P1
VALVE

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

ARM OUT PILOT SECONDARY PRESSURE

pi

P1 PUMP
PROPORTIONAL
VALVE PSV-P1

ARM OUT PILOT SECONDARY PRESSURE

pi
P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

ARM OUT PILOT SECONDARY PRESSURE

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

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

21-13
21. MECHATRO CONTROL SYSTEM

21.1.8 BUCKET DIGGING (DUMP) CONFLUX CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
PILOT
VALVE P2 P1

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

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 UNLOAD
PROPORTIONAL
VALVE PSV-D

BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE

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

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

21-14
 21. MECHATRO CONTROL SYSTEM

21.1.9 BUCKET DIGGING ANTI-CAVITATION CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
TRAVEL LEFT
ARM 1 SPEED

ARM 2 SPEED
N&B
SELECTOR

BUCKET
OPTION

SWING

BOOM
VALVE

STRAIGHT
P2 UNLOAD
SOLENOID

TRAVEL
PILOT
VALVE
P2 P1

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

BUCKET DIGGING PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

BUCKET DIGGING PILOT SECONDARY PRESSURE

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

BUCKET DIGGING PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS TRAVEL STRAIGHT
PROPORTIONAL
VALVE PSV-C

BUCKET DIGGING PILOT SECONDARY PRESSURE

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

ENGINE SPEED (COMMAND VALUE)

MECHATRO
CONTROLLER
P1 PUMP PRESSURE pi : PROPORTIONAL VALVE
SECONDARY PRESSURE

21-15
21. MECHATRO CONTROL SYSTEM

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

21-16
 21. MECHATRO CONTROL SYSTEM

21.1.10 SWING PRIORITY CONTROL

BOOM UP CONFLUX

P1 UNLOAD
PILOT

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
VALVE

TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
P2 P1

LOW
PRESSURE
SENSOR

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

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

MECHATRO pi : PROPORTIONAL VALVE

SWING PILOT SECONDARY PRESSURE CONTROLLER SECONDARY PRESSURE

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

21-17
21. MECHATRO CONTROL SYSTEM

21.1.11 TRAVEL STRAIGHT CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
OPTIONAL

ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
PILOT VALVE N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
P2 UNLOAD
SOLENOID

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

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

TRAVEL STRAIGHT SIGNAL

pi
PILOT SIGNAL TRAVEL STRAIGHT
PROCESS PROPORTIONAL
VALVE PSV-C

PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

PILOT SECONDARY PRESSURE

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

21-18
 21. MECHATRO CONTROL SYSTEM

(1) Judgment travel straight

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






  
 



 


 

 


 

21-19
21. MECHATRO CONTROL SYSTEM

21.1.12 PRESSURE RELEASE CONTROL

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
GAUGE CLUSTER PILOT
VALVE
P2 P1

SE-23 SE-22

ENGINE

PRESSURE
RELEASE
CONTROL ENGINE SPEED
CONTROL

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

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

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

21-20
 21. MECHATRO CONTROL SYSTEM

21.1.13 N&B SWITCH CONTROL (OPTION)

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

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

BUCKET
OPTION
SE-29

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD

TRAVEL
P2 P1

A MODE

B MODE

GAUGE CLUSTER

pi

B MODE SWITCH MECHATRO

CONTROLLER

pi : OUTPUT OF N&B SELECTOR SOLENOID

(1) Nibbler circuit

1) Select A mode through gauge cluster.
2) Nibbler display appears on gauge cluster.
3) The return oil from the nibbler passes through selector valve and option spool and led to tank line of main
control valve.
4) When selecting A mode through gauge cluster, the breaker pressure sensor has not function to output.
It is in normal when there is no output from sensor in A mode, and in cases of other than above, error display
is output to gauge cluster.
(2) Breaker circuit
1) Select B mode through gauge cluster.
2) Breaker display appears on gauge cluster.
3) The return oil from the breaker passes through selector valve and directly returns into hydraulic oil tank.
4) When selecting B mode through gauge cluster, the breaker pressure sensor outputs signal.
It is in normal when there is an output from sensor in B mode, and in cases of other than above, error display
is output to gauge cluster.

21-21
21. MECHATRO CONTROL SYSTEM

21.1.14 OPTION CONFLUX CONTROL (OPTION)

BOOM UP CONFLUX

P1 UNLOAD

TRAVEL RIGHT
ARM 1 SPEED

ARM 2 SPEED
TRAVEL LEFT
N&B
SELECTOR

BUCKET
OPTION

SWING
VALVE

BOOM
STRAIGHT
SOLENOID

P2 UNLOAD
PILOT VALVE

TRAVEL
P2 P1

SINGLE / CONFLUX
LOW
SWITCH
PRESSURE
SENSOR
SE-11

pi
PILOT SIGNAL
PROCESS P2 PUMP
PROPORTIONAL
VALVE PSV-P2

OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P1 PUMP
PROPORTIONAL
VALVE PSV-P1

OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
PROCESS P2 UNLOAD
PROPORTIONAL
VALVE PSV-B

OPTION PILOT SECONDARY PRESSURE

pi
PILOT SIGNAL
P1 UNLOAD
PROCESS PROPORTIONAL
VALVE PSV-D

OPTION PILOT SECONDARY PRESSURE

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

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

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

21-22
 21. MECHATRO CONTROL SYSTEM

21.2 MECHATRO CONTROLLER

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

EMERGECY ACCEL DIAL

SWING PARKING
BRAKE RELEASE
GAUGE SWITCH
CLUSTER

SAFETY
LOCK
LEVER
RIGHT
CONTROL
LEVER
WITH ATT
BOOST SW.

FUSE &
STARTER SWITCH RELAY BOX

ACCEL DIAL
DETAIL A

(2) Gauge cluster

No. Name
11 1 Engine coolant temperature gauge
2 Fuel level gauge
22:00
3 Screen change switch
H
4 Buzzer stop switch
5 Work mode select switch
1
6 Washer switch
7 Wiper switch
2
3 8 Travel high speed, low speed select switch
9 Auto accel switch
10 10 Select switch
6
4 9 8 5 7 11 Multi display (LCD)

21-23
21. MECHATRO CONTROL SYSTEM

(3) Screen selection by work mode select switch

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

• S mode: For standard excavating work

• H mode: For heavy duty excavating work
• B mode: For works with breaker
• A mode: For demolition works with crusher
(Nibbler)
10:25
S
• The initial setting (default) of work mode had been set
to "S" mode at factory.
As for the work mode after the engine starts, the
mode that was used the last time engine was stopped
is automatically set.
Check that the selected mode conforms to the work
before starting work.
• Check that the attachment in use conforms to the
work mode before starting work. If not conformed,
select proper mode with the work mode select switch.
• The operation under improper work mode may cause
damage to machine.

Work mode Display Contents

S mode
10:25 "S mode"is suitable for standard digging and loading works and is in
fuel saving and is maintained well-balanced relations with workload.

H mode
10:25 "H mode"is suitable for heavy duty digging work which gives priority
to the workload at the high speed.

B mode
10:25 For the work with breaker, select "B mode" without fail.

A mode
10:25 For the work with crusher (nibbler), select "A mode".

For the work with breaker, select "B mode" without fail.
The work with breaker in any mode other than "B mode" may cause damage to the hydraulic equipment and
breaker.

21-24
 21. MECHATRO CONTROL SYSTEM

1) Pump flow rate adjustment (A mode /B mode)

No. Switches 1 2 3 4
1 Screen change switch
2 Buzzer stop switch
3 KPSS work mode select switch
4 Washer switch
5 Wiper switch
6 Travel speed select switch
7 Auto accel switch 5
8 Select switch 8 7 6
Fig. 21-1

According to some kind of attachment, it is required to change the flow rate for service circuit. Change the flow rate
in accordance with the procedure mentioned below.
In this machine, last set flow rate has been stored and the initial flow rate is 210L/min. The adjustment (increase or
decrease) of flow rate is changeable by 10L/min step.

Main screen Attachment mode (A mode)

10:25 Flow
rate 294 L/m
Flow
rate 100 L/m
Flow
rate 100 L/m

Enter
H A A
(a) (b) (d)
Increase/Decrease

In Breaker mode (B mode)

Flow Flow Flow

rate 294 L/m rate 100 L/m rate 100 L/m

Enter
B B
(c) (d)
Screen in Attachment/Breaker mode Increase/Decrease
A mode B mode When the conflux switch is tuned
on, the double flow rate is displayed.
Flow Flow
rate 294 L/m rate 294 L/m

A B
(b) (c)

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

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

21-25
21. MECHATRO CONTROL SYSTEM

(4) MAINTENANCE SCREEN DISPLAYS

This screen displays the remaining time to the end of recommended replacement/change interval specified for
filter/oil.
For the initial set value of recommenced replacement/change time, see the following table.

Replacement interval
Item Default
Engine oil 500 Hr
Fuel filter 500 Hr
Hydraulic oil filter 1,000 Hr
ASIA 2,000 Hr
Hydraulic oil
OCEANIA 5,000 Hr

This menu is available for confirmation of the following items.

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

1. Remaining time display to the engine oil change

This display shows the remaining time to the coming engine oil change. 492Hr
ENGINE OIL
H

2. Remaining time display to the coming fuel filter replacement

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

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

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

4. Remaining time display to the coming hydraulic oil change

This display shows the remaining time to the coming hydraulic oil 1992Hr
change. HYD. OIL
H

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

21-26
 21. MECHATRO CONTROL SYSTEM

(5) Gauge cluster display

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

SELF DIAGNOSIS / WARNING

MACHINE CONDITION
H
MULTI DISPLAY INDICATIONS

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

. Warning These descriptions indicate error codes.

CAUTION LOW ENG OIL

W009 W005 PREHEAT W011
ATTACHMENT PRESS.

HIGH ENG
AUTO IDLE STOP WATER TEMP.
W006 CHARGE ERROR

POWER BOOST LOW ENG WATER

ON LEVEL
W004 LOW FUEL LEVEL

WARM FINISH WARM-UP DRAIN WATER SEPA W010 WARM AUTO WARMING UP

DATA
CPU COMMUNICATION CLOGGED AIR FLTR W008 CHANGE ENG OIL
ERROR

SWING BRAKE
ENGINE STOP
DISENGAGED

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

21-27
21. MECHATRO CONTROL SYSTEM

21.2.2 SELF DIAGNOSIS DISPLAY

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


!
 


 


 




   
 

  

 


(3) Self diagnosis display items

As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure type with
the aid of error code.
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21-28
 21. MECHATRO CONTROL SYSTEM

Note) The numbers in the column of "page for reference" show the related page in Chapter 51 Engine.

21-29
21. MECHATRO CONTROL SYSTEM

21.2.3 SERVICE DIAGNOSIS DISPLAY FUNCTION

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

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

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

21-30
 21. MECHATRO CONTROL SYSTEM

(2) Service diagnosis display screen (Example)

The service diagnosis display screen list is shown below. The conditions for display are H mode, engine low
speed and lever to neutral position.)
1) Service diagnosis mode No.1
No. Displays Contents No. Displays Contents
1 4
NO.1 NO.4 RELAY
MAIN CONT. P/N
YN22E00001F1 P/No. indication K-1 AIS RELAY 2 OFF Indicated value
PROGRAM VERSION K-2 SAFETY RLY OFF Indicated value
1-VER 11.11 Program version indication K-3 ENG STOP OFF Indicated value
2-VER 00.00 MERIT controller program version KEY SWITCH OFF Key switch
START SWITCH OFF Starter switch
SERVICE DIAG 1 Service diagnosis mode CHARGE LIVE Alternator
K-4 LOCK LEVER OFF Indicated value
SWITCH OFF Switch

2 5
NO.2 ENG NO.5 PRESS.SENSOR
G-3 SPEED SET 2205 No load setting rpm B-1 BOOM RAISE
MEAS1 2201 Actual rpm 1 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS2 2201 Actual rpm 2 (Engine controller) B-2 BOOM LOWER
G-5 ENG PRS. LIVE Engine oil pressure 3.5V 2.6M Sensor voltage / Pressure converted value
WATER TEMP 100 OFF Coolant temperaturre sensor B-3 ARM OUT
MODE HM Work mode 3.5V 2.6M Sensor voltage / Pressure converted value
H-1 ACCEL VOLT. 4.2V Potentiometer voltage B-4 ARM IN
POS. 100% Voltage % indication 3.5V 2.6M Sensor voltage / Pressure converted value
ECU OUTPUT 0.5V Accel output voltage to engine B-5 BUCKET DIG
controller 3.5V 2.6M Sensor voltage / Pressure converted value
B-6 BUCKET DUMP
3.5V 2.6M Sensor voltage / Pressure converted value

3 6
NO.3 SOL.VALVE NO.6 PRESS.SENSOR
F-1 POWER BOOST B-7 SWING
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-9 TRAVEL(R)
SWITCH OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
F-2 SWING-BRAKE B-10 TRAVEL(L)
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-16 P1 OPT.
RELEASE SW OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
F-3 1/2-TRAVEL B-17 P2 OPT.
COMP. OFF Set value in computer 3.5V 2.6M Sensor voltage / Pressure converted value
MEAS. OFF Measured value B-18 DOZER 1
SWITCH OFF Switch 3.5V 2.6M Sensor voltage / Pressure converted value
B-19 DOZER 2
3.5V 2.6M Sensor voltage / Pressure converted value

21-31
21. MECHATRO CONTROL SYSTEM

7 16
NO.7 P.SENSOR PROPO-V NO.16 PRESS.SENSOR
C-1 PUMP P1 B-11
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
C-2 PUMP P2 B-12
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
C-3 BOOM-HEAD B-13
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
C-4 BOOM-ROD B-14
3.5V 32.6M Sensor voltage / Pressure converted value 3.5V 12.6M Sensor voltage / Pressure converted value
PROPO-VALVE B-15
E-3 OPT RELIEF 1 Set value in computer / Converted value from pressure 3.5V 12.6M Sensor voltage / Pressure converted value
COMP. 600mA 14.5M Measured value / Converted value from pressure B-20
MEAS. 600mA 14.5M 3.5V 12.6M Sensor voltage / Pressure converted value
E-4 OPT RELIEF 2 Set value in computer / Converted value from pressure
COMP. 600mA 14.5M Measured value / Converted value from pressure

8 NO.8 PROPO-VALVE
18
NO.18 DIGITAL INPUT
D-1 P1 UN-LOAD(BP-CUT) DI1 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI2 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI3 OFF ON/OFF indication
D-2 P2 UN-LOAD(BP-CUT) DI4 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI5 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI6 OFF ON/OFF indication
See
D-3 S-TRAVEL DI7 OFF ON/OFF indication
Mechatro
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI8 OFF ON/OFF indication
controller
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI9 OFF ON/OFF indication
connector
D-6 ARM IN-2-SPEED DI10 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI11 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI12 OFF ON/OFF indication
DI13 OFF ON/OFF indication
DI14 OFF ON/OFF indication
9 19 NO.19 DIGITAL INPUT
NO.9 PROPO-VALVE
E-1 P1 PUMP DI15 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI16 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI17 OFF ON/OFF indication
POWER SHIFT 100mA Power shift DI18 OFF ON/OFF indication
FLOW RATE 100L Flow rate of pump P1 DI19 OFF ON/OFF indication
E-2 P2 PUMP DI20 OFF ON/OFF indication
COMP. 600mA 4.5M Set value in computer / Converted value from pressure DI21 OFF ON/OFF indication
MEAS. 600mA 4.5M Measured value / Converted value from pressure DI22 OFF ON/OFF indication
POWER SHIFT 100mA Power shift DI23 OFF ON/OFF indication
FLOW RATE 100L Flow rate of pump P2 DI24 OFF ON/OFF indication
DI25 OFF ON/OFF indication
DI26 OFF ON/OFF indication
DI27 OFF ON/OFF indication
DI28 OFF ON/OFF indication
10 20
NO.10 SENSOR,SWITCH NO.20 DIGITAL INPUT
H-9 FUEL LEVEL DI29 OFF ON/OFF indication
4.5V 90 Fuel level DI30 OFF ON/OFF indication
H-10 HYD.OIL TEMP DI31 OFF ON/OFF indication
4.5V 30 Hydraulic oil temperature DI32 OFF ON/OFF indication
GLOW OFF Glow switch DI33 OFF ON/OFF indication
AIR FILTER LIVE Air filter clogging DI34 OFF ON/OFF indication
WATER SEPA. LIVE Water separator clogging DI35 OFF ON/OFF indication
ENG OIL FILTER LIVE Engine oil filter clogging DI36 OFF ON/OFF indication
FRONT WINDOW OFF Front window open/close switch DI37 OFF ON/OFF indication
DOUBLE FLOW ON Conflux/Single flow select switch DI38 OFF ON/OFF indication
KPSS SW OFF KPSS switch DI39 OFF ON/OFF indication
HEATER OFF Command from air heater DI40 OFF ON/OFF indication
ENG OIL LEVEL LIVE Engine oil level DI41 OFF ON/OFF indication
COOLANT LEVEL LIVE Coolant level DI42 OFF ON/OFF indication
11 21
NO.11 SOL.VALVE NO.21 DIGITAL OUTPUT
F-4 OPT SELECT DO1 COMP. OFF Set value in computer
COMP. OFF Set value in computer MEAS. OFF Measured value
MEAS. OFF Measured value (Feed back value) DO2 COMP. OFF Set value in computer
MEAS. OFF Measured value
SPOOL POS. NIB Spool position DO3 COMP. OFF Set value in computer
SELECT SWITCH NIB Mode of selector valve MEAS. OFF Measured value
F-5 FAN PUMP DO4 COMP. OFF Set value in computer
COMP. OFF Set value in computer MEAS. OFF Measured value
MEAS. OFF Measured value DO5 COMP. OFF Set value in computer
F-6 MEAS. OFF Measured value
COMP. OFF Set value in computer DO6 COMP. OFF Set value in computer
MEAS. OFF Measured value MEAS. OFF Measured value
DO7 COMP. OFF Set value in computer
MEAS. OFF Measured value
12 22
NO.12 POTENTIO. NO.22 DIGITAL OUTPUT
H-2 BOOM DO8 COMP. OFF Set value in computer
3.5V 137 Sent value from sensor / Converted value from angle MEAS. OFF Measured value
H-3 ARM DO9 COMP. OFF Set value in computer
3.5V 137 Sent value from sensor / Converted value from angle MEAS. OFF Measured value
DO10 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO11 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO12 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO13 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO14 COMP. OFF Set value in computer
MEAS. OFF Measured value

21-32
 21. MECHATRO CONTROL SYSTEM

No. Displays Contents No. Displays Contents

23 27
NO.23 DIGITAL OUTPUT NO.27 MERIT SYSTEM
DO15 COMP. OFF Set value in computer
MEAS. OFF Measured value COMMUNICATION OFF Status of communication in MERIT controller
DO16 COMP. OFF Set value in computer 4
MEAS. OFF Measured value
DO17 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO18 COMP. OFF Set value in computer 0412051200
MEAS. OFF Measured value
DO19 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO20 COMP. OFF Set value in computer
MEAS. OFF Measured value
DO21 COMP. OFF Set value in computer
MEAS. OFF Measured value
24 28
NO.24 DIGITAL OUTPUT NO.28 ENG CONT.
DO22 COMP. OFF Set value in computer TRANS.COUNT. 100 Counted number of transmission error
MEAS. OFF Measured value RECEIVE COUNT. 100 Counted number of reception error
DO23 COMP. OFF Set value in computer DIAG STATUS 9 Diagnosis status
MEAS. OFF Measured value NUMBER OF DIAG 100 Numbers of error
DO24 COMP. OFF Set value in computer BOOST PRESS. 100 Boost pressure
MEAS. OFF Measured value BOOST TEMP. -100 Boost temperature
DO25 COMP. OFF Set value in computer BAROMETRIC P. 100 Atmospheric pressure
MEAS. OFF Measured value FUEL TEMP. -100 Fuel temperature
DO26 COMP. OFF Set value in computer FUEL CONS. 200 Fuel consumption
MEAS. OFF Measured value INTAKE TEMP. -100 Intake air temperature
DO27 COMP. OFF Set value in computer ENG PRESS. 300 Engine oil pressure
MEAS. OFF Measured value GLOW OFF Glow output from ECU
DO28 COMP. OFF Set value in computer ENG STOP OFF Engine stop command from ECU
MEAS. OFF Measured value TORQUE 1000 Calculated torque of ECU
25
NO.25 WIPER SYSTEM
WIPER SW OFF Wiper switch
RISEUP SW OFF Wiper rise-up switch
REVERSE SW OFF Wiper reverse rotation switch
PREVENT ARC OFF Wiper motor ark prevention
CW MOTOR RLY OFF relay
CCW MOTOR RLY OFF Wiper normal rotation relay
WASHER SW OFF Wiper reverse rotation relay
MOTOR RELAY OFF Washer switch
Washer motor relay

2) Service diagnosis mode No.2

No. Displays Contents No. Displays Contents

1 33
NO.1 NO.33 BUCKET
MAIN CONT. P/N C-1 P1-PRES 13.9M Pump pressure sensor
YN22E00001F1 P/No. indication C-2 P2-PRES 13.9M Pump pressure sensor
PROGRAM VERSION E-1 P1-PSV 600mA Command current
1-VER 11.11 Program version indication E-2 P2-PSV 600mA Command current
2-VER 00.00 MERIT controller program version D-1 P1-UL(BPC) 600mA Command current
D-2 P2-UL(BPC) 600mA Command current
SERVICE DIAG 2 Service diagnosis mode D-3 S-TRAVEL 600mA Command current
B-5 BUCKET DIG 1.9M Bucket digging pressure sensor
B-6 BUCKET DUMP 1.9M Bucket dump pressure sensor
G-3 ENG SPEED 2205 Engine actual speed
POWER SHIFT 100mA Power shift current

31 NO.31 BOOM
34
NO.34 TRAVEL
C-1 P1-PRES 13.9M Pump pressure sensor C-1 P1-PRES 13.9M Pump pressure sensor
C-2 P2-PRES 13.9M Pump pressure sensor C-2 P2-PRES 13.9M Pump pressure sensor
E-1 P1-PSV 600mA Command current E-1 P1-PSV 600mA Command current
E-2 P2-PSV 600mA Command current E-2 P2-PSV 600mA Command current
D-1 P1-UL(BPC) 600mA Command current D-1 P1-UL(BPC) 600mA Command current
D-2 P2-UL(BPC) 600mA Command current D-2 P2-UL(BPC) 600mA Command current
B-1 BOOM RAISE 1.9M Boom up pressure sensor D-3 S-TRAVEL 600mA Command current
B-2 BOOM LOWER 1.9M Boom down pressure sensor B-9 TRAVEL(R) 13.9M Travel right pressure sensor
G-3 ENG SPEED 2205 Engine actual speed B-10 TRAVEL(L) 13.9M Travel left pressure sensor
POWER SHIFT 100mA Power shift current Pi-P1 13.9M Pilot pressure at travel straight (P1 side)
Pi-P2 13.9M Pilot pressure at travel straight (P2 side)
G-3 ENG SPEED 2205 Engine actual rpm
POWER SHIFT 100mA Power shift current

32 35
NO.32 ARM,SWING NO.35 OPT
C-1 P1-PRES 13.9M Pump pressure sensor C-1 P1-PRES 13.9M Pump pressure sensor
C-2 P2-PRES 13.9M Pump pressure sensor C-2 P2-PRES 13.9M Pump pressure sensor
E-1 P1-PSV 600mA Command current E-1 P1-PSV 600mA Command current
E-2 P2-PSV 600mA Command current E-2 P2-PSV 600mA Command current
D-1 P1-UL(BPC) 600mA Command current D-1 P1-UL(BPC) 600mA Command current
D-2 P2-UL(BPC) 600mA Command current D-2 P2-UL(BPC) 600mA Command current
D-3 S-TRAVEL 600mA Command current D-3 S-TRAVEL 600mA Command current
D-6 ARM-IN-2 600mA Command current E-3 OPT RELIEF 600mA Command current
B-3 ARM OUT 13.9M Arm out pressure sensor B-16 P1 OPT 1.9M P1 side option pressure sensor
B-4 ARM IN 13.9M Arm in pressure sensor B-17 P2 OPT 1.9M P2 side option pressure sensor
B-1 BOOM RAISE 13.9M Boom up pressure sensor F-4 OPT SELECT NIB Optional selector SOL (Nibbler line)
B-7 SWING 13.9M Swing pressure sensor DOUBLE FLOW SW NIB Conflux/ Single selector switch
G-3 ENG SPEED 2205 Engine actual speed G-3 ENG SPEED 2205 Engine actual rpm
POWER SHIFT 100mA Power shift current POWER SHIFT 100mA Power shift current

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21. MECHATRO CONTROL SYSTEM

3) Service diagnosis mode No.3

No. Displays Contents No. Displays Contents

1 43
NO.1 NO.43 MACHINE-INFORM.
MAIN CONT. P/N HOUR METER 3550 Hour meter of controller
YN22E00001F1 P/No. indication TRIP METER 3500 Trip meter of controller
PROGRAM VERSION OPERATION 3300 All accumulated operating time
1-VER 11.11 Program version indication TRAVEL 300 All accumulated traveling time
2-VER 00.00 MERIT controller program version SWING 3000 All accumulated swing time
HAMMER 100 All accumulated breaker operating time
SERVICE DIAG 3 Service diagnosis mode CRANE 100 All accumulated high-reach crane operating time
STARTER 1200 All accumulated starter operating time

41 44
NO.41 ADJUSTMENT 1 NO.44 MACHINE-INFORM.
ENG PUMP PRESS.
HI-IDLE 2205 Engine speed high idle TOTAL 10Hr Pump pressure distribution (%)
PUMP LEVEL1 24% 22% Total / In the last 10 hours
ACT I 515mA Current at pump adjustment LEVEL2 50% 50% Total / In the last 10 hours
15mA Current correction at pump adjustment LEVEL3 25% 25% Total / In the last 10 hours
PUMP P 35.0M Pressure at pump adjustment LEVEL4 1 % 3% Total / In the last 10 hours
ESS N 2040 Engine speed sensor rpm
UN-LOAD WATER TEMP.
P1 600mA P1 unload corrective current TOTAL 10Hr Coolant temperature distribution (%)
P2 600mA P2 unload corrective current LEVEL1 24% 22% Total / In the last 10 hours
BOOM 137 137 Angle adjustment LEVEL2 50% 50% Total / In the last 10 hours
ARM 137 137 Angle adjustment LEVEL3 25% 25% Total / In the last 10 hours
OFFSET 137 137 Angle adjustment LEVEL4 1 % 3% Total / In the last 10 hours
INTER-B 137 137 Angle adjustment

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 21. MECHATRO CONTROL SYSTEM

(3) Service diagnosis data list

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

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

H mode Hi idle S mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 0.2~2.0 M C-1 P1-PRES 0.2~2.0 M
C-2 P2-PRES 0.2~2.0 M C-2 P2-PRES 0.2~2.0 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 350 mA E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 750 mA D-2 P2-UL(BPC) 750 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 2070~2130 G-3 ENG SPEED 1870~1930
POWER SHIFT 0 mA POWER SHIFT 0 mA

Operation No.3 : Boom up in full lever operation & relief Operation No.4 : Boom up in full lever operation & in operation
H mode Hi idle H mode Hi idle

No.31 BOOM No.31 BOOM

C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 13.0~18.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 13.0~18.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 630~770 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 630~725 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
B-1 BOOM RAISE 3.0 M B-1 BOOM RAISE 3.0 M
B-2 BOOM LOWER 0.0 M B-2 BOOM LOWER 0.0 M
G-3 ENG SPEED 2050~2200 G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA POWER SHIFT 0 mA

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21. MECHATRO CONTROL SYSTEM

Operation No.5 : Boom down in full lever operation & in

operation
H mode Hi idle
No.31 BOOM
C-1 P1-PRES 5.0~9.0 M
C-2 P2-PRES 0.2~2.0 M
E-1 P1-PSV 600~620 mA
E-2 P2-PSV 350 mA
D-1 P1-UL(BPC) 427~477 mA
D-2 P2-UL(BPC) 750 mA
B-1 BOOM RAISE 0.0 M
B-2 BOOM LOWER 3.0 M
G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA

Operation No.6 : Arm-in in full lever operation & relief Operation No.7 : Arm-in in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 9.0~13.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 9.0~13.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 750~770 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 750~770 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 200 mA D-6 ARM-IN-2 395 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 3.0 M B-4 ARM IN 3.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 2050~2200 G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA POWER SHIFT 0 mA

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 21. MECHATRO CONTROL SYSTEM

Operation No.8 : Operation No.9 :

Arm-out in full lever operation & relief Arm-out in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 15.0~22.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 15.0~22.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 570~680 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 570~680 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 3.0 M B-3 ARM OUT 3.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 0.0 M B-7 SWING 0.0 M
G-3 ENG SPEED 2050~2200 G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA POWER SHIFT 0 mA
* Measure the values after a lapse of 5 minutes or after * Measure the values after a lapse of 5 minutes or after
release of low temperature mode release of low temperature mode

Operation No.10 : Operation No.11 :

Swing in full lever operation & relief Swing in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.32 ARM, SWING No.32 ARM, SWING
C-1 P1-PRES 0.2~2.0 M C-1 P1-PRES 0.2~2.0 M
C-2 P2-PRES 28.0~35.8 M C-2 P2-PRES 10.0~15.0 M
E-1 P1-PSV 350 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 615~770 mA E-2 P2-PSV 770 mA
D-1 P1-UL(BPC) 750 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
D-6 ARM-IN-2 750 mA D-6 ARM-IN-2 750 mA
B-3 ARM OUT 0.0 M B-3 ARM OUT 0.0 M
B-4 ARM IN 0.0 M B-4 ARM IN 0.0 M
B-1 BOOM RAISE 0.0 M B-1 BOOM RAISE 0.0 M
B-7 SWING 3.0 M B-7 SWING 3.0 M
G-3 ENG SPEED 2050~2200 G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA POWER SHIFT 0 mA

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21. MECHATRO CONTROL SYSTEM

Operation No.12 : Operation No.13 :

Bucket digging in full lever operation & relief Bucket digging in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 7.0~11.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 7.0~11.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 670~770 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 600~620 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 720 mA D-3 S-TRAVEL 720 mA
B-5 BUCKET DIG 3.0 M B-5 BUCKET DIG 3.0 M
B-6 BUCKET DUMP 0.0 M B-6 BUCKET DUMP 0.0 M
G-3 ENG SPEED 2050~2200 G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA POWER SHIFT 0 mA

Operation No.14 : Operation No.15 :

Bucket dump in full lever operation & relief Bucket dump in full lever operation & in operation
H mode Hi idle H mode Hi idle
No.33 BUCKET No.33 BUCKET
C-1 P1-PRES 33.0~35.8 M C-1 P1-PRES 15.0~24.0 M
C-2 P2-PRES 33.0~35.8 M C-2 P2-PRES 15.0~24.0 M
E-1 P1-PSV 470~585 mA E-1 P1-PSV 550~770 mA
E-2 P2-PSV 470~585 mA E-2 P2-PSV 550~770 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 360 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 720 mA D-3 S-TRAVEL 720 mA
B-5 BUCKET DIG 0.0 M B-5 BUCKET DIG 0.0 M
B-6 BUCKET DUMP 3.0 M B-6 BUCKET DUMP 3.0 M
G-3 ENG SPEED 2050~2200 G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA POWER SHIFT 0 mA

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 21. MECHATRO CONTROL SYSTEM

Operation No.16 : Operation No.17 :

P2 side option in full lever operation & relief P2 side option in full lever operation & relief
A mode Hi idle B mode Hi idle
No.35 OPT No.35 OPT
C-1 P1-PRES 22.5~26.0 M C-1 P1-PRES 0.2~2.0 M
C-2 P2-PRES 22.5~26.0 M C-2 P2-PRES 22.5~26.0 M
E-1 P1-PSV 530~665 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 530~665 mA E-2 P2-PSV 770 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 360 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 720 mA D-3 S-TRAVEL 350 mA
E-3 OPT RELIEF 0 mA E-3 OPT RELIEF 0 mA
B-16 P1 OPT 0.0 M B-16 P1 OPT 0.0 M
B-17 P2 OPT 2.0~2.6 M B-17 P2 OPT 2.0~2.6 M
F-4 OPT SELECT NIB F-4 OPT SELECT BRK
DOUBLE FLOW SW. ON DOUBLE FLOW SW. OFF
G-3 ENG SPEED 2050~2200 G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA POWER SHIFT 0 mA
* Conflux switch is ON. Relief set pressure is value of * Conflux switch is OFF. Relief set pressure is value of
shipping. shipping.

Operation No.18 : Operation No.19 :

Travel right in full lever operation & travel idling Travel left in full lever operation & travel idling
H mode Hi idle H mode Hi idle
No.34 TRAVEL No.34 TRAVLE
C-1 P1-PRES 7.0~13.0 M C-1 P1-PRES 0.2~2.0 M
C-2 P2-PRES 0.2~2.0 M C-2 P2-PRES 7.0~13.0 M
E-1 P1-PSV 770 mA E-1 P1-PSV 350 mA
E-2 P2-PSV 350 mA E-2 P2-PSV 770 mA
D-1 P1-UL(BPC) 360 mA D-1 P1-UL(BPC) 750 mA
D-2 P2-UL(BPC) 750 mA D-2 P2-UL(BPC) 360 mA
D-3 S-TRAVEL 350 mA D-3 S-TRAVEL 350 mA
B-9 TRAVEL(R) 2.0~2.5 M B-9 TRAVEL(R) 0.0 M
B-10 TRAVEL(L) 0.0 M B-10 TRAVEL(L) 2.0~2.5 M
Pi-P1 0.0 M Pi-P1 0.0 M
Pi-P2 0.0 M Pi-P2 0.0 M
G-3 ENG SPEED 2050~2200 G-3 ENG SPEED 2050~2200
POWER SHIFT 0 mA POWER SHIFT 0 mA

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21. MECHATRO CONTROL SYSTEM

21.2.4 TROUBLE HISTORY DIAGNOSIS

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

(1) How to display

1) Turn starter switch on.
2) Press buzzer stop switch for 10 seconds continuously 5 times and the trouble history screen is displayed.
(Example)
No errors NO ERROR

Error detected in the past

3) Transmit trouble history data (One or many) and hour meter to gauge cluster.
• Hour meter and 4 failure data are displayed on screen.
• In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
4) Paging (Up and down)

• Press washer switch ( ), and the item moves upward.

• Press wiper switch ( ), and the item moves downward.

5) Turn starter switch off, and the display is disappeared.

(2) How to delete contents of trouble history

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

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

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 21. MECHATRO CONTROL SYSTEM

21.2.5 TROUBLE DIAGNOSIS MODE

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

For details of how to use, refer to "Chapter 46 TROUBLESHOOTING TROUBLE DIAGNOSIS MODE".

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21. MECHATRO CONTROL SYSTEM

21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE

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

Screen change Buzzer stop KPSS work mode

switch switch select switch

Interval of replacement of parts is mentioned below. Washer

switch
• Engine oil : 500 Hr
• Fuel filter : 500 Hr
Select Wiper
• Hydraulic filter : 1,000 Hr switch switch
Auto accel Travel speed
• Hydraulic oil : 2,000 Hr (ASIA) switch select switch
5,000 Hr (OCEANIA)

Procedure Operating Procedure Display on Multidisplay

After several seconds,

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

Press " " switch press once display

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

Press " " switch press once select

switch once and the display for the engine 250 Hr Press select switch 250 Hr
3 ENGINE OIL ENGINE OIL
oil change reverses. once more.
H

When required to adjust the interval to the coming

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

When desired to return to the initial set time,

press " " buzzer stop switch once. 500 Hr To set the desired interval, 500 Hr
5 Press " " select switch once and the set ENGINE OIL press the select switch ENGINE OIL

time is stored. H

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

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 21. MECHATRO CONTROL SYSTEM

21.2.7 ADJUSTING PROCEDURE OF DISPLAY

(1) For operator

1) Auto idling stop

No. Switchs 1 2 3 4
1 Screen change switch
2 Buzzer stop switch
3 KPSS work mode select switch
4 Washer switch
5 Wiper switch
6 Travel speed select switch
7 Auto accel switch 5
8 Select switch 8 7 6
Fig. 21-2

Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST

H
(a) (b)
AUTO IDLING STOP
(d)
AUTO WARM-UP AUTO IDLE STOP AUTO IDLE STOP
OFF OFF ON

FEED FEED FEED

(c)

(e)
AUTO IDLE STOP AUTO IDLE STOP
OFF ON

OFF ON OFF ON

1. Press select switch (8) in main screen (a) for operator and display "SWITCH STATUS CLOCK/CONTRAST"
select screen (b).
2. Press select switch (8) again and display "AUTO WARM-UP OFF" screen (c).

3. In operation of FEED (4), the "AUTO IDLE STOP OFF" screen (d) is displayed.

4. In operation of FEED (4), the color of "OFF" portion reverses and the "AUTO IDLE STOP OFF" screen
(e) is displayed.

5. Switch from "OFF" to "ON" in operation of FEED (4) and set it by pressing selector switch (8).
6. When auto idling is functioning, the "AUTO IDLE STOP" is displayed on the multi-display.
7. Turn starter key switch off once and store the auto idling stop setting as a memory.

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21. MECHATRO CONTROL SYSTEM

2) Clock Adjustment Switches

No. Switches 1 2 3 4
1 Screen Change Switch
2 Buzzer Stop Switch
3 KPSS Work Mode Select Switch
4 Washer Switch
5 Wiper Switch
6 Travel Speed Select Switch
7 Auto Accel Switch
5
8 Select Switch 8 7 6

Main screen (a)

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

(c) (d) (e)

SWITCH STATUS ADJUST CLOCK Y M D H M Enter
CLOCK/CONTRAST ADJ CONTRAST 06 04 01 13 15

Select Year/Month/Day/Hour/Minute Increase/Decrese

1. Turn starter key switch on and display main screen (a) for operator, and then press select switch (8) and
display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).

2. In operations of FEED (4) and FEED (5), move cursor to "CLOCK/CONTRAST" screen (c) and then
press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed.

3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK" and then press select
switch (8) and the "ADJUST CLOCK" screen (e) is displayed.

4. Select any of "Y•M•D•H•M" in operation of FEED (4) and FEED (5) and vary the values in operations
of FEED (4) and FEED (5).
5. After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting is
completed, and then the screen returns to main screen (a).

21-44
 21. MECHATRO CONTROL SYSTEM

3) Contrast Adjustment Switches

No. Switches 1 2 3 4
1 Screen Change Switch
2 Buzzer Stop Switch
3 KPSS Work Mode Select Switch
4 Washer Switch
5 Wiper Switch
6 Travel Speed Select Switch
7 Auto Accel Switch
5
8 Select Switch 8 7 6

Main screen
SWITCH STATUS
10:25 CLOCK/CONTRAST

H
(a) (b)

(c) (d) (a)

SWITCH STATUS ADJUST CLOCK
CLOCK/CONTRAST ADJ CONTRAST 10:25
H

(e) (f)
ADJUST CLOCK ADJ CONTRAST Enter
ADJ CONTRAST 55555

Adjustable range
11111~99999 Increase/Decrease
(Default 55555)

1. Turn starter key switch on and display main screen (a), and press select switch (8) and display "SWITCH
STATUS CLOCK CONTRAST" select screen (b).

2. In operations of FEED (4) and FEED (5), move cursor to "SWITCH STATUS CLOCK CONTRAST"
screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is
displayed.

3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK ADJ CONTRAST" and then
press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (e) is displayed.
4. Press select switch (8) and the "ADJ CONTRAST 55555" screen (f) is displayed.

5. Vary the values by pressing the desired figure in operations of FEED (4) and FEED (5).
The available setting range is in 9 steps from "11111" to "99999".
[Example] 11111 (faint) → 99999 (clear) * The initial set value is 55555.
6. Press select switch (8) and the adjusted values are stored as a memory and the contrast adjustment is
completed, and then the screen returns to main screen (a).

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21. MECHATRO CONTROL SYSTEM

(2) Function for service

Following items are provided for adjustment of service function.

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

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 21. MECHATRO CONTROL SYSTEM

21.2.8 MECHATRO CONTROL EQUIPMENT

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

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

27 22 18 16 12 28 22
CN101 CN102 CN103 CN104

CN105 CN106 CN107 CN108 CN109

9 21 7 2 16 21 9 21 7 21

21

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

2) List of connectors

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

21-47
21. MECHATRO CONTROL SYSTEM

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

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

21-48
 21. MECHATRO CONTROL SYSTEM

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

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

21-49
21. MECHATRO CONTROL SYSTEM

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

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

21-50
 21. MECHATRO CONTROL SYSTEM

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

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

21-51
21. MECHATRO CONTROL SYSTEM

(2) Gauge cluster (symbol C-2)

1) General view

MULTI
DISPLAY LCD

COOLANT
TEMPERATURE
GAUGE
FUEL LEVEL
GAUGE
MATED SIDE
AMP 040
HOUSING : 174044-2
TERMINAL : 173681-2
SCREEN CHANGE
SWITCH ETC.

BUZZER STOP SWITCH WORK MODE SWIHCH

2) Connector CN-600 (Harness side)

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

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

4) Summary of display and drive item

No. Item Remarks

1 Monitar display LCD dot 120×168
2 Gauge display (Coolant temp., Fuel level) Stepping motor
3 —
4 Buzzer Piezo-electricity type
5 Screen change switch
6 Buzzer stop switch
7 Work mode select switch
8 Back light LED

21-52
 21. MECHATRO CONTROL SYSTEM

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

1) General view

(Overhead view of box)

LABEL INSIDE

Note) These circles indicate the parts

which are used in standard specification

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

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

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

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

LOCATION OF CONNECTORS (Seen from backside)

LOCATION OF RELAY & FUSE

LABEL OF RELAY & FUSE BOX

No. CODE IN CIRCUIT PARTS NAME

21-53
21. MECHATRO CONTROL SYSTEM

2) Circuit diagram

21-54
 21. MECHATRO CONTROL SYSTEM

21-55
21. MECHATRO CONTROL SYSTEM

21-56
 21. MECHATRO CONTROL SYSTEM

(4) High pressure sensor : YN52S00048P1

ECONOSEAL SERIES MARK (+)> SPECIFICATION :

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

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

O-RING P14 PIPE

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

(5) Low pressure sensor : LC52S00019P1

A AMP MQS CONNECTOR 3 POLE (B TYPE)

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

CONNECTOR TERMINAL POSITION

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

VIEW A

19 21.9 HEX

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

DETAIL OF SENSOR CONNECTOR SPECIFICATION :

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

21-57
21. MECHATRO CONTROL SYSTEM

[MEMO]

21-58
 22. HYDRAULIC SYSTEM
TABLE OF CONTENTS

22.1 SUMMARY.......................................................................................................................22-3
22.2 HYDRAULIC CIRCUITS AND COMPONENTS...............................................................22-4
22.3 COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS........................................22-8
22.4 NEUTRAL CIRCUIT.........................................................................................................22-8 22
22.5 TRAVEL CIRCUIT ...........................................................................................................22-10
22.6 BUCKET CIRCUIT...........................................................................................................22-12
22.7 BOOM CIRCUIT ..............................................................................................................22-14
22.8 SWING CIRCUIT .............................................................................................................22-18
22.9 ARM CIRCUIT .................................................................................................................22-20
22.10 COMBINED CIRCUIT ......................................................................................................22-26
22.11 PRESSURE DRAINING
(RELEASING) CIRCUIT ..................................................................................................22-30

Book Code No. S5LC2211E02

22-1
22. HYDRAULIC SYSTEM

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC2211E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)
S5LC2211E02
Revision February, 2007 ↑ K
(ASIA, OCE)

22-2
 22. HYDRAULIC SYSTEM

22.1 SUMMARY
The hydraulic circuits are built up with the following functions and features in order to achieve easy operability, safety,
mass volume handling and low fuel consumption.
Table22-1

Perfor- Device
mance Function Features

Travel straight Travel straight at combined operation

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

Auto parking brake Automatic braking when parking

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

(simultaneous operation of arm in and swing motions) swing press digging

Easy operability and safety

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

Pilot safety lock system Cut out of pilot circuit by safety lock lever.
Lock valve (boom / arm) Protect boom and arm from unexpected drop (Natural fall).
Multi control valve (Oceania) Changeable to 4 operating pattern with only 1 lever.

Pressurized hydraulic oil tank To prevent hydraulic oil from entering dust and to
promote self suction ability of pump
Suction strainer Remove dust on suction side.
Line filter ; pilot circuit To prevent pilot operating circuit from malfunctioning
Others

Return circuit To prevent hydraulic oil from contamination

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

solenoid proportional valve of the variable displacement pump

Pump

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

Arm conflux circuit Speed up of arm operation

Bucket conflux circuit For speed-up of bucket operation (digging & dump)
Optimum operation by work mode select (H,S,A,B) Efficient operation in all work modes
consumption

Auto accel Reduce fuel consumption and noise by lowering engine

computer
Low fuel

Micro

speed when control lever is in neutral position.

22-3
22. HYDRAULIC SYSTEM

22.2 HYDRAULIC CIRCUITS AND

COMPONENTS
STD. SCHEMATIC HYD. LINES LC01Z00072P1 (SE, ASIA) / LC01Z00070P1 (OCEANIA)
Item Component name Part No. Model No.
LC10V00014F1 K5V140DTP (SE. Asia : without PTO.)
1 Hyd. pump assy
LC10V00015F1 K5V140DTP (Oceania : with PTO.)
2 Control valve (main) LC30V00028F1 KMX15YD
3 Swing motor unit LC15V00022F1 M5X180-CHB
4 Travel motor unit LC15V00023F1 M4V290 / 170F-RG6.5F
5 Boom cylinder (RH & LH) LC01V00044F1 ø100×ø140×1550
LC01V00054F2 ø120×ø170×1788 (SE. ASIA)
6 Arm cylinder
LC01V00054F1 ø120×ø170×1788 (Oceania)
LC01V00055F2 ø100×ø150×1193 (SE. ASIA)
7 Bucket cylinder
LC01V00055F1 ø100×ø150×1193 (Oceania)
8 Swivel joint YN55V00053F1
9 Pilot valve (ATT) YN30V00111F1 PV48K2
10 Pilot valve (travel) YN30V00105F1 6TH6 NRZ
11 Inline filter YN50V00020F1 Y-457400
12 Suction strainer LC50V00004F1 BS281J0A007A
13 Solenoid valve assy YN35V00047F1 8KWE5A-30
14 Return filter LC52V01001F1 FZ1F180A001A
15 Air breather YN57V00004F1 AB0210GA008A
Multi control valve (lever less) YN30V00113F1 Australia : STD
16
Multi control valve (with lever) YN30V00117F1 New zealand : STD
17 Restrictor YN21V00005F1 07381-00000

The part numbers may be changed due to modification,

so use only the numbers for references.

22-4
 22. HYDRAULIC SYSTEM

22.2.1 STANDARD

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

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

PG
VA VA DB

REG REG

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

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT

15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT

A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)

A8 ARM2
PSV-A 17

T2 P2
LC01Z00070P1 03
13

22-5
22. HYDRAULIC SYSTEM

22.2.2 N&B SPECIFICATION (OPTION)

N&B specification YN01Z00162P1

NO. PARTS PART No. MODEL No.
50 SELECTOR VALVE YN30V00104F1 VBY-174B
51 STOP VALVE 24100P3133F1
52 PILOT VALVE YN30V00080F1 16030-00000
53 RELIEF VALVE YN22V00021F1 KRX16EK22
P2 P1 T1 T2

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

MAIN PUMP CONFLUX FLOW OF NIBBLER CONFLUX "ON"

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

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

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

51
LEFT
NIBBLER

NOTE 4
HYD.TANK 53 RIGHT

BREAKER

PBo 52
OPTION
PAo NIBBLER & BREAKER
PILOT VALVE
24.5MPa Ao
Bo T
P
24.5MPa
B C1 C2 A
SOL/V BLOCK LEVER
A1 LOCK P
SE-11

50 SV-13
Ps C PL
P
SE-29

YN01Z00162P1 01

22-6
 22. HYDRAULIC SYSTEM

This page is blank for editing convenience.

22-7
22. HYDRAULIC SYSTEM

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

22-8
 22. HYDRAULIC SYSTEM

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

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

PG
VA VA DB

REG REG
651
652 M

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

643
a3
532 8
646 a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT

15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT

A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)

A8 ARM2
PSV-A 17

T2 P2
LC01Z00070P1 03
13
Fig. 22-1 NEUTRAL CIRCUIT : Positive control function at safety lock lever down (unlocked position)

22-9
22. HYDRAULIC SYSTEM

22.5 TRAVEL CIRCUIT 22.5.2 2-SPEED TRAVEL SOLENOID COMMAND

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

22-10
 22. HYDRAULIC SYSTEM

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

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

PG
VA VA DB

REG REG

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

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT

15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT

A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)

A8 ARM2
PSV-A 17

T2 P2
LC01Z00070P1 03
13
Fig. 22-2 TRAVEL CIRCUIT : Travel 2nd speed, RH & LH simultaneous operation.

22-11
22. HYDRAULIC SYSTEM
22.6 BUCKET CIRCUIT
This section describes the following.
(1) Bucket digging pilot circuit
(2) Auto accel operation
(3) Flow control in the work mode
(4) Bucket digging travel straight main circuit
(5) Bucket spool stroke limiter
22.6.1 PILOT CIRCUIT FOR BUCKET DIGGING
(1) Mechatronics :
1) When the operation for bucket digging is
performed, the pilot proportional secondary
pressure is delivered through port 1 of the right
pilot V (9), flows to PAc port, and acts on the low
pressure sensor (SE-1), and at the same time
the bucket spool is switched.
2) The voltage output by low pressure sensor
inputs in mechatro controller. The mechatro
controller performs signal processing and
outputs current corresponding to the increase
of pump flow rate to pump proportional valves
(PSV-P1) and (PSV-P2) on the P1 and P2
pump sides, and at the same time the
command current is output to P1 unloading
valve (PSV-D), P2 unloading valve (PSV-B) and
travel straight proportional valve (PSV-C).
In the following pages, the relation of operation
of low pressure sensor to both the increase of
pump flow rate and unloading proportional
valve is the same. Therefore the explanation is
omitted.
3) The secondary pressure output by P1 pump
proportional valve (PSV-P1) and P2 pump
proportional valve (PSV-P2) exerts on pump
regulator, actuating the pump onto the delivery
flow increase side.
4) The secondary pressure delivered in P1
unloading valve (PSV-D) and P2 unloading
valve (PSV-B) is led to PBp1, PCb, PBp2 and
PCa ports provided in control valve (2).
The secondary pressure from proportional
valve which has exerted on PBp1 and PBp2
ports holds the by-pass cut spool on CLOSE
side, like the operation in the lever neutral
position.
The secondary pressure from proportional
valve which has exerted on PCb and PCa ports
switches the unloading spool in CLOSE side.
22-12
5) The secondary pressure delivered in travel 3) With the function of pilot circuit, the oil flow is
straight proportional valve (PSV-C) is led to switched from bucket spool, and is fed into
PTb port provided in control valve (2) and shifts bucket cylinder head side through AC port of C/
the travel straight valve one stage. V (2). On the other hand, the return oil from
cylinder rod (R) side is throttled by bucket spool
22.6.2 AUTO ACCELERATION OPERATION
and returns to tank circuit from BC port of C/V
(1) Principle : (2).
Auto acceleration actuates according to signals
References :
from low pressure sensor.
• In bucket dumping operation, the travel straight
(2) Operation :
valve also switches like digging operation,
<When lever is set to neutral position>
resulting in confluence with travel straight.
In the event where the sensor does not receive
• When the bucket operation and other operation
signal for 4 seconds or more even though the
are simultaneously performed, the travel straight
acceleration dial is set to MAX position, the engine
valve does not actuate, resulting in single flow of
speed should be raised to 1000rpm.
bucket circuit.
<When lever is operated>
When the pressure 0.6MPa (87psi) is input to low 22.6.5 BUCKET SPOOL STROKE LIMITER
pressure sensor in STD specification (travel,
(1) Purpose :
bucket, swing, arm), proportional voltage from low
To secure simultaneous operability of boom and
pressure sensor inputs in mechatro controller, and
arm on boosting up attachment pressure (Pump
then the engine speed returns to the dial set
flow rate decreases.) and to prevent cavitations at
position corresponding to the lever operation.
low engine speed
22.6.3 STAND-BY CURRENT CONSTANT (2) Operation :
CONTROL On boosting up attachment pressure, pilot primary
(1) Principle : pressure exerts on PCc port of C/V(2) through
When the engine speed is intermediate speed or attachment booster solenoid valve, operates stroke
lower, command current value to have the pump limiter of bucket spool, and throttle oil path of spool.
delivery rate constant is output. As a result, P1 pump pressure increases, making
the simultaneous operation of boom up and bucket
(2) Operation :
digging possible.
Even if the engine speed specified by acceleration
Even though the engine speed is low, similarly the
potentiometer is low speed, as the delivery rate
cavitations can be prevented by actuating the
corresponds to the intermediate speed, the
stroke limiter.
actuator moves earlier than the movement
equivalent to the control lever angle rate in light
load operation.
22.6.4 BUCKET DIGGING AND TRAVEL
STRAIGHT CONFLUENCE (CONFLUX)
MAIN CIRCUIT
(1) Operation :
1) The oil delivered through A1 port of P1 pump
goes into P1 port of C/V (2), opens load check
valve LCc through parallel circuit and enters in
bucket spool.
2) On the other hand, the oil delivered through P2
port of P2 pump goes into P2 port of C/V (2),
confluences with oil from P1 pump through
travel straight valve, and goes into bucket
spool. (Confluence of oil from 2 pumps)
 22. HYDRAULIC SYSTEM

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

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

PG
VA VA DB

REG REG

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

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT

15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT

A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)

A8 ARM2
PSV-A 17

T2 P2
LC01Z00070P1 03
13
Fig. 22-3 BUCKET CIRCUIT : Bucket digging (Travel straight conflux), Auto-accelation and Standby flow rate constant control

22-13
22. HYDRAULIC SYSTEM

22.7 BOOM CIRCUIT

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

22.7.1 BOOM RAISE PILOT CIRCUIT

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

22.7.2 BOOM UP 2 PUMPS CONFLUX MAIN

CIRCUIT IN C/V
(1) Purpose :
Boom up speed up
(2) Principle :
Confluxing oil from 2 pumps
(3) Operation :
1) The oil delivered through A1 port of P1 pump
flows into C/V (2) P1 port, and branches into
bypass circuit and parallel circuit. Since P1
unloading valve is closed, the boom spool is
moved and bypass circuit is closed, the oil
opens load check valve LCb through parallel
circuit and flows into boom spool.
2) Then the oil passes through boom spool, opens
lock valve of boom lock valve CRb, and is led
into H side of boom cylinder through C/V (2) Ab
port.
3) Meanwhile, the oil delivered from the A2 port of
the P2 pump enters the P2 port of C/V (2) and
due to shut off the P2 unloading valve, the oil
then passes through the parallel circuit and via
the restrictor on the circumference of the boom
conflux spool, pushes the load check valve
CCb open from the boom conflux circuit, and
combines the oil delivered by the P1 pump
internally.
4) The return oil from boom cylinder R side flows
into tank circuit through boom spool from C/V
(2) Bb port.

22-14
 22. HYDRAULIC SYSTEM

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

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

PG
VA VA DB

REG REG

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

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT

15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT

A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)

A8 ARM2
PSV-A 17

T2 P2
LC01Z00070P1 03
13
Fig. 22-4 BOOM CIRCUIT : Boom up operation, Confluence function.

22-15
22. HYDRAULIC SYSTEM

This section describes boom lower operation. 22.7.5 CONSTANT RECIRCULATION FUNCTION
(1) Boom down pilot circuit OF BOOM DOWN MAIN CIRCUIT
(2) Prevention of natural fall by lock valve and (1) Purpose :
actuation at lowering Prevention of cavitation during boom
lowering motion.
(3) Constant recirculation function of boom down main
circuit (2) Principle :
The oil returning from the boom cylinder head (H) is
22.7.3 BOOM DOWN PILOT CIRCUIT recirculated to the rod (R).
(1) Operation : (3) Operation :
1) If the boom down operation is performed, the When the oil is supplied to the boom cylinder rod
secondary pilot proportional pressure comes (R) side during boom down operation, the boom
out of portáC of the right pilot valve (9) and acts moves faster than it should do in some cases by the
upon the low pressure sensor (SE-4). self weight of the attachment.
At the same time, the pressure acts upon the On that occasion, the circuit pressure on the rod (R)
PBb port of C/V (2). side is on the negative side.
2) The voltage output of the low pressure sensor The oil supplied to the boom cylinder rod (R) flows
(SE-4) enters the mechatro controller and into the A1 port of the P1 pump and the P1 port of
processed in it. C/V. The oil then passes through the boom spool
and goes out of the Bb port.
3) Then, the proportionl secondary pressure fed
On that occasion, the oil returning from the head
into C/V (2) PBb port and branches off in two
(H) goes through the recirculation path in the boom
lines and switches boom spool and releases
spool, pushes the check valve in the spool open, is
boom lock valve.
recirculated to the Bb port and is supplied to the rod
22.7.4 PREVENTION OF NATURAL FALL BY (R). When the (R) pressure is larger than the head
LOCK VALVE AND ACTUATION AT (H) pressure, the check valve in spool closes.
LOWERING Thereupon, the recirculation is stopped.
(1) Purpose :
Prevention of natural fall when the lever is neutral
(2) Principle :
The oil is prevented from returning to the boom
spool by the poppet seat of the boom lock valve.
(3) Operation :
In the boom down action, the selector valve is
changed over by the secondary proportional
pressure of PBb port. Then the poppet spring
chamber of the lock valve CRb gets through the
drain line (Dr) and makes the lock valve poppet
open.
When the boom lever is at neutral, the drain line on
the lock valve CRb poppet spring chamber is
closed which causes the poppet closed.
The result is that the oil returning from the boom
cylinder head (H) to the boom spool is held and
makes the leak from the boom spool zero.
Thus the boom cylinder is prevented from making a
natural fall.

22-16
 22. HYDRAULIC SYSTEM

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

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

PG
VA VA DB

REG REG

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

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT

15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT

A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)

A8 ARM2
PSV-A 17

T2 P2
LC01Z00070P1 03
13
Fig. 22-5 BOOM CIRCUIT : Boom down operation & Prevention of natural boom falling.

22-17
22. HYDRAULIC SYSTEM

22.8 SWING CIRCUIT 22.8.2 SWING AUTO PARKING BRAKE

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

2) The voltage output by the low pressure sensor
is input in the mechatro controller, and is signal-
processed.
3) Then, the secondary pressure led into PBs port
of C/V (2) switches the swing spool.
3) The swing parking solenoid (SV-1) is excited
five seconds after the pressure of the swing low
pressure sensors (SE-5) is reduced to zero.
In the case of arm in operation, the swing
parking solenoid (SV-1) is excited the moment
the pressure of the arm in low pressure sensor
(SE-7) is reduced to zero. This causes the
mechanical brake to operate.

22.8.3 SWING MAIN CIRCUIT

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

22.8.4 SWING MOTOR CIRCUIT

(1) Anti cavitation circuit at swing deceleration
(2) Shockless relief valve that prevents the swing
motor from being reversed.

22-18
 22. HYDRAULIC SYSTEM

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

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

PG
VA VA DB

REG REG

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

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT

15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT

A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)

A8 ARM2
PSV-A 17

T2 P2
LC01Z00070P1 03
13
Fig. 22-6 SWING CIRCUIT : Swing operation (LH)

22-19
22. HYDRAULIC SYSTEM
22.9 ARM CIRCUIT
This section describes the following operations.
(1) Arm in, light-load operating pilot circuit
(2) Arm in, light-load variable normal recirculation main
circuit / internal conflux main circuit
22.9.1 ARM IN, LIGHT-LOAD OPERATING PILOT
CIRCUIT
(1) Purpose :
Speed-up and Anticavitation when the arm is at
light loaded.
(2) Principle :
The oil returning from the arm cylinder rod (R) is
recirculated variably to the head (H) at arm 2 spool
in C/V.
(3) Operation :
1) When the arm in operation is performed, the
secondary pilot proportional pressure gets out
of port 7 of the left pilot valve (9) and acts upon
the low pressure sensor (SE-7).
At the same time, the pressure is branched off
in two flows, acts upon the Paa1 port and the
PLc2 port, changes over the arm spool and the
arm lock valve CRar. releases.
2) The output voltage by the low pressure sensor
is input into mechatro controller, and is pilot
signal-processed, and is output to P1, P2 pump
proportional valve (PSV-P1), (PSV-P2) and arm
2 inverse proportional valve (PSV-A).
3) The secondary pressure from pilot proportional
valve, which is reduced by arm 2 inverse
proportional valve (PSV-A) switches arm 2
spool.
From arm out
P/V
22.9.2 ARM-IN, LIGHT-LOAD VARIABLE
NORMAL RECIRCULATION, INTERNAL
CONFLUX MAIN CIRCUIT
(1) Operation :
1) The P2 pump delivery oil flows in travel left
section through P2 port of C/V (2) and is
branched off in by-pass circuit and parallel
circuit, but because arm 1 spool is switched, the
delivery oil which goes through parallel circuit
opens load check valve LCa and is flowed into
arm 1 spool.
2) On the other hand, P1 pump delivery oil flows in
P1 port of C/V (2), and the flows in travel
straight section and travel right tandem path.
Then because arm 2 spool was switched, the
delivery oil opens load check valve LCAT2,
goes through arm 2 spool, and confluences
22-20
with P2 pump delivery oil in the valve section,
and then is flowed into arm cylinder head (H)
side through Aa port of C/V (2).
3) The return oil from arm cylinder (R) side flows
in Ba port of C/V (2) and passes through the Ba
port because the arm lock valve CRar is open,
and is flowed into arm 2 spool through arm 1
spool.
4) Because arm 2 spool is switched to normal
recirculation position, causing restriction of
passage to tank, the return oil from arm cylinder
(R) side flows into arm cylinder (H) side.
• Because, at light load, the pressure in
cylinder rod (R) side is higher than that in
the head (H) side, it opens the check valve
housed-in arm 2 spool and is recirculated in
the head (H) side, resulting in the speed up
of arm-in operation at light load.
5) Cavitations prevention control in arm-in
operation
Command current is output to arm 2 solenoid
proportional valve by signal processing of E/G
speed and arm-in pilot pressure, accordingly
the arm 2 spool is switched to neutral
(cavitations prevention) position, resulting in
cavitations prevention.
Position of arm 2 spool
Neutral position
(Anticavitation position)
Normal recirculation position
Recirculation
From arm 2 inverse
proportional valve
Reference :
In light-load arm-in operation (normal recirculation,
conflux), when the attachment to which the circuit in
P1 pump side is applied is operated, the meter-in
path of arm 2 spool is closed, resulting in single flow
operation.
Spool position at arm in,
light load and combined operation
(This position is not shown in hydraulic diagram)
Neutral position Meter-in passage
(Close)
Normal recirculation opsition
Arm 2 spool
 22. HYDRAULIC SYSTEM

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

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

PG
VA VA DB

REG REG

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

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT

15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT

A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)

A8 ARM2
PSV-A 17

T2 P2
LC01Z00070P1 03
13
Fig. 22-7 ARM CIRCUIT : Arm in (Light load) operation, Arm variable recirculation & Anti cavitation function

22-21
22. HYDRAULIC SYSTEM

This section describes the following operations. 4) The return oil returns directly into tank circuit
(3) Arm in, heavy load operating pilot circuit because arm 2 spool is switched to
(recirculation cut) recirculation cut position.
(4) Arm in, heavy load operating sequence confluxed
Position of arm 2 spool
main circuit
Neutral position Recirculation cut position
22.9.3 ARM IN, HEAVY LOAD OPERATING
PILOT CIRCUIT
From arm out
(1) Operation :
P/V
1) In arm-in operation, when the heavy loading is
From arm 2 inverse
applied to arm and the P2 pump pressure proportional valve
increases to the set pressure, the voltage
output by P2 pump pressure sensor (SE-23) is
converted to signal (signal processing) by
mechatro controller, consequently the current
of arm 2 solenoid proportional valve is
controlled according to the load pressure and
the arm variable recirculation is cut.
When the recirculation is cut, internal
confluence is held similarly to that in light load
operation.
2) Left pilot valve actuation due to arm-in
operation is equivalent to that at light load
operation.

22.9.4 ARM IN, HEAVY LOAD OPERATING

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

22-22
 22. HYDRAULIC SYSTEM

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

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

PG
VA VA DB

REG REG

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

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT

15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT

A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)

A8 ARM2
PSV-A 17

T2 P2
LC01Z00070P1 03
13
Fig. 22-8 ARM CIRCUIT : Arm in (Heavy load) operation, Arm confluence & recirculation cut function

22-23
22. HYDRAULIC SYSTEM

This section describes the following operations.
(5) Arm out pilot circuit
(6) Arm out 2 pumps conflux main circuit
(7) Natural fall protection with arm lock valve
22.9.5 ARM OUT PILOT CIRCUIT
(1) Operation :
1) When the arm out operation is performed, the
secondary pilot proportional pressure gets out
of port 8 of the left pilot valve (9), and acts upon
the low pressure sensor (SE-8). At the same
time, the oil is branched off in two flows and act
upon the PBa1 and Pba2 ports of C/V (2).
2) The operating proportional secondary pressure
flowed in Pba1 port of C/V (2) switches the arm
1 spool.
3) Then, the operating secondary pressure flowed
in PBa2 port of C/V (2) switches the arm 2 spool
valve.
22.9.7 NATURAL FALL PROTECTION WITH ARM
LOCK VALVE
(1) Purpose :
To prevent the arm from falling naturally by the
weight of the arm & bucket.
(2) Principle :
Complete seat of the return circuit against the arm
spool of the arm cylinder (R) side circuit.
(3) Operation :
1) When the secondary pressure for arm
operation disappears and the arm cylinder
stops, the pressure on the rod (R) side passes
through the selector of the lock valve from the
Ba port of C/V, acts the back pressure on the
lock valve CRar and seats the lock valve.
2) Since the oil flow into the arm spool from the
lock valve is shut off completely, natural fall of
the arm due to oil leaks through the arm spool
is prevented.

22.9.6 ARM OUT 2 PUMPS CONFLUX MAIN

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

22-24
 22. HYDRAULIC SYSTEM

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

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

PG
VA VA DB

REG REG

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

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT
BOOST
15 14 PL
CMR1
CHECK ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT

A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)

A8 ARM2
PSV-A 17

T2 P2
LC01Z00070P1 03
13
Fig. 22-9 ARM CIRCUIT : Arm out operation, Confluence function

22-25
22. HYDRAULIC SYSTEM
22.10 COMBINED CIRCUIT
This section describes only the difference in combined
operation.
(1) Boom up / travel, pilot circuit
(2) Boom up / travel, main circit
22.10.1 BOOM UP / TRAVEL, PILOT CIRCUIT
(1) Operation :
<Operation: Different point of pilot circuit from
independent operation >
1) The mechatro controller outputs command
current to travel straight solenoid proportional
valve after signal processing, and the solenoid
valve outputs secondary pressure and acts on
PTb port of C/V (2).
2) Then the pressure of PTb port switches the
travel straight valve one step.
22-26
22.10.2 BOOM UP / TRAVEL, MAIN CIRCUIT
(1) Purpose :
To insure straight travel movement during travel
operation even if the attachment is operated.
(2) Principle :
The travel action and the attachment action are
actuated by separate pumps.
(3) Operation :
1) P1 pump delivery oil flows through P1 port of C/
V(2) and branches off in P1 parallel circuit and
travel straight spool.
P2 pump delivery oil flows through P2 port of C/
V(2) and branches off in P2 tandem circuit and
travel straight spool.
2) The delivery oil flowed into P1 parallel circuit of
P1 pump opens check valve CT1 and LCb and
flows in boom spool, which exerts on boom up
operation.
The delivery oil flowed into travel straight spool
of P1 pump opens check valve CT2 because
the travel straight spool is shifted, and flows in
boom conflux spool and exerts on boom up
operation with the internal oil conflux.
(In travel straight operation, P1 pump delivery
oil exerts on swing operation of attachment.)
3) The delivery oil flowed into P2 tandem circuit of
P2 pump flows in left travel spool to travel
leftward.
The delivery oil flowed into travel straight spool
of P2 pump flows in right travel spool because
the travel straight spool is shifted and exerts on
the right travel operation.
(In travel straight operation, P2 pump delivery
oil exerts on travel operation.)
4) However, a portion of the flow is led to the travel
straight spool notch restriction. The speed of
attachments like travel, boom, etc. is adjusted
by the circuit of restriction.
 22. HYDRAULIC SYSTEM

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

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

PG
VA VA DB

REG REG

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

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT

15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT

A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)

A8 ARM2
PSV-A 17

T2 P2
LC01Z00070P1 03
13
Fig. 22-10 COMBINED CIRCUIT : Boom up & Travel forward 1st speed operation, Travel straight function.

22-27
22. HYDRAULIC SYSTEM
In this section, the independent operation is omitted
and describes difference in combined operation.
(3) Swing / Arm in light load, pilot circuit
(4) Swing / Arm in, swing priority main circuit
22.10.3 SWING / ARM IN LIGHT LOAD, PILOT
CIRCUIT
(1) Operation :
1) On operating swing (left) and arm in motions
simultaneously, mechatro controller outputs
command current to travel straight solenoid
proportional valve (PSV-C) and arm 2 solenoid
inverse proportional valve according to signal
processing, and this proportional valve outputs
secondary pressure, which acts on PTb port
and PAa2 port of C/V(2).
2) PTb port pressure switches the travel straight
spool 2 steps, and the PAa2 port pressure
switches the arm 2 spool to the forced
recirculation position.
22-28
22.10.4 SWING / ARM IN, SWING PRIORITY MAIN
CIRCUIT
(1) Purpose :
Stable swing speed.
(2) Principle :
Raise the oil pressure flowing to arm cylinder, and
give a priority of the delivery of P2 pump to swing
operation.
(3) Operation :
1) The swing main circuit operates with P2 pump
flow. But on P2 pump circuit side, the flow goes
to the swing circuit and arm circuit
simultaneously because the swing circuit and
arm circuit are parallel. Then since the return oil
from arm cylinder rod (R) side is restricted in
the arm 2 spool because the arm 2 spool is
switched to forced recirculation position, the
pressure of return oil is raised, causing the rise
of circuit pressure on the arm cylinder head (H)
side.
2) At the same time meter-in of arm 2 spool closes
and arm in conflux is therefore cancelled, and
delivery oil from P2 pump and P1 pump are
combined in the parallel circuit on P2 pump side
because the travel straight spool was switched.
The conflux oil of P1 and P2 delivery oil in high
pressure flows in swing side taking priority over
all others.
This operation is called "Swing Priority Circuit".
Position of arm 2 spool
Position of forced recirculation
Neutral position Meter-in passage
(Close)
From From arm 2
arm out inverse
P/V proportional valve
Normal recirculation opsition
Arm 2 spool
 22. HYDRAULIC SYSTEM

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

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

PG
VA VA DB

REG REG

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

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT

15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
LCAP2
SV-2 PBa2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT

A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)

A8 ARM2
PSV-A 17

T2 P2
LC01Z00070P1 03
13
Fig. 22-11 COMBINED CIRCUIT : Swing / Arm in operation, swing priority function

22-29
22. HYDRAULIC SYSTEM
22.11 PRESSURE DRAINING
(RELEASING) CIRCUIT
This section describes the following operations.
(1) Pressure drain (releasing) pilot circuit
(2) Pressure drain (releasing) main circuit
22.11.1 PRESSURE RELIEVING PILOT CIRCUIT
(1) Purpose :
To release the pressure in main circuit for piping
repair works.
(2) Principle :
After the mode is switched to "Pressure Relief
Mode" with switch on gauge cluster, mechatro
controller outputs the following commands.
1) Minimum tilting command value to pump
proportional valve (PSV-P1, PSV-P2).
2) Output "Pressure relief control speed command
value" at ECU. (Electric system)
3) Stand-by command value to P1, P2 unloading
proportional valves
How to switch to "Pressure release mode"
1) Select the service diagnosis mode.
(Keeping pressing of the "BUZZER STOP
SWITCH" [ ] on gauge cluster, turn the starter
key on.)
2) Select the service adjustment mode 1.
(Under the condition that "Screen No.1" of
"Service diagnosis mode 1" is indicated,
keeping pressing of the "BUZZER STOP
SWITCH", press the selector switch [ ] 3
times. When "LANGUAGE/LOGO",
"ADJUSTING MODE 1" and "PRESET BY
FACTORY" are displayed, press [ ] or [ ]
switch, and highlight "ADJUSTING MODE 1",
and then press "Selector Switch" again.)
3) When "ADJUSTING MODE 1" screen is
displayed, press [ ] or [ ] switch, and "DRAIN
HYD. OFF" screen appears.
4) Press "Selector Switch" and highlight "OFF",
and press [ ] switch to change to "DRAIN
HYD. ON", and then press "Selector Switch"
again.
22-30
(3) Operation :
1) Pump proportional valve reduces the pump flow
rate to the minimum.
2) Unloading proportional valves (PSV-D, PSV-B)
output secondary pressure and the secondary
pressure flows in PCb, PCa ports of C/V(2) and
switches the P1, P2 unloading valves to OPEN
position.
22.11.2 PRESSURE RELEASE MAIN CIRCUIT
(1) Operation :
When the hydraulic pressure releasing is
performed, make sure to place bucket on the
ground.
When the operating lever is shifted to neutral during
engine running, "DRAINING HYD. PRESS." is
displayed on the gauge cluster while the mode
switch is changed to pressure relieving mode. In
this time the intermittent buzzer sounds
continuously. When right and left operating levers
are operated 4 or 5 times to their full stroke,
pressure is relieved.
After draining pressure is completed, turn off the
starter key and buzzer sound stops. If the pump
pressure is determined to be more than 1 MPa (145
psi) by the output value of the high pressure sensor
or the high pressure sensors (SE-22,23) are
broken, "FAIL DRAIN HYD. PRESS" is displayed
and the buzzer sounds continuously. In that case,
also the buzzer is not stopped unless the engine
key is turned to OFF. Repeat the pressure releasing
procedure once again.
(2) Hydraulics :
If the travel straight valve is turned to the pressure
release position, the oil delivered by each pump is
unloaded to the tank passage. If the spools are
switched by pilot operation, the remaining pressure
from the actuators may be relieved to the tank
circuit, i.e. the main circuit pressure may be
released.
 22. HYDRAULIC SYSTEM

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

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

PG
VA VA DB

REG REG

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

a3
8
a4
Dr

5.0MPa
M A B
a5
195kw B1
/2100min-1 B3 Dr3 A3

PTO
(OCEANIA) 2
11 MAIN CONTROL VALVE P2 P1 T1 T2 SWING RIGHT
34.3MPa
37.8MPa SWING LEFT

15 14 PL
CMR1
ARM OUT
ARM IN
PTb CMR2 PBL BUCKET DUMP
TRAVEL BUCKET DIGGING BOOM UP
P1UNLOAD PRIORITY TRAVEL LEFT BOOM DOWN
PCb PAL
AL SE1 SE2 SE3 SE4 SE7 SE8
BL
12 CT2 CP2
BOOM 1
P P
2
P P
3 4 5 6 7
P P
8
T3
HYD.TANK TRAVEL RIGHT P2UNLOAD CONFLUX
PAr CT1 PB1

BR CP1
PCa K M H
AR
PBr CCb
PAs
Dr 1 2 3 4 5 6 7 8
SE5
BOOM LCb LCs Pss
SWING P
PBb PBs 16
As (OCEANIA)

(ROD)Bb
37.7MPa Bs
PAa1
9
CRb
LCa RH LH
(HEAD)Ab
39.7MPa ARM 1
SOL/V BLOCK PBa1
PAb BUCKET
P1 CYLINDER
LEVER
A1 LOCK 37.7MPa
SV-4
LCc Aa (HEAD)
PCc
PBc
BUCKET
7 P T
ARM
P T
SWING BOOM
A2 P/B & BUCKET & SWING
SV-1 37.7MPa
TRAVEL
(ROD)Bc
CRar
PLc2
ARM
CYLINDER 6
1/2 SPEED (HEAD)Ac RH LH
P T
A3 CHANGEOVER Ba (ROD)
SV-3 39.7MPa
39.7MPa
PAc
ATT LCAT2
A4 BOOSTING ARM 2
SV-2 PBa2 LCAP2
LCo OPTION
PAo
5 10
BOOM
PSV-B
A5 P2UNLOAD 17 Ao
Bo
CYLINDER RIGHT TRAVEL FORWARD
3 6 4
P SE9
1 5 2
P SE10
PAa2 RIGHT TRAVEL REVERSE
MU PBo LEFT TRAVEL FORWARD
TRAVEL PBp1 LEFT TRAVEL REVERSE
A6 PRIORITY P1 BYPASS P2 BYPASS PBp2
PSV-C CUT CUT

A7 P1UNLOAD
PSV-D (T3b) (T3a) (T4a) (Dr4)
(P3) (P4)

A8 ARM2
PSV-A 17

T2 P2
LC01Z00070P1 03
13
Fig. 22-12 PRESSURE DRAIN (RELEASE) CIRCUIT : At pressure release mode.

22-31
22. HYDRAULIC SYSTEM

[MEMO]

22-32
 23. ELECTRIC SYSTEM
TABLE OF CONTENTS

23.1 ELECTRIC CIRCUIT DIAGRAM......................................................................................23-3

23.2 ELECTRICAL EQUIPMENT LIST....................................................................................23-7
23.3 HARNESS........................................................................................................................23-8
23.3.1 HARNESS LIST......................................................................................................23-8
23.3.2 INSTRUMENT PANEL ASSY.................................................................................23-9
23.3.3 CONTROLLER INSTALL........................................................................................23-10 23
23.3.4 TUNER INSTALL....................................................................................................23-10
23.3.5 UPPER ELECTRIC ASSY ......................................................................................23-11
23.3.6 UPPER HARNESS ASSY (1/6) ..............................................................................23-12
23.3.7 ENGINE HARNESS ASSY .....................................................................................23-25
23.3.8 UPPER HARNESS ASSY (FLOOR PLATE) (1/2)..................................................23-27
23.3.9 CAB HARNESS ASSY ...........................................................................................23-33
23.3.10 BOOM HARNESS ASSY........................................................................................23-36
23.3.11 INSTALLING BOOM LIGHT ...................................................................................23-36
23.3.12 INSTALLING UPPER LIGHT..................................................................................23-37
23.3.13 CAB LIGHT INSTALL .............................................................................................23-37
23.3.14 FLASHER LAMP INSTALL.....................................................................................23-38
23.3.15 ALARM ASSY.........................................................................................................23-38

Book Code No. S5LC2311E02

23-1
23. ELECTRIC SYSTEM

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC2311E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)
S5LC2311E02
Revision February, 2007 ↑ K
(ASIA, OCE)

23-2
 23. ELECTRIC SYSTEM

23.1 ELECTRIC CIRCUIT DIAGRAM

DC-DC CONVERTER,
ROOM LIGHT TUNER
CIGARETTE LIGHTER
HORN, HORN RELAY

FUEL SUPPLY PUMP

ENG. CONTROLLER
ENG. CONTROLLER
RELAY, HOUR METER

KEY SW. STARTER RELAY

ACTUATOR POWER
APPLICABLE YN11-45001-

GAUGE CLUSTER
IT CONTROLLER
MACHINE No. YQ11-06001-

AUTO GREASE
CONTROLLER

CONTROLLER

CONTROLLER
LEVER LOCK
LC10-07001-

BATTERY RELAY
MECHATRO

MECHATRO
C-8 : ENGINE CONTROLLER ENG. HARNESS
YC10-03501-

BACK UP
BACK UP
SUPPLY

TUNER
ENG. SPEED SENSOR
FOR ECU
SH7 SHIELD
E-1 : FUSE & RELAY BOX

EGR VALVE 1
R-26 :
LEVER LOCK RELAY

EGR VALVE 2
SK330-8

SOLENOID,
HIGH REACH,
LMN/BH

AIR CON.
AIR CON.

RADIATOR COOLANT
LEVEL CONTROLLER,
FLASHER, REAR WORK
LIGHT, TRAVEL ALARM,
ONE WAY CALL
DC-DC CONVERTER
WORK LIGHT
GAUGE CLUSTER

WIPER, WASHER

CAB WORK LIGHT

CAB WORK LIGHT

ROOF WIPER

OPT. BUCKET CONTROL

OPT. 4

OPT. 1

OPT. 3
OPT. HAND CONTROL

AIR CON. (AMP.) SK350LC-8 ONLY

ENGINE CONTROLLER INJECTOR 1

CHECK CONNECTOR
SH1 SHIELD

INJECTOR 2
E-12 : E-12 :
BATTERY BATTERY SH2 SHIELD
STARTER CABLE
INJECTOR 3
SH3 SHIELD
E27 :
ACCEL REDUNDANT
R-1 : VOLUME
E-15 : BATTERY RELAY INJECTOR 4
FUSIBLE LINK
SH4 SHIELD

R-23 :
AUTO IDLE STOP RELAY 1 R-24 : R-25 : INJECTOR 5
AUTO IDLE ENG. EMERGENCY
STOP RELAY 2 STOP RELAY SH5 SHIELD
KEY ON
POSITION

INJECTOR 6
PREHEATING

SH6 SHIELD
START

TERMINAL
ENGINE START
ACC
OFF

ON

IN THE CASE OF
R-3 : SK330-8, SK350LC-8
GLOW RELAY GLOW
CYLINDER
DISCRIMINATION
G SENSOR

SW-1 : BOOST SENSOR

KEY SW.
E-2 :
ALTERNATOR
M-1 : C-1 :
STARTER MOTOR MECHATRO CONTROLLER COMMON RAIL
(TCO-60-2) PRESS. SENSOR
R-4 :
SAFETY RELAY
SUCTION
CONTROL VALVE
(FUEL PUMP (SCV))
C-6 :
R-2 : AUTO GREASE CONTROLLER
STARTER RELAY E-3 : HOUR METER
SHIELD FUEL PUMP SENSOR
CHARGE
KEY ON
PREHEATING
WATER TEMP SENSOR

C-5 :
CONTROL : (SENSOR POWER RADIATOR COOLANT SW-27 :
SOURCE, CPU) LEVEL CONTROLLER RADIATOR COOLANT LEVEL SW.

OUT SOURCE :
(PSV, SOL. MOTOR)
R-28 : ALTERNATOR RELAY

CONTROL : (SENSOR POWER

SOURCE, CPU)
WATCH IC TO 2/4
SW-28 :
(1/4)
WATER SEPARATOR SW.
LC03Z00036P1 02

23-3
23. ELECTRIC SYSTEM

C-1 : MECHATRO CONTROLLER (TCO-60-2)

FROM 1/4

SE-16 : ACCEL POTENTIO

PRESS. SENSOR

SE-1 : BUCKET DIGGING

C-8 : ENG. CONTROLLER

SE-2 : BUCKET DUMP
ENG. HARNESS

SE-3 : BOOM UP

POSITION
INJECTOR 1
SE-4 : BOOM DOWN

RELEASE
NORMAL
SW-4 :
TERMINAL SWING PARKING BRAKE RELEASE SW.
INJECTOR 2 SE-7 : ARM IN SV-1 :
SWING PARKING BRAKE SOL.

SE-8 : ARM UP
INJECTOR 3 SV-3 : TWO SPEED SELECT SOL.

SE-5 : SWING
SV-2 : POWER BOOST SOL.
IN CASE OF
INJECTOR 4 SK200-8, SE-9 : TRAVEL RIGHT PSV-B : P2 UNLOAD
SK210LC-8 PROPORTIONAL SOL.

SE-10 : TRAVEL LEFT PSV-C : TRAVEL PRIORITY

PROPORTIONAL SOL.

SE-22 : PUMP P1
PSV-D : P1 UNLOAD
PROPORTIONAL SOL.

SE-23 : PUMP P2
PSV-A : ARM TWO-SPEED INVERSE
PROPORTIONAL SOL.

SE-20: P1 OPT. PSV-P1 : PUMP P1

PROPORTIONAL SOL.
C-2 : GAUGE CLUSTER

SE-11 : P2 OPT.
PSV-P2 : PUMP P2
PROPORTIONAL SOL.

ENG. WATER TEMP INDICATOR

PSV-E : OPT RELIEF ADJUSTMENT
PROPORTIONAL SOL. 1

SE-15 : FUEL SENSOR PSV-H : ARM CUSHION

FUEL METER
PROPORTIONAL SOL.

PSV-I : OPT RELIEF ADJUSTMENT

PROPORTIONAL SOL. 2

OPT
SW-20 : POWER BOOST SW. RIGHT

SE-13 : ENG. SPEED SENSOR

SHIELD

SHIELD

DISPLAY BUZZER MODE WASHER

SELECT SW. STOP

ENTER DECEL TRAVEL WIPER

TO 3/4
2-SPEED

(2/4)
LC03Z00036P1 02

23-4
 23. ELECTRIC SYSTEM

C-1 : MECHATRO CONTROLLER (TCO-60-2)

FROM 2/4

R-17 : EXTRA RELEASE RELAY

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

E-5 : HORN HIGH

E-5 : HORN LOW
SW-10 : HORN SW. LEFT

SE-28 : EXTRA PRESS

EXTRA RELEASE SW-5 : HORN SW. RIGHT

EU(OPT)
(WIPER RELAY) OPT.

SW-15 : R-31 :
CONFLUX/SINGLE SELECT SW. PREVENT SPARK RELAY
R-29 :
WIPER MOTOR RELAY L-5 : ROOM LIGHT
OPT
M-3 : WIPER MOTOR

R-30 :
WIPER MOTOR REVERSING RELAY
SW-44 :
EXTRA PRESS. SW.
EU

E-14 : CIGARETTE LIGHTER

R-32 :
WINDOW WASHER MOTOR RELAY M-4 : WASHER MOTOR
E-1 : FUSE & RELAY BOX
SW-11 : R-26 : SV-4 :
LEVER LOCK LEVER LOCK CONTROL LEVER LOCK SOL. E-10 : E-11 :
SW. RELAY RECEIVER DRIER AIR COMPRESSOR CLUTCH
STOP R-6 :
REVERSE WORK LIGHT RELAY

GROUND
OUTPUT AIR CON.
AMP.
SW-19 : WIPER INTERLOCK SW.

SW-35 : HEAVY LIFT SW.

EU
COOLING
UNIT

SE-29 : R-8 : TRAVEL ALARM RELAY

OPT. SELECTOR DETECT SENSOR
E-13 :
TRAVEL ALARM

SV-13 : OPT. SELECTOR SOL.

SW-13 : TRAVEL ALARM SW.

OPT JAPAN: OPT

USA: STD
SW-12 : OCEANIA: STD
OVER LOAD ALARM SELECT SW-17 : ROOF WIPER SW.
POSITION

SW. E-7 : TUNER AM & FM

M-9 : ROOF WIPER MOTOR

OFF
ON

TERMINAL E-8 : SPEAKER LEFT

SE-26 :
PRESS. SENSOR : BOOM HEAD FM / AM
EU(FOR OVER LOAD ALARM)
E-9 : SPEAKER RIGHT
(BACK-UP)
EU

ROOF WIPER

TO 4/4

(3/4)
LC03Z00036P1 02

23-5
23. ELECTRIC SYSTEM

C-1 : MECHATRO CONTROLLER (TCO-60-2) C-1 : MECHATRO CONTROLLER (TCO-60-2)

FROM 3/4

C-6 : AUTO GREASE CONTROLLER

R-26 : SV-6 :
LEVER LOCK RELAY SW-33 : REVOLUTION
SE-24 : REVOLUTION RIGHT SOL
PRESS SENSOR : BOOM HEAD R-12 :
REVOLUTION RIGHT SW.
RIGHT RELAY
M-8 : GREASE MOTOR

SE-25 :
PRESS SENSOR : BOOM ROD E-2 :
ALTERNATOR

SV-7 :
SW-34: REVOLUTION
SE-17 : BOOM POTENTIO. R-13 : REVOLUTION LEFT SOL
REVOLUTION LEFT SW.
OPT. LEFT RELAY
AUTO GREASE
SE-19 : ARM POTENTIO. REVOLUTION N&B

L-6 : BOOM WORKING LIGHT

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

(CASE OF HAND CONTROL

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

EASY OPERATING NIBBLER

TRAVEL
FIXED

SW-41 :
OFF

TERMINAL
HIGH REACH
CRANE SW.
(FIXED)

(TRAVEL)

C-1 : MECHATRO CONTROLLER (TCO-60-2)

OPT.
HIGH REACH CRANE

SV-14 :
QUICK COUPLER OPERATION SOL. L-4 :
SWING FLASHER RIGHT & WORKING LIGHT 9P CONNECTOR
SWING FLASHER & WORKING LIGHT

SW-59 :
QUICK COUPLER SW-37 :
OPERATION SW. TRAVEL INDEPENDENT SW.

EU OPT. USA
QUICK COUPLER

DOWNLOAD

(4/4)
LC03Z00036P1 02

23-6
 23. ELECTRIC SYSTEM

23.2 ELECTRICAL EQUIPMENT LIST

GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No. GROUP CODE NAME PARTS No.
MECHATRO CONTROLLER YN22E00214F1 L-1 BOOM WORK LIGHT (LH) YW80S00001F1 PRESSURE SENSOR :
C-1 SE-1 LC52S00019P1
(C) CONTROLLER

(TCO-60-2) (HARD) L-2 DECK WORK LIGHT (RH) YT80S00002F2 BUCKET DIGGING
C-2 GAUGE CLUSTER YN59S00021F2 SWING FLASHER (LH) & REAR PRESSURE SENSOR :
L-3 YM80S00001F1 SE-2

(L) LIGHT
AIR-CON CONTROLLER WORK LIGHT BUCKET DUMP
C-4 YN20M01468P1
(INCLUDING PANEL) SWING FLASHER (RH) & REAR SE-3 PRESSURE SENSOR : BOOM UP
L-4 YM80S00001F2
ENGINE COOLANT LEVEL WORK LIGHT PRESSURE SENSOR :
C-5 VHS834701230B SE-4

(SE) SENSOR
CONTROLLER L-5 ROOM LIGHT YT80S00001P1 BOOM DOWN
C-8 ENGINE CONTROLLER VH89661E0010 L-6 BOOM WORK LIGHT (RH) YW80S00001F1 SE-5 PRESSURE SENSOR : SWING
D-4 DIODE HARNESS ACCESSORY L-7 CAB WORK LIGHT FRONT (For SE.Asia) YT80S00002F2 SE-7 PRESSURE SENSOR : ARM IN

(M) MOTOR
D-5 DIODE ACCESSORY OF RELAY BOX M-1 STARTER MOTOR VHS281002894A SE-8 PRESSURE SENSOR : ARM OUT
D-6 DIODE M-3 WIPER MOTOR YN53C00012F2 SE-9 PRESSURE SENSOR : TRAVEL RH
D-9 DIODE M-4 WASHER MOTOR YN54C00001F1 SE-10 PRESSURE SENSOR : TRAVEL LH
(D) DIODE

D-10 DIODE M-9 ROOF WIPER MOTOR YN76S00005P1 SE-11 (PRESSURE SENSOR : P2 OPT.)
D-12 DIODE ARM 2 SPEED SE-13 E/G SPEED SENSOR VHS894101290A
D-13 DIODE PSV-A INVERSE YN35V00049F1 SE-15 FUEL SENSOR YN52S00045F1
D-14 DIODE PROPO.VALVE SE-16 ACCEL POTENTIOMETER YN52S00032P1

(P) PROPORTIONAL
D-15 DIODE P2 UNLOAD (YN35V00047F1) SE-20 (PRESSURE SENSOR : P1 OPT.) LC52S00019P1

SOLENOID VALVE
PSV-B YN35V00048F1
D-16 DIODE PROPO.VALVE SOLENOID SE-22 PRESSURE SENSOR : PUMP P1 YN52S00048P1
D-17 DIODE TRAVEL STRAIGHT VALVE ASSY SE-23 PRESSURE SENSOR : PUMP P2
PSV-C
E-1 FUSE AND RELAY BOX YN24E00016F2 PROPO.VALVE SWING PARKING
SV-1 YN35V00051F1
E-2 ALTERNATOR VHS270402500 P1 UNLOAD BRAKE SOL.

(SV) SOLENOID
PSV-D
E-3 HOUR METER YT58S00006P1 PROPO.VALVE POWER BOOST
SV-2 (YN35V00047F1) YN35V00050F1
E-5 HORN HIGH LC53S00001D1 P1 PUMP SOL
PSV-P1 YN35V00052F1 SOLENOID
E-6 HORN LOW LC53S00001D2 PROPO.VALVE (LC10V00014F1) TWO SPEED
SV-3 VALVE ASSY
E-7 TUNER AM/FM (For Oceania) YN54S00046P1 P2 PUMP PUMP SELECT SOL
PSV-P2
E-8 SPEAKER LEFT (For Oceania) YN54S00050P1 PROPO.VALVE SAFETY LOCK
SV-4
E-9 SPEAKER RIGHT (For Oceania) R-1 BATTERY RELAY YN24S00008F1 LEVER SOL
E-10 RECEIVER DRYER YN54S00041P1 R-2 STARTER RELAY VHS283001271A SW-1 KEY SWITCH YN50S00026F1
E-11 AIR-CON COMPRESSOR YX91V00001F1 R-3 GLOW RELAY VHS286201420A SWING PARKING BRAKE RELEASE
SW-4 YN50S00047P1
E-12 BATTERY YN72S00014P1 R-4 SAFETY RELAY YN24S00010P1 SWITCH
E-13 TRAVEL ALARM (For Australia) YN53S00004F1 R-5 HORN RELAY SW-5 HORN SWITCH (RH) YN50E00017P1
(E) ELECTRIC FITTINGS

E-14 CIGARETTE LIGHTER YN81S00003P1 R-6 WORKING LIGHT RELAY SW-7 E/G OIL PRESSURE SWITCH VHS835301471D
E-15 FUSIBLE LINK LC13E01175S002 R-8 TRAVEL ALARM RELAY (For Australia) SW-8 AIR FILTER CLOGGING SWITCH YR11P00008S005
E-27 ACCEL REDUNDANT VOLUME YN52S00052P1 R-10 CAB WORK LIGHT RELAY (For SE.Asia) SW-10 HORN SWITCH (LH) YN50E00017P1
R-19 FLASHER RELAY YY24S00001F1 SW-11 SAFETY LOCK LEVER SWITCH YN50S00041F1
R-23 AUTO IDLE STOP RELAY 1 YN24S00010P1 SW-13 TRAVEL ALARM SWITCH (For Australia) YN50S00040DF
R-24 AUTO IDLE STOP RELAY 2 (CONFLUX/SINGLE SELECT
SW-15 YN50S00040DD
R-25 ENGINE EMERGENCY STOP RELAY SWITCH)
(R) RELAY

(SW) SWITCH
R-26 LEVER LOCK RELAY SW-17 (SKYLIGHT WIPER SWITCH) YN50S00040D9
R-28 ALTERNATOR RELAY SW-19 WIPER INTERLOCK SWITCH YT50S00004P1
WIPER MOTOR RELAY SW-20 POWER BOOST SWITCH (RH) YN50E00017P1
R-29 YN24S00012P2
(NORMAL ROTATION) SW-21 POWER BOOST SWITCH (LH)
WIPER MOTOR RELAY SW-27 COOLANT LEVEL SWITCH VHS834601510A
R-30
(REVERSE ROTATION) SW-28 WATER SEPARATOR SWITCH VHS233002800A
WIPER MOTOR RELAY SW-55 BOOM WORK LIGHT SWITCH YN50S00040D1
R-31
(ARC PREVENTION)
R-32 WASHER MOTOR RELAY

NOTE : The parts number may be changed due to the improvement of machine, so use the number for reference only. LC03Z00036P1 02

23-7
23. ELECTRIC SYSTEM

23.3 HARNESS
23.3.1 HARNESS LIST

INDEX No. EQUIPMENT HARNESS

REMARKS
ASSY No. PART No.
GROUP ITEM NAME ITEM NAME
SE. ASIA OCEANIA SE. ASIA OCEANIA
3.2 INSTRUMENT PANEL ASSY YN17M00053F1 YN17M00054F1
3.3 CONTROLLER INSTALL (ENGINE) YN22E00220F1
CONTROLLER INSTALL YN22E00219F1
3.4 RADIO INSTALL YN54E00008F1 YN54E00017F1
3.5 UPPER ELECTRIC ASSY LC03E00008F1
3.6 UPPER HARNESS ASSY LC13E00031F1 1 HARNESS LC13E01184P3 UPPER
2 CABLE LC13E01145P2 BATTERY ~ BATTERY
UPPER FRAME

3 CABLE LC13E01176P2 BATTERY ~ RELAY

4 CABLE LC13E01245P1 BATTERY ~ GROUND
5 CABLE LC13E01175P2 STARTER
6 HARNESS LC13E01185P3 ECU HARNESS
48 CABLE LE13E01006P1 FLOOR GROUND
51 CABLE LC13E01177P1 ENGINE GROUND
54 CABLE LC13E01180P2 GLOW RELAY ~ STARTER RELAY
3.7 ENGINE HARNESS ASSY LC16E00010F1 1 HARNESS LC16E01029P2 ENGINE SUB
20 HARNESS LC16E01028P1 AIR CONDITIONER SUB
3.8 UPPER HARNESS ASSY LC13E00032F1 1 HARNESS YN13E01449P3 FLOOR
(FLOOR PLATE) 4 HARNESS LC13E01186P1 CAB SUB
9 CABLE LE13E01005P1 FLOOR GROUND
BOOM CAB

3.9 CAB HARNESS LC14E00023F1 1 HARNESS YN14E01102P3 CAB

3.10 BOOM HARNESS ASSY LC15E00008F1 1 HARNESS 2479Z3130D1 BOOM
3.11 BOOM LIGHT INSTALL LC80E00004F1
3.12 DECK LIGHT INSTALL YN80E00049F1
LIGHT

3.13 CAB LIGHT INSTALL YN80E00058F1 6 HARNESS YN02C01760P1 CAB LIGHT

3.14 FLASHER LAMP INSTALL LC80E00011F1
ALARM 3.15 ALARM ASSY YN53E00015F1

The parts number may be changed due to the improvement of machine, so use the number for reference only.

23-8
 23. ELECTRIC SYSTEM

23.3.2 INSTRUMENT PANEL ASSY

TIGHTENING TORQUE
YN17M00053F1 (09) SE. Asia 1.5N.m (1.1lbf.ft)
INSTRUMENT PANEL ASSY TIGHTENING TORQUE SEMS BOLT TIGHTENING TORQUE
YN17M00054F1 (09) Oceania
5.2N.m (3.8lbf.ft) 5.2N.m (3.8lbf.ft)
ITEM PART NAME PART No. Q'TY REMARKS 2 PLACES INSTALL TO CAB
TAPPING SCREW
3-2 POTENTIO METER YN52S00032P1 1 TAPPING
SEMS BOLT DUCT ASSY SCREW
3-10 KEY SWITCH YN50S00026F1 1 K250 2 PLACES
TIGHTENING TORQUE TAPPING SCREW
4-2 CIGARETTE LIGHTER YN81S00003P1 1 2.8N.m (2.1lbf.ft) TIGHTENING TORQUE
5.2N.m (3.8lbf.ft)
5-2 HOUR METER YT58S00006P1 1
SECTION BB SECTION DD SECTION EE
10 GAUGE CLUSTER YN59S00021F2 1
46-3 SPEAKER YN54S00050P1 2
TIGHTENING TORQUE TIGHTENING TORQUE
TIGHTENING TORQUE 5.0N.m (3.7lbf.ft) 8.5N.m (6.3lbf.ft)
TIGHTENING TORQUE 5.0N.m (3.7lbf.ft) INSTALL SEMS BOLT
5.0N.m (3.7lbf.ft) INSTALL SEMS BOLT TO CAB
INSTALL SEMS BOLT
INSTALL SEMS TO CAB
TIGHTENING TORQUE TO CAB
4.1N.m (3.0lbf.ft) BOLT TO CAB
2 PLACES
SEMS BOLT

TIGHTENING TORQUE
4.1N.m (3.0lbf.ft)

TIGHTENING TORQUE TIGHTENING TORQUE

23.5N.m (17.3lbf.ft) 5.0N.m (3.7lbf.ft)
3 PLACES
SEMS BOLT

SECTION AA

VIEW
SEMS BOLT
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
TIGHTENING TORQUE
TIGHTENING TORQUE 0.43N.m (0.32lbf.ft) TIGHTENING TORQUE
TIGHTENING TORQUE TIGHTENING TORQUE
. .
8.5N m (6.3lbf ft) 8 PLACES 5.0N.m (3.7lbf.ft)
5.0N.m (3.7lbf.ft) TIGHTENING TORQUE 4 PLACES
5.0N.m (3.7lbf.ft) 4.9N.m (3.6lbf.ft) SEMS BOLT TAPPING SCREW
SEMS BOLT TIGHTENING TORQUE INSTALL SEMS BOLT
SEMS BOLT
12.0N.m (8.9lbf.ft) TO CAB
INSTALL
SEMS BOLT
TO CAB

SEMS BOLT
4 PLACES
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
SECTION CC

TIGHTENING TORQUE
5.2N.m (3.8lbf.ft)
SEMS BOLT VIEW
INSTALL TAPPING SCREW TIGHTENING TORQUE
TO A/C 5.0N.m (3.7lbf.ft)

23-9
23. ELECTRIC SYSTEM

23.3.3 CONTROLLER INSTALL 23.3.4 TUNER INSTALL

CONTROLLER INSTALL(ENGINE) YN22E00220F1 (03) YN54E00008F1 (03) SE. Asia

TUNER INSTALL (01) Oceania
ITEM PART NAME PART No. Q'TY REMARKS YN54E00017F1
1 CONTROLLER ENGINE ACSSESSORY 1 C8:ECU TIGHTENING TORQUE ITEM PART NAME PART No. Q'TY REMARKS
1.7N.m (1.3lbf.ft)
5 CONTROLLER ENGINE ACSSESSORY 1 C5:COOLANT LEVEL ASSEMBLE WITH THE 1 TUNER YN54S00044P1 1
NUT OF ACCESSORY 6 CABLE YN17M01072P1 ANTENNA
1
CONTROLLER INSTALL YN22E00219F1 (07) TIGHTENING TORQUE
12N.m (8.9lbf.ft)
ITEM PART NAME PART No. Q'TY REMARKS ASSEMBLE WITH THE
NUT OF ACCESSORY
2 SWITCH YN50S00047P1 1 SLEWING PARKING RELEASE
7 POTENTIO METER YN52S00052P1 1 ENGINE EMERGENCY MODE

INSTALL THE CONER

IN THIS DERECTION
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
2 3 PLACES
SEMS BOLT RELAY BOX ASSY
TIGHTENING TORQUE
5.2N.m (3.8lbf.ft) TIGHTENING TORQUE
TAPPING SCREW 5.2N.m (3.8lbf.ft)
TAPPING SCREW
UPPER
HEXAGON NUT SEMS BOLT
TIGHTENING TORQUE
TOOTHED LOWER 2.8N.m (2.1lbf.ft)
HEXAGON NUT
LOCK WASHER

HORN WASHER

SECTION AA SEMS BOLT

TIGHTENING TORQUE
2.8N.m (2.1lbf.ft)
VIEW VIEW

SEMS BOLT
TIGHTENING
TORQUE
2.8N.m (2.1lbf.ft)

VIEW

PASS CABLE THROUGH

TIGHTENING TORQUE THE HOLE FOR HOSE
2.8N.m (2.1lbf.ft) CLAMP CABLE
SEMS BOLT USING BACK OF
CLIP FLOOR PLATE

TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
SEMS BOLT
SEMS BOLT
TIGHTENING TORQUE
5.0N.m (3.7lbf.ft)
CLIP
CLIP
PUT SURPLUS
CABLE INTO CAB CLAMP CABLE WITH HARNESS
INSIDE TOGETHER
CONNECT CABLE WITH PASS CABLE THROUGH THE HOLE CABLE ARRANGEMENT
CAB SIDE ANTENNA FOR HARNESS

23-10
 23. ELECTRIC SYSTEM

23.3.5 UPPER ELECTRIC ASSY

UPPER ELECTRIC ASSY LC03E00008F1 (02)

ITEM PART NAME PART No. Q'TY REMARKS

1 BATTERY RELAY YN24S00008F1 1
2 HORN LC53S00001D1 1 HIGH
3 HORN LC53S00001D2 1 LOW AFTER INSTALLING GLOW RELAY AND STARTER RELAY
TO BRACKET (A), ASSEMBLE THIS BRACKET
TIGHTENING TORQUE
23.5N.m (17.3lbf.ft)
SEMS BOLT

BRACKET

GLOW RELAY
HORN (LOW)

SEMS BOLT
HORN (HIGH)
TIGHTENING TORQUE
15.5N.m (11.4lbf.ft)

STARTER RELAY

B TERMINAL
NUT C TERMINAL
BATTERY RELAY BOX TIGHTENING TORQUE
17.5N.m (12.9lbf.ft)
2 PLACES
SEMS BOLT
TIGHTENING
TORQUE
10.7N.m (7.9lbf.ft)

TIGHTENING TORQUE
10.7N.m (7.9lbf.ft)
CONNECT SEMS BOLT
AFTER CHECKING CONNECT HARNESS AS SHOWN
GROUND
NO PAINT IS HERE TO AVOID SHORT CIRCUIT ON
SEMS BOLT HORN (HIGH)
POWER SOURCE WIRING
CONNECT HARNESS AS SHOWN HORN (LOW)
TO AVOID SHORT CIRCUIT ON
POWER SOURCE WIRING SEMS BOLT
INSTALL BOLT FROM
TIGHTENING TORQUE
FRONT SIDE
11.7N.m (8.6lbf.ft)
MAX

(BLACK) (BLACK)

(GREEN ORANGE) (GREEN ORANGE)

SECTION BB (BATTERY RELAY BOX)

VIEW (COVER INSTALL)

VIEW VIEW

23-11
23. ELECTRIC SYSTEM

23.3.6 UPPER HARNESS ASSY (1/6)

L-2 : SE-5 :
SE-28 :
UPPER HARNESS ASSY LC13E00031F1 (07) DECK WORKING PRESS. SENSOR : CLIP FIX WHITE TAPING POSITION
PRESS. SENSOR : SV-11 :
LIGHT RIGHT SWING
ITEM PART NAME PART No. Q'TY REMARKS EXTRA PRESS EXTRA PRESS.RELEASING SOL SW-28 :
SE-15 : NOTE 5
FUEL SENSOR WATER SEPARATOR SW.
1 HARNESS LC13E01184P3 1 UPPER TO TRAVEL ALARM
2 CABLE LC13E01145P2 1 BATTERY ~ BATTERY
PSV-P2 : PUMP 2 PROPORTIONAL SOL.
3 CABLE LC13E01176P2 1 BATTERY ~ RELAY
SE-23 : PRESS. SENSOR : PUMP P2
4 CABLE LC13E01245P1 1 BATTERY ~ GROUND
5 CABLE LC13E01175P2 1 STARTER SE-22 : PRESS. SENSOR : PUMP P1

6 HARNESS LC13E01185P3 1 ECU HARNESS PSV-P1 : PUMP 1 PROPORTIONAL SOL.

48 CABLE LE13E01006P1 1 FLOOR GROUND

51 CABLE LC13E01177P1 1 ENGINE GROUND
54 CABLE LC13E01180P2 1 GROW RELAY ~ STARTER RELAY A SE-13 :
C ENGINE SPEED
E-6 : HORN LOW SENSOR
E-5 : HORN HIGH TO HARNESS
OF ENGINE
CLIP

TO ATT HARNESS

UPPER HARNESS
STARTER CABLE

INSTALL THE CABLES TO TERMINALS

SO AS TO AVOID INTERFERENCE INSERT HARNESS IN
WITH CAP AND BRACKET SLIT OF INSULATION
TO RADIATOR COOLANT LEVEL SW.
GROUND FLOOR
BATTERY TO ENG ROOM RIGHT
GROUND CABLE
SEMS BOLT P - 31 FLOOR HARNESS GROUND
CONNECT SEMS BOLT TUNER
AFTER CHECKING ATTACHMENT BOOST SWITCH (RH) BATTERY RELAY CLIP
CLIP CLIP TO CAB TO AIR FILTER CLIP
NO PAINT IS HERE FIX WHITE ECU HARNESS BOX FIX WHITE TAPING
NOTE 2 HORN SWITCH (RH) CLOGGING SW. E-10 :
TAPING TO SOLENOID POSITION
HORN SWITCH (LH) RECEIVER DRIER
POSITION BLOCK
GROUND CABLE BATTERY RELAY ATTACHMENT BOOST SWITCH (LH)
BATTERY CABLE
CABLE TO ATT HARNESS TO AIR FILTER CLOGGING SW.
WASHER MOTOR B TO RECEIVER DRYER TO BATTERY RELAY BOX
CLIP TO ENGINE
NOTE 1 TO SWING FLASHER
CLIP
DETAIL OF BATTERY FIX WHITE TAPING STARTER
POSITION CABLE

FIX WHITE TAPING

POSITION
CLIP CLIP
CLIP CLIP CLIP CLIP
TO ENGINE SPEED SENSOR FIX WHITE TAPING
UPPER HARNESS POSITION
TO TRAVEL ALARM
ECU HARNESS
NOTES: (4) UNLESS OTHERWISE SPECIFIED, THE
(1) TIGHTENING TORQUE OF INSTALLING PROCEDURE IS SHOWN BELOW.
CLIP BATTERY TERMINALS ARE 3.4N.m (2.5lbf.ft). CLIP
(2) TIGHTENING TORQUE OF
GROUNDING CABLES ARE 10.7N.m (7.9lbf.ft).
(3) UNLESS OTHERWISE SPECIFIED
TIGHTENING TORQUE IS SHOWN BELOW. HARNESS
M8 : 23.5N.m (17.3lbf.ft)
M10 : 46.1N.m (34.0lbf.ft)
CLIP
M12 : 79.4N.m (58.6lbf.ft) (5) PLACE THE SLIT OF CORRUGATED TUBE
SECTION AA DOWNWARD AND INSTALL IT.

