Manual de Excavadores Case Cx350b y Otros, Hidráulico

Copyright ©
CRAWLER EXCAVATORS
CX350B - CX370B
SERVICE MANUAL
TABLE OF CONTENTS
SECTION SECTION No. REFERENCE No.
Safety, General Information and Standard Torque Data .............................................. 1001 7-27691EN
General Specifications and Special Torque Settings ................................................... 1002 SM350B370B1002-0EN
Service Connector Kit .................................................................................................. 4000 SM350B370B4000-0EN
Elecrical Functions and Service Support ..................................................................... 4001 SM350B370B4001-0EN
Elecrical Equipment and Electrical Circuit Diagrams ................................................... 4020 SM350B370B4020-0EN
Engine Error Code (DTC)............................................................................................. 4021 SC160B4021-0EN
Main Body Error Code (DTC)....................................................................................... 4022 SC160B4022-0EN
Specifications, Troubleshooting, Checks and Hydraulic Pressure Settings ................. 8001 SM350B370B8001-0EN
Hydraulic Functions...................................................................................................... 8020 SM350B370B8020-0EN
Hydraulic Component Functions .................................................................................. 8030 SM350B370B8030-0EN
Air Conditioner Functions and Troubleshooting ........................................................... 9006 SC210B9006-1EN
Draft / Temporary Shop Manual ................................................................................... 9950 SM350B370B9950-0EN
Large Size Hydraulic Schematics ............................................................................ Pocket KSJ12480-E01
Large Size Electrical Schematics.............................................................................. Pocket KSR11440-E02
NOTE: CNH Company reserves the right to make changes in the specification and design of the machine without prior notice
and without incurring any obligation to modify units previously sold.
The description of the models shown in this manual has been made in accordance with the technical specifications known as of
the date of design of this document.
Copyright © 2008 CNH France S.A.

Printed in France
CNH Lep SMCX350B370BTOC-0EN July 2008
Copyright ©
Lep SMCX350B370BTOC-0EN Issued 07-08

Copyright ©
1001
Section
1001
SAFETY, GENERAL INFORMATION

AND TORQUE SPECIFICATIONS

Printed in France
CNH Lep 7-27691EN February 2006
Copyright ©
1001-2
TABLE OF CONTENTS
GENERAL INFORMATION .......................................................................................................................................3
SAFETY..................................................................................................................................................................... 4
STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS............................................................................... 6
WARNING : This symbol is used in this manual to indicate important safety messages. Whenever you see
! this symbol, carefully read the message that follows, as there is a risk of serious injury.
Lep 7-27691EN Issued 02-06

Copyright ©
1001-3
GENERAL INFORMATION
Cleanning Gears
Clean all metal parts except bearings, in a suitable Check all gears for wear and damage. Replace gears
cleaning solvent or by steam cleaning. Do not use that have wear or damage.
caustic soda for steam cleaning. After cleaning, dry
and put oil on all parts. Clean oil passages with Oil seals, O-rings and gaskets
compressed air. Clean bearings in a suitable cleaning
Always install new oil seals, O-rings and gaskets. Put
solvent, dry the bearings completely and put oil on
petroleum jelly on seals and O-rings.
the bearings.
Inspection Shafts
Check all shafts that have wear or damage. Check
Check all parts when the parts are disassembled.
the bearing and oil seal surfaces of the shafts for
Replace all parts that have wear or damage. Small
damage.
scoring or grooves can be removed with a hone or
crocus cloth. Complete a visual inspection for Service parts
indications of wear, pitting and the replacement of
parts necessary to prevent early failures. Always install genuine Case service parts. When
ordering refer to the Parts Catalog for the correct part
Bearings number of the genuine Case replacement items.
Failures due to the use of other than genuine Case
Check bearings for easy action. If bearings have a
replacement parts are not covered by warranty.
loose fit or rough action replace the bearing. Wash
bearings with a suitable cleaning solvent and permit Lubrication
to air dry. DO NOT DRY BEARINGS WITH
COMPRESSED AIR. Only use the oils and lubricants specified in the
Operator’s or Service Manuals. Failures due to the
Needle bearings use of non-specified oils and lubricants are not
covered by warranty.
Before you press needle bearings in a bore always
remove any metal protrusions in the bore or edge of
the bore. Before you press bearings into position put
petroleum jelly on the inside and outside diameter of
the bearings.

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1001-4
SAFETY
This symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED. The message that follows the
! symbol contains important information about safety. Carefully
read the message. Make sure you fully understand the
causes of possible injury or death.
To prevent injury always follow the Warning, Caution

and Danger notes in this section and throughout the
manual. WARNING: Before starting engine, study
Operator’s Manual safety messages. Read
Put the warning tag shown below on the key for the all safety signs on machine. Clear the area of
keyswitch when servicing or repairing the machine. other persons. Learn and practice safe use
One warning tag is supplied with each machine. of controls before operating.
Additional tags Part Number 331-4614 are available
from your service parts supplier
! It is your responsibility to understand and
f o l l o w m a n u f a c tu r e r s i n s tr u c t i o n s o n
. machine operation, service and to observe
pertinent laws and regulations. Operator’s
WARNING: Read the operator’s manual to and Service Manuals may be obtained from
your Case dealer.
! familiarize yourself with the correct control
functions.
WARNING: If you wear clothing that is too

WARNING: Operate the machine and loose or do not use the correct safety
equipment controls from the seat position equipment for your job, you can be injured.
! only. Any other method could result in Always wear clothing that will not catch on
serious injury. ! objects. Extra safety equipment that can be
required includes hard hat, safety shoes, ear
protection, eye or face protection, heavy
WARNING: This is a one man machine, no gloves and reflector clothing.
! riders allowed.
WARNING: When working in the area of the

! fan belt with the engine running, avoid loose
clothing if possible, and use extreme caution.
WARNING: When doing checks and tests

on the equipment hydraulics, follow the
! procedures as they are written. DO NOT
change the procedure.
WARNING: When putting the hydraulic

cylinders on this machine through the
! necessary cycles to check operation or to
remove air from a circuit, make sure all
people are out of the way.

Copyright ©
1001-5
WARNING: Use insulated gloves or mittens WARNING: When servicing or repairing the
! when working with hot parts. machine, keep the shop floor and operator’s
compartment and steps free of oil, water,
! grease, tools, etc. Use an oil absorbing
WARNING: Lower all attachments to the material and/or shop cloths as required. Use
ground or use stands to safely support the safe practices at all times.
! attachments before you do any maintenance
or service.
WARNING: Some components of this
machine are very heavy. Use suitable lifting
WARNING: Pin sized and smaller streams ! equipment or additional help as instructed in
of hydraulic oil under pressure can penetrate this Service Manual.
the skin and result in serious infection. If
hydraulic oil under pressure does penetrate
the skin, seek medical treatment
WARNING: Engine exhaust fumes can
immediately. Maintain all hoses and tubes in
! good condition. Make sure all connections
cause death. If it is necessary to start the
engine in a closed place, remove the exhaust
are tight. Make a replacement of any tube or
hose that is damaged or thought to be
! fumes from the area with an exhaust pipe
extension. Open the doors and get outside
damaged. DO NOT use your hand to check
air into the area.
for leaks, use a piece of cardboard or wood.
WARNING: When the battery electrolyte is

WARNING: When removing hardened pins frozen, the battery can explode if (1), you try
such as a pivot pin, or a hardened shaft, use to charge the battery, or (2), you try to jump
start and run the engine. To prevent the
! a soft head (brass or bronze) hammer or use
a driver made from brass or bronze and a
! battery electrolyte from freezing, try to keep
steel head hammer. the battery at full charge. If you do not follow
these instructions, you or others in the area
can be injured.
WARNING: When using a hammer to
remove and install pivot pins or separate
parts using compressed air or using a
! grinder, wear eye protection that completely
encloses the eyes (approved goggles or
other approved eye protectors).
WARNING: Use suitable floor (service)

jacks or chain hoist to raise wheels or tracks
! off the floor. Always block machine in place
with suitable safety stands.

Copyright ©
1001-6
STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS

Tightening of cap screws, nuts
Tighten alternately so that tightening torque can be applied evenly. The numbers in the figure below indicate the
order of tightening.
JS00481A
Cap screws which have had Loctite used (white residue remains after removal) should be cleaned with loght oil or
suitable cleaning solvent and dried. Apply 2-3 drops of Loctite to the thread portion of the cap screw and then
tighten.
Torque table
Tighten cap screws and nuts according to the table below if there are no other special instructions.
Cap Screw Name Size (Size) M6 M8 M10 M12 M14 M16 M18 M20
[mm] 10 13 17 19 22 24 27 30
Spanner
[in.] 0.39 0.51 0.67 0.75 0.87 0.95 1.06 1.18
Cap Screw
Tightening [Nm] 6.9 19.6 39.2 58.8 98.1 156.9 196.1 294.2
torque [lb-ft] 5.1 14.5 28.9 43.4 72.3 115.7 144.6 217
[mm] 5 6 8 10 12 14 14 17
Spanner
Socket [in.] 0.20 0.24 0.32 0.39 0.47 0.55 0.55 0.67
Head Cap
Screw [Nm] 8.8 21.6 42.1 78.5 117.7 176.5 245.2 343.2
Tightening
torque
[lb-ft] 6.5 15.9 31.1 57.9 86.9 130.2 181 253.2

Copyright ©
1002
Section
1002
SPECIFICATIONS
AND SPECIAL TORQUE SETTINGS

Printed in France
CNH Lep SM350B370B1002-0EN July 2008
Copyright ©
1002-2
TABLE OF CONTENTS
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see this
! symbol, carefully read the message which follows. Your safety depends on it.
TYPE, SERIAL NUMBER

AND YEAR OF MANUFACTURE OF THE MACHINE..................................................................................................... 3
Machine ....................................................................................................................................................................... 3
Engine .......................................................................................................................................................................... 3
Serial numbers of the components .............................................................................................................................. 3
FLUIDS AND LUBRICANTS ............................................................................................................................................ 4

Hydraulic fluid .............................................................................................................................................................. 4
Transmission component oil ........................................................................................................................................ 4
Grease ......................................................................................................................................................................... 4
Engine Oil .................................................................................................................................................................... 5
Engine fuel, maintenance of fuel filters and fuel storage ............................................................................................. 6
Anti-freeze/Anti-corrosion............................................................................................................................................. 8
Environment ................................................................................................................................................................. 8
Plastic and resin parts.................................................................................................................................................. 8
SPECIFICATIONS ........................................................................................................................................................... 9
Main data ..................................................................................................................................................................... 9
Performance ................................................................................................................................................................ 9
Main body dimensions ................................................................................................................................................. 9
Engine ........................................................................................................................................................................ 10
Cooling system .......................................................................................................................................................... 10
Capacity of coolant and lubricants ............................................................................................................................. 10
Air conditioning .......................................................................................................................................................... 10
Hydraulic oil filter........................................................................................................................................................ 10
Fuel filter .................................................................................................................................................................... 10
Operating devices ...................................................................................................................................................... 11
Hydraulic system........................................................................................................................................................ 12
Swing unit .................................................................................................................................................................. 14
Travel lower body....................................................................................................................................................... 14
Work Unit ................................................................................................................................................................... 15
COMPONENT WEIGHT................................................................................................................................................. 17
Major component weight ............................................................................................................................................ 17
Other component weight ............................................................................................................................................ 19
SPECIAL TORQUE SETTINGS..................................................................................................................................... 20
MACHINE OVERALL DIMENSIONS ............................................................................................................................. 24
Lep SM350B370B1002-0EN Issued 07-08

Copyright ©
1002-3
TYPE, SERIAL NUMBER
AND YEAR OF MANUFACTURE OF THE MACHINE
For all part orders, request for information or assistance, always specify the type and the serial number of the machine
to your Case dealer.
Fill in the following lines with the required information: Type, serial number, year of manufacture of the machine and the
serial numbers of the hydraulic and mechanical components.
Machine
CT04A171A
(1) Type .......................................................................................................................................................................

(2) Serial number ........................................................................................................................................................
(3) Year of manufacture...............................................................................................................................................
Engine
Make and type.............................................................................................................................................................
Serial number..............................................................................................................................................................
Serial numbers of the components

Hydraulic pump ...........................................................................................................................................................
Swing reduction gear ..................................................................................................................................................
Travel reduction gears .................................................................................................................................................
Control valve ...............................................................................................................................................................

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1002-4
FLUIDS AND LUBRICANTS
Lubricants must have the correct properties for each application.
WARNING: The conditions of use for individual fluids and lubricants must be respected.
!
Hydraulic fluid
CASE/AKCELA hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system.
The type of fluid to be used depends on the ambient temperature.
Temperate climates: -20°C to +40°C (-4° to 104° F)
CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)
Hot climates: 0°C to +50°C (32° to 122° F)
CASE/AKCELA: AW HYDRAULIC FLUID 68 HV (MS 1216. ISO VG 68. DIN 51524 PART 3 CATEGORY HVLP)
Cold climates: -25°C to +20°C (-13° to 68° F)
CASE/AKCELA: AW HYDRAULIC FLUID 32 (MS 1216. ISO VG 32. DIN 51524 PART 2)
Biodegradable fluid: -30°C to +40°C (-22° to 104° F)
This yellow-colored fluid is miscible with standard fluid. If used to change standard fluid, it is advised to drain the circuit
completely before refilling with this fluid.
CASE/AKCELA: HYDRAULIC EXCAVATOR FLUID BIO (MS 1230. ISO VG 46. DIN 51524 PART 2 HV)
Transmission component oil

Extreme pressure oil used for enclosed transmission components.
CASE/AKCELA: GEAR 135H EP (SAE 80W-90. API GL 5. MIL-L-2105 D. MS 1316. ZF TE-ML 05A)
Grease
CASE/AKCELA: MOLY GREASE 251H EP-M (251H EP-M. NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap and molybdenum disulphide.
CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (251H EP. NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap and calcium.
CASE/AKCELA: PREMIUM GREASE EP2 (NLGI 2)
"Extreme Pressure" multipurpose grease with lithium soap.
Hydraulic breakers
CASE/AKCELA: MULTIPURPOSE GREASE 251H EP (NLGI 2).
Lep SC350B370B1002-0EN Issued 07-08

Copyright ©
1002-5
Engine Oil
THE CASE/AKCELA No. 1 engine oil is recommended
for your engine. This oil ensures proper lubrication of
your engine for all operating conditions.
If the CASE/AKCELA Multigrade "No. 1 ENGINE OIL"
cannot be obtained, use the oil corresponding to one of
the following categories: ACEA E7. API CI-4.
CP02N001
Oil viscosity / Oil range
1
2
2
3
3
CT02M001
1) With mineral base

(2) With semi-synthetic base
(3) With synthetic base

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1002-6
Engine fuel, maintenance of fuel filters and fuel storage
In order to meet the emission control regulation of 3rd-stage, the engine components have been made precisely and
they are to be used under high-pressure conditions.
Therefore, the specified fuel must be used for the engine.
As a matter of course, not only the guarantee will not be given for the use of a fuel other than the specified but also it
may invite a serious breakdown.
In addition, since suitable specifications for the fuel filter elements have been established for this engine, use of the gen-
uine filter is essential.
The following describes the specifications and the requirements of the fuel to be applied, and maintenance of the fuel
and the fuel elements.
Fuel to be applied
Selection of fuel
Following conditions must be met for the diesel engines, that is the one;
1 In which no dust even fine one is mixed,
2 With proper viscosity,
3 With high cetane rating,
4 With good flow properties in lower temperature,
5 With not much sulfur content, and
6 With less content of carbon residue
Applicable standards for diesel fuel
Applicable Standard Recommendation
JIS (Japanese Industrial Standard) NO.2
DIN (Deutsche Industrie Normen) DIN 51601
SAE (Society of Automotive Engineers)
Based on SAE-J-313C NO. 2-D
BS (British Standard)
Based on BS/2869-197 Class A-1
EN590
If a standard applied to the fuel for the diesel engine is stipulated in your country, check the standard for details.
Requirements for diesel fuel
Although conditions required for the diesel fuel are illustrated above, there are other requirements exerting a big
influence on its service durability and service life.
Be sure to observe the following requirements for selecting fuel.
Sulfur content............................................................................... 2500 ppm or less
HFRR*.......................................................................................... 460 mm or less
Water content............................................................................... 0.05 wt% or less
* HFRR (High-Frequency Reciprocating Rig.): An index showing lubricating properties of the fuel.
Sulfur content reacts to moisture to change into sulfuric acid after combustion.
Use of a fuel containing much sulfur content allows it to accelerate internal corrosion and wear.
In addition, much sulfur content quickens deterioration of engine oil allowing its cleaning dispersive property to be
worse which results in acceleration of wear of sliding portions.
HFRR is an index that indicates lubricating property of a fuel.
Large value of the index means poor lubrication so that seizure of the machine components may result if such a
fuel is used.
Since a fuel with high HFRR value also has lower viscosity, it can easily be leaked out.

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1002-7
If the fuel is mixed with the engine oil, the oil is diluted to deteriorate its lubricating property resulting in accelera-
tion of wear.
Water content allows inside of the fuel tank to rust which in turn blocking the fuel line and the fuel filter.
IMPORTANT : In cold weather, fill the fuel tank at the end of the day's work, in order to prevent the formation of conden-
sation.
This may also cause wear and seizure of the machine components.
If atmospheric temperature goes below the freezing point, moisture content in the fuel forms fine particle of ice
allowing the fuel line to be clogged.
IMPORTANT : Obtain table of analysis for the fuel you are using from the fuel supplier to confirm that it meets the crite-
ria described above.
IMPORTANT : If a fuel which does not meet the specifications and the requirements for the diesel engine, function and
performance of the engine will not be delivered. In addition, never use such a fuel because a breakdown of the engine
or an accident may be invited.
Guarantee will not be given to a breakdown caused by the use of a improper fuel.
Some fuels are used with engine oil or additives mixed together with diesel engine fuel.
In this case, do not use these fuels because damage to the engine may result as the fuel has been contaminated.
It is natural that the emission control regulation of 3rd-stage will not be cleared in case where a fuel that does not
meet the specifications and the requirements is used.
Use the specified fuel for compliance of the exhaust gas control.
IMPORTANT : It you use diesel fuel which contains much sulfur content more than 2500 ppm, be sure to follow the
items below for the engine oil selection and maintenance of engine parts. Guarantee will not be given to breakdowns
caused by not to follow these items.
1 Selection of engine oil
Use API grade CF-4 or JASO grade DH-1.
2 Exchange the engine oil and engine oil filter element by the periodical interval reported on the Operator’s
Manual.
3 Inspect and exchange the EGR (*)parts and fuel injector parts of engine every 3000 hour of use.
* EGR: Exhaust Gas Recircultion
Maintenance of fuel filters
Be sure to use the genuine fuel filters.
The fuel injection system is precisely constructed and the genuine filter employs finer mesh than conventional fil-
ters to improve protection of machine equipment.
If a filter with coarse mesh is used, foreign object passing through the filter enters into the engine so that machine
equipment can wear out in a short period of time.
IMPORTANT : If a fuel filter other than the genuine filter is used, guaranty will not be applied to a fault caused by the
use of a wrong filter.
Two kinds of fuel filter, the pre-filter and the main filter, are mounted on the machine.
Be sure to use the genuine fuel filters and replace them at the periodic intervals reported on the operator’s Man-
ual.
IMPORTANT : Since the pre-filter also has a function of water separation, discharge water and sediment when the float
reaches lower part of the filter elements. CHECK EVERY DAY before to start the engine.
Time to replace filters may be advanced according to properties of the fuel being supplied.
• Therefore, take measures to prevent dust or water from being entered in the fuel tank when supplying fuel.
• When supplying fuel directly from a fuel drum can, leave the drum as it stands for a long period of time to supply
clean fuel standing above a precipitate.
• If it is hard to leave the drum for a long period of time, install a fuel strainer and a water separator before the fuel
tank of the machine to supply clean fuel.
Water drain cock is provided on the bottom side of the fuel tank.
• Drain water before starting the engine every morning.
• In addition, remove the cover under the tank once a year to clean up inside of the tank.

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1002-8
Fuel storage
Long storage can lead to the accumulation of impurities and condensation in the fuel. Engine trouble can often be
traced to the presence of water in the fuel.
The storage tank must be placed outside and the temperature of the fuel should be kept as low as possible. Drain off
water and impurities regularly.
Anti-freeze/Anti-corrosion
Use anti-freeze in all seasons to protect the cooling system from corrosion and all risk of freezing.
CASE/AKCELA: PREMIUM ANTI-FREEZE (MS 1710)
For areas where the temperature goes down to -38°C (-36.4°F), mix 50/50 with water.
IMPORTANT : Do not mix products of a different origin or brand. The same product must be used when topping up the
system.
Environment
Before carrying out any maintenance operation on this machine and before disposing of used fluids or lubricants,
always think of the environment. Never throw oil or fluid on the ground and never place it in leaking receptacles.
Contact your local ecological recycling centre or your CASE Dealer to obtain information on the correct method of dis-
posing of these lubricants.
Plastic and resin parts

When cleaning plastic parts, the console, the instrument panel, the indicators etc... avoid using petrol, kerosene, paint
solvents etc... Use only water, soap and a soft cloth.
The use of petrol, kerosene, paint solvents etc... causes discoloration, cracks or deformation of these parts.

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1002-9
SPECIFICATIONS
Main data
Model name
CX350B (LC type), CX350B (NLC type), CX370B (LC type) and CX370B (NLC type) Hydraulic Excavator
Operating weight
CX350B (LC type).........................................................................................................................35900 kg (79145 lbs)
CX350B (NLC type) ......................................................................................................................34300 kg (75618 lbs)
CX370B (LC type).........................................................................................................................36340 kg (80115 lbs)
Engine output ....................................................................................................................................... 202 kW / 2000 rpm
Performance
Swing speed....................................................................................................................................................... 9.8 Tr/min.
Travel speed:
Low Speed..................................................................................................................................... 3.5 km/h (2.17 mph)
High Speed .................................................................................................................................... 5.5 km/h (3.42 mph)
Maximum drawbar pull .......................................................................................................................... 265 kN (59574 lbf)
CX370B (NLC Type) ......................................................................................................................... 264 kN (59349 lbf)
Grade ability ........................................................................................................................................................70% (35°)
Ground pressure
CX350B (LC type)......................................................................................... 64 kPa (600 mm (23.62 in) grouser shoe)
CX350B (NLC Type) ..................................................................................... 64 kPa (600 mm (23.62 in) grouser shoe)
Main body dimensions

Main body width .............................................................................................................. See machine overall dimensions
Main unit length:
CX350B (LC type), CX370B (LC type) ......................................................................................... 5750 mm (227.36 in)
CX350B (NLC type), CX370B (NLC type) .................................................................................... 5910 mm (232.67 in)
Main unit width ....................................................................................................................................3200 mm (125.98 in
Upper swing body width .................................................................................................................... 3020 mm (118.89 in)
Cab width ............................................................................................................................................ 1000 mm (39.36 in)
Main unit height................................................................................................................................. 3130 mm (123.22 in)
Swing radius (rear end)..................................................................................................................... 3450 mm (135.82 in)
Swing body rear end distance........................................................................................................... 3420 mm (134.64 in)
Swing body rear section bottom height ............................................................................................... 1210 mm (47.63 in)
Distance between tumblers:
Overall track length:
Overall track width............................................................................................................................. 3200 mm (125.98 in)
Distance between tracks ................................................................................................................... 2600 mm (102.36 in)

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1002-10
Width of track shoe:
CX350B (LC type) ........600 mm (23.62 in) (Option: 700 mm (27.56 in), 800 mm (31.50 in), 850 mm (33.46), 900 mm
(35.43 in))
CX350B (NLC type), CX370B (LC type), CX370B (NLC type)600 mm (23.62 in) (Option: 700 mm (27.56 in), 800 mm
(31.50 in))
Minimum ground clearance (To bottom of lower frame) ........................................................................ 480 mm (18.89 in)
Engine
Name.......................................................................................................................................................... ISUZU, 6HK1X
Type: 4-cycle, water-cooled, overhead camshaft, common rail injection (electric control),
with air-cooling type inter-cooler turbo with air-cooling.
No. of cylinders - bore x stroke...........................................................................6-dia. 115 mm x 125 mm (4.53 x 4.92 in)
Displacement........................................................................................................................................7790 cc (475 cu.in)
Compression ratio ....................................................................................................................................................... 17.5
Rated output...............................................................................................................................202± 3.0 kW / 2000 min-1
Maximum torque............................................................................................................... 1080Nm (797 lb-ft) / 1500 min-1
Engine dimensions (LxWxH) ......................................................... 1357 x 995.4 x 1162.5 mm ( 53.42 x 39.19 x 45.74 in)
Oil pan ...................................................................................................................................... All direction 35°, inclinable
Starter, reduction type ...................................................................................................................................... .24 V, 5 kW
Alternator, AC type ............................................................................................................................................. 24 V, 50 A
Battery .......................................................................................................................................... 2x 12V/24V,128 Ah/5 Hr
Cooling system
Fan type............................................................................ diameter 850 mm (33.5 in), suction type-6blades resin & steel
Pulley ratio................................................................................................................................................... .80 (reduction)
Direction of rotation ....................................................................................... Right (viewed from fan side); compliant with
Radiator capacity................................................................................................................................................... 96.0 kW
Fin type .................................................................................................................................................................. wavy
Fin space ............................................................................................................................................. 2.0 mm (0.08 in)
Oil cooler capacity ................................................................................................................................................. 66.6 kW
Fin type ..................................................................................................................................................................Wavy
Fin space ........................................................................................................................................... 1.75 mm (0.07 in)
Inter-cooler capacity .............................................................................................................................................. 29.9 kW
Fin type ...............................................................................................................................................triangular straight
Fin space ............................................................................................................................................. 2.0 mm (0.08 in)
Fuel cooler capacity ................................................................................................................................................ 1.7 kW
Fin type .................................................................................................................................................................. wavy
Fin space ............................................................................................................................................. 2.0 mm (0.08 in)
Capacity of coolant and lubricants

Coolant ........................................................................................................................................................ 30 L (7.92 gal)
Fuel ............................................................................................................................................................ 578 L (153 gal)
Lubricant for engine........................................................................................................................................ 38 L (10 gal)
Lubricant for travel reduction gear (per side)................................................................................................. 11 L (2.9 gal)
Lubricant for swing reduction gear (per side) ................................................................................................ 6 L (1.59 gal)
Hydraulic oil............................................................................................................................................... 350 L (92.5 gal)
Capacity of hydraulic oil tank..................................................................................................................... 175 L (46.2 gal)
Air conditioning
R134 gas load ..............................................................................................................................................1Kg (2.20 Ibs)
Hydraulic oil filter

Suction filter (inside tank) ....................................................................................................................................105 mesh
Return filter (inside tank) ........................................................................................................................................... 6 μ m
Pilot line filter (inside housing)................................................................................................................................... 8 μ m
Fuel filter
Main filter.................................................................................................................................................................... 4 µm
Pre-filter.................................................................................................................................................................... 10 µm

Copyright ©
1002-11
Operating devices
Operator's seat
Location: left side
Structure: Adjustable forward and back and up and down, reclining mechanism, with seat suspension.
Cab
Sealed steel type, all reinforced glass.
Levers and pedals
For travel use: Lever and pedal type (hydraulic pilot type) (x2)
For operating machine use: Lever type (hydraulic pilot type) (x2)
Instruments and switches
Work mode select switch: 3 modes (SP / super power, H / heavy duty, A / automatic)
Travel mode select switch: Low-speed / high-speed switch type
One-touch idle: Knob switch type
Engine emergency stop: Switch type
Monitor device
Machine status display (full-dot liquid crystal)
Work mode selection status: SP / H / A
Instruments (full-dot liquid crystal, except for hour meter)
Fuel gauge: bar graph indicator
Engine coolant temperature gauge: bar graph indicator
Hydraulic oil temperature gauge: bar graph indicator
Hour meter: digital type
Machine Status and Warning Alarms (full-dot liquid crystal and warning tone) *Items have a warning alarm
Over heat* Battery charge* Faulty electrical system*
Refill fuel* Engine oil pressure* Refill coolant*
Engine preheat Auto warm-up Air cleaner clogged
Anti-theft device triggered Faulty engine system Engine emergency stop
Lighting
Working light Boom up: 24V, 70W (x1)
Cab top: 24V, 70W (x1)
Interior light 4V, 10W (x1)
Horn: electric horn (x2)

Other
Wiper with intermittent function, Window washer, Air conditioner, Rear view mirrors (left and right), Clock

Copyright ©
1002-12
Hydraulic system
Hydraulic pump drive system, directly coupled to the engine (no transmission)
Main pump
Manufacturer............................................................................................................................................... Kawasaki
Pump type .............................................................................................. double variable displacement piston pump
Displacement volume .......................................................................................................... 150 cm3 ( cu in) x 2 /rev
Rated operating pressure .......................................................................................................... 34.3 MPa (4975 psi)
Maximum operating pressure .................................................................................................... 37.3 MPa (5410 psi)
Input revolution speed.............................................................................................................................. 1930 min-1
Maximum discharge flow ........................................................................... 290 L/min (76.60 gpm) x 2 at 1930 min-1
Pilot pump
Pump type ............................................................................................................................................... Gear pump
Displacement volume ............................................................................................................ 15 cm3 (0.91 cu in)/rev
Operating pressure ...................................................................................................................... 3.92 MPa (568 psi)
Maximum flow ................................................................................................... 29 L/min (7.66 gpm) (at 1930 min-1)
Input horsepower ............................................................................................................................................ 2.8 kW
Control method
Hydraulic simultaneous constant output control.
Maximum flow adjustment control through external commands (negative control).
Setting horsepower adjustment control through external command milli-amp.
Control Valve
Model; 4-spool section: integrated (1) or 5-spool section: integrated (1)
Operation method: hydraulic pilot method: travel, swing and operating machine
Maximum flow .................................................................................................292.5 L / min (77.27 gpm) at 1950 min-1
Main relief set pressure........................................... standard; 34.3 MPa (4975 psi), power boost 37.3 MPa (5410 psi)
Overload set pressure...................................................................................... when boom down; 27.4 MPa (3974 psi)
.............................................................................................................................................other: 39.2 MPa (5685 psi)
Foot relief set pressure ............................................................................................................... 2.55 MPa (369.85 psi)
Functions
Straight travel circuit
Boom up / arm 2 pumps internal flow
Boom and arm load holding circuit
Boom-down regenerative circuit
Bucket-close regenerative circuit
Arm-in forced regenerative circuit
Swing priority variable orifice (for arm operation)
2 pumps flow
Variable foot relief
Hydraulic Cylinders
Boom cylinder (x2)
Cylinder bore .............................................................................................................................Ø145 mm (Ø5.70 in)
Rod diametre .............................................................................................................................Ø100 mm (Ø3.93 in)
Maximum retracted lenghth ........................................................................................................ 2090 mm (82.28 in)
Stroke ......................................................................................................................................... 1495 mm (58.85 in)
Arm (dipper) cylinder
Cylinder bore .............................................................................................................................Ø170 mm (Ø6.69 in)
Stroke ......................................................................................................................................... 1748 mm (68.81 in)
Bucket cylinder
Cylinder bore ............................................................................................................................... 150 mm (Ø5.90 in)
Stroke ......................................................................................................................................... 1210 mm (47.63 in)

Copyright ©
1002-13
Cushion Valve
Port size
A-P ports ............................................................................................................................................................G3/8
R-V ports ............................................................................................................................................................G1/4
Rotating Joint
Operating pressure
High pressure passage (ABCD) ............................................................................................... 34.3 MPa (4975 psi)
Drain port (T) ................................................................................................................................. 1.0 MPa (145 psi)
Pilot port (P) .................................................................................................................................. 3.9 MPa (566 psi)
Flow
High pressure passage (ABCD) ............................................................................................ 360 L/min (95.10 gpm)
Drain port (T) ........................................................................................................................... 40 L/min (10.57 gpm)
Pilot port (P) .............................................................................................................................. 31 L/min (8.19 gpm)
Port A; forward right ...................................................................................................................................................G1
Port B; forward left .....................................................................................................................................................G1
Port C; backward right ...............................................................................................................................................G1
Port D; backward left..................................................................................................................................................G1
Port T; drain port ....................................................................................................................................................G1/2
Port P; pilot port ..................................................................................................................................................... G1/4
Solenoid Valve
Maximum flow .......................................................................... P -> B: 25 L/min (6.60 gpm) Other: 5 L/min (1.32 gpm)
Rated pressure ............................................................................................................................. 4.5 MPa (652.67 psi)
Port size
P, T, B port ..........................................................................................................................................................G3/8
C1, C2, C3, C4, C5 ports ...................................................................................................................................G1/4
Solenoid specifications
Operating voltage ................................................................................................................................ DC 20 to 32 V
Power consumption .................................................................................................................................. 17 W max.
Hand control valve
Manufacturer................................................................................................................................................... Kawasaki
Operating pressure .......................................................................................................................... 3.92 MPa (569 psi)
Secondary pressure, primary short type .......................................................... 0.64 to 2.45 MPa (92.82 to 355.34 psi)
Operating angle
Ports 1, 3 .............................................................................................................................................................. 19°
Ports 2, 4 .............................................................................................................................................................. 25°
Port 1, 3 Port 2, 4
4.0 4.0
Secondary pressure (MPa)
3.0 3.0
Secondary
pressure
2.0 2.0
Secondary
pressure
1.0 1.0
0 0
2 4 6 7 2 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.)
RST-03-01-001B

Copyright ©
1002-14
Foot control valve
Manufacturer ................................................................................................................................................... Kawasaki
Operating pressure .......................................................................................................................... 3.92 MPa (569 psi)
Secondary pressure, primary short type........................................................... 0.64 to 2.45 MPa (92.82 to 355.34 psi)
Operating angle...................................................................................................................................................... 12.4°
3.9

3.0
2.0
1.0
Secondary
pressure
0
2 4 5.5
Push rod stroke (mm)
0 5 10 12.4
Pedal operating angle (deg.)
Swing unit
Swing circle; swing bearing type (with internal gears)
Swing hydraulic motor (1).............................................................. fixed displacement piston motor (with parking brake).
Intake amount .......................................................................................................................................... 180.1 cm3/rev
Operating pressure ........................................................................................................................ 30.4 MPa (4409 psi)
Operating flow ..................................................................................................................................................290L/min
Mechanical brake torque....................................................................................................................... 1010.8 Nm min.
Brake off pressure..................................................................................................................... 3.1 MPa max. (449 psi)
Relief valve set pressure ................................................................................................................ 30.4 MPa (4409 psi)
Reduction gears ................................................................................................ planetary gear 2-stage reduction system
Reduction ratio .................................................................................................................................................... 27.143
Swing parking brake; mechanical lock (operational lever linkage type)
Travel lower body

Travel hydraulic motor (x2) ......................................................................................... Variable displacement piston motor
Displacement .................................................................................................. 290.7/170.1 cm3 (17.73/10.38 cu in)/rev
Operating pressure ........................................................................................................................ 34.3 MPa (4975 psi)
Operating flow ......................................................................................................................... 292.5 L/min (77.27 gpm)
Brake torque........................................................................... 47.38 KNm (34945 Ib-ft) min. (including reduction gear)
Relief valve set pressure ....................................................................................... 35.8 to 37.8 MPa (5192 to 5482 psi)
Automatic 2-speed switch-over pressure (with parking brake)....................................................... 26.5 MPa (3843 psi)
Reduction gear .......................................................................................................Planetary gear 2-stage reduction gear
Reduction ratio .................................................................................................................................................... 40.467
Travel brake .................................................................................................................................................. Hydraulic lock
Parking brake ................................................................................................... Mechanical lock (travel lever linkage type)
Track shoe
Model ....................................................................................................................... Assembly type triple grouser shoe
Number of shoes (per side)........................................................................................................................................ 48
Shoe width ........................................................................................ 600 mm (23.62 in), (optional 800 mm, (31.49 in))
Grouser height ...................................................................................................................................... 36 mm (1.41 in)
Link pitch ............................................................................................................................................. 216 mm (8.50 in)
Roller
Number of upper rollers (per side) ............................................................................................................................... 2
Number of lower rollers (per side)................................................................................................................................ 8
Track belt tension adjuster............................................................................... Grease cylinder type (with cushion spring)
Mounting length of spring ...................................................................................................................... 779 mm (30.66 in)
Copyright ©
1002-15
Work Unit
Model ................................................................................................................................................. Backhoe attachment
Components / dimensions / working dimensions
Standard bucket capacity:
Heaped .............................................................................................................................................................. 1.40 m3
Leveled .............................................................................................................................................................. 1.04 m3
Bucket width:
CX350B (LC Type), (NLC Type)...................................................................................................... 1300 mm (51.18 in)
Bucket width with side cutter:
Bucket weight with side cutter:
CX350B (LC Type), (NLC Type)........................................................................................................1150 kg (2535 lbs)
CX370B (LC Type), (NLC Type)........................................................................................................1480 kg (3263 lbs)
Boom length ...................................................................................................................................... 6450 mm (253.93 in)
Boom 6450 mm (253.93 in)

CX350B (LC type), (NLC Type) Super Short
Standard arm Long arm Short arm
arm
3250 mm 4040 mm 2630 mm 2210 mm
Arm (dipper) length
127.95 in) (159.05 in) (103.54 in) (87.00 in)
1680 mm
Bucket radius
(66.14 in)
Bucket wrist angle 173°
11170 mm 11900 mm 10670 mm 11400 mm
Maximum digging radius
(439.76 in) (468.50 in) (420.07 in) (448.81 in)
10980 mm 11720 mm 10470 mm 11720 mm
Maximum digging radius at ground line
(432.28 in) (461.41 in) (412.20 in) (461.41 in)
7340 mm 8140 mm 6730 mm 8140 mm
Maximum digging depth
(288.97 in) (320.47 in) (264.95 in) (320.47 in)
6350 mm 7150 mm 5970 mm 5080 mm
Maximum vertical straight wall digging depth
(249.99 in) (281.49 in) (235.03 in) (199.99 in)
10370 mm 10670 mm 10320 mm 9850 mm
Maximum digging height
(408.26 in) (281.49 in) (406.29 in) (387.79 in)
7230 mm 7540 mm 7140 mm 6770 mm
Maximum dump height
(284.64 in) (296.84 in) (281.10 in) (266.53 in)
4500 mm 4560 mm 4630 mm 4660 mm
Minimum swing radius at front
(177.16 in) (179.52 in) (182.28 in) (183.46 in)
8480 mm 8490 mm 8540 mm 8650 mm
Height for minimum swing radius at front
(333.85 in) (334.25 in) (336.21 in) (340.55 in)

Copyright ©
1002-16
Boom 6450 mm (253.93 in)

CX370B (LC type), (NLC Type) Super Short
Standard arm Short arm
arm
3250 mm 2630 mm 2210 mm
Arm (dipper) length
127.95 in) (103.54 in) (87.00 in)
1680 mm
Bucket radius
(66.14 in)
Bucket wrist angle 173°
11170 mm 11900 mm 10670 mm
Maximum digging radius
(439.76 in) (468.50 in) (420.07 in)
10980 mm 11720 mm 10470 mm
Maximum digging radius at ground line
(432.28 in) (461.41 in) (412.20 in)
7340 mm 8140 mm 6730 mm
Maximum digging depth
(288.97 in) (320.47 in) (264.95 in)
6350 mm 7150 mm 5970 mm
Maximum vertical straight wall digging depth
(249.99 in) (281.49 in) (235.03 in)
10370 mm 10670 mm 10320 mm
Maximum digging height
(408.26 in) (420.07 in) (406.29 in)
7230 mm 7540 mm 7140 mm
Maximum dump height
(284.64 in) (296.84 in) (281.10 in)
4500 mm 4560 mm 4630 mm
Minimum swing radius at front
(177.16 in) (179.52 in) (182.28 in)
8480 mm 8490 mm 8540 mm
Height for minimum swing radius at front
(333.85 in) (334.25 in) (336.21 in)

Copyright ©
1002-17
COMPONENT WEIGHT
Major component weight
RST-11-01-001A
Weight information is approximate
A) Operating weight
CX350B (LC type) ....................................................................................................................34300 kg (75618 lbs)
CX350B (NLC type)..................................................................................................................34000 kg (74957 lbs)
CX370B (LC type) ....................................................................................................................36340 kg (80115 lbs)
B) Upper mechanism (including counterweight and turntable bearing)
CX350B (LC type) ....................................................................................................................14040 kg (30952 lbs)
CX370B (LC type) ....................................................................................................................15030 kg (33135 lbs)
C) Counterweight
CX350B (LC type) ...................................................................................................................... 6410 kg (14131 lbs)
CX350B (NLC type).................................................................................................................... 6410 kg (14131 lbs)
CX370B (LC type) ...................................................................................................................... 7400 kg (16314 lbs)
CX370B (NLC type).................................................................................................................... 7400 kg (16314 lbs)
D) Lower mechanism (with standard grouser shoe)
CX350B (LC type) ....................................................................................................................12300 kg (27116 lbs)
CX370B (LC type) ....................................................................................................................12470 kg (27491 lbs)
E) Main Unit Weight
CX350B (LC type) ....................................................................................................................27270 kg (60119 lbs)
CX370B (LC type) ....................................................................................................................28430 kg (62677 lbs)
Copyright ©
1002-18
F) Attachments
CX350B (LC type).......................................................................................................................6950 kg (15322 lbs)
CX350B (NLC type) ....................................................................................................................6950 kg (15322 lbs)
CX370B (LC type).......................................................................................................................7840 kg (17284 lbs)
CX370B (NLC type) ....................................................................................................................7840 kg (17284 lbs)
G) Boom (including cylinders)
CX350B (LC type).........................................................................................................................3970 kg (8752 lbs)
CX370B (LC type).........................................................................................................................4250 kg (9369 lbs)
H) Arm (dipper) (including cylinders and linkage)
CX350B (LC type).........................................................................................................................1820 kg (4012 lbs)
CX370B (LC type).........................................................................................................................2090 kg (4607 lbs)

Copyright ©
1002-19
Other component weight
Engine ......................................................................................................................Approximately 640 kg (1410 lbs)
Air cleaner ...........................................................................................................................................13.6 kg (30 lbs)
Hydraulic pump ..................................................................................................................................188 kg (414 lbs)
Control valve ......................................................................................................................................193 kg (425 lbs)
Cushion valve....................................................................................................................................12.5 kg 27.5 lbs)
Swing motor and reduction gear assembly ........................................................................................435 kg (959 lbs)
Travel motor and reduction gear assembly (2) ...................................................................................399 kg (880 lbs)
Rotary joint.........................................................................................................................................106 kg (233 lbs)
Turtable bearing ...............................................................................................................................540 kg (1190 lbs)
5 solenoid valve bank.........................................................................................................................6.7 kg (14.7 lbs)
Hand control valve .............................................................................................................................1.9 kg (4.18 lbs)
Foot control valve .............................................................................................................................7.8 kg (17.19 lbs)
Cab ....................................................................................................................................................255 kg (562 lbs)
Muffler ....................................................................................................................................................20 kg (44 lbs)
Radiator total weight ...........................................................................................................................140 kg (309 lbs
Oil cooler............................................................................................................................................34 kg (75 lbs)
Radiator ..........................................................................................................................................21.1 kg (47 lbs)
Air cooler.........................................................................................................................................19.9 kg (44 lbs)
Fuel cooler .....................................................................................................................................1.2 kg (2.65 lbs)
Idler wheel..........................................................................................................................................165 kg (364 lbs)
Upper roller ............................................................................................................................................43 kg (95 lbs)
Lower roller ..........................................................................................................................................60 kg (132 lbs)
Tension damper assembly .................................................................................................................254 kg (560 lbs)
Recoil spring assembly...............................................................................................................119.4 kg (263 lbs)
Grease cylinder assembly ..............................................................................................................41.3 kg (91 lbs)
Yoke ................................................................................................................................................39.8 kg (88 lbs)
Threaded rod.....................................................................................................................................50.3 kg (111 lbs)
Track chains
600 mm (23.62 in) (48 shoe) .....................................................................................................2217 kg (4888 lbs)
700 mm (26.56 in) (48 shoe) .................................................................................................... 2473 kg (5452 lbs)
800 mm (31.5 in) (48 shoe) ...................................................................................................... 2618 kg (5772 lbs)
850 mm (33.5 in) (48 shoe) .......................................................................................................2735 kg (6030 lbs)
900 mm (35.5 in) (48 shoe) ...................................................................................................... 2817 kg (6210 lbs)
Boom cylinder ....................................................................................................................................279 kg (615 lbs)
Arm (dipper) cylinder........................................................................................................................462 kg (1019 lbs)
Bucket cylinder ...................................................................................................................................276 kg (608 lbs)

Copyright ©
1002-20
SPECIAL TORQUE SETTINGS
Screw Wrench Torque setting
No. Component
(Ø) (mm) lb-ft
1* Travel motor M24 36 900-1051 664-775
2* Sprocket M20 30 521-608 384-448
3* Idler wheel M16 24 267-312 197-230
4* Upper roller M20 30 521-608 384-448
5* Lower roller M24 36 902-1049 665-774
6* Chain guide M24 36 902-1049 665-774
7 Shoe M24 32 1236-1510 912-1114
8 Counterweight M33 50 1685-1960 1243-1446
9* Turntable (frame) M24 36 900-1050 664-774
10 * Swing unit M24 36 900-1050 664-774
11 * Mount M20 30 289-337 213-248
12 * Engine Front Bracket M10 17 64-73 47-54
13 * Rear Bracket M12 19 109-127 80-93
14 * Radiator M10 24 147-176 108-130
15 * Flange M10 17 64-73 47-54
Hydraulic pump
16 * Pump M20 17 367-496 271-366
17 * Hydraulic reservoir M16 24 233-276 172-203
18 * Fuel reservoir M16 24 233-276 172-203
19 * Control valve M16 24 267-312 197-230
20 * Lock bar M12 24 267-312 197-230
Center Joint
21 * Joint M16 19 54-64 40-47
M16 24 78-80 57-59
22 Cab
M10 17 35-42 26-31
23 Battery M10 17 20-29 15-21
NOTE: Use Loctite 262 or an equivalent on retaining screws of those components marked with an asterisk (*).

Copyright ©
1002-21

Copyright ©
1002-22

Copyright ©
1002-23

Copyright ©
1002-24
MACHINE OVERALL DIMENSIONS
CS00K520A
(CX350B LC TYPE)
Arms (dippers) 2.20 m 2.60 m 3.25 m 4.00 m
(A) ................................................................. 3.51 m .................. 3.50 m................ 3.26 m................. 3.48 m
(B) ................................................................. 3.13 m .................. 3.13 m................ 3.13 m................. 3.13 m
(C) ............................................................... 11.26 m ................ 11.13 m.............. 11.05 m............... 11.09 m
(D) ................................................................. 5.91 m .................. 5.91 m................ 5.91 m................. 5.91 m
(E) ................................................................. 3.02 m .................. 3.02 m................ 3.02 m................. 3.02 m
(F) ................................................................. 1.21 m .................. 1.21 m................ 1.21 m................. 1.21 m
(G) ................................................................. 3.42 m .................. 3.42 m................ 3.42 m................. 3.42 m
(H) ................................................................. 4.98 m .................. 4.98 m................ 4.98 m................. 4.98 m
(I)................................................................... 4.04 m .................. 4.04 m................ 4.04 m................. 4.04 m
(J) .................................................................. 2.60 m .................. 2.60 m................ 2.60 m................. 2.60 m
(K) (standard pads) ....................................... 0.60 m .................. 0.60 m................ 0.60 m................. 0.60 m
(L) (with 600 mm track pads) ........................ 3.20 m .................. 3.20 m................ 3.20 m................. 3.20 m
(M)................................................................. 0.48 m .................. 0.48 m................ 0.48 m................. 0.48 m
(CX350B NLC TYPE)
Arms (dippers) 2.20 m 2.60 m 3.25 m 4.00 m
(A) ................................................................. 3.51 m .................. 3.50 m................ 3.26 m................. 3.48 m
(B) ................................................................. 3.13 m .................. 3.13 m................ 3.13 m................. 3.13 m
(C) ............................................................... 11.26 m ................ 11.13 m.............. 11.05 m............... 11.09 m
(D) ................................................................. 5.91 m .................. 5.91 m................ 5.91 m................. 5.91 m
(E) ................................................................. 3.02 m .................. 3.02 m................ 3.02 m................. 3.02 m
(F) ................................................................. 1.21 m .................. 1.21 m................ 1.21 m................. 1.21 m
(G) ................................................................. 3.42 m .................. 3.42 m................ 3.42 m................. 3.42 m
(H) ................................................................. 4.98 m .................. 4.98 m................ 4.98 m................. 4.98 m
(I)................................................................... 4.04 m .................. 4.04 m................ 4.04 m................. 4.04 m
(J) .................................................................. 2.39 m .................. 2.39 m................ 2.39 m................. 2.39 m
(K) (standard pads) ....................................... 0.60 m .................. 0.60 m................ 0.60 m................. 0.60 m
(L) (with 800 mm pads) ................................. 3.19 m .................. 3.19 m................ 3.19 m................. 3.19 m
(M)................................................................. 0.48 m .................. 0.48 m................ 0.48 m................. 0.48 m

Copyright ©
1002-25
CS00K520A
(CX370B LC TYPE)
Arms (dippers) 2.20 m 2.60 m 3.25 m
(A) ............................................................................ ...................3.51 m ................3.50 m .................3.26 m
(B) ............................................................................ ...................3.13 m ................3.13 m .................3.13 m
(C)............................................................................ .................11.26 m ..............11.13 m ...............11.05 m
(D)............................................................................ ...................5.91 m ................5.91 m .................5.91 m
(E) ............................................................................ ...................3.02 m ................3.02 m .................3.02 m
(F) ............................................................................ ...................1.21 m ................1.21 m .................1.21 m
(G)............................................................................ ...................3.42 m ................3.42 m .................3.42 m
(H)............................................................................ ...................4.98 m ................4.98 m .................4.98 m
(I) ............................................................................. ...................4.04 m ................4.04 m .................4.04 m
(J)............................................................................. ...................2.60 m ................2.60 m .................2.60 m
(K) (standard pads).................................................. ...................0.60 m ................0.60 m .................0.60 m
(L) (with 600 mm track pads) ................................... ...................3.20 m ................3.20 m .................3.20 m
(M) ........................................................................... ...................0.48 m ................0.48 m .................0.48 m
(CX370B NLC TYPE)
Arms (dippers) 2.20 m 2.60 m 3.25 m
(A) ............................................................................ ...................3.51 m ................3.50 m .................3.26 m
(B) ............................................................................ ...................3.13 m ................3.13 m .................3.13 m
(C)............................................................................ .................11.26 m ..............11.13 m ...............11.05 m
(D)............................................................................ ...................5.91 m ................5.91 m .................5.91 m
(E) ............................................................................ ...................3.02 m ................3.02 m .................3.02 m
(F) ............................................................................ ...................1.21 m ................1.21 m .................1.21 m
(G)............................................................................ ...................3.42 m ................3.42 m .................3.42 m
(H)............................................................................ ...................4.98 m ................4.98 m .................4.98 m
(I) ............................................................................. ...................4.04 m ................4.04 m .................4.04 m
(J)............................................................................. ...................2.39 m ................2.39 m .................2.39 m
(K) (standard pads).................................................. ...................0.60 m ................0.60 m .................0.60 m
(L) (with 800 mm pads)............................................ ...................3.19 m ................3.19 m .................3.19 m
(M) ........................................................................... ...................0.48 m ................0.48 m .................0.48 m

Copyright ©
1002-26
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Copyright ©
Section
4000
SERVICE CONNECTOR KIT
4000

Printed in France
CNH Lep SM350B4000-0EN July 2008
Copyright ©
4000-2
TABLE OF CONTENTS
SERVICE CONNECTOR KIT................................................................................................................................... 3
DETAILS OF SERVICE CONNECTOR KITS .................................................................................................................. 3
MEASUREMENT TOOLS .......................................................................................................................................... 4
Service connector ............................................................................................................................................. 4
Lep SM350B4000-0EN Issued 07-08

Copyright ©
4000-3
SERVICE CONNECTOR KIT
1 Details of service connector kits
• kit 380050017 includes connectors No. 1 to No. 38
CX CX
90 CX B
No. Name Tier 2 Tier 3
Series Series
Series Series
1 Throttle motor (12P) • - - -
2 Throttle motor (12P) (main harness side) • - - -
3 Stop motor (6P) • • - -
4 Stop motor (6P) (main harness side) • • - -
5 Solenoid valve (2P) • • • •
Hydraulic pump electromagnetic proportional valve 1 (2P) (main
6 • • • •
harness side)
7 Hydraulic pump electromagnetic proportional valve 2 (2P) • • • •
8 Pressure switch (2P) • • • •
9 Pressure switch (2P) (main harness side) • • • •
10 Receiver dryer (2P) • • • •
11 Oil filter switch (1P) • - - -
12 Oil filter switch (1P) (main harness side) • - - -
13 Backup sensor (2P) - • - -
16 Engine governor A (8P) - • - -
17 Engine governor B (6P) - • - -
18 Engine governor B (3P) - • - -
19 Oil temperature sensor (2P) - • • •
20 Pressure sensor (3P) - • • -
21 Atmospheric pressure sensor/pressure sensor (3P) - - • •
22 Suction air temperature sensor (2P) - - • •
23 Glow (1P) - - • •
24 Fuel pump (6P) - - • •
25 EGR (8P) - - • •
26 Injector (12P) - - • •
27 Sensor (20P) - - • •
28 Breaker ECM main harness assembly - - • •
29 Fan motor proportional valve (2P) - - • -
30 Fan motor reverse valve (2P) - - • -
31 Fuel sensor/solenoid valve (2P) - - - •
32 Angle sensor (3P) (liftcrane specifications) - - - •
33 Fuel feed pump (2P) - - - •
34 Fuel pump harness (3P) - - - •
35 Fuel pump (2P) - - - •
36 Air conditioner compressor (1P) - - - •
37 Engine sensor (20P) - - - •
38 Engine EGR (8P) - - - •

Copyright ©
4000-4
2 Measurement tools
1 Service connector
1) For throttle motor (12P)
446 436 740
V L GB 820
B
150
150
450
0
15
0
15 Gr
150
B 435
100 150
50 G
Gr R Br 450 821 150
WY W Y O 448 428 824 823 150 822

15 R
0
15
0
150
821
150
Br
448
823 824 428 WY
O Y W KHP11810
2) For throttle motor (12P) (main harness side)

446 436 740
Lg LgR BW 820
R
150
150
450
0
15
0
15 L
150
R BW LgR Lg 820 740 436 446 435
100 150
50 WG
B L 822 435 450 150
428 448 150 822

15 G
0
15
0
150
821
150
448
823 824 428 GB
W Y GL KHP11820
3) For stop motor (6P)

817
LW
0 816
15
L
150
L 816 100
50 150
718
150 B
15
0
819
LY
240
LR KHP11830

Copyright ©
4000-5
4) For stop motor (6P) (main harness side)
817
LW
0 816
15
L
150
L 100
50 150
718
150 B
15
0
819
LY
240
LR
KHP11840
5) For solenoid valve (2P)

BrG
100
BrG BrB
100 150
50
100 101
150 BrB
101
KHP11850
6) For hydraulic pump electromagnetic proportional valve 1 (2P) (main harness side)
BrB
102
BrB BrG
100 150
50
102 103
150 BrG
103
KHP11860
7) For hydraulic pump electromagnetic proportional valve 2 (2P)

BrG
104
BrG BrB
100 150
50
104 105
150 BrB
105
KHP11870
8) For pressure switch (2P)

L
106
L BY
100 150
50
106 107
150 BY
107
KHP11880
9) For pressure switch (2P) (main harness side)

BY
108
BY L
100 150
50
108 109
150 L
109
KHP11890
10)For receiver dryer (2P)

G
814
G G
100 150
50
814 850
150 G
850
KHP11900

Copyright ©
4000-6
11)For oil filter switch (1P)
100
50 150
110 110
LB LB KHP11910
12)For oil filter switch (1P) (main harness side)

100
50 150
111 111
LB LB
KHP11920
13)For backup sensor (2P) - CX130 to CX290

0.5 O
01A
0.5 W 0.5 O 50
150
50
50
02A 0.5 W
KHP1576
14)For backup sensor (2P) - CX330 to CX460

0.5 O
01A
0.5 W 0.5 O 50
150
50
50
02A 0.5 W
KHP1732
15)For backup sensor (2P) - CX800

R
497
R G
50
150
50
497 487
50
487
G KHP11930

Copyright ©
4000-7
16)For engine gouvernor A (8P)
1.25RG
01A
1.25Br
02A
0.85GR
03A
50
0.85 0.85 1.25
WL GR RG
50
0.85 0.85 0.85
YG Y WY 0.85WL
50
04A
500 50
04A 03A 02A 01A 50
50
08A 07A 06A 05A
0.85WY
50 05A
50
50
0.85L
50
05B 06A
1.25 1.25 0.85 0.85 0.85Y

07A
0.85YG
08A
KHP1578
17)For engine gouvernor B (6P)

1.25LG
01A
0.85BG
02A
50
0.85 1.25
0.85 0.85
WG
50
02A 500 1.25GrB

50 50
03A
05A 04A 03A
50
50
01B 02B
50
0.85BW
03B 04B 05B
04A
1.25 0.85
LG BG
1.25
GrB
0.85WG
05A
KHP1579

Copyright ©
4000-8
18)For engine gouvernor B (3P)
0.85
LG
200 0.85LG
50 50
01A 50 01A
01B
0.85
LG
KHP1580
19)For oil temperature sensor (2P)

0.85BP
01A
0.85PL 0.85BP 50
50 150
02A 01A
50
02A
0.85PL KHP1575
20)For pressure sensor (3P)
0.85 0.85
02A 01A 200 0.85BW
WY BW 50 50
01A
0.85
WL 03A 50
50
0.85WY
50
02A
0.85 0.85
BW WY 01B 02B
0.85
WL 03B 03A
0.85WL KHP1577
21)For atmospheric pressure sensor (3P)

200 0.85YL
50 50
01A 02A 03A 01A
50
0.85 0.85 0.85

50
50
YL BY Y
0.85BY
02A
03B 02B 01B
0.85 0.85 0.85 03A

Y BY YL 0.85Y KHP11020
22)For suction air temperature sensor (2P)

0.85BO
01A
A
50
300
50
01A 02A
A
50
0.85BO 0.85OL
02A
0.85OL KHP11030

Copyright ©
4000-9
23)For glow (1P)
3B
01A
6
50
50 200
3B 01A
50
50
6
02A
3LR 02A 3LR
KHP11060
24)For fuel pump (6P)
KHP11070
25)For EGR (8P)
KHP11080

Copyright ©
4000-10
26)For injector (12P)
KHP11090
27)For sensor (20P)
KHP11100

Copyright ©
4000-11
28)For breaker ECM main harness assembly
a) Wire harness for ECM to knob
Engine controller C-2 Engine controller C-1

KHP11970-KHP11980

Copyright ©
4000-12
b) Wire harness for main harness to knob
Engine controller KHP11970-KHP11990
c) Wire harness for joint knob

1.250 1.250
150
50 50
001 001
50
1.250
002
KHP11970-KHP12000
29)For fan motor proportional valve (2P) - CX460 to CX800

1.25YG
01A
50
50 600
1.25 1.25
1 5
Y
YG BY 01A 02A
50
50
01B
1.25
5 1.25 02A 01B
BY Y 1.25Y
KHP11040

Copyright ©
4000-13
30)For fan motor reverse valve (2P) - CX460 to CX800
1.25RW
01A
50
50 800
01A 02A
50
1.25RW 1.25B
02A
1.25B KHP11050
31)For Solenoid valve and fuel sensor (2P)

0.85 0.85 0.85
01A
W L L
02A 01A
50 0
10
100
10
0.85 0.85 50 0
L W
01B 02B
0.85
02A
W
KHP13650
32)For angle sensor (3P)

0.85 0.85 0.85 0.85
01A
R W B B
03A 02A 01A 0

50 10
100 100 0.85

02A
0.85 0.85 0.85 W
B R 50
10
0
03B
0.85
03A
R
KHP13660
33)For fuel feed pump (2P)

0.85 0.85
B PW 0.85
01A
PW
01A
50 0
10
100
10
50 0
0.85 0.85
PW B
0.85
02A
B KHP13670
34)For fuel pump harness (3P)

0.85 0.85 0.85
B GW 01A
GW
02A 01A
0
03A 50 10
0.85
YL 100 100 0.85
02A
B
50
0.85 0.85 10
0
GW B
01B 02B
03B 0.85
03A
YL
0.85
YL KHP13680

Copyright ©
4000-14
35)For fuel pump (2P)
0.85 0.85 0.85
B LR 01A
LR
02A 01A
50 0
10
100
0.85 0.85 10
50 0
LR B
01B 02B
0.85
02A
B KHP13690
36)For air conditioner compressor (1P)
0.85
01A
W
50
100 150 0.85

01A
W
50
0.85
01A
W
KHP13700
37)For engine sensor (20P)

0.85
01A G
0.85
02A L
0.85
04A GrR
50
50
0.85
V
50
0.85 0.85
GrR BW L G 04A 03A 01A
50
0.85
RG V 08A 06A 05A WR
0.85
R
0.85
BY 12A 11A 09A 50
0.85 0.85 0.85
16A 08A
GR W
50 RG
LgR BrR BR 19A

50
0.85
50 09A RY
0.85 0.85 0.85

01B 02B 03A 04B 50 10A 0.85
G GrR YB
0.85 0.85
V RG 05B 07B
50 300 50
0.85 0.85
RY R 11A BY
0.85 0.85
W GR 13B 15B
50
0.85
BR BrR LgR 17B 18B 19B 12A R
50
0.85
13A W
50
0.85
50 14A G
0.85
50
15A WL
50
50
0.85
16A
50
GR
0.85
17A BR
0.85
18A BrR
0.85
19A LgR
KHP13710

Copyright ©
4000-15
38)For engine EGR (8P)
01A 0.85
L
02A 0.85
GR
50
03A 0.85
50
0.85 0.85 0.85 0.85 GW
GB GW GR L 04A 50
0.85 0.85 0.85 0.85
WR WB WL LW 08A 05A 50
50 04A 0.85
GB
200
50
50
05A 0.85
0.85 0.85 LW
L GR GW GB
50
0.85 0.85 0.85 0.85
WL WB
06A 0.85
50
WL
50
07A 0.85
WB
08A 0.85
WR
KHP13720

Copyright ©
4000-16
NOTES
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Copyright ©
4001
Section
4001
ELECTRICAL AND ENGINE FUNCTIONS,

&
SERVICE SUPPORT

Printed in France
Copyright ©
4001-2
TABLE OF CONTENTS
ELECTRIC CIRCUITS OPERATION EXPLANATION .................................................................................................. 7

Explanation of Electrical Functions ..................................................................................................................... 7
Engine Speed Control ............................................................................................................................................ 9
Throttle Control .................................................................................................................................................... 9
Idling Control (auto / one-touch) ......................................................................................................................... 13
Idling Start .......................................................................................................................................................... 14
Auto Warm Up .................................................................................................................................................... 15
Engine Start / Stop Control ................................................................................................................................. 16
Engine Start / Stop Judgment ............................................................................................................................ 16
Power-Cut Delay ................................................................................................................................................ 17
Engine Emergency Stop .................................................................................................................................... 18
Neutral Start ....................................................................................................................................................... 19
Pump Control ....................................................................................................................................................... 20
Work Mode Control ............................................................................................................................................ 20
Pump Horsepower Boost Control ....................................................................................................................... 21
Pump Horsepower Cut Control .......................................................................................................................... 22
Power Save Control ........................................................................................................................................... 23
Swing ..................................................................................................................................................................... 25
Swing Brake ....................................................................................................................................................... 25
Free Swing (North America Only) ...................................................................................................................... 26
Swing Lock (for maintenance) ............................................................................................................................ 27
Swing Relief Cut ................................................................................................................................................. 28
Swing Speed Limit ............................................................................................................................................. 30
Travel ..................................................................................................................................................................... 31
Travel Speed Switchover ................................................................................................................................... 31
Travel Alarm ....................................................................................................................................................... 32
Valve Control ........................................................................................................................................................ 34
Lever Lock .......................................................................................................................................................... 34
Solenoid Sticking Prevention ............................................................................................................................. 35
Pressure Boost Control ...................................................................................................................................... 36
Monitor Control .................................................................................................................................................... 38
Bar Graph (coolant temperature gauge, oil temperature gauge, fuel gauge) .................................................... 38
Accessories .......................................................................................................................................................... 44
Horn ................................................................................................................................................................... 44
Working Light ..................................................................................................................................................... 45
Wiper & Washer ................................................................................................................................................. 46
Room Lamp ........................................................................................................................................................ 48
Radio Mute ......................................................................................................................................................... 50
Others .................................................................................................................................................................... 51
Anti-Theft ............................................................................................................................................................ 51
Battery Save Function ........................................................................................................................................ 52
Alternator Power Generation Detection ............................................................................................................. 53
Overload Alarm (Europe only) ............................................................................................................................ 54
Options .................................................................................................................................................................. 56
Option Line Control ............................................................................................................................................ 56
Option Line Control ............................................................................................................................................ 59
Feed Pump Automatic Stop ............................................................................................................................... 61
Return Filter Clogging Detected ......................................................................................................................... 64
Beacon (Europe Only) ........................................................................................................................................ 65

Copyright ©
4001-3
ELECTRICAL PARTS AND WIRING ASSEMBLY DIAGRAM ....................................................................................67
Main Frame ............................................................................................................................................................67
Description ............................................................................................................................................................69
Cab .........................................................................................................................................................................71
Description ............................................................................................................................................................73
EXPLANATION OF ENGINE FUNCTION ....................................................................................................................75
Engine Function Explanation table .....................................................................................................................75
EGR (Exhaust Gas Recirculation) ......................................................................................................................77
Relationship between ECM and sensor actuators ..............................................................................................79
Cautions for Maintenance ...................................................................................................................................80
Explanation of Engine Control ............................................................................................................................83
Engine Start/Stop Judgment ...............................................................................................................................87
SERVICE SUPPORT ....................................................................................................................................................89
Screen Operations ................................................................................................................................................89
Screen Display List ...............................................................................................................................................91
CHK (status display) Screen List ........................................................................................................................91
MAIN ...............................................................................................................................................................91
MNT ................................................................................................................................................................94
H / W-A ...........................................................................................................................................................96
H / W-B ...........................................................................................................................................................99
H / W-M .........................................................................................................................................................102
DIAG (trouble diagnosis) Screen ......................................................................................................................103
Screen ..........................................................................................................................................................103
Operation ......................................................................................................................................................104
Reset ............................................................................................................................................................104
HR (usage log) Screen List ...............................................................................................................................105
MAIN .............................................................................................................................................................105
ENG ..............................................................................................................................................................107
CFG (setting change) Screen ...........................................................................................................................110
Operation ......................................................................................................................................................110
Screen ..........................................................................................................................................................111
CAL (troubleshooting support) Screen ..............................................................................................................113
Operation ......................................................................................................................................................113
Screen ..........................................................................................................................................................113
Check the Monitor Switch (Self-diagnosis function) ..........................................................................................115
Screen ..........................................................................................................................................................115
Configuration ................................................................................................................................................115
Differences from CHK screen [CHK | H/W-M | 1] .........................................................................................116
Option Flow Setting ...........................................................................................................................................117
Screen ..........................................................................................................................................................117
Flow setting ...................................................................................................................................................117
Anti-theft Setting ...............................................................................................................................................119
Anti-theft setting and password registration ..................................................................................................119
Anti-theft function operation ..........................................................................................................................120
Model Setting ....................................................................................................................................................121
Engine Screen Information ...............................................................................................................................123
Purpose ........................................................................................................................................................123
How to go to this screen ...............................................................................................................................123
Engine start restriction ..................................................................................................................................123
Screen ..........................................................................................................................................................123
Operating method .........................................................................................................................................123
Monitor operation method .............................................................................................................................124
Engine Information (Q resistance, QR code, engine serial number) Copying Method .................................125
Rewriting Injector QR Codes ........................................................................................................................126
When Replacing Computer A at the Same Time ..........................................................................................127
Engine Information Obtained Timing ............................................................................................................127
Redoing Engine Information Obtained ..........................................................................................................127
Trouble Display .............................................................................................................................................127

Copyright ©
4001-4
Screen Display Details ....................................................................................................................................... 128
Message Display List ....................................................................................................................................... 128
Trouble Display .................................................................................................................................................. 130
Diagnostic Trouble Code Display ..................................................................................................................... 130
Main Unit Diagnostic Trouble Code List ........................................................................................................... 131
Diagnostic Trouble Code (Monitor Display) ..................................................................................................... 137
Sensor Trouble Operation Table ...................................................................................................................... 143
EPF (engine protection feature) ....................................................................................................................... 145
ELECTRICAL INSPECTION OF COMPONENTS ..................................................................................................... 147
Measurement method ........................................................................................................................................ 147
Hydraulic Pump Electromagnetic Proportional Valve ....................................................................................... 147
Solenoid Valve (5 stack) .................................................................................................................................. 148
Oil Temperature Sensor ................................................................................................................................... 149
Pressure Sensor .............................................................................................................................................. 150

Copyright ©
4001-5
CNH-EST DIAGNOSTIC TOOL
The EST (Electronic Service Tool) system allows diagnoses on machines and engines by detecting the operating
parameters of electronic control components (control units, sensors etc.). It is also capable of reading fault codes.
To use this tool, please refer to the book provided during the CXB series training sessions.

Copyright ©
4001-6
This page has been left blank intentionally

Copyright ©
4001-7
ELECTRIC CIRCUITS OPERATION EXPLANATION
Explanation of Electrical Functions
Item Control Contents

1 Throttle Control The engine speed, work mode, and boosted pressure state are
switched by the throttle volume.
Engine 2 Idling Control With auto / one-touch switchover function
Speed
3 Idling Start Runs the engine at low idle speed when it starts up.
Control
4 Auto Warm Up If the coolant temperature is low, warm-up operation is executed
automatically when the engine starts
1 Engine Start / Stop Judgment based on engine speed from ECM
Judgment
Engine Start 2 Power-Cut Delay When key ON OFF, 4-second delay; when engine running OFF, 7-
/ Stop second delay
Control 3 Engine Emergency When the emergency stop switch is pressed, the ECM recognizes
Stop this and stops the engine.
4 Neutral Start Control Engine start load (cell not turning) when lever locked
1 Work Mode Control Linked with the throttle, the SP / H / A mode is switched over and
the pump horsepower is controlled.
2 Pump Horsepower Control pump horsepower milli-amp in accordance with the work
Boost Control mode selected.
Pump
3 Pump Horsepower Cut The milli-amp for pump horsepower control proportional valve is
Control
Control reduced by the transient load control, engine stall prevention
control, and PID control conditions.
4 Power save Control The negative control relief pressure for non-operation is varied and
the negative control pressure is lowered to reduce the pump load.
1 Swing Brake When the upper and swing are not operated, the swing brake is
operated automatically and during travelling too
2 Swing Free Swing Swing option for North America
(option)
3 Swing Lock There is a swing lock function (for servicing) with monitor
Swing
operations.
4 Swing Relief Cut When a swing starts, the flow is reduced with the front side
proportional valve and the excess oil is eliminated.
5 Swing Speed Limit The front side flow is controlled to suppress the speed rise due to
increased pump flow
1 Travel Speed Travel speed low-speed / high-speed switchover
Travel Switchover
2 Travel Alarm Buzzer sounded (for 10 seconds) during travel
1 Lever Lock Operation is not possible unless the gate lever is raised.
2 Solenoid Sticking When key ON, solenoid switched ON / OFF for 0.25 second.
Valve Prevention
Control 3 Pressure Boost Control The computer automatically raises the pressure from 34.3 MPa
(433 bar / 4975 psi) => 36.8 MPa (368 bar / 5338 psi) when
necessary.
1 Monitor Bar Graph Bar graph display of coolant temperature, oil temperature, and fuel
Monitor level on monitor
Control 2 Monitor Function Output port control method change, lift crane and option screen
added to display screens, etc.

Copyright ©
4001-8
Item Control Contents

1 Horn Switching between one or two horns with horn volume select switch
2 Working Light Right housing and boom light illumination (option setting for two
lights at top of cab)
Accessories 3 Wiper & Washer Wiper with rise-up used (intermittent, continuous, washer)
4 Room Lamp The room lamp lights up when the door is opened and lights up for
exactly 30 seconds from when the door is opened with the key OFF.
5 Radio Mute Mute switch setting on the knob
1 Anti-Theft Anti-theft set with password input to monitor
2 Battery Save Function When the key is ON, no output to travel switchover, boost, power
save, bucket lock, option switchover and free swing solenoid valve.
Others
3 Alternator Power Alternator L terminal voltage judged with 10 V comparator
Generation Detection
4 Overload Alarm Only mounted on machines for Europe
1 Option Line Control Switchover crusher / breaker with just rocker switch in cab
2 Option Line Control There are five flow settings each for the breaker and crusher, for a
total of 10 settings.
3 Feed Pump Automatic Feed pump automatic stop. Full tank detected by fuel level sensor
Stop and the pump stopped automatically
Options
4 Return Filter Clogging Alarm issued when return filter clogged (only for breaker
Detected specifications)
5 Beacon Control Standard for Europe.
(rotating light)
6 DC-DC Converter Convert 24 V into 12 V

Copyright ©
4001-9
Engine Speed Control
1. Throttle Control
1) Throttle display
a) Configuration
Throttle display data
Throttle display
Target engine speed
1 Monitor 3 Engine
2 Computer A 4 Throttle volume
b) Summary
The throttle volume voltage signal is first input to Computer A. Computer A converts the voltage signal to a
target speed and sends it to the ECM with CAN communications.
At the same time, Computer A sends the throttle display data to the monitor.
2) Throttle volume position detection
a) Configuration
1 2
5V
3 AD
GND
RE06004-012
1 Throttle volume
2 Computer A
3 Potentiometer

Copyright ©
4001-10
b) Structure
The detent and notches provide a click feel (15 notches; Notch 1 is the "SP mode" position).
Hysteresis about 2.5°
(Right turn)
When the detent
Small notch: 4 to 15 Large notch: 1 to 3 reaches the N- position,
it is judged to beat
Notch N.
(Left turn)
When the detent
reaches the N+ position,
it is judged to be at
Notch N.
Left turn Right turn Notch number (1 to 15)
Notch N
Detent
detent position detection:
Hysteresis is used to
absorb error.
c) Characteristic
Target engine speed Hysteresis

min-1
1900
1800
1700
900
Detent position (notch number)

15 14 13 4 3 2 1
(AUTO) (H) (SP) SE06009-001

Copyright ©
4001-11
d) Potentiometer characteristic
Voltage (V)
Angle (deg)
Throttle operation range
Trouble Normal Trouble
Potentiometer operation range
e) Throttle volume degree of opening calculation

The throttle volume degree of opening (%) that can be checked on the CHK screen is calculated with the
standard below.
100% => When the detent is in the 1+ position
0% => When the detent is in the 15- position
Therefore, even if the detent is in the 1 position (SP), this does not necessarily mean that the degree of
opening is 100%.
In the same way, even if the detent is in the 15 position, the degree of opening is not necessarily 0%.

Copyright ©
4001-12
f) Table
For the angle, voltage, and degree of opening for each detent position, see the following table.
Degree of
Detent Angle [degree] Voltage [V]
opening [%]
1+ 131.2 4.86 100.0
1 128.7 4.77 98.0
1- 126.2 4.67 96.1
2+ 109.6 4.06 83.0
2 107.1 3.97 81.1
2- 104.6 3.87 79.1
3+ 95.2 3.53 71.7
3 92.7 3.43 69.8
3- 90.2 3.34 67.8
4+ 88.0 3.26 66.1
4 85.5 3.17 64.1
4- 83.0 3.07 62.2
5+ 80.8 2.99 60.4
5 78.3 2.90 58.5
5- 75.8 2.81 56.5
6+ 73.6 2.73 54.8
6 71.1 2.63 52.8
6- 68.6 2.54 50.9
7+ 66.4 2.46 49.1
7 63.9 2.37 47.2
7- 61.4 2.27 45.2
8+ 59.2 2.19 43.5
8 56.7 2.10 41.5
8- 54.2 2.01 39.6
9+ 52.0 1.93 37.8
9 49.5 1.83 35.9
9- 47.0 1.74 33.9
10+ 44.8 1.66 32.2
10 42.3 1.57 30.2
10- 39.8 1.47 28.3
11+ 37.6 1.39 26.5
11 35.1 1.30 24.6
11- 32.6 1.21 22.6
12+ 30.4 1.13 20.9
12 27.9 1.03 18.9
12- 25.4 0.94 17.0
13+ 23.2 0.86 15.2
13 20.7 0.77 13.3
13- 18.2 0.67 11.3
14+ 16.0 0.59 9.6
14 13.5 0.50 7.6
14- 11.0 0.41 5.7
15+ 8.8 0.33 3.9
15 6.3 0.23 2.0
15- 3.8 0.14 0.0

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4001-13
2. Idling Control (auto / one-touch)
7
5
8
9
2
6 10
11
ECM
4 RE06009-002
1 Monitor display 5 One-touch idle switch 9 Pressure sensor (upper)

2 Computer A 6 Throttle volume 10 Pressure sensor (swing)
3 Engine 7 1st option pressure switch 11 Pressure sensor (travel)
4 Coolant temperature sensor 8 2nd option pressure switch ECM Engine Control Module
Operation explanation:
a) Auto / one-touch switchover function
The operator can switch between one-touch and auto by pressing the auto idle switch on the monitor in the
figure below.
When auto idle is ON, the LED at the side of the switch lights up.
b) Auto idle control (A)

1. When auto idle is set, if the lever is left continuously unoperated for 5 seconds, the engine speed
automatically becomes the auto idle speed (1200 min-1).
This five-second setting for auto idle operation is the default setting value. This setting can be changed
to from 1 to 30 seconds with service support operations.
2. When the lever is operated, the engine speed is automatically returned to the engine speed set for the
throttle volume.
3. Even with auto idle set, it is possible to move to auto idle or return from auto idle by pressing the knob
switch (one-touch idle switch) on the right operation lever.
c) One-touch idle control
When auto idle is not set, regardless of lever operation, it is possible to move to auto idle or return from
auto idle by pressing the knob switch (one-touch idle switch) on the right operation lever.
The idling speed for one-touch idle control is 900 min-1.

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4001-14
d) Idling speed
1. Auto idling speed => 1200 min-1
2. One-touch idling speed => 900 min-1.
3. Low idling speed => 900 min-1.
The speeds above are the default values. They can be set to from 900 to 1600 min-1 with service support
operation (See Screen Operation in Service Support). However, the settings are based on the following
conditions.
Low idle speed = One-touch idle speed ≤ Auto-idle speed
(The one-touch idle speed and auto-idle speed settings can be changed).
3. Idling Start
a) When the engine starts, the engine speed becomes the low idle speed regardless of the throttle position.
b) When the low idle speed is changed, the engine speed is controlled at this new speed.
c) During an idling start, the idling icon (A) is displayed at the top left of the monitor.
No message is displayed
.
d) An idling start is ended in the following cases and control becomes normal.
1. When the one-touch idle switch is pressed
2. When the throttle volume is operated
3. When the operation lever is operated (upper, travel, swing pressure sensor ON)
e) Back-up operation
1. Sensor trouble
If trouble occurs in a sensor (upper, travel, swing), the idling start is ended.
2. Throttle volume trouble
Even if the throttle volume is operated, the idling start is not ended. Also, even if the idling start is ended
with some other method, the throttle cannot be adjusted.
3. One-touch idle switch trouble
Even if the switch is pressed, the idling start is not ended.

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4001-15
4. Auto Warm Up
If the coolant temperature is low when the engine starts up, warm-up operation is executed, automatically raising the
engine speed in steps.
a) Auto warm up is used if the coolant temperature is lower than 50 °C (122°F) when the engine starts.
b) If the coolant temperature is 50 °C (122°F) or higher, auto warm up is not used and an "idling start" is executed.
c) Operation
The engine speed is raised in steps from the low idle speed until 1900 rpm as below.
When the low idle speed is changed, the engine speed starts from the newly set speed.
The warm up time is the same, 14 minutes.
When the coolant temperature reaches 50 °C (122°F), the engine speed falls immediately to low idle (Idling
start).
1900 min-1
Low idle 1500 min-1

1300 min-1
1200 min-1
Low idle
1000 min-1
5 minutes 3 minutes 3 minutes 3 minutes
d) Monitor display
During auto warm up, the “Auto warm up icon” (A) is displayed at the top left of the monitor.
e) In the cases below, auto warm up is ended and operation shifts to "idling start".
1. When the coolant temperature reaches 50 °C (122°F)
2. When the one-touch idle switch is pressed
3. When the entire auto warm up process ends (after 14 minutes)
f) In the cases below, auto warm up is ended and operation shifts to the engine speed for the throttle position.
1. When the lever is operated (as detected by a pressure sensor)
2. When the throttle volume is operated
g) Back-up operation
1. Sensor trouble
If trouble occurs in a sensor (upper, travel, swing, coolant temperature sensor), auto warm up is not
operated. Also, even trouble occurs in a sensor partway through a warm up, the warm up is ended and
operation shifts to normal control.
2. One-touch idle switch trouble
Even if the switch is pressed, auto warm up is not ended.
3. Throttle volume trouble
Even if the throttle volume is operated, the auto warm up is not ended

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4001-16
Engine Start / Stop Control
1. Engine Start / Stop Judgment
a) Configuration
Engine
Speed
Engine
ECM
1 Computer A
2 Cam sensor
3 Crank sensor
b) Summary
Engine start and stop is judged based on the engine speed sent from the ECM with CAN communications.
c) Judgment value
Start 500 min-1, Stop 200 min-1
Start
Stop
200 min-1 500 min-1

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4001-17
2. Power-Cut Delay
a) Configuration (fuses etc. omitted)
1 Computer A 5 Load A
2 Key switch 6 Power supply
3 Battery relay 7 Key switch signal
4 Battery 8 Battery relay hold
b) Summary
After the key is switched OFF, after the battery relay is held for a certain period, the power supply is cut off.
c) Purpose
1. This secures time after the key is switched OFF for data to be written in the EEPROM in the ECM and
Computer A.
2. This waits until the engine completely stops to avoid load dumping.
d) Operation
1. When the key is ON, the battery relay is held by the battery relay hold output (OUT1) from the ECM and
the key switch.
2. After the key is switched OFF, the battery relay is only held by the ECM.
3. After it detects the key going OFF through the key switch signal input (IN1), the ECM starts the count
down.
4. After a certain time has passed, the ECM stops output to the battery relay and the battery relay goes
OFF.
At the same time, the power supply to electrical parts, including the ECM and computer is cut (Except
the backup power supply).
5. The time from the key being switched OFF until the power supply goes OFF (the delay time) depends on
whether or not the engine was started.
• After the key is switched ON, if the key is switched OFF without the engine being started = about 4
seconds.
• If the key is switched OFF after the engine was started = about 7 seconds.

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4001-18
3. Engine Emergency Stop

Function for stopping the engine in an emergency
When the emergency stop switch on top of the left console is pressed, the engine is stopped regardless of the
key switch position.
1 Monitor display 3 Engine

2 Computer A 4 Emergency stop switch
a) Circuit
1. When the emergency stop switch is pressed, a 24 V signal enters the ECM input port.
2. When the 1) signal enters, the ECM controls the injector, suction control valve, and EGR valve to stop
the engine.
3. The emergency stop switch signal enters computer A too and computer A sends the engine stop
command to the ECM with CAN communications.
4. At the same time, computer A sends the emergency stop and buzzer instructions to the monitor with
serial communications.
b) Display, alarm
1. When the emergency stop switch is switched ON, the "ENGINE STOP" message is displayed on the
monitor.
2. Even if there is another message, the "ENGINE STOP" message is displayed with priority for five
seconds after the switch is switched ON.
3. At the same time as 1), the buzzer in the monitor buzzes intermittently at 1 Hz.
4. If any kind of trouble is detected during the 1 Hz intermittent buzzing of 3), after the 5-second continuous
buzzing, which is the trouble alarm, the buzzing returns to the 1 Hz intermittent buzzing.
5. Even if the buzzing continues after the switch ON/OFF message display (for 5 seconds), the message
display is not extended.
6. The above message display and buzzer operate whether the engine is running or stopped.
c) An emergency stop takes priority over any other control and stops the engine.
• The engine stops even during lifting magnet suction, during elevator cab rising, and fan reverse
operation (large machine only).
d) When an emergency stop is made, it is not recorded in the trouble log.
e) The engine can be cranked with the emergency stop switch ON, but the engine will not start.

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4001-19
4. Neutral Start
a) Purpose and summary
The engine will not start with the gate lever lifted (It will not crank).
This prevents accidental operation if the operation lever is accidentally bumped into when the engine is
started.
b) Configuration
Gate lever
Down (OFF)
Up (ON)
1 Key switch 5 Starter cut relay

2 Gate lock limit switch 6 Lever lock solenoid
3 Starter motor 7 Battery relay
4 Safety relay
c) Operation
When the gate lever is raised (and the limit switch comes ON), the starter cut relay is excited, the excitation
to the safety relay is cut off, and the engine does not crank. At this time, nothing in particular is displayed
on the monitor.