23-12
 23. ELECTRIC SYSTEM

23.3.6 UPPER HARNESS ASSY (2/6)

SEMS BOLT TIE UP CORRUGATED PART OF

CLIP HARNESS WITH PRESSURE SENSOR
USING PLASTIC TIE
TIGHTENING TORQUE SV-11 : SE-5 :
F TERMINAL
3.43N.m (2.5lbf.ft) EXTRA PRESS SOL. (OPT) FIX WITH HARNESS PRESS SENSOR : SWING
S TERMINAL USE NUT OF ATTACHED IN THE ELBOW
GLOW RELAY TIE UP HARNESS SE-29 :
WITH SOLENOID VALVE PRESS SENSOR :
GLOW RELAY ~ STARTER RELAY USING PLASTIC TIE FIX WITH THE CLIP SELECTOR DETECTION
GLOW RELAY (OPT)

SE-28 :
GLOW RELAY TIGHTENING TORQUE PRESS SENSOR :
C TERMINAL
CONNECT TO 3.8N.m (2.8lbf.ft) EXTRA PRESS (OPT)
2P CONNECTOR B TERMINAL USE NUT OF ATTACHED
FOR HARNESS STARTER RELAY
OF ATTACHED CLIP
FIX A HARNESS BY CLIP
CLIP ON SOL. BLOCK BEHIND
FIX WITH THE CLIP
CLIP
WHEN THERE IS NO OPTION
STARTER RELAY OF SE-28, 29, SV-13,
TIE UP THIS HOSE HERE CLIP
FIX A HARNESS OF CLIP
SV-13 : ON PIPE METAL FITTING
CLIP INSTALL THE LOCK OF
THE FUSE BOX COVER UPWARD OPT SELECTOR SOL

BATTERY RELAY VIEW

SEMS BOLT DETAIL C (EXTRA SOL. INSTALL)

CLIP
FIX TWO HARNESS
WITH CLIP
TIE UP CORRUGATED PART OF
CLIP HARNESS WITH SOLENOID VALVE
CONNECT THIS CONNECT THIS USING PLASTIC TIE
TERMINAL WITH TERMINAL WITH
PSV-P1 :
STARTER CABLE BATTERY CABLE PSV-P2 : PUMP P2 PROPORTIONAL SOL.
PUMP P1
TIGHTENING TORQUE TIGHTENING TORQUE
PROPORTIONAL SOL. TIE UP CORRUGATED PART OF
7.8N.m (5.8lbf.ft) MAX 7.8N.m (5.8lbf.ft) MAX TO PUMP
HARNESS WITH PRESSURE SENSOR
USING PLASTIC TIE PROPORTIONAL SOL FIX WHITE TAPING POSITION
UPPER HARNESS
CLIP CLIP
STARTER CABLE
CLIP
BATTERY RELAY CABLE

CLIP
FIX WHITE TAPING
POSITION
CLIP
UPPER HARNESS FIX A HARNESS
SE-23 : ON GUARD
TO GUARD PRESS SENSOR :
CLIP SE-22 : PUMP P2
FIX CONNECTOR PRESS SENSOR :
TO THE BRACKET PUMP P1

VIEW (PUMP P1, P2 PROPORTIONAL SOL. INSTALL)

TO SWING FLASHER
2P 1P 3P (PRESS SENSOR : PUMP P1, P2 INSTALL) TO WATER SEPARATOR SW

VIEW
BATTERY RELAY

VIEW

23-13
23. ELECTRIC SYSTEM

23.3.6 UPPER HARNESS ASSY (3/6)

CONNECT CONNECTOR WITH "CN4-1" CONNECT CONNECTOR WITH "CN5"

TAG OF ITEM 1 : HARNNESS TAG OF ITEM 6 : HARNNESS E-1 :
C-8 : ENGINE CONTROLLER
E-1 : FUSE & RELAY BOX FUSE & RELAY BOX

C-1 :
CAB SUB HARNESS
MECHATRO CONTROLLER
34P CONNECTOR 32P CONNECTOR 31P CONNECTOR C-8 :
ENGINE CONTROLLER CONNECT THE "CNT-2" TAGGED
WITH "CN-1F" TAG WITH "CN-3F" TAG WITH "CN-5F" TAG
CONNECTOR WITH FLOOR HARNESS
35P (A) CONNECTOR 35P (B) CONNECTOR
WITH "CN-2F" TAG WITH "CN-4F" TAG

VIEW

C-1 : MECHATRO CONTROLLER
CONNECT WITH
CONNECT CONNECTOR CONNECT CONNECTOR
BLUE CONNECTOR TO
WITH "CN4-2" WITH "CN1"
ACCELERATION
TAG OF ITEM 1 : HARNNESS TAG OF ITEM 1 : HARNNESS
EMERGENCY VOLUME
SET A WHITE TAPING PART OF UPP HARNESS
TO WHITE TAPING PART OF FLOOR HARNESS.
AND FIX TO FLOOR HARNESS. CLIP

31P CONNECTOR 17P CONNECTOR CONNECT 1P CONNECTOR TO CAB SUB HARNESS R-19 :
16P CONNECTOR
TAG : CNT-3 FLASHER RELAY
28P CONNECTOR 24P CONNECTOR
FIX WHITE TAPING POSITION OF UPPER HARNESS
VIEW AND ECU HARNESS TO THE FLOOR HARNESS WITH CLIP
CLIP

CLIP
FLOOR HARNESS
TIE UP UPPER HARNESS,
FLOOR HARNESS,
ECU HARNESS AND
C-8 : CAB SUB HARNESS
ENGINE CONTROLLER

ECU HARNESS GROUND

ECU HARNESS, C-5 :
FIX WHITE TAPING GROMMET
UPPER HARNESS GROUND RADIATOR COOLANT
POSITION LEVEL CONTROLLER
CLIP TIGHTEN SEMS BOLT
AFTER CHECKING
SEMS BOLT NO PAINT IS HERE FIX WHITE
ECU HARNESS CLIP
6 PLACES TAPING POSITION FIX UPPER HARNESS AND
FLOOR HARNESS NOTE 2 FLOOR HARNESS TO THE
PUT WHITE TAPING STAND IN CASE OF
POSITION HERE UNCONNECTION, TIE UP
GROMMET HARNESS AND FIX HARNESS
CONNECT 1P CONNECTOR
TO CAB HARNESS (GND) UPPER HARNESS

P - 3 ECU HARNESS GROUND ENGINE CONTROLLER

UPPER HARNESS GROUND CHECK CONNECTOR
UPPER HARNESS ENGINE CONTROLLER
P - 2 ECU HARNESS GROUND
CHECKER (FOR OUTSIDE MONITOR) P - 10 / P - 11 UPPER HARNESS GROUND
THE EARTH OF UPP MECHATRO CONTROLLER
HARNESS DO THE CLIP
ECU HARNESS DISTRIBUTION PLAN FIX WHITE TAPING
TO REVERSE OF POSITION
ECU HARNESS P - 9 UPPER HARNESS GROUND FIX THE CONNECTOR
OPT SELECTOR CHANGEOVER SOLENOID WITHOUT INTERFERENCE
P - 16 UPPER HARNESS GROUND LEVER LOCK SOLENOID IN AIR-CON DUCT
DECK WORK LIGHT (RH) ATT. BOOST SOLENOID
PUT WHITE TAPING POSITION HERE SWING FLASHER (LH) TRAVEL 2 SPEEDS SOLENOID P - 14 UPPER HARNESS GROUND
"CNT-1" WITH TAG, CONNECTOR OF RADIATOR COOLANT LEVEL CONTROLLER
& REAR WORK LIGHT SWING PARKING SOLENOID
CONNECT TO FLOOR HARNESS
VIEW WATER SEPARATOR SWITCH P - 15 UPPER HARNESS GROUND
P - 1 ECU HARNESS GROUND SWING FLASHER (RH) RADIATOR COOLANT LEVEL SWITCH
ENGINE CONTROLLER & REAR WORK LIGHT AIR FILTER CLOGGING SWITCH
P - 18 UPPER HARNESS GROUND P - 13 UPPER HARNESS GROUND BATTERY RELAY (COIL)
CAB HARNESS (GROUND) FUSE & RELAY BOX DIODE (GLOW RELAY)
FLASHER RELAY GLOW RELAY (COIL)

FUSE & RELAY BOX CONNECTION

23-14
 23. ELECTRIC SYSTEM

23.3.6 UPPER HARNESS ASSY (4/6)

FASTEN WHITE TAPING PART OF

AIR CONDITIONER SUB HARNESS
AND UPP HARNESS OF CLIP
CLIP E-10 :
RECEIVER DRYER
FIX WHITE TAPING POSITION
CLIP
TIE UP CORRUGATED PART OF
HARNESS WITH RECEIVER DRYER
USING PLASTIC TIE
UPPER HARNESS
SW-27 :
RADIATOR COOLANT LEVEL SW
AIR CON. HARNESS IS
CONNECTED TO UPP TIE UP CORRUGATED PART OF
HARNESS. HARNESS WITH RECEIVER DRYER
USING PLASTIC TIE
CLIP
AIR CONDITIONER CLIP
SUB HARNESS E-10 :
RECEIVER DRYER
STARTER CABLE
DETAIL F
CLIP
UPPER HARNESS
FIX UPP HARNESS AND
STARTER CABLE TO THE
STAY WITH CLIP. CLIP

SW-8 : TO BATTERY RELAY BOX E-10 :

AIR FILTER CLOGGING SW RECEIVER DRYER

FIX WHITE TAPING POSITION

CLIP

TO STARTER
TIE UP CORRUGATED PART OF
CLIP HARNESS WITH SWITCH USING
PLASTIC TIE
CLIP

FIX WHITE TAPING

POSITION

VIEW

CLIP
FIX WHITE TAPING POSITION FIX WHITE TAPING POSITION

BATTERY RELAY BOX

BATTERY RELAY CABLE

CLIP
FIX A HARNESS OF
CLIP ON GUARD UPPER HARNESS
STARTER CABLE
VIEW
AIR FILTER CLOGGING SW. INST VIEW

23-15
23. ELECTRIC SYSTEM

23.3.6 UPPER HARNESS ASSY (5/6)

TIGHTENING TORQUE TIGHTENING TORQUE

28.5N.m (21.0 lbf.ft) NUT
28.5N.m (21.0lbf.ft)
CLIP CLIP
GLOW
INSTALL THE TERMINAL ALTERNATOR (B)
OF UPP HARNESS IN TIGHTENING TORQUE FIX A CONNECTOR
THIS DIRECTION. 3.2 ~ 4.4N.m (2.4 ~ 3.2lbf.ft) WITH CLIP ON BRACKET
ENGINE TO STARTER MOTOR
ACCESSORIES HARNESS
TO STARTER MOTOR AND GLOW
GROUND
ENGINE GROUND CABLE
FIX A CONNECTOR
CLIP ON BRACKET

CLIP

CLIP
CLIP

ENGINE SUB HARNESS

E
ENGINE
CLIP
SUB HARNESS CLIP
F FIX UPP HARNESS AND
ENG. SUB HARNESS BY CLIP

CLIP
FIX WHITE TAPING
POSITION
UPPER HARNESS
STARTER CABLE

CLIP
CLIP UPPER HARNESS ECU HARNESS CLIP FIX WHITE TAPING
VIEW (DETAIL OF ALTERNATOR) FIX WHITE TAPING POSITION
POSITION
ENGINE GROUND CABLE

VIEW VIEW

INSTALL THE TERMINAL OF

LEVEL GAUGE TUBE ENG. EARTH IN THIS DIRECTION

TIGHTENING TORQUE
12 ~ 15N.m (8.9 ~ 11.1lbf.ft)

INSTALL THE RUBBER CAP

SE-13 : ON UPPER SIDE
ENGINE SPEED SENSOR
GROUND
FIX A CONNECTOR TO BRACKET
ENGINE
NUT
ENGINE TIGHTEN AFTER
GROUND CABLE CHECKING
UPPER HARNESS NO PAINT IS HERE
M-1 : STARTER MOTOR STARTER CABLE NOTE 2
ECU HARNESS
TIGHTENING TORQUE
3.5 ~ 5.5N.m (2.6 ~ 4.1lbf.ft) VIEW
CLIP
C TERMINAL
SECTION BB
FIX WHITE TAPING
POSITION
CLIP FIX WHITE TAPING
STARTER CABLE FIX WHITE TAPING POSITION
ENGINE
POSITION CLIP SUB HARNESS
UPP HARNESS

CLIP
FIX A WHITE TAPING
OF HARNESS BY
VIEW
CLIP ON BRACKET UPPER HARNESS

DETAIL OF ENGINE SPEED SENSOR INSTALLATION DETAIL OF E

23-16
 23. ELECTRIC SYSTEM

23.3.6 UPPER HARNESS ASSY (6/6)

SW-56 :
CLIP FUEL SUPPLY AUTO STOP SW.(OPT)
FIX A 2P CONNECTOR ON BRACKET
L-2 :
DECK WORK
LIGHT (RH) CLIP

SE-15 : E-13 :
FUEL SENSOR TRAVEL ALARM
CONNECT A HARNESS FIX WHITE TAPING POSITION
INSIDE OF CAP CLIP
INSTALL THE "ALARM"
TAGGED CONNECTOR
ON BRACKET
UPPER FLAME

CLIP
CLIP
FIX A HARNESS IT THROUGH
UNDER THE BRACKET OF
CLIP SW-28 : FASTEN HARNESS
WATER SEPARATOR SW.
FIX WHITE TAPING
POSITION
CLIP
FIX TO UPP HARNESS
CLIP DETAIL A
FIX WHITE TAPING
POSITION

VIEW (DETAIL OF TRAVEL ALARM INSTALL)

VIEW

C-1 :
SV-3 :
MECHATRO CONTROLLER E-1 :
TWO-SPEED SELECT SOL.
PSV-B:P2 FUSE AND RELAY BOX SW-16 :
SV-1 : ARM TWO-SPEED INVERSE PROPORTIONAL SOL. FIX ENGINE ROOM LIGHT
SV-2 :
SWING PARKING BRAKE SOL. CONNECTOR TO THE BRACKET
POWER BOOST SOL. PSV-C :
SV-4 : TRAVEL STRAIGHT PROPORTIONAL SOL.
LEVER LOCK SOL. PSV-D :
P1 UNLOAD PROPORTIONAL SOL. CAB SUB HARNESS

PSV-A :
CONNECT TO ROTATION
WHITE TAPING POSITION ARM TWO-SPEED INVERSE PROPORTIONAL SOL.
PARKING RELEASE SW.

CLIP
FIX UPPER HARNESS AND "CNT-2" WITH TAG, CONNECTOR OF
ECU HARNESS TO THE FLOOR HARNESS CONNECT TO FLOOR HARNESS CLIP
FIX A HARNESS WITH
CLIP ON HOLE OF
FIX WHITE TAPING POSITION OF GUARD
UPPER HARNESS AND ECU HARNESS
TO THE FLOOR HARNESS
TIE UP UPPER HARNESS,
FLOOR HARNESS,
CLIP UPPER HARNESS
ECU HARNESS AND
FIX WHITE TAPING POSITION CAB SUB HARNESS
FLOOR HARNESS

ECU HARNESS

DETAIL B (DETAIL OF PSV BLOCK)

TO UNDER FLOOR

VIEW

23-17
23. ELECTRIC SYSTEM

23.3.6.1 UPPER HARNESS (1/4) : LC13E01184P3

SE-15 : FUEL SENSOR

TO BE INSTALLED ITEM 2 CAP.

E-6 :
HORN LOW
L-2 : SEALING PLUG TO BE SV-8 :
TAPING AFTER DECK WORKING ARM PUSH/
SUPPLY INSERTED IN TO ALL
BUNDLED LIGHT RIGHT PULL PORT
WITH SUPPLY SELECT SOL.
TAPING AFTER WITH
BUNDLED SW-56 :
FUEL SUPPLY
AUTO STOP SW. SE-13 :
ENGINE SPEED SENSOR
SEALING PLUG TO BE M-11 : SUPPLY
INSERTED IN TO ALL FUEL SUPPLY PUMP WITH

SEALING PLUG TO BE WHITE TAPING

WHITE TAPING
INSERTED IN TO ALL

TAPING SE-44 :
TAPING TAPING AFTER
WHITE TAPING SEALING PLUG TO BE EXTRA PRESS. SW SHIELD UNCONNECTED
BUNDLED
SEALING PLUG TO BE INSERTED IN TO ALL SEALING
INSERTED IN TO ALL PLUG
TAPING TAPING
SUPPLY TAPING
WITH SUPPLY SEALING PLUG TO BE
WITH INSERTED IN TO ALL
E-5 :
HORN HIGH SUPPLY SUPPLY
SEALING WITH WITH E-2 : ALTERNATOR
PLUG
SUPPLY SEALING PLUG TO BE
WITH INSERTED IN TO ALL SEALING PLUG
INSTALL CTB-5 (2 PIECES) TO BE INSERTED CAP TO BE INSTALLED
TO ENGINE SUB
IN TO ALL
SUPPLY SE-11 : SE-5 :
WITH EXTRA PRESS. BUCKET DUMP
RELEASING SOL CUT SOL WHITE TAPING
SE-28 : SUPPLY
TAPING PRESS. SENSOR WITH
EXTRA PRESS
DOUBLE
SPLICE SEALING PLUG TO BE
INSERTED IN TO ALL

TAPING L-1 :
BOOM WORKING LIGHT TAPING AFTER SE-5 :
SEALING PLUG TO BE PRESS SENSOR :
BUNDLED INSERTED IN TO ALL SWING

WHITE TAPING
SEALING SUPPLY TAPING AFTER
PLUG WITH BUNDLED WHITE TAPING

TAPING

WHITE TAPING
TAPING
INSTALL CTB-6 (2 PIECES)
WHITE TAPING
SEALING PLUG TO BE
INSERTED IN TO ALL
WHITE TAPING SUPPLY SUPPLY
SEALING WITH WITH
PLUG
SUPPLY
CORRUGATE TUBE WITH
TAPING TAPING SEALING
SEALING PLUG
SUPPLY SEALING PLUG TO BE PSV-F : OPT, RELIEF PSV-1 : OPT, RELIEF PV-16 :
PLUG SEALING PLUG TO BE
WITH INSTALL CTB-6 (2 PIECES) INSERTED IN TO ALL ADJUSTMENT ADJUSTMENT BUCKET CONTROL SOL
PROPORTIONAL SOL 1 PROPORTIONAL SOL 2 INSTALL CTB-6 (2 PIECES) INSERTED IN TO ALL
WHITE TAPING
SUPPLY SUPPLY SUPPLY
WITH WITH WITH
SW-8 :
SEALING PLUG TO BE AIR FILTER
INSERTED IN TO ALL CLOGGING SW.

SEALING PLUG TO BE WHITE TAPING

SECTION A-A INSERTED IN TO ALL SEALING PLUG TO BE SEALING PLUG TO BE SEALING PLUG TO BE
INSERTED IN TO ALL INSERTED IN TO ALL INSERTED IN TO ALL

23-18
 23. ELECTRIC SYSTEM

23.3.6-1 UPPER HARNESS (2/4) : LC13E01184P3

SE-29 :
PRESS SENSOR :
SELECTOR DETECTION SEALING PLUG TO BE E-10 :
INSERTED IN TO ALL RECEIVER DRYER
(DIRECT CONNECTION)

SUPPLY
WITH
SV-4 : WHITE TAPING
OPERATING SW-27 :
LEVER LOCK SOL RADIATOR COOLANT LEVEL SW

SUPPLY CAP TO BE INSTALLED

SV-1 : SEALING PLUG TO BE
WITH R-1 :
SWING PARKING INSERTED IN TO ALL
SEALING PLUG TO BE BATTERY RELAY
BRAKE SOL.
INSERTED IN TO ALL STARTER TERMINAL C
SV-13 : OPT. SELECTOR SOL. R-3 :
GLOW RELAY (COIL)
PSV-P1 :
SV-3 : PUMP P1 PROPORTIONAL SOL.
TWO-SPEED SELECT SOL. SUPPLY
WITH
WHITE TAPING

CAP TO BE INSTALLED
SV-2 :
POWER BOOST SOL. INSTALL CTB-3
TAPING GLOW RELAY
TAPING
PSV-P2 : (COMMON)
PUMP P2
PROPORTIONAL SOL.

PSV-B : TAPING
WHITE TAPING
P2 UNLOAD
PROPORTIONAL SOL. DOUBLE
SE-23 : INSTALL CTB-3 SPLICE
PRESS SENSOR :
PUMP P2 WHITE TAPING

CAP TO BE INSTALLED
PSV-C :
TRAVEL STRAIGHT SE-22 : GLOW RELAY (NO)
PROPORTIONAL SOL. PRESS SENSOR :
PUMP P1
SUPPLY
SW-28 : WITH
WHITE TAPING
WATER SEPARATOR SW. R-1 :
PSV-D : BATTERY RELAY (COIL) R-2 :
P1 UNLOAD L-13 : STARTER RELAY (COIL)
PROPORTIONAL SOL. TRAVEL ALARM
SEALING PLUG TO BE L-3 :
INSERTED IN TO ALL SWING FLASHER LEFT
& REAR WORKING LIGHT
SUPPLY SEALING PLUG TO BE
WITH INSERTED IN TO ALL
WHITE TAPING SEALING PLUG TO BE
INSERTED IN TO ALL
TAPING AFTER
BUNDLED

SUPPLY
WITH

SUPPLY
WITH TAPING AFTER
BUNDLED TAPING
WHITE TAPING
PSV-A :
ARM TWO-SPEED SEALING PLUG TO BE
INVERSE INSERTED IN TO ALL
L-4 :
PROPORTIONAL SOL. SWING FLASHER RIGHT L-10 : WHITE TAPING
& REAR WORKING LIGHT HIGH REACH
ROTARY LIGHT
SUPPLY SUPPLY
WITH WITH

SEALING PLUG TO BE
INSERTED IN TO ALL SEALING PLUG TO BE SW-16 :
INSERTED IN TO ALL ENGINE ROOM LIGHT

23-19
23. ELECTRIC SYSTEM

23.3.6-1 UPPER HARNESS (3/4) : LC13E01184P3

WHITE TAPING

WHITE TAPING

R-19 :
FLASHER RELAY
DOUBLE
SPLICE

DOUBLE TO HARNESS (CAB) TO HARNESS (CAB SUB)

SPLICE
TAPING

DOUBLE TAPING
SPLICE
C-5 :
RADIATOR COOLANT LEVEL
CONTROLLER

DOUBLE
SPLICE

OPT. (HAND CONTROL) SUPPLY WITH C-1 : MECHATRO CONTROLLER

SUMITOMO 6409-0075
DOUBLE CAP TO BE INSTALLED 7034-1280
SPLICE
WHITE TAPING M-1 : STARTER MOTOR (TO C TERMINAL)
FRAME GND OF UNDER FLOOR

TAPING

TO FLOOR HARNESS
TO GLOW

WHITE TAPING

TAPING RED TAPING

TAPING WHITE TAPING

DOUBLE DOUBLE WIRE WIRE WIRE SIZE FROM CONNECTION TO

SPLICE SPLICE NO COLOR
DOUBLE
SPLICE

TO AIR-CONDITIONER SUB HARNESS

E-1 : FUSE & RELAY BOX

23-20
 23. ELECTRIC SYSTEM

23.3.6-1 UPPER HARNESS (4/4) : LC13E01184P3

WIRE WIRE WIRE SIZE FROM CONNECTION TO WIRE WIRE WIRE SIZE FROM CONNECTION TO WIRE WIRE
WIRE SIZE FROM CONNECTION TO
NO COLOR NO COLOR NO COLOR

CONNECTORS SELECTION TABLE

CONNECTOR PART. NUMBER

NAME MANUFUC,
(PIN NUM,) HOUSING TERMINAL

SHIELDED
CABLE
(2 CORE)

23-21
23. ELECTRIC SYSTEM

23.3.6.2 BATTERY CABLE : LC13E01145P2 23.3.6.5 STARTER CABLE : LC13E01175P2

3.8 (0.15")
300 (11.8")
2870 (9'5")
16 ")
TERMINAL (0.63") 0. 33
50 (1.97") 50 (1.97") 8.4(

CAP 70 700 310 240 70

(0.89")
WHITE TAPING

22.5
YAZAKI 7034-1283 (2.76") (27.6") (12.2") (9.45") (2.76")

CORRUGATE TUBE
TO BE INSTALLED CAP TERMINAL
TERMINAL
WIRE No.35
TERMINAL TERMINAL
INSTALL CORRUGATE TUBE CAP TO BE
INSTALLED
CAP CAP
SUPPLY YAZAKI 7034-1283
WITH

23.3.6.3 BATTERY RELAY CABLE : LC13E01176P2 TERMINAL

WIRE No.36
260 (10.2") TAPED DOUBLY

CAP TAPING
YAZAKI 7034-1283

40 (1.57")

20 (0.79")
TWO TERMINALS ARE IN TOUCH WITH
EACH OTHER TO THEIR BACK AND
BUNDLED BY TAPING, CAP TO BE INSTALLED

TERMINAL DETAIL A
CAP TERMINAL

TAPED IN TWO TURNS

23.3.6.4 BATTERY GROUNDING CABLE : LC13E01245P1

440 (17.3")

40 (1.57")

TERMINAL
TERMINAL
CAP TAPED IN TWO TURNS

23-22
 23. ELECTRIC SYSTEM

23.3.6.6 ECU HARNESS (1/2) : LC13E01185P3

DOUBLE DOUBLE DOUBLE

SPLICE SPLICE SPLICE

E-27:
TO FUSE & RELAY BOX ACCEL REDUNDANT
RESISTOR
WHITE TAPING

WHITE TAPING TO ENGINE CONTROL

HARNESS
INSTALL
WHITE TAPING
DOUBLE CORRUGATE

WHITE TAPING

SEALING
PLUG

SUPPLY WITH
SUMITOMO 6409-0073 TO HARNESS (FLOOR)
TAPING

SUPPLY WITH
SUMITOMO 6409-0603
TAPING

SUPPLY WITH
SUMITOMO 6409-0072

TAPING

WHITE TAPING

SH8 SHIELD UN-CONNECTED

WHITE TAPING

C-6 : ENGINE CONTROLLER

23-23
23. ELECTRIC SYSTEM

23.3.6-6 ECU HARNESS (2/2) : LC13E01185P3 23.3.6.7 FLOOR GROUNDING CABLE : LE13E01006P1

100 (3.94")
WIRE WIRE
WIRE SIZE FROM CONNECTION TO
WIRE WIRE
WIRE SIZE FROM CONNECTION TO
LA308 5B E E 5B E
NO COLOR NO COLOR
1PAM
YAZAKI 7122-3010

23.3.6.8 ENGINE GROUNDING CABLE : LC13E01177P1

450 (17.7")

TERMINAL TERMINAL

SHIELDED CABLE
(2 CORE)
CORRUGATED TUBE TO BE INSTALLED

23.3.6.9 RELAY CABLE : LC13E01180P2

TAPED DOUBLY
LE-SS 180 (7.09")
SHIELDED CABLE
(2 CORE)
CAP TO BE INSTALLED
LE-SS
SHIELDED CABLE
CAP
(2 CORE) YAZAKI 7034-1280

LE-SS
SHIELDED CABLE
(2 CORE)
SHIELDED CABLE
(2 CORE)

TERMINAL TERMINAL
HEAT SHRINKAGE TUBE TO BE INSTALLED
LE-SS
CONNECTORS SELECTION TABLE
SHIELDED CABLE
(2 CORE)
CONNECTOR PART. NUMBER CONNECTOR PART. NUMBER
LE-SS
NAME MANUFUC, NAME MANUFUC,
SHIELDED CABLE HOUSING TERMINAL HOUSING TERMINAL
(PIN NUM,) (PIN NUM,)
(2 CORE)

LE-SS
SHIELDED CABLE
(2 CORE)

23-24
 23. ELECTRIC SYSTEM

23.3.7 ENGINE HARNESS ASSY

HARNESS (ECU)
ENGINE HARNESS ASSY LC16E00010F1 (02)
ENGINE ACCESSORY
FIX A HEATER HOSE AND
ITEM PART NAME PART No. Q'TY REMARKS AIR CON. ACCESSORY
FIX AN AIR CON. ACCESSORY HARNESS BY CLIP OF INT
1 HARNESS LC16E01029P2 1 ENGINE SUB HARNESS OF CLIP TO HOLE
OF AIR COMPRESSOR
20 HARNESS LC16E01028P1 1 AIR CONDITIONER SUB CLIP
B TERMINAL
FIX A HEATER HOSE AND
AIR CON. ACCESSORY
HARNESS BY CLIP
NEAR THE BRED.
CLIP

M-1 : STARTER MOTOR

REMOVE AND CANCEL
THE HARNESS OF
CONNECT AIR CON.
ATTACHMENT FOR
ACCESSORY HARNESS
C TERMINAL
WITH AIR CON. SUB
HARNESS

CLIP
TIGHTENING TORQUE INSTALL BOLT AND BOLT OF
25.5N.m (18.8lbf.ft) AIR COMPRESSOR TOGHETHER AIR CON. SUB HARNESS

STARTER CABLE

AIR CON. HARNESS IS CONNECTED

TO UPP HARNESS DETAIL OF AIR COMPRESSOR
TIGHTENING TORQUE
CLIP 25.5N.m (18.8lbf.ft) USE THE EXISITING BOLT
ENGINE GROUND CABLE TIGHTENING TORQUE
3.2 ~ 4.4N.m (2.4 ~ 3.2lbf.ft)
HARNESS (UPP)
CLIP
TIGHTENING TORQUE
ENG. COOLANT 46.1N.m (34.0lbf.ft)
THERMO SENSOR FIX WHITE TAPING POSITION
(FOR ECU) CLIP
INSTALL WASHER
COOLANT THRMO SENSOR (ECU) UNDER THE CLIP

TIGHTENING TORQUE
3.2 ~ 4.4N.m (2.4 ~ 3.2lbf.ft)
ALTERNATOR (B)

FIX WHITE TAPING POSITION

CLIP FIX A HARNESS WITH
CLIP ON BRACKET OF
ENG. ACCESSORY
CLIP

HARNESS
(ENGINE SUB)

ALTERNATOR (L, R)
SW-7 :
ENG. OIL PRESS. SW.
ENGINE SIDE
FIX THE PLATE TO
ENGINE BRACKET
TIGHTENING TORQUE
25.5N.m (18.8lbf.ft) E-2 : ALTERNATOR

SW-7 : (FOR PLATE FIX)

VIEW TIGHTENING TORQUE
ENGINE OIL PRESS SW
25.5N.m (18.8lbf.ft) DETAIL OF ALTERNATOR

23-25
23. ELECTRIC SYSTEM

23.3.7-1 ENGINE SUB-HARNESS : LC16E01029P2 23.3.7-20 AIR CONDITIONING SUB-HARNESS : LC16E01028P1

E-11 :
SW-7 : ENGINE OIL PRESS. SW. TO UPPER HARNESS TO AIR COMPRESSOR

WHITE TAPING WHITE TAPING

ENGINE COOLANT CONNECTORS SELECTION TABLE

THERMO SENSOR (FOR ECU)
WHITE TAPING PART. NUMBER
CONNECTOR
NAME MANUFUC,
(PIN NUM,) HOUSING TERMINAL

WHITE TAPING SEALING PLUG

TO UPP HARNESS

E-2 : ALTERNATOR

E-2 : ALTERNATOR
SEALING PLUG

23-26
 23. ELECTRIC SYSTEM

23.3.8 UPPER HARNESS ASSY (FLOOR PLATE) (1/2)

SE-3 :
UPPER HARNESS ASSY LC13E00032F1 (10)
PRESS SENSOR :
NOTE : 1. ATTACHMENT OF WELDING CLIP WITHOUT DIRECTIONS IS
SE-4 :
PRESS SENSOR : BOOM RAISING
MADE INTO THE FOLLOWING.
ITEM NAME PARTS No. Q'TY REMARKS
BOOM LOWERING CLIP
1 HARNESS YN13E01449P3 1 FLOOR
SE-1 : HARNESS
4 HARNESS LC13E01186P1 1 CAB SUB HARNESS TO WASHER MOTOR PRESS SENSOR :
BUCKET DIGGING
9 CABLE LE13E01005P1 1 FLOOR HARNESS GROUND SE-2 :
PRESS SENSOR : SE-7 : SW-1 :
BUCKET DUMP PRESS SENSOR : KEY SW.
ARM IN
SE-8 : SW-16 :
PRESS SENSOR : ACCEL POTENTIO
E-1 : FUSE & RELAY BOX ARM OUT
SW-1 : KEY SWITCH
CLIP
USE THE HOLE OF SEAT FASTEN HARNESS BY CLIP CAB HARNESS
SE-16 : WITH BRACKET OF MULTI CLIP
STAND AND FIX HARNESS BUNDLE AFTER
ACCEL POTENTIO NOT USE CLIP CASE BY MULTI
WITH CLIP * CLIP HARNESS DIVERGES
FIX WHITE TAPING
DETAIL A : A CASE OF MULTI
POSITION
(For Oceania)
TO WASHER MOTOR
FIX A HARNESS ON SENSOR
BLOCK WITH CLIP
TO WASHER MOTOR
FIX A HARNESS TO CLIP OF
CLIP CAB SIDE COVER
VIEW
PUSH CONTROL LEVER MOST FRONTWARD
AND FIX THIS SLACK HARNESS WITH CLIP
SE-1 :
SW-12 :
PRESS SENSOR :
SW-35 : OVER LOAD ALARM SELECT SW.
BUCKET DIGGING
HEAVY LIFT SW. CONNECT SWITCH TO TAGGED
SE-8 : SE-2 : CONNECT SWITCH "OVER L" CONNECTOR
PRESS SENSOR : PRESS SENSOR : TO TAGGED "HEAVY"
ARM OUT SW-13 : CONNECTOR
SE-7 : SE-3 : BUCKET DUMP
PRESS SENSOR : PRESS SENSOR : TRAVEL ALARM SW.
BOOM RAISING IN CASE OF TRAVEL SW-40 :
ARM IN SE-4 :
FIX A CORRUGATERD ALARM SPEC., ROTARY LIGHT SW.
PRESS SENSOR : CONNECT SWITCH TO CONNECT SWITCH TO TAGGED "ROTARY"
TUBE NOT CONTACT
M-CONNECTOR BOOM LOWERING TAGGED "ALARM" CONNECTOR
LOCK OF CONNECTOR
DETAIL A : A CASE OF SENSOR TOWER CONNECTOR
SENSOR CLIP
(For SE. Asia) FIX A HARNESS
OF SW. SIDE
CLIP CLIP
FIX A HARNESS PART OF CLIP
SE-20 : PRESS SENSOR : P1 OPT WHITE TAPING WITH CLIP FIX A CLIP ON HOLE
OF STAND SIDE
TIGHTENING TORQUE 10.7N.m (7.9lbf.ft)
TIGHTEN AFTER CHECKING NO PAINT HERE CLIP
FIX A CLIP ON HOLE SW-20 :
NUT
FLOOR HARNESS GROUND OF STAND SIDE POWER BOOST SW. RIGHT
TO PRESS SENSOR, FASTEN FLOOR HARNESS
TUNER CONNECT WITH EARTH MULTI, (YELLOW TAPING)
CABLE OF UPPER WITH LEVER SW.
OVER LOAD ALARM SW. WASHER MOTOR SW-33 :
FRAME HARNESS
HEAVY LIFT SW. REVOLUTION RIGHT SW. (OPT)
TOGETHER
(RED TAPING)
TRAVEL INDEPENDENT CHANGE SW.
SE-10 : SW-5 :
ATT BOOST SW. (RH)
PRESS SENSOR : HORN SW. RIGHT (OPT) (BLUE TAPING)
HORN SW. (RH)
TRAVEL LEFT
ATT BOOST SW. (LH)
SE-9 :
HORN SW. (LH) PRESS SENSOR :
DC-DC CONVERTER TRAVEL RIGHT E-7 :
WASHER MOTOR TUNER CLIP
SE-11 : CLIP FIX WHITE TAPING
PRESS SENSOR : FIX WHITE TAPING POSITION
P2 OPT CLIP FIX A CLIP ON HOLE
POSITION
FIX WHITE TAPING OF SEAT SIDE
THROUGH THE HARNESS
POSITION
AT SEAT SIDE OF BRACKET
CLIP
FIX WHITE TAPING POSITION TO THE FRONT SIDE OF FLOOR PLATE

23-27
23. ELECTRIC SYSTEM

23.3.8 UPPER HARNESS ASSY (FLOOR PLATE) (2/2)

SW-10 : E-1 :
HORN SW. LEFT (OPT) (BLUE TAPING) FUSE & RELAY
SW-21 : BOX C-1 :
POWER BOOST SW. LEFT (OPT)
MECHATRO CONNECT THE "CNT-2" TAGGED
(YELLOW TAPING) C-8 : ENG. CONTROLLER CONTROLLER CONNECTOR WITH "UPPER HARNESS"
SW-34 :
REVOLUTION LEFT SW. (OPT)
(RED TAPING) CONNECT TO SWING
PARKING RELEASE SW.

CONNECT THE "CNT-4" TAGGED

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

CONNECT TO CAB HARNESS

PUSH CONTROL LEVER

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

CONNECT TO SWING
DETAIL OF FUSE & RELAY BOX CONNECTION PARKING RELEASE SW.

FIX TO THE UPPER PART CONNECT THE "CNT-2"

OF PLATE WITH CLIP TAGGED CONNECTOR
WITH "UPPER HARNESS"

CONNECT THE "CN3-2" TAGGED

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

FIX TO THE LOWER PART

OF PLATE WITH CLIP

34P CONNECTOR 22P CONNECTOR 28P CONNECTOR 22P CONNECTOR TO UNDER

VIEW FLOOR
SECTION AA

23-28
 23. ELECTRIC SYSTEM

23.3.8-1 FLOOR HARNESS (1/3) : YN13E01449P3

SE-9 :
PRESS SENSOR :
TRAVEL RIGHT
SW-1 :
KEY SW.

WHITE TAPING SUPPLY WITH

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

SUPPLY TAPING AFTER TAPING AFTER

WITH BUNDLED BUNDLED
SUPPLY WITH SUMITOMO 6409-0603
SE-11 :
PRESS SENSOR : WHITE TAPING
SEALING PLUG TO BE P2 OPT
INSERTED IN TO ALL
WHITE TAPING
TAPING
SE-10 :
PRESS SENSOR :
TRAVEL LEFT

SE-20 :
PRESS SENSOR : SE-16 :
P1 OPT ACCEL POTENTIO

TAPING AFTER
BUNDLED TO ECU HARNESS
WHITE TAPING

TAPING
WHITE TAPING WHITE TAPING
WHITE TAPING TAPING
SUPPLY WITH
WHITE TAPING
SUPPLY WITH DOUBLE TO UPPER HARNESS
SPLICE
AMP 1565123-1 WHITE TAPING

DOUBLE
SPLICE
SW-43 :
JIB PRESS SW.
TO FRAME GND. M-4 :
WASHER MOTOR
TAPING

SEALING PLUG TO BE
INSERTED IN TO ALL

SW-4 :
SWING RELEASE SW.

SE-8 : SE-1 :
PRESS SENSOR : PRESS SENSOR :
ARM OUT BUCKET DIGGING

SE-7 : SE-2 : E-1 :

PRESS SENSOR : PRESS SENSOR : FUSE & RELAY BOX
ARM IN BUCKET DUMP

SE-4 : SE-3 :
PRESS SENSOR : PRESS SENSOR :
BOOM LOWERING BOOM RAISING

23-29
23. ELECTRIC SYSTEM

23.3.8-1 FLOOR HARNESS (2/3) : YN13E01449P3

    
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23-30
 23. ELECTRIC SYSTEM

23.3.8-1 FLOOR HARNESS (3/3) : YN13E01449P3

23-31
23. ELECTRIC SYSTEM

23.3.8-4 CAB SUB-HARNESS : LC13E01186P1

TO HARNESS (UPPER)

E-1 :
FUSE & RELAY BOX

TO CAB HARNESS

23.3.8-9 FLOOR GROUNDING CABLE : LE13E01005P1

100 (3.94")

1PAF
YAZAKI 7123-3010

23-32
 23. ELECTRIC SYSTEM

23.3.9 CAB HARNESS ASSY

CAB HARNESS ASSY LC14E00023F1 (06)

ITEM NAME PARTS No. Q'TY REMARKS E-1 :

1 HARNESS YN14E01102P3 1 CAB FUSE & RELAY BOX
C-1 :
MECHATRO CONTROLLER
CAB SUB HARNESS

E-23 :
12V SOCKET
E-9 :
SPEAKER RIGHT
CONNECT TO
FLOOR HARNESS

TIGHTENING TORQUE 4.4N.m CONNECT TO

E-14 : FIX WHITE CONNECT WITH CAB WORK LIGHT
TIGHTEN SEMS BOLT AFTER CAB SUB HARNESS
CIGARETTE TAPING
CHECKING NO PAINT IS HERE FIX WHITE CONNECT WITH ROOM LIGHT
LIGHTER POSITION
SEMS BOLT TAPING
CLIP CONNECT WITH WIPER INTERLOCK SW. CLIP
CAB HARNESS GROUND POSITION
GAUGE CLUSTER FIX TO CLIP ON THE DUCT
CAB WORK LIGHT SW. CAB HARNESS
AIR-CON UNIT
UPPER HARNESS (GND)
CLIP
BOOM DECK WORK LIGHT SW. FIX WHITE TAPING
CAB WORK LIGHT FRONT POSITION
WIPER INTERLOCK SW.
HOUR METER E-8 :
WIPER MOTOR SPEAKER LEFT
CIGARETTE LIGHTER
12V POWER SOURCE SOCKET SW-15 : FLOOR HARNESS
SKY ROOF WIPER (OPT) CONFLUX / SINGLE
CONFLUX / SINGLE CHANGE SW. CAB SUB CONNECT TO
SELECT SW.
CAB WORK LIGHT HARNESS UPPER HARNESS
SW-55 :
BOOM , DECK TO AIR
CONNECT WITH
FLOOR HARNESS WORKING CONDITIONER UNIT
CAB WORK LIGHT
LIGHT SW.
UPPER HARNESS
C-2 :
GAUGE CLUSTER
DETAIL A
CLIP

CLIP
SW-41 :
HIGH REACH CRANE SW.
E-3 : CONNECT THE SWITCH
HOUR METER WITH "CRANE" TAGGED
BLACK CONNECTOR
SW-15 :
SW-17 : SW-26 :
M-3 : CONFLUX / SINGLE SELECT SW.
ROOF WIPER SW. CAB WORK LIGHT SW.
WIPER MOTOR CONNECT THE SWITCH WITH "CONFLUX"
CONNECT THE SWITCH CONNECT THE SWITCH WITH "CAB LIGHT"
TAGGED GREEN CONNECTOR
WITH "WIPER" TAGGED TAGGED NATURAL COLOR CONNECTOR
SW-55 :
BOOM , DECK WORKING LIGHT SW. NATURAL COLOR
E-4 :
CONNECTOR E-4 :
CONNECT THE SWITCH WITH "BOOM, DECK" CIGARETTE LIGHTER
CIGARETTE LIGHTER
TAGGED BLUE CONNECTOR
TO AIR
CONDITIONER UNIT FIX TO THE BRACKET

FIX WHITE TAPING CLIP

POSITION
TIE UP FLOOR HARNESS WITH
CLIP
CAB HARNESS USING CLIP

WR B

DETAIL B
DETAIL OF HOUR METER

23-33
23. ELECTRIC SYSTEM

23.3.9-1 CAB HARNESS (1/2) : YN14E01102P3

E-8 : SPEAKER LEFT

DOUBLE
WHITE TAPING SPLICE

DOUBLE
TAPING AFTER SPLICE
BUNDLED
TO CAB WORKING LIGHT
TO CAB WORKING LIGHT

DOUBLE
SPLICE E-9 :
DOUBLE
SPLICE SPEAKER RIGHT

WHITE TAPING

TO ROOF WIPER
E-23 : SHIELD UN-CONNECTED
12V SOCKET
TAPING TAPING C-2 :
GAUGE CLUSTER

L-5 : ROOM LIGHT

TAPING WHITE TAPING

M-3 : WIPER METER

DOUBLE
SW-19 : SPLICE
WIPER INTERLOCK SW. E-3 :
DOUBLE SW-17 : HOUR METER
TO CAB GND. SPLICE ROOF WIPER
SW-41 : SW-15 :
SW.
HIGH REACH CONFLUX / SINGLE
CRANE SW. SELECT SW.
TO ROTALY LIGHT C-4 : E-14 :
TO HARNESS (FLOOR) CIGARETTE LIGHTER
AIR CONDITIONER UNIT WHITE TAPING SW-55 :
TO HARNESS (UPP)
DOUBLE BOOM, DECK
SPLICE
WORKING LIGHT SW.
SW-26 :
CAB WORK LIGHT
SW.
DOUBLE
SPLICE

WHITE TAPING
TAPING TAPING AFTER TAPING AFTER
BUNDLED BUNDLED

TAPING
TO CAB HARNESS

23-34
 23. ELECTRIC SYSTEM

23.3.9-1 CAB HARNESS (2/2) : YN14E01102P3

23-35
23. ELECTRIC SYSTEM

23.3.10 BOOM HARNESS ASSY 23.3.11 INSTALLING BOOM LIGHT

BOOM HARNESS ASSY LC15E00008F1 (05) INSTALLING BOOM LIGHT LC80E00004F1 (04)

ITEM NAME PARTS No. Q'TY REMARKS ITEM NAME PARTS No. Q'TY REMARKS
1 HARNESS 2479Z3130D1 1 BOOM HARNESS 1 LIGHT YW80S00001F1 2

TO UPPER
HARNESS POINT THIS LAMP TO BUCKET BOTTOM CENTER.
INSTALL THE LAMP SO THAT THE LIGHT BEAM POINTS THE
BOTTOM OF BUCKET, IN THE CONDITION THAT AREM IS
23.3.10-1 BOOM HARNESS : 2479Z3130D1 EXTENDED FULLY (ARM OUT) AND BUCKET IS CLOSED FULLY. 1

YAZAKI
CAP : 7120-1010
TERMINAL : 7115-1050

TIGHTENING TORQUE
18.6N.m (13.7lbf.ft)

SECTION AA
YAZAKI
CAP : 7120-1010 YAZAKI
TERMINAL : 7115-1050 HOUSING : 7122-2810
BRANCH WITH SPLICE TERMINAL : 7114-2020

23-36
 23. ELECTRIC SYSTEM

23.3.12 INSTALLING UPPER LIGHT 23.3.13 CAB LIGHT INSTALL

INSTALLING UPPER LIGHT YN80E00049F1 (01) CAB LIGHT INSTALL YN80E00058F1 (02) SE. Asia

ITEM PART NAME PARTS No. Q'TY REMARKS ITEM PART NAME PARTS No. Q'TY REMARKS
1 LIGHT YT80S00002F2 1 1 LIGHT YT80S00002F2 1
6 HARNESS YN02C01760P1 2
7 SWITCH YN50S00040D4 1
8 RELAY YN24S00010P1 1

6
bb
OPT WORK CONNECT TOINST-PANEL
LIGHT RELAY 8 HARNESS

7
CONNECT WITH
MAIN HARNESS

VIEW
VIEW
VIEW
aa

NOTE :
ITEM 1, TIGHTENING TORQUE 18.6N.m (13.7lbf.ft)

MAIN HARNESS TIGHTENING TORQUE

GROMMET
46.1N.m (34lbf.ft)
PAINT PANGIN SEAL
2 PLACES FROM SURFACE
CLIP
BUNDLE HARNESS AND
NUT (SUPPLIED WITH LIGHT) GROMMET TIE WITH CLIP
1 PAINT PANGIN SEAL SEMS-BOLT
FROM SURFACE TIGHTENING TORQUE
DETAIL aa 46.1N.m (34lbf.ft)
DETAIL bb
HOW TO INSTALL LIGHT AT RIGHT SIDE DECK

23-37
23. ELECTRIC SYSTEM

23.3.14 FLASHER LAMP INSTALL 23.3.15 ALARM ASSY

FLASHER LAMP INSTALL LC80E00011F1 (02) ALARM ASSY YN53E00015F1 (01)

ITEM PART NAME PARTS No. Q'TY REMARKS ITEM PART NAME PARTS No. Q'TY REMARKS
1 FLASHER LAMP YM80S00001F1 1 FOR LH 1 ALARM YN53S00004F1 1
2 FLASHER LAMP YM80S00001F2 1 FOR RH 3 SWITCH YN50S00040DF 1
4 RELAY YN24S00010F1 1

TIGHTENING
CONNECT WITH CONNECTOR OF SWING
TORQUE
FLASHER (SUPPLIED WITH UPP HARNESS) 23.5N.m
(17.3lbf.ft)
SEMS BOLT
E-13 :
TRAVEL ALARM
1

UPP
HARNESS

VIEW
1 2
SW-13 :
TRAVEL ALARM SW.
CONNECT WITH NAME TUBE OF "ALARM"
3

4
SHOWING REAR VIEW (C/W) TRAVEL ALARM RELAY

NOTE : TIGHTENING TORQUE OF ITEM 1 AND 2 TO BE UNDER 3~3.9N.m (2.2~2.9lbf.ft)

DETAIL OF FUSE & RELAY BOX

RIGHT CONSOLE BOX

23-38
 24. COMPONENTS SYSTEM
TABLE OF CONTENTS

24.1 HYDRAULIC COMPONENTS .........................................................................................24-3

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

Book Code No. S5LC2411E02

24-1
24. COMPONENTS SYSTEM

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC2411E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)
S5LC2411E02
Revision February, 2007 ↑ K
(ASIA, OCE)

24-2
 24. COMPONENTS SYSTEM

24.1 HYDRAULIC COMPONENTS

24.1.1 HYDRAULIC PUMP • REGULATOR

24.1.1.1 SUMMARY
(1) Outside view and Hydraulic port

5
EYE BOLT (M10)

a3 PSV2
Dr

A3 2X4-M12
Depth 22

A1 A2
B3

a4 VIEW
PSV1
MAX. FLOW RATE ADJUSTING SCREW
PH1 PH2
4 PSV1 4
PSV2 PSV2

MIN. FLOW MIN. FLOW RATE

2 2 ADJUSTING SCREW
RATE
ADJUSTING a3
SCREW
PH1 PH2 PH2 PH1
a4
a1 3 a1
a2
a2 B3
B3
B1
Dr B1
A3

Dr3 a5
A1 A2 5
1 A2
Dr3

Hydraulic ports
Q'TY Code Ports name Size
No. Parts
SE.Asia Oceania A1,2 Delivery port SAE 6000psi 1"
1 Main pump assy 1 B1 Suction port SAE 2500psi 2 1/2"
2 Regulator assy 2 Dr Drain port PF3/4-20
3 Gear pump assy(for pilot) 1 PSV1,2 Servo assist port PF1/4-13
4 Solenoid proportional reducing valve 2 PH1,2 Pressure sensor port PF3/8-17
5 PTO unit 1 a1~a4 Gauge port PF1/4-15
a5 Gauge port PF1/4-14
A3 Delivery port of gear pump PF1/2-19
B3 Suction port of gear pump PF3/4-20.5
Dr3 Drain port of gear pump PF3/8-15

Fig. 24-1 Hydraulic pump • regulator

24-3
24. COMPONENTS SYSTEM

(2) Hydraulic circuit diagram

(FRONT) PSV1 a1 A1 PH1 PH2 A2 a2 PSV2 (REAR)

(KDRDE5K) (KR3G-YTOK-HV) (KR3G-YTOK-HV) (KDRDE5K)

Solenoid proportional Solenoid proportional

reducing valve (PSV-1) reducing valve (PSV-2)

Regulator Regulator

a3 Dr a4
Engine Gear pump for pilot
a5
Main pump
B1 B3 Dr3 A3

PTO gear case

Fig. 24-2 Hydraulic circuit diagram of pump

(3) Specifications

Main pump
Item Gear pump
SE. Asia Oceania
Pump assy LC10V00014F1 LC10V00015F1 -
Parts No.
Single Pump LC10V00020F1 YN10V00014F3
Pump model K5V140DTP1K9R-YT0K-HV ZX10LGRZ2-07G
Max.displacement capacity cm3 140 X 2 10
Revolution Rated min-1(Clockwise seen from shaft end) 2100
Rated 34.3 (4980)
Pressure MPa (psi) 5.0 (725)
ATT boost pressure 37.8 (5480)
Max. flow L/min (gal/min) 294 (78) X 2 at 7.8MPa (1130 psi) 21 (5.5)
Max. input horse power kW (PS) 195 (265) 3.4 (4.6)
Max. input torque N.m (lbf.ft) 886 (653) 14.7 (10.8)
Part No. LC10V01005F1
Model KR3S-YTOK-HV
Regulator Electric flow control, positive flow control,
Control function
total power control at emergency mode and power shift control

Others With solenoid proportional reducing valve (KDRDE5K-31/30C50)

Weight kg (lb) 141 (310) 143 (315)

24-4
 24. COMPONENTS SYSTEM

24.1.1.2 HYDRAULIC PUMP

24.1.1.2.1 CONSTRUCTION
(1) Main pump

953 806 789 532 Apply adhesive (Three Bond No.1305N) 724 901 808 954 717 151 152 211
886 214 548 531 702 792 534 A
535 732
717
261
406

824
774
111

B B

127
123
710 04
212
401 251 490 271 153 156 157 468 313 124 710 116 467 466 312 885 314 141 271 113
728 727 725
Tightening torque 05

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

24-5
24. COMPONENTS SYSTEM

(2) Gear pump (For pilot)

700 354 351

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

434

Delivery port : PF1/2

Tightening torque :
53N.m (39.1 lbf.ft)

311

312

732 307 850

434 355
Drain port : PF3/8 310 308 309 466
725
710 435 361 353 Tightening torque :
34.3N.m (25.3 lbf.ft)

No. Parts Q’ty No. Parts Q’ty

307 Poppet 1 361 Front case 1
308 Seat 1 433 Flange socket; M8×40 2
309 Ring 1 434 Flange socket; M8×55 2
310 Spring 1 435 Flange socket; M8×20 4
311 Adjust screw 1 466 VP plug ; PF1/4 1
312 Lock nut ; M14×1.5 1 700 Ring 1
351 Gear case 1 710 O-ring ; 1B G95 1
353 Drive gear 1 725 O-ring ; 1B P11 1
354 Driven gear 1 732 O-ring ; 1B P16 1
355 Filter 1 850 Locking ring 1

24-6
 24. COMPONENTS SYSTEM

(3) PTO gear case (For Oceania)

125
711 468
118 825 710 728

117
126
326 262
115
128
826

414
435
886

885

No. Parts Q’ty No. Parts Q’ty

115 Idle shaft 1 435 Flange socket ; M10×20 4
117 2nd gear 1 468 VP plug ; PF3/4 1
118 3rd gear 1 710 O-ring ; 1B G80 1
125 Ball bearing 2 711 O-ring ; 1B G85 1
126 Roller bearing 1 728 O-ring ; 1B P24 1
128 Bearing spacer 2 825 Snap ring 1
262 Cover 2 826 Snap ring 1
326 Gear case 1 885 Sprig pin 1
414 Capscrew ; M10×20 4 886 Pin 2

24-7
24. COMPONENTS SYSTEM

24.1.1.2.2 OPERATION
The pump assy is equipped with two pumps
arranged on the same axis that are connected with
gear (116) and distribute the rotating power to the REGULATOR
gear trains on a different axis. Thus the engine
rotation is transmitted to front shaft (111) that drives
the two pumps and, at the same time, drives the
auxiliary pump (OPT) arranged on another shaft. 116
The pump assy consists largely of the rotary group,
the main part of the pump that makes rotary on; the 111
swash plate group that changes the delivery rate;
the valve block group that selects between oil
suction and delivery ; and the PTO group (OPT)
that transmits the drive power to the auxiliary pump.
(1) Rotary group
PTO GEAR CASE
The rotary group consists of shaft(111), cylinder
OCEANIA
block (141), piston (151), shoe (152), plate (153), AUXILIARY PUMP
spherical bushing (156), and cylinder spring (157). (OPT)
The shaft is supported by bearings (123) and (124) Fig. 24-4 Construction of hydraulic pump
at its both ends. The shoe, which is caulked to the
piston, forms a spherical joint and relieves it of
thrust force that is generated by load pressure.
Further, the piston is provided with a pocket so it
moves lightly on shoe plate (211), taking hydraulic
balance.
The sub group of the piston-shoe is pressed
against the shoe plate by the cylinder spring, via the
retainer plate and the spherical bushing, so that it
moves smoothly over the shoe plate. The cylinder
block (141) is also pressed against valve plate
(313) by the action of cylinder spring (157).

313
124

312

111

116
124
314
141
157
156
151
. 153
152
211

Fig. 24-5 Rotary group

24-8
 24. COMPONENTS SYSTEM

(1) Swash plate group 532

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

Fig. 24-7 Valve block group

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

24-9
24. COMPONENTS SYSTEM

24.1.1.3 REGULATOR

24.1.1.3.1 CONSTRUCTION

PSV B PSV 418

413
079
757 D
439
438

725
730
a3
656 643

438 924
D
801

722 543 755 545 541 724 B 466, 755 708 644 646 645 728
VIEW C SECTION B-B

641 655 654 836 651 652 601

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

614 631 627

C
613
898 802
875
A 732
611 753

733

756
622 621 623 625 626 887 763
SECTION A-A

At start and
emergency mode

662 642 Tightening torque

Tightening torque
543 545 541 Item No. Thread size
466 N.m (lbf.ft)
At normal
412,413 M8 29 (21)
755 E 438,439 M6 12 (8.9)
418 M5 6.9 (5.1)
466 PF 1/4 36 (27)
496 496 NPTF1/16 8.8 (6.5)
755 E 630 M30X1.5 160 (118)
801 M8 16 (12)
SECTION E-E SECTION D-D 802 M10 19 (14)

Fig. 24-9

24-10
 24. COMPONENTS SYSTEM

No. Parts Q'ty No. Parts Q'ty No. Parts Q'ty

412 Socket bolt ; M8X50 2 628 Adjusting screw (C) 1 732 O-ring ; 1B P16 1
413 Socket bolt ; M8X70 2 629 Cover (C) 1 733 O-ring 1
418 Socket bolt ; M5X12 2 630 Lock nut ; M30X1.5 1 734 O-ring ; 1B G25 1
438 Socket bolt ; M6X20 8 631 Sleeve (For PF) 1 753 O-ring ; 1B P9 1
439 Socket bolt ; M6X25 5 641 Pilot cover 1 755 O-ring ; 1B P11 7
466 VP plug ; PF1/4 3 642 Spool 1 756 O-ring ; 1B P26 1
496 Plug ; NPTF1/16 17 643 Pilot piston 1 757 O-ring ; 1B P12.5 1
541 Seat 2 644 Spring seat (Q) 1 763 O-ring ; 1B G35 1
543 Stopper 1 2 645 Adjusting stem (Q) 1 801 Nut ; M8 1
545 Ball 2 646 Pilot spring 1 802 Nut ; M10 1
601 Casing 1 651 Sleeve 1 814 Snap ring 1
611 Feed back lever 1 652 Spool 1 836 Snap ring 1
612 Lever (1) 1 653 Spring seat 1 858 Snap ring 2
613 Lever (2) 1 654 Return spring 1 874 Pin ; o 4X11.7L 1
614 Fulcrum plug 1 655 Set spring 1 875 Pin ; o 4X8L 2
615 Adjusting plug 1 656 Block cover 1 876 Pin ; o 5X8L 2
621 Compensating piston 1 662 Spring 1 887 Pin 1
622 Piston case 1 708 O-ring ; 1B G75 1 897 Pin ; o 5X19L 1
623 Compensating rod 1 722 O-ring ; 1B P6 3 898 Pin ; o 7.5X11L 1
624 Spring seat (C) 1 724 O-ring ; 1B P8 8 924 Socket screw ; M8X20 1
625 Outer spring 1 725 O-ring ; 1B P10 1 041 Sub-check valve 2
626 Inner spring 1 728 O-ring ; 1B P18 1 079 Solenoid proportional reducing valve 1
627 Adjusting stem (C) 1 730 O-ring ; 1B P22 1
The codes in a rectangle represent adjust screws.
Do not tamper with the adjust screws as much as possible.

24-11
24. COMPONENTS SYSTEM

24.1.1.3.2 OPERATION
(1) Control function
Control function …… Electric flow control.
•Positive flow control.
•Total horsepower control.
Emergency mode control.
•Hydraulic positive control.
•Hydraulic total horsepower control

(2) Summary
The regulator KR3S-YTOK for the in-line type axial piston pump K5V series is composed of the control
mechanism as mentioned below:
1) Electric flow control and positive flow control
The tilting angle of the pump (delivery rate) is controlled by controlling the current command value of the
solenoid proportional reducing valve attached to the regulator. The regulator makes positive flow control
(positive control) that increases the delivery rate as the secondary pressure of the solenoid proportional
reducing valve rises. Since this function permits the output power of the pump to be varied, it is possible to
attain optimum power according to the operating condition. Also, since the pump delivers only the necessary
oil flow, the machine does not consume excessive power.

2) Constant power control at emergency mode

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

(3) Explanation of operation

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

the command current value corresponding to the

movement of control devices. This relation is
shown in right figure.

Command current I
Fig. 24-10

24-12
 24. COMPONENTS SYSTEM

a. Flow rate increase (See Fig. 24-11)

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

the spool (652) connected to feedback lever

moves towards (D). When the spool moves
towards (D), the port CL connected to tank port
is open and the pressure in servo piston large
bore diameter chamber is released,
consequently the servo piston (532) moves
towards (E) according to delivery pressure Pd1
in small bore diameter piston chamber, resulting Pd1
in the rise of flow rate. Since the feed back lever CL port

is connected to the servo piston and spool, the a3

feed back lever rotates at (F) fulcrums with the Hydraulic circuit diagram
B
movement of the servo piston towards (E),
consequently the spool is returned to the original Fig. 24-11
position. With this movement, the opening of
spool sleeve gradually closes, and the servo
piston stops at the position the opening closes
completely.

24-13
24. COMPONENTS SYSTEM

b. Flow rate decrease (See Fig. 24-12)

 
  
As the command current value I is reduced, the    

secondary pressure P2 of electromagnetic 



 
proportional pressure-reducing valve is reduced,
 "
and by pressing pilot piston (643) in (G) direction 
it stops at the position the pilot spring force (646)
balances the secondary pressure P2. The $   
movement of pilot piston is transferred to lever 2 

(613) through pin (875), and rotates at (H) 
fulcrum in arrow direction. Furthermore the lever 
#
2 movement is transferred to feedback lever !


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

in the reduction of tilt angle, and finally the flow 
rate is reduced. Since the feed back lever is %
& 
& 

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

as shown in Fig. 24-13.

The operation of power control is the same as
the flow rate control, and is explained below.

Delivery output (Pd1)

Fig. 24-13

24-14
 24. COMPONENTS SYSTEM

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

 
Because the delivery pressure Pd1 acts on the    

  
compensating rod stepped section with the rise   
  
of self pump delivery pressure Pd1 the    $
compensating rod (623) is pushed towards (M),

and moves to the position the delivery pressure !
Pd1 balances the spring force of outer spring
& # 

(625) and inner spring (626). The movement of
'
compensating rod is transferred to lever 1 (612) 

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

consequently the flow rate is also reduced. Since !() ) 
0
the feed back lever is connected with servo
piston and spool, the feed back lever rotates at Fig. 24-14
(R) fulcrum with the movement of the servo
piston towards (Q), consequently the spool is
returned to the original position. With this
movement, the opening of spool sleeve
gradually closes, and the servo piston stops at
the position the opening closes completely.

24-15
24. COMPONENTS SYSTEM

b. Flow rate recovery operation (See Fig. 24-15)

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

rate is raised. Since the feed back lever is Hydraulic circuit daigram
connected to servo piston and spool, the feed B

back lever rotates at (X) fulcrum with the Fig. 24-15

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

24-16
 24. COMPONENTS SYSTEM

4) Power shift control

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

Delivery flow rate Q

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

24.1.1.3.3 ADJUSTING THE REGULATOR

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

Tightening set screw (954) decreases the delivery

rate, as indicated in Fig. 24-17.
Only the maximum flow varies, but other control
characteristics remain unchanged.

Adjust screw no. 954

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

(2) Adjusting the minimum flow (See Fig. 24-3)

Adjust the minimum flow by loosening nut (806) and
by tightening socket screw (953) (or loosening it).
Delivery flow rate Q

Tightening socket screw increases the delivery

rate, as indicated in Fig. 24-18.
Other control characteristics remain unchanged in
the same way as maximum flow adjustment, care
should be used of the fact that overtightening may
increase a required power at the maximum delivery
pressure (at relieving action).
Input current I (Pilot pressure Pi)
Adjust screw no. 953
Fig. 24-18 Adjusting the min. delivery flow
No. of turns for tightening 1/4
Pilot pressure Pi (Input current I) No change
Min. increase in delivery flow L/min (gal/min) 4.6 (1.2)

24-17
24. COMPONENTS SYSTEM

(3) Adjusting the input horsepower

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

Delivery flow rate Q

tightening adjust screw (628) (or loosening it).
Tightening the adjust screw shifts the control
chart to the right and increases the input
horsepower, as indicated in Fig. 24-19.
Since turning the adjust screw C (628) by N turns
changes the setting of the inner spring (626),
return the adjust screw C (627) by NX1.48 turns
at first. Delivery pressure (Pd1)
Fig. 24-19 Adjusting the input horsepower (1)
Adjust screw no. 628
No. of turns for tightening 1/4
Increase delivery pressure MPa (psi) 2.06 (299)
Increase in input torque N.m (lbf.ft) 50 (36.9)

2) Adjusting the Inner Spring (See Fig. 24-9)

(At emergency mode)
Adjust it by loosening nut (802) and by adjust
Delivery flow rate Q

screw (C) (627) (or loosening it). Tightening the

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

Adjust screw no. 627

No. of turns for tightening 1/4
Increase inflow L/min (gal/min) 12 (3.2) Delivery pressre (Pd1)
Fig. 24-20 Adjusting the input horsepower (2)
Increase in input torque N.m (lbf.ft) 58.7 (43.3)

(4) Adjusting the flow control characteristics (See Fig.

24-9)
Adjust them by loosening nut (801) and socket bolt
Delivery flow rate Q

(924) (or loosening it). Socket bolt causes the

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

Adjust screw no. 924

No. of turns for tightening 1/4
Increase Pilot pressure MPa (psi) 0.18 (26)
Input current I (Pilot pressure Pi)
Decrease in delivery flow L/min (gal/min) 18.5 (4.9)
Fig. 24-21 Adjusting the flow control
characteristics

24-18
 24. COMPONENTS SYSTEM

24.1.1.3.4 CAUSES OF FAULT RESULTING FROM REGULATOR

When trouble due to this regulator occurs, disassemble
and inspect it referring to "Chapter LC33-II"
(1) When the engine is overloaded,
Load every unit of pump, and check on pumps on
the right and left sides for possible damages. When
pumps on both sides are failed, check on them for
the following failures 1), 2). When pump on the one
side is failed, start checking from para. 3).
1) Check that the power shift command current I is
normal.
2) The power shift pressure is low.
• Check the dither of amp.
• Replace solenoid proportional reducing
valve.
3) Stick of compensating piston (621) and
compensating rod (623)
• Disassemble and clean it.
4) Stick of pin (898)
• Disassemble and clean it.
(2) The max. flow rate is not delivered.
1) Check that pilot differential pressure Pi is normal.
2) Stick of pilot piston (643)
• Disassemble and clean it.
3) Stick of spool (652)
• Disassemble and clean it.
4) Stick of pin (898)
• Disassemble and clean it.
Note : When the damage of part is severe, replace the
part with new one.

24-19
24. COMPONENTS SYSTEM

24.1.1.4 CONTROL CURVE OF PUMP

300 1471
(79) (1085)
2100min-1: Hmode Input revolution ;2100 min-1
Q Input horse power ;195 kW (265ps)
1900min-1: S Input torque ;886 N.m (653lbf.ft)
250
(66) [1]
Reference value in ( ).
[2] Two pumps are loaded at the same time
[3]
Delivery flow rate Q [ L/min ](gal/min)

200 981
(53) (724)

150
(40)
[1] 183kW (249ps) H mode at traveling or optional working
[2] 154kW (209ps) H mode at operating attachment
[3] 149kW (203ps) S mode at operating attachment
100 490
(26) (360)

Tin N.m (lbf.ft)

Input torque
50
(13)
Min.Flow(at 2100min-1)

0 5 10 15 Delivery 20 25 30 35 40[MPa]
(725) (1450) (2175) pressure (2900) (3625) (4350) (5075) (5800)(psi)
300 725mA Pd
1471
(79) 290L(77gal) (1085)
Q 2000min-1
300mA 12.0MPa [4] 156kW (212ps) (Pf=0MPa) (72 gal)
(1740psi) : At emergency mode
288L Input revolution ;2100 min-1 271L
250
(P t e

(76gal) Input horse power ;195 kW (265ps)

f= me

(66)
A
4. rg

Input torque ;886 N.m (653lbf.ft)

9M e
Pa ncy

[4]
I-Q Curve
)(7 m

Pd=7.8MPa at Qmax
10 od

Reference value in ( ).
Delivery flow rate Q [ L/min ](gal/min)

200 (1131psi) 981

ps e

Two pumps are loaded at the same time (724)

i)

(53)
Pf:Power shift pressure (Reference value)
23.8MPa
147L
150 (39gal)
(40)

100 490
(26) (360)
Tin N.m (lbf.ft)

38.0MPa
Input torque

Tin (5510psi)
50 84L
(13) (22gal)
Min.Flow(at 2100min-1)
400mA
30L
(8gal)
0 5 10 15 Delivery 20 25 30 35 40[MPa]
(725) (1450) (2175) pressure (2900) (3625) (4350) (5075) (5800)(psi)
Pd
0 1 2 3 Pilot pressure 4 [MPa]
(145) (290) (435) Pi (580)(ps)

24-20
 24. COMPONENTS SYSTEM

24.1.2 CONTROL VALVE

24.1.2.1 SPECIFICATIONS

24.1.2.1.1 OUTSIDE VIEW

PTb

PBL

P2 CT2

CP2

CT1

P1

Pcb PAL

CT1 T1
T2
PTb P1 unload CT2
PCb PAL
Travel PL PCb Travel left PBL
PAL AL BL P2 unload
straight CMR1 CMR2 Ar CP2
USE FOR YN30V00101

Br PAr PCa
PBr Travel PAr PB1 Boom
F1

PB1
Ab right conflux CCb Bs
PAb CP1 (HEAD) As
Bb PBs Swing
Boom PBb PBs PAs
(ROD) Aa
PBb Pss
LCb CRb PC LCs
PAc Bucket PCc PBa1 Pss
Ac Bc PBc Arm 1 PLc2 CRa (HEAD) PAa1
PBa1
(HEAD) (ROD) Ba
LCc LCa
PCAP2 LCAT2 MU PBa2 PAo (ROD)
PAa2 Arm 2 PBa2 PAo Option PBo
Ao Bo
LCo
PBp1 PBp2

(P3) (P2)

PBa2 PAo

PBp1 PBp2
PAa2
Arm 2 Option
PBo
PAc PAa1
Bucket Arm 1
(P4) PAa
(P3) PAb
Boom Swing

PBr PCa
Travel right P2 unload
(T3)
PTb
Travel PBL Travel left
straight
PAa2 PBo

A
VIEW A

Fig. 24-22 Outside view

24-21
24. COMPONENTS SYSTEM

24.1.2.1.2 PORTS

Port size Tightening torque Ports Description

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

24-22
 24. COMPONENTS SYSTEM

Port size Tightening torque Ports Description

Ao Optional pilot port
Bo Optional pilot port

24.1.2.1.3 SPECIFICATIONS

Item
Model
Maximum flow rate [L/min (gal/min)]
Maximum set pressure [MPa (psi)]
Main relief valve set pressure [MPa (psi)]
When power boost pressure
Overload relief valve set pressure
(Boom head, Bucket head, Arm rod) [MPa (psi)]
Overload relief valve set pressure
(Boom rod, Bucket rod, Arm head) [MPa (psi)]
Specifications
KMX15YD/B44031
294 (78) × 2
37.8 (5481) (Pump port)/ 39.7 (5757) (Actuator port)
Std 34.3 (4970) [at 135×2 L/min (at 36×2 gal/min)]
37.8 (5480) [at 125×2 L/min (at 33×2 gal/min)]
39.7 (5757) [at 30 L/min (at 8 gal/min)]
37.8 (5481) [at 30 L/min (at 8 gal/min)]

24-23
24. COMPONENTS SYSTEM

24.1.2.2 CONSTRUCTION AND OPERATION

24.1.2.2.1 CONSTRUCTION
(1) Control valve

J
154 164 101
P2

T2 T1

PAL PBL
YT1
J

PB1 PCa
YBG1

P2-20
PBs PAs
YS1

Pss

PBa1 PAa1
YA1

PAo PBo
YP1

(P4)
163 162 163 169 155 162
SECTION A-A

154 164
P1
102

973 973

PTb PCb
P1-20

973
973
PBr PAr
YT1

973

PAb PBb
YB 2

973 PBc 973

PCc
PAc
YK2

974 973
PAa2 PBa2
YA
G2

974

(P3)
162 162 169 155 163 162
SECTION B-B

Fig. 24-23 Section (1/6)

24-24
 24. COMPONENTS SYSTEM

T2
H 273x10 273x10 H
PCb PAL
P1 unload
Travel left
(Travel straight)
C C

USE FOR YN30V00101F1

977 PAr
PB1 Boom conflux
Travel right (P2 unload)

D 978x2 D
PBs

Boom Swing

E PCc
PBb E
PBa1 Pss

Bucket
Arm 1
F F
PBa2 PA
PAo

Arm 2 MU Option

G G
K PBp1 PBp2
K

(P3) B A
PBa2 PAo

PBp1 PBp2

274x4
275x4
213
(P4)
(P3)

212

PAa2 PBo

273x10 273x10

Fig. 24-24 Section (2/6)

24-25
24. COMPONENTS SYSTEM

  $!#- &'# #'"+ 

  
 
 

 

 

 

 


  

 

 

 
 
 
 
 

 


 
 
 

  


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

   
 

 

 
 
 

 

  
 



 
 
 



 
  

 

   


 
 $!#- 

Fig. 24-25 Section (3/6)

24-26
 24. COMPONENTS SYSTEM

Swing 204
203 PBs
333 Boom
PBb Pss
333
331
336 331
322
321 336
603 AbR
331 322
211
261 321
266 266
160
160 331
514 261
303
524 As 161
CRb
556 162
164 Ab 163
511 511
521 523
LCb LCs
551 556
164 164
Bb
Bs 162

161

301
264 266
264
266
BbR 160 PAs 206
602 PAb
559 SECTION E-E
560 164 551
Bucket
208
209
PCc
216 201
333 Arm 1 333
331 PBa1
PBc
331
336 336
322 322
321 321
BaR
602 BcR 603
331 331
261 261
211
304 160
514
524
CRar
Bc 556
Ba 164
511 511
521 521
LCc LCa
551 551
164 164

Ac
162 Aa

161

264 302
603 PAc PAa1 264
205 AcR SECTION F-F 205
AaR 602
Fig. 24-26 Section (4/6)

24-27
24. COMPONENTS SYSTEM

201
333 Arm 2 Option 201
331 PBa2 PAo 333
340
328 331
321
336
331
324
261
AoR 323
604
MU 331
308
162 261
162 311
162
511 Ao

521
LCAT2 511
551
164 521
515 LCo
521 LCAP2 551
551 164
164
Bo
162

161

604
BoR
264 264
PAa2 PBo
205
205
SECTION G-G

T2

161

P1
T1
511
521 163
CT1
551
163
164
162
P2 511
521
CT2
551
164

SECTION H-H

Fig. 24-27 Section (5/6)

24-28
 24. COMPONENTS SYSTEM

PBp1 PBp2

207
160 606 606
278x5 266
264 264

527 528 163

T2 T1
517
518

SECTION J-J
SECTION K-K

Fig. 24-28 Section (6/6)

24-29
24. COMPONENTS SYSTEM

Tightening torque Tightening torque

No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
101 Casing A 1 321 Spring 5
102 Casing B 1 322 Spring 4
220~250 (162~184) 154 Plug PF3/4 3 323 Spring 3
110~130 (81~96) 155 Plug PF1/2 2 324 Spring 3
20~24 (15~18) 159 Plug PT1/4 MEC (Pre-coat bolt) 1 325 Spring 1
7.8~9.8 (5.8~7.2) 160 Plug PT1/16 MEC (Pre-coat bolt) 5 326 Spring 1
161 O-ring 7 327 Spring 3
162 O-ring 15 328 Spring 1
163 O-ring 11 329 Spring 3
164 O-ring 19 331 Spring seat 24
169 O-ring 2 16~18 (12~13) Loctite #262 333 Spacer bolt 12
201 Cover 5 336 Stopper 10
202 Cover 4 339 Stopper 1
203 Cover 1 340 Stopper 1
204 Sub cover 1 511 Poppet 11
205 Cover 6 512 Poppet 2
206 Cover 1 514 Poppet 2
207 Back pressure check valve cover 1 515 Poppet 1
208 Cover 1 517 Poppet 1
209 Cover 1 518 Poppet 1
9.8~14 (7.2~10.3) 211 Lock valve selector sub 2 521 Spring 11
212 Plate 1 522 Spring 2
213 Plate 1 523 Spring 1
216 Piston 1 524 Spring 2
261 O-ring ; 1B G50 12 527 Spring 1
264 O-ring ; 1B G40 10 528 Spring 1
266 O-ring ; 1B P7 5 230~260 (170~192) 551 Plug 13
25~34 (18~25) 273 Socket bolt ; M8×25 40 130~150 (96~111) 552 Plug 2
98~120 (72~89) 274 Socket bolt ; M12×25 4 230~260 (170~192) 556 Plug 3
98~120 (72~89) 275 Socket bolt ; M12×35 4 559 Plug 1
25~34 (18~25) 278 Socket bolt ; M8×35 5 560 O-ring 1
301 Boom spool sub 1 562 O-ring ; 1B P20 2
302 Arm 1 spool 1 69~78 (51~58) 601 Main relief valve 1
303 Swing spool 1 69~78 (51~58) 602 Port relief valve 3
304 Bucket spool 1 69~78 (51~58) 603 Port relief valve 3
305 Boom conflux spool 1 69~78 (51~58) 604 Relief valve plug assy 2
306 Travel spool 2 98~120 (72~89) 606 Bypass cut valve 2
307 Travel straight spool 1 140~180 (103~133) 973 Socket bolt ; M14×160 8
308 Arm 2 spool sub 1 140~180 (103~133) 974 Socket bolt ; M14×140 2
309 P1 unload spool 1 977 Name plate 1
310 P2 unload spool 1 978 Rivet 2
311 Option spool 1

24-30
 24. COMPONENTS SYSTEM

(2) Main relief valve (Two step relief) (601)

Fig. 24-29 Main relief valve (Two step relief)

Tightening torque Tightening torque

No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
69~78 (51~58) 103 Plug ; M27 1 562 Back up ring 1
104 Adjust screw 1 611 Poppet 1
121 C-ring 1 613 Stopper 1
122 Spacer 1 614 Piston 1
123 C-ring 1 621 Spring 1
124 Filter stopper 1 652 Adjust screw 1
125 Filter 1 661 O-ring 1
163 O-ring 1 663 O-ring 1
512 Plunger 1 664 O-ring 1
521 Spring 1 28~31 (21~23) 671 Lock nut ; M14 1
541 Seat 1 46~52 (34~38) 673 Lock nut ; M24 1
561 O-ring 1 1

24-31
24. COMPONENTS SYSTEM

(3) Over load relief valve (602,603)

Fig. 24-30 Over load relief valve

Tightening torque Tightening torque

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

24-32
 24. COMPONENTS SYSTEM

(4) Arm 2 spool (308)

308 318 341 362 372 352

Fig. 24-31 Arm 2 spool

Tightening torque Tightening torque

No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
308 Spool 1 33~35 (24~26) Loctite #638 352 Plug 1
318 Plunger 1 362 O-ring 1
341 Spring 1 372 Buckup ring 1

(5) Boom spool (301)

301 317 340 361 371 350

Fig. 24-32 Boom spool

Tightening torque Tightening torque

No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
301 Spool 1 16~18 (12~13) Loctite #638 350 Plug 1
317 Plunger 1 361 O-ring 1
340 Spring 1 371 Buckup ring 1

(6) Travel straight spool (307)

307 361 371 350

Fig. 24-33 Travel straight spool

Tightening torque Tightening torque

No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
307 Spool 1 361 O-ring 1
16~18 (12~13) Loctite #638 350 Plug 1 371 Backup ring 1

24-33
24. COMPONENTS SYSTEM

(7) Lock valve selector (211)

101

164
171
201

321
PLc A B Dr
166 541 167 511 161
Fig. 24-34 Lock valve selector

Tightening torque Tightening torque

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

24-34
 24. COMPONENTS SYSTEM

(8) Bypass cut valve (606)

! ! " "

2 2E

6 ,H

   
Fig. 24-35 Bypass cut valve

Tightening torque Tightening torque

No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
98~120 (72~89) 101 Plug 1 301 Plunger 1
102 O-ring 1 302 Spring 1
201 Poppet 1 69~78 (51~58) 401 Plug 1
202 Spring 1 402 O-ring 1

24-35
24. COMPONENTS SYSTEM

(9) Swing shuttle valve cover (204)











 
 

 











Fig. 24-36 Swing shuttle valve cover

Tightening torque Tightening torque

No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
166 O-ring 1 542 Seat 1
202 Cover 1 25~29 (18~21) 554 Plug 1
541 Steel ball 1 7.9~9.8 (5.9~7.2) 555 Plug 1

24-36
 24. COMPONENTS SYSTEM

(10)Boost check valve (517)

104

107

102

101

Fig. 24-37 Boost check valve

Tightening torque Tightening torque

No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
101 Poppet 1 20~29 (15~21) Loctite #262 104 Plug 1
102 Poppet 1 107 Spring 1

24-37
24. COMPONENTS SYSTEM

24.1.2.2.2 HYDRAULIC CIRCUIT DIAGRAM

P1 T1 T2 P2

CMR1

PL CMR2
PTb PBL

Travel straight
PCb PAL Travel left
P1 unload
AL
CT2 CP2 BL

CT1
(T3) Boom conflux
Travel right PAr PCa
P2 unload
CP1
Br
Ar PB1
PBr CCb

PBs
Dr
LCb LCs Pss

Boom PAb PAs Swing

As
Bs
(RO D) Bb
PBa1
CRb LCa

(HE AD) Ab

PAa1 Arm 1
PBb

LC c Aa (HEAD)

Bucket PAc

CRa
(ROD) B c PLc2
(HEAD) Ac
Ba (ROD)

PCc
PBc
LCAT2

LCAP2 LCo

Arm 2 PAa2 PAo Option

Ao
Bo

PBo
PBa2
MU
PBp1 PB p2

(P3) (P4)

Fig. 24-38 Hydraulic circuit diagram

24-38
 24. COMPONENTS SYSTEM

24.1.2.2.3 OPERATION
(1) In neutral position
The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through unloading
valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through
tank port T1. And when the operation of unloading valve is impossible due to failure of electric control system,
because the by-pass cut valve (606) located on the downstream of center by-pass passage (52) opens, the
hydraulic oil through hydraulic pump P1 port passes through travel straight spool (306), and then flows though
the center by-pass passage (52) which passes through travel right, boom, bucket and arm 2 and the by-pass cut
valve (606) on P1 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to
the hydraulic tank through tank port T1.
The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure circuit
(D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to the hydraulic
oil from hydraulic pump P1. And when the operation of unloading valve is impossible, because the by-pass cut
valve (606) located on the downstream of center by-pass passage (55) opens, the hydraulic oil through hydraulic
pump P2 port passes through main passage, and then flows though the center by-pass passage (55) which
passes through travel left, swing, arm 1 and option and the by-pass cut valve (606) on P2 side, and flows into
low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.

(D)
Pss

606
517 52
306

YP1 YS1 YT1

YA1 YBG1

T1

P2
P1

P2-20
YAG2 YK2 Y B2 YT1
P1-20

309
310
55 606
(D)
PBc

Connected to low
pressure circuit of P2
PCc

side casing

Fig. 24-39 In neutral position

24-39
24. COMPONENTS SYSTEM

(2) Actuation in travel operation

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


 
 



 
 




 

Fig. 24-40 In left reverse travel (at PBL is pressurized)

24-40
 24. COMPONENTS SYSTEM

2) In travel straight operation

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







   
 




 




 
   
     
   
     

   

Fig. 24-41 Movement of travel straight spool

24-41
24. COMPONENTS SYSTEM

(3) Actuation in bucket operation

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

PAc

PCc PBc

Bc Ac
LCc

321 (D)
322 304 511

(R) (H)
Fig. 24-42 In bucket digging operation (Stroke limiter ON)

24-42
 24. COMPONENTS SYSTEM

2) In bucket dumping operation

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



  
  !"!



 





  

  

Fig. 24-43 In bucket dumping operation

24-43
24. COMPONENTS SYSTEM

(4) Boom
1) In boom up operation
On starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves rightward
against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional
valve [XI] acts on port PCa and switches unloading spool (309).
And the pilot pressure enters port PB1 and boom conflux spool (305) is switched against the force of springs
(325) (326) and the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches
unloading spools (310).
The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load
check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing through
U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ab).
In the meantime, the return oil from boom cylinder rod side (R) passes through between the perimeter of
boom spool (301) and casing, flows through low pressure circuit (D) and boost check valve (517), and
returns to the hydraulic tank through tank port T1.

(R) (R)

(H) (H)

301 53 511 321

(D) 514 322
BH chamber
LCb CRb
Bb Ab

PAb PBb

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

24-44
 24. COMPONENTS SYSTEM

2) In boom up conflux operation

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








  




  

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

24-45
24. COMPONENTS SYSTEM

3) In boom down operation

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

(R)
(R)

(H) (H)

53 511 321
317 514 322
301 BH chamber
LCb CRb
Bb Ab

PAb PBb

(D)

Fig. 24-46 In boom down operation

24-46
 24. COMPONENTS SYSTEM

(5) Arm operation

1) In arm out operation
On starting arm out operation, the pilot pressure enters ports PBa1 and PBa2, and arm 1 spool (302) moves
rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid
proportional valve [X2] acts on port PCa and switches unloading spool (310).
And the pilot pressure also enters PBa2, and arm 2 spool (308) is switched against the force of springs (321)
(328) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and switches
unloading spools (309).
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load
check valve LCa (511), and flows into AR chamber through between the perimeter of arm 1 spool (302) and
casing through U-shaped passage.
In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass passage (52)
and pushes and opens load check valve LCAT2 (511) and enters U-shaped passage, and pushes and opens
load check valve LCAP2 (515) provided with orifice, and flows into U-shaped passage. And then the
hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing, and enters AR chamber
through casing inside passage (RR) and confluences the hydraulic oil from hydraulic pump P2 side.
The conflux hydraulic oil opens lock valve poppet CRar (514) and is supplied to arm cylinder rod side (R).
In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of arm
1 spool (302) and casing and passes though low pressure circuit (D’) and casing inside passage (HH) and
then flows into low pressure circuit (D’) through between the perimeter of arm 2 spool (308) and casing.
The return oil in low pressure circuit (D’) returns to hydraulic tank through tank port T1 without passing
through boost check valve (517).

(R) (H) 302

AR
322 321 chamber 514
211 CRar
511 LCa
Ba Aa

56
PBa1 PAa1 P1

(D')
Arm 1 (D) LCAT2 LCAP2

RH (D') P1
RR HH PAa2 PBa2
52 Dr Dr
(D')
Arm 2 To arm 1 spoo
Aa (HEAD)
PAa2 Ba
PBa2 (ROD)
To pilot cut valve
53

MU

515
328
321 308 511 LCAT2 LCAP2
Fig. 24-47 In arm out operation

24-47
24. COMPONENTS SYSTEM

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

On starting arm in operation, the pilot pressure enters ports PAa1 and PLc2, and arm 1 spool (302) moves
leftward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid
proportional valve [X2] acts on port PCa and switches unloading spool (310). At the same time, since the
spool of lock valve selector (211) is switched, the spring chamber of lock valve poppet CRar (514) is
connected to the drain circuit and the retention of poppet (514) is released.
And the pilot pressure enters PAa2 through solenoid proportional valve [XR], and arm2 spool (308) moves
leftward against the force of springs (321) (328) and the secondary pressure of solenoid proportional valve
[X1] acts on port PCb and switches unloading spools (309). But in light load operation, because the solenoid
proportional valve [XR] actuates and arm 2 spool (308) stays in the position of circuit (I).
The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load
check valve LCa (511), and flows into port (Aa) through between the perimeter of arm 1 spool (302) and
casing through U-shaped passage. In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows
through center by-pass passage (52) and pushes and opens load check valve LCAT2 (511) and enters U-
shaped passage, and also the oil from parallel passage (53) pushes and opens load check valve LCAP2
(515) provided with orifice and flows into U-shaped passage. And then the hydraulic oil flows through
between the perimeter of arm 2 spool (308) and casing from U-shaped passage and enters port (Aa) through
casing inside passage (HH) and confluences the hydraulic oil from hydraulic pump P2 side.
The conflux hydraulic oil is supplied to arm cylinder head side (H) through port (Aa).
In the meantime, the return oil from arm cylinder rod side (R) enters the control valve through port (Ba).
Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1 spool (302) is
released, the return oil pushes and opens lock valve poppet CRar (514) and enters AR chamber. The return
oil in AR chamber is led to arm 2 spool (308) through arm 1 spool (302) and casing inside passage (RR),
because arm 2 spool (308) connects to low pressure passage (D) at circuit (I) with small area, the partial
return oil flows between perimeter of arm 2 spool (308) and casing. The oil returns to hydraulic oil tank from
tank port T1 through low pressure passage (D) and via boost check valve (517). But the most of volume of
return oil flows into arm 1 spool (302).
The return oil from chamber AR passes through the perimeter of arm 1 spool (302) and casing, and flows
through casing inside passage (RH) and is led to the inside of arm 2 spool (308) through circular notch (a)
of arm 2 spool (308). In light load operation, since the return oil contains higher pressure than that of arm
cylinder head side (H) with the self weight of arm, etc. the hydraulic oil inside of arm 2 spool (308) passes
through check valve (317) and flows into casing inside passage (HH) and the supplied to arm cylinder head
side (H) again. (Arm recirculation function)
(R) (H) 302
AR
322 321 chamber 514
211 CRar 511 LCa
Ba Aa

56
PBa1 PAa1 P1

(D')
Arm 1 (D) LCAT2 LCAP2
(D') P1
RR 52 RH PAa2 PBa2
(D) HH Dr Dr

Arm 2
(a) To arm 1 spool
Aa (HEAD)
PBa2 PAa2
[XR] Ba
(ROD)
53 To pilot cut valve

MU Circuit (I)
317
328 515
308 (D)
321 319 511 LCAT2 LCAP2
Fig. 24-48 In arm in operation (At light load: arm recirculation function)

24-48
 24. COMPONENTS SYSTEM

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

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

(R) (H) 302

AR
322 321 chamber 514
211
CRar
511 LCa
Ba Aa

56

PBa1
PAa1
P1

Arm 1 (D')
(D') (D)
LCAT2 LCAP2
RR 52 RH P1
(D) HH
PAa2 PBa2
Dr Dr
Arm 2 (a)

PBa2 PAa2 To arm 1 spool

[XR] Aa (HEAD)
53 Ba
(ROD)
MU To pilot cut valve
Circuit (II)
317
328 515
308 319 (D) LCAP2
321 511 LCAT2

Fig. 24-49 In arm in operation (In heavy load operation)

24-49
24. COMPONENTS SYSTEM

(6) Swing operation

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











 
   

 



  
Fig. 24-50 Swing operation

24-50
 24. COMPONENTS SYSTEM

(7) Spool actuation for operation in option

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

 






 


  

 












Fig. 24-51 Spool actuation for operation in option

24-51
24. COMPONENTS SYSTEM

(8) Lock valve operation

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

$
% & '
(
  

( )&%*
+*
   

  
 



 


  
  

 
  !" #


 

 

 


Fig. 24-52 Lock valve operation (At boom spool neutral position)

24-52
 24. COMPONENTS SYSTEM

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

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

Return oil from RH CHAMBER

boom cylinder head
514 Lock valve selector
511
BH CHAMBER 541
Sb
CRb PLc
Ab Dr
(a) (b) 321

A A PLc Sa Sb Dr

SECTION A-A
Sa

321 322

PBb

(D)
301
Dr
Fig. 24-53 Lock valve selector operation (At boom down operation)

24-53
24. COMPONENTS SYSTEM

(9) By-pass cut valve

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

[X1]

PBp1

301 302
(b)
(C)
Dr

201 101

(a)
(D)

52

Fig. 24-54 By-pass cut valve (In normal operation)

24-54
 24. COMPONENTS SYSTEM

2) At the time when failure occurred

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

PBp1

302
301
(b)
(C)
Dr

201 101

(a)
(D)
202

52

Fig. 24-55 By-pass cut valve (In condition of failure)

24-55
24. COMPONENTS SYSTEM

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

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












  
 



   




   
Fig. 24-56 Boost check valve operation

24-56
 24. COMPONENTS SYSTEM

2) By-pass check valve

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

527

528
(D') T2
518
T1
102

517
(D)

Fig. 24-57 By-pass check valve operation

24-57
24. COMPONENTS SYSTEM

This page is blank for editing convenience.

24-58
 24. COMPONENTS SYSTEM

24.1.3 PILOT VALVE (ATT)

24.1.3.1 OUTLINE
(1) Outside view

5-PF3/8
Single operating angle Single operating angle T=49.0 (36.1)
(Port 2, 4) (Port 1, 3)

The adjust nut

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

Part No. YN30V00111F1

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

PORT 1, 3 PORT 2, 4

(580)4.0 4.0(3.0) (580)4.0 4.0(3.0)

Secondary pressure [MPa (psi)]

Secondary pressure [MPa (psi)]

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

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

(464)3.2 (464)3.2
(435)3.0 3.0(2.2) (435)3.0 3.0(2.2)
SINGLE OPERATING TORQUE SINGLE OPERATING TORQUE

2.21(1.63) 2.29(1.69)
(290)2.0 2.0(1.5) (290)2.0 2.0(1.5)
SECONDARY PRESSURE SECONDARY PRESSURE

(145)1.0 1.0(0.74) (145)1.0 1.0(0.74)

0.94(0.69) 0.94(0.69)
(87)0.6 (87)0.6
1.17 (0.86) 1.17 (0.86)
0.98 (0.72) 0.98 (0.72)
0 0 0 0
0 1.1 2 4 6 7 0 1.12 4 6 8 9.4
PUSH ROD STROKE (mm) PUSH ROD STROKE (mm)

0 5 10 15 19 0 5 10 15 20 25
Operating angle (deg.) Operating angle (deg.)

P T

1 3 2 4
HYDLAULIC SYMBOL

24-59
24. COMPONENTS SYSTEM

24.1.3.2 CONSTRUCTION

Apply Loctite #277

312

302
501 Apply grease on
301 rotating and sliding sections.
Be careful the
Apply grease on top section
assembling direction
212
213
151
*246
*218-2
211
214
*218-1
216-2 216-1

241-2 241-1
201-2
Secondary 201-1
pressure 217
adjusting shim
101 221

PORT 2,4 PORT 1,3

Fig. 24-58 Pilot valve (ATT)

Tightening Tightening
torque No. Name Q’ty torque No. Name Q’ty
N•m (lbf•ft) N•m (lbf•ft)
101 Casing 1 *218-1 Seat 2
151 Plate 1 *218-2 Seat 2
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
212 Push rod 4 *246 Spring 4
213 Seal 4 47.1 (34.7) 301 Joint : M14 1
214 O-ring : 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (50.6) 312 Adjust nut : M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4
Note) The parts marked * may not be equipped depending on valve type.

24-60
 24. COMPONENTS SYSTEM

24.1.3.3 OPERATION
(1) Lever in neutral (See Fig. 24-59)
The action of spring (509) (for secondary pressure
setting) that determines the output pressure of the
pilot valve does not act upon spool (201).
Therefore, spool (201) (for return) is pushed up by
spring (221) [spring seat (216)]. The output ports
(2,4) connect with the T port. The result is that the
output pressure is equal to the tank pressure.
216

509

221

201

PORT (2,4) PORT (1,3)

Fig. 24-59 Lever in neutral

(2) When the pilot lever is tilted (See Fig. 24-60 )
When the lever is tilted and the push rod (511)
strokes, the spool (201) [spring seat (216)] moves
downward to make the port P to connect with the
port 2, 4, with the result that the oil of the pilot pump


flows to the port 2 ,4 to produce a pressure.