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4001-20
Pump Control
1. Work Mode Control
a) Purpose:
Work mode control enables the operator to select the work mode to match the work contents, for example
emphasizing speed, emphasizing fuel economy, etc.
At the same time, the engine speed is adjusted (throttle adjustment).
Work mode display
Work mode display
Target engine speed
ECM
1 Monitor 6 Boost solenoid

2 Computer A 7 P1 pressure sensor
3 Engine 8 P2 pressure sensor
4 Throttle volume 9 N1 pressure sensor
5 Pump horsepower control proportional valve 10 N2 pressure sensor
b) Operation:
1. Manual switchover (main mode)
The operator can select one of the following work modes by turning the throttle volume.
For the correspondence between the throttle volume detents and the work modes, see the attached
table.
Mode Aim Display Monitor buzzer

The buzzer buzzes twice when
(1) SP mode Speed emphasis
this is selected.
Balances speed and The buzzer buzzes once when

(2) H mode
fuel economy this is selected.
Fuel economy
(3) A mode No buzzing
emphasis
2. Automatic switchover (submode)

Each of the main modes that can be selected manually has two sub-modes (high and low).
These sub-modes are switched automatically based on the sensor input values.
For the high and low milli-amps, refer to the explanation of the 2. Pump Horsepower Boost Control in
next page.

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4001-21
2. Pump Horsepower Boost Control
a) Purpose:
Controls pump horsepower according to the work mode (engine speed)..
Control milli-amp
Volume position (detent position) 1 2 3 4 to 8 9 to 15
Work mode SP H AUTO
Engine speed (min-1) 1900 1800 1700 1699 to 1300 1299 to 900
Milli-amp for pump horsepower
500 500 500 380 50
control proportional valve (mA)
Boosted pressure Automatic Automatic Normal
b) Operation:
1. Controls milli-amp to the pump horsepower control proportional valve according to the selected work
mode (engine speed).
2. Increase/decrease control of milli-amp is not performed according to load variation.
3. When SP mode is selected, the engine rotation increases to 2050 min-1 if low-speed (1st speed) travel is
performed.

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4001-22
3. Pump Horsepower Cut Control

a) Purpose:
The pump milli-amp is controlled in order to prevent black smoke under overload and engine speed drop and
in order to improve energy saving.
The control methods are the following three.
1. Overload reduction control
2. Engine stalling prevention control
3. PID control
ECM 3
RE06004-002
1 Computer A 4 P1 pressure sensor

2 Pump 5 P2 pressure sensor
3 Engine 6 Pump horsepower control proportional valve
b) Overload reduction control

When the engine is under overload, the milli-amp to the pump horsepower proportional valve first drops to
50mA.
After that, the milli-amp is gradually raised while watching the difference between the actual engine speed
and the target engine speed.
Overload reduction control is executed in all work modes.
• The engine is judged to be overloaded when the following conditions are met.
1. Sharp lever operation
When there is sharp lever operation, this is judged from the upper pressure sensor state.
2. Operation for high loads and sharp loads
Judged from the P1 or P2 pump pressure sensor and from the pump main pressure boost state.
c) Engine stalling prevention control
When the target engine speed is 1300 min-1 or less, the milli-amp is 50 mA.
d) PID control
When the engine actual speed falls 30 min -1 or more below the target engine speed, the milli-amp is
gradually lowered to I Min.
When the difference of the actual engine speed from the target engine speed falls below 30 min-1 the milli-
amp rises to the target for the each mode.
Backup control
If trouble occurs in a pressure sensor (P1, P2, upper), the overload restriction control is not carried out.
If trouble occurs in the pump horsepower control proportional valve, the output from the computer stops.

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4001-23
4. Power Save Control

a) Purpose:
Purpose
When no lever is operated, the pump load is reduced with the control below to reduce fuel consumption.
The control methods are the following 2.
1. The negative control relief pressure is varied and the negative control pressure is lowered to reduce the
pump load.
2. The pump discharge volume is set to the minimum flow.
2
7 7
8 9
10
1
3
6
RST-05-06-001u
1 Computer A 6 Travel pressure sensor

2 Control valve 7 Negative control foot relief valve
3 power save solenoid 8 Pump 1
4 Upper pressure sensor 9 Pump 2
5 Swing pressure sensor 10 P1 flow control proportional valve
b) Operation explanation
1. Normal operation
If more than 1 sec. passes with all the sensor signals to the computer A OFF (upper, travel, and swing
pressure), the computer A judges that no lever is being operated and outputs to the P1 flow control
proportional valve and the power save solenoid valve.
1) P1 pump discharge volume reduced.
1. The milli-amp for P1 flow volume proportional valve is increased from 50 mA to 740 mA.
2. The P1 pump swash plate is switched to the minimum tilting and the discharge volume is set to its
minimum.

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4001-24
2) P2 pump discharge volume reduced.
1. When the power save solenoid valve is switched, the pilot source pressure is fed to the P2 pump
negative control port via the solenoid valve.
2. The P2 pump swash plate is switched to the minimum tilting and the discharge volume is set to its
minimum.
3) Negative control pressure reduction.
1. When the power save solenoid valve is switched, the negative control foot relief valve spring
chamber is linked with the tank line and the negative control foot relief valve setting pressure drops
from 3 MPa to 1 MPa
2. By reducing the negative control relief pressure, the pressure within the circuit is reduced, and the
horsepower used by the pump is reduced. This saves energy.
2. Operation when the engine is stopped with the key ON.
When the engine stops, the battery save function works and there is no output to the P1 flow control
proportional valve or the power save solenoid valve.
3. Operation for trouble.
If an abnormality occurs on either the input side (upper, swing, travel pressure sensors) or the output
side (P1 flow control proportional valve, power save solenoid valve), the system treats this as operation
being underway and control is fixed to the following.
Milli-amp to the P1 flow volume valve … 50 mA, the power save solenoid valve is always OFF.
c) Caution
During a trouble, even if the abnormality is ended, trouble mode does not end until the key is switched OFF.
1 sec. 1 sec.
Flow proportional valve 740 mA
50 mA
Power save solenoid ON
OFF
Pressure sensor ON
(upper)
OFF
Pressure sensor ON
(travel)
OFF
Pressure sensor ON
(swing)
OFF RST-05-06-001v

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4001-25
Swing
1. Swing Brake
a) Configuration
For North
America
Engine actual
speed
1 Horn volume select switch 8 Swing brake solenoid

2 Computer A 9 Accumulator
3 Engine 10 Swing Motor
4 Working light switch 11 Swing Brake
5 Auto idle switch 12 Free swing solenoid
6 Upper pressure sensor 13 Free swing switch (momentary)
7 Swing pressure sensor

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4001-26
b) Braking function during upper operation
When the upper pressure sensor is ON, the brake goes OFF, one second after upper pressure sensor goes
OFF, the brake comes ON.
c) Braking control through swing operation
When the swing pressure sensor is ON, the swing brake goes OFF (Swing brake solenoid = OFF).
Five seconds after the swing pressure goes OFF, the swing brake comes ON (Swing brake solenoid = ON).
d) Swing lock with key OFF
When the key is OFF (during power-cut delay), the swing brake comes ON unconditionally
.
Power-cut delay
b) c) b), c) d)
1 second 5 seconds 5 seconds

1 second
Swing brake
solenoid
Upper pressure
sensor
Swing pressure
sensor
Engine state
Key switch
2. Free Swing (North America Only)

a) Free swing switchover
When the free swing switch is pressed, the free swing mode is switched ON <=> OFF. When the
(momentary) key is OFF, always start with free swing OFF (Previous data reset).
b) Free swing control
When free swing is ON, the free swing solenoid is ON and the swing brake solenoid is OFF.
c) Mode display
When free swing is ON, the icon in the figure below is displayed on the monitor.
d) Battery save
While the engine is stopped with the key ON, if free swing is switched ON, the icon is displayed, but the free
swing solenoid valve does not come ON. It does come ON after the engine starts.
Free swing

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4001-27
3. Swing Lock (for maintenance)

This is used for measuring the swing relief pressure and other maintenance tasks.
a) Swing lock switching
In order to prevent accidental operation under certain special circumstances, sometimes the swing brake
need to be left ON all the time. "Swing lock" At this time, the swing lock can be switched ON / OFF by
holding down the "horn volume select switch", the "working light switch", and the "auto idle switch" at the
same time for 3 seconds.
When turning the key to ON, always start with the swing lock OFF (Previous data reset).
b) Swing lock control
When the swing lock is ON, even if the upper or the swing is operated, the swing brake keep working. Be
particularly careful about swing operation because the swing brake plate is dragged.
(The swing pilot pressure is not shut off. This is no more than a simple swing lock).
c) Competition with free swing
If the swing lock is used, even if free swing is ON, the swing brake solenoid comes ON and the free swing
solenoid goes OFF (Swing lock priority).
d) Mode display
When swing lock is ON, the icon in the figure below is displayed on the monitor.
Swing lock
e) Time chart (free swing & swing lock)

Power-cut Power-cut
delay delay
Swing brake ON
solenoid
OFF
Free swing ON
solenoid
OFF
Engine state RUN
STOP
START
Key swing ON
OFF
Free swing ON
OFF
ON
Swing lock
OFF
3-b) 3-c) 2-a) 3-a)

2-d) The Previous
data is hold
f) Trouble mode
If trouble occurs in an input (upper / swing pressure sensor), communications (CAN), or output (swing
brake solenoid / free swing solenoid), the system goes into trouble mode. In trouble mode, the swing brake
solenoid is OFF and the free swing solenoid is OFF. Even if the trouble is recovered from, this does not
recover the system from trouble mode.

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4001-28
4. Swing Relief Cut
Purpose:
When swing single operation is running, the pump flow is reduced, and the excess oil ejected from the swing
motor relief valve is eliminated.

4'
1 Computer A 8 Boom 2 15 Travel (right)

2 Throttle volume 9 Swing 16 P1 pressure sensor
3 Travel pressure sensor 10 Option 1 17 P2 pressure sensor
4 Option 1 pressure switch 11 Travel (left) 18 Regulator
5 N1 pressure sensor 12 Arm (2) 19 P1 flow control proportional valve
6 N2 pressure sensor 13 Boom
7 Arm (1) 14 Bucket
a) Operation conditions for swing relief cut control
The swing relief cut control provides relief when the pressure is boosted for the start of the swing due to
sharp swing operation and the drained off excess oil is held to the lowest amount possible. The purpose is
to provide an energy saving effect.
Control is executed when all the conditions below are satisfied.
1. Sharp swing operation => When the swing lever is operated, this is judged from the swing pilot pressure
sensor pressure rise.
2. Within 1 second after start of swing
3. Travel non-operation => Travel pressure sensor OFF
4. No attachments other than boom down are operating.
• That no attachment is operating is judged from the N2 negative control pressure and P1 pressure
sensor.
5. Option line non-operation => Option pressure sensor OFF

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4001-29
b) Control contents
For the swing relief cut operation, after the milli-amp to the P1 flow control proportional valve is increased
and the P1 flow is reduced, while checking the P1 pump discharge pressure, the system gradually reduces
the output milli-amp to the P1 flow control valve and raises the P1 pump flow to the constant swing speed.
• Swing relief cut control flow
Independent swing + sharp operation judged => Swing relief cut operation => Milli-amp to P1 flow
control proportional valve => P1 pump flow reduced => Milli-amp gradually decreased while watching
swing pressure fall status => P1 pump flow increased
NOTE: P1 flow control proportional valve: milli-amp (high) => P1 pump flow (low); milli-amp (low) => P1 pump
flow (high)
c) Swing relief cut end conditions
1. When swing operation is stopped
2. Travel ON
3. Boom up, arm out / in, bucket open / closed
4. Boom down sharp operation
5. Boom down pressure boost

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4001-30
5. Swing Speed Limit

Purpose:
With the increase in the pump maximum flow, the swing speed at maximum flow is too fast. Therefore, the P1
pump flow is controlled to suppress the speed rise. (Control only in SP mode)
P1 maximum discharge volume held down from 285 L/min to 280 L/min for independent swing operation.

4'
1 Computer A 8 Boom 2 15 Travel (right)

2 Throttle volume 9 Swing 16 P1 pressure sensor
3 Travel pressure sensor 10 Option 1 17 P2 pressure sensor
4 Option 1 pressure switch 11 Travel (left) 18 Regulator
5 N1 pressure sensor 12 Arm (2) 19 P1 flow control proportional valve
6 N2 pressure sensor 13 Boom
7 Arm (1) 14 Bucket
a) Operation conditions for swing speed limit control
Control is executed when all the conditions below are satisfied.
1) Swing single full lever operation … Judged from the N1 and N2 negative control pressure sensors and
P1 and P2 pressure sensors
2) Travel non-operation … Travel pressure sensor OFF
3) The work mode is SP mode
b) Control contents
The output milli-amp to the P1 flow control valve is set to the maximum of 370 mA and the P1 pump flow is
held down to 280 L/min.
c) Swing speed limit end conditions
1) Travel operation => Immediate end (to prevent off travel)
2) Other attachment operation => Gradual end (to reduce shock)
3) Option circuit operation

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4001-31
Travel
1. Travel Speed Switchover
The travel motor tilt revolution angle is changed by switching the travel speed between low speed and high
speed with the switch.
However, in high-speed mode, if the drive force becomes high due to the functioning of the travel motor itself,
the tilt revolution angle is automatically switched to low speed.
After that, when the drive force becomes low, the slope automatically returns to high speed.
Switch data
Engine actual speed
1 Computer A 4 Travel motor

2 Engine 5 Travel high-speed solenoid
3 Travel high-speed select switch 6 Key switch
a) Operation
1. When the key is ON, the speed becomes low speed. The previous travel mode is reset.
(If the service support operation is changed, it is possible to hold the previous data).
2. Each time the travel high-speed switch is pressed, the speed is switched between low speed and high
speed. During high speed, the LED at the top left of the switch lights up.
3. While the engine is stopped with the key ON, if the high speed travel switch is pressed, the solenoid does
not operate. The LED lights up.
(To prevent the battery being run down).
4. In high-speed mode, the tilt revolution angle is automatically switched between low speed and high
speed by the travel motor drive force.
However, the electrical control remains at high speed, the high-speed LED remains lit, and the solenoid
remains ON.

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4001-32
b) Trouble mode
If an abnormality occurs in communications (CAN) or computer solenoid output, the speed is fixed to low
speed (The travel high-speed solenoid comes OFF).
Key switch
Engine
Travel high-speed
switch
LED
Travel high-speed
solenoid
High speed
Travel motor
Low speed
Drive voltage rise
Drive voltage fall
2. Travel Alarm
a) Configuration
Travel alarm
Intermittent buzzing control is handled by

the travel alarm itself. In other words, while
the travel alarm is ON, computer A buzzes
the buzzer intermittently as it wants.
For North
America:
Standard
1 Computer A Travel alarm mode select switch (alternator)

3
2 Travel pressure sensor
b) Travel alarm (automatic stop)

When the travel pressure sensor comes ON due to travel operation, the travel alarm starts 1 Hz intermittent
buzzing. This buzzing automatically stops after 10 seconds.
c) Travel alarm (continuous buzzing)
When the travel alarm mode select switch is switched ON, the buzzer buzzes continuously during travel
(Function for North America only).
d) Signals when key is ON
After the key is switched ON, the travel alarm sounds for 0.4 second as a signal.

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4001-33
e) Time chart
0.4 seconds 10 seconds

10 seconds 10 seconds
ON
Travel alarm
OFF
Travel pressure ON
sensor
OFF
ON
Key switch
OFF
Travel alarm ON
mode select
switch OFF
d) b) c) Mode switchover
during travel
f) Trouble mode
If trouble occurs in the travel pressure sensor, the machine goes into trouble mode and the travel alarm is
always OFF.

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4001-34
Valve Control
1. Lever Lock
Gate lever
Down (OFF)
UP (ON)
1 Gate lock limit switch 3 Lever lock solenoid

2 Starter cut relay 4 Battery relay
When the battery relay is excited by the key being switched ON, the power enters the lever lock limit switch.
When the gate lever is raised, the lever lock switch (limit switch) comes ON and the lever lock solenoid is
operated (For details on neutral star t control, see Neutral Star t in Explanation of Functions and
Operations).

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4001-35
2. Solenoid Sticking Prevention

a) Target solenoid
• Travel high-speed switchover solenoid
• Boost solenoid
• Option switchover solenoid
• Fan reverse solenoid (only for models with hydraulic drive fan)
• Free swing solenoid
• Bucket lock solenoid (only lift crane application machines)
Because the swing brake, power save solenoid, and electromagnetic proportional solenoid go ON and
OFF frequently in regular work, they are not subject to control.
b) Operation
When key ON, switched ON / OFF for 0.25 second.
After that, control is normal control. Control ends before the engine starts, so the machine does not operate
accidentally.
ON
Key switch
OFF
ON Normal control
Solenoid
OFF
0.25 second0.25 second

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4001-36
3. Pressure Boost Control

a) Configuration
Message and icon
Engine load rate
1 Computer A 6 2nd option line pressure switch 11 P2 pressure sensor

2 Engine 7 Control valve 12 Pump 1
3 Upper pressure sensor 8 Main relief valve 13 Pump 2
4 Travel pressure sensor 9 Boost solenoid 14 Regulator
5 Option line pressure switch 10 P1 pressure sensor
b) During upper operation (upper pressure sensor = ON), the next time the high-load conditions are met, the boost
solenoid valve on the 5 stack solenoid valve comes ON, and the main relief valve pressure rises from 34.3 MPa
(343 bar / 4975 psi) to 36.8 MPa (369 bar / 5337 psi).
Conditions:
When the engine load ratio rises and the P1 or P2 pump pressure is boosted.
c) Auto power boost (ended by time restriction)
When the work mode is SP or H, the boost continues a maximum of 8 seconds, then is automatically ended
(boost solenoid = OFF). When the work mode is A, this time restriction is eliminated and the pressure
boost is always available.
d) Auto power boost (ended by operation stop)
Even before the time limit for auto power boost, if the upper pressure sensor goes OFF, the boost is ended.
e) Boost prohibition
During travel (travel pressure sensor = ON) or the breaker is in use (option line pressure switch = ON
and breaker mode), the boost is not used (Actuator protection).

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4001-37
f) Auto power boost setting
Auto pressure boost can be switched ON / OFF and boost for breaker operation enabled / disabled with
service support operation.
g) During boosting, the monitor displays an icon.
.
Icon
h) Time chart (when work mode = SP or H)

Less than 8 seconds
0.1 second 8 seconds 0.1 second 0.1 second 0.1 second
Boost solenoid
High-load conditions
Upper pressure
sensor
Message and icon
Travel pressure sensor

OR / AND
Option pressure sensor
c) d) e) b)
i) Trouble mode
If trouble occurs in an input (upper pressure sensor / travel pressure sensor), output (boost solenoid) or
communications (CAN), the system goes into trouble mode. In trouble mode, the boost solenoid is fixed to
OFF.
• Even if trouble occurs in UART communications, the system does not go into trouble mode.
• Trouble in the (2nd) option line pressure switch cannot be detected.
j) Recovery from trouble mode
Even if the trouble is recovered from, trouble mode continues.

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4001-38
Monitor Control
1. Bar Graph (coolant temperature gauge, oil temperature gauge, fuel gauge)
1) Coolant temperature gauge
a) Configuration
Display data
Coolant
temperature 4
data
ECM
. 8-level bar graph type
. Displayed on monitor LCD
Gauge . The left is the gauge level 3 display state.

level
: 1 2 3 4 5 6 7 8
1 Coolant temperature gauge 3 Computer A

2 Monitor 4 Coolant temperature sensor
b) Operation summary
The ECM reads the coolant temperature from the coolant temperature sensor installed on the engine and
send to computer A through CAN communication. After computer A receives the coolant temperature, it
judges the gauge level, and sends the display data to the monitor with UART communications.

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4001-39
c) Gauge coolant temperature
The gauge level is judged based on the figure below.
Gauge level
Temperature
d) Preventing flickering
When the temperature moves up or down near the gauge level fluctuation threshold (for example 51 °C
[124°F]), the gauge goes on and off repeatedly causing flickering. In order to prevent that, the gauge level
is judged using the temperature (judgment coolant temperature) after the following processing.
• Judgment coolant temperature = Average of the coolant temperatures obtained the past 32 times
• Coolant temperature obtained period = 1 second
• Bar graph update period = 32 seconds (updates when the 32nd coolant temperature obtained)
e) Trouble mode
If trouble occurs in the coolant temperature sensor or CAN bus, the bar graph itself is not displayed.
1. If there is a short, the bar graph display is immediately ended.
2. For a disconnection, the display goes off 3 minutes after the engine starts.
If trouble occurs in UART communications (computer => monitor), the display is fixed at the last state sent.
When the trouble is recovered from, the display returns to normal.
For a disconnection, when the key is switched OFF more than three minutes after the engine starts, then
ON again, the display is recovered.
Trouble
Recovery
Non-display state
(oil temperature sensor
breakdown) or CAN bus
4'
• Coolant temperature obtained during trouble:
If a meaningless coolant temperature were obtained and the processing in d) carried out, display upon
recovery would be strange. In order to prevent this, the coolant temperature is not obtained during a
coolant temperature sensor or CAN bus trouble.
f) Message display
When the gauge level reaches 8, "OVERHEAT" is displayed on the monitor and the buzzer buzzes.

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4001-40
2) Oil temperature gauge

a) Configuration
4
2
<= Return
Display data
=> suction (to pump)

. 8-Level bar graph type
. display on monitor LCD
Gauge level
1 2 3 4 5 6 7 8 .The left is the gauge level 3 display state.
RE06004-018
1 Oil temperature gauge 4 Hydraulic oil tank

2 Monitor 5 Oil temperature sensor
3 Computer A
Computer A reads the oil temperature from the oil temperature sensor installed in the hydraulic oil tank
outlet pipe and judges the gauge level. The gauge level is sent to the monitor with UART communications.

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4001-41
c) Gauge and oil temperature
The gauge level is judged based on the figure below.
Gauge level
Oil temperature
d) Preventing flickering
When the temperature moves up or down near the gauge level fluctuation threshold (for example 25 °C
[77°F]), the gauge goes on and off repeatedly causing flickering. In order to prevent that, the gauge level is
judged using the temperature (judgment oil temperature) after the following processing.
• Judgment oil temperature = Average of the oil temperatures obtained the past 32 times
• Oil temperature obtained period = 1 second
• Bar graph update period = 32 seconds (updates when the 32nd oil temperature obtained)
e) Trouble mode
If trouble occurs in the oil temperature sensor, the bar graph itself is not displayed (Only for trouble due to
short).
If trouble occurs in UART communications (send: computer -> monitor), the display is fixed at the last state
sent.
Trouble
Recovery
Non-display state
(oil temperature sensor
breakdown)
4'
• Oil temperature obtained during trouble.

If a meaningless oil temperature were obtained and the processing in d) carried out, display upon
recovery would be strange. In order to prevent this, the oil temperature is not obtained during an oil
temperature sensor trouble.
f) Message display
When the gauge level reaches 8, "OVERHEAT" is displayed on the monitor and the buzzer buzzes.

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4001-42
3) Fuel gauge
a) Configuration
Full
Empty
Amount allowing
one more hour of
work
. 8-level bar graph type
. Displayed on monitor LCD
. The left is the gauge level 3 display state.

Gauge level 1 2 3 4 5 6 7 8
RE06004-0
1 Monitor 3 Fuel tank

2 Computer A 4 Fuel sensor
Computer A reads the fuel level from the fuel sensor installed in the fuel tank and judges the gauge level.
The gauge level is sent to the monitor with UART communications.

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4001-43
c) Relationship between gauge level and lever angle
Lever angle
percentage %
Gauge level
Overhead
Rated
Full
8
407.5
100% 395.5
7
82% 335.5
6
67% 275.7
5

Ł 52% 213.1
4
38% 156.3
3
22% 98.0
2
Reserve
0% Reserve
1
37.8
Empty
The remaining amount is measured

from the top of the drain
R: lever angle Percentage (%)

Gauge level and fuel level (L)
1 2 3 4 5 6 7 8
(R ≤ 0%) (R < 22%) (R < 38%) (R < 52%) (R < 67%) (R < 82%) (R < 100%) (R ≥ 100%)
≤ 37.8 < 98.0 < 156.3 < 213.1 < 275.7 < 335.5 < 395.6 ≥ 407.5
d) Message display
When the gauge level reaches 1, "LOW FUEL" is displayed on the monitor and the buzzer buzzes (See
"Message Display List").
e) Preventing flickering
When the fuel surface in the tank shakes and the fuel sensor lever angle moves up or down near the gauge
level fluctuation threshold (for example 7%), the gauge goes on and off repeatedly causing flickering.
In order to prevent that, the gauge level is judged using the lever angle (judgment lever angle) after the
following processing.
• Lever angle acquisition period = 1 second
• Bar graph update period = 5 seconds
• The judgment value when the bar graph is updated = average lever angle over the past 20 seconds
f) Trouble mode
If trouble occurs in the fuel sensor, the bar graph itself is not displayed.
If trouble occurs in UART communications, the display is fixed at the last state sent.
(Send: Computer A => Monitor)
g) Lever angle obtained during trouble
If lever angle were obtained and the processing in e) carried out, display upon recovery would not be
normal.
In order to prevent this, the lever angle is not obtained during a fuel sensor trouble.

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4001-44
Accessories
1. Horn
Basic operation
a) When the horn switch is pressed, the horn is driven via a relay.
b) When the volume select switch is switched ON, the LED indicator lights up and only the left horn sounds (Horn
volume down).
The volume select switch state is retained even when the key is switched OFF (The previous data is held).
c) Communications with computer
When this switch is pressed, the signal is first sent to the computer and processed.
Then, the drive command is sent to the monitor and the monitor drives the right horn (R) relay.
d) Trouble mode
If there is an error in UART communications, the monitor goes into trouble mode.
In trouble mode, the monitor carries out the operation in b) on its own without receiving commands from the
computer.
However, the previous data is not held (The monitor always starts up with normal volume).
When the error is recovered from, trouble mode ends too and the monitor returns to normal mode
z
Switch signal Drive

command
1 Monitor panel 6 Horn (L) relay

2 Horn volume select switch (with led indicator) 7 Horn (R) relay
3 Horn switch 8 Horn (R)
4 Computer A 9 Horn (L)
5 Key switch

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4001-45
2. Working Light
Basic operation
a) When turning the key to ON, always start with the working light OFF (Previous data reset).
b) Each time the working light switch is pressed, the working light is switched between ON and OFF (Momentary).
When this light is ON, the LED indicator lights up.
c) Communications with computer
When the working light switch is pressed, the signal is first sent to the computer and processed.
Then, the light command is sent to the monitor and the monitor drives the relay.
d) Trouble mode
If there is an abnormality occurs in UART communications, the monitor goes into trouble mode.
In trouble mode, the monitor carries out the operation in b) on its own rather than commands from the
computer.
When the communications error is recovered from, trouble mode is exited and the monitor returns to
normal mode.
See
«Air Conditioner»
Switch Light
signal command
For expansion
1 Monitor panel 6 Working light relay (cab)

2 Working light switch (with LED indicator) 7 Working light (boom)
3 Computer A 8 Working light (tool etc.)
4 Key switch 9 Working light (cab top)
5 Working light relay (upper)

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4001-46
3. Wiper & Washer

a) Configuration
LED
WIPER (INT)
OPEN
WIPER (CNT)
OPEN
WASHER
Switch signal Drive command
1 Monitor panel 6 Computer A

2 Washer switch 7 Key switch
3 Wiper switch (with LED indicator) 8 Wiper motor
4 Monitor 9 Washer motor
5 Front window limit SW
b) Wiper basic operation

When the wiper switch is pressed, it switches to the next state in the order: intermittent operation =>
continuous operation => OFF => intermittent. In intermittent operation, the I LED is lit and in continuous
operation, the II LED lights up (When the wipers are OFF, both are OFF). When turning the key ON, always
start from OFF (Previous data reset).
c) Washer basic operation
While the washer is pressed, the washer operates.
d) Wipers linked with washer
While the washer switch is pressed, after 0.5 second, the washer starts to operate linked with the wipers.
When the washer switch is released, the washer stops, and after two wipes, the wipers stop too.
1. Auto rise up
Even during wiper operation, if the key is turned OFF, the wipers are automatically stopped and
retracted.
2. Overload prevention
If the blades are locked, the monitor output is stopped.

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4001-47
e) Front window open detection
If the front window is opened while the wipers or washer are operating, it is stopped.
The operations of b) and c) are not carried out while the front window is open.
f) Wiper computer duty
The wiper computer is responsible for b) - d). e) is provided by the monitor / computer detecting the front
window being opened and the output to the wiper computer being switched OFF.
g) Computer A duty
Computer A receives switch signals from the monitor through UART communications (wiper switch, washer
switch, front window limit switch).
This signal is processed by computer A and the three ports that control the wiper computer (WIPER (INT),
WIPER (CNT), and WASHER) are controlled as in the following time chart.
h) Time chart
0.5 second Double wipe

0.5 second
Double wipe
Wiper operation
mode
Operation Wiper LED
Washer
WIPER (INT)
Connection
to wiper WIPER (CNT)
controller
WASHER
Wiper switch
Input Washer switch
Front window
limit switch
2) 2)
1. During washer operation, wiper operations are handled automatically by the wiper controler even if there
is no output to WIPER (INT) or WIPER (CNT).
2. Wiper stop by front window open detection
3. Washer-linked wiper stop by front window open detection
i) Trouble mode
If there is an error in UART communications, the monitor cannot receive drive commands from computer A.
At this time, the monitor goes into trouble mode and executes the same control as for on its own as in h).
When the UART communications error is recovered from, the monitor recovers from trouble mode and
follows the drive commands from computer A.

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4001-48
4. Room Lamp
a) Configuration
OPEN
CLOSE
DOOR
See «Air
Conditioner»
1 Key switch 4 Room lamp

2 Clock unit 5 Door limit switch
3 Room lamp relay
• The clock unit is not connected with computer A or B and controls the room lamp relay on its own.
• For the (B) connection destination, see "Air Conditioner".
• The clock unit is connected to the backup power supply and continues to operate even if the key is
switched OFF.
b) Door link
When the room lamp switch is set to the DOOR position, the lamp lights when the door is open and goes
out when the door is closed.
c) Auto lamp off
In b), in order to prevent the battery from being run down, the room lamp goes out 30 seconds after the
door is opened. However, this function only works when the key switch is OFF. If it is ACC or ON, auto lamp
off does not work (Because even if the room lamp relay is OFF, power is supplied from ACC).
The only purpose of this auto lamp off function is to prevent the battery from being run down if the door is
left open with the key OFF.

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4001-49
d) Time chart
The time chart shows how the function in c) works. The room lamp switch is set to DOOR.
30 seconds
30 seconds 30 seconds 30 seconds 30 seconds
Room lamp
Room lamp
relay
Door limit
switch
Key switch
1. Door linked room lamp

2. Even after the door is closed, the room lamp relay is ON for 30 seconds.
3. 30 seconds is counted from the last time the door was opened.
4. After 30 seconds, the lamp goes off automatically.
5. Auto lamp off does not work if the key switch is ON or ACC.
6. When the key is switched OFF, the lamp goes out (After power-cut delay).
e) Trouble mode
Since the clock unit does not have a trouble detection function for either input (IN1) or output (OUT1), it
does not go into trouble mode.
f) Time chart
This shows the operation when the room lamp switch is ON.
30 30 30
seconds seconds seconds
Room lamp
Room lamp relay
Door limit switch

ON = OPEN
OFF = CLOSED
Key switch
1. If the key is OFF, the lamp goes out automatically after 30 seconds
2. Auto lamp off does not work if the key switch is ON or ACC.
3. Power-cut delay

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4001-50
5. Radio Mute
a) Configuration
1 Mute switch (knob) 5 Speaker (R) relay

2 Clock unit 6 Speaker (L)
3 Radio 7 Speaker (R)
4 Speaker (L) relay
b) Summary and purpose

The radio volume can be switched ON / OFF with one-touch by switching the speaker (L, R) signal lines on
and off with a relay.
c) Operation
Each time the mute switch on the knob is pressed, the radio volume is switched between ON <=> OFF
(Momentary).
When the key is switched ON, the radio always starts with mute off (normal radio volume, previous data
reset).
d) Battery save
In order to prevent the battery from being run down, when the key is at ACC (accessory), the radio is
always set to mute off (normal radio volume).
ON
Mute
OFF
Speaker (L / R) ON
relay
OFF
ON
Mute switch
OFF
ON
Key switch ACC
OFF
Momentary Previous data Battery save Previous data

reset reset

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4001-51
Others
1. Anti-Theft
a) Anti-theft control
If the anti-theft password does not match (anti-theft is not ended), the machine operation is controlled.
1 Computer A 5 Travel pressure sensor

2 Engine 6 Upper pressure sensor
3 P1 pressure sensor 7 Swing brake solenoid
4 P2 pressure sensor 8 Travel alarm
1. If the engine is started without ending the anti-theft, the machine is controlled as follows:
1. The engine speed is fixed at low idle.
2. The swing brake cannot be released (Solenoid operation is not possible).
3. The travel alarm buzzes continuously.
2. In the state in 1., if any of the following operations is executed, the engine is forced to stop.
1. Upper or travel operation (Detected by the corresponding sensor)
2. The P1 or P2 pressure rises to 5 MPa (50 bar / 725 psi) or higher.
3. The engine load is 50% or higher for two seconds cumulative.
4. The upper, travel, P1, or P2 pressure sensor is removed.
3. Even in the state in 1., the anti-theft control can be ended by inputting the correct password.

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4001-52
2. Battery Save Function

a) Summary and purpose
In order to prevent the battery from being run down when the key is ON and the engine is stopped, solenoid
and proportional valve output is suppressed.
b) Operation
See the table below.
Control targets Operation when the engine is stopped with the key ON.
Travel high-speed Fixed to OFF (low-speed) whether the travel speed select switch ON or OFF
switchover solenoid However, the LED at the side of the switch is linked with the switch.
Power save solenoid Fixed to OFF (power save OFF)
Fixed to OFF (free swing OFF) whether the free swing switch ON or OFF
Free swing solenoid
However, the free swing icon on the monitor is linked with the switch.
Fixed to OFF (crusher side) whether the breaker / crusher mode switch ON or
Option return line
OFF
switchover solenoid
However, the attachment icon on the monitor is linked with the switch.
Fixed to OFF (no boost) regardless of the work mode (throttle volume position)
Boost solenoid
However, the status icon on the monitor is linked with the throttle
0 mA, so the standby milli-amp for detecting disconnections of 50 mA does not
Pump horsepower
flow
proportional valve
Disconnections are only detected after the engine has started
Pump flow Same as above
proportional valve

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4001-53
3. Alternator Power Generation Detection

a) Configuration (fuses etc. omitted)
10 V Comparator
1 To load
4
10 V B
IN1
2 L
3
IN2
ECM
B: Charge
L: Running signal
R: Initial excitation
E: GND
- + - +
RE06
1 Computer A 3 Battery relay

2 Key switch 4 Alternator
b) Separated from battery voltage

When the battery relay is closed, by looking not at the B terminal, where the battery voltage is applied, but
rather to the independent L terminal, defects in the alternator alone are detected (The battery voltage is
monitored by the ECM (IN2)).
c) Operation
Alternator L terminal output voltage judged with 10V comparator
ON when L terminal voltage ≥ 10 V
OFF when L terminal voltage < 10 V. * The threshold value of 10 V has a tolerance of ±1 V.
d) Power generation defect judgment
If the 10V comparator input is OFF even though the engine is running, it is judged that there is a power
generation defect. For details on the judgment conditions, see the "Main Unit Diagnostic Trouble Code
List".

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4001-54
4. Overload Alarm (Europe only)

a) Configuration
Buzzer, message
1 Overload alarm switch (alternate) 4 Boom cylinder bottom pressure sensor

2 Monitor panel 5 Boom
3 Computer A 6 Boom cylinder
b) This function is only mounted on machines for Europe.

c) Alarm judgment
When the overload alarm switch is ON, the overload alarm is switched ON / OFF according to the following
conditions.
ON: (Boom cylinder bottom pressure ≥ set pressure) for 1 continuous second
OFF: (Boom cylinder bottom pressure ≤ set pressure - 2 MPa (- 20 bar / - 290 psi)) continuous for 1 second
• For the set pressure for each model, see "Overload set pressure".
• The set pressure can be changed with CFG (see the "Service Support" chapter).
d) Operation when alarm judgment ON
The "OVER LOAD" message is displayed on the monitor and the buzzer buzzes intermittently.
This message is handled as an "alert". For details, see "Message Display List".
e) Ending the alarm
To end an alarm that has been issued, either switch the overload alarm switch OFF or operate the
attachment in such a way that the judgment in c) goes OFF.
Note that there is no buzzer stop switch.
f) Trouble mode
If trouble occurs in the boom cylinder bottom pressure sensor, this function goes into trouble mode and the
alarm judgment is fixed to OFF.
Even if the trouble is recovered from, trouble mode continues until the key is switched OFF.
g) Trouble judgment
The boom cylinder bottom pressure sensor trouble judgment is made after the overload alarm switch has
come ON once.

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4001-55
h) Time chart
1 second 1 second 1 second 1 second 1 second
ON
Message
OFF
ON
Monitor buzzer
OFF
ON
Alarm judgment
OFF
Boom cylinder Set pressure

bottom pressure
Set pressure
- 2 MPa
Overload alarm ON
switch
OFF

Copyright ©
4001-56
Options
1. Option Line Control
a) Configuration [Multi purpose circuit with 2nd option line]
Crusher
Rotation
Center OR
bypass
cut
OPTION 1
(Pedal type)
The hydraulic pressure

source is different.
The ground
treatment is
different.
(Knob switch type)
1 Monitor panel 10 Shut-off valve

2 Breaker mode switch 11 2 pumps flow solenoid valve
3 Option select switch 12 Option switchover solenoid valve
4 Crusher mode switch 13 1st option pedal
5 2 pumps flow switch 14 1st option pressure switch
6 2nd option control valve 15 1st option switch (L)
7 4th pump 16 1st option switch (R)
8 Control valve 17 Computer A
9 3-direction valve

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4001-57
Option select switch switchover (breaker mode <=> crusher mode)
Operation:
When the option select switch is set to the breaker mode switch side, the option switchover solenoid valve
is operated and the shut-off valve is switched to the 3-direction valve. When the switch is switched to
crusher mode, the option switchover solenoid valve goes OFF.
Option 2
(Pedal type)
(Knob switch type)
1 2nd option pedal

2 2nd option switch (L)
3 2nd option switch (R)
2 pumps flow select switch (1 pump <=> 2pumps)

Operation:
When the 2 pumps flow switch is switched ON, the solenoid valve for 2 pumps flow to 2 pumps flow.
Difference between pedal type and knob switch type
For the pedal type, solenoid valve for 2 pumps flow hydraulic pressure source is the secondary pressure
via the option 1 pedal shuttle, but for the knob switch type, the solenoid for the 2 pumps flow pressure
source comes directly from the gear pump.
Therefore, when the 2 pumps flow switch is switched ON, operation becomes always 2 pumps flow.
In order to prevent this, whereas for the pedal type the ground treatment for the 2 pumps flow switch is to
ground directly, with the knob switch type, it is set so that the switch is not grounded unless one or the other
of the option switches is ON.
• Be careful. The shuttle valve is built into the option 1 pedal remote control valve.

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4001-58
Mode select switch
When the breaker mode switch / crusher mode switch is pressed, the option line mode changes as follows.
Breaker 1 Breaker 2 Breaker 5

mode mode mode
Breaker 1
mode
Normal dig Normal dig
Crusher 1
mode
Crusher 1 Crusher 2 Crusher 5
mode mode mode
• The factory setting is that only breaker 1 mode and crusher 1 mode can be selected.
• With settings on the service screen, the number of modes can be increased to five each for the breaker
and for the crusher, for a total of 10.
b) For a), the following icons are displayed according to the mode.
Breaker mode Crusher mode Normal dig mode
1: None
2:
3:
4:
5:

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4001-59
2. Option Line Control

a) Configuration [Multipurpose circuit with 2nd option line (pedal type)]
1
3 8
4 9
5 10
6
IN1 7 11
12
IN2
13
24 V
18
14
19 20
IN3
21
15
There are two operation methods: the pedal type and the knob switch
16 type. With either type, when the pedal or knob switch is operated the
switch input port (IN3, IN4 = «option select and operating method» IN4,
IN5) is the same. (In other words, there is no need to be aware of the
difference in operating method).
IN4
17 The explanation below uses the pedal method.
RE06009-004
1 Computer A 12 Swing pressure sensor

2 N2 pressure sensor 13 Travel pressure sensor
3 Arm (1) 14 Option pedal
4 Boom (2) 15 Option pressure switch
5 Swing 16 2nd option pedal
6 Option 1 17 2nd option pressure switch
7 Travel (left) 18 Boost solenoid
8 Arm (2) 19 P1 pump
9 Boom (1) 20 P2 pump
10 Bucket 21 P1 flow control proportional valve
11 Travel (right)

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4001-60
b) Option line operation control
The table below shows the control for operation of the single option and compound operation.
Option line mode Breaker Crusher Option 2

1st option pressure 1st option pressure 2nd option pressure
switch => ON switch => ON switch => ON
Operation
(IN3 is ground) (IN3 is ground) (IN4 is ground)
Single Compound Single Compound Single Compound
Boost cut Yes Yes No
Flow restriction Yes Yes No No function (4th pump)
Engine speed /
Pump horsepower According to the command for the work mode selected with the throttle
milli-amp
• The flow is not cut for compound crusher operation (To secure speed for compound operation).
• Since the breaker often works while the machine is jacked up with the boom (compound operation), the
flow is cut even for compound work (The same as the engine reduction for the current breaker).
• The pressure boost is cut when Option 1 and Option 2 are operated at the same time (Boost cut
priority).
• The engine speed and pump horsepower milli-amp are according to the work mode currently selected
with the throttle (cannot be forced to change to another mode only for breaker/crusher).
c) Option 1 single operation judgment conditions
When all the conditions below are satisfied, it is judged that this is single operation.
Conditions:
1st option pressure switch => ON Swing pressure sensor => OFF
Travel pressure sensor => OFF N2 pressure sensor ≥ 2.4 MPa (24 bar / 348 psi)
d) Flow cut
The maximum flow for option line operation is restricted to the flow for the option line mode selected with
"Option line selection and 2 pumps flow".
Also, be careful about the fact that since the flow set for the option line is the flow for SP mode, when used
in H/A mode, the flow is slightly less than the display.
When neither the braker or crusher mode is selected (normal mode), the minimum flow amount 50L/min
(13.2 gpm) is produced when the pedal is pressed. (For prevention of damage to attachments)
e) Trouble mode
If a trouble occurs in input (swing pressure sensor, travel pressure sensor, N2 pressure sensor) or output
(boost solenoid, flow proportional valve), the machine goes into trouble mode and
• Output command to boost solenoid = fixed to OFF
• Output command to flow proportional valve = fixed to OFF
Trouble mode continues until the key is switched OFF.

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4001-61
3. Feed Pump Automatic Stop
a) Configuration
Full
100%
Empty
0%
The accessory switch is fixed ON.
Manual
(momentary)
Automatic
(alternate)
When ON, auto feed is disabled.

When OFF, auto feed is enabled.
Actual speed
1 Computer A 6 Oil feed pump

2 Feed switch 7 Feed stop relay
3 Fuel sensor 8 Full tank detection buzzer
4 Fuel tank 9 Engine
5 Oil feed start relay
Feed pump main unit accessory (original) switch. This must be fixed ON beforehand in order to use this
function.

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4001-62
b) Operating method
1. With the engine stopped and the key ON, if the feed switch is flipped down to the Auto side, the fuel feed
starts.
2. When the tank is full, the fuel feed stops automatically and the buzzer buzzes to announce that.
3. Returning the feed switch to the center stops the buzzer.
4. To feed more fuel
Press the feed switch manual side. The fuel is fed while the switch is pressed.
c) Computer control targets
Input = Fuel sensor (0 to 100%), engine state (running / stopped)
Output = Feed stop relay
d) System state (when relay OFF)
When the feed switch is set to the Auto side, the start relay comes ON and the pump operates.
e) System state (when relay ON)
When the feed switch is set to the Auto side, the start relay goes OFF, and the pump does not operate.
Also, the buzzer buzzes.
f) Feed stop relay control (while engine stopped and key ON)
When (fuel level < 94% continuously for 3 seconds), OFF (auto feed enabled)
When (fuel level ≥ 94% continuously for 3 seconds), ON (auto feed disabled).

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4001-63
g) Time chart
f) e)
1) 3) 4) 5)
3 sec. 3 sec.
Full tank detection buzzer
ON
Feed pump
OFF
ON
Feed relay
OFF
3 sec.
Feed stop relay ON
OFF
MANU
Feed switch OFF
AUTO 3 sec.
94 %
Fuel level
RUN
Engine states
STOP
START
Key switch ON
OFF
6) 6) 6) 7)
RST-05-06-001bk
1. Even if the level falls below 94 %, no fuel can be fed as the engine is running.
2. Stopped, so fuel can be fed.
3. Fuel feed is not possible unless the key is switched ON.
4. If the engine is started during fuel feeding, the fuel feed stops.
5. When the operator forgets and leaves the switch switched to the Auto side, the pump operates during the
power-cut delay (When fuel level under 98%).
6. Power-cut delay.
h) Trouble mode
If trouble occurs in an input (fuel sensor), output (feed stop relay) or communication (CAN), the system
goes into trouble mode and the feed stop relay is fixed to OFF. Be careful. In trouble mode, even if the feed
switch is set to Auto, the fuel feed is not stopped.

Copyright ©
4001-64
4. Return Filter Clogging Detected

a) Configuration
Return oil
OFF for a clog

ON for normal
1 Computer A
2 Return filter clog pressure switch
3 Hydraulic oil tank
4 Return filter
b) Return filter clog pressure switch specifications

ON: 0.1 MPa OFF: 0.08 MPa
(1 bar / 14.50 psi) (0.8 bar / 11.60psi)
ON
OFF 0.08 MPa 0.1 MPa

(0.8 bar / 11.60 psi) (1bar / 14.50 psi)
c) Detection cancellation when breaker used

When the breaker is used, the return oil pressure pulse is intense, so clog detection is not attempted.
d) Detection cancellation when oil temperature low
When the oil temperature is less than 30°C (86°F), its viscosity rises and filter pressure damage increases,
so clog detection is not attempted.

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e) Solution for machines with no breaker setting
Machines with no breaker setting from c) (= machines with no return filter clog pressure switch)
Even with these machines, filter clogs would be detected. In order to prevent this, a special connector is set
that is always shorted.
Always-shorted special
connector
1 Computer A
f) Disconnection detection
When the key is ON, if IN1 was OFF before the engine was star ted, the situation is judged to be a
disconnection abnormality.
5. Beacon (Europe Only)

a) Configuration
Up to here is the
common harness
1 Beacon switch (alternate)

2 Computer A
3 Beacon
b) Destination
This function is for Europe.
c) Operation
The beacon is driven via the beacon relay linked with the beacon switch.
This function is not mediated by the computer.

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ELECTRICAL PARTS AND WIRING ASSEMBLY DIAGRAM
Main Frame

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Description
Code Part name Q'ty Code Part name
1 Working light 24 V × 70 W 1 1 Fuel tank
2 Horn; Electric (low) 1 2 Sump tank
3 Horn; Electric (high) 1 3 Round terminal M8; Ground G2
4 Terminal cap M5 × 3.8 1 4 Window washer tank
5 Wire harness; Frame (Main) 1 5 Reserve tank
6 Pressure sensor (5 MPa) 5 6 Condenser (with electric fan)
7 Battery 180G51 with terminal 2 7 Dryer receiver
8 Terminal cap (black) 1 8 Round terminal M8; Alternator ground
9 Battery cable; Ground 1 9 Swing frame
10 Terminal cap (red) 2 10 Wire color: red stripe on yellow background
11 Battery cable; Bridge 1 11 Wire color: red stripe on blue background
12 Terminal cap (red) 1 12 Wire color: black
13 Battery cable; B+ (Relay) 1 13 Fuel sensor
14 Battery cable; Relay (Starter) 1 14 Engine support; Front
15 Pressure sensor (50 MPa) 2 15 C starter motor (round terminal M5)
16 Thermo-sensor 1 16 Engine ground (attached to engine main unit)
17 Travel alarm 1 17 Alternator (attached to engine main unit)
18 Working light 1 18 Inlet pipe bracket (air cleaner)
19 Terminal cap M4 × 2.0 2 19 Platform (L)
20 Battery relay 1 20 AEH0017 safety relay (attached to engine main unit)
21 Terminal cap 2 21 Wire color: white stripe on red background
Wire color: red
22 Fuse; High current (Model A3) 1 22 Wire color: red stripe on blue background
Wire color: red stripe on green background
23 Fuse (fusible link) 1 23 Wire color: red stripe on white background
24 Ground wire; Floor 1 24 Wire color: red stripe on light green background
25 Terminal cap M6 × 5.3 1 25 Engine controller
26 Wire harness; Light (Main frame) 1 26 Round terminal M6; Alternator B (wire color: red)
27 Round terminal M5; Alternator E (wire color: black)
28 Hydraulic pump
29 Air conditioner compressor
30 Starter motor (attached to engine main unit)

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CN. 106 Safety relay S, R, E: 3-pin CN. 147 Travel alarm: 2-pin
CN. 107 Safety relay B: 1-pin CN. 149 Engine controller C-1: 81-pin
CN. 108 Safety relay C: 1-pin CN. A0 Engine controller C-2: 40-pin
CN. 110 Alternator L, R: 2-pin CN. A1 Engine harness A: 20-pin
CN. 113 Pump electromagnetic proportional valve: 2-pin CN. A2 Engine harness B: 12-pin
CN. 114 Pump proportional valve: 2-pin CN. A3 Engine harness C: 8-pin
CN. 115 Pressure sensor P1: 3-pin (no ID tape) CN. A4 Engine harness D: 6-pin
CN. 116 Pressure sensor P2: 3-pin (yellow ID tape) CN. A5 Engine harness E: 1-pin
CN. 117 Pressure sensor: 3-pin CN. A6 Suction air temperature sensor: 2-pin
CN. 118 Pressure sensor: 3-pin CN. A7 Cab main harness A: 2-pin
CN. 119 Pressure sensor: 3-pin CN. B1 Cab main harness B: 8-pin
CN. 120 Pressure sensor: 3-pin (blue ID tape) CN. B2 Cab main harness C: 18-pin
CN. 121 Pressure sensor: 3-pin (red ID tape) CN. B3 Cab main harness D: 22-pin
CN. 125 Oil temperature sensor: 2-pin CN. B4 Cab main harness E: 20-pin
CN. 127 Lock lever SOL. V: 2-pin (yellow ID tape) CN. B5 Cab main harness F: 14-pin
Battery relay ground: 1-pin
CN. 128 Swing brake SOL. V: 2-pin (white ID tape) CN. B6 (The connector should be fastened with an M8 clamp
with a band (S).)
CN. 129 2-stage travel SOL. V: 2-pin (red ID tape) CN. C0 Receiver dryer: 2-pin
CN. 130 2-stage relief SOL. V: 2-pin (yellow ID tape) CN. D12 Air conditioner compressor: 1-pin
CN. 131 Power save SOL. V: 2-pin (green ID tape CN. D13 Fusible link: 2-pin
CN. 134 Filter indicator: 2-pin CN. F1 Fusible link: 2-pin (yellow ID tape)
CN. 135 Fuel sensor: 2-pin CN. F2 Key fuse: 2-pin (no ID tape)
CN. 136 Electromagnetic fuel pump: 2-pin CN. F3 ECM fuse: 2-pin (red ID tape)
CN. 138 Reserve tank: 2-pin CN. F4 CONT fuse: 2-pin (blue ID tape)
CN. 139 Vacuum sensor: 2-pin CN. F5 GPS fuse: 2-pin (yellow ID tape)
CN. 144 Housing lamp: 2-pin CN. F6 Condenser fan: 2-pin
Boom light: 2-pin
CN. 145 (The connector should be fastened with an M6 clamp with a CN. T5 Travel alarm: 2-pin
band (S).)
CN. 146 Boom light harness: 2-pin

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Cab

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Description
Code Part name Q'ty Code Part name
1 Automatic lighter 1 1 Trim; Front (upper)
2 Cap; Blind (rocker switch) 7 2 Trim; Side (upper)
3 Wire harness; Cab (Sub) 1 3 Frame main harness
4 Wire harness; Cab (Main) 1 4 Clock
5 Relay; Changeover (24 V) 10 5 Monitor display
6 Antenna code 1 6 Wiper motor (cab accessory)
7 Wire harness; Console (right) 1 7 Wiper controller (cab accessory)
8 Wire harness; Short console (right) 1 8 Cover; Top (Console right)
9 Wire harness; Console (left) 1 9 Cover; Top (Console left)
10 Wire harness; Short console (left) 1 10 Air conditioner panel
11 Car radio; AM/FM ST (12/24 V) JPN 1 11 Atmospheric pressure sensor (engine accessory)
12 Switch; Starter (assembly) 1 12 Engine controller (engine accessory)
13 Ground wire; Cab 1 13 Operators cab
14 Switch; Rocker (E. STOP) 1 14 Floor
15 Bracket; Harness 1 15 Knob (memory clear) white ID tape
16 Bracket; Radio 2 16 Knob (diagnostic switch) red ID tape
17 Fuse box (cab main harness accessory)
Boom light: 2-pin

CN. 1 Safety relay S, R, E: 3-pin CN. Q2 (The connector should be fastened with an M6
clamp with a band (S).)
CN. 2 Safety relay B: 1-pin CN. Q3 Boom light harness: 2-pin
CN. 3 Safety relay C: 1-pin CN. Q4 Maintenance connector: 12-pin
CN. 4 Alternator L, R: 2-pin CN. R1 Starter switch: 6-pin
CN. 5 Pump electromagnetic proportional valve: 2-pin CN. R2 Right knob switch: 8-pin
CN. 6 Pump proportional valve: 2-pin CN. R3 Throttle volume: 3-pin
CN. 7 Pressure sensor P1: 3-pin (no ID tape) CN. R5 Rocker switch 1: 10-pin
CN. 8 Pressure sensor P2: 3-pin (yellow ID tape) CN. R6 Rocker switch 2: 10-pin
CN. 10 Pressure sensor: 3-pin CN. R7 KAB seat: 2-pin (fastened with red tape)
CN. 11 Pressure sensor: 3-pin CN. T1 Air conditioner unit A: 10-pin
CN. A8 Pressure sensor: 3-pin CN. T2 Air conditioner unit B: 18-pin
CN. B1 Pressure sensor: 3-pin (blue ID tape) CN. T3 Air conditioner panel A: 14-pin
CN. B2 Pressure sensor: 3-pin (red ID tape) CN. T4 Air conditioner panel B: 22-pin
CN. B3 Oil temperature sensor: 2-pin CN. Q1 J1939: 3-pin (fastened with red tape)
CN. B4 Lock lever SOL. V: 2-pin (yellow ID tape) CN. R4 Radio: 9-pin
CN. B5 Swing brake SOL. V: 2-pin (white ID tape) RL. 01 Main
CN. B6 2-stage travel SOL. V: 2-pin (red ID tape) RL. 02 Glow (white marking)
CN. B7 2-stage relief SOL. V: 2-pin (yellow ID tape) RL. 03 Lamp 1
CN. C1 Power save SOL. V: 2-pin (green ID tape RL. 04 Lamp 2 (white marking)
CN. C2 Filter indicator: 2-pin RL. 05 Horn L
CN. C3 Fuel sensor: 2-pin RL. 06 Horn R (white marking)
CN. C4 Electromagnetic fuel pump: 2-pin RL. 07 Speaker R
CN. L1 Reserve tank: 2-pin RL. 08 Speaker L (white marking)
CN. L2 Vacuum sensor: 2-pin RL. 09 Room lamp
CN. L3 Housing lamp: 2-pin RL. 10 Beacon (white marking)

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EXPLANATION OF ENGINE FUNCTION
1. Engine Function Explanation table
Name Function
Receives the high-pressure fuel sent under pressure from the supply pump, holds the
Common rail
fuel pressure, and distributes the fuel to each injector.
Pressure limiter Operates to allow pressure within the common rail to escape if the pressure in the
(common rail common rail becomes abnormally high.
component part)
Flow damper (common Installed on the discharge port of each injector. Suppress pressure pulses in the
rail component part) common rail and prevent fuel supply to the injectors when there is pipe damage.
Common rail pressure Detects the pressure inside the common rail, converts it to a voltage, and sends that
sensor (common rail voltage to the ECM.
component part)
Injector Controlled by the ECM and injects the fuel.
Raise the fuel pressure and send it under pressure to the common rail by using the
Supply pump
force of the engine rotation.
SCV (suction control Controls the fuel pressure (discharge quantity) sent to the common rail.
valve) (supply pump The ECM controls the time during which power is on to the SCV to increase or decrease
component part) the amount of fuel discharged.
Fuel temperature Detects the fuel temperature and sends it to the ECM.
sensor (supply pump Used for supply pump control etc.
component part)
EGR (Exhaust Gas Recirculates part of the exhaust gas in the intake manifold and mixes the EGR gas with
Recirculation) the suction air to reduce the combustion temperature and reduce NOx.
EGR valve The EGR valve operation (open and close) timing and the lift amount are controlled by
signals from the ECM. (The valve lift amount is detected by the EGR position sensor)
(EGR position sensor)
EGR cooler Cools the high-temperature EGR gas by using the engine coolant.
Increases the amount of EGR by suppressing back flow of the EGR gas and letting it
Lead valve
flow only in one direction.
ECM Constantly monitors the information from each sensor and controls the engine system.
(engine control
module)
QOS Determines the glow time according to the engine coolant temperature, operates the
glow relay, and makes starting at low temperatures easy and also reduces white smoke
(quick on start system) and noise immediately after the engine starts.
Sends a signal to the ECM when the projection section of the engine flywheel passes
CKP sensor this sensor.
(crank position The ECM identifies the cylinders through this sensor input, determines the crank angle,
sensor) and uses this information to control the fuel injection and to calculate the engine speed.
In case of trouble in the CKP sensor, the CMP sensor provides a back-up function.
Detects the engine oil pressure and sends it to the ECM.
Oil pressure sensor
Used for oil pressure drop alarms etc.
Engine coolant Detects the engine coolant temperature and sends it to the ECM.
temperature sensor Used for fuel injection control, QOS control, etc.
Sends a signal to the ECM when the engine camshaft cam section passes this sensor.
The ECM identifies the cylinders through this sensor input, determines the crank angle,
CMP sensor and uses this information to control the fuel injection and to calculate the engine speed.
(cam position sensor) Also provides a back-up function in case of trouble in the CKP sensor.
However, if there is trouble in the CMP sensor system, there is no change in the
behavior while the engine turns, but after it stops, restarting is difficult.
Atmospheric pressure Detects the atmospheric pressure and sends it to the ECM. The injection quantity is
sensor corrected according to the atmospheric pressure.

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Name Function
Suction air Detects the suction air temperature and sends it to the ECM. Optimizes the fuel
temperature sensor injection quantity.
Detects the boost (suction air pressure) inside the intake pipe and sends it to the ECM.
Boost pressure sensor
Used to control fuel injection with the boost pressure.
Boost temperature Detects the boost temperature and sends it to the ECM. Used for fuel injection control
sensor etc.

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2. EGR (Exhaust Gas Recirculation)

A B
9
10
1
2
C
3
4
D
5 6
1. EGR valve 8. Boost temperature sensor

2. EGR position sensor 9. EGR cooler
3. Engine speed 10. Lead valve
4. Engine coolant temperature sensor A. Coolant out
5. Engine load B. Coolant in
6. Intake air temperature sensor C. Exhaust gas
7. Boost pressure sensor D. Suction air
EGR system is an abbreviation of «Exhaust Gas Recirculation» system. The EGR system recirculates part of
exhaust gas into intake manifold and mixes inactive gases with the suction air to reduce the combustion
temperature and suppress the generation of nitrogen oxides (NOx). The EGR quantity is controlled by the
operation (opening and closing) of the EGR valve installed between exhaust manifold and the intake manifold.
The ERG quantity is determined from the engine speed and engine load ratio (fuel injection quantity) and the
EGR amount is controlled. A cooling system (EGR cooler) is installed in the EGR gas path to cool the high-
temperature EGR gas with this EGR cooler. This cooled EGR gas is mixed with new air intake to make the
combustion temperature lower than with normal EGR, which contributes to the reduction of NOx. (Cooled
EGR)
Furthermore, a lead valve is used in the EGR system to suppress EGR gas back flow and allow the EGR gas
to only flow in one direction.

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Engine load etc.
N° EGR control during idling
Engine speed
RST-06-03-001g
The ECM operates the motor according to such engine states as the speed and load and controls the EGR
valve lift amount.1
The valve lift amount is detected by the EGR position sensor.The sections shown in darker color in the
diagram have a larger valve lift amount. The darkest color indicates a lift amount near 100 %.

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4001-79
3. Relationship between ECM and sensor actuators
Engine Control Module

Sensor Actuator
Trottle signal
Engine speed Injection quantity control

Injection timing control
Cylinder
identification signal
Correction signal
Injection pressure control
1. Throttle volume (Computer A)

2. Crank shaft position sensor
3. Camshaft position sensor
4. Other sensors
5. Injector
6. Common rail pressure sensor
7. Supply pump
8. EGR valve

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4. Cautions for Maintenance

Cautions concerning fuel used
With common rail engines, the supply pump and injector are lubricated by the fuel running through them.
Therefore, if any fuel other than diesel is used, this leads to engine trouble, so use of non-specified fuel is
strictly prohibited.
Please be aware that troubles resulting from the use of non-specified fuel are not covered by the warranty.
Specified fuel
See section 1002 about detail of CASE approval fuel.
The parts of the fuel system (injector internal part etc.) and the holes and gaps that form the fuel path are
made with extremely high precision
Therefore, they are extremely sensitive to foreign matter. Foreign matter in the fuel path can damage it, so
use great care to keep out foreign matter.
1. Clean and care for the fuel line and its surroundings before starting other maintenance.
2. Those working on the fuel line must have hands clean of dirt and dust. Wearing gloves while working is
strictly prohibited.
3. After removing fuel hoses and fuel pipes, always seal the hoses and pipes by covering the open sections
with plastic bags or the like.
4. When replacing parts, do not open the packing for the new parts until it is time to install them.
5. Do not reuse any gaskets or O-rings. Replace them with new ones.
Do not reuse fuel system high pressure fuel lines or injector pipes. If they are removed, replace them
with new parts.
Do not replace a pressure limiter, fuel temperature sensor or flow damper alone. If there is any
problem, replace the common rail assembly and all the fuel pipes.
1 Injector pipe 4 Common rail pressure sensor

2 Flow damper 5 Pressure limiter
3 Common rail

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4001-81
The SCV and fuel temperature sensor are installed on the supply pump main unit and cannot be individually
replaced.
Always replace the supply pump assembly.
1. Fuel temperature sensor

2. SCV (suction control valve)
Judging individual cylinders as OK or not by starting up the engine and loosening the injection pipes is strictly
prohibited when there is engine trouble. (Never do this. The high-pressure fuel sprays out dangerously.)
1. Injector pipe

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4001-82
Be careful. High voltage of 118 V or higher is applied to the injectors. Disconnect the battery cable ground
before replacing injectors.
1. Injector
2. Injector harness
3. Injector nut

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4001-83
Explanation of Engine Control
1) Fuel Injection Quantity Correction
The ECM calculates the basic injection quantity with the throttle volume boost sensor, CKP sensor, CMP
sensor, and other signals.
According to the common rail pressure, engine coolant temperature, and other conditions at this time, the
ECM controls the SCV and controls the injector electrified time to attain optimum injection timing and correct
the injection quantity.
2) Starting Q Correction
The engine starting Q correction is terminated at the idling speed.
Also, below the system recognition engine speed (30 min-1), the ECM cannot recognize engine rotation, so
starting Q correction and engine starting become impossible.
• Minimum engine starting speed is 60 min-1
3) Preheat Control (QOS quick on start)
The ECM determines the glow timing (pre-glow, glow, and after-glow) according to the engine coolant
temperature and control the glow relay.
The QOS system makes starting at low temperatures easier and reduces white smoke and noise immediately
after starting.
When the key is switched ON, the ECM detects the coolant temperature with the signal from the engine
coolant sensor and varies the glow time to always obtain the optimum starting conditions.
Also, the after-glow function makes it possible to stabilize the idling rotation immediately after starting.
Also, if there is trouble in the engine coolant temperature sensor system, control assumes a fixed coolant
temperature of -20°C (-4°F) for engine starting and 80°C (176°F) for running.
Also, EGR control stops. (Thermostat valve opening temperature 82°C (200°F))
4) Atmospheric Pressure Correction (high altitude correction)
The ECM calculates the current altitude from the atmospheric pressure sensor signals.
The ECM controls the SCV and controls the injector electrified time to attain optimum fuel flow according to
the altitude and other conditions at the time.
Also, if there is sensor trouble, control assumes a fixed atmospheric pressure of 80 kPa (equivalent to an
altitude of 2000 m) and stops EGR control too.
Altitude torque
Output decline by environmental change Output decline under engine control

Torque (Nm)
Altitude (m)

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5) Control for Overheating

When the engine overheats, in order to protect the engine, if the engine coolant temperature exceeds 100°C
(212°F), fuel flow restriction is started.
If the temperature rises further, the fuel flow is further restricted.
If engine coolant temperature rises to 120°C (248°F), the engine is stopped.
The protection function is started 1 minute after the engine starts (In order to detect a stable coolant
temperature).
Setting Judgment time Engine control Recovery condition

100°C ECM: Reduced fuel injection quantity -
-
(212°F) CX controller: Normal
8th on coolant 7th or lower on coolant
105°C
temperature temperature gradation
(221°F)
gradation
110°C ECM: Reduced fuel injection quantity
5 seconds
(230°F) CX controller: Idling
120°C ECM: Reduced fuel injection quantity Key switched ON after engine
5 seconds
(248°F) CX controller: Engine stopped stopped
• The protection function does not work if any of the error codes below occurs.
0117 (Coolant temperature sensor abnormally low voltage)
0118 (Coolant temperature sensor abnormally high voltage)
2104 (Faulty CAN bus)
2106 (Faulty CAN time-out)
0090 (CAN communication error)
Overheat protection through Q control
120
100
Q Control ratio (%)
1000
80
1600
60
1800
40
2000
20
2050
0
95 100 108 113 118 123
Engine water temperature (°C)
SF04010-009

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6) Control for Boost Temperature Rise

If the boost temperature exceeds 80°C (176°F), fuel flow restriction is started.
If temperature rises to 90°C (194°F), the engine is stopped.
The protection function is star ted 1 minute after the engine star ts. (In order to detect a stable boost
temperature)
Judgment Engine control Recovery condition

Setting
time
80°C ECM: Normal State of 70°C (158°F) or less
5 seconds
(176°F) CX controller: Idling control continues for 30s
90°C ECM: Normal Key switched ON after engine
5 seconds
(194°F) CX controller: Engine stop control stopped
1112 (Boost temperature sensor abnormally low voltage)
1113 (Boost temperature sensor abnormally high voltage)
7) Control for Engine Oil Pressure Drop
If the engine oil pressure drops, the engine is stopped to prevent engine damage.
The protection function is started 30s after the engine starts. (In order to detect a stable engine oil pressure)
Judgment Engine control Recovery condition

Setting
time
ECM: Normal Key switched ON after engine
40 kPa 5 seconds
CX controller: Engine stop control stopped
0522 (Oil pressure sensor abnormally low voltage)
0523 (Oil pressure sensor abnormally high voltage)
1633 (Faulty 5 V power supply 3 voltage/sensor power supply)
8) Start Control (coolant temperature monitoring)
When the coolant temperature is 0°C (32°F) or lower, the ECM controls the fuel amount depending on the
coolant temperature, for stable engine starting.

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9) Long Cranking Control

For the purpose of reducing black smoke when starting the engine and as backup in case adequate starting Q
(fuel injection) is not obtained, for example due to injector wear, after the stipulated time after the start of
cranking, the starting Q is raised the stipulated amount to improve startability.
Pattern with normal Pattern in with cranking time

cranking time is at least 1 second
Key switch
START
ON
OFF 1 second
Idling cranking
Engine Speed
UP-Q
Starting Q ST-Q
NL-Q
0
RF04004-002
ST-Q. Standard starting Q NL-Q. Q for no load

UP-Q. Starting Q after increase
10)Starting Control for Reduced Number of Cylinders
When the fact that there is a stopped injector is detected with trouble diagnosis (when an error code is
detected), for the purpose of emergency escape, the fuel injection quantity is corrected to secure engine
startability.
The injection quantity for the troubled injector is allocated to the normal injectors. (The total injection
quantity is made the same.)
• The injector correction factors are as follows.
Number of effective cylinders 6 5 4 3 2 1 0

Correction factor 1.0 1.2 1.5 2.0 1.0 1.0 1.0
CAUTION: No control if there is trouble in injectors for 5 or more cylinders. No control if an injector
has a mechanical trouble.
11)Normal Stop (key switch OFF operation)
1. The key switch is set OFF.
2. When the ECM recognizes that the key is OFF, [3.] to [5.] are carried out at the same time.
3. Injector injection quantity calculation stop
4. Suction control valve (SCV) full close instruction
5. EGR valve full close instruction, EGR valve initial correction
6. When the operations in [3.] to [5.] end, the trouble log etc. are written to the EEPROM in the ECM.
7. The main relay is switched OFF and the power feed to the ECM is switched OFF.

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5. Engine Start/Stop Judgment

Engine start and stop is judged based on the engine speed sent from the ECM with CAN communication.
Judgment values Start: 500 min-1
Stop: 200 min-1
Start
Stop
Configuration diagram
1. Computer A
2. Engine speed
3. ECM
4. CKP sensor signal
5. CMP sensor signal

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SERVICE SUPPORT
Screen Operations
1) Screen Shift
Key ON
(Anti-theft protection ON)

(Authentication OK)
(Anti-theft protection OFF)
(Model selection not completed)
(Model selection completed) (Authentication OK)
All reset One-touch

idle switch
No error pressed 5 times
3 seconds
3 seconds elapse
Breaker or crusher switch
3 seconds Flow reset
10 seconds
1 second 3 seconds
3 seconds Main Unit

(Service)
1 second
(Engine Service)
DIAG reset
10 seconds
or HR reset
10 seconds
CFG reset
10 seconds
Exit this mode by

switching OFF the
key
Screen on which the engine S/N,

Q adjustment, and QR can be
viewed

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4001-90
a) Operation for shifting to service support screen
1. If both the travel high-speed switch and the horn volume select switch on the switch panel are held down
for 3 seconds, the display switches to the service support screen.
2. If both the high-speed travel switch and the horn volume select switch on the switch panel are held down
again for 1 second, the display returns to the normal screen.
Normal screen Service support screen
Hold down for 024.6

3 seconds 1800 013.7
0350 02.56
Hold down for 0120 00.93
1 second
b) Service support screen switching operation
B C
1 2 3
D
CH K MA I N 1 P1 000.0 MPa
Eng 0000 min-1 P2 000.0 MPa
Power 0000 mA N1 00.00 MPa
Flow 0000 mA N2 00.00 MPa
A
A Mode select switch 1 Mode (switching with high speed travel switch A)
B Section select switch 2 Section (switching with horn volume select switch B)
C Page (-) 3 Page (switching: forward with light switch D and back with washer
D Page (+) switch C)
[Mode] [Section] [Page]

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Screen Display List
1. CHK (status display) Screen List
In CHK mode, in addition to the machine status (milli-amp, oil pressures, temperatures, etc.), it is possible to
check sensor and switch input/output states, as well as the angle, load ratio and work radius, etc. at the
applied machine (liftcrane application machine, lifting magnet machine).
Section
Select switch
Page (-)
Page (+)
1 Section 2 Page
NOTE: From the CHK mode screen, if the wiper switch and the light switch are held down for 3 seconds,
the display shifts to the model selection screen.
A) MAIN
1) Engine and pump
Eng : Engine speed
CHK MAI N 1 P1 000.0 MPa Power : Actual milli-amp for horsepower control
proportional valve
Eng 0000 min -1 P2 000.0 MPa
Flow : Actual milli-amp for flow control proportional
Power 0000 mA N1 00.00 MPa valve
Flow 0000 N2 00.00 P1 : Pump1 Discharge pressure
mA MPa
P2 : Pump2 Discharge pressure
N1 : Pump1 Negative control pressure
2) Temperature and pressure

Coolnt : Radiator coolant temperature
CHK MA I N 2 Baro 0000 h Pa HydOil : Hydraulic oil temperature
Coolnt 0000 EngOil 0000 FuelT : Fuel temperature
˚C k Pa
Baro : Barometric pressure
HydOil 0000 ˚C BstT 0000 ˚C EngOil : Engine oil pressure
FuelT 0000 ˚C Air 0000 ˚C BstT : Boost temperature
Air : Suction air temperature
3) Load and boost

Eng : Engine speed
CHK MA I N 3 P1 000.0 MPa Load : Load ratio
Power : Actual milli-amp for horsepower control
Eng 0000 min-1 P2 000.0 MPa proportional valve
Load 0000 % BstT 0000 ˚C P1 : Pump 1 Discharge pressure
P2 : Pump 2 Discharge pressure
Power 0000 mA BstP 0000 kPa
BstT : Boost temperature
BstP : Boost pressure

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4) Load and milli-amp for horsepower control proportional valve
Eng : Engine speed
CHK MAI N 4 P1 000.0 MPa Load : Load ratio
Eng 0000 min -1 P2 000.0 MPa Power : Actual milli-amp for horsepower control
proportional valve
Load 0000 % N1 00.00 MPa P1 : Pump 1 Discharge pressure
Power 0000 mA N2 00.00 MPa P2 : Pump 2 Discharge pressure
N1 : Pump 1 Negative control pressure
5) Target and actual milli-amp for horsepower control proportional valve

Eng : Engine speed
CH K MAI N 5 -4- Load : Load ratio
Power : Actual milli-amp for horsepower control
Eng 0000 min-1 tEng 0000 min -1 proportional valve
Load 0000 % ThVol 0000 % -4- : *
Power 0000 tPower 0000 tEng : Target engine speed
mA mA
ThVol : Throtle volume degree of opening
tPower : Target milli-amp for horsepower control
proportional valve
6) Target and actual milli-amp for flow control proportional valve

Eng : Engine speed
CHK MAIN 6 P1 000.0 MPa Power : Actual milli-amp for horsepower control
Eng 0000 min -1 N1 00.00 MPa proportional valve
Flow : Actual milli-amp for flow control proportional
Power 0000 mA Swg 00.00 MPa valve
Flow 0000 mA tFlow 0000 mA P1 : Pump 1 Discharge pressure
Swg : Swing pilot pressure
tFlow : Target milli-amp for flow control proportional
valve
7) Target and actual milli-amp for hydraulic fan proportional valve

Eng : Engine speed
CH K MAIN 7 HydOil 0000 ˚C Coolnt : Radiator coolant temperature
Fan : Actual milli-amp for hydraulic fan proportional
Eng 0000 min-1 FuelT 0000 ˚C valve
Coolnt 0000 ˚C BstT 000 ˚C HydOil : Hydraulic oil temperature
FuelT : Fuel temperature
Fan 0000 mA tFan 000 mA
BstT : Boost temperature
tFan : Target milli-amp for hydraulic fan proportional
valve
8) Pilot pressure
CHK MAI N 8 Upr 00.00 MPa P2 : Pump2 Discharge pressure
Cyl(B) : Boom bottom pressure
P1 000.0 MPa Swg 00.00 MPa
Upr : Upper pilot pressure
P2 000.0 MPa Trv 00.00 MPa Swg : Swing pilot pressure
Cyl(B) 000.0 MPa AmCls 00.00 MPa Trv : Travel pilot pressure
AmCls : Arm-in pilot pressure

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9) Hydraulic circuits; Input/ouput and pressure

CHK MA I N 9 P1 000.0 MPa P2 : Pump2 Discharge pressure
In P2 000.0 N1 : Pump1 Negative control pressure
MPa
Out1 N1 00.00 MPa
Out2 N2 00.00 MPa
Hydraulic circuit input /output state ( = OFF, = ON )
In Out1 Out2
1 5 9
2 6 10
3 7 11
4 8 12
1 Pressure sensor; Arm in 7 Solenoid; Boost
2 Pressure sensor; Travel 8 Solenoid; Swing brake
3 Pressure sensor; Swing 9 Relay; Travel alarm
4 Pressure sensor; Upper 10 Solenoid; Fan reverse (large machine only)
5 Solenoid; Free swing / beacon 11 Solenoid; Option line switchover
6 Solenoid; Travel high-speed switchover 12 Solenoid; Power save
10)Electrical circuits; Input/ouput

Eng : Engine speed
CHK MA I N 10 Eng 0000 -1 Coolnt : Radiator coolant temperature
min
Batt : Battery voltage
In Coolnt 0000 ˚c
FuelLv : Fuel sensor
Out1 Batt 0000 V
Out2 FuelLv 0000 %
Electrical circuit input /output state ( = OFF, = ON )
In Out1 Out2
*
1
*
4
*7
2 5 8
3 6 9
1 Switch; Anti-theft protection 6 Glow signal

2 Battery charge 7 Engine stop due to trouble
3 Switch; Key 8 Low idle restriction due to trouble
4 A/C coolant temprerature transmission 9 Restriction on milli-amp for horsepower control
5 Relay; Feed pump automatic stop proportional valve due to trouble

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B) MNT
1) Computer S Information
CHK 1 4401 2
MNT 1 4 0140
2 0035
1 4401 5 4132 3
3 4783
2 0035 6 31 3
4 0140
3 4783 7 0530 4
5 4132
7 0530 1 6 31 3
5 7
* The longitude and latitude are displayed when the continuous GPS 6 8
position measurement time is 5 minutes or longer.
CHK MNT 2 4 0052 1 0605
1 0605 5 0130 2 2803 9

2 2803 6 0130 3 1432
3 1432 7 0122 4 0052 10
* UTC (universal time coordinate) is the global standard time.

5 0130 11
* Displayed after the completion of GPS position measurement. 6 0130
* For 3D position measurement, the altitude can be measured. 12
* GCC is a land station. 130 is the GCC for Japan (122 is South Korea). 7 0122
1 GPS continuous position measurement time (for example, 5 minutes 30 second of continuous position
measurement)
2 Computer S part number bottom 4 digit display (example, KHR14401)
3 Latitude: inside the O, 0 = North hemisphere, 1 = Southern hemisphere (example, 35 degrees 47.83 minutes)
4 Longitude: inside the O, 0 = Longitude east, 1 = Longitude west (example, 140 degrees 41.32 minutes
longitude east)
5 GPS position measurement status
0 = GPS not yet operating
1 = GPS measuring
2 = 2D measurement status
3 = 3D measurement status
8 = GPS module abnormality
9 = GPS antenna abnormality
6 Satellite communication status
0 = No satellite supplement
1 = Satellite supplement
9 = Satellite communication abnormality
7 Default setting send status
0 = Default setting send wait
1 = Send inhibit wait
2 = ACK send wait
3 = Default setting send complete
4 = Default settings send complete, sending permitted
8 Blank
9 UTC (Universal Time Coordinate) (example: May 28, 2006, 03:14:32)
10 Altitude (Example: 52 m)
11 Send GCC number
12 Supplementary GCC number

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CHK MNT 3 4 0028

1 0324 3
1 0324 5 0128
2 0020
2 0020 6 0001 4 5
3 0248 7 0001
3 0248 6
4 0028 7
6 0001 1
5 0128 8
7 0001 2
Event send setting
The default state is fuel volume warning, anti-theft operation warning event send inhibited.
These can be changed to enabled with signals from the web server. When this signal is received, No. 4 becomes the
display below.
Fuel volume Anti-theft operation warning Anti-theft operation warning

Nr. 4 warning (without position information) (with position information)
0028 Inhibited Inhibited Inhibited
0156 Enabled Inhibited Inhibited
0220 Enabled Enabled Inhibited
0188 Enabled Inhibited Enabled
0092 Inhibited Enabled Inhibited
0060 Inhibited Inhibited Enabled
1 Engine start enable setting

0 = Inhibited, 1 = Enabled
2 Send destination count
* The send destination is the server, so it is fixed at 1.
3 Time until next sending (example: 3 hours 24 minutes more until the next sending)
4 Send wait message count (example: 2)
5 Q1200 status
0 = Waiting
1 = Sending
4 = Receiving
5 = Receiving complete
6 Send distribution setting (not set)
0248 = STD
0252 = Liftcrane specifications
7 Event send setting
0028 = Default
8 Send inhibition setting (not set)
0 = Sending default settings
128 = Default settings send complete

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C) H / W-A
1) Digital input / output
CHK H / W -A 1 DI1
DO1 DI2
DO2 DI3
DO3 DI4
Input /output state ( = OFF, = ON )
DO1 DO2 DO3

1 5
2 6
*
3 7
*
4 8
*9
DI1 DI2
10 14
11 15
12 16
13 17
DI3 DI4
* 20
*
18
21
22
19
*
1 Solenoid; Power save 12 Switch; Anti-theft
2 Solenoid; Boost 13 Switch; One-touch idle
3 Solenoid; Travel high-speed switchover 14 Switch; Travel alarm / overload
4 Solenoid; Swing brake 15 Switch; Free Swing (North America)
5 Buzzer; Travel alarm 16 Switch; Pressure (2nd option)
6 Solenoid; Option line switchover 17 Switch; Pressure (Option)
7 Solenoid; Free swing (North America) 18 Switch; Fan reverse (large machine only)
8 Solenoid Fan reverse (large machine only 19 Switch; Clog (Return filter)
9 Relay; Feed pump 20 Alternator
10 Switch; Clog (Air cleaner) 21 Switch; Engine emergency stop
11 Switch; Level Coolant 22 Switch; Key

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2) Digital output / output monitor
CHK H / W -A 2 -4-
DO1 DOM1
DO2 DOM2
DO3 DOM3
DO1 DO2 DO3

1 5
2 6
*
3 7
*
4 8
*
9
-4- DOM1
* 1
* 2
* 3
* 4
DOM2 DOM3
5 *
6
7
*
8
*
9
1 Solenoid; Power save 6 Solenoid; Option line switchover
2 Solenoid; Boost 7 Solenoid; Free swing ( North America)
3 Solenoid; Travel high-speed switchover 8 Solenoid; Fan reverse (large machine only)
4 Solenoid; Swing brake 9 Relay; Feed pump
5 Buzzer; Travel Alarm (North America)
3) Potentio-meter voltage
Pot1 : Sensor pressure P1
CHK H / W -A 3 Pot4 0000 V Pot2 : Sensor pressure P2
Pot3 : Sensor pressure N1
Pot1 0000 V Pot5 0000 V
Pot4 : Sensor pressure N2
Pot2 0000 V Pot6 0000 V Pot5 : Sensor pressure Swing
Pot3 0000 V Pot7 0000 V Pot6 : Sensor pressure Upper
Pot7 : Sensor pressure Travel
4) Potentio-meter and sensor voltage (Resistance)

Pot8 : Sensor pressure Arm in
CHK H / W -A 4 Sn1 0000 V Pot9 : Sensor throttle
Pot10 : Sensor pressure Overload
Pot8 0000 V Sn2 0000 V
Sn1 : Sensor temperature Hydraulic oil
Pot9 0000 V Sn1 0000 Ω Sn2 : Sensor level Fuel
Pot10 0000 V Sn2 0000 Ω Sn1 : Sensor temperature Hydraulic oil
Sn2 : Sensor level Fuel

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5) PWM data
PWM# : PWM channel number
CHK H / W -A 5 duty 0000 % actcur : Actual milli-amp for horsepower control
proportional valve
PWM# 1 freq 0000 Hz tgtcur : Target milli-amp for horsepower control
actcur 0000 mA volt 0000 V proportional valve
____ duty : Duty
tgtcur 0000 mA ovc
freq : Frequency
volt : Voltage
ovc : Overcurrent detection status
(+: Overcurrent, - Normal)
6) PWM data
CHK H / W -A 6 duty 0000 % actcur : A c t u a l m i l l i - a m p fo r h y d r a u l i c fa n
proportional valve
PWM# 2 freq 0000 Hz tgtcur : Ta r g e t m i l l i - a m p fo r hy d r a u l i c fa n
actcur 0000 mA volt 0000 V proportional valve
____ duty : Duty
tgtcur 0000 mA ovc
freq : Frequency
volt : Voltage
7) PWM data
CHK H / W -A 7 duty 0000 % actcur : Actual milli-amp for flow control proportional
valve
PWM# 3 freq 0000 Hz tgtcur : Target milli-amp for flow control proportional
actcur 0000 mA volt 0000 V valve
____ duty : Duty
tgtcur 0000 mA ovc
freq : Frequency
volt : Voltage
8) Frequency and communication

FreqIn : Frequency input
CHK H / W -A 8 RS232 CAN : CAN reception state
UART : UART reception state
FreqIn 0000 Hz -5-
RS232 : RS232C communication state
CAN -6- -5- : *
UART -7- -6- : *
-7- : *
Input /output state ( = Receiving)
CAN
1
2
3
1 Computer S reception state
2 Computer B reception state
3 ECM reception state

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D) H / W-B
1) Computer B digital input / output
CHK H /W -B 1 DI1
DO1 DI2
DO2 DI3
DO3 DI4

DO1 DO2 DO3
1
* * *
2
* *
3
* *
* *
DI1 DI2 DI3
4 *
5
*
6
* *
7
*8 *
*
IDI4
*
*
*
*
1 Solenoid; lever lock 6 Switch; Interference (Temporary release)
2 Rotating light and bucket lock 7 Switch; Lifting magnet mode
3 Buzzer; Crane 8 Switch; Interference (Shut-off release)
4 Switch; Crane Mode
5 Switch; Crane (Display switching)

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2) Digital output / output monitor
CHK H /W -B 2 -4-
DO1 DOM1
DO2 DOM2
DO3 DOM3

DO1 DO2 DO3
1
* * *
2
* *
3
* *
* *
-4- DOM1 DOM2
* *1 *
* 2
*
* 3
*
* *
DOM3
*
*
*
*
1 Solenoid; Lever lock
2 Rotating light and bucket lock
3 Buzzer; Crane
3) Potentio-meter voltage
Pot1 : Sensor; Angle boom
CHK H /W -B 3 Pot4 0000 V Pot2 : Sensor; Angle arm
Pot3 : Sensor; Angle offset
Pot1 0000 V Pot5 0000 V
Pot4 : Sensor; Pressure bottom
Pot2 0000 V Pot6 0000 V Pot5 : Sensor; Pressure rod
Pot3 0000 V Pot7 0000 V Pot6 : *
Pot7 : *
4) Potentio-meter and sensor voltage (resistance)

Pot8 : *
CHK H /W -B 4 Sn1 0000 V Pot9 : *
Pot10 : *
Pot8 0000 V Sn2 0000 V
Sn1 : *
Pot9 0000 V Sn1 0000 Ω Sn2 : *
Pot10 0000 V Sn2 0000 Ω Sn1 : *
Sn2 : *

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5) PWM data
CHK H / W -A 5 duty 0000 % actcur : Actual milli-amp for boom propor tional
valve
PWM# 1 freq 0000 Hz tgtcur : Target milli-amp for boom propor tional
actcur 0000 mA volt 00.00 V valve
duty : Duty
tgtcur 0000 mA ovc ----
freq : Frequency
volt : Voltage
6) PWM data
CHK H / W -A 6 duty 0000 % actcur : Actual milli-amp for offset proportional
valve
PWM# 2 freq 0000 Hz tgtcur : Target milli-amp for offset proportional
actcur 0000 mA volt 00.00 V valve
duty : Duty
tgtcur 0000 mA ovc ----
freq : Frequency
volt : Voltage
7) PWM data
CHK H / W -A 7 duty 0000 % actcur : Actual milli-amp for arm proportional valve
tgtcur : Target milli-amp for arm proportional valve
PWM# 3 freq 0000 Hz
duty : Duty
actcur 0000 mA volt 00.00 V freq : Frequency
tgtcur 0000 mA ovc ---- volt : Voltage
8) Frequency and communication

FreqIn : Frequency input
CHK H / W -A 8 RS232 CAN : CAN reception state
UART : UART communication state
FreqIn 0000 Hz -5-
RS232 : RS232C communication state
CAN -6- -5- : *
UART -7- -6- : *
-7- : *
Input /output state ( = Receiving)
CAN
1
2
3
1 Computer S reception state
2 Computer B reception state
3 ECM reception state

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E) H / W-M
1) Monitor
CHK H /W -M 1 DI1
DO1 DI2
DO2 DI3
DO3 DI4

DO1 DO2 DO3
1 * *
2 * *
3 * *
4 5 *
DI1 DI2
6 10
7 11
8 12
9 13
DI3 IDI4
*
14 *
15 *
16 *
*
1 Working light 9 Switch; Horn volume select
2 Motor Washer 10 Switch; Breaker select
3 Wiper CNT 11 Switch; Limit Front window
4 Wiper INT 12 Switch; Wiper
5 Relay; horn volume switchover 13 Switch; Washer
6 Switch; Working light 14 Switch; Reserve
7 Switch ; Travel high-speed select 15 Switch; 2 pumps flow
8 Switch; Auto idle select 16 Switch; Crusher select

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2. DIAG (trouble diagnosis) Screen

1. In diagnosis mode, you can check from the contents for the trouble currently occurring to a log
of trouble that has occurred in the past.
1 Status occurence count 4 Diagnostic trouble code

2 Initial occurence time 5 Cursor movement
3 Final occurence time
• In "DTC-1" through "DTC-4", the data is displayed in order from the most recently occurring trouble
code.
• The cursor is moved with the wiper switch and auto idle switch.
(The cursor moves between "DTC-1" and "DTC-4").
* There is no "section" in diagnosis mode.
• The information for the trouble code for the location under the cursor is displayed in the order "ST/OC",
"1st", "Last".
• The mark displayed at the left most of "ST/OC" shows whether or not the trouble is currently
occurring.
• The black circle means the trouble is currently occurring.
• The clear circle means the trouble is not occurring now, but has occurred in the past.
• "1st" indicates the time at which this trouble occurred the first time and "last" indicates the time at which
this trouble occurred the last time.
2. For details on "diagnostic trouble codes" that can be read in diagnosis mode and their contents, see the
"Main Unit Diagnostic Trouble Code List"
A) Screen
(C)
D I AG MAI N 1 DTC1 7002 4
1 St/Oc 005 DTC2 0238

2 1st 0010 hr DTC3 ----
3 Last 0901 hr DTC4 ----
1. Displays the status at the cursor(C) and the occurrence count.