 


Fig. 24-60 When the lever is tilted
(3) Lever held (See Fig. 24-61)
When the pressure at ports (2,4) rises to a level
equivalent to the action of spring (509) that is set by
tilting the lever, the hydraulic pressure balances the
spring action. When the pressure of ports (2,4)
rises above a set value, ports (2,4) and the P port
close while ports (2,4) and the T port open. When
the pressure at ports (2,4) falls below a set value, 509
ports (2,4) and the P port open while ports (2,4) and
the T port close. Thus the secondary pressure is
T PORT
kept constant.
P PORT

PORT (2,4) PORT (1,3)

Fig. 24-61 When the lever is held

24-61
24. COMPONENTS SYSTEM

(4) Operation in the area where the tilting angle of the

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

24-62
 24. COMPONENTS SYSTEM

24.1.4 PILOT VALVE (TRAVEL)

24.1.4.1 OUTLINE
(1) Outside view

Tightening torque
Port size N.m (lbf.ft) Port name Function
1 LH travel forward port
2 LH travel reverse port
PF3/8 30 (22) 3 RH travel forward port
4 RH travel reverse port
T Tank port
5 LH travel pressure sensor port
PF1/4 16.7 (12.3) 6 RH travel pressure sensor port
P Pilot primary pressure port

(2) Specifications

P T
Item Specifications
Part No. YN30V00105F1
Type 6TH6NRZ
Primary pressure 4.9MPa (711psi)
Secondary pressure 0.54~2.35MPa (78~341 psi)
Rated flow 25 L/min (6.6 gal/min)
Weight Approx. 8kg (18 lbs)
1 5 2 3 6 4
Hydraulic symbol

(3) Performance characteristics

Secondary pressure
[MPa (psi)] Secondary pressure

2.35 + 0.15
(340 + 22)

0.54 + 0.1
(78 + 15) 0
1 30' 11 30' Pedal angle (degree)
(4.7 + 0.5) 2 30' 12 30'
6.4 + 0.64
7.7 + 0.77
(5.7 + 0.6)
12.7 + 1.27
(9.4 + 0.9)
Operating Operating torque
torque
[N.m (lbf.ft)] Control diagram

24-63
24. COMPONENTS SYSTEM

24.1.4.2 Construction and operation

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

5
3

8 10
3
11 12
4
10

9
9

7 6
2

control ports 1-3 P line control ports 2-4

T line

24-64
 24. COMPONENTS SYSTEM

24.1.5 SWING MOTOR UNIT

24.1.5.1 SPECIFICATION
(1) General view

Tightening
Symbol Port name Port size torque
N.m (lbf.ft)
A,B Main port SAE 3/4"
DB Drain port PF1/2 108 (80)
M Make-up port PF1 216 (159)
PA,PB Pressure measuring port 2-PF1/4 36 (27)
PR Parking brake release port PF1/4 36 (27)
Gear oil level gauge or
IP,L,AR Air breather port or PT3/4 98 (72)
Gear oil filling port
IP, L, AR
12- 22 Through

DB
B
PB

M
PR PA
A

THREAD FOR
EYE BOLT 2-M12

PR

DB
RELIEF VALVE
PB PA
M DB

A,B
M
PA PB PR

A B

Hydraulic diagram

24-65
24. COMPONENTS SYSTEM

(2) Specifications

Swing motor unit part No. LC15V00025F1

Part No. LC15V00022F1
Type M5X180CHB-10A-60B/295
Displacement cm (in )
3 3 180.1 (11.0)
Working pressure MPa (psi) 32.4 (4700)
Max. pressure MPa (psi) 39.2 (5680)
Hydraulic motor

Working flow L/min (gal/min) 294 (77.7)

Braking torque N•m (lbf•ft) 860~1121 (634~827)
Brake release
MPa (psi) 2.4~5.0 (348~725)
pressure
Relief set pressure MPa (psi) 29.0 (4205)
Weight kg (lbs) 72.5 (160)
Anti- Part No. YN22V00014F4
reaction valve Type 2KAR6P72/240-712
block Weight kg (lbs) 2.5 (5.5)
Hydraulic motor assy weight kg (lbs) 75 (165)
Part No. LC32W00007F1
Speed reduction type Planetary 2-stage
Reduction unit

Reduction ratio 27.143

Lubricate oil Gear oil SAE90 (API class GL-4 grade)
Lubricate oil volume 7.4 L (1.96 gal)
Grease Extreme pressure lithum base #2 grease
Grease volume kg (lbs) Approx. 1.7 (3.7)
Weight kg (lbs) 371 (818)
Total weight kg (lbs) 446 (983)

24-66
 24. COMPONENTS SYSTEM

24.1.5.2 CONSTRUCTION
(1) Swing motor

702 712

351

ARRENGEMENT OF BRAKE SPRING

355

401

488 469
051-1 051

100
151
162 052 161 171

303 984
A A 163 985 391 390 444
131
451
472 400-1
400-2
712 400 052

702 707 SECTION A-A

706

986

742

743
994

111

491 101
121 123 122 124 114 301 443

24-67
24. COMPONENTS SYSTEM

Tightening torque Tightening torque

No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
177 (130) 051 Relief valve ; M33-P1.5 2 69 (51) 400 Anti-reaction valve ; M22-P1.5 2
051-1 O-ring ; 1B G30 2 400-1 O-ring ; 1B P20 2
052 Anti-reaction valve sub 1 400-2 Backup ring 2
Casing for anti-reaction
100 1 431 (318) 401 Socket bolt ; M20×45 4
valve
101 Drive shaft 1 443 Roller bearing 1
111 Cylinder 1 444 Roller bearing 1
114 Spring plate 1 451 Pin 2
121 Piston 9 539 (398) 469 ROMH plug; M36-P1.5 2
122 Shoe 9 472 O-ring ; W1516,WG44 1
123 Set plate 1 488 O-ring ; 1B P34 2
124 Shoe plate 1 491 Oil seal 1
131 Valve plate 1 702 Brake piston 1
36 (27) 151 Plug ; PF1/4 2 706 O-ring ; W1516,WG42 1
161 O-ring ; 1B P11 2 707 O-ring ; W1516,WG45 1
162 O-ring ; 1B P12 2 712 Brake spring 14
163 O-ring ; 1B P6 2 742 Friction plate 3
29 (21) 171 Socket bolt ; M8×55 4 743 Separator plate 4
301 Casing 1 2.7 (2.0) 984 Plug ; PF1/2 1
303 Valve casing 1 5.6 (4.1) 985 Plug ; PF1 1
351 Plunger 2 0.9 (0.66) 986 Plug ; PF1/4 1
355 Spring 2 98 (72) 994 Plug ; PT3/4 1
390 Name plate 1
391 Rivet 2

24-68
 24. COMPONENTS SYSTEM

(2) Swing reduction unit

34

22 11 27 25 24 3
4
SURFACE
5 OF LUBE OIL
10 3
23 6 20 35
7 8 3 VIEW
11 15
26 12
9 17 30 36, 37, 38, 39
14 31
3
28
29 18

33 32
13
21 19 16
2
1
DETAIL aa

aa

Tightening torque Tightening torque

No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
1 Pinion 1 21 Ring 1
2 Shaft 1 22 Thrust washer 6
3 #1 Sungear 1 23 Thrust washer 8
4 #1 Planetary pinion 3 24 Snapring 1
5 #1 Spider assy 1 25 Snapring 3
6 #2 Sungear 1 26 Spring pin 4
7 #2 Planetary pinion 4 539±54 (398±40)*1 27 Capscrew ; M20×200 12
8 Ring gear 1 28 Grease fitting 1
9 #2 Spider assy 1 29 Relief fitting 1
10 Shaft 4 69.1±4.4 (51±3)*2 30 Tube 1
11 Needle bearing 11 69.1±4.4 (51±3)*2 31 Elbow 1
12 Roller bearing 1 69.1±4.4 (51±3)*2 32 Plug 1
13 Roller bearing 1 33 Cap 2
14 Oil seal 1 279±30 (206±22)*1 34 Capscrew 2
15 Housing 1 35 Wire ø1.6×250 1
16 Oil seal 1 36 Shim ; t=0.1 1
17 Sleeve 1 37 Shim ; t=0.2 1
18 Sleeve 1 38 Shim ; t=0.3 1
19 Plate 1 39 Shim ; t=0.5 1
20 Plate 1
*1 : Apply Three Bond #1360K.
*2 : Apply seal tape or Loctite #577.
*3 : Apply Loctite #515.

24-69
24. COMPONENTS SYSTEM

24.1.5.3 OPERATION

24.1.5.3.1 OPERATION OF HYDRAULIC MOTOR

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

shown on the figure on the right, the hydraulic

pressure acts upon piston (121) and creates force F2
F in the axial direction. F1

The force F may be divided into force F1 vertical to F

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

via pistons (121) and causes drive shaft to turn so

as to produce a rotating moment.
The cylinder block (111) has nine pistons equally
arranged. Rotating torque is transmitted to drive
Valve
shaft by turns by pistons connected to inlet port of plate
high pressure oil. Shoe Shoe Piston
(131)

If the oil supply and discharge directions are plate

(122) (121)
(122)
reversed, the drive shaft rotates in the opposite
direction. Low pressure oil High pressure oil

Theoretical output torque T can be given by the

following equation.

P X q P ; Effective differential pressure MPa OUTLET INLET (a)

T=
2X q ; Displacement per revolution cc/rev

Fig. 24-62 Operation of hydraulic motor

24.1.5.3.2 VALVE CASING SECTION

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

DIRECTIONAL VALVE

Fig. 24-63 Operation of anti-cavitation check

plunger

24-70
 24. COMPONENTS SYSTEM

(2) Operation of relief valve Chamber h

Orifice m Spring (321) Piston I (302)
1) Consider where the relief valve is pressurized.
The pressure at the P, R ports is equal to the tank
pressure at the beginning, as shown in Fig. 24-
64. P
The relief valve begins to operates when the
hydraulic pressure that is determined by the Pressure R Chamber g
product of the pressure-receiving area A1 of receiving Plunger(301) A3 A2 Orifice n A4
area A1
plunger(301) and the pressure P balances the Fig. 24-64 Functional explanation of relief valve (1)
hydraulic pressure that is determined by the
product of the pressure-receiving area A2 of the Orifice m Spring (321) Chamber h
Pin (303) Piston I (302)
plunger(301) and the pressure Pg of chamber g.
Thereafter, the pressure of chamber g rises and
the piston 1 (302) begins to stroke. The load to
spring (321) increases by this movement of the P
piston.
As the result, the relief pressure P is raised and R
controlled in the pressure boost time t1 from P1 Plunger(301) Orifice n Chamber g
till Ps. Fig. 24-65 Functional explanation of relief valve (2)
This process is explained in the following in the
relationships between the movements of the Orifice m Spring (321) Chamber h
Pin (303) Piston I (302)
components shown in (2) to (4) of Fig. 24-
65~Fig. 24-67and the relief pressure :
a. Condition shown in Fig. 24-65.
P
If the P port of the relief valve is pressurized,
pressure is built up in chamber g via the
R
restrictor m of plunger (301). Orifice n
The hydraulic pressure acting on plunger Plunger(301) Chamber g
(301) increases and when it balances the load Fig. 24-66 Functional explanation of relief valve (3)
Fsp of spring (321), the relief valve performs Orifice m Spring (321) Pin (303) Piston I (302)
relieving action by the pressure P1.
This relationship is expressed as :
P1×A1=FSP1+Pg1×A2
where FSP1 : P
primary set load value of spring (321)
b. Condition shown in Fig. 24-66. R
The pressure of chamber g acts upon the Plunger(301) Orifice n Chamber g
pressure-receiving area A3-A4 of piston 1
Fig. 24-67 Functional explanation of relief valve (4)
(302). When the hydraulic pressure rises
above the load of spring (321), the piston 1
begins to move to the left.
On that occasion, since the machine turns to
the left while discharging the oil of chamber h
arranged between piston 1 and adjust plug
(401) into chamber g via orifice n provided in
piston 1 (302), chamber h serves as a
dumping chamber.
The load of the spring increases slowly till Fig. 24-68 Pressure boost characteristics
piston 1 reaches the end of the adjust plug.
The relief pressure P rises smoothly.

24-71
24. COMPONENTS SYSTEM

c. Condition shown in Fig. 24-67.

The machine does not travel to the left further
when piston 1 (302) arrives at the end of
adjust plug (401). Therefore, the relief valve
keeps its normal relieving action whereby the
relief pressure is held at P2.
In the processes 1 to 3 above, the relief
pressure changes as shown in Fig. 24-68.
2) Function when the relief valve pressure is
reduced
Let us consider the pressure of the P port is
reduced.
When the pressure at port P is reduced to zero,
the pressure of chamber g falls to the tank
pressure level. The result is that the plunger
(301) which is now open moves to the left and is
seated on seat (341). At the same time, the
piston 1 (302) moves to the right by the action of
spring (321) and returns to the condition of Fig.
24-64.
(3) Operation of anti-reaction valve

Fig. 24-69 Hydraulic circuit diagram for anti-

reaction valve.
1) Neutral condition :
Fig. 24-69 illustrates the relationship between
the neutral condition of the anti-reaction valve
and the hydraulic circuits. Now, let us consider a
L
braking condition in which brake pressure
generates on the AM port side.
k
322 313 321 311
Fig. 24-70 Neutral condition
2) When brake pressure occurs : m n
If pressure (P) generates at the AM port, it
passes through the passage L, the hole on the
shaft of seat (313) and the passage m of plunger P=PS
(311) and is led to the n chamber.
L
When the pressure P rises above a value (Ps)
set by spring (321), plunger (311) compresses
spring (321) and shifts it to the left. 322 313 321 311
Seat (313) compresses weak spring (322) as
Fig. 24-71 When brake pressure occurs
pushed by plunger (311) and moves to the left.

24-72
 24. COMPONENTS SYSTEM

3) At anti-reaction action p t
When inertia load stops moving (point Y Fig. 24-
73), brake pressure (P) tries to fall.
When P<Ps, plunger (311) moves toward the P<PS
right return side by the action of spring (321). L
Seat (313) tries to move to the right by the action
of spring (322), but since chamber p provides k
damping action by orifice g, the return of the seat 322 313 g r 321 311
makes a time delay with regard to the return of
Fig. 24-72 At anti-reaction action
the plunger.
Consequently, seat t opens. This makes a P Y
passage connecting the AM port and BM ports or
PS
both ports of the hydraulic motor by way of
→t→r→k. The result is that the pressures at the
AM and BM ports become equal (Pb), falling into PB
X
the condition at point Z in Fig. 24-73. Z
This prevents the hydraulic motor from swing T

shock by the closing pressure of the AM port. Fig. 24-73 Pressure change diagram of anti-
reaction operation

24.1.5.3.3 OPERATION OF BRAKE SECTION

The cylinder (111) is jointed by drive shaft (101) and a
spline. Separator plate (743) is fixed in its
circumferential direction by circular grooves provided in
casing (301).
Now, if the friction plate (742) splined to the outer 702
circumference of the cylinder is pressed against casing 712 743
(301) via separator plate (743) and brake piston (702)
742
by the action of brake spring (712), frictional force is
created between friction plate (742) and casing (301)
111 301
and between separator plate (743) and brake piston
(702). The frictional force bounds the drive shaft to 301 101
brake the motor.
Fig. 24-74 Operation of swing brake
In the meantime, when brake release pressure applied
to the oil chamber formed between brake piston (702)
and casing (301) overcomes the spring force, the brake
is released as brake piston (702) moves till friction plate
(742) is separated from casing (301).

24-73
24. COMPONENTS SYSTEM

24.1.5.3.4 SWING REDUCTION UNIT

The swing reduction unit is used to reduce the rotating Ring gear (Fixed) Planetary shaft
speed which is transmitted by the hydraulic motor and
to convert it to the strong turning force (torque).
This swing speed reduction unit is equipped with
Spider
planetary speed reducing mechanism.
The planetary mechanism is made up of sun gear, Sun gear
planetary pinion, planetary shaft, spider and ring gear,
as shown in Fig. 24-75.

For the operation of the 1st stage planetary, the

hydraulic motor rotates #1 sun gear (3). Sun gear (3) is
engaged with planetary pinion (4) and rotates, but since Planetary pinion

ring gear (8) is fixed, planetary pinion (4) revolves about Fig. 24-75 Planetary mechanism
sun gear (3) with the planetary shaft and spider (5). Swing motor

The role of spider is to hold the planetary pinion and 4 3

planetary shaft and transmits the power from the 8
planetary pinion to the spider through the planetary
shaft. 5
The #1 spider (5) is linked with #2 sun gear (6) by the 6
involute spline, and transmits the power to the 2nd 9
stage planetary mechanism.
For the operation of the 2nd stage planetary, the power Housing
is transmitted to #2 sun gear (6)→#2 planetary pinion 7
(7)→#2 spider (9) similarly to the 1st stage. The #2 Bearing
spider (9) is linked with pinion shaft (2) by the involute 2
spline, and pinion (1) is engaged with the swing gear
fixed on the undercarriage (lower frame) and rotates.

Bearing 1

Fig. 24-76 Function of reduction unit

24-74
 24. COMPONENTS SYSTEM

24.1.6 TRAVEL MOTOR

24.1.6.1 SPECIFICATION
(1) Appearance

PRESSURE MEASUREMENT PORT

2-G (PF)1/4
(MB,MA)

PILOT PORT
G(PF) 1/4 (P)

BEARING CENTER

VALVE PORT
2-G (PF) 1
(VA,VB)
DRAIN PORT
2-G (PF)1/2
18-M24 (D1,D2)

G (PF) 3/4
FILL PORT
LEVEL PORT OIL LEVEL

G (PF) 3/4
DRAIN PORT VIEW Y
Fig. 24-77 Travel motor

Rotation direction
Tightening
Oil inlet Oil outlet Rotation direction Port
Port size torque Function
port port (Viewed from valve port side) name
N•m (lbf•ft)
VA VB Right (Clockwise) P PF1/4 36 (26.6) Pilot (2 speed changeover) port
VB VA Left (counter clockwise) D1, D2 PF1/2 98.1 (72.4) Drain port
VA, VB PF1 255 (188) Motor drive port
MA, MB PF1/4 29.4 (21.7) Pressure measurement

24-75
24. COMPONENTS SYSTEM

(2) SPECIFICATIONS

Part No. LC15V00023F1

TRAVEL MOTOR UNIT
Type M4V290 / 170F-RG6.5F
Part No. —
Type —
Reduction ratio 40.467
Reduction unit Number of reduction stages 2
Lube oil capacity L (gal) 9.5 (2.5)
Lube oil capacity specification Gear oil SAE90API GL4 or GL5
Weight kg (lbs) —
Part No. LC15V00026F1
Type M4V290 / 170F
cc/rev
Max. displacement 290.7 (17.7)
(cu•in/rev)
cc/rev
Min. displacement 170.1 (10.4)
(cu•in/rev)
Relief valve set pressure MPa (psi) 35.0 (5075)
Travel motor
2 peed changeover pilot
MPa (psi) 5.0 (725)
pressure
Parking brake torque N•m (lbf•ft) 902 or more (665)
Parking brake release pressure MPa (psi) Less than 1.54 (223)
Working 0.2 (29)
Allowable drain pressure MPa (psi)
Surge 0.98 (142)
Weight kg (lb) —
Unit weight (with oil) kg (lb) 399 (880)

24-76
 24. COMPONENTS SYSTEM

24.1.6.2 CONSTRUCTION

24.1.6.2.1 TRAVEL MOTOR

Fig. 24-78 Travel motor

No. NAME No. NAME No. NAME

1 Casing 21 Breake piston 41 Restrictor spring (brake valve)
2 NPT 1/16 plug 22 D-ring (small dia.) 42 G1/8 plug
3 Oil seal 23 D-ring (big dia.) 43 O-ring 1B P8
4 Retaining ring IRTW68 24 Rear cover 44 Check valve
5 Expander plug MB800-040 25 NPT 1/16 plug (MEC) 45 Check valve spring
6 Shifter piston 26 Spool assy (M4V RBV) 46 M6 restrictor (0.6)
7 Piston seal 27 Spring holder (M4V RBV) 47 O-ring 1B P12.5
8 Steel ball 25 28 Spring (M4V150RBV) 48 M8 restrictor (0.8)
9 Shaft 29 M42 plug (4V RBV) 49 O-ring 1B P15
10 Bearing HR32209J 30 O-ring 1B G40 50 O-ring 215.57×2.62
11 Pivot 31 Pilot valve spool dia. ø10 (M4V290) 51 Bearing HR32207C
12 Swash plate 32 Pin (MRC03) 52 Shim
13 Cylinder block 33 Spring holder (MRC03) 53 Parallel pin M68×12
14 Cylinder spring 34 Spring (MRC03) 54 Valve plate
15 Spring holder 35 G3/8 pilot valve plug 55 Brake spring
16 Ball joint 36 O-ring 1B P14 56 HEX. socket head bolt M18×50
17 Shoe retainer 37 Connector (MRC03) 57 Overload relief valve ORV-240L
18 Piston assy 38 G1/4 plug 58 Coupling
19 Separating plate 39 O-ring 1B P11 59 Retaining ring C-type 40
20 Friction plate 40 Restrictor (brake valve) 60 G1/2 plug
61 O-ring 1B P18

24-77
24. COMPONENTS SYSTEM

24.1.6.2.2 REDUCTION UNIT

Fig. 24-79 Reduction unit

No. NAME No. NAME No. NAME

1 Housing 11 Thrust washer 2 21 Spring pin 6×36
2 Bearing 245BA35S1GS 12 Needle bearing FBNP-608660 22 Sun gear 1
3 Ring gear 13 Carrier pin 2 23 Thrust plate
HEX. socket head bolt
4 14 Spring pin 10×50 24 Cover
M18×110
HEX. socket head bolt
5 Floating seal 368 15 Sun gear 2 25
M10×30
6 Shim 16 Carrier 1 26 Plug G3/4
7 Lock washer 17 Planetary gear 1 27 O-ring 1B P24
8 Support ring 18 Thrust washer 1
9 Carrier 2 19 Needle bearing FBNP-406040
10 Planetary gear 2 20 Carrier pin 1

24-78
 24. COMPONENTS SYSTEM

24.1.6.3 MAKEUP OF TRAVEL MOTOR

The travel motor consists mainly of the rotary group that generates rotating power, the parking brake that prevents
the machine from moving by itself while it is parked, the variable displacement mechanism that switches over the
motor capacity to the large or small mode, the overload relief valve that is built in the rear cover, and the brake valve
(counterbalance valve) that controls the hydraulic circuits.
(1) Rotary group
Cylinder block (13) is inserted in the gear tooth grooves of the spline of shaft (9) that is supported by bearings
(10, 51) at it both ends. The cylinder block (13) is pressed against rear cover (24) with valve plate (54) by the
action of spring (14).
9 piston assy (18) slide over shoe plate (12), while stroking in cylinder block (13).
A bearing retainer is arranged at the end face of piston assy (18) to reduce the sliding resistance. The action of
spring (14) is transmitted to spring retainer (15), ball joint (16), and shoe retainer (17) and presses the end face
of piston assy (18) against shoe plate (12) so the piston assy moves close to the surface of shoe plate (12).

(2) Parking brake

Seven separator plates (19) and six friction plates (20) are inserted by turns in the spline grooves in the outer
surface of cylinder block (13) and are pressed against casing (1) by the action of 14 springs (55) via brake piston
(21).

(3) Variable displacement mechanism

The variable displacement mechanism consists of pivot (11) supporting shoe plate (12) that is put in two
semispherical concaves provided in shoe plate tilting piston (6) that tilts shoe plate on pivot (11) tilting stopper
(H) supporting the piston at a certain position; the pilot valve that admits the pressurised oil to the tilting piston
(6) by an external command; and three check valves (44) that take out the highest of the external command
activated pilot pressure, the motor inlet pressure and the motor outlet pressure and that sends it to the pilot valve.

(4) Overload relief valve

The overload relief valve consists of socket (57-1) that has valve seat (57-3) metallically seating rear cover (24)
of the motor and screwed up in rear cover (24) valve (57-2) engaged with socket (57-1) that is tangential in
contact with valve seat (57-3) by the action of adjust spring (57-9) connecting piston (57-4) that is inserted in
valve (57-2) and serves also as an oil path to pilot body (57-6) piston (57-7) that is put in pilot body (57-6) and
pressed against plug (57-5) and shim (57-8).

     










 
 








 
 !

  
  !  


  
  !

 
  !  


 
  !




Fig. 24-80 Construction of overload relief valve

24-79
24. COMPONENTS SYSTEM

(5) Brake valve portion

1) Spool
By shifting the spool (26), the discharged oil from hydraulic motor is automatically shut off or restricted
according to the condition and give the effect of holding, accelerating, stopping and counterbalance
operations.

2) Check valve (built in the spool)

This valve is located in the oil supplying passage to hydraulic motor, and at the same time functions to lock
oil displacement. Therefore, this valve serves as not only a suction valve but also a holding valve for
hydraulic motor.

Spool control pressure : 0.59~0.95 MPa (86~138 psi)

Check valve cracking pressure : 0.015 MPa (2.2 psi)
CHECK VALVE

Fig. 24-81 Brake valve portion

24-80
 24. COMPONENTS SYSTEM

24.1.6.4 FUNCTIONS OF TRAVEL MOTOR

(1) Motor
High pressure oil delivered from hydraulic pump is led to inlet port that is provided in the brake valve portion and,
through the rear cover (24) and valve plate (54), led to cylinder block (13).
As shown in Fig. 24-82 (a), high pressure oil is supplied to the pistons which are on one side of the line Y–Y that
connects upper and lower dead points and produces force F1.
F1=P×A (P : pressure, A : area of piston section)
The swash plate (12) with inclined angle of divides this force F1 into thrust force F2 and radial force F31-F34
(or F35). (Fig. 24-82 (b)) This radial force is applied to axis Y-Y as turning force and generate drive torque of T.
T=r1•F31+r2•F32+r3•F33+r4•F34
(In case high pressure oil is applied to five pieces of pistons, r5 F35 should be added.)
This drive torque is transmitted via cylinder block (13) to driving shaft (9).

Fig. 24-82
(2) Parking Brake
Parking brake is released when high pressure oil, selected by the brake valve portion that is connected directly
to the rear cover (24), is applied to the brake piston (21). Otherwise the braking torque is always applied.
This braking torque is generated by the friction between the separating plates (19), inserted into the casing (1),
and friction plates (20), coupled to cylinder block (13) by the outer splines.
When no pressure is activated on the brake piston (21), it is pushed by the brake springs (55) and it pushes
friction plates (20) and separating plates (19) towards casing (1) and generates the friction force which brakes
the rotation of cylinder block (13) and hence the shaft (9).

Fig. 24-83 Parking brake portion

24-81
24. COMPONENTS SYSTEM

(3) Capacity Control Mechanism

Fig. 24-84 typically shows the capacity control mechanism.
When high speed pilot line is charged with the pressure PA that overcome the spring (34), the spring (34) is
compressed and spool (31) shifts to the right to connect the port P and port C.
Then, the highest pressure is selected by the check valve (44) from inlet and outlet pressure of the motor and
high speed pilot line pressure and pushes shifter piston (6). As a result, swash plate (12) turns around the line
L which connect the two pivots (11) as shown by dotted lines. The turn stops at the stopper (1-1) of casing and
swash plate (12) keeps the position.
In this case, the piston stroke become shorter and motor capacity become smaller and motor rotates faster,
around 1.71 times, by the same volume of oil.
When no pressure is in the high speed pilot line PA, spool (31) is pushed back by the spring (34) and pressure
that pressed the shifter piston (6) is released to the hydraulic tank through restrictor (46).
Here, nine pistons are there and they equally spaced on the swash plate (12). The force that summed up those
of pistons comes to almost the center of the swash plate (12) as shown. Since the pivots (11) are off-set by S
from the center, the rotating force of product S and the force moves swash plate (12) to the former position and
the speed returns to low.
When the power demand exceeds the engine power, such as in steep slope climbing or turning at high speed
mode, the system step down to the low speed automatically. The mechanism is that: pump pressure is led to the
port PB (Fig. 24-84) and this pressure activate on pin (32). When the pressure at PB exceeds predetermined
value, spool (31) returns to the left by the counter-pressure against pin (32) and the pressure on the shifter piston
(6) through port C is released to the tank and the motor comes to low speed.
When PB goes down, the spool (31) moves to the right and the speed become high.

TO COUNTERBALANCE VALVE
(BRAKE VALVE)

HIGH SPEED PILOT LINE

(EXTERNAL PILOT)

LOAD
APPLICATION POINT

Fig. 24-84 Capacity control Mechanism

24-82
 24. COMPONENTS SYSTEM

(4) Function of overload relief valve

Two pieces of overload valves are located at cross-over position in the counterbalance circuit of brake valve and
have the following functions:
1) When hydraulic motor starts, keep the driving pressure below predetermined value and while accelerating,
bypasses surplus oil to return line.
2) When stopping the motor, keep the brake pressure, that develops on the outlet side of motor, under the
predetermined value to stop the inertial force.
3) To accelerate sharply while starting, and to mitigate the braking shock while stopping. For these purposes,
the developed pressure is kept comparatively low for a short period, then keep the line pressure as normal
value. While the pressure is low, meshing of reduction gears, crawler and sprocket etc. can be smoothly
done and the shock are absorbed.
When starting, "A" port pressure of overload valve increases, this pressure is applied to the effective diameter
of valve (57-2) which seats on the valve seat (57-3) and, at the same time, is delivered, via small hole, to the
connecting piston (57-4) located inside the valve (57-2) and the piston bore pressure increases up to "A" port
pressure. The valve (57-2) opposes to adjusting spring (57-9) by the force of the pressure exerted on the area
difference between valve seat's effective diameter and piston bore and keep the predetermined pressure.
When hydraulically braking, the piston (57-7) is at the left position by the driving pressure, and when "A" port
pressure increases, the pressure is applied also to the piston (57-7) through the small hole in the valve (57-2)
and piston (57-7) moves rightward until it touches the cap (57-5). In this while, the valve (57-2) maintains "A"
port pressure at comparatively low against the adjusting spring (57-9) force and exhaust oil to "B" port side. After
the piston reached to the plug, the valve acts the same as at starting.

CAP
CONNECTING PISTON (57-5)
PORT B (57-4)
VALVE SEAT
(57-3)

PORT A

VALVE ADJUSTING SPRING PISTON

SMALL HOLE (57-2) (57-9) (57-7)

Fig. 24-85 Function of overload relief valve

24-83
24. COMPONENTS SYSTEM

(5) Function of brake valve

1) Holding operation (see Fig. 24-86)
When the control valve is at neutral position, VA and VB ports are connected to the tank, and the spring (28)
located on both spool ends holds the spool (26) at central position. Therefore, the passages from VA to MA
and VB to MB are closed, which result in closing MA and MB ports connected to hydraulic motor.
Since the passage to parking brake is connected to the tank line, the brake cylinder pressure is equal to the
tank pressure and the brake is applied by the springs. Thus, the rotation of the motor is mechanically
prevented. If external torque is exerted on the motor shaft, the motor would not rotate as usual by this parking
brake.
In case the brake should be released for some reason, pressure is built on MA or MB port. But, due to oil
leakage inside hydraulic motor or so, high-pressure oil escapes from the closed circuit and motor rotates a
bit. So, the cavitation tends to occur in the lower pressure side of the closed circuit. Then, the check valve,
built in the spool (26), operates to avoid the cavitation and opens the passage from VA to MA or from VB to
MB. Then the oil equivalent to the leakage is sucked from the tank line to the closed circuit.

SPRING SPRING

Fig. 24-86 Holding Operation

24-84
 24. COMPONENTS SYSTEM

2) Accelerating operation (see Fig. 24-87)

When VA and VB ports are connected respectively to pump and tank by operating the control valve, hydraulic
oil from pump is forwarded through VA port to push open the check valve provided inside spool (26), and oil
flows to motor via MA port to rotate the motor.
Therefore, the pressure increases and negative brake is released by the pressure supplied from pump. At
the same time, the pressure of pilot chamber increases to push and move the spool (26) leftwards,
overcoming the spring (28) force. Thus, the return line from MB to VB opens to rotate the motor.
In case inertia load is too big to start rotation, accelerating pressure reaches the set pressure of relief valve
and high pressure oil is being relieved while the motor gains the rotational speed. As the rotational speed
goes up, the relieved volume decreases, and finally the motor rotates at a fixed speed.


 

    

  



 

 





Fig. 24-87 Accelerating Operation

24-85
24. COMPONENTS SYSTEM

3) Stopping operation (see Fig. 24-88)

Returning the control valve to neutral position while running the motor, the oil supply is cut off and VA and
VB ports are connected to the tank line. Then the pressure of the pilot chamber located on both spool ends
become equal, and the spool (26) returns to the neutral position by spring (28) force. Thus, the passage from
MA to VA is closed.
Owing to the inertia force of the load, the hydraulic motor tends to continue the rotation. Here, the motor
functions as a pump and forwards the oil to MB port but the passage is blocked and MB port pressure
increases. Then the relief valve opens to relieve the pressure and rotational speed decelerates and at last
the motor stops.
Negative brake release pressure is gradually lowered due to the restrictor and finally the brake works and
the motor is mechanically stopped.




 







Fig. 24-88 Stopping operation

24-86
 24. COMPONENTS SYSTEM

4) Counterbalance operation (see Fig. 24-89)

Counterbalance operation is required to decelerate slowly the hydraulic motor while absorbing inertia force.
In case the hydraulic oil is gradually decreased from pump to VB port, the drive shaft of hydraulic motor tends
to rotate faster than that matched to the volume of oil supply. Consequently, the pilot chamber pressure on
MB to VB side decreases and the spring (28) force moves the spool (26) leftwards towards neutral position.
Therefore, the area of passage from MA to VA becomes smaller and the pressure on MA side rises due to
increased resistance in the passage and the motor receives hydraulic braking effect.
If the motor rotates slower than that matched to the volume of supplied oil, the pilot chamber pressure on
VB port increases, and spool (26) moves rightwards to enlarge the area of passage from MA to VA.
Therefore the braking effect becomes smaller and the rotational speed of motor is controlled to correspond
to the volume of supplied oil. In order to give stable counterbalance operation, the restrictors (40) are set in
the pilot chamber to damp the spool (26) movement.
The parking brake is released during pressure adjusting action of the spool (26).

CHECK VALVE CHECK VALVE WITH RESTRICTOR

WITH RESTRICTOR

PILOT CHAMBER PILOT CHAMBER

SPRING
SPRING

Fig. 24-89 Counterbalance operation

24-87
24. COMPONENTS SYSTEM

24.1.6.5 FUNCTION OF REDUCTION GEAR

Reduction unit slows down the rotating speed of motor

 
  

and converts motor torque to strong rotating force.
This reduction unit utilizes two stages, planetary
reduction system.  


Planetary reduction system consists of sun gear,    



planetary gears, (planetary) carriers, and ring gear.
When the sun gear (s) is driven through input shaft,
planetary pinions (b), rotating on their center, also
 
move, meshing with fixed ring gear (a), around sun
gear (s).   

This movement is transferred to carrier (k) and deliver
the torque.
This mechanism is called planetary gear mechanism.

  

 



  


  





Fig. 24-90 Planetary gear mechanism

See Fig. 24-91 on the right.
a
When the sun gear S1 is driven by input shaft,
planetary action occurs among gears S1, a and b and
b d
revolution of gear b transfers the rotation of carrier K1
to second sun gear S2, and also evokes planetary
action between gear S2, a and d. S1 S2
This time, because carrier K2 is fixed to frame, gear d
drives ring gear a and then ring gear a rotates to drive
sprocket.
K1 K2

Fig. 24-91 Two stages reduction gear

24-88
 24. COMPONENTS SYSTEM

24.1.7 SWIVEL JOINT

24.1.7.1 GENERAL VIEW

VIEW Y

VIEW Z

Fig. 24-92 General view of swivel joint

24.1.7.2 SPECIFICATIONS

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

24-89
24. COMPONENTS SYSTEM

24.1.7.3 CONSTRUCTION

2 places Apply Three Bond

#1805 to stem

2 places
VIEW Y

5 places
Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242
SECTION HH

Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242

Fig. 24-93 Construction

No. Name Q’ty No. Name Q’ty

1 Body 1 7 O-ring(G95 1A) 1
2 Stem 1 8 Capscrew (M8×20) 2
3 Thrust plate 1 9 Capscrew (M8×30) 3
4 Cover 1 12 Plug 1
5 Seal 5 13 O-ring 2
6 Seal 1

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

24-90
 24. COMPONENTS SYSTEM

24.1.8 CYLINDER

24.1.8.1 SPECIFICATIONS
(1) General view

B A
n gth gth
n
d le d le
de te
xten rac
ly e et
Fu
l l ly r
Fu

Part No. and Manufacturing No.

Stamp position

Fig. 24-94 General view of cylinder

(2) Specifications
Unit : mm (ft-in)

Center distance of
Part No. of Cylinder bore / pins Dry weight
Use Stroke Cushion
cylinder assy Rod Dia. Full extend B / Full kg (lbs)
retract A
ø140 / ø100 1,550 3,651 / 2,101 With cushion on
Boom LC01V00044F1 269 (593)
(5.51" / 3.94") (5'1") (11'12" / 6'11") rod side
SE.Asia LC01V00054F2 ø170 / ø120 1,788 4,281/ 2493 With cushion on
Arm 504 (1,111)
Oceania LC01V00054F1 (6.69" / 4.72") (5'10") (14'1" / 8'2") both sides
SE.Asia LC01V00055F2 ø150 / ø100 1,193 3,005 / 1,812 With cushion on
Bucket 265 (584)
Oceania LC01V00055F1 (5.91" / 3.94") (3'11") (9'10" / 5'11") rod side

24-91
24. COMPONENTS SYSTEM

24.1.8.2 CONSTRUCTION AND FUNCTION

24.1.8.2.1 CONSTRUCTION
(1) Boom cylinder

T= Tightening torque ; N.m (lbf.ft)

25 24 12 T=367 (271) 22 23

B
-0.5

-0.5
130 0

130 0
With hole
DETAIL B (1 place) DETAIL C
T=8000 (5900)
T=56.9 (42.0)

9 8 7 6 3 4 5 11 10 2 1 13 14 16 17 18 19 15 20 21

Slit
Orientation of cut off part
of cushion bearing (13)

Fig. 24-95 Construction of boom cylinder

P/No LC01V00044F1
No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty
1 Cylinder tube 1 10 O-ring 1 19 Slide ring 2
2 Piston rod 1 11 Buckup ring 1 20 Set screw; M14 1
3 Rod cover 1 12 Socket bolt; M18×80 12 21 Steel ball 1
4 Bushing 1 13 Cushion bearing 1 22 Pin bushing 1
5 Snap ring 1 14 Cushion seal 1 23 Wiper ring 2
6 Buffer ring 1 15 Piston 1 24 Pin bushing 1
7 U-ring 1 16 Seal ring 1 25 Wiper ring 2
8 Buckup ring 1 17 Buckup ring 2
9 Wiper ring 1 18 Slide ring 2

24-92
 24. COMPONENTS SYSTEM

(2) Arm cylinder

T= Tightening torque ; N.m (lbf.ft)

T=711 (524)
29 28 12 28 29

B
-0.5

-0.5
140 0

140 0
DETAIL B

Stake 2 places after tightening

T=96.6(71)

T=17000(12540)
22
9 7,8 6 4 5 3 12 10,11 2 1 13 15 16 19 21 23 27 25 24
14 17 18 20 26

With hole
(1 place)
Orientation of cut
off part of cushion
bearing (13)
SLIT SLIT

Fig. 24-96 Construction of arm cylinder

LC01V00054F2 SE.Asia
P/No
LC01V00054F1 Oceania
No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty
1 Cylinder tube 1 11 Buckup ring 1 21 Piston nut 1
2 Piston rod 1 12 Socket bolt; M22×95 12 22 Set screw; M16 1
3 Rod cover 1 13 Cushion bearing 1 23 Steel ball 1
4 Bushing 1 14 Cushion seal 1 24 Cushion bearing 1
5 Snap ring 1 15 Piston 1 25 Cushion seal 1
6 Buffer ring 1 16 Seal ring 1 26 Stopper 2
7 U-ring 1 17 Buckup ring 2 27 Snap ring 1
8 Buckup ring 1 18 Slide ring 2 28 Pin bushing 2
9 Wiper ring 1 19 Slide ring 2 29 Wiper ring 4
10 O-ring 1 20 Shim 1

24-93
24. COMPONENTS SYSTEM

(3) Bucket cylinder

T= Tightening torque ; N.m (lbf.ft)

24 23 12 T=520 (384) 23 24

B
-0.5

-0.5
130 0

130 0
DETAIL B

Stake 2 places after tightening

T=56.9(42)
T=10000(7376)

21
9 8 7 6 3 4 5 12 11,10 2 1 13 14 15 16 17 18 19 20 22

With hole
(1 place)

Orientation of cut off part

of cushion bearing (13)

Fig. 24-97 Construction of bucket cylinder

LC01V00055F2 SE.Asia
P/No
LC01V00055F1 Oceania
No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty
1 Cylinder tube 1 9 Wiper ring 1 17 Slide ring 2
2 Piston rod 1 10 O-ring 1 18 Slide ring 2
3 Rod cover 1 11 Buckup ring 1 19 Shim 1
4 Bushing 1 12 Socket bolt; M20×95 12 20 Piston nut 1
5 Snap ring 1 13 Cushion bearing 1 21 Set screw; M14×2 1
6 Buffer ring 1 14 Piston 1 22 Steel ball 1
7 U-ring 1 15 Seal ring 1 23 Pin bushing 4
8 Buckup ring 1 16 Buckup ring 2 24 Wiper ring 4

24-94
 24. COMPONENTS SYSTEM

HYDRAULIC CYLINDER CONSTRUCTION (See Fig. 24-95)

By construction the hydraulic cylinder consists mainly of cylinder tube assy (1), piston rod assy (2) that takes out the
motion of pistons reciprocating in the cylinder tube assy, and cylinder head (3) that serves as both a lid and a guide.
Cylinder tube assy (1) is equipped with a pin mount (clevis) that connects piston rod assy (2) with other parts.
In addition to these main components, seal ring (16) and back-up ring (17) are located between cylinder tube assy
(1) and piston rod assy (2); buffer ring (6), U-ring (7) back-up ring (8) and wiper ring (9) are located between piston
rod assy (2) and cylinder head (3); and an O-ring (10) and a back-up ring (11) are placed between cylinder tube assy
(1) and cylinder head (3)

24.1.8.2.2 OPERATION
If pressurized oil is fed alternatively to the oil inlet and Cushion bearing (13) Chamber "A" Passege "B"
outlet provided in the cylinder, force acts on the piston Tank
which in turn causes the piston rod (2) to extend and Piston (15)
Rod (2)
retract.
Rod side
Head side
(1) Operation of cylinder with cushion
1) Cushion on rod side
The cushion mechanism is provided to prevent Rod cover (3)
Cushion stroke
the generation of shock when the moving speed
of piston (15) is not reduced and strikes cylinder Fig. 24-98 Cushion mechanism on the rod side
head (3).






An oil in chamber "A" returns to the tank by
passing through passage "B" at a fixed flow rate
in a intermediate stroke state (Fig. 24-98) of
pressing head side. Next, in a state of just before
stroke end (Fig. 24-99), cushion ring (13)   
 
plunges into passage "B".
At this time, an oil in chamber "A" passes
clearance "D" and mouth gap "C", an oil flow
volume returning to tank suddenly drops and the
piston part movement slows down. Fig. 24-99 Cushioning action on the rod side
2) Cushion on head side (See Fig. 24-100)  
This construction is similar to the one of cushion
 
 
on rod side. In a state of intermediate stroke
     
   
pressing rod side, an oil in chamber "A" returns
to tank by passing through passage "B" at a fixed
flow rate.
Next, in a state of just before stroke end, cushion
bearing (22) plunges into passage "B". At this
time, the oil in chamber "A" flows only through
clearance "D" and mouth gap "C" of cushion seal
   
(23). So the returning oil volume drops suddenly 
  
and the piston movement slows down.

 
 
Fig. 24-100 Cushion mechanism on the head side

24-95
24. COMPONENTS SYSTEM

This page is blank for editing convenience.

24-96
 24. COMPONENTS SYSTEM

24.2 ELECTRIC EQUIPMENT

24.2.1 ELECTRIC EQUIPMENT LIST

Group Code Name Parts No.

C - 1 Mechatro controller YN22E00214F1
(C) Controller

C - 2 Gauge cluster YN59S00021F2

C - 4 Air-con controler (including panel) YN20M01468P1
C - 5 Radiator coolant level controller VHS834701230
C - 8 Engine controller VH89661E0010
D - 4 Diode Harness accessory
D - 5 Diode Accessory of relay box
D - 6 Diode ↑
D - 9 Diode ↑
↑
(D) Diode

D - 10 Diode
D - 12 Diode ↑
D - 13 Diode ↑
D - 14 Diode ↑
D - 15 Diode ↑
D - 16 Diode ↑
D - 17 Diode ↑
E - 1 Fuse and Relay box YN24E00016F2
E - 2 Alternator VHS270402500
E - 3 Hour meter YT58S00006P1
E - 5 Horn high LC53S00001D1
E - 6 Horn low LC53S00001D2
(E) Electric fittings

E - 7 Tuner AM / FM (for Oceania) YN54S00046P1

E - 8 Speaker left (for Oceania) YN54S00050P1
E - 9 Speaker right (for Oceania) ↑
E - 10 Receiver dryer YN54S00041P1
E - 11 Air-con compressor YX91V00001F1
E - 12 Battery YN72S00014P1
E - 13 Travel alarm (for Australia) YN53S00004F1
E - 14 Cigarette lighter YN81S00003P1
E - 15 Fusible link LC13E01175S002
E - 27 Accel redundant volume YN52S00052P1
L - 1 Boom work light (LH) YW80S00001F1
L - 2 Deck work light YT80S00002F2
L - 3 Swing flasher (LH) & work light unit YM80S00001F1
(L) Light

L - 4 Swing flasher (RH) & work light unit YM80S00001F2

L - 5 Room light YT80S00001P1
L - 6 Boom work light (RH) YW80S00001F1
L - 7 Cab work light (for SE.Asia) YT80S00002F2
L - 9 Boom cyl. light (for SE.Asia) YT80S00002F1

24-97
24. COMPONENTS SYSTEM

Group Code Name Parts No.

M - 1 Starter motor VHS281002894A
(M) Motor

M - 3 Wiper motor YN53C00012F2

M - 4 Washer pump motor YN54C00001F1
M - 9 Roof wiper motor YN76S00005P1
Arm 2 speed inverse propo.
PSV - A YN35V00049F1
(P) Proportional

valve
solenoid valve

(YN35V00047F1)
PSV - B P2 unload propo. valve YN35V00048F1
Solenoid valve assy
PSV - C Travel straight propo. valve ↑
PSV - D P1 unload propo. valve ↑
PSV - P1 P1 pump propo. valve (YN10V00023F1) YN35V00052F1
PSV - P2 P2 pump propo. valve Pump ↑
R - 1 Battery relay YN24S00008F1
R - 2 Starter relay VHS283001271A
R - 3 Glow relay VHS286201420A
R - 4 Safety relay YN24S00010P1
R - 5 Horn relay ↑
R - 6 Working light relay ↑
R - 8 Travel alarm relay (for Australia) ↑
R - 9 Cab working light relay (for SE.Asia) YN24S00010P1
(R) Reray

R - 19 Flasher relay YY24S00001F1

R - 23 Auto idle stop relay 1 YN24S00010P1
R - 24 Auto idle stop relay 2 ↑
R - 25 Engine emergency stop relay ↑
R - 26 Lever lock relay ↑
R - 28 Alternator relay ↑
R - 29 Wiper motor relay (Normal rotation) YN24S00012P2
R - 30 Wiper motor relay (Reverse rotation) ↑
R - 31 Wiper motor relay (Arc prevention) ↑
R - 32 Washer motor relay ↑
R - 45 Boom cyl. working light relay (for SE.Asia) YN24S00010P1

24-98
 24. COMPONENTS SYSTEM

Group Code Name Parts No.

SE - 1 Pressure sensor : Bucket digging LC52S00019P1
SE - 2 Pressure sensor : Bucket dump ↑
SE - 3 Pressure sensor : Boom up ↑
SE - 4 Pressure sensor : Boom down ↑
SE - 5 Pressure sensor : Swing ↑
SE - 7 Pressure sensor : Arm in ↑
(SE) Sensor

SE - 8 Pressure sensor : Arm out ↑

SE - 9 Pressure sensor : Travel RH ↑
SE - 10 Pressure sensor : Travel LH ↑
SE - 11 (Pressure sensor : P2 OPT.) ↑
SE - 13 E/G speed sensor VHS894101290A
SE - 15 Fuel sensor YN52S00045F1
SE - 16 Accel potentiometer YN52S00032P1
SE - 20 (Pressure sensor : P1 OPT.) LC52S00019P1
SE - 22 Pressure sensor : Pump P1 YN52S00048P1
SE - 23 Pressure sensor : Pump P2 ↑
SV - 1 Swing parking brake SOL. YN35V00051F1
(SV) Solenoid

SV - 2 Power boost SOL (YN35V00047F1) YN35V00050F1

SV - 3 Two speed select SOL Solenoid valve assy ↑
SV - 4 Safety lock lever SOL ↑
SW - 1 Key switch YN50S00026F1
SW - 4 Swing parking brake release switch YN50S00047P1
SW - 5 Horn switch (RH) YN50E00017P1
SW - 7 E/G oil pressure switch VHS835301471D
SW - 8 Air filter clogging switch YR11P00008S005
SW - 10 Horn switch (LH) YN50E00017P1
SW - 11 Safety lock lever switch YN50S00041F1
(SW) Switch

SW - 13 Travel alarm switch (for Australia) YN50S00040DF

SW - 15 (Conflux/single select switch) YN50S00040DD
SW - 17 (Skylight wiper switch) YN50S00040D9
SW - 19 Wiper interlock switch YT50S00004P1
SW - 20 Power boost switch (RH) YN50E00017P1
SW - 21 Power boost switch (LH) ↑
SW - 26 Cab work light switch (SE.Asia) YN50S00040D4
SW - 27 Coolant level switch VHS834601510A
SW - 28 Water separator switch VHS233002800A
SW - 55 Boom, deck work light switch YN50S00040D1

24-99
24. COMPONENTS SYSTEM

24.2.2 SPECIFICATION OF ELECTRIC EQIUPMENTS

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
C-1
Maker Sinko Electric Co. Ltd
Controller
Rated voltage DC24V
YN22E00214F1
Weight 4.2 kg (9.3 lbs)
Mechatro controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~

C-2
Maker Nippon seiki Co., Ltd
Controller
Rated voltage DC24V
YN59S00021F2
Insulation More than 3M at 500V megger
Gauge cluster
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~

C-4
Controller

 

YN20M01468P1



  
Air-con Controller 


 


 

YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~

24-100
 24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
C-5
Rated voltage DC24V
Controller
Maker's (Hino) P/No. S8347-01230
VHS834701230
Controller
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~

Hino P/No. : 82580-8050A

(YAZAKI : 7382-1680)
Hino P/No. : 82580-8870A
(YAZAKI : 7283-1080)

Measurement circuit Pin arrangement

C-8
Controller Maker's P/No. 89661-E0010
VH89661E0010 Rated voltage 24V (DC)
Engine controller Working voltage 16~32V (DC)
Operating voltage
LC10 - 07001 ~ (at starter ON) 9~32V (DC)
YC10 - 03501 ~ Back-up source
(reference value) 5mA MAX (BAT=24V)

Connector 167 pins Male

24-101
24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E-1
Fuse capacity and circuit
Fuse & Relay box
YN24E00016F2
Fuse & Relay
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~

Front side of machine

E-2
Alternator M6
B terminal
VHS270402500
B
Generator
LC10 - 07001 ~
YC10 - 03501 ~

4 pin connector (Water proof)

Terminal arrangement Hino P/No. 82560-2390
(Eqivalent to sumitomo 6188-0631 )
VIEW B
Connector
Hino P/No. 82580-8640
(Eqivalent to sumitomo 6189-0351)

E-3
Hour meter Movement Quarts
Operating voltage 10~80VC
YT58S00006P1 GM terminal : 2962447
GM connector : 2962448
Service meter
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~

24-102
 24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E - 5, 6
Type Bottom L : Low sound
Horn H : High sound
Rated voltage DC24V
LC53S0001D1 (High) STAMP
Operating voltage range DC20~30V
LC53S0001D2 (Low)
Sound level 113+5dB(A)/2m
Warning sound
420+20Hz high sound
YN11 - 45001 ~ Basic frequency 350+20Hz low sound
YQ11 - 06001 ~ Insulation resistance More than 3M /DC500V
LC10 - 07001 ~
YC10 - 03501 ~ o 8.5

E-7
Maker SOKEN Co,.Ltd.
Tuner
Part name AM/FM radio
YN54S00046P1
Radio (AM & FM)
(Oceania)
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~

E - 8, 9
Maker SOKEN Co., Ltd.
Speaker
Maker parts No. SOK104A004
YN54S00050P1
Rated input 10W
Radio
Impedance 8
LY01 - 00101 ~
Frequency 33.3Hz
LC10 - 07001 ~
YC10 - 03501 ~

E - 10
Maker Sanden Corp.
Receiver dryer
Airtight test pressure 3.5MPa (508 psi)
YN54S00041P1
Pressure proof test pressure 5.3MPa (769 psi)
Air-con
Breaking test pressure 9.8MPa (1420 psi) Outlet (To unit)
YN11 - 45001 ~ Desiccant moisture 17% or over than the
weight of desiccant
YQ11 - 06001 ~ adsorption capability (Include initial absorption 2%)
LC10 - 07001 ~ Refrigerant HFC-134a
YC10 - 03501 ~ Inner volume/Desiccant 578cm3/300g Inlet (From condenser)

24-103
24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E - 11
Air-con compressor
 

  !"#!"""
YX91V00001F1

 
 $%&
Air-con

   &"""'
YX03 - 01601 ~
  () *
YX04 - 01773 ~

 #+ &

YX05 - 02001 ~
 ,-#%".+ /
YN11 - 45001 ~
  
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~

E - 12
Type 115F51
Battery
Voltage 12V
YN72S00014P1
Capacity (5HR) 96Ah
Power
Weight (Incl. fluid) Approx. 26.5kg (58.4 lbs)
YN11 - 45001 ~
Electrolyte Approx. 6.7 L (1.77 gal)
YQ11 - 06001 ~
LC10 - 07001 ~ Negative
terminal
Positive
terminal

YC10 - 03501 ~
(0.67")
(0.67")
Taper

Taper

17
17

17.9 19.5
(0.705") (0.768")
502 (19.76")
180 (7.09")
210 (8.27")
215 (8.47")

24-104
 24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
E - 13 GND AV 0.5 Black
Model BA3111A
Alarm
Rated voltage DC 12V~36V
YN53S00004F1 Power AV 0.5 Red / Green

Travel alarm AMP Econoseal J series Mark II water-proof

Housing : 174354-2 Harness seal : 172888-2
(Australia) Terminal : 171661-1 Retainer : 1-174355-1

YN11 - 45001 ~ VIEW A

YQ11 - 06001 ~
LC10 - 07001 ~ Vinyl tube
YC10 - 03501 ~

E - 14
Cigarette lighter
 


 !" #$
YN81S00003P1
  % ,

*
Cigarette lighter -
.
YN11 - 45001 ~

  &  '

  
   (%$ 


YQ11 - 06001 ~
LC10 - 07001 ~
  )
*'+#%
YC10 - 03501 ~
/
0
*

E - 15
Fusible link
   
    
LC13E01175S002
Fuse
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~

E - 27
Resistance 2
Rated voltage DC 5V
Resister for emergency
Resistance 2 TOCOS
(Potentio meter) Parts E-27 RA30YME20FB202
YN52S00052P1
Engine emergency After soldering,
insulate this part
volume with heat shrinkable tube
Clip
YN11 - 45001 ~
Adhesive
YQ11 - 06001 ~
LC10 - 07001 ~
Fix this resistance with tape HOUSING : 172131-5
YC10 - 03501 ~ PVC tube (Black) TERMINAL : 170340-1
Dial
VIEW I

24-105
24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
L - 1, 6
Light (Halogen)
 
 
 

YW80S00001F1
Boom work light (LH, RH)
LC08 - 06201 ~
YC08 - 03001 ~ 

LC09 - 06201 ~
YC09 - 03701 ~
YN11 - 45001 ~

 
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
L - 2,7
Light (Halogen) Type BL84-200
Bulb DC 24V,70W
YT80S00002F2
Effective area of lens 71cm2
Deck work light
Cab working light front
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~

L-3
Meker Knight beam (Imasen)
Light
Type BL46-146
YM80S00001F1
Bulb DC 24V, 25W
Flasher lamp (LH)
Lighting cycle 90 times / min
Rear work light
YN11 - 45001 ~
AV0.85 W
YQ11 - 06001 ~ AV0.85 Y REAR WORKING
LC10 - 07001 ~ SWING LIGHT LIGHT
YC10 - 03501 ~ AMP PART NO.
HOUSING : 174259-2
L-4 TERMINAL : 171661-1
AV0.85 R
Light HARNESS SEAL : 176886-2 AV0.85 B SWING LIGHT
LOCK PLATE : 1-174260-1 GND
YM80S00001F2 VIEW I
Flasher lamp (RH)
Rear work light
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
SECTION A-A

24-106
 24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
L-5
Bulb 24V,5W Body
Light
Note) Equivalent to 2456Z322F1 Lens
YT80S00001P1
Room light
YT02 - 04001 ~
YT03 - 05293 ~
YT04 - 07001 ~ Bulb
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ SECTION A-A Door
Switch
YC10 - 03501 ~
M-1 B Terminal : M8X1.25
Rated output DC 24V, 15kW A
Motor
Yazaki P/No.
VHS281002894A Terminal : 7114-6047
Pinion gear
Connector : 7282-3013-30 (Black)
Starter motor Hino P/No. : 82580-6720
YN11 - 45001 ~ Mating connector
Hino P/No. : 82580-6730
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~

VIEW A

M-3
159800-5710
Motor Denso corp. P/No. (Motor only)
YN53C00012F2 Rated voltage 24V
Wiper motor Swing angle Applox. 80
YN11 - 45001 ~ Controller

YQ11 - 06001 ~ Wiper motor 24V

LC10 - 07001 ~
YC10 - 03501 ~
Wiper sw
OFF-Stop
Stop signal ON-Start

Reverse signal
Electric diagram

M-4
Rated voltage DC 24V
Motor (Reservoir)
Injection flow 600cc (0.16 gal) / min or more
YN54C00001F1
Capacity 1.5L (0.4 gal)
Window washer
Injection pressure 88.3 kPa (12.8 psi) or more
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~

24-107
24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
R-1
At start 24V2000A(0.1 sec) Terminal A
Relay Rated voltage / current At charge 28V120A(Continuous) VIEW A
YN24S00008F1 Exciting current 0.4A or less / 24V
Lock section
Battery relay Contact pressure 37.2N {8.4 lb} or more Terminal A
YN11 - 45001 ~ Closed circuit voltage 16V or less VIEW I
Terminal B
YQ11 - 06001 ~ Open circuit voltage 7V or less HOUSING AMP
GND terminal

LC10 - 07001 ~
174359-2
Insulation resistance 3M or more/500V megger RETAINER AMP
1-174360-7
YC10 - 03501 ~ TERMINAL AMP
171661-1
WIRE PROOF PLUG AMP
172888-2

VIEW Z Terminal L
Flowing direction of
main current F HOUSING YAZAKI
o 9 X 30L
Terminal A Terminal B Terminal B Heart shrinkage tube 7123-4210-30
AVS 1.25G
F TERMINAL YAZAKI
AVS 1.25B 7116-3251*
z GND wire
WIRE PROOF PLUG
I Terminal B Terminal L 7157-3580-60
F HOUSING YAZAKI AVS 1.25L Terminal B
7123-4220-30
F TERMINAL YAZAKI
P coil 7116-3251
REAR HOLDER YAZAKI
7157-6801-30
H coil WIRE PROOF PLUG
7157-3580-60

Bracket groud
Circuit diagram
o 7.0 X 150L
Corrugete tube (Black)

Fusible link assy B o 7.0 X 150L

Fusible link assy A Corrugete tube (Black)

R-2 Length of coupler harness

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

Blue
Vynil tube (Red) M6
Terminal C Terminal B
Electric diagram

E (AVX 0.85mm2 Black)

E (AVX 0.85mm2 Blue)

Tape

M6

24-108
 24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
R-3
Hino P/No. S2862-01420A
Relay
Rated voltage DC 24V
VHS286201420A
Rated load 100A flow
Glow relay
Min. operating voltage DC 18V or less
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
S terminal
YC10 - 03501 ~

(Red)
Name plate
F terminal

Connector
090 II Non water-proof male 2P blue
SW terminal Hino P/No. 82580-7320A
Yazaki P/No. 7282-1020-90
Mating connector
090 II Non water-proof female 2P
Hino P/No. 82580-7330A
L terminal Yazaki P/No. 7383-1020-**
Electric diagram

R - 4,5,6,8,9,23,
24,25,26,28,45 Maker Tyco Electronics
Maker's p/No. V23074-A2002-A403
Relay
Type Micro relay A
YN24S00010P1
Rated voltage DC 24V
Safety relay
Horn realy Contact 1C
Work light relay * Accessory of relay box
Travel alarm relay
Cab working light relay
Auto idle stop relay 1, 2
Engine emergency stop relay Pin assignment
Lever lock relay
Alternator relay
Wiper motor relay
Washer motor relay
Boom cyl. working light relay
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
Terminal arrangement

24-109
24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
R - 19
Relay
YY24S00001P1 UPPER
Flasher relay
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~

TERMINAL NUMBER

R - 29,30,31,32
Maker's P/No. V23134-A0053-C643
Relay
Parts name Relay
YN24S00012P2
Rated voltage DV 24V
Wiper motor relay
Washer motor relay Contact 1C
YN11 - 45001 ~ * Accessory of relay box
YQ11 - 06001 ~
Pin assignment
LC10 - 07001 ~
YC10 - 03501 ~

SE - 1 ~ 5, 7 ~ 11,20
Pressure sensor


    
(Low pressure) 
  
  

 

 

 ! 

LC52S00019P1
Bucket dig and dump,
( )* +, - "$$-+"
Boom up and down,  ' +, -
" "*+- "$$-+" .-(/-
Swing, +- $(/ $  "$$-+"$ 0"1*$% 2 3#45653#&
+- $(/ 2 4545#
Arm in and out, & " 0-7 &4 %"/ /(+-
Travel RH and LH and other 3 "1+ 1+ 0( $-** *-(/ 2 45656#&
YN11 - 45001 ~  "8- 
YQ11 - 06001 ~ "# $%
&' && .&!
LC10 - 07001 ~
YC10 - 03501 ~
SE - 13
Output voltage 2.8V or more
Speed sensor
Clearance 1.0mm
VHS894101290A Sumitomo : 090-II (4P : B)
E/G speed sensor P/No. : 6188-0265
Hino. P/No.
YN11 - 45001 ~ Sensor side : 82580-6120A (B)
Harness side : 82580-6130A (B)
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~

M16 x 1 Hex. : 17
Hex. : 22
Tightening torque : 47N.m (34.7 lbf.ft)

24-110
 24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SE - 15
Float operation
Fuel sending unit
Float Resistance
YN52S00045F1 +0.1
FULL 10 -0.6
Fuel level
3/4 (19)
YN11 - 45001 ~
1/2 32+5
YQ11 - 06001 ~
1/4 (49.5)
LC10 - 07001 ~
EMPTY 85 +10
0
YC10 - 03501 ~

Machine side controller

Float

Electric diagram VIEW A

SE - 16
Total resistance value
Potentio meter
Effective electric angle
YN52S00032P1
Number of notches
Accel dial
Source voltage
YT02 - 04001 ~
Notch part
YT03 - 05293 ~
YT04 - 07001 ~ Potentio
YN11 - 45001 ~ 3MA JM II + AMP
Bracket
YQ11 - 06001 ~ HOUSING : 174359-2
TERMINAL : 171661-1
LC10 - 07001 ~
YC10 - 03501 ~ Dial

SE - 22, 23 Electric diagram (Arrangement)

Pressure range 0~50MPa (7250 psi)
Pressure sensor
Max. allowable press. 120MPa (17400 psi)
(High pressure)
Operating source voltage 5+0.5V DC
YN52S00048P1
100M or more/DC50V megger
P1 pump Insulation resistance
(Between casing and terminal)
P2 pump
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ Source (+)
P3/8
YC10 - 03501 ~ Tightening torque Output (+) Econo seal J series
: 73.5 N.m O ring P14 Common (+) (Mark II (+)
(54.2 lbf.ft) JIS B2401 3 pole

24-111
24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
PSV - A, B, C, D
Proportional solenoid valve
Hydraulic solenoid valve
Hydraulic symbol A5 to A8
(YN35V00047F1)
YN35V00048F1
YN35V00049F1
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~

HYDRAULIC SYMBOL
Arm 2 speed

P1 unload

Travel straight

P2 unload

Attachment boost

Travel 1,2 speed

Swing parking

Lever lock
PSV - P1, P2
Solenoid Type KDRDE-5K AMP MARK II
Max. feed press 13.7MPa (1987 psi) HOUSING : 174354-2
YN35V00052F1 TERMINAL : 173706-1
Rated feed press 5.0MPa (725 psi) Orifice Spring
Pump P1, P2 HEX 10
Allowable back press 1MPa (145 psi) Spool T=7.4N.m
proportional valve (5.5lbf.ft)
Control pressure range 0~2.7MPa (392 psi)
YN11 - 45001 ~
Rated voltage DC 24V
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
Sleeve O-ring Solenoid Seal nut
1B P20

SV - 1, 2, 3, 4
Rated pressure 5.0 MPa (725 psi)
Solenoid directional
Solenoid directional
Rated voltage DC 24V
valve (8 spool) assy pressure

Hydraulic symbol Solenoid proportional Dither current 100Hz,200mA P-P P1, P2, T, A1, A8 port PF3/8
valve Coil resistance 17.5 (at 20C)
A1 to A4 A2~A7 port PF1/4
AMP MARK II AMP MARK II
(YN35V00047F1) Connector specification HOUSING 174354-2
TERMINAL 173706-1
YN35V00050F1
YN35V00051F1
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~

24-112
 24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 1 Auto return
Switch
Connection
YN50S00026F1 Terminal
Position
Starter switch
Auto return
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ VIEW A Terminal
YC10 - 03501 ~ arrangement

SW - 4
Single-pole double-throw
Switch Type (alternate) Insulation tape
R B W
YN50S00047P1 Rated DC30V, 10A
Swing parking brake Insulation resistance
release
Vinyl tube
YN11 - 45001 ~ YAZAKI
T No.
YQ11 - 06001 ~ Contact construction : Position Red (2) 7122-2237
7114-2020
LC10 - 07001 ~ Swing parking release
YC10 - 03501 ~ Normal

White (3) Blue (1)

SW - 5, 10, 20, 21

     )* +,   
Switch ,        (-
 

YN03M01861F1
(Right grip)
  ! "# #$
  %   % &
YN03M01862F1 '$! (
(Left grip)
Horn, ATT Power boost
YN11 - 45001 ~
YQ11 - 06001 ~ ((  
(, ./01,+ 23*" 4  (5
LC10 - 07001 ~ ((  
(,  %#6,+ 7 "*8 7
6  4((  
( 9  '"5
YC10 - 03501 ~
SW - 7
Type Normal close
Switch
Working pressure 39.2~58.8kPa (5.7~8.5psi)
VHS835301471D
Rating DC 24V/12W
E/G oil pressure switch More than 100M / 090 II Water proof connector
Insulation resistance DC500V megger
YN11 - 45001 ~ Color : Black
Hino P/No. : 82580-6830
YQ11 - 06001 ~ Yazaki P/No. : 7383-1114
LC10 - 07001 ~
YC10 - 03501 ~

24-113
24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 8
Switch
 
 
YR11P00008S005
 
 
Air cleaner 
Clogging switch  
YT02 - 04001 ~
YT03 - 05293 ~
YT04 - 07001 ~
YN11 - 45001 ~ 
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~
SW - 11
Switch
  
 
YN50S00041F1 

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

 ! 

 

 ! 

"# 
SW - 13
Rated voltage DC 24V
Switch
Single pole single throw
YN50S00040DF Type (alternate)
Travel alarm (Australia) More than 1M /
Insulation resistance DC500V megger UP
YN11 - 45001 ~
YQ11 - 06001 ~ Terminal connector
LC10 - 07001 ~ Position
Connector

YC10 - 03501 ~

SW - 15
Rated voltage DC 24V
Switch
Single pole single throw
YN50S00040DD Type (alternate)
Conflux / single flow More than 1M /
Insulation resistance DC500V megger UP
switching (OPT)
YN11 - 45001 ~ Terminal connector
YQ11 - 06001 ~ Position
Connector

LC10 - 07001 ~
YC10 - 03501 ~

24-114
 24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 17
Rated voltage DC 24V
Switch
Single pole single throw
YN50S00040D9 Type (alternate)
Roof window wiper More than 1M /
Insulation resistance DC500V megger UP
switch (OPT)
YN11 - 45001 ~ Terminal connector
YQ11 - 06001 ~ Position
Connector

LC10 - 07001 ~
YC10 - 03501 ~

SW - 19
Switch
Rated voltage DC 12V
YT50S00004P1
Rated load 1A
Voltage drop 0.2V or less
Wiper inter lock
Insulation resistance 5M or more
YN11 - 45001 ~
Operation force Initial motion 0.8+0.3
0 kg
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~

Max. stroke
SW - 26
Rated voltage DC 24V
Switch
Single pole single throw
YN50S00040D4 Type (alternate)
Cab work light switch More than 1M /
Insulation resistance DC500V megger UP
YN11 - 45001 ~
YQ11 - 06001 ~ Terminal connector
LC10 - 07001 ~ Position
Connector

YC10 - 03501 ~

SW - 27
Purpose Coolant level detection
Switch
Working temperature -40 ~130
VHS834601510A
Coolant level switch Hino P/No. : 82580-71708
Sumitomo P/No. : 6188-0110
YN11 - 45001 ~
Electrode side
YQ11 - 06001 ~
LC10 - 07001 ~
YC10 - 03501 ~ CONNECTOR
Housing side
(To ground) Mating connector
M18, P=1.5 Hino P/No. : 82580-71808
Sumitomo P/No. : 6189-0189

24-115
24. COMPONENTS SYSTEM

File No.
Name of part
Part No. Specification Description
Use
Applicable Machine
SW - 28
Switch
VHS233002800A
Fuel filter
YN11 - 45001 ~
YQ11 - 06001 ~
LC10 - 07001 ~ Fuel outlet
Fuel inlet
YC10 - 03501 ~

Deposit container

Drain

Water proof connector

Yazaki 7383-7028-40

SW - 55
Switch
 
  

      
YN50S00040D1 


Boom work light switch  
 

 
 !"" %$
# 
YN11 - 45001 ~
YQ11 - 06001 ~
#
 
LC10 - 07001 ~ $


YC10 - 03501 ~

24-116
 25. AIR-CONDITIONER SYSTEM
TABLE OF CONTENTS

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

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

Book Code No. S5LC2511E02

25-1
25. AIR-CONDITIONER SYSTEM

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC2511E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)
S5LC2511E02
Revision February, 2007 ↑ K
(ASIA, OCE)

25-2
 25. AIR-CONDITIONER SYSTEM

25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER)

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

25.1.1 AIR CYCLE

• Heater
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is
performed with hot air (heating) at the heater core of air-con unit, and then the heated air blows off from grille
through duct.

• Cooler
Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is
performed with cold air (dehumidifying and cooling) at the evaporator of air-con unit, and then the cooled air
blows off from grille through duct.

• Heater system
The heater recycles (circulates) the cooling water in the engine, and the hot water delivered by the engine flows
in the heater core of air-con unit and then heat exchange is performed.
The intake air is heated and the heated air blows off from the grille provided on the inside of cab.
The blow off air temperature is controlled by the temperature control switch on the control panel, and the
operation is controlled by air mixing damper on the air-con unit.

25-3
25. AIR-CONDITIONER SYSTEM

25.1.2 AUTO AIR CONDITIONER SYSTEM OUTLINE

AIR CONDITIONER CONTROL PANEL

COMPRESSOR

SOLAR RADIATION SENSOR COMPRESSOR DRIVE SOURCE

REFRIGERANT
AIR MIXED DAMPER SIGNAL PRESSURE SWITCH

AIR-CON BLOWER REVOLUTION SIGNAL

AIR OUTLET SWITCHING SIGNAL CONTROLLER

INNER AIR SENSOR

EVAPORATION SENSOR
INNER AIR AND OUTER AIR
SWITCHING SIGNAL

OUTER AIR INTAKE

MOTOR
VENT ACTUATOR
INNER AIR
MOTOR
ACTUATOR

AIR CONDITIONER UNIT FACE

FOOT MOTOR BLOWER

ACTUATOR CONTROLLER

25-4
 25. AIR-CONDITIONER SYSTEM

25.2 COMPONENT AND CONSTRUCTION

25.2.1 COMPONENT

27

33 30
27-1

40

32

39

27-3 27-4

27-2
35

35-8 35-6

35-11
35-1

35-2 35-5

34 35-7

35-10 35-9

Fig. 25-1 Air-conditioner group

A/C ASSY LC20M00033F1 (07)

No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty

27 Air-conditioner assy 1 33 Pulley 1 35–7 L hose 1
27–1 Air-conditioner unit 1 34 Condenser 1 35–8 L hose : Ø 15.5 1
27–2 Hose 2 35 Air dryer assy 1 35–9 S tube : Ø 16 1
27–3 Clamp 2 35–1 Receiver dryer 1 35–10 L tube : Ø 8.5 1
27–4 Filter 1 35–2 Bracket 1 35–11 D tube : Ø 12 1
30 Panel assy 1 35–5 S hose : Ø 24.5 1 39 Filter 1
32 Compressor 1 35–6 D hose 1 40 Solar radiation sensor 1

25-5
25. AIR-CONDITIONER SYSTEM

25.2.2 CONSTRUCTION
(1) Air conditioner unit

49

47
48

46 44

31
42 31
41
50
3 1

45 1
A
1 32 43

39

37
38

36

40

B
2

33

Fig. 25-2 Air conditioner unit (1/2)

25-6
 25. AIR-CONDITIONER SYSTEM

14 16

6 1 1 31
1
5
15

1
31
62
1 3

1 1
D
E 4
7
28 1
A 1 1
27
1

20
26
13
C 60
11

29

23
21 22
24 82
24
83
51 54 79
9 63
78 23 C 84 61

17
E
18

31
D
B
10
19
12
1 25

3
31
77

Fig. 25-3 Air conditioner unit (2/2)

25-7
25. AIR-CONDITIONER SYSTEM

AIR-CON UNIT YN20M00107F2 (03)

No. Parts Q’ty No. Parts Q’ty No. Parts Q’ty

1 Screw M5×16 23 21 Expansion valve 1 44 MA mode lever 1
2 Main harness 1 22 O-ring 1 45 Foot lever 1
3 MA air mix 3 23 O-ring 2 46 Face lever cam 1
4 Blower controller 1 24 Screw M5×40 2 47 Vent lever cam 1
5 Upper casing 1 25 Thermistor 1 48 Face rod 1
6 Air mix door 1 26 Thermistor holder 1 49 Vent rod 1
7 Air mix lever 1 27 Heater core 1 50 Foot rod 1
8 Lower casing 1 28 Pipe holder 1 51 Plate 1
9 Air mix door sub 1 29 Thermistor 1 54 Screw 1
10 Air mix lever sub 1 31 Screw M4×30 9 60 Casing packing A 1
11 Blower 1 32 Upper casing 1 61 Casing packing B 1
12 Lever MA air mix 1 33 Lower casing 1 62 Casing packing C 1
13 Intake door 1 36 Foot door 1 63 O-ring 1
14 MA intake lever 1 37 Vent door 1 77 Packing 1
15 Intake lever 1 38 Face door 1 78 Tube 1
16 Intake rod 1 39 KK box upper packing 1 79 Tube 1
17 Air mix rod 1 40 KK-box lower packing 1 82 Tube 1
18 Air mix rod sub 1 41 Vent lever 1 83 Bracket 1
19 Relay 2 42 Face lever 1 84 Lower casing 1
20 Evaporator 1 43 Foot joint lever 1

(2) Receiver dryer

REFRIGERANT 2
INLET
REFRIGERANT
OUTLET

2-M6
1

No NAME Q'TY
1 PRESSURE SWITCH 1
3 2 SIGHT GLASS 1
4 3 DESICCANT 1
4 SUCTION PIPE 1
5 5 FILTER 1
6 RECEIVER TANK 1

Fig. 25-4 Receiver dryer

25-8
 25. AIR-CONDITIONER SYSTEM

25.3 PIPING
25.3.1 AIR CONDITIONER

35 6
7
JAM NUT FOR
TENSION PULLEY
T=46.1 (33)
50

33 3
10 13 6
17
54
14
25 21
1 22
INITIAL BELT TENSION 5 23
49 25
When the belt is pushed
by the force of 27N,
51
adjust the deflection N
of N part to be 5mm 4 15 25
9
10

11

6 12
52 25
3
32
25
57
6 58 50
52

E 30
D

40

27

C
B
A
25

1
12 E
25
16
2 25
25

39 25

25
8
34
8
56

1 59
2 25
24 24
53
8
5 24
8 5 18
8
6
2
6 6
20
8 55 11
C A B

Fig. 25-5

1. Apply oil for refrigerant R134a to the O-rings of all air-conditioner hose fittings.
2. Refrigerant volume : 900±50 g (2±0.1 lbs)
3. Tightening torque : T=N•m (lbf•ft)

25-9
25. AIR-CONDITIONER SYSTEM

Air conditioner LC20M00033F1 (07)

Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
1 Hose : L = 4150 1 24 Clip 3
2 Hose : L = 3050 1 25 Clip 13
3 Bracket 2 27 Air conditioner assy 1
4 V-belt 1 30 Panel 1
3.92~4.9 (2.9~3.6) 5 Clip 4 32 Compressor assy 1
46.1 (34.0) 6 Sems bolt : M10×25 7 33 Pulley assy 1
4.9 (3.6) 7 Sems bolt : M6×20 2 34 Condenser 1
10.7 (7.9) 8 Sems bolt : M8×20 5 35 Air dryer assy 1
23.5 (17.3) 9 Capscrew : M8×100 4 39 Filter 1
10 Washer 6 40 Solar radiation sensor 1
11 Tube for S hose : L = 2450 1 49 Connector 1
12 Tube for heater : L = 3300 1 23.5 (17.3) 50 Sems bolt : M8×25 4
13 Tube for L hose : L = 1800 1 51 Clip 1
14 Tube for D hose : L = 2100 1 52 Clip 2
15 Tube for L hose : L=180 1 53 Bracket 1
16 Tube for heater : L = 1800 1 23.5 (17.3) 54 Capscrew : M8×20 2
17 Bracket 1 55 Grommet 1
18 Hose : L = 130 1 56 Grommet 1
3.92~4.9 (2.9~3.6) 20 Clip 2 4.4 (3.2) 57 Capscrew : M6×50 4
21 Bracket 1 58 Washer 4
46.1 (34.0) 22 Capscrew : M10×50 3 59 Tube for L hose : L=100 1
23 Washer 3 46.1 (34.0) 60 Sems bolt : M10×20 2

UNIT CONNECTION TUBE ASSY COMPRESSOR CONNECTION BOLT

UNIT CONNECTION BOLT D TUBE (11)
D D HOSE (6)
27 AIR CONDITIONER ASSY S
S TUBE (9)

32 COMPRESSOR ASSY

RECEIVER CONNECTION BOLT

S HOSE (5)

L TUBE (10)

L HOSE (8) L HOSE (7) 34 CONDENSER

Note :
Numbers in ( ) shows the number in Fig. 25-6. 35 RECEIVER DRYER RECEIVER DRYER MOUNTING BRACKET

25-10
 25. AIR-CONDITIONER SYSTEM

25.3.2 AIR DRYER ASSY

A
5

8
A
C
5

6
6
B
4
5

3
10 3

2 11

8
9
1

6 5
7

B C
Fig. 25-6

Air dryer assy LC96V00019F1 (02)

Tightening Tightening
torque No. Parts Q’ty torque No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
1 Receiver dryer 1 7 L hose 1
2 Bracket 1 8 L hose 1
3 Capscrew : M8×25 2 9 S tube 1
4 Capscrew : M6×25 2 10 L tube 1
5 S hose 1 11 D tube 1
6 D hose 1

25-11
25. AIR-CONDITIONER SYSTEM

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

25-12
 25. AIR-CONDITIONER SYSTEM

(3) Characteristics of Refrigerant (Fig. 25-7) PRESSURE

In general, the fluid (general term of gas and liquid) MPa(psi)
R134a
has the following qualities: 4(580)

1) As a gas under certain pressure is cooled down,

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

25-13
25. AIR-CONDITIONER SYSTEM

25.4.2 COOLING CIRCUIT

Fig. 25-8 illustrates the cooling circuit of the car air-
conditioner.
In this circuit diagram, the portion that cools the air of INSIDE OF COMPARTMENT(CAB)
the compartment is the evaporator. The object air is
cooled off by utilizing the fact that the refrigerant takes
heat off the surrounding area as evaporation heat as it
evaporates in the cooling circuit. Since the part at which EVAPORATOR EXPANSION
VALVE
vaporization of the refrigerant takes place is the BLOWER
evaporator, cooled air is constantly delivered to the
circumference of the evaporator by the blower fan. In INSIDE OF ENGINE
the meantime, liquid refrigerant (slightly wet vaporized S D ROOM
refrigerant) is fed into the evaporator, when "cooling" COMPRESSOR COOLING FAN

effect is attained.
For instance, in order to cool the air to 15°C (59°F), the
refrigerant can not absorb evaporation heat from the air RECEIVER
DRYER
unless it evaporates at a temperature lower that 15°C
(59°F). For that purpose, it can be seen from Fig. 25-7 CONDENSER
that the pressure of the refrigerant in the evaporator
must be less than 0.51 MPa (74psi). Fig. 25-8 Construction of cooling circuit
Furthermore, the cooling effect deteriorates unless the
feed rate of the refrigerant is controlled so that all of the
refrigerant supplied to the evaporator vaporizes and
turns into dry vapor.
Consequently, the cooling circuit is so constructed that
the evaporator can cool down an object (air in this case)
sufficiently (i.e. so as to decrease the pressure in the
evaporator) and that an adequate amount of refrigerant
can be fed to the evaporator.
The feed rate of the refrigerant is controlled by the
expansion valve, but the pressure in the evaporator is
held low by the throttling action of the expansion valve
and the suction action of the compressor. The
compressor acts as a pump that allows the refrigerant
to circulate. The compressive action of the compressor
and the heat exchange (heat radiation) action of the
condenser transform the refrigerant in a dry vapor state
back to a liquid state.

25-14
 25. AIR-CONDITIONER SYSTEM

25.4.3 COMPONENT PARTS

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

25-15
25. AIR-CONDITIONER SYSTEM

Fig. 25-10 shows how the block type expansion

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

25-16
 25. AIR-CONDITIONER SYSTEM

(3) Compressor (See Fig. 25-12.)

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

Fig. 25-13 Condenser

25-17
25. AIR-CONDITIONER SYSTEM

(5) Receiver dryer ( See Fig. 25-14.)

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

25-18
 25. AIR-CONDITIONER SYSTEM

25.5 DISASSEMBLY AND ASSEMBLY

25.5.1 PRECAUTIONS TO BE EXERCISED IN OPERATION
(1) Special Refrigerator Oil
Unit : N.m (lbf.ft)
This air-conditioner uses special refrigerator oil
SP20 for use with new refrigerant R134a. Oils other PIPE FASTENING PART TIGHTENING TORQUE
than SP20 may not be used. Since SP20 tends to
D hose and compressor (M8 bolt) 19.6~24.5 (14~18)
absorb moisture and may corrode paint and resin,
the following points must be noted: D hose and condenser 19.6~24.5 (14~18)

1) Do not keep open all pipe connections on a new L hose and condenser 11.8~14.7 (8.7~11)
compressor and the component parts of the
L hose and receiver dryer (M6 bolt) 7.8~11.8 (5.8~8.7)
installed refrigeration circuit
(Remove valves and caps at the pipe openings L hose and air-conditioner unit 11.8~14.7 (8.7~11)
of the compressor, just before connecting pipes. S hose and air-conditioner unit 29.4~34.3 (22~25)
If you have removed a pipe joint for repair, put a
cap to both ports immediately.) Expansion valve 1.96~2.45 (1.4~1.8)

2) Use care so SP20 does not adhere to the

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

2) Screws and Bolts

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

25-19
25. AIR-CONDITIONER SYSTEM

25.5.2 DISASSEMBLY AND ASSEMBLY OF UNIT

(1) Removing inner air filter

 

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


  

Fig. 25-15
(2) Removing selector box
MODE ACTUATOR PLUS SCREW
Remove 6 plus screws, remove connector MAIN HARNESS
connected to the mode actuator on mode selector
box, and separate the mode selector box from the
unit.

CONNECTOR
(3) Removing main harness SELECTOR BOX
Pull out 3 harness clamps from the unit, and UNIT
disconnect all connected connectors and remove
harness on the body from the unit.
Fig. 25-16
(4) Removing upper unit case AIR MIX LEVER PLUS SCREW
1) Remove air MIX rod and air MIX rod sub from air
MIX lever.
2) Remove 12 plus screws which are used to install
the upper and lower unit casings.
Pull out the upper unit casing upward giving
attention to the thermistor harness so as not to
UPPER UNIT
be caught by the casing. CASING

AIR MIX
ROD SUB
AIR MIX
ROD SUB

LOWER UNIT CASING

Fig. 25-17

25-20
 25. AIR-CONDITIONER SYSTEM

(5) Replacing blower controller UPPER UNIT CASING

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

* Do not disassemble the blower controller.

PLUS SCREW BLOWER CONTROLLER

Fig. 25-18
(6) Removing heater core
PIPE CLAMP
1) After draining the coolant, remove heater hose HEATER CORE
PLUS SCREW
from the heater core.
2) Remove 1 plus screw, and remove pipe clamp EVAPORATOR ASSY
which is used to secure the heater core and then BLOWER MOTOR
remove the heater core from the lower unit
casing.
3) Install it by the reverse procedure of removal.

(7) Replacing blower motor

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

* Do not remove the fan from the blower motor.

LOWER UNIT CASING

2) Install it by the reverse procedure of removal.
Fig. 25-19
(8) Replacing evaporator and expansion valve
1) Take the evaporator with expansion valve off
EVAPORATOR
from the lower casing.
2) Remove evaporator sensor with sensor holder
from the removed evaporator. SENSOR HOLDER
3) Insert the sensor holder into the new evaporator 105mm
at the position shown in Fig. 25-20 and install the (4.1 inch)
evaporator sensor again.

11TH ROWS OF FIN

EVAPORATION SENSOR

Fig. 25-20

25-21
25. AIR-CONDITIONER SYSTEM

4) Remove 2 socket bolts M5×40 with Allen wrench

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

* When assembling again, fit O-ring paying

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

* Do not apply undue force to pipe of evaporator

outlet. This undue stress causes the leak of
refrigerant from "A" part of evaporator. EXPANSION VALVE
Moreover, when tube assembly (27-6) (see Fig.
25-1) connected with expansion valve is
SOCKET BOLT M5X40(2 PCS.)
disconnected from expansion valve, similar
careful work is necessary.
Fig. 25-21

(9) Replacing motor actuator

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

c) Remove 3 plus screws and remove the

motor actuator with MA lever air MIX from the
unit.
d) Remove the MA lever air MIX from the
removed motor actuator, and install it on new
motor actuator by the reverse procedure of
removal. PLUS SCREW 3PCS.
AIR MIX ACTUATOR

Fig. 25-23

25-22
 25. AIR-CONDITIONER SYSTEM

3) Replacing inner and outer air switching actuator

MA INTAKE LEVER

a) Disconnect connector connected to the

motor actuator. INTAKE ROD
PLUS SCREW
b) Remove intake rod from MA intake lever. (3PCS.)

c) Remove 3 plus screws and remove the

motor actuator with MA intake lever from the
CONNECTOR
unit.
d) Remove the MA intake lever from the
removed motor actuator, and install it on new
motor actuator by the reverse procedure of
removal.

INNER AND OUTER AIR SWITCHING ACTUATOR

Fig. 25-24

25-23
25. AIR-CONDITIONER SYSTEM

25.6 CHARGING REFRIGERANT

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

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

(2) Storage and Transportation

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

• Be careful about overcharge of gas.

• Fasten pipes to a specified torque.

25-24
 25. AIR-CONDITIONER SYSTEM

25.6.2 OPERATING PROCEDURE

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

Vacuum making operation Refrigerant filling operation

More than Leave it as it is,

30 min. for five minutes.
Begin vacuum Stop vacuum Check Fill in Check for Fill in
making making air-tightness refrigerant gas leak refrigerant
Lower than
-750mmHg Gauge indicates
abnormality
Charge refrigerant gas to a gauge
Check and correct joints pressure of 0.1MPa (14 psi)

(3) Tools

No. Parts Q’ty Sketch Service No. Parts Q’ty Sketch Service
Low pressure
4 Quick joint 1
Gauge side
1 1
manifold For service can
5 T joint 1
valve
Red :
high pressure side
Charging Blue : Service can
2 3 6 2 For service can
hose low pressure side valve
Yellow :
vacuum pump side

Vacuum
High pressure For vacuum
3 Quick joint 1 7 pump 1
side pump
adapter

25-25
25. AIR-CONDITIONER SYSTEM

25.6.3 CHARGING PROCEDURE

25.6.3.1 VACUUM MAKING OPERATION

(1) Connecting gauge manifold (See Fig. 25-25)
HIGH
1) Close the high pressure valve (HI) and the low LOW PRESSURE PRESSURE GAUGE
pressure valve (LO) of the gauge manifold. GAUGE GAUGE MANIFOLD
(CLOSED)LOW HIGH PRESSURE
2) Connect the charging hoses (red and blue) with PRESSURE VALVE VALVE(CLOSED)
the service valves of the compressor. RED
BLUE
Red hose :
High pressure side (HI) of the gauge HIGH
PRESSURE YELLOW
manifold→high pressure side (DIS) of SIDE
compressor DIS
LOW
Blue hose : PRESSURE
Low pressure side (LO) of gauge manifold→low SIDE
SUC
pressure side (SUC) of compressor
COMPRESSOR VACUUM PUMP(STOP)

Fig. 25-25
• Do not mistake the high pressure hose for the low
pressure hose in any circumstances when BLUE

connecting them. Put the hose in firmly till a clicking RED

sound is heard.

CHARGING
3) Connect the center valve of the gauge manifold
HOSE
with the charging hose of the vacuum pump. (GAS VALVE)

Fig. 25-26 Connecting gauge manifold

Some kinds of gauge manifolds are not equipped with

an open/close valve in the center.

25-26
 25. AIR-CONDITIONER SYSTEM

(2) Vacuum making (See Fig. 25-27)

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

If the gauge indication swings toward 0, there is

somewhere that is leaking. Retighten pipe joints, make
vacuum again and make sure of no leakage.

25-27
25. AIR-CONDITIONER SYSTEM

25.6.3.2 GAS CHARGING OPERATION

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

Fig. 25-28 Gas charging operation

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

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

25-28
 25. AIR-CONDITIONER SYSTEM

(3) Charging from low pressure side (See Fig. 25-30)

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

Fig. 25-30 Gas charging operation

(Low pressure side)
5) Open the low pressure valve of the gauge
SIGHT GLASS
manifold and the service can valve and fill in
refrigerant till air bubbles of the sight glass of the
receiver go away. (See Fig. 25-30)
[Total amount of gas to be charged :
900g±50g (2.0±0.11 lbs)]
6) When refrigerant charge is over, close the low
pressure valve of the gauge manifold and the
service can valve.
RECEIVER DRYER

• Do not open the high pressure valve of the

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

25-29
25. AIR-CONDITIONER SYSTEM

(4) Criterion for checking the amount of refrigerant

filled in

JUDGMENT OF REFRIGERANT LEVEL THROUGH THE SIGHT GLASS OF RECEIVER DRYER

After A/C is turned on, only a little

PROPER LEVEL bubbles are seen and thereafter light
milky white is seen.

After A/C is turned on,

OVERCHARGE no air bubbles are seen.

After A/C is turned on, continuous

UNDERCHARGE
air bubbles are seen.

• If the air-conditioner is run with poor refrigerant

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

(5) Removing Gauge Manifold

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

25-30
 25. AIR-CONDITIONER SYSTEM

This page is blank for editing convenience.

25-31
25. AIR-CONDITIONER SYSTEM

25.7 ELECTRIC CIRCUIT

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

MAKER : YAZAKI CORP.

MAKER : YAZAKI CORP. HOUSING No. : 7122-6060
HOUSING No. : 7123-6060-40 REAR HOLDER : 7157-6260-30
TERMINAL : 7116-2871 TERMINAL : 7114-2871

NIPPON AMP KK
170889-1
170003-5
PRESSURE SWITCH
(RECEIVER DRYER)

MAKER : SUMITOMO
HOUSING No. : 6189-0094
MAKER : YAZAKI CORP. HARNESS SEAL : 7160-8234
7120-8019 TERMINAL : 1500-0110
CP3.96MA
FUSE 20A LIGHT SWITCH
POWER SUPPLY FOR
NIGHT LIGHTING

MAKER : YAZAKI CORP. MAKER : YAZAKI CORP. A/C MAIN POWER

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

FUSE 5A

MAKER : YAZAKI CORP. MAKER : YAZAKI CORP.

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

MAKER : YAZAKI CORP.

JAE IL-AG5-7S-S3C1 HOUSING No. : 7123-2228
TERMINAL : AG5-C1-5000 TERMINAL : 17111

COMPRESSOR

NIPPON AMP KK 174056-2 JAE IL-AG5-7S-S3C1

TERMINAL : 175062-1 TERMINAL : AG5-C1-5000

JAE IL-AG5-7S-S3C1
TERMINAL : AG5-C1-5000 MAKER : YAZAKI CORP.
HOUSING No. : 7123-2249
TERMINAL : 17111

NOTE) 1. THe double chain lines indicate the wiring

on the excavator side. MACHINE SIDE WIRING (PARTS)
2. The connector colors indicate the cord colors seen
from the connecting part.
P W B R Y G L Br Lg O
LIGHT
PINK WHITE BLACK RED YELLOW GREEN BLUE BROWN GREEN ORANGE

Fig. 25-32 Electric diagram (1/2)

25-32
 25. AIR-CONDITIONER SYSTEM

CCU (OPERATION PANEL + CONTROLLER)

EVA SENSOR

AIR INLET SENSOR

SUN SENSOR

MOTOR ACTUATER
(FOR AIR MIX)

MOTOR ACTUATER
BLOWER OFF RELAY (FOR MODE)

BLOWER MOTOR

BLOWER AMP

MOTOR ACTUATER
(REC/FRESH)
COMPRESSOR RELAY

AIR CONDITIONER SIDE

WIRING (PARTS) IN THE CAB

Fig. 25-33 Electric diagram (2/2)

25-33
25. AIR-CONDITIONER SYSTEM

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

(2) Blower controller (TKS-B215A1)

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

TERMINAL NO.
CONTINUITY
1 2 3
CONTINUED Lg L
TESTER NOT CONTINUED
CONTINUED(DIODE PARALLEL
AND FORWARD DIRECTION FLOW)

In normal operation
1. Disconnect the connector of blower amplifier.
2. Check continuity between terminals on the
blower amplifier side.
Fig. 25-35
* The installing position is provided on the left side
of air-con unit.

25-34
 25. AIR-CONDITIONER SYSTEM

(3) Relay
Four-electrode relay is used for the blower OFF
relay and compressor relay.
1) Blower OFF relay
The blower OFF relay turns on after receiving the
signal from the control amplifier.
When the blower OFF relay turns on, the source
voltage is supplied to the blower motor and the
blower motor starts running.
2) Compressor relay
The relay ON—OFF is tripped by the control
amplifier and electronic thermostat control. Fig. 25-36
3) Relay inspecting items
1. Relay (24-4PE)
2. Coil resistance: 320
3. Specified voltage: DC20V~30V
4. Be careful about the coil side of relay because
this relay has polarity.
5. Inspection: Inspect the continuity between 3
and 4 according to the conditions mentioned
below.
20~30V applied between terminals 1-2:
Continued
20~30V not applied between terminals 1-2: Not
continued
(4) Air mix actuator
Air mix actuator is installed at the center of air-con
unit, and opens and closes air mix damper through
the link.
The air mix actuator contains potentiometer which
is switched by being coupled to the shaft of
actuator.

When the target air mix door position is determined CONTROL AMPLIFIER MOTOR ACTUATOR

through the temperature control switch, the control LIMITER

COOL
unit reads the level of potentiometer of the actuator, POTENTIO 5V

and determines the rotating direction of motor in

POTENTIO
POTENTIO GND

either normal rotation or reverse rotation. Then as

the motor rotates, the contact point is moved, and HOT

when the contact point is detached or the output

signal of control unit turns OFF, the motor stops
rotating. Fig. 25-37

25-35
25. AIR-CONDITIONER SYSTEM

(5) The actuator for inner and outer

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

The actuator for inner and outer air flow select

contains position detection switch which is
switched with the movement of shaft of the
actuator. AMPLIFIER MOTOR ACTUATOR

When the inner and outer damper position is set by

the inner and outer switch on the control panel, the
control unit reads the signal of the position
detection switch in the actuator and determines the INNER AIR SIDE

rotation direction of motor in either normal rotation OUTER AIR SIDE

or reverse rotation. Then as the motor rotates, the LIMITER

position detection switch also rotates and makes it

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

0.02MPa(2.9psi) 0.59MPa(86psi)

ON

OFF
0.20MPa(29psi) 3.14MPa(455psi)
(LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)

(8) Solar radiation sensor

This solar radiation sensor, which is used to correct
the solar radiation to the auto air conditioner
detects the strength and solar orientation of
sunbeam after transforming them into current by
means of photo diode.
Inspection : Check for the continuity between
Fig. 25-41
terminals.

25-36
 25. AIR-CONDITIONER SYSTEM

25.8 TROUBLESHOOTING

Air temperature does not fall. Note : M/A is motor

actuator
* is any of the
numbers 0 ~ 9.
If AUTO switch or A/C switch is pushed,
"HL.E" is indicated on the set temp. display of the panel.
NO YES

"HL.*" is shown on the set temp.
display of the panel.
NO YES
A snow mark ( ) on
the panel is flashing.
. Connector for air mix M/A is
disconnected or in poor contact.
. Air mix M/A is failed.
. Main harness shows poor continuity.
A snow mark ( )
on panel is flashing. Inspect and correct or replace parts.
NO YES

. Inner air sensor or harness is disconnected or shorted. . Both inner air sensor and
. Inner air sensor connector is disconnected or in poor contact. evaporation sensor are
disconnected or shorted.
See section monitor mode. . Controller failed.

See section monitor mode.

Inspect and correct or replace parts.

A
NO YES

Blowout temp. falls if temp. is set . Evaporation sensor connector

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

Air mix damper is Cool air flowing

in COOLMAX. into inner air sensor Inspect and correct or replace parts.

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

NO YES

. Inspect, correct or replace M/A failed or controller

M/A lever link. is out of order.
. After cleaning lever link,
apply grease.
Replace.

25-37
25. AIR-CONDITIONER SYSTEM

Air temperature does not rise. Note : * is any of

the numbers 0 ~ 9.

HL.E is shown on the set temp. display of the panel.

NO YES

"HL. " is shown on the set temp.

* . Connector for air mix M/A is
display of the panel. disconnected or in poor contact.
. Air mix M/A is failed.
NO YES . Main harness shows poor continuity.
. Inner air sensor or harness is disconnected or shorted.
. Inner air sensor connector is disconnected or in poor contact. Inspect and correct or replace parts.
See section monitor mode.
NO YES
Inspect and correct or replace parts.

NO YES
Blowout temp. rises at blowout
mode if temp. is set at
HOT MAX 32.0 (64.4 )
NO YES

Air mix damper is Warm air is flowing into

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

NO YES
Inspect and replace.

. Inspect, correct or M/A failed or controller

replace M/A lever link. is out of order.
. Clean lever link and apply grease.
Replace.

25-38
 25. AIR-CONDITIONER SYSTEM

Blower motor does not run.

At air flow HI, battery voltage acts across

Note 1) both terminals (+) and (-) of blower motor.

NO YES

Battery voltage acts across red Blower motor fails.

(+) and body of blower motor.
NO YES Replace.

Inspect blower motor relay. Blower motor Approx. 10V acts across light green wire
Note 2) rotates if white / red wire and red wire of and grounding of blower amplifier.
blower motor relay are direct connected.
NO YES
NO YES

Controller is out of order. Remove blower amplifier and check for

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

Battery voltage acts across white /

red wire and body of blower motor relay. Eliminate cause Inspect and
and replace repair harness.
NO YES blower amplifier.

Inspect and repair Blower turns if orange wire of blower motor relay
harness or replace. is connected with ground.
NO YES

Replace relay. Inspect and correct harness

or replace controller.

Note 1) Measure with connector set.

Note 2) Always turn off air-conditioner, starter key switch and light switch before work.

25-39
25. AIR-CONDITIONER SYSTEM

Blower motor speed does not change.

CASE (1)
Note) is any of the
"HL. " is shown on the set temp. display of the panel.
* *
numbers 0 ~ 9.
NO YES

Replace blower . Inner air sensor or harness is disconnected or shorted.

amplifier controller. . Inner air sensor connector is disconnected or in poor contact.
See section monitor mode.

Inspect and correct or replace parts.

CASE (2)

Does not blower motor speed

change because the setting mode
is other face mode?
YES NO

Is door or front window open? See CASE (1).

YES NO

The limiting or control operation See CASE (1).

is actuated by door switch or
front window switch.

25-40
 25. AIR-CONDITIONER SYSTEM

Magnet clutch does not engage.

Snow mark ( ) lights

if A/C switch is pressed.
No Yes

Snow mark ( ) flickers and E is Voltage acts upon clutch.

shown on panel display.
No Yes

To A On page 25-37. Voltage is applied to Clutch faulty.

pressure switch harness.
No Yes

Voltage acts across white / green wire and Pressure switch is faulty or refrigerant
Ground (Black) connector connected to excavator. gas is under charged or overcharged.

No Yes
Refer to troubleshooting
for refrigeration cycle.
Inspect clutch Inspect air-conditioner
fuses. harness. No fault.
No Yes

Replace harness. Replace controller.

Inner air and outer air do not change over.

Inner / outer air mode display on

operation panel is flickering.
No Yes

M/A lever includes foreign matter Connector of inner/outer air

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

M/A failed Remove foreign matter

and replace parts. Inspect or replace.

Replace

25-41
25. AIR-CONDITIONER SYSTEM

Modes do not change.

Mode display (Mark of person)

on operating panel is flickering.
No Yes

M/A rod does not disengage. Mode M/A connector is

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

Repair. When rod is removed and cam is operated

by hand, it is heavy. (more than 19.6N.)
No Yes

M/A or controller is out of order. . Cam or damper shaft includes

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

. Remove foreign matter or replace parts.

. Clean cam and apply new grease.

25-42
 25. AIR-CONDITIONER SYSTEM

Trouble with refrigeration cycle.

Both high and low pressures are lower.

Low pressure is higher.

NO YES
Air bubbles are seen in sight glass.
Air bubbles are seen in High pressure
sight glass. is lower.
NO YES

Cooling does not work Oil comes out from

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

High pressure
is lower.

Air bubbles are seen in sight glass.

NO YES

High pressure gets Condenser is

lower slowly. fouled or clogged.

High pressure YES NO

circuit before
receiver is Air bubbles are hard to
clogged up. go out even if water
is poured on condenser.

Remove Clean
clogging or condenser. Air is mixed.
replace parts. Make vacuum and
refill refrigerant.

25-43
25. AIR-CONDITIONER SYSTEM

25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL

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

25.9.1 POSITION OF INDICATION FOR FAILURE.

The error is indicated on 3 digits segment.

25.9.2 EXPLANATION OF INDICATION FOR FAILURE.

(1) Failure of Motor Actuator
1) HL.E is indicated on 3 digits segment.

Check harness or connector to motor actuator

for the air mix damper for disconnection.

2) MODE is flickering.

Check harness or connector to motor actuator

for the air outlet damper for disconnection.

3) R/F is flickering.

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

25-44
 25. AIR-CONDITIONER SYSTEM

(2) Failures of sensors

1) HL.* is indicated on 3 digits segment.

Check the inner air sensor or the harness for disconnection

and short circuit, and also connectors for disconnection.

(* is any of the numbers 0 to 9.)

2) **E and mark are flickering.

(** is displayed leaving the present set temperature value.)

Check evaporator sensor or the harness for disconnection

and short circuit, and also connectors for disconnection.

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

(3) Communication error of control amplifier and panel

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

 

 

          
  
   
    

25-45
25. AIR-CONDITIONER SYSTEM

25.9.3 EXPLANATION OF MONITOR MODE

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


  
   
 


(2) Operation of monitor mode

SPEED UP AND DOWN

INNER OR OUTER
SWITCH FOR BLOWER
AIR INLET SELECT
SWITCH (R/F)

ON/OFF SW

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

SEGMENT ASSIGNMENT LIST

0 INNER AIR SENSOR

1 EVAPORATOR SENSOR

2 SOLAR RADIATION SENSOR

(Excluding above mentioned indications, for example "from 3 to 9 and from B to F" are not used at service work.)

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

Notes)
1. The air conditioner is turned off while the monitor mode is in operation, and all switches are not available for
operation and setting until the monitor mode is cancelled.
2. Even if each sensor is corrected while the monitor mode is in operation, the error display is memorized.
Therefore turn on ON/OFF switch again, and the error display is disappeared.

25-46
 25. AIR-CONDITIONER SYSTEM

(3) Contents of monitor mode display

Refer to the list of segment display exclusively used for monitor and the list of segments in three digits.
1) Example 1

When the segment exclusively used for monitor indicates 0

(displays the inner air sensor condition),
since the segment indicates 3F, the sensor is in normal
operating condition according to the list of 3 segments.
--> The inner air sensor is in normal operating condition.

2) Example 2

When the segment exclusively used for monitor indicates 1

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

3) Example 3

When the segment exclusively used for monitor indicates 2

(displays the solar radiation sensor condition), since the
segment indicates FF,the sensor is in short-circuiting condition
according to the list of 3 segments.
-->The solar radiation sensor is in short-circuiting condition.

4) List of 3 segments

SECOND SEGMENT

INNER AIR SENSOR DISCONNECTION

EVAPORATOR SENSOR DISCONNECTION
SOLAR RADIATION SHORT-CIRCUITING
THIRD SEGMENT

EACH SENSOR IS NORMAL

SOLAR SENSOR 5V SIDE SHORT-CIRCUITING

INNER AIR SENSOR SHORT-CIRCUITING

EVAPORATOR SENSOR SHORT-CIRCUITING

25-47
25. AIR-CONDITIONER SYSTEM

[MEMO]

25-48
31. DISASSEMBLING AND ASSEMBLING
TABLE OF CONTENTS

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

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

31

Book Code No. S5YN3118E01

31-1
31. DISASSEMBLING AND ASSEMBLING

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5YN3118E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)
SK200–8 : YN11-45001~
↑ August, 2006 ↑ K
SK210LC–8 : YQ11-06001~
SK250-8: LQ12-06001~
↑ October, 2006 ↑ K
SK260LC–8 : LL12-05001~
↑ December, 2006 SK850LC: LY01-00101~ ↑ K
E235BSR : YF05-02001~ ↑
↑ February, 2007 K
E235BSR(N)LC : YU05-02001~ (NHK)

31-2
 31. DISASSEMBLING AND ASSEMBLING

31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY

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

31.1.2 INDICATION OF TIGHTENING TORQUE

Tightening torque is indicated as follows, for example ;
T=98N•m(72 lbf•ft)
Tolerance is ±10% unless otherwise specified.
• Refer to "Chapter 11 TOOLS" for standard tightening torque.

31-3
31. DISASSEMBLING AND ASSEMBLING

[MEMO]

31-4
 32. ATTACHMENT
TABLE OF CONTENTS

32.1 REMOVING AND INSTALLING.......................................................................................32-3

32.1.1 ATTACHMENT ASSY.............................................................................................32-3
32.1.2 BUCKET .................................................................................................................32-3
32.1.3 ARM........................................................................................................................32-6
32.1.4 BOOM.....................................................................................................................32-9
32.2 DISASSEMBLING AND ASSEMBLING...........................................................................32-15
32.2.1 CYLINDER..............................................................................................................32-15

32

Book Code No. S5LC3211E01

32-1
32. ATTACHMENT

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC3211E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)

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

32-2
 32. ATTACHMENT

32.1 REMOVING AND INSTALLING

32.1.1 ATTACHMENT ASSY

(D) ARM CYLINDER HEAD PIN

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

(E) ARM CYLINDER

BOOM
ROD PIN CYLINDER
2. BUCKET

3. ARM
(G) BUCKET
CYLINDER HEAD PIN
(J) BUCKET DRIVE PIN
BUCKET CYLINDER (I) IDLER LINK PIN BUCKET LINK
IDLER LINK (H) BOOM CYLINDER
(H) BUCKET CYLINDER ROD PIN (K) BUCKET ATTACHING PIN HEAD PIN

Fig. 32-1 Front attachment and position

32.1.2 BUCKET

32.1.2.1 REMOVING BUCKET

(1) Put the machine in position to remove bucket.

Fig. 32-2 Position to remove bucket

(2) Removing capscrew (1)
1
Loosen the double nut (2) and pull out the capscrew
(1).

O-RING
2

1
SECTION A-A
Fig. 32-3 Removing capscrew (1)

32-3
32. ATTACHMENT

(3) Removing bucket attaching pin (K)

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

Fig. 32-4 Removing bucket attaching pin

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

Fig. 32-5 Removing bucket drive pin

32.1.2.2 ATTACHING BUCKET

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

• When aligning the pin holes, do not put your

finger in the pin holes, but align them visually.
• Check the seals for damaged and replace as
necessary.
• When inserting the pin, coat the shaft with
grease.

Fig. 32-6 Attaching bucket

32-4
 32. ATTACHMENT

32.1.2.3 PROCEDURE FOR ADJUSTING CLEARANCE

Adjustment of clearance between bucket and arm +1.0 +0.039"
381 -0.5 (15" -0.020" )
(1) Shift O-ring (3) toward the bucket boss, using a New bucket
spatula. (a→b) 11 : WASHER
8 : LOCK B
WASHER 3 : O-RING
7 : CAPSCREW b
(2) When adjusting clearance (B), bring the non- a
adjusting side of the bucket in contact with the arm.

(3) Measure clearance (B) and check that it is within

1.0mm (0.04in).
12 :
BUSHING
(4) Adjust clearance (B) where it is more than 1.0mm
(0.04in). 13 : PLATE

(5) An average of 5 shims (10) of 1mm (0.04in) 10 : SHIM 9 : PIN

Install pin (9) until the top of pin
thickness are set in the plate (13) fixed by the three is even surface with bushing.
capscrews (7). The clearance can be decreased by
Fig. 32-7 Adjusting clearance between
1mm (0.04in) if one shim is removed.
bucket and arm
: 30mm,
Tightening torque : 314N•m (232 lbf•ft)

(6) After adjustment, tighten the capscrews evenly.

• The gap exceeding the specified dimension
causes early wear.

(7) Operate the bucket and confirm that the total sum
of both clearance is within 1.0mm (0.04in).

(8) Replace O-ring (3) on its original position.

• When shifting O-ring (3) by means of a spatula, use

care so as not to damage O-ring (3).
• Remove shims (10), push out bushing (12)
rightwards by means of three capscrews (7) and
adjust clearance (B) so it settles within the standard
value evenly all round.

32-5
32. ATTACHMENT

32.1.3 ARM

32.1.3.1 REMOVING ARM

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

Fig. 32-8 Position to remove arm

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

Plug both end of disconnected pipes.

Plug : Tools section 11.5.2-(4)
Tools section 11.5.2-(5)
OIL PAN
When the removal of bucket cylinder is not
required, skip to procedure (6). Fig. 32-9 Disconnecting piping of bucket cylinder

(3) Removing bucket cylinder rod pin (H)

After adjustment of shim, the total gap
1) Loosen nut (10), remove capscrew M20×160 (9), should be within 0.6~1.0mm (0.02~0.04in).
and push out pin (H). SHIM

9,10
H
: 30mm

2) Retract cylinder rod.

SECTION D-D
Fig. 32-10 Detail of bucket cylinder rod pin (H)

(4) Removing cylinder head pin (G)

3
Loosen nut (3), remove capscrew M20×165 (2), 2
and push out pin (G).

: 30mm
SHIM
After adjustment of shim,
the total gap should be
within 0.6~2.0mm
(0.02~0.08in).

G
SECTION A-A

Fig. 32-11 Detail of bucket cylinder head pin (G)

32-6
 32. ATTACHMENT

(5) Removing bucket cylinder

Sling tube of bucket cylinder with nylon sling, and
remove it.
Bucket cylinder weight : 260 kg (573 lbs)

Fig. 32-12 Slinging bucket cylinder

(6) Removing arm cylinder rod pin (E)
Install plastic shims Apply grease to inner wall
Put a wooden block between the arm cylinder and of bushing 2,3
to cylinder side.
the boom.
Loosen nut (3), remove capscrew M20×180 (2),
and push out arm cylinder rod pin (E).
E
: 30mm

Retract arm cylinder rod, and return pin (E) to the

original position (hole).
SHIM
After adjustment of shim, the total gap
BLOCK should be within 0.6~2.0mm (0.02~0.08in).
B
SECTION B-B

Fig. 32-13 Detail of arm cylinder rod pin (E)

B

A
A

(7) Removing boom top pin (F) Install plastic shims

Loosen capscrew M16×35 (2), plate (1), and pull to arm side.
Apply grease to inner wall
out boom top pin (F). of bushing

: 24 mm

Insert pin (F) into the original hole. F

1,2
Apply Loctite #242

After adjustment of shim,

the total gap should be within
0.5mm (0.02in).
SECTION A-A

Fig. 32-14 Detail of boom top pin (F)

32-7
32. ATTACHMENT

(8) Slinging arm assy

Sling arm with nylon sling and remove it.

Arm weight : 1,275 kg (2,811 lbs)

Fig. 32-15 Slinging arm assy

32.1.3.2 ATTACHING ARM

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

CLEARANCE

: 30 mm

5) When installing the arm and the cylinder, inspect

the clearance in the thrust direction of the pins
and decide the thickness of shims by referring to
the Maintenance Standard.
6) When attaching the shims, attach resin shim first
and then fill gap with iron shim.
7) Tightening torque

Tightening torque
Classfication Size
N.m lbf.ft
M16 147 108
Metric threads M16 279 206
(BOOM TOP)
M20 181 133
1/8" 16.7 12.3
PF,PT threads
1/4" 36.3 26.8

32-8
 32. ATTACHMENT

32.1.4 BOOM

32.1.4.1 PREPARATION FOR REMOVING AND ATTACHING BOOM

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

32.1.4.2 REMOVING BOOM

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

BLOCK

Fig. 32-16 Position to remove boom

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

STAND

Fig. 32-17 Lifting up boom cylinder temporarily

(3) Press the boom cylinder rod pin (C) Install plastic shims
At the one side of pin (C), loosen nut (5), remove to cylinder side.
capscrew (4) (M20×190), and remove collar (3). After adjustment of shim,
And push pin (C) to the end of boom boss. the total gap should be within
0.6~2.0mm (0.02~0.08in).

4,5
: 30 mm
4,5
(4) Preparing for disconnecting cylinder pipes C
Retract the above mentioned cylinder rod, and 3
place one side of cylinder on stand. (See Fig. 32- 3
17) SHIM
SHIM
Apply grease to inner wall
of bushing

SECTION A-A
Fig. 32-18 Detail of boom cylinder rod pin (C)

32-9
32. ATTACHMENT

(5) Disconnecting the arm cylinder and bucket cylinder

pipings
Release pressure from arm and bucket circuit and
bleed air in hydraulic tank, and then disconnect
pipe at (A1), (A2), (A3), (A4) and hose (5), (6), (8),
(10).
A1

: 41 mm

: 12 mm A2

A3

Plug both end of disconnected pipes. A4

6
Plug : Tools section 11.5.2-(4) 5
Tools section 11.5.2-(5) 8 10

Fig. 32-19 Boom piping disconnection

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

Weight of single boom : 2,670 kg (5,890 lbs)

Boom assy temporary lift up procedure

32-10
 32. ATTACHMENT

(7) Removing boom foot pin (A) Install plastic shims to boom side.
1) Remove capscrew (3) M20×60, and plate (2).

After adjustment of shim,

the total gap should be within
: 30 mm 0.5mm (0.02in).

2) Draw out pin (A). A

3
Apply loctite
2 #242 to bolt.

Apply grease to inner wall 2

of bushing
SECTION A-A
Fig. 32-20 Details of boom foot pin (A) section
(8) Hoisting boom assy
Hoist and remove boom assy.

Weight of single boom : 2,670 kg (5,890 lbs)

D
D

Boom assy hoisting procedure

32-11
32. ATTACHMENT

(9) Completion of removal of front attachments

When the removing and attaching of cylinder are
not required, the work is finished.

(10)Removing and installing arm cylinder

1) Disconnect hose (F1) and (F2) at position A. F2
G1
After disconnection of hose, plug both ends of
hose.

Install plastic F1 A
shim to After adjustment of
cylinder side. shim, the total gap
should be within
Plug : Tools section 11.5.2-(4) Plugs for ORS fitting 0.6~1.0mm 2,3
(0.02~0.04in).
Tools section 11.5.2-(5) Plugs for half clamp SHIM Apply
grease
to inner
:41 mm wall of
bushing
:12 mm
D
2) Removing arm cylinder head pin (D) SECTION D-D
Loosen nut (3), remove capscrew M20×180 (2) Fig. 32-21 Removing arm cylinder
and pull out pin (D).

: 30mm

3) Removing arm cylinder

Weight of arm cylinder : 504 kg (1,110 lbs)
(11)Removing and installing boom cylinder
1) Disconnect hose (C2) at the position B and plug
both end.

D1
Plug both end of disconnected pipes. C1

Plug : Tools section 11.5.2-(4)

Tools section 11.5.2-(5)
E1

C2
: 41mm B
E2 C2

Fig. 32-22 Removing and installing boom cylinder

32-12
 32. ATTACHMENT

2) Removing boom cylinder foot pin (B) Apply grease to inner wall
(See Fig. 32-23,Fig. 32-24) of bushing
Loosen nut (5), remove capscrews M20×190 (4) 4,5 B
and pull out pin (B).
B Install plastic
4,5 shim to
cylinder side.
: 30mm

After adjustment of shim,

3) Remove boom cylinder (2). the total gap should be within
Weight of boom cylinder : 269 kg (590 lbs) 0.6~1.0mm (0.02~0.04in).
SECTION B-B
4) Remove another boom cylinder the same way.
Fig. 32-23 Removing and installing boom cylinder
head pin (B)

32.1.4.3 ATTACHING BOOM

(1) Attaching boom foot pin (A)
First of all, insert boom foot pin (A) and install the
boom assy.
Attach it in the reverse procedure of removing, A
paying attention to the following points.
1) When aligning the pin holes, do not put your
finger in the pin holes, but align them visually.
2) Check that the dust seals is not damaged and
replace as necessary.
3) When inserting the pin, coat the shaft with
grease. Fig. 32-24 Boom foot pin (A)
4) Pin lock nut handling procedure
(0.02")

CLEARANCE

5) When installing the arm and the cylinder, inspect

the clearance in the thrust direction of the pins
and decide the thickness of shims by referring to
the Maintenance Standard.
6) When attaching the shims, attach resin shim first
and then fill gap with iron shim.
7) Tightening torque

Tightening torque
Classfication Size
N.m lbf.ft
Metric threads M20 181 133
1/8" 16.7 12.3
PF,PT threads 1/4" 36.3 26.8
3/8" 73.5 54.2

32-13
32. ATTACHMENT

This page is blank for editing convenience.

32-14
 32. ATTACHMENT

32.2 DISASSEMBLING AND ASSEMBLING

32.2.1 CYLINDER

32.2.1.1 PREPARATION BEFORE DISASSEMBLY

Before assembly, secure a dustfree workshop and necessary equipment and facilities.

32.2.1.1.1 WORK AREA

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

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

32-15
32. ATTACHMENT

32.2.1.1.3 NECESSARY TOOLS

Tools and jigs vary with types of cylinder, but it is necessary to prepare the tools in Table32-1 as a guideline.
Table32-1 List of Tools and Jigs
Tool / Jig Remarks Tool / Jig Remarks
Hammer 1. Steel hammer Spatula Metallic one with smooth corners.
2. Wooden or plastic mallet
Screwdriver A few types of large and small sizes Gimlet A sharp-point tool may be used in place of a
gimlet.
Chisel Flat chisel Special jig 1. For removing and press-fitting bushing.
(A), (D), (C)
2. For press-fitting wiper ring. (D)
3. For inserting and reforming seal ring.
(E),(F),(G),(H)
See para 32.2.1.9 for detail)
Vise One having an operation wide enough to Rust
hold cylinder head O.D. and tube remover
mounting pins (clevis)
Wrench 1. Eye wrench Measuring 1. Slide caliper
2. Allen wrench instruments 2. Micrometer
3. Extension pipe for wrenches
3. Cylinder gauge ( Fig. 32-25)
4. V-block

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

32.2.1.1.4 EXTERNAL CLEANING

The cylinder taken off the excavator has dust and
foreign matter, and grease is usually adhered to the
clevis part. For this reason, remove external soil and
contamination from the cylinder with water and steam Fig. 32-25 Cylinder gauge
before bringing it into the workshop.
• The following describes the construction of boom
cylinder. When disassembling and servicing the
cylinder, confirm the construction of cylinder
referring to Parts Manual.

32.2.1.1.5 DISCHARGING OIL

Place a wooden-block on the work bench and place the
WOODEN BLOCK
cylinder on it to prevent it from rotating. Charge air into
ports A and B alternately to actuate the piston rod till the
PORT B
hydraulic oil in the cylinder is drained out. At this time, V BLOCK
connect a suitable hose to each port so that the
hydraulic oil may not gush out. PORT A

AIR

OIL PAN
Fig. 32-26 Preparation

32-16
 32. ATTACHMENT

32.2.1.2 CONSTRUCTION OF CYLINDER (GENERAL EXAMPLE OF CYLINDER)

25 24 12 24 25

PS1/8
PT1/4
SLIT 15

ONE HOLE
DETAIL 6 DETAIL B
DETAIL C
Piston with piston nut type

9 8 7 6 4 5 3 11 10 2 1 13 14 15 17 16 18 19 *20 *21 22 23

SLIT
C

Fig. 32-27 Construction of general cylinder

No. Parts name Q’ty No. Parts name Q’ty No. Parts name Q’ty
1 Cylinder tube 1 10 O-ring 1 19 Slide ring 2
2 Piston rod 1 11 Back-up ring 1 20 Shim *1
3 Rod cover 1 12 Socket bolt 12 21 Piston nut *1
4 Bushing 1 13 Cushion bearing 1 22 Setscrew ; M12 1
5 Snap ring 1 14 Cushion seal 1 23 Steel ball 1
6 Buffer ring 1 15 Piston 1 24 Pin bushing 2
7 U-ring 1 16 Seal ring 1 25 Wiper ring 4
8 Back-up ring 1 17 Back-up ring 2
9 Wiper ring 1 18 Slide ring 2
Note : In case of piston with piston nut type, the parts with * are not used.

32-17
32. ATTACHMENT

32.2.1.3 DISASSEMBLY
• When disassembling and servicing the cylinder,
check the construction and the availability of
service parts as well as necessary tools and jigs
on separate Parts Manual.
• The figures in parentheses after part names
correspond to those in Fig. 32-27.
• The following explanation and quantities are for
a general use cylinder which has separated
piston and piston nut.
In case that piston and piston nut are combined,
the construction differs from separated type,
refer to the sentence in parenthesis.

32.2.1.3.1 REMOVING ROD COVER AND PISTON ROD

(1) Hold the clevis section of the tube in a vise.

Use mouth pieces so as not to damage the machined

surface of the cylinder tube. Do not make use of the
outside piping as a locking means.

(2) Pull out piston rod (2) about 200mm (8in). Because
the piston rod is heavy, finish extending it with air
200mm
pressure after the above-mentioned oil draining (8")
operation.
(3) Loosen and remove socket bolts (12) of the rod
cover in sequence.

Fig. 32-28
Cover the extended piston rod (2) with cloths to prevent
it from being accidentally damaged during operation. ALLEN WRENCH 12

(4) Strike the corner of the rod cover flange by means

of a plastic mallet till rod cover (3) comes off.

Turn counterclockwise

3
Cover here with cloths
2
Fig. 32-29

32-18
 32. ATTACHMENT

• At this time, the weight of piston rod (2) is loaded KNOCK THIS EDGE
on rod cover (3). Therefore, lift the top end of the WITH A PLASTIC MALLET.
LIFT HERE.
piston rod with a hoist to the extent that only the
rod weight may be held.

3
2
Fig. 32-30 Drawing out piston rod assy (2).
(5) Draw out the piston rod assy from cylinder tube (1). LIFT HERE. 1

PULL STRAIGHT
SIDEWAYS
Since the piston rod assy is heavy in this case, lift the HORIZONTALLY
tip of the piston rod (2) with a hoist and draw it out.
However, when piston rod (2) has been drawing out to
approximately two thirds of its length, lift it in its center OIL PAN
to draw it completely. However, since the plated surface
Fig. 32-31 Method of drawing out
of piston rod (2) is lifted, do not use a wire rope which
the piston rod assy
may score the surface, but use a strong cloth belt or a
rope.

(6) Place the removed piston rod on a horaizontal

wooden V-block.
PISTON ROD ASSY

• Cover a V-block with cloths.

WOODEN V-BLOCK
(PLACE CLOTHS)
Fig. 32-32 Method of placing the piston rod
(7) Remove slide ring (18) and (19) from piston (15). 15
Remove slide ring by
widening the slit toward
the arrow

19

18

Fig. 32-33 Remove slide ring (18) and (19)

32-19
32. ATTACHMENT

32.2.1.3.2 REMOVING PISTON ASSY

(1) Fix piston rod (2) by holding its clevis section in a 3 WOODEN BLOCK
vise. Fix the piston rod (2) securely as piston nut 2
(21) is tightened to a high torque. 15
21

• Note that the tightening torque differs with the type,

the working pressure and the mounting method of
the piston (15), though the rod diameter remains
the same.
• It is also necessary to place a suitable supporting
block near the piston (15). In case a V-block is
WOODEN V-BLOCK
used, put cloths or something over the rod to (PLACE CLOTHS)
prevent it from damage.
Fig. 32-34 How to loosen piston nut (21)
(2) Scrape off the caulked part of setscrew (22) of
piston nut (21) by means of a hand drill and loosen
22 DRILL
setscrew (22) and remove ball (23).

:6 mm
21
23
Fig. 32-35 Removing setscrew (22) and ball (23)
(3) Loosen and remove piston nut (21) or [piston (15)].

TURN COUNTER
• Since piston nut (21) is tightened to a high torque,
CLOCKWISE.
use a eye wrench suitable for the outside diameter 15
of piston nut (21). EYE WRENCH
21
• In case that piston and piston nut are combined,
Fig. 32-36 How to loosen piston nut (21)
apply the eye wrench to hexagonal part of piston
and loosen the piston directly.

(4) Remove piston (15) by tapping with plastic mallet,

supporting weight of piston (15) with hoist.

In case that piston and piston nut are combined, the

shim (20) is not used.
4 15

Fig. 32-37 Removing piston (15)

32-20
 32. ATTACHMENT

(5) After removing cushion bearing (13) and cushion

LIFT WITH A HOIST. STRIKE WITH
seal (14), separate rod cover (3) from piston rod (2).
A PLASTIC MALLET.
If it is too hard to slide it, knock the flanged part of
PULL STRAIGHT.
rod cover (3) with a plastic mallet. But when
drawing it out, lift rod cover (3) by hoist and pull it
NOTE:
straight horizontally. DO NOT
DAMAGE
PISTON ROD
SURFACE.

Take care so rod bushing (4) and the lip of packings

(6,7,8,9) may not be damaged by thread of the piston
3 4 6 8,7 9 2
rod (2).
Fig. 32-38 Removing rod cover (3)

32.2.1.3.3 DISASSEMBLING PISTON ASSY

(1) Remove seal ring (16) and back-up ring (17).
HAMMER

Cut the seal ring (16) by tapping it with a screwdriver or SCREWDRIVER (OR CHISEL)
a chisel. Take care not to strike it too hard, otherwise
the groove may be damaged. BACK-UP RING SEAL
17 RING
16

USE CARE NOT

15 TO DAMAGE O-RING
THE GROOVE.
Fig. 32-39 Removing seal ring (16) and
back-up ring (17)

32-21
32. ATTACHMENT

32.2.1.3.4 DISASSEMBLING ROD COVER ASSY

(1) Remove O-ring (10) and back-up ring (11).
SPATULA
Remove back-up ring (11) and O-ring (10) in that
order. Remove back-up ring (11) and O-ring (10) by 10
pulling and stretching them with an spatula like
earpick. 11

Fig. 32-40 Removing the outer circumferential seal

of rod cover (3)
(2) Remove buffer ring (6), U-ring (7) and back-up ring GIMLET
(8). Each seal is fixed in the groove on the bore and
removing in flawless is impossible.
8
Stab each seal with a gimlet and pull it out of the
groove.
3 7
6

Take care in this operation not to damage the grooves.

Fig. 32-41 Removing the inner circumferential seal

of rod cover (3)
(3) Remove wiper ring (9). When taking out wiper ring

 
(9), fix rod cover (3) in a vise. 

 
  

 

Fig. 32-42 Removing wiper ring (9)

(4) Remove snap ring (5) and bushing (4).
Remove snap ring (5) first, and remove bushing (4). CHUCK ASSY TOOL A PRESS HERE
But the bushing (4) is press fitted in rod cover (3),
so push it out by press with jig as shown in the
figure.
See para 32.2.1.9.3 (1) for removing. BUSHING 4

BLOCK TOOL C

Fig. 32-43 Removing rod bushing (4)

32-22
 32. ATTACHMENT

32.2.1.3.5 REMOVING PIN BUSHING

(1) Apply driver to wiper ring (25) of cylinder tube (1) PUSH WITH A PRESS.
and piston rod (2), and strike it by hammer lightly. JIG J
(2) Push out pin bushing (24) press fitted in cylinder
tube (1) and piston rod (2) with press.

24 BASE
Fig. 32-44 Drawing out pin bushing (24)

32.2.1.4 CLEANING
(1) After disassembly the cylinder, wash all parts with
commercial detergent.

Never use benzene(gasoline, thinner, etc.) because it

may be damage the rubber, etc.

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

32.2.1.5 ASSEMBLING PIN BUSHING

Start assembling the following sub assy
• Cylinder tube assy
• Piston assy
• Rod cover assy

32.2.1.5.1 ASSEMBLING PIN BUSHING

(1) Press fit pin bushing (24) in cylinder tube (1) and PUSH WITH A PRESS
piston rod (2) respectively with press. 2
(2) Press fit wiper ring (25) in the upper and lower sides
24
of cylinder tube (1) and piston rod (2) respectively
with press.

• Before press fitting, apply grease on wiper ring and

boss hole. OIL HOLE LOCATION
• Before press fitting the pin bushing, align the Fig. 32-45 Press fitting of pin bushing (24)
position of oil hole.

32-23
32. ATTACHMENT

32.2.1.5.2 ASSEMBLING OF PISTON ASSY

(1) The fitting of seal ring (16) requires special tool as  
 
shown in Fig. 32-46. Seal ring (16) is pushed in by
  
press, etc. with pushing in tool as shown in the
figure. (The O-ring of seal ring (16) and back-up
   
ring (17) on one side should be installed
beforehand.)

 
Heat them, and they may be soften. But never heat
them over 100°C (212.0°F) or more.

(2) Fit back-up ring (17) on the other side. After fitting,
correct it immediately to prevent from expansion of Fig. 32-46 How to fit seal ring (16)
seal ring (16) with correcting jig (H) as shown in Fig.
 
32-47. 



 
• For piston, stop it once tentatively (for 3 to 5
seconds), and then push it in fully.
• After fitting, wind tape around seal ring (16) 2 or 3
times, and remove it immediately before piston (15)
is inserted in cylinder tube (1).
• Fit slide rings (18) (19) at the same time when
piston (15) is inserted in cylinder tube (1).
Fig. 32-47 Installing seal ring (16)

32.2.1.5.3 ASSEMBLING ROD COVER ASSY

(1) Press fit bushing (4) in rod cover (3) with bushing PRESS HERE. (STRAIGHT DOWN)
press-fitting jig (A). Then, fit snap ring (5) in the PRESS FITTING JIG (A)
groove. Apply hydraulic oil on internal surface of
4
rod cover (3).
GROOVE FOR
FIXING SNAP RING (5)

Press bushing till bushing

The snap ring (5) can not be fitted when the bushing (4) comes in contact with
3 this face.
is not press-fitted fully to the stop end.

(2) Apply grease to wiper ring (9), and fit wiper ring (9), PRESS HERE. (STRAIGHT DOWN)
directing the lip side toward the groove of retainer
tool (D). And set retainer tool (D) on rod cover (3) RETAINER TOOL (D)
and press fit wiper ring (9) with press.

U-RING GROOVE

Fig. 32-48 Press fitting of bushing (4)

32-24
 32. ATTACHMENT

(3) Fit buffer ring (6), back-up ring (8) and U-ring (7) in INSERT U-RING INTO GROOVE FROM THIS SIDE.
their grooves in that order. Before setting packings,
coat them with hydraulic oil (or vaseline if not
available). If you forget the coating, the packings
may be scored. When attaching seals, deform them
in a heart shape as illustrated.

• U-ring (7) is harder than other packing and it would

be difficult to deform them in a heart shape. In such
a case, put a U-ring in the groove obliquely by hand Fig. 32-49 Inserting a seal into the inner
as deep as possible and push in the last part with a circumference of rod cover.
push bar till it is set with a click.
PUSH BAR (WOOD OR PLASTIC)
• Buffer ring (6) should be fitted taking care of the 10
fitting direction. The reverse fitting may cause
11
deformation, damage, etc. of the piston due to high Tube side
pressure generated between the buffer ring and U- 3
ring.
• If U-ring (7) is set upside down, the lip may be
damaged. Check that it is positioned correctly.
• Attach back-up ring (11) on the open air side of O-
ring (10). (See Fig. 32-50).

7
8
9
Fig. 32-50 How to fit U-ring (7)

32.2.1.5.4 INSERTING ROD COVER ASSY TO PISTON ROD

Inserting rod cover (3) to piston rod assy by the

following procedure.
  
  

(1) Fix piston rod assy on working bench. 

(2) Install rod cover (3) on piston rod (2) with inserting
guide jig (I) as shown in Fig. 32-51 paying attention

for the lip section of U-ring not to be caught on the
stepped section.
Fig. 32-51 Inserting rod cover (3)

• For the rod the outer diameter of piston installing

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

32-25
32. ATTACHMENT

32.2.1.5.5 ASSEMBLING PISTON ASSY ONTO PISTON ROD

(1) Install cushion on the extraction side, cushion PISTON
bearing (13) and cushion seal (14) by the following 13
procedure. 14
1) Put cushion seal (14) on it, directing the slit
machined side toward the piston side.
2) Fit cushion bearing (13) on it directing the
flattening side as shown in Fig. 32-52.

FLAT SECTION
Direct slit toward
piston side
Fig. 32-52 Cushion mechanism on extension side
(2) When cushion is installed on the retraction side, fit

 
 

cushion bearing (13) and cushion seal (14) by the   

following procedure.   
1) Fit cushion bearing before fitting piston nut. The
nut attached obstructs the fitting of cushion  
bearing.
2) Put cushion seal on it, directing the slit machined
side toward the piston side.
3) Fit cushion bearing on it directing the flattening
 
side as shown in Fig. 32-53.    

    
!

" #  
"
4) Put stopper in the groove. Push cushion bearing
to stopper fully, and drive snap ring. Use plastic Fig. 32-53 Cushion mechanism on retraction side
mallet in order not to damage the rod, cushion
bearing.

Cushion seal and cushion bearing should be fitted

taking care of the fitting direction. If they are fitted in
reverse directions, the cushion does not effective.
After installing cushion, be sure that the cushion
bearing moves up and down, and right and left.

32-26
 32. ATTACHMENT

(3) Insert shim (20), and tighten piston nut (21) or 21

[piston (15)] till it gets tight.
Always tighten the piston nut (21) or [piston (15)] of
each piston to specified torque
(Refer to 32.2.1.7.3). EYE WRENCH

• In case that piston and piston nut are combined, the

Fig. 32-54 Tightening piston nut (21)
shim (20) is not used. Apply the eye wrench to
hexagonal part of piston and loosen the piston ANTI-LOOSENING
22 CAULKING 20
directly. 2
23
• Always correct the threads in piston nut (21) or
[piston (15)] before fixing piston nut, using a
tapping.
• Insufficient tightening torque causes an inner leak
and a damage of thread. And over tightening torque
causes a bulge of cushion bearing and a V-BLOCK
deformation of piston contacted surface. 21
• Clean and decrease (with solvent) the parts of Fig. 32-55 Attaching setscrew (22)
piston assembly, and dry it, then tighten this piston
22 18 19
assembly. 2
(4) Put steel ball (23) into hole and tighten setscrew
(22).

: 6mm
After tightening the setscrew to a specified torque,
caulk the two places of the thread of the piston nut 21 V-BLOCK
side to secure the setscrew.
Fig. 32-56 Attaching slide ring (18), (19)
See para 32.2.1.7.3 for torque.
(5) Attach two slide rings (18) and (19). Take off vinyl
tape wound around the perimeter of piston (15),
apply high-quality grease (or vaseline) to slide ring
(18), (19) and attach the slide rings in a manner that
they may be coiled around the groove. Set the slide
rings about 180 degrees apart with each other so
that the slits may not point to the same direction.

32-27
32. ATTACHMENT

32.2.1.5.6 OVERALL ASSEMBLY

(1) Place a V-block on a work bench (A wooden V-
1
block is preferable.). Place the cylinder tube assy
(1) on it and fix the assy by passing a wooden bar LIFT
through the clevis pin hole to lock the assy.
(2) Insert the piston rod assy into the cylinder tube
assy, while lifting and moving the piston rod assy
with a hoist. In this operation, apply hydraulic oil (or STRAIGHT
PREVENT TURNING
vaseline) to the inner surface of the tube mouth and WITH WOODEN BAR.
the circumference of the piston. Align the center of
the piston rod assy with the center of the cylinder
tube assy and put it in straight forward. When Fig. 32-57 Inserting piston rod assy
inserting, make sure that slide rings (18), (19) on
the perimeter of the piston is not out of the groove.
(3) Tighten socket bolt (12). Match the bolt holes of the 12
rod cover flange to the threaded holes in the
cylinder assy, and screw in socket bolts (12) one by PLACE CLOTH
one. Tighten the bolts to a specified torque, taking
care so the bolts may not be tightened unevenly.
See para. 32.2.1.7.3 for torque.

: 14 mm
ALLEN WRENCH
TURN CLOCKWISE
Fig. 32-58 Tightening socket bolts (12)

Take care so as not to damage the rod surface by

accidentally slip a wrench. Covering the rod surface
with cloth is recommended to prevent damage to it.

32-28
 32. ATTACHMENT

32.2.1.6 INSPECTION AFTER ASSEMBLY

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

• Do not raise the hydraulic pressure above the H R

maximum pressure of 37.8MPa (5480psi) for the
cylinder of the machine.
• Grease coated on the O-rings and the seals of the
HYDRAULIC CYLINDER
rod cover may come out. Wipe it off and retest the
Fig. 32-59 External leak test
cylinder in such a case.

(2) Leak test MEASURE THE

1) Apply a test pressure to the retracting and INTERNAL LEAK.
extending sides of the cylinder for three minutes
independently, and check that the rod section
and the welds have external leaks and
permanent deformation. For an internal leak test,
connect the cylinder with a test unit as shown in
Fig. 32-60. FROM DIRECTIONAL VALVE
Fig. 32-60 Internal leak test
2) After completing the test, apply a plug to each


port and store the cylinder. (Fig. 32-61)

• For storage, place the cylinder on wooden V-

blocks and bring the cylinder to the most  
retracted condition. Fig. 32-61 How to store the cylinder

32-29
32. ATTACHMENT

32.2.1.7 MAINTENANCE STANDARDS

32.2.1.7.1 INSPECTION AFTER DISASSEMBLY

Visually inspect all parts after cleaning to see that excessive wear, crack and other damage that are detrimental to
use are not present.
(1) Inspection Item
Part Name Inspecting Section
1. Neck of rod pin
2. Weld on rod hub
3. Stepped part to which
piston is attached
4. Threads
5. Bend
Piston rod 6. Plated surface
7. Rod
8. Bushing at mounting part
1. Weld on bottom
2. Weld on head
Cylindertube 3. Weld on hub
4. Tube interior
5. Bushing at mounting part
1. Bushing
Rod cover
Table32-2
Inspection Item Remedy
Presence of crack Replace.
Presence of crack Replace.
Presence of crack Replace.
Presence of seizure Recondition or replace
Measure degree of bend (See
Refer to (Table32-3)
Fig. 32-62)
Check that:
1) Plating is not worn off to 1) Replace or replate
base metal
2) Rust is not present on plating. 2) Replace or replate
3) Recondition, replate or
3) Scratches are not present.
replace.
Wear of O. D. Recondition, replate or replace.
Wear of I. D. Replace.
Presence of crack Replace.
Presence of crack Replace.
Presence of crack Replace.
Presence of damage Replace if oil leak is seen.
Wear on inner surface Replace.
1) Wear on inner surface 1) See para. 32.2.1.7.2
2) Replace if score is deeper than
2) Flaw on inner surface
coating.

(2) Repair method

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

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

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

32-30
 32. ATTACHMENT

32.2.1.7.2 LIMIT OF SERVICEABILITY

Serviceability limits represent the limits of wear on the
sliding surfaces of the cylinder tube and the rod that
have no such damage as may degrade the sealing
effect.
(1) Clearance between piston rod and rod bushing
Replace the bushing if the clearance between the
piston rod and the rod bushing exceeds 0.25mm
(0.01in).
(2) Bend of piston rod
The allowable bend of the rod is maximum 1mm /
1m (0.04"/3’3"). For measurement, support both
ends of the parallel section of the piston rod with V-
blocks, set a dial indicator in the center between the
two V-block turn the piston rod, and read the
difference between the maximum and minimum Fig. 32-62 Measuring Method
deflection on the dial indicator.
Table32-3 shows an example of measurement.

Table32-3 Example of Measurement

Distance between Deflection of the dial indicator
V-blocks in the middle of the rod. Remedy
m (ft-in) mm (in)

1 (3’3") 1 (0.04") Replace

Even if the bend is within the above limit, the cylinder

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

32.2.1.7.3 TIGHTENING TORQUE

B A C Unit : N.m (lbf.ft)

A B C
Cylinder Piston nut
or [Piston] Socket bolt Setscrew
Boom 8000 (5900) 367 (270) 56.9 (42)
Arm 17000 (12540) 711 (520) 96.6 (71)
Bucket 10000 (7380) 520 (380) 56.9 (42)

32.2.1.7.4 VOLUME OF OIL LEAK

The oil leak rates as mentioned in 1.6 (2) of Inspection after Assembly are as shown in INSPECTION AFTER
ASSEMBLY32.2.1.6 (2).

Cylinder Volume of Internal Oil Leak

Boom 1.0cc (0.06 cu•in) or below / 3min
Arm 1.0cc (0.06 cu•in) or below / 3min
Bucket 1.0cc (0.06 cu•in) or below / 3min

32-31
32. ATTACHMENT

32.2.1.8 TROUBLESHOOTING
Table32-4
Trouble Failed Parts Cause
1. Oil leak through sliding 1. Back-up ring 1. Foreign matter is trapped in the
surface of piston rod. Oil bore of back-up ring
ring is formed on piston 2. Lips on outer and inner diameter
rod, and the ring grows up surfaces of back-up ring are
to oil drops, and they drip. scored.
3. Other back-up ring are failed.
2. U-ring 1. Foreign matter is trapped in the
OIL LEAKS FROM HERE bore of ring.
2. Score is present on the bore of ring. 2. Replace U-ring.
3. Other rings are failed.
3. Buffer ring 1. Foreign matter is trapped in the
bore of ring.
2. Score is present on the bore of ring. 2. Replace buffer ring.
3. Other rings are failed.
4. Wiper ring 1. Foreign matter is trapped in the
bore of wiper ring.
2. Lip on the bore of wiper ring is
scored.
3. Another wiper ring is failed.
5. Piston rod 1. Score is present on the sliding
surface of piston rod.
2. Hard chromium plating has peeled 2. Replate.
off
2. Oil leaks from the 1. O-ring 1. O-ring is damaged.
circumference of rod cover. 2. Backup ring 1. Back-up ring is damaged.
3. Cylinder tube 1. Swelling of cylinder tube.
Remedy
1. Remove foreign matter.
2. Replace back-up ring.
3. Replace back-up ring
1.Remove foreign matter.
3. Replace U-ring.
1.Remove foreign matter.
3. Replace buffer ring.
1.Remove foreign matter.
2. Replace wiper ring.
3. Replace wiper ring.
1.Smooth out the sliding surface with
an oilstone. If leakage occurs even
if the sliding surface is finished
below 1.6S, rod packings may be
scored. Disassemble and inspect it
and replace rod packings as
required.
If leak will not stop by that
treatment, replace piston rod.
1. Replace O-ring.
1. Replace back-up ring.
1. Replace cylinder tube.

OIL LEAKS FROM HERE

3. Oil leaks from welds. 1. Cylinder tube 1. Welds of cylinder are broken. 1. Replace cylinder tube.

WELDS
4. Cylinder falls by it-self. 1. Piston seal
[When the rod is loaded with
a static load equal to the
maximum working pressure
multiplied by the area of the
2. Slide ring
cylinder bore, the maximum
movement of the piston is 3. Piston rod
more than 0.5mm (0.02") in
ten minutes.]
1. Foreign matter is trapped in the 1. Remove foreign matter
sliding surface of seal ring.
2. Score is present on the sliding
2. Replace seal ring..
surface of seal ring.
1. Sliding surface of slide rings is
1. Replace slide ring.
scored.
1. Elongation.Piston rod and piston 1. Replace piston rod.
are elongated. (Loose nut)

32-32
 32. ATTACHMENT

32.2.1.9 JIGS LIST

32.2.1.9.1 SPECIAL JIG LIST (POSSIBLE TO SUPPLY)

When assembling, the following jigs are required.
Table32-5
Described
Application Shape
paragraph
A D

For removing and press 32.2.1.3.4,

fitting bushing EDGE OF C 32.2.1.5.2
CHUCK

D
For press fitting wiper
32.2.1.5.2
ring

E H
F

For correcting seal ring 32.2.1.5.2

INSERTING JIG CORRECTING JIG

I
For inserting rod cover 32.2.1.5.4

For above jigs, contact our dealer.

(The Jig No. List provided by cylinder maker is shown in the following page.)

32-33
32. ATTACHMENT

Special Jig No. List

(1) For jigs for rod cover, select jig corresponding to respective rod diameter.
(2) For jigs for piston, select jig corresponding to the cylinder bore.
Table32-6
Application rod diameter [mm (in)] Kit No. of maker
65 (2.56") 3006J-56001
70 (2.76") 3007J-06001
75 (2.95") 3007J-56001
80 (3.15") 3008J-06001
85 (3.35") 3008J-56001
Jig for rod cover
90 (3.54") 3009J-06001
removing & installing
95 (3.74") 3009J-56001
100 (3.94") 3010J-06001
105 (4.13") 3010J-56001
110 (4.33") 3011J-06001
115 (4.53") 3011J-56001
120 (4.72") 3012J-06001
Application cylinder bore [mm (in)] Kit No. of maker
95 (3.74") 3009J-51001
100 (3.94") 3010J-01001
105 (4.13") 3010J-51001
110 (4.33") 3011J-01001
115 (4.53") 3011J-51001
Jig for seal ring 120 (4.72") 3012J-01001
inserting & 125 (4.92") 3012J-51001
correcting 130 (5.12") 3013J-01001
135 (5.32") 3013J-51001
140 (5.51") 3014J-01001
145 (5.71") 3014J-51001
150 (5.91") 3015J-01001
160 (6.30") 3016J-01001
170 (6.69") 3017J-01001

32-34
 32. ATTACHMENT

32.2.1.9.2 OTHER SPECIAL JIGS (PREPARED BY SERVICE SHOP)

(1) Bushing removing jig (Symbol J)

80 (3.15") MATERIAL : Mild steel

(0.59")(0.59")
50 15 15 Unit : mm (inch)

12-S
(1.97")
(0.08") d D Cylinder Used
(0.08") 5 (0.2")
C2 R2 R0.2 90 (3.54") 103 (4.06") Bucket
(0.008")
10 12-S
100 (3.94") 113 (4.45") Boom (Head Side)

-0.2 (-0.008")
-0.4 (-0.016")
-0.5 (-0.02")
-1 (-0.04")

25-S 110 (4.33") 123 (4.84") Arm, Boom (Rod Side)

-3 (-0.12")
-4 (-0.16")

Fig. 32-63 Bushing removing jig

(2) Wrench for piston nut or [piston]

Unit : mm (inch)
B Cylinder Used
115 (4.53") Boom, Bucket
135 (5.32") Arm

Fig. 32-64 Wrench for piston nut or [piston]

32-35
32. ATTACHMENT

32.2.1.9.3 SPECIAL JIG HANDLING PROCEDURE

(1) How to remove bushing from rod cover.
1) Attaching chuck assy tool
Insert tool in rod cover slowly until the edge top
end of chuck assy reaches to the end of bushing -,/-
(4).

• Special attention must be paid so that the

inner surface of rod cover is not damaged by
the edge of tool.
• Attach top on the position 5mm (0.2 in) from
the bushing end face so that the edge does
not protrude from the end face.

)
4
5 (0.197")

(CHUCK)

2) Tightening chuck assy tool temporarily

a. Fit allen wrench to the head of adjuster bolt on


the top end of tool, and insert lever in the
round hole on the rear end of tool.
b. Fix it with allen wrench and lever to the
position where the tool does not drop even if
the rod cover is raised, inclining it forward and
rearward.

• Move rod cover onto the working bench

holding tool attached.
• Be careful not to drop it on foots, etc. 
 


32-36
 32. ATTACHMENT

3) Attaching tools for retainer

Put retainer on the press bench directing the
wiper ring fitting section of rod cover upward, D
then put retainer tool (D) on the rod cover.
FLANGE
• Fit retainer tool as shown in the right figure
directing large diameter section (flange
section) upward.
• Clean the surface of press bench, and take
care for the tool bottom face not to be
damaged by foreign matter like dust, chip, etc.

4) Cutting into of the edge of chuck PRESS HERE

Press the upper section of retainer tool gradually
so that the edge of chuck tool (A) cuts into the
bushing surface.
Set the pressing force to 2~3 tons (4410~6615
lbs).

After completion of pressing, tighten adjuster bolt

again by hand.

• Press it with retainer tool (D).

CHUCKING JIG A

32-37
32. ATTACHMENT

5) Setting of tools for block

Prepare block (C), and put rod cover (3) on it
aligning them.
Select corresponding block (C) in shape,
dimensions, etc. from the table shown below.

oD
15 (0.59") 15 (0.59")

od 10

10
Unit : mm (inch)
Class
(Nominal size) d D h
o55 (2.17) 62 (2.44) 88 (3.46) 80 (3.15)
o60 (2.36) 67 (2.64) 96 (3.78) 80 (3.15)
o65 (2.56) 72 (2.83) 96 (3.78) 80 (3.15)
o70 (2.76) 77 (3.03) 100 (3.94) 80 (3.15)
o75 (2.95) 82 (3.23) 110 (4.33) 80 (3.15)
o80 (3.15) 87 (3.43) 112 (4.41) 80 (3.15)
o85 (3.35) 92 (3.62) 124 (4.88) 90 (3.54)
o90 (3.54) 97 (3.82) 135 (5.31) 90 (3.54)
o95 (3.74) 102 (4.02) 145 (5.71) 90 (3.54)
C
o100 (3.94) 107 (4.21) 145 (5.71) 90 (3.54)
o105 (4.13) 112 (4.41) 150 (5.91) 90 (3.54)
o110 (4.33) 117 (4.61) 165 (6.50) 90 (3.54)
o115 (4.53) 122 (4.80) 170 (6.69) 90 (3.54)
o130 (5.12) 137 (5.39) 190 (7.48) 90 (3.54)

6) Removing of bushing
a. Move block (C) and rod cover (3) with tool
under the press.
b. Press the upper part of retainer tool (D) slowly
until bushing (4) is take out from rod cover (3)
D
(until there is a sound that the chuck tool (A)
drops on the work bench)
• The force of 3 tons (6615 lbs or less) is
necessary to press it out.
The stroke of press ram is about 32~52mm
(1.26in~2.04in). (But it varies according to the
difference of dimension of cylinder head.)

• Press it with retainer tool (D).

When the block and rod cover assy are not

aligned, interrupt the work and align the block
and rod cover assy.

32-38
 32. ATTACHMENT

7) Removing of rod cover

a. Remove block (C) with rod cover (3) near side,
remove retainer tool (D) from rod cover (3),
and then move rod cover (3) to other place.
b. Take out the chuck tool (A) with bushing from
block (C).

4
Do not work under the press because it is very
dangerous.
A

8) Removing of bushing
a. Place chuck tool (A) with bushing (4)
sideways, and loosen adjuster bolt with allen
wrench and lever.
b. Place the chuck tool (A) vertically and turn the
adjuster by hand until the wedge is raised
about 5mm (0.2 in).
c. Remove the wedge from the edge of chuck.



• Clean the surface of work bench, and be

careful for the tool not to be damaged by 4
foreign matters like dust, chips, etc.

32-39
32. ATTACHMENT

9) Tightening of adjuster bolt

Tighten the chuck tool (A) the bushing (4) is
removed to the extent that there is no gap
  
between the chuck and the wedge upper face,
turning the adjuster bolt by hand.



• This special tool differs according to the
corresponding piston rod diameter.
• The chuck edge is an important portion. Take
care of handling and storage.

 

32-40
 32. ATTACHMENT

(2) Rod cover bushing press-fitting procedure

4
1) Temporary setting of head bushing
Put rod cover (3) on the press-working bench
directing the tube connection upward.

Set bushing (4) on the inner surface of rod cover

(3) temporarily.

• Make sure that the inner and outer surfaces of

bushing (4) are free from foreign matter.

2) Setting chuck assy tool (A)

Insert the chuck assy tool (A) in temporary-set
bushing (4) directing the flange downward, and
set it on rod cover (3).
A

• Be sure that the adjuster bolt is tightened to

the extent that there is no gap between
adjuster of chuck assy (A) and wedge.






32-41
32. ATTACHMENT

3) Attaching retainer tool

Put retainer tool (D) on the wedge stepped
section of chuck assy tool (A) slowly directing the
flange upward.

• Align chuck assy (A) and the wedge.

STEP OF WEDGE

4) Preparation for press-fitting PRESS RAM

Move the rod cover on which chuck tool (A) and
retainer tools are attached under the press.

• Adjust it so that the press ram is centered to

the tool. RETAINER(D)

CHUCK(A)

BUSHING(4)

BUSHING PRESS-
FITTING PART

32-42
 32. ATTACHMENT

5) Press-fitting of bushing
Push the head of retainer (D) with press, and
press fit bushing (4) to the specified position of
rod cover (3) slowly.

• The pressing force should be held 5 tons STEP OF WEDGE

(11025 lbs) or less, keeping the required force
for the press-fitting.
• Raise the pressure gradually adjusting the
force by means of pressure adjusting valve of
press unit.
• Be sure that the end face of bushing is located
on the interior of the groove for snap ring.
When it is located on near place, press fit and
adjust the location again.

LIFTING THREAD

RETAINER JIG (D)

ADJUSTER BOLT

WEDGE

CHUCK TOOL ASSY (A)

CHUCK

BLOCK TOOL (C)

Bushing removing and press fitting jig (For reference only)

32-43
32. ATTACHMENT

[MEMO]

32-44
 33. UPPER STRUCTURE
TABLE OF CONTENTS

33.1 REMOVING AND INSTALLING.......................................................................................33-3

33.1.1 OPERATOR SEAT .................................................................................................33-3
33.1.2 CAB ........................................................................................................................33-4
33.1.3 BATTERY ...............................................................................................................33-6
33.1.4 GUARD...................................................................................................................33-8
33.1.5 UNDER COVER .....................................................................................................33-14
33.1.6 FUEL TANK ............................................................................................................33-15
33.1.7 HYDRAULIC TANK ................................................................................................33-17
33.1.8 HYDRAULIC PUMP................................................................................................33-21
33.1.9 AIR CLEANER........................................................................................................33-26
33.1.10 MUFFLER...............................................................................................................33-27
33.1.11 COUNTERWEIGHT................................................................................................33-29
33.1.12 RADIATOR & OIL COOLER...................................................................................33-30
33.1.13 ENGINE ..................................................................................................................33-36
33.1.14 CONSOLE COVER ................................................................................................33-39
33
33.1.15 MULTI CONTROL VALVE (Only for Oceania) .......................................................33-40
33.1.16 CONTROL VALVE..................................................................................................33-41
33.1.17 PILOT VALVE (FOR ATT) ......................................................................................33-44
33.1.18 PILOT VALVE (FOR TRAVEL)...............................................................................33-45
33.1.19 SWING MOTOR UNIT............................................................................................33-47
33.1.20 SWIVEL JOINT.......................................................................................................33-49
33.1.21 UPPER FRAME......................................................................................................33-52
33.2 DISASSEMBLING AND ASSEMBLING...........................................................................33-54
33.2.1 HYDRAULIC PUMP • REGULATOR ......................................................................33-54
33.2.2 CONTROL VALVE..................................................................................................33-80
33.2.3 PILOT VALVE (ATT)...............................................................................................33-111
33.2.4 PILOT VALVE (FOR TRAVEL)...............................................................................33-121
33.2.5 SWING MOTOR UNIT............................................................................................33-130
33.2.6 SWIVEL JOINT.......................................................................................................33-157

Book Code No. S5LC3311E02

33-1
33. UPPER STRUCTURE

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC3311E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)
S5LC3311E02
Revision February, 2007 ↑ K
(ASIA, OCE)

PREFACE
(1) This Manual describes all the procedures from removing to installing, arranging them by item.
(2) This Manual consists [Removing and installing], and [Disassembling and assembling].
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
(4) The removing and installing procedure does not completely cover all possible situations because of differences
of field condition and defective section.
(5) Recognize well that the service man must decide a work procedure before proceeding to repair. When deciding
the work procedure, choose an item that is needed, familiarize yourself with the contents of the work and itemize
the work procedure, before starting work.
(6) Disconnect the negative terminal of battery first, when the removing and the installing of the electric component
and wiring are performed.
(7) The explanatory note and figure of this manual may differ from the actual machine by the difference in
specification.

33-2
 33. UPPER STRUCTURE

33.1 REMOVING AND INSTALLING

33.1.1 OPERATOR SEAT

33.1.1.1 REMOVAL
(1) Preparation for removal
1) Remove the head rest (A1-1) of the operator’s
A1-1
seat (A1) to ease handling.
2) Move the whole control stand to its foremost A1
position.
3) Move the operator’s seat to its forward end. C1
4) Incline the reclining seat as forward as possible.
C2
(2) Remove operator’s seat. (Include upper rail.) B2
C1
1) With the above-mentioned condition, remove C2
two cap screws (B2) M8×20 from the upper rail.
Then move the control stand to its rearmost end
and remove two capscrews (B2) M8×20.
1
: 6 mm
8
2) Remove the operator’s seat. [about 20kg (44
lbs).]
Carry out the following operations as required.
3) Remove seat belt (C1).
4) Remove armrest (A3)(A4).
5) Remove bracket assy (1), rail (8).

Fig. 33-1 Disassembling and Assembling seat

33.1.1.2 INSTALLATION
Install it in reverse procedure of removing according to
the tightening torque table.
A4


   A5


 


 
 

A2

  # & $%

   $% '#($ &' A6


  !"# $& )(# %($
A1

Reference : Movement on rail

A3
Upper rail …… Fixed on lower surface of seat
[Forward 80mm (0.26in), backward 80mm (0.26in)]
A5
Lower rail …… Fixed on seat stand.
[Forward 60mm (0.19in), backward 60mm (0.19in)]
Amount of adjustment of seat height
[Up; 23mm (0.07in), down; 37mm (0.16in)] Fig. 33-2 Disassembling and Assembling armrest

33-3
33. UPPER STRUCTURE

33.1.2 CAB

33.1.2.1 REMOVAL
(1) Remove floor mat.
A7
(2) Remove cover (A7)
Lift cover (A7) upwards and remove it. (Fixed with
2 clips)
(3) Remove cover assy (A1)
1) Loosen 4 sems bolts (A22) M6×16 and lift cover
assy (A1) up.
2) Disconnect each connector for both speakers.
Then remove cover assy (A1). A22
(4) Remove the harness connector (See Chapter 23) A1
1) Disconnect connectors of cab harness (CN-
515), (CN-518), (CN-71), (CN-72) and (CN-500)
at rear right of cab.
2) Disconnect antenna cable coming from backside
of tuner at rear left of cab. Fig. 33-3 Disassembly and assembly of cover (7)
(5) Remove the plastic tube for the window washer and cover assy (A1)
from the rear left of cab.
(6) Remove the right panel of cab
1) Remove 2 caps (A29) loosen 2 sems bolts (A40)
M6×25 and 1 sems bolt (A39) M6×16. And right A3
A14
panels (A4) and (A4-2) are freed.
: TORX driver T30
2) Lift cover (A3) upwards and remove it. (Fixed
A22
with 3 clows and 2 clips)
B2
3) Unfix 3 harness clips (A4-8) of inside on right A40
A4-8
panel (A4-2). And free the harnesses connected A29
A4
to key switch.
A4-8 A39
4) With harnesses are connected condition, install A40
key switch cover (A3) to bracket (A1) of rear cab A4-8
temporally. (See Fig. 33-5)
5) Disconnect harness connectors of work light A29 A4-2
switch on right panel (A4), air conditioner panel
and cigarette lighter, and remove right panel (A4) A22
and (A4-2). (See Chapter 23)
6) Loosen sems bolts (A22) M6×16 and (A23)
M6×40 one each, and remove front panel (A5-2)
with air conditioner duct.
: Plus driver
A5-2

A23
Fig. 33-4 Disassembly and assembly of right panels
(A4-2), (A3) and (A5-2)

33-4
 33. UPPER STRUCTURE

RELAY BOX
ASSY

Fig. 33-5 Move switch cover assy

(7) Remove cab attaching bolt
1) 5 capscrews (A1) M12×65 and 1 capscrew (A3)
M12×30. (Mark ) B4

2) 2 nuts (B4) M16 (Mark )

(8) Slinging cab
1) Remove two plastic plugs at the front of the
ceiling of the cab. Then place a wire sling with A3
eye rings and a hook around the cab, as shown
in Fig. 33-7.
A1
2) Then lift up slowly avoiding interference with
surroundings.
Fig. 33-6 Removing and installing cab mounting
Wire with hook ;
bolts.
Length 1.5m (4ft 11in)×Dia. 8mm
(0.315in)×3pcs.
Weight of cab ; Approx. 250kg (550 lbs)

33.1.2.2 INSTALLATION
Install it in reverse order of removing according to the
Tightening Torque Table.
Allen Tightening torque EYE BOLT
Tightening position wrench
N·m (lbf·ft)
M10
HEX
Nut M16 (B4) 24 191 (140)
Capscrew (A1)(A3) 19 79.4 (60)
Torx driver
Sems bolt M6 (A39)(A40) (T30) 8.5 (6.3)
Sems bolt M6 (A22)(A23) Plus driver 5.0 (3.7)

Fig. 33-7 Slinging cab

33-5
33. UPPER STRUCTURE

33.1.3 BATTERY

33.1.3.1 REMOVING
(1) Open left panel assy (21).
1) Open it with starter key.
2) Open left panel assy (21).
3) Fix it with stay.

(2) Remove battery cover (A2)

Loosen nut (A7) M10 and remove battery cover
(A2).

: 17 mm
(3) Remove battery cable
1) Remove cable (C4) [between the earth and
battery (–)]. 21
(Always remove (-) terminal first and install it at
Fig. 33-8
last.)
2) Cable (C2) [between battery (+) and (-)]
+"
3) Cable (C3) [between battery (+) and battery
relay] +

: 13 mm

Follow the battery removal order.

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

(4) Remove battery (B1)

1) Loosen 2 capscrews (A4) M10×235.
Fig. 33-9 Removing and installing battery cable
: 17 mm
A7
2) Remove plate (A3). A2
3) Remove battery (B1).

A4
A3
B1

Fig. 33-10 Removing and installing battery

33-6
 33. UPPER STRUCTURE

33.1.3.2 INSTALL
(1) Install the battery in the reverse order of removing.
Hold down plate (A3) against battery (B1), and
tighten capscrew (A4).

: 17 mm,
Tightening torque : 10.8N•m (8.0 lbf•ft)
(2) Installing grounding cable
Install grounding cable (C4) last. Especially care
must be taken that the grounding face is free from
painting, rust, etc.

: 13 mm

33-7
33. UPPER STRUCTURE

33.1.4 GUARD

33.1.4.1 PREPARATION FOR REMOVAL

(1) Remove guard in the following procedure. 3
1 2
Remove the guards in the order of
(11)→(7)→(8)→(5)→(3)→(2)→(21)→(23)→(22)→ 8
7
(6) and (1). 22
(2) All the locked cover, open them using starter key.

5 11
23
6
21
Fig. 33-11 Arrangement of guard assy

33.1.4.2 REMOVE GUARD

(1) Remove bonnet assy (11)

1) Unlock catches (2) and unlatch catches (2), (3),
and open bonnet (11). !

2) Remove four nuts (7) M12.

3) Remove bonnet (11).

: 19 mm
Weight : 60kg (132 lbs)

%
Fig. 33-12 Removing bonnet assy (11)
(2) Remove guard (7) %
1) Remove 3 sems bolts (38) M12×25 on upper !&

side. !'

2) Remove 4 sems bolts (39) M12×25 on the side.

!'
3) Remove guard (7)

: 19 mm
Weight : 11kg (24 lbs)

Fig. 33-13 Removing guard (7)

33-8
 33. UPPER STRUCTURE

(3) Remove guard (8) and guard assy (5).

!"
1) Remove 4 sems bolts (34) M12×25.
&
2) Remove a sems bolt (39) M12×30.
3) Remove guard (8). #
!'
4) Remove 6 sems bolts (39) M12×30. !'
5) Remove guard assy (5). !"

!" !'
: 19 mm
Weight :
guard (8) : 13kg (29 lbs)
!'
guard assy (5) : 23kg (51 lbs)
Fig. 33-14 Removing guard (5),(8)
(4) Remove stay (3)
1) Remove 2 sems bolts (38) M12×25.
2) Remove 2 sems bolts (40) M12×40. 3
3) Remove stay (3).
38
: 19 mm
Weight : 8.6kg (19 lbs)

40

Fig. 33-15 Removeing stay (3)

(5) Remove guard (2)
39
1) Remove 2 sems bolts (39) M12×25.
2) Remove connector for right side deck light. 2
3) Remove guard (2).
Deck light
: 19 mm
Weight : 5kg (11 lbs)

Fig. 33-16 Removing guard (2)

(6) Remove panel assy (21) 21
1) Unlock panel assy (21).
2) Remove 4 nuts (4) M10.
3) Remove panel assy (21).

: 17 mm 4
Weight : 17kg (37 lbs)

Fig. 33-17 Removing panel assy (21)

33-9
33. UPPER STRUCTURE

(7) Remove panel assy (23)

"
1) Remove 4 nuts (4) M10.
2) Remove panel assy (23).

: 17 mm
Weight : 17kg (37 lbs)

!
Fig. 33-18 Removing panel assy (23)
(8) Remove panel assy (22)
22
1) Unlock and open panel assembly (22).
2) Remove 4 nuts (4) M10.
3) Remove panel assy (22).

: 17 mm
Weight : 17kg (37 lbs)

Fig. 33-19 Removing panel assy (22)

(9) Remove guard assy (17) and guard (15), (16).
1) Remove 7 sems bolts (38) M12×25 and guard
assy (15), (17), (16) in order.
#
: 19 mm
Weight : !&
guard (15) : 6.5kg (14 lbs)
guard (16) : 3.5kg (7.7 lbs)
guard assy (17) : 2kg (4.4 lbs)
%

$

!&
!&

Fig. 33-20 Removing guard assy (17) and guard

(15), (16).

33-10
 33. UPPER STRUCTURE

(10)Remove beam (11), pillar (10), panel (4) "

!'
1) Remove 2 sems bolts (39) M12×30 and remove
beam (11).
2) Remove 7 sems bolts (39) M12×30.
3) Remove panel (4), pillar (10) in order.

: 19 mm
Weight :
beam (11) : 6.8kg (15 lbs)
pillar (10) : 17kg (37 lbs)
panel (4) : 3kg (6.6 lbs)


!'
!'
Fig. 33-21 Removing beam (11), pillar (10), panel (4)
(11)Remove beam (6), pillar (9), (12) 11
Remove battery relay box in advance and remove
pillar (12). (See Chapter 23) 39
39

1) Remove 6 sems bolts (39) M12×30 and remove

5
beam (6). 5

2) Loosen 5 sems bolts (39) M12×30.

6
: 19 mm
3) Remove pillar (9), (12).
Weight :
pillar (9) : 13kg (29 lbs)
pillar (12) : 5kg (11 lbs)
beam (9) : 19kg (42 lbs) 13
12
38
39

39

39

Fig. 33-22 Removing and installing of beam (6),

pillar (9),(12)
(12)Remove plate (49), guard assy (13)
1) Loosen 2 sems bolts (38) M12×25.
!'
2) Remove plate (49).

: 19 mm
"' !'
Weight : 1.2kg (2.6 lbs)
3) Loosen 2 sems bolts (38) M12×25. Fig. 33-23 Removing and installing of plate (49)
(Refer to Fig. 33-22)
4) Loosen 5 sems bolts (5) M12×30.

: 19 mm
5) Remove guard assy (13)
Weight : 17kg (37 lbs)

33-11
33. UPPER STRUCTURE

(13)Remove guard assy (1) and (2)

#
1) While air cleaner is removed, loosen hose clamp 
of engine intake and disconnect the hose.
2) Loosen 8 sems bolts (5) M12×30.
3) Remove guard assy (2),(1) in order.

: 19 mm
Weight :
guard assy (2) : 12kg (26 lbs)
guard assy (1) : 20kg (44 lbs) 5

Fig. 33-24 Removing and installing of guard assy

(1),(2)
(14)Remove guard assy (4), guard (3) 5
1) Loosen 7 sems bolts (5) M12×30. "

: 19 mm
3
2) Remove guard assy (4), guard (3)
Weight :
guard assy (4) : 8kg (18 lbs)
guard (3) : 11kg (24 lbs)

Fig. 33-25 Removing and installing of guard assy

(4) and guard (3)
(15)Remove plate (18)
39
Loosen 3 sems bolts (39) M12×30, and remove
plate (18).
39
: 19 mm
Weight : 2.9kg (6.4 lbs)
18

39

Fig. 33-26 Removing and installing of plate (18)

33-12
 33. UPPER STRUCTURE

(16)Remove cover assy (1)

1) Unlock the locks and open cover (1-2).
2) Remove 4 sems bolts (39) M12×30.
3) Remove cover assy (1).

: 19 mm
Weight : 30kg
39
1-2
(17)Remove other brackets, as required.

Fig. 33-27 Remove cover assy (1)

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

Unit : N.m (lbf.ft)

Size Nut Sems bolt
M8 - 23.5 (17.3)
M10 46.1 (34.0) 46.1 (34.0)
M12 - 79.4 (58.6)

33-13
33. UPPER STRUCTURE

33.1.5 UNDER COVER

33.1.5.1 REMOVAL
(1) Remove under cover (1,2,3,4,5,6,7,8)
1) Remove attaching sems bolts (9) M12×30.
2) Remove covers.

: 19 mm

        
  !"  #$%$& ! "  
  !"  #$%$
& !$ "
  !"  #$%$& !
$ "
  !"  #$%$& !$ "
  !
"  #$%$
& !$ "
  !"  #$%$& !$ "
  !"  #$%$
& ! $ "
  !"  #$%$& ! $ "

Fig. 33-28 Under cover assy

33.1.5.2 INSTALLATION
(1) Install under cover (1,2,3,4,5,6,7,8)

: 19 mm
Tightening torque : 79.4 N•m (60 lbf•ft)

33-14
 33. UPPER STRUCTURE

33.1.6 FUEL TANK

33.1.6.1 PREPARATION FOR REMOVAL

(1) Draining fuel. (See Fig. 33-30) 9 32
1) Unlock cap (B2) with a starter key and open it.
2) Loosen valve (A8) under the tank.
20
25
3) Draining fuel
Capacity of tank : 580L (153gal) A B
(2) Remove stay (3) and guard (2).
(See 33.1.4 GUARD)
(3) Remove the connector for level sensor (A4).
(See Fig. 33-30)
(4) Remove fuel hose
1) Loosen clip (20),(25) and draw out hoses (32)
and (9).
2) Put in plugs that match the hose bore. B

Fig. 33-29 Removing fuel hose (9), (28)

33.1.6.2 REMOVAL
(1) Remove 6 capscrews (A1) M16×45. B2

: 24 mm
(2) Hook the wire to the lifting eye on the fuel tank assy
A6 C1
(C1) and remove the fuel tank. A4
Weight : 203kg (448 lbs)
(3) Remove shim (A3).

Record the shim locations.

A3
A1

A8
Fig. 33-30 Removing fuel tank

33-15
33. UPPER STRUCTURE

33.1.6.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
Tank attaching bolt (A1) M16×45

: 24 mm, Apply Loctite #262

Tightening torque : 191 N•m (140 lbf•ft)

If the gap (looseness) between tank mount and frame

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

(2) Tightening torque

Tightening torque
No. Name Q'ty N.m (lbf.ft)
A1 Capscrew 6 191 (140)
A6 Machine screw 5 1.96 (1.4)
A8 Stop valve 1 34 (25)

33-16
 33. UPPER STRUCTURE

33.1.7 HYDRAULIC TANK

33.1.7.1 PREPARATION FOR REMOVAL

(1) Remove bonnet assy (11) panel assy (2), guard (8)
8
and other guards necessary to remove the
2
hydraulic oil tank.
11
(See 33.1.4 GUARD.)

Fig. 33-31 Remove guard

(2) Release internal pressure of tank 
Remove cap on air breather and push valve (head
of bolt) by your finger.
   
 

Keep pressing until the hissing stops.
Fig. 33-32 Bleeding internal pressure of tank
(3) Remove cover (C2). C5
1) Remove 6 sems bolts (C5) M10×25. C5
C3
: 17 mm
2) Remove cover (C2). C2
3) Remove suction strainer (B2).

(4) Remove cover (C3).

1) Remove 6 capscrews (C5) M10×25. B

: 17 mm C
2) Remove cover (C3). B2
D
3) Remove filter element (B6).
B6
D
(5) Turn the handle of element assy (B), and Air
breather
disassemble the removed filter element (B6). D
Disassemble parts : (B), (C), (D)×3, (E), (F)
E
(6) Draining hydraulic oil
F Hyd.tank
Place pump in tank and draw up hydraulic oil.
Capacity of tank : 186 L (49gal)

Fig. 33-33 Remove cover (C2), (C3)

33-17
33. UPPER STRUCTURE

33.1.7.2 REMOVAL
(1) Draw out the suction hose (A3)
Remove 2 clips (A17) of the tank side and pull out
hose (A3). A17

2 : Flat-blade screwdriver

A16
A3
At installing suction hose,
apply PERMATEX to the
inner end of both hoses.

Fig. 33-34 Removing and installing the suction

hose
(2) Disconnecting the main pipe return hose

1) Loosen 2 sems bolts (18) M12×35, and remove

6
return hose (3).
4
: 19 mm
S/M
2) Remove drain hose (4) of pump Dr

: 36 mm C/V
T2 18
3) H/P
Remove drain hose (6) of swing motor 3 Dr

Fig. 33-35 Removing main piping return hose

: 27 mm
(3) Disconnecting pilot return hose
1) Remove pilot hose (A1).

: 22 mm
A1

2) Remove pilot hose (A11).

C/V
: 22 mm DR A14
PT
T
3) Remove pilot hose (A14). S/V
T
A11
: 22 mm
Fig. 33-36 Remove pilot return hose

(4) Remove drain hose (2) of pilot pump

: 22 mm

Fig. 33-37 Removing pump drain hose

33-18
 33. UPPER STRUCTURE

(5) Remove hydraulic tank attaching bolt

Remove 4 capscrews (A1) M20×45.

: 30 mm

(6) Slinging hydraulic oil tank

Place a wire sling, using the lifting plate on top of
the tank.
Tank weight : Approx : 170kg (375 lbs)

A3
(7) Remove shim (A3).
A1
Fig. 33-38 Removing hydraulic tank

Record the shim locations.

33.1.7.3 INSTALLATION
(1) Cleaning hydraulic oil tank
(2) Cleaning suction hose
(3) Cleaning mount of tank.
Installing is done in the reverse order of removing.
(4) Install 4 mounting capscrews (A1) M20×45 with
Loctite #262. (See Fig. 33-38.)

: 30 mm, Apply Loctite # 262

Tightening torque : 373 N•m (275 lbf•ft)

If the gap (looseness) between tank mount and frame

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

33-19
33. UPPER STRUCTURE

(5) Connection of suction hose (A3) (See Fig. 33-34) O-RING

1) Apply PERMATEX on pipe side of hose
connection and insert it.
2) Put the hose with clip (A17).
C
Tightening torque : 5.39 N•m (4.0 lbf•ft)
(6) Assembling return element
Assemble filter element by the use of element kit
(B-100). (See Fig. 33-33,Fig. 33-39) B2
D
SUCTION
STRAINER
LC50V00004F1
1. Three elements (D) are used as one set.
F
2. Replace O-ring (C) and packing (F) with new ones ELEMENT KIT
respectively. (B-100)
LC52V01001R300
(7) Install return element (B6). (See Fig. 33-33) Fig. 33-39 Element & suction strainer
(8) Installing suction strainer (B2)
(9) Tighten sems bolts (C5) M10×25 that attach tank
covers (C2), (C3).
M10 Tightening torque : 46.1 N•m (34.0 lbf•ft)

Replace O-ring fitted on the back side of tank cover with

new one.

33-20
 33. UPPER STRUCTURE

33.1.8 HYDRAULIC PUMP

33.1.8.1 PREPARATION FOR REMOVAL

(1) Release pressure in hydraulic oil tank.
C5
(See 33.1.7HYDRAULIC TANK)
(2) Remove six sems bolts (C5) M10×25.
C2
(3) Remove cover (C2)
Suction
: 17 mm stopper

(4) Take out suction strainer.

(5) Install suction stopper.
Suction
For suction stopper, see chapter 11. Tools. strainer

Hyd.tank

Fig. 33-40 Suction stopper installing

(6) Remove guards
7
1) Open bonnet assy (1).
2) Remove panel assy (22), guard (7), (15), (16)
and guard assy (17). (See 33.1.4GUARD)
3) Remove those parts that are required to remove
the hydraulic pump such as the fuel filter assy.
4) Remove drain hose at the bottom of the muffler.
15

38

17

16

Fig. 33-41 Removing guards

33-21
33. UPPER STRUCTURE

33.1.8.2 REMOVAL
(1) Loosen 8 capscrews (A19) M12×40 and remove
half clamp (A11). And disconnect 2 hoses (A1),
(A2) from the delivery side. A3

: 10 mm A19
(2) Remove pilot pump suction hose (1)
(See Fig. 33-43) A11 4

: 36 mm A8
(3) Remove suction hose (A3) and drain hose (4) A11

1) Remove 4 capscrews (B2) M12×30. PUMP A1-

C/V P1
A2 a2
A9
: 10 mm A9
a1

2) Remove elbow (B1) of suction hose (A3) from

pump. B2

3) Remove drain hose (4) (Dr).

A1 PUMP A2-
C/V P2
: 36 mm B1
Fig. 33-42 Removing hoses

(4) Removing other hoses

A3
1) Disconnect hoses of the following ports. TANK-
Dr3
PUMP Dr3
2
Hose
Port No. Tool Remarks

Dr3 2 22 Drain
B3
3
*Psv1 12 19 Pilot primary pressure P1 side

*Psv2 3 19 Pilot primary pressure P2 side

Psv1 A13 19, 22 Pilot pump delivery

12
Psv2

Psv1

Remove the parts marked * only if necessary. 1

PUMP B1- A13
PUMP B3 S/V P1-
PUMP Psv1
2) Attach tags to hoses to identify. B1
P1

3) Put a plug in the hoses and the pump.

Fig. 33-43 Removing other hoses

33-22
 33. UPPER STRUCTURE

(5) Remove connector Using Zip-tie, clamp the corrugated PSV-P2:

Remove 4 connectors of all pressure sensors and part of harness to the solenoid. P2 pump
CLIP proportional
proportional valves. valve
PSV-P1:
P1 pump
proportional valve

Engine
side

Using Zip-tie, clamp

the corrugated part CLIP SEMS BOLT
of harness to the Tightening torque 25.5N.m
pressure sensor. (19 lbf.ft)

SE-22: SE-23:
Pressure sensor : Pressure sensor :
P1 pump P2 pump
Fig. 33-44 Removing connector
(6) Remove main pump
0
1) Put a wire sling on the hydraulic pump and
tension the wire sling a little. Loosen 8
3
capscrews (4) M10×35.

: 17 mm
2) Draw out the power take-off assy from the
flywheel housing slowly, adjusting the tension of 4
1
the wire rope.
On that occasion, the assembly is drawn out with
the insert NA (2-3) remaining on the flywheel 2-6
2-4
side.
3) Remove element (2-1) from the tip of the spline
shaft.
4) Remove 4 capscrews (2-6) M20×50 that fasten
2-5
insert R (2-4) and remove insert R (2-4). 2-7
2-2 2-3
: 17 mm
5) Remove hub (2-2)
If you loosen 2 set screws (2-7) M20×25, hub
2-8 2-1
comes off from the spline shaft of the pump.
2
: 17 mm 2-9
6) Remove 4 capscrews (2-5) M20×60 that fasten
the insert NA (2-3) with the engine side flywheel,
as necessary. Then remove and spring pin (2-8) Fig. 33-45 Removing pump
from insert NA (2-3).

: 17 mm
7) Removing bracket (1)
Loosen 4 capscrews (3) M20×55, and remove
bracket (1) from pump (0).

33-23
33. UPPER STRUCTURE

33.1.8.3 INSTALLATION
Installing is done in the reverse order of removing.
(1) Installing bracket (1)
Tighten bracket (1) with capscrew (3) and install
bracket temporarily.

: 17 mm
Tightening torque : 431 N•m (318lbf•ft)
Apply Loctite #262
(2) Installing hub (2-2)
Put hub (2-2) into the pump spline till it enters 3mm
(0.12in) from the end face of the spline (See Fig.
33-46 Detail aa). Then install two set screws (2-7)
and fix them together.

: 17 mm
Tightening torque : 210 N•m (155 lbf•ft)
(3) Install spring pin (2-9)
Put spring pin (2-9) into hub (2-2).
(4) Installing insert R (2-4)
Install insert R (2-4) into hub (2-2) by means of
capscrews (2-6) coated with Loctite #262.

: 17 mm
Tightening torque : 465 N•m (343 lbf•ft)
(5) Installing element (2-1)
Put element (2-1) into hub (2-2) and insert R (2-4).
(6) Installing insert NA (2-3)
Put spring pin (2-8) into insert NA (2-3) and install it
to the engine flywheel by means of capscrews (2-
5).

: 17 mm
Tightening torque : 465 N•m (343 lbf•ft)

(See Fig. 33-45 about above mentioned (1) ~ (5).)

33-24
 33. UPPER STRUCTURE

(7) Installing the pump (See Fig. 33-45,Fig. 33-46)

Lift the pump with bracket (1). Place coupling (2) in
the groove of element (2-1) so as to receive insert 2-6
NA (2-3). 2
(8) Coat 8 capscrews (4) M10×35 with Loctite #262
and put them in place.
aa
: 17 mm
Tightening torque : 64.7N•m (48 lbf•ft) 2-7
T=210N.m (155 lbf.ft)
(9) Fasten hoses (A1), (A2) on the delivery side with 2-8
half clamp (A11) and 8 capscrews (A19) M12×40. SPRING PIN
(4 places) 3
T=431N.m (318 lbf.ft)
(See Fig. 33-42) Apply Loctite #262
1
T=465N.m (343 lbf.ft)
: 10 mm Do not use Loctite
(The attached bolts are coated
4
Tightening torque : 62.2N•m (46 lbf•ft) with micro capsule coating)
T=64.7N.m (48 lbf.ft)
Apply Loctite #262
(10)Install suction hose (A3) with 4 capscrews (B2)
M12×30. (SeeFig. 33-42) 4

: 10 mm
Tightening torque : 66.7 N•m (49 lbf•ft)
(11)Install the hydraulic piping by referring to
"HYDRAULIC SYSTEM".
3
56 (2.2")
(12)Installing the hose (See Fig. 33-43) (0.118") DRAIN HOLE (Bottom)
DETAIL aa VIEW I

 

  

 
 

     Fig. 33-46 Installing hydraulic pump

    !  
     
    " "#
(13)Installing pressure sensor connector and
proportional valve connector.
(14)Remove suction stopper
(15)Install suction strainer

When the pump is replaced, replenish more than 1L

(0.26gal) of hydraulic oil from the drain port (Dr).

(16)Bleed air in pump Dr

Dr 0
Bleed air by loosening the drain port (Dr).
(17)Check hydraulic oil level.
(18)Start engine and check it for oil leak and noise.
(19)Attach drain down pipe under engine muffler.
(20)Install guards
(See Fig. 33-41,Fig. 33-20)


 


 

  
    

     

Fig. 33-47 Bleed air port (Dr) in pump

33-25
33. UPPER STRUCTURE

33.1.9 AIR CLEANER

33.1.9.1 PREPARATION FOR REMOVAL

(1) Opening bonnet assy (11).
11
(See 33.1.4 GUARD)
(2) Open panel assy (21).
(See 33.1.4 GUARD)
(3) Remove Panel assy (23).
(See 33.1.4 GUARD)
(4) Unplug terminals on indicator (1-8) wiring.
(See Fig. 33-49)
23
21
Fig. 33-48 Preparation for removal

33.1.9.2 REMOVAL
(1) Pulling out hose (3).
aa
3 Insert width of hose : 45 mm
1) Loosen clips (5) on both sides of hose (3). 6 (1.77")
2
6 bb
2) Pulling out hose (3)
: Flat-blade screw driver
(2) Remove air cleaner assy (1)
1) Remove 4 sems bolts (7) M10×25 ENGINE
A
5
: 17 mm
1 1-8
2) Remove air cleaner assy (1) from plate (4). 4

Fasten the item 6

30 (1.18")

in the drawed direction

Tightening torque Tightening torque
5.9N.m(4.4lbf.ft) 5.9N.m
5 (4.4lbf.ft)
6 7

")
.77 1-2
(1
45 Insert width
of hose
1-3
DETAIL aa DETAIL bb 1-6
A

Fig. 33-49 Removing air cleaner

33.1.9.3 INSTALLATION
(1) Installing is the reverse order of removing with
attention paid to the following items:
1) Put in air hoses (2), (3) to the end as shown in
Fig. 33-49.
2) Tightening torque : FILTER ELEMENT (1-3) FILTER ELEMENT (1-2)
(LC11P00018S003) (LC11P00018S002)
No. Name Tightening torque N.m (lbf.ft) O-RING (1-6)
1-8 Indicator 3.9 (2.9) (EB11P00001S003)

7 Sems bolt 39.2 (29) (Apply Loctite #262)

5,6 Clip 5.9 (4.4)

33-26
 33. UPPER STRUCTURE

33.1.10 MUFFLER

33.1.10.1 PREPARATION FOR REMOVAL

(1) Remove bonnet assy (11) and guard (7). 11 7 22
(2) Remove panel assy (22).
(3) Remove guard (15), (16) and guard assy (17).
(See Fig. 33-20)

Fig. 33-50 Preparation for removal

33.1.10.2 REMOVAL
(1) Remove U bolt (4).


1) Remove 4 nuts (10) M8.

: 13 mm  "
2) Remove 2 U bolts (4). 
(2) Remove clamp assy (5)
1) Remove 2 capscrews (9) M10×35 

: 17 mm  


2) Separate clamp assy (5) from muffler (1). 
(3) Removing other parts
Remove brackets (2) as necessary.

: 19 mm

## 
 &#

+)
,  ' & #&&$ $

) &
&  * %$


          
  ! "#  !$%&&
    $$    '   %
'$  & $ #'
( $$ $ #'  

Fig. 33-51 Removing and installing the muffler

33-27
33. UPPER STRUCTURE

33.1.10.3 INSTALLATION
Installing is the reverse order of removing with attention
paid to the following items:
(1) Procedure of fastening U bolt (4) (See Fig. 33-51)
1) Tighten 4 nuts (A) till there is no space and make
sure that the dimension C is even all around.
2) Tighten nuts (A) to specified torque and confirm
the C dimensions on the right and left once
again.
3) Tighten nuts (B) to specified torque and make
sure that U bolts are not inclined.
4) Tightening torque
Nut A : 8.8 N•m (6.5 lbf•ft)
Nut B : 10.8 N•m (8.0 lbf•ft)
(2) Installing clamp assy (5)
1) Place the end of clamp (5) 10mm (0.40in) away
from the tip of the muffler slit so the joint of clamp
does not extend over the slit in the muffler. (See
Fig. 33-51)
2) Install the clamp assy (5) in the illustrated
direction.
(3) Tightening torque :

No. Name Tightening torque N.m (lbf.ft)

8 Sems bolt 108 (80) (Apply Loctite #262)
9 Capscrew 85 (63)
16 Nut 69 (51)

(4) Replacing parts

Name Part No.

Muffler (1) LC12P00014P1

33-28
 33. UPPER STRUCTURE

33.1.11 COUNTERWEIGHT

33.1.11.1 PREPARATION FOR REMOVAL

(1) Remove bonnet assy (11). (See 33.1.4 GUARD) 11

Fig. 33-52 Lifting up counterweight

33.1.11.2 REMOVAL
(1) Lifting up counterweight temporarily C1
Hook wire rope to slinging jig, and lift it and stretch
wire rope to the degree where it is providing no
slack temporarily.
Weight of counterweight ; (Semi-weighted)
Approx. 8,130kg (17,920 lb)
(2) Removing counterweight (C1)
1) Remove 4 capscrews (A1) M36×420.

: 55 mm
2) Remove shim (A3), (A4), (A5). (Select)
3) Remove counterweight (C1).

A3
A4
A5

A1

A2

Fig. 33-53 Removing counterweight

33.1.11.3 INSTALLATION
(1) Install counterweight in the reverse order of
removing.
(2) Install shim (A3), (A4), (A5) as it was. (select) Less than two shim
adjustment
(3) Slinging counterweight A3,A4,A5
Check that the attaching bolts can be screwed in by
hand.
(4) Apply Loctite #262 on capscrews (A1), and tighten
them with washers (A2).

: 55 mm A1,A2
Tightening torque : 2,940 N•m (2,170 lbf•ft) Fig. 33-54 Fastening the counterweight attaching
(5) Remove slinging tools, and install bonnet assy (11). capscrew

33-29
33. UPPER STRUCTURE

33.1.12 RADIATOR & OIL COOLER

33.1.12.1 PREPARATION FOR REMOVAL

(1) Bleed air from the hydraulic tank and install the
suction stopper.(See 33.1.7 and 33.1.8)
(2) Remove bonnet assy (11)
(See 33.1.4 GUARD)
(3) Remove beam (4). (See 33.1.4 GUARD)
(4) Open panel assy (21). (See 33.1.4 GUARD)
(5) Remove battery (See 33.1.3 BATTERY)
(6) Removing under cover installed on lower side of "
radiator.
Fig. 33-55 Removing under cover (4)
1) Remove 4 sems bolts (9) M12×30.
2) Remove cover (4).

: 19 mm
(7) Drain down of radiator
Put container 18L (4.8gal) under drain valve hose
8
for draining water.
[Water capacity of radiator : 11L (2.9gal)] 40

(8) Remove hose from radiator sub tank (1) 30

Remove clip of radiator cap side and disconnect
hose (8). 3
42 36

35

Do not loosen the joints of the hoses related to the air-

conditioner. Otherwise the refrigerant leaks.
11
(9) Move air-conditioner condenser and receiver tank
1) Loosen 2 sems bolts (50) M8×25 and 2 sems 1
bolts (6) M10×25.
9 26

: 13 mm, 17 mm
2) Move a set of air-conditioner condenser and
receiver tank. Fig. 33-56 Removing hose of sub tank (1)
(10)Disconnect connector of coolant level switch (B5).
(See Fig. 33-58) $
!# %

#
!
$

!
#%
#
Fig. 33-57 Moving condensers and receiver tank

33-30
 33. UPPER STRUCTURE

33.1.12.2 REMOVAL
(1) Remove radiator stay (A1), (A6). * 
1) Remove 4 sems bolt (A2) M12×35.

: 19 mm
2) Remove 2 stays (A1), (A6). *
*!
(2) Remove water hose (2),(3)
1) Loosen the hose bands (33) for water hose (2). * 
* *
: Flat-blade screwdriver )
2) Remove hose (2).
*&
3) Loosen hose band (33) on water hose (3).
: Flat-blade screwdriver )$
4) Remove hose (3).

*'
)
)

)"
Fig. 33-58 Removing radiator assy
(3) Remove hoses (4)(5) for inter-cooler ! !
$ '
1) Remove two fixing U-bolts (22) from tube (13). !"
% '
$ "
: 13 mm #
%
2) Loosen 2 sems bolts (29) M8×25. !
!! "
!! !
: 17 mm %
!
# &
3) Loosen hose bands (32) and remove hose (4). &

: Flat-blade screwdriver
4) Loosen hose bands (32), (34) and remove hose
(6). ! 
!! !
: Flat-blade screwdriver "
5) Loosen hose bands (32) and remove hose (5). 35
!
#
: Flat-blade screwdriver !

Fig. 33-59 Removing hose for radiator/inter-cooler

(4) Remove guard (15), (16) (See Fig. 33-56)
1) Remove 5 sems bolts (27) M10×20.
2) Remove guard (15), (16).

: 17 mm

33-31
33. UPPER STRUCTURE

(5) Disconnecting hydraulic oil hose (1), (2)

1) Loosen 2 capscrews (21) M12×55 for attaching
clamp (15). 18
O/C OUT-
C/V T2
2) Place an oil pan under the hose joint. Loosen 4 1
sems bolts (18) M12×35, and remove hoses (1)
and (2).
(6) Remove radiator assy. (See Fig. 33-58)
1) Remove 4 sems bolts (A4) M20×45.
A
: 30 mm 2
C/V T1-
O/C IN
: 30 mm
2) When lifting the engine fan, shift the radiator so A
it does not interfere with the engine fan.
3) Plug up pipe ends with clean cloth, etc.
4) Removing radiator
Place a wire sling in the lifting eyes of the radiator
assy and remove the assy by crane.
Weight : 142kg (313 lbs) 18
19 17

15

9
21
A
Fig. 33-60 Removing hydraulic oil hose (1), (2)

33-32
 33. UPPER STRUCTURE

33.1.12.3 INSTALLATION
(1) Installing is done in the reverse order of removing. 97
")
(1.
And removed clips of hose should be clamped at (1 .58
") 50
40
original position.
")
58
(2) Install radiator assy (1.
40

Place a wire sling in the lifting eyes of the radiator

")
and move it to original position temporally. And 4
(1 0
40
(1 50
(1.
97
.5 .5
install hydraulic hose, radiator hose and hose of 8"
)
8"
)
50 7")
inter-cooler. Regarding Inserting width of hose. (1.
9

(See Fig. 33-61) ")

58
(1.
40
(3) Radiator attaching bolt
Apply Loctite #262 on 4 semsbolts (A4) M20×45.

: 30 mm
")
Tightening torque : 500 N•m 369 lbf•ft) (1.
58
40
(4) Adjust the clearance between the fan and the
")
97
radiator shroud all around the circumference, as 50
(1.
")
below : (1.
97
50
Circumferential direction:
18±3mm (0.71in±0.12in)
Back and forth:
44±5mm (1.73in±0.2in) Fig. 33-61 Inserting width of hose

(5) Clean the plastering area of the insulation

thoroughly before plastering it. Adjust the engine fan
so its rear end sticks
(6) Making up hydraulic oil and LLC (Long Life out 44mm (1.73 in) from 44 5
(1.73in 0.2 in)
Coolant) the radiator shroud.

After completion of other installation, make up

hydraulic oil and water.
Coolant volume of engine body : 13 L (3.4gal)
Coolant capacity of radiator : 11 L (2.9gal)
Hydraulic oil capacity of oil cooler : 12 L (3.2gal)

Fig. 33-62 Back-and-forth adjusting position of

radiator

33-33
33. UPPER STRUCTURE

33.1.12.4 PROCEDURE OF DISASSEMBLING AND ASSEMBLING THE RADIATOR/INTER COOLER CORE

(1) Preparation for disassembly and assembly
1) Remove one under cover at the bottom of the 15 15 15
radiator.
2) Wait till the engine coolant cools down so you do
not get burned. Then remove the cap of the
radiator, discharge the coolant by opening the
drain valve located at the back bottom and
receive it in a container. 22 20 22 21
* In case of removing inter cooler only, the above
mentioned work is not necessary. RADIATOR COOLANT LEVEL SWITCH 21

(2) Disassembly
1) Loosen each 2 bolts (22) at head and bottom of
shroud, remove upper plate (20) and lower plate
(19).
2) Disconnect wiring connector of radiator coolant
level switch. Inter- Radiator Oil
cooler cooler
3) Loosen 6 sems bolts (22) M10×20 attaching
plate assy (21), remove plate assy (21).
4) Loosen 2 capscrews (15) M10×50 attaching
radiator core.
5) After confirming that the coolant has been
drained out completely, loosen and remove only
the radiator side of hose bands (33) at the top
and bottom of the radiator. (See Fig. 33-59)
DRAIN VALVE
6) Lift and remove radiator core using lifting eyes
and hoist on the radiator core.
Weight : 20kg (44lbs)
Confirm the missing of rubber bushing (14)
14
under the radiator core.
7) Loosen 2 capscrews (15) M10×50 attaching the Detail of radiator
core mounting part
top of the inter-cooler core.
8) Loosen and remove only the inter-cooler side of
hose bands (32) at the top and bottom of the
inter-cooler. (See Fig. 33-59)
9) Lift and remove inter-cooler using lifting eyes
and hoist on the inter-cooler.
Confirm the missing of rubber bushing (14)
22
under the inter-cooler. 19

VIEW A

Fig. 33-63 Removing radiator and inter-cooler

33-34
 33. UPPER STRUCTURE

10) Disconnection of oil cooler hose

Disconnect hoses from upper and lower of
cooler, and drain hydraulic oil. (See Fig. 33-60)
11) Lift cooler temporally using cooler head flange
for slinging.
12) Loosen 4 bolts (16) M8×25 attaching oil cooler.
13) Lift the oil cooler.

There is no predetermined sequential order in

removing radiator core, inter-cooler core and oil cooler.
Removing these components can be done as
necessary.

(3) Installing
Installing is done in the reverse order of removing.

33-35
33. UPPER STRUCTURE

33.1.13 ENGINE

33.1.13.1 PREPARATION FOR REMOVING

(1) Remove battery ground (See 33.1.3 BATTERY)
(2) Remove bonnet and guard (See 33.1.4 GUARD ) Remove under cover (See 33.1.5 UNDER COVER)
(3) Remove air cleaner hose (See 33.1.9 AIR CLEANER)
(4) Remove counterweight (See 33.1.11 COUNTERWEIGHT)
(5) Remove radiator hose and inter-cooler hose (See 33.1.12 RADIATOR & OIL COOLER)
(6) Remove fuel hose and heater hose, and if necessary disconnect air-con hose.
(7) If necessary, remove pump, muffler and radiator.
(8) Remove harness connector (Refer to ELECTRIC SYSTEM)
1) Remove E/G ground cable
2) Starter cable - Starter B terminal
3) Remove the connector that connects the upper harness with the engine and ECU harness.
4) Upper harness
CN-206-E/G sub harness
P22-Alternator B terminal
CN-136-E/G speed sensor
CN-141, CN142-Pump proportional valve
CN-139, CN-140-P1,P2 pump pressure sensor
CN-212-Glow
M-1-Starter motor C terminal

Prepare a stand, which withstands the weight of the engine assy and can place the removed engine firmly. (Refer
to Tools)

THERMOSTAT GASKET

OIL PLUG
ASSY
FUEL FILTER
OIL FILTER ELEMENT
ELEMENT

ALTERNATOR V BELT (2 PIECES)

V BELT
(COMPRESSOR)

STARTER

ENGINE
V BELT (3 PIECES)

Fig. 33-64 Outside view of engine

33-36
 33. UPPER STRUCTURE

33.1.13.2 REMOVAL

22 22
12
12

23 23

15 15

13 14

13 14

11
19 19
28 21
24
25
B C
5
6
2

7
3

A
6
8

17
20 30
18
33
16 C A

35 29
28

10 C

31
32

36

Fig. 33-65 Dismantling and mounting engine

33-37
33. UPPER STRUCTURE

(1) Remove hose of engine oil filter

Place oil pan under the connection of filter (1), and disconnect hoses (7), (8), (9) at positions.

: 17 mm, 41 mm
(2) Plug connector of filter side and hose.
(3) Loosen engine mounting bolt of frame
1) Loosen 4 nuts (19) M18.

: 27 mm
2) Loosen 4 capscrews (23) M18×150.
3) Remove 4 plates (14).
4) Remove upper rubber mounts (13) and (14) 2 each.
(4) Slinging engine body

Prepare a stand, which withstands the weight of the engine assy and can place the removed engine firmly. (Refer
to "Tool".)

1) Sling engine hooking wire to lifting lugs on the front and rear sides.
Weight: Approx. 685 kg (1,510 lbs)
Wire: ø6 (0.236")×1m (3ft 3in) - 2pcs.
(5) Position engine on the stand stably.
(6) Remove 4 rubber mounts (13), (14).

33.1.13.3 INSTALLATION
Installing is done in the reverse order of removing.
(1) Tightening torque
Tightening torque
No. Name Remarks
N.m (lbf.ft)
6 Bolt 26.5 (20)
20 Sems bolt 46.1 (34)
Apply Loctite
21 Sems bolt 46.1 (34) #262
Apply Loctite
22 Sems bolt 115 (85) #262
Apply Loctite
23 Capscrew 226 (167) #271

33-38
 33. UPPER STRUCTURE

33.1.14 CONSOLE COVER

33.1.14.1 REMOVAL
(1) Removing right-hand console cover
1) During pushing 4 locked claws of boot retaining
plate (4) with flat-blade screw driver, lift the plate
(4) and remove it.
: Flat-blade screwdriver
2) Loosen 3 sems bolts (16) M6×15.

: Plus screw driver
3) During lifting right upper console cover (3A) up;

disconnect connector of tuner and antenna.   
Move boot (3) upwards and remove console
cover (3A).
• Removing of boot and lever is unnecessary. Fig. 33-66 Removing plate (4)
4) Loosen 3 sems bolts (16A) M6×15 and remove 16
lower console (4). 3A
: Plus screw driver 16
(2) Removing left-hand console cover 16A
16B
1) Remove the boot retaining plate (4) in the same
way as right-hand console cover. (See Fig. 33- 5 16B 4 16A
66) 16B
: Flat-blade screwdriver
16C
2) Loosen 2 sems bolts (A6) M8×20 and remove left
armrest assy.
6
: 13 mm
3) Loosen 4 sems bolts (16B) M6×15.
: Plus screw driver
4) Remove the left upper console cover (5) in the
same way as right-hand console cover.
5) Loosen 2 sems bolts (16C) M6×15 while lifting
left under console cover (6) up, and remove left Fig. 33-67 Removing console covers
lower console cover.

33.1.14.2 INSTALLATION
Install it in reverse order of removing according to the
tightening torque table.
A6
Item Bolts Tightening torque N.m (lbf.ft)

16~16C Sems bolt M6 8.5 (6.3)

A6 Sems bolt M6 23.5 (17.3)

Fig. 33-68 Removing left armrest

33-39
33. UPPER STRUCTURE

33.1.15 MULTI CONTROL VALVE (Only for Oceania)

33.1.15.1 PREPARATION FOR REMOVAL

(1) Bleed pressure air in hydraulic oil tank (See 33.1.7
HYDRAULIC TANK)
(2) Remove under cover (3). (See 33.1.5 UNDER
COVER)
(3) Open the left panel assy (23) located at rear of cab.
(See 33.1.4 GUARD)

Fig. 33-69 Removing multi control valve

33.1.15.2 REMOVAL
(1) Attach tag on which hose name is entered to the
2
remote control hoses between multi control valve 8 P/V 5
and pilot V, and write numbers P1 to P8 on it. P/V P/V 1
See Tools 11.5 PLUG (3) P/V
4 P2 P5
: 19 mm, 22 mm P/V
P8 0 P1
(2) Attach tag on which hose name is entered to the 7 6
remote control hoses between multi control valve P/V P4 P6 P/V
and main control valve, and write numbers C1 to C8
P7
on it. 3
See Tools 11.5 PLUG (3) P/V P3

: 19 mm, 22 mm
(3) Remove 4 sems bolts (B9) M8×20, and remove Fig. 33-70 Connection between multi control valve
multi control valve (0) with bracket (B5) from and P/V
machine.

33.1.15.3 INSTALLATION
(1) Installing is done in the reverse order of removing PBb
PBc B16
(2) Relations between pilot valve and multi control C/V C/V PBs
valve hose C4 C/V
C2
C5 C1
P/V Hose ISO Multi Mark-
Port Size Color Control pattern port ing C6
1 3/8 Red Bucket digging P1 1 0 PBa1
2 3/8 Blue
Right side

Bucket dump P2 2
C / V C / V CPAc
/V
3 3/8 Green Boom up P3 3 PAs
4 3/8 Gray Boom down P4 4 C8
P 1/4 Black Pilot primary - -
T 3/8 Black Drain - - C3
C/V
5 3/8 Gray Swing left P5 5 PAb
C7
6 3/8 Red Swing right P6 6 C/V
Left side

PAa1
7 3/8 Blue Arm in P7 7
8 3/8 Green Arm out P8 8
P 1/4 Black Pilot primary - -
T 3/8 Black Drain - -
B5
B11
(3) Tightening torque
Fig. 33-71 Removing hoses between main C/V and


 


 

  
multi C/V
  

     

33-40
 33. UPPER STRUCTURE

33.1.16 CONTROL VALVE

33.1.16.1 PREPARATION FOR REMOVING

(1) Remove guard (8)
(See 33.1.4 GUARD)
(2) Remove under cover (5).
(See 33.1.5 UNDER COVER)
(3) Install the suction stopper to the hydraulic oil tank. 5
(4) Remove the hoses in Fig. 33-73 and Fig. 33-74.

Mark each hose with a port name before removing it.

Tightening torque
284N.m(209 lbf.ft)

3 Tightening torque
235N.m (173 lbf.ft)

Fig. 33-72 Removing the standard main control

valve

33.1.16.2 REMOVAL
(1) Remove 4 capscrews (3) M16×45, and remove
control valve (5) by hoist.

: 24 mm
Weight :Approx. 252kg (556 lbs)

33.1.16.3 INSTALLATION
(1) Installing is done in the reverse order of remove.
1) Install control valve by tightening 4 capscrews (3) M16×45.

: 24 mm
Tightening torque : 284 N•m (209 lbf•ft)
2)
Connector / Bolt Hose nut
Tread
size Ports Opposing Tightening Opposing Tightening Remarks
Name torque torque
flats N.m (lbf.ft) flats N.m (lbf.ft)
Pss,PLc2,PBp1,PBp2,PL,
PF1/4 PB1,PTb,PCa,PCb,PCc 19 36 (27) 19 29 (21)
ORS Joint
PAa1,PBa1,Pab,PBb,Pac,
PBc,PAL,PBL,Par,PBr,Pas,
PF3/8 PBs,PAa2,PBa2,Pao,Pbo,DR 22 74 (55) 22 49 (36)
PF3/4 MU 36 165 (122) 36 118 (87)
Ar,Br,AL,BL,As,Bs,Aa,Ba,Ac,Bc 14 42.4 (31)
M10 Ab,Bb Sems bolt 14 57 (42)
P1,P2 17 62.2 (45)
M12 T1,T2 17 96 (70)

(2) Check for oil leak and operation.

33-41
33. UPPER STRUCTURE

Functions Ports Ports on upper sides Ports Functions

LEFT RIGHT
P2 bypass cut PBp2 PBp1 P1 bypass cut

Option PAo PBa2 Arm 2 in

Mu Make-up line
Arm (R) relief valve -
- Bucket (R)relief valve
Arm 1 out PBa1
PBb Boom down
Swing (LH) PBs
- Boom (H) relief valve
Boom conflux PB1 PAr Travel right forward
Travel left forward PAL - Main relief valve
Tank return T2 PCb P1 unload

Ports on rear sides (on machine)

LEFT RIGHT

P1 P1 pump

P2 P2 pump

Ports on right sides (on machine)

UPPER SIDE LOWER SIDE
Bucket dump BC

Bucket dump PBc

Bucket (H) stroke limit PCc AC Bucket digging

Boom up Ab Bb Boom down

Drain Dr BR Travel right reverse

Travel right forward AR

ATT power boost PL

Fig. 33-73 Control valve ports (1/2)

33-42
 33. UPPER STRUCTURE

* 




   
 
 

 * 


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'(& '(& 



  

 
   
 
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&* '(& $'+! '(&
     #  

 
    
 

 
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    " ! 
 