...7002 error now occuring / trouble has occured 5 times in the past.
St/Oc 005 Status
005 Occurence count
[Status]
• Displays whether the diagnostic trouble code under the cursor is current or from the past.
• For , the trouble is current or continuing.
• For , the status is normal or recovered.
(The trouble is not occurring now, but has occurred in the past).
[Occurrence count]
• The number of times that diagnostic trouble code under the cursor has occurred

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2. Displays the time at which the trouble under the cursor first occurred
1st 0010 ...Occurred first at 10 hours

hr
3. Displays the time at which the trouble under the cursor last occurred
Last 0901 ...Occurred last at 901 hours

hr
4. Diagnostic trouble code
The troubles are sorted with the last one to occur at the top of the list.
The diagnostic trouble code under the cursor is displayed in (1) - (3).
...7002 (faulty N1 pressure sensor)
DTC1 7002
...0238 (Boost pressure sensor abnormally high voltage)
DTC2 0238
For details on diagnostic triuble code, see the Main Unit Diagnostic Trouble Code
DTC3 ----
List.
DTC4 ----
Maximum display count
4 codes per page X 16 pages = 64 diagnostic trouble codes are displayed. From the 65th code onward, the
oldest code is erased. However, even though these codes are not displayed, the data is retained.
B) Operation
1) Cursor up/down:
Up operation ... wiper switch
1 Down operation ... auto idle switch
2) Page forward / back:
Forward operation ... light switch
Back operation ... washer switch
2
C) Reset
If the washer switch and the light switch are held down for 10 seconds, the trouble log is reset.

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3. HR (usage log) Screen List

In HR mode, operation times for mechanical parts, electrical parts, etc., operation counts for switches
and solenoids, as well as pressure distributions, etc. can be displayed.
Section
Select switch
Page (-)
Page (+)
1 Section 2 Page
A) MAIN
1) Main unit operating time
KeyOn : Computer A power supply ON time
HR MA I N 1 Upr 0000 hr EngOn : Alternator power generating time
Work : Machine operating time
KeyOn 0000 hr Swg 0000 hr (Upper ON or travel ON)
EngOn 0000 hr Trv 0000 hr Upr : Upper operating time
Work 0000 TrSolo 0000 Swg : Swing operating time
hr hr
Trv : Travel operating time
TrSolo : Travel single operation time
2) Electrical part operating time

WpInt : Wiper (intermittent) operating time
HR MA I N 2 WLight 0000 hr WpCnt : Wiper (continuous) operating time
Wsh : Washer operating time
WpInt 0000 hr HornLo 0000 hr
WLight : Working light ON time
WpCnt 0000 hr DrOpn 0000 hr HornLo : Horn volume low time
Wsh 0000 hr WinOpn 0000 hr DrOpn : *
WinOpn : Front window open time
3) Idle time
1 : Auto idle time
HR MA I N 3 4 0000 hr 2 : One-touch idle time
3 : Boosted pressure time
1 0000 hr 5 0000 hr
4 : Low-speed travel time
2 0000 hr 6 0000 hr 5 : High-speed travel time
3 0000 hr 7 0000 hr 6 : *
7 : *
4) Pressure switch operation count

1 : Upper pressure sensor (ON count X 1000)
HR MA I N 4 4 0000 times 2 : Swing pressure sensor (ON count X 1000)
3 : Travel pressure sensor (ON count X 1000)
1 0000 times 5 0000 times
4 : Arm-in pressure switch (ON count X 1000)
2 0000 times 6 0000 times 5 : 1st option pressure switch (ON count X 1000)
3 0000 times 7 0000 times 6 : 2nd option pressure switch (ON count X 1000)
7 : *

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5) Operation switch operation count
1 : Key ON count X 10
HR MAI N 5 4 0000 times 2 : Engine start count X 10
3 : Front window open count X 10
1 0000 times 5 0000 times
4 : *
2 0000 times 6 0000 times 5 : Boost solenoid ON count X 1000
3 0000 times 7 0000 times 6 : Swing brake solenoid ON count X 1000
7 : Power save solenoid ON count X 1000
6) Work mode
1 : Mode usage time SP-hi
HR MAI N 6 4 0000 hr 2 : Mode usage time SP-lo
3 : Mode usage time H-hi
1 0000 hr 5 0000 hr
4 : Mode usage time H-lo
2 0000 hr 6 0000 hr 5 : Mode usage time A1-hi
3 0000 hr 7 0000 hr 6 : Mode usage time A1-lo
7 : Mode usage time (other than above)
7) Breaker usage time

1 : Breaker 1 operation time
HR MAI N 7 4 0000 hr 2 : Breaker 2 operation time
1 0000 hr 5 0000 hr
2 0000 hr 6 0000 hr 5 : Breaker 5 operation time
3 0000 hr 7 0000 hr 6 : Breaker 1-5 operation time
7 : *
8) Crusher usage time

1 : Crusher 1 operation time
HR MAI N 8 4 0000 hr 2 : Crusher 2 operation time
1 0000 hr 5 0000 hr
2 0000 hr 6 0000 hr 5 : Crusher 5 operation time
3 0000 hr 7 0000 hr 6 : Crusher 1-5 operation time
7 : *
9) P1 pressure (P) distribution

1 : P < 10 MPa Time
HR MAI N 9 4 0000 hr 2 : 10 MPa ≤ P < 15 MPa Time
3 : 15 MPa ≤ P < 20 MPa Time
1 0000 hr 5 0000 hr
4 : 20 MPa ≤ P < 25 MPa Time
2 0000 hr 6 0000 hr 5 : 25 MPa ≤ P < 30 MPa Time
7 : 35 MPa ≤ P Time
10)P2 pressure (P) distribution

1 : P < 10 MPa Time
HR MAI N 10 4 0000 hr 2 : 10 MPa ≤ P < 15 MPa Time
3 : 15 MPa ≤ P < 20 MPa Time
1 0000 hr 5 0000 hr
4 : 20 MPa ≤ P < 25 MPa Time

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11)N1 pressure (P) distribution
1 : P < 10 MPa Time
HR MA I N 11 4 0000 hr 2 : 10 MPa ≤ P < 15 MPa Time
3 : 15 MPa ≤ P < 20 MPa Time
1 0000 hr 5 0000 hr
4 : 20 MPa ≤ P < 25 MPa Time
12)N2 pressure (P) distribution

1 : P < 10 MPa Time
HR MA I N 12 4 0000 hr 2 : 10 MPa ≤ P < 15 MPa Time
3 : 15 MPa ≤ P < 20 MPa Time
1 0000 hr 5 0000 hr
4 : 20 MPa ≤ P < 25 MPa Time
13)P1 + P2 pressure (P) distribution

1 : P < 20 MPa Time
HR MA I N 13 4 0000 2 : 20 MPa ≤ P < 30 MPa Time
hr
3 : 30 MPa ≤ P < 40 MPa Time
6 : 60 MPa ≤ P < 70 MPa Time
3 0000 hr 7 0000 hr
14)Oil temperature (T) distribution

1 : T< 45°C Time (bar graph 1st and 2nd gradation)
2 : 45°C ≤ T< 60°C Time (bar graph 3rd gradation)
HR MA I N 14 4 0000 hr
3 : 60°C ≤ T < 80°C Time (bar graph 4th gradation)
1 0000 hr 5 0000 hr 4 : 80°C ≤ T < 88°C Time (bar graph 5th gradation)
2 0000 hr 6 0000 hr 5 : 88 °C ≤ T < 95 °C Time (bar graph 6th gradation)
6 : 95 °C ≤ T < 98 °C Time (bar graph 7th gradation)
3 0000 hr 7 0000 hr
7 : 98 °C ≤ T Time (bar graph 8th gradation)
B) ENG
1) Oil temperature / coolant temperature / pressure maximum values
(Measured starting 10 minutes after engine started)
Coolnt : Radiator coolant temperature
HR ENG 1 Air 0000 ˚C HydOil : Hydraulic oil maximum temperature
FuelT : Fuel maximum temperature
Coolnt 0000 ˚C BstT 0000 ˚C Air : Suction air maximum temperature
HydOil 0000 ˚C BstP 0000 kPa BstT : Boost maximum temperature
BstP : Boost maximum pressure
FuelT 0000 ˚C EngOil 0000 kPa
EngOil : Engine oil minimum pressure

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2) Engine actual speed (S) distribution
1 : S < 1025 min-1 Time
HR ENG 2 4 0000 2 : 1025 min-1 ≤ S < 1225 min-1 Time
hr
3 : 1225 min-1 ≤ S < 1425 min-1 Time
1 0000 hr 5 0000 hr 4 : 1425 min-1 ≤ S < 1625 min-1 Time
2 0000 hr 6 0000 hr 5 : 1625 min-1 ≤ S < 1825 min-1 Time
6 : 1825 min-1 ≤ S < 2025 min-1 Time
3 0000 hr 7 0000 hr
7 : 2025 min-1 ≤ S Time
3) Coolant temperature (T) distribution

1 : T < 77 °C Time (bar graph 1st and 2nd gradation)
HR ENG 3 4 0000 hr 2 : 77 °C ≤ T < 82 °C Time (bar graph 3rd gradation)
2 0000 hr 6 0000 hr
7 : 105 °C ≤ T Time (bar graph 8th gradation)
4) Fuel temperature (T) distribution

1 : T < 40 °C Time
HR ENG 4 4 0000 hr 2 : 40 °C ≤ T < 50 °C Time
1 0000 hr 5 0000 hr 3 : 50 °C ≤ T < 60 °C Time
4 : 60 °C ≤ T < 70 °C Time
2 0000 hr 6 0000 hr 5 : 70 °C ≤ T < 80 °C Time
3 0000 hr 7 0000 hr 6 : 80 °C ≤ T < 90 °C Time
7 : 90 °C ≤ T Time
5) Suction air temperature (T) distribution

1 : T < -20 °C Time
HR ENG 5 4 0000 hr 2 : -20 °C ≤ T < 0 °C Time
1 0000 hr 5 0000 hr 3 : 0 °C ≤ T < 15 °C Time
4 : 15 °C ≤ T < 30 °C Time
2 0000 hr 6 0000 hr
5 : 30 °C ≤ T < 45 °C Time
3 0000 hr 7 0000 hr 6 : 45 °C ≤ T < 60 °C Time
7 : 60 °C ≤ T Time
6) Boost temperature (T) distribution

1 : T < 50 °C Time
HR ENG 6 4 0000 hr 2 : 50 °C ≤ T < 80 °C Time
1 0000 hr 5 0000 hr 3 : 80 °C ≤ T < 110 °C Time
4 : 110 °C ≤ T < 140 °C Time
2 0000 hr 6 0000 hr
5 : 140 °C ≤ T < 170 °C Time
3 0000 hr 7 0000 hr 6 : 170 °C ≤ T < 200 °C Time
7 : 200 °C ≤ T Time
7) Atmospheric pressure (P) distribution

1 : P < 600 hPa Time
HR ENG 7 4 0000 hr 2 : 600 hPa ≤ P < 690 hPa Time
1 0000 hr 5 0000 hr 3 : 600 hPa ≤ P < 780 hPa Time
4 : 780 hPa ≤ P < 870 hPa Time
2 0000 hr 6 0000 hr
5 : 870 hPa ≤ P < 960 hPa Time
3 0000 hr 7 0000 hr 6 : 960 hPa ≤ P < 1050 hPa Time
7 : 1050 hPa ≤ P Time

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8) Engine oil pressure (P) distribution
1 : P < 0 kPa Time
HR ENG 8 4 0000 hr 2 : 0 kPa ≤ P < 150 kPa Time
1 0000 hr 5 0000 hr 3 : 150 kPa ≤ P < 300 kPa Time
4 : 300 kPa ≤ P < 450 kPa Time
2 0000 hr 6 0000 hr
5 : 450 kPa ≤ P < 600 kPa Time
7 : 750 kPa ≤ P Time
9) Boost pressure (P) distribution

1 : P < 150 kPa Time
HR EN G 9 4 0000 hr 2 : 150 kPa ≤ P < 180 kPa Time
4 : 210 kPa ≤ P < 240 kPa Time
2 0000 hr 6 0000 hr
5 : 240 kPa ≤ P < 270 kPa Time
7 : 300 kPa ≤ P Time
10)Load ratio (R) distribution

1 : R < 30 % Time
HR EN G 10 4 0000 hr 2 : 30 % ≤ R < 40 % Time
1 0000 hr 5 0000 hr 3 : 40 % ≤ R < 50 % Time
4 : 50 % ≤ R < 60 % Time
2 0000 hr 6 0000 hr
5 : 60 % ≤ R < 70 % Time
3 0000 hr 7 0000 hr 6 : 70 % ≤ R < 80 % Time
7 : 80 % ≤ R Time
11)Load ratio (R) distribution for SP mode

1 : R < 30 % Time
HR EN G 11 4 0000 hr 2 : 30 % ≤ R < 40 % Time
1 0000 hr 5 0000 hr 3 : 40 % ≤ R < 50 % Time
4 : 50 % ≤ R < 60 % Time
2 0000 hr 6 0000 hr
5 : 60 % ≤ R < 70 % Time
3 0000 hr 7 0000 hr 6 : 70 % ≤ R < 80 % Time
7 : 80 % ≤ R Time
12)Load ratio (R) distribution for H mode

1 : R < 30 % Time
HR EN G 12 4 0000 hr 2 : 30 % ≤ R < 40 % Time
1 0000 hr 5 0000 hr 3 : 40 % ≤ R < 50 % Time
4 : 50 % ≤ R < 60 % Time
2 0000 hr 6 0000 hr
5 : 60 % ≤ R < 70 % Time
3 0000 hr 7 0000 hr 6 : 70 % ≤ R < 80 % Time
7 : 80 % ≤ R Time

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4. CFG (setting change) Screen

The item where the cursor is located flashes.
Can be changed
The cursor appears if the auto

idle switch is held down
• Hold down the auto idle switch for 1 second. The cursor is displayed and the value starts to flash.
• The flashing value can be changed with the washer switch /working light switch.
• When the travel high-speed switch is pressed, value is finalized and the change is reflected in the actual
machine.
• When the horn volume select switch is pressed, the change is cancelled
A) Operation
CFG MAI N 1 PrUp1 ++++

Cursor LowIdl 1000 min-1 PrUp2 ----
AtIdl1 0010 sec PwrAj 0300 mA
AtIdl2 0005 min-1 -7-
1) View mode (screen switching operation)

1) Switching to edit mode
Hold down the auto idle switch for one second.
The mode switches to edit mode and the cursor is
displayed.
1
Forward operation => light switch
Back operation => washer switch
2
2) Edit mode (setting change operation)
1) Cursor up / down:
Up operation => wiper switch
4 Down operation => auto idle switch
1 2) Numeric value increase / decrease:
Increase value => light switch
3 Decrease value => washer switch
3) Enter: Enters the set contents.
4) Cancel: Cancels the set contents.
When (3) and (4) is executed, this exits edit mode
2 and shifts the mode to view mode (the cursor
disappears).
3) Reset
If the washer switch and the light switch are held down for 10 seconds, the setting contents are reset and all
settings return to their default values.

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B) Screen
1) MAIN 1
CFG M A IN 1 PrUp1 ++++

LowIdl 1000 min -1 PrUp2 ----
AtIdl1 0005 sec PwrAj 300 mA
AtIdl2 1200 -1 -7-
min
Item name Explanation Setting range Default value

LowIdl Low idling speed Min speed to Auto-idle speed 1000
AtIdl1 Auto idling shift time 1 to 30 5
AtIdl2 Auto idling speed Low idling speed to 1500 1200
PrUp1 Auto pressure boost yes / no + : YES, - : NO +
PrUp2 Auto pressure boost for option line usage yes / no + : YES, - : NO -
PwrAj Transient load minimum mili-amp 50 to 400 300
-7- High altitude correction milli-amp 0 to 250 0
NOTE: PwrAj is the previous high altitude mode.
2) MAIN 2
CFG M A IN 2 CoolDn
TrSpd ____ EPF ++++
TrAlm1 ++++ Unit 0000

TrAlm2 0010 sec -7-

TrSpd Travel speed previous data held yes / no + : YES, - : NO -
TrAlm1 Travel alarm buzzing yes / no + : YES, - : NO +
TrAlm2 Travel alarm automatic stop time 1 to 30 10
CoolDn
EPF EPF (Engine Protection Feature) yes / no + : YES, - : NO +
Unit Display unit 0: MPa, 0
1: PSI,
2: kgf/cm2
-7-
* Display unit contents … MPa = (MPa,°C), PSI = (psi, °F), kgf/cm2 = (kgf/cm2, °C)

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3) MAIN 3
CFG MAI N 3 MntMsg ++++

Spd1 min -1 Cycle 0500 hr
Spd2 -1 Remain 0500
min hr
OvLd 0000 MPa -7- ++++

Spd1
Spd2
OvLd Pressure at which alarm starts
MntMsg "SERVICE DUE" display yes / no + : YES, - : NO +
Cycle "SERVICE DUE" display range 0 to 5000 500
Remain Time until next "SERVICE DUE" display 0 to 5000 500
-7- New harness yes / no + : YES, - : NO +
* OvLd is an option for Europe.
-7- is battery charge and engine emergency stop port substitution.

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5. CAL (troubleshooting support) Screen
A) Operation
C AL MAI N 1 P1 000.0 MPa

Cursor tEng 1000 min-1 P2 000.0 MPa
tPower 0000 mA N1 00.00 MPa
tFlow 0000 mA N2 00.00 MPa
1) View mode (screen switching operation)

1) Switching to edit mode
Hold down the auto idle switch for one second.
The mode switches to edit mode and the cursor is
displayed.
1 Forward operation => light switch
Back operation => washer switch
2) Edit mode (setting change operation)

1) Cursor up / down:
Up operation => wiper switch
4 Down operation => auto idle switch
2) Numeric value increase / decrease:
1 Increase value => light switch
3 Decrease value => washer switch
3) Enter: Enters the set contents.
4) Cancel: Cancels the set contents.
Use the travel high-speed select switch or the
horn volume select switch to cancel. Exits edit
2 mode and shifts the mode to view mode (the
cursor disappears).
B) Screen
1) Engine pump override 1

tEng Target engine speed 500 to max speed Low idling
tPower Target milli-amp for horsepower control proportional valve 50 to 740 50
tFlow Target milli-amp for flow control proportional valve 50 to 740 50
P1 P1 pressure - -
P2 P2 pressure - -
N1 N1 pressure - -
N2 N2 pressure - -

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2) Engine pump override 2
CAL MAIN 2 P1+P2 0 0 0 . 0 MPa

-1
tEng 1000 min Eng 0000 min-1
tPower 0500 mA Power 0000 mA
tFlow 0500 mA Flow 0000 mA

tEng Target engine speed 500 to max speed Low idling
tPower Target milli-amp for horsepower control proportional valve 50 to 740 50
tFlow Target milli-amp for flow control proportional valve 50 to 740 50
P1+P2 P1+P2 pressure - -
Eng Actual engine speed - -
Power Actual milli-amp for horsepower control proportional valve - -
Flow Actual milli-amp for flow control proportional valve - -
3) Hydraulic pressure drive fan override

Eng Actual engine speed - -
Coolnt Coolant temperature - -
tFan Target milli-amp for hydraulic fan proportional valve fan current - -
HydOil Oil temperature - -
FuelT Fuel temperature - -
BstT Boost temperature - -
Fan Actual milli-amp for hydraulic fan proportional valve fan current - -

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6. Check the Monitor Switch (Self-diagnosis function)
A) Screen
After the key is switched ON, the "CASE" logo screen is displayed on the monitor.
At this time, the display can be switched to the monitor switch check screen by pressing the one-touch idle
switch five times.
The switch contents are as follows:

WIPER SW Wiper Switch
SW1 Front window limit switch WASHER SW Washer Switch
SW2 Breaker mode switch W. LAMP SW Working light switch
SW3 Crusher mode switch T. MODE SW Travel high-speed select switch
SW4 2 pumps flow switch A. IDLE SW Auto idle switch
SW5 Not Used HORN VOL. SW Horn volume select switch
B) Configuration
6 Wiper switch
1 Washer switch
Working light switch
Travel high-speed
select switch
EXT-SW1 Auto idle switch
2
Horn volume select
switch
EXT-SW2
3
EXT-SW3
4
EXT-SW4
5 No communications
with computer A
(Monitor alone)
Not used EXT-SW5

x
1 Switch panel 4 Breaker mode switch

2 2 pumps flow switch 5 Crusher mode switch
3 Front window limit switch 6 Monitor
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C) Differences from CHK screen [CHK | H/W-M | 1]
Monitor main unit input / output can also be checked on the CHK screen.
However, for the CHK screen, after the switch input is sent to computer A with communication, the switch input
is processed by computer A and the results are sent to the monitor as screen data and displayed.
On the monitor switch check screen, the switch input recognized by the monitor itself is displayed directly on
the screen (without involving communications or Computer A), so it is possible to diagnose purely the switches
themselves.

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7. Option Flow Setting
A) Screen
When three seconds have passed, the logo screen shifts to the user screen.
With the user screen being displayed, if either the "breaker" or "crusher" rocker switch on the right panel is held
down for 3 seconds, the "option flow setting screen" is displayed on the monitor.
Option line icon: Displays the option

line for which the flow is set (select for
the breaker 1/2/3/4/5 and crusher 1/2/
3/4/5).
D i s p l ay s t h e m a x i m u m f l o w fo r
1 pump.
D i s p l ay s t h e m a x i m u m f l o w fo r
2 pumps.
Pump discharge pressure (P1 pump
main pressure).
B) Flow setting
1. Press the breaker or crusher mode switch to select the mode to set the flow for.
Rocker switch
1
2 4
1 Flow increase 3 Crusher mode (1 to 5) switchover

2 Flow decrease 4 Breaker mode (1 to 5) switchover

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2. The flow setting for the selected mode is selected by pressing the wiper switch or auto idle select switch.
The flow setting can be set to 10 levels from Level 1 to Level 10.
CAUTION: The set flow is the flow value when SP mode is selected.
Be careful. If run with the engine speed reduced, the actual flow is not the flow displayed.
Unit
1 pump flow (flow Level 1) L / min 285
2 pumps flow (flow Level 1) L / min 571
3. There is no need to do anything to finalize the setting. End by leaving this screen or switching OFF the
key.
The factory settings for each mode are as follows.
There are no 4 or 5 settings for the breaker or crusher. Just a hyphen is displayed for these settings.
Mode Flow display

Breaker circuit 1 / Crusher 1 Level 3 flow
Breaker circuit 4 / Crusher 4 (Not used)
Breaker circuit 5 / Crusher 5

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8. Anti-theft Setting
A) Anti-theft setting and password registration

1) Enabling the anti-theft function
With the key OFF, connect the anti-theft knob terminal.
When the male and female knob terminals are connected on the cab main harness in the rear cover, the anti-
theft function is enabled.The factory setting is for these knob terminals to be disconnected.
Anti-theft setting knob
Connect VG (purple / green) and BG (black /
green)
2) Setting the password

When the knob terminals are connected, then the key switched ON, the following screen is displayed.
Enter any 4-digit number made up of the numbers 1 to 9.
(If all four digits are not input, "ERROR" is displayed).
Input by using the monitor switches as follows.
When the Enter button is pressed, the password is stored into memory and display returns to the normal
screen.
1 Enter 3 Numeric value increase / decrease

2 Cursor movement
3) Changing the password

If the password has been forgotten or it is desired to change the password, if the knob terminal in A)1) is
disconnected and the key switched ON, the password is cleared. To re-input the password, repeat the
procedure in b).

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B) Anti-theft function operation

1) Enabling the anti-theft function
1. If the key is switched twice in a row ON => OFF => ON => OFF with the engine stopped, the anti-theft
function is switched ON.
(All the key switching operations must be done within 2 seconds)
2. When the anti-theft comes ON, the monitor buzzes and the "key" icon is displayed.
(Once the anti-theft is switched ON, this icon is displayed while the power is OFF)
3. The next time the key is switched ON, the anti-theft operates and the password input screen is displayed.
Input the password made up of 4 digits 0 to 9.
Input by using the monitor switches below.
If an incorrect number is input, "ERROR" is displayed and the buzzer buzzes.
The key must be switched OFF, then ON again before the password can be re-input.
1 Enter 3 Numeric value increase / decrease

2 Cursor movement
2) Disabling the anti-theft function

1. If the engine is stopped by switching OFF the key, the anti-theft function does not operate.
2. To disable the anti-theft function, disconnect the anti-theft knob terminals VG (purple/green) and BG
(black/green). The registered password is canceled.

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9. Model Setting
If the model selection has not been completed, immediately after the key is switched ON, the "Model select screen"
is displayed
1 MACHINE : CX ???? - ?? CRANE : ?

TERRITORY : ? A. INTF : ?
LANGUAGE : ?? CONT. A ERR CONT. B ERR
4
SPEC. :? MONITOR ERR ECM ERR
ATT.No. :?
CONT.A : KHR 10020-00 CONT.B : KHR 14000-00
2 3
1 Cursor 3 Computer B; Part number

2 Computer A; Part number 4 Error display section
1. For the "CONT.A" item, the part number for computer A is automatically displayed.
2. In the same way, if computer B is connected (for the liftcrane application or interference prevention
application), the part number for computer B is automatically displayed for the "CONT. B" item.
3. Items that must be input are displayed with '?'.
MACHINE : Model CX160B,CX180B,CX210B,CX230B, CX240B,CX290B ...
TERRITORY : Destination 2 = CASE NA, 3= CASE EU
LANGUAGE : Language (0: Japanese, 1: English, 2: Thai, 3: Chaina, 4: German, 5: French,
6 : I ta l i a n , 7 : S p a n i s h , 8 : Po r t u g u e s e, 9 : D u t c h , 1 0 : D a n i s h ,
11: Norwegian, 12: Swedish, 13: Finnish, 14: Turkish, 15: Arabic,
16: Malay, 17: Indonesian, 18: Icon)
SPEC : Main unit specifications (input 0)
ATT.No. : Attachment specification (input 0)
CRANE : 0: No crane, 1: Crane
A.INTF : 0: No interference prevention function, 1: Interference prevention function - '1'
4. Input operating method

Input by using the monitor switches as follows.
When the model select screen is displayed on the monitor, the normal monitor switch functions do not
work.
1) Enter button
3 2) Numeric value change
3) Cursor movement
1
2
When the throttle volume position or all the input is complete, press " " (Enter button).
(The throttle volume must always be at the "H" mode position).
If the input is inappropriate (*), "CONT. A. ERR" is displayed.
* When there is still an item left with "?" displayed or the combination of model, destination, specification,
and the like is inappropriate.

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5. On the model setting screen, the ECM part number is automatically checked.
If the input model and the ECM part number do not correspond, “ECM ERR” is displayed.
6. Even after the model selection is complete, it is possible to change just the "LANGUAGE", "CRANE", or
"ATT. NO." setting without an all reset, which is discussed below.
7. All reset
• On the model select screen, if the washer switch and the light switch are held down for 3 seconds, the
data below is erased (All reset).
8. All reset
• On the model select screen, if the washer switch and the light switch are held for 10 seconds, data in
the table below is erased.
Difference between all reset and half reset
Reset ....................................................................... O
Not reset........................................................................ x
Reset when model information has changed. ............ Δ
Half reset All reset
Computer A memory information Model information (*1) O O
Control data (*2) O O
Usage log (*3) x O
Trouble log (*4) x O
Engine information (*5) x O
Computer B memory information Angle sensor compensation value Δ O
Liftcrane/interference prevention usage log Δ O
Computer S memory information Transmission information (*6) x O
*1 Contents displayed on model selection screen

*2 Contents displayed on CFG screen
*3 Contents displayed on HR screen
*4 Contents displayed on DIAG screen
*5 Contents displayed on engine service screen
*6 When transmission information is reset, transmission with the G@NAV server is restarted from the initial send.
In this case, transmission with the G@NAV server cannot be done until a send permission signal is sent
from the control center.

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10. Engine Screen Information
A) Purpose
It has been made possible to copy the engine information (Q adjustment, QR code, engine serial number)
stored in the ECM to the new ECM when the ECM and injector are replaced.
B) How to go to this screen

See the service support screen operation.
C) Engine start restriction

When this screen is displayed, the engine cannot be started.
D) Screen
The engine information held in computer A can be checked as follows.
The information inside the ECM is checked by changing the display mode with the method shown in "Replacing
computer A at the Same Time".
1. Pages 1 to 6: Injector cylinder 1 to 6 QR code.
1) Page
2) QR code 24 digits
3) Error code
4) Indicates the display mode.

Currently displays the information in
computer A
2. Page 7: Q resistance data

1) Q resistance data 3 digits
3. Page 8: Engine serial (number)

1) Engine serial number 6 digits
4. ECM Part Number

1) ECM part number
E) Operating method
See the Engine Maintenance Standards
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F) Monitor operation method

1) View Mode.
Display mode (switching between information

in controller A / information in ECM)
page +/-
Each time this switch is pressed, the second
line of each page is switched as follows.
Hold down for one second to shift to Edit Mode

AA AA (Mode displaying information (only valid while QR code displayed and when in
in computer A) "AA AA" mode)
Be careful. Shifting to edit mode will not be done
EE EE (Mode displaying information when in "EE EE" mode
in ECM)
Hold down for three seconds to start copying the engine
information.
For details see "Engine Information Copying Method"
2) Edit Mode
Can only be shifted to during QR code display.
Cancel editing and exit edit mode Value increased
Cursor movement
Start the QR code writing and exit edit mode.
For details see "Rewriting Injector QR Codes" Value decreased

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G) Engine Information (Q resistance, QR code, engine serial number) Copying Method

If the ECM is replaced with a new one for any reason, the engine information is copied with the procedure
below
1. Connect the service ECM and check the following.
• The old ECM information must still be in computer A.
• The ECM must match the model (Check on the ECM parts nimber screen).
• No display for faulty computer A EEPROM or faulty EEPROM on ECM.
2. Go to the engine information screen, then hold down for 3 seconds. The buzzer buzzes and the copy
starts.
• The display may be any page (1 to 8) and either display mode (computer A or ECM).
When held for three seconds, the

buzzer buzzes.
During copying, the display is as below. During writing, the error code 99 is displayed.
Wait about 10 seconds.
When the copy ends normally, the error code 00 is displayed.
When the copy ends abnormally, error code displayed.
• Example: Starting copying from the Q resistance screen.
Error Code:
00: Normal.
01: Message interruption.
02: Message internal trouble.
03: Outside instruction value constant.
04: Engine running.
98: Faulty EEPROM
99: Writing
During rewriting, the mode display
section is "0".
3. When the copy ends normally, check that the information has been rewritten by switching the key switch
OFF => ON once.

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H) Rewriting Injector QR Codes

When an injector is replaced, input and write the QR codes with the following procedure.
1. Arrange for the replacement injector.
Input the part below from the character array written on the injector
QR Code
QR Code
Injector ASM
Input section 24 digits
Input the QR codes one at a time.

Engine information screen Pages 1 to 6 (6 cylinders engine) correspond to the injectors with those
numbers (See the figure below.)
Engine front
1 2 3 4 5 6 Engine rear
Injector No.
2. Hold down the idle switch for 1 second to shift the Edit mode.
Hold down for 1 second
3. Cursor is displayed.
ENG. INF 1
5A 52 70 1E 35 DD 21 57 00 1F 5A
BD AA AA 00 Cursor displayed

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4. Move the cursor with the washer and light switchs. Use the wiper and the auto idle switchs to raise and
lower the value and input the QR codes written on the injector.
Value increased / decreased
Cursor
movement
Error Code:
00: Normal.
ENG. INF 1 01: Message interruption.
5A 52 70 1E 35 DD 21 57 00 1F 5A 02: Message internal trouble.
BD AA AA 00 03: Outside instruction value constant.
04: Engine running.
98: Faulty EEPROM
99: Writing
Cursor only moves as
far as here
5. When the QR code input is complete, press .

The buzzer buzzes once and the writing starts.
The error code 99 (writing) is displayed. When the copy ends normally, the error code 00 is displayed.
When the writing ends abnormally, the buzzer buzzes twice and the error code is displayed. (To cancel
input, press the horn switch)
6. Switch OFF the key switch, then ON again and check that the QR codes have been written.
I) When Replacing Computer A at the Same Time

If the ECM and computer A have trouble at the same time and the engine information inside the ECM cannot
be used, restore the engine information with the procedure below.
1. Rather than a service ECM, arrange for an ECM with the engine information already written into it and
use that as the replacement.
• An ECM with the engine information already written into it means one into which the Q resistance
data has been written with EMPS.
2. Input the injector QR codes one at a time (with the procedure in the preceding item).
J) Engine Information Obtained Timing

The engine information is acquired only the first time the key is switched ON after assembly.
K) Redoing Engine Information Obtained

To re-aquire the engine information, on the engine information screen, hold down the washer switch and the
light switch for 10 seconds.
L) Trouble Display
If the engine information cannot be displayed correctly due to an ECM time-out, CAN communications trouble,
or faulty EEPROM, the display is all Fs.
• Display for faulty ECM EEPROM, CAN communications trouble, or ECM time-out
ENG. INF 1
FF FF FF FF FF FF FF FF FF FF FF
FF EE EE 00

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Screen Display Details
1. Message Display List
Display Message Display ON timing Display OFF timing
type
When the "engine oil pressure abnormally low" trouble
LOW OIL PRESS Warning occurs
When the "ECM mismatch" trouble occurs.

CHECK ENGINE Warning Also, when a diagnostic trouble code is sent from the ECM
When any of the troubles below occur

Pressure Sensors; (P1), (P2), (N1), (N2), (Overload),
(Bottom), (Rod), (Upper), (Swing), (Travel),(Arm in)”,
Sensor; Fuel level,
Temperature Sensors; (Oil),
Angle Sensors; (Boom), (Arm), (Offset), None Does not go off
Pressure switch; (Return filter clog), while the key is ON.
Solenoid; (Swing brake), (Travel high-speed), (Power
save), (Option return circuit),(Free swing) (Fan reverse),
ELEC. PROBLEM
Warning (Bucket lock) (Lever lock),
(*1)
Air conditioner signal output,
Relay; Feed pump automatic stop,
Buzzer; Liftcrane"
Rotating light,
Proportional valve; (Horsepower pump), (Pump flow),
(Fan reverse),(Boom) , (Offset), (Arm)”,
Communication (monitor), (ECM), (computer B),
(computer S),
CAN bus
When any of the troubles below occur When all the troubles
"Abnormally high coolant temperature 1", "Abnormally below are recovered
high oil temperature" from "Abnormally high
OVERHEAT Warning
coolant temperature 1"
"Abnormally high oil
temperature"
When the "Coolant level low" trouble occurs
LOW COOLANT Warning
When the "Abnormally low alternator voltage" trouble

ALTERNATOR Warning occurs
None Does not go off
CHECK HYD.OIL When the "Return filter clogged" trouble occurs while the key is ON.
Warning
FILTER
When the "Air cleaner clogged" trouble occurs
AIR FILTER Warning
When the "Abnormally high boost temperature 1" trouble When the "Abnormally
occurs high boost
BOOST TEMP.HIGH Warning
temperature 1" trouble
is recovered from
When the "Fuel level drop" trouble occurs When the "Fuel level
LOW FUEL Warning low" trouble is
recovered from
When the breaker mode is ON and 2nd speed merge is
SWITCH TO 1-PUMP Alert ON When the conditions on
the left are no longer
When the engine emergency stop switch is ON met
ENGINE STOP Alert

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Display Message Display ON timing Display OFF timing

type
During one-touch idling or auto idling
ENGIN IDLING Icon
During auto power boost When the conditions on

POWER UP Icon
the left are no longer
When power ON to glow plug met
ENG. PRE HEAT Icon
During auto warm up

AUTO WARMUP Icon
When the key is ON and the hour meter has reached the After 1 minute after the
SERVICE DUE Status regulation time key was switched ON
(*1) Even if one of the following troubles occurs, "ELEC. PROBLEM" is not issued.
"BZ travel alarm", "Monitor thermistor", "Air conditioner coolant signal output"
Message type:
1. Status (Message only)
2. Alert (The intermittent alarm continues to sound at one-second intervals)
3. Warning (The continuous alarm sounds for just 5 seconds)
4. Icon (Only an icon is displayed).

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Trouble Display
1. Diagnostic Trouble Code Display
1) Purpose and summary
When a trouble occurs, the diagnostic trouble code (DTC) is displayed on the user screen.
This enables the operator to verbally communicate the trouble to the service engineer.
2) Screen
Displayed with the ! mark next to the work mode followed by a four-digit number.
If there is no trouble, nothing at all is displayed.
ELEC. PROBLEM
3) Trouble display
The "ELEC. PROBLEM" or "CHECK ENGINE" message is displayed.
When trouble occurs, the corresponding diagnostic trouble code is displayed. If the message makes clear
the trouble location, the location is not displayed elsewhere.
For details, see the "Main Unit Diagnostic Trouble Code List". All the diagnostic trouble codes sent from the
ECM are subject to display.
4) Displayed trouble status

Only current and ongoing troubles are displayed.Troubles that have been recovered from are not displayed.
5) Multiple trouble display

When multiple troubles occur, they are displayed in turn at intervals of five seconds.

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2. Main Unit Diagnostic Trouble Code List

1) Electrical troubles (input) [7000-7199]
Diagnostic
trouble code Occurrence judgment Recovery judgment
Trouble location Trouble mode Judgment timing Prerequisites
Dis-
DTC Conditions Conditions
play
Ground short/
Sensor; disconnection Voltage ≤ 0.25 V
Immediately after
Pressure 7000 O key switched ON None 0.25 V < Voltage < 4.75 V
(P1) Power supply short Voltage ≥ 4.75 V
Ground short/
Immediately after
Pressure 7001 O None 0.25 V < Voltage < 4.75 V
key switched ON
(P2) Power supply short Voltage ≥ 4.75 V
Ground short/
Immediately after
key switched ON
(N1) Power supply short Voltage ≥ 4.75 V
Ground short/
Immediately after
key switched ON
(N2) Power supply short Voltage ≥ 4.75 V
Ground short/
Immediately after EU selected as
Pressure 7004 O 0.25 V < Voltage < 4.75 V
key switched ON destination
(Overload) Power supply short Voltage ≥ 4.75 V
Ground short/
Immediately after Liftcrane
Pressure 7005 O 0.25 V < Voltage < 4.75 V
(Bottom) key switched ON selected
Power supply short Voltage > 4.75 V
Ground short/
Pressure 7006 O Immediately after Liftcrane 0.25 V < Voltage < 4.75 V
key switched ON selected
(Rod) Power supply short Voltage ≥ 4.75 V
Ground short/
disconnection Voltage ≤ 0.25 V
Sensor; 7020 O Immediately after None 0.25 V < Voltage < 4.75 V
Pressure (Upper) key switched ON
Power supply short Voltage ≥ 4.75 V
Ground short/
Pressure (Swing) key switched ON
Ground short/
Pressure (Travel) key switched ON
Ground short/
Pressure 7023 O Immediately after None 0.25 V < Voltage < 4.75 V
key switched ON
(Arm in) Power supply short Voltage ≥ 4.75 V
Disconnection Resistance ≥ 100 Ω

Sensor; Immediately after
Fuel level
7040 O
key switched ON
None 2Ω < Resistance < 100Ω
Short Resistance ≤ 2 Ω
Resistance ≥
3 minutes after
Sensor;
Disconnection
engine starts 67 200 Ω 111 Ω < Resistance <
Oil 7041 O None (Voltage ≥ 4.93 V ) 67 200 Ω
temperature
Immediately after Resistance ≤ 111 Ω (0.5 V < Voltage < 4.93 V)
Short
key switched ON (Voltage ≤ 0.5 V)
Monitor Disconnection
Immediately after Trouble bit received No trouble bit received from
thermistor 7045 X key switched ON None from monitor monitor
(*1) Short
Ground short/
disconnection
Liftcrane or Voltage ≤ 0.2 V
Sensor; 7060 O Immediately after interference 0.2 V < Voltage < 4.8 V
Angle (Boom) key switched ON prevention
Power supply short selected Voltage ≥ 4.8 V

Copyright ©
4001-132
Diagnostic
Occurrence judgment Recovery judgment
trouble code
DTC Dis- Conditions Conditions
play
Ground short/
Sensor; disconnection
Immediately after interference
Angle 7061 O 0.2 V < Voltage < 4.8 V
key switched ON prevention
(Arm) Power supply short selected Voltage ≥ 4.8 V
Ground short/
Sensor; disconnection
Immediately after interference
Angle 7062 O 0.2 V < Voltage < 4.8 V
key switched ON prevention
(Offset) Power supply short selected Voltage ≥ 4.8 V
From immediately
Pressure switch Disconnection 7063 O after key switched None Pressure switch = Pressure switch = ON
return filter clog ON until engine OFF
starts
For items for which X is displayed, the “ELEC. PROBLEM” message is not displayed. Also, there is no DTC
display on the user screen.
However, the DTC is recorded on the service (DIAG) screen.

Copyright ©
4001-133
2) Electrical troubles (output) [7200-7399]
Diagnostic Occurrence judgment Recovery judgment

trouble code
Dis-
DTC play Conditions Conditions
Disconnection
Solenoid;
7200 O
Immediately after
None Output ≠ Output = Output monitor
Swing brake key switched ON Output monitor
Short
Solenoid; Disconnection
Travel 7201 O
Immediately after
key switched ON Output monitor
high-speed Short
Disconnection
Solenoid;
7202 O
Immediately after
Boost key switched ON Output monitor
Short
Disconnection
BZ travel alarm 7203 X Immediately after None Output ≠ Output = Output monitor
(*1) key switched ON Output monitor
Short
Disconnection
Solenoid;
7204 O
Immediately after
Power save key switched ON Output monitor
Short
Disconnection
REL feed pump 7205 O Immediately after None Output ≠ Output = Output monitor
stop key switched ON Output monitor
Short
Solenoid; Disconnection
Option return 7206 O
Immediately after
circuit Short
Disconnection
Solenoid; 7207 O Immediately after None Output ≠ Output = Output monitor
Free swing key switched ON Output monitor
Short
Disconnection
Solenoid;
7208 O
Immediately after
Fan reverse key switched ON Output monitor
Short
Air conditioner Disconnection

coolant
7209 X
Immediately after
temperature key switched ON Output monitor
signal output (*1) Short
Disconnection
BZ liftcrane 7210 O
Immediately after
Short
REL Disconnection
rotating light and 7211 O
Immediately after
bucket lock key switched ON Output monitor
Short
Disconnection
Solenoid; 7212 O Immediately after None Output ≠ Output = Output monitor
Gate lock key switched ON Output monitor
Short
Proportional Disconnection After engine starts Milli-amp ≤ 30 mA

valve; 7240 O None 30 mA < Milli-amp < 3 A
Horsepower Immediately after
pump Short key switched ON Milli-amp ≥ 3 A

Immediately after
Pump flow Short key switched ON Milli-amp ≥ 3 A

Immediately after
Fan Short key switched ON Milli-amp ≥ 3 A

Copyright ©
4001-134
Diagnostic
Occurrence judgment Recovery judgment
trouble code
DTC Dis- Conditions Conditions
play

Immediately after
Boom Short
key switched ON Milli-amp ≥ 3 A

Immediately after
Arm Short key switched ON Milli-amp ≥ 3 A

Immediately after
Offset Short key switched ON Milli-amp ≥ 3 A

Copyright ©
4001-135
3) Mechanical troubles [7400-7599]
Diagnostic Occurrence judgment Recovery judgment

trouble code
Dis-
Coolant Coolant temperature Coolant temperature
Abnormally high temperature
7400 O
temperature 1 sensor = Normal ≥ 105°C (221°F) < 105°C (221°F)
CAN
Coolant Abnormally high 1 minute after Coolant temperature Coolant temperature
7402 O communication
temperature temperature 2 engine starts
= Normal ≥ 110°C (230°F) < 105°C (221°F)
ECM 5 V power
Abnormally high supply voltage = Coolant temperature Coolant temperature
7403 O
temperature 3 Normal ≥ 120°C (248°F) < 120°C (248°F)
Abnormally high 1 minute after Oil temperature Oil temperature Oil temperature
Oil temperature 7404 O
temperature engine starts sensor = Normal ≥ 95°C (203°F) < 95°C (203°F)
Boost
temperature
sensor =
Normal,
Abnormally high CAN Boost temperature Boost temperature
7405 O
Boost temperature 1 1 minute after communication ≥ 80°C (176°F) ≤ 70°C (158°F)
temperature engine starts = Normal,
ECM 5 V power
supply voltage =
Normal
Abnormally high Boost temperature Boost temperature
7406 O
temperature 2 ≥ 90°C (194°F) < 90°C (194°F)
Abnormally low 10s after engine Generated voltage
Alternator voltage 7420 O None Generated voltage > 10 V
voltage starts ≤ 10 V
Immediately after
Coolant level Drop 7421 O None Level SW = ON Level SW = OFF
key switched ON
Oil pressure
sensor =
Normal,
CAN Pressure
Engine oil Abnormally low 30s after engine Pressure
7422 O communication
pressure pressure starts = Normal, ≤ 40 kPa (5.8 PSI
> 40 40 kPa (5.8 PSI)
ECM 5 V power
supply voltage =
Normal
10s after engine
Air cleaner Clog 7423 O None Vacuum SW = ON Vacuum SW = OFF
starts
10s after engine Return filter
Return filter Clog 7424 O pressure switch Pressure SW = OFF Pressure SW = ON
starts = Normal

Copyright ©
4001-136
4) Faulty communication [7600-7799]
Diagnostic Occurrence Recovery judgment

trouble code judgment
Dis-
Immediately after Bus off or error When the occurrence

CAN bus Faulty bus 7600 O None
key switched ON passive conditions are not met
Faulty reception Packets not coming When the occurrence

from monitor conditions are not met
Communication 7601 O Immediately after None Reception from
monitor Faulty key switched ON monitor When the occurrence
transmission Defective packet conditions are not met
received
Communication Immediately after Messages not When the occurrence
ECM Time out 7602 O key switched ON None coming from ECM conditions are not met
Liftcrane or
Messages not
Communication Time out 7603 O Immediately after interference coming from When the occurrence
computer B key switched ON prevention conditions are not met
selected computer B
Messages not
Communication Immediately after When the occurrence
computer S Time out 7604 O key switched ON None coming from conditions are not met
computer S
ECM Mismatch 7605 O 10 s after engine Model selection Model ≠ ECM None. No recovery
starts completed calibration No.
Previously stored
Previously stored
EEPROM Faulty data 7606 X
Immediately after
None checksum ≠ checksum =
key switched ON Current calculated Current calculated checksum
checksum

Copyright ©
4001-147
ELECTRICAL INSPECTION OF COMPONENTS
Measurement method
1. Hydraulic Pump Electromagnetic Proportional Valve
• Remove the connector of the electromagnetic pro-
portional valve (horsepower, P1 flow) connected to
the hydraulic pump. CN.114
CN.113: For electromagnetic proportional valve.
CN.114: For flow proportional valve.
CN.113
SI10002-001
• Connect 2P service connectors (A) in between the Harness on pump side

removed connectors.
• Be careful at this time that the knob terminals do not A
make the lines intersect.
NI10001-010
• For the tester connections, check that the harness

from the operator's seat side is brown/black (BrB) BrB BrB
(service connector side is the same color), and con-
Harness on opera-
nect the red tester terminal to the operator's seat tor’s seat side
side and the black tester terminal to the hydraulic
pump side.
• After connection is completed, start the engine and
check the milli-amp of each mode at the maximum
rotation.
NI10001-011
Control milli-amp *= When the target engine speed is 1300 min-1 or less, milli-amp for pump
horsepower control proportional valve is 50 mA.
Volume position (detent position) 1 2 3 4-8 9 - 15
Work mode (upper) SP H A
CX350B Engine speed (min-1) 1900 1800 1700 1699 - 1300 1299 - 900
Milli-amp for pump horsepower control
500 500 500 380 50
proportional valve (mA)
Pressure boost Auto Auto Normal

Copyright ©
4001-148
2. Solenoid Valve (5 stack)
• Remove the 1 connector (A) attached to the solenoid
valve to be measured.
1 5 stack solenoid valve

2 For swing brake (white)
3 For pressure boost (yellow)
A
4 For travel 2nd speed (red)
5 For power save (green)
6 For lever lock (blue)
2 3 4
1
5 6
SI10002-002
• There are 5 solenoid valves that are attached, but

Solenoid valve
the application of each location is as explained in the
diagram on the right.(view from front)
Color bands are attached to the connector sections.
Functions are different for each color, so use caution
when measuring.
NI10001-013
• Connect 2P service connectors (A) in between the

Solenoid valve
removed connectors.(solenoid valve side only)
NI10001-014
• For the tester connections, connect the red and black

terminals to the service connector knob terminals.
• After connection is complete, check the resistance.
Resistance 40 Ω¶ (at 20°C)
* The resistance value changes to a slight degree
due to temperature
NI10001-015

Copyright ©
4001-149
3. Oil Temperature Sensor
• Remove the oil temperature sensor (A).
• Connect 2P service connectors (B) to the removed A
sensors.
• For the tester connections, connect the red and black
terminals to the service connector knob terminals.
• After connection is complete, slowly raise the tem-
perature and check the resistance.
Resistance value for each temperature (Unit: kΩ)

Oil temperature Oil temperature sensor
20°C 2.45
30°C 1.66
40°C 1.15
50°C 0.81
60°C 0.58
SI10002-003
70°C 0.43
80°C 0.32
C: Thermo meter B
D: Beaker
E: Sensor C
F: Tripad
G: Spirit lamp
D E
G
NI10001-017

Copyright ©
4001-150
4. Pressure Sensor
• Remove the connector of the pressure sensor connected to the hydraulic pump.
P2
N2
P1 N1
SI10002-004
• Connect 3P service connectors (A) in between the

removed connectors.
• For the tester connections, connect the red terminal A
to the service connector knob terminals WY (white/
yellow).Connect the black terminal to the ground.
• After connection is complete, turn the key switch ON
and check the voltage.
For engine-side sensor OK/NG judgment, see the

engine troubleshooting manual.
NI10001-019

Copyright ©
4001-151
• Pressure sensor voltage
P1, P2 pressure sensors N1, N2, Negative control pressure sensor

Pressure (MPa) Voltage (V) Pressure (MPa) Voltage (V)
50 4.5 5.0 4.5
43.7 4 4.37 4
37.5 3 3.75 3
25.0 2 2.5 2
17.5 1 1.25 1
0 0.5 0 0.5
(50)
5 4.5V
4
Pressure (MPa)
0
1 2 3 4
Voltage (V) NI10001-020
percentage [%]
Gauge level
Lever angle
Lever angle [%] Resistance [Ω]

Overhead
FULL 8
100% 100 10.0
7
82% 82 22.6
6
67% 67 33.1
5

Ł 52% 52 43.6
4
38% 38 53.4
3
22% 22 64.6
2
Reserve
0% 0 80.0
1
EMPTY
* The remaining amount is measured from the top part of the NI10001-021
drain

Copyright ©
4001-152
NOTES
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Copyright ©
Section
4020
ELECTRICAL EQUIPMENT
&
ELECTRIC CIRCUIT DIAGRAMS
4020

Printed in France
Copyright ©
4020-2
TABLE OF CONTENTS
ELECTRICAL EQUIPMENT LAYOUT DIAGRAM .......................................................................................................... 3

Overall View ............................................................................................................................................................. 3
Main Unit Left Side Layout Diagram (radiator chamber) .......................................................................................... 4
Engine Section Layout Diagram ............................................................................................................................... 5
Main Unit Right Side Layout Diagram (pump chamber) ........................................................................................... 6
Main Unit Center Section Layout Diagram ............................................................................................................... 7
Cab Layout Diagram 1 ............................................................................................................................................. 8
Controller A .......................................................................................................................................................... 9
Relay .................................................................................................................................................................... 9
ECM (engine control module) .............................................................................................................................. 9
Fuse box .............................................................................................................................................................. 9
Atmospheric pressure sensor .............................................................................................................................. 9
TECH II service connector ................................................................................................................................... 9
EST service connector ......................................................................................................................................... 9
Computer A service connector ............................................................................................................................. 9
Computer S service connector ............................................................................................................................. 9
Layout Around Operator Seat ................................................................................................................................ 10
Stand-Alone Parts Diagram ................................................................................................................................... 11
Connection Connector Pin Layout ......................................................................................................................... 27
Computer A ........................................................................................................................................................ 27
Monitor ............................................................................................................................................................... 28
ELECTRIC CIRCUIT DIAGRAM .................................................................................................................................. 29
List of components ................................................................................................................................................. 29
Option Circuit ......................................................................................................................................................... 31
Sequence Circuit Diagram ..................................................................................................................................... 33
BLOC DIAGRAM .................................................................................................................................................... 35
Computer A ........................................................................................................................................................ 35
Computer S ........................................................................................................................................................ 36
ECM (Engine Control Module) ........................................................................................................................... 37
Monitor Display .................................................................................................................................................. 38
Air Conditioner ................................................................................................................................................... 39
Lever Lock .......................................................................................................................................................... 40
Horn ................................................................................................................................................................... 40
Working Light ..................................................................................................................................................... 41
Option ................................................................................................................................................................. 41
Others ................................................................................................................................................................ 42
Electrical Symbol List ......................................................................................................................................... 43
ELECTRICAL CONNECTOR WIRING DIAGRAM ....................................................................................................... 44
Main Frame Harness .......................................................................................................................................... 45
CAB ........................................................................................................................................................................ 46
Cab Main Harness ............................................................................................................................................. 47
Cab Sub Harness ............................................................................................................................................... 48
In Cab ................................................................................................................................................................. 51
ENGINE HARNESS ............................................................................................................................................... 53
CONSOLE .............................................................................................................................................................. 54
Console Right Harness ...................................................................................................................................... 54
Console Left Harness ......................................................................................................................................... 54

Copyright ©
4020-3
ELECTRICAL EQUIPMENT LAYOUT DIAGRAM
Overall View
SE01009-505
1 Main unit left side (radiator chamber)

2 Engine
3 Main unit right side (pump chamber)
4 Main unit center section
5 In cab

Copyright ©
4020-4
Main Unit Left Side Layout Diagram (radiator chamber)
Shuttle valve back diagram
1
5 8
6
4 7 11
10
SE01009-501b
Location of fuses
14
SE01009-501a
1 Air cleaner sensor 6 Fuse: ECM 20A (F4) 11 Battery relay

2 Suction air temperature sensor 7 Fuse: computer 20A (F5) 12 Receiver dryer sensor
3 Fusible link 65A (F1) 8 Fuse: key GPS 15A (F6) 13 Battery
4 Fusible link 60A (F2) 9 Swing pilot pressure sensor
5 Fuse: key 15A (F3) 10 Safety relay

Copyright ©
4020-5
Engine Section Layout Diagram
1 2 6
5
8
9 10
12
11
7 SE01009-502
1 Engine coolant temperature sensor 7 Starter motor

2 Boost pressure sensor 8 Engine hydraulic pressure sensor
3 Overheat switch 9 Suction control valve
4 Common rail pressure sensor 10 Fuel temperature sensor
5 EGR valve 11 Cam position sensor
6 Boost temperature sensor 12 Crank position sensor

Copyright ©
4020-6
Main Unit Right Side Layout Diagram (pump chamber)
2
3
14
10
11
12
13
7
5 8
6 9
SE01009-503
1 Charge fuel pump 8 Boosted pressure

2 P1 pressure sensor 9 Travel high speed
3 P2 pressure sensor 10 N1 pressure sensor
4 5 stack solenoid valve 11 P1 flow control proportional valve
5 Power save 12 Horsepower control proportional valve
6 Lever lock 13 N2 pressure sensor
7 Swing lock 14 Oil temperature sensor

Copyright ©
4020-7
Main Unit Center Section Layout Diagram
1 Upper pressure sensor

2 Travel pressure sensor

Copyright ©
4020-8
Cab Layout Diagram 1
1 Air conditioner solar radiation sensor 7 Monitor display 13 Air conditioner control panel
2 Clock 8 12 V socket 14 Emergency stop switch
3 Cigar lighter 9 Wiper motor 15 Rocker switch
4 Knob 10 Radio 16 Gate lock limit switch
5 Wiper controller 11 Throttle volume
6 Rocker switches (4) 12 Key cylinder

Copyright ©
4020-9
1) Controller A
2) Relay
R1 Main relay R5 Horn relay L R9 Room lamp relay
R2 Glow relay R6 Horn relay R R10 Beacon relay
R3 Lamp relay R7 Speaker relay R R11 Starter cut relay
R4 Lamp relay (CAB) R8 Speaker relay L
3) ECM (engine control module)
4) Fuse box
F7 Memory, cab light, car radio (10 A) F17 Fuel filler pump (20 A)
F8 Engine pre-heating (30 A) F18 Clock (10 A)
F9 Optional (10 A) F19 Cigarette lighter, operator’s seat (15 A)
F10 Air conditioning, heater (5 A) F20 DC rectifier (10 A)
F11 Air conditioning condenser fan (15 A) F21 Rotating beacon / Travel Alarm (10 A)
F12 Air conditioning compressor (5 A) F22 Not used (15 A)
F13 Solenoid (10 A) F23 Fuel supply electric pump (10 A)
F14 Windshield wiper/washer (15 A) F24 Not used (15 A)
F15 Horn (10 A) F25 Hydraulic control cancellation (10 A)
F16 Cab light (15 A) F26 Working lights (15 A)
5) Atmospheric pressure sensor
6) TECH II service connector
7) EST service connector
8) Computer A service connector
9) Computer S service connector

Copyright ©
4020-10
Layout Around Operator Seat
Right console
Left console
1 Cup holder
2 Key switch
3 Rocker switch base
4 AM / FM radio
5 Tilt lever
6 Throttle volume
7 Ashtray
8 Air conditioner control panel
9 Gate lever
10 Emergency stop switch

Copyright ©
4020-11
Stand-Alone Parts Diagram
Name No. Shape Circuit Remarks
Safety relay K8 Model: 24 V DC
Battery relay K7 For +24 V DC
Starter motor M1 5.0 kW-24 V
Alternator G2 50 A-24 V
Battery G1
Washer motor M4

Copyright ©
4020-12

Fusible link (F1) F1 Model: 65A
Fusible link (F2) F2 Model: 50A
Fuse box (F3, F3 Model: 20A & 15A

F4, F5, F6)
F4
F5
F6
Throttle volume R3
Starter switch S1 Model: 24 V DC

Copyright ©
4020-13

Fuel level sensor R5
Electromagnetic M20 Model: 24 V DC

pump
Reserve tank S55

limit switch
Vacuum sensor S71
Glow plug R1

Copyright ©
4020-14

EGR motor M15 4JJ1
8
7
EGR position 6
5
sensor B53 4
3
2
1
4HK1-6HK1
5
6
7
8
1
2
3
4
Common rail B52

pressure sensor
Cam angle B50

sensor
Crank angle B49

sensor
Oil pressure B21

sensor
Boost pressure B47

sensor
Boost B51
temperature
sensor

Copyright ©
4020-15

Fuel B3
temperature
sensor
Suction control Y35

valve
Injector
Suction air B6
temperature
sensor
Engine coolant B1
temperature
sensor
Atmospheric B48
pressure sensor
Computer A A1

Copyright ©
4020-16

Relay R Model:
24 V DC
DC-DC U1
converter
Alarm B82
(feed pump)
Feed pump M14
Feed pump S61

switch
Lamp (right side E1 Model:

housing) 24 V 70 W

Copyright ©
4020-17

Lamp (boom) E2 Model:
24 V 70 W
Lamp (cab top) E3 Model:

24 V 70 W
Speakers
(R & L)
Monitor display P4
Pressure B42 Model:

sensors B44 50.0 MPa
(P1) (P2)
Pressure Model:
sensors 5.0 MPa
(N1) (N2) B43
(swing) B40
(upper side) B22
(travel) (arm-in) B26
B27
B33

Copyright ©
4020-18

Pressure switch B28 Model:
(option) 0.49 MPa
(second option)
Pressure switch S61

(filter)
5-way solenoid Y2
valve
Y3
Y4
Y5
Y6
2-way solenoid Y9
valve (knob
Y27
switch type)
2-way solenoid Y9
valve (pedal
Y27
type)

Copyright ©
4020-19

P1 flow control Y11
proportional
valve
Horsepower Y7
control
proportional
valve
Free swing S22 Nor th America

switch Only
CAB seat air X6

suspension
connector
Free swing Y18 Nor th America

solenoid Only
( CX130B/CX160/210/240B)(CN.134)
(CX290B)(CN.133)
Hydraulic oil B2
temperature
sensor

Copyright ©
4020-20

Clock P9
Knob right (with P3 Model:

one-touch with two switches
switch)
Knob right (with P3 Model:

one-touch with four switches
switch)
(short type)
Knob left (with P2 Model:

horn switch and with two switches
radio mute)
Knob left (with P2 Model:

horn switch and with four switches
radio mute)
(short type)
Travel alarm H2 Basic frequency:

2560 Hz
Nor th Amecrica
only

Copyright ©
4020-21

Horn (low) B81 Basic frequency:
370 Hz
Horn (high) B81 Basic frequency:

415 Hz
Diode (washer M4
motor)
Lever lock limit S51

switch
Radio connector X8
Lamp E4 Model: 24 V, 10 W
(room lamp)

Copyright ©
4020-22

Accessory X15 Model: 12 V DC
socket
Cigar lighter E51 Model: 24V
Air conditioner E52

unit
Limit switch S54

(front window)
(door)
Wiper controller A4

Copyright ©
4020-23

Wiper motor M3
Solar radiation B61

sensor
Receiver drier S52

(switch)
Air conditioner Y8
compressor
(magnetic
clutch)
Motor actuator M5
(air mix) (mode)
(recycle /
refresh)
Evaporator B5
sensor

Copyright ©
4020-24

Interior R4
temperature
sensor
Relay K17
(compressor)
(blower OFF)
Blower motor M8
Blower amp A6
Air conditioner P6
switch panel
Option select S14

switch (breaker /
crusher)

Copyright ©
4020-25

Option select
switch (breaker)
Option select
switch (crusher)
2nd speed S35

merge select
switch (2 pumps
flow)
Emergency stop S9
switch
Over load S13 Europe Only

warning

Copyright ©
4020-26

Travel alarm S28 Nor th America
switch Only
Beacon switch S6 Europe Only

Copyright ©
4020-27
Connection Connector Pin Layout
1) Computer A
COMPUTER A
1PIN 12PIN
CN. C4
11PIN 22PIN
1PIN 7PIN
CN. C3
6PIN 12PIN
1PIN 9PIN
CN. C2
8PIN 16PIN
1PIN 14PIN
CN. C1
13PIN 26PIN
RST-05-02-001b

Copyright ©
4020-28
2) Monitor
9PIN 20PIN
1PIN 10PIN
RST-05-02-001a

Copyright ©
4020-29
ELECTRIC CIRCUIT DIAGRAM
List of components
(AS SHOWN ON THE FOLLOWING DIAGRAMS) K11 RELAY-WORKING LIGHT (CAB)
A1 COMPUTER K17 BLOWER OFF RELAY
A2 ENGINE CONTROLLER K30 REFUEL PUMP RELAY
A4 WIPER CONTROLLER K31 REFUEL PUMP STOP RELAY
A6 BLOWER CONTROLLER K32 RELAY, HYDRAULIC FAN
A9 AIR CONDITIONER CONTROLLER K33 MAIN RELAY
B1 COOLANT TEMPERATURE SENSOR K34 RELAY STARTER CUT
B2 HYDRAULIC OIL TEMPERATURE SENSOR K35 RELAY ROOM LAMP
B3 FUEL TEMPERATURE SENSOR K36 RELAY SPEAKER LEFT
B5 EVAPORATOR SENSOR K37 RELAY SPEAKER RIGHT
B6 AIR INTAKE TEMPERATURE SENSOR K38 RELAY HORN LEFT
B21 ENGINE OIL PRESSURE SWITCH K39 RELAY HORN RIGHT
B22 SWING PILOT PRESSURE SWITCH K51 RELAY CONDENSER
B23 BREAKER / CRUSHER PILOT PRESSURE SWITCH M1 STARTER MOTOR
B26 UPPER PILOT PRESSURE SENSOR M3 WIPER MOTOR
B27 TRAVEL PILOT PRESSURE SENSOR M4 WASHER MOTOR
B28 SECOND OPTION PILOT CIRCUIT 1 PRESSURE SWITCH M5 MOTOR (AIR CHANGING)
B42 PUMP PRESSURE SENSOR (P1) M6 AIR VENT DIRECTION CONTROL MOTOR
B43 PUMP PRESSURE SENSOR (NEGA-CONT. P1) M7 MOTOR ACT (AIR-MIX)
B44 PUMP PRESSURE SENSOR (P2) (BLUE BAND) M8 BLOWER MOTOR
B45 OVERLOAD INDICATOR PRESSURE SWITCH M9 AIR CONDITIONER CONDENSER FAN MOTOR
B47 BOOST PRESSURE SENSOR M14 FUEL FEED PUMP MOTOR
B48 AMBIENT AIR (BAROMETRIC) PRESSURE SENSOR M15 EXHAUST GAS RECIRCULATION MOTOR
B49 CRANKSHAFT POSITION SENSOR P1 INSTRUMENT PANEL
B50 CAMSHAFT POSITION SENSOR P2 SWITCH PANEL (LEFT-HAND)
B51 BOOST TEMPERATURE SENSOR P3 SWITCH PANEL (RIGHT-HAND)
B52 COMMON RAIL PRESSURE SENSOR P4 MONITOR DISPLAY
B53 EXHAUST GAS RECIRCULATION VALVE POSITION P5 HOURMETER
SENSOR P6 AIR CONDITIONER CONTROL PANEL
B61 SUNLOAD SENSOR P9 CLOCK
B81 HORN P10 SWITCH PANEL
B82 REFUEL PUMP STOP ALARM R1 GLOW PLUG
E1 WORKING LIGHT (UPPERSTRUCTURE) R3 THROTTLE VOLUME
E2 WORKING LIGHT (ATTACHMENT) R4 THERMISTOR INNER TEMPERATURE
E3 WORKING LIGHT (CAB) R5 FUEL SENSOR
E4 CAB LIGHT S1 KEY SWITCH
E51 CIGARETTE LIGHTER S2 TRAVEL MODE SWITCH
E52 AIR CONDITIONER S4 AUTO IDLE SWITCH
F1 FUSE 65A ; MAIN FUSE FOR F8 TO F26 S6 ROTARY LIGHT SWITCH
F2 FUSE 50A ; MAIN FUSE FOR F1 S9 ENGINE EMERGENCY STOP SWITCH
F2 FUSE 50A ; MAIN FUSE FOR F1 S10 WORKING LIGHT SWITCH
F3 FUSE 15A ; KEY SWITCH AND MAIN FUSE FOR F7 S11 WIPER SWITCH
F4 FUSE 20A ; MAIN RELAY AND ENGINE STOP S12 WASHER SWITCH
F5 FUSE 20A ; COMPUTEUR CONTROL AND INSTRUMENT S13 OVERLOAD SWITCH
PANEL S14 BREAKER / CRUSHER SWITCH
F6 FUSE 15A ; CONTROLLER S S15 HORN SWITCH
F7 FUSE 10A ; MEMORY, CAB LIGHT, RADIO S16 IDLE SWITCH
F8 FUSE 30A ; ENGINE PRE-HEATING S18 COUNTERWEIGHT REMOVAL MAIN SWITCH
F9 FUSE 10A ; OPTION LINE S19 COUNTERWEIGHT RAISING/ LOWERING SWITCH
F10 FUSE 5A ; AIR CONDITIONER HEATER UNIT S20 COUNTERWEIGHT ARM RAISING/LOWERING SWITCH
F11 FUSE 15A ; AIR CONDITIONER BLOWER S22 FREE SWING SWITCH (NORTH AMERICA)
F12 FUSE 5A; AIR CONDITIONER COMPRESSOR S28 TRAVEL ALARM SWITCH (NORTH AMERICA)
F13 FUSE 10A ; SOLENOID S33 OPTION 2 SOLENOID VALVE SWITCH
F14 FUSE 15A; WIPER AND WASHER S34 OPTION 2 SOLENOID VALVE SWITCH
F15 FUSE 10A; HORN S35 CRUSHER OPTION TWO FLOW SOLENOID VALVE
F16 FUSE 15A ; LAMP (BOOM, HOUSE) SWITCH
F17 FUSE 20A; FUEL FILLER PUMP S51 HYDRAULIC FUNCTION CANCELLATION LEVER SWITCH
F18 FUSE 10A ; CLOCK, BACK MONITOR S52 AIR CONDITIONING COMPRESSOR CLUTCH SWITCH
F19 FUSE 15A ; CIGAR. LIGHTER, CAB SEAT S53 DOOR LIMIT SWITCH
F20 FUSE 10A ; DC /DC CONVERTER S54 FRONT WINDOW LIMIT SWITCH
F21 FUSE 10A ; BEACON S55 RESERVE TANK LOW SWITCH
F22 FUSE 15A ; SPARE S56 RESERVE TANK LOW SWITCH
F23 FUSE 10A ; FUEL SUPPLY PUMP S61 REFUEL PUMP SWITCH
F24 FUSE 15A ; SPARE S62 AIR CLEANER SENSOR
F25 FUSE 10A ; LEVER LOCK (GATE) S64 COOLING HYDRAULIC MOTOR SWITCH
F26 FUSE 15A ; LAMP (CAB) S69 RADIO MUTE SWITCH
F34 FUSE BOX S70 HORN VOLUME SWITCH
G1 BATTERY S71 PRESSURE SWITCH FILTER INDICATOR (BREAKER
G2 ALTERNATOR OPTION)
H1 AUDIBLE WARNING DEVICE U1 DC-DC (24V-12V) CONVERTER
H2 TRAVEL ALARM W1 ANTENNA
K2 RELAY-GLOW PLUG X2 ROTARY LIGHT CONNECTOR
K5 RELAY-ROTARY LIGHT X3 OPTIONAL POWER CONNECTOR
K6 RELAY-AIR CONDITIONER CONDENSER FAN X4 ENGINE TEST POINT CONNECTOR
K7 RELAY BATTERY X5 CONTROLLER TEST POINT CONNECTOR
K8 RELAY SAFETY X6 CAB SEAT COMPRESSOR MOTOR CONNECTOR
K9 RELAY-COUNTERWEIGHT REMOVAL X7 LUBRICATOR CONNECTOR
K10 RELAY-WORKING LIGHT (UPPERSTRUCTURE / X8 RADIO CONNECTOR
ATTACHMENT) X9 ANTI-THEFT SYSTEM CONNECTOR
Copyright ©
4020-30
X15 ACCESSORY SOCKET
X23 CLEAR MEMORY 1
X24 CLEAR MEMORY 2
Y2 PILOT PRESSURE SOLENOID VALVE (BLUE BAND)
Y3 SWING BRAKE SOLENOID VALVE (WHITE BAND)
Y4 2 STAGE TRAVEL SOLENOID VALVE (RED BAND)
Y5 POWER-UP SOLENOID VALVE (YELLOW BAND)
Y7 MAIN PUMP POWER PROPORTIONAL SOLENOID
Y8 AIR CONDITIONER MAGNET CLUTCH
Y9 CRUSHER OPTION TWO FLOW SOLENOID VALVE
Y11 MAIN PUMP FLOW PROPORTIONAL SOLENOID
Y12 COUNTERWEIGHT RAISING SOLENOID VALVE
Y13 COUNTERWEIGHT LOWERING SOLENOID VALVE
Y14 COUNTERWEIGHT ARM RAISING SOLENOID VALVE
Y15 COUNTERWEIGHT ARM LOWERING SOLENOID VALVE
Y18 FREE SWING SOLENOID VALVE (NORTH AMERICA)
Y23 OPTION 1 SOLENOID VALVE
Y24 OPTION 1 SOLENOID VALVE
Y25 OPTION 2 SOLENOID VALVE (RED BAND)
Y26 OPTION 2 SOLENOID VALVE (BLUE BAND)
Y27 HAMMER RETURN CIRCUIT SOLENOID VALVE
Y31 COOLING HYDRAULIC MOTOR SOLENOID VALVE
Y32 PROPORTIONAL SOLENOID FOR COOLING HYDRAULIC
MOTOR
Y33 SUPPLY PUMP VALVE (PCV1)
Y34 SUPPLY PUMP VALVE (PCV2)

Copyright ©
4020-31
Option Circuit
Y27
Y9
Y23
Y24
C Y25
K30 K31 S61
Y26
Option line circuit
(Knob Switch Type)
Option line circuit

(Pedal type) Y27
B82
C Y9
B23
M14
B28
B
Option line circuit Refuel Pump
S19 S20
Y12
Y13
Y14
Y15
A
S18
Counterweight removal

Copyright ©
4020-32
NOTES
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Copyright ©
4020-33
Sequence Circuit Diagram
R101
B G1 G2 ACC M ST
Cigar lighter
R103
R102
F19 HEAT G1
YR210 B
OFF
YR212 B712 B711
S1 ACC
F4
F3
YR211 YR211 X6
To KAB. SEAT M14 ON
E51
RW120
ST
RG125
Fuel pump
F23
LgR530
GrR009
WR290
PW230 B753 B700
M RW120
K34
RW121
DC / DC converter PW231 B754
LgR520 B779
BR
BR
U1 B600
F7
WR521
F20 OR220 BG609
6 R157 R150 R11
2 Safety relay
R002
F2 WR003
12 V output RY280 R11
CN45 3 GrR010
LR104 S
B750 B700
12 V output WR281 YR974 R7 YW970
K36 WR003
B K8
R105
CN46 1 R(+) E
Radio BY971
WR282
R(-) BrR523
R
WR291 R8 LW972
ACC X8 LR975
F5
L(+) Y004
F1
B705 B700 BL973 C
5 R152 L(-)
(ACC)
Accessory socket 12V X15 Back-up
B710
W130
GND
R106
BW706 R001
CN47 4 B Starter motor
K37 CLOCK Y004
S M1 E
Y904 Y904
WR293 R8
LG832 Left knob S69
Cab light 70 W P9 S / W (mute)
K11 WR292 R7
LG831 LG
4 7
L852 BG622
E3 R155 R BG
BrR523
Cab light 70 W 2 5 Alternator
F26 R4 G
GrR185 GrR185 GR903 B R153 R9 YL829 YL 8
3 Br016
Y L
F18 LgR160 LgR
6
B797
GrR186 R4 WR824 Boom light 70 W
Y900
1 G015
R G2 E
B740
E2 Monitor 2
R155 R155 R030 R030 B
K10 GW Pulverizer Breaker / crusher switch
House light 70 W
LW180
R3
Y900 L901 B741 P1
17 BG S14 E4
OR853
E1 16
LW
R9
R9
F16
LW180 LW181 WR823 WR
Breaker
OPT 2nd speed S / W Room lamp
Y BG S51 Lever lock L / S Lever lock solenoid Y2
Y BG
LR906
LR906
R3 9 15 S35 K35 OFF
BG
VW170 OR850 B760
Front window L / S (1) LR DOOR VY
YG BG ON
Horn S / W 6
F15 LgW175 LgW176 B722
S54 VY480
R5
G851
S15 20
BG
G G
K2 Glow plug
R1
(L) 14
F8 R2
LgW175 R5 LR907 LR907 B747 BrW BrW525 BrR524 R107 WR020 L021 L021
H 7
K38 LR908
(R) H1 Wiper controller
R6 YR909 B749 GrR
H 3 10
LgW177 YR Washer
R6
LY830 LY
8
18
LR F14
A4 WV841 B742
Computer A 19 BrR190 2 M
1
K39 LR489
CNC1-4
A1 1
W135
Wiper motor
GW228
BG613 GrR
13 VW
M4
YR 7
V809 PL056 PL056 12 VR
CNC2-12 4 8 M
BO450 LR
CNC1-1 PW055 PW055 11
CNC2-4 13 GW
Throttle LY430 5
R3 volume
CNC1-25
WL061
6
GR M3
Y410 CNC2-10
CNC2-7 BrR523
W060
Auto / Manual CNC2-3
WR063 LgR531
S/W CNC3-12
F17 VR866 WR062
CNC3-11
GW215
L867 L868 YL820 CNC2-2
BW064
PB082
X4
R13 CNC4-17
LgR530
GrR337 46 DIAG S/W
L867 R13 WR917 ECM 52
PB082 PB083 BG691
W133 F25 Glow relay
S61 K31 R13
CNC4-22
W132
R112 VW170
BrR339
BrR916
B B759 CNC4-11 R2 10 A2 MEMORY CLEAR
WR521
CNC4-12
W131
W130
LR336
24
32
BrY084 BG692
X23
M14 VR866
R12
B758 CNC4-1 K2
K30 CNC1-8
BrR523
LgR531
RG125 RG125
R1
WR330
2
Main relay
YR332 BG608
R12
CNC1-7
Engine stop S / W WR331 5
21 R1 K33
GW215 LR915 YR333
M
B757
S9 RG126 LG340
47
40
107 L371
WR062
F22
BW064
WL061
CKP
BG694
W140 LG528
DIAGNOSTIC S52 B49
W060
BrW236 BrW236 BrW236 CN9-1 G372
CN9-2 106
VW817 CN9-12
B737 Connector BW689
sensor
CN9-3 PL080 108
F21 BG634 38
LgR532
VY480
GW225 GW226 GW227 R10 VW858 CN9-13 11 4 7 12 2
BG635 P042 W373
CN9-14 99
X4 18 CMP
H2
GW225
A
W840
CNC4-18
K5
PG045
P044
CN9-11 CN9-6 BY069
8 EST PG043 98
L374
sensor
B50
CN9-10 CN9-7 Y065 37 BL687
Free swing 1 connector (B) 100
F13 Travel alarm YL066 B790
4 Magnetic clutch
GR250 GR257 VY806 CN9-8 3 1
PB082 Dust S / W Y8
Y18 CNC4-14 GL910 R12
BG693
BG690
Swing brake SOL GW226
R10 To X2 CN9-9
YR067
6 5
K6 BrR GW980 W981 B 87 W307
Common
beacon C/R PL080 rail
R251 VG800 7
82 L317 B52
Y3 CNC4-6 connector Connection to controller B B720
L318
pressure
Travel 2nd speed SOL P040 P040 P046 A F12 90 sensor
R252 LG801
CNC2-6 C X5 R151 LR205 R R12
BrW556
CN29-18 G327
Y4 CNC4-4
DEUTSCH
B 101
Boosted pressure EST connector (A)
A6
B721
CN28-6 P6 GB363
PG047 PL081 PL080 94 U EGR position B53
Y5
R253 YG802
CNC4-7 CNC2-14
PG041 PG041
D E M8 Filter check 93 GW364
V sensor
Blower amp W557 GR365
Power save P042 P042 CN29-21
A9 92 W
R254 BrG803 Blower motor WG558
Y27 Y6 CNC4-3 PG043 PG043
F11
WR200
R13
LR RL BrY551
CN29-22
M CN29-13
WR360 M15
LG528 LG528 LB550 CN29-12 111 U EGR
F9 LW260 LY807 B23 CNC1-20
F10 103 WB361 V M
CNC4-15 VR547 VW548 WL362
valve motor
OPT 2nd speed R13 CN29-8 110 W
BrY855 VY463
Y9 CNC1-3
VR195
CN28-14
80
WB303
(S31) Knob R Evaporator sensor Oil pressure
GL861 GL861 B714 B
K17 B5 L560 67
Y313 B21
Y23 CN28-2
BY323
sensor
79
(S32) Knob L Fuel sensor Temperature sensor
GL412 BG660
R4 Sb559 RG316 BY Coolant
temp. sensor B1
B713
Y24 GW862 CNC1-15
R5 BG620
CN28-1 84
Computer S CN28-5
(S33) Knob R Air cleaner sensor 83 YG315 BY Fuel B3
Solar radiation sensor temperature sensor
Y25 YL863 B724
CNC1-16 LW471 BG661
S62 P048 RB145
F6
R115
WY563
CN28-7
95
RW304
(S34) Knob L PG049

CNC7-8
CNC7-16
CNC6-1
CNC6-2
B61 WL564
CN28-8
L314
Boost
91 pressure B47
Y26 YG864 B723 Filter indicator CNC6-12
Motor actuator
GR541
CN29-2 GW324 sensor
YL472 BG663 109
GY464
CNC1-17
CNC1-5 S71 CNC6-13
LgR533 (air mix) M
GR312 RL
CNC6-7 G555 74 Boost B51
One-touch IDL
CN29-17 temp. sensor
Air conditioner RW368
YL475 BG610 105
CNC2-15 S16 M7 GW542
S/W
113 RW369
SCV (suction
Y35
CN29-3 panel control valve)
Reserve tank L / S LY540 CN29-1 RG366
89
GrW470 BG662 GL553
CNC2-8 S55 BL549
CN29-15
97 RG367
CN29-11
Anti-theft protection setting knob 121 W350 Injector #1
VG481 BG632
CNC2-16 Motor actuator LY
X9 (mode) YL552 119
L352
CN29-14
B Injector #2
YR543
CN29-4
WB356
114
W400
CNC1-11
Pump horsepower proportional valve M6 M
Y554
YR940 CN29-16
CNC3-3 Injector #3
Y420
B42 P1 sensor CNC1-21
CNC3-6
BY941 Y7 BARO 117
G354
YW544 (atmospheric pressure)
L421 CN29-5
P2 sensor CNC1-9 Pump flow proportional valve sensor
B44 Motor actuator
LR545
CN29-6 W300 116 R351 Injector #4
Lg422 LR942 61
B43 N1 sensor CNC1-22 CNC3-2
(recirculate) M YL310 115
WR357
Br423 CNC3-5
BL943 Y11 LG562 B48 71
B43 N2 sensor CNC1-10 M5 CN28-4
Injector #5
Swing G424 B701 B701 G320
60
B22 P sensor CNC1-23 CNC4-5
CNC4-16
B702 LW546
120
Y353
Upper side V425 CN29-7 G321 L311

B26 P sensor
CNC1-12
CNC4-2
BG601 BG601 VY480
CN28-9
B6 72
Injector #6
Travel YG426 BG602 LgR532 Suction air temperature P355
B27 P sensor
CNC1-24 CNC4-13
Over load CN29-20 sensor 118
Y904 B770
WG488 BG612 CN28-13 1
CNC1-18 S13 B771
GR428 3
B45 HBCV CNC1-26
OL822 OL822 4
B772
sensor CNC4-19 CN28-11
BW440 CNC1-14 BG670
CN28-10 43
BG671
Oil temperature sensor 62
BW451
B2 BrW411 CNC1-2
Front window L / S (2) 81
BG672
VG478 BG615
S54
* Front window L / S (1) and (2) are the same switches.