 
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Fig. 33-74 Control valve ports (2/2)

33-43
33. UPPER STRUCTURE

33.1.17 PILOT VALVE (FOR ATT)

33.1.17.1 PREPARATION FOR REMOVING

The removing procedure for right and left is the same,
so the preparation for left side is described here.
(1) Put attachment on ground, stop engine and release
pressure in tank.
(2) Remove left console cover (5), (6) assy referring to
Section 33.1.14CONSOLE COVER.
3
(3) Disconnect harness connector for horn at 2-1
position.
5
(4) Attach a tag to the hose to make assembly work
easier. *

Fig. 33-75 Installing and removing boot and lever

part

33.1.17.2 REMOVAL
(1) Remove hoses from your side to far side in order.  
: 19 mm, 22 mm
(2) Move the boot (3) up and loosen nut (5).
(See Fig. 33-75)

 
: 22 mm

  
 
  

(3) Turn and loosen lever (2-1) tightened in pilot valve,      
and remove lever assy in a set. (See Fig. 33-75) )*+ ) *
$% & ' !!& 

(4) Remove 4 capscrews (A14) M6×25. (See Fig. 33- $&  !!& 

76) $& 

: 5 mm ,$- .).
(5) Remove pilot valve. )*+ ) *
(6) Plug hose ends.
! " "
Plug PF1/4, PF3/8 (& & ' #    
/0 / ! " "
Fig. 33-76 Pilot valve connector

33.1.17.3 INSTALLATION
Install it in the reverse order of removal and tighten it. Front of machine
T Arm (R) Boom (R)
: 5 mm T = 11.8 N•m (11 lbf•ft) capscrew (Green) T (Gray)
(A14) Bucket (R)
Swing (R) (Blue)
(Red)
Swing (L)
(Gray)

Make sure the tightening torque for capscrews, Bucket (H) P

(Red)
because pilot valve is made of aluminum. Arm (H) (Blue) P
Boom (H) (Green)
LEFT SIDE RIGHT SIDE
Fig. 33-77 Pilot valve port position (from upper
side)

33-44
 33. UPPER STRUCTURE

33.1.18 PILOT VALVE (FOR TRAVEL)

33.1.18.1 PREPARATION FOR REMOVING

(1) Release pressure in hydraulic oil tank (See 33.1.7
HYDRAULIC TANK)
(2) Remove under cover (1) (See 33.1.5 UNDER
COVER)
A1
(3) Remove floor mat (B1). A8
A2 A7

A6
A7
A5

B1

A8

Fig. 33-78 Removing floor mat, pedal and and lever

33.1.18.2 REMOVAL
(1) Separate the two pressure sensors SE-9 (A9) and A14
A9
SE-10 (A9) at the connector. A1
T : Tightening torque
: 24 mm N.m (lbf.ft)
SE-9
(2) Attach tag, and discount connectors and hoses 6
(A2), (A3), (A4), (A5) T=16.7 (12)
A9 5 T T=30 (22)
: 19 mm (P port) P
A2

: 22 mm (T port, 1~4 port)

3 A5
SE-10 PT
A2 PT T
(3) Plug hose ends C/V P
T=30 (22) 4
Plug PF1/4, PF3/8 PAr
A3
1
(4) Remove 4 sems bolts (A8) M8×20, and remove
2
C/V BLOCK
right and left pedals (A5), (A6). Opposing PAL
B10
A4
PF3/8 flats 22 BLOCK
: 13 mm PF1/4 B11
A3
(5) Remove 4 sems bolts (A7) M10×20 and remove
right and left lever (A1), (A2).
VALVE SIDE HOSE SIDE
: 17 mm
VALVE SIDE T PORT CONNECTOR
(6) Remove 4 sems bolts (A14) M10×30.
PF3/8
Opposing Opposing
: 17 mm flats 22 flats 9 Mark "F"
(7) Remove pilot valve lifting it upward. PF1/4 PF1/4 PF1/4
(8) Stop up holes with plugs PF1/4.
HOSE SIDE
PORT P PORT CONNECTOR
CONNECTOR (With filter)

Fig. 33-79 Installing and Removing pilot valve

33-45
33. UPPER STRUCTURE

33.1.18.3 INSTALLATION
Install it in the reverse order of removal and tighten it.
Sems bolt (A14)

: 17 mm T = 37 N•m (27.3 lbf•ft)

Sems bolt (A7)

: 17 mm T = 46.1 N•m (34.0 lbf•ft)

Sems bolt (A8)

: 13 mm T = 23.5 N•m (17.3 lbf•ft)

Pressure sensor

: 24 mm T = 16.7 N•m (12.3 lbf•ft)

33-46
 33. UPPER STRUCTURE

33.1.19 SWING MOTOR UNIT

33.1.19.1 PREPARATION FOR REMOVING

(1) Park machine on firm level ground and place
attachment on ground.
(2) Remove the guard (8).
(See 33.1.4 GUARD)
(3) Operate the switch on gauge cluster and select the
pressure release mode, and then release the inner
pressure in circuit by operating control lever. (See
22.11 HYDRAULIC SYSTEM PRESSURE
DRAINING(RELEASING) CIRCUIT)
(4) Bleed air from the hydraulic oil tank and attach to
each hose a tag showing port name and other
information.

33.1.19.2 REMOVAL
(1) Remove hose. E 5
S/J
Dr
1) Remove hose (7) from the connector in the 7 C/V
Mu
makeup port M. 6
M A16 HYD.
: 41 mm A19 TANK
A
2) Remove 2 hoses (5), (6) from the Tee in the drain B A1
port Dr.
C/V
As
: 36 mm A2
C/V
3) Remove hose (A5) from the elbow of the PG port Bs

(For swing parking brake) (See Fig. 33-81)

: 19 mm
4) Loosen 8 capscrews (A19) M10×30 and remove
half clamp (A16). And disconnected A,B port
hoses (A1), (A2) from the motor.

: 8 mm Fig. 33-80 Removing swing unit piping

Put in plugs half clamp, PF1, PF3/4, PF1/2, and
PF1/4 into the removed ports. 2 2

A5

PG
1
S/V
A2

Fig. 33-81 Removing swing unit

33-47
33. UPPER STRUCTURE

(2) Removing the swing unit

Remove 14 capscrews (1) M24×70.

: 30 mm
1) Remove two plastic caps (2) M12 at the top of
the swing motor and install eye bolts.
: Flat-blade screwdriver
2) Put a wire sling in the eye bolts and remove the
swing motor unit.
Weight of swing motor unit ;
Approx. 446kg (983 lbs) (Include reduction assy)

33.1.19.3 PREPARATION FOR INSTALL

(1) Clean mating surfaces of swing motor unit and upper frame.
Tools : spatula, wash oil
(2) Apply Loctite #515 on entire mounting surface of swing motor unit.

33.1.19.4 INSTALLATION
Install the swing motor unit in the reverse order of
1
disassembly, confirming the orientation of the swing
Coat all the mounting
motor unit. surface of the swing
motor with Loctite #515
(1) Tighten 14 capscrews (1) M24×70. equivalent.

: 36 mm
Detail of swing motor unit assy mount
Tightening torque : 932N•m (687 lbf•ft) Apply
Loctite #262
(2) Fill inside from motor drain port to casing with
hydraulic oil before piping for drain
(3) Piping tightening torque

   




  
  # $ '&()
 ! # % )%)
1
 " # & $$' Apply Loctite #262
equivalent.
  #  ' LEVEL GAUGE Tightening torque
932N.m (687 lbf.ft)
Put sealing tape on the thread
portion of tube for level gauge.
Tightening torque 108N.m (80 lbf.ft)

Fig. 33-82 Installing swing motor unit

33.1.19.5 PREPARATION FOR DRIVE

(1) Before starting operation, check that gear oil #90 (API grade GL-4) level of swing reduction is sufficient.
Amount of oil : 7.4L (2.0gal)
(2) When starting operation, operate motor in low idling and at low speed for several minutes, and check it for
possible oil leak and noise.

33-48
 33. UPPER STRUCTURE

33.1.20 SWIVEL JOINT

33.1.20.1 PREPARATION FOR REMOVING

Remove boom piping hose

33.1.20.2 REMOVAL
(1) Remove travel motor hose and tube
1) Remove 2 hoses (A9). (E port : PF1/2)

: 27 mm, Tightening torque : 78.5 N•m (58 lbf•ft)

2) Remove tubes (A1), (A2). (A, B port : PF1)

: 41 mm, Tightening torque : 275 N•m (203 lbf•ft)

3) Remove tubes (A3), (A4). (C, D port : PF1)

: 41 mm, Tightening torque : 275 N•m (203 lbf•ft)

4) Remove 2 hoses (A10). (F port : PF1/4)

: 19 mm, Tightening torque : 29.4 N•m (22 lbf•ft)

A B

C D
(TRAVEL MOTOR) (TRAVEL MOTOR)
VB (LOWER) VA (LOWER)
REVERSE A,B,C,D-PF1 REVERSE
(LH) (RH)
VA (UPPER) E-PF1/2 VB (UPPER)
F-PF1/4
FORWARD FORWARD

T : Tightening torque
of connector
N.m (lbf.ft)

SWIVEL JOINT
B A4
F
B2
T=36.3 (26.8)
A2

T=255 (188)

C
T=255
A
(188) D

A10
E
B3

T=108 (79.7)
A3
A1
T=108 (79.7)
B3 A9
E

A9

Fig. 33-83 Removing piping (lower side)

33-49
33. UPPER STRUCTURE

(2) Disconnecting the hoses on the top part of swivel A4

joint
1) Remove drain hose (5). (E port : PF1/2)
5
: 27 mm
Tightening torque : 78 N•m (58 lbf•ft)
A7
2) Remove hoses (A3), (A9).
(A, C port : 1-3/16-12UN)

: 36 mm
Tightening torque : 177 N•m (130 lbf•ft)
3) Remove hoses (A4), (A7).
(B, D port : 1-3/16-12UN) A3
A9
: 36 mm A16
Tightening torque : 177 N•m (130 lbf•ft)
A8
4) Remove hose (A8).
(Travel 2-speed change over port : PF1/4)

: 19 mm
Tightening torque : 29 N•m (21 lbf•ft) Fig. 33-84 Disconnecting the hoses on the top part
of swivel joint
(3) Remove whirl-stop of swivel joint.
27 26 Tightening torque
1) Loosen the nut (27) M24. 157N.m (116 lbf.ft)

2) Remove a capscrew (26) M24×130.

: 36 mm
mm
13 At assembling,
this distance
should be 13mm (0.512in).

Fig. 33-85 Removing whirl-stop nut & the capscrew

(4) Remove joint for piping (See Fig. 33-83,Fig. 33-84)

 

1) Remove 2 connectors (B2). (F port)       %)

2) Remove connector (1) (F port) for travel 2-speed

 


change over. (PF1/4)       %
    
: 19 mm 
  
 !
 "
(5) Remove seal (B4)    #

$  %
1) Remove 6 capscrews (B8) M10×25. %

: 17 mm %  
  $

2) Remove clip (B9). %  #$
  
#
 $ !  &'( %
: Flat-blade screwdriver #    

3) Remove plate (B5), seal (B4). Fig. 33-86 Removing seal (B4)

33-50
 33. UPPER STRUCTURE

(6) Remove capscrew for installation

Attach eye bolt, lift it up temporarily, and remove 3
capscrews (C2) M12×25.

: 19 mm % &#
(See 11.7 SPECIAL TOOLS No.9 Plug)

# $

 


  


 
   ! "# 

Fig. 33-87 Removing capscrew for installation

(7) Slinging the swivel joint
Weight : Approx. 28kg (62 lbs)

33.1.20.3 INSTALLATION
(1) Installing is done in the reverse order of removing.
Piping tightening torque

Tightening torque N.m (lbf.ft)

Size Tool.
PF HEX O-ring type Hydraulic hose
Connector
1/4 19 36 (27) 29 (22)
3/8 22 74 (54) 49 (36)
1/2 27 108 (80) 78 (58)
3/4 36 162 (120) 118 (87)
1 41 255 (180) 137 (100)
1-3/16-12UN 36 - 177 (130)

(2) Check for oil leak and the hydraulic oil level.
(3) Check for operating.

33-51
33. UPPER STRUCTURE

33.1.21 UPPER FRAME

33.1.21.1 PREPARATION FOR REMOVING

(1) Remove attachment
(See chapter 32)
(2) Remove cab (See 33.1.2 CAB)
(3) Remove guard (See 33.1.4 GUARD)
(4) Remove counterweight
(See 33.1.11 COUNTERWEIGHT)
(5) Remove swivel joint
(See 33.1.20 SWIVEL JOINT)

Fig. 33-88 Temporarily lift upper frame

33.1.21.2 REMOVAL
(1) Lifting up upper frame temporarily



Temporarily lift the unit at three points ; the upper
frame lifting jig (Refer to Tool "chapter 11"), the 2
lifting holes near the boom foot pin and the angle
steel at the back of the upper frame.
(2) Marking match marks on swing bearing
Put match marks on upper frame and swing
bearing.

Fig. 33-89 Matching mark on swing bearing and

upper frame
(3) Removing upper frame attaching bolts
Remove 34 capscrews (10) M24×135 and a reamer
bolt (11) used to install swing bearing and upper
frame.

: 36 mm
(4) Slinging upper frame
Sling according to Fig. 33-88, and remove upper
frame and put it on a stand.
Weight : Approx. 5ton (11,000lbs)

Fig. 33-90 Removing upper frame attaching bolts

33-52
 33. UPPER STRUCTURE

33.1.21.3 INSTALLATION
(1) Installing is done in the reverse order of removing. Apply Loctite #515 to the race surface
(2) Cleaning mating surfaces of upper frame and swing over the whole circumference (shaded area)
on the inside of capscrew.
bearing.
(3) Apply Loctite #515 to the inside of the capscrews
on the contact surface.
(4) Slinging upper frame
Match marks and install it with a reamer bolt (11)
and a washer (12) temporarily.

Apply Loctite #262

equivalent.
T=932N.m (687 lbf.ft)
Confirm the reamer bolt positions referring to Fig. 33- 10,11
92.
Fig. 33-91 Bearing mount

 
  

: 36 mm Apply Loctite #262

Tightening torque : 932 N•m (687 lbf•ft)
Apply Loctite #262
(5) Install swing bearing
Install 34 capscrews (10) M24×135.

: 36 mm Apply Loctite #262

Tightening torque : 932 N•m 687lbf•ft)

Fig. 33-92 Reamer bolt position (*) Apply Loctite to

shaded area

33-53
33. UPPER STRUCTURE

33.2 DISASSEMBLING AND ASSEMBLING

33.2.1 HYDRAULIC PUMP • REGULATOR

33.2.1.1 HYDRAULIC PUMP

33.2.1.1.1 Structural exploded view

(1) Main pump

983 531
981 . 534
548 792
702
B 532
732 X
789 Z
535 W
886 Y
953 A
806

728
468
113
127
123
127
824 271

325 808
717
04 490 954 546901
251 312
725
401 407 490
C

124
727 886
314
717 D
141 546
157 E
156
151 153 885 727
. 886
152 467
B 725
211 466
214 406
212 261 D
774 E
710
F

A
116
724 710
717
313 326
124 F 414 05

111
C

885
Fig. 33-93 Structural exploded view of main pump

33-54
 33. UPPER STRUCTURE

Marks in Fig. 33-112 show the position where regulator is installed.

No. Name Q'ty No. Name Q'ty No. Name No.

111 Shaft(F) 1 314 Valve plate (L) 1 724 O-ring ; 1B P8 16
113 Shaft(R) 1 325 Sensor block 1 725 O-ring ; 1B P11 9
116 1st gear 1 326 Cover 1 727 O-ring ; 1B P14 3
123 Roller bearing 2 401 Socket bolt ; M20X210 8 728 O-ring ; 1B P24 4
124 Needle bearing 2 406 Socket bolt ; M8X20 4 732 O-ring ; 1B P18 2
127 Bearing spacer 3 407 Socket bolt ; M6X55 3 774 Oil seal 1
141 Cylinder block 2 414 Socket bolt ; M10X20 4 789 Backup ring P18 2
151 Piston 18 466 VP plug ; PF1/4 2 792 Backup ring G35 2
152 Shoe 18 467 VP plug ; PF3/8 2 806 Nut ; M16 2
153 Retainer 2 468 VP plug ; PF3/4 4 808 Nut ; M20 2
156 Spherical bushing 2 490 Plug ; NPTF1/16 32 824 Stop ring 2
157 Cylinder spring 18 531 Tilt pin ; M24X2 2 885 Valve plate pin 2
211 Shoe plate 2 532 Servo piston ; M24X2 2 886 Spring pin 4
212 Swash plate 2 534 Stopper (L) 2 901 Eye bolt ; M10 2
214 Tilting bushing 2 535 Stopper (S) 2 953 Socket screw ; M16X35 2
251 Swash plate support 2 546 Spacer 2 954 Set screw ; M20 2
261 Seal cover (F) 1 548 Feed back pin 2 04 Gear pump 1
271 Pump casing 2 702 O-ring ; 1B G35 2 05 PTO gear case 1
312 Valve block 1 710 O-ring ; 1B G95 2
313 Valve plate (R) 1 717 O-ring ; 1B G145 4
The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.

Tightening torque of bolt, plug, nut and servo piston

Tightening torque
No. Thread size
N.m (lbf.ft)
401 M20 430 (317)
406 M8 29 (21)
407 M6 12 (8.9)
414 M10 57 (42)
466 PF 1/4 36 (27)
467 PF 3/8 74 (55)
468 PF 3/4 170 (125)
490 NPTF1/16 8.8 (6.5)
531,532 M24X2 240 (177)
806 M16 130 (95)
808 M20 240 (177)

33-55
33. UPPER STRUCTURE

(2) Gear pump (For pilot)

700 354 351

Suction port : PF3/4 433
Tightening torque : 73.5N.m (59 lbf.ft)

434

Delivery port : PF1/2

Tightening torque :
53N.m (39 lbf.ft)

311

312

732 307 850

434 355
Drain port : PF3/8 310 308 309 466
725
710 435 361 353 Tightening torque :
34.3N.m (25 lbf.ft)

Fig. 33-94

No. Name Q’ty No. Name Q’ty

307 Poppet 1 361 Front case 1
308 Seat 1 433 Flange socket ; M8×40 2
309 Ring 1 434 Flange socket ; M8×55 2
310 Spring 1 435 Flange socket ; M8×20 4
311 Adjust screw 1 466 VP plug ; PF1/4 1
312 Lock nut ; M14×1.5 1 700 Ring 1
351 Gear case 1 710 O-ring ; 1B G95 1
353 Drive gear 1 725 O-ring ; 1B P11 1
354 Driven gear 1 732 O-ring ; 1B P16 1
355 Filter 1 850 Snap ring 1

33-56
 33. UPPER STRUCTURE

33.2.1.1.2 Disassembly and assembly of main pump

(1) Tools
Tool Part
The right list shows the tools required for remove
and install. Name Size mm Size Item No.
5 M6 407
(2) Disassembling procedure 6 M8 406
Allen wrench
1) Selecting a place for disassembly. 8 M10 414
• Choose a clean place. 14 M16 953
17 M20 401
• Spread rubber sheet or cloth on work bench
to protect parts from damaging. Eye wrench 19 PF1/4 466
Socket wrench 24 M16 806
2) Cleaning
Wrench ; Double 30 M20 808, 954
Remove dust and rust, etc. on pump surface with single 36 PF3/4 468
wash oil. Crescent wrench Medium size 1pc.

Driver Flat bladed 2pcs.

Hammer Plastic
Plier Snap ring
Steel bar 10X8X200
Torque wrench
3) Drain oil
REGULATOR
Drain out the oil in the pump casing by removing
drain port plug (466), (468).

: 19 mm, 36 mm

• Drain out oil from the plug of the front pump

and the rear pump.

4) Removing regulator and PTO gear casing

Remove the socket bolts [412, 413, 414 (See
Fig. 33-93, Fig. 33-112)]. Then remove the
regulator and the PTO cover (326).

: 6 mm, 8 mm

• Regarding the disassembly of the regulator,

refer to article of Regulator.

5) Remove gear pump
 

Remove the socket bolts (435). Then remove the 

gear pump (04).

: 6 mm

6) Remove socket bolt (401)

Loosen socket bolts (401) that fasten swash
plate support (251), pump casing (271) and
valve block (312).

: 17 mm
Fig. 33-95 Remove socket bolt (401)

33-57
33. UPPER STRUCTURE

7) Disassembling the pump casing and the valve

312 271
block
Place the pump level on a work bench with its
mounting surface of the regulator facing down.
Then separate pump casing (271) and valve
block (312).

• When facing the mounting surface of the

regulator down, place a rubber sheet on a
work bench so as not to score the mounting
surface.
Fig. 33-96 Disassembling the pump casing (271)
• When the pump casing has been separated and the valve block (312)
from the valve block, draw out the 1st gear
(116) at the same time.
8) Drawing out the cylinder assy %
Draw out cylinder (141) out of pump casing (271)
"##%
in parallel to shaft (111). At the same time draw
out piston (151), plate (153), spherical bushing #!
(156) and cylinder spring (157). #$

• Use care so as not to score the sliding

surface of the cylinder, spherical bushing,
shoe and the swash plate.

Fig. 33-97 Drawing out the cylinder assy

9) Remove seal cover (F)
406
Remove socket bolt (406) M8 and seal cover F
(261). 261
: 6 mm

• The seal cover (F) may be drawn out with

ease if it is taken out by tightening bolts in the
tapped holes (M6 tap) of the seal cover (F).
• An oil seal is fitted to seal cover (F).
Therefore, use care so as not to score the oil
seal.
Fig. 33-98 Removing seal cover F (261)

33-58
 33. UPPER STRUCTURE

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. 33-99 Separating the swash plate (251) support

and the pump casing (271)
11) Remove shoe plate and swash plate
Draw out shoe plate (211) and swash plate (212)
%
from pump casing (271).

  

Fig. 33-100 Removing shoe (211) and swash plate

(212)
12) Drawing out the shaft
Tap lightly the shaft end (111, 113) by means of a #
plastic hammer and draw out the shaft from the
swash plate support.
!

Fig. 33-101 Drawing out the shaft (111), (113)

33-59
33. UPPER STRUCTURE

13) Remove valve plate

Remove valve plate (313, 314) from valve block
(312).

312
• The valve plate may come off during the
operation under 7).
314
(313 :
Opposite Side)

Fig. 33-102 Removing valve plates (313), (314)

14) Remove other parts 531
If necessary, remove stopper (L) (534), stopper
(S) (535), servo piston (532) and tilting pin (531)
from pump casing (271), and remove needle
534
bearing (124) from valve block (312). 806 535
532

• When removing the tilting pin, use care so as

not to score the head of the tilting pin, using
a jig. 808
• It is hard to separate the tilting pin from the
servo piston in some cases as Loctite is 312
124
coated on the mating part between them. 271

Use care so as not to score the servo piston

by applying undue force. 251
• Do not draw out needle bearings except
when their service life has ended.
• Do not loosen hex nuts (806),(808) of valve
block (312) and swash plate support (251). A
set flow rate changes.
Fig. 33-103 Removing other parts

33-60
 33. UPPER STRUCTURE

(3) Installing procedure

1) Precautions to be exercised in installation
Assembly is a reverse order of disassembly, but
notice the following.
1. Repair scored parts at disassembly. Get
replacements ready beforehand.
2. Wash parts sufficiently in cleaning oil and dry
them with jet air.
3. Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
4. In principle, replace sealing parts such as O-
rings and oil seals.
5. Tighten socket bolts and plugs to specified
torques in this manual, using a torque
wrench.
6. Do not mix up front pump parts with rear
pump parts.
2) Installing swash plate support
%
Attach swash plate support (251) to pump casing
(271) by tapping the swash plate support lightly
with a plastic hammer.

• When the servo piston, the tilting pin, the

stopper (L) and the stopper (S) have been
removed, install them to the pump casing
beforehand.
• When tightening servo piston and tilting pin,
use a jig so as not to damage the head of the #
tilting pin and feedback pin.
Coat the screwed part with Loctite #262.
Fig. 33-104 Installing swash plate support (251)
3) Installing swash plate #
Place the pump casing with its mounting surface %#!
of the regulator facing down, insert the tilting
bushing of the swash plate into tilting pin (531),
and fit swash plate (212) to swash plate support
(251) properly.

• Confirm by the fingers of your both hands

that swash plate moves smoothly. 
• The shaft be installed easily if grease is
applied to the sliding parts of swash plate
and swash plate support.
• Do not damage the sliding surface of shoe
plate. Fig. 33-105 Installing swash plate (212)

33-61
33. UPPER STRUCTURE

4) Installing shaft
Install shaft (111) fitted with bearing (123),
bearing spacer (127) and snap ring (824), to
swash plate support (251).
251

• Do not knock on the shaft with a hammer or

something. 123
• Fix the bearing by lightly tapping the outer
127,824
race of it by means of a plastic hammer and
set it exactly to the end by using a steel rod
and others.

111

Fig. 33-106 Installing shaft (111)

5) Installing seal cover
Assemble seal cover (F) (261) to pump casing
(271) and fix it with socket bolts (406). %

: 6 mm $
Tightening torque : 29 N•m (22 lbf•ft)
"$
• Coat the oil seal in seal cover (F) with a thin
film of grease.
• Handle the oil seal with sufficient care so it is
not scored.

Fig. 33-107 Installing seal cover F (261)

6) Inserting piston cylinder sub
Assemble the piston cylinder sub [cylinder block
141(151,152,157)
(141), piston (151), shoe (152), plate (153),
spherical bushing (156) and cylinder spring 156
(157)].
Align the spherical bushing with the cylinder 153
spline and insert them into the pump casing.

Fig. 33-108 Inserting piston cylinder sub

7) Installing valve plate
Install valve plate (313), (314) to valve block
(312) by aligning pin.

312
• Do not mistake the suction and delivery sides
of the valve plate.
314
(313 :
Opposite Side)

Fig. 33-109 Installing valve plates (313), (314)

33-62
 33. UPPER STRUCTURE

8) Installing valve block 312 271

Install valve block (312) to pump casing (271) 401
and fasten them together with socket bolts (401).

: 17 mm
Tightening torque ; 430 N•m (320 lbf•ft)

• Work will be promoted if assembly is started

from the rear pump.
• Exercise care so as not to mistake the
direction of the valve block (312). (Install it so
Fig. 33-110 Installing valve block (312)
the regulator comes up as seen from the
front side and the suction flange comes on
the right.)
• Insert the 1st gear into the valve block
beforehand and connect it with the spline of
the shaft.
9) Installing gear pump
Install gear pump (04) and fasten them together
with socket bolts (435).

: 6 mm
Tightening torque ; 17 N•m (12.5 lbf•ft)

10) Installing regulator and PTO cover REGULATOR

Pinch feedback pin of tilting pin in feedback lever
of the regulator and PTO cover (326), install the
regulator and fasten socket bolt.
(412)(413) (See Fig. 33-112]
Socket bolt (412)(413) …… For regulator

: 6 mm,
Tightening torque ; 29 N•m (21 lbf•ft)
Socket bolt (414) …… PTO Cover (326)

: 8 mm,
Fig. 33-111 Installing regulator and PTO cover
Tightening torque ; 57 N•m (42 lbf•ft)

• Do not mistake the front regulator for the rear

regulator.

11) Installing drain port plug

The work is complete when drain port VP plugs
(466), (468) have been set.

: 19 mm, 36 mm
Tightening torque ; 36 N•m (27 lbf•ft)
Tightening torque ; 170 N•m (125 lbf•ft)

33-63
33. UPPER STRUCTURE

33.2.1.1.3 MAINTENANCE STANDARDS

(1) Replacement standards for abrasive parts
Replace or readjust parts that exceed the following standards of wear.
However, always replace such parts that show excessive damage on appearance.

mm (in)
Recommended
Standard
Part name and inspection item value Remedy
dimension
forreplacement
Clearance between piston and cylinder
0.043 0.070
bore Replace piston or cylinder.
(0.0017 ) (0.0028 )
(D-d)
Gap between piston and caulked part of
shoe 0 ~ 0.1 0.3
Replace piston shoe assy.
(0.004 ) (0.012 )
( )
Thickness of shoe 5.4 5.0
Replace piston shoe assy.
(t) (0.213 ) (0.197 )
Free height of cylinder spring 47.9 47.1
Replace cylinder spring.
(L) (1.886 ) (1.854 )
Combined height of retainer plate and
23.8 22.8 Replace a set of spherical bushing or
spherical bushing
(0.937 ) (0.898 ) retainer plate.
(H-h)
Cylinder over pin dia. (spline in cylinder) 35.17 35.57
Replace cylinder, spherical bushing.
spline in spherical bushing. (1.385 ) (1.400 )

  

 
         
   


       


 
     
      
   

33-64
 33. UPPER STRUCTURE

(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face)

Valve plate (sliding section) Surface roughness requiring

3-Z
Swash plate (shoe plate face) correction
Cylinder (sliding section) Standard surface roughness
Less than 0.4Z (lapping)
Roughness of each surface (correction value)

33.2.1.1.4 Troubleshooting
(1) Locating causes of troubles
The pump is usually fitted with a regulator, auxiliary valves and auxiliary pumps, and this makes fault location
extremely difficult. However, faults would be found out easily if the following check items were attended to.
1) Inspecting the filter and drain oil
Inspect the filter element to check for abnormal contaminations. Some metallic particles will be deposited on
it as the shoe and the cylinder wear off. In case metallic particles are found in large quantity, the elements
may be damaged. In that case check the drain oil in the pump casing as well.
2) Checking for abnormal vibration and sound
Check that the pump does not vibrate and make an abnormal sound.
Check that the hunting of the regulator and the attached valveÅfs relief valve are of regular frequency. In
case vibration and sound are abnormal, the pump may be making a cavitation or internally broken.
3) When two pumps are used
In case two single pumps or motors are used or when a double pump is used. change pump pipelines. This
will make clear that the pumps are faulty or the circuit after the pumps is faulty.
4) Pressure measurements
If the problem is related to control functions, avoid disassembling the pumps carelessly, but look for causes
by measuring pressures.

(2) Troubleshooting
1) Overloading to engine

Cause Remedy Remarks

1. Revolution and pressure are higher 1) Set pressure to specified value.
than set values.
2. Regulator torque is set higher than 2) Readjust regulator. 2)Refer to Regulator Manual.
normal.
3. PumpÅfs internal parts are seized or 3) Replace damaged parts. 3) Check filter and drain oil to see if
broken. abnormal wear particles are present.
4. Regulator is piped incorrectly. 4) Pipe regulator correctly.

2) Pump’s oil flow rate is extremely low and delivery pressure is not available.

Cause Remedy Remarks

1. Regulator is out of order 1) Repair regulator. 1) Refer to Regulator Manual.
2. Pump’s internal parts are seized or 2)Replace damaged parts. 2)Check filter and drain oil.
broken.
3. Attached pump is out of order 3) Replace damaged parts. 3) Remove attached pump and check
shaft joint.
4. Attached valve is out of order. 4) Check attached valve. 4) Refer to Manual for Attached Valve.
Particularly poppet, seat and
spring.
5. Regulator is piped incorrectly. 5) Pipe correctly.

33-65
33. UPPER STRUCTURE

3) Abnormal Sound and Vibration

Cause Remedy Remarks

1. Cavitation
2. Caulked part of shoe is broken.
3. Cylinder is cracked
4. Pump is installed improperly.
5. Regulator is hunting.
6. Relief valve in attached valve is
hunting.
1) Prevent cavitation.
Check that hydraulic oil is not
clouded.
2)Replace piston shoe and shoe
plate.
3) Replace cylinder.
4) Correct installation.
5) Repair regulator,
6) Repair attached valve.
1-1) The boost pressure is low.
1-2) The attached pump is in trouble.
1-3) The suction pipe is inhaling air.
1-4) The suction resistance is high.
5) See Regulator Manual.
6) See the Manual for Attached Valve.

33-66
 33. UPPER STRUCTURE

This page is blank for editing convenience.

33-67
33. UPPER STRUCTURE

33.2.1.2 REGULATOR

33.2.1.2.1 Structural exploded view

626
625
624
753
627
623
621 D 728
B 645
611
622 F
733 874 646
613
732 875 644
631 612
898 875
652
A 643
651
836 G E
897 C
655
654
653
814
630
438

629

763
802
628
756
801
924
412
656 413

438 757

Y
W
Z D
418 079 E
041 876
755 X 615
601 755
722 858
466 496 734
755 G
887
708 F

A 876
662 B 724 614
439 C
642 730 725 8-724 755
858
041 755
755 466
466 755

641

Fig. 33-112 Structural exploded view of regulator

33-68
 33. UPPER STRUCTURE

Marks in Fig. 33-93 show the position where regulator is installed.

No. Name Q'ty No. Name Q'ty No. Name No.

412 Socket bolt ; M8X50 2 628 Adjust screw (C) 1 732 O-ring ; 1B P16 1
413 Socket bolt ; M8X70 2 629 Cover (C) 1 733 O-ring 1
418 Socket bolt ; M5X12 2 630 Lock nut ; M30X1.5 1 734 O-ring ; 1B G25 1
438 Socket bolt ; M6X20 8 631 Sleeve (For PF) 1 753 O-ring ; 1B P9 1
439 Socket bolt ; M6X25 5 641 Pilot cover 1 755 O-ring ; 1B P11 7
466 VP plug ; PF1/4 3 642 Spool 1 756 O-ring ; 1B P26 1
496 Plug ; NPTF1/16 17 643 Pilot piston 1 757 O-ring ; 1B P12.5 1
541 Seat 2 644 Spring seat (Q) 1 763 O-ring ; 1B G35 1
543 Stopper 1 2 645 Adjust stem (Q) 1 801 Nut ; M8 1
545 Ball 2 646 Pilot spring 1 802 Nut ; M10 1
601 Casing 1 651 Sleeve 1 814 Snap ring 1
611 Feed back lever 1 652 Spool 1 836 Snap ring 1
612 Lever (1) 1 653 Spring seat 1 858 Snap ring 2
613 Lever (2) 1 654 Return spring 1 874 Pin ; 4X11.7L 1
614 Fulcrum plug 1 655 Set spring 1 875 Pin ; 4X8L 2
615 Adjust plug 1 656 Block cover 1 876 Pin ; 5X8L 2
621 Compensating rod 1 662 Spring 1 887 Pin 1
622 Piston case 1 708 O-ring ; 1B G75 1 897 Pin ; 5X19L 1
623 Compensating rod 1 722 O-ring ; 1B P6 3 898 Pin ; 7.5X11L 1
624 Spring seat (C) 1 724 O-ring ; 1B P8 8 924 Socket screw ; M8X20 1
625 Outer spring 1 725 O-ring ; 1B P10 1 041 Check valve sub 2
626 Inner spring 1 728 O-ring ; 1B P18 1 079 Solenoid proportional 1
627 Adjusting stem (C) 1 730 O-ring ; 1B P22 1 reducing valve

The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.

Tightening torque of bolt, plug and nut

Tightening torque
No. Thread size
N.m (lbf.ft)
412,413 M8 29 (21)
438,439 M6 12 (8.9)
418 M5 6.9 (5)
466 PF 1/4 36 (26)
496 NPTF1/16 8.8 (6.5)
630 M30X1.5 160 (118)
801 M8 16 (12)
802 M10 19 (14)

33-69
33. UPPER STRUCTURE

33.2.1.2.2 Disassembly and assembly

(1) Tools
The right list shows the tools required for remove

 
and install. 
 
   

  
(2) Disassembling procedure  ! " !#   
1) Selecting a place for disassembly.   


$  " !#   
• Choose a clean place. %  ! " !#
    
• Spread rubber sheet or cloth on work bench
to protect parts from damaging. &'   +- -
(  
2) Cleaning
)* " !#
Remove dust and rust, etc. on regulator surface  
! !0
with wash oil.
  + .//
3) Drain oil !  
Drain out the oil in the pump casing by removing ,
 ./
drain port plug (468).

3) Remove regulator (SeeFig. 33-112)

438 656 413 412
Remove socket bolts (412, 413) and separate
the regulator from the pump body.
629
: 6 mm

4) Remove port plate (See Fig. 33-112)

Remove socket bolt (438) and separate the port
438
plate (656).
601
: 5 mm

Fig. 33-113 Removing regulator

5) Remove cover (See Fig. 33-112)
Remove socket bolts (438) and remove cover
(C) (629).

: 5 mm

• The cover is equipped with adjust screws 624,625,626

(628), adjust stem (627), lock nut (630), hex 627
nut (801) and set screw (924). Do not loosen
801
those screws and nuts. If they are loosened,
preadjusted set pressure and flow values 629( 628 )
change.

630 924
Fig. 33-114 Removing cover (C) (629)

33-70
 33. UPPER STRUCTURE

6) Remove compensating parts

M4 BOLT 645
(See Fig. 33-112 (D) section, See Fig. 33-114,
644,646
Fig. 33-115)
After removing the cover (C) (629) sub assy, take
out outer spring (625), inner spring (626) and
601
spring seat (624) from the compensating part.
Then take out adjust stem (645), pilot spring
(646) and spring seat (644) from the pilot part.

• Adjust stem (645) comes out easily if an M4

bolt is used.
Fig. 33-115 Removing compensating parts
7) Remove pilot cover and the set spring
Remove socket bolt (439) and pilot cover (641).
Once the pilot cover comes off, separate set
spring (655) from the pilot section.
(Fig. 33-112 (A) and (B) section)

: 5 mm

439
641

Fig. 33-116 Removing pilot cover (641) and set

spring (655)
8)Remove spring seat, return spring and sleeve
(Fig. 33-112 (A) section)
Remove snap ring (814). Then remove spring
814(653)
seat (653), return spring (654) and sleeve (651).

• Sleeve (651) is equipped with snap ring 654,

(836). 651(836)
• When removing snap ring (814), return
spring (654) comes out : Use care so as not
to lose it.

Fig. 33-117 Removing spring seat (653), return

spring (654) and sleeve (651)
9) Remove adjust plug (Fig. 33-112 (F),(G) section)
emove snap ring (858) and take out fulcrum plug
(614) and adjust plug (615). &#&

• Fulcrum plug (614) and adjust plug (615) $#

come off easily if a M6 bolt is used.
$"

Fig. 33-118 Removing adjust plug (615)

33-71
33. UPPER STRUCTURE

$"

Fig. 33-119 Removing fulcrum plug (614)

10) Remove lever (Fig. 33-112 (G) section)
Remove lever 2 (613).
Do not draw out pin (875).

• The work is eased if tweezers is used.

$!&%#

Fig. 33-120 Removing lever 2 (613)

11) Remove feedback lever
Draw out pin (874) and remove feedback lever &%"
(611).

• Push out pin (874) [pin dia : ø4mm (0.157in)]

from above with a slender steel rod so as not
to interfere with lever 1 (612). $

Fig. 33-121 Removing feedback lever (611) [1]

$
Fig. 33-122 Removing feedback lever (611) [2]

33-72
 33. UPPER STRUCTURE

12)Remove lever (Fig. 33-112 (F) section)

Remove lever 1 (612). $
$
Do not draw out pin (875). &%"
&'%
&%# $!
13) Remove pilot piston and spool &%#
(Fig. 33-112 (C),(A) section)
Draw out pilot piston (643) and spool (652).

14) Remove piston casing, compensating piston

and compensating rod (Fig. 33-112 (B) section)
Draw out piston casing (622), compensating $"!
piston (621) and compensating rod (623).

• Piston casing (622) comes out from the $ !

opposite side of the piston casing if $ $ 
compensating rod (623) is pushed out. %!!
%!
$!
&'& $#
$#
&!$
$##
$#"
$#!
&"

Fig. 33-123 Part of exploded view of regulator

15) Remove spool (642) and spring (662)
"$$
Remove VP plug (466) from pilot cover (641),
and draw out spool (642) and spring (662).

This completes disassembly.

$$
$"

"$$

$"
Fig. 33-124 Part of exploded view of regulator

33-73
33. UPPER STRUCTURE

(3) Installing procedure :

Assembly is the reverse order of disassembly. Do
the work paying attention to the following :
• Repair those parts that were damaged during
disassembly and prepare replacement parts
beforehand.
• If foreign matter enters, it causes malfunction;
clean parts thoroughly in cleaning oil, blow them
with jet air and assemble parts in a clean place.
• Always tighten bolts and plugs to the specified
torque. The tolerance of torque should be within
10%.
• Do not fail to coat the moving parts with clean
hydraulic oil, before assembly.
• In principle, replace seals such as O-ring.
1) Installing compensating rod (Fig. 33-112 (B)

section)


Assemble compensating rod (623) into the 
compensating hole of casing (601). 
 
 
2) Assembling lever 
Put the pin pressed in lever 1 (612) into the
groove of the compensating rod (623). Then
assemble the lever to the pin (875) that is
pressed in the casing.
Fig. 33-125 Part of exploded view of regulator
3) Assembling spool and sleeve (See Fig. 33-112
PIN (874)
(A) section)
Assemble spool (652) and sleeve (651) into the
spool hole of the casing.

• Make sure that the spool and the sleeve (652) SPOOL FEEDBACKLEVER(611
move smoothly in the casing.
• Beware of the direction of the spool. Fig. 33-126 Direction of the spool (652)

4) Assembling feedback lever

 


 
Assemble feedback lever (611). Then put pin
(874) into the pin hole of the feedback lever.

• The work is eased if the pin is put in the




   




 
  
feedback lever a little, beforehand.   
  

• Take care so as not to mistake the direction
of the feedback lever.

Fig. 33-127 Assembling feedback lever (611)

33-74
 33. UPPER STRUCTURE

5) Assembling pilot piston (See Fig. 33-112 (C)

section)
Assemble pilot piston (643) into the positive
control hole of the casing.

• Make sure that the pilot piston moves $!&%#

smoothly.

6) Assembling lever (See Fig. 33-112 (G) section)

Place pin (875) pressed in lever 2 (613) into the
groove of the pilot piston and assemble lever 2
(613). Fig. 33-128 Assembling lever 2 (613)

7) Installing fulcrum plug (See Fig. 33-112 (F)

section)
Assemble fulcrum plug (614) so pin (875) 614(875,858)
pressed in the fulcrum comes in the pin hole of
lever 2 (613). Then fit snap ring (858).

Fig. 33-129 Installing fulcrum plug (614)

8) Installing adjust plug (See Fig. 33-112 (G)
section)
Insert adjust plug (615) and fit a snap ring (858). &#&

• Use care so as not to mistake the holes into $#

which the fulcrum and adjust plug are
inserted. $"
• At this point, operate the feedback lever and
make sure that the gap is not large and that
the lever moves smoothly.

Fig. 33-130 Installing adjust plug (615)

9) Installing return spring and the spring seat
(See Fig. 33-112 (A) section)

Assemble return spring (654) and spring seat 
(653) into the spool hole and fit snap ring (814).




Fig. 33-131 Installing return spring (654) and spring

seat (653)

33-75
33. UPPER STRUCTURE

10) Assembling compensating parts (See Fig. 33-

112 (A),(B) section)
Assemble set spring (655) into the spool hole.
Place compensating piston (621) and piston
casing (622) into the compensating hole and
attach pilot cover (641). Then fasten them
together with socket bolts (438), (439).

: 5 mm
Tightening torque ; 12 N•m (8.7 lbf•ft) $ $ 
Fig. 33-132 Assembling compensating parts
11) Installing spool and spring
"$$
Assemble spool (642) and spring (662) into pilot
cover (641), and tighten VP plugs (466).

$$
$"

"$$

$"
Fig. 33-133 Assembling spool (642)
12) Assembling into the pilot hole and the 644,645,646
compensating hole 626
(See Fig. 33-112 (E),(D) section)
Put spring seat (644), pilot spring (646) and 625(624)
adjust stem (645) into the pilot hole. Then
assemble spring seat (624), inner spring (626)
and outer spring (625) into the compensating
hole.

• Do not mistake the direction of the spring

Fig. 33-134 Assembling into the pilot hole and
seat.
compensating hole

13) Installing cover

Attach cover (C) (629) fitted with adjust screws
(628), (925), adjust stem (627), lock nut (630),
nut (801) and socket bolt (924). Then fasten
them with socket bolts (438).

: 5 mm 624,625,626
Tightening torque ; 12 N•m (8.7 lbf•ft) 627
801
14) Installing block cover (See Fig. 33-113) 629( 628 )
Attach block cover (656).

: 5 mm
630 924
Tightening torque ; 12 N•m (8.7 lbf•ft)
Fig. 33-135 Installing cover (C) (629)
This completes assembly.

33-76
 33. UPPER STRUCTURE

33.2.1.3 PTO GEAR CASING (For OCEANIA)

33.2.1.3.1 Structural exploded view

414
117 128

216 435
826 886 711
128 326

414
115
886 262
728
885 125 468

118
125
825
710 435
435

414

262
414

Tightening torque Tightening torque

No. Parts name Q’ty No. Parts name Q’ty
N•m (lbf•ft) N•m (lbf•ft)
115 Idle shaft 1 33 (25) 435 Flange socket ; M10×20 4
117 2nd gear 1 74 (54) 468 VP plug ; PF3/4 1
118 3re gear 1 710 O-ring ; 1B G80 1
125 Ball bearing 2 711 O-ring ; 1B G85 1
126 Roller bearing 1 728 O-ring ; 1B P24 1
128 Bearing spacer 2 825 Snap ring 1
262 Cover 2 826 Snap ring 1
326 Gear casing 1 885 Spring pin 1
33 (25) 414 Socket bolt ; M10×20 4 886 Pin 2

33-77
33. UPPER STRUCTURE

33.2.1.3.2 Disassembly and assembly

(1) Tools
Tool name Dimension
The right list shows the tools required for remove
Allen wrench Opposing flats 8,10mm
and install.
For snap ring RR-20
(2) Disassembling procedure Plier
For snap ring RR-72
1) Selecting a place for disassembly.
• Choose a clean place.
• Spread rubber sheet or cloth on work bench
to protect parts from damaging.
2) Cleaning
Remove dust and rust, etc. on pump surface with
wash oil.
3) Drain oil
Drain out the oil in the pump casing by removing
drain port plug (468).

: 27 mm
• Drain out the oil from the plugs of the front
pump and the rear pump.
4) Remove cover FLANGE SOCKET (M10)
Remove the socket bolts (414). Then remove the Tightening torque : 33N.m (25 lbf.ft)}
cover (262).

: 8 mm
5) Remove PTO gear casing 414
Remove flange socket (435) and PTO gear
casing.

: 8 mm

262 COVER
PTO GEAR CASING

414

262 COVER
Fig. 33-136 Removing gear pump

HOLE FOR FLANGE

SOCKET (435)

PTO
GEAR CASING

Fig. 33-137 Removing PTO gear casing

33-78
 33. UPPER STRUCTURE

6) Removing the 2nd gear, the roller bearing and HOLE FOR
the bearing spacer IDLE SHAFT (115)
Draw out the spring pin (885) and remove idle
shaft (115). Then draw out 2nd gear (117), roller
bearing (126) and bearing spacer (128). 117 (126,128)
• Roller bearing (126) can not be separated
from 2nd gear (117).

Fig. 33-138 Removing 2nd gear (117)

7) Removing the 3rd gear and the ball bearing
Remove snap ring (825) and draw out 3rd gear
(118) and ball bearing (125).
• Ball bearing (125) can not be separated from 125
3rd gear (118).

118

Fig. 33-139 Removing 3rd gear (118) and ball

bearing (125)
(3) Installing procedure
Assembly is a reverse order of disassembly, but
notice the following.
1) Repair scored parts at disassembly. Get
replacements ready beforehand.
2) Wash parts sufficiently in cleaning oil and dry
them with jet air.
3) Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
4) In principle. replace sealing parts such as O rings
and oil seals.
5) Tighten socket bolts and plugs to specified
torques in Service Standard, using a torque
wrench.
6) Do not mix up front pump parts with rear pump
parts.

33.2.1.3.3 Maintenance standards

In case a pitching (1 pit is more than 1mm (0.039in), while the area ratio is more than 5%.) is seen on the gear tooth
surface of 2nd gear (117) and 3rd gear (118), replace the gears. Replace the gears also in case they show excessive
damage.

33-79
33. UPPER STRUCTURE

33.2.2 CONTROL VALVE

33.2.2.1 SECTIONAL VIEW

154 164 101

P2

T2 T1

PAL PBL

PB1 PCa

PBs PAs

Pss

PBa1 PAa1

PAo PBo

(P4)
163 162 163 169 155 162
SECTION A-A
154 164
P1
102

973 973

PTb PCb

973
973
PBr PAr

973

PAb PBb

973 PBc 973

PCc
PAc

974 973
PAa2 PBa2

974

(P3)
162 162 169 155 163 162
SECTION B-B

Fig. 33-140 Section (1/6)

33-80
 33. UPPER STRUCTURE

T2
H 273x10 273x10 H
PCb PAL
P1 unload
Travel left
(Travel straight)
C C

USE FOR YN30V00101F1

977 PAr
PB1 Boom conflux
Travel right (P2 unload)

D 978x2 D
PBs

Boom Swing

E PCc
PBb E
PBa1 Pss

Bucket
Arm 1
F F
PBa2 PA
PAo

Arm 2 MU Option

G G
K PBp1 PBp2
K

(P3) B A
PBa2 PAo

PBp1 PBp2

274x4
275x4
213
(P4)
(P3)

212

PAa2 PBo

273x10 273x10

Fig. 33-141 Section (2/6)

33-81
33. UPPER STRUCTURE

  $!#- &'# #'"+ 

  
 
 

 

 

 

 


  

 

 

 
 
 
 
 

 


 
 
 

  


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

   
 

 

 
 
 

 

  
 



 
 
 



 
  

 

   


 
 $!#- 

Fig. 33-142 Section (3/6)

33-82
 33. UPPER STRUCTURE

Swing 204
203 PBs
333 Boom
PBb Pss
333
331
336 331
322
321 336
603 AbR
331 322
211
261 321
266 266
160
160 331
514 261
303
524 As 161
CRb
556 162
164 Ab 163
511 511
521 523
LCb LCs
551 556
164 164
Bb
Bs 162

161

301
264 266
264
266
BbR 160 PAs 206
602 PAb
559 SECTION E-E
560 164 551
Bucket
208
209
PCc
216 201
333 Arm 1 333
331 PBa1
PBc
331
336 336
322 322
321 321
BaR
602 BcR 603
331 331
261 261
211
304 160
514
524
CRar
Bc 556
Ba 164
511 511
521 521
LCc LCa
551 551
164 164

Ac
162 Aa

161

264 302
603 PAc PAa1 264
205 AcR SECTION F-F 205
AaR 602
Fig. 33-143 Section (4/6)

33-83
33. UPPER STRUCTURE

201
333 Arm 2 Option 201
331 PBa2 PAo 333
340
328 331
321
336
331
324
261
AoR 323
604
MU 331
308
162 261
162 311
162
511 Ao

521
LCAT2 511
551
164 521
515 LCo
521 LCAP2 551
551 164
164
Bo
162

161

604
BoR
264 264
PAa2 PBo
205
205
SECTION G-G

T2

161

P1
T1
511
521 163
CT1
551
163
164
162
P2 511
521
CT2
551
164

SECTION H-H

Fig. 33-144 Section (5/6)

33-84
 33. UPPER STRUCTURE

PBp1 PBp2

207
160 606 606
278x5 266
264 264

527 528 163

T2 T1
517
518

SECTION J-J
SECTION K-K

Fig. 33-145 Section (6/6)

33-85
33. UPPER STRUCTURE

Tightening torque Tightening torque N•m

No. Parts name Q’ty No. Parts name Q’ty
N•m (lbf•ft) (lbf•ft)
101 Casing A 1 321 Spring 5
102 Casing B 1 322 Spring 4
220~250(162~184) 154 Plug PF3/4 3 323 Spring 3
110~130(81~96) 155 Plug PF1/2 2 324 Spring 3
20~24(15~18) 159 Plug PT1/4 (Capsule coating) 1 325 Spring 1
7.8~9.8(5.8~7.2) 160 Plug PT1/16 (Capsule coating) 5 326 Spring 1
161 O-ring 7 327 Spring 3
162 O-ring 15 328 Spring 1
163 O-ring 11 329 Spring 3
164 O-ring 19 331 Spring seat 24
169 O-ring 2 16~18(11~13) Loctite #262 333 Spacer bolt 12
201 Cover 5 336 Stopper 10
202 Cover 4 339 Stopper 1
203 Cover 1 340 Stopper 1
204 Cover sub 1 511 Poppet 11
205 Cover 6 512 Poppet 2
206 Cover 1 514 Poppet 2
207 Back pressure check valve cover 1 515 Poppet 1
208 Cover 1 517 Poppet 1
209 Cover 1 518 Poppet 1
9.8~14(7.2~13) 211 Lock valve selector sub 2 521 Spring 11
212 Plate 1 522 Spring 2
213 Plate 1 523 Spring 1
216 Piston 1 524 Spring 2
261 O-ring 12 527 Spring 1
264 O-ring 10 528 Spring 1
266 O-ring 5 230~260(170~192) 551 Plug 13
25~34(18~25) 273 Socket bolt 40 130~150(96~111) 552 Plug 2
98~120(72~89) 274 Socket bolt 4 230~260(170~192) 556 Plug 3
98~120(72~89) 275 Socket bolt 4 559 Plug 1
25~34(18~25) 278 Socket bolt 5 560 O-ring 1
301 Bom spool sub 1 562 O-ring 2
302 Arm 1 spool 1 69~78(51~58) 601 Main relief valve 1
303 Swing spool 1 69~78(51~58) 602 Over load relief valve 3
304 Bucket spool 1 69~78(51~58) 603 Over load relief valve 3
305 Boom conflux spool 1 69~78(51~58) 604 Plug assy for relief valve hole 2
306 Travel spool 2 98~120(72~89) 606 By-pass cut valve 2
307 Travel straight spool 1 140~180(103~133) 973 Socket bolt 8
308 Arm 2 spool sub 1 140~180(103~133) 974 Socket bolt 2
309 P1 unload spool 1 977 Name plate 1
310 P2 unload spool 1 978 Pakerrizing rivet 2
311 Option spool 1

33-86
 33. UPPER STRUCTURE

33.2.2.2 PREPARATION FOR DISASSEMBLY

(1) General precautions
1) As all the hydraulic components are precisely machined, it is essential to carry out disassembly and
reassembly in an especially clean location.
2) When handling the control valve, take special care to prevent the entry of foreign matter, such as dust or
sand.
3) Cap each port of the control valve before removing the valve from the machine. Before disassembly, confirm
that each cap is in place and then clean the exterior of the assembly.
Use a workbench. Lay a clean sheet of paper or rubber mat over the workbench.
4) When carrying or moving the control valve, hold the body, and never put pressure on a lever, an exposed
spool, or the end cover. Handle the valve with care.
5) Tests(for relief characteristics, leaks, overload valve setting, flow resistance, etc.) that are desired after
disassembly and reassembly require hydraulic testing apparatus.
For this reason, do not disassemble hydraulic units that you are capable of disassembling but cannot test or
adjust.
Prepare beforehand washing fluid, hydraulic oil, grease, etc. .
(2) Tools
Prepare the following tools before disassembling the control valve.

No. Tools Q’ty Remarks

a Vise 1
Box end 1 of each
b 24mm, 27mm, 32mm
wrench size
1 of each
c Allen wrench 5mm, 6mm, 10mm, 12mm, 14mm, 22mm
size
d Spanner 1 32 mm
e Loctite #262 1
f Spatula 1
g Pincers 1
Adjustable
h 1
wrench

33.2.2.3 DISASSEMBLY
The figures in parentheses after part names in this
manual represent those item numbers in the structural
sectional drawing under Fig. 33-140 to Fig. 33-145.
(1) Place the control valve on a work bench so as to
locate back pressure check valve upwards.

Disassemble the valve in a clean place, and be careful

not to damage flange surfaces or plate mounting
surfaces.

Fig. 33-146 Preparation for disassembly

33-87
33. UPPER STRUCTURE

33.2.2.3.1 Disassembling P1 unload spool

(1) Loosen the socket bolts (273) and remove the
spring cover (202) and the O-ring (261) for P1
unload spool.

Fig. 33-147 Removing spring cover (202) for P1

unload spring cover
(2) Draw out, from casing B (102), as a assy of P1
unload spool (309), spring seat (331), springs
(327), (329), stopper (336) and bolt (333).

When drawing out the spool assy, use care so as not to

score casing B (102).

Fig. 33-148 Drawing out P1 unload spool assy (309)

(3) Fix the P1 unload spool assy with vise via a
protective plate (aluminum plate, etc.) and remove
bolt (333). Then separate spring seat (331), springs
(327), (329) and stopper (336) from P1 unload
spool (309).

Fig. 33-149 Disassembling P1 unload spool assy

(309)

33-88
 33. UPPER STRUCTURE

33.2.2.3.2 Disassembling the travel spool (left travel and right travel)
(1) Loosen the socket bolts (273) and remove the
spring cover (201) and the O-ring (261) for travel.

Fig. 33-150 Removing spring cover (201)

(2) Draw out the assy of travel spool (306), spring seat
(331), springs (323), (324), stopper (336) and bolt
(333) from casing A (101) or casing B (102).

When drawing out the spool assy, take care so as not

to score the casing A (101) or the casing B (102).

Fig. 33-151 Drawing out travel spool (306) assy

(3) Fix the travel spool assy with vise via a protective
plate (aluminum plate, etc.). Remove bolt (333) and
separate spring seat (331), springs (323), (324) and
stopper (336) from travel spool (306).

Fig. 33-152 Removing right travel

spring cover (201)

Fig. 33-153 Disassembling travel spool (306) assy

33-89
33. UPPER STRUCTURE

33.2.2.3.3 Disassembling the boom conflux spool

(1) Loosen socket bolts (273) and remove spring cover
(201) for boom conflux and O-ring (261).

(2) Draw out the assy of boom conflux spool (305),

spring seat (331), springs (325), (326), stopper
(339) and bolt (333) from casing A (101).

When drawing out the spool assy, use care so as not to

score casing A (101).
Fig. 33-154 Removing spring cover (202)

(3) Fix the boom conflux spool with vise via a protective
plate (aluminum plate, etc.) and remove bolt (333).
Then separate spring seat (331), springs (325),
(326) and stopper (339) from boom conflux spool
(305).

Fig. 33-155 Drawing out boom conflux spool (305)

assy

33.2.2.3.4 Disassembling the boom spool

(1) Loosen socket bolts (273) and remove spring cover
(203) for boom spool and O-ring (261), (266).

(2) Draw out the assy of boom spool (301), spring seat
(331), springs (321), (322), stopper (336) and bolt
(333) from casing B (102).

When drawing out the spool assy, take care so as not

to score casing B (102).
Fig. 33-156 Removing spring cover (203)

33-90
 33. UPPER STRUCTURE

(3) Fix the boom spool assy with vise via a protective
plate (aluminum plate, etc.) and remove bolt (333).
Then separate spring seat (331), springs (321),
(322) and stopper (336) from boom spool (301). Do
not disassemble boom spool (301) further unless
there is special reason.

Fig. 33-157 Drawing out boom spool (301) assy

33.2.2.3.5 Disassembling the swing spool

(1) Loosen the socket bolts (273) and remove the
spring cover sub (204) and the O-ring (261), (266)
for swing. Do not disassemble spring cover sub
(204) further unless there is special reason.

(2) Draw out the assy of swing spool (303), spring seat
(331), springs (321), (322), stopper (336) and bolt
(333) from casing A (101).

Fig. 33-158 Removing spring cover sub (204)

When drawing out the spool assy, use care so as not to
score casing A (101).

(3) Fix the swing spool assy with vise via a protective
plate (aluminum plate, etc.) and remove bolt (333).
Then separate spring seat (331), springs (321),
(322) and stopper (336) from swing spool (303).

Fig. 33-159 Drawing out swing spool (303) assy

33-91
33. UPPER STRUCTURE

33.2.2.3.6 Disassembling bucket spool

(1) Loosen socket bolts (273) and remove bucket
spring cover (209) and O-ring (261).

Fig. 33-160 Removing spring cover (209)

(2) Draw out the assy of bucket spool (304), spring
seat (331), springs (321), (322), stopper (336) and
bolt (333) from casing B (102).

When drawing out the spool assy, use care so as not to

score casing B (102).

Fig. 33-161 Drawing out bucket spool (304) assy

(3) Fix the bucket spool assy with vise via a protective
plate (aluminum plate, etc.) and remove bolt (333).
Then separate spring seat (331), springs (321),
(322) and stopper (336) from bucket spool (304).

(4) When needed to disassemble the spring cover of

bucket spool, loosen plug (551) with casing B (102)
installed. After removed cover (209) from casing B
(102), remove plug (551) and then take out piston
(216).

Fig. 33-162 Disassembling bucket

spring cover (209)

33-92
 33. UPPER STRUCTURE

33.2.2.3.7 Disassembling arm 1 spool

(1) Loosen socket bolts (273), and remove spring
cover (201) and O-ring (261) of arm 1 spool.

(2) Draw out the assembly which is consist of arm 1

spool (302), spring seat (331), spring (321, 322),
stopper (336) and bolt (333) from casing A (101).

When drawing out the spool assy, use care so as not to

score casing A (101).
Fig. 33-163 Removing arm 1 spring cover (201)

(3) Fix the arm 1 spool assy with vise via a protective
plate (aluminum plate etc.) and remove bolt (333).
Then remove spring seat (331), spring (321, 322)
and stopper (336) from arm 1 spool (302).

Fig. 33-164 Disassembling arm 1 spool (302) assy

33.2.2.3.8 Disassembling arm 2 spool

(1) Loosen socket bolts (273), and remove spring
cover (201) and O-ring (261) of arm 2 spool.

(2) Draw out the assembly which is consist of arm 2

spool (308), spring seat (331), spring (321, 328),
stopper (340) and bolt (333) from casing B (102).

When drawing out the spool assy, use care so as not to

Fig. 33-165 Removing arm 2 spring cover (201)
score casing B (102).

(3) Fix the arm 2 spool assy with vise via a protective
plate (aluminum plate etc.) and remove bolt (333).
Then remove spring seat (331), spring (321, 328)
and stopper (340) from arm 2 spool (308). Do not
disassemble arm 2 spool (308) further unless there
is special reason.

Fig. 33-166 Disassembling arm 2 spool (308) assy

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33.2.2.3.9 Disassembling option spool

(1) Loosen socket bolts (273), and remove spring
cover (201) and O-ring (261) of option spool.

(2) Draw out the assembly which is consist of option

spool (311), spring seat (331), spring (323, 324),
stopper (336) and bolt (333) from casing A (101).

When drawing out the spool assy, use care so as not to

score casing A (101).
Fig. 33-167 Removing option spring cover (201)

(3) Fix the option spool assy with vise via a protective
plate (aluminum plate etc.) and remove bolt (333).
Then remove spring seat (331), spring (323, 324)
and stopper (336) from option spool (311).

Fig. 33-168 Disassembling option spool assy (311)

33.2.2.3.10 Disassembling travel straight spool

(1) Loosen the socket bolts (273) and remove the
spring cover (202) and the O-ring (261) for travel
straight.

(2) Draw out the assy of travel straight spool (307),

spring seat (331), springs (327), (329), stopper
(336) and bolt (333) from casing B (102).

When drawing out the spool assy, take care so as not

Fig. 33-169 Drawing out travel straight
to score the casing B (102).
spool (307) assy

(3) Fix the travel straight spool assy with vise via a
protective plate (aluminum plate, etc.). Remove
bolt (333) and separate spring seat (331), springs
(327, 329) and stopper (336) from travel straight
spool (307).

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33.2.2.3.11 Disassembling P2 unload spool

(1) Loosen socket bolts (273), and remove spring
cover (202) of P2 unload spool and O-ring (261).

(2) Draw out the assembly which is consist of P2

unload spool (310), spring seat (331), spring (327,
329), stopper (336) and bolt (333) from casing A
(101).

When drawing out the spool assy, use care so as not to

Fig. 33-170 Removing P2 unload spring cover (202)
score casing A (101).

(3) Fix the P2 unload spool assy with vise via a

protective plate (aluminum plate etc.) and remove
bolt (333). Then remove spring seat (331), spring
(327, 329) and stopper (336) from P2 unload spool
(310).

Fig. 33-171 Disassembling P2 unload

spool assy (310)

33.2.2.3.12 Removing spool covers

(1) Travel, bucket, arm 1, arm 2 and option
Loosen socket bolts (273) and remove spool cover
(205) and O-ring (264).

(2) Swing
Loosen socket bolts (273) and remove spool cover
(206) and O-ring (264), (266). Do not disassemble
spool cover (206) further unless there is special
reason.

(3) Boom
Loosen socket bolts (273) and remove spool cover Fig. 33-172 Removing spool cover (205),(206)
(206) and O-ring (264). Do not disassemble spool
cover (208) further unless there is special reason.

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33.2.2.3.13 Removing relief valve and plug assy for relief valve hole
(1) Remove the main relief valve (601) and overload
relief valve (602), (603) and plug assy (604) from
the casing.

• Distinguish overload relief valve between (602) and

(603) with a tag to prevent them from being
confused during reassembly, as they are the same
in appearance and shape but differ in pressure
setting.
Fig. 33-173 Removing main relief valve (601)
• Regarding the disassembly of the relief valves
themselves, do not disassemble it.

Fig. 33-174 Removing overload relief valve (602)

and (603)

Fig. 33-175 Removing plug assy (604) for relief

valve hole

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33.2.2.3.14 Removing by-pass cut valve

(1) Remove by-pass cut valve (606) from the casing.

Remove the by-pass cut valve, giving particular

attention to the poppet (606-201) and spring (606-202)
which may be remained on the inside of casing.

Fig. 33-176 Removing by-pass cut valve (606)

33.2.2.3.15 Removing lock valve selector valve sub

(1) Loosen socket bolt (211-171) and remove lock
valve selector valve sub (211) from the casing.
Further disassembly of the lock valve selector sub
is not allowed.

Fig. 33-177 Removing lock valve selector sub (211)

33.2.2.3.16 Removing back pressure check valve

(1) Loosen socket bolt (278) and remove back
pressure check valve (207) from the casing.

Fig. 33-178 Removing back pressure check valve

cover (207)

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(2) Remove springs (527), (528), boost check valve

poppet sub (517) and by-pass check valve poppet
(518) from the casing. The further disassembly of
boost check valve poppet sub (517) is not allowed.

Replace control valve so that the spool cover face

directs downward.

When replacing, take care so as not to score the spool

cover.
Fig. 33-179 Removing boost check valve sub (517)
and by-pass check valve poppet (518)

33.2.2.3.17 Removing plate

(1) Loosen socket bolts (274), (275) and remove plates
(212), (213).
(2) After removing plates, remove all O-rings (162),
(163) remained on the casing side.

Fig. 33-180 Removing plate (212),(213)

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33.2.2.3.18 Removing check valve

(1) Remove plugs of load check valve, conflux check
valve, etc. and then remove poppet (511) and
spring (521).
(2) Load check valve on the swing section
Remove plug (556) and then remove poppet (511)
and spring (523).

The plug and spring in use differ from the above (1). Do
not mix the parts when assembling parts again.

(3) Load check valve on arm 2 section Fig. 33-181 Removing plug (551),(556),(552)
Remove plug (551) and then remove poppet (515)
and spring (521).

The poppet in use differs from the above (1). Do not mix
the parts when assembling parts again.

(4) Lock valve

Remove plug (556) and then remove poppet (514)
and spring (524).

Fig. 33-182 Removing poppet (511),(512),(514),(515)

The plug, poppet and spring in use differ from the

above (4). Do not mix the parts when assembling parts
again.

(5) Main relief valve

Remove plug (552) and then remove poppet (512)
and spring (522).

The plug, poppet and spring in use differ from the

above (5). Do not mix the parts when assembling parts
again.

The plugs in which the procedure for disassembly is not

included in the above procedure are usually used to
block auxiliary holes and holes caused by casting. Do
not disassemble further if unnecessary.

33.2.2.3.19 Disassembling casing

Further disassembly of the casing is not allowed.

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33.2.2.3.20 Inspection after disassembly

Thoroughly clean all disassembled parts with wash oil, and dry them with jet air. Place each part on a clean sheet
of paper or cloth for inspection.
(1) Control valve
1) Inspect the entire surface of each part for burrs, scratches, cuts, and other defects.
2) Confirm that the O-ring groove surface of the casing or the block is free from foreign matter, dents or rust.
3) If the check valve seat of the casing or the block has dents or damage on its surface, smooth it by lapping.

Take care not leave lapping compound behind in the casing or block.

4) Confirm that O-ring or the outer circumference of the sliding part of a manual spool is free from scratches,
dents, and the like. Remove any small defects with an oil stone or lapping compound.
5) Manually confirm that all sliding and fitted parts move smoothly. Confirm that all grooves and passages are
free from foreign matter.
6) Replace any broken or deformed spring with new one.
7) Of a relief valve malfunctions, repair it by following the relief valve disassembly and reassembly procedures.
8) Replace all O-ring with new ones.

(2) Relief valve

1) Make sure that the poppet and the seat surface at the tip of the seat are without fault and that the contact
surface is even all over.
2) Manually confirm that the main poppet slides smoothly onto and off the seat.
3) Confirm that the outer circumference of the main poppet and the inner circumference of its seat are free from
defects such as scratches.
4) Confirm that each spring is free from breakage, deformation, and excessive wear.
5) Confirm that the orifices of the main poppet and its seat are not clogged.
6) Replace all O-rings with new ones. (Between casing and seal)

33.2.2.4 REASSEMBLY
(1) Here, only the reassembly procedures are described. Regarding drawings, refer to the disassembly procedures.
(2) Figures in parentheses after part names in this instruction represent those item numbers in the structural
sectional drawing. (Fig. 33-140 to Fig. 33-145)
(3) Precautions on reassembling O-ring
1) Confirm that O-rings are free from defects caused by poor handling.
2) Apply thin coat of grease or hydraulic oil to O-rings and their mating parts.
3) Do not stretch O-rings to the extent that they become permanently set.
4) When installing O-rings, do not roll them into place. Twisted O-rings do not easily untwist by themselves after
installation, and can cause oil leaks.
5) Use a torque wrench to tighten each attaching bolt. Tighten to the specified torque in "Maintenance
Standards."

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33.2.2.4.1 Installing check valve

(1) Load check valve, conflux check valve, and so on
Attach poppet (511) and spring (521) in place, place O-ring (164) in plug (551) and tighten them to the specified
torque. (9 places)
(2) Load check valve of swing section
Attach poppet (511) and spring (523) in place, place O-ring (164) in plug (556) and tighten them to the specified
torque. (1 place)
(3) Load check valve of arm 2 section
Attach poppet (515) and spring (521) in place, place O-ring (164) in plug (551) and tighten them to the specified
torque. (1 place)
(4) Lock valve section
Attach poppet (514) and spring (524) in place, place O-ring (164) in plug (556) and tighten them to the specified
torque. (2 places)
(5) Main relief valve section
Attach poppet (512) and spring (522) in place, place O-ring (562) in plug (552) and tighten them to the specified
torque. (2 places)

Take care to prevent misassembling of parts and assembling position error because the parts in (1) to (5) are similar
in shape.

33.2.2.4.2 Assembling plate

(1) Place O-rings (162), (163) in casing.
(2) Attach plates (212), (213) and tighten socket bolts (274), (275) to the specified torque.

Replace control valve so that this plate face directs downward.

33.2.2.4.3 Assembling back pressure check valve

(1) Attach boost check valve poppet sub (517), by-pass check valve poppet (518) and springs (527), (528).
(2) Attach O-rings (264), (266) in back pressure check valve cover, attach it to casing A (101) and tighten socket
bolt (278) to the specified torque.

33.2.2.4.4 Assembling lock valve selector sub

(1) Attach lock valve selector sub (211) to the casing and tighten socket bolt (211-171) to the specified torque.

33.2.2.4.5 Assembling by-pass cut valve

(1) Attach by-pass cut valve (606) to casing and tighten it to the specified torque.

Take care to prevent drop of poppet (606-201) and spring (606-202) when attaching by-pass cut valve.

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33.2.2.4.6 Assembling relief valve and relief valve hole plug assembly
(1) Tighten main relief valve (601), port relief valves (602), (603) and relief valve hole plug assembly (604) in
respective place to the specified torque.

Assemble it giving attention to the label attached when disassembling to prevent mistake because the port relief
valves (602), (603) are similar in shape.

33.2.2.4.7 Assembling P2 unload spool

(1) Hold the mid section of P2 unload spool (310) with vise provided with protection plate (aluminum plate, etc.), fit
spring seat (331), springs (327), (329) and stopper (336) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform P2 unload spool (310) because of careless over clamping.

(2) Place P2 unload spool assembly in item (1) in casing A (101).

Place P2 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover (202) with O-ring (261) attached to the spring side of P2 unload spool assembly and tighten
socket bolt (273) to the specified torque.

33.2.2.4.8 Assembling travel straight spool

(1) Hold the mid section of travel straight spool (307) with vise provided with protection plate (aluminum plate, etc.),
fit spring seat (331), springs (327), (329) and stopper (336) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform travel straight spool (307) because of careless over clamping.

(2) Place travel straight spool assembly in item (1) in casing B (102).

Place travel straight spool assembly in casing B (102) carefully. Do not squeeze it into place.

(3) Attach spring cover (202) with O-ring (261) attached to the spring side of travel straight spool assembly, and
tighten socket bolt (273) to the specified torque.

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33.2.2.4.9 Assembling spool in option

(1) Hold the mid section of spool in option (311) with vise provided with protection plate (aluminum plate, etc.), fit
spring seat (331), springs (323), (324) and stopper (336) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform option spool (311) because of careless over clamping.

(2) Place spool assembly in option in item (1) in casing A (101).

Place option spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover (201) with O-ring (261) attached to the spring side of spool assembly in option and tighten
socket bolt (273) to the specified torque.

33.2.2.4.10 Assembling arm 2 spool

(1) Hold the mid section of arm 2 spool (308) with vise provided with protection plate (aluminum plate, etc.), fit spring
seat (331), springs (321), (328) and stopper (340) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform arm 2 spool (308) because of careless over clamping.

(2) Place arm 2 spool assembly in option in item (1) in casing B (102).

Place arm 2 spool assembly in casing B (102) carefully. Do not squeeze it into place.

(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 2 spool assembly and tighten
socket bolt (273) to the specified torque.

33.2.2.4.11 Assembling arm 1 spool

(1) Hold the mid section of arm 1 spool (302) with vise provided with protection plate (aluminum plate, etc.) and fit
spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform arm 1 spool (302) because of careless over clamping.

(2) Place arm 1 spool assembly in item (1) in casing A (101).

Place arm 1 spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 1 spool assembly, and tighten
socket bolt (273) to the specified torque.

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33. UPPER STRUCTURE

33.2.2.4.12 Assembling bucket spool

(1) Hold the mid section of bucket spool (304) with vise provided with protection plate (aluminum plate, etc.), fit
spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform bucket spool (304) because of careless over clamping.

(2) Place bucket spool assembly in item (1) in casing B (102).

Place bucket spool assembly in casing B (102) carefully. Do not squeeze it into place.

(3) Attach spring cover (209) with O-ring (261) attached to the spring side of bucket spool assembly and tighten
socket bolt (273) to the specified torque.
(4) Attach piston (216) to spring cover (209), place O-ring (164) in plug (551) and tighten to the specified torque.

33.2.2.4.13 Assembling swing spool

(1) Hold the mid section of swing spool (303) with vise provided with protection plate (aluminum plate, etc.), fit spring
seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform swing spool (303) because of careless over clamping.

(2) Place swing spool assembly in item (1) in casing A (101).

Place swing spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover sub (204) with O-rings (261), (266) attached to the spring side of swing spool assembly and
tighten socket bolt (273) to the specified torque.

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33.2.2.4.14 Assembling boom spool

(1) Hold the mid section of boom spool (301) with vise provided with protection plate (aluminum plate, etc.), fit spring
seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform boom spool (301) because of careless over clamping.

(2) Place boom spool assembly in item (1) in casing B (102).

Place boom spool assembly in casing B (102) carefully. Do not squeeze it into place.

(3) Attach spring cover (203) with O-rings (261), (266) attached to the spring side of boom spool assembly and
tighten socket bolt (273) to the specified torque.

33.2.2.4.15 Assembling boom conflux spool

(1) Hold the mid section of boom conflux spool (305) with vise provided with protection plate (aluminum plate, etc.),
fit spring seat (331), springs (325)(326) and stopper (339) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform boom conflux spool (305) because of careless over clamping.

(2) Place boom conflux spool assembly in item (1) in casing A (101).

Place boom conflux spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover (202) with O-ring (261) attached to the spring side of boom conflux spool assembly and
tighten socket bolt (273) to the specified torque.

33.2.2.4.16 Assembling travel spool (travel right and left)

(1) Hold the mid section of travel spool (306) with vise provided with protection plate (aluminum plate, etc.), fit spring
seat (331), springs (323), (324) and stopper (336) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform travel spool (306) because of careless over clamping.

(2) Place travel spool assembly in item (1) in casing A (101) or casing B (102).

Place travel spool assembly in casing A (101) or casing B (102) carefully. Do not squeeze it into place.

(3) Attach spring cover (201) with O-ring (261) attached to the spring side of travel spool assembly and tighten
socket bolt (273) to the specified torque.

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33. UPPER STRUCTURE

33.2.2.4.17 Assembling P1 unload spool

(1) Hold the mid section of P1 unload spool (309) with vise provided with protection plate (aluminum plate, etc.), fit
spring seat (331), springs (327), (329) and stopper (336) and tighten bolt (333) to the specified torque.

• Apply Loctite #262 when tightening bolt (333).

• Take care not to deform P1 unload spool (309) because of careless over clamping.

(2) Place P1 unload spool assembly in item (1) in casing A (101).

Place P1 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.

(3) Attach spring cover (202) with O-ring (261) attached to the spring side of P1 unload spool assembly and tighten
socket bolt (273) to the specified torque.

33.2.2.4.18 Assembling spool cover, and so on

(1) Travel, bucket, arm 1, arm 2, option
Place O-ring (264) in spool cover (205) and tighten socket bolt (273) to the specified torque.
(2) Swing
Place O-rings (264), (266) in spool cover (206) and tighten socket bolt (273) to the specified torque.
(3) Boom
Place O-ring (264) in spool cover (208) and tighten socket bolt (273) to the specified torque.

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33.2.2.5 MAINTENANCE STANDARDS

33.2.2.5.1 Inspection of components

Part name Inspection item Criterion and remedy

Casing 1) Look for scratches, rusting and corrosion. 1) If any of the following parts are damaged,
replace the casing.
• Sliding part of casing hole and spool,
particularly the land, to which holding
pressure is applied.
• Area of sealing part that is in contact with
O-ring.
• Sealing and seating part of main or
overload relief valve.
• Area of seating part or sliding part of
poppet.
• Sealing part of plug.
• Defects of other parts that seem to
prevent normal function.
Spool 1) Look for scratches, galling, rusting and 1) If a detectable defect with your fingernail is
corrosion. found on the sliding part of the outer
circumference, replace the spool.
2) Insert the spool in the casing bore, and 2) If the spool damages the O-ring or does
move it while turning it. not move smoothly, repair or replace the
spool.
Poppet If spring is damaged, replace it.
1) Look for damage on the poppet and the 1) If the seat of poppet or spring are
spring. damaged, correct or replace it.
2) If the poppet moves lightly without
2) Insert the poppet in the casing, and move catching, it is normal.
it.
Spring and related parts 1) Look for rust, corrosion, deformation, and 1) If damaged heavily, replace.
breakage of the spring, spring seat,
stopper, spacer bolt and cover.
Main relief valve 1) Look for rust and damage on outer 1) Replace.
Port relief valve surface.
By-pass cut valve 2) Inspect the contact face of the valve seat. 2) If damaged, replace.
3) Inspect the O-ring, backup ring, and seal. 3) As a general rule, replace all parts with
new ones. (Between casing and seal)

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33.2.2.6 TROUBLESHOOTING
(1) If an abnormal condition is noticed, check to see if the problem is with the control valve itself, one of the main
pumps, the gear pump, or a circuit. To this end, you will need to measure pilot pressure, pump delivery pressure,
load pressure, etc. If any part of the system is to be disassembled for inspection, follow the disassembly and
reassembly procedures in this manual.
(2) Dust is the enemy of hydraulic components. Pay strict attention to protection from dust. If any part of the system
is to be disassembled, take dust protection measures beforehand.
(3) Moving parts must be handled with care. If they are damaged, smooth the damage using an oil stone or the like.
(4) Take care not to damage the contact face of O-rings. A damaged contact face will certainly cause oil leaks.

33.2.2.6.1 Control valve

Trouble Cause Remedy

1. Travel does not 1) Malfunctioning main relief valve. 1) Check travel relief valve pressure
occur. • Foreign matter between main poppet • Disassemble and clean. If damaged
Slow to start up and seat. heavily, replace the assy as a unit.
(or poor power).
• Same as above.
Slow response.
• Foreign matter between poppet and • Correct sticking part with oil stone.
seat.
• Replace spring.
• Sticking main poppet.
• Remove foreign matter.
• Broken or deformed spring.
• Readjust, and tighten lock nut to
• Clogged main poppet throttle. specified torque.
• Loosened adjusting screw.

2. Machine does not 1) Malfunctioning travel straight valve. 1) Check pilot pressure.
move straight during • Sticking spool. • Correct sticking part with oil stone.
simultaneous
• Replace spring.
operation of travel
• Broken or deformed spring. • Remove foreign matter.
and attachment.
• Clogged small hole in spool.
2) Malfunctioning main relief valve. 2) Remove main relief valve.

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 33. UPPER STRUCTURE

Trouble Cause Remedy

3. Excessive natural 1) Excessive clearance between casing and 1) Replace spool.
falls of attachment spool.
under its own weight 2) Spool is not completely in neutral position. 2) Check secondary pilot pressure.
when spool is in • Foreign matter between casing and • Disassemble, clean and smooth
neutral. spool, or sticking spool. sticking part with oil stone.
• Broken or deformed spring. • Replace spring.
• Clogged pilot circuit. • Remove foreign matter.
3) Malfunctioning overload relief valve. Refer 3) Check overload relief valve pressure.
to item 1. 1) above. (See 33.2.2.3.20 (2))
(See 33.2.2.3.20 (2)) • Clean and check damage on seat
• Foreign matter between valve seat and surface.
casing.
4) Lock valve function is faulty. 4) Replace
(Arm, boom)
• Foreign matter between poppet seat • Disassemble, clean.
and casing. • Correct stuck part with oil stone or
• Poppet is stuck. replace.
• Replace spring.
• Broken or deformed spring. • Replace lock valve selector assy.
• Selector spool is stuck.
4. When raising 1) Malfunctioning load check valve. 1)
attachment, at first it • Foreign matter between poppet and • Disassemble and clean. If heavily
drops. casing. damaged, replace control valve.
• Correct sticking part with oil stone.
• Replace spring.
• Sticking poppet.

• Broken or deformed spring.

5. Bucket, boom, arm or 1) Malfunctioning main spool. 1) Check secondary pilot pressure.
swing does not • Excessive clearance between casing • Replace spool.
operate. and spool. • Disassemble and clean.
Slow to start up (or
• Foreign matter between casing and • Correct stuck part with oil stone.
poor power).Slow
spool.
response. • Replace spring.
• Sticking spool.
• Remove foreign matter.

• Broken or deformed return spring.

• Clogged pilot circuit.
2) Malfunctioning main relief valve. Refer to 2) Check main relief valve pressure. Refer to
item 1. 1) above. item 1. 1) above.
(See 33.2.2.3.20 (2)) (See 33.2.2.3.20 (2))
3) Malfunctioning overload relief valve. Refer 3) Check overload relief valve pressure.
to item 1. 1) above. (See 33.2.2.3.20 (2))
(See 33.2.2.3.20 (2))

33-109
33. UPPER STRUCTURE

Trouble Cause Remedy

6. Boom conflux does 1) Malfunctioning conflux valve. 1) Measure pilot pressure.
not operate. • Excessive clearance between casing • Replace spool.
and spool. • Disassemble and clean.
• Foreign matter between casing and • Correct stuck part with oil stone.
spool.
• Replace spring.
• Sticking spool.
• Remove foreign matter.

• Broken or deformed return spring.

• Clogged pilot circuit.

33.2.2.6.2 Relief valve

Trouble Cause Remedy

1.No pressure rise. Main or pilot poppet of relief valve is sticking Check for foreign matter on each poppet.
and valve is open, or there is foreign matter Confirm that each component slides
on valve seat. smoothly.
If failure is found, replace it in an assembly.
2. Unstable relief Main or pilot poppet of relief valve seat is If failure is found, replace it an assembly.
pressure. damaged.
3. Incorrect relief 1) Wear due to foreign matter. 1) Replace damaged assembly
pressure setting. 2) Loosened locknut or adjusting screw. 2) Adjust pressure.
4. Oil leak. Confirm that each component operates
smoothly. Replace damaged or worn
1) Damaged seat. component.
Damaged O-ring. 1) If failure is found, replace it an assembly.
2) Sticking component due to foreign matter. 2) Confirm that there are no scratches,
scores, or foreign matter present before
reassembling.
If failure is found, replace it an assembly.

33-110
 33. UPPER STRUCTURE

33.2.3 PILOT VALVE (ATT)

33.2.3.1 CROSS-SECTIONAL VIEW

312
302
Apply grease on
501 rotating and
Apply grease on 301 sliding sections.
Be careful the
top section assembling
212 direction
213
151
* 246
* 218-2
211
214
* 218-1
216-2 216-1

241-2 241-1
201-2
201-1
217
Secondary
pressure 101 221
adjusting shim
Designed value
t=0.4 (0.061 in),
1 pc

PORT PORT
2,4 1,3
Fig. 33-183 Pilot valve (For ATT)
Apply loctite #277 to areas marked

Tightening torque Tightening torque

No. Parts Q’ty No. Parts Q’ty
N•m (lbf•ft) N•m (lbf•ft)
101 Casing 1 *218-1 Seat 2
151 Plate 1 *218-2 Seat 2
201-1 Spool 2 221 Spring 4
201-2 Spool 2 241-1 Spring 2
211 Plug 4 241-2 Spring 2
212 Push rod 4 *246 Spring 4
213 Seal 4 47.1 (35) 301 Joint : M14 1
214 O-ring ; 1B P20 4 302 Circular plate 1
216-1 Spring seat 2 68.6 (51) 312 Adjust nut : M14 1
216-2 Spring seat 2 501 Boots 1
217 Washer 2 (Shim) 4
Note) The parts marked * might not be equipped depending on valve type.

33-111
33. UPPER STRUCTURE

33.2.3.2 DISASSEMBLY
(1) Plug each port of pilot valve, and clean it with
kerosine. 501
P port : PF1/4
1~4 and T port : PF3/8
(2) Fix pilot valve with vise via a protective plate
(Alminum plate etc.), and remove boots (501).

Fig. 33-184 Removing boot (501)

(3) Remove adjusting nut (312) applying spanners to
adjusting nut (312) and circular plate (302).
312
: 22mm, 32mm

302

Fig. 33-185 Removing adjusting nut (312)

(4) Remove circular plate (302)
302
: 32mm

Fig. 33-186 Removing circular plate (302)

Fig. 33-187 Circular plate is removed

33-112
 33. UPPER STRUCTURE

Fig. 33-188 Installing Jig A

(5) Turn joint (301) in counterclockwise with Jig A to
remove.
Jig A : See 33-120.

: 24mm
301

When the force of return springs (221) is strong, never

loosen joint (301). If loosened, it might result in jumping
out of plate (151), plug (211) and push rod (212).
Remove joint (301) pressing plate (151) downward with
two fingers. Fig. 33-189 Removing joint (301)

(6) Remove plate (151)

• When the force of return springs (221) are 151
strong, press plate to let it come up slowly.

Fig. 33-190 Removing plate (151)

• When the force of return springs (221) are weak,
plug is left in casing (101) due to sliding
resistance of O-ring (214).

Pull plug (211) out with a driver.

To prevent personal injury, plug (211) must be removed

slowly and evenly until the return spring (221) force is
completely released.
211

Fig. 33-191 Removing plug (211)

33-113
33. UPPER STRUCTURE

(7) Remove push rod (212), plug (211), pressure

reducing valve assy (spool), return springs (221)
from casing (101). 212

211

Record combination of port holes on casing and the 221

pulled out parts. The stroke differs according to
direction.

101

Fig. 33-192 Removing push rod, plug, pressure

reducing valve and spring
(8) Push springs (241-1), (241-2) in the range of 7mm
(0.276in) that the movement of spring seats (216- 216-1
216-2
1), (216-2) and shift the seats (216) in a side
direction, and remove spools (201-1), (201-2)
through the larger hole of seat.

Never push down spring seat (216-1) in 7mm (0.276in)

or more. (For port 1,3)
201-1
Never push down spring seat (216-2) in 9.4mm
201-2
(0.370in) or more. (For port 2,4)
Fig. 33-193 Removing spool (201)
(9) Remove spool (201-1), (201-2), spring seats (216-
1), (216-2), spring (241-1), (241-2) and washer 241-1 216-1
(217). 241-2 216-2

217

201-1
201-2

Fig. 33-194 Disassembling pressure reducing valve

(10)Remove spring (*246), spring seat (*218-1), (*218-
2) from push rod (212). *218-1 *246 214
*218-2

The parts marked * might not be equipped depending

on valve type.

212
211

Fig. 33-195 Disassembling push rod

33-114
 33. UPPER STRUCTURE

(11)Pull out push rod (212) from plug (211).

(12)Remove O-ring (214) from plug (211).

212

Fig. 33-196 Removing push rod (212)

(13)Remove inside seal (213) from plug (211) with
small driver.

213

Fig. 33-197 Removing seal (213)

33.2.3.3 CLEANING PARTS

(1) Clean parts with wash oil roughly.
(2) Clean parts with wash oil completely.
(3) Dry parts by swabbing clean rag.
(4) Apply rust preventives on parts.

33.2.3.4 ASSEMBLING
(1) Fit washer 2 (217), springs (241-1), (241-2), spring
seats (216-1), (216-2) to spool (201-1), (201-2). 201-1 241-1 216-1
216-2
201-2 241-2

217

Fig. 33-198 Assembling pressure reducing valve

33-115
33. UPPER STRUCTURE

(2) Push spring (241-1), (241-2) in the range of that the

movement of spring seats (216-1), (216-2) in a side 216-1
direction, and install spools (201-1) through the 216-2
larger hole of spring seat. (See Fig. 33-193)

Never push down spring seat (216-1) in 7mm (0.276in)

or more. (For port 1,3)
Never push down spring seat (216-2) in 9.4mm 201-1
(0.370in) or more. (For port 2,4) 201-2

Fig. 33-199 Installing spools (201-1), (201-2)

(3) Place spring (221) into ports 1,3 of casing (101),
and then install pressure reducing valve assy in it. PRESSURE REDUCING
VALVE ASSY
Place springs (221) into ports 2,4 and install it.

221

Install the removed respective assy into respective

holes. 101

Fig. 33-200 Installing pressure reducing valve assy

(4) Fit O-ring (214) and seal (213) into plug (211).
• Apply hydraulic oil on surface of push rod. 211

214 213
PLUG (211)
SEAL (213)

-RING (214)

PUSH ROD
(212) Apply hydraulic oil

For the assembling

direction of seal (213). Fig. 33-201 Installing O-ring (214) and seal (213)

(5) Insert push rod (212) in plug (211) and install spring
(*246) and spring seat (*218-1) to push rod (212) on
port 1,3 side.
And install spring seat (*218-2) to push rod on port
2,4 side.

The parts marked * might not be equipped depending

on valve type.
212 211 246 218-1
Fig. 33-202 Assembling push rod, spring (246) and
seat (218)

33-116
 33. UPPER STRUCTURE

(6) Fit plug (211) assy to casing (101).

1) When the force of spring (211) is weak, it stops
at the position where it is pushed in by the sliding
resistance of O-ring (214).

101 211

Fig. 33-203 Installing plug assy

2) When the force of spring (221) is strong, attach
plate (151) and press 4 push rods by hand at the 301
same time, and tighten joint (301) temporarily.
• Install spool (201) straight and evenly into the
hole of casing (101).
• Take care so that plug (211) and plate (151) do
not jump out of casing (101).

151

Fig. 33-204 Installing plug assy and plate (151)

(7) Install joint (301) on casing (101) with jig A securely.
Jig A : See 33-120.
Tightening torque : 47.1 N•m (35±2.2 lbf•ft)

101
A

Fig. 33-205 Installing joint (301)

33-117
33. UPPER STRUCTURE

(8) Install circular plate (302) to joint (301)

• Screw it in until it comes in contact with 4 push rods 312

(212) equally.
• The exceeding of screw in may cause malfunction
of machine. 302

(9) Screw adjusting nut (312) in until it touches circular

plate (302), and tighten it applying spanner to stop
circular plate returning.
Fig. 33-206 Installing circular plate (302)
: 32mm

: 22mm
• Apply Loctite #277 to threads of joint.
Tightening torque : 68.6 N•m (51 lbf•ft)
(10)Apply heat-resisting grease to joint (301) rotating
section and the top of push rod (212).
(11)Cover it with boots. GREASE

(12)Spray rust preventives through each port and

attach plug respectively.

301
212

Fig. 33-207 Applying grease to joint section and

push rod

33-118
 33. UPPER STRUCTURE

33.2.3.5 MAINTENANCE STANDARDS

Check item Standard Remarks

When leakage quantity reaches to 1000cc/ min.
or more where handle is set in neutral position,
Conditions
or to 2000cc/min. or more in operation, replace
Leakage Primary pressure 2.94 MPa (426 psi)
spool with new one.
Hydraulic oil viscosity 23 cSt
If leaked, even if the spool is replaced, replace
pilot valve assy with new one.
When the wear of sliding section is 10 more
This condition may be the same as the
Spool than the that of non sliding section, replace it
above.
with new one.
Push rod When the wear of top is 1mm (0.04in) or more, replace it with new one.
When looseness of 2mm (0.08in) or more on
In case of the looseness due to the
Looseness of control circular plate (302) on control section and joint
loosening on tightening section, adjust
section section (301) due to wear is pro- duced, replace
it.
them with new ones.
When trouble such as noise, hunting, drop of
primary pressure, etc. has occurred in op-
eration, and it does not restore after taking
Stability of operation
corrective action according to below 33.2.3.6 (
TROUBLESHOOTING), replace pilot valve
assy with new one.

• O-ring, etc. should be replaced with new one at every disassembling.

• If socket bolt (125) was loosened, seal washer (121) should be replaced.

33.2.3.6 TROUBLESHOOTING
It is very difficult to find defective section. The following table explains the several estimated causes. For repair, refer
to the estimated causes and corrective actions.
The following table explains general phenomenon, estimated causes and corrective actions. However, most
machine problems are not caused by the failure of only one part, but involve relations with other parts. Therefore
corrective action other than those described in this table is often required. The following table does not cover causes
and corrective actions for all the troubles. So it may be necessary to perform further investigation of troubles and
causes.

Trouble Cause Remarks

1) Primary pressure is insufficient. 1) Secure primary pressure.
2) Secondary pressure springs (241) are
2) Replace with new ones.
broken or fatigued.
Secondary pressure
3) Clearance between spool (201) and
does not rise . 3) Replace spool (201).
cas-ing (101 ) is abnormally large.
4) Disassembly and reassembly or
4) Handle has a looseness.
replace handle section.
1) Sliding parts are caught. 1) Repair the unsmoothed section.
Secondary pressure is
2) Tank line pressure varies. 2) Bring pressure directly to oil tank.
unstable.
3) Air has mixed into pipeline. 3) Bleed air by operating it several times.
Secondary pressure is 1) Tank line pressure is high. 1) Bring pressure directly to oil tank.
high 2) Sliding parts are caught. 2) Correct.

33-119
33. UPPER STRUCTURE

33.2.3.7 JIG
(1) Jig for removing and installing joint (301)

29 (1.14") (1)
Material ; SCM415 (N)
26.5 (1.04") Carburizing and Quenching
(2) BUSHING
23.5 (0.925")
Material ; S45C
(0.512")
13

19 (0.748") SECTION AA
69 (2.72")
54 (2.13")
50 (1.97")
46 (1.81")

25 (0.984")

A A
(0.669")
17

23 (0.906")

27 (1.06")

31 (1.22")

Installing condition on joint

16
(1.63") * (1) and (2) are tight fitted
)
12"
(0.5 3
R1

Sectional drawing of jig

0.5X15

15.5 (0.61") 6.5 (0.256")

(0.02")

(0 R5
12.5 (0.492")

.2 .8
28 R
") (0. 4.5 C0.5
17
7") (0.02")
(0.374")
9.5

C0.5
(0.02")

11.6 Material ; SCM415 (N)

(0.457") Carburizing and Quenching
Q'ty ; 2
Detail of bushing

33-120
 33. UPPER STRUCTURE

33.2.4 PILOT VALVE (FOR TRAVEL)

33.2.4.1 CONSTRUCTION

T=Tightening torgue
N.m (lbf.ft) 12-o

12-o

7-h
12-o
12-y
5 12-y
12-x 12-x

13

6 8
f

d
Loctite 262 10
g
T=3 (2.2)
g
14
T=5 (3.7) q 11
r 15
u
t T=4 (3)
7-i T=30 (22)
15
7-k T=1.2 (0.9)
7-h u
15 t T=4 (3)
7-j t 14
u
r
q
17 21 T=5 (3.7)
Loctite 262 21
21
z
r 21
w' T=3-5 (2.2~3.7)

Fig. 33-208 Exploded view of pilot valve

No. Parts Q’ty No. Parts Q’ty

5 Rubber boots 2 12-x Seal ø14×20×3 6
6 Foot pedal (Switch plate) (2) 12-y Wiper ring 6
6-d Switch plate 2 13 Damper spring 4
6-f Regulation screw M8×28 4 14 Check valve kit (2)
6-g Set screw M5×8 4 14-q Plug M8 2
7 Retaining plate kit (1) 14-r Ball M6, 35 2
7-h Plate 1 15 Orifice (4)
7-i Capscrew M10×20 2 15-u Plug M6 4
7-j Shaft 2 15-t Orifice M6, ø0.6 4
7-k Set screw M4×10 2 17 Shuttle valve kit (2)
8 Flange kit 4 17-w’ Shuttle valve & orifice 2
10 Control spool 4 17-r Ball M6, 35 2
11 Return spring 4 17-z Orifice M5, ø0.8 2
12 Damper flange kit (4) 21 Plug 4
12-o Damper plunger ø14 4

33-121
33. UPPER STRUCTURE

33.2.4.2 DISASSEMBLY AND ASSEMBLY

(1) Boot replacement

  

The pilot control unit does not need to be removed from

the machine to perform this operation.

1) Remove both faulty boots.

(using a flat screw driver if necessary)
2) Replace both boots with a new one.
* Reassembly : 
   

• First fit the lower part of the rubber boot on

the retaining plate between the 2 switch
plates
• Then put the lower part in the external
groove of the retaining plate
• Finish by fitting the upper part of the rubber
boot on the switch plate.

Fig. 33-209
(2) Switch plate removal
1) Remove :

• The pilot control unit from the machine.
• Both rubber boots (See 33.2.4.2 (1))
2) Remove the screw locking the axis using a 2mm
socket wrench. (See Fig. 33-210 No.1)
* Reassembly :
• Apply a droplet of Loctite #262 on the 
 

locking screw thread.
• Torque :1.2 N•m (0.89 lbf•ft)    


3) Fit a M3 screw on the switch plate axis in order

to remove it
(Using pliers if necessary). (See Fig. 33-210
No.2)  

 
* Reassembly :
• Position the axis so that the hole is aligned
with the locking screw as shown on the
picture (See Fig. 33-210 No.3)
4) Mark out the position of the switch plate before  
removing it.
Fig. 33-210
5) Repeat the operation for the second switch plate.
6) Reassemble parts in reverse order.

33-122
 33. UPPER STRUCTURE

(3) Switch plate adjustment

If the switch plate is replaced, it is necessary to adjust

the regulation screws.

 


1) Unscrew the 2 locking screws using a 2,5mm  

socket wrench (See Fig. 33-211) 

* Reassembly :
• Apply a droplet of Loctite #262 on the
locking screw thread.
• Torque :3 N•m 2.2 (lbf•ft)
2) Set the switch plate horizontally.
3) Screw on simultaneously both regulation screws
using a flat screw driver (5,5×150) until feeling Fig. 33-211
some resistance.

Do not misadjust the two damping screws. (See Fig.

33-212)
Regulation Damping screws
screws to already adjusted
4) Tighten the locking screws to hold the regulation adjust and glued
screws in position.
5) Repeat the operation for the second switch plate
making sure both switch plates are parallel. (See
Fig. 33-211) SWITCH PLATE
The figure is shown
from the backside.
(4) Retaining plate removal
Fig. 33-212
1) Remove
• The pilot control unit from the machine.
• Both rubber boots (See 33.2.4.2 (1))
• Both switch plates (See 33.2.4.2 (2))
2) Unscrew simultaneously both screws holding the
retaining plate using a 8mm socket wrench.
(See Fig. 33-213)
* Reassembly :
• Apply a droplet of Loctite #262 on the screw
thread.
• Torque :30 N•m (22 lbf•ft)

Fig. 33-213

33-123
33. UPPER STRUCTURE

3) Lift the retaining plate to remove it.

(See Fig. 33-214)
* Reassembly :
• Use the retaining plate to insert the 4 guides
into the body simultaneously and
perpendicularly.
(See Fig. 33-214 left side)
4) Reassemble parts in reverse order.
5) Drain the pilot control unit (See 33.2.4.3).

Fig. 33-214
(5) Damping plunger seals replacement
1) Remove
• The pilot control unit from the machine.
• Both rubber boots. (See 33.2.4.2 (1))
• Both switch plates (See 33.2.4.2 (2))
• The retaining plate (See 33.2.4.2 (4))
WIPER RING
2) Remove the wiper ring of the damping plunger
1 2 DAMPER PLUNGER
(1).
(See Fig. 33-215 No.1) Fig. 33-215
* Reassembly :
• Replace with a new wiper ring.
 



Always place the damping plunger prior to the wiper


ring, and make sure the wiper ring is correctly
positionned.   

3) Remove the damping plunger (2).  

(Fig. 33-215 No.2)   

Fig. 33-216
4) Using a needle, remove the seal placed inside 
  

the body (See Fig. 33-217 No.3, 4)  
* Reassembly :
• Replace with a new seal and grease it.

3 4 
Fig. 33-217

33-124
 33. UPPER STRUCTURE

• Squeeze the seal between your fingers to

obtain a 8-shape.
(See Fig. 33-218 No.5)
• Insert the seal within the groove with your
fingers (lip in bottom position).
(See Fig. 33-218 No.6, 7)
• Push the seal against the side using the 5 6
round head of a small socket wrench. (Fig.
33-218 No.8)

During the reassembly, make sure the seal is correctly

positionned, and pay attention not to damage nor twist
it. 7 8
5) Repeat the operation for the other 3 assemblies. Fig. 33-218

6) Extract the damping springs from the body (using

flat nose pliers).
7) Inspect the damping springs. If defects are
detected, replace the 4 springs.
8) Reassemble parts in reverse order.
(6) Guide/plunger and regulation unit replacement
1) Remove
• The pilot control unit from the machine.
• Both rubber boots (See 33.2.4.2 (1))
• Both switch plates (See 33.2.4.2 (2))
• The retaining plate (See 33.2.4.2 (4)) DAMPER
PLUNGER
2) Guide/plunger replacement :
BODY
• Insert the end of a thin screwdriver between
the guide and the body, carefully lift the guide
to remove it from the body.

Hold the guides with the other hand during the

extraction operation to limit the effect of the return
spring.

3) Remove the guide / plunger assembly.

4) Repeat the operation for the other 3 sub-
assemblies.
5) Visually check that the guides / plungers are in
good condition. If defects are present, replace
the 4 sub-assemblies.

Fig. 33-219

33-125
33. UPPER STRUCTURE

6) Guide/plunger and relulation unit replacement

• Extract the regulation units from the body
(using flat nose pliers).
• Inspect the regulation units. If defects are
detected on the parts, replace the 4 units.
7) Return spring replacement :
• Extract the return springs from the body
(using flat nose pliers).

Fig. 33-220
• Inspect the return springs. If defects are
detected, replace the 4 springs.

8) Reassemble parts in reverse order.

Fig. 33-221
(7) Throttle kit replacement
1) Remove
• The pilot control unit from the machine
• Both rubber boots (See 33.2.4.2 (1))
• Both switch plates (See 33.2.4.2 (2))
• The retaining plate (See 33.2.4.2 (4))
• The damping plungers and springs (See
33.2.4.2 (5))

Fig. 33-222

33-126
 33. UPPER STRUCTURE

2) Unscrew the screw using a 3mm socket wrench.

(See Fig. 33-222)
* Reassembly :
• Apply a droplet of Loctite #262 on the screw
thread
• Screw on until it sets just above the body.
(See Fig. 33-223)
3) Unscrew the throttle using a 3mm socket
wrench.
* Reassembly :
• Torque :4 N•m (3 lbf•ft)
4) Repeat the operation for the other 3 assemblies.
SCREW
5) Replace with new screws and new throttles.
6) Reassemble parts in reverse order.

THROTTLE

Fig. 33-223
(8) Shuttle valve kit removal
1. Remove the pilot control unit from the machine

The pilot control unit does not need to be disassembled

to perform this operation.

2) Unscrew the shuttle valve using a 4mm socket

wrench. (See Fig. 33-224 and Fig. 33-225)
* Reassembly :
• Thoroughly clean the body to remove any
trace of loctite. Fig. 33-224

• Apply a droplet of Loctite #242 on the

shuttle valve thread.
• Torque :4 N•m (3 lbf•ft)

Wait for 8 hours before using the machine to let the

Loctite #242 dry completely.

Fig. 33-225

33-127
33. UPPER STRUCTURE

3) Put the body up-side-down to remove the shuttle

valve and the ball. (See Fig. 33-227)
4) Unscrew the throttle using a 2,5mm socket
wrench.
* Reassembly:
• Hand tighten.
5) Repeat the operation for the other
subassemblies.
6) Inspect the shuttle valves, balls and throttles. If
defects are detected, replace all the assemblies.
7) Reassemble parts in reverse order.
Fig. 33-226

 
  


Fig. 33-227
(9) Check valve kit removal
1) Remove the pilot control unit from the machine

The pilot control unit does not need to be disassembled

to perform this operation.

2) Unscrew the check valve plug using a 4mm

socket wrench.
(See Fig. 33-228)
* Reassembly :
• Drain the pilot control unit
(See 33.2.4.3)
Fig. 33-228
• Torque :5 N•m (3.7lbf•ft)
3) Put the body up-side-down to remove the ball.
4) Repeat the operation for the second check valve
kit.
5) Inspect the check valve plugs, O-rings and balls.
If defects are detected, replace all the
assemblies. (See Fig. 33-229)
6) Reassemble parts in reverse order.

CHECK VALVE
PLUG

BALL
Fig. 33-229

33-128
 33. UPPER STRUCTURE

33.2.4.3 DRAIN OF HYDRAULIC PILOT CONTROL UNIT

(1) When removing the retaining plate, the throttle kit or
the shuttle valve kit, it is necessary to drain the pilot
unit.
(2) Reassemble the pilot unit control completely.
(3) Install the pilot unit control in the machine.
(4) Slightly unscrew the check valve plug using a 4mm
socket wrench. (See Fig. 33-230)
(5) Switch on the machine.
(6) Operate gently the pedal until the bubbles
disappear.
(7) Tighten the check valve plug.
• Torque : 5 N•m (3.7 lbf•ft)
(8) Repeat the operation for the other check valve plug.

Fig. 33-230

33-129
33. UPPER STRUCTURE

33.2.5 SWING MOTOR UNIT

33.2.5.1 CONSTRUCTION
(1) Swing motor

702 712

351

ARRENGEMENT OF BRAKE SPRING

355

401

488 469
051-1 051

100
151
162 052 161 171

303 984
A A 163 985 391 390 444
131
451
472 400-1
400-2
712 400 052

702 707 SECTION A-A

706

986

742

743
994

111

491 101
121 123 122 124 114 301 443

Fig. 33-231 Swing motor

33-130
 33. UPPER STRUCTURE

Tightening Tightening
torque No. Parts Q'ty torque No. Parts Q'ty
N•m (lbf•ft) N•m (lbf•ft)
177 (130) 051 Relief valve ; M33-P1.5 2 391 Rivet 2
051-1 O-ring ; 1B G30 2 69 (51) 400 Anti-reaction valve ; M22-P1.5 2
052 Anti-reaction valve sub 1 400-1 O-ring ; 1B P20 2
100 Casing for anti-reaction valve 1 400-2 Backup ring 2
101 Drive shaft 1 431 (320) 401 Socket bolt ; M20×45 4
111 Cylinder 1 443 Roller bearing 1
114 Spring plate 1 444 Roller bearing 1
121 Piston 9 451 Pin 2
122 Shoe 9 539 (398) 469 ROMH plug ; M36-P1.5 2
123 Set plate 1 472 O-ring 1
124 Shoe plate 1 488 O-ring ; 1B P34 2
131 Valve plate 1 491 Oil seal 1
36 (27) 151 Plug ; PF1/4 2 702 Brake piston 1
161 O-ring ; 1B P11 2 706 O-ring 1
162 O-ring ; 1B P12 2 707 O-ring 1
163 O-ring ; 1B P6 2 712 Brake spring 14
29 (22) 171 Socket bolt ; M8×55 4 742 Friction plate 3
301 Casing 1 743 Separator plate 4
303 Valve casing 1 2.7 (2.0) 984 Plug ; PF1/2 1
351 Plunger 2 5.6 (4.1) 985 Plug ; PF1 1
355 Spring 2 0.9 (0.65) 986 Plug ; PF1/4 1
390 Name plate 1 98 (72) 994 Plug ; PT3/4 1

33-131
33. UPPER STRUCTURE

(2) Swing reduction unit

34

22 11 27 25 24 3
4
SURFACE
5 OF LUBE OIL
10 3
23 6 20 35
7 8 3 VIEW
11 15
26 12
9 17 30 36, 37, 38, 39
14 31
3
28
29 18

33 32
13
21 19 16
2
1
DETAIL aa

aa

Fig. 33-232 Sectional view of swing reduction unit

Tightening torque Tightening torque

No. Parts Q'ty No. Parts Q'ty
N•m (lbf•ft) N•m (lbf•ft)
1 Pinion 1 21 Ring 1
2 Shaft 1 22 Thrust washer 6
3 #1 sun gear 1 23 Thrust washer 8
4 #1 pinion 3 24 Snap ring 1
5 Spider assy 1 25 Snap ring 3
6 #2 sun gear 1 26 Spring pin 4
7 #2 pinion 4 539 (398) 27 Socket bolt ; M20×200 12
8 Ring gear 1 28 Grease fitting 1
9 Spider 1 29 Relief fitting 1
10 Shaft 4 30 Tube ; L=213 1
11 Needle bearing 11 69.1 (51.0) 31 Elbow 1
12 Spherical bearing 1 69.1 (51.0) 32 Plug 1
13 Spherical bearing 1 33 Cap 2
14 Oil seal 1 279 (206) 34 Capscrew ; M16×40 2
15 Housing 1 35 Wire ; ø1.6×250 1
16 Oil seal 1 36 Shim ; t=0.1 1
17 Sleeve 1 37 Shim ; t=0.2 1
18 Sleeve 1 38 Shim ; t=0.3 1
19 Plate 1 39 Shim ; t=0.5 1
20 Plate 1

33-132
 33. UPPER STRUCTURE

33.2.5.2 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR

33.2.5.2.1 TOOLS

Tools Remarks
Relief valve M33×P1.5 41mm
Socket wrench
Anti-reaction valvevalve M22×P1.5 24mm
M8, M20 6,10,12,17mm
Allen wrench ROMH PLUG M36×P1.5 17mm
ROH PLUG PF1/4, PF1/2, PF1 6mm, 8mm, 14mm
Screwdriver Flat-bladed type, medium size 2 pcs.
10×8×200(0.39"×0.31"×7.87")
Steel bar
(key material) 1 pc.
Hammer Plastic hammer 1 pc.
10~45 (7.2~33)
Torque wrench N•m (lbf•ft) 40~180 (29~130)
120~480 (87~350)
Slide hammer bearing puller
14 (0.551")

85 (3.35")
75 (2.95")
30 (1.18")
15 (0.591")

35 (1.38")

5
2. 2")
R1 .49
M16 (0
Through
Brake piston drawing tool
100 (3.94")
44 (1.73")
8 (0.315")

M16
4
(0.158")

BRAKE PISTON
DRAWING TOOL

o 8 (0.315") BRAKE PISTON

CASING

33-133
33. UPPER STRUCTURE

33.2.5.2.2 DISASSEMBLY
(1) General cautions
1) Hydraulic components are precision products
and have small clearance. Therefore, assemble
and disassemble in a less dusty clean place. Use
clean tools and cleaning oil and handle
components with full care.
2) If a component is removed from the main body,
clean the area around the ports thoroughly and
plug them up so no dust and water do not enter.
When fitting them back to the body, do not
remove the plugs till piping is completed.
3) Study the structural drawing before the work
begins and prepare necessary parts according to
your purpose and the scope of work. Seals and
O-rings once removed can not be used again.
Some parts can not be supplied as single parts
and available only in sub assy. Prepare such
parts according to the parts manual.
4) The piston and the cylinder block are shop fitted
when new. If you intend to reuse them, put a
matching mark on the piston and the cylinder
block.

(2) Disassembly procedure

The figures in parentheses after part names in this
manual represent those item numbers in Fig. 33-
231
1) Draining oil
Remove the drain plug and drain hydraulic oil
from casing (301).
2) Preparation for removing the valve casing 052
Fix the motor on a work bench so the drive shaft
(101) end comes down. On that occasion, put a 303 051
matching mark on the mating parts of casing
(301) and valve casing (303). 712

702
• Choose a clean place, and lay with a rubber
sheet or a cloth on a work bench. Handle the
valve casing with care so parts do not have
dents.

101 301
Fig. 33-233 Removing valve casing (303)

33-134
 33. UPPER STRUCTURE

3) Loosen relief valve (051) and separate it from !#

valve casing (303).

: 41 mm
!##
!!
4) Loosen anti-reaction valve sub assy (052) and
remove from valve casing (303). (See Fig. 33-
233)
"$'
: 6 mm

5) Separate ROMH plug (469) from valve casing

(303) and draw out spring (355) and plunger
(351). " #
Fig. 33-234 Removing relief valve (051),
: 17 mm
anti-reactionvalve (052),
anti-cavitation plunger (351)
6) Loosen socket bolt (401) and separate valve
and valve casing (303)
casing (303) from casing (301). If the socket bolt
(401) are loosened, the valve casing floats off


casing (301) by the force of brake spring (712). 
 
 
Then separate valve plate (131) from valve 

casing (303).

: 17 mm

7) Draw out brake spring (712) from brake piston

(702).

8) Put the claw of the brake piston removing jig in
the concaved part of brake piston (702). Fig. 33-235 Removing brake piston (702)
Tighten 2 bolts of jig simultaneously, and draw
out the brake piston (702) with the jig, from the
123 121 111
casing.
122

9) Lay the motor on its side again and draw out

cylinder block (111) from drive shaft (101). Then 124
draw out piston (121), set plate (123), spring
(114) and shoe plate (124). 101

Handle the parts with care so as not to score the sliding

surfaces of cylinder block (111) and shoe (122).

301 742 743

Fig. 33-236 Drawing cylider block (111), piston sub

assy, friction plate (742) and separator plate

33-135
33. UPPER STRUCTURE

10) Draw out friction plate (742) and separator plate

(743) from casing (301). 301

11) Draw out drive shaft (101) from casing (301),

while lightly tapping the side face of valve casing
(303) in drive shaft (101), using a plastic mallet. PLASTIC
MALLET

• Do the following work as required.

101

a. Drawing the inner race of roller bearing (443)

from drive shaft (101), using a press. 443

• Do not reuse the removed bearing.

Fig. 33-237 Removing drive shaft (101)
b. Drawing out the outer race of roller bearing (443) PRESS
from casing (301), by lightly tapping the steel rod
101
from the oil seal (491) housing side.
(Do not reuse the bearing.)

c. Separate the outer race of roller bearing (444)

443
from valve casing (303), using a slide hammer
bearing puller.

Put the inner race

on the press bench.

Fig. 33-238 Removing inner race of

roller bearing (443)

33-136
 33. UPPER STRUCTURE

33.2.5.2.3 ASSEMBLY
(1) General precautions
1) Repair those parts damaged after disassembly
and prepare replacement parts beforehands.
2) Clean all parts thoroughly in cleaning oil and dry
them with jet air.
3) Always coat the moving parts with clean
hydraulic oil, before assembly.
4) Replace such seals as O-ring and oil seal in
principle.
5) Tighten socket bolts and plugs to specified
torques, using a torque wrench.

(2) Assembly procedure OUTPUT SHAFT SIDE

The figures in parentheses after part names in this 101
manual represent those item numbers in the Fig.
33-231.
1) Preparation for assembly 443
Place casing (301) on a proper bench so its valve
casing (303) faces upward.

• This operation is necessary only when the

roller bearing is removed.

2) Shrinkage fit the inner race of roller bearing (443)

into drive shaft (101).

444
3) Shrinkage fit the inner race of roller bearing (444)
to drive shaft (101). Fig. 33-239 Assembling the inner race of bearings
(443), (444)
• This operation is necessary only when the oil
seal is removed.
Fit oil seal (491) to casing (301). On that
occasion, coat the lip of the oil seal with
grease and check the direction of it, before
fixing it.

4) Assemble the outer race of roller bearing (443)

into casing (301), by lightly tapping the steel rod.

5) Attach drive shaft (101) to casing (301).

443 491
101 301
Fig. 33-240 Fitting oil seal (491), outer race of
roller bearing (443), and drive shaft (101)

33-137
33. UPPER STRUCTURE

6) Place casing (301) as shown in Fig. 33-241 and

insert shoe plate (124).
On that occasion, the shoe plate does not come
off if it is coated with grease.
The larger
chamfer side
124

443 301

101

Fig. 33-241 Inserting shoe plate (124)

7) Set the set plate (123) and spring (114), then set  !
piston sub (121, 122) assy.

8) Assemble piston sub assy (121, 122) fixed in 

retainer plate (123) into cylinder (111). Match it to
the spline of drive shaft (101) and insert it in  
place.
"




Fig. 33-242 Inserting cylinder assy
9) Replace casing (301) with oil seal (491) facing
downward and assemble separator plate (743) 743
and friction plate (742) into casing (301), in that
order. 742
Assemble four separator plates and three friction
plates.

491 301

Assemble the same phases of four slits in the gears of

friction plate (742).
Assemble four slits in the four claws of separator plate Position of
(743) in the position of Fig. 33-243. separator plate (743)

PG PORT
Fig. 33-243 Installing of separator plate (743),
friction plate (742).

33-138
 33. UPPER STRUCTURE

10) Fit O-rings (706), (707) to casing (301). In that

702
case, if the O-rings are coated with grease, they
are hard to tear off when brake piston (702) is
inserted.

11) Assemble brake piston (702) into casing (301).

12) Assemble brake spring (712) into brake piston

(702). In that case, make sure that a spring is
placed securely in the spot faced part of the
brake piston. SLIT (OPPOSITE SIDE)
PG PORT
• This operation is necessary only where roller Fig. 33-244 Assembling brake piston
bearing (444) is removed.

13) Insert the outer race of roller bearing (444) into

valve casing (303), while lightly tapping the steel
rod placed on the outer race, using a hammer.

14) Assemble valve plate (131) into valve casing

(303) and fit O-ring (472) in it.

15) Install valve casing (303) to casing (301) and

fasten them with socket bolts (401).

: 17 mm,
Tightening torque : 431 N•m (320 lbf•ft)

16) Fit plunger (351) and spring (355) to valve

casing (303). Then tighten ROMH plug (469)
fitted with O-ring (488) against valve casing
(303).

: 17 mm,
Tightening torque : 539 N•m (398 lbf•ft)

17) Fit relief valve (051) to valve casing (303).

: 41 mm,
Tightening torque : 177 N•m (130 lbf•ft)

18) Fit anti-reaction sub assy (052) to valve casing

(303).

: 6 mm,
Tightening torque : 29 N•m (22 lbf•ft)

33-139
33. UPPER STRUCTURE

33.2.5.3 DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT

33.2.5.3.1 TOOLS

Code Tool name Remarks

Material : Mild steel 520 (20.5")

390 (15.4")

230 (11.8")
a Stand

Material : Mild steel o 180 (7.1")

o 153 (6.0")
Spherical bearing (13)
b

130 (5.1")
removing jig

Material : Mild steel t=4.5 (0.177")

Spherical bearing (12) 0
c 10 4")
removing jig o .9
(3

190 (7.48")

(0.354")
Material : Mild steel
Oil seal (16) 162 (6.38")
d

9
installing jig

Material : Mild steel o 150 (5.91")

o 132 (5.2")

Spherical bearing (13)

120 (4.72")
e or more
press-fit jig (0.354")

Material : Mild steel o 186 (7.32")

Oil seal (14) o 160 (6.3")
f
9

installing jig
(2.36")

Material : Mild steel

60

Spherical bearing (12)

g o 125
press-fit jig (4.92")
o 195 (7.68")

i Snap ring plier For shaft

j Torque wrench 140 N•m (100 lbf•ft) class
k Plastic hammer (Wooden mallet)
m Press 30 ton (66150 lb) class
n Flat-bladed screw driver
p General tools Allen wrench, Steel bar
Thread sealant Three Bond #1360K
q
Sealant Loctite #515

33-140
 33. UPPER STRUCTURE

33.2.5.3.2 DISASSEMBLY
The numbers in parentheses correspond to the ones in
construction drawings Fig. 33-231.
(1) Preparation
1) Before disassembly, clean the outside of the
reduction unit thoroughly and check for no
damage and scoring.
2) Drain gear oil from the reduction unit.
3) Disconnect the drain tube.
4) Matching Mark
To facilitate the reassembly of the unit, put
matching mark on the joining parts of the housing
before disassembly.

(2) Disassembling swing motor from reduction unit

1) Preparation for disassembly
Place the reduction unit assy on a stable work 27
bench as shown in Fig. 33-245, remove plug
(32), drain out oil and put a matching mark on the
matching surface of the figure on the right.

MATCHING
2) Removing swing motor assy MARK
Loosen all socket bolt (27) (M20). Attach eye
bolts (M12) in the lifting bolt holes in the top
surface of the swing motor and lift the assy by
crane.
If it is hard to remove the swing motor assy from
the reduction unit, float it by inserting a flat-blade Fig. 33-245 Removing swing motor assy
screwdriver in the groove of the flange.
5
: 17 mm 3

(3) Disassembling reduction unit

1) Remove #1 sun gear (3). 8

2) Removing #1 spider assy (5).

The spider assy (5) [consisting of thrust washer
(22), #1 pinion (4), needle bearing (11) and snap
15
ring (25)] can be removed from the spline easily
if it is lifted up in that condition.
Fig. 33-246 Removing #1 sun gear and
#1 spider assy

33-141
33. UPPER STRUCTURE

3) Removing ring gear (8)

Attach eye bolts (M16) to the top surface of ring
gear (8) and lift the ring gear lightly by a wire #2 SPIDER ASSY
sling.
Put a flat-blade screwdriver (n) into the matching 8
surface of ring gear (8) and housing (15) and
remove ring gear (8) by lightly tapping the outer
circumference of the ring gear with a plastic
mallet (k). 15

Fig. 33-247 Removing ring gear (8)

4) Remove #2 sun gear and #2 spider assy. #2 SPIDER ASSY
Draw out #2 sun gear (6) and remove the #2
6
spider assy.
Regarding the disassembly of the #2 assy, refer
to par. (4) which will come up later.

Fig. 33-248 Removing #2 spider assy

• Particularly if no failure is found, the further
disassembly (under condition shown in Fig.
33-249) is not allowed.
Check on parts for possible failure according
to the inspection procedure shown in item
33.2.5.4.2 separately in this condition.
And we recommend that the pinion shaft and
housing assy are replaced together as one
set. But if it is unavoidably necessary to
replace a part of them, follow the procedure
shown below.
• If no failure is found in this step, the
disassembly later is not required.
Fig. 33-249
5) Remove pinion (1) EYE BOLT (M8)
34,35
Place housing (reduction) (15) upwards remove 20
wire (35).
Loosen 2 capscrews (M16×40) and remove plate 1
(20). Attach eyebolt (M8) to pinion (1) and hoist
pinion (1). 16

: 24mm
• When oil seal (16) is separated from housing
(15), oil seal (16) and is pinion (1) are 15
removed together.

Fig. 33-250

33-142
 33. UPPER STRUCTURE

6) Remove plate (19)

DRIVER
Remove ring (21) from groove of housing (15)
using flat blade driver (n). 19
21
And remove plate (19).
15

Fig. 33-251 Removing plate (19)

7) Pulling out shaft PRESS
Pull shaft (2), sleeve (18) and spherical bearing 2
(lower) (13) out by means of press while
supporting housing (15) as shown in the figure.
12

• Spherical bearing (upper) (12) and oil seal 14

(14) are left in the housing. 18
15
13

JIG (a)

Fig. 33-252 Pulling out shaft (2)

8) Removing spherical bearing (lower) (13) PRESS
Pull sleeve (18) and spherical bearing (lower) PLATE
(13) out by means of jigs (b) while supporting
pinion shaft assy as shown in the figure. JIG (b)
Press force : 30t
• Do not use the removed bearing.

18

13

Fig. 33-253 Removing spherical bearing (lower) (11)

33-143
33. UPPER STRUCTURE

9) Removing spherical bearing (upper) HAMMER (k)

Set housing (15) as shown in the figure, insert jig
(c) between bearing (12) and oil seal (14) and FLAT-BLADE
STEEL BAR SCREWDRIVER
remove bearing (12) by striking from the upper
side.
14

10) Remove oil seal (14) from housing (15).

• Do not use the removed oil seal and bearing. 12

15

JIG (c)
Fig. 33-254 Removing spherical bearing
(upper) (12) and oil seal (14)
(4) Disassembling spider assy
25 11 22
1) Disassembling #1 spider assy 4
1. Remove retaining ring (25) with a plier (i).
22 5
2. Remove thrust washers (22), pinion (4) needle
bearing (11).

Fig. 33-255 Disassembling #1 spider assy

• The shaft attached to spider assy (5) is caulked.

When replacing parts, replace the spider assy as a
set.
• Pinions (4) can not be replaced singly. Replace
them it in a set of three.

2) Disassembling #2 spider assy 10 9

23
1. Drive spring pin (26) into shaft (10) using steel 7
bar 8 to 9 in diameter.
2. Draw out shaft (10) from spider (9) and
remove thrust washer (23), pinion (7) and 11
needle bearing (11).
23

26
Fig. 33-256 Disassembling #2 spider assy
Pinions (7) can not be replaced singly. Replace them it
in a set of four.

33-144
 33. UPPER STRUCTURE

33.2.5.3.3 ASSEMBLY
(1) Preparation
1) Sufficiently clean every part with wash oil and dry
it with compressed air.

2) Check on every part for failure.

(2) Assembling pinion (1), shaft (2)

1) Attaching oil seal
16 JIG (d)
Attach oil seal (16) to pinion (1) by means of jig
(d).

Fig. 33-257 Attaching oil seal (16)

2) Applying gear oil
Apply gear oil to the perimeter of axis of shaft (2)
lightly to prevent seizure.
3) Fitting spherical bearing (lower)

Seal sufficient grease in spherical bearing  
(lower) (13) and after inserting sleeve (18), press
fit it in shaft (2) by means of jig (e).
Press force : 4~5t  

• Since the bearing is formed with a partition at

the center section, seal grease in it from both
sides.





Fig. 33-258 Fitting spherical bearing (lower)

33-145
33. UPPER STRUCTURE

4) Apply sufficient grease to the pinion shaft assy.

Grease : Lithium extreme-pressure grease
(SHELL Albania EP2 or equivalent)
: 1.7kg (3.75 lbf)
/4-)5-

Fig. 33-259 Apply grease

(3) Placing shaft assy in
1) Place housing (15) on level bench.
2) Attach eye bolt to screw (M10) at the axis end of
shaft assy, and perpendicularly hang up pinion
shaft assy and place it in the housing.

• Horizontally orient the outer race of spherical

bearing and insert it in by striking lightly.
If the outer race is tilted, it is hard to insert 15
even if striking. Then do not force to insert it
in, but take it away once and horizontally
orient the outer race twice and insert it in
again.

Fig. 33-260 Placing pinion shaft assy in

3) Assembling plate (19)
Place plate (19) and attach ring into groove of
housing, and fix plate. 19 21

15

Fig. 33-261 Assembling plate (19)

33-146
 33. UPPER STRUCTURE

4) Installing pinion (1)

Attach eyebolt (M18) to pinion (1), and hoist it, 
 
then insert into shaft (2).
Install pinion (1) securely by hammering. 
Attach plate (20) to shaft (2) by tightening 2 
capscrews (34) (M16×40), and install it on pinion
(1). 

: 24mm
Tightening torque : 279N•m (206 lbf•ft)
(Apply Three Bond #1360K)
• To prevent the loosing of capscrew (34) tie up the       
 
     ! "#
capscrew with wire (35) as shown in right figure.
$ 

%& '



 
Fig. 33-262 Installing pinion (1)
5) Set housing assy so that the pinion directs
JIG (f)
downward.

6) Fit oil seal (14) in housing (15) by means of jig (f).

• Apply Loctite #515 to the perimeter of oil 14
seal.
15
• Fill one third (1/3) of the space of the groove-
shaped section provided on the oil seal (12)
lip with grease.
• Insert it horizontally giving attention to the lip
of oil seal so as not be damaged.

Fig. 33-263
7) Press fit spherical bearing (upper) (12) in shaft
 
(2) and housing (15) at the same time by means
of jig (g).
 
In this case insert sleeve (17) in advance.



Fig. 33-264 Spherical bearing (upper) Press-fitting

33-147
33. UPPER STRUCTURE

(4) Assembling spider assy

25 11 22
1) Assembling #1 Spider assy 4
a. Coat the bore surface of pinion (4) with
22 5
grease. Put pinion (4) on thrust washer (22)
and assemble needle bearing (11) into the
bore surface
b. Fit thrust washers (22) and pinion (4) as in Fig. Fig. 33-265 Assembling #1 spider assy
33-266 and fit snap ring (25) by means of
pliers (i).

i
Fix the snap ring with the sharp edge on the motor side
(top side in the position of Fig. 33-266).

SNAP RING (28) 22

Motor side
5

25 4

Fig. 33-266 Fixing snap ring

2) Assembling #2 Spider assy GEAR SIDE SLIT

Caulk two
a. Coat the bore surface of pinion (7) with points with
grease. Put pinion (7) on thrust washer (23) a punch.
Beware the direction
and fit needle bearing (11) to the bore surface. of spring pin
b. Fit thrust washer (23) and pinion (7) as in Fig.
33-267 insert shaft (10) into spider (9) and
drive spring pin (26). 6~7mm 6~7mm
(0.24~0.28 in) (0.24~0.28 in)
VIEW I
10 9
23
7

Insert shaft (10) into spider (9) so spring pin hole (26) is
aligned.
11
Inthis case direct the oil hole of shaft (10) to outside of
spider assembly. 23

26
Fig. 33-267 Assembling #2 spider assy
(5) Installing #2 spider assy
#2 SPIDER ASSY
Insert #2 spider assy in spline axis of shaft (2).

Fig. 33-268 Assembling #2 spider assy

33-148
 33. UPPER STRUCTURE

(6) Installing #2 sun gear (3)

3
Install #2 sun gear (3) directing the spline upward.

Fig. 33-269 Installing #2 sun gear (3)

(7) Installing ring gear (8)
Apply a thin film of sealant Loctite #515 to the
matching surface of housing (15) and ring gear (8) #2 SPIDER ASSY
and assemble them, aligning the gear teeth and
according to the matching marks given. 8

Align
maching
marks.
15

Fig. 33-270 Installing ring gear (8)

(8) Installing #1 spider assy
1) Mesh the #1 spider assy with ring gear (8) and 3 #1 SPIDER ASSY
set them in place.
2) Mesh #1 sun gear (3) with #1 pinion (4) and set 8
them in place.
4

(9) Fit drain tube (30) and plug (32).

: 10 mm
15
(10)Filling Lube Oil
Fill in 7.4L (2.0gal) of gear oil SAE90 (API Service Fig. 33-271 Installing #1 spider assy
Grade GL-4).

(11)Installing swing motor assy

Attach eye bolts (M12) in the tapped holes of the

 

swing motor and put a wire sling in them

Coat the matching surface of ring gear (8) with
sealant Loctite #515, insert the spline joint of the
swing motor and match the matching marks.
Coat socket bolts (27) with sealant Three-Bond
1360K and fasten them.



: 17 mm,
Tightening torque : 539 N•m (398 lbf•ft)

Fig. 33-272 Installing swing motor assy

33-149
33. UPPER STRUCTURE

33.2.5.4 MAINTENANCE STANDARDS

33.2.5.4.1 SWING MOTOR

(1) Replacement standards for parts
The following are the standards to determine whether or not parts may be reused from values taken at
disassembly. These are only general standards and in case the motor displays poor performance or parts shows
extreme damage and discoloration before disassembly, it is most important to determine how many parts should
be replaced, depending upon the purpose of disassembly and the remaining service life of the motor that the
user expects.

Recommended
Standard
Value for
Item Dimension Remedy
Replacement
mm (in)
mm (in)
Clearance between piston and
cylinder bore
(D-d)
0.032 0.062
Replace piston or cylinder.
(0.0013) (0.0024)
@ ,

Gap between piston and caulked part

of shoe ( )

0.3
0 Replace piston and shoe assy.
(0.0112)

Thickness of shoe (t)

6.0 5.8
Replace piston and shoe assy.
(0.236) (0.228)
J

Thickness of friction plate

4.0 3.6
Replace.
J (0.157) (0.142)

33-150
 33. UPPER STRUCTURE

(2) Standard for correcting sliding surfaces

If the surface roughness of the sliding surface of parts exceeds the following standard, correct it or replace the
parts.

Standard for correcting sliding surfaces

Standard surface Surface roughness
Name of parts
roughness requiring correction
Shoe 0.8—Z (Ra=0.2) (lapping) 3—Z (Ra=0.8)
Shoe plate 0.4—Z (Ra=0.1) (lapping) 3—Z (Ra=0.8)
Cylinder 1.6—Z (Ra=0.4) (lapping) 12.5—Z (Ra=3.2)
Valve plate 0.8—Z (Ra=0.2) (lapping) 6.3—Z (Ra=1.6)

• Lap each sliding surface to a standard roughness level or finer.

• If the spherical sliding surface of the spring (114) and cylinder (111) are roughened, replace parts in pairs.

33-151
33. UPPER STRUCTURE

33.2.5.4.2 SWING REDUCTION GEAR

(1) Inspection at disassembly
1) Spacer and thrust washer
a. Inspect that the parts are not seized or worn abnormally or unevenly.
b. Inspect and measure the parts to see that the wear does not exceed the allowable values.

2) Gears
a. Inspect that the gear teeth do not show pitting and seizure.
b. Inspect by dye penetrant examination that the bottom of the teeth does not show cracks.

3) Bearing
Turn the bearing and check that it does not develop abnormal sound, catching and other faults.
Do not reuse spherical bearing

4) O-rings and oil seals

Do not reuse O-rings and oil seals; always replace them with new ones at reassembly.

(2) Inspection after assembly

1) Operation
Check to see that #1 sun gear (3) is not faulty when turned by hand.

2) Checking for oil leak and oil condition

Check for oil leak.
Check the oil level by level gauge and confirm that the oil is not dirty. If the oil is short, replenish gear oil
SAE90 (API Service Grade GL-4).

33-152
 33. UPPER STRUCTURE

(3) Maintenance standards

LUBE OIL LEVEL

Unit : mm (in)
Code Item Repairable level Service Limit Remedy
A Wear in #1 planetary shaft ø43
0
1.693" -0.0004" Replace entire spider assy.
No flaking
B Wear in #2 planetary shaft ø29
0
1.693" -0.0004" Replace four shafts as a set.
There should be no pitting
Replace
Condition of tooth face exceeding 1.6mm (0.0630in) dia,
C Gears (Planetary pinion should be
abnormal wear or seizure.
replaced in a set of four.)
Condition of tooth flank There should be no cracks.
D Thickness of thrust washer +0.1 +0.0039"
1.4 0.0551" Replace
1.6 -0.1 0.063" - 0.0039"

E Thickness of thrust washer +0.1 +0.0039"

1.4 0.0551" Replace
1.6 -0.1 0.063" - 0.0039"

Wear in shaft
0
F (Diameter of part coming in contact ø150 -0.100 0
5.91" -0.0004" ø149.9 5.90" Replace
with oil seal )
Apply Three-Bond 1360K and
G Socket bolt tightening torque M20— 539 N•m (398 lbf•ft)
tighten to specified torque.
Gear oil SAE90
H Lube oil 7.4 L (2.0 gal) Replenish or replace.
(API Service Grade GL-4)

33-153
33. UPPER STRUCTURE

33.2.5.5 TROUBLESHOOTING

33.2.5.5.1 SWING MOTOR

(1) Hydraulic motor does not rotate.

Trouble Cause Remedy

Pressure does not rise. 1. Relief valve pressure in circuit is not
adjusted correctly.
2. Malfunction of relief valve.
2-1. Sticking plunger.]
2-2. Orifice on plunger is clogged.
3. Plunger seat is faulty.
4. Anti-reaction valve seat is faulty.
Pressure rises 1. Overload.
2. Moving parts are seized.
3. Brake release pressure is not working on
the motor
4. Brake piston is stuck.
5. Spool for releasing brake is stuck.
6. Friction plate is seized.
1. Set to correct value.
2.
2-1. Correct the stuck areas or replace the
plunger.
2-2. Disassemble and clean.
3. Check the seat surface and replace the
plunger if scored.
4. Replace the anti-reaction valve cartridge
or block.
1. Eliminate overload.
2. Inspect and repair piston, shoe and
cylinder valve plate.
3. Check circuit and correct it.
4. Disassemble and check.
5. Disassemble and check.
6. Disassemble, check and repair.

(2) Rotating direction is reverse.

Trouble Cause Remedy

Rotating direction is 1. Motor’s assembling direction is reversed. 1. Assemble correctly.
reverse. 2. Piping inlets and outlets are reversed. 2. Pipe correctly.

(3) Revolution does not rise to set value.

Trouble Cause Remedy

Revolution does not 1. Oil inflow is deficient. 1. Check pump’s delivery rate and circuits
rise to set value to motor.
2. Oil leaks are excessive due to high 2. Lower oil temperature.
temperature.
3. Sliding surfaces are worn or damaged. 3. Replace.

33-154
 33. UPPER STRUCTURE

(4) Brake torque is insufficient.

Trouble Cause Remedy

Brake torque 1. Friction plate is worn.
isinsufficient.
2. Brake piston is stuck.
3. Brake release pressure is not released.
4. Break release spool is stuck.
5. Spline of friction plate is damaged.
1. Disassemble and check. Replace if wear
is beyond standard value.
2. Disassemble and check.
3. Check and correct circuit.
4. Disassemble and check.
5. Disassemble and check. Replace
damaged part.

(5) The swing motor drifts much.

Check the drain rate of the hydraulic motor. If it is less than 4 L/min (1.1 gal/min), you should think that the motor
is not faulty.

Trouble Cause Remedy

The swing motor drifts 1.Relief valve malfunctions. 1. Replace.
much when it is Same as (1). Same as (1).
actuated by external 2. Plunger seat is faulty. 2. Replace.
torques. (e.g. Machine
3. Seat of the anti-reaction valve is no good. 3. Replace the anti-reaction valve cartridge
is on a slope.)
or block.

(6) Oil leaks

1) Oil leak from oil seal

Trouble Cause Remedy

Oil leaks from oil seal 1. Lip of seal catches contaminant and
damaged.
2. Shaft is damaged or worn.
3. Casing inner pressure has risen
abnormally high, with the result that lip of
oil seal is flipped.
4. Shaft is rusted.
1. Replace oil seal.
2. Shift the lip and shaft positions or replace
oil seal.
3. Repair drain piping if clogged up.
4. Disassemble and correct.

2) Oil leak from matching surface

Trouble Cause Remedy

Oil leak from matching 1. O-ring is missing. 1. Set O-ring correctly and assemble it.
surface 2. O-ring has a scratch. 2. Replace.
3. Seal surface has a scratch. 3. Disassemble and correct.
4. Bolt is loose or damaged. 4. Tighten to specified torque or replace.

33-155
33. UPPER STRUCTURE

33.2.5.6 REDUCTION UNIT


  

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33-156
 33. UPPER STRUCTURE

33.2.6 SWIVEL JOINT

33.2.6.1 CONSTRUCTION VIEW

2 places Apply Three Bond

#1805 to stem

2 places
VIEW Y

5 places
Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242
SECTION HH

Tightening torque
30.4 N.m (22.4 lbf.ft)
Apply Loctite #242

Fig. 33-273 Construction of swivel joint

No. Part name Q’ty No. Part name Q’ty

1 Body 1 7 O-ring (G95 1A) 1
2 Stem 1 8 Socket bolt (M8×20) 2
3 Thrust plate 1 9 Socket bolt (M8×30) 3
4 Cover 1 12 Plug 1
5 Seal 5 13 O-ring (P80) 2
6 Seal assy 1

33-157
33. UPPER STRUCTURE

33.2.6.2 DISASSEMBLY AND ASSEMBLY

33.2.6.2.1 Tools

No. Tool Name Used for Remarks

Hammer 1. Steel hammer
a
2. Wooden or plastic mallet
b Rubber mat Disassembly 750 mm (30in) square or more
Wrench Assembly 1. Allen wrench
c 2. Double-ended and single-ended wrench
3. Extension pipe
d Torque wrench Assembly 98 N•m (72 lbf•ft)
Pin Grind the tip of "a nail" to shape
as a screwdriver.
e Disassembly

Spatula Make from a hack-saw blade

Disassembly Approx. 120mm (4.72in)

f
Assembly

Remove the edge completely

Vinyl tape and make corner round smooth.

Disassembly
g Vise Vise movable over 150mm (6in)
Assembly
h Loctite # 242
i Lubricating oil Hydraulic oil or vaseline
j Cleaning oil

33.2.6.2.2 Apparatus
(1) Hoist or crane
The lifting device should be capable of lifting the swivel joint assy.
(2) Work bench
The work bench should have an area of 1.2m×1.5m (4ft×5ft).
(3) Others
Also prepare cloth, wooden block and oil pan.

33.2.6.2.3 Cleaning outside

Clean the swivel joint to be free from dirt and dust, using steam and cleaning oil.
• Keep all ports plugged up while cleaning.

33-158
 33. UPPER STRUCTURE

33.2.6.2.4 Disassembly
The part numbers used in this disassembly procedure 2
correspond to those of a construction drawing in Fig. 1
33-273. 4
9
(1) Removing cover
1) Mark cover (4) and body (1) with matching marks
for convenient reassembly.
2) Place a V-block on a work bench, place a swivel
joint set on the side, fix it and loosen socket bolt
ALLEN WRENCH
(9) by means of a pipe and wrench. Alternately,
the swivel joint may be fixed by holding stem (2) V-BLOCK PIPE
in a vise.

: 6 mm Fig. 33-274 Removing cover (4)

3) Remove cover (4) from body (1) and draw out O-
ring (7) from cover (4).
%

"

Fig. 33-275 Removing O-ring (7)

(2) Removing thrust plate   
Loosen socket bolt (8) fastening thrust plate (3), in  
  
the same manner as the removing of the above- 

  
mentioned cover.

: 6 mm



When removing thrust plate (3) by fixing body (1),

support stem (2) so it may not fall down.



Fig. 33-276 Removing thrust plate (3)

(3) Removing stem Wooden block for Secure with hands. 1 BODY
Place body (1) on a V-block. Put a wooden block protector
against stem (2) via the body so about half of the 2 STEM
stem is covered by the wooden block and knock it
out using a mallet.
By hitting out the stem over about 1/2 from the
body, it can be easily pulled out by hand.
Stem weight : 10.5 kg (23 lbs)

WORK BENCH V-BLOCK

Fig. 33-277 Drawing out stem (2)

33-159
33. UPPER STRUCTURE

(4) Removing sealing parts

SPATULA (f)
1) Remove rings (13) of seal assemblies (6) and (5)
with spatula (f).
13

Pay attention to the body (1) not to be damaged by the

top edge of spatula (f).

Fig. 33-278 Removing O-ring (13)

2) Pierce slipper ring of seal assemblies (6) and (5)
with pin (e) and remove them from the seal SLIPPER RING
groove. Fig. 33-279 shows only one pin, but use
two pins to remove it securely.
BACKUP RING
DETAIL (6)

O-RING
GROOVE

SEAL (6) PIN (e) SEAL GROOVE

ASSY

OIL GROOVE
SEAL (5) SEAL GROOVE

Fig. 33-279 Removing out seal assy (5)(6)

33.2.6.2.5 Assembly
Prior to assembly, clean each parts (excluding the O-
ring and seal), and arrange in the sequence of
assembly.
Apply grease on the groove of seal to be installed on
seal assembly (6) and O-ring (13).
(1) Assembling seals to body
1) Apply hydraulic oil to O-ring (13) thinly and insert
it in O-ring groove.
Check the twist of O-ring

33-160
 33. UPPER STRUCTURE

2) Slipper ring is assembled, after first inserting the

backup ring, by slightly-distorting the shape as
shown in Fig. 33-280. Also after inserting all of
the seals, be certain that these are installed in
the seal groove by use of the spatula.
3) Assemble seal (5) by the same procedure above
mentioned.

Fig. 33-280 Inserting slipper ring (6)

Remove grease, hydraulic oil and vaseline from the
groove of seal.
And insert seal (5).
Seals (5) have no back-up ring.

(2) Assembling stem

Press in by applying your weight by your hands.
Lightly coat the outer circumference of stem (2) and
the inner surface of body (1) with grease or vaseline
and slowly insert stem (2) into body (1).
2 STEM

• If stem (2) is pressed in too fast, the seal may be

damaged. Do it slowly. O-RING 13

• The clearance between body (1) and stem (2) is 1 BODY

SEAL ASSY 6
about 0.1mm (0.004in). Push stem straight along
the shaft center. SEAL 5

WORK BENCH

Fig. 33-281 Inserting stem (2)

(3) Assembling thrust plate
& !
1) While holding stem (2) and body (1), match the
hole of thrust plate (3) and the stem (2) hole.
2) Next, after removing any oil from the thread of
socket bolt (8), coat it with Loctite #242 and
tighten to stem (2).

: 6 mm,
Tightening torque : 30.4 N•m (22 lbf•ft)

Fig. 33-282 Tightening socket bolt (8)

33-161
33. UPPER STRUCTURE

(4) Assembling cover

1
After installing O-ring (7) to cover (4) and aligning MATCHING MARK
the matching marks of the cover (4) and body (1),
coat socket bolt (9) with Loctite #242 and tighten it 9
which will then complete assembly.
"
: 6 mm,
Tightening torque : 30.4 N•m (22 lbf•ft)

ALLEN WRENCH

PIPE

Fig. 33-283 Tightening socket bolt (9)

33-162
 33. UPPER STRUCTURE

33.2.6.3 MAINTENANCE STANDARDS

33.2.6.3.1 Inspection procedure and remedy

Interval Check Item Checking Procedure Remedy

Seal for oil leakage Replace O-ring or dust seal , if any oil
2,000hr Check oil leakage outside
outside leakage can be found.
4,000hr All sealing parts Replace all sealing parts such as slipper
In principle, seal with back-up ring and O-ring.
disassemble All sliding parts
and check re- Check abnormal wear, scoringor
Repair or replace referring to their
gardless of corrosion caused by foreignmatters or
limit of service.
oil leakage or seizure.
not.
When All parts Repair or replace referring to their limit of
Check them for seizure, foreignmatters,
disassembled service.
abnormal wear, anddefect of seals.
for repair O-rings and dust seal should be replaced.

33.2.6.3.2 Service limit of the parts

Parts Maintenance Standards Remedy

Sliding surface with
Plating worn or peeled due to seizure or contamination. Replace
sealing sections
Sliding surface between 1) Worn abnormally or damaged more than 0.1mm
Replace
body and stem other than (0.004in) in depth due to seizure or contamination.
Body, Stem sealing sections 2) Damaged less than 0.1mm (0.004in) in depth. Smooth with oilstone.
1) Worn more than 0.5mm (0.02in) or abnormality. Replace
Sliding surface with thrust 2) Worn less than 0.5mm (0.02in). Smooth
plate 3) Damage due to seizure or contamination repairable
Smooth
within wear limit 0.5mm (0.02in).
1) Worn more than 0.5mm (0.02in) or abnormality. Replace
Sliding surface with thrust 2) Worn less than 0.5mm (0.02in). Smooth
Cover
plate 3) Damage due to seizure or contamination
Smooth
repairable within wear limit 0.5mm (0.02in).

33-163
33. UPPER STRUCTURE

Parts Maintenance Standards Remedy

1) Protruded excessively from seal groove.

 
Replace
(With back-up ring)

 

2) Slipper ring 1.5mm (0.06in) narrower than seal groove,

or narrower than back-up ring.

Replace
Slipper ring
(With back-up ring)
1.5mm (0.02in)
(max.)

BACKUP RING
3) Worn unevenly more than 0.5mm (0.02in)

0.5mm (0.02in) Replace

(max.) (With back-up ring)

33-164
 33. UPPER STRUCTURE

33.2.6.3.3 Inspection after assembly

After completion of assembly, inspection for oil leakage, 
pressure resistance, etc., using a device as shown in
Fig. 33-284.
(1) High pressure port (A,B,C,D and F port) 
Install a directional valve and pressure gauge to the  



stem side port and body side port respectively, and
while watching the pressure gauge (for high 
pressure) installed on the body side and also by
regulating high pressure relief valve (7), gradually  



increase the pressure and when the pressure has 
reached 1.5 times the maximum working pressure,
close stop valve (3) and lock in the hydraulic oil in 
the swivel. Keep stop valve (6) on the low pressure
relief valve side closed at this time.
Check that it is free from looseness, deformation, 
breakage, etc. under three minutes pressurizing.
And, the oil leakage must be checked for the first 1
minute, and if there be a pressure drop for any
reason, the pressure drop should be in 10% of the
trapped pressure.
This checking must be carried out for every circuit.


  
Fig. 33-284 Hydraulic circuit for inspection
equipment
(2) Low pressure port (E port)

  
 
Similar to the high pressure port, install a directional
valve and pressure gauge on each port of the stem &# ' (  
   
side and body side.  )'%

Open stop valve (6) on the side of low pressure   

relief valve (5) and while watching the pressure
 
 !
gauge (for low pressure) connected to the body
" ! " 

   *
side and also by regulating low pressure relief valve 
   +%,- .  /
(5), gradually increase the pressure and check for
outside leakage with a color check at a pressure of  
 !

0.49MPa (71psi). " ! " 

  

##   .0   1 %
 /


 !

 $ 
%

33.2.6.3.4 Troubleshooting

Trouble Cause Remedy

1. External leakage of hydraulic oil
2. Internal leakage of hydraulic oil
3. Swivel stem seized
4. Loose swivel stem and cover
Defective O-ring & seal Replace all seals.
1) Defective slipper seal 1) Replace all seals.
2) Sliding face worn excessively 2) Replace assy.
1) Stem and body seized 1) Grind and hone.
Replace assy, if stem and body are too loose
and causing oil leakage.
2) Inappropriate swivel stopper bracket 2) Reinstall
Secure 2~3mm (0.08~0.12in) allowance for
bolt stopper.
Socket bolt tightened insufficiently. Retighten.

33-165
33. UPPER STRUCTURE

[MEMO]

33-166
 34. TRAVEL SYSTEM
TABLE OF CONTENTS

34.1 REMOVING AND INSTALLING.......................................................................................34-3

34.1.1 DESIGNATION OF UNDERCARRIAGE ................................................................34-3
34.1.2 CRAWLER..............................................................................................................34-3
34.1.3 UPPER ROLLER ....................................................................................................34-7
34.1.4 LOWER ROLLER (TRACK ROLLER) ...................................................................34-13
34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) ...........................................................34-20
34.1.6 SPROCKET ............................................................................................................34-27
34.1.7 TRAVEL MOTOR ...................................................................................................34-30
34.1.8 SWING BEARING ..................................................................................................34-32
34.2 DISASSEMBLING AND ASSEMBLING OF EQUIPMENT ..............................................34-35
34.2.1 TRAVEL MOTOR ...................................................................................................34-35
34.2.2 CONSTRUCTION OF REDUCTION UNIT .............................................................34-37
34.2.3 TRAVEL MOTOR ASSEMBLY ...............................................................................34-38
34.2.4 TRAVEL MOTOR ASSEMBLY ...............................................................................34-46
34.2.5 TRAVEL MOTOR ...................................................................................................34-51
34.2.6 TRAVEL MOTOR TROUBLESHOOTING ..............................................................34-54
34.2.7 REDUCTION UNIT DISASSEMBLY.......................................................................34-56 34
34.2.8 ASSEMBLING ........................................................................................................34-62
34.2.9 MAINTENANCE STANDARD.................................................................................34-68

Book Code No. S5LC3411E02

34-1
34. TRAVEL SYSTEM

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC3411E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)
S5LC3411E02
Revision February, 2007 ↑ K
(ASIA, OCE)

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

34-2
 34. TRAVEL SYSTEM

34.1 REMOVING AND INSTALLING

34.1.1 DESIGNATION OF UNDERCARRIAGE

8. SWING BEARING
2. CRAWLER
7. TRAVEL MOTOR
5. FRONT IDLER 6. SPROCKET
GUARD
LOWER FRAME
GREASE NIPPLE OF 3. UPPER ROLLER
THE TRACK SPRING
ADJUSTER 4. LOWER ROLLER
Fig. 34-1 Designation and location of undercarriage

34.1.2 CRAWLER

34.1.2.1 REMOVING CRAWLER

(1) Position the machine to remove crawler.
(2) Pushing out master pin.
1) Find the master pin and place it in its removing/
fixing position in Fig. 34-3.
2) Loosen the grease nipple and slacken crawler.

: 19 mm

• When loosening the grease nipple of the adjuster, do

Fig. 34-2 Crawler removing position
not loosen it more than one turn.
• Where grease does not come out well, move the
machine back and forth. The over loosening of
grease nipple may cause it to jump out incurring
danger of injury. So be careful not to over loosen the
STOPPER PIN
grease nipple.

3) Pushing out master pin

Remove stopper pin at the end of the master pin,
hold a tool against the master pin, and hit it with
a hammer.
(Refer to Fig. 34-7 Fixing the master pin.)
REMOVING /
FIXING POSITION
OF MASTER PIN
Fig. 34-3 Removing / fixing position of master pin
• When using a big hammer, wear protective goggles
and a long-sleeved uniform so you do not injure
yourself by flying objects.

34-3
34. TRAVEL SYSTEM

(3) Removing crawler

Put attachment on ground so that weight is not



loaded to the lower frame, and remove track link
assy rotating sprocket.

Crawler end section may fall on the ground just before

extending it on the ground incurring danger of injury.
Please keep well away from the equipment.
Fig. 34-4 Removing crawler

34.1.2.2 INSTALLING
Installing is done in the reverse order of removing.
(1) Checking crawler installation direction.
Place the track links on the ground so they

converge, facing the front idler, as shown in the 


figure on the right.

(2) Installing crawler

1) Preparation for installation
Treat paint flaking protection with care not to
damage lower frame.
2) Winding crawler Fig. 34-5 Installing direction of crawler
Insert a crowbar into the master pin hole, lift the
lower frame 1 to 2cm above the ground level by
holding it by hand so the machine body weight is
not exerted on the shoe. Retract the sprocket to
help push the back winding of the crawler.

(3) Preparation for press fitting master pin

1) Preparing for installation
Put square wood under the shoe plate.
2) Aligning master pin holes
Aligning master pin holes through fine
adjustment turning sprocket. Fig. 34-6 Winding crawler

• When using a big hammer, exercise care so you are

not injured by flying objects the same way as when
pushing out the master pin.
• Coat the master pin with molybdenum disulfide
grease, before pressing it in.

(4) Press fitting of master pin

Apply press fitting jig on master pin, and strike it PRESS FITTING JIG ON MASTER PIN
with a mallet to press fit.
Fig. 34-7 Press fitting of master pin
(5) Set the stopper pin.

34-4
 34. TRAVEL SYSTEM

(6) Adjusting crawler tension (See Fig. 34-8)

After installing, adjust tension of crawler.

: 19 mm

  
 
 
        

  
  

Fig. 34-8 Adjusting crawler tension

34.1.2.3 CONSTRUCTION

1-3
1-8 1

1-1
1-7 7
1-4
1-2 3,4,5
1-6

1-5
1-9 1-10
1-11 6
Fig. 34-9 Track link assy & shoe plate

SK330-8 SK350LC-8
SHOE LC60D00010F3 SHOE LC60D00011F3
ASSY LC60D00010F1 ASSY LC60D00011F1
No. NAME Q'ty No. NAME Q'ty
1 •Link assy LC62D00004F1 1 1 2 •Link assy LC62D00004F2 1 1
1–1 ••Track link R 43 43 2–1 ••Track link R 46 46
1–2 ••Track link L 43 43 2–2 ••Track link L 46 46
1–3 ••Master link R 2 2 2–3 ••Master link R 2 2
1–4 ••Master link L 2 2 2–4 ••Master link L 2 2
1–5 ••Bushing 43 43 2–5 ••Bushing 46 46
1–6 ••Pin 43 43 2–6 ••Pin 46 46
1–7 ••Master bushing 2 2 2–7 ••Master bushing 2 2
1–8 ••Master pin 2 2 2–8 ••Master pin 2 2
1–9 ••Collar 4 4 2–9 ••Collar 4 4
1–10 ••Seal 86 86 2–10 ••Seal 92 92
1–11 ••Pin 2 2 2–11 ••Pin 2 2
3 •Shoe 600mm 45 — 3 •Shoe 600mm 48 —
5 •Shoe 800mm — 45 5 •Shoe 800mm — 48
6 •Bolt LC60D01001P1 180 180 6 •Bolt LC60D01001P1 192 192
7 •Nut 2420Z1414 180 180 7 •Nut 2420Z1414 192 192

34-5
34. TRAVEL SYSTEM

34.1.2.4 MAINTENANCE STANDARD

E F
G D D
B

C
H

Fig. 34-10

Unit : mm (in)
Repairable
No. Item Standard value Service limit Remedy
level
215.9±0.15 220 224
A Link pitch Replace the link
(8.5000±0.0059) (8.66) (8.82)
assy if the service
B O.D. of bushing ø 68.0 (2.6772
+0.0020
0 ) ø 64 (2.52) ø 63 (2.48)
limit is exceeded
C Height of link 124±0.25 (4.8819±0.0098) 118 (4.65) 116 (4.57)
Basic
Tolerance Fit Fit
dimension
Interference between bushing
D + 0.05 Interference
and link ø 68.0 Interference
Shaft

(+0.0020) 0.05
(2.6772) 0 Replace
0 (0.0020)
+ 0.05 Interference
Interference between track pin ø 46.0 Interference
Shaft

E (+0.0020) 0.05
and link (1.8110) 0
0 (0.0020)
+ 0.05 Interference
Interference between master ø 45.63 Interference
Shaft

F (+0.0020) 0.05 Replace Link

pin and link (1.7965) 0
0 (0.0020)
1.5 (0.06) 8 (0.32) 10 (0.39)
G Clearance between links Replace
(both side) (both side) (both side)
H Tightening torque of shoe bolt 1180 N•m (870 ft•lbs) Reassembly

34.1.2.5 TOOLS AND JIGS

(1) Tightening tools

Unit : mm
Name Opposing flats

19, 32
Socket

(2) Jig

Name Shape

Master pin fixing jig for iron

crawler

34-6
 34. TRAVEL SYSTEM

34.1.3 UPPER ROLLER

34.1.3.1 UPPER ROLLER ASSY

Upper roller assy LC64D00003F1

Item Name Q’ty Remarks
1 Roller assy 4 24100N7035F3
2 Capscrew 4 M20×150
3 Washer 8
4 Nut 4

34.1.3.2 REMOVING
(1) Preparation for removal " ! !
Remove crawler (Above mentioned).

(2) Removing upper roller (1)

1) Remove nuts on support tightening section, and
also remove capscrew (2) M20 × 150.

: 30 mm

Fig. 34-11 Removing upper roller

34.1.3.3 INSTALLING
Installing is done in the reverse order of removing. Center of machine
(1) Inspection
Before reassembling, check it that it rotates smooth
manually and for leakage.
3,4
1
(2) Installing upper roller (1)
1) To install the upper roller, turn up nut (4) toward
the center of machine.
2,3
2) Insert it until collar comes in contact with support.

3) Apply Loctite #262 on capscrew M20×150, and

tighten it to the specified torque.

: 30 mm
Tightening torque : 539 N•m (400 lbf•ft)

Fig. 34-12 Installing upper roller

34-7
34. TRAVEL SYSTEM

34.1.3.4 CONSTRUCTION

Roller assy part No. 24100N7035F3 5 4 1 13 3 2

No. Name Q'ty No. Name Q'ty
1 Roller 1 8 -ring 1A P95 1
2 Shaft 1 9 Socket bolt 2
3 Collar 1 M12X30 10
4 Plate 1 10 Plug PT1/4 1
5 Cover 1 11 Snap ring 1
6 Bushing 2 13 Floating seal 1

11 8 6

Fig. 34-13 Construction of upper roller

34.1.3.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly 11
1) Draining out oil 9 8
Remove plug (10) and drain out oil. 4
10
: 6mm 5

2) Removing snap ring (11)

Mount the end face inside upper roller (1) on
stand jig (f) and separate snap ring (11), using
snap ring pliers.
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). Fig. 34-14 Preparation for disassembly

5) Removing plate (4)

Loosen two socket bolts (9) and draw out plate
h
(4) from roller (1).

: 10mm
2

13
6) Removing shaft (2)
Put the extrusion jig (h) against the end face of 3
shaft (2) and push shaft (2) with collar (3) for
floating seal (13), using a press or hammer.
f

Fig. 34-15 Extruding shaft

34-8
 34. TRAVEL SYSTEM

7) Removing floating seal (13). (Upper roller side)

Take out floating seal (13) from roller (1). 13

Fig. 34-16 Taking out floating seal

8)Removing floating seal (13). (Shaft side)
Remove from collar (3), floating seal (13) that is
13
located on the side from which shaft (2) was
disparted. 3

Collar (3) is press fitted into shaft (2). Therefore do not

disassemble it.

Fig. 34-17 Removing floating seal

9) Removing bushing (6)
Push with press.
Since the bushing is thin, machine it on a lathe or
i
scrape it off, exercise care so as not to damage
the bore of roller (1).
6

(2) Assembly
Assembly of the upper roller is done in the reverse
1
order of disassembly.
1) Place upper roller (1) on the top end face of jig f
(f), with its floating seal setting side 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 molybdenum
disulfide grease. Fig. 34-18 Pushing in bushing

3) Put jig (i) into bushing (6) and press it in, using 13
13
the bore of the bushing and the bore of the roller
as guides. 3 1

If you fail in this operation by pressing the bushing

unevenly, the bushing is distorted and gets
unserviceable. In that case, do not re-use the bushing
as it may develop malfunctioning after assembly.

Fig. 34-19 Fixing floating seal

34-9
34. TRAVEL SYSTEM

4) Installing floating seals (13).

Two floating seals (13) make a pair. Attach one 2
floating seal to retainer fixed in shaft (2), and
another to the inside of upper roller (1).
1

• Prior to placing floating seal (13) in, apply

engine oil lightly to seal surface.

5) Inserting shaft (2).

Coat shaft (2) with a thin film of oil and insert it
into upper roller (1).

6) Installing plate (4). Fig. 34-20 Inserting shaft

Mount upper roller (1) on the stand jig (f) and
11
attach plate (4) to the end face of the shaft with
bolt (9). 9 8
4
: 10mm,
Tightening torque : 114.7N•m (85 lbf•ft) 5

7)Installing O-ring (8). 1

Fit O-ring (8) to the groove of cover (5).
• Apply grease to O-ring.

8) Installing cover (5).

Attach cover (5) to upper roller (1). Use a press
in this operation as a press fit is used.
f

9) Installing snap ring (11).

Fix snap ring (11) into upper roller (1), using snap
ring pliers.
Fig. 34-21 Installing cover

10) Filling oil

Fill in 100cc (6.1cu•in) of engine oil API grade
CD #30 through the plug hole in cover (5).

11) Installing plug (10).

5
Wind seal tape around plug (10) and screw it into
the plug hole of cover (4).
1
: 6mm,
Tightening torque : 23N•m (17 lbf•ft)

• After assembling the upper roller, confirm that

oil is not leaking from it and that it rotates f
smoothly by hand.

Fig. 34-22 Filling oil

34-10
 34. TRAVEL SYSTEM

34.1.3.6 MAINTENANCE STANDARD

C
D D

F
J H

Unit : mm (in)
No. Item Standard value Service limit Remedy
A Dia. ø 185 (7.28) ø 175 (6.89)
Reinforcement
B Tread dia. ø 160 (6.30) ø 150 (5.91)
weld, repair or
C Width 95 (3.74) 85 (3.35)
replace
D Flange width 19 (0.748) 15 (0.591)
Basic
Tolerance Standard Limit
dimension
Clearance between shaft and -0.025
E
bushing ø 65 (-0.0010) Clearance Clearance
Shaft

(2.5591) -0.040 — 0.8 (0.0315) Replace bushing.

(-0.0016)
+ 0.030
Interference between roller ø 70 Interference Clearance
Hole

F (+0.0012)
and bushing (2.7559) — 0
0
Tightening torque of socket
H 114.7 N•m (85 lbf•ft) Apply loctite #262
bolt
J Oil Engine oil API grade CD #30, 100cc (6.1cu•in) Refill or replace
Roller rotation Roller rotates smoothly by hand.

34-11
34. TRAVEL SYSTEM

34.1.3.7 TOOLS AND JIGS

(1) Tightening tools

Unit : mm
Name Opposing flats

30
Socket

Allen wrench 6,10

(2) Jigs

Unit : mm (in)
No. Name Shape
160 (6.30")
120 (4.72") 200 (7.87")

f Stand jig

50 (1.97")
For extruding
h
(1.18")

shaft
(1.953" +0.004" )
+0.1
0

0
69.5
(2.74")

64.6

Bushing fixing
i
jig
20 65 (2.56")
(0.787")
85
(3.35")

34-12
 34. TRAVEL SYSTEM

34.1.4 LOWER ROLLER (TRACK ROLLER)

34.1.4.1 LOWER ROLLER ASSY

  
  

  

 
 
 "   1
  ! #     2 Apply loctite #262
T=731N.m (540 lbf.ft)

Fig. 34-23 Lower roller assy

34.1.4.2 REMOVAL
(1) Preparation for removal
1) Loosen the tension of the crawler, lift up the
lower frame by the front attachment and stop the
engine in that condition.
2) Place a safety block (wooden) at the front and
back of the lower frame. SAFETY BLOCK
(SQUARE
TIMBERS)
(2) Removing track guide (See Fig. 34-25)
Remove capscrews (8) M24×52 and remove track Fig. 34-24 Preparation for removal
guide (5).

: 36mm
Weight of track guide : Approx. 40kg (88 lb)
9 2 5 9
8 SK330-8 8
(3) Remove lower roller
Remove capscrews (2) and remove lower roller (1).

: 32 mm
9 2 5 9
Weight of lower roller : Approx. 57kg (126 lb) 8 SK350LC-8 8

Fig. 34-25 Installing track guide

34.1.4.3 INSTALLATION
(1) Installation of lower roller
Lower SK330-8 STD LC01F00019F1
Coat mounting capscrews (2) with Loctite #262 and
group SK350LC-8 LC LC01F00017F1
fasten all four capscrews temporarily. Then tighten
them to a specified torque. No. Name Q'ty
2 Track guide LC63D00004P1 2 2
: 32 mm 5 Capscrew ; M24 X 52 8 8
Tightening torque : 731N•m (540 lbf•ft) 8 Capscrew ; M24 X 35 16 16
(2) Installation of track guide 9 Washer 16 16
Capscrews (8) with Loctite #262 and fasten all four
capscrews temporarily. Then tighten them to a
specified torque.

: 36 mm
Tightening torque : 932N•m (690 lbf•ft)
(3) Adjusting tension of crawler.
Tighten grease nipple and fill it with grease.

: 19 mm, Tightening torque : 59N•m (43 lbf•ft)

34-13
34. TRAVEL SYSTEM

34.1.4.4 CONSTRUCTION

 
 
  4 1 6 7 5 2 8


 '  '(

 
 
 
 
  
 !"# 
 $!"  2
3
 
!"#  
 %&!"#  ) * Fig. 34-26 Construction of lower roller
 $#  $+,

34.1.4.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
1) Drain oil L
Remove plug (8) and drain out oil.

: 6mm 2

2) Removing pin (5) 5

Put both ends of lower roller assy on the V-
shaped blocks (K), apply push-out bar (L) on
upper end face of pin (5), and push pin (5) out
striking with mallet.
K

3) Removing collar (2), O-ring (7)

Put lower roller on jig (M) for repair stand so that
the shaft (3) is perpendicularly located, apply
Fig. 34-27 Pushing out collar fixing pin (5)
push-out jig (P) on shaft end on upper side, and
push shaft (3) until the O-ring (7) separate from
collar (2) with press or mallet, and take out collar
(2) and O-ring (7).
7 Jig P
4) Removing shaft (3)
2
Reverse the top and bottom of the lower roller,
push shaft (3), and remove collar (2) and O-ring
1
(7) as one unit.

The shaft (3) extrusion operation may cause the Jig M

remaining lube oil to flow out. Prepare an oil container
beforehand.

Fig. 34-28 Removing shaft (3), collar (2)

34-14
 34. TRAVEL SYSTEM

5) Removing collar (2), O-ring (7)

6
Remove O-ring (7) from shaft (3) that was drawn
out in the previous paragraph.

6) Removing floating seal (6)

Remove floating seal (6) from collar (2).
2
7) Removing floating seal (6)
Remove floating seal (6) from roller (1).
Fig. 34-29 Removing floating seal (6)

Fig. 34-30 Removing floating seal (6)

8) Removing bushing (4)
Since thickness of bushing (4) is thin [thickness
is 3.9mm (0.15in)], remove it through lathe or N
strip it with care not damage inner hole of roller
and place upper roller (1) on jig (M) for repair
1
stand and apply the end of push-out jig (N) 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 Jig M

damage the surface. Put the extrusion jig (N) uniformly
over the circumference of bushing (4) and extrude it
perpendicularly little by little. Fig. 34-31 Extruding bushing (4)

34-15
34. TRAVEL SYSTEM

(2) Installing 7 3
1) Attach O-ring (7) to one side
Install O-ring (7) to groove on shaft.

• Grease O-ring.
• Replace O-ring with new one without fail at Fig. 34-32 Attach O-ring (7) to one side
reassembling.

2) Press fitting bushing (4)

Jig Q
Align inner hole of roller (1) and bushing (4) and
press fit it vertically in capacity of press fit load,
5ton (11000 lb), in the condition that bushing 4

push-in jig (Q) is inserted into bushing (4).

• Apply molybdenum disulfide grease on press-

fit section of bushing, and press fit it in
ordinary temperature.
• Bushing which fails to press-fit because of the
one-side pressing should not be fitted.
Fig. 34-33 Press fitting bushing (4)
3) Press fitting collar (2)
6
Fit O-ring (7) to the one side of shaft (3) mating
pin hole of collar (2) on which floating seal (6) is
5
fit with pin hole of shaft (3) in advance. Use the
press of capacity 17 ton (37500 lb) or more.
3
• Care should be taken not to damage O-ring
(7) while press-fitting collar (2) to shaft (3).
2

4) Inserting pin (5)

Press-fit pin (5) to pin hole on aligning pin holes Fig. 34-34 Inserting pin (5)
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
1
roller (1).

• Check that the seal surface is free from flaws, 6

rusts, etc. before reusing the floating seal.

6) Inserting roller (1)

3
Insert roller (1) from the side where collar (2) is
not press-fitted to the shaft (3). 2
7

Fig. 34-35 Inserting roller (1)

34-16
 34. TRAVEL SYSTEM

7) Installing O-ring (7) Press

Install O-ring (7) to groove on shaft.

• Grease O-ring.
• Replace O-ring with new one without fail at 2
reassembling. PIN HOLE
7

8) Press fitting collar (2)

Press-fit collar (2) to shaft (3).
3

• Press-fit collar (2) on aligning pin (5) hole.

9) Inserting pin (5)

Press-fit pin (5) in to the pin hole mating pin hole
of collar (2) with pin hole on the end side of shaft
(3).

Fig. 34-36 Installing O-ring (7), collar (2)

10) Filling oil 8 Apply anaerobic sealant
Remove plug (8) and fill in 430cc (26.14cu•in) of Tightening torque
engine oil API grade CD#30. 23N.m (17 lbf.ft)

11) Check it for leakage

Before tightening plug (8), check it for leakage in
the condition of air pressure 0.2 MPa (28 psi).

12) Installing plug (8)

2
Apply anaerobic sealant on plug (8), and tighten
it in the plug hole on the collar (2) end face.

: 6 mm,
Tightening torque : 23 N•m (17 lbf•ft) Fig. 34-37 Installing filling oil plug (8)

After assembling the lower roller, confirm that oil is not

leaking and that the roller rotates smoothly by hand.

34-17
34. TRAVEL SYSTEM

34.1.4.6 MAINTENANCE STANDARD

C C
G

A
E
B

Fig. 34-38 Lower roller (Track roller)

Unit : mm (in)
Repairable
No. Item Standard value Service limit Remedy
level
A O.D. of flange ø 216 (8.50) — — Reinforcementwel
B Tread dia. ø 175 (6.89) ø 160 (6.30) ø 154 (6.06) d, repair or replace
C Flange width 27 (1.06) — —
Basic
Tolerance Fit Fit
dimension
Clearance between shaft
-0.060
D and bushing
ø 75 (-0.0024) Clearance Clearance Replace bushing.
Shaft

(Wrapped bushing)
(2.9528) -0.090 0.7 (0.276) 1.0 (0.394)
(-0.0035)
Interference between ø 83 ±0.030 Interference Clearance
Hole

E
roller and bushing (3.2677) (±0.0012) 0.01 (0.0004) 0
F Oil Engine oil API grade CD #30, 430cc (26.14cu•in) Refill
Execute air leak test at 0.2MPa (28psi) before tightening the
G Plug (8)
plug.
Roller rotation Rotates smoothly by hand. Reassembly

34-18
 34. TRAVEL SYSTEM

34.1.4.7 TOOLS AND JIGS

(1) Tightening tools

Unit : mm
Name Opposing flats

19, 32, 36
Socket

Allen wrench 6

(2) Jig

Unit : mm (in)
No. Name Shape

K V-block 6.5 (0.26")

150 (5.91")
Pin (5)
L
extrusion rod
16 (0.630")

300 (11.8")
Bushing
N
extrusion rod

400 (15.7")
150 (5.91")

175 (6.89")

M Stand jig

400 (15.7")
P Shaft extrusion jig
(2.91")
74

104 (4.09")
(1.18")
30
100 (3.94")
70 (2.76")

Q Bushing fixing jig

74.6 +0.1
0
(2.94" +0.004
0 )

34-19
34. TRAVEL SYSTEM

34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY)

34.1.5.1 FRONT IDLER ASSY

 

  Apply loctite #262 or equivalent
 
   


T=540N.m (400 lbf.ft)
1
 

  
3 2
 

 !
  &

 
"#
$  ' ( 

 %

 "" 

The grease nipple is on the

outer side of the frame 4
T=58.8N.m (43 lbf.ft)

Fig. 34-39 Front idler assy

34.1.5.2 REMOVING
(1) Preparation for removal
Remove crawler. (Above mentioned)

(2) Removing idler assy

Sling idler assy, and push it forward with bar.
Weight of crawler • idler assy (one side) BAR
: 362 kg (798 lb)

Keep away from the front side of front idler.

(3) Installing
Installing is done in the reverse order of removing.

(4) Where idler assy (1) has to be separated

Loosen capscrew (3), and separate idler assy (1)
from idler adjuster assy (2). Fig. 34-40 Removing and installation the front idler
1
: 30 mm
Weight of idler assy : 176 kg (388 lb)
Weight of idler adjuster assy :186 kg (410 lb)

• The separated idler assy (1) should be placed on 2

square timbers.

Fig. 34-41 Separating idler assy (1) from idler

adjuster

34-20
 34. TRAVEL SYSTEM

34.1.5.3 IDLER ASSY

34.1.5.3.1 CONSTRUCTION

 
 

    8

6

 
 '
2

 
 ' 7
5
  ! 
3 I
 "# $%& 

 '$% 
4 VIEW I
 $%&   1
 ()$%&  * +

 '#&  ',-

Fig. 34-42 Idler assy

34.1.5.3.2 REMOVING AND INSTALLING

(1) Removing 5
R
1) Drain oil
Remove plug (8) on the side of collar (2) to drain.

: 5 mm

2) Removing pin (5)

Apply pin push bar (jig R) to the top of pin, and
push out striking bar (jig R) lightly by hammer. Fig. 34-43 Removing pin (5)

Push with press

3) Removing collar (2)
Put idler (9) on repair stand (U), apply push-out S
3
jig (S) on shaft (3), push out shaft (3) with collar 2
(2), then remove collar (2).

U
2

Fig. 34-44 Removing collar (2)

4) Removing collar (2) from shaft (3) Push with press
If removal of collar (2) on the opposite side is
required, turn over front idler and proceed with S
3 2
the procedure described in Par. 3).

Fig. 34-45 Removing collar (2)

34-21
34. TRAVEL SYSTEM

5) Removing bushing (4)

1 T 4
With idler (1) mounted on the stand, tap bushing
(4) lightly by hammer, while placing the bushing
drawing rod (T) against the end face of bushing
(4) evenly all round, till it comes out.

6) Removing floating seals (6)

Take out floating seals (6) from idler (1), collar
U
(2). If you intend to re-use floating seals (6),
confirm that there is no scoring and rusting on
the contact surface and store the floating seals
Fig. 34-46 Removing bushing (4)
in pairs by placing card board between the
sealing faces.

7) Removing O-ring (7)

Separate O-ring (7) from shaft (3).
(2) Assembly
Push with press V 1
1) Pressing in bushing (4) 4
Align inner hole of idler (1) and bushing (4) and
press fit it vertically with press so that jig (V) for
bushing press-fitting is inserted into bushing (4).

2) Installing O-ring (7)

Fit O-ring (7) to O-ring groove on shaft (3).
Fig. 34-47 Pressing in bushing (4)
• Apply grease to O-ring

3) Installing collar (2) (See Fig. 34-48) Pressing

Press fit the O-ring (7) installed side of shaft (3)
into collar (2), and drive pin (5). 3

4) Installing floating seal (6)

2
Fit the half of floating seal (6) on each side of
5
collar (2) and idler (1).

5) Inserting idler (1)

Fig. 34-48 Installing collar (2), shaft (3)
Insert floating seal (6) fitted side of idler (1) into
shaft (3). 3
6

6) Installing floating seal (6)

Fit floating seal (6) on the other side of idler (1). 1

Fig. 34-49 Inserting idler (9) and installing floating

seal (6)

34-22
 34. TRAVEL SYSTEM

7) Installing collar (2)

8
Fit the half of floating seal (6) on the other collar 2
(2), press fit it in shaft (3), and drive pin (5) in with 5
hammer.
1
8) Filling oil • Inspection
Fill in 350cc (21.36cu•in) of engine oil API grade
CD #30 through the plug hole of collar (2), wind
seal tape and tighten plug (8).

: 5 mm, Fig. 34-50 Installing collar (2) and filling oil

Tightening torque : 17 N•m (12 lbf•ft)

• After installing the idler assy to the idler

adjuster assy, make certain that no oil leaks
from floating seal and plug (8) and that idler
(1) rotates smoothly.

34-23
34. TRAVEL SYSTEM

34.1.5.3.3 MAINTENANCE STANDARD

204 (8.03")
C

D
A
B

Fig. 34-51 Front idler

Unit : mm (in)
Repairable
No. Item Standard value Service limit Remedy
level
A Dia. Of idler projection ø 609 (24.0) — —
B Tread dia. ø 564 (22.2) ø 557 (21.9) ø 554 (21.8) Replace
C Flange width 102 (4.02) 96 (3.78) 94 (3.70)
Basic
Tolerance Fit Fit
dimension
Clearance between shaft and – 0.072
D
ø 85 (-0.0028) Clearance Clearance
Shaft

bushing
(3.3465) –0.126 1.5 (0.059) 2.0 (0.079)
Replace bushing.
(-0.0050)
+ 0.035
Interference
Interference between idler and ø 89 (+0.0014) Clearance
Hole

E 0.01
bushing (3.504) 0 0
(0.0004)
(0)
F Oil Engine oil API grade CD#30, 350cc (21.4cu•in) Refill
Idler rotation Rotates smoothly by hand. Reassemble

34-24
 34. TRAVEL SYSTEM

34.1.5.3.4 TOOLS AND JIGS

(1) Tightening tools

Unit : mm
Name Opposing flats

30
Socket

Allen wrench 5

(2) Jigs

Unit : mm (in)
No. Name Shape
18 (0.71")

(1.18")
30
R Pin striking jig
150 15
(5.91") (0.591")

400 (15.7")
(3.31")

S Shaft push out jig

84
(0.63)
16

350 (13.8")

T Bushing drawing rod

Applox 200 (8")

Applox
800 (32")

U Stand
Applox
500 (20")

2 Piece
(0.71")

115 (4.53")
18
100 (3.94")

Bushing Press fitting

82 (3.23")

V
jig

+0.1
84.6 0

(3.33" +0.004
0 )

120 (4.72")
W Collar Press fitting jig
(1.18")
30

34-25
34. TRAVEL SYSTEM

34.1.5.4 IDLER ADJUSTER ASSY

34.1.5.4.1 CONSTRUCTION


 
  

  3 4 5 10 2 1 6 7 8

! 
"#


$ 

()*
 
%$ +,)*- 
$ (
 

$   
 
$ +,)*- ,)*     9
$ .) 
 
Fig. 34-52 Idler adjuster assy
&$ ./)*-    
' ) * 
)* %
   

34.1.5.4.2 MAINTENANCE STANDARD

No. Item Standard value

A Installed length of spring 554mm (21.8in)
About. 685mm
B Free length of spring
(27.0in)
C Stroke 53mm (2.09in)
D Set length 797mm (31.4in)
Nor scoring and
E Outside view of piston
rusting
Tightening torque of
F 59N•m (43 lbf•ft)
grease nipple

C F
A, B
D

34-26
 34. TRAVEL SYSTEM

34.1.6 SPROCKET

34.1.6.1 REMOVING
(1) Preparation for removal
Remove crawler referring to Section 2. "Crawler",
lift up crawler frame with attachment, and put it on
square timbers to float and stabilize. (See 34.1.2,
CRAWLER)

Fig. 34-53 Preparation for removal

(2) Removing sprocket
Loosen twenty six capscrews (3) M20×55, for the
attaching of the sprocket by means of a socket and
remove the sprocket (1).

Weight of sprocket : 75kg (165 lb)

:30 mm

1
3

Fig. 34-54 Removing sprocket

34.1.6.2 INSTALLING
(1) Check before installing
Check the mating portion of the travel reduction unit
and the sprocket, eliminate burrs and
contamination thoroughly and install the sprocket.

(2) Securing sprocket temporarily

Coat the sprocket attaching capscrews (3) with
Loctite #262 and fasten the sprocket temporarily.

(3) Securing sprocket completely

Remove the wooden blocks under the truck frame,
bring the machine down on the ground and tighten
the sprocket.

: 30 mm
Tightening torque : 539 N•m (400 lbf•ft)

Fig. 34-55 Securing sprocket temporarily

34-27
34. TRAVEL SYSTEM

34.1.6.3 MAINTENANCE STANDARD (LC51D01008P1)

215.9mm
Pitch Number of teeth 21
(8.5in)
Specification
ø68mm
Roller dia. Pitch dia. 732.47 (28.8in)
(2.68in)

C
A
Fig. 34-56 Sprocket

Unit : mm (in)
No. Name Standard value Repairable level Service limit Remedy
Reinforcement weld,
A O.d. Of sprocket ø 755 (29.7) ø 747 (29.4) ø 745 (29.3)
repair or replace.
B Width of sprocket teeth 85
0
(3.35 -0.157 ) 79 (3.11) 77 (3.03) Replace.
Reinforcement weld,
C O.D. of sprocket bottom ø 664.05 (26.1) ø 656 (25.8) ø 654 (25.7)
repair or replace.

34.1.6.4 TOOLS AND JIGS

(1) Tightening tools

Unit : mm
Name Opposing flats

30
Socket

34-28
 34. TRAVEL SYSTEM

(2) Sprocket tooth profile gauge : W

Fig. 34-57 Tooth profile gauge (Full scale)

34-29
34. TRAVEL SYSTEM

34.1.7 TRAVEL MOTOR

34.1.7.1 TRAVEL MOTOR

Apply loctite #262

Travel motor LC53D00010F1 or equivalent
6-1 T=539N.m
No. Name Q'ty Remarks (400 lbf.ft)
3 36 6-3
Capscrew M24 X 65
6 Travel motor assy (2) LC53D00011F1
6-1 Travel motor assy 2 LC15V00023F1 6-2
6-2 Sprocket 2 2404N431
3
6-3 Capscrew 52 M20 X 55 Apply loctite #262
or equivalent
T=932N.m
(690 lbf.ft)

Fig. 34-58 Installing travel motor

34.1.7.2 REMOVING
(1) Preparation for removal
Remove crawler, lift up crawler frame using
attachment, and put it on square timbers to float
and stabilize.
To release inner pressure from the hydraulic circuit
after stopping the engine. Put the starter switch in
the "ON" position and, with the safety lock lever in 6
operating condition, operate the left / right travel
lever in full stroke several times and press the travel
1-2 speed change switch several times to release 1
the inner pressure from the hydraulic circuit.
When you press the valve from above the gum cap
Fig. 34-59 Removing and installing cover (1)
of the air breather on top of the hydraulic tank, the
internal pressure of the hydraulic tank is released.
(2) Removing cover (1)
Remove sems bolt (6) M12×25 and also remove
cover (1).

: 19 mm
(3) Preparation of oil pan
(4) Removing hydraulic pipe
Remove all pipes connecting to travel motor. Then
plug up all pipes and joint section to protect them
from entry of dust.
Fig. 34-60 Removing and installing hydraulic pipe
: 19mm, 27mm, 32mm, 41mm
Refer to hydraulic pipe plug 5-1 (Refer to LC11
Tools).
plug for flare hose 5-2 (3) (Refer to LC11 Tools)

34-30
 34. TRAVEL SYSTEM

(5) Removing sprocket

Removing fifty two (both side) capscrews (6-3)
M20.

: 30 mm

6-3

Fig. 34-61 Removing and installing sprocket

(6) Loosening travel motor attaching bolts (3) Remove pipes. (Disconnect)
Apply match marks on travel motor and crawler
frame, and remove thirty six (both side) capscrews
(3) M24.

: 36 mm
3

Fig. 34-62 Removing and installing travel motor

attaching bolts
(7) Slinging travel motor assy
Sling travel motor with nylon sling applied on the
side close to sprocket installing section and remove
the motor.

Weight of motor : About. 400kg (882 lb)

Fig. 34-63 Slinging travel motor

34.1.7.3 INSTALLING
Installing of the travel motor piping is performed in the
reverse order of removal.
    
 


    
1) Cleaning
Check that contact surface of travel motor and
   $%& %. / 1+ /%
crawler frame is free from burr and stain. 
 $&' .+&2.+ 3 4
+/ /.(2/. 5
+
6&/&
2) Tightening torque $&( ,+.2,'
+( / + +.12'(
Tighten capscrew and hydraulic pipes to the
torque specified in "Tightening Torque".
!
   )!%*' %. &. ' &% 0
 " )!+*' +/ %%1 10
 # +,  , ( ,, ''% +&,
3) Before pipng for draining, fill casing with
 )!%*' %. +/ &/ /
hydraulic oil from drain port of motor.
)!%*&- &0- %(1 1(
At starts the machine, run the motor slowly at )!+*' +/ %/& %&(-
engine low idling for several minutes, and check )!% '% &,, %11
oil leakage and abnormal sound from motor.

34-31
34. TRAVEL SYSTEM

34.1.8 SWING BEARING

34.1.8.1 SWING BEARING ASSY

   

  
    


     !

 

 " # !
Front

Inner S zone position

of swing bearing

SECTION AA
Fig. 34-64 Swing bearing assy

34.1.8.2 REMOVING
(1) Matchmarks
SWING BEARING
Remove upper structure, apply matchmarks on
inner race of swing bearing and lower frame. OUTER RACE

INNER RACE
(2) Remove thirty six capscrews (2) M24×80 for
installation inner race. MATCHMARKS

: 36 mm

(3) Drawing out grease

Remove grease in grease bath.
Fig. 34-65 Matchmarks

(4) Removing swing bearing SWING BEARING

Attach eyebolt on swing bearing and sling it. EYE BOLT

Weight of swing bearing : 540kg (1,190 lb)

GREASE BATH

Fig. 34-66 Removing and installing swing bearing

34-32
 34. TRAVEL SYSTEM

34.1.8.3 INSTALLING
(1) Cleaning
Clean it completely so that installing surfaces of
swing bearing and lower frame are free from dust
and stain.
(2) Installing
Install swing bearing on lower frame meeting the Front
matchmarks and positioning the S mark on inner
race as shown in the Fig. 34-67.
(3) Temporary fastening of inner race
Coat the threads of the capscrews (2) with Loctite
#262 and tighten all the capscrews (2) temporarily.

: 36 mm
Inner S zone position
(4) Regular tightening of inner race of swing bearing
Tighten the capscrews (2) at 180 degrees intervals Fig. 34-67 Location of S mark on swing bearing
alternately to a specified torque.

: 36 mm 1
Tightening torque : 932 N•m (690 lbf•ft)
(5) Filling grease.
Fill grease bath with 28.7kg (63 lb) of grease 2 Apply Loctite #262 or equivalent
(NIHON GREASE CO.LTD EP-2K) or equivalent. T=932N.m (690 lbf.ft)

SECTION AA
Fig. 34-68 Removing and installing capscrew (2)

34.1.8.4 CONSTRUCTION

Assy part No. LC40F00018F1 6

1
No. Name Q'ty No. Name Q'ty 8
9
1 Outer race 1 6 Seal 1 7
2 Inner race 1 7 Taper pin 1 3,4
3 Ball 105 8 Plug 1
4 Retainer 105 9 Grease nipple 1 5
5 Seal 1 (PT1/8) 2

Fig. 34-69 Cross-sectional view of swing bearing

34.1.8.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly Eye bolt
6 2
1) Take out seal (5) fitted in the groove in the outer 7
circumference under inner race (2) and seal (6)
fitted in the groove in the inner circumference on 1
top of outer race (1) and place them level on a Square
wooden
square wooden block or something. block
2) 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 center of the plug 5
and using a puller. Fig. 34-70 Removing swing bearing

34-33
34. TRAVEL SYSTEM

4) While rotating outer race (1) little by little, take out 

ball (3) and retainer (4) through plug hole, in that
order.

"
!

Fig. 34-71 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 equivalent, fit
   
seal (5) and place it on a surface plate.
2) Lower outer race (1) to the position where upper 
surface of inner race (2) and lower portion of seal
 
   
groove is mated, put adjusting washer under
outer race (1) so that outer raceway surface of Fig. 34-72 Inserting balls (3)
ball (3) aligns with inner raceway, and support it.
EYE BOLT
3) Insert ball (3) and retainer (4), on which grease
is applied, through plug (8) hole on outer race
(1), alternately.
HOOKED
ROD

To insert ball (3) and retainer (4), use a push rod, etc.,
to protect persons from injury from inserting fingers into 4
plug hole.
SQUARE WOODEN BLOCK
4) Fit plug (8) to outer race (1) while checking it for
direction and position of taper pin hole. Fig. 34-73 Inserting retainer (4)
5) Coat seal (6) with adhesive Cyano Bond PX-
3000 equivalent and fit it in the groove of outer
race (1).
6) Check that grease nipple (9) is properly fitted,
and fill it with grease. Then, check bearing for
smooth rotation and flaws on seal lip portion.
• Shell Alvania EP#2 240cc (14.64cu•in)

34.1.8.6 MAINTENANCE STANDARD

Maintenance standard concerning wear of swing bearing is described in the section 13.6, "Maintenance Standard
and Test Procedure" MEASURING SWING PERFORMANCES in the separate volume.

34-34
 34. TRAVEL SYSTEM

34.2 DISASSEMBLING AND ASSEMBLING OF EQUIPMENT

34.2.1 TRAVEL MOTOR

Fig. 34-74 Travel motor

No. NAME No. NAME No. NAME

1 Casing 21 Breake piston 41 Restrictor spring (brake valve)
2 NPT 1/16 plug 22 D-ring (small dia.) 42 G1/8 plug
3 Oil seal 23 D-ring (big dia.) 43 O-ring 1B P8
4 Retaining ring IRTW68 24 Rear cover 44 Check valve
5 Expander plug MB800-040 25 NPT 1/16 plug (MEC) 45 Check valve spring
6 Shifter piston 26 Spool assy (M4V RBV) 46 M6 restrictor (0.6)
7 Piston seal 27 Spring holder (M4V RBV) 47 O-ring 1B P12.5
8 Steel ball 25 28 Spring (M4V150RBV) 48 M8 restrictor (0.8)
9 Shaft 29 M42 plug (4V RBV) 49 O-ring 1B P15
10 Bearing HR32209J 30 O-ring 1B G40 50 O-ring 215.57×2.62
11 Pivot 31 Pilot valve spool dia. ø10 (M4V290) 51 Bearing HR32207C
12 Swash plate 32 Pin (MRC03) 52 Shim
13 Cylinder block 33 Spring holder (MRC03) 53 Parallel pin M6 8×12
14 Cylinder spring 34 Spring (MRC03) 54 Valve plate
15 spring holder 35 G3/8 pilot valve plug 55 Brake spring
16 Ball joint 36 O-ring 1B P14 56 HEX. socket head bolt M18×50
17 Shoe retainer 37 Connector (MRC03) 57 Overload relief valve ORV-240L
18 Piston assy 38 G1/4 plug 58 Coupling
19 Separating plate 39 O-ring 1B P11 59 Retaining ring C-type 40
20 Friction plate 40 Restrictor (brake valve) 60 G1/2 plug
61 O-ring 1B P18

34-35
34. TRAVEL SYSTEM

• Overload relief valve

Fig. 34-75 Structure of overload relief valve

No. Name No. Name

57–1 Socket 57–8 Shim
57–2 Valve 57–9 Adjusting spring
57–3 Valve seat 57–10 O-ring 1B P7
57–4 Coupling piston 57–11 Backup ring T2 P7
57–5 Cap 57–12 O-ring 1B G25
57–6 Pilot body 57–13 Backup ring T2 G25
57–7 Piston

34-36
 34. TRAVEL SYSTEM

34.2.2 CONSTRUCTION OF REDUCTION UNIT

Fig. 34-76 Reduction unit

No. NAME No. NAME No. NAME

1 Housing 11 Thrust washer 2 21 Spring pin 6×36
2 Bearing 245BA35S1GS 12 Needle bearing FBNP-608660 22 Sun gear 1
3 Ring gear 13 Carrier pin 2 23 Thrust plate
HEX. socket head bolt
4 14 Spring pin 10×50 24 Cover
M18×110
HEX. socket head bolt
5 Floating seal 368 15 Sun gear 2 25
M10×30
6 Shim 16 Carrier 1 26 Plug G3/4
7 Lock washer 17 Planetary gear 1 27 O-ring 1B P24
8 Support ring 18 Thrust washer 1
9 Carrier 2 19 Needle bearing FBNP-406040
10 Planetary gear 2 20 Carrier pin 1

34-37
34. TRAVEL SYSTEM

34.2.3 TRAVEL MOTOR ASSEMBLY

34.2.3.1 TOOLS

Name Specifications etc.

Hex. key Width across flat 5, 6, 8, 10, 14 mm
Snap ring prier For bore Dia. 32mm - 58mm, for shaft….. Dia. 60mm - 80mm
Plastic hammer 1 piece
Screw driver Minus (-), medium size, 2 pieces
Torque wrench For 98.1N•m, 324N•m, 441N•m (72.4 lbf•ft, 239 lbf•ft, 325 lbf•ft)
Gear (bearing) puller Work size : dia. 75 X width 45 can be handled (e.g. Asahi-tool GP75)
Seal tape, kerosene, grease, hydraulic oil, waists, Compressed air,
Others
etc.
21 (0.83") e.g. Supertool co., ltd unicrump FT-6
10 (0.394") 160 (6.3")

(2.76")
(0.79")
20

70
100 (3.94")

(1.46")
37
P.C.D. 251 (9.88")
o 280 (11.0")

o 215 (8.47")

o 195 (7.68")

Jig for pulling out brake piston (2pieces)

Hex. socket head bolt 2-M6 X100 (3.94") o 12 (0.47")

o 60 (2.36")

(1.58")
(0.95")
o 40
o 24
2-M18X35 (1.38")
(0.26")
o 6.5

2 - 20 (0.79")
drill hole
20 (0.79")
100 (3.94")

Jig for pulling out brake piston (2pieces)

25 (0.98") ")
0.08
R2(
In case of using Hex. socket
head bolt for mounting
100 (3.94")

rear cover M18 25

50
(1.97") 100 (1.26")
15 (0.59") (3.94")
Guide pin for rear cover (2 pieces)
10 - Plain washer 18
120 (4.72")
2-M18X50 (1.97")
o 42 (1.65")
10mm (0.394")

(1.42")
8.2 (0.32")

.5 )
o 36

Jig for inserting brake piston R0 .02"

More than

o 67.5 (2.66")
(0
o 90 (3.54")
3
(0.12")
Jig for inserting oil seal
Jig for inserting rear bearing

34-38
 34. TRAVEL SYSTEM

34.2.3.2 DISASSEMBLY
a. GENERAL INSTRUCTIONS
(1) Generally, hydraulic equipment is precisely
manufactured and clearances between each parts
are very narrow.
Therefore, disassembling and assembling works
should be performed on the clean place where
dusts hardly gather.
Tools and kerosene to wash parts should also be
clean and handled with great care.
(2) When motor is removed from the host machine,
wash around the ports sufficiently, and put the
plugs so that no dust and / or water may invade.
Take off these plugs just before the piping works
when re-attach it to the host machine.
(3) Before disassembling, review the sectional drawing
and prepare the required parts, depending on the
purpose and the range of disassembling.
Seals, O-rings, etc., if once disassembled, are not
reusable. There are some parts that should be
replaced as a sub-assembly.
Consult with the parts book in advance.
(4) The piston can be inserted to whichever cylinder
block for the initial assembling.
However, their combination should not be changed
if they are once used. To reuse them, put the
matching mark on both pistons and cylinder block
before disassembling.
(5) Take great care not to pinch your hand between
parts while disassembling nor let fall parts on your
foot while lifting them.

b. DISASSEMBLY PROCEDURES
(1) Removing accessory valves
Before disassembling motor, remove accessory
valves.

According to disassembling purpose, select the valves

to be removed.
However, you cannot disassemble the motor without
removing overload relief valve (57).

There is dread of the burn, disassemble motor after

cooling it to ambient temperature.

34-39
34. TRAVEL SYSTEM

1) Remove M42 plug (29) and O-ring (30).

2) Remove spring (28), spring holder (27) and

spool assy (26).

Put the matching mark on both spool assy (26) and rear
cover (24) so that spool assy (26) should not be
reversed on re-assembling.
It is impossible to disassemble this spool assy (26)
further because spool assy (26) is fixed by adhesive.

3) Remove plug (42), O-ring (43), check restrictor

spring (41) and restrictor (40).

4) Remove overload relief valves (57).

When removing overload relief valve (57), valve seat

(57-3) easily comes off, so take great care not to fall into
the rear cover (24) or lose.

5) Remove pilot valve plug (35) and then, remove

O-ring (36), pilot valve spring (34), spring holder
(33), pilot valve spool (31) and pin (32).

6) Remove coupling (58).

34-40
 34. TRAVEL SYSTEM

(2) Disassembling motor

1) Place the motor with the shaft horizontal, remove Hole for releasing
brake (Left) GUIDE PIN
Hex. socket head bolts M18×50 (56) of rear
cover (24) leaving two on diagonally upper and
lower position.

: 14mm

2) Install two guide pins diagonally into rear cover

(24).
(Purpose: Prevention of falling rear cover)

3) Loosen slowly and simultaneously the remaining

two Hex. socket head bolts M18×50 (56).

4) Remove rear cover (24) and brake springs (55)

taking care cylinder block (13) is not coming out
stuck with rear cover (24). Fig. 34-77 Removing rear cover

• Do not fall, at this moment, valve plate (54), brake

springs (55), outer race of rear bearing (51) and/or
O-rings (50), (47), (49).
• There are shims (52) under the outer race of rear
bearing (51). Take a great care not to lose.

5) Remove valve plate (54) without pulling out

cylinder block (13).

Put the matching mark on both valve plate (54) and rear
cover (24) so that valve plate (54) should not be
reversed on re-assembling.

6) Using removed He×. socket head bolts M18 × 50

(56), fasten two mount metals so as to push in
cylinder block (13) without damaging it then inner
race of rear bearing (51) comes out. (See Fig.
34-78)

7) Put two fingers of gear (bearing) puller under the

inner race of rear bearing (51) and remove the
race.

51

Fig. 34-78 Removing rear bearing

34-41
34. TRAVEL SYSTEM

8) Attaching a hand on brake piston (21), supply

plant air through oil hole for releasing brake and
push out the piston (21). Hole for releasing brake

Be aware of brake piston (21) popping out.

In case of using jig for pulling out brake piston (21),
install jigs to M6 thread (2 places) of brake piston (21)
and pull out brake piston (21).

9) Put as a mark on a piston assy (18) such as a

paper pipe and put a matching mark on cylinder Fig. 34-79 Enlargement figure of matching surface
block (13) so that they can be re-assembled at of casing
the same position as before.

10) Remove rotary group (cylinder block (13),

spring holder (15), nine piston assys (18), shoe
retainer (17), ball joint (16) and cylinder spring
(14)) as an assembly.

11) Remove separating plates (19) and friction

plates (20).

12) Remove nine piston assys (18), shoe retainer

(17) and ball joint (16) from rotary group
simultaneously.

13) Remove spring holder (15) and cylinder springs

(14).

• Put piston assys (18) into the cylinder block (13)

matching the matching mark with shoe retainer (17) Paper pipe
as if assembled.
Matching
The purpose is to put piston assys (18) in the same
mark
bore of cylinder block (13) as before when
reassembled.
• Take care not to scratch sliding surfaces.
Do not reuse damaged ones. Fig. 34-80 Removing cylinder block
• It is impossible to disassemble piston and shoe
because they are calked together.

Above disassembling is mentioned as a motor only and

naturally can be applied to the motor with reduction
gears.
The situation is rather easier for with reduction gears
because the shaft is rather restricted by a gear to move.

34-42
 34. TRAVEL SYSTEM

14) Remove swash plate (12).

Hole for shifting shifter piston

15) Do not detach shifter piston assy (6), (7), (8).
If it needs to detach, attach a hand on shifter
piston and supply plant air through the hole
shown in Fig.19 and push it out.

Be aware of shifter piston (6) popping out. Fig. 34-81 Enlargement figure of matching surface
of casing
16) Shaft (9) can comes out now.

17) If front bearing (10) happen to be changed,

remove inner races and outer races using
bearing puller if needed and exchange to new
ones as an assembly.

• When changing bearings (10), (51), shaft(9),

casing(1) or rear cover (24), it affects the clearance
of the bearings.
Therefore, shim (52) should be adjusted.
• Shim (52) adjustment should be performed by
measuring correctly the clearance for shim and
change shim that meets the clearance. (See Fig. 34-
83)
Other jigs and tools are needed to measure and
decide the thickness of the shim.
• Do not remove pivots (11). If it needs to disassemble Fig. 34-82 Remove swash plate
them, put matching mark on pivots (11) with swash
plate (12).
• Never detach oil seal (3) only for the purpose of
inspecting it. If disassembled, remove retaining ring
IRTW68 (4) first and remove oil seal (3).Never fail to
replace oil seal (3) with new one.

34-43
34. TRAVEL SYSTEM

18) Deciding shim (52) thickness for tapered roller

bearings.

This work should be done only when you have changed

bearings (10), (51), shaft (9), casing (1) or rear cover
(24).

1. Measure the assembling width "E" (See ).

Fig. 34-83 Deciding shim thickness

Take care not to incline shaft (9).

2. Measure the depth "F" of rear cover (24)

Measure them at crossed 4 places on the circuit, then

calculate their mean value.

3. When thickness of shim (52) to be used is

placed as "S", the clearance "Y" can be
calculated as follows :
Y=F-(E+S)

4. Select one or two shim (52) so as the

clearance "Y" to come to 0-0.1 mm (0~0.004")
(clearance) on this unit.

(3) Disassembling overload relief valve

As a rule, overload relief valve (57) should be
handled as one service part. If there are any trouble
on overload relief valve (57) , replace as an
assembly.

Fig. 34-84 Disassembling overload relief valve

34-44
 34. TRAVEL SYSTEM

GREASE

Valve seat (57-3) is fitted in bore of socket (57-1) at

clearance fit.
When removing overload relief valve (57), valve seat
(57-3) easily comes off, so take great care not to lose.
When assembling overload relief valve (57) to rear
cover (24), apply grease sufficiently on engagement
part not to drop valve seat (57-3).
Fig. 34-85 Engagement part

34-45
34. TRAVEL SYSTEM

34.2.4 TRAVEL MOTOR ASSEMBLY

34.2.4.1 GENERAL INSTRUCTIONS

(1) Wash each parts sufficiently with kerosene, and
blow them by plant air.
(2) Assemble sliding parts after coating clean hydraulic
oil on them.
(3) Take great care not to pinch your hand between
parts or tools while assembling nor let fall parts on
your foot while lifting them.

34.2.4.2 ASSEMBLING PROCEDURES

(1) Coat outer surface of oil seal (3) and inner face of
casing (1) with grease. Using jig, rightly and evenly
press in the oil seal (3) into casing (1).
Jig for Inserting oil seal
(2) Fix oil seal (3) by retaining ring (4).
(3) Put the outer race of bearing (10) on casing (1) (this
fit is loose), and press the inner race on shaft (9)
(this fit is tight).

It is easier to fit inner race if the inner race is heated or

boiled under 100 degrees centigrade.
Never over heat!

(4) Insert shaft (9) into casing (1) after coating grease
on the contact surface to oil seal (3) lip.
(5) Put shifter piston assy (6), (7), (8) into casing (1).

Fig. 34-86 Inserting oil seal

• Insert shifter piston assy not to incline
• When inserting shifter piston assy, apply grease
sufficiently on piston seal (7) and take a great care
not to cut piston seal (7).

(6) Insert pivots (11) into the casing (1).

• Take care to match the matching mark with
casing (1) and also to coincide the direction of
sliding trace on sphere surface with those
contact trace on swash plate (12) if the motor
was operated a certain hours.

(7) Apply grease sufficiently on three spherical recess

of swash plate (12) and assemble it in casing (1).

Fig. 34-87 Assembling swash plate

34-46
 34. TRAVEL SYSTEM

(8) Insert piston assys (18), shoe retainer (17), ball

joint (16), spring holder (15), cylinder spring (14) on
to cylinder block (13) as shown and then insert the
whole assembly to shaft (9).

Piston assys (18) should be inserted into the same bore

as before.

(9) Rightly knock in the inner race of rear bearing (51)

to the rear end of shaft (9) by using jig (A1) and
plastic hammer (A2).

(10)Install all the separating plates (19) and friction

plates (20) alternately between casing (1) and Fig. 34-88 Assembling rotary group
cylinder block (13) adjusting on the notches and
splines. Separating plates (19) comes both first and
last.
(11)Insert brake piston (21) into casing (1) using Plastic
inserting jig (B) after attaching D-rings (22), (23) to hammer

brake piston (21).

Apply grease sufficiently on D-rings (22), (23). Insert

brake piston (21) by using inserting jig not to incline.
Two kinds of D-rings are used on brake piston (21). The
larger one (23) is first inserted into the hole, then the
smaller one (22) enters.
It is impossible to see how the smaller ring goes into the
hole. Therefore, never push it forcibly into the hole.
Otherwise, it may be scraped off by the edge of the hole
of casing (1).