Copyright ©
4020-34
NOTES
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Copyright ©
4020-35
BLOC DIAGRAM
1) Computer A
Computer A
LR489
CNC1-4 BG613
GW228
V809
A1
Monitor
PL056 PL056
P1
BO450 CNC2-12 4
CNC1-1 PW055 PW055
CNC2-4 13
R3 Throttle volume
LY430
CNC1-25
Y410 WL061 WL061
CNC2-7 CNC2-10 12
W060 W060
Auto / Manual CNC2-3 7
WR063 EST
S/W CNC3-12 connector (B)
F17 VR866 WR062 WR062
GW215 CNC3-11 4
YL820 BW064 BW064 BG694
L867 L868 CNC2-2 11 2
R13 CNC4-17
L867 R13 WR917 Engine stop S / W F4

S61 CNC1-20
LG528 RG126 RG125 R103 R101
R13
BrR916 B759
B W133
CNC4-22
W132 S9
K31 CNC4-11
W131
G1
CNC4-12 F5 BR
W130 W130 LR104
CNC4-1
F21
H2 Safety relay
GW225
A CNC4-18
Travel alarm
CNC1-8
BrR523 BrR523
R
K8
F13 Free swing
GR250 GR257 VY806
Y18 CNC4-14
KEY S / W
Swing brake SOL S1
R251 VG800 Alternator
Y3 CNC4-6 Br016
L
Travel 2nd speed SOL
R252 LG801 CNC1-7
LgR531 G015
R G2
Y4 CNC4-4
Boosted pressure
R253
Y5 YG802
CNC4-7
Power save ECM
Y27 Y6 R254 BrG803
CNC4-3 CNC2-6
P040 P042
18
F9 A2
LW260 LY807
CNC4-15 PG041 PG043
CNC2-14 37
OPT 2nd speed
BrY855 VY463
CNC1-3
Y9
(S31) Knob R
GL861 GL861 B714 B
Y23
(S32) Knob L
GW862 B713 Fuel sensor
Y24 CNC1-15 GL412 BG660
R5
(S33) Knob R
Y25 YL863 B724 Air cleaner sensor
LW471 BG661
(S34) Knob L CNC1-16 S62
Y26 YG864 B723
GY464 Filter indicator
CNC1-17
CNC1-5
YL472 BG663 S71
One-touch IDL
YL475 BG610
CNC2-15 S16
Reserve tank L / S
GrW470 BG662
CNC2-8 S55
Anti-theft protection setting knob
VG481
CNC2-16 BG632
X9
W400 Pump horsepower proportional valve

CNC1-11
YR940
CNC3-3
B42 P1 sensor
Y420 CNC1-21
CNC3-6
BY941 Y7
L421 CNC1-9
B44 P2 sensor Pump flow proportional valve
Lg422 LR942
CNC3-2
B43 N1 sensor CNC1-22
BL943 X11
Br423 CNC1-10 CNC3-5
B43 N2 sensor
Swing G424 CNC1-23 CNC4-5
B701 B701
B22 P sensor CNC4-16
B702
Upper side V425 CNC1-12
B26 P sensor CNC4-2
BG601 BG601
Travel YG426 BG602
B27 P sensor CNC1-24 CNC4-13
Over load
WG488 BG612
CNC1-18
B45 HBCV GR428

CNC1-26
sensor
BW440
S13
CNC1-14 Air conditioner S / W panel
Oil temperature sensor
BW451 BrW411 CNC4-19 OL822 OL822
CN28-11 P6
B2 CNC1-2

Copyright ©
4020-36
2) Computer S
Computer S
F6 15A RB145
CNC6-1
RB CNC6-2
CNC6-12 B
B
CNC6-13
LgR530 LgR533
M CNC6-7
CN54
GW070
CN54-2 CNC7-6
YR074
CN54-8 CNC7-4
GL071
CN54-3 CNC7-14
YL075
CN54-9 CNC7-13
Computer A
PG041
A1 CNC2-14
Computer B
PG047 PG049
CNCR2-14 CNC7-16
PG051
CNA0-23
Computer A
P040
A1 CNC2-6
Computer B
P044 PG049
CNCR2-6 CNC7-16
P042
CNA0-18
RE03003-003

Copyright ©
4020-37
3) ECM (Engine Control Module)
KEY S/W ECM G372

LgR530 LR336 24 L371
ST M 107
Glow relay G370 CKP sensor
LgR338 BrR339 BW689
R2 10 108
R11
GrR009 BrR009 GrR010 GrR337 W373
46
L374 CMP sensor
98
BL687
100
Main relay
BG608 YR332 87 W307
R1 21
YR333 L317 Common rail
40 82
L318
pressure sensor
90
F4 R1
RG125 WR330 G327
2 101
WR331 5
94 GB363 U
Engine stop S / W 93 GW364 EGR position sensor
V
RG126 LG340 92 GR365
47 W
111 WR360 U
DIAGNOSTIC Connector 103 WB361 V M EGR valve motor
CN51 WL362
110 W
BG691 DIAG S/W PB083 PB082 WB303

52 80
CN55 Y313
67 Oil pressure sensor
BG692 MEMORY CLEAR BrY084 79
BY323
32
RG316 BY
84 Coolant temperature sensor
83 YG315 BY
Fuel temperature sensor
RW304
95
91 L314 Boost
Computer A pressure sensor
GW324
109
GR312 RL
P040 P042 74
CNC2-6 18 Boost temperature sensor
PG041 PG043 RW368
CNC2-14 37 105
113 RW369 SCV (suction control valve)
89 RG366
97 RG367
Injector #1
121 W350
L352
119
Injector #2
B356
114
Injector #3
G354
117
BARO
(atmospheric pressure) Injector #4
sensor 116 R351
W300 R357
61 R351 115
116
YL310
71 Injector #5
G320 120 Y353

60
Injector #6
Suction air temperature
sensor 118 P355
G321 L311
72
B770
1
B771
3
B772
4
BG670
43
BG671
62
BG672
81

Copyright ©
4020-38
4) Monitor Display
M4
A4 Wiper controller
Washer
F14 BrR190 2
WV841
M
B742
1
Wiper motor
GrR
13 VW
YR 7
12
8
VR M M3
LR 11
GW
5
GR
6
P1 Monitor Display S14

Breaker / crusher switch
19 WIPER INT OUT1
GW Crusher
18 WIPER CNT OUT2 IN3 CRUSH S / W 17 BG
LW
IN2 BREAKER S / W 16
3 WASHER OUT3 Breaker
S35 OPT 2nd speed
S/W
BG
Y
Computer A IN4 OPT 2ND SPEED 15
CNC2-4
PW055
13 MON TXD UART S54 Front window L / S
A1
PL056 YG BG
CNC2-12 4 MON RXD UART IN1 FRONT WINDOW 6
VG
F5 W130 W135
1 BATT BG
GND 20
F7 R155 Alternator
2 IGN
BrW525
HOUR 7 L
G2
CLOCK
G
P9 8 14 ILUMI
Cab light 70 W
K11 E3
Cab light 70 W
R4
GR903
F26 GrR185 WR824
R4 Boom light 70 W
F16 Y900 B740
LW180 WR823 WR 9 LAMP OUT4
E2
R3
House light 70 W
R3 L901 B741
Y900
K10
F15 LgW175
R6
LY830
8 HORN VOL OUT5 E1
S15 Horn S / W
G851 G B722
K39 R5
(L)
R5 LR907 B747
H
K38 (R)
R6 YR909 B749
H
K39 H1
RE03003-005

Copyright ©
4020-39
5) Air Conditioner
K6 S52 Y8
Dust S / W Magnetic clutch
R12
BrR GW980 W981 B
B720
F12
LR205 R BrW556 BrW556
R12 CN29-18
B721
CN28-6 A9
A6 Filter check
K17 M8 W557
Blower amp CN29-21
Blower motor WG558
F11 R13 CN29-22
WR200 LR RL BrY551
M CN29-13
LB550 CN29-12
F10
VR547 VW548
R13 CN29-8
VR195
CN28-14
Evaporator sensor
L560
B6 CN28-2
Temperature sensor
Sb559
R4 CN28-1
BG620
CN28-5
Solar radiation
WY563
sensor B61 CN28-7
WL564
CN28-8
GR541 GR541
Motor actuator CN29-2
(air mix) M
G555 G555
CN29-17
M7
GW542 GW542
CN29-3
LY540 LY540 CN29-1
GL553 GL553 CN29-15
BL549 BL549
CN29-11
Motor actuator LY
Air conditioner
S/W
(mode) YL552 YL552 CN29-14 panel
B
YR543 YR543
CN29-4
M6 M Front window
Y554 Y554 L/S
CN29-16
BG615
CN28-10
YW544 YW544
CN29-5 S54
LR545 LR545
Motor actuator CN29-6
(recirculate) M
M5 LG562 LG562 CN28-4
S1
LW546 LW546
CN29-7
KEY S / W
LgR530 LgR532
B M CN29-20
Computer A
OL822
CNC4-19 CN28-11
K10 A1
R3 Y900 Y904
CN28-13
Room lamp
OFF
E4
R9 DOOR VY480
LR906 CN28-9
ON
K35
RE03003-006

Copyright ©
4020-40
6) Lever Lock
Lever lock L / S Lever lock solenoid

F25 VW170 OR850 B760
S51 Y2
KEY S / W
S1 BG609 B600
B M ST R11
F3 RW120 R11 Safety relay
K34 GrR010 K7
S
BrR523 B750 B700

R E
Computer A
BrR523
CN1-8
A1 Alternator
Br016
L G2
G015
R
RE03003-007
7) Horn
S15
K38
Horn S / W
F15 LgW175 LgW176 G851 G B722
R5
Horn
Horn (L)
LgW175 R5 LR907 LR907 B747
H H1
LR908
Horn (R)
R6 YR909 B749
H H1
K39 Monitor S / W
LgW177 LY830
R6 CN5-8 P1
RE03003-008

Copyright ©
4020-41
8) Working Light
Cab light 70 W
K11 E3
R4 Cab light 70 W
F26 GrR185 GR903
GrR185
E3
GrR186 R4 WR824
Monitor S / W
F16
LW180 LW181 WR823 E1
R3 CN5-9
R3
House light 70 W
LW180 Y900 L901 B741
E2
K10 Boom light 70 W
Y900 B740
E1
RE03003-009
9) Option
Y27
F9 Breaker
LW260 LW260 LY807 LY807
B23 VY463
OPT(2SP)
LW261 BrY855 LG856 GL858
Y9
(LB856)
S31
OPT1 LEV R-R Knob (R)
LW262 GL861 GL861 B714
Y23
OPT1 LEV R-L

S32 Knob (L)
LW263 GW862 GW862 B713
Y24
S33 Knob (R)

OPT2 LEV L-R
LW264 YL863 YL863 B724
Y25
YL466
S34 Knob (L)

OPT2 LEV L-L
LW265 YG864 YG864 B723
Y26
YG467
GY464
A1
RE03003-010

Copyright ©
4020-42
10) Others
E51 Cigar lighter

F19
YR210 B
YR212 B712 B711

YR211 YR211 To CAB. SEAT X6
M14 Fuel pump

F23
PW230 B753 B700
M
PW231 B754
DC / DC converter
F20 OR220
U1
CN22-6
F7 R150 R157
CN22-2
12 V output RY280
CN45 CN22-3
12 V output WR281
CN46 CN22-1
WR282
B705 B700
CN22-5
Accessory socket 12V X15
BW706
CN47 CN22-4
RE03003-011

Copyright ©
4020-43
11) Electrical Symbol List
Symbol Name Symbol Name

Fuse Variable solenoid valve
Diode Resistor
LED Variable resistor
Toggle switch "a" contact Variable resistor
Push switch "a" contact Alarm
A
Limit switch "a" contact Buzzer
B
Limit switch "b" contact Horn
H
Relay coil Motor
R M
Relay contact "a" contact Solar radiation sensor
R
Relay contact "b" contact Speaker

R
Solenoid valve Lamp

Copyright ©
4020-44
ELECTRICAL CONNECTOR WIRING DIAGRAM
1 Eng. cont. c-2 11 Fix connector (CN.155F) with red tape.

2 Eng. cont. c-1 12 Fix connector (CN.124F) with red tape.
3 White tape 13 Fix connector (CN.T4M) with red tape.
4 Red tape 14 Fix connector (CN.150F) with red tape.
5 Blue tape 15 Fix connector (CN.133F) with red tape.
6 Yellow tape 16 Fix connector (CN.148F) with red tape.
7 Green tape 17 Fix connector (CN.T6F) with red tape.
8 Position of label 18 Fix connector (CN.137F) with red tape.
9 Horn (right) 19 Fix connector (CN.126F) with red tape.
10 Horn (left)
CN.100 Safety relay S, R, E: 3-pin CN.146F Boom lamp harness

CN.101 Safety relay B: 1-pin CN.147F Washer motor
CN.102 Safety relay C: 1-pin CN.148F Washer diode
CN.103 Alternator L, R: 2-pin CN.149F Travel alarm
CN.104 Pump electromagnetic proportional valve: 2-pin CN.150F Beacon harness
CN.109 Pump proportional valve: 2-pin CN.155F Fuel pump harness
CN.111 Pressure sensor P1: 3-pin (no ID tape) CN.105M Battery relay GND
CN.112 Pressure sensor P2: 3-pin (yellow ID tape) CN.108M Safety relay: C
CN.139 Pressure sensor: 3-pin CN.A0F Eng. cont. C-1
CN.106F Pressure sensor: 3-pin CN.A1F Eng. cont. C-2
CN.107F Pressure sensor: 3-pin CN.A3F Engine harness: B
CN.110F Pressure sensor: 3-pin (blue ID tape) CN.A4F Engine harness: C
CN.113F Pressure sensor: 3-pin (red ID tape) CN.A5F Engine harness: D
CN.114F Oil temperature sensor: 2-pin CN.A7F Intake air temp.
CN.115F Lock lever SOL. V: 2-pin (yellow ID tape) CN.A2M Engine harness: A
CN.116F Swing brake SOL. V: 2-pin (white ID tape) CN.A6M Engine harness: E
CN.117F 2-stage travel SOL. V: 2-pin (red ID tape) CN.B1F Cab main harness: A
CN.118F 2-stage relief SOL. V: 2-pin (yellow ID tape) CN.B2F Cab main harness: B
CN.119F Power save SOL. V: 2-pin (green ID tape CN.B3F Cab main harness: C
CN.120F Filter indicator: 2-pin CN.B4F Cab main harness: D
CN.121F Fuel sensor: 2-pin CN.B5F Cab main harness: E
CN.124F Electromagnetic fuel pump: 2-pin CN.B6F Cab main harness: F
CN.125F Reserve tank: 2-pin CN.D12F Reciever drier
CN.126F Vacuum sensor: 2-pin CN.D13F Aircon compressor
CN.127F Housing lamp: 2-pin CN.F1M Fusible link 65 A
CN.128F Swing brake SOL. V CN.F2M Fusible link 60 A
CN.129F 2 stage travel SOL. V CN.F3F Fuse: KEY
CN.130F 2 stage relief SOL. V CN.F4F Fuse: ECM
CN.131F Power save SOL. V CN.F5F Fuse: CONT.
CN.133F Free swing harness CN.F6F Fuse: GPS
CN.134F Filter indcator CN.T4M Lubricator
CN.135F Fuel level sensor CN.T5F Condenser fan
CN.136F Elec. fuel pump CN.T6F Condenser fan diode
CN.137F Elec. fuel pump diode CN.G1 GND G1
CN.138F Reserve tank CN.G2 GND G2
CN.144F House lamp CN.G3 Alternator GND

Copyright ©
4020-45
Main Frame Harness
3
3
12
19
9 18
5
4 3
13
10
6
11 3
15
7
4
3
3 8 3
14 3
17
5 3
4
6
1 2 3
16
KSR11400-E01 KSR11400-E01

Copyright ©
4020-46
CAB
1 Yellow tape 11 Fix connector (CN.79F) with red tape.
2 White tape 12 Fix connector (CN.21F) with red tape.
3 Red tape 13 Fix connector (CN.23F) with red tape.
4 Blue tape 14 Fix connector (CN.9F) with red tape.
5 Position of label 15 Fix pin terminal of circuit no. 481 & 632 with red tape.
Connect pin terminal of circuit no. 524 & 525 and fix with
6 Hour meter 16
red tape.
7 Fuse box KHR16012
8 Immobilizer SW
9 Fix connector (CN.80F) with yellow tape.
10 Fix connector (CN.24F) With red tape.
CN.1F Cab harness: A CN.79F Diode

CN.9F Crane harness CN.80F GPS unit
CN.10F Main relay CN.4M Cab harness: A
CN.11F Glow relay CN.5M Cab harness: B
CN.12F Lamp relay CN.7M Console (R) harness: A
CN.13F Lamp CAB relay CN.8M Console (R) harness: B
CN.14F Horn L relay CN.A8F Swing baro sensor
CN.15F Horn R relay CN.B1M Frame main harness: A
CN.16F Spk. R relay CN.B2M Frame main harness: B
CN.17F Spk. L relay CN.B3M Frame main harness: C
CN.18F Room lamp relay CN.B4M Frame main harness: D
CN.19F Beacon relay CN.B5M Frame main harness: E
CN.22F Dc converter CN.B6M Frame main harness: F
CN.24F Joint connector CN.B7M Option line harness
CN.25F GNDConnector CN.C1F Controller CN-1
CN.20F Starter cut relay CN.C2F Controller CN-2
CN.21F Back monitor CN.C3F Controller CN-3
CN.23F Option power CN.C4F Controller CN-4

Copyright ©
4020-47
Cab Main Harness
2 2 2 2 2
4
11
15
6 2
9
1 16 14
7 2 3
12
10
13 4
KHR16002-E00 KHR16002-E00

Copyright ©
4020-48
Cab Sub Harness
1 Blue tape
2 White tape
3 Red tape
4 Position of label
5 Diag. switch
6 Memory clear
7 Fix connector (CN.50M) with red tape.
CN2F Cab harness: B

CN4F Cab main harness: A
CN5F Cab main harness: B
CN6F Console (L) harness
CN50M J1939 Connector
CN51F Diag. connector
CN52F EST Connector: A
CN53M EST Connector: B
CN54F GPS jumper harness
CN54M GPS service connector

Copyright ©
4020-49
Cab Sub Harness
4
1 7 3
6
1
KHR15992-D01

Copyright ©
4020-50
NOTES
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Copyright ©
4020-51
In Cab
090
to CLOCK HARNESS MONITOR DISPLAY
5 111A 4 138A 3 137A 2 128B 1 120A 9 133A 8 132A 7 124A 6 119A 5 163A 4 130A 3 108A 2 128A 1 129A
0.85Y/R 0.5 L/G 0.5 Y/L 0.5 R 0.5 Lg/R 0.5 W/R 0.5 L/Y 0.85 Br/W 0.5 Y/G 0.5 V/W 0.5 P/L 0.5 Gr/R 1.25 R 1.25 W
12 200B 11 110A 10 109A 9 135A 8 136A 7 123A 6 210E 20 210A 19 106A 18 107A 17 126A 16 125A 15 127A 14 135A 13 131A 12 11 10
0.85 B 0.5 W/Y 0.5 W/L 0.5 G 0.5 L 0.5 Y 0.85B/G 1.25B/G 0.5 L/R 0.5 Y/R 0.5 G/W 0.5 L/W 0.5 Y 0.5 G 0.5 P/W
WIPER CONTROLER
AMP : 172498-1
6 101A 5 100A 4 3 2 105A 1 104A

0.5 G/R 0.5 G/W NC NC 0.5 W/V 0.85Br/R
CLIP *(x 7)
13 108A 12 107A 11 106A 10 200D 9 8 103A 7 102A
0.5 Gr/R 0.5 Y/R 0.5 L/R 1.25 B NC 0.5 V/R 0.5 V/W
EARTH
200A
CN-A 1.25 B
WIPER MOTOR *
YAZAKI : 7323-2262
1
3 101A 2 1 100A
0.5 G/R NC *
*
0.5 G/W
6 103A 5 200C 4 102A
0.5 Y/R 1.25 B 0.5 Y/W

Copyright ©
4020-52
In cab
GPS UNIT A
1 151A 2 151B 3 151C 4 151D 5 166A 6 164A 7 152A 8 154A 9 210G 10 172A 11 169A
1.25R/B 1.25R/B 0.85R/B 0.85R/B 0.5 W/L 0.85 Br/R 0.85 Lg/R 0.5 B/Y 0.85B/G 0.85 L/G 0.85 Y
12 200E 13 200F 14 200G 15 200H 16 167A 17 165A 18 153A 19 168A 20 210H 21 171A 22 170A
1.25 B 1.25 B 0.85 B 0.85 B 0.5 W/Y 0.85 Br/Y 0.5 G/R 0.5 V/Y 0.85B/G 0.85 L/Y 0.85 B/Y
GPS UNIT B
1 174A 2 175A 3 157A 4 161A 5 220A 6 159A 7 210J 8 155A

0.85 L/R 0.85Y/G 0.5 P/L 0.5 Y/R 0.5 B/L 0.5 G/W 0.5 B/G 0.5 P
9 173A 10 176A 11 158A 12 177A 13 162A 14 160A 15 210K 16 156A
0.85L/W 0.5 V/G 0.5 P/W 0.5 V/R 0.5 Y/L 0.5 G/L 0.5 B/G 0.5 P/G
ACCESSORY SOCKET (12V)

141A 140A
0.85B/W 0.85W/R
OPT. LINE SELECT SW OPT. 2SPEED SW

8 1 126A 2 210B 3 125A 10 8 1 2 210C 3 127A 10
0.5 G/W 0.5 B/G 0.5 L/W * 0.5 B/G 0.5 Y
7 4 5 6 9 7 4 5 139A 6 134A 9
0.5 L/G 0.5 Br/Y
Front Rear
3 2
*
MAIN HARNESS A
1 128A 2 129A 3 120A 4 111A 5 104A 6 105A 7 137A 8 138A 9 112A 10 140A
1.25 R 1.25 W 0.5 Lg/R 0.85Y/R 0.85 Br/R 0.5 W/V 0.5 Y/L 0.5 L/G 0.5 L/R 0.85W/R
11 124A 12 130A 13 131A 14 132A 15 133A 16 114A 17 115A 18 116A 19 117A 20 121A 21 210A 22 141A
0.85Br/W 0.5 P/L 0.5 P/W 0.5 L/Y 0.5 V/R 0.5 B/Y 0.5 Y/W 0.5 B/L 0.5 L/W 1.25G/R 1.25B/G 0.85B/W
2
CLIP
MAIN HARNESS C
1 163A 2 164A 3 165A 4 166A 5 167A 6 168A 7 169A 8 170A
0.5 V/W 0.85 Br/R 0.85 Br/Y 0.5 W/L 0.5 W/Y 0.5 V/W 0.85 Y 0.85 B/Y
3 9 171A 10 172A 11 173A 12 174A 13 175A 14 176A 15 177A 16 17 18 200J
MAIN BODY
HARNESS
0.85 L/Y 0.85 L/G 0.85L/W 0.85 L/R 0.85Y/G 0.5 V/G 0.5 V/R NC NC 1.25 B
4
CLIP
MAIN HARNESS B
1 151A 2 152A 3 153A 4 154A 5 155A 6 156A 7 157A 8 158A 9 220A
1.25R/B 0.85Lg/R 0.5 G/R 0.5 B/W 0.5 P 0.5 P/G 0.5 P/L 0.5 P/W 0.5 B/L
10 159A 11 160A 12 161A 13 162A 14 136A 15 122A 16 118A 17 134A 18 139A 19 110A 20 109A
0.5 G/W 0.5 G/L 0.5 Y/R 0.5 Y/L 0.5 L 0.5 V/Y 0.5 V/G 0.5 Br/Y 0.5 L/G 0.5 W/Y 0.5 W/L
*
CLIP
210F 121A
0.5 B/G 1.25G/R
* TO HARNESS ROOF
118A 119A 200A
0.5 V/G 0.5 Y/G 1.25 B
113-D020-A
116A 114A
0.5 B/L 0.5 B/Y to SPEAKER
117A 115A
0.5 L/W 0.5 Y/W
122B 112A to HARNESS ROOM LAMP

0.5 V/Y 0.5 L/R
1 White marking
2 Yellow tape
3 Blue tape
Part number entry the two ends must
4
be pasted on with tape

Copyright ©
4020-53
ENGINE HARNESS
1 2 3 4
0.75 1.25 1.25
G/B R R
5 6 7 8
0.75 0.75
L/R L/Y
H95
H94 6
5
1 2 3 4
0.75 1.25 1.25
L W W
5 6 7 8
1
5 0.75 0.75
B /W L/W G/R 1 2 3 4
0 .7 5 0 . 7 5 0 . 7 5 0 . 7 5
L G/Y G/W G/B
H1 5 6 7 8
0 .7 5 0 . 7 5 0 . 7 5 0 . 7 5
3 L / W W/ L W / B W / R
E80
1 2
0. 75 0. 75
12
B / Y R/ B
3 1 2 3
0. 75 0.75 0.75 0.75
R R/L L R/W E93
1 2
E90
E75
0.75 0.75
B/ Y Y/ G 11
1 7
1 2
0.75 0.75
R / L B/ R
E163
E164 9 1 2
0.75 0.75
4 R/W R/B
1
0 .7 5 E161
G
13
1 2 3
0. 5 0. 5 0. 5
L/ W Br L
1 2 3
0.75 0.5 0.5
E113 B/W V/W Y
2 E112
14
1 2
1 2 3 0.5 0.5
0.75 0.75 0.75
B/Y L/Y W/B
E76 Y V /W
8 E98
10
1 2 3 4
0.5 0.5 0.75 0.5
Y V/W B Y
5 6 7 8
0.5 0.75 0.75 0.75
V/W B/W R/B R/W
4 3 2 1 9 10 11 12
1.25 1.25 0.75 0.75 0.75 0.5
W R W/B L/Y B/ Y L
3 2 1 4 3 2 1 8 7 6 5 13 14 15 16
0. 75 0. 75 0 .7 5 0.75 0 .75 0.75 0 . 7 5 0 . 7 5 0 .7 5 0 . 7 5 0.5 0.5 0.75 0.75
Y / G R/ W R /B G/Y G/W G /B L L / R L/Y L/W Br L/W B/R L 1
6 5 4 8 7 6 5 12 11 10 9 17 18 19 20 5
0. 75 0 .7 5 0.75 0.75 0.75 0.75 0.75 0.75 B/W
G R W/L W/ B W/R G/R G/B R/L
H6 H8 H12 H20 H22
1 Water sensor 6 Injector 2 (# 4. 5. 6) 11 Fuel temperature sensor

2 Common rail sensor 7 Boost pressure sensor 12 EGR valve
3 Glow plug 8 Oil pressure sensor 13 SCV
4 Overheat switch 9 Boost temperature sensor 14 Cam angle sensor (G)
5 Injector 1 (# 1. 2. 3) 10 Crank position sensor

Copyright ©
4020-54
CONSOLE
1) Console Right Harness
CN39F CN36F
CN
0.85
611
WR
0.85
491
LgR
50
2
2 3
80
50
1 CN8F
120
40 330
150
20
120 120 80 540 360 80 475 450 430 410 009 152 120
610 710 211 492 491 971 974
50
YL
50
0.85
R RW
50
YR
CN37F
712 212 711 211 4
B YR 0.85B 0.85YR
CN7F
CN44F CN43F
KHR15971-C01
CN35M
1 Fix connector (CN.44F) with red tape. CN.7F Cab main harness: A CN.37F Knob (right) switch
2 White tape CN.8F Cab main harness: B CN.39F Crane switch
3 Fix connector (CN.43F) with red tape. CN.34F Starter switch CN.43F KAB seat
4 Position of label CN.35M Throttle volume CN.44F Diode
CN.36F Radio
Console Left Harness
1 2 3
KHR15981-C00
1 White tape CN.6M Cab harness CN.29F Air Conditioner panel: B

2 Position of labelPosition of label CN.26F Air Conditioner unit: A CN.30F Limit switch
3 Red tape CN.27F Air Conditioner unit: B CN.31F Engine stop SW
CN.28F Air Conditioner panel: A CN.32F Knob (left) switch

Copyright ©
4021
Section
4021
ENGINE ERROR CODE (DTC)

Printed in France
CNH Lep SC160B4021-0EN July 2007
Copyright ©
4021-2
TABLE OF CONTENTS
Special tools......................................................................................................................................... 4
On-board check procedure for sensors ............................................................................................... 5
DTC: 0087 Common rail low pressure fault (No pressure feed in supply pump)................................ 6
DTC: 0088 Common rail pressure is abnormally high (1st or 2nd stage)......................................... 11
DTC: 0089 Common rail pressure fault (Excessive pressure feed in supply pump) ........................ 14
DTC: 0090 SCV drive system open circuit, +B short or ground short .............................................. 18
DTC: 0107 Barometric pressure sensor circuit fault (low voltage fault) ............................................ 22
DTC: 0108 Barometric pressure sensor fault (high voltage fault) ..................................................... 26
DTC: 0112 IAT (Intake air temperature) sensor fault (low voltage fault)............................................ 30
DTC: 0113 IAT (Intake air temperature) sensor fault (high voltage fault) .......................................... 34
DTC: 0117 Engine coolant temperature sensor fault (low voltage fault) ........................................... 39
DTC: 0118 Engine coolant temperature sensor fault (high voltage fault) ......................................... 44
DTC: 0182 FT (Fuel temperature) sensor fault (low voltage fault) .................................................... 50
DTC: 0183 FT (Fuel temperature) sensor fault (high voltage fault) .................................................. 54
DTC: 0192 Common rail pressure sensor fault (low voltage fault).................................................... 59
DTC: 0193 Common rail pressure sensor fault (high voltage fault) .................................................. 64
DTC: 0201 Open circuit in No.1 injection nozzle drive system ......................................................... 68
DTC: 0219 Overrun............................................................................................................................ 84
DTC: 0237 Boost sensor pressure fault (low voltage fault) ............................................................... 86
DTC: 0238 Boost sensor pressure fault (high voltage fault).............................................................. 90
DTC: 0335 CKP (crankshaft position) sensor fault (no signal).......................................................... 94
DTC: 0336 CKP (crankshaft position) sensor fault (signal fault)....................................................... 98
DTC: 0340 CMP (camshaft position) sensor fault (no signal) ......................................................... 102
DTC: 0341 CMP (camshaft position) sensor fault (signal fault) ...................................................... 106
DTC: 0380 Glow relay circuit fault ................................................................................................... 110
DTC: 0487 EGR position sensor fault.............................................................................................. 115
DTC: 0488 EGR valve control fault.................................................................................................. 119
DTC: 0522 Engine oil pressure sensor fault (low voltage fault) ...................................................... 123
DTC: 0523 Engine oil pressure sensor fault (high voltage fault)..................................................... 127
DTC: 0601 ROM fault....................................................................................................................... 132
DTC: 0603 EEPROM fault ............................................................................................................... 133
DTC: 0606 CPU fault ....................................................................................................................... 134
DTC: 0611 Charge circuit fault (bank 1) .......................................................................................... 135
DTC: 0612 Charge circuit fault (bank 2) .......................................................................................... 137
Lep SC160B4021-0EN Issued 07-07

Copyright ©
4021-3
DTC: 1093 No pump pressure feed................................................................................................. 139
DTC: 1095 Pressure limiter open .................................................................................................... 144
DTC: 1112 Boost temperature sensor fault (low voltage fault) ........................................................ 150
DTC: 1113 Boost temperature sensor fault (high voltage fault)....................................................... 155
DTC: 1173 Overheat ........................................................................................................................ 159
DTC: 1261 Injection nozzle common 1 drive system fault .............................................................. 163
DTC: 1262 Injection nozzle common 2 drive system fault .............................................................. 169
DTC: 1345 CMP (camshaft position) sensor out of phase.............................................................. 175
DTC: 1625 Main relay fault .............................................................................................................. 177
DTC: 1630 A/D conversion fault....................................................................................................... 182
DTC: 1632 Voltage fault in 5 V power supply 2 ............................................................................... 183
DTC: 2104 CAN Bus fault ................................................................................................................ 195
DTC: 2106 CAN time out fault ......................................................................................................... 198

Copyright ©
4021-4
SPECIAL TOOLS
CNH-EST DIAGNOSTIC TOOL (SCAN TOOL)
The EST (Electronic Service Tool) system allows diagnoses on machines and engines by detecting the
operating parameters of electronic control components (control units, sensors etc.). It is also capable of
reading fault codes.
To use this tool, please refer to the book provided during the CXB series training sessions.
BREAKER BOX AND DMM
Name
1. Breaker box
2. DMM

Copyright ©
4021-5
ON-BOARD CHECK PROCEDURE FOR SENSORS
Name
1. Coupling connector between
engine - the machine
2. Machine harness
3. Sensor connector
4. Engine harness
A. Disconnect the coupling connector, and check the sensor from engine harness connector.
B. Disconnect the connector from sensor, and short the wiring of sensor connector.
C. Check the harness from coupling connector for open circuit.
• If both steps 1 and 2 are faulty, repair the harness.
Check from step 1 again.
• If only step 1 is faulty, replace the sensor.

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4021-6
DTC (error code): 0087 Common rail low pressure fault (No pressure feed in supply pump)
• Intense engine vibration

• Rough idling
• Output lowering
• Black smoke emitted
• Excessive output is possible.
Step 1
Perform the Service Support check.
Step 2
Is the procedure completed? No Go to
Check the fuel system in the following
procedure. Service Support check.
1. Check the high pressure pipe and low Yes
pressure pipe for looseness in the
connection (fuel leakage), crush or clogging.
2. Check the fuel pipe, fuel filter, and inside of
the fuel tank for freeze or waxing. (at cold No Is the fuel system normal?
temperature)
3. Check the feed pipe inside the fuel tank for
clogging of foreign matter.
Yes
Step 3
Repair or replace the faulty parts.
Is the procedure completed?
Yes
Go to Step 18.
Step 4
Check for rise of fuel level in the oil level gauge
or light oil odor.
No Is the trouble detected?

Step 5
Check the connection of the fuel pipe in each Yes
injector, and replace the injector if oil leakage
is confirmed.
Note:
For work procedure, refer to “Engine section” in
the service manual.
Yes
Go to Step 18.
Step 7
Check the injector.
1. Clear the DTC.
Step 6 No
Refer to the screen of DIAG (Trouble
Is the scan tool (KW communication) Go to Step 20.
Diagnosis) in the Service Support for how to
available?
clear DTCs.
2. Start the engine.
3. Select the “Boost temperature sensor” from
the menu.
4. Select the “Injection stop at each injector” in
the “Common rail system”.
Is there any cylinder of which engine
5. Press the “OFF” soft key to stop the fuel No
injection in the cylinder one by one, and vibration and engine sound did not
check the change in engine sound. change when it is stopped?
Yes
Go to Step 9.
Step 8
Replace the injector in the cylinder of which
engine sound did not change when it is
stopped.
Note:
the service manual.
Yes
Go to Step 18.
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4021-7
Step 9
From Step 7
Check the common rail pressure.
1. Turn the key switch to “ON”.
2. Check for “Common rail pressure” on the
data display using scan tool.
3. Start the engine and run it at idle.
4. Check for “Differential fuel rail pressure” on
the data display using scan tool. Specified value
5. Race it quickly about 5 times. At engine stopped: Differential pressure
6. Check for “Differential fuel rail pressure” on -30 MPa
the data display using scan tool. At idling, racing: ±5 Mpa
No
Is “Differential fuel rail pressure”
within the specified value?
Step 10
Yes
Go to Step 16.
1. Turn the key switch to “OFF”.
2. Disconnect the common rail pressure sensor
connector.
4. Check for “Common rail pressure sensor” on
the data display using scan tool. Specified value
4.8V
Is the “Common rail pressure sensor”
No
the specified value or more?
Yes
Step 11
1. Check the signal circuit between common
rail pressure sensor and ECM for short
circuit to signal circuits of other sensors
using breaker box or DMM.
2. If the trouble is detected, repairs as required. No Is the trouble detected?
Step 13 Yes
Go to Step 18.
Check the version of ECM software.
1. Refer to “Flash Tool (EMPS)” in this section
for check and rewriting of ECM.
2. Rewrite the software if version upgraded is
Step 12
necessary. No
Note: Is EMPS available?
EGR valve position learning is required after
replacing or rewriting the ECM. Yes
[EGR valve position learning procedure]
3. Wait for 10 seconds or more.
No Is the procedure completed?
Step 14
Replace the ECM. Yes
Note: Go to Step 1.
replacing or rewriting the ECM.
2. Turn the key switch to “OFF”. No Is the procedure completed?
Yes
Go to Step 16.
Step 15
Replace the common rail (common rail
pressure sensor).
Yes
Go to Step 18.

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4021-8
Step 16 From Step 14

Clear the DTC.
1. Refer to the screen of DIAG (Trouble
clear DTCs.
Specified value
the menu.
±5MPa
4. Select the “Rail pressure control” in the
No Is “Differential fuel rail pressure” within
Common rail system”.
the specified value?
5. Press the “Up” soft key to check the value of
“Differential fuel pressure”.
Yes
Step 17
Replace the supply pump.
Step 18
Check the DTC again. Is the procedure completed?
1. Connect all the harnesses.
2. Clear the DTC. Yes
clear DTCs.
3. Turn the key switch to “OFF” for 10 seconds
or more. No Is DTC:0087 detected?
4. Test run with the “Preconditions when DTC
is set”.
Yes
5. Check the DTC. Go to Step 2.
Step 19
Check if DTC is detected.
Is other DTC detected? No

Verify repair.
Yes
Go to each DTC diagnosis.
Step 20 From Step 6

Use the injector checker to stop injection in the
injector, and check the change in engine
sound.
No vibration and engine sound did not
Step 21 change when it is stopped?
Replace the injector in the cylinder of which
engine sound did not change when it is Yes
stopped.
Note:
the service manual.
Step 22
Yes
1. Turn the key switch to OFF.
connector.
3. Measure the voltage between the common
Specified value
rail pressure sensor power supply terminal
4.8V
and the ground.
No Is the DMM indication the specified value
or more?
Yes
Go to Step 23. Go to Step 24.

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4021-9

1. Check the signal circuit between common
rail pressure sensor and ECM for short
using Breaker box or DMM. No
2. If the trouble is detected, repair as required. Is the trouble detected? Go to Step 12.
Yes
Go to Step 18.
From Step 22
Step 24
Check the DTC again.
2. Clear the DTC.
Diagnosis) in the Service Support for how to No Is DTC:0087 detected?
clear DTCs.
or more. Yes
5. Test run with the “Preconditions when DTC Go to Step 17.
is set”.
6. Check the DTC.
Go to Step 19.
Block diagram

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4021-10
Diagnostic aid
Followings are suspected as the cause.
• Injector internal trouble
• Supply pump internal trouble
• Air in the fuel system
• Fuel system pipe fault (fuel leakage, clogging, crush, etc.)
• Fuel filter fault (clogging)
• Fuel tank fault (clogging)
• Pressure limiter trouble (operation under specified pressure, degradation of sealability)
• ECM trouble
• Common rail pressure sensor trouble
Breaker box inspection procedure

Perform the inspection in the following procedure if there is such an instruction to use breaker box in the step.
After inspection, return to the diagnostic step.
Step Item to be Inspection Measuring condition Breaker box Normal Abnormal

checked method terminal No. Value value
11, 23 Short circuit to Voltage • Disconnect the 82-Ground 0V 1V
other signal circuit measurement sensor connector 90- Ground or more
• Key switch “ON”

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4021-11
DTC (error code): 0088 Common rail pressure is abnormally high (1ｓt or 2nd stage)
• Rough idling
• Output lowering
• Engine blow up fault
Step 1
Step 2 Is the procedure completed? No Go to

1. Start the engine. Service Support check.
2. Check the DTC. Yes
3. Are the fuel-related parts only just replaced?
Air bleeding may not be performed
sufficiently after replacing fuel-related parts.
Bleed air again. Check the DTC after
bleeding air. No
Is any of the DTC:0088, 0192, 0193, or
1635 detected?
Yes Go to the relevant

DTC detected.
Step 4
1. Turn the key switch to “OFF” for 30 seconds Step 3
No
or more. Is the scan tool (KW communication)
2. Start the engine. available?
the data display using scan tool. Yes
Step 5 Specified value

1. Check the fuel return pipe between the Differential pressure ±5 MPa
supply pump and the fuel tank for breakage, (at idle) No
twist, etc. Is “Differential fuel rail pressure” within Go to “Diagnostic aid”.
2. Check for clogging or twisting in the vent the specified value?
hose of the fuel tank.
3. Check for foreign matter in the fuel tank.
4. If the trouble is detected, repair as required.
Yes
Step 6
1. Replace the common rail (common rail No Is the procedure completed?
pressure sensor) since it seems that
abnormal value of the pressure sensor is
detected. Yes
Note:
the service manual.
2. Check the DTC.
Step7 No Is the trouble detected?

Note: Yes
the service manual.
Step8
Check the DTC again. Yes
2. Clear the DTC.
Diagnosis) in the Service Support for how to No
Is DTC:0088 detected?
clear DTCs.
or more.
Yes
Go to Step 9.
is set”.
6. Check the DTC. From Step 8

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4021-12
Step 9
Check if other DTC is detected.

Verify repair.
Yes
Block diagram
Preconditions when DTC is set.

1st stage
• Key switch input voltage is 18V or more.
• DTC: 0088, 0192, 0193, or 1635 is not detected.
• Actual rail pressure is 2 MPa or more and 70 min-1 or more.
2nd stage
• Key switch input voltage is 18 V or more.
• Actual rail pressure is 2 MPa or more and 70 min-1 or more.
Diagnostic aid
If the intermittent trouble is suspected, followings may be the cause.
Lep• Improper
SC160B4021-0EN
connection of harness connector Issued 07-07
• Defective harness routing
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4021-13

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4021-14
DTC (error code): 0089 Common rail pressure fault (Excessive pressure feed in supply
pump)
• Rough idling
• Output lowering
Step 1

Step 2 Service Support check.
1. Start the engine. Yes
2. Check the DTC.
Is any of the DTC: 0089, 0192, 0193, or

No
1635 detected?
Yes Go to each
DTC diagnosis.
Step 4 Step3
1. Turn the key switch to “OFF” for 30 seconds Is the scan tool (KW communication) No
or more. available? Go to Step 12.
3. Check for “Differential fuel rail pressure” on Yes
the data display using scan tool.
Specified value
Differential pressure: ±5 MPa
Step 5
Is “Differential fuel rail pressure” within
1. Turn the key switch to “OFF”. No the specified value?
2. Wait for 2 minutes before the common rail
internal pressure goes down.
3. Turn the key switch to “ON”. Do not start Yes
engine. Go to “Diagnostic aid”.
Step 6
2. Disconnect the SCV connector. Specified value
3. Check the SCV harness connector terminal Differential pressure: -30 MPa
for poor contact, intermittent trouble, etc.
No Is “Differential fuel rail pressure” the
4. Disconnect the ECM harness connector. specified value?
5. Check the ECM harness connector terminal
for poor contact, intermittent trouble, etc. Yes
Step 7 Is the trouble detected? No

Go to Step 9.
2. Disconnect the common rail pressure sensor Yes
connector. Go to Step 10.
3. Check the common rail pressure sensor
harness connector terminal for poor contact
intermittent trouble, etc.
4. Disconnect the ECM harness connector.
5. Check the ECM harness connector terminal No Is the trouble detected?
for poor contact, intermittent trouble, etc.
6. If the trouble is detected, repair as required. Yes
Go to Step 10.
Step 8
pressure sensor).
Note:
the service manual.
Yes
Go to Step 10.

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4021-15
Step 9
From Step 6
Note:
the service manual.

Step 10
1. Connect all the harnesses. Yes
2. Clear the DTC.
No Is DTC: 1093 detected?
clear DTCs.
4. Turn the key switch to “OFF” for 10 seconds Yes
or more. Go to Step2.
is set”.
6. Check the DTC.
Is other DTC detected?

No
Verify repair.
Step 11
Check if other DTC is detected. Yes
Step 12 Go to each DTC diagnosis.

1. Visually check the harness between the
ECM and the common rail pressure sensor
for damage.
Is the procedure completed? No
Go to Step 5.
Yes
Go to Step 5.

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4021-16
Block diagram

• Key switch input voltage is 18V or more.
• Engine coolant temperature is 60 °C or more and 375 min-1 or more.
• Duty to SCV is 40 % or less, or SCV target pressure feed is 90 mm3/sec or less.

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4021-17
Diagnostic aid
• Improper connection of harness connector
• Worn harness cladding
• Wire disconnection inside harness cladding
Following inspections are necessary to detect these causes.
• Improper connection of harness connector and ECM connector
– Poor connection of terminal from connector
– Unmatched terminals are fitted.
– Damage of connector lock
– Poor contact between terminal and wire
• Damaged harness
– Visually check the harness for damage.
– Check the relevant items on the scan tool data display while moving the connector and the harness
which are related to the sensor. The variation of the display indicates the faulty part.

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DTC (error code): 0090 SCV drive system open circuit, +B short or ground short
• Engine stall and/or engine blow up are possible

depending on the condition of open/short circuit.
• Excessive output
Step 1

No Go to
Service Support check.
Yes
Step 2
No
Is the scan tool (KW communication)
Step 3
available?
1. Connect the scan tool.
3. Check for “SCV F/B” on the data display
Yes
using scan tool.
Specified value
No 50mA
Is the “SCV F/B” the specified value or
less?
Step 4
1. Check for followings in the circuit between Yes
SCV and ECM using breaker box or DMM.
Refer to “Breaker box inspection procedure”.
Note:
If breaker box is not available, refer to
“On-board check procedure for sensors”. Is the trouble detected?
No
• Short circuit to ground
• Open circuit
• High resistance Yes
2. If the trouble is detected, repair or replace as Go to Step 12.
required.
Step5
1. Check for followings in the circuit between
SCV and ECM using breaker box or DMM.
Note:
“On-board check procedure for sensors”.
• Short circuit between terminals Is the trouble detected?
• Short circuit to power supply circuit or No
ignition power supply circuit
2. If the trouble is detected, repair or replace as
required.
Yes
Go to Step 12.
Go to Step 6.

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4021-19
From Step 5
Step 6
Check the SCV body.
2. Remove the harness from the SCV.
3. Measure the resistance between the SCV Specified value
connector terminals. Between terminals: 3.2±0.3 Ω;
Each terminals to SCV body: ∞Ω
No (at nomal temperature )
Is the resistance specified value?
Step 7
Replace the supply pump (SCV). Yes
Note:
the service manual.
Step 8
3. Refer to the screen of DIAG (Trouble Go to Step 12.
clear DTCs.
or more.
is set”.
6. Check the DTC.
Is DTC:0090 detected? No
Go to “Diagnostic aid”.
Step 10
1. Check the version of ECM software. Yes
Refer to “Flash Tool (EMPS)” for check and Step 9
rewriting of ECM. No
2. Rewrite the software if version upgraded is Is EMPS available?
necessary.
Yes
Note:
replacing or rewriting the ECM. No Is the procedure completed?
2. Turn the key switch to “OFF”. Yes
Step 11
Replace the ECM.
Note:
replacing or rewriting the ECM. Is the procedure completed?
No Is DTC:0090 detected?
Step 12
Go to Step 2.
2. Clear the DTC.
clear DTCs.
or more.
is set”. Is other DTC detected? No
6. Check the DTC. Verify repair.
Step 13 Yes

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4021-20
Block diagram
Diagnostic aid
• Damaged harness

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4021-21
Perform the inspection in the following procedure if there is such an instruction to use breaker box in the
step.
Step Item to be checked Inspection Measuring condition Breaker box Terminal Normal Abnormal
method No. value value
4 Open circuit/ Resistance • Disconnect the 105 – SCV terminal 5Ohm or 10 Mega
high resistance measurement SCV connector. 113 – SCV terminal less Ohm
• Key switch “OFF” 89 – SCV terminal or
97 – SCV terminal more
Short circuit to Resistance • Disconnect the 105 – Ground 10 Mega 100 Ohm
ground measurement SCV connector. 113 – Ground Ohm or
• Key switch “OFF” 89 – Ground or less
97 – Ground more
5 Short circuit Resistance • Disconnect the 105 – 89 10 Mega 100 Ohm

between terminals measurement SCV connector. 105 – 97 Ohm or
• Key switch “OFF” 113 – 89 or less
113 – 97 more
Short circuit to Voltage • Disconnect the 105 - GND 0V 18V

power supply measurement SCV connector. 113 - GND or
circuit • Key switch “ON” 89 - GND more
97 - GND
Short circuit to Voltage • Disconnect the 105 - GND 0V 1V

other signal circuit measurement SCV connector. 113 - GND or
• Key switch “ON” 89 - GND more
97 - GND

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4021-22
DTC (error code): 0107 Barometric pressure sensor circuit fault (low voltage fault)
Due to back-up equivalent to 2,000 m
• Black smoke emitted at high altitude

• Output lowering at low altitude
Step 1
Perform the
Step 3 Is the procedure completed? No
Check the value for barometric pressure
sensor using scan tool. Yes
3. Check the value for “Barometric pressure
Step 2
sensor” using scan tool.
Is the scan tool (KW communication) No
available? Go to Step 14.
Step 4
Check for installation condition of the Yes
barometric pressure sensor, ECM and coupling
connector.
1. Check for play or looseness in the
connection. Specified value
2. If the trouble is detected, repair or 0.5V
replace as Is the “Barometric pressure sensor” No Go to
required the specified value or less? “Diagnostic aid”.
Step 5
2. Disconnect the barometric pressure sensor
connector.
3. Short between the barometric pressure
sensor connector power supply terminal and
the signal terminal using jump cable.
4. Turn the key switch to “ON”. Yes
5. Check the value for “Barometric pressure Go to Step 9.
Specified value
Step 6 4.8V
1. Check for followings in the power supply Is the “Barometric pressure sensor”
circuit between ECM and barometric No
pressure sensor using breaker box or DMM.
Refer to “Breaker box inspection procedure.”
Yes
Note: Go to Step 8.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace as No Is the trouble detected?
required.
Yes
Step 7 Go to Step 9.
1. Check for followings in the signal circuit
between ECM and barometric pressure
sensor using breaker box or DMM.
Refer to “Breaker box inspection procedure”. No
Note: Is the trouble detected?
“On-board check procedure for sensors”. Yes
• Short circuit to barometric pressure sensor Go to Step 12.
ground circuit
• Open circuit Go to Step 9.
• High resistance
required.

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4021-23
From Step 5 and 17 From Step 4 and 6

Step 8
Replace the barometric pressure sensor.
Go10to Step 9.
Step
1. Check the version of ECM software.
Refer to “Flash Tool (EMPS)” for check and Is the procedure completed?
rewriting of ECM.
necessary. Yes
Note:
[EGR valve position learning procedure] Step 9
No Is EMPS available?
3. Wait for 10 seconds or more. Yes
Step 11
Replace the ECM.
Note: Is the procedure completed?
Yes
Step 12 Is the procedure completed?

clear DTCs.
4. Turn the key switch to “OFF” for 10 seconds No Is DTC: 0107 detected?
or more.
is set”. Yes
Step 13

Verify repair.
Yes
From Step 2
Step 14
2. Check the display of barometric pressure.
Specified value No Go to
Step 15 127kPa (error value) “Diagnostic aid”.
Check for installation condition of the Does the display of “Barometric pressure”
barometric pressure sensor, ECM and coupling show error value?
connector. (Check the barometric pressure
sensor circuit for open circuit or ground short.) Yes
1. Check for disconnection, play or looseness
in the connection.
2. If the trouble is detected, repair or replace as Is the trouble detected?
No
required.
Yes
Go to Step 16.

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4021-24
From Step 15
Step 16
1. Check for followings in the power supply
circuit between ECM and barometric
Note:
• Open circuit No Is the trouble detected?
• High resistance
required. Yes
Go to Step 12.
Step 17
Refer to “Breaker box inspection
procedure”.
Note:
• Short circuit to barometric pressure sensor
ground circuit
• Open circuit Yes
• High resistance Go to Step 12.
required.
Go to Step 8.
Block diagram

• DTC: 1630 or 1632 is not detected.

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4021-25
Diagnostic aid
• Damaged harness
– Check the relevant items on the scan tool data display while moving the connector and the harness which
are related to the sensor. The variation of the display indicates the faulty part.

Step Item to be checked Inspection Measuring condition Breaker box Normal Abnormal
method Terminal No. value value
61 – Sensor 100Ω 10MΩ
Open circuit/ Resistance • Disconnect the connector power
6, 16 high resistance measurement sensor connector. supply terminal or less or more
• Key switch “OFF”
71 – 60 10MΩ 100Ω
Short circuit to Resistance • Disconnect the
7, 17 ground circuit/ measurement sensor connector. 71 – GND or more or less
ground • Key switch “OFF”
Open circuit/ Resistance • Disconnect the connector signal
high resistance measurement sensor connector. terminal or less or more

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4021-26
DTC (error code): 0108 Barometric pressure sensor fault (high voltage fault)

• Output lowering at low altitude
Step 1
Step 3 Perform the

Check the value for barometric pressure Service Support check.
sensor using scan tool.
1. Connect the scan tool. Yes
sensor” using scan tool. Step 2
No
Step 4 available?
Check for installation condition of the
barometric pressure sensor, ECM and coupling Yes
connector.
2. If the trouble is detected, repair or replace as 3.8V
required. Is the “Barometric pressure sensor” No Go to
Step 5 “Diagnostic aid”.
connector.
3. Turn the key switch to “ON”. No Is the trouble detected?
Yes
Go to Step 12.
Step 6
1. Check the signal circuit between ECM and
barometric pressure sensor for short circuit
to the power supply circuit or ignition power
supply circuit using breaker box or DMM. Specified value
Refer to “Breaker box inspection procedure”. 0V
Note: Is the “Barometric pressure sensor”
No
If breaker box is not available, refer to the specified value or less?
On-board check procedure for sensors”.
Important: Yes
If the barometric pressure sensor circuit is Go to Step 8.
shorted to the power supply circuit, the sensor
may be broken.
required.
Yes
1.Check for followings in the ground circuit
• High resistance
required. Go to Step 9.

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4021-27
Step 8
From Step 5 and 17 From Step 7
Replace the barometric pressure sensor.
Step 10
1. Check the version of ECM software. Is the procedure completed?
Refer to“Flash Tool (EMPS)” for check and
rewriting of ECM.
2. Rewrite the software if version upgraded is Yes
necessary.
Note:
replacing or rewriting the ECM. Step 9
No
[EGR valve position learning procedure] Is EMPS available?
Step 11
Replace the ECM. No Is the procedure completed?
Note:
Yes
Step 12
2. Clear the DTC.
clear DTCs. No Is DTC:0108 detected?
or more.
5. Test run with the “Preconditions when DTC Yes
is set”. Go to Step 2.
6. Check the DTC.
Step 13
No
Is other DTC detected? Verify repair.
Yes
Step 14 From Step 2

2. Check the display of barometric pressure.
Specified value
127kPa
Step 15 (error value)
Check for installation condition of the No
Does the display of “Barometric pressure”
barometric pressure sensor, ECM and coupling Go to
show error value?
connector. “Diagnostic aid”.
(Check the barometric pressure sensor circuit
for short to +5V line or battery power supply Yes
circuit.)
connection. No Is the trouble detected?
required.
Yes
Go to Step 16.

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4021-28

barometric pressure sensor for short circuit
supply circuit using breaker box or DMM.
Note:
Important:
If the barometric pressure sensor circuit is
may be broken. No Is the trouble detected?
Yes
1. Check for followings in the ground circuit
sensor
using breaker box or DMM. Refer to
“Breaker box inspection procedure”.
Note:
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace as Yes
Go to Step 8.
Block diagram


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4021-29
Diagnostic aid
• Damaged harness

Step Item to be checked Inspection Measuring condition Breaker box Normal Abnormal
method Terminal No. value value
0V 18V
6,16 power supply circuit measurement sensor connector. 71 – Ground or more
100Ω 10MΩ
Open circuit/ Resistance • Disconnect the 60 – Sensor
7,17 high resistance measurement sensor connector. connector ground or less or more
• Key switch “OFF” terminal

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4021-30
DTC (error code): 0112 IAT (Intake air temperature) sensor fault (low voltage fault)
• White smoke emission possible when

starting at low temperatures
Step 1
Perform the
Yes
Step 3 Step 2
Check the value for IAT sensor using scan tool. No
1. Connect the scan tool. available?
3. Check the value for “Intake air temperature
Yes
Specified value
Step 4 0.1V
Check for installation condition of the IAT Is the “Intake air temperature sensor” less No
sensor, ECM and coupling connector. than the specified value? Go to “Diagnostic aid”.
connection. Yes
required.
Step 5
Yes
1. Turn the key switch to “OFF”. Go to Step 11.
2. Disconnect the IAT sensor connector.
Specified value
4.8V
Step 6
1.Check for followings in the signal circuit No Is the “Intake air temperature sensor”
more than the specified value?
between ECM and IAT sensor using breaker
box or DMM. Yes
Note:
• Short circuit to IAT sensor ground circuit
• Short circuit to ground No Is the trouble detected?
required.
Yes
Go to Step 11.
Step 7
Replace the IAT sensor.
Yes

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4021-31
Step 9 From Step 6
Refer to “Flash Tool (EMPS)” for check and
rewriting of ECM.
necessary. Step 8
No
Step 10
Replace the ECM.
Note:
Yes
3. Wait for 10 seconds or more. Is the procedure completed?
Step 11 Yes
2. Clear the DTC.
clear DTCs.
or more. Yes
is set”.
6. Check the DTC.
Step 12

Verify repair.
Yes
Step 13
From Step 2
2. Check the display of intake air temperature.
Specified value
Step 14 214°C
Check for installation condition of the IAT (error value)
No
sensor, ECM and coupling connector. (Check Does the display of “Intake air temperature” Go to “Diagnostic aid”.
the IAT sensor circuit for ground short.) show error value?
connection. Yes
required.
No Is the trouble detected
Yes
Go to Step 11.
Go to Step 15.

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4021-32
From Step 14
Step 15
1.Check for followings in the signal circuit
box or DMM.
Refer to “Breaker box inspection procedure”. No Id the trouble detected?
Note:
• Short circuit to IAT sensor ground circuit Go to Step 11.
required.
Go to Step 7.
Block diagram
Recovery from failure.

• Fault judgement needs 3 to 10 minutes.

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4021-33
Diagnostic aid
• To make sure the correct performance of the IAT
sensor, check with various temperatures using the
reckoner table between temperature and resistance.
If the sensor is faulty, operationality may be affected.
If the intermittent trouble is suspected, followings may
be the cause.
Following inspections are necessary to detect these
causes.
• Damaged harness
– Check the relevant items on the scan tool data display
while moving the connector and the harness which are related to the sensor. The variation of the display
indicates the faulty part.

checked method Terminal No. value value
72 – 60 10MΩ 100MΩ
6,15 ground circuit/ measurement sensor connector. 72 – Ground or more or less
ground
Intake air temperature - resistance table

1000
100
10
)
Resistance(
0.1
0.01
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Intake air temperature( ) E0112-5

Copyright ©
4021-34
DTC (error code) :0113 IAT (Intake air temperature) sensor fault (high voltage fault)
• White smoke emission possible when

starting at low temperatures
Step 1
Perform the
Check the value for IAT sensor using scan tool.
Yes
Step 2
No
Step 4 available?
Check for installation condition of the IAT
sensor, ECM and coupling connector. Yes
connection.
2. If the trouble is detected, repair or replace as Specified value
required. 4.95V
Is the “Intake air temperature sensor”
No
Step 5 Go to “Diagnostic aid”.
2. Disconnect the IAT sensor connector.
Yes
3. Short the IAT sensor connector signal
terminal to the ground terminal using jump No Is the trouble detected?
cable.
5. Check the value for “Intake air temperature Yes
sensor” using scan tool. Go to Step 13.
Step 6
Specified value
IAT sensor for short circuit to the power
0V
supply circuit or ignition power supply circuit
Is the “Intake air temperature sensor”
using breaker box or DMM. No
the specified value or less?
Note:
If breaker box is not available, refer to Yes
Go to Step 9.
Important:
If the IAT sensor circuit is shorted to the power
supply circuit, the sensor may be broken.
2. If the trouble is detected, repair as required. No Is the trouble detected?
Step 7 Yes
1. Check for followings in the signal circuit Go to Step 13.
box or DMM.
Note:
“On-board check procedure for sensors”. No Is the trouble detected?
• Open circuit
• High resistance
Go to Step 8.

Copyright ©
4021-35
From Step 7
Step 8
box or DMM.
Note:
• Open circuit
• High resistance
required. Yes
Step 9 From Step 5 and 19

Replace the IAT sensor.

1. Check the version of ECM software. Refer to
“Flash Tool (EMPS)” for check and rewriting
of ECM. Yes
necessary.
Note:
EGR valve position learning is required after Step 10
No
replacing or rewriting the ECM. Is EMPS available?
No
Replace the ECM.
Note: Yes
Step 13 Yes
2. Clear the DTC.
3. Refer to the screen of DIAG (Trouble No Is DTC:0113 detected?
clear DTCs.
or more. Go to Step 2.
is set”.
6. Check the DTC.
Step 14
Check if other DTC is detected. Is other DTC detected? No
Verify repair.
Yes

Copyright ©
4021-36
From Step 2
Step 15
2. Check the display of intake air temperature.
3. Display of intake air temperature is 214°C
due to back-up mode after fault judgment.
Specified value
214°C
(error value) No
Step 16
Check for installation condition of the IAT
Does the display of “Intake air Go to “Diagnostic aid”.
temperature” show error value?
sensor, ECM and coupling connector.
1. Check for play or looseness in the Yes
connection.
2. If the trouble is detected, repair or replace
required.
Step 17
1. Check the signal circuit between ECM and Yes
IAT sensor for short circuit to the power Go to Step 13.
Note:
If breaker box is not available, refer to No Is the trouble detected?
Important:
If the IAT sensor circuit is shorted to the power Yes
supply circuit, the sensor may be broken. Go to Step 13.
Step 18
1. Check for followings in the signal
circuitbetween ECM and IAT sensor using
breakerbox or DMM.
Note:
• Open circuit
• High resistance
required.
Yes
Go to Step 13.
Step 19
1. Check for followings in the ground
circuitbetween ECM and IAT sensor using
breaker box or DMM.
Note:
• Open circuit
• High resistance
required. Yes
Go to Step 13.
Go to Step 9.

Copyright ©
4021-37
Block diagram

• Fault judgment needs 3 to 10 minutes.
Diagnostic aid
• To make sure the correct performance of the IAT
sensor, check with various temperatures using the reckoner table between temperature and resistance.
be the cause.
causes.
• Damaged harness
– Check the relevant items on the scan tool data display
while moving the connector and the harness which are related to the sensor. The variation of the
display indicates the faulty part.

Copyright ©
4021-38


72 – Ground 0V 18V
Short circuit to Voltage • Disconnect the
6, 17 Power supply measurement sensor connector. or more
circuit
72 – Sensor 10MΩ 100MΩ

Open circuit / Resistance • Disconnect the
7, 18 high resistance measurement sensor connector. connector signal or less or more
terminal

Open circuit / Resistance • Disconnect the
8, 19 measurement sensor connector. connector signal or less or more
high resistance
terminal
Intake air temperature - resistance table

1000
100
10
)
Resistance(
0.1
0.01
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Intake air temperature( ) E0113-4

Copyright ©
4021-39
DTC (error code): 0117 Engine coolant temperature sensor fault (low voltage fault)
• At normal temperature: Black smoke emission, greater engine

combustion noise possible.
• During idling at low atmospheric temperatures: Rough idling,
engine stall, white smoke emission possible.
Step 1
Perform the
Yes
Step 3
Check the value for ECT sensor using scan Step 2
tool. No
1. Connect the scan tool. available?
3. Check the value for “Engine coolant Yes
temperature sensor” using scan tool.
Specified value
Step 4 0.1V
Check for installation condition of the ECT Is the “Engine coolant temperature
sensor, ECM and coupling connector. sensor” the specified value or less? No
1. Check for play or looseness in the Go to “Diagnostic aid”.
connection.
required.
Step 5
2. Disconnect the ECT sensor connector.
Yes
Go to Step 11.
4. Check the value for “Engine coolant
temperature sensor” using scan tool.

1. Check for followings in the signal circuit 4.8V
between ECM and ECT sensor using Is the “Engine coolant temperature sensor”
No the specified value or more?
breaker box or DMM.
Note: Yes
• Short circuit to ECT sensor ground circuit
2. Measure the resistance of ECT sensor to
check that the value is within normal range.
required. Yes
Go to Step 11.
Step 7
Replace the ECT sensor.
Yes
Go to Step 11.
No Step 8 Yes
Is EMPS available?

Copyright ©
4021-40
Step 9
1. Check the version of ECM software. From Step 8
rewriting of ECM.
necessary.
Note:
replacing or rewriting the ECM. No Is the procedure completed?
Step 10
Replace the ECM.
Note:
Step 11
2. Clear the DTC.
3. Refer to the screen of DIAG (Trouble No Is DTC:0117 detected?
clear DTCs.
is set”.
6. Check the DTC.
Step 12

Verify repair.
Yes
Step 13
1. Start the engine. From Step 2
2. Check the display of the engine coolant
temperature.
Display of engine coolant temperature
is 214°C due to back-up mode
Specified value
after fault judgment.
214°C
(error value)
Does the display of “Engine coolant No
temperature” show error value? Go to Step 11.
Step 14
Check for installation condition of the ECT Yes
connection.
required.
Go to Step 15.

Copyright ©
4021-41
From Step 14
Step 15
between ECM and ECT sensor using
breaker box or DMM.
Note:
If breaker box is not available, refer to No Is the procedure completed?
• Short circuit to ECT sensor ground circuit
2. Measure the resistance of ECT sensor to Go to Step 7.
check that the value is within normal range.
required.
Block diagram


Copyright ©
4021-42
Diagnostic aid
• DTC may be set at a overheat condition.
• After starting the engine, the thermostat begins to
open when the engine coolant temperature rises
(85°C {185°F}), and the engine coolant temperature is stabilized.
• To make sure the correct performance of the ECT sensor, check with various temperatures using the
be the cause.

• Improper connection of harness connector and
ECM connector
• Damaged harness
– Check the relevant items on the scan tool data
display while moving the connector and the harness

Copyright ©
4021-43


84 – 79 10MΩ 100Ω
6, 15 Ground circuit/ measurement sensor connector. 84 - Ground or more or less
ground
Engine coolant temperature - resistance table
100
Resistance (K ohm)
10
0.1
-50 0 50 100
Engine coolant temperature (˚C)
E0117-4

Copyright ©
4021-44
DTC (error code): 0118 Engine coolant temperature sensor fault (high voltage fault)
• At normal temperature: Black smoke
emission, greater engine combustion noise
possible.
• During idling at low atmospheric
temperatures: Rough idling, engine stall,
white smoke emission possible.
Step 1
Perform the
Check the value for ECT sensor using scan
tool.
3. Check the value for “Engine coolant
temperature sensor” using scan tool. Step 2
No
available?
Step 4
Check for installation condition of the ECT Yes
connection.
Specified value
4.85V
required.
Is the “Engine coolant temperature No
sensor” the specified value or more?
Step 5
Yes
3. Short the ECT sensor connector signal
terminal to the ground terminal using jump No Is the trouble detected?
cable.
5. Check the value for “Engine coolant Yes
temperature sensor” using scan tool. Go to Step13.
Step 6
Specified value
ECT sensor for short circuit to the power
0V
No Is the “Engine coolant temperature
sensor” the specified value or less?
Note:
Yes
Go to Step 9.
Important:
If the ECT sensor circuit is shorted to the
power supply circuit, the sensor may be
broken.

Step 7
1.Check for followings in the signal circuit
between ECM and ECT sensor using Yes
breaker box or DMM. Go to Step 13.
Note:
“On-board check procedure for sensors”. No
• Open circuit Is the trouble detected?
• High resistance
Go to Step 8.

Copyright ©
4021-45
Step 8
1. Check for followings in the ground circuit From step 7
breaker box or DMM.
Note:
• Open circuit
required.
From step 5
Step 9

Step 11
Refer to “Flash Tool (EMPS)” for check and Yes
rewriting of ECM.
necessary.
Note: Step 10
No
EGR valve position learning is required after Is EMPS available?
[EGR valve position learning procedure] Yes
3. Wait for 10 seconds or more. No Is the procedure completed?
Step 12 Yes
Replace the ECM.
Note:
Yes
Step 13
2. Clear the DTC.
Diagnosis) in the Service Support for how to No Is DTC: 0118 detected?
clear DTCs.
or more.
Yes
Go to Step 2.
is set”.
6. Check the DTC.
Step 14

Verify repair.
Yes

Copyright ©
4021-46
Step 15 From Step 2

2. Check the display of the “Engine coolant
temperature”.
Display of engine coolant temperature is
214°C due to back-up mode after fault Specified value
judgment. 214°C
(error value)
No
Step 16 Does the display of “Engine coolant Go to “Diagnostic aid”.
Check for installation condition of the ECT temperature” show error value?
connection.
required.
Step 17 Yes
1. Check the signal circuit between ECM and Go to Step 13.
ECT sensor for short circuit to the power
Note:
Important: Go to Step 13.
If the ECT sensor circuit is shorted to the
power supply circuit, the sensor may be
broken.
Step 18
breaker box or DMM.
Note:
• Open circuit
• High resistance
required. Yes
Go to Step 13.
Step 19
1.Check for followings in the ground circuit
breaker box or DMM.
Note:
• Open circuit
required.
Go to Step 9.

Copyright ©
4021-47
Block diagram

• 3 minutes or more has elapsed after starting engine.

Copyright ©
4021-48
Diagnostic aid
• After starting the engine, the thermostat begins to open
when the engine coolant temperature rises ( 85°C {185°F}),
and the engine coolant temperature is stabilized.
• To make sure the correct performance of the ECT sensor,
check with various temperatures using the
causes.
ECM connector
• Damaged harness
– Check the relevant items on the scan tool data
display while moving the connector and the harness
which are related to the sensor. The variation
of the display indicates the faulty part.

Copyright ©
4021-49


84 – Ground 0V 18V
6, 17 Power supply measurement sensor connector. or more
circuit
Open circuit / Resistance • Disconnect the connector signal
7, 18 high resistance measurement sensor connector. terminal or less or more
Open circuit / Resistance • Disconnect the connector ground
8, 19 measurement sensor connector. terminal or less or more
high resistance
Engine coolant temperature - resistance table
100
Resistance (K ohm)
10
0.1
-50 0 50 100
Engine coolant temperature (˚C)
E0117-4

Copyright ©
4021-50
DTC (error code): 0182 FT (Fuel temperature) sensor fault (low voltage fault)
Operationality is affected.
Step 1
Perform the
Yes
Step 2
No
Step 3 Is the scan tool (KW communication) Go to Step 13.
Check the value for FT sensor using scan tool. available?
2. Start the engine. Yes
3. Check the value for “Fuel temperature
Specified value
0.1V
Step 4 Is the “Fuel temperature sensor” the No
specified value or less? Go to “Diagnostic aid”.
Check for installation condition of the FT
connection.
required. No Is the trouble detected?
Step 5 Yes
2. Disconnect the FT sensor connector.
Specified value
4.8V
Step 6 Is the “Fuel temperature sensor” the
No specified value or more?
between ECM and FT sensor using breaker
box or DMM. Yes
Note:
If breaker box is not available, refer “On-board
check procedure for sensors”.
• Short circuit to FT sensor ground circuit
• Short circuit to ground No Is the trouble detected?
required.
Yes
Go to Step 11.
Step 7
Replace the supply pump (FT sensor).
Yes
Go to Step 11.
Go to Step 8.

Copyright ©
4021-51
Step 9 From Step 6

rewriting of ECM.
2. Rewrite the software if version upgraded is No Step 8
necessary. Is EMPS available?
Note:
EGR valve position learning is required after Yes
2. Turn the key switch to “OFF”. No
Step 10
Note:
Yes
Step 11
2. Clear the DTC.
Diagnosis) in the Service Support for how to No
clear DTCs. Is DTC:0182 detected?
or more. Yes
5. Test run with the “Preconditions when DTC Go to Step 2
is set”.
6. Check the DTC.
Step 12

Verify repair.
Yes
From Step 2
Step 13
2. Check the display of “Fuel temperature”.
Display of fuel temperature is 214°C due to Specified value
back-up mode after fault judgment. 214°C
(error value)
Does the display of “Fuel temperature”
Step 14 Show error value?
No
Check for installation condition of the FT Go to “Diagnostic aid”.
connection.
Yes
required. No Is the trouble detected?
Yes
Go to Step 11.
Go to Step 15.

Copyright ©
4021-52
From Step 14
Step 15
box or DMM.
Refer to “Breaker box inspection procedure”. No Is the trouble detected?
Note:
• Short circuit to FT sensor ground circuit Go to Step 11.
required.
Go to Step 6.
Block diagram


Copyright ©
4021-53
Diagnostic aid
• When the engine cold (before starting engine),
check if the temperatures of the FT sensor and IAT sensor are close.
ECM connector
• Damaged harness


6, 15 83 – 79 10MΩ 100Ω
Ground circuit/ measurement sensor connector. 83 - Ground or more or less
ground

Copyright ©
4021-54
DTC (error code): 0183 FT (Fuel temperature) sensor fault (high voltage fault)
Not in particular
Step 1
Perform the
Yes
Step 3 Step 2
Check the value for FT sensor using scan tool. Is the scan tool (KW communication) No
1. Connect the scan tool. available? Go to Step 15.
3. Check the value for “Fuel temperature Yes

Check for installation condition of the FT 4.85V
sensor, ECM and coupling connector. Is the “Fuel temperature sensor” the No
1. Check for play or looseness in the specified value or more? Go to “Diagnostic aid”.
connection.
required.
Step 5 No Is the trouble detected?

2. Disconnect the FT sensor connector.
3. Short the FT sensor connector signal Yes
terminal to the ground terminal using jump Go to Step 13.
cable.
sensor”using scan tool.
Specified value
0V
Step 6
No Is the “Fuel temperature sensor” the
specified value or less?
FT sensor for short circuit to the power
using breaker box or DMM. Yes
Go to Step 9.
Note:
Important: No Is the trouble detected?
If the FT sensor circuit is shorted to the power
supply circuit, the sensor may be broken.
Go to Step 13.
Step 7
box or DMM.
Note: No Is the trouble detected?
• High resistance
Go to Step 13.
required.
Go to Step 8.

Copyright ©
4021-55
Step 8 From Step 7

box or DMM.
Note:
• Open circuit
required.
From Step 5
Step 9
Replace the supply pump (FT sensor).
Step 11 Yes
rewriting of ECM.
Step 10
necessary. No

Step 12 N
Replace the ECM.
Note: Yes
Yes
Step 13
2. Clear the DTC.
clear DTCs. No Is DTC: 0183 detected?
or more.
Yes
Go to Step 2.
is set”.
6. Check the DTC.
Step 14

Verify repair.
Yes

Copyright ©
4021-56
From Step 2
Step 15
2. Check the display of “Fuel temperature”.
Display of fuel temperature is 214°C due to
back-up mode after fault judgment.
Specified value
214°C
Step 16 (error value)
Check for installation condition of the FT Does the display of “Fuel temperature”
sensor, ECM and coupling connector. show error value? No
1. Check for play or looseness in the Go to “Diagnostic aid”.
connection.
required.

FT sensor for short circuit to the power
supply circuit or ignition power supply circuit Yes
using breaker box or DMM. Go to Step 13.
Note:
Important:
If the FT sensor circuit is shorted to the power
supply circuit, the sensor may be broken. Yes
2. If the trouble is detected, repair as required. Go to Step 13.
Step 18
box or DMM.
Note:
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace as Is the trouble detected?
required.
N
Yes
box or DMM.
If breaker box is not available, refer to N
Yes
• High resistance
required.
Go to Step 9.

Copyright ©
4021-57
Block diagram

• 3 minutes or more has elapsed after starting engine.

Copyright ©
4021-58
Diagnostic aid
• When the engine cold (before starting engine),
check if the temperatures of the FT sensor and IAT sensor are close.
ECM connector
• Damaged harness

step.

6 83– GND 0V 18V
power supply circuit measurement sensor connector. or more
7 83 – Sensor 100MΩ 10MΩ

8 109 – Sensor 100Ω 10MΩ

Open circuit/ Resistance • Disconnect the connector ground

Copyright ©
4021-59
DTC (error code): 0192 Common rail pressure sensor fault (low voltage fault)

• Hunting
Step 1
Step 3 Perform the

Check the value for common rail pressure Service Support check.
sensor using scan tool.
3. Check the value for “Common rail pressure
sensor” using scan tool. Step 2
Step 4
Check for installation condition of the common Yes
rail pressure sensor, ECM and coupling
connector.
1. Check for play or looseness in the Specified value
connection. 0.7V (at idle)
2. If the trouble is detected, repair or replace as Is the “Common rail pressure sensor”
required. output voltage the specified
value or less?
No
Step 5 Yes
connector.
4. Check the value for “Common rail pressure Yes
Step 6
Specified value
circuit between ECM and common rail
0V
Is the “Common rail pressure sensor”
Refer to “Breaker box inspection procedure”. No output voltage specified value?
Note:
• High resistance
required.
Step 7
Yes
between ECM and common rail pressure
Note:
• Short circuit to common rail pressure No Is the trouble detected?
sensor ground circuit
Yes
Go to Step 12.
required.
Go to Step 9.

Copyright ©
4021-60
From Step 5
Step 8
pressure sensor).
Note:
the service manual. Is the procedure completed?
Step 10
rewriting of ECM. From Step 7
necessary.
Note: No Step 9
EGR valve position learning is required after Is Flash Tool (EMPS) available?
Step 11 No Is the procedure completed?

Replace the ECM.
Note:
Step 12
Yes
2. Clear the DTC.
clear DTCs.
or more.
is set”. Yes
Go to Step 2.
6. Check the DTC.
Step 13

Verify repair.
Yes

Copyright ©
4021-61
From Step 2
Step 14
Check for installation condition of the common
connector.
1. Check for play or looseness in No Is the trouble detected?
Yes
Go to Step 12.
Step 15
connector.
Specified value
0V
4. Connect the DMM between the common rail No Does the DMM indicate the specified
pressure sensor signal terminal and the
value?
ground.
Yes
Go to Step 8.
Go to Step 6.

Copyright ©
4021-62
Block diagram


Copyright ©
4021-63
Diagnostic aid
• Damaged harness

step.

6 100Ω 10MΩ
Open circuit/ Resistance • Disconnect the 87 – Sensor
high resistance measurement sensor connector. connector signal or less or more
7 82 – 101 10MΩ 100Ω

Open circuit/ Resistance • Disconnect the 90 – 101
high resistance measurement sensor connector. 82 – Ground or more or less
• Key switch “OFF” 90 – Ground
82– Sensor 100Ω 10MΩ
• Key switch “OFF” 90 – Sensor
connector signal
terminal

Copyright ©
4021-64
DTC (error code): 0193 Common rail pressure sensor fault (high voltage fault)
• Engine stall possible

• Output lowering
Step 1
Perform the
Check the value for common rail pressure
sensor using scan tool. Yes
3. Check the value for “Common rail pressure Step 2
sensor” using scan tool. Is the scan tool (KW communication) No
Step 4
Yes
connector.
connection. 4.5V
2. If the trouble is detected, repair or replace as Is the “Common rail pressure sensor”
required. more than the specified value?
No
Step 5 Yes
2. Disconnect the common rail pressure sensor No
connector. Is the trouble detected?
4. Check the value for “Common rail pressure Yes

1. Check for followings in the power supply 4.8V
circuit between ECM and common rail Is the “Common rail pressure sensor”
pressure sensor using breaker box or DMM. No the specified value or less?
Note:
Yes
If breaker box is not available, refer to Go to Step 9.
• Open circuit
• High resistance
required.
Step 7
1. Check for followings in the signal circuit No
between ECM and common rail pressure Is the trouble detected?
Refer to “Breaker box inspection procedure”. Yes
Note: Go to Step 13.
• Open circuit
• High resistance
required.
Yes
Go to Step 13.
Go to Step 8.

Copyright ©
4021-65
From Step 7
Step 8
between ECM and common rail pressure
sensor using breaker box or DMM. No Is the trouble detected?
Note:
• Open circuit
• High resistance From Step 5 and 16
required.
Step 9
Replace the common rail (common rail Is the procedure completed?
pressure sensor).
Note:
For work procedure, refer to “Engine section” in Yes
the service manual.
Step 11 Step 10
1. Check the version of ECM software. No
Is EMPS available?
rewriting of ECM.
Yes
necessary.
Note: No Is the procedure completed?
Step 12
Replace the ECM. Is the procedure completed?
Note:
Step 13
1. Connect all the harnesses. No Is DTC: 0193 detected?
2. Clear the DTC.
Diagnosis) in the Service Support for how to Yes
clear DTCs. Go to Step 2.
or more.
is set”.
6. Check the DTC.
Step 14 No
Check if other DTC is detected. Verify repair.
Yes

Copyright ©
4021-66
Step 15
From Step 2
connector.
connection.
2. If the trouble is detected, repair or replace as No Is the trouble detected?
required.
Yes
Step 16
Go to Step 13.
connector.
3. Turn the key switch to “ON”. Specified value
4. Connect the DMM between the common rail 4.8V
pressure sensor power supply terminal and Is the DMM indication less than the
the signal terminal. No specified value?
Yes
Go to Step 9.
Go to Step 6.
Block diagram

Copyright ©
4021-67
Diagnostic aid
• Damaged harness


6 82 – Ground 0Ｖ 18Ｖ
power supply measurement sensor connector. 90 – Ground or more
circuit • Key switch “ON”
7 82 – Sensor 100Ω 10MΩ

• Key switch “OFF” 90 – Sensor
connector signal
terminal
8 101– Sensor 100Ω 10MΩ
high resistance measurement sensor connector. or less or more
terminal

Copyright ©
4021-68
DTC (error code): 0201 Open circuit in No.1 injection nozzle drive system
• Rough idling
• Output lowering
Step 1
Perform the
Check the DTC.
or more.
3. Check the DTC.
Step 3 Is DTC detected? No

1. Turn the key switch to “OFF”. Go to “Diagnostic aid”.
2. Remove the coupling connector (CN.A3)
Yes
from the cylinder head cover case.
3. Measure the resistance between the
coupling connector terminals (power supply Specified value
terminal — 0.45±0.1 Ώ
No. 1 cylinder injector drive signal terminal). (20°C)
No Is the resistance the specified
value or less?
Step 4
ECM and coupling connector (CN.A3) using
Yes
breaker box or DMM.
Is the trouble detected?
Note: Go to Step 8.
• High resistance
Step 5
Check for installation condition of the injector
terminal nut.
1. Remove the cylinder head cover.
2. Check the injector terminal nut for looseness No Is the trouble detected?
etc.
Yes
Go to Step 13.
Step 6
Check for installation condition of the coupling
connector.
1. Check for play or looseness in the No Is the trouble detected?
connection.
Yes
Go to Step 13.
Step 7
1. Check for following in the circuit between
injector terminal and coupling connector.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace as No Is there any trouble in the circuit?
required.
Yes
Go to Step 13.
Go to Step 9.