Jig for inserting

rear bearing Or

Jig for inserting

brake piston

10 - Plain washer 18

Fig. 34-89 Inserting brake piston

34-47
34. TRAVEL SYSTEM

Guide pin

When changing bearings (10), (51), shaft (9), casing (1)

or rear cover (24), it affects the clearance of the
bearings. Therefore, shim (52) should be adjusted.
Refer to Chapter 34.2.3.2 b (2)-18) "Deciding shim (52)
thickness for tapered roller bearings" 34-44 and decide
shim (52) thickness.

(12)Install two guide pins diagonally on casing (1).

(Purpose: Guide for installing rear cover)

(13)Lay down rear cover (24) to mount valve plate (54)

coinciding matching mark made prior to
disassembling and also place brake springs (55)
with ample grease to be attached to rear cover (24)
while assembling. Also set shim (52), outer race of Fig. 34-90 Inserting brake piston
rear bearing (51) and O-rings (50), (47), (49) on
rear cover (24).

(14)Insert rear cover (24) to casing (1) along the guide

pin, and install two Hex. socket head bolts M18×50
(56) diagonally upper and lower position and tight
them to assemble rear cover (24) parallely.
Then, install the rest of Hex. socket head bolts
M18×50 (56) and remove guide pin and install two
the remainder.

: 14mm
Tightening torque : 324N•m (239 lbf•ft)

When removing outer race of rear bearing (51), install

shim (52) without fail.
Confirm that O-rings (47), (49), (50) are installed to rear
cover (24).

(15)Assemble coupling (58).

34-48
 34. TRAVEL SYSTEM

(16)Assemble spring (34), spring holder (33), pilot

valve spool (31) and pin (32) to rear cover (24), and
then install pilot valve plug (35) with O-ring (36).
Tightening torque : 49.0~58.8N•m (36.1~43.4 lbf•ft)

(17)Assemble overload relief valves (57).

: 32 mm
Tightening torque : 98~117.6N•m (72.3~86.7 lbf•ft)

Valve seat (57-3) is fitted in bore of socket (57-1) at

clearance fit. When assembling overload relief valve
(57) to rear cover (24), valve seat (57-3) easily comes Fig. 34-91 Assembling accessory valves
off, so take great care not to lose and apply grease
sufficiently on engagement part not to drop valve seat
(57-3).

(18)Assemble restrictor (40) and restrictor spring (41)

to rear cover (24), and then install G1/8 plug (42)
with O-ring (43).
Tightening torque : 14.7N•m (10.8 lbf•ft)

In case of assembling NEW restrictor (40), fit valve seat

of restrictor (40) with rear cover (24).
(After inserting restrictor (40) to rear cover (24), knock
restrictor (40) slightly by hammer.)

(19)Inserting spool assy (26) to rear cover (24)

coinciding matching mark made prior to
disassembling, and then assemble spring holder
(27) and spring (28).

Spool assy (26) is unsymmetry. Insert spool assy (26)

in an appropriate direction.

(20)Assemble M42 plug (29) with O-ring (30).

Tightening torque : 441~461N•m (325~329 lbf•ft)

34-49
34. TRAVEL SYSTEM

34.2.4.3 INITIAL PRE-CONDITIONING OPERATION

(1) Drain charge
Fill up hydraulic oil in the motor casing after
assembling.
M4V290/170F motor has two drain ports (G1/2).
Bleed air in motor casing from un-piping port (upper
side).

(2) Initial Pre-conditioning operation

Operate motor 5 minutes at low speed mode and
low-idle, check if there are abnormal noise or leak
of oil.

34-50
 34. TRAVEL SYSTEM

34.2.5 TRAVEL MOTOR

34.2.5.1 MAINTENANCE STANDARD OF PARTS

The followings are the general maintenance standards. However, it is the most important to determine which parts
should be replaced, depending on the characteristics before disassembling, damages and discoloration of exterior
view, the purpose of disassembling, the expected remaining service life, etc..

ITEM & MEASURING METHOD JUDGING CRITERIA & DISPOSITION

(1) Sliding surface of: cylinder block, Allowable
Check Items Criteria Disposition
valve plate and swash plate Roughness
Measure the surface roughness by Surface roughness;
roughness tester. cylinder block Replace or
below 0.4Z below 3.0Z
valve plate Repair
Measure the surface hardness of swash plate
swash plate by hardness tester.

Lap together the surfaces of both cylinder block and valve plate to remedy
their roughness. (Lap with #1200 powder)

Allowable
Check Items Criteria Disposition
Hardness
Swash plate Over HS78 HS74 Replace
(2) Clearance between piston and Allowable
Check Items Criteria Disposition
cylinder block Clearance
Outer diameter of 0.01mm (0.0004") 0.05mm
Measure outer dia. of piston and piston d max - d min (0.0020")
bore of cylinder block at least 3 Inner diameter of 0.01mm (0.0004") 0.022mm
Replace piston
places in the longitudinal direction cylinder bore (0.0009")
or cylinder block
with micrometer, and obtain: D max - D min
Clearance D-d 0.037~0.047mm 0.065mm
max. outer dia. = d max (0.0015"~0.0019") (0.0026")
min. outer dia. = d min
min. inner dia. = D min
max. inner dia. = D max
In exchanging pistons, replace all of nine pistons at the same time

34-51
34. TRAVEL SYSTEM

ITEM & MEASURING METHOD JUDGING CRITERIA & DISPOSITION

(3) Play between piston and shoe Allowable
Check Items Criteria Disposition
Roughness
With the jig of Fig, hold down the
shoe on work stand, and pull up
the piston vertical direction to Play between calked 0~0.1mm 0.3mm
Replace piston
measure the play between piston piston and shoe (0~0.004") (0.018")
and shoe.
(See Fig)

(1.34" +0.008"
+0.004" )
Dial gauge o34 ( +0.2
+0.1)

85 (3.35")
Piston

Jig
MagnetStand

26 (1.02")
Shoe

Work stand

o32 (1.26")
Method Play
o43 (1.69")

Jig
Fig. 34-92 Method

Allowable
ITEM & MEASURING METHOD Check Items Criteria Disposition
Roughness
(4) Parking brake torque

Replace all
After completion of assembly, set
902N•m 812N•m separator and
the torque wrench on the shaft Parking brake torque
(670 lbf•ft) (600 lbf•ft) friction plates
end, and measure the braking
springs
torque generated when the shaft
starts to rotate.
Standard of replacing friction and
separating plate.

Standard of replacing friction and separating plate

When measuring parking brake
torque, it needs to disassemble
Measure the total thickness of 6 pieces of friction plate and 7 pieces of
traveling unit to motor and
separating plate. And if the total thickness is below the following allowable
reduction gear portion, and it’s so
value, replace all separating and friction plates and springs.
hard.
The right allowable value is a
Criteria: 33.04 mm (1.30") (Dimension in the drawing)
standard of replacing friction and
Allowable Thickness : 31.5 mm (1.24")
separating plate
If it is impossible to disassemble
traveling unit, refer to the right
value.

34-52
 34. TRAVEL SYSTEM

ITEM & MEASURING METHOD JUDGING CRITERIA & DISPOSITION

(5) Shaft If the depth of shaft wear is less than 0.05 mm (0.002"), the shaft is reusable.
Measure the wear at contacting
surface of oil seal (3) with the
surface roughness tester.
• In case of replacing the shaft (9), replace oil seal (3) at the same time.

(6) Bearing Replace bearings (10), (51) before hour meter of host machine indicates
10,000 hours.
Replace bearing (10), (51) after
decided hours.

• In case replacing the bearings(10), (51), replace both inner and outer
races at the same time.
• Also the bearing shims (52) must be re-adjusted when replaced shaft (9)
and/or bearings (10), (51). Contact dealers for jigs and tools required.

(7) Splines If the wear of splines is less than 0.3 mm (0.012"), the spline is reusable.
Replace if the wear of splines
exceeds the allowable value.
(8)Overload relief valve Replace relief valve part as an assembly each time the host machine works
for 10,000 hours.
Do not try to adjust the valve,
since special hydraulic test bench
is required for inspecting and
adjusting the pressure.

34.2.5.2 TIGHTENING TORQUE

Item Description Size Tightening torque N•m (lbf•ft)

(29) Plug M42 441~461 (325~340)
(35) Plug (Pilot valve) G3/8 49.0~58.8 (36.1~43.4)
(38) Plug G1/4 29.4 (21.7)
(42) Plug G1/8 14.7 (10.8)
(56) Hex. socket head bolt M18 324±32.4 (239±23.9)
(57) Overload relief valve M27 98.1~118 (72.4~87.0)
(60) Plug G1/2 98.1 (72.4)

34-53
34. TRAVEL SYSTEM

34.2.6 TRAVEL MOTOR TROUBLESHOOTING

CAUSE OF TROUBLE AND REMEDY
The followings are the general instructions to be followed when some troubles occur with hydraulic motors.

34.2.6.1 GENERAL INSTRUCTIONS

(1) Judge the nature of abnormality before trouble shooting, and ascertain if the same symptom has occurred before
or not.
Review if the motor itself is actually troubled.
(2) In many cases, the wear is caused by dusts.
Take great care to prevent dusts in disassembling and assembling.
(3) All the parts especially those of moving parts should be carefully handled, and be careful not to score or scratch
the sliding surfaces.
(4) Be careful not to score the seating surface for O-ring, etc..
We recommend you to replace O-rings with the new ones, if once disassembled.

34.2.6.2 CAUSE OF TROUBLE AND REMEDY

(1) Hydraulic motor never starts

Symptom Cause Remedy

Pressure never Malfunction of built-in relief valve. Repair or replace relief valve
increases
Pressure 1. Parking brake is not released 1. After inspection of clogging, repair or replace
increases (Clogging of restrictor)
2. Parking brake is not released 2. Re-install the spool in correct direction
(Spool is installed in wrong direction)
3. Stuck friction or separating plate of parking 3. Replace friction and separating plate
brake portion
4. Stuck brake piston 4. Repair outer dia. of brake piston or replace it.
5. Seizure of sliding portion 5. Check, repair or replace piston shoe, swash
plate, cylinder block valve plate etc..
6. Malfunction of spool 6. Repair or replace
(Stick between spool and body)
(Clogging of restrictor)

(2) Hydraulic motor rotates weakly

Symptom Cause Remedy

Set pressure of Malfunction of spool Repair or replace
overloadvalve is (Stick between spool and body)
correct, but brake
is released
belatedly
Parking brake is High oil viscosity. Raise oil temperature or change the hydraulic
released, but oil
motor is hard to
start
Parking brake is 1. Check clogging of choke
1. Parking brake is not completely released.
released, but
(Clogging of choke of pressure release
motor starts
passage)
weakly
2. Relief valve catches small particles 2. Wash relief valve, check or replace seat of it
3. Seizure of sliding portion 3. Check, repair or replace sliding portion

34-54
 34. TRAVEL SYSTEM

(3) Drive shaft never rotate up to the set value

Symptom Cause Remedy

Rotation of drive 1. Shortage of oil coming in 1. Check oil flow or hydraulic circuit to motor.
shaft never
reaches the set
value
2. Large wear or flaw made on shoe, cylinder 2. Check, repair or replace the parts
block or valve plate

(4) Brake refuses to work

Symptom Cause Remedy

Brake refuses to Malfunction of parking brake Check, repair or replace brake piston, friction
work plate, spring, etc.
1. Worn friction plate
2. Broken spring
Brake works on Repair or replace or clean up
counter lever Malfunction of spool
operation
1. Stick between spool and body
2. Stick of check valve or that by small particle
3. Clogging of restrictor

(5) Oil leakage

Symptom Cause Remedy

Oil leakage 1. Loose Hex. socket head bolt or plug 1. Fasten it with given torque
2. O-ring is torn off 2. Replace O-ring
3. Oil leaks inside gear casing 3. Replace oil seal

(6) Would not shift from high to low

Symptom Cause Remedy

Would not shift Stick of spool of pilot valve Replace pilot valve assy.
from high to low

(7) Abnormal noise

Symptom Cause Remedy

Abnormal noise appear Malfunction of spool Bleed air
together with big vibration when Air is caught inside brake valve
brake is slowly applied or oil is Stick between spool and body Repair or replace
supplied to other circuits while
motor is running

(8) Hunting occurs while descending the slope

Symptom Cause Remedy

Severe hunting Malfunction of spool Repair or replace
while inching • Stick between spool and body
• Restrictor is not seated completely
Interference with parking brake Repair or replace
• Permanent set or broken spring

34-55
34. TRAVEL SYSTEM

34.2.7 REDUCTION UNIT DISASSEMBLY

34.2.7.1 TOOLS
jigs and measuring instruments.

No. Tools Application

1 Torque wrench 0~490N•m (0~360 lbf•ft)
2 Allen wrench Opposing flats 8mm, 14mm
3 Stand
500 min
(19.7")

(7.87")
390

200
(15.4")

t=16 (0.63")

4 Micro depth meter 0~15mm (0~0.591")

5 Caliper 0~150mm (0~5.91")
6 Eye bolt M10, M20 3pcs. each
7 Pin Spring pin (14), (21) ø5.5×80 (3.15"), ø9.5×60 (2.36")
8 Press machine It is used to insert the angular bearing and fix the lock washer.Capacity 3 tons
(6610 lb)
9 Others Cleaning oil, Detergent, Gear oil, Grease,
Loctite#242, #515, Seal tape, rag and others

34.2.7.2 DISASSEMBLY
(1) Preparation before removal
1) The travel unit removed from the machine has dust and mud. Wash them with cleaning oil.

2) Loosen drain or oil filling plug (26) and drain the oil out of the reduction unit.

When oil is hot, pressure is built up inside. Take care as the oil gushes out in some cases.

3) Putting matching marks

Put a matching mark on the outside of each matching surface so it may be installed where it was.

• The numbers in the parentheses after part names correspond to those in the assembly drawing on Fig. 34-
76.

34-56
 34. TRAVEL SYSTEM

(2) Setting reduction unit (or whole propelling unit) on

work stand
1) Remove Hex. socket head bolts M10×30 (25) at
3 places from cover (24) almost equally apart
each other, then install M10 eye bolts. Lift up the
unit using them and place it on work stand with
cover (24) upward.

Take great care not to pinch your hand between parts

while disassembling nor let fall parts on your foot while
lifting them.
Lift the parts up horizontally.

Fig. 34-93 Setting propelling unit on work stand

(3) Removing cover
1) Remove the rest of Hex. socket head bolts
M10×30 (25) that secure cover (24).

: 8mm
25

2) As the cover (24) is adhered to ring gear (3), 24

remove cover (24) by lightly hammering
slantwise upward by wooden bar aiming at
projection of cover (24).

Fig. 34-94 Removing bolts

24

17

Fig. 34-95 Removing cover

34-57
34. TRAVEL SYSTEM

(4) Removing carrier 1 assy

1) Remove thrust plate (23).

2) Screw three M10 eye bolts in carrier 1 (16) and 16

lift up and remove carrier 1 as sub-assy (16),
(17), (18), (19), (20), (21). 17
(18,19,20,21)

3) Remove sun gear 1 (22).

Fig. 34-96 Removing carrier 1 assy

(5) Removing carrier 2 assy
1) Remove sun gear 2 (15).
9
2) Screw three M10 eye bolts in carrier 2 (9) and lift
up and remove carrier 2 as sub-assy (9), (10),
(11), (12), (13), (14).

10
(11,12,13,14)

Fig. 34-97 Removing carrier 2 assy

(6) Disassembling housing assy
1) Remove support ring (8).
8

Fig. 34-98 Removing support ring

2) Take off lock washers (7) by tapping on screw
driver or on similar tool placed at parting surface
of them.

Fig. 34-99 Removing lock washer

34-58
 34. TRAVEL SYSTEM

3) Screw three M10 eye bolts in ring gear (3) almost

equally apart each other, then lift it up
horizontally and remove housing ass'y including
ring gear (3), housing (1), angular bearing (2), a
piece of floating seal (5) and Hex. socket head
bolts M18×110 (4) together.

Fig. 34-100 Removing housing assy

(7) Disassembling housing assy
1) Screw three M20 eye bolts in housing (1) almost
equally apart each other. Lift up the housing assy
and place it on work stand with housing (1)
upward.
Put a mating mark outside of housing (1) and ring
gear (3).
Over 300 (11.8")

2) Remove floating seal (5) from housing (1).

3) Remove Hex. socket head bolts M18×110 (4),

leaving two of them diagonally.

: 14mm
Fig. 34-101 Disassembling housing assy

4) Loosen the rest two Hex. socket head bolts

M18×110 (4) and tap lightly the head of them
then ring gear (3) can be easily removed from
housing (1).

• Take care not to damage the sliding surface of

floating seal (5) or its O-ring.
• Bearings (2) have been tightly press fitted in housing
(1). Don't remove the bearings (2) unless otherwise
their exchange is needed.
In case bearings (2) removed, don't re-use them.
New bearings (2) should be used and shim (6)
adjusting be required.

34-59
34. TRAVEL SYSTEM

(8) Removing floating seal

1) Remove a piece of floating seal (5) of motor side.

Fig. 34-102 Removing floating seal (23)

(9) Disassembling carrier 1 assy
20

When carrier pins 1 (20) are to be re-used, mark each 16

pin with its mated hole of carrier 1 (16) to assure the
same combination as before.

Fig. 34-103 Disassembling carrier 1 assy

1) Knock spring pins 6×36 (21) fully into carrier pins
1 (20). 21

20
2) Tap carrier pins 1 (20) out from carrier 1 (16).
16
3) Remove thrust washers 1 (18), planetary gears
1 (17) and needle bearings (19).
16
4) Knock out spring pins 6×36 (21) from carrier pins
16
1 (20) for re-assembling.

18
When carrier pin 1 (20) or planetary gear 1 (17) is
needed to be exchanged, three pins or three gears
should be all exchanged. 17 19
17
Fig. 34-104 Disassembling carrier 1 assy

34-60
 34. TRAVEL SYSTEM

(10) Disassembling carrier 2 assy

14
13
When carrier pins 2 (13) are to be re-used, mark each 9
pin with its mated hole of carrier 2 (9) to assure the 9
same combination as before.

1) Knock spring pins 10×50 (14) fully into carrier

pins 2 (13).
9 10
2) Tap carrier pins 2 (13) out from carrier 2 (9).

3) Remove thrust washers 2 (11), planetary gears 2 11

(10) and needle bearings (12).

4) Knock out spring pins 10×50 (14) from carrier

pins 2 (13) for re-assembling. 12

Fig. 34-105 Disassembling carrier 2 assy

When carrier pin 2 (13) or planetary gear 2 (10) is

needed to be exchanged, three pins or three gears
should be all exchanged.

34-61
34. TRAVEL SYSTEM

34.2.8 ASSEMBLING
(1) GENERAL INSTRUCTIONS
9
1) Clean every part by kerosene and dry them by air
blow. Surfaces to be applied by Loctite must be
degreased by solvent.
10 (11,12)

2) Check every parts for any abnormals.

3) Each Hex. socket head bolt should be used with

Loctite #242 applied on its threads.
Fig. 34-106 Assembling carrier assy
4) Apply gear oil slightly on each part before
assembling.

5) Take great core not to pinch your hand between

parts while assembling nor let fall parts on your
foot while lifting them.

(2) Assembling carrier 2 assy

10 (11,12)
1) Install planetary gears 2 (10), needle bearings
(12) and thrust washer 2 (11) into carrier 2 (9).

2) Install carrier pins 2 (13) into carrier 2 (9) where

14
the holes for spring pins 10×50 (14) are to be in
line with those of carrier 2 (9). 9

3) Install spring pins 10×50 (14) into carrier 2 (9)

and at the same time into carrier pins 2 (13). Fig. 34-107 Drive spring pin
(Sink spring pins of 1 - 2 mm (0.04"~0.08") from
surface)

4) Calk carrier 2 (9) on diagonally position to

prevent spring pin 10×50 (14) from coming out.

(3) Assembling carrier 1 assy (See Fig. 34-106).

1) Install planetary gears 1 (17), needle bearings
(19) and thrust washers 1 (18) into carrier 1 (16).

2) Install carrier pins 1 (20) into carrier 1 (16) where

the holes for spring pins are to be in line with
Cauking
those of carrier 1 (16). position

3) Install spring pins 6×36 (21) into carrier 1 (16)

14
and at the same time into carrier pins 1 (20).
(Sink spring pins of 1 - 2 mm (0.04"~0.08")from Fig. 34-108 Caulking the spring pin
surface)

4) Calk carrier 1 (16) on diagonally position to

prevent spring pin 6×36 (21) from coming out.

34-62
 34. TRAVEL SYSTEM

(4) Installing main bearing and floating seal

5
1) Install main bearing (2) to inner surface of
housing (1).

2) Install a piece of floating seal (5) on motor casing

and also install another piece of floating seal (5)
on housing (1).

Fig. 34-109 Install floating seal (5)

Correct Incorrect Incorrect

Fig. 34-110 Install direction of floating seal (5)

(5) Assembling housing assy LOCTITE #515
1) Apply Loctite #515 on mating surfaces of
housing (1) and ring gear (3) without a gap.

2) Install three M20 eye bolts equally apart on

housing (1). Using the eye bolts, hang the
housing (1) by wire rope and place it on ring gear
(3), coinciding mating marks.

3) After applying Loctite #242 on the threads of 25

pieces of Hex. socket head bolts M18×110 (4),
tighten them with torque wrench.

: 14mm
Tightening torque : 377.3N•m (278 lbf•ft)

• Clean the groove for floating seals (5) to eliminate

oil, dust, paint or other foreign material. Fig. 34-111 Assembling housing assy

• Apply gear oil slightly on sliding surfaces of floating 20 (0.79") 20 (0.79")

seals (5) before assembling but strictly dry on O-
rings and on its grooves.
• Confirm that O-ring of floating seals (5) are not
twisted and that floating seals are correctly installed.
i.e. parallel as shown each other between housing Sork 20mm (0.79") length from the
tip of bolt in Loctite #242.
(1) and motor casing after assembled. (See Fig. 34-
110) Fig. 34-112 How to apply Loctite #242

• It is recommended to use jig to install floating seal.

34-63
34. TRAVEL SYSTEM

(6) Deciding shim thickness for angular bearings

This work should be done only when you have to

change motor casing, housing (1), bearings (2) or lock
washers (7). Unless otherwise use the same shim (6)
as before.

1) Fit in two bearings (2) on housing (1) pressing

their outer laces.
2) Press inner laces of two bearings (2) lightly and
evenly, measure the assembling width "A" of
inner laces.

3) Measure the motor side assembling width "B" for

bearings (2).
S
D A
4) Measure the groove width "C" of motor casing.
C B

5) Measure the thickness "D" of lock washers (7).

Fig. 34-113 Deciding shim thickness

Measure them at 4 places evenly apart on the

circumferences then calculate and use those mean
values.
Measure them to the accuracy of 0.01 mm (0.0004").

6) When thickness of shim (6) to be used is placed

as "S", the clearance "X" can be calculated as
follows :
X=(B+C)-(A+D+S)

7) Select a shim (6) so as the clearance X to come

to -0.08 mm (interference)~ +0.02 mm
(clearance) (-0.0031"~0.0008") on this unit.

34-64
 34. TRAVEL SYSTEM

(7) Installing housing assy Press

1) Place motor on work stand with the shaft upward,
and put the selected shim (6) on the bearing
mating surface of motor casing.

2) Install three M10 eye bolts on ring gear (3)

almost equally apart and lift it up. Descend it
concentric with motor and put bearings (2) on
housing (1) into motor casing. Use press
machine and press inner lace of bearing (2) into
full depth.

Fig. 34-114 Pressing housing assy in

3) While pressing inner lace of bearing (2), install
lock washers (7) into groove.

Fig. 34-115 Installing lock washer

4) Install support ring (8) over outside of lock
7 8
washers (7).

Fig. 34-116 Installing support ring

34-65
34. TRAVEL SYSTEM

(8) Assembling carrier 2 assy CARRIER 2 PLANETARY GEAR 2

1) Install three M10 eye bolts equally apart on
carrier 2 (9).
Using the eye bolts, hang the carrier 2 assy by
wire rope and place three planetary gears 2 (10)
as shown on Fig. 34-117, put carrier 2 assy into
ring gear (3) and mesh the splines to those of
motor.
VB VA

2) Insert and mesh sun gear 2 (15) on center.

NOTCH (CARRIER 2) PORT
Fig. 34-117 Installing direction of carrier 2

Positioning carrier 2 assy as Fig. 34-117 is important to

9
obtain better lubrication.

SUN GEAR 2 (15)

Fig. 34-118 Assembling carrier 2 assy

(9) Assembling carrier 1 assy
16
1) Install three M10 eye bolts equally apart on
carrier 1 (16). Using the eye bolts, hang the
carrier 1 assy by wire rope and place it in ring
gear (3), rotate planetary gears 1 (17) by hand
and adjust carrier 1 (16) to mesh with sun gear 2
(15).

2) Making sure that coupling is on the shaft end,

SUN GEAR 1 (22)
install sun gear 1 (22) on center.

3) Place thrust plate (23) on carrier 1 (16).

16
SHARP EDGE R
23
THRUST PLATE
Face sharp edged side to cover (24). (See Fig. 34-119)
COVER
Fig. 34-119 Assembling carrier 1 assy

34-66
 34. TRAVEL SYSTEM

(10)Installing cover
1) Apply Loctite#515 on mating surfaces of cover 24
(24) and ring gear (3) and install cover (24) on
ring gear (3). LOCTITE #515
3

2) After applying Loctite #242 on the threads of 18

pieces of Hex. socket head bolts M10×30 (25),
tighten them with torque wrench. 25

Fig. 34-120 Installing cover (24)

: 8mm,
Tightening torque : 68.6N•m (50.6 lbf•ft)

(11)Filling gear oil

1) Fill gear oil (SAE #90 API class GL-4 or GL-5, 9.5
litters (2.5 gal)) from two G3/4 ports.
2) Tighten taper screw plugs (26).

: 14mm
Tightening torque : 147.1N•m (108 lbf•ft)

34-67
34. TRAVEL SYSTEM

34.2.9 MAINTENANCE STANDARD

34.2.9.1 INSPECTION BEFORE ASSEMBLING

(1) Thrust washer
1) Check if there are seizure, abnormal wear or uneven wear.
2) Check if the wear is over the allowable limit.
(2) Gears
1) Check if there are pitting or seizure on the tooth surface.
2) Check if there are clacks on the root of tooth by die check.
(3) Bearings
Rotate by hand to see if there are something unusual such as noise or uneven rotation.
(4) Floating seal
Check flaw or score on sliding surfaces or on O-rings.

34.2.9.2 MAINTENANCE STANDARD OF PARTS

The followings are the general maintenance standards.
However, it is most important to determine which parts D E C
should be replaced, depending on the characteristics
shown before disassembling, damages or discoloration
of exterior view, the purpose of disassembling, the
expected remaining service life etc.. A

Fig. 34-121

Maintenance standards
Mark Items Criteria Allowable limit Disposition
Smooth, without abnormal Replace 3 pieces
A Wear of planetary shaft ←
wear or seizure as a set
Replace (Replace 3
Smooth, without abnormal Not over 1.6mm (0.063") of
B Condition of tooth surface pieces as a set for
wear or seizure pitching nor cracks at root
planetary gears)
Adjust shim
Thrust clearance of angular From -0.08 mm To 0.02 mm
C ← thickness
bearings (2) (-0.0031"~0.0008")
[Refer to 34.2.8(6)]
Thickness of thrust washer 1 From 3.3 mm To 3.7 mm 0.1 mm (0.004")
D Replace
(18) (0.13"~0.15") of wear
Thickness of thrust washer 2 5.5±0.2mm 0.1 mm (0.004")
E Replace
(11) (0.21"~0.22") of wear
4.5±0.16mm 0.15 mm (0.006")
F Thickness of thrust plate (23) Replace
(0.171"~0.183") of wear
G Lubrication oil 2,000 working hours (engine hour meter) Replace

34-68
 34. TRAVEL SYSTEM

34.2.9.3 TIGHTENING TORQUE

Use torque wrench when tightening the following Hex. socket head bolts and plugs.

ITEM Description Size Tightening torque

N•m (lbf•ft)
378±37.8 (279±28)
4 Hex. socket head bolt M18×110
(with applying Loctite#242)
68.6±6.8 (50.6±5)
25 Hex. socket head bolt M10×30
(with applying Loctite#242)
26 Taper plug G3/4 147±14.7 (108±11)

34.2.9.4 INSPECTION AFTER ASSEMBLED

(1) Quantity of lubrication
After installed the propelling unit, position the drain port at lowest position and check if lubrication oil comes out
when loosen the level plug.
(2) Rotating inspection
Put the unit on the test stand and rotate with no load and check if there are abnormal noise or leak of oil. Take
care not to overspeed the motor. Rotate within specified flow rate.

34-69
34. TRAVEL SYSTEM

[MEMO]

34-70
 46. TROUBLE SHOOTING
(BY ERROR CODES)
TABLE OF CONTENTS

46.1 JUDGMENT OF ACTUAL THING AT SITE .....................................................................46-3

46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING .......................................46-4
46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER ....................................................46-4
46.4 TROUBLESHOOTING BY ERROR CODE......................................................................46-4

46

Book Code No. S5YN4618E02

46-1
46. TROUBLE SHOOTING (BY ERROR CODES)

Issue Date of Issue Applicable Machines Remarks

SK330-8 : LC10-07001~ S5YN4618E01
First edition July, 2006 K
SK350LC-8 : YC10-03501~ (ASIA, OCE)
SK200-8 : YN11-45001~
↑ August, 2006 ↑ K
SK210LC-8 : YQ11-06001~
SK250-8 : LQ12-06001~
↑ October, 2006 ↑ K
SK260LC-8 : LL12-05001~
SK200-8 : YN11-45001~ S5YN4618E02
Revision February, 2007 K
SK210LC-8 : YQ11-06001~ (ASIA, OCE)
SK330-8 : LC10-07001~
↑ ↑ ↑ K
SK350LC-8 : YC10-03501~

46-2
 46. TROUBLE SHOOTING (BY ERROR CODES)

Preface
Troubleshooting provides process locating for the
cause of trouble in the order that trouble occurred. This
manual describes how to solve the specific
phenomenon systematically as early as possible. For
troubleshooting concerning the inside of equipment,
refer to troubleshooting for each manual of equipment.

Fig. 46-1 Attending the field to verify actual thing.

46.1 JUDGMENT OF ACTUAL THING AT SITE

(1) Get to the site as quickly as possible.
Verify model, serial number, situation of trouble and
field, and notify person of arrival time.
(2) Verify background of trouble occurred
1) Model name and serial number
2) Kind of attachment
Check that the combination of attachment is
proper or that the operating method is not
unreasonable.
3) Operating time by hour-meter
4) History of trouble occurred and additional works.
5) Recurrence of past trouble, or problems on the
Fig. 46-2 Verifying background of trouble occurred.
additional works.
(3) How to diagnose trouble
1) Verify defective part
2) Make the condition of trouble again
3) Where defective parts can not be verified,
surmise causes systematically.
4) Verify reasons for surmise
5) Report methods, procedure, and period for
repairing to user.
(4) Explanation of the cause of trouble
1) Explain the cause of trouble to clients. For
example, oil leak through piston is caused by
Fig. 46-3 Confirm the symptoms of the trouble.
flaws on the piston rod. And the method of using
the machines should be explained so that the
same kind of trouble does not reoccur.
2) Treatment of damaged parts
The damaged parts to be claimed and returned
are evidence so they should be handled with
care. Protect them from entry of water, soils, etc.
into port of hydraulic unit, etc. and return them.
And also use care not to flaw and damage those Fig. 46-4 Diagnosing fail by means
surfaces. troubleshooting.

46-3
46. TROUBLE SHOOTING (BY ERROR CODES)

46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING

Classify failures into the following 3 types and carry out the troubleshooting.

No. Classes of failure Troubleshooting

A When error code after self-diagnosis is displayed Carry out troubleshooting according to the error
on gauge cluster code.
B When no failure is detected currently but error code When it is hard to recreate the failure situation, cancel
after self diagnosis is remained in trouble history the data in the history and reproduce the failed
situation or suppose the cause according to the
troubleshooting by error code, and then repair it.
C When error code after self diagnosis is not • Carry out troubleshooting according to instructions
displayed or is not remained in the history in Chapter 47 "TROUBLESHOOTING BY
TROUBLE".
• Carry out troubleshooting according to instructions
in Chapter 48 "TROUBLE DIAGNOSIS MODE".

46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER

If the fuse of mechatro controller has blown, the following display appears on the gauge cluster.
(1) The blown fuse of mechatro controller
a. Blown fuse 5A of mechatro controller :
"DATA COMMUNICATION ERROR" is displayed on the gauge cluster in the condition where the controller
program is not executed.
b. Blown fuse 20A of mechatro controller
The controller functions normally but the power supply applied when the controller drives the solenoid, etc.
stops.
Many error codes are displayed on the gauge cluster.
D013, D023, D033, D063,
E013, E023, F021

46.4 TROUBLESHOOTING BY ERROR CODE

When error code was displayed on the gauge cluster with the aid of self-diagnosis display function, carry out the
troubleshooting referring to applicable page in the contents of error codes.

Error Code Trouble Described

page
A015 Engine adjustment (A adjustment) is not adjusted yet or is failed. 46-7
A025 Pump propo. valve adjustment (B adjustment) is not adjusted yet or is failed. 46-7
A035 Unload valve adjustment (C adjustment) is not adjusted yet or is failed. 46-8
A215 Written data of ROM adjustment data is incorrect. 46-8
A225 Writing of ROM adjustment data is incorrect. 46-9
A235 Written data of ROM hour meter data is incorrect. 46-9
A245 Writing of ROM hour meter data is incorrect. 46-10
A255 Writing of proportional valve adjustment data is incorrect. 46-10
B012 Incorrect output of boom up pressure sensor 46-11
B013 Disconnection of boom up pressure sensor 46-11
B014 Short-circuit of boom up pressure sensor 46-12
B022 Incorrect output of boom down pressure sensor 46-12
B023 Disconnection of boom down pressure sensor 46-13
B024 Short-circuit of boom down pressure sensor 46-13

46-4
 46. TROUBLE SHOOTING (BY ERROR CODES)

Error Code Trouble Described

page
B032 Incorrect output of arm out pressure sensor 46-14
B033 Disconnection of arm out pressure sensor 46-14
B034 Short-circuit of arm out pressure sensor 46-15
B042 Incorrect output of arm in pressure sensor 46-15
B043 Disconnection of arm in pressure sensor 46-16
B044 Short-circuit of arm in pressure sensor 46-16
B052 Incorrect output of bucket digging pressure sensor 46-17
B053 Disconnection of bucket digging pressure sensor 46-17
B054 Short-circuit of bucket digging pressure sensor 46-18
B062 Incorrect output of bucket dump pressure sensor 46-18
B063 Disconnection of bucket dump pressure sensor 46-19
B064 Short-circuit of bucket dump pressure sensor 46-19
B072 Incorrect output of swing pressure sensor 46-20
B073 Disconnection of swing pressure sensor 46-20
B074 Short-circuit of swing pressure sensor 46-21
B092 Incorrect output of travel right pressure sensor 46-21
B093 Disconnection of travel right pressure sensor 46-22
B094 Short-circuit of travel right pressure sensor 46-22
B102 Incorrect output of travel left pressure sensor 46-23
B103 Disconnection of travel left pressure sensor 46-23
B104 Short-circuit of travel left pressure sensor 46-24
B113 Disconnection of pressure sensor of optional selector positioning 46-24
B114 Short-circuit of pressure sensor of optional selector positioning 46-25
B162 Incorrect output of P1 optional side pressure sensor 46-25
B163 Disconnection of P1 side optional pressure sensor 46-26
B164 Short-circuit of P1 side optional pressure sensor 46-26
B172 Incorrect output of P2 optional side pressure sensor 46-27
B173 Disconnection of P2 side optional pressure sensor 46-27
B174 Short-circuit of P2 side optional pressure sensor 46-28
C012 Incorrect output of P1 pump pressure sensor 46-28
C013 Disconnection of P1 pump pressure sensor 46-29
C014 Short-circuit of P1 pump pressure sensor 46-29
C022 Incorrect output of P2 pump pressure sensor 46-30
C023 Disconnection of P2 pump pressure sensor 46-30
C024 Short-circuit of P2 pump pressure sensor 46-31
C033 Disconnection of boom head pressure sensor 46-31
C034 Short-circuit of boom head pressure sensor 46-32
C043 Disconnection of boom rod pressure sensor 46-32
C044 Short-circuit of boom rod pressure sensor 46-33
D012 Failure of output transistor ON at P1 unload proportional valve 46-33
D013 Disconnection of P1 unload proportional valve 46-34
D022 Failure of output transistor ON at P2 unload proportional valve 46-34
D023 Disconnection of P2 unload proportional valve 46-35
D032 Failure of output transistor ON at travel straight proportional valve 46-35
D033 Disconnection of travel straight proportional valve 46-36
D062 Failure of output transistor ON at arm in high speed proportional valve 46-36
D063 Disconnection of arm in high speed proportional valve 46-37
E012 Failure of output transistor ON at P1 pump proportional valve 46-37

46-5
46. TROUBLE SHOOTING (BY ERROR CODES)

Error Code Trouble Described

page
E013 Disconnection of P1pump proportional valve 46-38
E022 Failure of output transistor ON at P2 pump proportional valve 46-38
E023 Disconnection of P2 pump proportional valve 46-39
F011 Failure of output transistor OFF and GND short of attachment boost SOL valve 46-39
F013 Failure of output transistor ON and disconnection of attachment boost SOL valve 46-40
F021 Failure of output transistor OFF and GND short of swing parking SOL valve 46-40
F023 Failure of output transistor ON and disconnection of swing parking SOL valve 46-41
F031 Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve 46-41
F033 Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve 46-42
F041 Failure of output transistor OFF and GND short of optional selector SOL valve 46-42
F043 Failure of output transistor ON and disconnection of optional selector SOL valve 46-43
G032 Overrun of speed sensor of direct input Mechatro-controller 46-43
G033 Disconnection of speed sensor of direct input Mechatro-controller 46-44
G042 Overrun of speed sensor of direct input Mechatro-controller and received data from E/G controller. 46-44
G043 Disconnection of speed sensor of direct input Mechatro-controller and received data from E/G controller. 46-45
H013 Disconnection of acceleration potentio 46-46
H014 Power short-circuit of acceleration potentio 46-46
H023 Disconnection of boom angle potentio 46-47
H024 Power short-circuit of boom angle potentio 46-47
H033 Disconnection of arm angle potentio 46-48
H034 Power short-circuit of arm angle potentio 46-48
H091 Failure of GND short-circuit of fuel sensor 46-49
H093 Disconnection of fuel sensor 46-49
I111 Received error of CAN1 communication (passive error) 46-50
I113 Received error of CAN1 communication (time-out) 46-50
I313 Received error of cluster communication (time-out error) 46-51
K014 Adhesion of battery relay terminal 46-51
R014 Failure of arc prevention relay of wiper motor 46-52
R024 Failure of normal rotation relay of wiper motor 46-53
R034 Failure of reverse rotation relay of wiper motor 46-54
R044 Failure of washer motor relay 46-55
R134 Failure of swing flasher relay 46-55
R144 Failure of swing flasher relay 46-56
R154 Failure of travel alarm relay 46-56
R164 Failure of auto idling stop relay 2 46-57
R174 Failure of engine forcible stop relay 46-58
R184 Failure of lever lock relay 46-59
R214 Failure of safety relay 46-59

46-6
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-1
Error code A015
Trouble Not yet adjusted engine or failed adjustment of engine (A adjustment)
Judging Engine adjustment is missed. Or it is impossible to set the adjusting value within the adjusting
condition range.
Symptom Deviated from the reqired value, but no problem in normal operations.
Control in the
Rotate with the default engine
event of failure
Returned in
The engine adjustment is completed normally.
normal condition
Service Screen No. 2 G-3 SPEED SET
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 •Checking Carry out engine adjustment (A adjustment). When "ERROR ENG" was
displayed during adjustment, refer to the section "Adjustment procedure -
Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3

Table46-2
Error code A025
Trouble Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment)
Judging Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value within
condition the adjusting range.
Symptom Deviated from the rated output, but no problem in normal operation
Control in the
Workable with the default proportional valve output.
event of failure
Returned in
The pump proportional valve adjustment is completed normally.
normal condition
Service Screen No. 9 E-1 P1 PUMP
diagnosis Screen No. 9 E-2 P2 PUMP
checking screen Screen No.
Checking object Checking contents and remedy
1 •Checking Carry out pump adjustment (B adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3

46-7
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-3
Error code A035
Trouble Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment)
Judging The adjustment of unload valve is missed. Or the adjusting value can not be set in the adjusting
condition range.
Symptom It is not normal output, but no problem in normal operation
Control in the
Work with the aid of output by default proportional valve.
event of failure
Returned in
The adjustment of unload valve is completed normally.
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
diagnosis Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
checking screen Screen No.
Checking object Checking contents and remedy
1 •Checking Carry out adjustment of unload valve (C adjustment).
When"ERROR PUMP" was displayed during adjustment, refer to the section
"Adjustment procedure - Measures to be taken with the adjustment failed"
2 • Mechatro controller Check that the error is corrected after replacement of controller.
3

Table46-4
Error code A215
Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the content of memory is correct or not. (Trouble history only)
condition
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3

46-8
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-5
Error code A225
Trouble The data of ROM adjustment is written incorrectly.
Judging
Check adjustment data, and judge the data is correct or not.
condition
Symptom It is not normal output, but no problem in normal operation
Control in the
Control can be done by default value.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3

Table46-6
Error code A235
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is correct or not. (Trouble history only)
condition
Symptom No affect.
Control in the
Control at side of correct memory data.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3

46-9
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-7
Error code A245
Trouble The data of ROM hourmeter is written incorrectly.
Judging
Check hourmeter memory, and judge the data is incorrect.
condition
Symptom The hour meter data which was judged as error is taken as 0 Hr. No problem in normal operation
Control in the
Normal control is available.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3

Table46-8
Error code A255
Trouble The data of proportional valve adjustment is written incorrectly.
Judging
Check proportional valve adjustment data, and judge the data is incorrect.
condition
Symptom It is not normal output, but no problem in normal operation
Control in the
Using fixed value of proportional valve correction data, usual control is done.
event of failure
Returned in
It does not regain. Replace controller.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 Mechatro controller Check that the error is corrected after replacement of controller.
2
3

46-10
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-9
Error code B012
Trouble Boom up pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The boom up operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-1 BOOM RAISE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor When B012 is cancelled and other error occurs by turning starter switch on
SE-3 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B012 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-126F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-10
Error code B013
Trouble Boom up pressure sensor’s wiring disconnects.
Judging
The input voltage from boom up pressure sensor is less than 0.1V.
condition
Symptom The boom up speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency
Control in the
mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-1 BOOM RAISE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor When B013 is cancelled and other error occurs after exchanging the
SE-3 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B013 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-126F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-11
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-11
Error code B014
Trouble Boom up pressure sensor’s power source is shortcut.
Judging
The input voltage from boom up pressure sensor is 4.7V or more.
condition
Symptom The boom up speed slows down.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-1 BOOM RAISE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom up pressure sensor When B014 is cancelled and other error occurs after exchanging the
SE-3 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom up When B014 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-126F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-12
Error code B022
Trouble Boom down pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The boom down operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-2 BOOM LOWER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch on
SE-4 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down When B022 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-127F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-12
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-13
Error code B023
Trouble Boom down pressure sensor’s wiring is disconnecting.
Judging
The input voltage from boom down pressure sensor is 0.1V or less.
condition
Symptom The boom down operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-2 BOOM LOWER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the
SE-4 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down When B023 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-127F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-14
Error code B024
Trouble Boom down pressure sensor’s power source is shortcut.
Judging
The input voltage from boom down pressure sensor is 4.7V or more.
condition
Symptom The boom down operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-2 BOOM LOWER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch on
SE-4 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom down When B024 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-127F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-13
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-15
Error code B032
Trouble Arm-in pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the sensor after
condition starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The arm-out operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-3 ARM OUT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor When B032 is cancelled and other error occurs by turning starter switch on
SE-8 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out When B032 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-131F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-16
Error code B033
Trouble Arm-out pressure sensor’s wiring is disconnecting.
Judging
The input voltage from arm-out pressure sensor is 0.1V or less.
condition
Symptom Shock at stopping of arm-out is great.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-3 ARM OUT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor When B033 is cancelled and other error occurs after exchanging the
SE-8 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out When B033 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-131F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-14
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-17
Error code B034
Trouble Arm-out pressure sensor’s power source is shortcut.
Judging
The input voltage from arm-out pressure sensor is 4.7V or more.
condition
Symptom Shock at stopping of arm-out is great.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-3 ARM OUT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-out pressure sensor When B034 is cancelled and other error occurs by turning starter switch on
SE-8 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-out When B034 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-131F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-18
Error code B042
Trouble Arm-in pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the arm-in
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The arm-in operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-4 ARM IN
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B042 is cancelled and other error occurs by turning starter switch on
SE-7 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in When B042 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-130F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-15
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-19
Error code B043
Trouble Arm-in pressure sensor’s wiring is disconnecting.
Judging
The input voltage from arm-in pressure sensor is 0.1V or less.
condition
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done
Symptom but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the
bucket bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1 and P2 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200mA.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-4 ARM IN
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B043 is cancelled and other error occurs after exchanging the
SE-7 connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in When B043 is displayed after the connector is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-130F and repair it if necessary.
CN-101F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-20
Error code B044
Trouble Arm-in pressure sensor’s power source is shortcut.
Judging
The input voltage from arm-in pressure sensor is 4.7V or more.
condition
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done
Symptom but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the
bucket bottom put on the ground.
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the
Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode)
event of failure
Set output of arm 2 arm-in proportional valve to 200mA.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-4 ARM IN
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in pressure sensor When B044 is cancelled and other error occurs by turning starter switch on
SE-7 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between arm-in When B044 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-130F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-16
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-21
Error code B052
Trouble Bucket digging pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket
condition digging pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The bucket digging operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-5 BUCKET DIG
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B052 is cancelled and other error occurs by turning starter switch on
SE-1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B052 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-22
Error code B053
Trouble Bucket digging pressure sensor’s wiring is disconnected.
Judging
The input voltage from bucket digging pressure sensor is 0.1V or less.
condition
Symptom The bucket digging speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-5 BUCKET DIG
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B053 is cancelled and other error occurs by turning starter switch on
SE-1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B053 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-17
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-23
Error code B054
Trouble Bucket digging pressure sensor’s power source is shortcut.
Judging
The input voltage from bucket digging pressure sensor is 4.7V or more.
condition
Symptom The bucket digging speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-5 BUCKET DIG
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B054 is cancelled and other error occurs by turning starter switch on
SE-1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B054 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-124F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-24
Error code B062
Trouble Bucket dump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the bucket dump
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The bucket dump operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 5 B-6 BUCKET DUMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B062 is cancelled and other error occurs by turning starter switch on
SE-2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B062 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-125F
CN-101F Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-18
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-25
Error code B063
Trouble Bucket dump pressure sensor’s wiring is disconnected.
Judging
The input voltage from bucket dump pressure sensor is 0.1V or less.
condition
Symptom The bucket dump speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-6 BUCKET DUMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B063 is cancelled and other error occurs by turning starter switch on
SE-2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B063 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-125F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-26
Error code B064
Trouble Bucket dump pressure sensor’s power source is shortcut.
Judging
The input voltage from bucket dump pressure sensor is 4.7V or more.
condition
Symptom The bucket dump speed slows down a little.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 5 B-6 BUCKET DUMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Bucket digging pressure sensor When B064 is cancelled and other error occurs by turning starter switch on
SE-2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between bucket digging When B064 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-125F Check wiring for possible failure according to the wiring checking procedure
CN-101F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-19
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-27
Error code B072
Trouble Swing pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the swing
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The swing operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-7 SWING
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B072 is cancelled and other error occurs by turning starter switch on
SE-5 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing When B072 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-28
Error code B073
Trouble Swing pressure sensor’s wiring is disconnected.
Judging
The input voltage from swing pressure sensor is 0.1V or less.
condition
Symptom The swing operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-7 SWING
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B073 is cancelled and other error occurs by turning starter switch on
SE-5 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing When B073 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-20
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-29
Error code B074
Trouble Swing pressure sensor’s power source is shortcut.
Judging
The input voltage from swing pressure sensor is 4.7V or more.
condition
Symptom The swing operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-7 SWING
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing pressure sensor When B074 is cancelled and other error occurs by turning starter switch on
SE-5 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between swing When B074 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-169F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-30
Error code B092
Trouble Travel right pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel right
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The travel right operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-9 TRAVEL (R)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B092 is cancelled and other error occurs by turning starter switch on
SE-9 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B092 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-21
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-31
Error code B093
Trouble Travel right pressure sensor’s wiring is disconnected.
Judging
The input voltage from Travel right pressure sensor is 0.1V or less.
condition
Symptom The Travel right operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-9 TRAVEL (R)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B093 is cancelled and other error occurs by turning starter switch on
SE-9 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B093 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-32
Error code B094
Trouble Travel right pressure sensor’s power source is shortcut.
Judging
The input voltage from Travel right pressure sensor is 4.7V or more.
condition
Symptom The Travel right operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-9 TRAVEL (R)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel right pressure sensor When B094 is cancelled and other error occurs by turning starter switch on
SE-9 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel right When B094 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-301F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-22
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-33
Error code B102
Trouble Travel left pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the travel left
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The travel left operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-10 TRAVEL (L)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B102 is cancelled and other error occurs by turning starter switch on
SE-10 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B102 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-34
Error code B103
Trouble Travel left pressure sensor’s wiring is disconnected.
Judging
The input voltage from Travel left pressure sensor is 0.1V or less.
condition
Symptom The Travel left operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-10 TRAVEL (L)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B103 is cancelled and other error occurs by turning starter switch on
SE-10 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B103 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-23
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-35
Error code B104
Trouble Travel left pressure sensor’s power source is shortcut.
Judging
The input voltage from Travel left pressure sensor is 4.7V or more.
condition
Symptom The Travel left operability becomes poor.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-10 TRAVEL (L)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel left pressure sensor When B104 is cancelled and other error occurs by turning starter switch on
SE-10 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between travel left When B104 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-302F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-36
Error code B113
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging
The input voltage from option selector position detect pressure sensor is 0.1V or less.
condition
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 16 B-11
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector position When B113 is cancelled and other error occurs by turning starter switch on
detect pressure sensor after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option When B113 is displayed after turning the starter switch on after the connector
selector position detect is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-162F and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-24
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-37
Error code B114
Trouble Option selector position detect pressure sensor’s wiring is disconnected.
Judging
The input voltage from selector position detect pressure sensor is 4.7V or more.
condition
Symptom When B mode is selected, option selector valve error is indicated.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 16 B-11
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector position When B114 is cancelled and other error occurs by turning starter switch on
detect pressure sensor after exchanging the connector with other sensor.
SE-29 Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between option When B114 is displayed after turning the starter switch on after the connector
selector position detect is exchanged with other sensor.
pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure
CN-162F and repair it if necessary.
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-38
Error code B162
Trouble P1 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P1 side option operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-16 P1 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B162 is cancelled and other error occurs by turning starter switch on
SE-20 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 side option When B162 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to
CN-304F the wiring checking procedure and repair it if necessary.
CN-102F Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-25
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-39
Error code B163
Trouble P1 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 side option pressure sensor is 0.1V or less.
condition
Symptom The P1 side option does not work.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-16 P1 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B163 is cancelled and other error occurs by turning starter switch on
SE-20 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 side option When B163 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-304F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-40
Error code B164
Trouble P1 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 side option pressure sensor is 4.7V or more.
condition
Symptom The P1 side option does not work.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the (Hydraulic pump emergency mode)
event of failure Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
But normal control is done when the left control pedal selection is ON.
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-16 P1 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 side option pressure sensor When B164 is cancelled and other error occurs by turning starter switch on
SE-20 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 side option When B164 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-304F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

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 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-41
Error code B172
Trouble P2 side option pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 side
condition option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P2 side option operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 6 B-17 P2 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensor When B172 is cancelled and other error occurs by turning starter switch on
SE-11 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 side option When B172 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to
CN-303F the wiring checking procedure and repair it if necessary.
CN-102F Check wiring for possible failure according to the wiring checking procedure
and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-42
Error code B173
Trouble P2 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 side option pressure sensor is 0.1V or less.
condition
Symptom The selection of conflux does not work.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-17 P2 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensor When B173 is cancelled and other error occurs by turning starter switch on
SE-11 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 side option When B173 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-303F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

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46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-43
Error code B174
Trouble P2 side option pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 side option pressure sensor is 4.7V or more.
condition
Symptom The selection of conflux does not work.
Set proportional valve output rate of P1 and P2 pumps to 0mA.
Control in the
(Hydraulic pump emergency mode)
event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 6 B-17 P2 OPT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 side option pressure sensor When B174 is cancelled and other error occurs by turning starter switch on
SE-11 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 side option When B174 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-303F Check wiring for possible failure according to the wiring checking procedure
CN-102F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-44
Error code C012
Trouble P1 pump pressure sensor outputs error
Judging After starter switch ON and engine does not start yet. And the input voltage from the P1 pump
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P1 pump operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 7 C-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C012 is cancelled and other error occurs by turning starter switch on
SE-22 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C012 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

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 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-45
Error code C013
Trouble P1 pump pressure sensor’s wiring is disconnected.
Judging
The input voltage from P1 pump pressure sensor is 0.1V or less.
condition
Symptom The delicate operability of P1 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C013 is cancelled and other error occurs by turning starter switch on
SE-22 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C013 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-46
Error code C014
Trouble P1 pump pressure sensor’s power source is shortcut.
Judging
The input voltage from P1 pump pressure sensor is 4.7V or more.
condition
Symptom The delicate operability of P1 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump pressure sensor When C014 is cancelled and other error occurs by turning starter switch on
SE-22 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 pump When C014 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-139F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

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46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-47
Error code C022
Trouble P2 pump pressure sensor outputs error.
Judging After starter switch ON and engine does not start yet. And the input voltage from the P2 pump
condition pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom The P2 pump operability becomes poor.
Control in the
Normal control
event of failure
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 7 C-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C022 is cancelled and other error occurs by turning starter switch on
SE-23 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C022 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-48
Error code C023
Trouble P2 pump pressure sensor’s wiring is disconnected.
Judging
The input voltage from P2 pump pressure sensor is 0.1V or less.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C023 is cancelled and other error occurs by turning starter switch on
SE-23 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C023 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

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 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-49
Error code C024
Trouble P2 pump pressure sensor’s power source is shortcut.
Judging
The input voltage from P2 pump pressure sensor is 4.7V or more.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump pressure sensor When C024 is cancelled and other error occurs by turning starter switch on
SE-23 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 pump When C024 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-140F Check wiring for possible failure according to the wiring checking procedure
CN-103F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-50
Error code C033
Trouble Boom head pressure sensor’s wiring is disconnected.
Judging
The input voltage from boom head pressure sensor is 0.1V or less.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-3 BOOM-HEAD
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom head pressure sensor When C033 is cancelled and other error occurs by turning starter switch on
SE-24 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom head When C033 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-706F Check wiring for possible failure according to the wiring checking procedure
CN-104F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-31
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-51
Error code C034
Trouble Boom head pressure sensor’s power source is shortcut.
Judging
The input voltage from boom head pressure sensor is 4.7V or more.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-3 BOOM-HEAD
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom head pressure sensor When C034 is cancelled and other error occurs by turning starter switch on
SE-24 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom head When C034 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-706F Check wiring for possible failure according to the wiring checking procedure
CN-104F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-52
Error code C043
Trouble Boom rod pressure sensor’s wiring is disconnected.
Judging
The input voltage from boom rod pressure sensor is 0.1V or less.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-4 BOOM-ROD
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom rod pressure sensor When C043 is cancelled and other error occurs by turning starter switch on
SE-25 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom rod When C043 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-705F Check wiring for possible failure according to the wiring checking procedure
CN-104F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-32
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-53
Error code C044
Trouble Boom rod pressure sensor’s power source is shortcut.
Judging
The input voltage from boom rod pressure sensor is 4.7V or more.
condition
Symptom Indication load value of High-reach crane becomes abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 7 C-4 BOOM-ROD
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom rod pressure sensor When C044 is cancelled and other error occurs by turning starter switch on
SE-25 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between boom rod When C044 is displayed after turning the starter switch on after the connector
pressure sensor and controller is exchanged with other sensor.
CN-705F Check wiring for possible failure according to the wiring checking procedure
CN-104F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-54
Error code D012
Trouble P1 unload proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Option conflux can not be done.
Control in the
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 unload proportional valve When D012 is cancelled and other error occurs by turning starter switch on
PSV-D after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 unload When D012 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-120F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-33
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-55
Error code D013
Trouble P1 unload proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Option conflux can not be done.
Control in the
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-1 P1 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 unload proportional valve When D013 is cancelled and other error occurs by turning starter switch on
PSV-D after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P1 unload When D013 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-120F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-56
Error code D022
Trouble P2 unload proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 unload proportional valve When D022 is cancelled and other error occurs by turning starter switch on
PSV-B after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 unload When D022 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-118F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-34
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-57
Error code D023
Trouble P2 unload proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Independent operations of boom up and of bucket digging/dump become slow.
Control in the
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-2 P2 UN-LOAD (BP-CUT)
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 unload proportional valve When D023 is cancelled and other error occurs by turning starter switch on
PSV-B after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between P2 unload When D023 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-118F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-58
Error code D032
Trouble Travel straight proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-3 S-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel straight proportional valve When D032 is cancelled and other error occurs by turning starter switch on
PSV-C after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Travel straight When D032 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-119F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-35
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-59
Error code D033
Trouble Travel straight proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Travel deviation occurs by combined operation of travel and attachment.
Control in the
Set Travel straight proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-3 S-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel straight proportional valve When D033 is cancelled and other error occurs by turning starter switch on
PSV-C after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Travel straight When D033 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-119F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-60
Error code D062
Trouble Arm-in spool 2 proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-4 ARM IN-2-SPEED
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in spool 2 proportional valve When D062 is cancelled and other error occurs by turning starter switch on
PSV-A after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Arm-in spool 2 When D062 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-121F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-36
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-61
Error code D063
Trouble Arm-in spool 2 proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom Operability of combined operation with arm-in becomes poor.
Control in the
Set Arm-in spool 2 proportional valve output to 0mA.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 8 D-4 ARM IN-2-SPEED
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm-in spool 2 proportional valve When D063 is cancelled and other error occurs by turning starter switch on
PSV-A after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
2 • Wiring between Arm-in spool 2 When D063 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-121F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-62
Error code E012
Trouble P1 pump proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump proportional valve When E012 is cancelled and other error occurs by turning starter switch on
PSV-P1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P1 pump When E012 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-141F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-37
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-63
Error code E013
Trouble P1 pump proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-1 PUMP P1
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P1 pump proportional valve When E013 is cancelled and other error occurs by turning starter switch on
PSV-P1 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P1 pump When E013 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-141F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-64
Error code E022
Trouble P2 pump proportional valve and output transistor ON are failure.
Judging
The feed-back value from proportional valve is 1000mA or more.
condition
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump proportional valve When E022 is cancelled and other error occurs by turning starter switch on
PSV-P2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P2 pump When E022 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-142F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-38
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-65
Error code E023
Trouble P2 pump proportional valve’s wiring is disconnected.
Judging The feed-back value from proportional valve is 100mA or less.
condition (If output is 100mA or less, judging is not done.)
Symptom The delicate operability of P2 pump related attachment becomes poor.
Control in the Set proportional valve output rate of P1 and P2 pumps to 0mA.
event of failure (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it
normal condition again.
Service Screen No. 9 E-2 PUMP P2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • P2 pump proportional valve When E023 is cancelled and other error occurs by turning starter switch on
PSV-P2 after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
When replacing of connector is executed, turn off power source once.
2 • Wiring between P2 pump When E023 is displayed after turning the starter switch on after the connector
proportional valve and controller is exchanged with other sensor.
CN-142F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
When replacing of connector is executed, turn off power source once.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-66
Error code F011
Trouble ATT boost solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom ATT boost is not available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-1 POWER BOOST
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • ATT boost solenoid valve When F011 is cancelled and other error occurs by exchanging the connector
SV-2 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between ATT boost When F011 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-117F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-39
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-67
Error code F013
Trouble ATT boost solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom ATT boost is not available or is leaving available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Service Screen No. 3 F-1 POWER BOOST
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • ATT boost solenoid valve When F013 is cancelled and other error occurs by exchanging the connector
SV-2 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between ATT boost When F013 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-117F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-68
Error code F021
Trouble Swing parking solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Swing parking is not available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-2 SWING-BRAKE
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing parking solenoid valve When F021 is cancelled and other error occurs by exchanging the connector
SV-1 for other solenoid valve. Check solenoid valve unit for possible failure. If
failure found, replace it.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between swing parking When F021 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-123F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-40
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-69
Error code F023
Trouble Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Swing parking is not available or is leaving available.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is output.
normal condition
Service Screen No. 3 F-1 POWER BOOST
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing parking solenoid valve When F023 is cancelled and other error occurs by exchanging the connector
SV-1 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between swing parking When F023 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-123F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-70
Error code F031
Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Travel 2 speed is not obtainable.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is 24V level while exciting command is output.
normal condition
Service Screen No. 3 F-3 1/2-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel 1, 2speed solenoid valve When F031 is cancelled and other error occurs by exchanging the connector
SV-3 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between travel 1, 2speed When F031 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-122F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-41
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-71
Error code F033
Trouble Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Symptom Travel 2 speed is not obtainable or is keeping 1 speed.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is grounding level while exciting command is not output.
normal condition
Service Screen No. 3 F-3 1/2-TRAVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel 1, 2speed solenoid valve When F033 is cancelled and other error occurs by exchanging the connector
SV-3 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between travel 1, 2speed When F033 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-122F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-72
Error code F041
Option selector solenoid valve and output transistor OFF are failure, and grounding is short-
Trouble
circuit.
Judging
The feed-back signal is grounding level while exciting command is output.
condition
Symptom Option selector valve does not change to breaker side.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is ground level while exciting command is output.
normal condition
Service Screen No. 11 F-4 OPT SELECT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector solenoid valve When F041 is cancelled and other error occurs by exchanging the connector
SV-13 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between option selector When F041 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-251F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-42
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-73
Error code F043
Trouble Option selector solenoid valve and output transistor ON are failure, and disconnection.
Judging
The feed-back signal is 24V level while exciting command is not output.
condition
Option selector valve does not change to breaker side or it does not change from breaker to
Symptom
nibbler.
Control in the
Normal control
event of failure
Returned in
The feed-back signal is ground level while exciting command is not output.
normal condition
Service Screen No. 11 F-4 OPT SELECT
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Option selector solenoid valve When F043 is cancelled and other error occurs by exchanging the connector
SV-13 for other solenoid valve.
Check solenoid valve unit for possible failure. If failure found, replace it.
2 • Wiring between option selector When F043 is displayed after the connector is exchanged with other solenoid
solenoid valve and controller valve.
CN-251F Check wiring for possible failure according to the wiring checking procedure
CN-105F and repair it if necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-74
Error code G032
Trouble Mechatro controller direct input speed sensor is overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
2 • Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure
sensor and controller and repair it if necessary.
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)

46-43
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-75
Error code G033
Trouble Mechatro controller direct input speed sensor, Disconnection
Judging
Voltage of alternator is 12V or more, and speed sensor indicates excess low engine rpm.
condition
Symptom Operate without problem.
Control in the
Receive rpm from engine controller and control the rpm.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
2 • Wiring between engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
CN-136F
CN-106F
3 • Mechatro controller Check that the error is corrected after replacement of controller.
(Controller is broken by only applying power to grounding of signal.)

Table46-76
Error code G042
Mechatro controller direct input speed sensor and received data from engine controller are
Trouble
overrun.
Judging
Engine rpm input is 3000rpm or more. (Only trouble history)
condition
Symptom Operate without problem.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
• Wiring between engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
2
CN-136F Especially check wiring for false disconnection and noise included.
CN-106F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
pressure sensor and controller Especially check wiring for false disconnection and noise included.
Check that the error is corrected after replacement of controller.
4 • Mechatro controller
(Controller is broken by only applying power to grounding of signal.)
5 • Engine controller Check that the error is corrected after replacement of controller.

46-44
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-77
G043
When cranking is executed for five seconds or more, this error code might be displayed. In case
Error code that the engine does not start, check by the table of "Section 47.3 Engine related
Troubleshooting". Execute the following check when the error code G043 is displayed after
starting the engine.
Mechatro controller direct input speed sensor and received data from engine controller are
Trouble
disconnected.
Judging Voltage of alternator is 12V or more, and speed sensor and receipt data from engine controller
condition indicate excess low engine rpm.
Symptom Engine speed down may cause extension by abrupt loading.
Control in the
Enter 0 rpm for engine speed. Enter 0 for ESS power shift command.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-3 MEAS 1 (for mechatro controller)
diagnosis Screen No. 2 G-3 MEAS 2 (receive from engine controller)
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine speed sensor Measure the resistance between terminals of speed sensor.
SE-13 Normal value: 1.6~2.0k
• Wiring between engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
2
CN-136F
CN-106F
3 • Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure
speed sensor and controller and repair it if necessary.
pressure sensor and controller
Check that the error is corrected after replacement of controller.
4 • Mechatro controller
(Controller is broken by only applying power to grounding of signal.)
5 • Engine controller Check that the error is corrected after replacement of controller.

46-45
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-78
Error code H013
Trouble Accel potentiometer is disconnected.
Judging
The input voltage from accel potentiometer is 0.1V or less.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 H-1 ACCEL VOLT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Accel potentiometer Measure the resistance between terminals of speed sensor. 1.6~2.4k
SE-16 Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-402F
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-79
Error code H014
Trouble Accel potentiometer’s power source is shortcut.
Judging
The input voltage from accel potentiometer is 4.7V or more.
condition
Symptom LOW idling is fixed.
Control in the
LOW idling is fixed.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 H-1 ACCEL VOLT.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Accel potentiometer Measure the resistance between terminals of accel potentiometer.
SE-16 1.6~2.4k
Turn the potentiometer and measure resistance between signal and GND.
2 • Wiring between accel Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-402F
CN-102F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-46
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-80
Error code H023
Trouble Boom angle potentiometer’s wiring is disconnected.
Judging
The input voltage from boom angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 12 H-2 BOOM
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0~6.0k
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between boom angle Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-702F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-81
Error code H024
Trouble Boom angle potentiometer’s power source is shortcut.
Judging
The input voltage from boom angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 12 H-2 BOOM
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Boom angle potentiometer Measure the resistance between terminals of boom angle potentiometer.
SE-17 4.0~6.0k
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between boom angle Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-702F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-47
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-82
Error code H033
Trouble Arm angle potentiometer’s wiring is disconnected.
Judging
The input voltage from arm angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 12 H-3 ARM
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-19 4.0~6.0k
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between arm angle Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-703F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-83
Error code H034
Trouble Arm angle potentiometer’s power source is shortcut.
Judging
The input voltage from arm angle potentiometer is 0.1V or less.
condition
Symptom Indications of rating load and working radius of High-reach crane become abnormal.
Control in the
Normal control
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 12 H-3 ARM
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Arm angle potentiometer Measure the resistance between terminals of arm angle potentiometer.
SE-19 4.0~6.0k
Turn the potentiometer and measure resistance between signal and GND.
Normal value: 0 to all resistance (4.0~6.0)k
2 • Wiring between arm angle Check wiring for possible failure according to the wiring checking procedure
potentiometer and controller and repair it if necessary.
CN-703F
CN-103F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-48
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-84
Error code H091
Trouble Fuel sensor grounding is short-circuited.
Judging
The input voltage from fuel sensor is 0.1V or less.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 10 H-9 FUEL LEVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ~ FULL 5
2 • Wiring between fuel Check wiring for possible failure according to the wiring checking procedure
sensor and controller and repair it if necessary.
CN-152F
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-85
Error code H093
Trouble Fuel sensor’s wiring is disconnection.
Judging
The input voltage from fuel sensor is 4.7V or more.
condition
Symptom Warning for low fuel level is indicated.
Control in the
Fuel level becomes 0%.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 10 H-9 FUEL LEVEL
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Fuel sensor potentiometer Move fuel sensor and measure the resistance between terminals of fuel
SE-15 sensor.
EMPTY 95 ~ FULL 5
2 • Wiring between fuel Check wiring for possible failure according to the wiring checking procedure
sensor and controller and repair it if necessary.
CN-152F
CN-104F
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-49
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-86
Error code I111
Trouble Reception of CAN1 communication is abnormal. (Passive error)
Judging
Reception from engine controller can not receive correctly.
condition
Symptom It has been affected little.
Control in the
Keep the last receiving condition.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiring between ECU Check wiring for possible failure according to the wiring checking procedure
and controller and repair it if necessary.
CN-3F (There is a possibility of false disconnection.)
CN-101F
2 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-87
Error code I113
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Reception from gauge cluster can not receive correctly. It has been affected little.
condition
Symptom It has been affected little.
Control in the
It can be operated in condition that coolant temperature is 20°C.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No. 2 G-5 WATER TEMP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiring between ECU Check wiring for possible failure according to the wiring checking procedure
and controller and repair it if necessary.
CN-3F
CN-101F
2 • Mechatro controller Check that the error is corrected after replacement of controller.

46-50
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-88
Error code I313
Trouble Reception of cluster communication is abnormal. (Time-out error)
Judging
Reception from gauge cluster can not receive correctly.
condition
Symptom Switch operation of gauge cluster can not be done.
Control in the
Keep the condition after immediately key-on is operated.
event of failure
Returned in
It returns automatically in normal condition.
normal condition
Service Screen No.
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiring between gauge cluster Check wiring for possible failure according to the wiring checking procedure
and controller and repair it if necessary.
CN-600F
CN-101F
2 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-89
Error code K014
Trouble Battery relay contact welded
Judging The power 24V is continuously supplied to controller for 40 seconds or more while the key switch
condition ON signal turned OFF
The power on the battery relay secondary side does not turn OFF even if the key switch is turned
Symptom
OFF.
Control in the
Normal control with key switch OFF
event of failure
Returned in Turn key switch ON.
normal condition Or when the power supply 24V to mechatro controller is stopped
Service Screen No. 4 K-1 AIS RELAY 2
diagnosis Screen No. 4 K-3 KEY SWITCH OFF
checking screen Screen No.
Checking object Checking contents and remedy
1 • Battery relay Turn key switch off and disconnect the connector (CN-256F) on the battery
R-1 relay coil. If 24V power lives on battery relay secondary side, check on battery
CN-256F relay for failure and replace it if failed.
Turn off the key switch, and remove the connector (CN-256F) on the battery
• Auto idle stop relay 2 relay coil side. If power of battery relay on secondary side falls, remove either
R-24 auto idling stop relay 2 or alternator relay.
2
• Alternator relay The failure may be occurred in case where the power falls after the relay was
R-28 removed, and therefore check on the relay unit and replace it with new one if
failed.
3 • Wiring between auto idle stop When K014 is left displayed with the relay removed
relay/alternator relay and Check that no power 24V is produced on relay (-) line according to the wiring
controller checking procedure and replace it if necessary.
CN-109F, CN2-1 When no failure found after checking on wiring and K014 is left displayed
• Fuse& relay box Replace fuse/relay box.
E-1
4 • Mechatro controller Check that the error is corrected after replacement of controller.

46-51
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-90
Error code R014
Trouble Wiper motor arc prevention relay error
Judging The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the
condition power source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 PREVENT ARC
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor arc prevention relay When error is cancelled after removing wiper motor arc prevention relay,
R-31 check relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between wiper motor arc
prevention relay and controller
CN-109F, CN2-1
• Fuse & relay box
E-1
3 • Mechatro controller
When R014 is left displayed with the relay removed
Check that no power 24V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
When no failure found after checking on wiring and R014 is left displayed
Replace fuse/relay box.
Check that the error is corrected after replacement of controller.

46-52
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-91
Error code R024
Trouble Wiper motor forward rotation relay error
Judging The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the
condition power source.
Symptom Wiper does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 CW MOTOR RLY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor forward rotation When error is cancelled after removing wiper motor forward rotation relay,
relay check relay unit for failure, replace it with new one if failed.
R-29 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between wiper motor
forward rotation relay and
controller
CN-109F, CN2-1
•Fuse & relay box
E-1
3 • Mechatro controller
When R024 is left displayed with the relay removed
Check that no power 24V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
When no failure found after checking on wiring and R024 is left displayed
Replace fuse/relay box.
Check that the error is corrected after replacement of controller.

46-53
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-92
Error code R034
Trouble Wiper motor reverse rotation relay error
Judging The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the
condition power source.
Symptom Wiper does not move after forward rotation.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 CCW MOTOR RLY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay,
relay check relay unit for failure, replace it with new one if failed.
R-30 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between wiper motor
forward rotation relay and
controller
CN-109F, CN2-1
•Fuse & relay box
E-1
3 • Mechatro controller
When R034 is left displayed with the relay removed
Check that no power 24V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
When no failure found after checking on wiring and R034 is left displayed
Replace fuse/relay box.
Check that the error is corrected after replacement of controller.

46-54
 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-93
Error code R044
Trouble Washer motor relay error
Judging
The mechatro controller output line to washer motor relay is short-circuited with the power source.
condition
Symptom Washer motor does not move.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 25 MOTOR RELAY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Washer motor relay When error is cancelled after removing washer motor relay, check relay unit
R-32 for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between washer motor
relay and controller
CN-112F, CN2-1
•Fuse & relay box
E-1
3 • Mechatro controller
When R044 is left displayed with the relay removed
Check that no power 24V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
When no failure found after checking on wiring and R044 is left displayed
Replace fuse/relay box.
Check that the error is corrected after replacement of controller.

Table46-94
Error code R134
Trouble Swing flasher relay error
Judging
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
condition
Symptom Right swing flasher does not light.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 22 D13
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher relay,
R-19 check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal condition.

2 • Wiring between swing flasher When R134 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F figure C) according to the wiring checking procedure and replace it if
necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

46-55
46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-95
Error code R144
Trouble Swing flasher relay error
Judging
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
condition
Symptom Left swing flasher does not light.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 22 D14
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Swing flasher relay When error is cancelled after removing connector (CN-74F) of swing flasher relay,
R-19 check relay unit for failure, replace it with new one if failed.
When resistance between relays (HB) and (HC) is 0 , it is in abnormal condition.

2 • Wiring between swing flasher When R144 is left displayed with the relay removed
relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper
CN-74F, CN-109F figure B) according to the wiring checking procedure and replace it if
necessary.
3 • Mechatro controller Check that the error is corrected after replacement of controller.

Table46-96
Error code R154
Trouble Travel alarm relay error
Judging
The mechatro controller output line to travel alarm relay is short-circuited with the power source.
condition
Symptom Travel alarm does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 23 D15
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Travel alarm relay When error is cancelled after removing of travel alarm relay, check relay unit
R-8 for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between travel alarm
relay and controller
CN-109F, CN2-2
•Fuse & relay box
E-1
3 • Mechatro controller
When R154 is left displayed with the relay removed
Check that no power 24V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
When no failure found after checking on wiring and R154 is left displayed.
Replace fuse/relay box.
Check that the error is corrected after replacement of controller.

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 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-97
Error code R164
Trouble Auto idle stop relay 2 relay error
Judging The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power
condition source.
Power source for mechatro controller often turns off.
Symptom
Auto idle stop relay 2 does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-1 AIS RELAY 2
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Auto idle stop relay 2 relay When error is cancelled after removing of auto idle stop relay 2, check relay
R-24 unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between auto idle
stop relay 2 and controller
CN-109F, CN2-2
•Fuse & relay box
E-1
3 • Mechatro controller
When R164 is left displayed with the relay removed
Check that no power 24V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
When no failure found after checking on wiring and R164 is left displayed.
Replace fuse/relay box.
Check that the error is corrected after replacement of controller.

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46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-98
Error code R174
Trouble Engine forcibly stop relay error
Judging The mechatro controller output line to engine forcibly stop is short-circuited with the power
condition source.
When key switch is turned off but engine does not stop.
Symptom
Engine auto idle stop function does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-3 ENG STOP
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Engine forcibly stop relay When error is cancelled after removing of engine forcibly stop relay, check
R-25 relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between engine
forcibly
stop relay and controller
CN-109F, CN2-2
• Fuse & relay box
E-1
3 • Mechatro controller
When R174 is left displayed with the relay removed
Check that no power 24V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
When no failure found after checking on wiring and R174 is left displayed.
Replace fuse/relay box.
Check that the error is corrected after replacement of controller.

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 46. TROUBLE SHOOTING (BY ERROR CODES)

Table46-99
Error code R184
Trouble Safety lock lever relay error
Judging The mechatro controller output line to safety lock lever relay is short-circuited with the power
condition source.
Symptom Safety lock lever timer does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-4 LOCK LEVER
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Safety lock lever relay When error R184 is cancelled after removing of safety lock lever relay, check
R-26 relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between safety lock
lever relay and controller
CN-109F, CN2-2
• Fuse & relay box
E-1
3 • Mechatro controller
When R184 is left displayed with the relay removed
Check that no power 24V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
When no failure found after checking on wiring and R184 is left displayed.
Replace fuse/relay box.
Check that the error is corrected after replacement of controller.

Table46-100
Error code R214
Trouble Safety relay error
Judging
The mechatro controller output line to safety relay is short-circuited with the power source.
condition
Symptom Safety relay does not actuate.
Control in the
Relay output is stopped.
event of failure
Returned in
When the power is OFF
normal condition
Service Screen No. 4 K-2 SAFETY RLY
diagnosis Screen No.
checking screen Screen No.
Checking object Checking contents and remedy
1 • Safety lock lever relay When error R214 is cancelled after removing of safety relay, check relay unit
R-26 for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.

2 • Wiring between safety lock
lever relay and controller
CN-109F, CN2-2
• Fuse & relay box
E-1
3 • Mechatro controller
When R214 is left displayed with the relay removed
Check that no power 24V is produced on relay (-) line according to the wiring
checking procedure and replace it if necessary.
When no failure found after checking on wiring and R214 is left displayed.
Replace fuse/relay box.
Check that the error is corrected after replacement of controller.

46-59
46. TROUBLE SHOOTING (BY ERROR CODES)

[MEMO]

46-60
 47. TROUBLESHOOTING
(BY TROUBLE)
TABLE OF CONTENTS

47.1 HYDRAULIC SYSTEM ....................................................................................................47-3

47.2 ELECTRIC SYSTEMS .....................................................................................................47-27
47.2.1 WIRING CHECKING PROCEDURE ......................................................................47-27
47.2.2 TROUBLE...............................................................................................................47-30
47.3 ENGINE RELATED TROUBLESHOOTING ....................................................................47-33

47

Book Code No. S5LC4711E02

47-1
47. TROUBLESHOOTING (BY TROUBLE)

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC4711E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)
S5LC4711E02
Revision February, 2007 ↑ K
(ASIA, OCE)

47-2
 47. TROUBLESHOOTING (BY TROUBLE)

47.1 HYDRAULIC SYSTEM

Preface:
The troubleshooting for the failures shown below is explained here.
Identify the failure and trouble and carry forward the troubleshooting in order of the failure item number.

(1) All controls do not function/slow

(2) Engine down/stalled
(3) Move at lever neutral position
(4) Poor fine operability
(5) Slow boom up, insufficient power
(6) Slow boom down, insufficient power for lifting up body
(7) Slow arm in, insufficient power
(8) Slow independent arm out (in the air)
(9) Slow bucket digging
(10)Slow bucket dumping
(11)Swing operation not functioned/slow
(12)Noise during swing operation
(13)Swing on a slope drifts when control lever is in neutral position
(14)Swing drifts when swing operation is stopped
(15)Slow travel speed/weak
(16)Travel deviation
(17)Travel 1st/2nd speed not changed
(18)Travel parking on a slope is not held
(19)Travel does not run straightly when both crawlers and attachment operated simultaneously.
(20)Slow breaker (crusher) operation, weak power
(21)Option selector valve malfunction: not switched to breaker circuit
(22)Option selector valve malfunction: not switched to nibbler circuit

47-3
47. TROUBLESHOOTING (BY TROUBLE)

(1) All controls do not function/slow

No. Sections Contents/normal value Corrective action, others

1 Fuse Check fuse No.4 If the fuse is blown out, check on
(10A) the short-circuited section.
2 Safety lever lock Carry out service No.4 K-4 switch: Check action of switch by tester,
switch diagnosis Push down the lever and it turns on, push or check that the power voltage
up and it turns off. is lowered by pushing the lever
down.
3 Safety lever lock Check that the Measure both terminals of solenoid Check solenoid unit for possible
switching solenoid is switched connector. 24V by pushing the lever down, failure.
correctly 0V by pushing it up Check harness for possible
failure.
4 Safety lever lock relay Carry out service No.4 K-4 lock lever: Check action of relay by tester
diagnosis Push down the lever and it turns off, push
up and it turns on.
5 Pilot pressure sensor •Stop engine stop and key is on position. Check 5V power for controller
All pilot low pressure sensors are 0MPa to
0.1MPa.
6 Solenoid valve for Measure pressure of About 0MPa by pushing the lever up, and Replace solenoid valve
safety lock lever solenoid A1 port 4MPa or more by push it down.
7 Pilot line filter Disassemble and Check filter for clogging Clean filter
check it visually
8 Pilot gear pump Measure pilot primary Check that it is 4MPa or more in high idling Check gear pump and the relief
pressure at gear valve for possible failure
pump
9 Multi control valve (in Change position Since all are blocked due to poor switching
case that travel is performance, check that the lever select
operable) pattern is set to the proper position.
10 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.3 Boom up full lever & relief proportional valve and controller
for possible failure.
11 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure 0.5~1.2MPa in boom up full lever and high
directly at the ports A7 idling operation
and A5 of 8 sections
solenoid block
12 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis. E-2 P2 pump largely differed from the actually
pump proportional •See Service Diagnosis Data List measured value, check
valve Operation No.18 Travel right full lever & proportional valve and controller
idling for possible failure.
Operation No.19 Travel left full lever &
idling
13 Secondary pressure of Measure the pump Check that pump proportional valve Replace proportional valve
pump proportional proportional valve secondary pressure is 2.7MPa or more in
valve secondary pressure right (left) travel full lever and high idling
directly in idling operation
operation. (Ports a3, Right travel: P1 pump proportional valve
a4) Left travel: P2 pump proportional valve

47-4
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

14 Main relief pressure Carry out service •See Service Diagnosis Data List Measure the relief pressure
diagnosis Operation No.3 Boom up full lever & relief actually
15 Check set pressure Check that P1 and P2 pump pressures are Reset or replace
32MPa in boom up full lever, high idling
and H mode operation.
16 Pump regulator Visual check When removing, free from abnormal Replace
resistance against sliding.
Free from abnormal damage, etc on
outside surface
Spring free from breakage, damage, etc.
17 Pump Visual check When removing, inside parts (cylinder Replace
block, piston, valve plate, shaft, etc.) are
free from abnormal resistance against
sliding, abnormal damage, etc.

(2) Engine down/stalled

No. Sections Contents/normal value Corrective action, others

1 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No. 1 Operation is nil proportional valve and controller
for possible failure.
2 Secondary pressure of Measure the pump Check that P1/P2 pump proportional Replace proportional valve
P1, P2 pump proportional valve valve pressures are within the range of
proportional valve secondary pressure 0.5 to 1.0MPa in control lever neutral
directly (Ports a3, a4) and high idling operation.
3 Pressure sensor of P1, Check pressure •See Service Diagnosis Data List Check pressure sensor and
P2 pump Operation No. 1 Operation is nil replace it if necessary
Operation No.3 Boom up full lever &
relief
4 Pump regulator Visual check When removing, free from abnormal Replace
resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring free from breakage, damage,
etc.
5 Pump Visual check When removing, inside parts (cylinder Replace
block, piston, valve plate, shaft, etc.)
are free from abnormal resistance
against sliding, abnormal damage, etc.

(3) Move at lever neutral position

No. Sections Contents/normal value Corrective action, others

1 Pilot pressure sensor Carry out service Check that targeted pilot pressure of Check remote control valve
diagnosis sensor is 0MPa in high idling
2 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
3 Main spool Check targeted spool Check that spool is free from abnormal Replace
visually damage and spring is free from
breakage
4 Over load relief valve Check targeted spool Free from dust entered in port relief Replace
visually valve. Seat is free from abnormality

47-5
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

5 Lock valve poppet Check targeted poppet Seat is free from abnormality Replace
(in case of boom and visually
arm)
6 Lock valve selector Exchange lock valve Check that the trouble is reversed Replace
(in case of boom and selector of boom/arm
arm) and boom/arm
7 Holding valve spool for Check that smooth Free from abnormal resistance against Replace
boom sliding of spool in sleeve sliding Do not pull spool out of sleeve
(in case of boom) forcibly.
8 Holding valve relief Check targeted spool Filter free from abnormal Replace
valve for boom visually contamination
(in case of boom)
9 Cylinder Check targeted cylinder Make sure of no problem of seals by Replace cylinder or seals
visually disassembling and investigation

(4) Poor fine operability

No. Sections Contents/normal value Corrective action, others

1 Pressure sensor Carry out service •See Service Diagnosis Data List Replace pressure sensor
diagnosis Operation No. 1 Operation is nil
•All low pressure sensors are 0MPa to
0.1MPa
2 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No. 1 Operation is nil proportional valve and controller
for possible failure.
3 Secondary pressure of Measure the Check that P1/P2 unloads secondary Replace proportional valve
unload proportional proportional valve pressures is within the range of
valve secondary pressure 2.7MPa or more in control lever neutral
directly at the ports A7 and high idling operation
and A8 of 8 sections
solenoid block
4 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No. 1 Operation is nil proportional valve and controller
for possible failure.
5 Secondary pressure of Measure the pump Check that P1/P2 pump proportional Replace proportional valve
P1, P2 pump proportional valve valve pressures are within the range of Check regulator
proportional valve secondary pressure 0.5~1.0MPa in control lever neutral
directly. (Ports a3, a4) and high idling operation
6 Slow return check valve Visual check Check that slow return check valve Clean and replace
of pilot line installed on pilot line is free from dust
(in case of boom up or entered
arm out)

47-6
 47. TROUBLESHOOTING (BY TROUBLE)

(5) Slow boom up, insufficient power

No. Sections Contents/normal value Corrective action, others

1 Boom up pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.3 boom up full lever and sensor
relief Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
control pressure of in boom up full lever and high idling When equipped with multi
boom up operation control valve, check it while
changing lever pattern
3 Pump pressure sensor Carry out service •See Service Diagnosis Data List When there is difference
diagnosis for P1, P2 Operation No.4 boom up full lever and between P1 and P2 pump
pump pressures in in operation pressures, check high pressure
operation. sensor.
4 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.3 Boom up full lever & proportional valve and controller
relief for possible failure.
5 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure 0.5~1.2MPa in boom up full lever and
directly at the ports A7 high idling operation
and A5 of 8 sections
solenoid block
6 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No.4 boom up full lever & in proportional valve and controller
operation for possible failure.
7 Secondary pressure of Measure the pump Check that P1/P2 pump proportional Replace proportional valve
P1, P2 pump proportional valve valve pressures are within the range of
proportional valve secondary pressure 2.1 to 3.0MPa in boom up full lever and
directly (Ports a3, a4) high idling operation
8 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean and replace
<Trouble> poppet and no contamination on orifice
Only P2 pressure is low. No problem for sliding ability of internal
piston (Check it through PBp2 port.)
9 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
10 Lock valve poppet Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Both P1 and P2 Free from abnormal damage, etc on damage)
pressures are low. outside surface
11 Conflux check valve Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Only P2 pressure is Free from abnormal damage, etc on damage)
high. outside surface
12 Holding valve for boom Visual check When removing, free from abnormal Replace
(poppet) resistance against sliding (Check on the casing side for
<Trouble> Free from abnormal damage, etc on damage)
Both P1 and P2 outside surface
pressures are high.

47-7
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

13 Boom spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Only P1 pressure is Spring is free from breakage. damage)
high.
14 Check boom spool and Disassembly and Free from abnormal resistance against Replace spool assembly
recirculation investigation sliding
<Trouble> Spring is free from breakage.
Only P1 pressure is low.
15 Conflux spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Only P2 pressure is Spring is free from breakage. damage)
high. Free from abnormal damage, etc on
outside surface
16 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 boom up full lever and
Relief pressure is low. relief
17 Over load relief valve Visual check (Head Pressure is 32MPa or more in boom up When only relief pressure of
<Trouble> side) full lever and high idling. Free from boom up is low, replace valve
Relief pressure is low. dust entered in over load relief valve.
Seat is free from abnormality

(6) Slow boom down/insufficient power for lifting up body

No. Sections Contents/normal value Corrective action, others

1 Boom down pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.5 boom down full lever sensor.
& in operation Check remote control valve.
2 Remote control valve Measure remote control Check that pressure is 3.0MPa or more Check remote control valve
pressure of boom down in boom down full lever and high idling When equipped with multi
directly operation control valve, check it while
changing lever pattern.
3 Actual measuring Carry out service P1 unload valve (cut valve) In case where the reading is
current value of P1 diagnosis •See Service Diagnosis Data List largely differed from the actually
unload proportional Operation No.5 boom down full lever & measured value, check
valve in operation proportional valve and controller
for possible failure.
4 Secondary pressure of Measure the Check that P1 unload secondary Replace proportional valve
P1 unload proportional proportional valve pressures are within the range of
valve secondary pressure 0.8~1.2MPa in boom down full lever
directly at the ports A7 of and high idling operation
8 sections solenoid
block.
5 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1 diagnosis •See Service Diagnosis Data List largely differed from the actually
pump proportional valve Operation No.5 boom down full lever measured value, check
& in operation proportional valve and controller
for possible failure.
6 Secondary pressure of Measure the pump Check that P1 pump proportional valve Replace proportional valve
P1 pump proportional proportional valve pressures are within the range of 1.9 to
valve secondary pressure 2.5MPa in boom down full lever and
directly (Ports a3, a4) high idling operation

47-8
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

7 Actual measuring Carry out service Check that the value is not change •Check pressure sensor of
current value of travel diagnosis regardless of operation travel
straight proportional •See Service Diagnosis Data List •In case where the reading is
valve Operation No. 1 Operation is nil largely differed from the
Operation No.18 Travel right full lever actually measured value, check
& idling proportional valve and
Operation No.19 Travel left full lever & controller for possible failure.
idling
8 Travel straight Measure directly the High idling pressure is 0.8MPa or less Replace proportional valve
proportional valve travel straight regardless neutral/operation
secondary pressure proportional valve
secondary pressure.
9 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
10 Lock valve poppet Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Boom down is low. Free from abnormal damage, etc on damage)
outside surface
11 Holding valve (poppet) Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding Free from (Check on the casing side for
Boom down is slow. abnormal damage, etc on outside damage)
surface
12 Boom spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Boom down is slow. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
13 Check boom spool and Disassembly and Free from abnormal resistance against Replace spool assembly
recirculation investigation sliding
<Trouble> Spring is free from breakage.
Machine can not be
lifted by supporting with
boom.
14 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 boom up full lever and
Relief pressure is low. relief
15 Over load relief valve Visual check Free from dust entered in port relief Replace
<Trouble> valve.
Machine can not be Seat is free from abnormality
lifted by supporting with
boom.

(7) Slow arm in, insufficient power

No. Sections Contents/normal value Corrective action, others

1 Arm in pressure sensor Carry out service •See Service Diagnosis Data List Check and replace pressure
diagnosis Operation No.6 arm in full lever and sensor
relief Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
pressure control pressure of arm in arm in full lever and high idling When equipped with multi
in operation control valve, check it while
changing lever pattern

47-9
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

3 Pump pressure sensor Carry out service •See Service Diagnosis Data List When there is difference
diagnosis for P1, P2 Operation No.7 arm in full lever and in between P1 and P2 pump
pump pressures in operation pressures, check high pressure
operation. sensor
4 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.6 Arm in full lever & proportional valve and controller
relief for possible failure.
5 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure 0.5~1.2MPa in arm in full lever and
directly at the ports A7 high idling operation.
and A5 of 8 sections
solenoid block.
6 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No.7 Arm in full lever & in proportional valve and controller
operation for possible failure.
7 Secondary pressure of Measure the pump Check that P1/P2 pump proportional Replace proportional valve
P1, P2 pump proportional valve valve pressures are 2.8MPa or more in
proportional valve secondary pressure arm in full lever and high idling
directly. (Ports a3, a4) operation. (Secondary pressure is
affected by oil temperature and
attachment weight)
8 Actual measuring Carry out service •See Service Diagnosis Data List In case where the reading is
current value of arm in diagnosis Operation No. 1 Operation is nil largely differed from the actually
spool 2 proportional Operation No.6 Arm in full lever & measured value, check
valve relief proportional valve and controller
Operation No.7 Arm in full lever & in for possible failure.
operation
9 Secondary pressure of Measure directly the Check that secondary pressure of Replace proportional valve
arm in spool 2 proportional valve proportional valve secondary
proportional valve secondary pressure at pressures are within the range of
the ports A8 (arm 2 following
spool) of 8 sections Lever neutral: 0MPa
solenoid block. Motion in the air: 1.7 to 2.2MPa
Arm in relief: 2.5MPa or more
10 Actual measuring Carry out service Check that the value is not change •Check pressure sensor of
current value of travel diagnosis regardless of operation travel
straight proportional •See Service Diagnosis Data List •In case where the reading is
valve Operation No. 1 Operation is nil largely differed from the
Operation No.18 Travel right full lever actually measured value, check
& idling proportional valve and
Operation No.19 Travel left full lever & controller for possible failure.
idling
11 Secondary pressure of Measure directly the 0.8MPa or less in high idling operation Replace proportional valve
travel straight proportional valve regardless of neutral/operation
proportional valve secondary pressure at
the ports A6 (travel
straight) of 8 sections
solenoid block

47-10
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

12 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
13 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 boom up full lever and
Relief pressure is low. relief
14 Over load relief valve Visual check (Head Pressure is 32MPa or more in arm in When only relief pressure of arm
<Trouble> side) and relief. in is low, replace valve
P1, P2 pressure is low. Free from dust entered in over load
relief valve.
Seat is free from abnormality
15 Over load relief valve Visual check (Rod side) Pressure is 32MPa or more in arm out When only relief pressure of arm
<Trouble> and relief. out is low, replace valve
P1, P2 pressure is low. Free from dust entered in over load
relief valve.
Seat is free from abnormality.
16 Arm 1 spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1, P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
17 Arm 2 spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1, P2 pressure is high Free from abnormal damage, etc on damage)
or low. outside surface
Spring is free from breakage.
18 Check arm 2 spool and Disassembly and Free from abnormal resistance against Replace spool assembly
recirculation investigation sliding
<Trouble> Spring is free from breakage.
Arm in power is poor.
19 Check lock valve poppet Visual check Free from abnormal resistance against Replace
<Trouble> sliding (Check on the casing side for
Both P1, P2 pressures Free from abnormal damage, etc on damage)
are high. outside surface

(8) Slow independent arm out (in the air)

No. Sections Contents/normal value Corrective action, others

1 Arm out pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.8 arm out full lever and sensor
relief Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
control pressure of arm in arm out full lever and high idling When equipped with multi
out operation control valve, check it while
changing lever pattern
3 Pump pressure sensor Carry out service •See Service Diagnosis Data List When there is difference
diagnosis for P1, P2 Operation No.9 arm out full lever and between P1 and P2 pump
pump pressures in in operation pressures, check high pressure
operation. sensor
4 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.8 Arm out full lever & proportional valve and controller
relief for possible failure.

47-11
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

5 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure 0.5~1.2MPa in arm out full lever and
directly at the ports A7 high idling operation
and A5 of 8 sections
solenoid block
6 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No.9 Arm out full lever & in proportional valve and controller
operation for possible failure.
7 Secondary pressure of Measure the pump Check that P1/P2 pump proportional Replace proportional valve
P1, P2 pump proportional valve valve pressures are within the range of
proportional valve secondary pressure 1.7 to 2.9MPa in arm out full lever and
directly (Ports a3, a4) high idling operation
(Secondary pressure is affected by oil
temperature and attachment weight)
8 Actual measuring Carry out service Check that the value is not change •Check pressure sensor of
current value of travel diagnosis regardless of operation travel
straight proportional •See Service Diagnosis Data List •In case where the reading is
valve Operation No. 1 Operation is nil largely differed from the
Operation No.18 Travel right full lever actually measured value, check
& idling proportional valve and
Operation No.19 Travel left full lever & controller for possible failure.
idling
9 Secondary pressure of Measure directly the 0.8MPa or less in high idling operation Replace proportional valve
travel straight proportional valve regardless of neutral/operation
proportional valve secondary pressure at
the ports A6 (travel
straight) of 8 sections
solenoid block
10 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
11 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 boom up full lever and
Relief pressure is low. relief
12 Over load relief valve Visual check (Rod side) Pressure is 32MPa or more in arm out When only relief pressure of arm
<Trouble> and relief. out is low, replace valve
P1, P2 pressure is low. Free from dust entered in over load
relief valve. Seat is free from
abnormality
13 Arm 1 spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
14 Arm 2 spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.

47-12
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

15 Check arm 2 spool and Disassembly and Free from abnormal resistance against Replace spool assembly
recirculation investigation (spring sliding
<Trouble> side) Spring is free from breakage.
Both P1, P2 pressures
are low.
16 Check lock valve poppet Visual check Free from abnormal resistance against Replace
<Trouble> sliding (Check on the casing side for
Both P1, P2 pressures Free from abnormal damage, etc on damage)
are high. outside surface

(9) Bucket digging is slow

No. Sections Contents/normal value Corrective action, others

1 Bucket digging pressure Carry out service •See Service Diagnosis Data List Check and replace pressure
sensor diagnosis Operation No.12 bucket digging full sensor
lever and relief Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
control pressure of in bucket digging full lever and high When equipped with multi
bucket digging idling operation control valve, check it while
changing lever pattern
3 Pump pressure sensor Carry out service •See Service Diagnosis Data List When there is difference
diagnosis for P1, P2 Operation No.13 Bucket digging full between P1 and P2 pump
pump pressures in lever and in operation pressures, check high pressure
operation. sensor
4 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.12 Bucket digging full proportional valve and controller
lever & relief for possible failure.
5 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure 0.5~1.2MPa in bucket digging full lever
directly at the ports A7 and high idling operation
and A5 of 8 sections
solenoid block
6 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No.13 Bucket digging full proportional valve and controller
lever & in operation for possible failure.
7 Secondary pressure of Measure the pump Check that P1 pump proportional valve Replace proportional valve
P1, P2 pump proportional valve pressures is 2.3MPa or more and P2
proportional valve secondary pressure pump proportional valve pressure is
directly (Ports a3, a4) 1.9 to 2.5MPa in bucket digging full
lever and high idling operation.
8 Attachment boost Carry out service No.3 POWER BOOST Check harness
solenoid command diagnosis Bucket digging COMP OFF MEAS Replace solenoid valve
OFF
9 Attachment boost Measure switching Check that pressure is 0MPa in bucket Replace solenoid valve
solenoid secondary valve secondary digging full lever and high idling
pressure pressure operation

47-13
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

10 Actual measuring Carry out service •See Service Diagnosis Data List In case where the reading is
current value of travel diagnosis Operation No.12 Bucket digging full largely differed from the actually
straight proportional lever & relief measured value, check
valve proportional valve and controller
for possible failure.
11 Secondary pressure of Measure directly the Check that travel straight secondary Replace proportional valve
travel straight proportional valve pressure is 2.7MPa or more in bucket
proportional valve secondary pressure at digging full lever and high idling
the ports A6 (travel operation
straight) of 8 sections
solenoid block
12 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean or replace
<Trouble> poppet and no contamination on orifice
Only P2 pressure is low. No problem for sliding ability of internal
piston (Check it through PBp2 port.)
13 Check stroke limiter Visual check When piston is removed from cover, it Replace
<Trouble> is free from abnormal resistance (Check on the casing side for
Both P1, P2 pressures against sliding damage.)
are high. Free from abnormal damage, etc on
outside surface
14 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
15 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
Operation No.3 Boom up full lever and
relief
16 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
17 Bucket spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Both P1, P2 pressures Free from abnormal damage, etc on damage)
are high. outside surface
Spring is free from breakage.
18 Over load relief valve Check targeted spool Free from dust entered in over load Replace
visually relief valve.
Seat is free from abnormality.

(10)Bucket dump is slow

No. Sections Contents/normal value Corrective action, others

1 Bucket dump pressure Carry out service
sensor diagnosis
2 Remote control valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
control pressure of
bucket dump
3 Pump pressure sensor Carry out service
diagnosis for P1, P2
pump pressures in
operation.
•See Service Diagnosis Data List
Operation No.14 Bucket dump full
lever and relief
in bucket dump full lever and high
idling operation
•See Service Diagnosis Data List
Operation No.15 Bucket dump full
lever and in operation
Check and replace pressure
sensor
Check remote control valve
When equipped with multi
control valve, check it while
changing lever pattern
When there is difference
between P1 and P2 pump
pressures, check high pressure
sensor

47-14
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

4 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.14 Bucket dump full proportional valve and controller
lever & relief for possible failure.
5 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure 0.5~1.2MPa in bucket dump full lever
directly at the ports A7 and high idling operation. Replace
and A5 of 8 sections proportional valve
solenoid block
6 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Carry out service Operation No.15 Bucket dump full proportional valve and controller
diagnosis. lever & in operation for possible failure.
7 Secondary pressure of Measure the pump Check that P1 pump proportional valve Replace proportional valve
P1, P2 pump proportional valve pressures is 1.6MPa or more and P2
proportional valve secondary pressure pump proportional valve pressure is
directly (Ports a3, a4) 1.6MPa or more in bucket dump full
lever and high idling operation.
8 Actual measuring Carry out service •See Service Diagnosis Data List In case where the reading is
current value of travel diagnosis Operation No.14 Bucket dump full largely differed from the actually
straight proportional lever & relief measured value, check
valve proportional valve and controller
for possible failure.
9 Secondary pressure of Measure directly the Check that travel straight secondary Replace proportional valve
travel straight proportional valve pressure is 2.7MPa or more in bucket
proportional valve secondary pressure at dump full lever and high idling
the ports A6 (travel operation
straight) of 8 sections
solenoid block
10 P2 by-pass cut valve Visual check No problem for sliding ability of main Clean and replace
<Trouble> poppet and no contamination on orifice
Only P2 pressure is low. No problem for sliding ability of internal
piston (Check it through PBP2 port.)
11 Check stroke limiter Visual check Free from abnormal damage and wear Replace
<Trouble> on outside of piston inside cover (Check on the casing side for
Pilot pressure is low. damage.)
12 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
13 Main relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.3 Boom up full lever and
Relief pressure is low. relief
14 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
15 Bucket spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
Both P1, P2 pressures Free from abnormal damage, etc on damage)
are high. outside surface
Spring is free from breakage.

47-15
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

16 Over load relief valve Check targeted spool Free from dust entered in over load Replace
visually relief valve.
Seat is free from abnormality.