Copyright ©
4021-69
Step 8
Check for installation condition of the ECM From Step 4
connector.
2. Remove the ECM.
Yes
Step 9
From Step7
1. Replace the No. 1 cylinder injector.
Note:
the service manual.
Step 11 Yes
“Flash Tool (EMPS)” for check and rewriting
of ECM.
necessary. Step 10
Note: No
Is EMPS available?

Step 12
Replace the ECM.
Note: Yes
Yes
Step 13
2. Clear the DTC.
or more. Yes
is set”.
6. Check the DTC.
Step 14
No
Yes

Copyright ©
4021-70
Block diagram
Cylinder No. and injection
Name
1. Cylinder No. 1
2. Cylinder No. 2
3. Cylinder No. 3
4. Cylinder No. 4
5. Cylinder block
6. Engine front
Fuel injection is performed to each
cylinder in the order of 1 — 3 — 4 — 2.

Copyright ©
4021-71
• Main relay power supply voltage is 18 V or more.
• 70 min-1 or more.
• DTC: 0201, 0611, or 1261 is not detected.
Diagnostic aid
• Damaged harness


4 119– Coupling 100Ω 10MΩ
Open circuit/ Resistance • Remove the coupling connector
high resistance measurement connector terminal (H-94) or less or more
• Key switch “OFF” (No.5)

Copyright ©
4021-72
DTC (error code): 0202 Open circuit No.2 injection nozzle drive system
• Rough idling
• Output lowering
Step 1
Step 2 Perform the

Check the DTC. Service Support check.
or more. Yes
3. Check the DTC.
Step 3
Is DTC detected? No
from the cylinder head cover case. Yes
coupling connector terminals (power supply
Specified value
terminal — No. 2 cylinder injector drive
0.45±0.1Ώ
signal terminal).
(20°C)
value or less?
Step 4
1. Check for followings in the circuit between Yes
breaker box or DMM.
Refer to “Breaker box inspection procedure”. Is the trouble detected? No
Note: Go to Step 8.
Go to Step 13.
• Open circuit
• High resistance
Step 5
terminal nut. No
1. Remove the cylinder head cover. Is the trouble detected?
2. Check the injector terminal nut for looseness
etc. Yes
Step 6
connector. No
1. Check for play or looseness in the Is the trouble detected?
connection.
Go to Step 13.
Step 7
• Open circuit
• High resistance No Is there any trouble in the circuit?
required.
Yes
Go to Step 13.
Go to Step 9.

Copyright ©
4021-73
Step 8 From Step 4

Check for installation condition of the ECM
connector.
2. Remove the ECM.
Yes
Step 9
From Step7
Note:
the service manual.
Yes
Step 11
rewriting of ECM.
2. Rewrite the software if version upgraded is Step 10
necessary. No
Is EMPS available?
Note:
Step 12
Note:
2. Turn the key switch to “OFF”. Is the procedure completed?
Yes
Step 13
2, Clear the DTC.
4, Turn the key switch to “OFF” for 10 seconds
or more.
Yes
5, Test run with the “Preconditions when DTC Go to Step 2.
is set”.
6. Check the DTC.
Step 14
No
Verify repair.
Yes

Copyright ©
4021-74
Block diagram
Name
1. Cylinder No. 1
2. Cylinder No. 2
3. Cylinder No. 3
4. Cylinder No. 4
5. Cylinder block
6. Engine front
Fuel injection is performed to each
cylinder in the order of 1 — 3 — 4 — 2.

Copyright ©
4021-75
• DTC:0202, 0612, or 1262 is not detected.
Diagnostic aid
• Damaged harness


4 118– Coupling 100Ω 10MΩ

Copyright ©
4021-76
• Rough idling
• Output lowering
Step 1
Perform the
Check the DTC.
1. Turn the key switch to “OFF” for more than
10 seconds. Yes
3. Check the DTC.

from the cylinder head cover case. Yes
coupling connector terminals (power supply Specified value
terminal — No. 3 cylinder injector drive 0.45±0.1Ω
signal terminal). (20°C)
Step 4 value or less?
ECM and coupling connector (CN.A3) using Yes
breaker box or DMM.
Note:
If breaker box is not available, refer to Is the trouble detected? No
“On-board check procedure for sensors”. Go to Step 8.
• Open circuit
• High resistance
Yes
Go to Step 13.
required.
Step 5
terminal nut.
etc.
Go to Step 13.
Step 6
connector.
connection.
Yes
Go to Step 13.
Step 7
• Open circuit
• High resistance
required.
Yes
Go to Step 13.
Go to Step 9.

Copyright ©
4021-77
From Step 4
Step 8
connector.
2. Remove the ECM.
connection.
Yes
From Step 7
Step 9
Note:
Yes
Step 11
rewriting of ECM.
necessary. No
Is EMPS available?
Note:
Yes
Step 12
Yes
Replace the ECM.
Note:
1. Turn the key switch to “ON”. Is the procedure completed?
Yes
Step 13
2. Clear the DTC.
Diagnosis) in the Service Support for how to No Is DTC:0203 detected?
clear DTCs.
10 seconds. Yes
is set”.
6. Check the DTC.
Step 14

Verify repair.
Yes

Copyright ©
4021-78
Block diagram
Name
1. Cylinder No. 1
2. Cylinder No. 2
3. Cylinder No. 3
4. Cylinder No. 4
5. Cylinder block
6. Engine front
Fuel injection order is 1 — 3 — 4 — 2.

Copyright ©
4021-79
Diagnostic aid
• Damaged harness

4 120 – Coupling 100Ω 10MΩ

Copyright ©
4021-80
• Rough idling
• Output lowering
Step 1
Perform the
Check the DTC.
10 seconds.
Yes
3. Check the DTC.

2. Remove the coupling connector (CN.A3) Yes
from
the cylinder head cover case.
3. Measure the resistance between the Specified value
coupling connector terminals (power supply 0.45±0.1Ω
terminal — No. 4 cylinder injector drive (20°C)
signal terminal). No Is the resistance the specified value or less?
Step 4 Yes
breaker box or DMM. Is the trouble detected? No
Note: Go to Step 8.
“On-board check procedure for sensors, Yes
Go to Step 13.
• Open circuit
• High resistance
required.
Step 5
terminal nut.
etc. Yes
Step 6
connector. No
1. Check for play or looseness in the Is the trouble detected?
connection.
Go to Step 13.
Step 7
• Open circuit
• High resistance
required.
Yes
Go to Step 13.
Go to Step 9.

Copyright ©
4021-81
From Step 4
Step 8
connector.
2. Remove the ECM.
connection.
Yes
Step9 From Step7
Note:
the service manual.
Step 11
rewriting of ECM.
necessary.
Note: Step 10
No
EGR valve position learning is required after Is EMPS available?
Step 12 No Is the procedure completed?

Replace the ECM.
Note:
Yes
Step 13 Yes
2. Clear the DTC.
clear DTCs.
4. Turn the key switch to “OFF” for 10 seconds No Is DTC:0204 detected?
or more.
6. Check the DTC.
Step14

Verify repair.
Yes

Copyright ©
4021-82
Block diagram
Name
1. Cylinder No. 1
2. Cylinder No. 2
3. Cylinder No. 3
4. Cylinder No. 4
5. Cylinder block
6. Engine front
Fuel injection order is 1 — 3 — 4 — 2.

Copyright ©
4021-83
Diagnostic aid
• Damaged harness


4 • Remove the coupling 117 – Coupling 100Ω 10MΩ
Open circuit/ Resistance connector connector
high resistance measurement • Key switch “OFF” terminal (H-94) or less or more
(No.8)

Copyright ©
4021-84
DTC (error code): 0219 Overrun
Output lowering
Step 1

Confirm the driving status (improper operation
of the vehicle due to engine over speed).
Yes
(Interview the operator for driving status in the
past.)
Has the vehicle been operated
No improperly?
Step 3
Tell the operator that it is the over speed
caused by improper operation, and give a
Yes
driving instruction.
Step 4
Yes
Check for adverse effect (fault in the engine
body) caused by the engine over speed.
Repair or replace if fault is found.

Step 5
2. Clear the DTC.
Diagnosis) in the Service Support for how to Is other DTC detected? No
clear DTCs. Verify repair.
or more. Yes
is set”.
6. Check the DTC.

Copyright ©
4021-85
Block diagram
Yes

Diagnostic aid
• Load (fluid pressure pump etc.) is light.
• Crankshaft position (CKP) sensor, camshaft position (CMP) sensor fault (signal fault etc.)
• Engine body fault (supply pump, injector, body, etc.)
• ECM internal trouble
• Check the connector for poor contact, the harness for fault such as wear or bend, and the wire inside the
harness for loosened wire causing short circuit to other circuits. Also, perform the function diagnosis to check
the operation and control of each part.
Repair if faulty.
• When this DTC is detected, check the engine body for trouble such as seizure and breakage.

Copyright ©
4021-86
DTC (error code): 0237 Boost sensor pressure fault (low voltage fault)
Black smoke emitted
Step 1

2. Check for “MAP (manifold absolute
pressure) sensor” on the data display using
Step 2
scan tool.
Step 4
Check for installation condition of the boost Yes
pressure sensor connector, ECM connector
and coupling connector.
connection. 0.1V
2. If the trouble is detected, repair as required. Is the “MAP (manifold absolute pressure) No
sensor” the threshold value or less? Go to “Diagnostic aid”.
Step 5
2. Disconnect the boost pressure sensor Yes
connector.
3. Short between the boost pressure sensor
connector power supply terminal and the
signal terminal using jump cable.
5. Check for “MAP (manifold absolute Go to Step 12.
scan tool.
Step 6
1. Check for followings in the power supply Specified value
circuit between ECM and boost pressure 4.8V
sensor using breaker box or DMM. No Is the “MAP (manifold absolute pressure)
Refer to “Breaker box inspection procedure”. sensor” the specified value or more?
Note:
Go to Step 8.
• Open circuit
• High resistance
Step 7
1. Check for followings in the signal circuit Yes
between ECM and boost pressure sensor Go to Step 12.
Note:
• Short circuit to boost pressure sensor
ground circuit
Go to Step 9.

Copyright ©
4021-87
From Step 5 and 17

Step 8
Replace the boost pressure sensor.
Step 10
rewriting of ECM. Yes
necessary. From Step 7
Note:
replacing or rewriting the ECM. No
Yes
No
Replace the ECM.
Note: Yes
Step 12 Yes
2. Clear the DTC.
clear DTCs.
is set”.
6. Check the DTC.
Step 13

Verify repair.
Yes
From Step 2
Step 14
2. Check the display of boost pressure sensor.
Specified value
508Mpa
error value
Does the display of “Boost pressure No
sensor” show error value? Go to “Diagnostic aid”.
Yes
Go to Step 15.

Copyright ©
4021-88
From Step 14
Step 15
Check for installation condition of the boost
connection.
Yes
Go to Step 13.
Step 16
circuit between ECM and boost pressure
Note:
Go to Step 12.
• Open circuit
• High resistance
Step 17
between ECM and boost pressure sensor
Note:
• Short circuit to boost pressure sensor No Is the trouble detected?
ground circuit
Yes
• High resistance
Go to Step 8.
Block diagram


Copyright ©
4021-89
Diagnostic aid
• Damaged harness


6,16 • Disconnect the 95 – Sensor 100Ω 10MΩ
Open circuit/ Resistance sensor connector. power supply or less or more
high resistance measurement • Key switch “OFF” terminal
7,17 • Disconnect the 91 – 109 10MΩ 100Ω

Short circuit to Resistance sensor connector. 91 – Ground or more or less
ground circuit/ measurement • Key switch “OFF”
ground
• Disconnect the 91– Sensor 100Ω 10MΩ
Open circuit/ Resistance sensor connector. connector signal or less or more

Copyright ©
4021-90
DTC (error code): 0238 Boost sensor pressure fault (high voltage fault )
Black smoke emitted
Step 1

Step 3
2. Check for “MAP (manifold absolute
Step 2
scan tool.
Step 4
Yes
2. If the trouble is detected, repair as required. 4.9V
Is the “MAP (manifold absolute pressure)
No
sensor” the specified value or more? Go to “Diagnostic aid”.
Step 5
connector.
4. Check for “MAP (manifold absolute No Is the trouble detected?
scan tool.
Yes
Go to Step 12.
Step 6
boost pressure sensor for short circuit to the
power supply circuit or ignition power supply Specified value
circuit using breaker box or DMM. 0.1V
Refer to “Breaker box inspection procedure”. No Is the “MAP (manifold absolute pressure)
Note: sensor” the specified value or more?
Important:
Yes
If the boost pressure sensor circuit is shorted Go to Step 8.
to the power supply circuit, the sensor may be
broken.
Step 7
Yes
Go to Step 12.
Note:
• Open circuit
• High resistance No Is the trouble detected?
Yes
Go to Step 12.
Go to Step 9.

Copyright ©
4021-91
From Step 5
Step 8
Replace the boost pressure sensor.
Step 10
Refer to “Flash Tool (EMPS)” for check Is the procedure completed?
and rewriting of ECM.
necessary.
Note: From Step 7
replacing or rewriting the ECM. Step 9
[EGR valve position learning procedure] No
1. Turn the key switch to “ON”. Is EMPS available?
Yes
Step 11 No
Note:
Step 12
2. Clear the DTC.
or more.
Yes
Go to Step 2.
is set”.
5. Check the DTC.
Step 13

Verify repair.
Yes
From Step 2
Step 14
2. Check the display of boost pressure sensor.
Specified value
508Mpa
error value
Does the display of “Boost pressure No
sensor” show error value? Go to “Diagnostic aid”.
Yes
Go to Step 15.

Copyright ©
4021-92
connection.
Step 16
1. Check the signal circuit between ECM and Yes
Go to Step 12.
boost pressure sensor for short circuit to the
power supply circuit or ignition power supply
circuit using breaker box or DMM.
Note: No Is the trouble detected?
If breaker box is not available, refer to ,
Important: Yes
If the boost pressure sensor circuit is shorted Go to Step 12.
to the power supply circuit, the sensor may be
broken.
Step 17
Note:
• Open circuit
Go to Step 8.
Block diagram


Copyright ©
4021-93
Diagnostic aid
ECM connector
• Damaged harness


6,16 • Disconnect the 0V 18V
Short circuit to Voltage sensor connector. 91 – Ground or more
Power supply measurement • Key switch “ON”
circuit
7,17 • Disconnect the 109– Sensor 100Ω 10MΩ

Open circuit/ Resistance sensor connector. connector ground or less or more

Copyright ©
4021-94
DTC (error code): 0335 CKP (crank position) sensor fault (no signal)
• Output lowering
• White smoke emitted
• Intense engine vibration possible
• Engine stall possible (restart is possible when CMP (camshaft
position) sensor is normal.)
Step 1

Step 2
Check for installation condition of the CKP
sensor.
Yes
2. Visually check the sensor for installation
condition such as play or looseness.
Step 3
Check for installation condition of the CKP Yes
connection.
2. If the trouble is detected, repair or replace as Is the procedure completed?
required.
Yes
Step 4
1. Clear the DTC.
Refer to “How to clear DTC:rocedure of
Trouble Diagnosis” in this section for how to Is DTC detected? No
or more.
Yes
3. Start the engine, and test run with the
“Preconditions when DTC is set”.
4. Check the DTC.

Check the CKP sensor body. Between terminals: 108.5 - 142.5 Ω
1. Turn the key switch to “OFF”. Each terminal -- ground: ∞ Ω
2. Remove the harness from the CKP sensor. No (at normal temperature)
3. Measure the resistance between the sensor
connector terminals. Is the resistance within the specified
value?
Step 6
ECM and CKP sensor using breaker box or
Yes
DMM.
Note: No
Is the trouble completed?
“On-board check procedure for sensors.
• Short circuit between terminals
• Short circuit to power supply circuit or
Step 7
Replace the CKP sensor. Yes
Go to Step 11.

Copyright ©
4021-95
From Step 6
Step 9
rewriting of ECM.
Step 8
necessary. No
Is EMPS available?
Note:
No
Step 10
Yes
Replace the ECM.
Note:
[EGR valve position learning procedure] Is the procedure completed?
Step 11
1. Connect all the harnesses. No Is DTC: 0335 detected?
2. Clear the DTC.
Diagnosis) in the Service Support for how to Yes
or more.
is set”.
5. Check the DTC.
Step 12
Check if other DTC is detected. Verify repair.
Yes

Copyright ©
4021-96
Block diagram

• Fault judgement needs cranking for about 10 seconds.
• CMP sensor pulse is normal.
• DTC: 0335, 0336, 0340, 0341, or 1345 is not detected.
• Engine is running.
Diagnostic aid
• Damaged harness
• For crank sensor fault, DTC won’t be detected unless the engine cranks for 14 revolutions. Especially when
running with low speed such as idling, engine stalls before cranking for 14 revolutions if no crank signal exist.
In this case, the back-up mode will not be active because DTC is not detected. Therefore, the engine can be
restarted even after it stalls, making it difficult to identify the fault. If the engine experienced stall, raise the
engine speed up to No Load Max, and check if crank sensor fault is detected while cranking for 14
revolutions. If crank sensor fault is detected at No Load Max, DTC will be detected. If intermittent trouble is
found, raise the engine speed up to No Load Max, and check if DTC is detected.

Copyright ©
4021-97


6 • Disconnect the 106 – Sensor 100Ω 10MΩ
Open circuit/ Resistance sensor connector. connector(-) or less or more
107 - Sensor
connector(+)
terminal
Short circuit • Disconnect the 106 – GND 10MΩ 100Ω
to ground Resistance sensor connector. or more or less
measurement • Key switch “OFF” 107 – GND
Short circuit • Disconnect the 106 – 107 10MΩ 100Ω

between terminals Resistance sensor connector. or more or less
measurement • Key switch “OFF”
Short circuit • Disconnect the 106 – GND 0V 18V

to power supply Voltage sensor connector. or more
circuit measurement • Key switch “ON” 107 – GND

Copyright ©
4021-98
DTC (error code): 0336 CKP (crank position) sensor fault (signal fault)
• Output lowering
• White smoke emitted
• Intense engine vibration possible
• Engine stall possible (restart is possible when CMP (camshaft
position) sensor is normal.)
Step 1
Step 2 Go to
Check for installation condition of the CKP Service Support check.
sensor.

Check for installation condition of the CKP
connection.
required. Is the procedure completed?
Step 4
Yes
1. Clear the DTC.
Refer to “How to clear DTC , Procedure of
Trouble Diagnosis” in this section for how to
clear DTCs.
Is DTC detected? No
2. Turn the key switch to “OFF” for 10 seconds Go to Step 12.
or more.
3. Start the engine, and test run with the Yes
4. Check the DTC.
Step 5
1. Check the CKP sensor circuit for short circuit
to other signal circuit using breaker box or No Is the trouble detected?
DMM.
required.
Step 6
Check the CKP sensor body. Specified value
Between terminals: 108.5 - 142.5 Ω
2. Remove the harness from the CKP sensor.
Each terminal -- ground: ∞ Ω
3. Measure the resistance between the sensor
No (at normal temperature)
connector terminals.
Is the CKP sensor normal?
4. Remove the CKP sensor and check the
sensortip for scratch or damage.
Yes
Go to Step 8.
Step 7
Replace the CKP sensor.
Yes
Go to Step 12.

Copyright ©
4021-99
From Step 6
Step 8
1. Visually check the flywheel for chipped
tooth.
2. If the trouble is detected, replace it.
Step 10
rewriting of ECM.
necessary.
Note:
Is EMPS available?
Yes
No
Replace the ECM.
Note: Yes
Step 12 Yes
2. Clear the DTC.
Diagnosis) in the Service Support for how to No Is DTC: 0335 detected?
clear DTCs.
is set”.
5. Check the DTC.
Step 13

Verify repair.
Yes

Copyright ©
4021-100
Block diagram

• CMP sensor pulse is normal.
• DTC: 0335, 0336, 0340, 0341, or 1345 is not detected.

Copyright ©
4021-101
Diagnostic aid
• Damaged harness
• For crank sensor fault, DTC won’t be detected unless the engine cranks for 14 revolutions. Especially when
running with low speed such as idling, engine stalls before cranking for 14 revolutions if
no crank signal exist. In this case, the back-up mode will not be active because DTC is not detected.
Therefore, the engine can be restarted even after it stalls, making it difficult to identify the fault. If the engine
experienced stall, raise the engine speed up to No Load Max, and check if crank sensor fault is detected while
cranking for 14 revolutions. If crank sensor fault is detected at No Load Max, DTC will be detected. If
intermittent trouble is found, raise the engine speed up to No Load Max, and check if DTC is detected.


5 Short circuit • Disconnect the 106 – Gound 0V 1V
to other signal Voltage sensor connector. or more
circuit measurement • Key switch “ON” 107 – Gound

Copyright ©
4021-102
DTC (error code): 0340 CMP (cam position) sensor fault (no signal)
• Engine does not start (restart).

• Behavior does not change during engine running.
Step 1
Step 2 No Go to
Check for installation condition of the CMP Is the procedure completed?
sensor.

Check for installation condition of the CMP
sensor,ECM and coupling connector. Yes
connection.
Step 4
Yes
1. Clear the DTC. No
Refer to “How to clear DTC, procedure of Is DTC detected?
Go to Step 11.
Trouble Diagnosis” for how to clear DTCs.
or more.
3. Start the engine, and test run with the
4. Check the DTC.
Step 5 No
Is the CMP sensor normal?
Remove the CMP sensor, and check the Go to Step 9.
sensor tip for scratch or damage.
Yes
Step 6
circuit between ECM and CMP sensor using
breaker box or DMM.
Note:
• High resistance
Yes
Go to Step 15.
required.
Step 7
between ECM and CMP sensor using
breaker box or DMM.
Note: Yes
• Open circuit
• High resistance
Go to Step 8.
required.

Copyright ©
4021-103
From Step 7
Step 8
1. Check for followings in the shield circuit
between ECM and CMP sensor using
breaker box or DMM.
Note:
• Open circuit
• High resistance
ignition power supply circuit From Step 5
required.
Step 9
Replace the CMP sensor. Is the procedure completed?
Step 10 Yes
1. Visually check the camshaft gear for fault.
2. Check the alignment mark in the timing gear.
3. If the trouble is detected, repair or replace it.
Step 11
Replace the supply pump. Yes
Note:
the service manual.

rewriting of ECM. Yes
necessary.
Note:
No
Step 14
Replace the ECM.
Note:
Yes
Step 15
Yes
1. Clear the DTC.
Refer to “How to clear DTC:rocedure of
Trouble Diagnosis” how to clear DTCs. No Is DTC: 0340 detected?
or more.
“Preconditions when DTC is set”. Go to Step 2.
4. Check the DTC.
Go to Step 16.

Copyright ©
4021-104
From Step 15
Step 16

Verify repair.
Yes
Block diagram

• CKP (crankshaft position) sensor pulse is normal.
• DTC:0335, 0336, 0340, 0341, 1345, or 1635 is not detected.

Copyright ©
4021-105
Diagnostic aid

• Damaged harness
• The cam gears are out of installation phase by one tooth.


6 Open circuit/ • Disconnect the 99– Sensor 100Ω 10MΩ
high resistance Resistance sensor connector. connector power or less or more
measurement • Key switch “OFF” supply terminal
Short circuit • Disconnect the 99 – Ground 10MΩ 100Ω

to ground Resistance sensor connector. or more or less
measurement • Key switch “OFF”

high resistance Resistance sensor connector. connector signal or less or more
measurement • Key switch “OFF” terminal
Short circuit • Disconnect the 98 – Ground 0V 18V

to power supply Resistance sensor connector. or more
circuit measurement • Key switch “ON”

high resistance Resistance sensor connector. connector shield or less or more
measurement • Key switch “OFF” terminal
Short circuit • Disconnect the 100 – Ground 0V 18V

to power supply Resistance sensor connector. or more
circuit measurement • Key switch “OFF”

Copyright ©
4021-106
DTC:0341 CMP (cam position) sensor fault (signal fault)
• Engine does not start (restart).

• Behavior does not change during engine running.
Step 1

Check for installation condition of the CMP Service Support check.
sensor.

Step 3
Check for installation condition of the CMP
connection.
Step 4 Yes
1. Clear the DTC.
Refer to “How to clear DTC, Procedure of
Trouble Diagnosis” for how to clear DTCs. No
2. Turn the key switch to “OFF” for 10 seconds Is DTC detected?
Go to Step 11.
or more.
4. Check the DTC.
Step 5
Remove the CMP sensor, and check the Is the CMP sensor normal? No
Go to Step 8.
sensor tip for scratch or damage.
Yes
Step 6
2. Remove the harness from the CMP sensor.
3. Connect the breaker box or DMM between
the CMP sensor terminals.
Note:
If breaker box is not available, refer to Specified value
“On-board check procedure for sensors”. 0V
No
4. Turn the key switch to “ON”. Is the DMM indication specified value?
Yes
1. Check the CMP sensor circuit for short
circuit to other signal circuit using breaker
box or DMM.
Note:
required.
Yes
Go to Step 14.
Go to Step 9.

Copyright ©
4021-107
From Step 6
Step 8
Replace the CMP sensor.
Yes
From Step 7
Step 9
1. Visually check the camshaft gear for fault.
2. Check the alignment mark in the timing gear.
3. If the trouble is detected, repair or replace it.
Step 10 Yes
Note:
the service manual.

rewriting of ECM.
Step 11
2. Rewrite the software if version upgraded is No
Is EMPS available
necessary.
Note:
Step 13
Note:
Yes
Step 14
1. Clear the DTC.
Trouble Diagnosis” for how to clear DTCs. No Is DTC:0341 detected?
or more.
“Preconditions when DTC is set”. Go to Step 2.
4. Check the DTC.
Step 15

Verify repair.
Yes

Copyright ©
4021-108
Block diagram

• CKP sensor pulse is normal.
• DTC: 0335, 0336, 0340, 0341, 1345, or 1635 is not detected.
Diagnostic aid
• Damaged harness

Copyright ©
4021-109


7 Short circuit • Disconnect the 98 – Ground 0V 1V
to other signal Voltage sensor connector. or more
circuit measurement • Key switch “ON”

Copyright ©
4021-110
DTC (error code): 0380 Glow relay circuit fault
Deterioration of startability
Step 1

Yes
Step 2
Step 3
2. Check for “Glow relay” on the data display
using scan tool.
No Is the “Glow relay” displayed “ON”?
Step 4
2. Hold it for 10 seconds or more.
using scan tool.
Is the “Glow relay” displayed “OFF”? No
Go to Step 9.
Step 5 Yes
Check for installation condition of the glow Go to “Diagnostic aid”.
relay, ECM connector and coupling connector.
connection.
Step 6
2. Remove the glow relay. Go to Step 12.
3. Short between the terminals 2 - 4 in the glow
relay installing portion using jump cable.
using scan tool. No Is the “Glow relay” displayed “ON”?
Step 7
Yes
Go to Step 11.
1. Check for following in the circuit between the
fuse and the glow relay.
• Open circuit
• Short circuit to ground circuit
• High resistance
Yes
Go to Step 12.
Go to Step 8.

Copyright ©
4021-111
Step 8
glow relay and ECM using breaker box or
DMM.
Refer to “Breaker box inspection procedure”. From Step 7
Note:
• Open circuit
• High resistance No
2. If the trouble is detected, repair as required. Is the trouble detected?
Yes
Step 9
2. Remove the glow relay.
using scan tool.
No Is the “Glow relay” displayed “OFF”?
Yes
Step 10
1. Check the circuit between glow relay and
ECM for short circuit to the power supply
circuit ignition power supply circuit using
breaker box or DMM.
Note:
Yes
Step 11
Replace the glow relay.

rewriting of ECM.
necessary. No Is EMPS available?
Note:
Step 14
Replace the ECM.
Yes
Go to Step 15.
Note:
Yes
Go to Step 15.

Copyright ©
4021-112
From Step 13 and 14

Step 15
2. Clear the DTC.
Trouble Diagnosis” in this section for how to
clear DTCs.
or more.
is set”. Yes
Step 16

Verify repair.
Yes
From Step 2
Step 17
Check for installation condition of the glow
Is the trouble detected? No
Go to Step 7.
1. Check for play or looseness in
Yes
Go to Step 12.

Copyright ©
4021-113
Block diagram

• Key switch input voltage is 16 V or more and 32 V or less.

Copyright ©
4021-114
Diagnostic aid
• Damaged harness


8
Open circuit/ Resistance • Disconnect the 10 - FL12 10MΩ 10MΩ
high resistance measurement relay. connector or less or more
• Key switch “OFF” No.1 terminal
Short circuit Resistance • Disconnect the 10 - Ground 10MΩ 10MΩ

to ground measurement relay. or more or less
10
Short circuit Voltage • Disconnect the 100 - Ground 0V 18V
to power supply measurement relay. or more

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4021-115
DTC (error code): 0487 EGR position sensor fault
Exhaust gas is affected.
Step 1

Check for installation condition of the EGR Service Support check.
valve connector, ECM connector and coupling
connector.
Yes
connection.
Step 3
ECM and EGR position sensor using
Yes
Go to Step 10.
breaker box or DMM.
Note:
• Short circuit to EGR position sensor
ground circuit
• Short circuit to ground Yes
• High resistance
Step 4
2. Clear the DTC.
Diagnosis) in Service Support for how to
clear DTCs. Is DTC:0487 detected? No
3. Turn the key switch to “OFF” for 10 seconds Go to “Diagnostic aid”.
or more, and then start the engine.
4. Warm-up the engine until the engine coolant Yes
temperature exceeds 80°C.
5. Check the DTC.
Step 5
Replace the EGR valve (EGR position sensor).
Note:
the service manual.

Step 6
2. Clear the DTC.
clear DTCs.
3. Turn the key switch to “OFF” for than 10 Is DTC:0487 detected? No
seconds or more, and then start the engine. Go to Step 11.
4. Warm-up the engine until the engine coolant
Yes
5. Check the DTC. Step 7
No
Is EMPS available?
Yes

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4021-116
Step 8
From Step 7
rewriting of ECM.
2. Rewrite the software if version upgraded
necessary.
Note:
Step 9
Replace the ECM.
Note:
Yes
Step 10
2. Clear the DTC.
Refer to the screen of DIAG(Trouble
Diagnosis) in Service Support for how to No
Is DTC:0487 detected?
clear DTCs.
or more. Yes
4. Warm-up the engine until the engine coolant Go to Step 2.
5. Check the DTC.
Step 11
Verify repair.
Yes

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4021-117
Block diagram

• Main relay input voltage is 18 V or more.
• DTC:1630 or 1635 is not detected.
Diagnostic aid
• Damaged harness

Copyright ©
4021-118

3 • Disconnect the 87 – EGR valve 100Ω 10MΩ
Open circuit/ Resistance EGR valve connector. connector or less or more
high resistance measurement • Key switch “OFF” sensor power
supply terminal
4 • Disconnect the 92 - 101 10MΩ 10MΩ
Short circuit Resistance EGR valve connector. 93 - 101 or more or less
to ground circuit/ measurement • Key switch “OFF” 94 - 101
ground 92 - GND
93 - GND
94 - GND
• Disconnect the 92 - EGR valve 100Ω 10MΩ
Open circuit/ Resistance EGR valve connector. connector position or less or more
high resistance measurement • Key switch “OFF” sensor signal W
terminal
93 - EGR valve
connector position
sensor signal V
terminal
94 - EGR valve
connector position
sensor signal U
terminal

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4021-119
DTC (error code): 0488 EGR valve control fault
Exhaust gas is affected.
Step 1

Yes
Step 2
Step 3
1. Perform “EGR control test” using scan tool. Yes
2. Press the “Up” “Down” soft key.
3. Check the value for “EGR position”.

Check the DTC again. No ± 3%
1. Connect all the harnesses. Is “EGR position” within the specified
2. Clear the DTC. value?
Diagnosis) in Service Support for how to Yes
clear DTCs.
or more, and then start the engine.
4. Warm-up the engine until the engine coolant Is DTC: 0488 detected? No
5. Check the DTC.
Yes
Go to Step 8.
Step 5
1. Check for followings in the motor drive circuit
between ECM and EGR motor using breaker
box or DMM.
Note:
• Open circuit
• Short circuit to power supply circuit or Yes
ignition power supply circuit Go to Step 11.
• High resistance
Step 6
Replace the EGR valve.
Note:
the service manual.
Step 7
2. Clear the DTC.
Refer to the screen of DIAG (Trouble No
Diagnosis) in Service Support for how to Is DTC: 0488 detected? Go to Step 12.
clear DTCs.
Yes
more than, and then start the engine.
temperature exceeds 80°C. Go to Step 8.
5. Check the DTC.

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4021-120
From Step 7
Step 9
rewriting of ECM.
Step 8
2. Rewrite the software if version upgraded is No
Note:
Yes
Step 10
Replace the ECM.
Note:
Step 11 Yes
2. Clear the DTC.
clear DTCs.
3. Turn the key switch to “OFF” for 10 seconds No
or more, and then start the engine. Is DTC:0488 detected?
temperature exceeds 80°C. Yes
Step 12

Verify repair.
Yes
Step 13 From Step 2

1. Remove the EGR valve.
2. Check the EGR valve for anchoring,
clogging, etc.
Go to Step 4.
Yes
Go to Step 5.

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4021-121
Block diagram

• Main relay input voltage is 20 V or more and 32 V or less.
• DTC:0487, 0488, 1630, or 1635 is not detected.
Diagnostic aid
• Damaged harness

Copyright ©
4021-122


5 Short circuit to Voltage • Disconnect the 111 – Ground 0V 18V

power supply measurement EGR valve connector. 103 – Ground or more
circuit • Key switch “ON” 110 – Ground
111 – Ground
Short circuit to Resistance • Disconnect the 103 – Ground 10 MΩ 100Ω
ground measurement EGR valve connector. 110 – Ground or more or less
111 – EGR valve
Open circuit/ Resistance • Disconnect the connector 100Ω 10 MΩ
high resistance measurement EGR valve connector. motor drive U or less or more
103 – EGR valve
connector
motor drive V
terminal
110 – EGR valve
connector
motor drive W
terminal

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4021-123
DTC (error code): 0522 Engine oil pressure sensor fault (low voltage fault)
Operationality is not affected.
Step 1
Perform the
Yes
Step 2
Step 3 No
Check the value for engine oil pressure sensor available?
using scan tool.
Yes
3. Check the value for “Engine oil pressure
sensor” using scan tool. Specified value
0.1V
Is the “Engine oil pressure sensor” the No
Step 4 specified value or less? Go to “Diagnostic aid”.
Check for installation condition of the engine oil
pressure sensor, ECM and coupling connector.
connection.
required.
Step 5
2. Disconnect the engine oil pressure sensor Go to Step 11.
connector.

1. Check for followings in the signal circuit 0V
between ECM and engine oil pressure No Is the “Engine oil pressure sensor” the
sensor using breaker box or DMM. specified value or more?
Note: Yes
• Short circuit to engine oil pressure sensor
ground circuit
required.
Yes
Go to Step 11.
Step 7
Replace the engine oil pressure sensor.
Yes
Go to Step 11.
Go to Step 8.

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4021-124
From Step 6
Step 9
rewriting of ECM. Step 8
No
2. Rewrite the software if version upgraded is Is EMPS available?
necessary.
Note: Yes
1. Turn the key switch to “ON”. No Is the procedure completed?
Step 10
Replace the ECM.
Note:
Yes
Step 11
2. Clear the DTC.
clear DTCs.
or more.
5. Check the DTC.
Step 12
2. Check the display of engine oil pressure. Specified value
1016 kPa
No
Step 13 (error value) Go to “Diagnosis aid”.
Check for installation condition of the engine oil Does the display of engine oil pressure show
pressure sensor, ECM and coupling connector. error value?
connection.
Yes
required.
Step 14
between ECM and engine oil pressure
Yes
Go to Step 11.
Note:
• Short circuit to engine oil pressure sensor
ground circuit
required.
Go to Step 7.

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4021-125
Block diagram

• DTC:1633 is not detected.

Copyright ©
4021-126
Diagnostic aid
• Damaged harness

6
Short circuit to Resistance • Disconnect the 67 – 79 10 MΩ 100Ω
ground circuit/ measurement sensor connector. 67 – Ground or more or less
ground • Key switch “OFF” 80 – 79
80 – Ground

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4021-127
DTC:0523 Engine oil pressure sensor fault (high voltage fault)
Step 1
Step 3 Perform the

Check the value for engine oil pressure sensor Service Support check.
using scan tool.
Step 2
Step 4
Check for installation condition of the engine oil
Yes
pressure sensor, ECM and coupling connector.
connection.
2. If the trouble is detected, repair or replace as Specified value
required. 4.85V
Is the “Engine oil pressure sensor” the No
specified value or more? Go to “Diagnostic aid”.
Step 5
2. Disconnect the engine oil pressure sensor Yes
connector.
3. Short the engine oil pressure sensor
connector signal terminal to the ground
terminal using jump cable. No Is the trouble detected?
Yes
Specified value
Step 6 0V
No Is the “Engine oil pressure sensor” the
engine oil pressure sensor for short circuit to specified value or less?
the power supply circuit or ignition power
supply circuit, using breaker box or DMM. Yes
Refer to “Breaker box inspection procedure”. Go to Step 9.
Note:
Important:
If the engine oil pressure sensor circuit is No Is the trouble detected?
may be broken. Yes
Go to Step 7.

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4021-128
Step 7 From Step 6
Note:
• Open circuit
required.
Step 8
sensor, using breaker box or DMM.
Note:
• High resistance
2. If the trouble is detected, repair or replace
as required.
From Step 5
Step 9
Replace the engine oil pressure sensor.

rewriting of ECM.
necessary.
Note: Step 10
EGR valve position learning is required after No
Yes
Step 12
Replace the ECM.
Note: Yes
Step 13
Yes
2. Clear the DTC.
Refer to the screen of DIAG (Trouble No Is DTC: 0523 detected?
clear DTCs.
Go to Step 2.
or more.
is set”.
5. Check the DTC.
Go to Step 14.

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4021-129
From Step 13
Step 14
Check if other DTC detected.

Verify repair.
Yes
Step 15
1. Start the engine. Go to each DTC diagnosis.
2. Check the display of engine oil pressure.
From Step 3
Step 16
engine oil pressure sensor for short circuit to
the power supply circuit or ignition power
supply circuit, using breaker box or DMM. Specified value
Refer to “Breaker box inspection procedure”. 1016 kPa No
Note: (error value) Go to “Diagnosis aid”.
If breaker box is not available, refer to Does the display of engine oil pressure
“On-board check procedure for sensors”. show error value?
Important:
If the engine oil pressure sensor circuit is Yes
may be broken.
Step 17
Go to Step 13.
Note:
• Open circuit
• High resistance
Yes
Go to Step 13.
required.
Step 18
Note:
• Open circuit
• High resistance
Go to Step 9.

Copyright ©
4021-130
Block diagram

• DTC: 1633 is not detected.

Copyright ©
4021-131
Diagnostic aid
• Damaged harness


6
Short circuit to Voltage • Disconnect the 0V 18V
Power supply measurement sensor connector. 67 – Ground or more
7
Open circuit/ Resistance • Disconnect the 67 – Sensor 100Ω 10MΩ
• Key switch “OFF terminal
8
high resistance measurement sensor connector. connector ground or less or more

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4021-132
DTC (error code): 0601 ROM fault
Engine stopped
Step 1

1. Clear the DTC.
Refer to the screen of DIAG (Trouble Yes
clear DTCs.
or more. No
3. Test run with the “Preconditions when DTC Is DTC: 0601 detected?
Go to “Diagnosis aid”.
is set”.
Step 4
Step 3
1. Check the version of ECM software. No
Is EMPS available?
rewriting of ECM.
necessary.
Note:
EGR valve position learning is required after No Is the procedure completed?
Step 5
Replace the ECM.
Note:
Step 6

Verify repair.
Yes

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4021-133
DTC (error code): 0603 EEPROM fault
Step 1
Step 2 No
Is the procedure completed? Go to
1. Clear the DTC. Service Support check.
clear DTCs.
10 seconds.
3. Test run with the “Preconditions when DTC Is DTC:0603 detected? No
is set”.
Step 4
Step 3
1. Check the version of ECM software. No Is EMPS available?
rewriting of ECM.
necessary.
Note:
EGR valve position learning is required after No
Step 5
Replace the ECM.
Note:
EGR valve position learning is required after Is the procedure completed?
Step 6

Verify repair.
Yes

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4021-134
DTC (error code): 0606 CPU fault
• Output lowering
• Unable to start
Step 1

1. Clear the DTC.
clear DTCs.
or more. No
3. Test run with the “Preconditions when DTC Is DTC:0606 detected?
is set”.
Step 4 Step 3
No
1. Check the version of ECM software. Is EMPS available?
rewriting of ECM.
Yes
necessary.
P
Note:
EGR valve position learning is required after No Is the procedure completed?
Step 5
Replace the ECM.
Note:
Step 6

Verify repair.
Yes

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4021-135
DTC (error code): 0611 Charge circuit fault (bank 1)
• Rough idling
• Output lowering
Step 1

Yes
Step 2
Step 3 available? Go to Step 12.
1. Make sure all the communication between
ECU and scan tool is normal. Yes
2. Make sure the system which require
programming operates normally.
3. Check the DTC.
Yes
between ECM terminals (1, 3, 4, 43, 62, 81)
and ECM ground terminal (E2) using breaker
box or DMM.
• Open circuit
Yes
Go to Step 10.
Step 5
2. Remove the ECM ground terminal (E2).
3. Check the ECM ground terminal (E2) for
intermittent trouble or poor contact.
Step 6
Yes
Go to Step 10.
2. Remove the ECM.
3. Check the ECM terminals (1, 3, 4, 43, 62,
81) for intermittent trouble or poor contact.
Yes
Go to Step 10.
Step 7
No
Is EMPS available?
Yes

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4021-136
Step 8
From Step 7
rewriting of ECM.
necessary. No Is the procedure completed?
Note:
Step 9
Replace the ECM.
Note:
Step 10
2. Clear the DTC.
or more.
is set”.
Go to Step 2.
5. Check the DTC.
Step 11
Check if other DTC is detected. No
Verify repair.
Yes
From Step 2
No Step 12
Is DTC: 0611 detected?
Yes
Go to Step 4.
Block diagram


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4021-137
DTC (error code): 0612 Charge circuit fault (bank 2)
• Rough idling
• Output lowering
Step 1

Yes
Step 2
1. Make sure all the communication between
ECU and scan tool is normal. Yes
2. Make sure the system which require
programming operates normally.
3. Check the DTC.
Go to Step 10.
Step 4
between ECM terminals (1, 3, 4, 43, 62, 81)
and ECM ground terminal (E2) using breaker
box or DMM.
• Open circuit
Yes
2. Remove the ECM ground terminal (E2).
3. Check the ECM ground terminal (E2) for
intermittent trouble or poor contact.
Step 6
Yes
Go to Step 10.
2. Remove the ECM.
3. Check the ECM terminals (1, 3, 4, 43, 62,
81) for intermittent trouble or poor contact.
Yes
Go to Step 10.
Step 7
No
Is EMPS available?
Yes

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4021-138
Step 8
From Step 7
rewriting of ECM.
necessary. No Is the trouble detected?
Note:
Step 9
Replace the ECM.
Note:
Step 10
2. Clear the DTC.
clear DTCs. No Is DTC: 0612 detected?
or more.
is set”.
Go to Step 2.
5. Check the DTC.
Step 11
Verify repair.
Yes
From Step 2
No Step 12
Is DTC: 0612 detected?
Yes
Go to Step 4.
Block diagram


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4021-139
DTC (error code): 1093 No pump pressure feed
• Intense engine vibration • Rough idling

• Output lowering • Engine blow up fault
• Black smoke emitted • Engine stall
• Excessive output is possible.
Step 1
Step 2 Go to
Check the fuel system in the following Service Support check.
procedure.
1. Check the high pressure pipe and low Yes
connection (fuel leakage), crush or
clogging.
Check the clogging in the following No Is the fuel system normal?
procedure.
• Fuel filter (main fuel filter, pre-fuel
filter, gauze filter) Yes
• Fuel tank (pump strainer)
• Fuel system pipe
2. Check the fuel pipe, fuel filter, and
inside of the fuel tank for freeze or
waxing. (at cold temperature)
3. Check the feed pipe inside the fuel tank
for clogging of foreign matter.
Step 3
Check the electromagnetic pump. Is the procedure completed?
1. Inspect the electromagnetic pump by
referring to “Electromagnetic pump Yes
inspection procedure”.
2. Repair or replace the faulty part.
Step 4
Check for rise of fuel level in the oil level gauge No
or light oil odor. Is the trouble detected?
Step 5 Yes
Check the connection of the fuel pipe in each
injector, and replace the injector if oil leakage
is confirmed.
Note:
For work procedure, refer to “Engine section” in Is the procedure completed?
the service manual.
Step 7
Yes
Go to Step 17.
Check the injector.
1. Clear the DTC.
Step 6
clear DTCs. Is the scan tool (KW communication) Go to Step 20.
2. Start the engine. available?
the menu. Yes
4. Select the “Injection stop at each injector” in
the “Common rail system”.
5. Press the “OFF” soft key to stop the fuel
injection in the cylinder one by one, and Is there any cylinder of which engine
check the change in engine sound. No vibration and engine sound did not
change when it is stopped?
Yes
Go to Step 8.
Go to Step 9.

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4021-140
From Step 7
Step 8
1. Replace the injector in the cylinder of which
engine sound did not change when it is
stopped in step 7.
Note:
For work procedure, refer to “Engine section” in Is the procedure completed?
the service manual.
Step 9
Yes
Go to Step 18.
1. Turn the key switch to “ON”. From Step 7
5. Race it quickly about 5 times. Specified value
6. Check for “Common rail pressure” on the At engine stopped:
data display using scan tool. -30MPa
At addling, racing:
±5MPa
Is each value of “Common rail pressure”
No (at engine stopped, idling and racing)
Step 10 around specified value?
connector. Go to Step 16.
Specified value
Step 11 4.8V
No
1. Check the signal circuit between common Is the “Common rail pressure sensor” the
rail pressure sensor and ECM for short specified value or more?
Note:
2. If the trouble is detected, repair as required. No
Step 13
Yes
1. Check the version of ECM software. Go to Step 18.
rewriting of ECM.
Step 12
necessary. No
Is EMPS available?
Note:
Step 14 Yes
Replace the ECM. Go to Step 18.
Note:
Go to Step 18.

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4021-141
Step 15
From Step 10
pressure sensor).
Note:
Step 16
Yes
1. Clear the DTC.
clear DTCs. From Step 9
the menu.
“Common rail system”.
5. Press the “Up” soft key to check the value of No Specified value
“Common rail pressure”. ±5Mpa
Is “Common rail pressure” within the
specified value?
Step 17 Yes
Note:
the service manual.

Step 18
2. Clear the DTC.
clear DTCs.
or more.
5. Check the DTC.
Step 19

Verify repair.
Yes
From Step 6
Step 20
Check the injector using injector checker.
Refer to “How to use injector checker, How
to Inspect Injector” for how to use injector
checker.
No vibration and engine sound did not
change when it is stopped?
Yes
Go to Step 8.
Go to Step 11.

Copyright ©
4021-142
Block diagram

• DTC: 0090, 0192, 0193, 1093, 1291, 1292, or 1635 is not detected.
• Engine coolant temperature is 60 °C or more.
Diagnostic aid
• Fuel system pipe fault (fuel leakage, clogging, crush, etc.)
• Fuel filter fault (clogging)
• Fuel tank fault (clogging)
• ECM trouble

Copyright ©
4021-143


11 82 – Ground 0V 1V
Short circuit Voltage • Disconnect the
to other signal measurement sensor connector. 90 – ground or more

Copyright ©
4021-144
DTC (error code): 1095 Pressure limiter open
• Output lowering
• Hunting
Step 1

Check the DTC again. Service Support check.
1. Check and record the DTC.
Diagnosis) in Service Support for for how to
clear DTCs.
Is DTC: 1095 detected? No
3. Check the fuel amount, and add fuel as Refer to “Diagnostic aid”.
required. If fuel is low, DTC:1095 may be
detected due to entry of air. Yes
4. Bleed air from the fuel.
• If air bleeding is insufficient, overshoot
exceeds 200 MPa and DTC will be
detected.
Note:
• Bleeding air from fuel must be performed
correctly, following the procedure.
• For work procedure, refer to “Engine
section” in the service manual.
5. Race it quickly about 5 times.
6. Check the DTC.
Step 3
Narrow down the cause.
1. Clear the DTC.
clear DTCs. Is DTC: 1095 detected?
2. Connect another pipe to the supply pump
inlet duct, and test run while supplying fuel. Yes
(At this time, replace the fuel hose with a Go to Step 16.
transparent hose to visually check for air
mixture in the fuel.)
3. Check the DTC.
Step 4
Check the fuel system in the following
procedure.
1. Check the high pressure pipe and low
connection (fuel leakage), crush or clogging.
Check the clogging in the following
No Is the fuel system normal?
procedure.
• Fuel filter (main fuel filter, pre-fuel filter, Yes
gauze filter) Go to Step 6.
• Fuel tank (pump strainer)
• Fuel system pipe
2. Check the fuel pipe, fuel filter, and inside of
the fuel tank for freeze or waxing. (at cold
temperature)
3. Check the feed pipe inside the fuel tank for
clogging of foreign matter.

Step 5
Repair or replace the faulty part.
Yes
Go to Step 17.

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4021-145
From Step 4
Step 6
5. Race it quickly about 5 times. Specified value
6. Check for “Differential fuel rail pressure” on At engine stopped:
the data display using scan tool. -30 MPa
At idling, racing:
±5 MPa
Is each value of “Fuel rail pressure” (at
No engine stopped, idling and racing) around
Step 8
2. Disconnect the common rail pressure sensor Go to Step 14.
connector.
Specified value
Step 9 0V
1. Check the signal circuit between common No Is the “Common rail pressure sensor”
rail pressure sensor and ECM for short specified value?
Note:
Yes
rewriting of ECM.
No
Note:
Step 12
Yes
Go to Step 13.
Replace the ECM.
Note:
Go to Step 13.

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4021-146
Step 13
From Step 8, 11, 12 and 20
pressure sensor).
Note:
Step 14
1. Restore the machine.
3. Clear the DTC.
From Step 7
clear DTCs.
is set”. Is DTC:1095 detected? No
Step 15
Yes
1. Replace the common rail.
Note:
the service manual.
3. Clear the DTC.
Refer to the screen of DIAG (Trouble Is DTC:1095 detected? No
clear DTCs.
is set”.
5. Check the DTC.
Step 16
1. Clear the DTC.
clear DTCs.
Specified value
If Tech2 is available, go to step 3.
±5Mpa
If Tech2 is not available, Go to Step 17.
No Is “Differential fuel rail pressure” within
the menu.
“Common rail system”.
Yes
5. Press the “Up” soft key to check the value of
“Differential fuel pressure”.
Step 17
Note:
• Bleed air completely after the parts are
replaced. If air bleeding is not sufficient,
DTC:1095 may be detected due to
overshoot of fuel pressure.
• For work procedure, refer to “Engine
section” in the service manual. Is the procedure completed?
Step 18
Yes
2. Clear the DTC.
Diagnosis) in Service Support for how to No Is DTC:0195 detected?
clear DTCs.
or more. Yes
is set”.
Go to Step 19.
5. Check the DTC.

Copyright ©
4021-147
From Step 14 and 19
Step 19

Verify repair.
Yes
Step 20
1. Turn the key switch to “OFF”. From Step 6
connector.
4. Connect the DMM between the common rail
pressure sensor connector signal terminal
and the ground.
Note: Specified value
If the display of DMM is not specified value, 0V
No Is the DMM indication specified value?
ECM side wiring, wrap-around in ECM or short
circuit may be the cause.
If it is specified value, ECM side wiring is Yes
normal. Go to Step 13.
Go to Step 9.

Copyright ©
4021-148
Block diagram

• DTC: 0090, 0192, 0193, 1093, 1291, 1292, or 1635 is not detected.
Diagnostic aid
• Air mixed in the high-pressure fuel pipe.
• Fuel system pipe fault (clogging etc.)
• Fuel filter fault (temporary clogging due to waxing at low temperatures, improper tightening of filter
cartridge, etc.)
• Fuel tank fault (temporary clogging, air mixed due to fuel shortage, air mixed due to modified fuel pipe
for additional tank etc.)
• ECM trouble
• Running out of fuel

Copyright ©
4021-149


9 82 – Ground 0V 1V
Short circuit Voltage • Disconnect the
to other signal measurement sensor connector. 90 – ground or more

Copyright ©
4021-150
DTC (error code): 1112 Boost temperature sensor fault (low voltage fault)
Step 1

Yes
Step 2
2. Check for “Boost temperature sensor” on the Yes

0.1V
Check for installation condition of the boost No
temperature sensor connector, ECM connector Is the “Boost temperature sensor” less Go to “Diagnostic aid”.
and coupling connector. than the specified value?
connection. Yes

2. Disconnect the boost temperature sensor
connector. Yes
3. Short between the boost temperature sensor Go to Step 12.
connector ground terminal and the signal
terminal using jump cable.
5. Check for “Boost temperature” on the data
display using scan tool. Specified value
4.8V
Step 6
No Is the “Boost temperature” more than the
1. Check for followings in the power supply specified value?
circuit between ECM and boost temperature
sensor, using breaker box or DMM. Yes
Note:
• Open circuit
• High resistance
Step 7
between ECM and boost temperature Go to Step 12.
Note:
• Short circuit to boost temperature sensor
ground circuit No Is the trouble detected?
• Open circuit
Yes
Go to Step 9.

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4021-151
From Step 5 and 8
Step 8
Replace the boost temperature sensor.
Yes
Step 10
rewriting of ECM.
necessary. Step 9
No
Step 11
Note:
Yes
Step 12
2. Clear the DTC.
Diagnosis) in Service Support for how to No Is DTC:1112 detected?
clear DTCs.
or more. Yes
4. Test run with the “Preconditions when DTC Go to step 2.
is set”.
5. Check the DTC.
Step 13

Verify repair.
Yes

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4021-152
From Step 2
Step 14
2. Check the display of boost temperature.

Check for installation condition of the boost 214°C
temperature sensor connector, ECM connector (error value) No
and coupling connector. Does the display of “Boost temperature” Go to “Diagnostic aid”.
1. Check for play or looseness in the show error value?
connection.
Step 16
circuit between ECM and boost temperature
• Open circuit
• High resistance
Step 17 Yes
between ECM and boost temperature
Note:
• Short circuit to boost temperature sensor
ground circuit
• High resistance
Go to Step 8.

Copyright ©
4021-153
Block diagram

Diagnostic aid
• Damaged harness

Copyright ©
4021-154

6 Open circuit/ Resistance • Disconnect the 74 – Sensor 100Ω 10MΩ
7 Short circuit to Resistance • Disconnect the 7 4 – 109 10MΩ 100Ω

ground circuit/ measurement sensor connector. 74 – Ground or more or less
ground • Key switch “OFF”


Copyright ©
4021-155
DTC (error code): 1113 Boost temperature sensor fault (high voltage fault)
Step 1

Yes
Step 3 Step 2
1. Turn the key switch to “ON”. Is the scan tool (KW communication) No
2. Check for “Boost temperature sensor” on the available? Go to Step 14.
Yes
Specified value
Step 4
4.95V
Check for installation condition of the boost No
Is the “Boost temperature sensor” the Go to “Diagnostic aid”.
temperature sensor connector, ECM connector specified value or more?
Yes
connection.

boost temperature sensor for short circuit to
the power supply circuit or ignition power Yes
Go to Step 12.
supply circuit, using breaker box or DMM.
Note:
Important:
If the boost temperature sensor circuit is
shorted to the power supply circuit, the sensor Yes
may be broken. Go to Step 11.
Step 6
between ECM and boost temperature
Note:
“On-board check procedure for sensors”. Is the trouble detected? No
• High resistance
Go to Step 11.
From Step 15
Step 7
Replace the boost temperature sensor. Is the procedure completed?
Yes
Go to Step 11.

Copyright ©
4021-156
From Step 6
Step 9
No
rewriting of ECM. Is EMPS available?
necessary. Yes
Note:
1. Turn the key switch to “ON”. No Is the procedure completed?
Step 10
Replace the ECM.
Note:
Yes
Step 11
2. Clear the DTC. No Is DTC: 1112 detected?
clear DTCs.
Yes
Go to Step 2.
or more.
is set”.
5. Check the DTC.
Step 12
Verify repair.
Yes

Copyright ©
4021-157
From Step 2
Step 13
2. Check the display of boost temperature.
Specified value
214°C
(error value)
Step 14 Does the display of “Boost temperature” No
Check for installation condition of the boost show error value? Go to “Diagnostic aid”.
temperature sensor connector, ECM connector
and coupling connector. Yes
connection.
Step 15
between ECM and boost temperature Yes
sensor, using breaker box or DMM. Go to Step 11.
Note:
• Open circuit
• High resistance
Go to Step 11.
Go to Step 7.
Block diagram

• Engine coolant temperature is 50 °C or more.
• 5 minutes have passed after engine starting.

Copyright ©
4021-158
Diagnostic aid
• Damaged harness


5 Short circuit to Voltage • Disconnect the 74 – Ground 0V 18V
power supply measurement sensor connector. or more
6 Open circuit/ Resistance • Disconnect the 109 – Sensor 100Ω 10MΩ

high resistance measurement sensor connector. connector ground or less or more

Copyright ©
4021-159
DTC (error code): 1173 Overheat
• Output lowering
• Fuel flow is regulated during overheat when
the temperature exceeds 108°C.
Step 1

Step 2 Yes
2. Check the DTC.
No Is DTC: 0088, or 1093 detected?
Yes Go to
the each DTC detected.
Step 3
Step 4
No
1. Turn the key switch to “OFF”. available?
2. Disconnect the ECT (engine coolant
temperature) sensor connector. Yes
4. Check for “Engine coolant temperature
Specified value
4.9V / - 40°C
Is the “Engine coolant temperature
Step 5 No sensor” the specified value or more?
1. Check the signal circuit between ECT
sensor and ECM for short circuit to signal
circuits of other sensors using breaker box or Yes
DMM.
Note:
Step 6
1. Check the engine coolant amount. Go to Step 10.
2. If insufficient, add engine coolant.
Refer to the screen of DIAG (Trouble Go to Step 13.
clear DTCs.
or more.
5. Start the engine, and check the DTC.

Go to Step 13.
Step 7
1. Check for following mechanical defects. Yes
(Refer to “Cooling system” of “Engine
section” in the service manual.)
• Clogging of radiator
• Defective radiator cap
• Loose fan belt No Is the trouble detected?
• Defective thermostat
• Defective water pump
• Defective cylinder head gasket Yes
2. If the trouble is detected, adjust or replace
Go to Step 13.
Go to Step 8.
as required.

Copyright ©
4021-160
From Step 7
Step 8

Step 9
1. Clear the DTC. Go to Step 13.
clear DTCs. From Step 5
or more.
is set”.
4. Check the DTC.
Step 11
Yes
rewriting of ECM.
necessary.
Step 10
Note: No Is EMPS available?
Step 12
Yes
Replace the ECM.
Note:
Yes
Step 13

Verify repair.
Yes
From Step 3
Step 14
4. Check the display of the “Engine coolant
Specified value
temperature”.
- 40°C
Is the “Engine coolant temperature” the No
specified value or more? Go to Step 5.
Yes
Go to Step 6.

Copyright ©
4021-161
Block diagram

• DTC:0117, 0118, 1630, or 1633 is not detected.

Copyright ©
4021-162
Diagnostic aid
• Damaged harness


Short circuit to Voltage • Disconnect the 84 – Ground 0V 1V
5
other signal circuit measurement sensor connector. or more

Copyright ©
4021-163
DTC (error code): 1261 Injection nozzle common 1 drive system fault
• Rough idling
• Output lowering
Step 1

1. Turn the key switch to “OFF”. Service Support check.
2. Remove the ECM-side harness connector
from the coupling connector (CN.A3).
Yes
3. Connect the DMM between the injector
power supply 1 circuit and the ground. Specified value
4. Turn the key switch to “ON”. 7.0V
CN.A3 female-side No. 1 Is the DMM indication the specified
No value or more?
Step 3
3. Measure the resistance between the injector
harness connector terminals.
Specified value
1.0Ω
CN.A3 male-side No. 1 and No. 4
Is the resistance the specified
value or less? No
Go to Step 18.
Step 4 Yes
harness connector, ECM connector and
coupling connector.
connection. No
2. If the trouble is detected, repair as required. Is the trouble detected?
Step 5 Yes
1. Check for followings in the injector power Go to Step 23.
supply 1 circuit using breaker box or DMM.
Note:
• Open circuit
• Short circuit to ground Go to Step 23.
Step 6
3. Measure the resistance between the No. 1 Specified value
cylinder injector drive circuit and the ground. 10MΩ
CN.A3 male-side No. 5 Is the resistance the specified
value or more? No
Go to Step 8.
Step 7
Yes
from the coupling connector (CN.A3). Specified value
10MΩ No
3. Measure the resistance between the No. 4
cylinder injector drive circuit and the ground. Is the resistance the specified Go to Step 9.
CN.A3 male-side No. 8 value or more?
Yes
Go to Step 10.

Copyright ©
4021-164
Step 8
From Step 6
1. Check the No. 1 cylinder injector drive circuit
between ECM and coupling connector
(CN.A3) for ground short circuit using
breaker box or DMM.
Note:
Yes
Go to Step 23.
From Step 7
Step 9
(CN.A3) for ground short circuit, using
breaker box or DMM.
Refer to “Breaker box inspection procedure”. Is the trouble detected? No
From Step 7
Step 10
2. Check for installation condition of the
injector harness. Is the trouble detected?
Yes
1. Remove the injector harness from the
injector.
No. 1 cylinder, No. 4 cylinder
2. Measure the resistance between each Specified value
injector terminal and the ground. 10MΩ
value or more? No
2. Remove the injector-side harness connector Yes
3. Connect the DMM between the No. 1
cylinder injector drive circuit and the ground. Specified value
CN.A3 female-side No. 5 0V
4. Turn the key switch to “ON”. Is the DMM indication specified value?
No
Yes
Go to Step 15.
Go to Step 13.

Copyright ©
4021-165
From Step 12
Step 13
2. Remove the injector-side harness connector
3. Connect the DMM between the No. 4 0V
cylinder injector drive circuit and Is the DMM indication the specified
the ground. No value or more?
CN.A3 female-side No. 8
Yes
Go to Step 16.
Step 14
3. Connect the DMM between the injector 7.0V
power supply 1 circuit and the ground. Is the DMM indication the specified
CN.A3 female-side No. 1 value or less? No
4. Turn the key switch to “ON”. Go to Step 21.
Yes
Go to Step 22.
Step 15
(CN.A3) for short circuit to the power supply From Step 12
circuit or ignition power supply circuit using
breaker box or DMM.
Note:
Go to Step 23.
Step 16
circuit or ignition power supply circuit, using
breaker box or DMM.
Note:
If breaker box is not available, refer to No
Go to Step 20.
Yes
Go to Step 23.
Step 17
1. Check the injector power supply 1 circuit
breaker box or DMM.
Note:
“On-board check procedure for sensors”. Is the trouble detected? No
Yes
Go to Step 23.

Copyright ©
4021-166
From Step 14
Step 18
Replace the injector harness.
Yes
Go to Step 23.
From Step 11
Step 19
Replace the injector.
Note:
For work procedure, refer to “Engine section”
in the service manual.
Yes
Go to Step 23.
Step 21
rewriting of ECM. From Step 5, 8, 9 and 15
necessary.
Note:
Is EMPS available?
Yes
Step 22
Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
or more.
is set”. Yes
Go to Step 2.
5. Check the DTC.
Step 24

Verify repair.
Yes

Copyright ©
4021-167
Block diagram

Diagnostic aid
ECM connector
• Damaged harness

Copyright ©
4021-168


5 Open circuit/ Resistance • Remove the ECM-side 121 – 100Ω 10MΩ
high resistance measurement harness connector from the Female-side or less or more
coupling connector. terminal
• Key switch “OFF” (CN.A3 No. 1)
Short circuit to Resistance • Remove the ECM-side 121 – Ground 10MΩ 100Ω
ground measurement harness connector from the or more or less
coupling connector.
8 Short circuit to Resistance • Remove the ECM-side 119 – Ground 10MΩ 100Ω
coupling connector.
coupling connector.
15 Short circuit to Voltage • Remove the ECM-side 119 – Ground 0V 18V
Power supply measurement harness connector from the or more
circuit coupling connector.

Copyright ©
4021-169
DTC (error code): 1262 Injection nozzle common 2 drive system fault
• Rough idling
• Output lowering
Step 1

1. Turn the key switch to “OFF”. Service Support check.
from the coupling connector (CN.A3). Yes
CN.A3 female-side No. 3 Is the DMM indication the specified
No value or more?
Step 3
2. Remove the ECM-side harness connector Yes
3. Measure the resistance between the injector
harness connector terminals.
CN.A3 male-side No. 3 and No. 2
Specified value
1.0Ω
Step 4 value or less? No
Check for installation condition of the injector Go to Step 18.
harness connector, ECM connector and
coupling connector. Yes
connection.

1. Check for followings in the injector power
supply 2 circuit using breaker box or DMM.
• Open circuit
• High resistance No
• Short circuit to ground Go to Step 20.
Yes
Go to Step 23.
Step 6
3. Measure the resistance between the No. 2
cylinder injector drive circuit and the ground.
Specified value No
CN.A3 male-side No. 7
10MΩ Go to Step 8.
Step 7 value or more?
3. Measure the resistance between the No. 3 Specified value
cylinder injector drive circuit and the ground. 10MΩ No
CN.A3 male-side No. 6 Is the resistance the specified Go to Step 9.
value or more?
Yes
Go to Step 10.

Copyright ©
4021-170
From Step 6
Step 8
1. Check the No.2 cylinder injector drive circuit
(CN.A3) for ground short circuit using
breaker box or DMM.
Note:
“On-board check procedure for sensors”. No
Yes
Go to Step 23.
Step 9
From Step 7
(CN.A3) for ground short circuit, using
breaker box or DMM.
Note:
Yes
Go to Step 23.
From Step 7
Step 10
2. Check for installation condition of the
injector harness.
Step 11 Yes
Go to Step 23.
1. Remove the injector harness from the
injector.
No. 2 cylinder, No. 3 cylinder
2. Measure the resistance between each
injector terminal and the ground. Specified value
10MΩ
Step 12 value or more? No
from the coupling connector (CN.A3). Yes
3. Connect the DMM between the No. 2
cylinder injector drive circuit and the ground.
CN.A3 female-side No.7 Specified value
4. Turn the key switch to “ON”. 0V
Is the DMM indication specified value?
No
Yes
Go to Step 15.
Go to Step 13.

Copyright ©
4021-171
From Step 12
Step 13
3. Connect the DMM between the No. 3 Specified value
cylinder injector drive circuit and 0V
the ground. Is the DMM indication the specified
CN.A3 female-side No. 6 No value or more?
Yes
Go to Step 16.
Step 14
CN.A3 female-side No. 3 7.0V
4. Turn the key switch to “ON”. Is the DMM indication the specified
value or less? No
Go to Step 17.
Yes
Go to Step 18.
Step 15
breaker box or DMM.
Note:
Yes
Go to Step 23.
Step 16
circuit or ignition power supply circuit, using
breaker box or DMM.
Note:
Yes
Go to Step 23.

Copyright ©
4021-172
From Step 14
Step 17
1. Check the injector power supply 2 circuit
(CN.A3) for short circuit to the power supply
circuit or ignition power supply circuit using Is the trouble detected? No
breaker box or DMM.
Note:
Yes
Go to Step 23.
2. If the trouble is detected, repair as required. From Step 14

Replace the injector harness.
Yes
Go to Step 23.
Step 19
From Step 11
Replace the injector.
Note:
For work procedure, refer to “Engine section”
in the service manual.
Step 21 Yes
1. Check the version of ECM software. Go to Step 23.
rewriting of ECM.
necessary.
Step 20
Note: No
Is EMPS available?
Step 22
Yes
Replace the ECM.
Note:
Yes
Step 23
2. Clear the DTC.
clear DTCs. Yes
or more.
is set”.
5. Check the DTC. No
Verify repair.
Step 24

Copyright ©
4021-173
Block diagram

Diagnostic aid
ECM connector
• Damaged harness

Copyright ©
4021-174
step.

5 Open circuit/ Resistance • Remove the ECM-side 116 – Female-side 100Ω 10MΩ
high resistance measurement harness connector from the terminal or less or more
coupling connector. (No. 3)
Short circuit to Resistance • Remove the ECM-side 116 – Ground 10MΩ 100Ω
coupling connector.
coupling connector.
coupling connector.

Copyright ©
4021-175
DTC (error code): 1345 CMP (camshaft positon) sensor out of phase
• Behavior does not change during engine

running.
• After engine stops, engine will not start.
Step 1
Step 2
1. Check the CMP sensor condition.
• Loose installation and rattling of sensor Yes
Step 3
1. Check for the condition of the CKP
(crankshaft position) sensor. Is the procedure completed?
• Loose installation and rattling of sensor
Yes
Step 4
1. Clear the DTC.
clear DTCs.
or more.
is set”.
4. Check the DTC.
• Stop the engine once, crank the engine for
4 to 5 seconds, and then check if
DTC:0340 is detected.
• If DTC:0340 is detected, judge as an open
circuit in cam sensor, and check and
repair the open circuit in CMP sensor.
After repair, crank the engine for 10 Is DTC:1345 detected?
seconds, and confirm that DTC:0340 and
DTC:1345 disappear.
Yes
Step 5
1. Check that the camshaft gear is installed
properly.
Step 6 Yes
1. Check that the flywheel is installed properly.
Step 7
1. Clear the DTC.
clear DTCs.
or more. No Is DTC: 1345 detected?
is set”.
4. Check the DTC.
Yes
Step 8
Check if other DTC detected. No
Yes
Copyright ©
4021-176
Block diagram

• Fault judgment needs cranking for about 10 seconds.
• DTC: 0335, 0336, 0340, 0341, 1345, or 1635 is not detected.
• CMP sensor signal is normal.
• CKP sensor signal is normal.
Diagnostic aid
ECM connector
• Damaged harness

Copyright ©
4021-177
DTC:1625 Main relay fault
Engine does not start or power supply cannot be

shut off.
Step 1

Yes
Step 2
Step 3
2. Check for “Main relay voltage” on the data
display using scan tool.
Specified value
Step 4
1. Turn the key switch to “OFF”. 1V
No
2. Check the DTC. Is the “Main relay voltage” the specified
value or more?
Yes
Step 5
1. Remove the main relay.
2. Check the DTC. Is DTC: 1625 detected? No Go to
Note: “Diagnostic aid”.
Refer to the machine’s manual for installing
position and installation/removal procedures of Yes
the main relay.
Step 6 Is DTC: 1625 detected? No

1. Check the circuit (contact point side) Go to Step 11.
between main relay and ECM for short circuit
to the power supply circuit or ignition power Yes
supply circuit using breaker box or DMM.
Note:
If breaker box is not available, refer to No
Go to Step 15.
Yes
Go to Step 12.
Step 7
Check for installation condition of the main
connection.
No
Yes
3. Short between the terminals 1 - 2 and 3 - 5
in the main relay installing portion Specified value
respectively using jump cable. 24V
4. Turn the key switch to “ON”. Is the “Main relay voltage” the specified
5. Check for “Main relay voltage” on the data
No
value or more?
display using scan tool.
Yes

Copyright ©
4021-178
From Step 8
Step 9
slowblow fuse and main relay.
• Open circuit
• High resistance
Yes
Go to Step 15.
Step 10
main relay and ECM using breaker box or
DMM.
Note:
• Open circuit
From Step 5, 8, 19 and 22

Step 11
Replace the main relay.
Step 13
rewriting of ECM.
Yes
necessary.
Note:
No Step 12
Step 14 No
Note:
Step 15
1. Connect all the harnesses. From 6, 7 and 9
2. Clear the DTC.
clear DTCs. Is DTC:1261 detected?
or more. Yes
is set”.
5. Check the DTC.
Step 16
Yes No

Copyright ©
4021-179
Step 17 From Step 2

4. Connect the DMM between the main relay
connector coil-side terminal and the ground.
Specified value
1V
No Is the DMM indication the specified
value or more?
Step 18 Yes
2. Check the DTC.
Step 19 Go to
1. Remove the main relay. “Diagnostic aid”.
Note:
Refer to the machine’s manual for installing
position and installation/removal procedures of
the main relay. Is DTC:1625 detected?
No
Go to Step 11.
Step 20 Yes
1. Check the circuit (contact point side)
between main relay and ECM for short circuit
supply circuit using breaker box or DMM. No
Is the trouble detected? Go to Step 15.
Note:
Go to Step 12.
Step 21
Check for installation condition of the main
connection.
Step 22
Yes
Go to Step 15.
4. Connect the DMM between the main relay
connector terminal (contact point side) and Specified value
the ground. 24V
Is the DMM indication the specified No
value or more? Go to Step 9.
Yes
Go to Step 11.

Copyright ©
4021-180
Block diagram

• 3 seconds or more has elpsed after turning the key switch to "ON".
• Main relay drive command is "ON".
Diagnostic aid
ECM connector
• Damaged harness
Copyright ©
4021-181

Step Item to be Inspection Measuring condition Breaker box Terminal Normal Abnormal
checked method No. value value
6 Short circuit to Voltage • Disconnect the relay. 2 – Ground 0V 18V
Power supply measurement • Key switch “ON” or more
circuit 5 – Ground
Open circuit/ Resistance • Disconnect the relay. 2 – Relay installing 100Ω 10MΩ
10
high resistance measurement terminal No.2 or less or more
• Key switch “OFF” 5 – Relay installing
terminal No.2
21 – Relay installing
terminal No.2
40 – Relay installing
terminal No.2
Short circuit to Resistance • Disconnect the relay. 2 – Ground 10MΩ 100Ω

ground measurement 5 – Ground or more or less
• Key switch “OFF” 21 – Ground
40 – Ground

Copyright ©
4021-182
DTC (error code): 1630 A/D conversion fault
• Output lowering
Step 1
Step 2
Check the DTC again. No Go to
1. Clear the DTC. Service Support check.
clear DTCs.
or more.
3. Test run with the “Preconditions when DTC Go to
is set”. Is DTC E1630 detected? No “Diagnostic aid”.
4. Check the DTC.
Yes
Step 4
Refer to “Flash Tool (EMPS)” for check and No Step 3
necessary. Yes
Note:
Step 5
Replace the ECM.
Note:
EGR valve position learning is required after Is the procedure completed?
Step 6

Verify repair.
Yes

Copyright ©
4021-183
DTC (error code): 1632 Voltage fault in 5V power supply 2

• Output shortage at low altitude
Step 1

Step 2
connector.
3. Connect the DMM between the barometric
pressure sensor power supply terminal and
the ground. Specified value
2. Disconnect the barometric pressure sensor Yes
connector.
3. Connect the DMM between the barometric
the ground.
Specified value
4.5V
Is the DMM indication the specified
value or less? No Go to
Step 4
1. Check the power supply circuit between “Diagnostic aid”.
barometric pressure sensor and ECM for Yes
short circuit to the battery power supply
breaker box or DMM.
Note:
Yes
Go to Step 9.
Step 5
1. Check the power supply circuit between
barometric pressure sensor and ECM for
ground short circuit using breaker box or
DMM.
Note:
Step 6 No
Is EMPS available? Go to Step 8.
Yes
Go to Step 7.

Copyright ©
4021-184
Step 7
rewriting of ECM.
necessary.
3. Wait for 10 seconds or more. From Step 6
Step 8
Replace the ECM.
Note:
From Step 4 and 5
Step 9
2. Clear the DTC.
Refer to the screen of DIAG (Trouble No Is DTC: 1632 detected?
clear DTCs.
Yes
or more.
is set”.
5. Check the DTC.
Step 10

Verify repair.
Yes

Copyright ©
4021-185
Block diagram


Copyright ©
4021-186
• At normal temperature: Black smoke

emission, greater engine combustion
noise possible.
• During idling at low atmospheric
temperatures: Rough idling, engine stall,
white smoke emission possible.
Yes
Step 1
No Go to
connector.
3. Connect the DMM between the engine oil
the ground. Specified value
connector.
3. Connect the DMM between the engine oil
the ground.
Specified value
4.5V
Step 4 value or less? No Go to
1. Check the power supply circuit between “Diagnostic aid”.
engine oil pressure sensor and ECM for Yes
short circuit to the battery power supply
breaker box or DMM.
Note:
On-board check procedure for sensors”. No Is the trouble detected?
Yes
Go to Step 9.
Step 5
engine oil pressure sensor and ECM for
DMM.
Note:
Step 6 No
Yes
Go to Step 7.

Copyright ©
4021-187
Step 7
rewriting of ECM.
necessary.
3. Wait for 10 seconds or more. From Step 6
Step 8
Replace the ECM.
Note:
From Step 4 and 5
Step 9
2. Clear the DTC.
clear DTCs.
or more.
is set”. Yes
Step 10

Verify repair.
Yes

Copyright ©
4021-188
Block diagram


Copyright ©
4021-189
Black smoke emitted
Step 1

Step 2
connector.
3. Connect the DMM between the boost
the ground.
5.5V
connector.
3. Connect the DMM between the boost
the ground.
Specified value
4.5V
value or less? No
Step 4
1. Check the power supply circuit between Yes
boost pressure sensor and ECM for short
circuit to the battery power supply circuit or
ignition power supply circuit using breaker
box or DMM.
Note:
Yes
Go to Step 9.
Step 5
boost pressure sensor and ECM for ground
short circuit using breaker box or DMM.
Note:
Step 6 No
Yes
Go to Step 7.

Copyright ©
4021-190
Step 7
rewriting of ECM.
necessary.
Step 8
Replace the ECM. From Step 6
Note:
Yes
Step 9
1. Connect all the harnesses. From Step 4 and 5
2. Clear the DTC.
clear DTCs.
or more.
5. Check the DTC.
Step 10

Verify repair.
Yes

Copyright ©
4021-191
Block diagram


Copyright ©
4021-192
• Engine blow up • Output lowering

• Black smoke emitted • Engine stall
Step 1

Step 2
connector.
the ground.
5.5V
Step 3
1. Turn the key switch to “OFF”. value or more?
connector. Yes
the ground.
Specified value
4.5V
Step 4 Is the DMM indication the specified
value or less? No
1. Check the power supply circuit between Go to “Diagnostic aid”.
common rail pressure sensor and ECM for
short circuit to the battery power supply Yes
breaker box or DMM.
Note:
Yes
Go to Step 9.
Step 5
common rail pressure sensor and ECM for
DMM.
Note:
If breaker box is not available, refer to,
Step 6
No
Yes
Go to Step 7.

Copyright ©
4021-193
Step 7
rewriting of ECM.
necessary.
From Step 6
Step 8
Replace the ECM.
Note:
Yes
Step 9
Check the DTC again. From Step 4 and 5
2. Clear the DTC.
clear DTCs.
or more.
5. Check the DTC.
Step 10

Verify repair.
Yes

Copyright ©
4021-194
Block diagram


Copyright ©
4021-195
DTC:2104 CAN Bus fault
Set to idle speed.
Step 1

Step 2
10 seconds. Yes
3. Check the DTC.
Step 3 Go to “Diagnostic aid”.
1. If the DTC:2104 is detected, and the history
and present troubles of DTC:2106 are
Yes
alternately detected, check the circuit
between ECM terminals (32) and (18) for the
following conditions.
• Short circuit
required. No Is the procedure completed?
3. Check if DTC is not detected again.
Step 4
Step 5
Is the breaker box available? Go to Step 15.
2. Remove the ECM. Yes
3. Connect the breaker box to the ECM.
4. Connect the breaker box with the ECM
harness.
CAN-High-side terminal and CAN-Low-side Specified value
terminal using breaker box. 50 - 70Ω
No Is the resistance within the specified
value?
Yes
Go to Step 13.
Step 6
1. Remove the ECM from the breaker box.
CAN-High- side terminal and CAN-Low-side
terminal using breaker box. Specified value
Approx. 120Ω
Is the resistance specified value? No
Go to Step 8.
Step 7
1. Connect the ECM to the breaker box.
2. Remove the computer A and the harness. Yes
terminal using breaker box.
Specified value No
Approx. 120Ω Go to Step 10.
Is the resistance specified value?
Yes
Go to Step 13.

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4021-196
Step 8
1. Check the CAN-Low circuit and CAN-High
circuit between ECM and machine control From Step 6 and 15
unit for short circuit to the power supply
breaker box or DMM.
Note:
2. If the trouble is detected, replace the Yes
harness. Go to Step 2.
Step 9
1. Check for followings in the CAN-Low circuit
and CAN-High circuit between ECM
machine control unit using breaker box
DMM.
Note: Is the trouble detected? No Replace
If breaker box is not available, refer to the machine control unit.
• High resistance
Go to Step 2.
From Step 7 and 16
Step 10
Step 11 No
Is EMPS available?
rewriting of ECM.
necessary.
Note:
Yes
3. Wait for 10 seconds or more. Verify repair.
Step 12
Replace the ECM.
Note:
Yes
From Step 16
Step 13
2. Clear the DTC.
Diagnosis) in Service Support for how to No Is DTC: 2104 detected?
clear DTCs.
or more. Yes
is set”.
5. Check the DTC.
Verify repair.
Step 14

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4021-197
From Step 4
Step 15
Remove the ECM, and measure the resistance
between the CAN-High-side terminal and CAN
Low- side terminal of the ECM connector.
Specified value
Approx. 120Ω
Is the resistance specified value? No
Go to Step 8.
Step 16
1. Install the ECM, and remove the machine Yes
control unit.
terminal of the machine control unit Specified value
connector. Approx. 120Ω
Is the resistance specified value? No Go to Step 10.
Yes
Go to Step 13.
Block diagram



8 • Remove all the relevant 18 – Ground 0V 18V
Short circuit to Voltage ECU connectors. 37 – Ground or more
Power supply measurement • Key switch “ON”
circuit
9 • Remove all the relevant 37 – Machine 100Ω 10MΩ

Open circuit/ Resistance ECU connectors. control unit or less or more
high resistance measurement • Key switch “OFF” 18 – Machine
control unit
Short circuit to • Remove all the relevant 18 – Ground 10MΩ 100Ω

Resistance ECU connectors. 37 – Ground or more or less
ground measurement • Key switch “OFF”

Copyright ©
4021-198
DTC (error code): 2106 CAN timeout fault
• It can not be controlled from the machine side
since CAN communication is disabled. The
engine speed becomes back-up speed specified
by each machine manufacturer. (1,500 min-1)
Step 1

Step 2
or more. Yes
3. Check the DTC.
Step 3
1. Check for followings in the CAN-Low circuit Yes
and CAN-High circuit between ECM and
computer A using breaker box or DMM.
Note:
• High resistance
Yes
Go to Step 11.
Step 4
1. Check for followings in the CAN-Low circuit
and CAN-High circuit between ECM and
computer A using breaker box or DMM.
Note:
• Short circuit to power supply circuit or No Is the trouble detected?
Yes
Go to Step 11.
Step 5
2. Clear the DTC.
clear DTCs.
or more.
is set”.
5. Check the DTC. Is DTC:2106 detected? No
Step 6
Yes
1. If the DTC:2104 is detected, and the history
and present troubles of DTC:2106 are
alternately detected, check the circuit
between ECM terminals (32) and (18) for the No Is the procedure completed?
following conditions.
• Short circuit
3. Check if DTC is not detected again. Go to Step 7.

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4021-199
From Step 6
Step 7
Replace the computer A.
Yes
From Step 6
Step 9
No
necessary. Yes
Note:
No
Yes
Step 10
Replace the ECM.
Note:

2. Clear the DTC.
Refer to the screen of DIAG (Trouble From Step 3 and 4
clear DTCs.
or more.
is set”.
5. Check the DTC.
Yes
Go to Step 2.
Step 12

Verify repair.
Yes

Copyright ©
4021-200
Block diagram

Diagnostic aid
ECM connector
• Damaged harness

Copyright ©
4021-201


4 Open circuit/ Resistance • Remove the machine 18 – Machine 100Ω 10MΩ
high resistance measurement control unit (ECU) control unit (ECU) or less or more
connector. connector
37 – Machine
control unit (ECU)
connector
terminal
5
Short circuit to Resistance • Remove the machine 18 – Ground 10MΩ 100Ω
ground measurement control unit (ECU) 37 – Ground or more or less
connector.
Short circuit to Voltage • Remove the machine 18 – Ground 0V 18V
power supply measurement control unit (ECU) 37 –Ground or more
circuit connector.

Copyright ©
4021-202
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Copyright ©
4022
Section
4022
MAIN BODY ERROR CODE (DTC)

Printed in France
Copyright ©
4022-2

Copyright ©
4022-3
TABLE OF CONTENTS
DTC (ERROR CODE): 7000 P1 PRESSURE SENSOR SIGNAL FAULT ......................................................................5
DTC (ERROR CODE): 7001 P2 PRESSURE SENSOR SIGNAL FAULT ......................................................................6
DTC (ERROR CODE): 7002 N1 PRESSURE SENSOR SIGNAL FAULT......................................................................7
DTC (ERROR CODE): 7003 N2 PRESSURE SENSOR SIGNAL FAULT......................................................................8
DTC (ERROR CODE): 7004 OVERLOAD PRESSURE SENSOR SIGNAL FAULT ......................................................9
DTC (ERROR CODE): 7020 UPPER PILOT PRESSURE SENSOR SIGNAL FAULT ................................................10
DTC (ERROR CODE): 7021 SWING PILOT PRESSURE SENSOR SIGNAL FAULT.................................................11
DTC (ERROR CODE): 7022 TRAVEL PILOT PRESSURE SENSOR SIGNAL FAULT ..............................................12
DTC (ERROR CODE): 7040 FUEL LEVEL SENSOR SIGNAL FAULT .......................................................................13
DTC (ERROR CODE): 7041 OIL TEMPERATURE SENSOR SIGNAL FAULT...........................................................14
DTC (ERROR CODE): 7045 MONITOR THERMISTOR FAULT. .................................................................................15
DTC (ERROR CODE): 7063 HYDRAULIC OIL FILTER CLOG SWITCH SIGNAL FAULT (WHITH BREAKER) .......16
DTC (ERROR CODE): 7063 HYDRAULIC OIL FILTER CLOG SWITCH SIGNAL FAULT (WHITHOUT BREAKER)17
DTC (ERROR CODE): 7200 SWING BRAKE SOLENOID SIGNAL FAULT................................................................18
DTC (ERROR CODE): 7201 TRAVEL 2ND SPEED SOLENOID SIGNAL FAULT......................................................19
DTC (ERROR CODE): 7202 POWER UP SOLENOID SIGNAL FAULT ......................................................................20
DTC (ERROR CODE): 7203 TRAVEL ALARM BUZZER SIGNAL FAULT (NA ONLY)..............................................22
DTC (ERROR CODE): 7204 POWER SAVE SOLENOID SIGNAL FAULT .................................................................23
DTC (ERROR CODE): 7209 AIR CONDITIONER WATER TEMPERATURE SIGNAL FAULT.) ................................24
DTC (ERROR CODE): 7240 PUMP FORCE POWER PROPORTIONAL VALVE SIGNAL FAULT............................26
DTC (ERROR CODE): 7241 P1 FLOW CONTROL PROPORTIONAL VALVE SIGNAL FAULT................................28
DTC (ERROR CODE): 7241 P1 FLOW CONTROL PROPORTIONAL VALVE SIGNAL FAULT................................30
DTC (ERROR CODE): 7402 ENGINE COOLANT TEMPERATURE IS ABNORMALLY HIGH (110°C OR MORE) ...30
DTC (ERROR CODE): 7403 ENGINE COOLANT TEMPERATURE IS ABNORMALLY HIGH (120°C OR MORE) ...30
DTC (ERROR CODE): 7404 ENGINE OIL TEMPERATURE IS ABNORMALLY HIGH (95°C OR MORE) .................30
DTC (ERROR CODE): 7405 BOOST TEMPERATURE IS ABNORMALLY HIGH (80°C OR MORE) .........................30
DTC (ERROR CODE): 7406 BOOST TEMPERATURE IS ABNORMALLY HIGH (90°C OR MORE) .........................30
DTC (ERROR CODE): 7420 ALTERNATOR VOLTAGE FAULT.................................................................................31
DTC (ERROR CODE): 7421 COOLANT LEVEL LOWERING SIGNAL IS DETECTED. .............................................32
DTC (ERROR CODE): 7422 ENGINE OIL PRESSURE ABNORMALLY LOW ...........................................................33
DTC (ERROR CODE): 7423 AIR FILTER CLOG SWITCH SIGNAL IS DETECTED. ..................................................34
DTC (ERROR CODE): 7424 HYDRAULIC OIL FILTER CHECK SIGNAL IS DETECTED. (WITH BREAKER) .........35

Copyright ©
4022-4
DTC (ERROR CODE): 7600 CAN BUS FAULT ........................................................................................................... 36
DTC (ERROR CODE): 7601 MONITOR COMMUNICATION FAULT .......................................................................... 37
DTC (ERROR CODE): 7602 ECM COMMUNICATION TIME OUT ............................................................................. 38
DTC (ERROR CODE): 7603 COMPUTER "B" COMMUNICATION TIME OUT .......................................................... 39
DTC (ERROR CODE): 7604 COMPUTER "S" COMMUNICATION TIME OUT .......................................................... 40
DTC (ERROR CODE): 7605 ECM MISMATCH............................................................................................................ 41

Copyright ©
4022-5
DTC (ERROR CODE): 7000 P1 PRESSURE SENSOR SIGNAL FAULT
Turn the key switch to "ON".
BLOCK DIAGRAM
The DTC:7000 is displayed. Computer A
Check the connected condition of

each connector.
P1 Pressure sensor
Check the output voltage of P1 pressure sensor at a screen of the

"Service & Support".
No 0.25V or less Check the P1 pressure sensor
4.75V or more
Disconnect the CN.115 after turning

the key switch to "OFF".
Measure the resistance between No.1 terminal and No.3 ter-

Yes Check the open circuit also the short circuit to "GND".
minal of the CN.115 P1 pressure sensor.
Yes
Approx. 10KΩ
Check the short circuit to power supply. Check the electrical connection between No.1 Cause/Procedure
No terminal of the CN.115 harness and "GND". The harness W400 and Y420 are faulty
Check the electrical connection between No.2 (short circuit).
Disconnect the CN.115 after turning Cause/Procedure Yes
terminal of the CN.115 harness and "GND".
the key switch to "OFF". The P1 pressure sensor is faulty. There is an electrical connection. Replace
Replace
No
Cause/Procedure
Check the electrical connection between No.3 Cause/Procedure
Measure the voltage between No.1 terminal of The harness W400 is faulty (short circuit).
the CN.115 harness and "GND". terminal of the CN.115 harness and "GND". The harness BW440 is faulty (open cir-
No
No cuit).
Replace
Approx. 5V There is an electrical connection
Repair or replace
Yes
Turn the key switch to "ON". Yes
Cause/Procedure
Measure the voltage between No.2 terminal of
The harness Y420 is faulty (short circuit). Cause/Procedure
the CN.115 harness and "GND". No Measure the voltage between No.1 terminal of
The harness W400 is faulty (open cir-
Replace the CN.115 harness and "GND".
4.75V or less No cuit).
Approx. 5V
Repair or replace
Yes
Cause/Procedure Yes
Measure the voltage between No.3 terminal of The harness BW440 is faulty (short cir- Cause/Procedure
the CN.115 harness and "GND". No cuit). Measure the voltage between No.2 terminal of
The harness Y420 is faulty (open circuit).
the CN.115 harness and "GND". No
0.25V or less Replace Repair or replace
0.25V or more
Yes
Cause/Procedure Yes
Cause/Procedure
The computer "A" is faulty. The computer "A" is faulty.
Replace Replace

Copyright ©
4022-6
DTC (ERROR CODE): 7001 P2 PRESSURE SENSOR SIGNAL FAULT
BLOCK DIAGRAM

each connector.
P2 Pressure sensor
Check the output voltage of P2 pressure sensor at a screen of the

No 0.25V or less Check the P2 pressure sensor
4.75V or more


minal of the CN.116 P2 pressure sensor.
Yes
Approx. 10KΩ
No
terminal of the CN.116 harness and "GND". The harness W400, W401 and L421 are
Cause/Procedure Check the electrical connection between No.2
Yes faulty (short circuit).
Disconnect the CN.116 after turning The P2 pressure sensor is faulty. terminal of the CN.116 harness and "GND".
the key switch to "OFF". There is an electrical connection. Replace
Replace
No
Cause/Procedure
Cause/Procedure
Measure the voltage between No.1 terminal of The harness W400 and W401 are faulty Check the electrical connection between No.3
terminal of the CN.116 harness and "GND". The harness BW440 and BW441 are
the CN.116 harness and "GND". No (short circuit).
No faulty (open circuit).
Approx. 5V Replace There is an electrical connection
Repair or replace
Yes
Cause/Procedure
Measure the voltage between No.2 terminal of The harness L421 is faulty (short circuit). Cause/Procedure
the CN.116 harness and "GND". No Measure the voltage between No.1 terminal of The harness W400 and W401 are faulty
Replace the CN.116 harness and "GND". (open circuit).
4.75V or less No
Approx. 5V Repair or replace
Yes
Cause/Procedure
Yes
Measure the voltage between No.3 terminal of The harness BW440 and BW441 are Cause/Procedure
the CN.116 harness and "GND". No faulty (short circuit). Measure the voltage between No.2 terminal of
The harness L421 is faulty (open circuit).
0.25V or less Replace
Repair or replace
0.25V or more
Yes
Cause/Procedure Yes
Cause/Procedure
Replace Replace

Copyright ©
4022-7
DTC (ERROR CODE): 7002 N1 PRESSURE SENSOR SIGNAL FAULT
BLOCK DIAGRAM

each connector.
N1 Pressure sensor
Check the output voltage of N1 pressure sensor at a screen of the

No 0.25V or less Check the N1 pressure sensor
4.75V or more


minal of the CN.117 N1 pressure sensor.
Yes
Approx. 10KΩ
No terminal of the CN.117 harness and "GND". The harness W400, W402 and Lg422
Check the electrical connection between No.2 are faulty (short circuit).
the key switch to "OFF". The N1 pressure sensor is faulty. There is an electrical connection. Replace
Replace
No
Cause/Procedure
Measure the voltage between No.1 terminal of The harness W400 and W402 are faulty
the CN.117 harness and "GND". terminal of the CN.117 harness and "GND". The harness BW440 and BW442 are
No (short circuit).
Replace
Repair or replace
Yes
Cause/Procedure Turn the key switch to "ON". Yes
Measure the voltage between No.2 terminal of The harness Lg422 is faulty (short cir-
the CN.117 harness and "GND". cuit). Cause/Procedure
No Measure the voltage between No.1 terminal of
The harness W400 and W402 are faulty
the CN.117 harness and "GND".
4.75V or less Replace No (open circuit).
Approx. 5V
Repair or replace
Yes
Cause/Procedure
Yes
the CN.117 harness and "GND". No faulty (short circuit). Measure the voltage between No.2 terminal of The harness Lg422 is faulty (open cir-
the CN.117 harness and "GND". No cuit).
0.25V or more Repair or replace
Yes
Cause/Procedure Yes
Cause/Procedure
Replace Replace

Copyright ©
4022-8
DTC (ERROR CODE): 7003 N2 PRESSURE SENSOR SIGNAL FAULT
BLOCK DIAGRAM

each connector.
N2 Pressure sensor
Check the output voltage of N2 pressure sensor at a screen of the

No 0.25V or less Check the N2 pressure sensor
4.75V or more


minal of the CN.118 N2 pressure sensor.
Yes
Approx. 10KΩ
No terminal of the CN.118 harness and "GND". The harness W400, W403 and Br423
the key switch to "OFF". The N2 pressure sensor is faulty. There is an electrical connection. Replace
Replace
No
Cause/Procedure Cause/Procedure
Measure the voltage between No.1 terminal of Check the electrical connection between No.3
The harness W400 and W403 are faulty The harness BW440 and BW443 are
the CN.118 harness and "GND". terminal of the CN.118 harness and "GND".
No (short circuit). faulty (open circuit).
No
Replace Repair or replace
Yes
Cause/Procedure
Measure the voltage between No.2 terminal of The harness Br423 is faulty (short circuit). Cause/Procedure
the CN.118 harness and "GND". No Measure the voltage between No.1 terminal of The harness W400 and W403 are faulty
Replace the CN.118 harness and "GND". (open circuit).
4.75V or less No
Yes
Cause/Procedure
Yes
the CN.118 harness and "GND". No faulty (short circuit). Measure the voltage between No.2 terminal of
The harness Br423 is faulty (open cir-
0.25V or more
Repair or replace
Yes
Cause/Procedure Yes
Cause/Procedure
Replace Replace

Copyright ©
4022-9
DTC (ERROR CODE): 7004 OVERLOAD PRESSURE SENSOR SIGNAL FAULT
BLOCK DIAGRAM
Check the connected condition of Pressure sensor

each connector. (HBCV)
Check the output voltage of overload pressure sensor at a screen

of the "Service & Support".
No 0.25V or less Check the overload pressure sensor
4.75V or more


minal of the CN.123 overload pressure sensor.
Yes
Approx. 10KΩ
No terminal of the CN.123 harness and "GND". The harness W400, W408 and Gr428
the key switch to "OFF". The overload pressure sensor is faulty. There is an electrical connection. Replace
Replace
No
Cause/Procedure
Measure the voltage between No.1 terminal of The harness W400 and W408 are faulty
the CN.123 harness and "GND". terminal of the CN.123 harness and "GND". The harness BW440 and BW448 are
No (short circuit).
Yes
Cause/Procedure
Measure the voltage between No.2 terminal of The harness Gr428 is faulty (short cir-
the CN.123 harness and "GND". Cause/Procedure
No cuit). Measure the voltage between No.1 terminal of
The harness W400 and W408 are faulty
the CN.123 harness and "GND".
4.75V or less Replace No (open circuit).
Approx. 5V
Repair or replace
Yes
Cause/Procedure Yes
Measure the voltage between No.3 terminal of The harness BW440 and BW448 are
Cause/Procedure
the CN.123 harness and "GND". No faulty (short circuit). Measure the voltage between No.2 terminal of The harness Gr428 is faulty (open cir-
Yes
Cause/Procedure Yes
Cause/Procedure
Replace Replace

Copyright ©
4022-10
DTC (ERROR CODE): 7020 UPPER PILOT PRESSURE SENSOR SIGNAL FAULT
BLOCK DIAGRAM

each connector. Pressure sensor
(Uupper pilot)
Check the output voltage of upper pilot pressure sensor at a screen

No 0.25V or less Check the upper pilot pressure sensor
4.75V or more


minal of the CN.120 upper pilot pressure sensor.
Yes
Approx. 10KΩ
No terminal of the CN.120 harness and "GND". The harness W400, W405 and V425 are
Check the electrical connection between No.2 faulty (short circuit).
the key switch to "OFF". The upper pilot pressure sensor is There is an electrical connection. Replace
faulty.
Turn the key switch to "ON". Replace
No
Cause/Procedure
Cause/Procedure
No
Yes
Cause/Procedure
The harness V425 is faulty (short circuit). Cause/Procedure
the CN.120 harness and "GND". No Measure the voltage between No.1 terminal of The harness W400 and BW405 are
Replace the CN.120 harness and "GND". faulty (open circuit).
4.75V or less No
Yes
Cause/Procedure
Yes
the CN.120 harness and "GND". faulty (short circuit). Measure the voltage between No.2 terminal of
No The harness V425 is faulty (open circuit).
Repair or replace
0.25V or more
Yes
Cause/Procedure Yes
Cause/Procedure
Replace Replace

Copyright ©
4022-11
DTC (ERROR CODE): 7021 SWING PILOT PRESSURE SENSOR SIGNAL FAULT
BLOCK DIAGRAM

(Swing pilot)
Check the output voltage of swing pilot pressure sensor at a screen

No 0.25V or less Check the swing pilot pressure sensor
4.75V or more


minal of the CN.119 swing pilot pressure sensor.
Yes
Approx. 10KΩ
No terminal of the CN.119 harness and "GND". The harness W400, W404 and G424
the key switch to "OFF". The swing pilot pressure sensor is There is an electrical connection. Replace
faulty.
Turn the key switch to "ON". Replace
No
Cause/Procedure
Cause/Procedure
No
Yes
Cause/Procedure
The harness G424 is faulty (short circuit). Cause/Procedure
the CN.119 harness and "GND". No Measure the voltage between No.1 terminal of The harness BW400 and BW404 are
Replace the CN.119 harness and "GND". faulty (open circuit).
4.75V or less No
Yes
Cause/Procedure Yes
the CN.119 harness and "GND". No Measure the voltage between No.2 terminal of
faulty (short circuit). The harness G424 is faulty (open cir-
0.25V or more
Repair or replace
Yes
Cause/Procedure Yes
Cause/Procedure
Replace Replace

Copyright ©
4022-12
DTC (ERROR CODE): 7022 TRAVEL PILOT PRESSURE SENSOR SIGNAL FAULT
BLOCK DIAGRAM

(Travel pilot)
Check the output voltage of travel pilot pressure sensor at a screen

No 0.25V or less Check the travel pilot pressure sensor
4.75V or more


minal of the CN.121 travel pilot pressure sensor.
Yes
Approx. 10KΩ
No terminal of the CN.121 harness and "GND". The harness W400, W406 and YG426
the key switch to "OFF". The travel pilot pressure sensor is faulty. There is an electrical connection. Replace
Replace
No
No
Yes
Cause/Procedure Turn the key switch to "ON". Yes
Measure the voltage between No.2 terminal of The harness YG426 is faulty (short cir-
Cause/Procedure
the CN.121 harness and "GND". faulty (open circuit).
4.75V or less Replace No
Yes
Cause/Procedure
Yes
the CN.121 harness and "GND". No faulty (short circuit). Measure the voltage between No.2 terminal of The harness YG426 is faulty (open cir-
Yes
Cause/Procedure Yes
Cause/Procedure
Replace Replace

Copyright ©
4022-13
DTC (ERROR CODE): 7040 FUEL LEVEL SENSOR SIGNAL FAULT
BLOCK DIAGRAM
The DTC:7040 is displayed.

Computer A
Check the connected condition of Float position and resistance
each connector.
Float Position Full half Empty
10 80 Fuel level sensor
Resistance (Ω) 38
(Tolerance 0-4) (Tolerance 0-10)
Check the resistance of fuel level sensor at a screen of the "Service # Temperature condition: 20±15°C
& Support".
100Ω or more
No 2Ω or less Check the short circuit.
Yes
Check the open circuit. the key switch to "OFF".
Cause/Procedure
Disconnect the CN.135 after turning Check an electrical connection between No.2
The harness GL412 is faulty (short cir-
the key switch to "OFF". terminal of the CN.135 harness and "GND".
No cuit).
There is no electrical connection.
Measure the resistance between No.1 terminal and Replace
Cause/Procedure
No.2 terminal of the CN.135 fuel level sensor (refer the
The fuel level sensor is faulty. Yes
table of float position and resistance). Turn the key switch to "ON".
No
Replace
The specified value Cause/Procedure
Measure the voltage between No.1 terminal of The harness BG660 and BG600 are
the CN.135 harness and "GND". No faulty (short circuit).
Yes 0V
Cause/Procedure Replace
Check an electrical connection between No.1 terminal The harness BG660 and BG600 are
of the CN.135 harness and "GND". faulty (open circuit). Yes
No Cause/Procedure
The computer "A" is faulty.
There is an electrical connection Repair or replace
Replace
Yes
Cause/Procedure
Measure the voltage between No.2 terminal of the The harness GL412 is faulty (open cir-
CN.135 harness and "GND". No cuit).
Yes
Cause/Procedure
Replace

Copyright ©
4022-14
DTC (ERROR CODE): 7041 OIL TEMPERATURE SENSOR SIGNAL FAULT
BLOCK DIAGRAM

Computer A
each connector.
Hyd. oil temp. sensor
Check the resistance (or output voltage) of oil temperature sensor

at a screen of the "Service & Support".
67200Ω (4.93V) or more
No 111Ω (0.5V) or Check the short circuit.

less
Yes
Check the open circuit. the key switch to "OFF".
Cause/Procedure
Disconnect the CN.125 after turning Check an electrical connection between No.2
The harness BrW411 is faulty (short cir-
the key switch to "OFF". terminal of the CN.125 harness and "GND".
No cuit).
Measure the resistance between No.1 terminal and Replace
Cause/Procedure
No.2 terminal of the CN.125 oil temperature sensor
The oil temperature sensor is faulty. Yes
(refer the table of oil temperature and resistance). Turn the key switch to "ON".
No
Replace
The specified value Cause/Procedure
the CN.125 harness and "GND". No faulty (short circuit).
Yes 0V
Cause/Procedure Replace
Check an electrical connection between No.1 terminal The harness BW451 and BW451 are
of the CN.125 harness and "GND". faulty (open circuit). Yes
No Cause/Procedure
There is an electrical connection Repair or replace
Replace
Yes
Cause/Procedure
Measure the voltage between No.2 terminal of the The harness BrW411 is faulty (open cir-
Yes
Cause/Procedure Float position and resistance
The computer "A" is faulty. Oil Temp. (°C) -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120
Resistance (Ω) 25400 15040 9160 5740 3700 2450 1660 1150 811 584 428 318 240 184 142 111
Replace

Copyright ©
4022-15
DTC (ERROR CODE): 7045 MONITOR THERMISTOR FAULT.
BLOCK DIAGRAM
The monitor thermistor is faulty.
Computer A Monitor
The DTC: 7045 (*) is displayed in a "DIAG" screen of the

Cause/Procedure
The monitor is faulty. Serial communication
Replace
Note:
*: A contrast compensation of the monitor thermistor should be adjusted at the time of the super-low temperature and the super high temperature.
When there is a fault in the monitor thermistor and it does not affect seriously to the monitor contrast, it is no need to replace the monitor due to its self adjustment function.

Copyright ©
4022-16
DTC (ERROR CODE): 7063 HYDRAULIC OIL FILTER CLOG SWITCH SIGNAL FAULT (WHITH BREAKER)
BLOCK DIAGRAM
Computer A

each connector and "GND". Press. switch
(Filter indication)
Check the hydraulic oil filter clog switch.

Check the electrical connection between No.1 terminal Cause/Procedure

and No.2 terminal of the CN.134 hydraulic oil filter clog The filter clog switch is faulty.
switch. No
Replace
There is an electrical connection.
Yes
Check the open circuit.

of the CN.134 harness and "GND". The harness BG663 is faulty (open cir-
No cuit).
Repair or replace
Yes
Cause/Procedure
Measure the voltage between No.2 terminal of the The harness YL472 is faulty (open cir-
Yes
Cause/Procedure
Replace

Copyright ©
4022-17
DTC (ERROR CODE): 7063 HYDRAULIC OIL FILTER CLOG SWITCH SIGNAL FAULT (WHITHOUT BREAKER)
BLOCK DIAGRAM
Computer A
Press. switch
Check the connected condition of (Filter indication)
each connector and "GND".


and No.2 terminal of the CN.134 jumper harness. The jumper harness is faulty (open cir-
No cuit).
Replace
Yes

of the CN.134 harness and "GND". The harness BG663 is faulty (open cir-
No cuit).
Repair or replace
Yes
Cause/Procedure
Measure the voltage between No.2 terminal of the The harness YL472 is faulty (open cir-
Yes
Cause/Procedure
Replace

Copyright ©
4022-18
DTC (ERROR CODE): 7200 SWING BRAKE SOLENOID SIGNAL FAULT
BLOCK DIAGRAM
Press. Sensor (swing)

each connector.
Press. Sensor (upper)

Check the fuse F1 (65A) in the fusible
link and the fuse F13 (10A) in the
fuse box go out. Crank Angle sensor
Engine controller
Check the swing brake.
Disconnect the CN.128 after turning Swing Brake

Cause/Procedure
Measure the resistance between No.1 terminal and
No.2 terminal of the CN.128 swing brake solenoid. The swing brake solenoid is faulty.
No Key Switch
From 34Ω to 47Ω Replace
Relay Battery
Yes
Check the short circuit.

Fusible link
Fuse box
Cause/Procedure
Measure the voltage between No.2 terminal of the The harness VG800 is faulty (short cir-
Cause/Procedure
0V Replace Check the electrical connection between No.2 The harness VG800 is faulty (open cir-
terminal of the CN.128 harness and "GND". cuit).
No
Yes There is an electrical connection.
Turn the key switch to "OFF". Repair or replace
Cause/Procedure
The harness R251, GR250, R109, R106 Yes
Check the electrical connection between No.1 terminal Turn the key switch to "ON".
of the CN.128 harness and "GND". No and R105 are faulty (short circuit).
Cause/Procedure
There is no electrical connection. Replace Measure the voltage between No.1 terminal of The harness R251, GR250, R109, R106
the CN.128 harness and "GND". No and R105 are faulty (open circuit).
Yes Approx. 12V Repair or replace
Yes
Cause/Procedure
Replace

Copyright ©
4022-19
DTC (ERROR CODE): 7201 TRAVEL 2ND SPEED SOLENOID SIGNAL FAULT
Turn the key switch to "ON". BLOCK DIAGRAM
Computer A
Press. Sensor (travel)
each connector.
Crank Angle sensor

Engine controller
fuse box go out.
Check the travel 2nd speed solenoid.

2 Stage travel

Cause/Procedure Key Switch

No.2 terminal of the CN.129 travel 2nd speed solenoid. The travel 2nd speed solenoid is faulty.
No Relay Battery
Yes
Check the short circuit. Fusible link

Fuse box
Cause/Procedure
Measure the voltage between No.2 terminal of the The harness LG801 is faulty (short cir-
Cause/Procedure
0V Replace Check the electrical connection between No.2 The harness LG801 is faulty (open cir-
No
Cause/Procedure
Cause/Procedure
Yes
Cause/Procedure
Replace

Copyright ©
4022-20
DTC (ERROR CODE): 7202 POWER UP SOLENOID SIGNAL FAULT

each connector.

fuse box go out.
Check the power up solenoid.

Cause/Procedure
No.2 terminal of the CN.130 power up solenoid. The power up solenoid is faulty.
No
Yes

Cause/Procedure
Measure the voltage between No.2 terminal of the The harness YG802 is faulty (short cir-
Cause/Procedure
0V Replace Check the electrical connection between No.2 The harness YG802 is faulty (open cir-
No
Cause/Procedure
Cause/Procedure
Yes
Cause/Procedure
Replace

Copyright ©
4022-21
BLOCK DIAGRAM
ComputerA
Engine controller
Throttle volume
Press. Sensor (P1)
Press. Sensor (P2)
Press. Sensor (travel)
Breaker/crusher pilot press.
2nd option line pilot press.
2 Stage relief
Key Switch
Relay Battery
Fusible link
Fuse box

Copyright ©
4022-22
DTC (ERROR CODE): 7203 TRAVEL ALARM BUZZER SIGNAL FAULT (NA ONLY)
Computer A
The DTC:7203 is displayed in the screen of the Press. Sensor (travel)
"DIAG" of the "Service & Support".

each connector.
Travel alarm
fuse box go out.
Check the travel alarm buzzer. Key Switch Relay Battery

Connect No.1 terminal of the CN.149 travel alarm Cause/Procedure

buzzer to the negative pole and No.2 terminal of it to the
positive pole of the battery, then check the operation of The travel alarm buzzer is faulty.
No
the travel alarm buzzer.
Replace Fusible link
The travel alarm buzzer sounds. Fuse box
Yes

Cause/Procedure
Cause/Procedure Check the electrical connection between No.1
terminal of the CN.149 harness and "GND" for The harness W840 is faulty (open cir-
Measure the voltage between No.1 terminal of the The harness W840 is faulty (short circuit).
0.4 seconds after turning the key switch to "ON". No cuit).
CN.149 harness and "GND". No
Replace
There is an electrical connection. Repair or replace
0V
Yes Yes
Turn the key switch to "OFF". Turn the key switch to "ON".
Check the electrical connection between No.2 terminal The harness GW225, R111, R106 and Measure the voltage between No.2 terminal of The harness GW225, R111, R106 and
of the CN.149 harness and "GND". R105 are faulty (short circuit). the CN.149 harness and "GND". No R105 are faulty (open circuit).
No
There is no electrical connection. Replace Approx. 12V Repair or replace
Yes Yes
Cause/Procedure
Replace

Copyright ©
4022-23
DTC (ERROR CODE): 7204 POWER SAVE SOLENOID SIGNAL FAULT
Computer A
The DTC:7204 is displayed. Press. Sensor (swing)

each connector.

link and the fuse F13 (10A) in the Press. Sensor (travel)
fuse box go out.
Crank Angle sensor
Check the power save solenoid.

Engine controller

Power save
Cause/Procedure
No.2 terminal of the CN.131 power save solenoid. The power save solenoid is faulty.
No
Key Switch
Relay Battery
Yes

Fusible link
Cause/Procedure
Measure the voltage between No.2 terminal of the The harness BrG803 is faulty (short cir- Fuse box
0V Replace Cause/Procedure
Check the electrical connection between No.2 The harness BrG803 is faulty (open cir-
Yes terminal of the CN.131 harness and "GND". cuit).
Turn the key switch to "OFF". No
Cause/Procedure There is an electrical connection. Repair or replace

Check the electrical connection between No.1 terminal The harness R254, GR250, R109, R106
of the CN.131 harness and "GND". No and R105 are faulty (short circuit). Yes
There is no electrical connection. Replace Cause/Procedure
Measure the voltage between No.1 terminal of The harness R254, GR250, R109, R106
Yes the CN.131 harness and "GND". No and R105 are faulty (open circuit).
Check the open circuit. Approx. 12V Repair or replace
Yes
Cause/Procedure
Replace

Copyright ©
4022-24
DTC (ERROR CODE): 7209 AIR CONDITIONER WATER TEMPERATURE SIGNAL FAULT.)
BLOCK DIAGRAM
Engine Controller Water temp. sensor

Computer A
The DTC:7209 is displayed in the screen of the "DIAG"


Air conditioner
each connector.


of the CN.28 harness and "GND". The harness OL822 is faulty (short cir-
No cuit).
Replace
Yes
Cause/Procedure
Measure the voltage between No.11 terminal of the The harness OL822 is faulty (open cir-
Yes
Cause/Procedure
Replace

Copyright ©
4022-25
NOTES
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Copyright ©
4022-26
DTC (ERROR CODE): 7240 PUMP FORCE POWER PROPORTIONAL VALVE SIGNAL FAULT
BLOCK DIAGRAM
Computer A Press. sensor (P1)
Press. sensor (P2)

Check the connected condition of Press. sensor (upper)

each connector.
Crank angle sensor

Reset the DTC in the screen of the "DIAG" of the "Serv-
ice & Support".
Engine controller
Pump power
The DTC:7240 is displayed. No
Yes
Check the pump force power proportional valve.
Yes
Disconnect the CN.113 after turning the key switch to "OFF".
Cause/Procedure
Check the electrical connection between No.1 The pump force power proportional
Cause/Procedure
terminal and No.2 terminal of the CN.113 pump valve is faulty.
Check an electrical connection between No.1 terminal The harness YR940 is faulty (short cir- force power proportional valve. No
of the CN.113 harness and "GND". No cuit).
Replace
There is no electrical connection Replace
Yes
Yes
Cause/Procedure
Replace
Go to next page, Item A

Copyright ©
4022-27
Item A
Disconnect the CN.B4.
Cause/Procedure
Check the electrical connection between No.1 terminal
Between the CN.113 and the CN.B4 of
of the CN.113 (female side) and No.17 terminal of the
No the harness YR940 is faulty (open circuit).
CN.B4 (female side).
Repair or replace
Yes
Cause/Procedure
No the harness BY941 is faulty (open circuit).
Repair or replace
Yes
Cause/Procedure
of the CN.B4 (male side) and No.3 terminal of the Between the CN.C3 and the CN.B4 of the
CN.C3 (female side). No harness YR940 is faulty (open circuit).
Yes
Cause/Procedure
CN.C3 (female side). No harness BY941 is faulty (open circuit).
Yes
Replace

Copyright ©
4022-28
DTC (ERROR CODE): 7241 P1 FLOW CONTROL PROPORTIONAL VALVE SIGNAL FAULT
BLOCK DIAGRAM
Computer A Press. sensor (swing)
Press. sensor (upper)
Press. sensor (travel)

each connector.
Crank angle sensor
Reset the DTC in the screen of the "DIAG" of the "Serv-

ice & Support". Engine controller
Pump flow
The DTC:7241 is displayed. No
Yes
Check the P1 flow control proportional valve.
Yes
Cause/Procedure
Check the electrical connection between No.1 The P1 flow control proportional valve is
Cause/Procedure terminal and No.2 terminal of the CN.114 P1
No faulty.
Check the electrical connection between No.1 terminal The harness LR942 is faulty (short cir- flow control proportional valve.
of the CN.114 harness and "GND". No cuit).
Replace
There is no electrical connection Replace
Yes
Yes
Cause/Procedure Check the open circuit.
Replace Go to next page, Item A

Copyright ©
4022-29
Item A
Disconnect the CN.B4.
Cause/Procedure
No the harness LR942 is faulty (open circuit).
Repair or replace
Yes
Cause/Procedure
No the harness BL943 is faulty (open circuit).
Repair or replace
Yes
Cause/Procedure
CN.C3 (female side). No harness LR942 is faulty (open circuit).
Yes
Cause/Procedure
CN.C3 (female side). No harness BL943 is faulty (open circuit).
Yes
Replace

Copyright ©
4022-30
DTC (ERROR CODE): 7241 P1 FLOW CONTROL PROPORTIONAL VALVE SIGNAL FAULT
DTC (ERROR CODE): 7402 ENGINE COOLANT TEMPERATURE IS ABNORMALLY HIGH (110°C OR MORE)
DTC (ERROR CODE): 7403 ENGINE COOLANT TEMPERATURE IS ABNORMALLY HIGH (120°C OR MORE)
BLOCK DIAGRAM
Start the engine, and warm it up per-
fectly.
Engine controller
Computer A
Water Temp. sensor
Yes
Cause/Procedure
Check the whole engine.
DTC (ERROR CODE): 7404 ENGINE OIL TEMPERATURE IS ABNORMALLY HIGH (95°C OR MORE)
BLOCK DIAGRAM
fectly.
Engine controller Fuel temp. sensor
Computer A

Yes
Cause/Procedure
DTC (ERROR CODE): 7405 BOOST TEMPERATURE IS ABNORMALLY HIGH (80°C OR MORE)
DTC (ERROR CODE): 7406 BOOST TEMPERATURE IS ABNORMALLY HIGH (90°C OR MORE)
BLOCK DIAGRAM
fectly. Boost temp. sensor
Engine controller
Computer A

Yes
Cause/Procedure

Copyright ©
4022-31
DTC (ERROR CODE): 7420 ALTERNATOR VOLTAGE FAULT.
The DTC:7420 is displayed in the screen of the "DIAG" Computer A

Key Switch
each connector.
Relay R11
Starter cut

Starter motor
Cause/Procedure
Check the electrical connection between No.2 terminal The harness Br016 and BrR523 are Alternator
of the CN.110 harness and "GND". faulty (short circuit).
No
There is no electrical connection. Replace
Yes
Check the alternator.
Lever lock
Start the engine.
Cause/Procedure Relay safety

Measure the voltage between No.2 terminal of the CN. The alternator is faulty.
110 harness and "GND". Yes
Replace
Less than 10V
No
Check if there is the open circuit.
Connect the CN.110 connector

after turning the key switch to OFF".
Disconnect the CN.C1 connector and

start the engine.
Cause/Procedure
Measure the voltage between No.8 terminal of the The harness Br016 and BrR523 are faulty
CN.C1 harness and "GND" circuit. (short circuit).
Yes
Less than 10V Replace
No
Cause/Procedure
Replace

Copyright ©
4022-32
DTC (ERROR CODE): 7421 COOLANT LEVEL LOWERING SIGNAL IS DETECTED.
"LOW COOLANT" is displayed. BLOCK DIAGRAM
Computer A
Limit switch
Supply the coolant. (reserve tank)
The DTC:7421 is displayed in the screen of the "DIAG" of the


each connector.
Check the coolant level switch.

Cause/Procedure
and No.2 terminal of the CN.138 coolant level switch. The coolant level switch is faulty.
No
Yes
Cause/Procedure
Replace

Copyright ©
4022-33
DTC (ERROR CODE): 7422 ENGINE OIL PRESSURE ABNORMALLY LOW
BLOCK DIAGRAM
The engine oil pressure is abnormally low.
Computer A Engine controller Oil press. sensor
Start the engine and wait for 30 sec-

onds or more.

Yes
Cause/Procedure

Copyright ©
4022-34
DTC (ERROR CODE): 7423 AIR FILTER CLOG SWITCH SIGNAL IS DETECTED.
BLOCK DIAGRAM
"AIR FILTER" is displayed.
Computer A
Clean or replace the air filter element.
Press. switch
Start the engine and wait for at least (Air cleaner)
10 seconds.
The DTC:7423 is displayed in the screen of the "DIAG" of the


each connector.
Check the air filter clog switch.

Cause/Procedure
and No.2 terminal of the CN.139 air filter glog switch. The air filter clog switch is faulty.
No
Yes
Cause/Procedure
Check the electrical connection between No.1 terminal The harness LW471 is faulty (short cir-
of the CN.139 harness and "GND". cuit).
No
Yes
Cause/Procedure
Replace

Copyright ©
4022-35
DTC (ERROR CODE): 7424 HYDRAULIC OIL FILTER CHECK SIGNAL IS DETECTED. (WITH BREAKER)
BLOCK DIAGRAM
"CHECK HYD. OIL FILTER" is displayed.
Computer A
Replace the hydraulic oil filter.

Press. switch
(Filter indicator)
The DTC: 7424 is displayed.

each connector and "GND".
Check the hydraulic oil filter clog switch.

Cause/Procedure
and No.2 terminal of the CN.134 hydraulic oil filter clog The hydraulic oil filter clog switch is faulty.
No
switch.
Replace
Yes
Cause/Procedure
Replace

Copyright ©
4022-36
DTC (ERROR CODE): 7600 CAN BUS FAULT
BLOCK DIAGRAM
CAN COMMUNICATION Computer A
Deutsch

each connector.
Check the short circuit. Computer S Computer B Engine controller

Check the electrical connection between the A terminal The harness P040, P042, P044 and P048 Is the DTC: 7600 displayed? The ECM is faulty.
of the CN.50 harness and "GND". are faulty (short circuit). No
No
Displayed Replace
Yes
Connect CN.A0 after turning the key
Yes switch to "OFF".
Cause/Procedure
Check the electrical connection between the B terminal The harness PG041, PG043, PG045 and
of the CN.50 harness and "GND". PG049 are faulty (short circuit). Turn the key switch to "ON" after dis-
No
connecting CN.C2.
Cause/Procedure
Is the DTC: 7600 displayed? The computer "A" is faulty.
Yes
Cause/Procedure No
The harness P040, P042, P044, P048, Displayed Replace
Check the electrical connection between the A terminal PG041, PG043, PG045 and P049 are
and the B terminal of the CN.50 harness. No faulty (short circuit). Yes
Connect CN.C2 after turning the key
There is no electrical connection. Replace switch to "OFF".
Yes
Connect CN.50. Turn the key switch to "ON" after dis-
connecting CN.CR2.
Check the ECM, the computer "A", the compu-
ter "B", and the computer "S". Cause/Procedure
Is the DTC: 7600 displayed? The computer "B" is faulty.
No
Turn the key switch to "ON" after dis- Displayed Replace
connecting CN.A0.
Yes
Cause/Procedure
The computer "S" is faulty.
Replace

Copyright ©
4022-37
DTC (ERROR CODE): 7601 MONITOR COMMUNICATION FAULT
Computer A Monitor

each connector.

SERIAL COMMUNICATION
Disconnect the CN.C5 after turning

Cause/Procedure
Check the electrical connection between No.12 terminal The harness PL056 is faulty (open cir-
of the CN.C2 harness and No.4 terminal of the CN.C5 cuit).
No
harness.
Repair or replace
Yes
Cause/Procedure
Check the electrical connection between No.4 terminal The harness PW055 is faulty (open cir-
of the CN.C2 harness and No.13 terminal of the CN.C5 No cuit).
harness.
Repair or replace
Yes
Cause/Procedure
Is the DTC:7601 displayed? The monitor is faulty.
No
Displayed Replace
Yes
Cause/Procedure
Replace

Copyright ©
4022-38
DTC (ERROR CODE): 7602 ECM COMMUNICATION TIME OUT
BLOCK DIAGRAM

Turn the key switch to "ON". Deutsch
Computer S Computer B Engine controller

each connector.
Are the DTC:7603 and DTC:7604 displayed at the Cause/Procedure

same time? Check the connection condition of the
Yes
CN.C2.
They are displayed.
No
Disconnect CN.C2 and CN.A0 after

turning the key switch to "OFF".
Cause/Procedure
Check the electrical connection between No. 6 terminal
of the CN. C2 harness and No.18 terminal of the CN. The harness P040 and P042 are faulty
A0 harness. No (open circuit).
Yes
Cause/Procedure
Check the electrical connection between No. 14 termi-
The harness PG041 and PG043 are
nal of the CN. C2 harness and No.37 terminal of the
faulty (open circuit).
CN. A0 harness. No
Repair or replace
Yes
Cause/Procedure
The ECM is faulty.
Replace

Copyright ©
4022-39
DTC (ERROR CODE): 7603 COMPUTER "B" COMMUNICATION TIME OUT
BLOCK DIAGRAM


each connector.

Yes
CN.C2.
They are displayed.
No
Disconnect CN.C2 and CN.CR2 after

Cause/Procedure
of the CN. C2 harness and No.6 terminal of the The harness P040 and P044 are faulty
CN.CR2 harness. No (open circuit).
There is an electrical connection. Replace
Yes
Cause/Procedure
CN.CR2 harness. No
Replace
Yes
Cause/Procedure
The computer "B" is faulty.
Replace

Copyright ©
4022-40
DTC (ERROR CODE): 7604 COMPUTER "S" COMMUNICATION TIME OUT
BLOCK DIAGRAM


each connector.

Yes
CN.C2.
They are displayed.
No
Disconnect CN.C2 and CN.C7 after

Cause/Procedure
of the CN. C2 harness and No.8 terminal of the CN.C7 The harness P040 and P048 are faulty
harness. No (open circuit).
There is an electrical connection. Replace
Yes
Cause/Procedure
CN.C7 harness. No
Replace
Yes
Cause/Procedure
The computer "S" is faulty.
Replace

Copyright ©
4022-41
DTC (ERROR CODE): 7605 ECM MISMATCH
BLOCK DIAGRAM

Computer A
The DTC:7605 is displayed. Engine controller
CAN COMMUNICATION
Do you select the correct screen of machine model Cause/Procedure

selection in the "Service & Support"? Select the screen for machine model
No
selection correctly.
The correct screen is selected.
Yes
Is the ECM to be applied to the machine model Cause/Procedure

installed? No Replace to the correct ECM to be applied
to the machine model.
It is installed.
Yes
Cause/Procedure
The ECM is faulty.
Replace

Copyright ©
4022-42
NOTE
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Copyright ©
8001
Section
8001
SPECIFICATIONS, TROUBLESHOOTING,
INSPECTIONS AND HYDRAULIC PRESSURE SETTING

Printed in France
CNH Lep SMCX350B370B8001-0EN July 2008
Copyright ©
8001-2
TABLE OF CONTENTS
WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see
! this symbol, carefully read the message which follows. Your safety depends on it.
SPECIFICATIONS .................................................................................................................................................... 5
SPECIAL TOOLS ...................................................................................................................................................... 5

Tester .................................................................................................................................................................... 5
HYDRAULIC EQUIPMENT LAYOUT........................................................................................................................ 7

Overall view .......................................................................................................................................................... 7
Pump chamber...................................................................................................................................................... 8
Swing body center section .................................................................................................................................... 9
Housing left side ................................................................................................................................................. 10
Cab ..................................................................................................................................................................... 11
IDENTIFICATION OF HYDRAULIC COMPONENTS ............................................................................................. 12

Pump................................................................................................................................................................... 12
Control valve ....................................................................................................................................................... 13
5 Way solenoid valve .......................................................................................................................................... 16
2 Way solenoid valve .......................................................................................................................................... 17
Remote control valves (upper side, travel).......................................................................................................... 18
Cushion valve ..................................................................................................................................................... 19
4 way multi-valve ................................................................................................................................................ 20
2 way multi-valve ................................................................................................................................................ 21
Direction valve / Shut-off valve............................................................................................................................ 22
Safety valve (Option for Europe)......................................................................................................................... 23
Manifolds............................................................................................................................................................. 23
Swing motor ........................................................................................................................................................ 25
Travel motor ........................................................................................................................................................ 26
Center joint.......................................................................................................................................................... 27
PREPARATION BEFORE INSPECTION................................................................................................................ 28

Releasing pressure in the hydraulic system and Pressure measurement preparations ..................................... 28
Procedures for pressure measurement from the monitor display ....................................................................... 29
Procedures for measuring hydraulic oil temperature from the monitor display ................................................... 30
Pressure measuring port..................................................................................................................................... 31
Control valve ....................................................................................................................................................... 32
Location of relief valves ...................................................................................................................................... 32
PRESSURE MEASUREMENT................................................................................................................................ 33
Main Pressure Measurement .............................................................................................................................. 33
Pilot pressure measurement ............................................................................................................................... 37
Negative pressure measurement ........................................................................................................................ 38
PRESSURE ADJUSTMENT ................................................................................................................................... 40
Lep SMCX350B370B8001-0EN Issued 07-08

Copyright ©
8001-3
Main pressure adjustment .................................................................................................................................. 40
Pilot pressure adjustment ................................................................................................................................... 43
HYDRAULIC PUMP FLOW MEASUREMENT PROCEDURE................................................................................ 44

Work preparations .............................................................................................................................................. 44
Flow measurement ............................................................................................................................................. 46
Flow curve .......................................................................................................................................................... 47
DRAIN VOLUME MEASUREMENT PROCEDURE................................................................................................ 48

Preparations ....................................................................................................................................................... 48
Travel motor drain volume measurement ........................................................................................................... 48
Swing motor drain volume measurement ........................................................................................................... 50
AIR BLEED PROCEDURE ..................................................................................................................................... 51

Hydraulic pump................................................................................................................................................... 51
Travel motor........................................................................................................................................................ 52
Swing motor........................................................................................................................................................ 53
Safety valve ........................................................................................................................................................ 54

Copyright ©
8001-4

Copyright ©
8001-5
SPECIFICATIONS
See section 1002.
SPECIAL TOOLS
Tester
1 2
3
CD01B005
2. FEMALE COUPLING JOINT E47894 (1)
PRESSURE TEST POINT 14X1.5 A3237549 (2)
MALE COUPLING JOINT WITH UNION (3) AND
PLUGS (4) CONTAINED IN THE SUITCASE CAS
CP96E001
30038
1. TEST KIT E5444449 FOR MULTI-HANDY 2051
The Multi-Handy tester can be used every day in the
workshop for normal operations.
The Multi-Handy can be used for:
Checking pressure (two pressure scales), maximum
pressure, differential pressure (P delta), temperature,
engine rpm and flow.
1 Multi-Handy 2051 tester .......................... D5444448
2 pressure detectors (0-600 bar)................ V5344460
2 straight unions for detector..................... W5344461
1 elbow union for detector .......................... X5344462
1 engine rpm detector ................................ Z5344463
3 cables (5 m long)..................................... E3144472
CD98M009
1 electric socket 220 V - 50 Hz .................. D5344467
3. 600 LITER FLOWMETER, ORDER THE
1 cigarette lighter cable .............................. E5344468
FOLLOWING:
1 instruction manual .................................... -------------
1 carrying case........................................... N5344476 ONE FLOWMETER RE3 Z5344486
TWO PLATES (M45X2) D4323359
TWO FLANGES (Ø 24) B8230183
FOUR HALF FLANGES D4024267
EIGHT SCREWS (12X75) Z1232983

Copyright ©
8001-6
CS99B532
4. SET OF UNIONS FOR PRESSURE TEST AND
HYDRAULIC FLOW CAS 30038.
CD99C002
5. SET OF HIGH PRESSURE HYDRAULIC HOSES
CAS XXXXX (INCLUDING TWO HIGH
PRESSURE HOSES).

Copyright ©
8001-7
HYDRAULIC EQUIPMENT LAYOUT
Overall view
SD01011-505
1 Left side housing

2 Swing body center section
3 Pump compartment
4 Hydraulic oil tank
5 Fuel tank

Copyright ©
8001-8
Pump chamber
2
1
11
8 10
SD01011-501
1 Hydraulic pump 7 P1 pressure sensor

2 Accumulator 8 Pilot pump
3 Pilot filter 9 N2 pressure sensor
4 5 stack solenoid valve 10 Horsepower control electromagnetic proportional valve
5 N1 pressure sensor 11 Hydraulic oil temperature sensor
6 P2 pressure sensor

Copyright ©
8001-9
Swing body center section
1 3
2
2 3
SD01011-502
1 Swing motor
2 Center joint
3 Control valve

Copyright ©
8001-10
Housing left side
SD01011-503
1 Cushion valve (with heat circuit) 4 2-way selector valve

2 Swing pilot pressure sensor 5 Oil cooler
3 2-way selector valve installation seating

Copyright ©
8001-11
Cab
1 2
RST 04 01 00
1 Travel remote control valve

2 Upper operation remote control valve

Copyright ©
8001-12
IDENTIFICATION OF HYDRAULIC COMPONENTS
Pump
Dr
Pi1
a5
P2
a4
A2 A1
Pi1
a2 a1 A3
a3
Dr3
P1 Pi2 Pi1
a6 P1
Psv
P2
B3
B1
Pi2
SD06012-001
Port Description Location

A1, A2 Discharge port SAE6000psi 1
B1 Suction port SAE2500psi 2-3
Dr Drain port G 3/4-23
P1 Proportional valve primary pressure port G 1/4-13
P2 P2 port G 1/4-13
Psv Servo assist port G 1/4-15
Pi1, Pi2 Negative control port G 1/4-13
a1, a2, a4, a5,
Gauge port G 1/4-15
a6
A3 Gear pump discharge port G 1/2-19
B3 Gear pump suction port G 3/4-20.5
a3 Gauge port G 1/4-14
Dr3 Drain port (gear pump) G 3/8-15

Copyright ©
8001-13
Control valve
2
3
4
1
7 10 12
8
11 9 SD06012-007
1 Boom up 7 Main a (normal use)

2 Arm in 8 Main b (boosted pressure)
3 Boom down 9 Standard lock nut
4 Bucket close 10 Boosted pressure adjusting screw
5 Arm out 11 Pressure boost adjusting screw
6 Bucket open 12 Standard pressure adjusting screw

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8001-14
Pn2
Pn1
Ps1
pb5 T1
A5
T8 B5
pb8 A3
B3
pb7 pb3 B2
pb6 A2
B1
A1
P1
PH pb1 pb2
BD06003-002
Port Port size Description

P1 SAE 6000psi 1 Pressure line
A1 SAE 5000psi 1 Left travel (forward) line
B1 SAE 5000psi 1 Left travel (backward) line
A2 SAE 5000psi 1 Option line
B2 SAE 5000psi 1 Option line
A3 SAE 5000psi 1 Swing right line
B3 SAE 5000psi 1 Swing left line
A5 SAE 5000psi 1 Arm-out line
B5 SAE 5000psi 1 Arm-in line
T1 Return line
pb1 G 1/4 Left travel backward pilot line
pb6 G 1/4 Right travel backward pilot line
pb3 G 1/4 Left swing pilot line
pb4 G 1/4 Boom 2-down drain line
pb5 G 1/4 Arm 1 in pilot line
pb7 G 1/4 Bucket-close pilot line
pb8 G 1/4 Boom 1-down pilot line
pb9 G 1/4 Arm 2-in pilot line
Pn1 G 1/4 Negative control power save signal
Pn2 G 1/4 Negative control power save signal
PH G 1/4 Pressure boost signal port
Ps1 G 1/4 Negative control line
T8 G 1/4 Heat circuit line
pb2 G 1/4 Option line

Copyright ©
8001-15
T2
Ps2
Pbu B8
pa5 pa9
A8
pa8
pa4 B7
A7
pa3
B6
A6
PA
pa7
PT
pa1
P2
DR3 pa6
BD06003-003
Port Port size Description

P2 SAE 6000psi 1 Pressure line
A6 SAE 5000psi 1 Right travel (forward) line
B6 SAE 5000psi 1 Right travel (backward) line
A7 SAE 5000psi 1 Bucket-open line
B7 SAE 5000psi 1 Bucket-close line
A8 SAE 5000psi 1 Boom-up line
B8 SAE 5000psi 1 Boom-down line
T2 Return line
pa1 G 1/4 Left travel forward pilot line
pa6 G 1/4 Right travel forward pilot line
DR3 G 1/4 Straight travel drain line
pa7 G 1/4 Bucket-open pilot line
pa3 G 1/4 Right swing pilot line
pa8 G 1/4 Boom 1-up pilot line
pa4 G 1/4 Boom 2-up pilot line
pa9 G 1/4 Arm 2-out pilot line
pa5 G 1/4 Arm 1-out pilot line
PA G 1/4 Upper signal
PT G 1/4 Travel signal
Ps2 G 1/4 Negative control line
Pbu G 1/4 Swing priority variable orifice switch signal
Pa2 G 1/4 Option line

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8001-16
5 Way solenoid valve
1 Power save
2 Lever lock
3 Swing lock
4 Pressure boost
5 Travel high speed
Port Location
C2 G1/4
C3 G1/4
C1 G1/4
C5 G1/4
C4 G1/4
P G3/8
B G3/8
T G3/8

Copyright ©
8001-17
2 Way solenoid valve
B1
A2
B2 A1
T
ND06008-020 ND06008-021
Port Location
A1 G1/4
B1 G1/4
A2 G1/4
B2 G1/4
T G1/4

Copyright ©
8001-18
Remote control valves (upper side, travel)
1. Remote control valve (left, right)
Right side Left side
4
2 T
2
P
T 4
3 P
1 1
P 3
4 T
1 2
3 3
P 1
4 T 2
RST-04-06-001g01 RST-04-06-001g02
Port Right side Left side Location

1 Bucket close Swing right G3/8
2 Boom-down Arm-in G3/8
3 Bucket open Swing left G3/8
4 Boom-up Arm-out G3/8
P Pressure Pressure G1/4
T Return Return G3/8
2. Remote control valve (Travel)
1 3
2 4 RST-04-06-001m

1 Backward left G1/4
2 Forward left G1/4
3 Backward right G1/4
4 Forward right G1/4
P Pressure G1/4
T Return G1/4

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8001-19
Cushion valve
1 Arm-in
2 Boom up
3 Swing right
4 Bucket close
5 Heat circuit line
6 Arm-out
7 Boom down
8 Swing left
9 Bucket open
10 Pressure sensor (swing)
11 Swing priority switching pilot line
12 Drain line

E, F Boom up G3/8
G, H Boom down G3/8
O, P Bucket open G3/8
M, N Bucket close G3/8
C, D Arm-out G3/8
A, B Arm-in G3/8
K, L Swing left G3/8
I, J Swing right G3/8
Q Swing pressure sensor signal G1/4
U - G1/4
S Swing priority orifice switch G1/4
V - G1/4
T Return G1/4
R Heat circuit G1/4

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8001-20
4 way multi-valve
Port Description (ISO format) Location

A Right remote control valve side port/ Boom up G1/4
C Right remote control valve side port/ Boom down G1/4
D Right remote control valve side port/ Bucket open G1/4
B Right remote control valve side port/ Bucket close G1/4
E Left remote control valve side port/arm out G1/4
G Left remote control valve side port/arm in G1/4
H Left remote control valve side port/swing left G1/4
F Left remote control valve side port/swing right G1/4
1 Cushion valve side port G1/4

Copyright ©
8001-21
2 way multi-valve
A
1
B
D
C
3 4
RST-04-06-001i01 RST-04-06-001i02
Remote control valve side Cushion valve side
Port Description (ISO format) Location

A Remote control valve side / swing-left port G3/8
B Remote control valve side / arm-in port G3/8
C Remote control valve side / swing-right port G3/8
D Remote control valve side / arm-out port G3/8

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8001-22
Direction valve / Shut-off valve
1. Direction valve
RST-04-06-0001R
Port Location
A G1
B G1
T1 G1
T2 G3/4
PP G1/4
DR G1/4
2. Shut-off valve
RST-04-06-0001S
Port Location
A G1
B G1
T G3/4
PP G1/4
DR G1/4

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8001-23
Safety valve (Option for Europe)
PL
A
DR SD06012-002
B port opening side
Port Remarks Location

Arm HBCV SAE 6000psi 1
A
Boom HBCV SAE J6000psi 1
Arm HBCV SAE 6000psi 31
B
Boom HBCV SAE J6000psi 1
C G1/4
DR G3/8
PL G1/4
Manifolds
1. Manifold under cab
T2 T5
T1 T3
T4
P2 P5
P1 P3
P4
RST-04-06-0001O
Port Location Port Location

P1 G3/8 T1 G3/8
P2 G3/8 T2 G3/8
P3 G3/8 T3 G3/8
P4 G1/4 T4 G1/4
P5 G1/4 T5 G1/4

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8001-24
2. Manifold (accumulator section)
RST-04-06-0001T
Port Location
P G1/2
P1 G1/4
P2 G1/4
P3 G1/2
P0 G3/8
3. Manifold (hydraulic oil tank section)
D1
D7
T1
A
D3
D6
T D2
A
G3/4
G1/2
SD06012-00
Port Location Port Location

D1 G3/8 T G1/2
D2 G1/4 T1 G3/8
D3 G1/4 D7 G3/8
D6 G1/4

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8001-25
Swing motor
DB
PA,PB
PG M
A
B
Dr
SGr
SD06012-004

M Make-up G1
DB Drain G1/2
G Brake release G 1/4
A Right swing -
B Left swing -
PA, PB Pressure measurement G1/4
Dr Gear oil drain port PT3/8
SGr Grease-up port PT1/8

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8001-26
Travel motor
SD06012-005

D1, D2 Drain port G1/2
P Pilot port G1/4
MA, MB Pressure detection port G1/4
VA, VB Main port G1

Copyright ©
8001-27
Center joint
D' C'
C
A
P
B
D T
D B A C
P'
A'
B'
C'
D'
T T
SD0

A' Forward right (connected to travel motor) G1
B' Forward left (connected to travel motor) G1
C' Backward right (connected to travel motor) G1
D' Backward left (connected to travel motor) G1
P' Pilot port (connected to travel motor) G1/4
T Drain port G1/2
A Forward right (connected to control valve) 500psi 1
B Forward left (connected to control valve 500psi 1
C Backward right (connected to control valve) 500psi 1
D Backward left (connected to control valve) 500psi 1
P Pilot port (connected to control valve) G1/4

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8001-28
PREPARATION BEFORE INSPECTION
WARNING: Hydraulic fluid output under pressure can penetrate the skin. Hydraulic fluid can also cause or
infect a slight skin cut. In the event of being injured by hydraulic fluid under pressure, consult a doctor
immediately. Any delay in obtaining treatment for an injury can cause a serious infection or reaction.
Before pressurizing the circuits, make sure that all the connections are correctly tightened and that the
! hoses and pipes are in good condition. Release pressure in the circuits completely before disconnecting
pipes or carrying out any operation on the hydraulic system. Always use a small piece of cardboard or
wood to detect leaks of fluid under pressure. Never use your hands.
WARNING: Any incorrect use or mainte- WARNING: The accumulator of this machine
nance of a construction machine can cause is charged with nitrogen under pressure. In
accidents. Only persons who have read, the event of incorrect operation of the circuit,
! understood and who observe the instructions
! change the accumulator. Never attempt to
in the operator's manual are accredited to repair it. Non-observance of these instruc-
use or maintain this machine. tions and the procedure shown below can
cause serious or fatal injury.
Releasing pressure in the hydraulic system and Pressure measurement

preparations
NOTE: Operation to be carried out before every service 7. Use the service check to check the hydraulic oil
operation on the hydraulic system. temperature.
1. Position the machine on hard, flat ground.
2. Open the bucket until the cylinder rod is completely CHK MAIN 2 Baro 0 0 3 . 9 in Hg
retracted. Coolnt 0185 ˚F EngOil 0 0 0 0 psi
3. Extend the dipper until the cylinder rod is com- HydOil 0122 ˚F Bst T 0104 ˚F
pletely retracted. Lower the boom so that the end of
the dipper is resting on the ground. Lower the tool
Fuel T 0113 ˚F Air 0086 ˚F
to the ground. RST-09-01-001K
4. Check with the diagnostic display in "SP" mode that
the following values are shown. 45 to 55°C
Oil temperature
113 to 131°F
CH K MA I N 1 P1 0 1 7 4 psi
If the oil temperature is low, raise the oil tempera-
Eng 1 8 0 0 rpm P2 0 1 7 4 psi
ture according to the warm-up operation procedure
Power 0 6 0 0 mA N1 4 4 2 . 4 psi in the operator’s manual.
Flow 0 7 2 7 mA N2 5 8 7 . 4 psi 8. Lower the pilot control cancellation lever.
9. Operate each control more than 10 times in both
RST-09-01-001H
directions to release pressure in the circuits.
Eng = Engine rpm 1900 rpm 10. Press the button located on the hydraulic reservoir
breather to release pressure in the reservoir.
Power = Electric current
500 mA (operating)
value
5. Lower the engine speed to idle for 30 seconds, then

shut down the engine.
6. Turn the starter key switch to "ON", without starting
the engine.
RST-09-01-001N

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8001-29
Procedures for pressure measurement from the monitor display
• Monitor and switch panel
4
3
1 2 5
RST-09-01-001a
1 Liquid crystal monitor 4 Design panel

2 Switch panel 5 Installation bracket
3 Hour meter
1. Pressure Measurement Method
The P1, P2, N1, and N2 pressure can be measured from the monitor display.
(The pilot pressure cannot be measured.)
2. Operating Method
If you hold down both the travel mode select switch and the horn volume select switch on the switch panel for 3 sec-
onds, the display switches to the service support screen.
The respective pressures are displayed in the service support screen's "P1" (P1 pump main pressure), "P2" (P2
pump main pressure, "N1" (N1 negative control pressure, and "N2" (N2 negative control pressure) columns.
If you again hold down both the travel mode select switch and the horn volume select switch on the switch panel for
1 second, the display returns to the normal screen.
Normal screen Service support screen

+
CHK MAIN 1 P1 0 1 7 4 psi
a Eng 1 8 0 0 rpm P2 0 1 8 8 psi
Power 0 6 0 0 mA N1 4 5 6 . 9 psi
b Flow 0 7 2 7 mA N2 5 8 7 . 4 psi
SI01009-002
a: Hold down for 3 seconds

b: Hold down for 1 second

Copyright ©
8001-30
Procedures for measuring hydraulic oil temperature from the monitor display
1. Hydraulic Oil Temperature Measurement Method
The hydraulic oil temperature can be measured from the monitor display.
2. Operating Method
If you hold down both the travel mode select switch and the horn volume select switch on the switch panel for 3 sec-
onds, the display switches to the service support screen.
With the travel mode select switch (mode select switch), set the mode to "CHK".
With the horn volume select switch (section switch), set the section "MAIN".
With the light switch (page +), switch to Page "30".
The hydraulic oil temperature is displayed in the "Hydoil" column.
1 3 4
MAIN/ENG...
2 5
CHK/DIAG/HR...
6
CHK MAIN 1 P1 0 1 7 4 psi

Eng 1 8 0 0 rpm P2 0 1 7 4 psi
Power 0 6 0 0 mA N1 4 5 6 . 9 psi
Flow 0 7 2 7 mA N2 5 8 7 . 4 psi
7 SI01009-003
Page switch operation
CHK MAIN 2 Baro 0 0 3 . 9 in Hg

Coolnt 0 1 8 5 ˚F Eng oil 0 1 2 4 psi
Hydoil 0 1 2 2 ˚F Bst T 0 1 0 4 ˚F
Fuel T 0 1 1 3 ˚F Air 0 0 8 6 ˚F
SI01009-004
N101005-002
1 Section 5 Page (-)

2 Mode 6 Page (+)
3 Page 7 Mode select switch
4 Section switch A Hydraulic oil temperature (°C)

Copyright ©
8001-31
Pressure measuring port
There are the following three ports for measuring the pressure.
• Main pressure: pressure ports (P1, P2)
• Negative control pressure: pressure ports (N1, N2)
• Pilot pressure: pressure port (P3)
1 2
Main pressure
- Pressure port: Measuring with P1, P2
( Remove the Main pressure sensor,
then Install the pressure gauge.)
5
Pilot pressure
Negative control pressure - Pressure port: Measuring with P3
- Pressure port: Measuring with N1, N2
( Remove the negative control pressure sensor,
then Install the pressure gauge.) SI01009-501
1 Pump 4 Negative control pressure: N1

2 Main pressure: P2 5 Negative control pressure: N2
3 Main pressure: P1 6 Pilot pressure: P3

Copyright ©
8001-32
Control valve
Location of relief valves
Pressure per
rotation of Measuring
Tools Set pressure
Position adjusting port
screw
Lock nut Adjusting screw Lock nut
27 mm 27 mm 34.3 MPa 21.3 Mpa
a Main (normal use) Monitor P1
1.06 in 1.06 in 4975 Psi 3089 Psi
1
Main (boosted 32 mm 27 mm 37.3 Mpa 28.4 Mpa
b Monitor P1
pressure) 1.26 in 1.06 in 5409 Psi 4119 Psi
39.2 Mpa 21.2 Mpa
2 Boom-up Monitor P2
5685 psi 3075 Psi
27.4Mpa 21.2 Mpa
3 Boom down Monitor P2
3974 psi 3075 Psi
39.2 Mpa 21.2 Mpa
4 Arm-in Monitor P1
17 mm 5685 psi 3075 Psi
0.67 in 6 mm 39.2 Mpa 21.2 Mpa
5 Arm-out Monitor P1
0.24 in 5685 psi 3075 Psi
39.2 Mpa 21.2 Mpa
6 Bucket close Monitor P2
5685psi 3075 Psi
39.2 Mpa 21.2 Mpa
7 Bucket open Monitor P2
5685 psi 3075 Psi
24 mm 3.92 Mpa 2.0 Mpa
8 Pilot
0.94 in 568.5 psi 290 Psi
2
4
3
1
4
1 8 2
SI01009-001
Main relief valve adjustment location details

1 Boosted pressure lock nut
2 Boosted pressure adjusting screw
3 Standard pressure adjusting screw
4 Standard lock nut

Copyright ©
8001-33
PRESSURE MEASUREMENT
Main Pressure Measurement
Pressure gauge installation
1. Install pressure gauges at the pump pressure mea- 3. Install adapters (3).
suring ports.
(Pressure ports: a1 / a2)
a2 a1 S101009-505
1
4. Install pressure gauges (4) on the adaptors (3) and
S101009-503
fasten.
a1: Can be measured a2: Can be measured

Travel left Travel right
Option Bucket
4
Swing
Arm 1 pump flow Arm 2 pumps flow
Boom 2 pumps flow Boom 1 pump flow
2. Remove the pressure sensor a2.
S101009-506
S101009-504

Copyright ©
8001-34
Attachment pressure measurement
Example: Arm-out pressure measurement
Measure with the following operations.
Engine speed 1900 min-1

1
Work mode SP mode
Lever operation Arm-out relief
Oil temperature 45 - 55°C
Measuring port 1 pump: P1 port
2 pumps: P2 port
Set pressure Boosted pressure: 37.3 MPa (5409
Psi)
Standard: 34.3 MPa (4975 psi)
1 Arm-out relief
When the attachment operates, since the pressure boost operates automatically, the set boosted pressure can be
checked for about 8 s. After 8 s or more, the standard set pressure can be checked.
Measure relieving each cylinder with the arm out/in, the bucket open/close, and the boom up.
Lever operation Arm out Arm in Bucket Bucket Boom up Boom down
open close
Work mode SP mode
Oil temperature 45 - 55°C (113 to 131°F)
1 pump flow P1 P1 P2 P2 P2 P2
measuring port
2 pumps flow P2 P2 No No P1 P1
measuring port
Boosted pressure 37.3 MPa 37.3 MPa 37.3 MPa 37.3 MPa 37.3 MPa 27.4 MPa
5409 Psi 5409 Psi 5409 Psi 5409 Psi 5409 Psi 3974 Psi
Standard pressure 34.3 MPa 34.3 MPa 34.3 MPa 34.3 MPa 34.3 MPa 27.4 MPa
4975 Psi 4975 Psi 4975 Psi 4975 Psi 4975 Psi 3974 Psi
Boom-down pressure measurement

For pressure measurement with the boom down,
put the arm cylinder at its out stroke end, open the
bucket, put the bucket tip on the ground, carry out
the boom-down operation, and measure.
2 Boom-down relief

Copyright ©
8001-35
Travel pressure measurement
1. Install the stopper (5) on the crawler sprocket (6) 2. Measure with the following operations
section and lock the travel motor.
6 5 Work mode SP mode (1st speed)

Lever operation Travel relief
45 to 55°C
Oil temperature
113 to 131°F
Left travel: P1 port
Measuring port
Right travel: P2 port
34.3 MPa
Set pressure
4975 Psi
RST-09-01-001W
Swing pressure measurement

1. Set the swing lock with the monitor. 2. Measure with the following operations

Work mode SP mode
Lever operation Swing relief
45 to 55°C
Oil temperature
113 to 131°F
Measuring port P1 port
30.4MPa
Set pressure
4409 Psi
3. After the end of pressure measurement, release

the swing lock with the monitor.
RST-09-01-001X
Swing lock switching

In order to prevent accidental operation under certain special circumstances, sometimes the swing brake need to be
left ON all the time. (Swing lock) At this time, you can switch the swing lock ON to OFF or OFF to ON by holding
down the "horn volume select switch", the "working light switch", and the "auto idle switch" at the same time for 2
seconds. When the swing is locked, an icon "P" appears on the liquid crystal monitor.

Copyright ©
8001-36
Option line pressure measurement
1. Close the option line stop valve (7). 3. Measure with the following operations.

Work mode SP mode
Pedal operation Option relief
Oil temperature 45 to 55°C
1 Pump: P2 port
Measuring port
2 Pumps: P1 port
* 29.4 MPa
Set pressure
* 4264 Psi
* Adjust the set pressure to match the specifica-

tions of the attachment used.
7 Factory Pressure Settings
Breaker circuit: 29.4 MPa (4264 Psi)
RST-09-01-001Y Shuttle, combine (crusher) circuit: 17.8 MPa (2581
2. With the option operation select switch in the cab, Psi)
switch to the option line to measure. (Breaker, shut-
tle).
RST-09-01-001Z

Copyright ©
8001-37
Pilot pressure measurement
1. Install a pressure gauge at the pump pressure 3. Install the pressure gauge (10) and measure the
measuring port. (Pressure port: P3). pressure.
10
P3
RST-09-01-001AA RST-09-01-001AC
2. Install the adapter (9).

Work mode SP mode
45 to 55°C
Oil temperature
113 to 131°F
3.9 Mpa
Set pressure
565.6 psi
RST-09-01-001AB

Copyright ©
8001-38
Negative pressure measurement
1.Remove the pump N1 or N2 pressure sensor connector (11), and remove the pressure sensor. (N1, N2: pressure port)
(The pressure sensor location becomes the measurement port.)
11
N1
11
N2
R101004-011
2.Install the pressure gauge at the port from which the N1 or N2 pressure sensor was removed.
12
13
12
13
R101004-012
12 Adapter
13 Ratchet

Copyright ©
8001-39
3.Measure the negative control pressure for each operation.
S101009-008
14 Pressure gauge

Work mode SP mode
Oil temperature 45 - 55Åé
P1 pump side: N1 port
Measuring port
P2 pumps side: N2 port
Set pressure 3.9 MPa max.

Copyright ©
8001-40
PRESSURE ADJUSTMENT
Main pressure adjustment
Adjustment preparation work
Pressure is adjusted with control valves.
The following preparations are required for adjusting with control valves.
1. Release the two engine hood lock levers (2). 3. Remove the screws (4), then remove the cover (5).
1
4
5
S101009-509
S101009-507
2. Open the engine hood (1). Always check that the
lock (3) is locked.
S101009-508

Copyright ©
8001-41
Main relief pressure adjustment
3. Standard pressure
Engine speed 1900 min-1 H Loosen the standard pressure lock nut (14) (27
Work mode SP mode mm, 1.06 in).
Lever operation Arm-in relief I Loosen the adjusting screw (13), lower below the
set pressure, then adjust on the tightening side.
45 to 55°C
Oil temperature J After adjustment, tighten the lock nut (14) while
113 to 131°F
fastening the adjusting screw (13) with a spanner.
K After locking, check the pressure. Repeat H), I),
Boosted pressure: and J) until the set pressure is correctly adjusted.
37.3 MPa L Stop the engine.
5409 Psi
Measurement pressure
Standard:
6
34.3 MPa
4975 Psi
Boost pressure:
28.4 MPa / rotation
Pressure per rotation of 4119 Psi / rotation
adjusting screw Standard:
21.3 MPa / rotation
3089 Psi / rotation
1. Before adjusting, remove the pilot hose (10) for the

boosted pressure signal connected to the main
relief valve (7), then plug the hose side. The proce-
dures for boosted pressure and standard pressure 7
are different.
2. Boosted pressure
A Loosen the standard pressure lock nut (14) (27
mm) and tighten the adjusting screw (13) (27 mm, 1.06
8
in). Fasten with a spanner (27 mm, 1.06 in) so that the
boosted pressure adjusting screw (12) does not turn.
B After tightening until the adjusting screw (13) stops
turning, tighten the lock nut (14).
C Start the engine and run it at maximum rotation. 9
D Move the arm lever to the in side, set the relief
state, and hold.
E Loosen the boosted pressure lock nut (11) (32 10
mm, 1.26 in) and adjust the set pressure with the
adjusting screw (12) (27 mm, 1.06 in).
• When lower than the set pressure, tighten.
• When higher than the set pressure, first lower below
the set pressure, then adjust on the tightening side.
F After adjustment, fasten the adjusting screw (12)
with a spanner (27 mm, 1.06 in), then tighten the lock
nut (11).
G After locking, check the boosted pressure side
pressure. Repeat A) to F) until the set pressure is cor-
rectly adjusted.
11
12 14 13
RI01001-003

Copyright ©
8001-42
Overload relief pressure adjustment
Engine speed 1900 min-1 15 Control valve

Work mode SP mode 16 Boom-up
45 to 55°C 18 Bucket-open
Oil temperature
113 to 131°F 20 Bucket-close
Measuring port P1 / P2 port
Boom down:
27.4 MPa
3974 Psi
Measurement pressure
Others: 19
39.2 MPa
5685 Psi 20
Pressure per rotation of 21.2 MPa / rotation
adjusting screw 3074 Psi / rotation
15
1. Since the overload relief pressure is set higher than
the main relief pressure, it is necessary to provi-
sionally set the main relief pressure higher than the 16
overload relief pressure. (Except for boom down)
2. Main Relief Pressure Provisional Setting
• Using the main pressure adjustment procedure for
reference, temporarily set the boosted pressure and
standard pressure to at least 39.2 MPa.
NOTE: For boom down (19), since the overload set
17
pressure is lower than the main relief set pressure,
there is no need to temporarily set the main relief pres-
sure. 18
3. Pressure adjustment
21
NOTE: For the position of each overload relief, see the
"Control Valve Relief Locations".
Example: Arm-out (17) overload relief adjustment
A Loosen the lock nut (21) and adjust by the turning
the adjusting screw (22).
• When higher than the set pressure, first loosen to a
pressure lower than the set pressure, then adjust on
the tightening side. 22
B After adjustment, lock the lock nut (21).
C After adjusting the overload relief pressure, adjust
23
the boosted pressure and standard pressure to their
normal values referencing the main pressure adjust-
ment procedure.
24
R101004-014

Copyright ©
8001-43
Swing relief pressure adjustment
Pilot pressure adjustment
Work mode SP mode Engine speed 1900 min-1
45 to 55°C Lever operation Neutral
Oil temperature
113 to 131°F
Measuring port P3
3.9 MPa
30.4 MPa Set pressure
Measurement pressure 565.6 Psi
4409 Psi
Pressure per rotation of 11.6 MPa/rotation 1) Pressure measurement
adjusting screw 1682 Psi/rotation a) Install the pressure gauge (28).
b) While holding the plug (26) with a wrench (24 mm
1. Using the swing pressure measurement procedure 0.94 in), adjust (27) with a hexagon wrench (6 mm 0.24
for reference, lock the swing, and check the swing in).
pressure.
28
27
25
26
24
SI01009-510 S101009-009
26
SI01009-511
BIO1003-007
2. Loosen the lock nut (25) and adjust by turning the
adjusting screw (24).
• When higher than the set pressure, first loosen to a
pressure lower than the set pressure, then adjust on
the tightening side.
3. After adjustment, lock the lock nut (25).

Copyright ©
8001-44
HYDRAULIC PUMP FLOW MEASUREMENT PROCEDURE
Work preparations
1. Check that the main unit is in its work posture (arm- 5. Install the vacuum pump (4) on the hydraulic oil
vertical). tank lid (3).
S109006-001
2. Bleed out the pressure. (See the details on Bleed- S109006-004
ing Pressure in the Pressure Measurement and 6. After setting the vacuum pump (4), switch on the
Adjustment Procedures.) power. (If the cable is too short, use an extension
NOTE: Check the swing stop. cable.)
3. Use a spanner (17 mm, 0.67 in) to remove the feed
port cover (2).
S109006-005
S109006-002 7. Use a hexagon wrench (8 mm, 0.31 in) to remove
4. Use the bolts removed in step 3 to install the the split flange and hydraulic hose. (This explana-
hydraulic oil tank lid (3). tion uses flow measurement at the P2 pump.)
4
2
5
7
S109006-003
S109006-006

Copyright ©
8001-45
8. Use the split flange to install the adaptor (flange 14. Install the (prepared) hydraulic hose on the flow
type) on the tip of the hydraulic hose removed in meter OUT side, then fasten with the spanner.
step 7. • When connecting, always check the connection posi-
9. Install the adaptor at the position from which the tions.
hydraulic hose was removed. • Always have the metering valve fully open.
10. When the parts are set as in the figure above, 15. Install pressure gauges on P1 and P2. (See "Main
remove the plug. Pressure Measurement".)
11. Use the spanner to connect the adaptor installed 16. Remove the vacuum pump and re-install the
on the pump in step 9. hydraulic oil tank the same way it was.
12. If necessary, install an "elbow adaptor" on the (pre- 17. Open the engine hood. (See "Main Pressure
pared) hydraulic hose connected to the flow meter Adjustment".)
IN side. 18. Remove the cover.
13. Install the hydraulic hose on the flow meter IN side, 19. Remove the pilot hose for the boosted pressure
then fasten with the spanner. signal, then plug the hose side. (See "Main Relief
Pressure Adjustment".)
14
10
11
15
13 16
12
S109006-007
8 Elbow adaptor 13 Hydraulic hose (OUT)

9 Adapter 14 Hydraulic hose
10 Hydraulic hose (IN) 15 Split flange
11 Flow meter 16 Adapter (flange type)
12 Metering valve

Copyright ©
8001-46
Flow measurement
1. When measuring the flow, position the workers as 3. Check the hydraulic oil temperature on the monitor
in the figure below. (50°C, 122°F). Check that the engine rotation and
• Worker 1: Work supervisor, pressure adjustment pump current are normal.
• Worker 2: Operator 4. The operator signals the arm-out relief operation to
• Worker 3: Flow, pressure measurement, recording worker 1.
5. Worker 2 lowers the arm-out port relief. (Min: 24
MPa (240 bar, 3481 Psi) (P1 + P2)
1
6. Start of flow measurement.
7. The arm-out relief operation is carried out.
3 8. Data measured in units of 2.0 MPa (20 bar, 290Psi)
(P1 + P2).
2
• The measurement is carried out from 24.0 to
76.0 MPa (240 to 760 bar, 3481 to 11023 Psi) and
ends when the maximum pressure is reached.
9. Remove the flow meters.
• Because from 40 MPa (400 bar, 5802 Psi) the pres-
sure exceeds the permitted value for the flow meter
pressure gauge maximum pressure.
10. Reset the arm-in port relief valve to normal pres-
RST-09-02-001I sure. (For details on this adjustment, see "PRES-
2. At the signal from the work supervisor, the operator SURE ADJUSTMENT".)
starts the engine. 11. Remove the pressure gauges etc. and put every-
thing back to normal.
4
SP
RST-09-02-001J

Copyright ©
8001-47
Flow curve
NC01009-001

Copyright ©
8001-48
DRAIN VOLUME MEASUREMENT PROCEDURE
Preparations
Measuring conditions
1st speed 1900 min-1

Engine speed
2nd speed 2050 min-1
Mode SP mode
About 50°C
Oil temperature
About 122°F
WARNING: The drain volume varies greatly with the oil temperature.
Travel motor drain volume measurement

1. Ground the arm as in the figure below, then make 3. Always lay a rag (6) underneath before removing
the shoe crawler on one side float. the drain hose (5).
4. Use a spanner to remove the drain hose (5).
(Always install a cap on the drain hose.)
RST-09-03-001A
2. Remove the bolts (4), then remove the cover (3).
3
6
S103008-501
5. Install the extension hose (7) for measurement on
the side of the motor from which the drain hose was
removed.
4
RST-09-03-001B
7
S103008-502

Copyright ©
8001-49
6. Prepare a waste oil receiver (8) and measuring 8. In SP mode at medium speed, relieve the travel
container (9) and set them as in the figure below. operation and at the same time the motor starts,
move the extension hose to the measuring con-
tainer (9).
(When the motor starts, start measurement with a
stop watch (11).)
9. After 30 seconds, move the extension hose to the
waste oil can (8).
10. Measure the volume of oil in the measuring con-
tainer as the drain volume for 30 seconds.
Forward Backward
1st 2nd 1st 2nd
speed speed speed speed
Right
Left
8 9 • Measure at least three times each for left, right,

advance, and retreat.
S103008-503
7. Catch the stopper (10) between the sprocket sec-
tion and the frame and lock the travel motor.
10
30 seconds
9
8
11
10
S103008-504
RST-09-03-001F

Copyright ©
8001-50
Swing motor drain volume measurement
1. Remove the two drain hoses (1) and put blind plugs
in the hose side of each.
1
60 seconds
4 5 6
RST-09-03-001J
4. In SP mode, relieve the swing operation and at the
S103008-505
same time the motor starts, move the extension
2. Install the extension hose (3) for measuring the
hose (3) to the measuring container (5).
drain volume on one side of the T nipple. Install the
(When the motor starts, start measurement with a
hose facing in a direction that makes measurement
stop watch.)
easy and install a blind plug (2) on the other side.
5. After 60 seconds, move the extension hose (3) to
the waste oil receiver (6).
6. Measure the volume of oil in the measuring con-
tainer (5) as the drain volume for 60 seconds.
• Measure at least three times each for left and right.
Right Left
2
S103008-506
3. Prepare a waste oil receiver and measuring con-
tainer (5) and set them as in the figure below.

Copyright ©
8001-51
AIR BLEED PROCEDURE
WARNING: Always bleed off any air in the hydraulic circuits after replacing the hydraulic oil, repairing or
! replacing hydraulic equipment, or removing hydraulic pipes.
Air bleed procedure mode (when bleeding, follow the procedure below
Hydraulic pump air Cylinder air Swing motor air Travel motor air
Check
bleeding bleeding bleeding bleeding
Hydraulic oil or
hydraulic pump
replacement
Cylinder
replacement
Swing motor
replacement
Travel motor
replacement
NOTE: Failure to completely bleed off all the air can reduce the service life of hydraulic equipment and lead to damage.
Hydraulic pump
1. Loosen the air bleed plug (1) and check that oil
oozes from the air bleed port (2).
2. If oil does not ooze out, remove the air bleed plug 1 2
(1), and fill hydraulic oil (3) from the air bleed port
(2) into the pump case.
3. Temporarily tighten the air bleed plug (1).
4. Run the engine at low idle, slightly loosen the air
bleed port, and run until oil oozes from the air bleed
port (2) section.
5. Completely tighten the air bleed plug (1).
3 2
S104009-001

Copyright ©
8001-52
Travel motor
1. Remove the bolt (2), then remove the cover (1). 3. Pour in of hydraulic oil (5) from the air bleed port.
5
1
RST-09-04-001C
2. Remove the hose (3) of drain port and elbow (4). S104009-003
4. When inside the motor is filled with hydraulic oil,
3 4 tighten the elbow and hose.
5. Start the engine and execute a slow travel opera-
tion.
6. Repeatedly travelling forward and backward bleeds
off the air.
S104009-002

Copyright ©
8001-53
Swing motor
1. Run the engine at low idle, loosen the air bleed
plug, and check that oil oozes from the air bleed
port section.
• Do not execute a swing operation.
2. If oil does not ooze out, stop the engine for now,
remove the air bleed plug, and fill hydraulic oil into
the motor case. 1
3. Temporarily tighten the air bleed plug.
4. Run the engine at low idle, slightly loosen the air
bleed port section, and run until oil oozes from the
air bleed port section.
2
5. Completely tighten the air bleed plug.
6. With the engine at low idle, slowly swing evenly left
and right at least two rotations.
Check
After the air bleeding is complete, stop the engine
for at least five minutes to allow any air bubbles in S104009-504
the hydraulic oil tank to dissipate.