(11)Swing does not move/slow

No. Sections Contents/normal value Corrective action, others

1 Swing pressure sensor Carry out service •See Service Diagnosis Data List Check and replace pressure
diagnosis Operation No.11 Swing full lever and sensor
in operation Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve
control pressure of in boom up full lever and high idling When equipped with multi
swing operation control valve, check it while
changing lever pattern
3 Swing parking brake Carry out service No.3 F-2 SWING-BRAKE Check swing pressure sensor
solenoid diagnosis Lever neutral: COMP. ON MEAS Check harness
ON Swing: COMP OFF MEAS OFF
Swing parking brake Measurement of Lever neutral: 0MPa Replace solenoid valve
4
solenoid solenoid valve A2 port In operation: 4MPa or more
5 Shuttle valve Visual check No contamination on spool cover Clean or replace
<Trouble> (short side) and orifice
Pilot pressure is low. No damage on spool cover (long side)
and shuttle
6 Pump pressure sensor Carry out service •See Service Diagnosis Data List Check high pressure sensor
diagnosis for P2 pump Operation No.11 Swing full lever and
pressures in operation in operation
7 Actual measuring Carry out service •No.8 D-2 P2 unload valve (cut valve) In case where the reading is
current value of P2 diagnosis •See Service Diagnosis Data List largely differed from the actually
unload proportional Operation No.11 Swing full lever & in measured value, check
valve operation proportional valve and controller
for possible failure.
8 Secondary pressure of Measure the Check that P2 unload secondary Replace proportional valve
P2 unload proportional proportional valve pressures are within the range of
valve secondary pressure 0.5~1.2MPa in swing full lever and high
directly at the ports A5 of idling operation
8 sections solenoid
block
9 Actual measuring Carry out service •No.9 E-2 P2 pump In case where the reading is
current value of P2 diagnosis largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No.11 Swing full lever & in proportional valve and controller
operation for possible failure.
10 Secondary pressure of Measure the pump Check that P2 pump proportional valve Replace proportional valve
P2 pump proportional proportional valve pressure is 2.7MPa or more in swing
valve secondary pressure full lever and high idling operation
directly (Ports a3, a4)
11 Actual measuring Carry out service Check that the value is not change •Check pressure sensor of
current value of travel diagnosis regardless of operation travel
straight proportional •See Service Diagnosis Data List •In case where the reading is
valve Operation No. 1 Operation is nil largely differed from the
(Check this trouble by Operation No.18 Travel right full lever actually measured value, check
only swing operation) & idling proportional valve and
Operation No.19 Travel left full lever & controller for possible failure.
idling

47-16
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

12 Secondary pressure of Measure directly the 0.8MPa or less in high idling operation Replace proportional valve
travel straight proportional valve regardless of neutral/operation
proportional valve secondary pressure at
(Check this trouble by the ports A6 (travel
only swing operation) straight) of 8 sections
solenoid block
13 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
14 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P2 pressure is low. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
15 Swing spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P2 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
16 Swing relief valve Check set pressure •See Service Diagnosis Data List Reset or replace
<Trouble> Operation No.10 Swing full lever and
Relief pressure is low. relief
17 Swing motor Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be free from
abnormal resistance against sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)
18 Swing reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
swing reduction gear metal powder. reduction gear
drain
19 Swing reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.

(12)Noise occurred at swing operation

No. Sections Contents/normal value Corrective action, others

1 Swing parking brake Carry out service No.3 F-2 SWING-BRAKE Check swing pressure sensor
solenoid diagnosis Lever neutral: COMP. ON MEAS. ON Check harness
Swing: COMP OFF MEAS OFF
2 Measurement of Lever neutral: 0MPa Replace solenoid valve
solenoid valve A2 port In operation: 4MPa or more
3 Boost check valve Visual check When removing, free from abnormal Replace
(Sound of cavitation at resistance against sliding
stopping) Spring is free from breakage.
4 By-pass check valve Visual check When removing, free from abnormal Replace
(Sound of cavitation at resistance against sliding
stopping) Spring is free from breakage.
5 Swing motor Visual check Disassemble and inspect abnormal Replace
(Brake valve/friction wear and scuffing
plate)
6 Swing motor piston Visual check When removing, free from abnormal Replace
resistance against sliding
Spring is free from breakage.

47-17
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

7 Swing reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
swing reduction gear metal powder. reduction gear
drain.
8 Swing reduction Visual check Tooth surface has no abnormally worn Replace
and chipped.

(13)Swing drifts on a slope while swing control lever is in neutral position

No. Sections Contents/normal value Corrective action, others

1 Swing pressure sensor Carry out service •Engine stop & starter key ON Check and replace pressure
diagnosis All pilot low pressure sensors are sensor
within range of 0 to 0.1MPa.
2 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
3 Swing parking brake Carry out service No.3 F-2 SWING-BRAKE Check swing pressure sensor
solenoid diagnosis Lever neutral: COMP. ON MEAS. ON Check harness
Swing: COMP OFF MEAS OFF Check parking brake release
switch
4 Measurement of Lever neutral: 0MPa Replace solenoid valve
solenoid valve A2 port In operation: 4MPa or more
5 Swing motor Visual check Disassemble and inspect abnormal Replace
(Brake valve/friction wear and scuffing
plate)
6 Parking brake Visual check Piston and friction plate do not have Replace
abnormal resistance against sliding
Free from spring damage

(14)Swing drifts at stopping

No. Sections Contents/normal value Corrective action, others

1 Shuttle valve
<Trouble>
Pilot pressure is low
2 Swing pressure sensor Carry out service
diagnosis
3 Swing relief valve
<Trouble>
Relief pressure is low.
4 Anti-reaction valve
5 Remote control valve
6 Swing motor
Visual check No contamination on spool cover Clean or replace
(short side) and orifice. No damage on
spool cover (long side) and shuttle.
•Engine stop & starter key ON Replace pressure sensor
All pilot low pressure sensors are
within range of 0 to 0.1MPa.
Check set pressure •See Service Diagnosis Data List Reset or replace
Operation No.10 Swing full lever and
relief
Visual check Free from dirt entering Clean or replace
Sliding part should be free from foreign
matter entering, abnormal damage and
wear.
Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
Visual check Inner parts (cylinder block, piston, Replace
valve brake etc) are to be free from
abnormal resistance against sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)

47-18
 47. TROUBLESHOOTING (BY TROUBLE)

(15)Travel speed is slow/poor

No. Sections Contents/normal value Corrective action, others

1 Travel right and left Carry out service •See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.18 Travel right full lever sensor
and idling Check remote control valve
Operation No.19 Travel left full lever
and idling
2 Remote control valve Measure directly remote Check that pressure is 2.1MPa or more Check remote control valve
control pressure of in travel right (left), forward (reverse)
travel right and left full lever and high idling operation
3 Actual measuring Carry out service •No.9 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.18 Travel right full lever proportional valve and controller
& idling for possible failure.
Operation No.19 Travel left full lever &
idling
4 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure followings in travel right (left), forward
directly at the ports A7 (reverse) full lever and high idling
and A5 of 8 sections operation
solenoid block Travel right (P1 unload): 0.5 to 1.0MPa
Travel left (P2 unload): 0.5 to 1.0MPa
5 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No.18 Travel right full lever proportional valve and controller
& idling for possible failure.
Operation No.19 Travel left full lever &
idling
6 Secondary pressure of Measure the pump Check that P1/P2 unload secondary Replace proportional valve
P1, P2 pump proportional valve pressures are within the range of
proportional valve secondary pressure followings in travel right (left), forward
directly (Ports a3, a4) (reverse) full lever and high idling
operation
Travel right (P1 pump): 2.7MPa or
more
Travel left (P2 pump): 2.7MPa or more
7 Actual measuring Carry out service Check that the value is not change •Check voltage of low pressure
current value of travel diagnosis regardless of operation sensor other than sensor for
straight proportional •See Service Diagnosis Data List travel
valve Operation No. 1 Operation is nil •In case where the reading is
Operation No.18 Travel right full lever largely differed from the
& idling actually measured value, check
Operation No.19 Travel left full lever & proportional valve and
idling controller for possible failure
8 Secondary pressure of Measure directly the 0.8MPa or less in high idling operation Replace proportional valve
travel straight proportional valve regardless of neutral/operation
proportional valve secondary pressure
9 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
Check sealing ability of shuttle valve
and entry of dust in orifice

47-19
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

10 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
11 Travel spool Visual check of targeted When removing, free from abnormal Replace
<Trouble> spool resistance against sliding (Check on the casing side for
Pump pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
12 Travel motor relief valve Check set pressure Check P1 and P2 pump pressures are If P1 is low, right travel motorÅfs
32MPa or more in right and left travel relief valve is failed.
levers full lever (relief operation at If P2 is low, left travel motorÅfs
locked crawler belt) and high idling relief valve is failed.
13 Travel motor Visual check Inner parts (piston, cylinder block, Replace
valve plate, brake valve spool) are to
be free from abnormal resistance
against sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)
14 Parking brake in travel Visual check When removing, free from abnormal Replace
motor resistance against sliding
No sticking on friction plate and
separator plate
15 Travel reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
travel reduction gear metal powder. reduction gear
drain
16 Travel reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.

(16)Travel deviation

No. Sections Contents/normal value Corrective action, others

1 Travel right and left Carry out service •See Service Diagnosis Data List Check and replace pressure
pressure sensor diagnosis Operation No.18 Travel right full lever sensor
and idling Check remote control valve
Operation No.19 Travel left full lever
and idling
2 Remote control valve Measure directly remote Check that pressure is 2.1MPa or more Check remote control valve
control pressure of in travel right (left), forward (reverse)
travel right and left full lever and high idling operation
3 Actual measuring Carry out service Check that the value is not change •Check voltage of low pressure
current value of travel diagnosis regardless of operation sensor other than sensor for
straight proportional •See Service Diagnosis Data List travel
valve Operation No. 1 Operation is nil •In case where the reading is
Operation No.18 Travel right full lever largely differed from the
& idling actually measured value, check
Operation No.19 Travel left full lever & proportional valve and
idling controller for possible failure.
4 Secondary pressure of Measure directly the 0.8MPa or less in high idling operation Replace proportional valve
travel straight proportional valve regardless of neutral/operation
proportional valve secondary pressure

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 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

5 Actual measuring Carry out service •No.8 D-1 P1 unload valve (cut valve) In case where the reading is
current value of P1/P2 diagnosis D-1 P2 unload valve (cut valve) largely differed from the actually
unload proportional •See Service Diagnosis Data List measured value, check
valve Operation No.18 Travel right full lever proportional valve and controller
& idling for possible failure.
Operation No.19 Travel left full lever &
idling
6 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of
proportional valve secondary pressure followings in travel right (left), forward
directly at the ports A7 (reverse) full lever and high idling
and A5 of 8 sections operation
solenoid block Travel right (P1 unload): 0.5 to 1.0MPa
Travel left (P2 unload): 0.5 to 1.0MPa
7 Actual measuring Carry out service •No.9 E-1 P1 pump In case where the reading is
current value of P1/P2 diagnosis E-2 P2 pump largely differed from the actually
pump proportional valve •See Service Diagnosis Data List measured value, check
Operation No.18 Travel right full lever proportional valve and controller
& idling for possible failure.
Operation No.19 Travel left full lever &
idling
8 Secondary pressure of Measure the pump Check that P1/P2 unload secondary Replace proportional valve
P1, P2 pump proportional valve pressures are within the range of
proportional valve secondary pressure followings in travel right (left), forward
directly (Ports a3, a4) (reverse) full lever and high idling
operation
Travel right (P1 pump): 2.7MPa or
more
Travel left (P2 pump): 2.7MPa or more
9 Exchange P1 for P2 Exchange delivery pipe Check the direction of deviation If the direction is changed,
of P1 for P2 inspect a pump. If the direction
is not changed, inspect a valve
and travel unit.
10 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage
Check sealing ability of shuttle valve
and entry of dust in orifice
11 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage
12 Travel spool Visual check of targeted When removing, free from abnormal Replace
<Trouble> spool resistance against sliding (Check on the casing side for
Pump pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage
13 Travel motor relief valve Check set pressure Check P1 and P2 pump pressures are If P1 is low, right travel motorÅfs
32MPa or more in right and left travel relief valve is failed.
levers full lever (relief operation at If P2 is low, left travel motorÅfs
locked crawler belt) and high idling relief valve is failed.
Replace as necessary

47-21
47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

14 Travel motor Visual check Inner parts (piston, cylinder block, Replace
valve plate, brake valve spool) are to
be free from abnormal resistance
against sliding.
Free from abnormal damage, etc on
outside surface (brake plate etc)
15 Travel reduction gear oil Take sample oil from Sampling oil does not include a lot of Disassemble and inspect
travel reduction gear metal powder. reduction gear
drain
16 Travel reduction Visual check Tooth surface is not worn abnormally Replace
and is not chipped.
17 Pump regulator Visual check When removing, free from abnormal Replace
resistance against sliding
Free from abnormal damage, etc on
outside surface
Spring free from breakage, damage,
etc.
18 Pump Visual check When removing, inside parts (cylinder Replace
block, piston, valve plate, shaft, etc.)
are free from abnormal resistance
against sliding, abnormal damage, etc.

(17)Travel 1/2 speed cannot be switched

(In case of the traveling under heavy loading (for example traveling on a slope or traveling on a soft ground), the
speed may sometimes does not change from 1st to 2nd because this machine equips the function of automatic
speed change.)

No. Sections Contents/normal value Corrective action, others

1 Travel 1/2 speed Carry out service Switch travel 1/2 speed to 2nd speed Check pressure sensor
switching solenoid diagnosis No.3 F-3 1/2-TRAVEL Check harness
Lever neutral COMP OFF MEAS OFF Check travel 1/2 speed switch
Travel operation COMP ON MEAS ON on gauge cluster
2 Travel 1/2 speed Measure A3 port Lever neutral: 0MPa Replace solenoid valve
switching solenoid pressure on solenoid In operation: 4MPa or more
valve
3 1/2 speed switching Visual check Check that spool is free from abnormal Replace
spool in travel motor damage and spring is free from (Check on the casing side for
breakage damage)
4 1/2 speed switching Visual check Free from entry of dust Remove dust or replace
orifice in travel motor
5 Tilting piston in travel Visual check Free from abnormal wear on piston Replace
motor and seal (Check on the casing side for
damage)

(18)Machine does not stay on a slope in traveling

No. Sections Contents/normal value Corrective action, others

1 Pilot pressure sensor Carry out service •Engine stop & starter key switch is ON Check pressure sensor and
diagnosis Targeted pilot low pressure sensor is replace as necessary
in range of 0 to 0.1MPa Check remote control valve
2 Remote control valve Check targeted remote Check that spool is free from abnormal Replace
control valve damage and spring is free from
breakage

47-22
 47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

3 Parking brake in travel Visual check When removing, free from abnormal Replace
motor resistance against sliding
Spring free from breakage, damage,
etc.
4 Orifice of passage for Visual check Free from entry of dust Remove dust or replace
parking brake in travel
motor

(19)Machine does not travel straight in simultaneous operation of traveling and attachment

No. Sections Contents/normal value Corrective action, others

1 Actual measuring Carry out service No.8 D-3 S-TRAVEL is should be •Check voltage of low pressure
current value of travel diagnosis COMP 580mA and MEAS 550 to sensor other than travel sensor
straight proportional 610mA in both travel full lever and in •In case where the reading is
valve boom up full lever at high idling largely differed from the
actually measured value, check
proportional valve and
controller for possible failure.
2 Secondary pressure of Measure directly the Check secondary pressure is within Replace proportional valve
travel straight proportional valve range of 1.8 to 2.2MPa in both travel
proportional valve secondary pressure full lever and in boom up full lever at
high idling
3 Travel straight spool Visual check When removing, free from abnormal Replace
resistance against sliding (Check on the casing side for
Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.

(20)Breaker works slowly and power is poor (In case of conflux, check p1 unload/pump and travel straight)

No. Sections Contents/normal value Corrective action, others

1 Pressure sensor for Carry out service •See Service Diagnosis Data List Check and replace pressure
optional attachment diagnosis Operation No.16 P2 side OPT full senso
lever and relief Check remote control valve
2 Remote control valve Measure directly remote Check that pressure is 2.1MPa or more Check remote control valve0
control pressure of in optional attachment full lever and
travel right and left high idling operation
3 Actual measuring Carry out service •See Service Diagnosis Data List •In case where the reading is
current value of P1/P2 diagnosis Operation No.16 P2 side OPT full largely differed from the
unload proportional lever and relief actually measured value, check
valve proportional valve and
controller for possible failure.
4 Secondary pressure of Measure the Check that P1/P2 unload secondary Replace proportional valve
P1, P2 unload proportional valve pressures are within the range of 0.5 to
proportional valve secondary pressure 1.2MPa
directly at the ports A7
and A5 of 8 sections
solenoid block
5 Actual measuring Carry out service •See Service Diagnosis Data List •Check voltage of low pressure
current value of travel diagnosis Operation No.16 P2 side OPT full sensor other than sensor for
straight proportional lever & relief optional attachment
valve •In case where the reading is
largely differed from the
actually measured value, check
proportional valve and
controller for possible failure.

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47. TROUBLESHOOTING (BY TROUBLE)

No. Sections Contents/normal value Corrective action, others

6 Secondary pressure of Measure directly the Check that travel straight secondary Replace proportional valve
travel straight proportional valve pressure is 2.7MPa or more in optional
proportional valve secondary pressure at attachment full lever and high idling
the ports A6 (travel operation
straight) of 8 sections
solenoid block
7 P1 by-pass cut valve Visual check No problem for sliding ability of main Clean or replace
<Trouble> poppet and no contamination on orifice
Only P1 pressure is low. No problem for sliding ability of internal
piston (Check it through PBp2 port.)
8 Relief pressure Check set pressure •See Service Diagnosis Data List Reset or replace
Operation No.16 P2 side OPT full
lever and relief
(Set value of factory shipment is
24.5MPa.)
9 Remote control valve Check targeted remote Check sealing ability of shuttle valve Replace
control valve and entry of dust in orifice.
10 Travel straight spool Visual check When removing, free from abnormal Replace
<Trouble> resistance against sliding (Check on the casing side for
P1 pressure is high. Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
11 Spool for optional Visual check When removing, free from abnormal Replace
attachment resistance against sliding (Check on the casing side for
<Trouble> Free from abnormal damage, etc on damage)
P1, P2 pressures are outside surface
high. Spring is free from breakage.
12 Over load relief valve Check targeted spool Free from dust entered in over load Replace
visually relief valve
Seat is free from abnormality.

(21)Selector valve for option malfunctions: Breaker circuit is not obtained.

(Indication of failure is displayed. For reference, see "Table47-1 Action of optional selector solenoid valve")

No. Sections Contents/normal value Corrective action, others

1 N&B selector spool Visual check When removing, free from abnormal Replace
resistance against sliding (Check on the casing side for
Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage
2 N&B selector solenoid Screw for emergency Check that the error indication is Replace solenoid valve
disappeared by turning emergency
screw
3 N&B selector solenoid Carry out service •No.11 F-4 Option selector is B mode Check solenoid valve
diagnosis COMP ON, MEAS ON Check harness
Spool position BRK
Selector switch BRK
4 N&B selector pressure Carry out service •No.16 B-11 Check pressure sensor
sensor diagnosis Data List Check harness
3.0MPa at B mode and 0.0MPa at A
mode

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 47. TROUBLESHOOTING (BY TROUBLE)

(22)Selector valve for option malfunctions: Nibbler circuit is not obtained.

(Indication of failure is displayed. For reference, see "Table47-1 Action of optional selector solenoid valve")

No. Sections Contents/normal value Corrective action, others

1 N&B selector spool Visual check When removing, free from abnormal Replace
resistance against sliding (Check on the casing side for
Free from abnormal damage, etc on damage)
outside surface
Spring is free from breakage.
2 N&B selector solenoid Carry out service •No.11 F-4 Option selector is A mode Check solenoid valve
diagnosis COMP OFF, MEAS OFF Check harness
Spool position NIB
Selector switch NIB

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47. TROUBLESHOOTING (BY TROUBLE)

Table47-1 Action of optional selector solenoid valve

Optional Selector
Safety lock Safety lock selector valve
Engine Work Spool Failure diagnosis
No. lever SW's lever relay's valve detecting Warning display
condition mode position display
input output COMP. pressure
MEAS. sensor
1 Running ON OFF A OFF Nibbler Normal — —
2 "SELECTOR VALVE [F042] displayed
Running ON OFF A ON Breaker Normal
FAILURE" simultaneously
3 "SELECTOR VALVE
Running ON OFF A OFF Breaker Normal —
FAILURE"
4 Running ON OFF A ON Nibbler Normal — [F042] displayed
5 Running ON OFF B ON Breaker Normal — —
6 "SELECTOR VALVE [F043] displayed
Running ON OFF B OFF Nibbler Normal
FAILURE" simultaneously
7 "SELECTOR VALVE
Running ON OFF B ON N&B Normal —
FAILURE"
8 Running ON OFF B OFF Breaker Normal — [F043] displayed
9 "SELECTOR VALVE
Running ON OFF — — — Failure [B113] displayed
FAILURE"
10 Stopping — — — — — — — —
11 — OFF — — — — — — —
12 — — ON — — — — — —

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 47. TROUBLESHOOTING (BY TROUBLE)

47.2 ELECTRIC SYSTEMS

47.2.1 WIRING CHECKING PROCEDURE
Check for continuity between connector terminals, CONNECTOR
presence or absences of short-circuit with other wires,
and presence or absences of short-circuit with machine
body grounding.
WIRE
(1) Checking for disconnection between connectors.
(When both ends measurement is easy because of
TESTER
short distance between connectors,)
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is zero (0), it is in normal
condition.

(When both ends measurement is difficult because

of long distance between connectors,)
Measure the resistance using tester. JUMPER
Pull out opposite connector first. WIRE
Where the resistance is zero (0), if the terminal on
one side is connected to frame body grounding with TESTER
jumper wire, it is in normal condition. FRAME BODY GROUNDING
The resistance is 1M or more when the terminal
on one side is not connected to frame body
grounding with jumper wire, it is in normal condition.

(2) Checking for presence or absence of short-circuit

with machine body
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is 1M or more, it is in normal
condition.
TESTER
FRAME BODY GROUNDING

(3) Checking for presence or absence of short-circuit

between wirings.
Measure the resistance using tester.
Pull out opposite connector first.
When the resistance is 1M or more, it is in normal
condition. TESTER

47-27
47. TROUBLESHOOTING (BY TROUBLE)

(4) Checking connector terminal for contact

Insert male terminal into female terminal unit, and INSERT
then check that the inserting force is equivalent to
other female terminals. MALE TERMINAL FEMALE TERMINAL
If looseness is there, replace the female terminal
with new one.
Clean the dirt terminal.

Do not insert the male terminal the thickness differs. It

may cause loose connection.

(5) Caution which should be paid in measuring voltage

When measuring the power supply to electric
equipment at connector position with the grounding
terminal contained inside of connector, measure
the voltage between grounding inside of connector
and power terminal.
When measuring the voltage between frame body
grounding and power source, the disconnection of
wiring to grounding inside of connector cannot be
identified.
Since the voltage may vary between with connector
connected and with connector not connected.
Measure the voltage with each connector
connected whenever possible.
(6) Checking the general view of connector CRIMPED
PART
a. Check the terminal crimped condition.
Pull one electric cable with the about 3kg force,
RUBBER
and make sure that the cable does not come out PLUG
RECEPTACLE.
of the terminal. CONTACT

When came out, replace the terminal and crimp PLUG

SEALING
it again. (is housed in plug)

b. Check connector for imperfect insertion DOUBLE LOCK

PLATE FOR PLUG
Check that all top ends form a line on the same DOUBLE LOCK
PLATE FOR CAP
position as seen from the connector engaged
side. CAP

When moved along, push it in further through TAB.CONTACT

wire inserting hole. RUBBER PLUG

c. Check connector for intruding of water.

Pull out the connector and check that the inside
is free from intruding of water.
When water intruding is found, check rubber plug
for damage and also that the sealing is fitted
properly.

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 47. TROUBLESHOOTING (BY TROUBLE)

(7) When abnormality occurs at intervals

When the abnormality situation can not be
reoccurred during checking operation, try the
following operations.
a. Check that variable of display exists or not on the
service diagnosis screen while shaking the
harness or giving shock by operating the
machine.
b. Check that variables of resistance and voltage
exist or not using tester while shaking the
harness.
c. Turn starter switch on and apply electricity
continuously, and check it again after the
temperature of wiring and equipment was raised.
(8) Checking on body grounding
Check attaching bolts of grounding terminal for
loosening.
And also check that there is no loose connection
due to corrosion.

There are multiple groundings like centralized

grounding box shown in the figure and battery
grounding, engine grounding, horn grounding fixed
together with horn, body grounding placed on
attaching section of boom working light.
Block of grounding is located
under floor plate of cab.

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47. TROUBLESHOOTING (BY TROUBLE)

47.2.2 TROUBLE
(1) Engine does not stop.
(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
(3) Auto accel does not actuate. (The engine speed does not automatically slow down.)
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
(5) Wiper does not function.

47-30
 47. TROUBLESHOOTING (BY TROUBLE)

(1) Engine does not stop.

No. Sections Contents/normal value Corrective action, others

1 Starter key switch Check signal of starter No.4 K-3 Key switch Check continuity between
key switch ON by OFF at starter key switch OFF position terminals of starter switch using
carrying out service ON at starter key switch ON position tester
diagnosis.
2 Engine forcible stop When ON is displayed No.4 K-3 Key switch Check on engine forcible stop
relay with the starter switch OFF at starter key switch OFF position relay
OFF, then pull out R-25 ON at starter key switch ON position
engine forcible stop
relay and carry out the
service diagnosis.
3 Wiring Voltage between line 0V when starter switch is OFF Check harness
No.62 among starter Check diode D-9 between
switch, engine forcible starter switch and auto idling
stop relay, mechatro stop relay 1
controller and the body
grounding

(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.

No. Sections Contents/normal value Corrective action, others

1 Fuse No.1 fuse (5A) Not blown fuse Check harness
Replace fuse
2 Mechatro controller Accel control Engine speed varies according to Check mechatro controller and
accel potentiometer operation. replace as necessary
(Use remote control because the auto
accel function is working.)
3 Wiring Transmission circuit line See "WIRING CHECKING Repair wiring
No.770 from mechatro PROCEDURE"
controller to gauge
cluster
4 Gauge cluster Gauge cluster Replace gauge cluster

(3) Auto accel does not actuate. (The engine speed does not automatically slow down).

No. Sections Contents/normal value Corrective action, others

1 Engine coolant Check engine coolant No.2 G-5 WATER TEMP Replace engine coolant sensor
temperature temperature by carrying Auto accel does not work in the
out service diagnosis. temperature -15°C or less.
Warm up and raise the coolant
temperature to – 15°C or more
2 Gauge cluster Indication of auto accel Mark "Display/not display" for auto Replace gauge cluster
accel switches by auto accel switch
operation on gauge cluster.
3 Low pressure sensor Service diagnosis Each control pressure of No.5 and Check low pressure sensor
No.6 is in the range of 0~0.1MPa at
control lever neutral position.

(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)

No. Sections Contents/normal value Corrective action, others

1 Low pressure sensor Service diagnosis Each control pressure of No.5 and Check low pressure sensor
No.6 is raised with control lever
operated.

47-31
47. TROUBLESHOOTING (BY TROUBLE)

(5) Wiper does not function

Wiping range of
forward and
reverse movements

Wiper motor
Rise up (storing) position Rise up limit switch's ON range
Upper reversing position Reverse limit switch's ON range
Lower reversing position

No. Sections Contents/normal value Corrective action, others

1 Fuse Check fuse No.20 Replace fuse
2 SW-19: Service diagnosis No.19 D125 Check wiper interlock switch
Wiper interlock switch Wiper switch display (D125) is OFF with front window closed. and repair it if necessary
Check according to "WIRING
CHECKING PROCEDURE" and
repair it if necessary
3 Rise up limit switch built- Service diagnosis No.25 Wiper system Check according to "WIRING
in wiper motor CHECKING PROCEDURE"
Reverse limit switch Switch action in operation

Normal condition
Rise up limit switch ON OFF OFF
Reverse limit switch ON ON OFF

4 R-31: Service diagnosis No.25 Wiper system

Arc prevention relay When started by forward rotation: STOP START (STOP) (REVERSE) (STOP) (FORWARD)
R-29: Arc prevention relay OFF ON ON ON ON OFF ON ON ON OFF ON
Forward rotation relay Forward rotation relay OFF ON ON ON ON OFF OFF OFF OFF OFF ON

R-30: Reverse rotation relay OFF OFF OFF OFF OFF OFF ON ON ON OFF OFF
Check that the relay is worked as shown in the table. Check that the relay is excited.
Reverse rotation relay * When the limit switch does not change in OFF after 4 seconds Check relay & fuse box and replace it
from the wiper startup, turn OFF all relay's outputs. if necessary.

47-32
 47. TROUBLESHOOTING (BY TROUBLE)

47.3 ENGINE RELATED TROUBLESHOOTING

Checking
Filters Liquid Leak, clogging

Air leak between turbocharger and intake manifold

Factors

Leak, clogging of fuel system and intruding of air

Contamination of water and fuel with oil
Breather hose crushed or clogged
Fan belt slipped, fan pulley worn

Poor or deteriorated battery

Shortage of fuel level

Improper fuel in use

Air cleaner clogged
Fuel filter clogged

Oil level of oil pan

Oil filter clogged

Muffler clogged
Engine oil leak
Coolant level
Trouble

Poor start ability (Take a long time)

Faulty starting

Faulty engine starting/engine does not rotate.

Faulty engine starting/engine rotates but no
exhaust gas (No fuel injection)

Faulty engine starting/exhaust gas is emitted

but engine does not start (With fuel injection)
Poor output Insufficient

Engine poor run-up (Low follow-up ability)

rotation

Rotation in bad condition (hunting)

Engine stalled during operation.
Output is lowered.
Overheating
Exhaust smoke is in black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Other failures

Early contamination of oil

Larger fuel consumption
Intruding of oil in coolant, back flow, reduction
of coolant quantity
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Vibration

47-33
47. TROUBLESHOOTING (BY TROUBLE)

Checking Electric equipment

Shovel side Shovel side Engine side

Loose mounting bolts, damage of mounting rubber

Factors

Radiator core clogged/fin clogged and crushed

Peeling of space insulation around radiator

Loose connection of battery cable terminal

Failure of radiator pressure cap

Failure of hydraulic system

Startup circuit wiring
Starter key switch

Hydraulic switch
Starter motor
Safety relay
Battery rely

Glow relay
Glow plug
Alternator
Trouble

Poor start ability (Take a long time)

Faulty starting

Faulty engine starting/engine does not rotate.

Faulty engine starting/engine rotates but no
exhaust gas (No fuel injection)

Faulty engine starting/exhaust gas is emitted

but engine does not start (With fuel injection)
Poor output Insufficient

Engine poor run-up (Low follow-up ability)

rotation

Rotation in bad condition (hunting)

Engine stalled during operation.
Output is lowered.
Overheating
Exhaust smoke is in black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Other failures

Early contamination of oil

Larger fuel consumption
Intruding of oil in coolant, back flow, reduction
of coolant quantity
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Vibration

47-34
 47. TROUBLESHOOTING (BY TROUBLE)

Intake and Lubrication Cooling

Fuel system exhaust system system
system

Factors

Seizing and interference of turbocharger

Seal of turbocharger worn, damaged
Turbocharger oil drain tube clogged

Leak and crush of hydraulic piping

Failure of thermostat (Not open)

Fuel leak into the head cover
Improper fuel injection time

Failure of regulator valve

Damage of water pump

Damage of EGR cooler
Failure of supply pump

Failure of relief valve

Failure of oil pump
Failure of injector
Trouble

Poor start ability (Take a long time)

Faulty starting

Faulty engine starting/engine does not rotate.

Faulty engine starting/engine rotates but no
exhaust gas (No fuel injection)

Faulty engine starting/exhaust gas is emitted

but engine does not start (With fuel injection)
Poor output Insufficient

Engine poor run-up (Low follow-up ability)

rotation

Rotation in bad condition (hunting)

Engine stalled during operation.
Output is lowered.
Overheating
Exhaust smoke is in black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Other failures

Early contamination of oil

Larger fuel consumption
Intruding of oil in coolant, back flow, reduction
of coolant quantity
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Vibration

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47. TROUBLESHOOTING (BY TROUBLE)

Engine body
Factors

Wear and damage of rear oil seal and seal surface

Damage and seizing of piston and connecting rod
Damage of engine oil cooler core and O-ring

Damage of cylinder head and head gasket

Wear and failure of valve and valve guide

Wear of piston ring and liner, ring stick

Strainer clogged, damage of oil pipe

Failure of injection holder sleeve

Damage of flywheel gear

Hole due to cavitation

Damage of dumper
Trouble

Poor start ability (Take a long time)

Faulty starting

Faulty engine starting/engine does not rotate.

Faulty engine starting/engine rotates but no
exhaust gas (No fuel injection)

Faulty engine starting/exhaust gas is emitted

but engine does not start (With fuel injection)
Poor output Insufficient

Engine poor run-up (Low follow-up ability)

rotation

Rotation in bad condition (hunting)

Engine stalled during operation.
Output is lowered.
Overheating
Exhaust smoke is in black
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Other failures

Early contamination of oil

Larger fuel consumption
Intruding of oil in coolant, back flow, reduction
of coolant quantity
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Vibration

47-36
 48. TROUBLESHOOTING
(TROUBLE DIAGNOSIS MODE)
TABLE OF CONTENTS

48.1 TROUBLE DIAGNOSIS MODE .......................................................................................48-3

48

Book Code No. S5YN4818E01

48-1
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5YN4818E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)
SK200–8 : YN11-45001~
↑ August, 2006 ↑ K
SK210LC–8 : YQ11-06001~
SK250-8 : LQ12-06001~
↑ October, 2006 ↑ K
SK260LC-8 : LL12-05001~
E235BSR : YF05-02001~ ↑
↑ February, 2007 K
E235BSR(N)LC : YU05-02001~ (NHK)

48-2
 48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

48.1 TROUBLE DIAGNOSIS MODE

The trouble diagnosis mode is used to automatically specify the failed sections for the troubles which can not be
detected by auto diagnosis function (the trouble can be specified by error code) like disconnection, abnormal output.
(1) Function
There are two types of trouble diagnosis mode.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and
engine system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system.
In any mode, with the attachment not operated, both selector valve and proportional valve are automatically
actuated, the sensor detects the machine condition and the mechatro controller identifies the normal
condition or failed condition of the system.
(2) How to use and flow chart
The operation is performed through gauge cluster.
No.1 Select service adjustment select screen.
(Switch starter key on while pressing buzzer stop switch and press select switch three times while pressing
buzzer stop switch on the service diagnosis screen No.1.)
No.2 Select Trouble diagnosis mode
(Move the cursor to the desired position with screen change switch " ", and press the select switch.)
No.3 Select either "DIAG MODE 1" or "DIAG MODE 2"
(Move the cursor to the desired position with screen change switch " ", and press the select switch.)
No.4 Go ahead the operation according to the instructions on the screen of cluster gauge.

No.1 No.2 No.3

SELECT SWITCH
LANGUAGE/LOGO 8 FAULT DIAG MODE DIAG MODE 1
BUZZER STOP SWITCH
ADJUSTING MODE 1 DIAG MODE 2
PRESET BY FACTORY
FEED SCREEN CHANGE SWITCH

CASE OF DIAG MODE 1

SENSOR CHECK START ENG LOWER BOOM DIAG MODE 1

ENGINE SPEED
RELEASE LOCK In diagnosis
CHECK 0000 rpm
PRESSURE
C-1 00.0M C-2 00.0M
TO GROUND LEVER START operation
PROPO-VALVE About 15 minutes
E-1 005mA E-2 005mA
D-1 300mA D-2 300mA

For the diagnosing items, see Table 48-1.

When required to stop in diagnosis
Turn engine on operation, press the buzzer stop switch
manually. BACK TO No.3 and the operation is forcedly stopped.

The data at the time of judgment

can be confirmed with the select
RESULT OF DIAGNOSIS RESULT OF DETAIL switch.
When
DIAG MODE 1 not failed, DIAG MODE 1 1 P1 UNLOAD
ENGINE SPEED
0000 rpm
END ENGINE STOP OK O K PRESSURE
C-1 00.0M C-2 00.0M
PROPO-VALVE
E-1 005mA E-2 005mA
DATA END FEED D-1 300mA D-2 300mA

The other judgments can be

Engine stops confirmed with the feed button.
automatically. RESULT OF DIAGNOSIS

When failed,
DIAG MODE 1 RESULT 1 1 P1 UNLOAD
ENGINE SPEED
P1 UN-LOAD PSV NG 0000 rpm

P1 UN-LOAD SPOOL NG NG PRESSURE

C-1 00.0M C-2 00.0M
PROPO-VALVE
DATA END FEED DATA END FEED E-1 005mA E-2 005mA
D-1 300mA D-2 300mA

The suspected trouble sections are displayed in order of

possibility. The suspected three sections in maximum are
BACK TO No.3 displayed. When desired to see other suspected trouble sections,
press feed " " button. For diagnosis results and corrective
actions to be taken, see Table 48-2.

Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the
attachment and it causes injury or death.Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis
mode after making sure of the bucket-grounded condition.
2. Before executing the trouble diagnosis mode, check each pressure sensor proportional valve and select valve for possible abnormality.
Check that the commands of proportional valve and select valve do not largely differ from the actually measured values through the service diagnosis.
The preliminary investigation of electric system makes the time saving and high precision diagnosis possible.
3. For the diagnosis results and the corrective actions to be taken, usually occurred troubles are taken as an example. When multiple troubles are occurred at the same time, there is a
case no accordance of diagnosis obtained. In this case, contact our dealer/distributor.
4. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring
to the trouble history.

48-3
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

No.4 CASE OF DIAG MODE 2

SENSOR CHECK START ENG

ENGINE SPEED
LOWER BOOM DIAG MODE 2
CHECK 0000 rpm
PRESSURE
C-1 00.0M C-2 00.0M
TO GROUND START
PROPO-VALVE
E-1 005mA E-2 005mA
D-1 300mA D-2 300mA

Turn engine on
Example: Case of boom up
manually. AT CONTROL LEVER IS
NEUTRAL WHEN FINISHING OF
DIAGNOSIS IS REQUIRED.
BOOM UP BOOM UP

OK BACK TO No.3
PRESSURE 0.0 MPa PRESSURE 1.5 MPa PRESSURE 3.0 MPa
SEARCHABLE OPERATION
Boom up
Boom down
In the normal condition, OK is
Bucket digging displayed when the control
lever is moved to stroke end.
Bucket dump
Arm in
Arm out
Swing
Travel right
Travel left
P1 side option
P1 side option

Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the
attachment and it causes injury or death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis
mode after making sure of the bucket-grounded condition. Place the bucket on the ground between both crawlers.
2. In the case of "DIAG MODE2", pump pressure is unloaded with unload valve in order not to actuate attachment.
When trouble diagnosis is performed, if the pump pressure is generated, the engine stops and "UN-LOAD PSV NG" is displayed. Check the troubled section according to indication.
3. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring
to the trouble history.

Table48-1 Failure diagnosis Mode-1/Diagnosis item

No. Display Contents of diagnosis
Is normal pressure generated in the condition that the flow rate at P1 side is minimum and
1 1 P1 UNLOAD
the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the minimum flow rate is relieved at P1
2 2 P1 UNLOAD
side?
Is normal pressure generated in the condition that the unload valve is fully opened, and P1
3 3 P1 UNLOAD
side flow rate is minimum?
Is normal pressure generated in the condition that the unload valve is in emergency position,
4 1 P2 UNLOAD
and P2 side flow rate is minimum?
Is normal pressure generated in the condition that the minimum flow rate is relieved at P2
5 2 P2 UNLOAD
side?
Is normal pressure generated in the condition that the unload valve is fully opened, and P2
6 3 P2 UNLOAD
side flow rate is minimum?
Is normal pressure generated in the condition that the flow rate at P1 side is emergency and
7 1 P1 PUMP
the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the unload valve is emergency, and P1
8 2 P1 PUMP
side flow rate is minimum?
Is normal pressure generated in the condition that the unload valve is in emergency position,
9 3 P1 PUMP
and P1 side flow rate is maximum?
Is normal pressure generated in the condition that the flow rate at P2 side is emergency and
10 1 P2 PUMP
the unloading valve is in the emergency position?
Is normal pressure generated in the condition that the unload valve is emergency, and P2
11 2 P2 PUMP
side flow rate is minimum?
Is normal pressure generated in the condition that the unload valve is in emergency position,
12 3 P2 PUMP
and P2 side flow rate is maximum?

48-4
 48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

Table48-1 Failure diagnosis Mode-1/Diagnosis item

No. Display Contents of diagnosis
Is normal pressure generated in the condition that P1 side flow rate is minimum, unload
13 1 TRAVEL-S
valve is emergency position and travel straight is stroked fully?
Is normal pressure generated in the condition that P2 side flow rate is minimum, unload
14 2 TRAVEL-S
valve is emergency position and travel straight is stroked fully?
Is rated engine speed obtained in the condition that P1 side flow rate increases little by little
15 1 P1 ENGINE
when P1 side flow rate is relieved?
Is rated engine speed obtained in the condition that P2 side flow rate increases little by little
16 2 P2 ENGINE
when P2 side flow rate is relieved?

When pump regulator does not have "Total power control of Emergency mode", "1 P1 PUMP" of No.7 and "1 P2
PUMP" of No.10 are not given a diagnosis.

Table48-2 Failure diagnosis Mode-1/Diagnosis and Remedy

Diagnosis (Display) Possible cause Remedy
Check each pressure sensor by
SENSOR CHECK Disconnection of pressure sensor, Short
service diagnosis and replace it if
NG circuit, Abnormal output
necessary
Secondary pressure is excessive high against
the command Check P1 unload proportional valve
P1 UN-LOAD PSV NG
Secondary pressure is excessive low against and replace it if necessary
the command
Stuck at full-stroke side Check P1 unload spool and replace it
P1 UN-LOAD SPOOL NG
Stuck at neutral side if necessary
Secondary pressure is excessive high against
the command Check P2 unload proportional valve
P2 UN-LOAD PSV NG
Secondary pressure is excessive low against and replace it if necessary
the command
Stuck at full-stroke side Check P2 unload spool and replace it
P2 UN-LOAD SPOOL NG
Stuck at neutral side if necessary
Stuck at closing side Check P1 by-pass cut valve and
P1 B-P CUT NG
Stuck at neutral side replace it if necessary
Stuck at closing side Check P2 by-pass cut valve and
P2 B-P CUT NG
Stuck at neutral side replace it if necessary
Secondary pressure is excessive high against
the command Check P1 pump proportional valve
P1 PUMP PSV NG
Secondary pressure is excessive low against and replace it if necessary
the command
Delivery rate is excessive large against the Check P1 pump regulator and replace
command it if necessary.
P1 PUMP NG
Delivery rate is excessive small against the Check P1 pump and replace it if
command necessary.
Secondary pressure is excessive high against
the command Check P2 pump proportional valve
P2 PUMP PSV NG
Secondary pressure is excessive low against and replace it if necessary
the command

48-5
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)

Table48-2 Failure diagnosis Mode-1/Diagnosis and Remedy

Diagnosis (Display) Possible cause Remedy
Delivery rate is excessive large against the Check P2 pump regulator and replace
command it if necessary.
P2 PUMP NG
Delivery rate is excessive small against the Check P2 pump and replace it if
command necessary.
Secondary pressure is excessive high against
the command Check travel straight proportional
S-TRAVEL PSV NG
Secondary pressure is excessive low against valve and replace it if necessary
the command
Stuck at full-stroke side Check travel straight spool and
S-TRAVEL SPOOL NG
Stuck at neutral side replace it if necessary
PUMP 1 PRESS. SENSOR Check P1 high pressure sensor and
Pressure is recognized lower than it is
NG replace it if necessary
PUMP 2 PRESS. SENSOR Check P2 high pressure sensor and
Pressure is recognized lower than it is
NG replace it if necessary
Set pressure decreases Check main relief valve and replace it
MAIN RELIEF NG
Set pressure increases if necessary
Check engine and replace it if
ENGINE NG Output is lowered
necessary
Check engine speed sensor and
E/G R SENSOR NG Characteristics is misaligned
replace it if necessary

48-6
 51. ENGINE
PREFACE

This service manual explains the single engine. Note that this manual is edited without
modification by based on the service manual of HINO MOTOR.

51

Book Code No. S5LC5111E02

51-1
51. ENGINE

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC5111E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)
S5LC5111E02
Revision February, 2007 ↑ K
(ASIA, OCE)

51-2
 63. MOUNTING
THE NIBBLER & BREAKER
TABLE OF CONTENTS

63.1 LIST OF ADDITIONAL PARTS........................................................................................63-3

63.1.1 ADDITIONAL PARTS FOR THE MODIFICATION TO NIBBLER & BREAKER .....63-3
63.2 SUMMARY.......................................................................................................................63-9
63.2.1 GENERAL PRECAUTIONS....................................................................................63-9
63.2.2 BASIC METHOD TO BE TAKEN WHEN MOUNTING ...........................................63-9
63.2.3 LAYING OF PIPING ...............................................................................................63-10
63.3 HYDRAULIC CIRCUIT DIAGRAM...................................................................................63-12
63.3.1 FUNCTION .............................................................................................................63-12
63.4 HYDRAULIC COMPONENTS .........................................................................................63-14
63.4.1 SELECTOR VALVE (50-1) : YN30V00104F1.........................................................63-14
63.4.2 OVERLOAD RELIEF VALVE (50-2) : YN22V00002F1 ..........................................63-14
63.4.3 PILOT VALVE (52) : YN30V00080F1.....................................................................63-15
63.5 MODIFICATION PROCEDURE FOR NIBBLER & BREAKER (N&B) .............................63-16
63.5.1 MODIFICATION ITEM ............................................................................................63-16
63.5.2 CONTROLS, OPERATORS ...................................................................................63-17
63.5.3 VALVE INSTALL.....................................................................................................63-18
63.5.4 CONTROL LINES (NIBBLER & BREAKER) ..........................................................63-19
63.5.5 HYD. LINES, UPPER .............................................................................................63-30
63.5.6 HYDRAULIC TANK ASSY......................................................................................63-33
63.5.7 PANEL ASSY, INSTRUMENT................................................................................63-34
63.5.8 NAME PLATE INSTALL .........................................................................................63-35
63.6 MODIFICATION PROCEDURE FOR ATTACHMENT FOR N&B....................................63-37
63.6.1 MODIFICATION ITEM ............................................................................................63-37
63.6.2 HYDRAULIC LINES, BOOM...................................................................................63-38
63.6.3 HYDRAULIC LINES, ARM......................................................................................63-42
63.6.4 CONNECTOR ASSY ..............................................................................................63-50
63.7 REMINDERS ON THE USE OF NIBBLER & BREAKERS ..............................................63-51
63.7.1 CHANGING OVER THE SELECTOR VALVE ........................................................63-51
63.7.2 FLUSHING METHOD .............................................................................................63-51
63.7.3 REPLACING HYDRAULIC OIL AND RETURN FILTER ........................................63-51
63.7.4 BASIC OPERATION...............................................................................................63-52
63.8 PRECAUTIONS TO BE EXERCISED ON BREAKERS OF DIFFERENT MANUFACTURERS.....63-54
63.9 REFERENCE...................................................................................................................63-57

Book Code No. S5LC6311E02

63-1
63. MOUNTING THE NIBBLER & BREAKER

Issue Date of Issue Applicable Machines Remarks

SK330–8 : LC10-07001~ S5LC6311E01
First edition July, 2006 K
SK350LC–8 : YC10-03501~ (ASIA, OCE)
S5LC6311E02
Revision February, 2007 ↑ K
(ASIA, OCE)

63-2
 63. MOUNTING THE NIBBLER & BREAKER

PREFACE
This manual deals with items necessary for changing standard specification machine to one with a nibbler & breaker
specification. Follow the procedure given here in when changing the machine specification in the field (service shop).

63.1 LIST OF ADDITIONAL PARTS

How to utilize the list of additional parts
This manual is compiled to change the standard machine to this specification on the basis of "Parts Manual" for the
standard machine. This list consists of additional parts and disused parts.
The manual consists roughly is divided into five parts, 1. Upper structure, 2. Boom, 3. Standard arm, and 4. Long
arm, 5. short arm each being assigned a kit number. In the case of the arm, select a connector suited for the
attachment (Nibbler, Breaker) for ordering.

63.1.1 ADDITIONAL PARTS FOR THE MODIFICATION TO NIBBLER & BREAKER

(1) Upper structure [NIBBLER & BREAKER]

Applicable
No. Part No. Parts name Q’ty Remarks
Machines
LC32T01411F1 Upper structure modification KIT No. NIBBLER & BREAKER ASIA LC10-07001~
YC10-03501~
LC32T01411F2 Upper structure modification KIT No. NIBBLER & BREAKER OCEANIA LC10-07001~
YC10-03501~
LC03M00015F1 • CONTROLS OPERATORS ASIA
LC03M00025F1 • CONTROLS OPERATORS OCEANIA
6 YN55M00004F1 •• PEDAL ASSY (1) ASIA, OCE.
6-1 YN26M00066P1 •• MAT, FLOOR (1) Cut STD mat
6-2 YN03M01852P1 •• PEDAL 1
6-3 YN03M01858P1 •• RUBBER 1
6-4 YN03M01684P1 •• LOCK ASSY 1
6-5 ZM73C08020 •• SEMS-BOLT 2
6-6 ZM73C10020 •• SEMS-BOLT 2

YN64H00190F1 • VALVE INSTAL

0 LC30V00028F1 •• CONTROL VALVE (1) STD
1 YN30V00104F1 •• SELECTOR VALVE 1
1-703 ZS23C12105 •• CAPSCREW (3)
1-704 ZS23C12080 •• CAPSCREW (1)
2 YN22V00002F1 •• OVERLOAD VALVE ASSY 2
3 PV02B01073D7 •• CAPSCREW 1

LC64H00105F1 • CONTROL LINES VALVE ASIA, OCE.

2 LC64H00109F1 •• CONTROL LINES, VALVE (1)
2-1 2444R963D11 •• HOSE 1
2-2 2444Z2892 •• TEE 1
2-3 HH25X04004G2 •• CONNECTOR 1
2-4 YX52S00013P1 •• SENSOR, PRESS 2
2-5 2444Z2894 •• ELBOW 2

63-3
63. MOUNTING THE NIBBLER & BREAKER

Applicable
No. Part No. Parts name Q’ty Remarks
Machines
LC68H00063F1 • CONTROL LINES, REMOTE ASIA, OCE
1 YN30V00080F1 •• VALVE, PILOT 1
2 2420R349D090 •• HOSE 2
3 2420R349D160 •• HOSE 1
4 2420R349D400 •• HOSE 1
5 HH25X04004G2 •• CONNECTOR 1
6 ZH22X04000 •• CONNECTOR 1
7 ZH32X04000 •• ELBOW 2
8 ZE72X04000 •• PLUG 1
9 YX52S00013P1 •• SENSOR, PRESS 1
10 HM83C10030G1 •• SEMS-BOLT 2
11 ZH22X04006 •• CONNECTOR 1

LC64H00090F1 • CONTROL LINES, BLOCK ASIA, OCE.

1 YN64H01337P1 •• BLOCK 1
2 ZM73C08020 •• SEMS-BOLT 3

LC64H00088F1 • CONTROL LINES, BLOCK ASIA, OCE.

1 YN64H01292P1 •• BLOCK 1
2 2420R349D125 •• HOSE 1
10 ZH32X04006 •• ELBOW 1

LC03H00055F1 • HYD. LINES, UPPER ASIA, OCE.

2 LC03H00053F1 •• HYD. LINES, UPPER (1)
2-1 LC03H01264D1 •• HOSE 1
2-2 LC03H01263D1 •• HOSE 1
2-3 LQ03H01282D2 •• HOSE 1
2-4 ZE12Q16000 •• PLUG 1
2-5 ZE12X16000 •• CLAMP HALF 2
2-6 ZE13X20001 •• CLAMP HALF 6
2-7 ZS18C14045 •• CAPSCREW 4
2-8 ZS28C14050 •• CAPSCREW 8
2-9 HM83C10030G1 •• SEMS-BOLT 4
2-10 HM83C10035G1 •• SEMS-BOLT 4
2-11 HM83C12035G1 •• SEMS-BOLT 4
2-12 ZW26K14000 •• LOCK WASHER 8
2-13 ZD12P03400 •• O-RING 2
2-14 ZD12P03800 •• O-RING 3
2-15 ZD12P04800 •• O-RING 2
2-16 ZW26X14000 •• LOCK WASHER 4

63-4
 63. MOUNTING THE NIBBLER & BREAKER

Applicable
No. Part No. Parts name Q’ty Remarks
Machines
LC33H00043F1 • HYD. TANK ASSY (1) ASIA, OCE.
2 LC33H00028F1 •• HYD. TANK ASSY (1)
2-6 LC52V01001F1 ••• FILTER ELEMENT (1)
2-6-R100 LS52V01001R300 •••• ELEMENT KIT
2 YN52V01011P1 •• FILTER ELEMENT 3
5 ZD11G09000 •• O-RING 1
6 YN52V01008S005 •• PACKING 1
8 ZD11G19000 •• O-RING 1

YN17M00049F1 • PANEL ASSY, INSTRUMENT ASIA

YN17M00052F1 • PANEL ASSY, INSTRUMENT OCEANIA
1 YN17M00053F1 •• PANEL ASSY, INSTRUMENT (1) ASIA BASE
1 YN17M00054F1 •• PANEL ASSY, INSTRUMENT (1) OCEANIA BASE
2 YN50E00021F1 •• SWITCH INSTALL (1)
2-2 YN50S00040DD •• SWITCH 1

YN22T00334F2 • NAME PLATE INSTALL ASIA

14 YN20T01837P1 •• LABEL 1
15 YN20T01836P1 •• LABEL 1

LC22T00094F3 • NAME PLATE INSTALL OCEANIA

17 PY20T01062P1 •• LABEL 1
18 YN20T01930P1 •• LABEL 1
19 YT20T01054P1 •• LABEL 1
20 YN20T01836P1 •• LABEL 1

(2) Boom [NIBBLER & BREAKER]

Applicable
No. Part No. Parts name Q’ty Remarks
Machines
LC42H00178F1 • HYD. LINES, BOOM ASIA, OCE. LC10-07001~
YC10-03501~
1 LC42H00155F1 •• HYD. LINES, BOOM (1)
2 LC42H00169P1 •• HYD. LINES, BOOM (1)
2-1 LC42H01795P1 ••• TUBE 1
2-2 LC42H01796P1 ••• TUBE 1
2-3 LC42H01780P1 •••• TUBE 1
2-4 LC42H01781P1 •••• TUBE 1
2-5 LS42H01021D1 ••• HOSE 2
2-6 YN42H02582P1 ••• PLUG 4
2-7 LC42H01909P1 ••• BRACKET 1
2-9 LC42H01914P1 ••• CLAMP 1

63-5
63. MOUNTING THE NIBBLER & BREAKER

Applicable
No. Part No. Parts name Q’ty Remarks
Machines
2-10 YN42H02348P1 ••• CLAMP 8
2-11 YN42H02363P1 ••• CLAMP 12
2-12 ZE13X20001 ••• CLAMP, HALF 8
2-14 ZD12P03800 ••• O-RING 4
2-15 ZM73C12030 ••• SEMS-BOLT 12
2-17 ZS18C12050 ••• CAPSCREW 2
2-18 ZS28C14050 ••• CAPSCREW 16
2-19 ZW16H12000 ••• WASHER 8
2-20 ZW26K14000 ••• LOCK WASHER 16
2-21 LC42H01269P1 ••• CLAMP 2
2-22 ZS18C12065 ••• CAPSCREW 6
3 LC42H00177F1 ••• HYD. LINES, BOOM (1)
3-1 LC42H01916P1 ••• BRACKET 1
3-2 LC42H01915P1 ••• BRACKET 1
3-3 ZM73C12040 ••• SEMS-BOLT 3

(3) STD arm [NIBBLER & BREAKER]

Applicable
No. Part No. Parts name Q’ty Remarks
Machines
LC43H00111F1 • ARM; STD ASIA, OCE. LC10-07001~
YC10-03501~
1 LC43H00101F1 •• HYD. LINES, ARM (1)
1-1 LC43H01269P1 ••• TUBE 1
1-2 LC43H01270P1 ••• TUBE 1
1-3 LC43H01011D2 ••• HOSE 2
1-4 24100P3133F1 ••• VALVE, STOP 2
1-5 LC43H01223P1 ••• CONNECTOR 2
1-6 ZE13X20001 ••• CLAMP, HALF 12
1-7 YN42H02361P1 ••• CLAMP 8
1-8 YN42H02321P1 ••• BUSHING 4
1-9 ZM73C12030 ••• SEMS-BOLT 8
1-10 ZS18C08025 ••• CAPSCREW 8
1-11 ZS28C14050 ••• CAPSCREW 16
1-12 ZS28C14070 ••• CAPSCREW 8
1-13 ZN18C14011 ••• NUT 8
1-14 ZW26K14000 ••• LOCK WASHER 16
1-16 YN43H01151P1 ••• WASHER 8
1-17 ZD12P03800 ••• O-RING 8
2 YN43H00200F1 ••• HYD. LINES, ARM (1)
2-1 YN43H01663P1 ••• BRACKET 2
2-2 ZS18C16040 ••• CAPSCREW 4

63-6
 63. MOUNTING THE NIBBLER & BREAKER

Applicable
No. Part No. Parts name Q’ty Remarks
Machines
2-3 ZW16H16000 ••• WASHER 4

(4) Long arm [NIBBLER & BREAKER]

Applicable
No. Part No. Parts name Q’ty Remarks
Machines
LC43H00122F1 •• ARM ASIA, OCE. LC10-07001~
YC10-03501~
1 LC43H00123F1 •• HYD LINES, ARM (1)
1-1 LC43H01283P1 •• TUBE 1
1-2 LC43H01284P1 •• TUBE 1
1-3 LS30H01078DC •• HOSE 2
1-4 24100P3133F1 •• VALVE STOP 2
1-5 LC43H01223P1 •• CONNECTOR 2
1-6 ZE13X20001 •• CLAMP HALF 12
1-7 YN42H02361P1 •• CLAMP 16
1-8 YN42H02321P1 •• BUSHING 8
1-9 ZD12P03800 •• O-RING 8
1-10 ZM73C12035 •• SEMS-BOLT 16
1-11 ZS18C08025 •• CAPSCREW 8
1-12 ZS28C14050 •• CAPSCREW 16
1-13 ZS28C14070 •• CAPSCREW 8
1-14 ZN18C14011 •• NUT 8
1-15 YN43H01151P1 •• WASHER 8
1-16 ZW26K14000 •• LOCK WASHER 16
2 YN43H00200F1 •• HYD. LINES, ARM (1)
2-1 YN43H01663P1 •• BRACKET 2
2-2 ZS18C16040 •• CAPSCREW 4
2-3 ZW16H16000 •• WASHER 4

(5) Short arm [NIBBLER & BREAKER]

Applicable
No. Part No. Parts name Q’ty Remarks
Machines
LC43H00107F1 • ARM ASIA, OCE LC10-07001~
YC10-03501~
1 LC43H00106F1 •• HYD. LINES, ARM (1)
1-1 LC43H01259P1 •• TUBE 1
1-2 LC43H01260P1 •• TUBE 1
1-3 LC43H01011DB •• HOSE 2
1-4 24100P3133F1 •• VALVE, STOP 2
1-5 LC43H01223P1 •• CONNECTOR 2
1-6 ZE13X20001 •• CLAMP, HALF 12

63-7
63. MOUNTING THE NIBBLER & BREAKER

Applicable
No. Part No. Parts name Q’ty Remarks
Machines
1-7 YN42H02361P1 •• CLAMP 8
1-8 YN42H02321P1 •• BUSHING 4
1-9 ZM73C12030 •• SEMS-BOLT 8
1-10 ZS18C08025 •• CAPSCREW 6
1-11 ZS28C14050 •• CAPSCREW 16
1-12 ZS28C14070 •• CAPSCREW 8
1-13 ZN18C14011 •• NUT 8
1-14 YN43H01151P1 •• WASHER 8
1-15 ZD12P03800 •• O-RING 8
1-16 ZW26K14000 •• LOCK WASHER 16
2 YN43H00200F1 •• HYD LINES, ARM (1)
2-1 YN43H01663P1 •• BRACKET 2
2-2 ZS18C16040 •• CAPSCREW 4
2-3 ZW16H16000 •• WASHER 4

(6) Connector assy (Select for using N & B maker attachment)

Applicable
No. Part No. Parts name Q’ty Remarks
Machines
1 YN43H00004F1 •• CONNECTOR ASSY 2 NPK
1 YN43H00005F1 •• CONNECTOR ASSY 2 TOKU, KRUPP
1 YN43H00006F1 •• CONNECTOR ASSY 2 NIBBLER

63-8
 63. MOUNTING THE NIBBLER & BREAKER

63.2 SUMMARY
63.2.1 GENERAL PRECAUTIONS
(1) Application of Nibbler & Breaker
Nibbler & Breaker ........... Applicable only when nibbler and breaker are mounted.
(2) Modifying Nibbler & Breaker
There are specific procedures to be followed when modifying nibbler & breaker. Therefore, when they are to be
modofied at our service shop, contact the nearest breaker and nibbler manufacturer's office, and obtain
instructions, so that you install the pipes and handle the machinery correctly.
(3) Differences Between Breaker Circuit and Nibbler Piping
• Breaker Piping:
There is a single oil flow from pump P2 to the breaker. The oil returns to the hydraulic tank directly. The flow is
single flow.

If the return oil from the breaker is fed back to the control valve, the pulsation of the breaker is transmitted to the
oil cooler. This causes the machine to break down.

• Nibbler Piping:
The oil flows to the nibbler is conflux flow : the oil flow is changed to the rod and the head of the nibbler cylinder.

63.2.2 BASIC METHOD TO BE TAKEN WHEN MOUNTING

When mounting the breaker or nibbler, always execute the following five items :
(1) Functions of the option valve :
The option valve transmits oil pressure to the nibbler or the breaker. It contains a spool that changes the flow of
the oil to the rod and the head of the nibbler cylinder. It also contains a single / conflux flow spool that selects a
single flow the A2 port of the main pump or conflux flow of the A1 and A2 ports of the main pump.
(2) Action of the single / conflux flow switch :
A solenoid valve is provided and the single / conflux select switch in the instrument panel, in order to operate
the single / conflux change spool.
(3) Installing the operation pedal :
A pedal and a pilot valve are mounted to the floor plate and a remote control piping is placed between the option
valve and pedal, in order to operate the breaker or the nibbler.
(4) Installing the selector valve :
On the nibbler & breaker attached machine, a selector valve is mounted to the main control valve in order to
change the oil flow for the breaker and for the nibbler.
(5) When the machine equipped with nibbler & breaker is modified, replace the return filter with new standard filter.

63-9
63. MOUNTING THE NIBBLER & BREAKER

63.2.3 LAYING OF PIPING

(1) Nibbler & Breaker specification

ARM
HYDRAULIC
PIPING

HYDRAULIC PIPING FOR BOOM

STOP
VALVE UPPER HYDRAULIC PIPING
RETURN HYDRAULIC PIPING
ARM
SELECTOR VALVE
(ADD-ON VALVE)
ARM TOP
PIPING
HYDRAULIC
BREAKER

OPERATING
PEDAL

FLOOR MAT

SINGLE / CONFLUX
FLOW SELECT SWITCH
MAIN CONTROL VALVE
REMOTE CONTROL PIPING

Fig. 63-1 Outside view of Nibbler & Breaker-attached machine

63-10
 63. MOUNTING THE NIBBLER & BREAKER

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63-11
63. MOUNTING THE NIBBLER & BREAKER

63.3 HYDRAULIC CIRCUIT DIAGRAM

63.3.1 FUNCTION

63.3.1.1 HYDRAULIC CIRCUIT FOR NIBBLER & BREAKER

P2 P1 T1 T2

PTb
P1 TRAVEL
UNLOAD PRIORITY
PCb

M
P2 UNLOAD

MAIN PUMP
PCa

51
LEFT NIBBLER

HYD.TANK 50-2 RIGHT

BREAKER

PBo 52
OPTION NIBBLER & BREAKER
PAo PILOT VALVE
24.5MPa Ao
Bo T
P
24.5MPa

SOL/V BLOCK LEVER B C1 C2 A

A1 LOCK
P
SE-11

50-1 SV-13
Ps C PL
P
SE-29

Fig. 63-2

63-12
 63. MOUNTING THE NIBBLER & BREAKER

N&B specification YN01Z00162P1

No. Part name Part No. Type
(50) Control valve assy LC30V00028F1 KMX15YD
50-1 Selector valve YN30V00104F1 VBY-174B
50-2 Relief valve YN22V00002F1 KRX16EK22
51 Stop valve 24100P3133F1
52 Pilot valve YN30V00080F1 16030-00000

Add this hydraulic circuit to the standard circuit of SK330-8, SK350LC-8 for completion.

• Switch operating (Nibbler & Breaker)

Switch position
Spec. Work mode Conflux/single Circuit flow
select
A Conflux Conflux
Nibbler
A Single Single
Breaker B Single Single

• Nibbler operating

Foot pedal depressing section ATT. hydraulic pressure lines

Depress toe section ATT. LH
Depress heel section ATT. RH

When using NIBBLER according to specification of NIBBLER installed choose conflux or single flow by "CONFLUX
/ SINGLE flow select switch"

(1) When the nibbler used

When conflux switch is selected, PSV-C of SOL/V Block (13) is excited and "TRAVEL PRIORITY VALVE"
switched. Consequently, delivery of pump P1 & P2 flow together and the flow opens the load check valve option
valve.
(2) When the breaker used
When B mode switch is selected by work mode switch, solenoid (SV-13) which is attached on selector valve (50-
1) is excited and the valve is switched. Consequently, return oil from breaker returns to tank circuit through T
port. In this case, this return oil does not flow via control valve.

63-13
63. MOUNTING THE NIBBLER & BREAKER

63.4 HYDRAULIC COMPONENTS

63.4.1 SELECTOR VALVE (50-1) : YN30V00104F1

4-M14-18

Hex. socet head

cap screw
(Tightening torque)
HYDRAULIC CIRCUIT

Emergency manual screw

Tightening torque Max. Tightening torque
6.9~7.9N.m 2.0N.m and below

Fig. 63-3

63.4.2 OVERLOAD RELIEF VALVE (50-2) : YN22V00002F1

P R

HYDRAULIC SYMBOL

Tightening torque Opposing

No. Screw size N.cm (lbf.ft) flats
101 M27X1.5 6865~7845 (5.06~5.79) 32
102 M27X1.5 6865~7845 (5.06~5.79) 30
671 M14 2746~3138 (2.03~2.31) 22

Fig. 63-4

63-14
 63. MOUNTING THE NIBBLER & BREAKER

63.4.3 PILOT VALVE (52) : YN30V00080F1

HYDRAULIC CIRCUIT

Secondary pressure Effort to operate

[MPa] [kgf/cm2] [kgf.cm] [N.m]

2.94 30 120 11.76
SECONDARY PRESSURE

OPERATING TORQUE
2.45 25 100 9.8
0.35+0.15 (24.0+1.5)
1.95 20 80 7.84

A 1.47 15 60 5.88
(4.5) 4.61
0.98 10 40 3.92
0.54+0.1 (5.5+1)
0.49 5 20 1.96
(11.3) 1.11

OPERATING ANGLE
Fig. 63-5

63-15
63. MOUNTING THE NIBBLER & BREAKER

63.5 MODIFICATION PROCEDURE FOR NIBBLER & BREAKER (N&B)

63.5.1 MODIFICATION ITEM
The main items that are needed to modify the standard machine into a N&B mounted machine are as follows :

Reference
No. Item Assy No. Main modification points
pages
ASIA LC03M00015F1 Add pedal assy and cutout of STD
5.2 Controls, operators 63-17
OCEANIA LC03M00025F1 floor mat
ASIA YN64H00190F1 Add selector valve and overload relief
5.3 Valve install 63-18
OCEANIA ↑ valve
ASIA LC64H00105F1
Main valve Add N&B valve control lines 63-19
OCEANIA ↑
ASIA LC68H00063F1
Remote valve Add P/V control lines 63-22
Control OCEANIA ↑
5.4
lines ASIA LC64H00090F1
Block Change to 1 option block 63-24
OCEANIA ↑
ASIA LC64H00088F1
Block control Add control lines 63-26
OCEANIA ↑
ASIA LC03H00055F1
5.5 Hyd. lines upper Add N&B lines 63-28
OCEANIA ↑
ASIA LC33H00043F1
5.6 Hyd. tank assy Replace return filter 63-33
OCEANIA ↑
ASIA YN17M00049F1
5.7 Panel assy, instrument Add single/conflux flow sw. 63-34
OCEANIA YN17M00052F1
ASIA YN22T00334F2
5.8 Name plate install Add label 63-35
OCEANIA LC22T00094F3

63-16
 63. MOUNTING THE NIBBLER & BREAKER

63.5.2 CONTROLS, OPERATORS

Install the additional parts listed in Table63-1 to the standard machine, as shown in Fig. 63-6.
Table63-1
LC03M00015F1 ASIA
Controls, operators
LC03M00025F1 OCEANIA
No. Part No. Name Q’ty Remarks
6 YN55M00004F1 Pedal assy (1) ←
6-1 YN26M00066P1 Mat, floor (1) ← Cut STD mat
6-2 YN03M01852P1 Pedal 1 ← RH
6-3 YN03M01858P1 Rubber 1 ←
6-4 YN03M01684P1 Lock assy 1 ←
6-5 ZM73C08020 Sems-bolt 2 ← M8×20
6-6 ZM73C10020 Sems-bolt 2 ← M10×20

Fig. 63-6 PEDAL ASSY ; YN55M00004F1

Make slits (notch) to face of the standard floor mat according to Fig. 63-7 and cut out the hatching.
Floor mat for N & B : YN26M00066P1

Fig. 63-7 Modification of floor mat

63-17
63. MOUNTING THE NIBBLER & BREAKER

63.5.3 VALVE INSTALL

(1) Modification procedure
Install the additional parts listed in Table63-2 to the control valve of the standard machine, as shown in Fig. 63-
8. On that occasion, some parts become unnecessary.
Table63-2
Modification of the control valve YN64H00190F1
No. Part No. Name Q’ty Remarks
0 LC30V00028F1 Control valve (1) STD
1 YN30V00104F1 Valve selector 1
2 YN22V00002F1 Valve assy, overload 2
3 PV02B01073D7 Cap 1
1-703 ZS23C12105 Capscrew (3) M12×105
1-704 ZS23C12080 Capscrew (1) M12×80

Fig. 63-8
(2) Parts to be disused
When the selector valve is installed, the parts shown in Table63-3 is disused from the standard machine.
Table63-3
Control valve (STD) LC30V00028F1
No. Part No. Name Q’ty Remarks
213 YN30V00101S213 Plate 1
275 ZS23C12035 Capscrew 4 M12×35

63-18
 63. MOUNTING THE NIBBLER & BREAKER

63.5.4 CONTROL LINES (NIBBLER & BREAKER)

63.5.4.1 MAIN CONTROL LINES

(1) Modification procedure
Install the additional parts listed in Table63-4 to the main valve control of the standard machine, as shown in Fig.
63-9.

• Before starting the modification work, check parts according to the Additional Parts List.
• When disconnecting and reconnecting pipes, take care, so as not to allow dirt and foreign matter to enter.

Table63-4
LC64H00105F1 ASIA
Controls lines, valve
↑ OCEANIA
No. Part No. Name Q’ty Remarks
1 LC64H00083F1 Control lines, valve (1) Base
2 LC64H00109F1 Control lines, valve (1) N&B
2-1 2444R963D11 Hose 1 PF1/4 L=550
2-2 2444Z2892 Tee 1 2-PF3/8-PF1/4
2-3 HH25X04004G2 Connector 1 PF1/4 with filter
2-4 YX52S00013P1 Sensor, press 1
2-5 2444Z2894 Elbow 2 PF1/4

Fig. 63-9 Control lines, valve ; LC64H00109F1

63-19
63. MOUNTING THE NIBBLER & BREAKER

(2) Parts to be disused

Table63-5
LC64H00104F1 ASIA STD
Control lines valve
↑ OCEANIA STD
No. Part No. Name Q’ty Remarks
1 LC64H00083F1 Control lines, valve (1) Base
2 YN64H00220F1 Control lines, valve (1) STD
2-1 ZH22X06000 Connector 1 PF3/8

Fig. 63-10

63-20
 63. MOUNTING THE NIBBLER & BREAKER

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63-21
63. MOUNTING THE NIBBLER & BREAKER

63.5.4.2 CONTROL LINES, REMOTE

(1) Modification procedure
Install the additional parts listed in Table63-6 to the remote control lines of the standard machine. as shown in
Fig. 63-11.
Table63-6
LC68H00063F1 ASIA
Control lines, remote
↑ OCEANIA
No. Part No. Name Q’ty Remarks
1 YN30V00080F1 Valve, pilot 1
2 2420R349D090 Hose 2 PF1/4 L=900
3 2420R349D160 Hose 1 PF1/4 L=1600
4 2420R349D400 Hose 1 PF1/4 L=4000
5 HH25X04004G2 Connector 1 PF1/4 with filter
6 ZH22X04000 Connector 1 PF1/4
7 ZH32X04000 Elbow 2 PF1/4
8 ZE72X04000 Plug 1 PF1/4
9 YX52S00013P1 Sensor, press 1 PF1/4
10 HM83C10030G1 Sems-bolt 2
11 ZH22X04006 Connector 1 PF1/4-PF3/8

Fig. 63-11 Control lines, remote ; LC68H00063F1

63-22
 63. MOUNTING THE NIBBLER & BREAKER

Fig. 63-12
(2) Parts to be disused
Concerning the remote control lines, the parts listed in Table63-7 and Fig. 63-18 are disused from the standard
machine.
Table63-7
LC03H00052F1 ASIA
Hyd. lins upp
↑ OCEANIA
No. Part No. Name Q’ty Remarks
3 ZE72X06000 Plug 1

63-23
63. MOUNTING THE NIBBLER & BREAKER

63.5.4.3 CONTROL LINES, BLOCK

(1) Modification procedure
Install the additional parts listed in Table63-8 to the remote control lines of the standard machine, as shown in
Fig. 63-13.
Table63-8
LC64H00090F1 ASIA
Control lines, Block
↑ OCEANIA
No. Part No. Name Q’ty Remarks
1 YN64H01337P1 Block 1
2 ZM73C08020 Sems-bolt 3

Fig. 63-13 Control lines, block ; LC64H00090F1

63-24
 63. MOUNTING THE NIBBLER & BREAKER

(2) Parts to be disused

Table63-9
YN64H00183F1 ASIA STD
Control lines, Block
↑ OCEANIA STD
No. Part No. Name Q’ty Remarks
1 YN64H01336P1 Block 1
2 ZM73C08020 Sems-bolt 3

Refer to floor plate view Fig. 63-13

Fig. 63-14

63-25
63. MOUNTING THE NIBBLER & BREAKER

63.5.4.4 CONTROL LINES, BLOCK

(1) Modification procedure
install the additional parts listed in Table63-10 to the remote control lines of the standard machine, as shown in
Fig. 63-15, but ( ) No is same as standard parts.
Table63-10
LC64H00088F1 ASIA
Control lines, Block
↑ OCEANIA
No. Part No. Name Q’ty Remarks
1 YN64H01292P1 Block 1
2 2420R349D125 Hose 1 PF1/4 L=1250
(3) 2420R349D135 Hose (1) PF1/4 L=1350
(4) 2420R349D140 Hose (1) PF1/4 L=1400
(5) HM83C10030G1 Sems-bolt (2)
(7) YN64H01288P1 Clamp (1)
(8) ZM73C10020 Sems-bolt (2)
(9) PY01P01043D8 Clip (1)
10 ZH32X04006 Elbow 1 PF1/4 -PF3/8

63-26
 63. MOUNTING THE NIBBLER & BREAKER

Fig. 63-15 Control lines, block ; LC64H00088F1

63-27
63. MOUNTING THE NIBBLER & BREAKER

(2) Parts to be disused

Table63-11
LC64H00087F1 ASIA STD
Control lines, Block
↑ OCEANIA STD
No. Part No. Name Q’ty Remarks
1 YN64H01291P1 Block 1

Fig. 63-16
(3) Parts to be disused
Concerning the block control lines, the parts listed in Table63-12 and Fig. 63-18 are disused from the standard
machine.
Table63-12
LC03H00052F1 ASIA
Hyd. lines, Upp
↑ OCEANIA
No. Part No. Name Q’ty Remarks
3 ZE72X06000 Plug 1

63-28
 63. MOUNTING THE NIBBLER & BREAKER

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63-29
63. MOUNTING THE NIBBLER & BREAKER

63.5.5 HYD. LINES, UPPER

(1) Assembling the additional parts listed in Table63-13 to the upper hyd. lines of the standard machine, as shown
in Fig. 63-17.

• Before starting the modification work, check parts according to the Additional Parts List.
• When disconnecting and reconnecting pipes, take care, so as not to allow dirt and foreign matter to enter.
• At assembly, use care of O-ring do not come off.
• Regarding the tightening torque of O-ring type joints, hydraulic hoses and Nut sleeve joints, refer to the
Remarks of Fig. 63-29 and the Tightening Torque Table.

Tightening torque
Tightening torque
Thread size Spanner (mm)
N•m (lbf•ft)
M12 19 121 (89)

Table63-13
LC03H00055F1 ASIA N&B
Hyd. lines, Upper
↑ OCEANIA N&B
No. Part No. Name Q’ty Remarks
1 LC03H00047F1 Hyd. lines, Upper (1) Base
2 LC03H00053F1 Hyd. lines, Upper (1) N&B
2-1 LC03H01264D1 Hose 1 1-1/4 L=1550
2-2 LC03H01263D1 Hose 1 1-1/4-1 L=1680
2-3 LQ03H01282D2 Hose 1 1-1/2 L=950
2-4 ZE12Q16000 Plug 1 1"
2-5 ZE12X16000 Clamp half 2
2-6 ZE13X20001 Clamp half 6
2-7 ZS18C14045 Capscrew 4
2-8 ZS28C14050 Capscrew 8
2-9 HM83C10030G1 Sems-bolt 4
2-10 HM83C10035G1 Sems-bolt 4
2-11 HM83C12035G1 Sems-bolt 4
2-12 ZW26K14000 Lock washer 8
2-13 ZD12P03400 O-ring 2
2-14 ZD12P03800 O-ring 3
2-15 ZD12P04800 O-ring 2
2-16 ZW26X14000 Lock washer 4

63-30
 63. MOUNTING THE NIBBLER & BREAKER

Fig. 63-17 Hyd. lines, upper ; LC03H00053F1

63-31
63. MOUNTING THE NIBBLER & BREAKER

(2) Parts to be disused

Concerning the upper hydraulic lines, the parts listed in Table63-14 and Fig. 63-18 are disused from the standard
machine.
Table63-14
LC03H00052F1 ASIA
Hyd. lines, Upp
↑ OCEANIA
No. Part No. Name Q’ty Remarks
1 YN03H01884P1 Plug 1
2 ZE12Q16000 Plug 1
4 HM83C10030G1 Sems-bolt 4
5 ZM73C12030 Sems-bolt 2
6 ZD12P04800 O-ring 1
7 ZD12P03400 O-ring 1

Fig. 63-18

63-32
 63. MOUNTING THE NIBBLER & BREAKER

63.5.6 HYDRAULIC TANK ASSY

When modifying from standard machine to N&B
Cap
machine, replace the return filter with new one.

Push Air breather

There is internal pressure in the hydraulic tank and
hydraulic circuit.
Be sure to release the internal pressure before
carrying out the inspection, maintenance work.

Remove cap on air breather and push valve (head of

bolt) to release inner pressure from hydraulic tank.
Fig. 63-19 Releasing inner pressure of hyd. tank

63.5.6.1 REPLACING PROCEDURE

Remove cap screws of hydraulic tank, and take out spring and element assy. Replace filter element by the procedure
shown in Table63-15 and Fig. 63-20.
Table63-15
LC33H00043F1 ASIA
Hyd. tank assy
↑ OCEANIA
No. Part No. Name Q’ty Remarks
2 LC33H00028F1 Hyd. tank assy (1)
2-6 LC52V01001F1 Filter element (1)
2-6-R100 LS52V01001R300 Element kit
2 YN52V01011P1 Filter element 3
5 ZD11G09000 O-ring 1
6 YN52V01008S005 Packing 1
8 ZD11G19000 O-ring 1

CAPSCREW
WASHER
COVER

SPRING
Turn this handle,
and remove element

CHECK VALVE

5
AIR BREATHER

HYD.TANK

PLATE
6

Fig. 63-20 Replace of return filter

63-33
63. MOUNTING THE NIBBLER & BREAKER

63.5.7 PANEL ASSY, INSTRUMENT

(1) Modification procedure
Install the additional parts listed in Table63-16 to the instrument panel assy of the standard machine, as shown
in Fig. 63-21, some parts to become unnecessary.
Table63-16
YN17M00049F1 ASIA
Panel assy, instrument
YN17M00052F1 OCEANIA
No. Part No. Name Q’ty Remarks
1 YN17M00053F1 Panel assy, instrument — (1) Asia base
1 YN17M00054F1 Panel assy, instrument (1) — Oce. base
2 YN50E00021F1 Switch install (1) ← N&B
2-2 YN50S00040DD Switch 1 ← Single/conflux flow sw.

Fig. 63-21 Switch install ; YN50E00021F1

(2) Parts to be disused
Table63-17
YN17M00051F1 ASIA
Panel assy, instrument
YN17M00055F1 OCEANIA
No. Part No. Name Q’ty Remarks
(1) YN17M00053F1 Panel assy, instrument — 1 Asia base
(1) YN17M00054F1 Panel assy, instrument 1 — Oce. base
(2) YN50E00014F1 switch install 1 1 Asia & Oce.
2-2 YN17M01282P1 Cap 1 1

Fig. 63-22

63-34
 63. MOUNTING THE NIBBLER & BREAKER

63.5.8 NAME PLATE INSTALL

Fit the labels shown in Table63-18 to the cab of the standard machine, according to Fig. 63-23, Fig. 63-24.
Table63-18
YN22T00334F2 ASIA
Name plate install
LC22T00094F3 OCEANIA
No. Part No. Name Q’ty Remarks
14 YN20T01837P1 Label 1 —
15 YN20T01836P1 Label 1 —
17 PY20T01062P1 Label — 1
18 YN20T01930P1 Label — 1
19 YT20T01054P1 Label — 1
20 YN20T01836P1 Label — 1

Fig. 63-23 Name plate install ; YN22T00334F2 (For ASIA)

63-35
63. MOUNTING THE NIBBLER & BREAKER

Fig. 63-24 Name plate install ; LC22T00094F3 (For OCEANIA)

63-36
 63. MOUNTING THE NIBBLER & BREAKER

63.6 MODIFICATION PROCEDURE FOR ATTACHMENT FOR N&B

63.6.1 MODIFICATION ITEM
Table63-19
Reference
Device Item N&B assy No. STD assy No.
pages
ASIA LC42H00178F1 LC42H00175F1 63-38
Boom Hyd. lines Boom (6.5m)
OCEANIA ↑ ↑ 63-40
ASIA LC43H00111F1 —
Hyd. lines Arm ; STD 63-42
OCEANIA ↑ —
ASIA LC43H00122F1 —
Arm Hyd. lines Arm ; LONG 63-46
OCEANIA ↑ —
ASIA LC43H00107F1 —
Hyd. lines Arm ; SHORT 63-48
OCEANIA ↑ —
N&B YN43H00006F1 —
Connector NPK YN43H00004F1 —
YN43H01646F1 63-50
assy TOKU YN43H00005F1 —
KRUPP ↑ —

63-37
63. MOUNTING THE NIBBLER & BREAKER

63.6.2 HYDRAULIC LINES, BOOM

(1) Modification procedure
Install additional parts listed in Table63-20 to the 6.5m (21ft-4in) Boom as shown in Fig. 63-25, Fig. 63-26, On
the occasion, some parts become unnecessary.
Table63-20
HYD. LINES BOOM LC42H00178F1 ASIA
6.5m (21ft-4in) ↑ OCEANIA
No. Part No. Name Q’ty Remarks
1 LC42H00155F1 Hyd lines, boom (1) BASE
2 LC42H00169F1 Hyd lines, boom (1) N&B
2-1 LC42H01795P1 Tube 1 ø42.7
2-2 LC42H01796P1 Tube 1 ø42.7
2-3 LC42H01780P1 Tube 1 ø42.7
2-4 LC42H01781P1 Tube 1 ø42.7
2-5 LS42H01021DT Hose 2 L=1380
2-6 YN42H02582P1 Plug 4 PF1
2-7 LC42H01909P1 Bracket 1
2-9 LC42H01914P1 Clamp 1
2-10 YN42H02348P1 Clamp 8
2-11 YN42H02363P1 Clamp 12
2-12 ZE13X20001 Clamp, half 8
2-14 ZD12P03800 O-ring 4 1B P38
2-15 ZM73C12030 Sems-bolt 12 M12×30
2-16 ZM73C12035 Sems-bolt (8) M12×35 Existing goods
2-17 ZS18C12050 Capscrew 2 M12×50
2-18 ZS28C14050 Capscrew 16 M14×50
2-19 ZW16H12000 Washer 8 M12
2-20 ZW26K14000 Lock washer 16 M14
2-21 LC42H1269P1 Clamp 2
2-22 ZS18C12065 Capscrew 6 M12×65
3 LC42H00177F1 Hyd. Lines, boom (1) N&B Bracket
3-1 LC42H01916P1 Bracket 1
3-2 LC42H01915P1 Bracket 1
3-3 ZM73C12040 Sems-bolt 4 M12×40

63-38
 63. MOUNTING THE NIBBLER & BREAKER

2-20, 2-18, 2-14, 2-12 2-5

2-12, 2-14, 2-18, 2-20

2-6
2-3
2-1

2-20, 2-18, 2-14, 2-12 2-5

2-6
2-4
2-2

2-19, 2-22

2-19, 2-22 2-21 2-15

2-21
2-11
2-15

2-11

2-16
2-16 2-10

2-9
2-15
2-19, 2-22
2-15
2-7 2-17, 2-19
2-11
2-11

Fig. 63-25 Hyd lines, boom ; LC42H00169F1

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63. MOUNTING THE NIBBLER & BREAKER

3-1

3-3

3-2

3-3

Fig. 63-26 Hyd lines, boom ; LC42H00177F1

(2) Parts to be disused
Table63-21
LC42H00175F1 ASIA
Hyd. lines, Boom
↑ OCEANIA
No. Part No. Name Q’ty Remarks
1 LC42H00153F1 Hyd lines, boom (1) STD
1-1 YN42H02357P1 Clamp 1
1-2 ZM73C12035 Sems-bolt 2
1-3 PV02B01073D3 Cap 16
2 LC42H00155F1 Hyd lines, boom (1) BASE

1-3

1-3

1-3
1-3
1-2

1-3

1-1

SECTION AA, BB

Fig. 63-27

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63-41
63. MOUNTING THE NIBBLER & BREAKER

63.6.3 HYDRAULIC LINES, ARM

63.6.3.1 HYDRAULIC LINES, ARM ; STD

(1) Install the additional parts listed in Table63-22 to the Arm as shown in Fig. 63-28 & Fig. 63-29
Table63-22
LC43H00111F1 ASIA
Hyd. lines, Arm (STD)
↑ OCEANIA
No. Part No. Name Q’ty Remarks
1 LC43H00101F1 Hyd. lines, Arm (1) N&B spec.
1-1 LC43H01269P1 Tube 1
1-2 LC43H01270P1 Tube 1
1-3 LC43H01011D2 Hose 2
1-4 24100P3133F1 Valve, stop 2
1-5 LC43H01223P1 Connector 2
1-6 ZE13X20001 Clamp, half 12
1-7 YN42H02361P1 Clamp 8
1-8 YN42H02321P1 Bushing 4
1-9 ZM73C12030 Sems-bolt 8 M12×30
1-10 ZS18C08025 Capscrew 8 M8×25
1-11 ZS28C14050 Capscrew 16 M14×50
1-12 ZS28C14070 Capscrew 8 M14×70
1-13 ZN18C14011 Nut 8 M14
1-14 ZW26K14000 Lock washer 16 M14
1-16 YN43H01151P1 Washer 8
1-17 ZD12P03800 O-ring 8 1B P38
2 YN43H00200F1 Hyd. lines, Arm (1) N&B spec.
2-1 YN43H01663P1 Bracket 2
2-2 ZS18C16040 Capscrew 4 M16×40
2-3 ZW16H16000 Washer 4

63-42
 63. MOUNTING THE NIBBLER & BREAKER

1-17, 1-14, 1-11, 1-6 1-3 1-6, 1-11, 1-14, 1-17

1-1

1-2 1-17, 1-14, 1-11, 1-6 1-6, 1-11, 1-14, 1-17

1-3

1-4

1-10, 1-16

1-4

1-7 1-8
1-10, 1-16

1-8, 1-7 1-7, 1-8

1-9
1-9

1-12
1-6
1-5

1-17

1-17

1-13

Fig. 63-28 Hyd. lines, arm ; LC43H00101F1 (STD arm)

63-43
63. MOUNTING THE NIBBLER & BREAKER

2-1

2-1

2-3, 2-2

Fig. 63-29 Hyd. lines, arm ; YN43H00200F1

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63-45
63. MOUNTING THE NIBBLER & BREAKER

63.6.3.2 HYDRAULIC LINES, ARM ; LONG

Install the additional parts listed in Table63-23 to the Arm as shown in Fig. 63-30 & Fig. 63-29.
Table63-23
LC43H00122F1 ASIA
Hyd. lines Arm (Long)
↑ OCEANIA
No. Part No. Name Q’ty Remarks
1 LC43H00123F1 Hyd. lines, Arm (1) N&B base
1-1 LC43H01283P1 Tube 1
1-2 LC43H01284P1 Tube 1
1-3 LS30H01078DC Hose 2
1-4 24100P3133F1 Valve stop 2
1-5 LC43H01223P1 Connector 2
1-6 ZE13X20001 Clamp half 12
1-7 YN42H02361P1 Clamp 16
1-8 YN42H02321P1 Bushing 8
1-9 ZD12P03800 O-ring 8 1B P38
1-10 ZM73C12035 Sems-bolt 16 M12×35
1-11 ZS18C08025 Capscrew 8 M8×25
1-12 ZS28C14050 Capscrew 16 M14×50
1-13 ZS28C14070 Capscrew 8 M14×70
1-14 ZN18C14011 Nut 8 M14
1-15 YN43H01151P1 Washer 8
1-16 ZW26K14000 Lock washer 16 M14
2 YN43H00200F1 Hyd. lines, Arm (1) N&B
2-1 YN43H01663P1 Bracket 2
2-2 ZS18C16040 Capscrew 4 M16×40
2-3 ZW16H16000 Washer 4 M16

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 63. MOUNTING THE NIBBLER & BREAKER

1-1 1-16, 1-12, 1-9, 1-6 1-3 1-6, 1-9, 1-12, 1-16

1-2 1-16, 1-12, 1-9, 1-6 1-3 1-6, 1-9, 1-12, 1-16

1-4

1-11, 1-15

1-4

1-15, 1-11

1-8, 1-7 1-7, 1-8

1-10 1-10

1-13
1-6
1-5
1-9 1-7 1-8

1-9
1-14

Fig. 63-30 Hyd. lines, arm ; LC43H00123F1 (Long)

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63. MOUNTING THE NIBBLER & BREAKER

63.6.3.3 HYDRAULIC LINES, ARM ; SHORT

Install the additional parts listed in Table63-23 to the Arm as shown in Fig. 63-31 & Fig. 63-29.
Table63-24
LC43H00107F1 ASIA
Hyd. lines, Arm (short)
↑ OCEANIA
No. Part No. Name Q’ty Remarks
1 LC43H00106F1 Hyd. lines, Arm (1) N&B base
1-1 LC43H01259P1 Tube 1
1-2 LC43H01260P1 Tube 1
1-3 LC43H01011DB Hose 2
1-4 24100P3133F1 Valve, stop 2
1-5 LC43H01223P1 Connector 2
1-6 ZE13X20001 Clamp, half 12
1-7 YN42H02361P1 Clamp 8
1-8 YN42H02321P1 Bushing 4
1-9 ZM73C12030 Sems-bolt 8 M12×30
1-10 ZS18C08025 Capscrew 6 M8×25
1-11 ZS28C14050 Capscrew 16 M14×50
1-12 ZS28C14070 Capscrew 8 M14×70
1-13 ZN18C14011 Nut 8 M14
1-14 YN43H01151P1 Washer 8
1-15 ZD12P03800 O-ring 8 1B P38
1-16 ZW26K14000 Lock washer 16 M14
2 YN43H00200F1 Hyd. lines, Arm (1) N&B spec.
2-1 YN43H01663P1 Bracket 2
2-2 ZS18C16040 Capscrew 4 M16×40
2-3 ZW16H16000 Washer 4

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 63. MOUNTING THE NIBBLER & BREAKER

1-1 1-16,1-15,1-11,1-6 1-3 1-6,1-11,1-15,11-6

1-2 1-16,1-15,1-11,1-6 1-3 1-6,1-11,1-15,11-6

1-4

1-10, 1-14
1-4

1-7 1-8
1-14, 1-10

1-8, 1-7 1-7, 1-8

1-9 1-9

1-12
1-6
1-5
1-15

1-15
1-13

Fig. 63-31 Hyd. lines, arm ; LC43H00106F1 (Short)

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63. MOUNTING THE NIBBLER & BREAKER

63.6.4 CONNECTOR ASSY

(1) Breaker
When using the machine with a breaker, attach the 2 1-5/16-UNF 1 3
below parts to the tip of the stop valve. For use with
NPK, TOKU and KRUPP breakers.

Connector assy
for NPK YN43H00004F1
No. Part No. Name Q'ty Remark

1 2444P1744D3 Connector 1
2 2444T2406 Plug 1 PF1-1/4
3 ZD12P03800 O-ring 1 1B P38

Fig. 63-32 Connector assy (NPK)

Connector assy
for TOKU, KRUPP YN43H00005F1 2 M45X1.5 1 3
No. Part No. Name Q'ty Remark

1 2444P1745D4 Connector 1
2 2420Z1228D5 Plug 1
3 ZD12P03800 O-ring 1 1B P38

PF1-1/4

Fig. 63-33 Connector assy (TOKU, KRUPP)

(2) Nibbler & breaker
When using the machine with a nibbler, attach the 2 M45X1.5 1 3
below parts to the tip of the stop valve.

Connector assy YN43H00006F1

No. Part No. Name Q'ty Remark

1 YN43H01006P1 Connector 1
2 2444T1329D6 Plug 1
3 ZD12P03800 O-ring 1 1B P38
PF1-1/4

Fig. 63-34 Connector assy (NIBBLER)

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 63. MOUNTING THE NIBBLER & BREAKER

63.7 REMINDERS ON THE USE OF NIBBLER & BREAKERS

63.7.1 CHANGING OVER THE SELECTOR VALVE
A nibbler & breaker-attached machine is equipped with a selector valve in both the operation circuit and the main
circuit. When running the machine after completion of modification, always set the selector valves according to a
nibbler or a breaker used.
(1) Switching selector valve
The selector valve (1) is used to change the flowing route of hydraulic oil.
Since the flow is automatically changed according to the selected work mode, the switching to proper work mode
is required depending on the attachment in use.

63.7.2 FLUSHING METHOD

After completion of piping work, connect the high pressure side and the low pressure side, as shown in Fig. 63-35,
open the stop valves on both sides and depress the operating pedal to perform flushing.
• Before beginning flushing, run the engine at low speed, depress the breaker operating pedal and then run the
engine at high speed.
• Perform flushing operation for at least 40 minutes, and during the operation, make sure of no oil leakage from
each of the connections of the newly attached breaker circuit and the nibbler & breaker circuits.

An example of flushing time (23 min) in a single process

Fig. 63-35 Flushing method

63.7.3 REPLACING HYDRAULIC OIL AND RETURN FILTER

Contamination and deterioration of hydraulic oil may develop malfunctioning of the control valve, early wear and
seizure of the hydraulic pumps and malfunctioning of the entire hydraulic circuits : always replace hydraulic oil at
regular intervalvs, based on Table63-25.
Table63-25
Inspection / Replacement intervals
Item
maintenance points First replacement 2 nd replacement Regular replacement
ASIA Every 600h
Hydraulic oil Hydraulic oil tank — —
OCEANIA Every 1000h
Return filter Hydraulic oil tank 50h 250h Every 250h

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63. MOUNTING THE NIBBLER & BREAKER

63.7.4 BASIC OPERATION

This machine is provided with breaker or nibbler single circuit and nibbler and breaker conflux circuit. To use breaker
or nibbler, select circuit appropriate to the specification through switch (1) on the left rear side of driver’s seat.
(1) Breaker and nibbler selector switch
1

Do not set this switch to nibbler combined flow

operation position when using breaker.

1) Switch position

Specification Switch Position Circuit

Breaker
Nibbler Single flow

Nibbler Conflux flow

Fig. 63-36

When nibbler a little flow rate requires is used, operate

it in " " condition.

(2) Operating pedal

Release pedal lock on the right front side of driver’s
seat to operate pedal.
A

Attachment operation by foot pedal.

Always check the foot pedal control pattern before
operation.
Always read operators manual before operating B
machine.

• Breaker Fig. 63-37

Foot pedal depressing section Operation

Depress toe section Breaker starts operation
Pedal in neutral positon Breaker stops operating

• Nibbler

Foot pedal depressing section Operation

Depress toe section Nibbler close
Depress heel section Nibbler open

Do not leave the machine with engine running.

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 63. MOUNTING THE NIBBLER & BREAKER

(3) Pedal lock device

This device is used to lock control pedal.
A
Move pin (1) forward and the pedal is unlocked. 1
Locked
Move pin (1) rearward and the pedal is locked.

B
Unlocked
Make sure to set the pedal lock to "LOCKED"
position while the breaker or nibbler is not used.
Unexpected contact with UNLOCKED position of
pedal may cause severe injury or death.
Do not put foot on the pedal except at the time of
operation using pedal. Fig. 63-38

A. Position ..... Locked

B. Position ..... Unlocked

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63. MOUNTING THE NIBBLER & BREAKER

63.8 PRECAUTIONS TO BE EXERCISED ON BREAKERS OF DIFFERENT

MANUFACTURERS
There are some differences between manufac-turers as to the piping to breakers and the handling of breakers. For
this reason, consult with the manufacturer when mounting a breaker in the field. The following is a summary of how
breakers should be handled that is extracted from manu-facturers’ catalog use and operation manuals.

This is a general outline of how breakers should be used and may differ with excavator models. Always contact the
breaker manufacturer before field mounting.

(1) Placing high and low pressure accumulators

• NPK
They must be placed basically (depending upon models).
• TOKU
They must be placed basically.
• KRUPP, OKADA, FURUKAWA
Check the oscillation of the pulsation of the breaker pressure and if pulsation is large, always install accumu-
lators.
Standard of judgment on the installation of accumulators
• High pressure side :
Measure the pulse oscillation by pressure on the high pressure side of the breaker at the inspection port for
the pump’s delivery pressure by actuating the breaker at the full revolution of the engine in mode H and set
the maximum pressure difference to within 20% of the excavator’s system pressure 350kgf/cm2 (4980psi).
In case it exceeds 20%, install a high pressure accumulator.

The pulse oscillation is 350×20%= 70kgf/cm2 (1000psi). Therefore, if it is more than this level, an accumulator
must be installed.

Install accumulator referring to the result of verification test.

max

min
Max. press-Min. press<System press X 20%
• Low pressure side :
Measure the inlet pressure of the line filter on the breaker side by actuating the breaker at full engine
revolution in the B mode, and in case the maximum pressure exceeds 55kgf/cm2 (780 psi), install a low
pressure accumulator.
Max. <55kgf/cm2 (780 psi)
Regarding the capacity and the charge pressure of accumulators, contact the breaker manufacturer before
installation.

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 63. MOUNTING THE NIBBLER & BREAKER

(2) Installation of the relief control valve is not necessary.

The pressure can be adjusted with the overload valve of control valve OPT2.

Only the B series TOKU machine requires a relief valve to be installed.

INSTALLATION OF A RELIEF VALVE

PLUG

N&B
LOW PRESSUSE SIDE
(RETURN)

N&B
HIGH PRESSUSE
SIDE

BOOM
Fig. 63-39 Relief valve mounting

6
4

2
3
TO TANK

RETURN SIDE
5 1

TO BREAKER OIL SUPPLY SIDE

1. HIGH PRESSURE HOSE 4. PLUG

2. NIPPLE 5. ELBOW
3. ADAPTER 6. RELIEF VALVE
Fig. 63-40

63-55
63. MOUNTING THE NIBBLER & BREAKER

(3) Restriction of engine revolution

• NPK
Full engine revolution may be used.
• TOKU, KRUPP, OKADA, TAISEI, FURUKAWA
There are restriction on the engine revolution. Since a specified revolution differs with breakers, follow the
breaker manufacturer’s inst-ructions.

In the case of a breaker for which the engine revolution is limited, the breaker does not increase impact power
and cycles even at full engine revolution.
Since extra hydraulic oil returns to the hydraulic oil via the relief valve, it causes the hydraulic oil temperature to
rise and the fuel consumption to increase. Plaster the label (furnished by the breaker maker) indicating the
revolution (Check the engine revolution.), to the throttle potentiometer position. Always observe the indicated
revolution.

(4) Changing over the breaker to high and low speeds

• NPK, TOKU, TAISEI, FURUKAWA
These breakers are not so constructed as to be switched over to high and low speed.
• KRUPP
Breakers on and after MKB1200 are constructed with a switching function. It can be operated from inside the
cab by the installation of a solenoid valve. For piping work, consult with the breaker manufacturer.

Piping work is not required in some cases if a high-low changeover function is not necessary at user’s request.
On that occasion, it is necessary to fix the changeover valve contained in the breaker to the low speed side
beforehand. Consult with the breaker manufacturer in that case. It is prohibited to use the high-low speed
changeover valve without laying high-low speed piping and without fixing the high-low speed changeover valve.

HIGH-LOW SPEED
CHANGEOVER VALVE

RELIEF VALVE HYDRAULIC

BREAKER

TO CONTROL VLAVE

TO TANK

CHECK VALVE

Fig. 63-41

63-56
 63. MOUNTING THE NIBBLER & BREAKER

63.9 REFERENCE
(1) Typical combinations are quoted from breaker manufacturer’s catalog use as below, but concerning applicable
breaker models, decide it after consultation with the breaker manufacturer.
When fitting a breaker, read through reminders on the use of breakers and cautions instructed by breaker
manufacturers.
Table63-26
Manufacturer Applicable Working press Oil volume used Total weight kg Total length Bucket capacity
breaker kgf/cm2 (psi) L/min (gal/min) (lbs) mm (in) m3 (cuyd)
120~140 160~200 1,450 2,156
H-10XB
(1,710~1,990) (42.2~52.8) (3,200) (84.9 )
NPK
130~150 35~60 410 1,644
H-4XE
(1,850~2,130) (9.24~15.8) (900) (64.7 )
100~140 110~140 1,000 0.55~0.70
TNB-10B
(1,420~1,990) (29.0~37.0) (2,210) (0.72~0.92)
120~140 140~160 1,400 0.70~0.90
TNB-14B
(1,710~1,990) (37.0~42.2) (3,100) (0.92~1.18)
100~160 45~80 391 1,476 0.25~0.35
TOKU TNB-6E
(1,420~2,280) (11.9~21.1) (860) (58.1 ) (0.33~0.46)
120~170 100~140 997 1,850 0.55~0.70
TNB-10E
(1,710~2,420) (26.4~37.0) (2,200) (72.8 ) (0.72~0.92)
130~170 130~170 1,550 2,190 0.70~0.90
TNB-14E
(1,850~2,420) (34.3~44.9) (3,400) (86.2 ) (0.92~1.18)
150~160 80~110 1,100~1,250 2,278 0.50~0.90
MKB1100
(2,130~2,280) (21.1~29.0) (2,430~2,760) (89.7 ) (0.65~1.18)
KRUPP
150~180 90~130 1,120~1,200 0.55~1.00
MKB1200
(2,130~2,560) (23.8~34.3) (2,470~2,650) (0.72~1.31)
150~170 100~120 1,330 [1,596] 0.60~0.90
TAISEI TF-150
(2,130~2,420) (26.4~31.7) (2,930) (62.8 ) (0.78~1.18)
160~180 125~150 1,400 2,119
FURUKAWA HB20G
(2,280~2,560) (33.0~39.6) (3,100) (83.4 )
[ ] Excludes chisels

General precautions to be exercised on the installation of breakers by different manufacturers

Table63-27
Manufacturer Installation of Installation of a Restriction of High-low speed changeover
accumulators relief valve enginerevolution
NPK × × Changeover type not available.
TOKU
× Changeover type not available.
Series B
TOKU
* × × Changeover type not available.
Series E
— KRUPP Changeover type available for large machines.
— OKADA Changeover type available on special request.
— FURUKAWA Changeover type not available.
— TAISEI Changeover type not available.
Adaptation test completed.
One that must be installed.
× One that does not need to be installed.
One that must be adjusted at installation.
* Capacity 1 liter, pressure is 70kgf/cm2 (1,000psi)

63-57
63. MOUNTING THE NIBBLER & BREAKER

[MEMO]

63-58