3
S104009-505

Copyright ©
8001-54
Safety valve
WARNING: The safety valve air bleeding work requires two workers: an operator and an air bleed worker.
Decide your signals beforehand and work safely. Set the main unit so that the arm safety valve is at the
! highest position. (See the figure below.)
Boom cylinder safety valve

1. Start the engine and lower the boom without jack-
ing up the main unit.
2. In the above state, loosen the hose mouthpiece at
the position in the figure.
3. Foaming hydraulic oil comes out from the hose
coupling section.
When foaming hydraulic oil stops coming out,
tighten the hose mouthpiece (1).
4. Execute steps 2 and 3 for the opposite side boom
cylinder too.
5. Check boom operations. If there is a delay in the
operation response, bleed the air again with the
same procedure.
S104009-004
Arm cylinder safety valve

1. For arm-in operations, bleed the air from the arm
cylinder safety valve using the same procedure as
for boom cylinder safety valve air bleeding.
S104009-507

Copyright ©
Section
8020
HYDRAULIC FUNCTIONS
8020

Printed in France
Copyright ©
8020-2
TABLE OF CONTENTS
HYDRAULIC FUNCTIONS.............................................................................................................................................. 3
HYDRAULIC COMPONENTS LIST ................................................................................................................................ 5
TRAVEL CIRCUITS ....................................................................................................................................................... 6
Travel Low-speed Circuit ........................................................................................................................................... 6
Travel High Speed Circuit .......................................................................................................................................... 8
Straight Travel Circuit ............................................................................................................................................... 10
SWING CIRCUITS ....................................................................................................................................................... 12
Swing Speed Limit Control Circuit ............................................................................................................................ 12
Swing Relief Cut-off Control Circuit .......................................................................................................................... 14
Swing Priority Circuit ................................................................................................................................................ 16
Swing Brake Circuit (independent operation of swing) ............................................................................................ 18
Swing Parking Circuit (lever in neutal) ..................................................................................................................... 20
Swing Parking Circuit (brake release) ...................................................................................................................... 22
Swing Parking Circuit (machine stop) ...................................................................................................................... 24
BOOM CIRCUITS ........................................................................................................................................................ 26
Boom-up Circuit (independent operation) ................................................................................................................ 26
Boom-up Circuit (compound boom-up + arm-in) ...................................................................................................... 28
Boom-down regenerative circuit ............................................................................................................................... 30
Boom-down tilting prevention circuit ........................................................................................................................ 32
Boom-down load holding valve circuit ...................................................................................................................... 34
ARM CIRCUITS ........................................................................................................................................................... 36
Arm-out Circuit ......................................................................................................................................................... 36
Arm-in forced regenerative circuit ............................................................................................................................ 38
Arm-in load holding valve circuit .............................................................................................................................. 40
BUCKET CIRCUITS ..................................................................................................................................................... 42
Bucket-open circuit .................................................................................................................................................. 42
Bucket-close Regenerative Circuit ........................................................................................................................... 44
NEGATIVE CONTROL CIRCUIT ................................................................................................................................. 46
Negative Control Circuit (power save solenoid OFF) ............................................................................................... 46
Negative Control Power Save Circuit (power save solenoid ON) ............................................................................ 48
Negative Control Circuit (bucket close, power save solenoid OFF) ......................................................................... 50
OTHER CIRCUITS ....................................................................................................................................................... 52
Cushion Circuit (arm out operation) ......................................................................................................................... 52
Cushion Circuit (arm-out operation stopped) ........................................................................................................... 54
Cushion Circuit (arm-out -> arm-in operation) ......................................................................................................... 56
Heat Circuit (lever in neutral) ................................................................................................................................... 58
Auto Pressure Boost Circuit (bucket close) .............................................................................................................. 60
OPTION CIRCUITS ...................................................................................................................................................... 62
Breaker Circuit (independent operation) .................................................................................................................. 62
Double-acting Circuit (hydraulic fork) ....................................................................................................................... 64
Multi-purpose Circuit (breaker Q control) ................................................................................................................. 66
Multi-purpose Circuit (2 pumps flow crusher) ........................................................................................................... 68
2nd Option Circuit (hydraulic rotation fork) ............................................................................................................... 70

Copyright ©
8020-3
HYDRAULIC FUNCTIONS
List of functions
(* New function; ** Changed function)
Functions Description Pages

Travel Circuits
Low speed circuit Sets the travel motor 2-stage tilting angle to a large angle to set low speed Page 6-7
Sets the travel motor 2-stage tilting angle to a small angle to set high speed.
The speed is automatically switched to low speed according to the load pressure
High-speed circuit on the travel motor. Page 8-9
In order to prevent hunting at high speed, if the travel pressure becomes 25.8 MPa
or higher, the speed is set to low speed
Straight travel
When there is an attachment or swing operation during traveling, travel is held
circuit Page 10-11
straight without curving.
(**)
Swing Circuits
Swing speed limit In order to increase the cylinder bore and attachment speed, the pump maximum
flow was increased, but in order to not increase the swing speed, when swing is
control circuit Page 12-13
operated alone, the pump flow is restricted with the proportional valve installed on
(*) the swing pump (front side).
For swing single operation, if swing is started with a sharp lever operation, the
Swing relief pump flow is reduced with the proportional valve installed on the swing pump (front
side).
cut-off control
Normally, this control eliminates the excess oil discharged from the swing relief Page 14-15
circuit
valve and reduces the horsepower consumption.
(*) When the swing speed rises, the pump discharge pressure falls, so the pump flow
is increased gradually while it is detected with the sensor.
1. Swing pushing is obtained by the swing priority variable orifice built into the con-
Swing priority trol valve.
Page 16-17
circuit 2. The swing priority variable orifice also works to secure the arm flow for bed
metering.
Swing brake Suctions in the oil from the make-up line in order to prevent cavitation when swing
Page 18-19
circuit stops.
1. When the swing lever is in neutral, swing parking works and is held at 100%.
2. When there is a swing lever or attachment operation, swing parking is released.
Swing parking
3. Swing parking works about 5 sec. after the swing lever is put into neutral.
circuit Page 20-25
4. When an attachment operation is stopped, if there is no swing operation, the
(**)
swing parking circuit works about 1 sec. later.
5. When the engine is stopped, swing parking works.
Boom Circuits
1. Single
The flow is merged internally by switching the boom (1) and (2) spool to raise
the speed.
Boom-up circuit Page 26-29
2. Compound
The swing priority variable orifice spool is switched to make movement in arm-in
compound operation smooth.
Boom-down
Regeneration within the boom (1) spool is used to increase speed and prevent
Regenerative Page 30-31
cavitation.
Circuit
Boom-down
tilting Prevention High pressure is suppressed with the bleed-off circuit and tilting is mitigated. Page 32-33
Circuit
1. By releasing the load hold valve built into the control valve, boom speed
Boom-down load becomes faster.
Page 34-35
hold valve circuit 2. Boom-down pilot pressure enables boom-down operation by releasing the load
holding valve.
Copyright ©
8020-4
Functions Description Pages

Arm Circuits
The flow is merged internally by switching the arm (1) and (2) spool to raise the
Arm-out circuit Page 36-37
speed.
Arm-in forced
The speed for compound operation is raised by the forced regeneration release
regenerative Page 38-39
valve in the control valve.
circuit
1. Load holding valve integrated in the control valve reduces natural drop on the
Arm-in load hold arm-in side.
Page 40-41
valve circuit 2. Arm-in pilot pressure enables arm-in operation by releasing the load holding
valve
Bucket circuit
Bucket-close
regenerative Regeneration within the bucket spool is used to increase speed and prevent cavita-
Page 44-45
circuit tion.
(*)
Negative control circuit
Negative control In the non-operation state, this circuit switches the negative control relief valve set
power save circuit pressure to reduce the pump discharge force and further reduce horsepower con- Page 46-49
(*) sumption.
Negative control For no-load operation, this circuit sets the hydraulic pump discharge volume to
Page 50-51
circuit minimum to reduce horsepower consumption.
Others
Softens the shock through the work of the cushion valve with heat circuit.
Cushion circuit This circuit is attached to the boom and arm pilot lines. There is no soft / hard Page 52-57
switch. (Inline is disused by the tuning
Auto pressure Boosts the main relief pressure from 34.3 - 36.8 MPa according to the engine load
Page 60-61
boost circuit ratio and circuit pressure.
Option circuits
The main control valve has an option section as standard so that it can support a
Breaker circuit Page 62-63
breaker, crusher or other special attachment.
Option flow
It is possible to set the flow for the breaker, crusher, or other special attachment
adjustment Page 64-65
application by just operating a switch in the cab. Maximum of 5 applications.
(*)
Multi purpose
It is possible to switch the circuit between the breaker and the crusher by just ope-
circuit switch Page 66-67
rating a switch in the cab.
(*)
2nd option circuit Option valve can be added to the top section of the control valve and a 2nd option
Page 68-69
(*) line can be installed easily.
NOTE: See the tables in the following pages for the relationship between each specification and the optional equipment.

Copyright ©
8020-5
HYDRAULIC COMPONENTS LIST
NOTE: See hydraulic schematic at the end of this document.
B22 SWING PILOT PRESSURE SWITCH
B23 BREAKER / CRUSHER PILOT PRESSURE SWITCH
B25 BREAKER PILOT PRESSURE SWITCH
B26 UPPER PILOT PRESSURE SENSOR
B27 TRAVEL PILOT PRESSURE SENSOR
B28 SECOND OPTION PILOT CIRCUIT 1 PRESSURE SWITCH
B40 PUMP PRESSURE SENSOR (NEGA-CONT. P2)
B42 PUMP PRESSURE SENSOR (P1)
B43 PUMP PRESSURE SENSOR (NEGA-CONT. P1)
B44 PUMP PRESSURE SENSOR (P2) (BLUE BAND)
B45 OVERLOAD INDICATOR PRESSURE SWITCH
S71 PRESSURE SWITCH FILTER INDICATOR (BREAKER
OPTION)
Y2 PILOT PRESSURE SOLENOID VALVE (BLUE BAND)
Y3 SWING BRAKE SOLENOID VALVE (WHITE BAND)
Y4 2 STAGE TRAVEL SOLENOID VALVE (RED BAND)
Y5 POWER-UP SOLENOID VALVE (YELLOW BAND)
Y6 POWER SAVE SOLENOID VALVE (GREEN BAND)
Y7 MAIN PUMP POWER PROPORTIONAL SOLENOID
Y9 CRUSHER OPTION TWO FLOW SOLENOID VALVE
Y11 MAIN PUMP FLOW PROPORTIONAL SOLENOID
Y25 OPTION 2 SOLENOID VALVE (RED BAND)
Y26 OPTION 2 SOLENOID VALVE (BLUE BAND)
Y27 HAMMER RETURN CIRCUIT SOLENOID VALVE
1 HYDRAULIC RESERVOIR
2 BREATHER
4 BY-PASS VALVE
5 SCREEN FILTER
6 RETURN FILTER
9 HYDRAULIC PUMP (OPTIONAL)
10 MAIN HYDRAULIC PUMP
15 MAIN CONTROL VALVE
16 HYDRAULIC SWIVEL
21 TRAVEL MOTOR
22 SWING MOTOR
23 TRAVEL MOTOR BRAKE
25 RIGHT BOOM CYLINDER
26 LEFT BOOM CYLINDER
27 DIPPER CYLINDER
28 BUCKET CYLINDER
29 BOOM SAFETY VALVE
30 DIPPER SAFETY VALVE
31 DIPPER LOAD HOLDING VALVE
32 BOOM LOAD HOLDING VALVE
42 OIL COOLER
43 RETURN MANIFOLD
44 OIL COOLER BY-PASS VALVE
45 NON-RETURN CHECK VALVE
51 ACCUMULATOR
53 BOOM & BUCKET CONTROL LEVER
54 SWING & DIPPER CONTROL LEVER
55 TRAVEL CONTROL PEDAL
57 BOOM & DIPPER CONTROL SHOCK ABSORBER
58 PILOT AND RETURN SYSTEM MANIFOLD
59 FILTER
60 PILOT SYSTEM MANIFOLD
71 SECOND OPTION CONTROL VALVE
72 CONTROL PEDAL (OPTIONAL)
73 SECOND OPTION CONTROL VALVE
75 HAMMER/CRUSHER SELECTOR
76 HAMMER/CRUSHER SELECTOR
82 PILOT CIRCUIT FILTER
83 SHUT-OFF VALVE (OPTIONAL)
85 PILOT FILTER
86 PILOT FILTER BY-PASS VALVE
90 HYDRAULIC BREAKER VERSION, PLUG
108 STRAIGHT TRAVEL VALVE
132 HAMMER/CRUSHER 2 SOLENOID VALVE BANK
133 5 SOLENOID VALVE BANK
134 2 SOLENOID VALVE BANK (SECOND OPTION)

Copyright ©
8020-6
Travel Circuits
Travel Low-speed Circuit
As an example, this section explains the forward travel operation.
The travel motor 2-stage tilting angle is a large angle side.Even if the travel switchover is set to the high-speed side,
switching the key switch OFF and then ON again always returns the system to this state.
By operating the travel remote control valve to the forward side, the pilot pressure oil is fed to the control valve pa1
port and switches the left travel spool to the forward side.
At the same time, the oil is also fed to the pa6 port to switch the right travel spool to the forward side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and the discharge oil from hydraulic pump
A2 enters the control valve P2 port. Each flows to the respective travel motor and causes forward travel through the
left and right travel spools being switched.
The return oil from the travel motor goes through the left and right travel spools and returns to the hydraulic oil tank.
The travel high-speed solenoid valve goes OFF, the travel motor P port oil connects with the tank line, and the travel
motor tilting angle moves to the large tilting side.
1 Travel motor 10 Console lever lock switch

2 Travel high-speed select switch 11 Hydraulic pump
3 Computer A 12 Travel remote control valve
4 Control valve 13 Check valve
5 Travel (left) 14 Oil cooler
6 Travel (right) 15 Backward left
7 Travel high speed 16 Forward left
8 Lever lock 17 Backward right
9 5 stack solenoid valve 18 Forward right
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-7
Overall View
4
P
T1 T2
VB VA
A
A VB
16
15 17 18
B6
A6
pa6 12
B1
A1 6 2 4
2 pa1
5
P1 P2
3 13
7
B T 8
10
C1
14 13
P
A1 A2 A3
9
11
SD04010-001a
Enlarged View
T1 T2
B6
A6
pa6
A1 6
5
P1 P2
SD04010-001b

Copyright ©
8020-8
Travel High Speed Circuit
As an example, this section explains the forward travel operation.
Sets the travel motor 2-stage tilting angle to a small angle to set high speed. The travel motor has an automatic
switchover function that switches the speed to low speed according to the load pressure on the travel motor only dur-
ing high-speed travel conditions.
At the same time, the oil is also fed to the pa6 port to switch the right travel spool to the forward side.
The return oil from the travel motor goes through the left and right travel spools and returns to the hydraulic oil tank.
Electrical signals are sent to the computer A by operation of the travel high-speed select switch and the computer A
sends electrical signals to the travel high-speed solenoid valve. Due to the switching of the travel high-speed solenoid
valve, the pilot pressure (3.9 MPa) from the C1 port enters the left and right travel motor P ports through the center
joint and sets the travel motor tilting angle to a small angle to raise the speed.
1 Travel motor 10 Console lever lock switch

2 Travel high-speed select switch 11 Hydraulic pump
3 Computer A 12 Travel remote control valve
5 Travel (left) 14 Oil cooler
6 Travel (right) 15 Backward left
7 Travel high speed 16 Forward left
8 Lever lock 17 Backward right
9 5 stack solenoid valve 18 Forward right
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-9
Overall View
4
P
T1 T2
VB VA
A
A VB
16
15 17 18
B6
A6
pa6 12
B1
A1 6 2 4
2 pa1
5
P1 P2
3 13
7
B 8
C1
10
14 13
P
A1 A2 A3
9
11
SD04010-002a
Overall View
T1 T2
B6
A6
pa6
A1 6
5
P1 P2

Copyright ©
8020-10
Straight Travel Circuit
As an example, this section explains simultaneous forward travel and boom-up operations.
In the same way, oil is also fed to the pa6 port to switch the right travel spool to the forward side.
Furthermore, the right forward travel pilot pressure oil separated internally from the control valve pa6 port switches the
straight travel signal (right). On the other hand, the travel pilot pressure oil separated internally from the pa1 port
switches the straight travel signal (left) via the straight travel signal (right).
If a boom-up operation is carried out during travel, the pilot pressure oil is fed via the cushion valve to the control valve
pa4 port and switches the boom (1) and (2) spools to the up side.
The upper (boom, arm, bucket, swing, option) pilot pressure oil separated internally from the control valve pa4 port is
fed to the straight travel valve via the straight travel signal (left) and the straight travel spool is switched.
The amount of switching of the straight travel spool varies with the upper pilot pressure.
(Because the pilot pressure is low for slight upper operation, the amount of switching of the straight travel spool is
slight to prevent sharp reduction in the travel speed.)
Through the straight travel valve being switched, it is possible for the control valve P1 pressurized oil to drive the left
and right travel motors and for the control valve P2 pressurized oil to drive the boom.
Because the left and right motors are driven by 1 pump, the left and right motors have the same pressure and straight
travel is possible. Furthermore, the P2 excess pressurized oil is fed to the travel side via the check valve with travel
merge orifice to minimize the drop in speed.
The same operations are carried out when travel and an upper actuator other than for the boom are operated simulta-
neously.
1 Travel motor 10 Straight travel signal (left) 19 Boom cylinder

2 Boom (up) 11 Straight travel signal (right) 20 Travel remote control valve
3 Boom (down) 12 Travel high-speed select switch 21 Check valve
4 Cushion valve 13 Computer A 22 Oil cooler
Remote control valve (boom,
5 14 Travel high speed 23 Backward left
bucket)
6 Control valve 15 Lever lock 24 Forward left
7 Travel (left) 16 5 stack solenoid valve 25 Forward right
8 Travel (right) 17 Console lever lock switch 26 Backward right
9 Straight travel valve 18 Hydraulic pump
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-11
Overall View
19
6
P P
T2
VA
A
VA VB
A8
24
23 25 26
1
B6
2 3 A6
pa6 20
F
B1
A1 8 2 4
E
7
P1 P2
4 10
11
21
14
T 1
15
C1
17
P 22 21
5
12 P
A1 A2 A3
4 16
18
13
3 2
SD04010-003a
Enlarged View
T1 T2
A8
B6
A6
pa6
A1 8
pa1 9
7
P1 P2
10
11
SD04010-003b

Copyright ©
8020-12
Swing Circuits
Swing Speed Limit Control Circuit
This control is for suppressing increases in the swing speed accompanying increased pump flow. (Only in SP mode)
For independent swing operation, due to the swing pilot pressure sensor and P1 pressure sensor input electric signal,
the computer A outputs a signal to the P1 flow control proportional valve.
The discharge oil from the hydraulic pump A3 is fed to the P1 flow control proportional valve.
The hydraulic pump A1 side discharge flow is reduced to 280 L/min by the signal output from the computer A to the P1
flow control proportional valve.
[1] Conditions under which the swing speed limit control is entered
• Independent full-lever swing operation
• Travel non-operation
• Work mode SP
[2] Conditions under which the swing speed limit control is ended
• Upper operation other than boom down
-> Gradual end (to reduce shock)
• Travel operation
-> Immediate end (to avoid off travel)
• Option operation
1 Swing motor 13 Swing brake

2 Swing 14 5 stack solenoid valve
3 Cushion valve 15 Console lever lock switch
N1 negative control pressure
4 Right swing 16
sensor
5 Left swing 17 P1 pressure sensor
P1 flow control proportional
6 Swing pilot pressure sensor 18
valve
Remote control valve (arm,
7 19 Hydraulic pump
swing)
Horsepower control propor-
8 Control valve 20
tional valve
9 Travel pilot pressure sensor 21 P2 pressure sensor
10 Upper pilot pressure sensor 22 Check valve
11 Computer A 23 Oil cooler
12 Lever lock
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-13
Overall View
T3 T1 T2
8
1
PR
2 B3
M
A3
Pa3
22
B A 23 22
3 4 5 20
J P1 PA P2
9 10
A1 A2 21
17 a1
11
I Q
6 16
a7
15
12
7 B
P P1 A3
18
B1
B3
C2
1 19
5 4 13
14
SD04010-004a
Enlarged View
T3 T1 T2
8
2 B3
A3
Pa3
P1 PA P2
9 10

Copyright ©
8020-14
Swing Relief Cut-off Control Circuit

This control aims for an energy-saving effect by controlling the pump in such a way as to minimize the excess oil
drained from the swing motor relief valve for the starting pressure boost for a independent sharp swing operation.
When a swing operation starts, due to the swing pilot pressure sensor and P1 pressure sensor input electrical signals,
computer A outputs a signal to the hydraulic pump P1 flow control proportional valve.
The discharge oil from the hydraulic pump A3 is fed to the P1 flow control proportional valve.
The output signal from computer A to the P1 flow control proportional valve controls the pilot pressure to reduce the
hydraulic pump A1 side discharge flow. Also, the input signal from hydraulic pump P1 pressure sensor controls the
pilot pressure to gradually increase the discharge flow.
[1] Swing relief cut-off control is executed when all the conditions below are satisfied.
• Travel non-operation
• Sharp independent swing operation or swing + boom-down operation
[2] Swing relief cut-off control ends when a condition below is satisfied.
• When swing operation is stopped
• Travel, boom-up, arm-out/in, or bucket-open/close operation
1 Swing motor 13 Swing brake

2 Swing 14 5 stack solenoid valve
3 Cushion valve 15 Console lever lock switch
4 Right swing 16
sensor
5 Left swing 17 P1 pressure sensor
6 Swing pilot pressure sensor 18
valve
7 19 Hydraulic pump
swing)
8 Control valve 20
tional valve
10 Upper pilot pressure sensor 22 Check valve
11 Computer A 23 Oil cooler
12 Lever lock
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-15
Overall View
T3 T1 T2
8
1
PR
2 B3
M
A3
Pa3
22
B A 23 22
3 4 5 20
J P1 PA P2
9 10
A1 A2 21
17 a1
11
I Q
6 16
a7
15
12
7 B
P P1 A3
18
B1
B3
C2
1 19
5 4 13
14
SD04010-005a
Enlarged View
T3 T1 T2
8
2 B3
A3
Pa3
P1 PA P2
9 10

Copyright ©
8020-16
Swing Priority Circuit

The swing pilot pressure is fed to the Pc3' port via the shuttle valve and holds the swing priority variable orifice to the
right side. By metering the parallel circuit, for arm and swing simultaneous operation, the swing pressure is boosted to
secure the swing force for pressing digging.
As an example, this section explains the right-swing and arm-in operation.
By moving the remote control valve to the right swing side, the pilot pressure oil is fed via the shuttle valve to the con-
trol valve pa3 port and switches the spool to the right swing side.
At this time, by moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to
the control valve pb5 port and switches the spool to the arm-in side.
At the same time, the pilot pressure oil from the shuttle valve S port is fed to the control valve Pc3' port to move the
swing priority variable orifice to the right side and hold it.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the parallel oil path to the
swing spool. Switching the spool lets the oil flow into the swing motor B port and the right swing operation is carried
out.
The discharge oil from hydraulic pump A2 enters the control valve P2 port, is fed from the parallel oil path to the arm
(2) spool and merges upstream of the arm (1) spool. Switching the spool lets the oil flow into the arm cylinder bottom
and the arm-in operation is carried out.
When the right swing and arm-in operations are carried out at the same time, the swing priority variable orifice on the
control valve P1 port parallel oil path moves and narrows, so the pressure is boosted to secure the swing force for
pressing digging.
1 Swing motor 15 Arm cylinder

2 Arm (in) 16 Arm (1)
3 Arm (out) 17 Swing
4 Right swing 18 Arm load holding valve spool
Arm load holding valve check
5 Left swing 19
valve
6 Cushion valve 20 Regeneration release valve
7 Swing pilot pressure sensor 21 Control valve
8 Shuttle valve 22 Swing priority variable orifice
9 Computer A 23 Arm (2)
10 24 Upper pilot pressure sensor
swing)
11 Lever lock 25 Hydraulic pump
12 Swing brake 26 Check valve
13 5 stack solenoid valve 27 Oil cooler
14 Console lever lock switch
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-17
Overall View
PR 21
15
18 19 20
DR1 T1 T2
A5
B5
pb5'
pb5
23
pc3'
16
B3
A3 22
pa3
3
2 3 4 5
B J S 17
A I
7 8 26
P1 PA P2
6 24
9
11 27 26
10 B
P
14
P
25
13
A1 A2 A3
C2
2
4 3 1
12
5 4
2 3
SD04010-006a
Enlarged View
21
18 19 20
T1
A5
B5
pb5'
pb5
23
p
16
22
pa
17
P1 P P2
SD04010-006b

Copyright ©
8020-18
Swing Brake Circuit (independent operation of swing)

As an example, this section explains the brake circuit operation after the end of a right swing operation.
When the remote control valve is returned to neutral from a right swing operation, the pilot pressure oil is cut off and
the control valve swing spool returns to neutral.
The pressurized oil fed to the swing motor A port from the control valve A3 port is cut. At the same time, the destina-
tion location is eliminated for the pressurized oil flowing from the swing motor B port to the control valve B3 port, so
the pressure rises to the swing motor relief valve set pressure. The pressure generated here becomes a brake force
and stops the motor.
When the swing is stopped, the swing motor continues to rotate for a while due to inertial force.In order to make up the
shortfall in the oil volume, oil is supplied from the make-up line connected to the swing motor M port from the control
valve T3 port to open the make-up check valve and oil is suctioned in to prevent cavitation.
1 Swing motor 9 Lever lock

2 Cushion valve 10 Swing brake
3 Right swing 11 5 stack solenoid valve
4 Left swing 12 Console lever lock switch
5 Swing pilot pressure sensor 13 Computer A
6 14 Control valve
swing)
7 Hydraulic pump 15 Oil cooler
8 Check valve 16 Upper pilot pressure sensor
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-19
Overall View
PR
14
T3 T1
B A
B3
A3
pa3
2
3 4
J
I Q
5
P1 P2 8
16
12
9 15 8
B
6
P P
A1 A2 A3
C2
13
1
10 11
4 3
SD04010-007a
Enlarged View
14
T3 T1
A3
P1 PA
A P2
6
SD04010-007b

Copyright ©
8020-20
Swing Parking Circuit (lever in neutal)
When the key is switched ON, the swing brake solenoid valve is switched by the electrical signal from computer A.
The swing motor PR port oil goes from the 5 stack solenoid valve C2 port through the swing brake solenoid, and
returns to the hydraulic oil tank to hold the swing parking brake.

6 14 Control valve
swing)
8 Oil cooler 16 Hydraulic pump
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-21
Overall View
PR
T3 T1
14
pc3'
B A
B3
pa3
2
3 4
J S
I Q
5 7
P1 P2
15
9 8 7
B
6 12
P P
16
A1 A2 A3
C2
10 13
1
11
4 3
SD04010-008a
Enlarged View
T1
14
A3
P1 PA P2

Copyright ©
8020-22
Swing Parking Circuit (brake release)

When the engine is started and the swing lever is in neutral, the swing brake solenoid valve comes ON (24 V input),
the pressure to the swing motor PR port is cut, and the swing parking brake works.
When the lever operation raises the reading to 0.5 MPa or higher at the pressure sensor in the swing pilot line, the
output from computer A to the swing brake solenoid valve goes OFF, the swing motor PR port pressure rises, the
swing parking brake is released, and swing becomes possible.
As an example, this section explains the right swing operation.
By carrying out the right swing operation on the remote control valve, the pilot pressure oil is fed to the control valve
pa3 port via the shuttle valve and switches the swing spool to the right swing side.
At the same time, computer A detects the swing pilot pressure sensor signal, judges that there is a swing operation,
the electrical signal output from computer A goes OFF, and the swing brake solenoid valve is switched.The pilot pres-
sure oil is fed to the swing motor PR port from the swing brake solenoid valve C2 port to release the swing parking
brake.
swing spool. Switching the spool lets the oil flow into the swing motor A port and the right swing operation is carried
out.
The pressurized oil from the swing motor B port goes through the swing spool and returns to the hydraulic oil tank.
When this is followed by an attachment operation, the pilot pressure is detected by the control valve PA port pressure
sensor and the swing parking brake continues to be released.
After the swing operation ends, if about 5 sec. pass with no upper operation, the swing brake solenoid valve output
from computer A comes ON and the swing parking brake works again.
After the swing ends, if this is followed by an upper operation or there is an upper operation within about 5 sec., when
about 1 sec. passes after the end of the upper operation, the swing parking brake works again.
The swing parking brake is also released for independent upper operations and when about 1 sec. passes after the
end of the upper operation, the swing parking brake works again.
Key Swing pilot Upper pilot pres- Swing brake Swing motor
switch pressure sensor sure sensor solenoid valve mechanical brake
OFF 0 MPa 0 MPa OFF ON
ON 0 MPa 0 MPa ON ON
ON 0.5 MPa min. 0 MPa OFF OFF
ON 0 MPa 0.5 MPa min. OFF OFF
ON 0.5 MPa min. 0.5 MPa min. OFF OFF
• Pilot pressure sensor judgment standard
• Operation is judged when at 0.5 MPa or above.
• Non-operation is judged when at 0.3 MPa or below.
1 Swing motor 7 Swing 13 Control valve

2 Cushion valve 8 Lever lock 14 Upper pilot pressure sensor
3 Right swing 9 Swing brake 15 Hydraulic pump
4 Left swing 10 5 stack solenoid valve 16 Check valve
5 Swing pilot pressure sensor 11 Console lever lock switch 17 Oil cooler
6 12 Computer A
swing)
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-23
Overall View
PR
T3 T1
13
pc3'
B A
B3
2 pa3
3 4
J 7
I Q
5
P1 P2 16
14
8 17 16
B
6 11
P P
15
A1 A2 A3
C2
9 12
1
10
4 3
SD04010-009a
Enlarged View
13
A3
pa3
P1 PA P2
4
SD04010-009b

Copyright ©
8020-24
Swing Parking Circuit (machine stop)

When the machine is stopped (the key is switched OFF), the swing motor PR port oil goes from the swing brake sole-
noid C2 port through the lever lock solenoid and returns to the hydraulic oil tank, holding the swing parking brake hold
status.

6 14 Control valve
swing)
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-25
Overall View
PR
T3 T1
14
pc3'
B A
B3
2 pa3
3 4
J
5 7
P1 P2
15
9 8 7
T
6 12
16
A1 A2 A3
C2
10 13
1
11
4 3
SD04010-010a
Enlarged View
14
A3
pa3
P1 PA P2
5
SD04010-010b

Copyright ©
8020-26
Boom Circuits
Boom-up Circuit (independent operation)
By operating the remote control valve to the boom-up side, the pilot pressure oil is fed via the cushion valve to the
control valve pa4 port and the boom (2) spool is switched. At the same time, the pilot pressure oil from the pa4 port
separated in the internal path is fed to the boom (1) pilot port and switches the boom (1) spool to the up side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port, is fed from the parallel oil path to the boom
(2) spool and merges downstream of the boom (1) spool. The discharge oil from hydraulic pump A2 is fed to the boom
(1) spool via the parallel oil path, merges with the discharge oil from boom (2), flows through the boom load holding
valve check valve and into the boom cylinder bottom side and the boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns into the hydraulic oil tank.
1 Cushion valve 12 Boom cylinder

2 Boom (up) 13 Travel pilot pressure sensor
3 Boom (down) 14 Upper pilot pressure sensor
4 Boom (2) 15 Console lever lock switch
5 16 Monitor display
bucket)
6 Lever lock 17 Computer A
7 Boost pressure relief 18 P1 pressure sensor
8 5 stack solenoid valve 19 P2 pressure sensor
9 Control valve 20 Hydraulic pump
Boom load holding valve check
10 21 Check valve
valve
11 Boom (1) 22 Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-27
Overall View
12
T1 T2
10
B8
11
1 pa4
2 3
F 4
P1 PT P P2
13 14
21
5
B 6
P
15 18 19 22 21
P
C3
A1 A2 A3
7 16
17
4
20
3 2 8
SD04010-011a
Enlarged View
T1
A8
B8
11
pa4
P1 PT PA
A P2
1
13 14
SD04010-011b

Copyright ©
8020-28
Boom-up Circuit (compound boom-up + arm-in)

As an example, this section explains the boom-up + arm-in compound operation (leveling work).
For leveling work, the boom-up pilot pressure oil is fed to the pbu port, the swing priority variable orifice is moved to
the left side and the restriction on the flow to the arm is released to smooth the arm movement.
By operating the remote control valve to the boom-up side and arm-in side, the pilot pressure oil is fed via the cushion
valve to the control valve pa4 port and pb5 port and switches the boom (1) and arm (1) spools. At the same time,
pressurized oil separated from the boom (1) side pilot internal path is fed from the pa8 port to the pbu port and the
swing priority variable orifice spool is switched to the left side.
boom (2) and arm (1) spools. Because the swing priority variable orifice spool in the parallel oil path is moved, the
restriction on flow to the arm is released and the oil flows through the arm (1) spool and into the arm cylinder bottom
side. This makes arm-in operation movement smooth.
The arm cylinder rod side return oil goes through the load holding valve check valve and the arm (1) spool and returns
to the hydraulic oil tank.
boom (1) spool. Switching the spool lets the oil flow through the boom load holding valve check valve and into the
boom cylinder bottom side and the boom-up operation is carried out.
When the circuit has an HBCV, the discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed
from the parallel oil path to the boom (1) spool.
Switching the spool lets the oil flow through the boom load holding valve check valve and HBCV check valve and into
the boom cylinder bottom side and the boom-up operation is carried out.
The boom cylinder rod side return oil goes through the boom (1) spool and returns to the hydraulic oil tank.
1 Arm cylinder 12 Arm (1) 23 Travel pilot pressure sensor

2 Arm (in) 13 Boom (2) 24 Upper pilot pressure sensor
3 Arm (out) 14 Arm load holding valve spool 25 Console lever lock switch
4 Boom (up) 15 Load holding valve check valve 26 Monitor display
5 Boom (down) 16 Regeneration release valve 27 Computer A
6 Cushion valve 17 Control valve 28 P1 pressure sensor
7 18 Swing priority variable orifice 29 P2 pressure sensor
bucket)
8 19 Arm (2) 30 Hydraulic pump
swing)
9 Lever lock 20 31 Check valve
valve
10 Boost pressure relief 21 Boom (1) 32 Oil cooler
11 5 stack solenoid valve 22 Boom cylinder
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-29
Overall View
22
1 17
14 15
16
DR1T1 T2
19
A5
B5
pb5'
pb9
pb5 18 20
6 2 3 4 5
12 A8
B8
B F
pbu pa8
pa4
21
13
A E
7
P1 PT P P2
23 24
4
4
31
5 8 9
P 25 28 29 32 31
P
C3
3
A1 A2 A3
26
10 27
30
11
2 3
SD04010-013a
Enlarged View
17
14 15
16
T1
19
A5
B5
pb5'
pb9
pb 18 20
12 A8
B8
pa8
21
13
P1 PT P P2
23
SD04010-013b

Copyright ©
8020-30
Boom-down regenerative circuit

By moving the remote control valve to the boom-down side, the pilot pressure oil is fed via the cushion valve to the
control valve pb8 port and switches the boom (1) spool to the down side.
boom (1) spool. Switching the spool lets the oil flow into the boom cylinder rod side and the boom-down operation is
carried out.
The pilot pressure oil from the pb8 port separated in the internal path is fed to the load holding valve spool and moves
the spool to the left. In this way, the load holding valve check valve spring chamber oil is connected to the tank line
through the load holding valve spool, the spring chamber pressure drops, and the load holding valve check valve is
opened.
When the circuit has an HBCV, the pilot pressure oil separated in the internal path operates on the HBCV PL port and
switches the spool. This opens the HBCV check valve. The boom cylinder bottom side pressurized oil goes through
the load holding valve check valve (passes through the HBCV check valve and goes through the load holding valve
check valve when the circuit has an HBCV) and is metered by the boom (1) spool regeneration orifice. Through this,
the return oil pushes open the check valve in the spool and is regenerated on the cylinder rod side. The lower the cyl-
inder rod side load pressure, the greater the volume of regeneration. When the cylinder rod side load pressure
becomes high, the check valve is closed and the cylinder bottom return oil goes through the boom spool (1) without
regeneration and returns to the hydraulic oil tank.
Because the circuit is configured in such a way that, even if the boom (1) spool is at full stroke, negative control pres-
sure is generated by the center bypass bleed-off oil path and the pump does not discharge full flow, the shortfall is
made up for with regeneration and engine output can be used effectively.
1 Load holding valve check valve 9 Boom (down) 17 Boom cylinder

2 Check valve 10 18 Boom (1)
bucket)
3 Oil cooler 11 Lever lock 19 Travel pilot pressure sensor
4 P1 pressure sensor 12 Boost pressure relief 20 Upper pilot pressure sensor
5 Orifice 13 5 stack solenoid valve 21 Console lever lock switch
6 Bleed-off 14 Control valve 22 Monitor display
7 Cushion valve 15 P2 pressure sensor 23 Computer A
8 Boom (up) 16 Hydraulic pump
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-31
Overall View
17
14
1
A8
B8
pb8 A8
B8
2
To tank line
To A2 pump 6 18
5
7 8 9
G P1 PT
T PA
A P2
19 20
2
10 11
B
4 15
P 21 3 2
P
C3
3
A1 A2 A3
22
12 23
2 16
13
9 8
SD04010-014a
Enlarged View
14
A8
B8
pb8
18
P1 PT
T P2
19 20
SD04010-014b

Copyright ©
8020-32
Boom-down tilting prevention circuit

By operating the remote control valve all the way to the boom-down side at once, even if the boom spool goes its full
stroke, negative control pressure is generated by the center bypass bleed-off oil path and the circuit is such that the
hydraulic pump does not discharge full flow, so the generation of high pressure is restrained and main unit tilt is
reduced. Since the shortfall in the oil volume is compensated by the regenerative circuit, the engine output can be
used effectively.
1 Load holding valve check valve 12 Control valve

2 Check valve 13 P2 pressure sensor
4 Bleed-off 15 Boom cylinder
5 Cushion valve 16 Boom (1)
8 19 Console lever lock switch
bucket)
9 Lever lock 20 Monitor display
10 Boost pressure relief 21 Computer A
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-33
Overall View
15
12
1
DR1 T1 T2
A8
B8
pb8 A8
B8
To tank line
To A2 pump 4 16
5 6 7
G P1 PT
T PA
A P2
17 18
2
8
B 9
22 13
P 19 3 2
P
C3
A1 A2 A3
10 20
21
2
14
11
7 6
SD04010-016a
Enlarged View
12
T2
A8
B8
16
P1 PT
T PA
A P2
17 18
SD04010-016b

Copyright ©
8020-34
Boom-down load holding valve circuit

When the remote control valve boom operation lever is in neutral, the oil at the boom cylinder bottom side is sealed by
the load holding valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the
boom.
By moving the remote control valve to the boom-down side, the pilot pressure oil is fed via the cushion valve to the
control valve pb8 port and switches the boom spool to the down side.
boom (1). Switching the spool lets the oil flow into the boom cylinder bottom side and the boom-down operation is car-
ried out.
the spool to the left. In this way, the load holding valve check valve spring chamber oil is connected to the tank line
opened.
The boom cylinder bottom side pressurized oil goes through the load holding valve check valve and the boom (1)
spool and returns to the hydraulic oil tank.

1 12 Oil cooler
valve
2 Load holding valve spool 13 Boom cylinder
3 Cushion valve 14 Boom (1)
6 17 Console lever lock switch
bucket)
8 Boost pressure relief 19 Computer A
10 Control valve 21 P2 pressure sensor
11 Check valve 22 Hydraulic pump
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-35
Overall View
13
10
2 DR1 T1 T2
A8
B8
pb8 B8
pb8
14
3 4 5
G P1 PT PA
A P2
15 16
6 11
7
B
20 21
P 17 12 11
C3
A1 A2 A3
8 18
19
2 22
9
5 4
SD04010-017a
Enlarged View
10
T2
A8
8
pb8
14
P1 PT PA
A P2
15 16
SD04010-017b

Copyright ©
8020-36
Arm Circuits
Arm-out Circuit
By moving the remote control valve to the arm-out side, the pilot pressure oil is fed via the cushion valve to the control
valve pa5 port and pa9 port and switches the arm (1) and (2) spools to the out side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to
the arm (1) spool. The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center
bypass oil path and through the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool.
Switching the arm spool lets the oil flow through the load holding valve check valve and into the arm cylinder rod side,
carrying out the arm-out operation.
When the circuit has an HBCV, switching the arm spool lets the oil flow through the load holding valve check valve to
push open the arm cylinder HBCV check valve and flow into the rod side, carrying out the arm-out operation.
The arm cylinder bottom side return oil goes through the arm (1) and (2) spools and returns to the hydraulic oil tank.
1 Arm cylinder 13 Travel pilot pressure sensor

2 Arm (in) 14 Upper pilot pressure sensor
3 Arm (out) 15 Console lever lock switch
4 Cushion valve 16 Monitor display
5 17 Computer A
swing)
6 Lever lock 18 P1 pressure sensor
8 5 stack solenoid valve 20 Hydraulic pump
10 Load holding valve check valve 22 Oil cooler
11 Arm (1) 23 Arm HBCV check valve
12 Arm (2) 24 Arm HBCV
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-37
Overall View
9
10
T1 T2
1 1
A5
B5
pa9
pa5
24 12
23
3 11
G1
1 (G3)
B
C
A
PL
with HBCV
2 3
P1 PT PA PH P2
13 14
C 4
5
21
B
6
P 18 19
15 22 21
P
C3
A1 A2 A3
16
7 17
20
2 3
8
SD04010-019a
Enlarged View
T1 T2
A5
B5
pa9
pa5
P1 PT PA PH P2
SD04010-019b

Copyright ©
8020-38
Arm-in forced regenerative circuit

By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control
valve pb5 port and pb9 port and switches the arm (1) and (2) spools to the in side.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and the arm-in operation is carried out.
the spool to the right. In this way, the load holding valve check valve spring chamber oil is connected to the tank line
opened.
The arm cylinder rod side pressurized oil goes through the load holding valve check valve and the arm (1) spool and
is metered by the forced regeneration release valve.Through this, the return oil pushes open the check valve in the
arm (1) spool and is forcibly regenerated on the cylinder bottom side, securing the arm speed for leveling work etc.
When the cylinder bottom load pressure becomes high, the forced regeneration release valve is switched to the large
metering side and the opening becomes larger. Through this, the check valve in the spool is closed and the cylinder
rod side return oil returns to the hydraulic oil tank via the arm spool (1) and forced regeneration release valve without
being regenerated.
1 Load holding valve spool 10 Cushion valve 19 Travel pilot pressure sensor
2 Load holding valve check valve 11 20 Upper pilot pressure sensor
swing)
3 Oil cooler 12 Lever lock 21 Console lever lock switch
4 Regeneration check valve 13 Boost pressure relief 22 Monitor display
5 Metering large 14 5 stack solenoid valve 23 Computer A
6 Metering small 15 Control valve 24 P1 pressure sensor
Forced regeneration release
7 16 Arm cylinder 25 P2 pressure sensor
valve
8 Arm (in) 17 Arm (1) 26 Hydraulic pump
9 Arm (out) 18 Arm (2) 27 Check valve
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-39
Overall View
1 2
DR1T1 T2
A5
A5 B5
pb9
pb5'
B5
pb5
pb5'
p
pb5 IN 18
17
4
16
7
6
5
8 9
15
P1 PT
T PA PH P2
19 20
A 10
11
27
B
12
P 24 25
21 3 27
P
C3
A1 A2 A3
22
13
23
26
8 9 14
SD04010-021a
Enlarged View
DR1T1 T2
A5
B5
pb9
pb5'
pb5
P1 PT PA PH P2
SD04010-021b

Copyright ©
8020-40
Arm-in load holding valve circuit

When the remote control valve arm operation lever is in neutral, the oil at the arm cylinder rod side is sealed by the
load holding valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the
arm.
By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control
valve pb5 port and pb9 port and switches the arm (1) and (2) spools to the in side.
Switching the arm spool lets the oil flow into the arm cylinder bottom side and the arm-in operation is carried out.
the spool to the right. In this way, the load holding valve check valve spring chamber oil is connected to the tank line
opened.
The arm cylinder rod side pressurized oil goes through the load holding valve check valve and the arm (1) spool and
returns to the hydraulic oil tank.
1 Load holding valve spool 13 Arm (1)

2 Load holding valve check valve 14 Arm (2)
3 Oil cooler 15 Travel pilot pressure sensor
4 Arm (in) 16 Upper pilot pressure sensor
6 Cushion valve 18 Monitor display
7 19 Computer A
swing)
12 Arm cylinder
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-41
Overall View
1 2
DR1 T1 T2
A5
A5 B5 pb9
pb5'
B5
pb5
pb5'
p
pb5 IN
14
13
12
4 5
11
P1 PT
T PA PH P2
15 16
A 6
7
23
8
B
P
20 21
17 23
3
P
C3
A1 A2 A3
18
9 19
22
4 5 10
SD04010-022a
Enlarged View
DR1 T1 T2
A5
B5 pb9
pb5'
pb5
P1 PT PA PH P2
SD04010-022b

Copyright ©
8020-42
Bucket Circuits
Bucket-open circuit
By moving the remote control valve to the bucket-open side, the pilot pressure oil is fed via the cushion valve to the
control valve pa7 port and switches the bucket spool to the open side.
bucket spool. Switching the spool lets the oil flow into the bucket cylinder rod side and the bucket-open operation is
carried out.
The bucket cylinder bottom side pressurized oil goes through the bucket spool and returns to the hydraulic oil tank.
1 Cushion valve 11 Travel pilot pressure sensor

2 Bucket (close) 12 Upper pilot pressure sensor
3 Bucket (open) 13 Console lever lock switch
bucket)
9 Bucket 19 Check valve
10 Bucket cylinder 20 Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-43
Overall View
T1 T2
10
B7
pa7
1
2 3
P
P1 P2
11 12
O
19
4 5
B
P
13 16 17 19
20
P
C3
A1 A2 A3
14
6 15
3
18
3 2 7
SD04010-023a
Enlarged View
T1 T2
B7
A7
pa7
P1 PT
T PA
A P2
11 12
SD04010-023b

Copyright ©
8020-44
Bucket-close Regenerative Circuit

By moving the remote control valve to the bucket-close side, the pilot pressure oil is fed via the cushion valve to the
control valve pb7 port and switches the bucket spool to the close side.
bucket spool. Switching the spool lets the oil flow into the bucket cylinder bottom and the bucket-close operation is
carried out.
The bucket cylinder rod side pressurized oil is metered by the bucket spool regeneration orifice.Through this, the
return oil pushes open the check valve in the spool and is regenerated on the cylinder bottom side. The lower the cyl-
inder rod side load pressure, the greater the volume of regeneration. When the cylinder rod side load pressure
becomes high, the check valve is closed and the cylinder bottom side return oil goes through the bucket spool without
regeneration and returns to the hydraulic oil tank.
1 Regeneration check valve 12 Bucket

2 Oil cooler 13 Bucket cylinder
3 Orifice 14 Travel pilot pressure sensor
4 Cushion valve 15 Upper pilot pressure sensor
5 Bucket (close) 16 Console lever lock switch
6 Bucket (open) 17 Monitor display
7 18 Computer A
bucket)
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-45
Overall View
11
T1 T2
B7 13
A7
pb7
B7
pb7
3 12
4
5 6
N
P1 P2
14 15
M
22
7 8
B
P
16 19 20 22
2
C3
3
A1 A2 A3
17
9 18
1
6 21
5
10
SD04010-024a
Enlarged View
11
T1 T2
A7 pb7
12
P1 PT
T PA
A P2
14 15
SD04010-024b

Copyright ©
8020-46
Negative Control Circuit
Negative Control Circuit (power save solenoid OFF)
When the remote control valve operation lever is set to neutral, the discharge oil from hydraulic pumps A1 and A2
goes from the control valve P1 and P2 ports through the center bypass oil path, and through the downstream negative
control variable relief, and returns to the hydraulic oil tank.
The discharged oil from pilot pump A3 enters the 5 stack solenoid valve P port, flows through the power save solenoid
valve, is fed to the control valve Pn1 and Pn2 ports, and holds the P1 and P2 negative control relief at the set pressure
of 2.55 MPa.
The negative control pressure oil separated from the center bypass oil path is fed from the Ps1 and Ps2 ports to the
hydraulic pump Pi1 and Pi2 ports, moves the pump tilting to the minimum flow side, and the pump discharge flow is
reduced.

1 P1 negative control relief 11
sensor
2 P2 negative control relief 12 P1 pressure sensor
4 Travel pilot pressure sensor 14
sensor
5 Upper pilot pressure sensor 15
tional valve
6 Computer A 16
valve
7 Console lever lock switch 17 Hydraulic pump
8 Lever lock 18 Check valve
9 Power save 19 Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-47
Overall View
2
1
ps1 pn1 T1 T2
Pn2
8 7
ps2
P
9
3
C4
18
10 19 18
12
A1 Psv A2
11
13 14
P1 PT PA P2
Pi1 15 Pi2
4 5
Servo piston Servo piston

6
High Low Low High
Flow Flow A3
16
B1
B3
17
SD04010-025a
Enlarged View
T1
Pn2
ps2
P1 PT PA P2
SD04010-025b

Copyright ©
8020-48
Negative Control Power Save Circuit (power save solenoid ON)

The purpose of this control is to reduce fuel consumption during standby by reducing the back pressure for the nega-
tive control signal.
When the remote control valve operation lever is set to neutral, the non-operation state signal enters the computer A
from the travel pilot pressure sensor and the upper pilot pressure sensor installed on the control valve PT port and PA
port. After about 1 sec., the power save solenoid valve is excited and switched ON by the signal output from computer
A, and the oil path is switched.
The pressurized oil from the control valve negative control relief Pn1 and Pn2 ports goes through the power save sole-
noid valve and returns to the hydraulic oil tank.
Therefore, the negative control relief set pressure is switched to low pressure to further reduce the A1 and A2 pump
discharge pressure.
With the system running this way, the negative control signal is cut off and the P1 and P2 pump discharge volume
increases.
The discharge oil from pilot pump A3 enters the 5 stack solenoid valve P port, flows through the power save solenoid
valve, is fed to the hydraulic pump P2 port from the C5 port, moves the A2 side pump tilting to the minimum flow side,
and this reduces the discharge flow.
At the same time, the discharge oil from the pilot pump A3 is fed to the hydraulic pump P1 port by the signal from
computer A to the P1 flow restriction proportional valve, moves the A1 side pump tilting to the minimum flow side, and
this reduces the discharge flow.

sensor
4 Computer A 13
tional valve
5 Console lever lock switch 14
valve
6 Lever lock 15 Hydraulic pump
7 Power save 16 Check valve
8 5 stack solenoid valve 17 Oil cooler
9
sensor
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-49
Overall View
ps1 pn1 T1 T2
Pn2
6 5
ps2
T
P
7
1
C4
16
C5
8 17 16
A2
9 12
10 11
P1 PT PA P2
Pi1 13 Pi2
2 3
4 P2
Low flow Low flow
P1 A3
14 B1
15 B3
SD04010-026a
Enlarged View
ps1 pn1 T2
Pn2
ps2
P1 PT PA P2
SD04010-026b

Copyright ©
8020-50
Negative Control Circuit (bucket close, power save solenoid OFF)

As an example, this section explains the bucket-close operations.
The discharge oil from the hydraulic pump A2 enters the control valve P2 port, is fed to the bucket spool, flows into the
bucket cylinder bottom side because of the spool switching and the bucket-close operation is carried out.
At the same time, the upper pilot pressure sensor signal is detected and through the signal output from computer A to
switch OFF the power save solenoid valve, pilot pressure oil enters the negative control relief, and the pressure
becomes the set pressure of 2.55 MPa.
Because the bucket spool switches and the pressurized oil on the center bypass downstream side is cut off, the Pi2
pump negative control pressure oil from the Ps2 port is eliminated, the pump tilting moves to the increase side, and
the flow is increased.
Also, the command milli-amp to the P1 flow control proportional valve is lowered and the pressurized oil from the
hydraulic pump A3 is cut off, but the negative control pressurized oil is fed from the control valve Ps1 port to the Pi1
port, moves the pump tilting to the minimum flow side, and the hydraulic pump A1 discharge volume is reduced.
1 Control valve 12 Power save

2 Travel pilot pressure sensor 13 5 stack solenoid valve
3 Upper pilot pressure sensor 14 P1 pressure sensor
4 Cushion valve 15 P2 pressure sensor
5 Bucket (close) 16
sensor
6 Bucket (open) 17
sensor
7 Bucket cylinder 18
valve
8 Computer A 19 Hydraulic pump
9 20 Check valve
bucket)
10 Console lever lock switch 21 Oil cooler
11 Lever lock
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-51
Overall View
p
ps1 p
pn1 T1 T2
Pn2
11 10
ps2
B T
7
P
12
C4 20
C5
B7
A7 21 20
pb7 13
A1 A2
15
14 17
8
16
P1 PT PA P2
2 3 Pi1 Pi2
1
Servo piston
P2
Low flow High flow
4 9 P1 A3
5 6 P
18
N
B1
19 B3
M 1
6
5 SD04010-027a
Enlarged View
Pn2
ps2
B7
A7
pb7
P1 PT PA P2
SD04010-027b

Copyright ©
8020-52
Other Circuits
As examples, this section explains the cases when an arm-out operation is carried out, when an arm-out operation is
stopped, and when an arm-out operation is followed by an arm-in operation.
Cushion Circuit (arm out operation)
When a remote control valve arm-out operation is carried out, the pilot pressure oil enters from the remote control
valve 2 port into the cushion valve, pushes up the internal check valve, and is fed to the control valve pa5 and pa9
ports.
At the same time, the cushion valve cushion spool is switched to the left.
The arm-in side oil pushed out from the control valve pb9 and pb5 ports passes from the cushion valve B port through
the cushion spool switched to the left and returns to the hydraulic oil tank.
At this time, the warmed oil from the return line enters the remote control valve through the cushion spool from the
cushion valve R port and returns to the hydraulic oil tank, so heat performance is improved.
1 Arm (in) 9 5 stack solenoid valve

2 Arm (out) 10 Control valve
3 Cushion spool 11 Arm (1)
4 Orifice 12 Arm (2)
5 Check valve 13 Console lever lock switch
6 Cushion valve 14 Hydraulic pump
7 15 Check valve
swing)
8 Lever lock 16 Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-53
Overall View
10
T8 T1 T2
11
12
pb5' pb9
pb5
pa9
1 2 6
4
B D R
3
P1 P2
A C T
5
15
8
B 13
P T
7 16 15
P
A1 A2 A3
2 4
9
14
1 2
SD04010-028a
Enlarged View
10
T1 T2
11 12
pb5' pb9
pb5
pa9
P1 P2
SD04010-028b

Copyright ©
8020-54
Cushion Circuit (arm-out operation stopped)

When the remote control valve arm-out operation is returned to neutral, the oil pushed out from the control valve pa5
and pa9 ports flows to the cushion valve D port through the cushion orifice and returns from the remote control valve
to the hydraulic oil tank.
Through this orifice, the arm spool moves to the neutral position without returning sharply, so the cushioning is
improved.
1 Arm (in) 9 Control valve

2 Arm (out) 10 Arm (1)
4 Orifice 12 Console lever lock switch
6 14 Check valve
swing)
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-55
Overall View
9
T8 T1 T2
10
11
pa9
1 2 5
4
D R SD04010-02
3
P1 P2
C T
14
7
B 12
P T
6 15 14
P
A1 A2 A3
4
8
13
2
1
SD04010-029a
Enlarged View
9
T8 T1
10 11
pa9
P1 P2
SD04010-029b

Copyright ©
8020-56
Cushion Circuit (arm-out -> arm-in operation)

When the lever is operating all at once from an arm-out operation to an arm-in operation (arm rattling operation), the
pilot pressure oil is fed from the remote control valve 2 port into the cushion valve A port, pushes up the internal check
valve, and reaches the control valve pb5 port and pb9 port.
At the same time, the cushion valve cushion spool is switched to the right.
At this time, the oil pushed out from the pa5 and pa9 ports does not pass through the cushion orifice, but passes
through the cushion spool that has been switched to the right and returns to the hydraulic oil tank, so response is
improved.

2 Arm (out) 10 Arm (1)
4 Orifice 12 Console lever lock switch
6 14 Check valve
swing)
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-57
Overall View
9
T8 T1 T2
10
11
pb5' pb9
pb5
pa9
1 2 5
4
B D R
3
P1 P2
A C T
14
7
12
P T
6
15 14
P
A1 A2 A3
2 4
8
13
1
2
SD04010-030a
Enlarged View
9
T8 T1 T2
10 11
pb5' pb9
pb5
pa9
P1 P2
SD04010-030b

Copyright ©
8020-58
Heat Circuit (lever in neutral)

The pilot line is equipped with a heat circuit to prevent response delay at low temperatures.
When the remote control valve operation lever is set to neutral, the discharge oil from hydraulic pumps A1 and A2
goes from the control valve P1 and P2 ports through the center bypass oil path, and returns to the hydraulic oil tank.
The pressurized oil from the control valve T8 port is fed to the cushion valve R port and returns through the cushion
spool to the hydraulic oil tank.
By circulating the oil inside the cushion spool, the temperature of the oil in the cushion valve is raised to improve heat
performance.

4 10 Check valve
swing)
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-59
Overall View
7
T8 T1 T2
1 2 3
P1 P2
10
11 10
5
B
P
8
4 A1 A2 A3
2
6
1 2
SD04010-031a
Enlarged View
7
T1 T2
P1 P2
SD04010-031b

Copyright ©
8020-60
Auto Pressure Boost Circuit (bucket close)

hen an attachment is operated, this circuit boosts the control valve main relief set pressure from 34.3 MPa to 37.3
MPa according to the engine load ratio and hydraulic load pressure, then ends the pressure boost after 8 sec.
As an example, this section explains bucket-close operations.
At the same time, the output signal from the upper pilot pressure sensor that detected the pressurized oil separated
from the pilot internal path is input to computer A, which judges that there is upper operation. Furthermore, computer
A judges that there is a boost in the main pump P1 and P2 pressure, outputs the ON (24 V) signal to the pressure
boost relief solenoid, switches the valve, and the pilot pressure oil is fed to the control valve main relief valve PH port
to hold the pressure boost relief set pressure for 8 sec.
There is no boost for the option circuit and during travel operation.
1 Cushion valve 11 Upper pilot pressure sensor

2 Bucket (close) 12 Console lever lock switch
3 Bucket (open) 13 Digging force incresed
bucket)
9 Bucket 19 Check valve
10 Bucket cylinder 20 Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-61
Overall View
T1 T2
10
B7
A7
1 2 3
P1 P2
M 11
4 18
5
B
12
P
15 16 18
19
P
C3
3
13 A1 A2 A3
6 14
3 2 7 17
SD04010-032a
Enlarged View
T2
B7
A7
P1 PA
A P2
11
SD04010-032b

Copyright ©
8020-62
Option Circuits
Breaker Circuit (independent operation)
By operating the option remote control valve to the breaker side, the pilot pressure oil is fed to the control valve pa2
port and switches the option spool.
The discharge oil from hydraulic pump A1 is fed from the control valve P1 port through the parallel oil path and fed to
the option spool. Switching the spool lets the oil flow from the relief valve A port through the B port and into the
breaker.
The breaker set pressure is set by this relief valve.
At this time, the option pilot pressure switch signal is detected, the P1 flow control proportional valve is controlled by
the output signals from the computer A to adjust the discharge flow.
The return oil from the breaker goes through the manifold and returns to the hydraulic oil tank.
Because the breaker operating flow can be set to 5 levels on the service support screen of the monitor display with
the ON signal from the breaker switch in the cab, the optimum operating flow can be selected.
1 Control valve 12 Console lever lock switch

2 Manifold 13 Lever lock
3 Relief valve 14 5 stack solenoid valve
4 Breaker 15 P1 pressure sensor
sensor
7 Computer A 18
sensor
8 Monitor display 19
valve
9 Breaker switch 20 Hydraulic pump
10 Option remote control valve 21 Check valve
11 Option pilot pressure switch 22 Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-63
Overall View
T1 T2
10
12
Breaker
ON
13
2 B
21
C1
B P P 22 21
11
A2
A
pa2
14
3
4
P1 PA P2 16
15 A1 A2
5 6 17 18
Flow
Reduce
P1 A3
9
19
B1
B3 20
SD05009-001a
Enlarged View
T1 T2
A2
pa2
P1 PA P2
5 6
SD05009-001b

Copyright ©
8020-64
Double-acting Circuit (hydraulic fork)
As an example, this section explains the case in which the hydraulic fork attachment is used.
By operating the option remote control valve to the fork close side, the pilot pressure oil is fed to the control valve pa2
port and switches the option spool to the close side.
The discharge oil from hydraulic pump A1 enters the control valve P1 port, is fed from the parallel oil path to the option
spool, flows into the hydraulic fork because of the option spool switching and operates to the close side.
At this time, the option pilot pressure switch signal is detected and the auto idle function is released.
The return oil from the hydraulic fork goes through the option spool and returns to the hydraulic oil tank.
1 Control valve 8 5 stack solenoid valve

2 Hydraulic fork 9 Console lever lock switch
3 Travel pilot pressure sensor 10 Hydraulic pump
4 Upper pilot pressure sensor 11 Option remote control valve
5 Monitor display 12 Option pilot pressure switch
6 Computer A 13 Check valve
7 Lever Lock 14 Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-65
Overall View
1
T1T2
11
2 B2
pb2 A2 Fork Fork
close open
pa2
C1
B P T A
P1 PA P2
3 4 12
6 13
7
B 9
14 13
P
A1 A2 A3
10
8
SD05009-002a
Enlarged View
1
T1T2
B2
pb2 A2
pa2
P1 PA P2
3 4
SD05009-002b

Copyright ©
8020-66
Multi-purpose Circuit (breaker Q control)
When the switch in the cab is flipped to the breaker side, the ON signal (24 V) is output from the computer A to the
option switchover solenoid valve to switch the valve.
The pilot pressure oil flows from the option switchover solenoid valve B1 port to the A1 port and is fed to the 3-direc-
tion valve PP port and shut-off valve PP port and each valve is switched.
Always switch the 2 pumps flow select switch to the 1 pump side.
By operating the option remote control valve to the breaker side, the pilot pressure oil is fed to the control valve pa2
port and switches the option spool.
the option spool. Switching the spool lets the oil flow from the shut-off valve A port through the B port and into the
breaker.
The breaker set pressure is set by the relief valve built into the shut-off valve.
The return oil from the breaker returns from the 3-direction valve A1 port through the T1 port and to the hydraulic oil
tank.
Because the breaker operating flow can be set to 5 levels on the service support screen of the monitor display, the
optimum operating flow can be selected.
1 Control valve 12 Lever lock

2 3-direction valve 13 5 stack solenoid valve
3 Shut-off valve 14
tional valve
4 Breaker 15 P1 pressure sensor
5 Option remote control valve 16 P2 pressure sensor
6 Option pilot pressure switch 17
sensor
7 Multi-purpose circuit switch 18
sensor
8 Computer A 19
valve
9 Monitor display 20 Hydraulic pump
Option switchover solenoid
10 21 Check valve
valve
11 Console lever lock switch 22 Oil cooler
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-67
Overall View
Pressure line
Tank line
Pilot pressure line
Pilot tank line
Electric line
11
10 13
B1
12
2
PP 1 A1 B
T1 T1 T2
A T2
B
P
21
22 21
A
B
4 T
3 PP
B2 14 16
A2 15 A1 Psv
pb2
17
pa2 18
5
Breaker
ON
P1 PA
Flow
Reduce
C1
P1 A3
B P A
19
B1
7 B3
9 20
6 8
SD05009-003a
Enlarged View
1
T1 T2
B2
pb2 A2
pa2
P1 PA
SD05009-003b

Copyright ©
8020-68
Multi-purpose Circuit (2 pumps flow crusher)
When the 2 pumps flow select switch in the cab is flipped to the 2 pumps flow side, the ON signal (24 V) is output from
the computer A to the 2 pumps flow solenoid valve to switch the valve.
When the multi-purpose circuit switch is flipped to the crusher side, the crusher circuit is formed without outputting a
signal from the computer A to the option switchover solenoid valve and without switching the valve.
At this time, the pilot signal does not go to the 3-direction valve or to the shut-off valve and the 3-direction valve forms
the A <-> B circuit.
By operating the option remote control valve to the crusher close side, the pilot pressure oil is fed to the control valve
pa2 port and switches the option spool.
At the same time, the pilot pressure oil flows from the solenoid valve for 2 pumps flow B2 port to the A2 port and is fed
to the control valve pcc port and the control valve neutral cut valve is switched.
The discharge oil from hydraulic pump A2 enters the control valve P2 port and goes through the center bypass oil
path and since the neutral cut valve has closed the port to the tank, the oil goes from the P3 port via the P4 port and
merges on the upstream side of the option spool.
the option spool. Switching the spool lets the oil flow from the shut-off valve A port through the B port and into the
crusher.
The return oil from the crusher returns from the 3-direction valve A port through the B port and the option spool and
returns to the hydraulic oil tank.
Because the crusher operating flow can be set to 5 levels on the service support screen of the monitor display, the
optimum operating flow can be selected.
1 3-direction valve 10 Monitor display 19 5 stack solenoid valve

2 Shut-off valve 11 Computer A 20 Console lever lock switch
3 Crusher 12 Multi-purpose circuit switch 21
tional valve
Option switchover solenoid
4 13 2 pumps flow select switch 22 P1 pressure sensor
valve
5 2 pumps flow solenoid valve 14 Control valve 23 P2 pressure sensor
6 Option remote control valve 15 Neutral cut valve 24
sensor
7 Check valve 16 Travel pilot pressure sensor 25
sensor
8 Oil cooler 17 Upper pilot pressure sensor 26
valve
9 Option pilot pressure switch 18 Lever lock 27 Hydraulic pump
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-69
Overall View
14 15
T1T2
1
P3
PP pcc
T1
A T2
B
B A
3 7
T
PP 8 7
B2
pb2 A2
pa2
P4
A1 P1 PA P2
B2 16 17
21
23
A2 A1 A2
5 10
6 22 25
24
11
18 20
Pulverizer Pulverizer
close open B
Flow
P Reduce
A3
B P T A 27
26
13 B1
12
B3
9
19
SD05009-004a
Enlarged View
14 15
T1T2
P3
pcc
B2
pb2 A2
pa2
P4
P1 PA P2
16 17
SD05009-004b

Copyright ©
8020-70
2nd Option Circuit (hydraulic rotation fork)
WhenAs an example, this section explains the case in which the hydraulic rotation fork attachment is used.
By operating the 2nd option remote control valve to the right swing side, the pilot pressure oil is fed to the control valve
par2 port.
The 4th hydraulic pump OUT discharge oil is fed to the control valve Pr port, goes through the 2nd option spool and
flows to the hydraulic rotation fork to operate to the right swing side.
At this time, the 2nd option pilot pressure switch signal is detected and the auto idle function is released.
The return oil from the hydraulic rotation fork goes through the 2nd option spool and returns to the hydraulic oil tank.
The oil in the 2nd option drain line returns to the hydraulic oil tank without going through the control valve.
1 Control valve 9 Oil cooler

2 Travel pilot pressure sensor 10 Hydraulic rotation fork
2nd option pilot pressure
switch
5 5 stack solenoid valve 13 Computer A
6 Console lever lock switch 14 4th pump
2nd option remote control
7 15 Hydraulic pump
valve
8 Check valve
Legend
Pressure Line
Tank line
Pilot pressure line
Pilot tank line
Electric Line

Copyright ©
8020-71
Overall View
BR2 10
AR2
pbr2
1 par2
Pr
7
T1 T2
SECOND OPTION
Swing Swing
right left
C1
B P T A
11
12
13
P1 P2
2 3
8
4
B
6
9 8
P
14
A1 A2 A3 OUT
15
5
SD05009-005a
Enlarged View
BR2
AR2
pbr2
1 par2
Pr
P1 P2
2 3
SD05009-005b

Copyright ©
8020-72
NOTES
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Copyright ©
Section
8030
HYDRAULIC COMPONENT FUNCTIONS
8030

Printed in France
CNH Lep SMCX350B370B8030-0EN July 2008
Copyright ©
8030-2
TABLE OF CONTENTS
HYDRAULIC PUMP ................................................................................................................................................. 3
Hydraulic Pump................................................................................................................................................ 3
Regulator ......................................................................................................................................................... 7
Gear Pump..................................................................................................................................................... 15
MOTOR .................................................................................................................................................................. 17
Travel Motor................................................................................................................................................... 17
Swing Motor ................................................................................................................................................... 29
VALVE .................................................................................................................................................................... 36
Control Valve ................................................................................................................................................. 36
5 Stack Solenoid Valve Operation Explanation ............................................................................................. 72
Upper Pilot Valve (remote control valve) ....................................................................................................... 73
Travel Pilot Valve (remote control valve) ....................................................................................................... 78
Cushion valve ................................................................................................................................................ 83
Selector Valve (4-way)................................................................................................................................... 87
Selector Valve (3-direction)............................................................................................................................ 91

Copyright ©
8030-3
HYDRAULIC PUMP
1. Hydraulic Pump
1) Explanation of structures and operations
This pump has a structure in which 2 pumps are coupled by the 1st gear (116) and the 2 pumps
can be driven at the same time through the rotation of the power source being transmitted to the
drive shaft F (111) on the front side. The oil suction and discharge port are located in the
connection section of the 2 pumps (specifically, the valve block (312)), and the suction port is
used in common by the front pump and rear pump. Pump structure and operation principles are
the same for the front and rear pumps. The front pump is explained below.
The pump can be roughly divided into the rotary group, which is the main part of the pump that
performs rotation, the swash plate group, which changes the discharge flow, and the valve cover
group, which switches between oil suction and discharge.
The rotary group is made up of the drive shaft F (111), cylinder block (141), piston shoes (151),
(152), holder plate (153), spherical bushing (156), and cylinder spring (157). The drive shaft is
supported at both ends with bearings (123), (124). Along with being caulked to the piston to
form a spherical joint, the shoe has a pocket section for balancing the hydraulic pressure in
order to reduce the thrust force generated by the load pressure and allow the shoe to slide
lightly on the shoe plate (211). The piston shoe sub-group is pressed against the shoe plate by
the cylinder spring via the holder plate and spherical bushing so that it can slide smoothly on the
shoe plate. Also, the cylinder block is pressed against the valve plate (314) by the cylinder
spring in the same way.
The swash plate group comprises the swash plate (212), shoe plate (211), swash plate support
board (251), tilting bushing (214), tilting pin (531), and servo piston (532). The swash plate is
supported by the swash plate support board at the cylindrically shaped section formed by the
opposite side of the shoe sliding surface. By leading the hydraulic pressure force controlled by
the regulator into the hydraulic pressure chambers on both sides of the servo piston, the servo
piston moves left and right. This moves the swash plate on the swash plate support board via
the tilting pin spherical section and changes the tilting angle.
The valve cover group comprises the valve block (312), valve plates (313), (314), and valve
plate pin (885). The valve plate, which has 2 oval-shaped ports, is installed on the valve block.
Its function is to feed oil to the cylinder block and recover it from the cylinder block. The oil
switched by the valve plate is connected through the valve block to the outside lines.
Now when the drive shaft is driven by the power source (motor, engine, etc.), the cylinder block
is also rotated at the same time via the spline coupling. When the swash plate tilts, the piston
located at the center of the cylinder block moves reciprocally relative to the cylinder while
turning with the cylinder block.
Therefore, if just one piston is looked at, during one cylinder block rotation the piston moves
away from the valve plate (oil intake stroke) for 180° and then moves toward the valve plate (oil
discharge stroke) for the remaining 180°. When the swash plate tilting angle is 0°, the piston
does not move through a stroke and oil is not discharged.

Copyright ©
8030-4
2) Hydraulic pump internal structure diagram
Code Part name QTY Component part (QTY)

04 Gear pump 1 set ZX15LHRZ2-07A-V
011 Piston, sub 2 sets 151 (9PC), 152 (9PC)
013 Cylinder, sub (R) 1 set 141 (1PC), 313 (1PC)
014 Cylinder, sub (L) 1 set 141 (1PC), 314 (1PC)
030 Swash plate, sub 2 sets 212 (1PC), 214 (1PC)
041 Check valve 1, sub 2 sets 541 (1PC), 543 (1PC), 545 (1PC)
042 Check valve 2, sub 2 sets 541 (1PC) 544 (1PC), 545 (1PC)
079 Electromagnetic proportional pressure reducing valve, sub 1 set KDRDE5KR-V3-V
530 Tilting pin, sub 2 sets 531 (1PC), 548 (1PC)
Code Part name QTY Code Part name QTY

111 Drive shaft (F) 1 531 Tilting pin 2
113 Drive shaft (R) 1 532 Servo piston 2
114 1st gear 1 534 Stopper (L) 2
123 Cylinder roller bearing 2 535 Stopper (S) 2
124 Needle roller bearing 2 541 Seat 4
127 Bearing spacer 4 543 Stopper 1 2
141 Cylinder block 2 544 Stopper 2 2
151 Piston 18 545 Steel ball 4
152 Shoes 18 548 Feedback pin 2
153 Holder plate 2 702 O-ring 2
156 Spherical bushing 2 710 O-ring 1
157 Cylinder spring 18 714 O-ring 1
211 Shoe plate 2 717 O-ring 2
212 Swash plate 2 724 O-ring 16
214 Tilt revolution bushing 2 725 O-ring 6
251 Swash plate support board 2 728 O-ring 4
261 Seal cover (F) 1 732 O-ring 2
271 Pump casing 2 774 Oil seal 1
312 Valve block 1 789 Backup ring 2
313 Valve plate (R) 1 792 Backup ring 2
314 Valve plate (L) 1 808 Hexagon nut 2
326 Cover 1 824 Stop ring 2
401 Hexagon socket head bolt 8 885 Valve plate pin 2
406 Hexagon socket head bolt 4 886 Spring pin 4
414 Hexagon socket head bolt 4 901 Eye bolt 2
466 VP plug 2 953 Hexagon socket head stop screw 2
467 VP plug 2 954 Stop screw 2
468 VP plug 4 981 Nameplate 1
490 Insert plug 27 983 Strike rivet 2
492 Insert plug 12

Copyright ©
8030-5
Overall View
SD02009-032
Drive shaft front side Drive shaft rear side

Drive shaft front side
3
Copyright ©
8030-6
Drive shaft rear side
5
6
B_B
SD02009-034

Copyright ©
8030-7
2. Regulator
1) Regulator operation explanation
Operation explanation (See the Regulator operation explanation diagram.)
1] Flow control
The pump discharge flow is controlled as desired with the pilot pressure Pi as in the figure below.
1- Flow reduction operation
Discharge flow Q
Pilot pressure Pi
When the pilot pressure Pi increases, the pilot piston (643) moves to the right and stops at the
location where the pilot spring (646) force and hydraulic pressure balance each other. The pin
(875) fixed to lever 2 (613) fits into the grooved section of the pilot piston (643), so, through the
movement of the pilot piston (643), lever 2 rotates with the B section (fastened by the fulcrum
plug (614) and pin (876)) as the fulcrum. The pin (897) fixed to the feedback lever (611)
projects into the large opening (C section) of lever 2 (613), so as lever 2 (613) rotates, the pin
(897) moves to the right. The pin (548) fixed to the tilting pin (531) that shakes the swash plate
(212) is bonded to the two-side width section (D section) of the feedback lever (611). There-
fore, as the pin (897) moves, the feedback lever (611) rotates with D section as the fulcrum.
Since the spool (652) is linked to the feedback lever (611) via the pin (874), the spool (652)
moves to the right.
When the spool (652) moves, the discharge pressure Pd1 is led to the servo piston large-
diameter chamber via the spool and CI port. The discharge pressure Pd1 is always led to the
servo piston small-diameter chamber. As a result, the servo piston is moved to the right due to
the surface area difference and reduces the flow.
When the servo piston (532) moves to the right, the D section also moves to the right. The
return spring (654) is mounted on the spool (652). Since force pulling the spool to the left is
always operating, the pin (897) is pressed into the large opening (C section) of lever 2 (613).
Therefore, accompanying the D section movement, the feedback lever (611) rotates around
the C section as the fulcrum and the spool (652) moves to the left. This movement causes the
open section between the sleeve (651) and the spool (652) to begin to close, and the servo
piston (532) stops at the point the open section fully closes.
2- Flow increase operation
When the pilot pressure Pi decreases, the pilot piston (643) is moved to the left by the pilot
spring (646) force and lever 2 (613) rotates with the B section as the fulcrum. The pin (897) is
pressed in the large opening (C section) of lever 2 (613) by the return spring (654) via the
spool (652), pin (874), and feedback lever (611), so accompanying rotation of lever 2 (613),
the feedback lever (611) rotates with the D section as the fulcrum and the spool (652) moves
to the left.
When the spool (652) moves, the CI port opens to the tank port, so the pressure in the large-
diameter chamber of the servo piston drains out, the servo piston (532) is moved to the left by
the discharge pressure Pd1 of the small-diameter section and the flow increases.
Accompanying the movement of the servo piston (532), the D section moves to the left, the
feedback lever (611) rotates with the C section as the fulcrum and the spool (652) moves to
the right. This operation continues until the open section between the spool (652) and sleeve
(651) closes, and then the servo piston stops at the point the open section fully closes.

Copyright ©
8030-8
3- High-pressure selection function
The pilot pressure Pi, which serves as the flow control signal, is the pressure for which high
pressure is selected from among multiple command pressures via the shuttle valve subassem-
bly (050).
KR3K-9Y04-HV selects the higher pressure from Pi1 or the proportional valve 2nd pressure
and KR3K-9X04-HV selects the higher pressure from Pi2 or the external command pressure
P2.
2) Horsepower control
As the load pressure increases, the pump tilting angle decreases and the overload of the engine
is prevented as in the diagram below. Since this regulator uses the simultaneous full-horsepower
control method, the tilting angles (displacement volumes) of the 2 pumps are controlled to be the
same value as in the following equation.
Tin=Pd1 x q/2π + Pd2 x q/2π = (Pd1+ Pd2) x q2π (q: Displacement volume)
(q: Displacement volume)
Horsepower control is the same as flow control and is briefly explained below.
(For detailed operation of each part, see the Flow control section.)
Discharge flow Q
Discharge pressure (Pd1 + Pd2)

1] Overload prevention operation
When the self pump discharge pressure Pd1 or the counterpart pump discharge pressure Pd2
rises, since Pd1 and Pd2 operate on the stepped section of the compensation piston (621), the
compensation rod (623) is pressed to the right and moves to the location where the force of the
outer spring (625) and inner spring (626) balance out the hydraulic pressure force. The move-
ment of the compensation rod (623) is transmitted to lever 1 (612) through the pin (875) and lever
1 (612) rotates around the pin (876) (E section) fastened to the casing (601). The pin (897) fixed
to the feedback lever (611) projects into the large opening (F section) of lever 1 (612), so as lever
1 (612) rotates, the feedback lever (611) rotates with the D section as the fulcrum and the spool
(652) moves to the right.
When the spool (652) moves, the discharge pressure Pd1 is led to the large-diameter section of
the servo piston via the CI port, the servo piston (532) is moved to the right, and the pump dis-
charge flow is decreased to prevent overload of the power source.
The servo piston (532) movement is transmitted to the feedback lever (611) via the D section.
The feedback lever (611) rotates with the F section as the fulcrum and the spool (652) moves to
the left. The spool (652) moves until the open section between the spool (652) and sleeve (651)
closes, and then the servo piston stops at the point the open section fully closes.
2] Flow return operation

If the self pump discharge pressure Pd1 or the counterpart pressure pump discharge pressure
Pd2 decreases, the compensation rod (623) is pressed back by the outer spring (625) and the
inner spring (626) and lever 1 (612) rotates about the E section. Accompanying the lever 1 (612)
rotation, the feedback lever (611) rotates around the D section as the fulcrum and the spool (652)
moves to the left. Because of this, the CI port opens to the tank port, the servo piston large-diam-
eter section pressure drains off, the servo piston (532) moves to the left and the pump discharge
flow increases.
The movement of the servo piston (532) is transmitted to the spool (652) by the feedback mecha-
nism, and this operation continues until the open section between the spool (652) and the sleeve
(651) closes.

Copyright ©
8030-9
3) Low tilting (low flow) command priority mechanism

As above, the flow control and the horsepower control tilting command is transmitted to the
feedback lever (611) and spool (652) via the large opening (C and F sections) of lever 1 (612)
and lever 2 (613) , but since the C and F sections have a structure in which a pin (É”5) projects
into a large hole (É”9), the pin (897) only contacts the lever that makes the tilting smaller and the
É”9 hole for the lever on the side that has the larger tilting command state does not contact the
pin (897), but is free. This type of mechanical selection method gives priority to flow control and
horsepower control commands with low tilting.
4) Power shift control (horsepower reduction control)
Use the power shift pressure Pf to arbitrarily control the pump set horsepower as in the diagram
below.
When the power shift pressure Pf increases, the compensation rod (623) is moved to the right
via the pin (898) and the compensation piston (621), so the pump tilting angle is reduced and
the horsepower setting is reduced in the same way as was explained for the operation to prevent
overload. By contrast, as the power shift pressure Pf decreases, the horsepower setting
increases.
Discharge flow Q
Discharge pressure (Pd1 + Pd2)

Copyright ©
8030-10
5) Regulator operation explanation diagram
F E
Leads to Cl port servo
piston large-bore chamber
Right direction
Left direction
KR3K-9Y04-HV KR3K-9X04-HV
Pi1 Pf P A A P Pf Pi2
1
1 a p
p a
Hydraulic circuit diagram Front Hydraulic circuit diagram Rear
B B
side side
1 Cl port

Copyright ©
8030-11
1) Front side regulator internal structure diagram
1
2
1 Front side regulator

2 Rear side regulator
Component part number (quantities) and

Code PART NAME QTY
model
050 Shuttle valve, sub 1st 545 (1PC), 546 (1PC), 547 (1PC)
079 Electromagnetic proportional pressure reduction valve 1st KDRDE5K-31/30C50-102
Code PART NAME QTY Code PART NAME QTY

- Regulator, sub 1 651 Sleeve 1
412 Hexagon socket head bolt 2 652 Spool 1
413 Hexagon socket head bolt 2 653 Spring seating 1
418 Hexagon socket head bolt 2 654 Return spring 1
436 Hexagon socket head bolt 4 655 Set spring 1
438 Hexagon socket head bolt 8 656 Blind cover 1
466 VP plug 1 708 O-ring 1
496 Insert plug 12 724 O-ring 9
545 Steel ball 1 725 O-ring 1
546 Seat 1 1 727 O-ring 1
547 Seat 2 1 728 O-ring 1
601 Casing 1 730 O-ring 1
611 Feedback lever 1 732 O-ring 1
612 Lever 1 1 733 O-ring 1
613 Lever 2 1 734 O-ring 1
614 Support point plug 1 735 O-ring 1
615 Adjusting plug 1 753 O-ring 1
621 Compensation piston 1 755 O-ring 3
622 Piston case 1 756 O-ring 1
623 Compensation rod 1 763 O-ring 1
624 Spring seating (C) 1 801 Hexagon nut 1
625 Outer spring 1 802 Hexagon nut 1
626 Inner spring 1 814 Stop ring 1
627 Adjusting ring (C) 1 836 Stop ring 1
628 Adjusting screw (C) 1 858 Locking ring 2
629 Cover (C) 1 874 Pin 1
630 Lock nut 1 875 Pin 2
631 Pf sleeve 1 876 Pin 2
641 Pilot cover 1 887 Pin 1
643 Pilot piston 1 897 Pin 1
644 Spring seating (Q) 1 898 Pin 1
645 Adjusting ring (Q) 1
924 Hexagon socket head stop screw 1
646 Pilot spring 1

Copyright ©
8030-12
D
B
C B_B
A_A
D_D
Hydraulic circuit SD02009-035

Copyright ©
8030-13
2) Rear side regulator internal structure diagram

Code PART NAME QTY Component part number (quantities) and model
050 Shuttle valve, sub 1st 545 (1PC), 546 (1PC), 547 (1PC)

- Regulator, sub 1 651 Sleeve 1
412 Hexagon socket head bolt 2 652 Spool 1
413 Hexagon socket head bolt 2 653 Spring seating 1
436 Hexagon socket head bolt 4 654 Return spring 1
438 Hexagon socket head bolt 8 655 Set spring 1
466 VP plug 1 656 Blind cover 1
496 Insert plug 6 722 O-ring 3
545 Steel ball 1 724 O-ring 9
546 Seat 1 1 725 O-ring 1
547 Seat 2 1 727 O-ring 1
601 Casing 1 728 O-ring 1
611 Feedback lever 1 730 O-ring 1
612 Lever 1 1 732 O-ring 1
613 Lever 2 1 733 O-ring 1
614 Support point plug 1 734 O-ring 1
615 Adjusting plug 1 735 O-ring 1
621 Compensation piston 1 753 O-ring 1
622 Piston case 1 755 O-ring 3
623 Compensation rod 1 756 O-ring 1
624 Spring seating (C) 1 763 O-ring 1
625 Outer spring 1 801 Hexagon nut 1
626 Inner spring 1 802 Hexagon nut 1
627 Adjusting ring (C) 1 814 Stop ring 1
628 Adjusting screw (C) 1 836 Stop ring 1
629 Cover (C) 1 858 Locking ring 2
630 Lock nut 1 874 Pin 1
631 Pf sleeve 1 875 Pin 2
641 Pilot cover 1 876 Pin 2
643 Pilot piston 1 887 Pin 1
644 Spring seating (Q) 1 897 Pin 1
645 Adjusting ring (Q) 1 898 Pin 1
646 Pilot spring 1 924 Hexagon socket head stop screw 1

Copyright ©
8030-14
C B_B
A
B
A B
A_A
D_D
Hydraulic circuit SD02009-036

Copyright ©
8030-15
3. Gear Pump
1) Gear pump internal structure diagram
Section X_X (2PLACES) SD02009-037
SD02009-038
Code PART NAME QTY Component part number (quantities) and model
350 Gear case, sub 1st 307 (1PC), 308 (1PC), 351 (1PC), 353 (1PC), 354 (1PC), 361 (1PC), 887 (2PC)

307 Poppet 1 433 Flange socket 2
308 Seat 1 434 Flange socket 2
309 Ring 1 435 Flange socket 4
310 Spring 1 466 VP plug 1
311 Adjusting screw 1 700 Angle ring 1
312 Lock nut 1 710 O-ring 1
351 Gear case 1 725 O-ring 1
353 Drive gear 1 732 O-ring 1
354 Driven gear 1 850 Locking ring 1
355 Filter 1 887 Pin 2
361 Front case 1

Copyright ©
8030-16
2) Explanation of structures and operations

Structure
The casing comprises the front case (361) and gear case (351). Inside the casing the drive gear
(353), driven gear (354) pair and the relief valve for setting the discharge pressure are installed.
The relief valve comprises the filter (355), poppet (307), seat (308), spring (310), ring (309),
adjusting screw (311), and lock nut (312).
In order to prevent oil leaking to the outside, an angle ring (700) and O-ring (710) are mounted
on the front case (361).
Operation
Oil suctioned in from suction port B 3 is discharged from discharge port A 3 by the drive and
driven gears.
The discharge oil is held at the set pressure of 3.9 MPa by the relief valve.
Unnecessary discharge oil is drained from the drain port via the relief valve.

Copyright ©
8030-17
MOTOR
1. Travel Motor
1) Structural diagram
48 49 47 46
46
43 36 36
2 5 55 24 53 25 44 45 42 57 37 31 33 32 34 35
8
6
7 52
9 51
54
58 59
4
3
10 38 39
11
60
61
1 16 12 15 14 17 18 19 20 22 23 21 50 13 56 29 28 27 26 40 41 42
30 43
SD02009-017
Figure 1: Travel motor structural diagram
1 Casing 22 D-ring (small bore) 43 O-ring 1B P8

2 NPT1/16 plug 23 D-ring (large bore) 44 Check valve
3 Oil seal 24 Rear cover 45 Check valve spring
Circle R retaining ring
4 25 NPT1/16 plug (mec) 46 M6 orifice (diameter 0.6)
IRTW68
5 Expansion plug 26 Spool assembly 47 O-ring 1B P12.5
6 Tilting piston 27 Spring receiver 48 M6 orifice (diameter 0.8)
7 Tilting piston seal 28 Spring 49 O-ring 1B P15
8 Steel ball 29 M42 plug 50 O-ring 215.57 × 2.62
9 Shaft 30 O-ring 1B G40 51 Bearing HR32207C
10 Bearing HR32209J 31 Pilot spool 52 Shim
11 Pivot 32 Pin 53 Parallel pin
12 Shoe plate 33 Spring receiver 54 Valve plate
13 Cylinder block 34 Spring 55 Brake spring
Hexagon socket head bolt
14 Cylinder spring 35 Pilot valve plug G3/8 56
M18 × 50
15 Spring receiver 36 O-ring 1B P14 57 Overload valve
16 Spherical joint 37 Joint 58 Coupling
17 Shoe retainer 38 G1/4 plug 59 C retaining ring 40 for hole
18 Piston assembly 39 O-ring 1B P11 60 G1/2 plug
19 Separator plate 40 Orifice (break valve) 61 O-ring 1B P18
20 Friction plate 41 Orifice spring (break valve)
21 Brake piston 42 G1/8 plug
Copyright ©
8030-18
2) Structure
The main components of the motor are the rotary group, which generates the rotation force, the
negative brake, which prevents self-travel when the machine is parked, the variable mechanism
section, which switches the motor capacity between high and low, and the overload valve, which
is incorporated into the rear cover.
There is also one other valve that plays a critical role in controlling the travel hydraulic circuits.
This valve is called the brake valve or counterbalance valve. See the section on the brake valve
for details on the functions of this valve.
1] Rotary group
The cylinder block (13) is fit into the teeth grooves on the spline of the shaft (9), which is sup-
ported at both ends by the bearings (10), (51). This cylinder block (13) is pressed against the rear
cover (24) together with the valve plate (54) by the cylinder spring (14).
The 9 piston assemblies (18) slide along the surface of the shoe plate (12) while moving in and
out of the cylinder block (13).There are hydrostatic bearings at both ends of the piston assembly
(18), and to reduce the sliding resistance as well as make the piston move without separating
from the surface of the shoe plate (12), the force of the cylinder spring (14) is transmitted through
the spring receiver (15), spherical joint (16), and shoe retainer (17) to press both ends of the pis-
ton assembly (18) against the shoe plate (12).
2] Negative brake
7 separator plates (19) and 6 friction plates (20) are fit into the spline groove around the outer
edge of the cylinder block (13) in an alternating pattern and are pressed against the casing (1) by
the 14 brake springs (55) via the brake piston (21).
3] Variable capacity mechanism section
This section comprises the pivot (11), which is fit into the 2 semispherical indentations on the
shoe plate (12) and supports the shoe plate (12), the tilting piston (6), which tilts the shoe plate
(12) around the pivot (11), the tilting stopper (1-1), which supports tilting at the determined posi-
tion, the pilot valve section, which brings pressurized oil to the tilting piston (6) according to exter-
nal commands, and 3 check valves (44), which extract the highest pressure out of either the
external command pilot pressure, the motor inlet pressure, and the motor outlet pressure, and
send the pressurized oil to the pilot valve section.

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8030-19
4] Overload valve
This comprises the socket (57-1), which holds the valve seat (57-3) which seats metal to the
motor rear cover (24) internal hole section and screws the valve seat (57-3) into the rear cover
(24) to fasten it, the valve (57-2), which is contacted to the valve seat (57-3) by the adjusting
spring (57-9) and which is fit into the socket (57-1) internal hole, the linking piston (57-4), which is
inserted into the valve internal hole and serves as the oil path to the pilot section body (57-6), the
piston (57-7), which is inserted into the pilot section body (57-6) and is pressed against the lid
(57-5), and the spring adjusting shim (57-8).
57-3 57-2 57-1 57-12 57-13 57-4 57-9 57-8 57-12 57-10 57-11 57-6 57-7 57-5
Figure 2: Overload valve structural diagram
Symbol Part name Symbol Part name

57-1 Socket 57-8 Shim
57-2 Valve 57-9 Adjusting spring
57-3 Valve seat 57-10 O-ring IB P7
57-4 Linking piston 57-11 Backup ring T2P7
57-5 Plugs 57-12 O-ring IB G25
57-6 Pilot section body 57-13 Backup ring T2G25
57-7 Piston

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8030-20
5] Brake valve section
Figure 3 Brake valve section
a Check valve
Spool swichover pressure 0.59 to 0.95 MPa (85.5 to 137.7 Psi)
Check valve cracking pressure 0.015 MPa (2.17 Psi)
1- Motor operation
The high-pressurized oil sent from the hydraulic pump flows from the inflow port in the rear
cover (2), passes the valve plate (8), and is led into the cylinder block (3). Table 1 shows the
inflow port, the discharge port, and the direction of rotation of the output shaft.
2- Check valve (built into spool)
At the same time this serves as the feed oil path for the hydraulic motor, it also fulfills the dis-
charge oil lock function.
Accordingly, at the same time it is the suction valve for the hydraulic motor, it serves as the
holding valve.

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8030-21
3) Function
1 2
Figure 4 Port position
Direction of rotation
Inflow port Discharge port
(as seen from shaft side)
VA VB Right (clockwise)
VB VA Left (counter-clockwise)
1] Motor operation
The high-pressure oil sent from the hydraulic pump enters from the inflow ports (VA, VB), flows
through the break valve section, rear cover (24), and valve plate (54), and is led into the cylinder
block (13).
The table shows the inflow port, the discharge port, and the direction of rotation of the output
shaft.
Figure 5 (a) Figure 5 (b)

As in Figure 5 (a), this high-pressure oil operates on each piston during 180°, with the Y-Y line
connecting the piston top dead center and bottom dead center as the boundary,
and generates force of F1=PXA (P: pressure; A: piston cross-sectional surface).
This force F1 becomes a thrust force F2 and radial forces F31 - F34 (or F35) due to the shoe
plate (12), which has a tilt revolution angle of α. (See Figure 5 (b).) These radial forces operate
as the rotation force of the Y-Y shaft and generate a torque of
T= (r1xF31) + (r2xF32) + (r3xF33) + (r4xF34)
(When high pressure operates on five piston, r5xF35 is added.)
This torque is transmitted to the shaft (9) spline via the cylinder block (13) and is transmitted to
the shaft (9).

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8030-22
2] Parking brake operation
The parking brake is released when high hydraulic pressure selected by the counterbalance sec-
tion installed in the rear cover operates on the brake piston (21).Brake torque is constantly being
produced if no pressure is operating.
This brake torque is generated by the force of friction between the separator plate (19) coupled
by the casing (1) and spline and the friction plate (20) coupled with the cylinder block (13) by the
spline.
When pressure is not operating on the brake piston section, the brake piston (21) is pressed by
the brake spring (55) and the brake piston (21) sandwiches the friction plate (20) and separator
plate (19) against the casing (1).
This sandwiching force generates friction force between the friction plate (20) and the separator
plate (19), which serves as brake torque that constrains the shaft (9) in addition to the cylinder
block (13).
9 1 19 20 21 13 55 24
SD02009-022
Figure 6 Parking brake section

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8030-23
3] Operation of variable capacity mechanism section
MA MB
b
44 44 44
8 6 1-1 18
T
PA
31
VA or VB
Pa P
C
c 46 34 32
11 11 12
SD02009-023
Figure 7: Operation of variable capacity mechanism section

a To couterbalance valve (brake valve)
b High-speed travel command line (external pilot)
c Force application point
Diagram 7 shows a model of the variable capacity mechanism section.
When pressure overcoming the spring (34) enters the high-speed travel command line PA, the
spring (34) is compressed, the spool (31) moves to the right, the P and C ports are connected,
the highest of the 3 pressures - motor pressure MA, motor pressure MB, and the high-speed
travel command line pressure - is selected by the check valve (44), and the tilting piston (6) is
pressed. Therefore, the shoe plate (12) tilts as shown by the broken line with the line (L) connect-
ing the 2 pivots (11) as the axis center and when the tilting stops at the point where it contacts the
tilting stopper (1-1), it holds that state.
As a result, the amount of the piston (18) coming in and out is reduced and the motor capacity
becomes small, so the motor rotates at high speed without increasing the amount of oil sent from
the hydraulic pump. For this machine, the capacity is about 1.71 time more.
On the other hand, when the high-speed travel command line PA pressure disappears, the spool
(31) is returned to the left by the spring (34), the oil that had been pressing against the tilting pis-
ton (6) passes through the orifice (46) and is released to the tank, and the force pressing against
the piston disappears.
Here, there are 9 pistons (18) distributed uniformly on the shoe plate (12) and they press against
the shoe plate (12). The force application point for the total force of these 9 pistons is positioned
about at the center of the shoe plate (12) as in the diagram and the pivots (11) are at a position S
away from the center, so a rotation force that is equal to S multiplied by the piston pressing force
returns the motor to its original state and the motor switches to low-speed travel. Also, when the
engine power is exceeded, for example when steering or climbing a steep hill at high speed, in
order to prevent the engine stalling, when the engine load exceeds the stipulated value, the
motor is automatically switched to low-speed.
When the hydraulic pump pressure (VA or VB) is led to the PB port of diagram 7, this pressure
operates on the pin (32). When the stipulated pressure is exceeded, the spool (31) is returned to
the left by the reaction force of the pin (32), the oil that had been pressing against the tilting pis-
ton (6) is released to the tank, and the shoe plate (12) tilts to configure the high-capacity motor so
that operation becomes low-speed travel.
When this pressure falls to or below the stipulated pressure, the spool (31) moves to the right
and operation becomes high-speed travel.
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8030-24
4] Overload valve operation
There are two overload valves. They are laid out on the cross-over and have the following action.
1- When the hydraulic motor is stopped, in order to prevent load inertia, the brake pressure
generated on the motor discharge side is held to no greater than a certain value.
2- In order to get sharp acceleration with driving at the stipulated set pressure when starting
the hydraulic motor and to attenuate the brake shock when stopping, what is called boost
attenuation operation is carried out. The pressure generated is held at low pressure for a
short time and the reduction gear, travel crawler sprocket section, etc. mesh smoothly,
then the circuit pressure is held at the stipulated set pressure.
When the A port pressure for the overload relief valve rises when the hydraulic motor starts,
this pressure is applied to the effective diameter section seating to the valve seat (57-3) of the
valve (57-2) and it is also applied to the linking piston (57-4) of the valve interior through the
small hole in the valve (57-2). The A port pressure rises and the valve (57-2) resists the adjust-
ing spring (57-9) with the surface area difference between the valve seat effective diameter
section and the linking piston hole diameter section and sets the stipulated set pressure.
When the hydraulic motor brakes, the piston (57-7) in the rear section is on the left side due to
the drive pressure and when the A port pressure rises, it is also applied to the piston (57-7)
through the small hole in the valve and the small hole in the linking piston (57-4) and moves
the piston to the right side until it contacts the lid (57-5).
During this time, the valve (57-2) resists the adjusting spring (57-9) and holds the A port pres-
sure to a comparatively low and releases oil to the B port.
After the piston (57-7) contacts the lid (57-5), operation is the same as when the motor starts.
57-3 57-4 57-5
c
57-2 57-9 57-7
SD02009-024
Figure 8 Operation of overload valve
a From the A port

b To the B port
c Small hole

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8030-25
5] Overload valve operation
1- Hold state (see diagram 9).
In the switchover valve neutral state, the VA and VB ports are connected to the tank and the
spool (26) is held in a central position by springs at both ends. Accordingly, because the VA ->
MA, VB -> MB paths are closed, the MA and MB ports that connect to the hydraulic motor on
either side are both in the closed state.
Also, because the parking brake release path is connected to the tank, the parking brake is in
the operation state and rotation of the hydraulic motor is mechanically stopped by the brake
spring force.
When an external force operates on the hydraulic motor, motor rotation is normally stopped by
the parking brake.
The parking brake will slide when torque higher than the parking brake force occurs, but hold-
ing pressure occurs in the MA or MB port side and rotation is held to a very small amount by
this holding pressure.
Also, when a small amount of rotation occurs with the hydraulic motor, high-pressure oil
escapes from the closed circuit and cavitation tends to form in the low-pressure side of the
closed circuit. The check valve built into the spool operates in order to prevent this cavitation, a
VA -> MA or VB -> MB path is formed, and an oil volume equal to the leaked volume is filled
into the closed circuit from the tank.
1 1
SD02009-025
Figure 9 Hold state
1 Spring

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8030-26
2- Acceleration operation (see diagram 10).
When the VA port connects to the hydraulic pump and the VB port connects to the tank
through switching of the switchover valve, pressurized oil from the hydraulic pump pushes up
the check valve within the spool from the VA port, this oil is fed to the hydraulic motor from the
MA port, and this makes the hydraulic motor rotate.
Also, pressurized oil is fed to the pilot chamber on the VA port side, and the spool (26) which
overcomes the spring force on the VB port side moves to the left. If this occurs, along with the
MB -> VB return path being formed, pressurized oil is fed to the parking brake release line and
the parking brake is released. Accordingly, the hydraulic motor rotates.
If the inertial load of the hydraulic motor is large, pressure required for acceleration is achieved
with the overload relief valve set pressure and the hydraulic motor increases the rotation speed
while relieving pressurized oil.
As the rotation of the hydraulic motor increases, the relief volume decreases and a constant
speed is eventually achieved.
2 2
1
1
SD02009-026
Figure 10 Acceleration operation
1 Spring
2 Pilot chamber

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8030-27
3- Stop operation (see diagram 11).
When the switchover valve is returned to the neutral position, oil sending is cut off, and the VA
and VB ports are connected to the tank during rotation of the hydraulic motor, pressure in the
pilot chambers on both ends of the spool becomes equal and the spool (26) is returned to the
neutral position through spring force.
This causes the MB -> VB path to close. However, the inertial force of the load will force rota-
tion of the hydraulic motor to continue. Pump operation occurs in the hydraulic motor and
hydraulic oil continues to be discharged into the MB port, but pressure increases because this
path is cut off. The overload relief valve operates and, as this happens, the speed of the
hydraulic motor gradually decreases and the motor eventually stops.
Also, the parking brake release pressure is slowly reduced because it is metered. The brake
eventually reaches the operation state and rotation of the hydraulic motor mechanically stops.
2 2
1
1
SD02009-027
Figure 11 Stop operation
1 Spring
2 Pilot chamber

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8030-28
4- Counterbalance operation (see diagram 12).
When the speed of the rotation hydraulic motor is reduced by load inertia, a counterbalance
operation is necessary.
If the hydraulic oil being fed to the VB port from the hydraulic pump is gradually decreased, the
hydraulic motor will rotate at a speed that is at or above the speed determined by the oil feed
volume due to inertial force. As a result, the pressure in the pilot chamber of the VB port side is
decreased and the spool (26) is pushed in the neutral direction to the left side by the spring
(28).
Accordingly, because the surface area of the MA -> VA path is reduced and path resistance
increases, pressure on the MA side increases and the hydraulic motor is affected by brake
operation.
If the motor rotation speed falls to or below the speed determined by the oil feed volume, pres-
sure in the pilot chamber on the VB port side increases, the spool (26) moves to the right,
brake operation is reduced in order to increase the surface area of the MA -> VA path, and the
rotation speed of the hydraulic motor is controlled to a speed that is equivalent to the oil feed
volume.
In order to perform stable counterbalance operations, orifices (40) are installed on the pilot
chambers on both ends in order to provide a damping effect on the spool (26).
The parking brake is released while the spool (26) is performing a pressure adjustment opera-
tion.
3 3
2 2
1
1
SD02009-028
Figure 12 Counterbalance operation
1 Spring
2 Pilot chamber
3 Check valve with orifice

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8030-29
2. Swing Motor
1) Swing motor operation explanation
1] Hydraulic motor section
As the diagram below shows, when the high-pressure oil passes through the valve plate (1)
intake-side port (a) and flows into the cylinder, the hydraulic pressure operates on the piston and
a force F is generated in the axial direction. This force F is divided into 2 vectors, a force F1 per-
pendicular to the swash plate (3) via the shoe (2) and a force F2 perpendicular to the shaft. This
force F2 is transmitted to the cylinder block (4) via the piston, generating a rotational couple
around the output shaft.
9 pistons are arrayed in the cylinder block. Rotation torque is transmitted sequentially to the out-
put shaft by multiple pistons linked with the high-pressure oil intake-side port.
When the oil in and out directions are reversed, the rotation of the output shaft also reverses.
The theoretical output torque T [Nm] is given by the following equation.
Figure 1 Motor section operation explanation diagram
1 Piston
2 Drive shaft
2] Valve casing section

1- Anti-cavitation check valve section
Because the system using this type of motor does not have a valve with a counter-balance
function, the motor sometimes rotates more than the quantity of oil fed.
In order to prevent cavitation due to insufficient oil, there is a check valve to take in the oil
shortfall.
Figure 2 Hydraulic circuit diagram

1 M Port
2 Control valve

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8030-30
3] Brake section
The cylinder (111) is coupled with the drive shaft (101) by the gear. Also, the separator plate
(743) is constrained for circumferential rotation by the arc groove cut into the casing (301).
When the friction plate (742) that is gear coupled to the cylinder outer circumference section is
pressed to the casing (301) by the brake spring (712) via the separator (743) and the brake piston
(702), friction force is generated between the friction plate and casing and between the separator
plate and the brake piston. The drive shaft is constrained and braked by this friction force.
On the other hand, when brake release pressure is applied to the oil chamber formed between
the brake piston and the casing and the hydraulic pressure wins out over the spring force, the
brake piston moves, the force pressing the friction plate against the casing disappears, and the
brake is released.
Spring
Hydraulic pressure
101
111
712 1
702
301
742
743
SD02009-039
Figure 3 Brake operation diagram

1 Oil chamber

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8030-31
4] Relief valve operation explanation (Relief valve model: KRD22EK10)
1- Operation explanation for when the relief valve is pressurized
In the case where the P port is pressurized with the tank pressure,
the P and R ports are initially at the tank pressure and the valve status is as shown in diagram
4 (1).
At the pressure where there is balance between the hydraulic pressure determined by the
product of the pressure P and the pressurized area A1 of the plunger (301) on the one hand
and the hydraulic pressure determined by the product of the spring (321) load FSP and
plunger (301) pressurized area A2 and the g chamber pressure Pg on the other, the relief
valve starts to operate.
After that, the g chamber pressure rises and the piston (302) starts its stroke. Accompanying
this movement, the load on the spring (321) increases.
Through the operation above, the relief pressure P is increased from P1 to Ps in the pressure
boost time t1.
This process is explained below in terms of the relationship between the movement state of
the parts in diagrams 4-(2) - (4) and the relief pressure.
1)State shown in diagram 4-(2)
When the relief valve P port is pressurized, pressure is generated in the g chamber via
the orifice m in the plunger (301).
When the hydraulic pressure operating on the plunger (301) increases and reaches the
pressure at which it balances the spring (321) load FSP, the relief valve carries out the
relief operation at pressure P1.
The relationship at this time is expressed by the following equation.
P1 × A1 = FSP1 + Pg1 × A2FSP1: Initial set load for the spring (321)
The g chamber pressure operates on pressurized areas A3 and A4 of the piston (302).
When this hydraulic pressure becomes larger than the load on the spring (321), the piston
starts to move to the left.
At this time, the oil in the h chamber formed between the piston and the adjusting plug
(401) is discharged into the g chamber via the orifice n set up on the piston (302) while
the piston moves to the left, so the h chamber functions as a damping chamber.
Through this, the spring load gradually increases until the piston reaches the adjusting
plug end section and the relief pressure P rises smoothly.
When the piston (302) reaches the adjusting plug (401) end section, it does not move far-
ther to the left, so the constant relief state is reached and the relief pressure is held at P2.
Through the processes (1) - (4) above, the relief pressure varies as in diagram 5.
2- Operation explanation for when the relief valve is depressurized
In the case where the P port pressure falls,
the P port pressure and the g chamber pressure fall together to the tank pressure when the
pressurization of the P port ends. Through this, the plunger (301) which was open moves to
the left and is placed in the seat (401). At the same time, the piston (302) also is moved to the
right by the spring (321) and returns to the state in diagram 4-(1).
3- section (S2).

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8030-32
1 2 34
(1)
P
R
A3 A2 8 A4
5 6 7
(2)
P
(3)
P
(4)
P
R
RST-04-02-001n01
Figure 4 Relief valve operation explanation diagram
1 Orifice m 5 A1 pressurized area

2 Spring (321) 6 Plunger (301)
3 Chamber h 7 Orifice n
4 Piston (302) 8 Chamber g
(4)
Ps
(3)
P1
(2)
(1)
t1
RST-04-02-001n02
Figure 5 Pressure boost characteristics

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8030-33
2) Swing motor internal diagram
SECTION A_A
a Identification mark

Copyright ©
8030-34

Copyright ©
8030-35
Code Part name Q’ty

Reverse prevention valve subas-
052 1 set
sembly
100 Casing 1
151 ROH plug 2
161 O-ring 2
162 O-ring 2
163 O-ring 2
171 Hexagon socket head bolt 4
400 Reverse prevention valve 2 set
400-1 O-ring 2
400-2 Backup ring 2
Code Part name Q’ty Code Part name Q’ty

051 Relief valve 2 set 401 Hexagon socket head bolt 4
051-1 O-ring 2 443 Roller bearing 1
10 Piston subassembly 1 set 444 Roller bearing 1
101 Drive shaft 1 451 Pin 2
111 Cylinder 1 469 ROMH plug 2
114 Plate spring 1 472 O-ring 1
121 Piston 9 488 O-ring 2
122 Shoe 9 491 Oil seal 1
123 Holder plate 1 702 Brake piston 1
124 Shoe plate 1 706 O-ring 1
131 Valve plate B 1 707 O-ring 1
20 Valve casing H2 subassembly 1 set 712 Brake spring 18
301 Casing JA1 1 742 Friction plate 2
303 Valve casing H2 1 743 Separator plate 4
351 Plunger H2 2 984 Masking plug 1 set
355 Spring H2 2 985 Masking plug 1 set
390 Nameplate 1 986 Masking plug 1 set
391 Driving tack 2 994 Insert plug 1

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8030-36
VALVE
1. Control Valve
Basic configuration
This valve is based on the main unit housing which combines the P1 side housing and P2 side
housing with the rear surfaces against each other and has a configuration that makes it possible
to mount the inlet, add-on section, and outlet on the P2 side housing top.
1) Operation
1] When all spools in neutral
1- Neutral path [Fig. 1, Fig. 2]
1)When Pn1 and Pn2 ports are pressurized
The oil fed from the P1 port enters the tank path (Ta) from the neutral path (L1) through
the low-pressure relief orifice (Lc1) and returns to T1 - T8 ports.
The oil fed from the P2 port enters the tank path (Ta) from the neutral path (R1) through
the low-pressure relief orifice (Rc1) and returns to the T1 - T8 ports.
The pressure in the pressure chambers (L2) and (R2) upstream from the low-pressure
relief valve is led into the pump from the ps1 and ps2 ports and controls the P1 and P2
pump discharge volume.
Also, if excess oil flows into the neutral path (L1), the poppet opens to provide low-pres-
sure relief. This prevents the ps1 and ps2 port pressures from becoming abnormally high.
2)When Pn1 and Pn2 ports are not pressurized
In this case, the low-pressure relief poppets open at lower pressure than in (a).
Therefore, the oil fed from the P1 port enters the tank path (Ta) from the neutral path (L1)
primarily through the low-pressure relief valve discharge port (L3) and returns to the T1 -
T8 ports.
Also, the oil fed from the P2 port enters the tank path (Ta) from the neutral path (R1) pri-
marily through the low-pressure relief valve discharge port (R3) and returns to the T1 - T8
ports.

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8030-37
L2
1 Lc1 ps1 T1
L3
Pn1
pc3
L4
Ta
L
T3 Ta
ps1
L1
2
(Section 5)
3
(Section 4)
L3
4
(Section 3)
5
(Section 2)
6
(Section 1)
S1-1 S1-2
L1
P1
P1 side
SD02009-012a

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8030-38
Ta Tr1 7
Ta
Rg 8
(Section R2 )
Pg
Ta Pr 9
R1
10
(Section R1)
R1
Ta
R3
T8
R1 R3
Pn2
11
(Section 9)
R4
Rc1 ps2 T2
R2 P3
R3 12
15
(Section 8)
13
(Section 7)
6
(Section 6)
R3
14
(Section ST)
R1
P2
Ta P2 side [Fig.1]
R
SD02009-012b
1 Low-pressure relief valve (L) 6 Travel 11 Arm 2

2 Arm 1 7 Outlet 12 Boom 1
3 Boom 2 8 Attachment 2 13 Bucket
4 Swing 9 Inlet 14 Straight travel
5 Option 10 Attachment 1 15 Low-pressure relief valve (R)

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8030-39
1
T3
Ta
T6 Ta T7
7
L5
pc3
L1
L1
6
Open Close
2 pb5 pa5
(Section 5)
5
Up Down
3 pb4 pa4
(Section 4) Ta
Ta 4
4 pb3 pa3
(Section 3)
5 pb2 pa2
(Section 2)
Ta L1 Ta
6 pb1 pa1
(Section 1)
T4
P1
Ta
L-L 2
Ta
SD02009-013a

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8030-40
Ta Ta
Ta
par2 pbr2 7
(Section R2 )
Pg
Ta Ta
R1 (Cylinder extension) (Cylinder retraction)
Down Up
par1 pbr1 8
(Section R1)
Ta R1
Ta
T8 9
7
T2
R1
6
Close Open
pa9 pb9 10
(Section 9)
5 Ta
Down Up
pa8 pb8 11
Ta (Section 8)
4
Close Open
pa7 pb7 12
(Section 7)
R1 Ta
pa6 pb6 13
(Section 6)
Ta
DR3 (Pst) 14
(Section ST)
T5
P2
Ta
1
2
3 R_R
Ta
[Fig.2]
SD02009-013b
1 Variable arm regeneration orifice 6 Travel 11 Boom 1

2 Arm 1 7 Attachment 2 12 Bucket
3 Boom 2 8 Attachment 1 13 Travel
4 Swing 9 Neutral cut 14 Straight travel
5 Option 10 Arm 2

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2- Signal, straight travel signal control valve, plate assembly [Fig. 3]
There are 2 signals, (a) and (b) below. The pilot signal for each spool for which a lever is oper-
ated is used to generate the pressure that is output.
The straight travel signal control valve integrates each signal pressure and controls straight
travel spool switchover. Also, the plate assembly has a function for picking up the pilot pres-
sures with the built-in shuttle.
1)Travel signal (PT)
The highest of the pilot pressures applied to the travel section 1 (pa1, pb1) and travel sec-
tion 6 (pa6, pb6) is selected and output to the PT port.
Therefore, when the travel spool is in the neutral position (no-load pilot pressure), no
pressure is generated at the PT port.

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8030-42
2)Front signal (PA)
The highest of the pilot pressures (pa2 - 9 and pb2 - 9) applied to sections 2 - 9 that use
the pressurized oil from the P1 and P2 pumps, except for the travel sections, is selected
and output to the PA port. (Note 1)
Therefore, when all the spools are in the neutral position (no-load pilot pressure), no pres-
sure is generated at the PA port.
Note: 1
When an add-on (main pump add-on) is used through the feed from P2, the branches for the
add-on pilot signals par1 and pbr1 are connected to the respective main unit valves, prs1 and
prs2 ports, and thus incorporated in the front signal PA selection area.
Be careful. If the above line connection is not done, the PA pressure will not rise through add-
on selection.
Also, when using 2 main pump add-ons, set the circuit so that maximum of the add-on pilot
pressures (par1 and 2, pbr1 and 2) can be taken out as desired and connect to either prs1 or
prs2.
1 PA 4
V2 RCV Remote
control valve
MCV
5
Pst
V1
6
RCV Remote
control valve
MCV
2
7
PT 8
RCV Remote
control valve 9
MCV
2
prs1
prs2 10
[Fig.3]
4 3
DR2
RST-04-02-001an
1 Straight travel signal control valve 6 Arm

2 Travel 7 Bucket
3 Main unit housing section (option) 8 Swing
4 Plate assembly 9 Option
5 Boom 10 Add-on (main pump)

Copyright ©
8030-43
2] Independent operation
1- Travel spool switchover [Fig. 4 and Fig. 5]
When a travel spool is switched by pressurizing from the travel (section 1) pilot port Pb1 (Pa1),
the oil fed from the P1 port flows from the neutral path (L1) through the spool neck section and
into the B1 (A1) port. The return oil returns to the tank path (Ta) from the A1 (B1) port through
the spool neck section.
When a travel spool is switched by pressurizing from the travel (section 6) pilot port Pb6 (Pa6),
the oil fed from the P2 port flows from the neutral path (R1) through the spool neck section or
path (S6-1) and into the B6 (A6) port.
When only travel is operated, the parallel path (R3) and the path (S6-1) have the same pres-
sure, so the poppet (S6-2) does not open. The return oil returns to the tank path (Ta) from the
A6 (B6) port through the spool neck section.

Copyright ©
8030-44
P4
S2-1 S2-2
A2 B2
1 L3
pb2 pa2 3
(Section 2)
Ta Ta
2 R1
pb6 pa6 4
(Section 6)
1 R3
[Fig.4]
S6-1 S6-2
A6 B6
RST-04-02-001ao01
1 Switching state
2 Neutral state
3 Option
4 Travel
A1 B1
Ta
1 L1 L3
pb1 pa1 3
(Section 1)
2 Ta
2
(pst) DR3 4
(Section ST)
R3
[Fig.5]
RST-04-02-001ao02
1 Switching state
2 Neutral state
3 Travel
4 Straight travel

Copyright ©
8030-45
2- Option spool switchover [Fig. 4]
When the option spool is switched by pressurizing from the option (section 2) pilot port Pb2
(Pa2), the neutral path (L1) is closed. The oil fed from the P1 port flows from the parallel path
(L3) through the load check valve (S2-2), path (S2-1), and the spool neck section, and into the
B2 (A2) port.
The return oil returns to the tank path (Ta) from the A2 (B2) through the spool neck section.
Also, when oil is fed from the P4 port, it passes through the inside of the load check valve (S2-
2) and merges with path (S2-1).

Copyright ©
8030-46
P4
S2-1 S2-2
A2 B2
1 L3
pb2 pa2 3
(Section 2)
Ta Ta
2 R1
pb6 pa6 4
(Section 6)
1 R3
[Fig.4]
S6-1 S6-2
A6 B6
RST-04-02-001ao01
1 Switching state
2 Neutral state
3 Option
4 Travel
A1 B1
Ta
1 L1 L3
pb1 pa1 3
(Section 1)
2 Ta
2
(pst) DR3 4
(Section ST)
R3
[Fig.5]
RST-04-02-001ao02
1 Switching state
2 Neutral state
3 Travel
4 Straight travel

Copyright ©
8030-47
3- Swing spool switchover [Fig. 6]
When the swing spool is switched by pressurizing from the swing (section 3) pilot port Pb3
(Pa3), the neutral path (L1) is closed. The oil fed from the P1 port flows from the parallel path
(L3) through the load check valve (S3-2), path (S3-1), and the spool neck section, and into the
B3 (A3) port.
The return oil returns to the tank path (Ta) from the A3 (B3) through the spool neck section.
S3-1 S3-2
A3 B3
DR1
1 L3
pb3 pa3 3
(Section 3)
Ta L1
2
pb7 pa7 4
(Section 7)
R3
A7 B7 [Fig.6]
RST-04-02-001aq
1 Switching state 3 Swing

2 Neutral state 4 Bucket

Copyright ©
8030-48
4- Bucket spool switchover [Fig. 7 and Fig. 8]
1)Close (regeneration) [Fig. 7]
When the bucket spool is switched by pressurizing from the bucket (section 7) pilot port
Pb7, the neutral path (R1) is closed. The oil fed from the P2 port flows through the parallel
path (R3), the load check valve (S7-2), path (S7-1), and the spool neck section, and into
the B7 port.
At the same time, the return oil from the A7 port returns to the tank path (Ta).
After part of the return oil pushes open the poppet (S7-3) inside the bucket spool, it
merges into the B7 port to prevent cylinder head side cavitation.
This is also accompanied by cylinder speed increases and P2 port pressure reductions
depending on the port pressure conditions.
Bucket close (regeneration)
A3 B3
DR1
L3
pb3 pa3 3
(Section 3)
Ta
1
R1 S7-3
pb7 pa7 4
(Section 7)
R3
2
A7 B7 [Fig.7]
S7-1 S7-2
RST-04-02-001ar
1 Neutral state 3 Swing

2 Switching state 4 Bucket

Copyright ©
8030-49
2)Open [Fig. 8]
When the bucket spool is switched by pressurizing from the bucket (section 7) pilot port
Pa7, the neutral path (R1) is closed. The oil fed from the P2 port flows through the parallel
path (R3),
the load check valve (S7-2), path (S7-1), and the spool neck section, and into the A7 port.
The return oil returns to the tank path (Ta) from the B7 port through the spool neck sec-
tion.
Bucket open
A3 B3
DR1
L3
pb3 pa3 3
(Section 3)
Ta
1
R1
Ta
pb7 pa7 4
(Section 7)
R3
2
A7 B7 [Fig.8]
S7-1 S7-2
RST-04-02-001as
1 Neutral state 3 Swing

2 Switching state 4 Bucket

Copyright ©
8030-50
5- Boom spool switchover [Fig. 9, Fig. 10, and Fig. 11]
1)Neutral [Fig. 9]
This valve mounts an anti-drift valve on the boom 1 cylinder head (A8) side.
In neutral, the poppet (AD1) is reliably seated by the pressure of the A8 port itself led
through path (AD2) and the spool (AD3) into the spring chamber (AD4) to cut off the
return oil from the A8 port.
Neutral
S4-1 S4-2
L3
pb4 pa4 1
(Section 4)
L1
R1
pb8 pa8 2
(Section 8)
R3
AD3 AD1 A8 B8 [Fig.9]

AD2 AD4 S8-1 S8-2
RST-04-02-001at
1 Boom 2
2 Boom 1

Copyright ©
8030-51
2)Boom up (2 pumps flow) [Fig. 10]]
When the boom 1 spool is switched by pressurizing from the boom 1 (section 8) pilot port
Pa8, the neutral path (R1) is closed. The oil fed from the P2 port flows through the parallel
path (R3), the load check valve (S8-2), and the spool neck section and into the A8 port.
Pa4, the neutral path (L1) is closed. The oil fed from the P1 port flows through the parallel
path (L3), the load check valve (S4-2), the spool neck section, and path (4) and merges
into the A8 port. The return oil returns to the tank path (Ta) from the B8 port through the
spool neck section.
Up (2 pumps flow)
S4-1 S4-2
L3
pb4 pa4 1
(Section 4)
L1
4 R1 Ta
pb8 pa8 2
(Section 8)
R3

AD2 AD4 S8-1 S8-2
RST-04-02-001au
1 Boom 2
2 Boom 1

Copyright ©
8030-52
3)Boom down (regeneration) [Fig. 11]
pb8, the neutral path (R1) is closed. The oil fed from the P2 port flows through the parallel
path (R3), the load check valve (S8-2), and the spool neck section and into the B8 port.
The pilot pressure applied to pb8 at this time moves the anti-drift valve spool (AD3)
through the path built into the housing at the same time that the spool is switched and
reduces the pressure of the spring chamber (AD4) to open the poppet (AD1).
Through this movement, the cutoff of the A8 port is released before the spool is switched.
After that, the return oil from the A8 port returns to the tank path (Ta).
Part of the return oil pushes open the poppet (S8-3) inside the boom 1 spool, passes
through path (S8-1), and merges into the B8 port to prevent cylinder rod side cavitation.
This is also accompanied by cylinder speed increases and P2 port pressure reductions
depending on the port pressure conditions.
Down (regeneration)
S4-1 S4-2
L3
pb4 pa4 1
(Section 4)
L1
4 R1
pb8 pa8 2
(Section 8)
R3
DR1
AD2 AD4 S8-1 S8-2
RST-04-02-001av
1 Boom 2
2 Boom 1

Copyright ©
8030-53
6- Arm spool switchover [Fig. 12 - 15]
1)Neutral [Fig. 12]
This valve mounts an anti-drift valve on the arm 1 cylinder rod side.
In neutral, the poppet (AD1) is led through path (AD2) and the spool (AD3) into the spring
chamber (AD4). It is reliably seated by the pressure of the A5 port itself to cut off the
return oil from the A5 port.
Neutral
AD2 AD1 S5-1 S5-2
AD3 AD4
A5 B5
L3
pb5 pa5 1
(Section 5)
L1
R1
pb9 pa9 2
(Section 9)
R3
S9-1
[Fig.12]
S9-2
prs1 prs2
RST-04-02-001aw
1 Arm 1
2 Arm 2

Copyright ©
8030-54
2)Arm in (2 pumps flow) [Fig. 13]
When the arm 1 spool is switched by pressurizing from the arm 1 (section 5) pilot port
Pb5, the oil fed from the P1 port flows from the neutral path (L1) through the load check
valve (S5-2), path (S5-1), and the spool neck section and into the B5 port. When the arm
2 spool is switched by pressurizing from the arm 2 (section 9) pilot port Pb9, the oil fed
from the P2 port flows from the neutral path (R1) through the load check valve (S9-2),
path (S9-1), the spool neck section, and path (6) and merges into the B5 port.
The pilot pressure applied to pb5 at this time moves the anti-drift valve spool (AD3)
through the path built into the housing at the same time that the spool is switched and
reduces the pressure of the spring chamber (AD4) to open the poppet (AD1). Through this
movement, the cutoff of the A5 port is released before the spool is switched.
After that, the return oil from the A5 port splits into the flow through the regeneration
check valve in the spool that is regenerated at the B5 port and the flow returning to the
tank path (Ta) through the regeneration control valve.
(For details on the regeneration function, see the regeneration valve operation explanation
in next section 3).)
Arm in (2 pumps flow)
AD2 AD1 S5-1 S5-2
AD3 AD4
A5 B5
DR1
L3
pb5 pa5 1
(Section 5)
L1
R1
pb9 pa9 2
(Section 9)
R3
S9-1
[Fig.13]
S9-2
prs1 prs2
RST-04-02-001ax
1 Arm 1
2 Arm 2

Copyright ©
8030-55
3)Arm in (variable regeneration) [Fig. 14]
For an arm-in operation, after the return oil from the A5 port passes through the notch (a),
it divides into 2 paths:
1. The return oil returns to the tank path (Ta) through the fixed orifice (d) in the regenera-
tion control valve, path (e), and the variable orifice (f).
2. The return oil passes through the fixed orifice (b) in the arm 1 spool, the regeneration
check valve (c), and the fixed orifice (i), then merges into the bridge path (S5-1).
Here, when the bridge path (S5-1) pressure goes higher due to the port B5 load pressure,
the regeneration control valve spool (h) is pressed through the regeneration control valve
piston (g), and the variable orifice (f) section opening surface area increases, so the quan-
tity of oil returning to the tank path (Ta) increases.
On the other hand, the quantity of oil regenerated in the B5 port decreases.
Though this variable mechanism, both the regeneration ratio for low loads is secured and
reduction in the return back pressure for high loads is established.
Arm in (variable regeneration)
AD2 AD1 S5-1 S5-2

AD3 AD4
A5 B5
DR1
L3
pb5 pa5 2
(Section 5)
L1
Ta b a i c
1
[Fig.14]
f e d h g
RST-04-02-001ay
1 Regeneration control valve (variable)

2 Arm 1

Copyright ©
8030-56
4)Arm out (2 pumps flow) [Fig. 15]
Pa5, the oil fed from the P1 port flows from the neutral path (L1) through the load check
valve (S5-2), path (S5-1), and the spool neck section and into the A5 port.
Pa9, the oil fed from the P2 port flows from the neutral path (R1) through the load check
valve (S9-2) and path (S9-1), merges into the arm 1 section path (S5-1) and heads toward
the A5 port through the arm 1 spool neck section. The return oil from the B5 port returns
to the tank path (Ta) through the spool neck section.
Arm out (2 pumps flow)
AD2 AD1 S5-1 S5-2
AD3 AD4
A5 B5
L3
pb5 pa5 1
(Section 5)
L1 Ta
R1 Ta
pb9 pa9 2
(Section 9)
R3
S9-1
[Fig.15]
S9-2
prs1 prs2
RST-04-02-001az
1 Arm 1
2 Arm 2

Copyright ©
8030-57
7- Arm parallel orifice [Fig. 16]
Metering by the spool is installed in the arm 1 parallel path of this valve to control the quantity
of oil fed to arm 1 for compound operations.
The oil fed from the arm 1 (Section 5) parallel path (L3) pushes open the poppet (S5-3) and
passes through the variable metering spool orifice (Lc8), then is connected to path (L5).
Here, the quantity metered by the orifice (Lc8) is adjusted by pressurizing the pilot port (Pbu).
1 Low-pressure relief valve (L) 3 For boom up (for Pbu pressurization)

2 Pbu signal path 4 For neutral

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8030-58
8- Relief valve
1)Main relief valve [Fig. 17]
The oil fed from the P1 port passes through the poppet (LP) and the oil fed from the P2
port passes through the poppet (RP) and path (3) and is led to the main relief valve. The
maximum pressure of the P1 and P2 side pumps is controlled by the operation of the main
relief valve.
P1
LP
L3
Ta T4
3
PH Ta T5
Ta
R3
RP
[Fig.17]
P2
RST-04-02-001bb
2)Overload relief valve [Fig. 18]

There is an overload relief valve at the boom 1, arm 1, bucket, and add-on cylinder ports
to prevent any abnormal rise in actuator pressure, for example due to an external force.
This relief valve is also equipped with a function for preventing cavitation (suction function)
by taking in oil from the tank when the cylinder port pressure becomes negative pressure.
R1 Ta
Pa8
R3
Suction function Operating

B8 [Fig.18]
S8-2
RST-04-02-001cb

Copyright ©
8030-59
3] Compound operation
1- Travel compound operation [Fig. 19, Fig. 20]
Under the conditions below when the travel left/right and the front system are operated at the
same time, the straight travel spool is switched, and the straight travel characteristic is main-
tained.
1 When the front is operated during travel left/right simultaneous operation (forward,
backward, or pivot turn)
2 When the left/right are operated simultaneously during front system operation
Front system operation is not affected by the switchover section or quantity of switchovers.
1)Signal circuit [Fig. 19]
(A)When the [Travel 1] side lever is operated, the pressure branched off from the valve
main unit pilot port passes through the filter and the shuttle, then switches the switcho-
ver valve [V1].
(B)When the [Travel 2] side lever is operated, the pressure branched off from the valve
main unit pilot port passes through the filter and the shuttle, then if the switchover valve
[V1] is switched, it switches the switchover valve [V2] through the path. On the other
hand, if the switchover valve [V1] is in the neutral state, the path is cut off by the
switchover valve [V1]. Therefore, if both (A) and (B) are established at the same time,
the straight travel spool internal path (Pst) is conducted to PA. Also, if either (A) or (B)
are established, the travel signal (PT) pressure rises.
(C)If at least one of the front systems is switched, the highest pressure of all the pilot pres-
sures in the front system is selected and is conducted to the front signal port (PA).
Therefore, if (A), (B), and (C) are established at the same time, the straight travel spool
switchover quantity is determined proportional to the front signal (PA) pressure through
the internal straight travel signal path (Pst). [Fig. 19] shows the example of a case of
travel left/right forward + boom up.

Copyright ©
8030-60
1 PA 4
V2
Up
5
Pst Down
V1 Close
6
Open
Advance
2 Close
Reverse 7
Open
Right
PT 8
Left
Advance 9
3
Reverse
prs1
prs2
10
[Fig.19]
4 11
DR2
RST-04-02-001bc
1 Straight travel signal control valve 5 Boom 9 Option

2 Travel 1 6 Arm 10 Add-on (main pump)
3 Travel 2 7 Bucket 11 Main unit housing section (option)
4 Plate assembly 8 Swing

Copyright ©
8030-61
2)Main unit circuit [Fig. 20]
When the straight travel spool is switched, the oil fed from the P1 port flows from the neu-
tral path (L1) to travel (section 1) and at the same time passes through path (2), the
straight travel spool neck section, and the neutral path (R1) and into travel (section 6) and
feeding to travel left and right becomes possible.
On the other hand, when the oil fed from the P2 port flows to the parallel path (R3), at the
same time it passes through the straight travel spool neck section and path (1) and into
the parallel path (L3), so it becomes possible to feed oil to the entire front system.
When the front system is switched during travel and that pressure becomes higher than
the load pressure on travel (section 6), part of the oil fed from the P2 port pushes up the
poppet (S6-2) from the parallel path (R3) and the oil flows through the orifice at the pop-
pet tip and merges into path (S6-1).
This softens the shock on the machine body of the sharp drop in speed caused by the
switchover to 1 pump travel.
As described above, because travel (sections 1 and 6) operates with the oil fed from the
P1 port and operations other than travel are operated with oil fed from the P2 port, travel
curving is prevented and straight travel characteristics are maintained during compound
operations.
Ta R1 Ta
pb6 pa6 2
(Section 6)
R3
1
R1
A6 S6-1 S6-2 B6
A1 B1
1
Ta
L1 L3
pb1 pa1 4
(Section 1)
2 Ta
1
R1 R2
(pst) DR3 3
(Section ST)
R3
[Fig.20]
RST-04-02-001bd
1 Switching state 3 Straight travel

2 Travel 4 Travel

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8030-62
4] Anti-drift valve
The anti-drift valve is mounted on the arm rod (boom head) side cylinder port to prevent the arm
(boom) cylinder from dropping naturally.
Also, the release signal operates led by the internal path from the pilot signal.
(The arm side (A5) is shown as a typical example.)
1- Neutral (A5 port hold)
1. The A5 port hold pressure passes from path (a) through path (b), through path (c), and is
conducted to the poppet (1) spring chamber (d).
2. Therefore, the A5 port pressurized oil is cut off by the seat section (S1) and the seat sec-
tion (S2).
a
DR1 A5
c pi
S2 b d 1 S1 1
RST-04-02-001be
1 Main spool
2- Release signal application
1. When the pi port is pressurized, the piston (2) moves and the spool (3) operates.
2. Furthermore, the spool (3) operates the poppet (4).
3. Then, the operation of the poppet (4) cuts off the conduction between the A5 port and the
spring chamber (d).
a
4
DR1 A5
c b pi S1
2 3 S2 d 1 1
RST-04-02-001bf
1 Main spool

Copyright ©
8030-63
3- Ending hold state
1. When the piston (2) operates further, the spring chamber (d) passes from path (c) through
path (e) and is conducted to the drain chamber [DR] through the (T2) section.
2. The spring chamber (d) pressure becomes the drain pressure and the main poppet (1)
operates
a
DR1 A5
pi
2 e S2 c b d 1 S1 1
RST-04-02-001bg
1 Main spool

Copyright ©
8030-64
5] Relief valve
1- Main relief valve operation
1. This relief valve is incorporated between the neutral path "HP" and the low-pressure path
"LP". The oil passes through the metering hole of the main poppet (C) and charges the
interior space (D). The sleeve (E) and the main poppet (C) operating on the different sur-
face areas [A] and [B] are seated securely.
C D
RST-04-02-001ch
2. When the neutral path "HP" pressure reaches the set pilot poppet spring force, the pilot
poppet (F) opens. The oil flows around the poppet, passes through the notch hole (G), and
is led to the low-pressure path "LP".
F
RST-04-02-001ci
3. Because the pilot poppet has opened, the (D) pressure drops and the main poppet (C)
opens, so the oil flows directly into the path "LP".
C D
RST-04-02-001cj
"Boosted pressure operation"
When pressure is applied to the pilot port "PH", the piston (H) is moved to the set position
by the plug (I). Because of this, the pilot spring force rises and the "HP" pressure rises.
H
RST-04-02-001ck

Copyright ©
8030-65
2- Overload relief valve operation
1. This relief valve is incorporated between the cylinder port "HP" and the low-pressure path
"LP". The oil passes through the metering hole of the piston (C) and charges the interior
space (G). The sleeve (K) and the main poppet (D) operating on the different surface
areas [A] and [B] are seated securely.
C D G
RST-04-02-001cl
2. When the cylinder port "HP" pressure reaches the set pilot poppet spring force, the pilot
poppet (E) opens. The oil flows around the poppet, passes through the notch hole (H), and
is led to the low-pressure path "LP".
E H
RST-04-02-001cm
3. Because the pilot poppet (E) has opened, oil flow is generated through the orifice (I) of the
piston (C), a pressure difference is generated between the path "HP" and the rear side of
the piston (C), and the piston (C) moves and is seated with the poppet (E).
I
RST-04-02-001cn
4. The flow of oil from the path "HP" to the rear side of the poppet (D) is only through the ring-
shaped gap between the poppet (D) and the piston (C) and through the orifice (F), so the
pressure difference increases.
Because of this, the poppet (D) opens and the oil flows directly into the path "LP".
F
RST-04-02-001co

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8030-66
3- Overload relief valve intake operation
1. This relief valve has a built-in anti-void unit that supplies oil if cavitation occurs at the cylin-
der port "HP".
When the cylinder port "HP" pressure is lower than the low-pressure side "LP", the sleeve
(K) is opened by the surface area difference between (A) and (B). Oil enters the cylinder
port "HP" from the low-pressure side "LP" to prevent cavitation.
6] Neutral cut spool [Fig. 21]

This valve is equipped as standard with a neutral cut spool in the P2 side housing neutral path
(R1) minimum flow (low-pressure relief valve upstream).
When the pcc port is pressurized and the neutral cut spool is switched, the path through the ori-
fice [Lc7] to low-pressure relief is cut off and output to the outside from the P3 port becomes pos-
sible.
1 Low-pressure relief valve (R)

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8030-67
7] Plate assembly [Fig. 22]
This valve is equipped with a plate assembly hermetically sealed with a gasket piling a plate on
the housing side surface.
The shuttle is built into the inside and this valve has a function for selecting and controlling the
spool pilot pressure.
Also, in order to protect the shuttle section from contamination from the outside, a filter is
mounted between the plates.
When removing, do not loosen the screws shown in the diagrams and be careful that internal
parts are not dispersed.
1
1
[Fig.22]
RST-04-02-001cd02 RST-04-02-001cd01
Long cap side Short cap side
1 Subassembly screw

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8030-68
8] Straight travel signal control valve [Fig. 19, Fig. 23]
This valve integrates the pilot pressure for the spool of the front system and travel selected with
each plate assembly and is used to switch the straight travel spool.
When the Travel 1 pilot pressure is pressurized, the spool [V1] is switched.
When the Travel 2 pilot pressure is pressurized at the same time, the spool [V2] can be switched.
Here, when the front system pilot pressure [PA] is pressurized, the PA pressure flows into Pst and
is led to the straight travel spool pilot chamber and the spool is switched.
V2 PA Pst
[Fig.23]
Travel 2 T1 Travel 1
RST-04-02-001ce
1 PA 4
V2
Up
5
Pst Down
V1 Close
6
Open
Advance
2 Close
Reverse 7
Open
Right
PT 8
Left
Advance 9
3
Reverse
prs1
prs2
10
[Fig.19]
4 11
DR2
RST-04-02-001bc
Straight travel signal control

1 5 Boom 9 Option
valve
2 Travel 1 6 Arm 10 Add-on (main pump)
Main unit housing section
3 Travel 2 7 Bucket 11
(option)
4 Plate assembly 8 Swing

Copyright ©
8030-69
9] Add-on [Fig. 24, Fig. 25]
1- Add-on main relief valve
The oil fed from the Pr port is led to the main relief valve. The Pr pump maximum pressure is
regulated by the operation of the main relief valve.
Pr Tr2
[Fig.24]
Ta Ta
RST-04-02-001cf
2- Spool section
When the spool is pressurized from the add-on (Section 10) pilot port par1 (pbr1) and
switched, the neutral path [Pg] is closed. The oil fed from the Pg port flows from the parallel
path [Rg] through the load check valve [S10-1], the path [S10-2], and the spool neck section,
and into the AR1 (BR1) port.
The return oil returns to the tank path [Ta] from the BR1 (AR1) through the spool neck section.
S10-2 S10-1
AR1 BR1
Rg
pbr1 par1
Pg
[Fig.25]
Ta Ta
RST-04-02-001cg

Copyright ©
8030-70
3- Low-pressure relief valve operation [Fig. 26, Fig. 27]
1. Signal pressure generation (when pin1 (pin2) port pressurized)
The oil fed from the pump port (P1 (P2)) flows through the neutral path (L1 (R1)), then
flows from the low-pressure relief path (L2 (R2)) through the orifice (Lc1 (Rc1)) and out
into the tank path (Ta).
At this time, the pressure generated in path (L2 (R2)) by the orifice (Lc1 (Rc1)) is led to the
low-pressure relief signal port (Ps1 (Ps2)).
When the (L2 (R2)) upstream main spool operates, the oil flowing through (L2 (R2)) is
reduced, so the (Ps1 (Ps2)) signal pressure becomes lower.
Lc1 L2 ps1
TL3
Pn1 L1 (R1)
[Fig.27]
Ta
RST-04-02-001cr
2. Relief operation
When excess oil flows in path (L2 (R2)), the poppet is operated by the pressure generated
in path (L2 (R2)) by the orifice (Lc1 (Rc1)).
Through this poppet operation, the oil flows from the path, through the notch hole path,
and out to the tank path [Ta]. This prevents the generation of excess pressure at the low-
pressure relief signal port.
Lc1 L2 ps1
TL3
Pn1 L1 (R1)
[Fig.27]
Ta
RST-04-02-001cr

Copyright ©
8030-71
4- Add-on main relief valve
1. Add-on main relief valve operation
This relief valve is incorporated between the neutral path "HP" and the tank path "LP". The
oil passes through the metering hole of the main poppet [1] and charges the interior space
[C].
Also, the sleeve [2] and the main poppet [1] operating on the different surface areas "A"
and "B" are seated securely.
1 C RST-04-02-001cs
2. When the neutral path "HP" pressure reaches the set pilot spring force, the pilot poppet [3]
opens.
The oil flows around the pilot poppet [3], passes from the notch hole [E] and through the
ring-shaped gap [D] and is led to the tank path "LP".
E D
3
RST-04-02-001ct
3. Because the pilot poppet [3] has opened, the interior space [C] pressure drops and the
and "B" are seated securely.
1 C 3 RST-04-02-001cu

Copyright ©
8030-72
2. 5 Stack Solenoid Valve Operation Explanation

1) External shape diagram and component parts
This valve is made up of the body and the electromagnetic switchover valve.
S2 S3 S1
S4
SP
1 2
SD02009-031
Normal closed-type solenoid: SP,S1,S3 Normal open type solenoid: S2 4 port- type solenoid: S4
1 Electromagnetic switchover valve 2 Body

2) Operation explanation
B T
C1
S1 SP
C3
P
S3
C2
S2
C4
C5
RST-04-02-001bz
Hydraulic circuit diagram

The pressurized oil fed from the P port feeds pressurized oil to the C1 - C5 ports according to
the excitation or non-excitation of electromagnetic switchover valves S1 - S4 resulting from
exciting electromagnetic switchover valve SP.
Electromagnetic switchover valves S1 and S3 -> Oil passing through when valve excited
Electromagnetic switchover valve S2 -> Oil passing through when valve not excited
Oil passing to C5 when valve excited
Electromagnetic switchover valve S4 ->
Oil passing to C4 when valve not excited

Copyright ©
8030-73
3. Upper Pilot Valve (remote control valve)

1) Structure
The structure of the remote control valve is as shown in the assembly cross-section diagram
(page 73). There is a longitudinal axial hole in the casing and the pressure reduction valve is
installed in it.
The pressure reduction valve comprises the spool (201), secondary pressure setting spring
(241), return spring (221), spring seating (216), and washer 2 (217). The secondary pressure
setting spring (241) is set so that the secondary pressure calculation is 0.5-1 MPa (depending
on the model). The spool (201) is pressed against the push rod (212) by the return spring (221).
When the push rod (212) is pushed down by tilting the handle or another operation, the spring
seating goes down at the same time and the secondary pressure setting spring (241) setting is
changed.
The casing (101) has the oil inlet (primary pressure) port P and the outlet (tank) port T and,
furthermore, the secondary pressure is taken out from the ports 1, 2, 3, and 4.
2) Function
1] Basic functions
The remote control valve is for controlling the control valve spool stroke quantity, direction, etc.
This is done by operating the pilot valve output pressure on the control valve spool end section.
In order to satisfy this function, the remote control valve is made up of the following elements.
1- Inlet port (P) to which the oil is fed from the hydraulic pump
2- Multiple output ports (1, 2, 3, 4) for operating the feed pressure from the inlet port on the
control valve spool end
3- Tank port (T) required for controlling the above output pressure
4- Spool connecting the output port to the inlet port or tank port
5- Mechanical means including a spring operating on the above spool in order to control the
output pressure
2] Main part functions
The function of the spool (201) is to switch the oil path either to have the hydraulic pressure fed
from the hydraulic pump received by the P port and lead the P port pressurized oil to the output
ports (1, 2, 3, and 4) or to lead the output port pressurized oil to the T port. The output pressure
operating on this spool (201) is determined by the secondary pressure setting spring (241).
In order to change the deflection quantity of the secondary pressure setting spring (241), the
push rod (212) is inserted into the plug (211) in such a way that it can slide.
The return spring (221) operates on the casing (101) and spring seating (216) and operates to
return the push rod (212) in the displacement zero direction regardless of the output pressure
and makes the spool (201) neutral return reliable. It also has the effect of a counter-force spring
for giving an operator an appropriate operation feel.

Copyright ©
8030-74
3) Operation
Operation of the remote control valve is explained based on the hydraulic circuit diagram (Figure
1) and operation explanation diagrams (Figure 2 to Figure 4). Figure 1 is a typical usage
example for the remote control valve.
5 6
P T
4
2
RST-04-02-001r
Figure 1: Remote control valve usage example
1 Pilot valve 4 Control valve

2 Pilot pump 5 Hydraulic motor
3 Main pump 6 Hydraulic cylinder

Copyright ©
8030-75
1] [When the handle is in neutral (See Figure 2.)
The force of the secondary pressure setting spring (241) that determines the remote control
valve output pressure does not operate on the spool (201). Therefore, the spool (201) is pushed
up by the return spring (221) (spring seating (216)) and the output ports (2 and 4) are connected
with the T port. Therefore, the output pressure is the same as the tank pressure.
216
241
221
201
(2, 4)
RST-04-02-001s
Figure 2: When the handle is in neutral

2] When the handle is tilted (See Figure 3.)
When the handle is tiled and the push rod (212) is moved through a stroke, the (spring seating
(216)) spool (201) moves down and the oil fed from the pilot pump flows out to the (2 and 4) ports
through the P port and the (2 and 4) ports and pressure is generated.
212
216
201
(2, 4) RST-04-02-001t
Figure 3: When the handle is tilted

Copyright ©
8030-76
3] When the handle is held (See Figure 4.)
When the handle is tilted and the port (2 and 4) pressure rises to the pressure equivalent to the
set spring force (241), the hydraulic pressure force and the spring force are in balance. When the
(2 and 4) ports pressure becomes higher than the set pressure, the (2 and 4) ports and the P port
close and the (2 and 4) ports and the T port open. When the (2 and 4) ports pressure becomes
lower than the set pressure, the (2 and 4) ports and the P port open and the (2 and 4) ports and
the T port close, so the secondary pressure is held constant.
241
(2, 4) RST-04-02-001u
Figure 4: When the handle is held

(secondary pressure at or above set pressure)
1 T port
2 P port
4] Operation in area in which the handle tilt is large (depends on the model)
For certain models, when the handle is flipped down beyond a certain angle, the spool top end
section touches the push rod bore bottom section and the output pressure goes into the state of
still being connected with the P port pressure.
Furthermore, with the structure in which the spring seating and spring are installed inside the
push rod, when the handle is flipped down beyond a certain angle, the push rod bore bottom sec-
tion and the spring touch, that spring force changes the 2nd pressure gradient and after that the
push rod bore bottom section and the spring seating top end section touch and the output pres-
sure goes into the state of remaining connected with the P port.

Copyright ©
8030-77
4) Structural diagram
P T
1 3 2 4
Hydraulic symbol
312
302
501 301
212-2 212-1
213
151
211
214
216-2 216-1
241-2
221-3 241-1
201
217
101 221-1
221-2
(2, 4) (1, 3) RST-04-02-001v
Code Part name Qty Code Part name Qty

101 Casing 1 217 Washer 2 4
151 Plate 1 221-1 Spring (port 1) 1
201 Spool 4 221-2 Spring (port 3) 1
211 Plug 4 221-3 Spring 2
212-1 Push rod 2 241-1 Spring 2
212-2 Push rod 2 241-2 Spring 2
213 Seal 4 301 Joint 1
214 O-ring 4 302 Disk 1
216-1 Spring seating 1 2 312 Adjusting nut 1
216-2 Spring seating 1 2 501 Bellows 1

Copyright ©
8030-78
4. Travel Pilot Valve (remote control valve)

1) Operation
The remote control valve with built-in damper (below, remote control valve with damper) is a
remote control valve that incorporates into the remote control valve main unit a damping function
for preventing the man-machine system hunting (lever hunting) phenomenon.
Operation of the remote control valve with damper is divided into 4.-(1)-1) Pressure reduction
valve section and 4.-(1)-2) Operation section damping mechanism section. The explanations in
these 2 sections are based on the hydraulic pressure circuit diagram, assembly section diagram,
and damping operation explanation diagram below. The figure below is a typical usage example
for the remote control valve.
5 6
P T
2
4
RST-04-02-001w
Hydraulic circuit diagram
1 Remote control valve 4 Control valve

2 Pilot pump 5 Hydraulic motor
3 Main pump 6 Hydraulic cylinder
1] Pressure reduction valve section
1- For the neutral state
The spool (301) is pushed up by the return spring (335) via the spring seating (311) and
washer 1 (215) and is in the neutral position shown in the assembly section diagram.
Therefore, since the output port is connected only to the port T by the spool switching function,
the pressure at output ports 1 and 2 is the same as the pressure at the port T.
2- When the remote control valve operation section is tilted from the neutral state
In the assembly section diagram, when the cam (420) is rotated clockwise, the port 1 side
push rod (214) is pushed down, the spool moves down via washer 1, the spring seating, the
secondary pressure setting spring (324), washer 2 (217), and washer 3 (313), the port P and
port 1 are connected, and the oil fed from the pilot pump flows to port 1 and generates pres-
sure.
When the port 1 pressure rises to the pressure equivalent to the secondary pressure setting
spring force that has been set by tilting the operation section, the hydraulic pressure on the
spool and the spring force come into balance and the port 1 output pressure is held constant.
The port 2 spool holds the neutral state and the oil from the control valve is discharged via the
port T.
Some specifications are of the type that near the maximum angle of the operation section, a
push rod directly touches the spool top section and forcibly pushes in the spool to connect the
port P and the output port so that they have the same pressure.

Copyright ©
8030-79
2] Operating section damping mechanism section
1- For neutral state
The push rod is pushed up by the damping springs (333 and 337) via the piston (224) and is in
the position shown in the assembly section diagram.
2- When the operation section is tilted from the neutral state (See Damping operation
explanation diagram (1).)
In the assembly section diagram, when the cam is rotated clockwise, the port 1 side push rod
is pushed down and the piston moves down.
At this time, the oil in the damping piston chamber is discharged from the piston metering hole
and the pressure generated at this time generates damping force.
On the other hand, the port 2 side push rod is moved up by the damping spring via the piston.
At this time, the tank chamber oil is suctioned in through the 3 ball check sections made up of
bushings (223) and steel balls (225) and into the damping piston chamber. The oil outside the
piston chamber drains out from the path that leads from the casing top end section to the port
T.
3- When the operation section is tilted back from a full tilt (See Damping operation
explanation diagram (2).)
In the assembly section diagram, after the cam is fully tilted clockwise, then rotated counter-
clockwise, the port 2 push rod is pushed down and the piston moves down.
At this time, as described above, the oil in the damping piston chamber is discharged from the
piston metering hole and the pressure generated at this time generates damping force.
On the other hand, the port 1 push rod is moved up by the return spring (335) and the damping
spring.
At this time, the tank chamber oil is suctioned in through the 3 ball check sections made up of
bushings and steel balls and into the damping piston chamber. Also, the oil outside the piston
chamber drains out from the path that leads from the casing top end section to the tank port.
In other words, the structure is such that damping force works for either tilt operation, from the
neutral position to the full tilt position or from the full tilt position to the neutral position.

Copyright ©
8030-80
Damping operation explanation diagram (see the following page)
1 Push rod 4 Piston chamber

2 Orifice 5 Oil
3 Piston

Copyright ©
8030-81

Copyright ©
8030-82
1) Assembly and section diagram
Code Part name Qty Code Part name Qty
101 Casing 1 271 Hexagon socket head bolt 2
151 Plug 2 301 Spool 4
201 Cover 2 311 Spring seating 4
202 Plug 4 313 Washer 3 4
203 Grease cup 4 324 Spring 4
210 NHU packing 4 335 Spring 4
212 O-ring 4 336 Spring 4
214 Push rod 4 337 Spring 4
215 Washer 1 8 412 Bushing 4
217 Washer 2 4 413 Camshaft 2
218 Spring seating 4 420 Cam 2
221 Locking ring 4 423 Hexagon socket head stop screw 2
223 Bushing 4 471 Stop screw 4
224 Piston 2D085 4 472 Lock nut 4
225 Steel ball 12 501 Bellows 2

Copyright ©
8030-83
5. Cushion valve
1) Valve summary
This valve is made up of a shuttle valve section and cushion valve section with heat circuit.
The cushion valve with heat circuit is connected between the hydraulic shovel control valve and
the pilot operation valve to reduce body shaking (cushion function) caused by emergency stop
operations by the operator.
This valve is equipped with a circuit with which the operator can deliberately disable the cushion
function for reverse operations.
The shuttle valve selects the high-pressure signal pressure from 2 signal pressure systems.
This valve has 2 circuits.
VIEW Y VIEW X SD02009-041
Figure 1 External shape diagram
SD02009-042
Figure 2 Hydraulic system diagram

Copyright ©
8030-84
1] Normal operation
The pressurized oil fed from the A port (or C, E, or G port) pushes up the check plunger and is
sent to the B port (or D, F, or H port). The pressurized oil that has passed through the B port oper-
ates on the control valve spool and operates the actuator. The oil pushed out from the control
valve spool passes through the D port (or B, F, or H port) and flows out to the T port.
RST-04-02-001aa
Figure 3
2] Cushion operation
When the pressurized oil fed from the pilot operation valve to the A port (or C, E, or G port) is
closed by the pilot operation valve, the pressurized oil that has operated on the control valve
spool is pushed back to the B port (or the D, F, or H port) by the return spring on the spool. The
returned oil passes through the check plunger metering orifice, is sent to the A port (or the C, E,
or G port), and is drained from the pilot operation valve. At this time, by passing through the
metering orifice, the pressurized oil holds down the control valve spool speed and reduces shak-
ing of the body. (Cushion function)
RST-04-02-001ab
Figure 4

Copyright ©
8030-85
3] Reverse operation
When the pressurized oil fed from the pilot operation valve to the A port (or C, E, or G port) is
switched to the C port (or A, E, or G port), the pressurized oil that has operated on the control
valve spool is pushed back to the B port. Because the pushed back oil flows out to the T port
without passing through the check plunger metering orifice, it does not hold down the control
valve spool speed, so the cushion function does not work.
RST-04-02-001ac
Figure 5
4] Heat circuit
When the pilot operation valve is in the neutral position, the oil fed to the R port passes through
the inside of the reverse operation spool, flows out to the T port, and heats up the inside of the
valve.
When pressurized oil is being fed from the pilot operation valve to the A port (or C, E, or G port),
the oil fed to the R port flows out to the C port (or A, E, or G port) and heats up the circuit to the
pilot operation valve and inside the valve.
RST-04-02-001ad01 RST-04-02-001ad02
Figure 6 Figure 7

Copyright ©
8030-86
5] Shuttle valve
The steel ball is pressed from the high pressure to the low pressure, of the pressure between the
I and J ports and the pressure between the K and L ports. Through this, the high-pressure oil is
fed to the S port or the Q port. In the same way, oil is fed to the U port at the higher of the pres-
sures between the M and N ports and between the O and P ports.
RST-04-02-001ae01 RST-04-02-001ae02
Figure 8 Figure 9

Copyright ©
8030-87
6. Selector Valve (4-way)

1) Structure
Pattern I: Pattern S: Pattern M: Pattern K:

ISO Old Sumitomo Old Mitsubishi Old Kobelco
RST-04-02-001af01
Circuit diagram
Operation, work
A Right valve, retraction 1 Boom, up
B Right valve, left side 2 Bucket, digging
C Right valve, push out 3 Boom, down
D Right valve, right side 4 Bucket, dirt removal
E Left valve, push out 5 Swing, right
F Left valve, right side 6 Arm, digging
G Left valve, pull in 7 Swing, left
H Left valve, left side 8 Arm, dirt removal
Circuit combination table

Type I: Type S: Type M: Type K:
ISO Old Sumitomo Old Mitsubishi Old Kobelco
A-1 A-1 A-8 A-6
B-2 B-2 B-7 B-7
C-3 C-3 C-6 C-8
D-4 D-4 D-5 D-5
E-8 E-5 E-3 E-3
F-5 F-6 F-2 F-2
G-6 G-7 G-1 G-1
H-7 H-8 H-4 H-4

Copyright ©
8030-88
15
16
1 14
Z
10 13 19 21 8 7 20 11617 21
3
5
2
22
4
18
9
12
Z_Z
SD02009-043
Diagram 1 Valve structure
1 Name plate 9 Cover 17 Steel ball

2 Pin 10 Lever 18 Oil seal
3 Spring 11 Plug with flange 19 O-ring
4 Knob 12 Hexagon socket head bolt 20 O-ring
5 Cover 13 Hexagon socket head bolt 21 O-ring
6 Spring 14 Rivet screw 22 Hexagon socket head plug
7 Casing 15 Spring pin
8 Shaft 16 Spring pin

Copyright ©
8030-89
This valve is a rotation type switch valve.
By connecting a line between the hydraulic shovel work remote control valve and the main
control valve and changing the lever (10) to the position for each type (rotating the shaft (8)), the
valve circuit has been changed and the operation type changed to that in Diagram 2.
For details on the valve structure (circuit diagram), see Diagram 1.
Arm dirt
removal Boom-down
Pattern I Left Right Bucket Bucket dirt

(ISO) swing L swing digging R removal
Arm Boom-up
digging
Right
swing Boom-down
Pattern S Arm dirt Arm Bucket Bucket dirt

(old Sumitomo) removal L digging digging R removal
Left Boom-up
swing
Arm
Boom-down digging
Pattern M Bucket dirt Bucket Left Right

(old Mitsubishi) removal L digging swing R swing
Boom-up Arm dirt

removal
Arm dirt
Boom-down removal
Pattern K Bucket dirt Bucket Left Right

(old Kobelco) removal L digging swing R swing
Boom-up Arm
digging
RST-04-02-001ag
Diagram 2 Operation method by type

Copyright ©
8030-90
3) Development diagram
21
13
15 18
16 4
20
11
17 10
3 2
17
1 6 9
20
11 Cannot be
disassembled
19
21
12
22
RST-04-02-001ah

Copyright ©
8030-91
7. Selector Valve (3-direction)

1) Structure
11 11
2
Z
B T1
T2
DR
PP
A
Z
B T1
10 7 5
9
3
1
9
12
10 6
4 12
A
Z-Z section
B T1 T2
DR PP
Circuit diagram
Figure 1
1 Cover 5 Body 9 Hexagon socket head bolt

2 Name plate 6 Cover 10 Hexagon socket head bolt
3 Spool 7 Spring 11 Rivet screw
4 Spring 8 Hexagon socket head bolt 12 O-ring

Copyright ©
8030-92
This valve switches the direction with the pilot pressure.
1] When the spool is neutral (PP port no load) Shuttle circuit, 2 pumps flow circuit selected
When the pilot pressure is not fed to the PP port, the spool (3) is held in the neutral position by
the spring (4), (7). The A port and the B port are connected and the T1 and T2 port pressurized
oil are cut off by the spool (3) (See Figure 2).
B
To control valve B
T1
4
PP
A RST-04-02-001aj
Figure 2
2] When the spool operates (PP port pressurized) Breaker circuit selected.
When pressure is fed to the PP port, force [F] (PP port pressure x spool cross-sectional area)
works on the spool (3) to the left direction.When F becomes larger than the spring (4), (7) set
load, the spool (3) moves to the left and the A port is connected with the T1 and T2 ports.
Also, at this time, the pressurized oil at the B port is cut off by the spool (3) (See Figure 3).
B T1 To T1 hydraulic oil tank
4
PP
A
RST-04-02-001ak
Figure 3

Copyright ©
Section
9006
AIR CONDITIONER FUNCTIONS

AND TROUBLESHOOTING
9006

Printed in France
Copyright ©
9006-2
TABLE OF CONTENTS
AIR CONDITIONNER OVERALL DIAGRAM ................................................................................................................. 3

Hose connection ...................................................................................................................................................... 3
Hose Connection (CX160B to CX240B) ................................................................................................................... 4
Hose Connection (CX290B) ..................................................................................................................................... 5
Hose Connection (CX350B/CX370B) ....................................................................................................................... 6
CAB .......................................................................................................................................................................... 7
Air conditioner unit ................................................................................................................................................... 8
Air Conditioner Circuit Diagram ................................................................................................................................ 9
EXPLANATION OF CONTROL .................................................................................................................................... 11
Back-up function .................................................................................................................................................... 11
Air Mix Motor Actuator Control ............................................................................................................................... 12
Blow Mode Motor Actuator Control ........................................................................................................................ 12
Refresh / Recirculate Switch Motor Actuator Control ............................................................................................. 13
Blower Amp Control ............................................................................................................................................... 14
Compressor Clutch Control .................................................................................................................................... 17
COOLMAX Control and HOTMAX Control ............................................................................................................. 18
Trouble Detection and Control after Trouble Detected ........................................................................................... 19
Monitor Mode ......................................................................................................................................................... 21
Door Switch Control ............................................................................................................................................... 23
Inside Air Filter Clogging Detection Control ........................................................................................................... 24
ACTUATOR INSPECTION ........................................................................................................................................... 26
Air Mix Motor Actuator Inspection .......................................................................................................................... 26
Refresh / recirculate Motor Actuator Inspection ..................................................................................................... 28
Mode Motor Actuator Inspection ............................................................................................................................ 30
SELF-DIAGNOSIS FUNCTION WITH PANEL DISPLAY ............................................................................................ 32
Trouble Display and Self-Check Procedure ........................................................................................................... 32
Air Conditioning troubleshooting ............................................................................................................................ 36
PART FUNCTION ........................................................................................................................................................ 42
Control Panel and Control Unit .............................................................................................................................. 42
Blower Amp ............................................................................................................................................................ 42
Relay ...................................................................................................................................................................... 43
Air Mix Actuator ...................................................................................................................................................... 43
Refresh / Recirculate Actuator ............................................................................................................................... 44
Blow Mode Actuator ............................................................................................................................................... 44
Evaporator Sensor ................................................................................................................................................. 44
Dual Pressure Switch ............................................................................................................................................. 45
Solar Radiation Sensor .......................................................................................................................................... 45

Copyright ©
9006-3
AIR CONDITIONNER OVERALL DIAGRAM
Hose connection
(B) 14 RETURN OUT
4 (c)
4 (c)
2 (a)
3 (b)
SUC
5 (e)
DIS
OUT IN IN OUT 6 (d)
13 (A) IN
1 (h)
10 (k)
OUT
OUT IN
11 (j)
Hose connection
Refer to pages 4 and 5 Refer to the page 6
Item Description Qty Item Description Qty
1 Air conditioner condenser 1 a Cooler hose (LIQUID2) 1
2 Cooler hose (LIQUID2) 1 b Cooler hose (SUCTION) 1
3 Cooler hose (SUCTION) 1 c Rubber hose 16 x 5600 2
4 Rubber hose 1 d Cooler hose (DISCHARGE) 1
5 Air conditioner compressor 1 e Air conditioner compressor 1
6 Cooler hose (DISCHARGE) 1 f Slide shaft 1
7 Tension pulley (with cover) 1 g Tension pulley (with cover) 1
8 Compressor bracket 1 h Air conditioner condenser 1
9 Slide shaft 1 j Dryer receiver (D60.5) 1
10 Cooler hose (LIQUID1) 1 k Cooler hose (LIQUID2) 1
11 Dryer receiver 1 l Bracket receiver (D60.5) 1
12 Belt 1 m V Belt B-45.5 1
13 Air conditioner unit 1
14 Engine 1
A Air conditioner unit
B Engine
C Heater (eng.return)
D White marking
E Heater (eng.outlet)
F Heater (unit.outlet)
G Heater (unit.inlet)
H Must be connected with the air conditioner unit
J White marking must be connected with the air
conditioner unit

Copyright ©
9006-4
Hose Connection (CX160B to CX240B)
A
10
2
11
3
1
3
Heater (ENG.RETURN)
C
4
5
8
4
9
D 5
7
6
3
E
LIQUID 2 2 3 SUCTION
3
F
B
Heater (ENG. OUT) 4 4 1

6
Heater
(ENG.RETURN).
D
3
3 11 10
11
C
Heater (ENG.RETURN) F
E
12
4
5
9 7 4
A
Copyright ©
9006-5
Hose Connection (CX290B)
KBR10450-E03
10
1
11
6 2
4
4
2
1
4
6
6
10
6
4
3
6
6
9
3
2
7
4
5
5
6
6
12
3
2

Copyright ©
9006-6
Hose Connection (CX350B/CX370B)
CONNECT AIRCON UNIT CONNECT AIRCON UNIT
Ha bH
F
A
G
cH
HEATER(ENG OUT)
cJ CONNECT AIRCON UNIT
k D
HEATER(ENG OUT)
CONNECT AIRCON UNIT
C
B
D a h B
F
C
c
c
D
m
E
c C
TIGHTENING TORQUE
c 9.6 to 24.5 Nm TIGHTENING TORQUE
h d 19.6 to 29.4 Nm
e
f
b
d
TIGHTENING TORQUE
11.8 to 14.7 Nm g
k
E
F
Copyright ©
9006-7
CAB
6 9
15
G H
9
6
A
1 B
I
Suction duct
15 D C Filter Interior air
2 8
Duct flange
6 Heater hose
Cooler hose Heater hose
Cooler hose
C
9
5
5
Operator's cab F 4
10
3
17
Cushion seal
Rubber grommet I
Filter case
H 10
11
12
13 4
14
Sensor air conditioner
(solar radiation)
2
Trim side (front upper) 13
Cover top (console left)
Duct DEF-A
7 8
Must be connected with console left harness. D 12
Wire harness (console left)
Duct FACE-A
B
Trim side (front lower) 11
Floor
A
16
KHR13970-D02
G Duct E

Copyright ©
9006-8
Cab Description (refer to the previous page)

Item Description Qty
1 Face grille 1
2 Control panel 1
3 Duct FACE-B 1
4 Duct FACE-C 1
5 Duct H & C BOX 1
6 Box HOT & COOL 1
7 Duct VENT (RIGHT) 1
8 Duct VENT (LEFT) 1
9 Box REAR 1
10 Duct; intake (FRESH) 1
11 Air conditioner unit 1
12 Duct FOOT 1
13 Duct DEF-C 1
14 Duct DEF-B 1
15 Face grille 6
16 Drain hose 2
17 Air filter 1
18 Box bracket (left) 1
Air conditioner unit
Item Description
1 Motor actuator (mode)
2 3 2 Compressor relay
1 4 3 Blower OFF relay
4 Motor actuator (refresh / recirculate switch)
5 Interior temperature sensor
6 Blower motor
7 Blower amp
8 Motor actuator (air mix)
9 Evaporator sensor
9
5
6
7

Copyright ©
9006-9
Air Conditioner Circuit Diagram
OFF ACC CONNECTION
RELAY BATTERY HEAT B G1 ST
G2 ACC M
G1 K7 S1 ON
HEAT
OFF
ACC
ON
- + - + ST
F12
KEY SWITCH
15A
1
1
3
2
6
4
F23 12V 12V 4
LgR
g
(CN.34)
BATTERY
1
2
LgR
RW
g
1
65A
TEMPERATURE SIGNAL
DOOR SWITCH SIGNAL
WINDOW SWITCH SIGNAL
KEY SWITCH SIGNAL

FUSIBLE LINK F1 2 P6 A9 1 LW LR
TEMP SENSOR(FRESH)
MODE_POTENTIO (SIG)
WINDOW-OPEN SW. IN
MODE M.ACT. LIMITER
R/F M.ACT.(RECYCLE)
BLOWER FEED-BACK
(F14) 5A
(F5) 15A
(
(F13)
AIR-MIX M.ACT.OUT1
AIR-MIX M.ACT.OUT2
SUNLOAD SENSOR2
SUNLOAD SENSOR1
R/F M.ACT.LIMITER
DOOR-OPEN SW.IN
MODE M.ACT.OUT2
R/F M.ACT.(FRESH)
MODE M.ACT.OUT1
SIG.WATER TEMP.
CCU POWER(IGN)
POWER(ILLUMI)
BLOWER GATE
POTENTIO (5V)
) 5A
15A
CCU GND
S53 S54
(
(
( )
)
)
COMPRESSOR
AIRCON
8
8
9
9
2
5
3
6
3
HEATER UNIT
AIRCON
AIRCON
BLOWER
K10
LgR
WG
W
WL
WY
BrW
G
Sb
BL
LG
YL
BrY
B
LB
GR
YW
YR
LW
GW
BG
GL
LY
VW
LR
VY
OL
VR
VG
Y
(UPPER)
RELAY LAMP
LgR
g LgR
g
VG
VY
VR
WR
LR
OL OL
POWER (ILLUM.)
( ) Y Y
WR
LR LR
VR
WY
WL
2 WY
B61 1 WL
WY WL
SUNLOAD
SENSOR 8
BG
GW 2 GW
S52 1 W 3 B
(CN.D12)
DUAL SWITCH
GW W
(RECIVER DRYER)
12 (CN.26)
BrW
WR
VW
BrY
VR
YW
LB
LW
LR
R
BL
Sb
16
W
B
13
11
15
7
9
8
5
3
2
8
9
1
W
Y8
BrW
GW
YW
WR
BrR
VW
BrY
LW
BG
LY GR B
YR
LG
RL
LY
17
YL
Sb
W
Y
V
YL GL Y G W WG L BG
MAGNET CLUTCH
13
W
(CN.D5)
(COMPRESSOR)
6
BG
L
WR
B5
(CN.D2)
VW
V WR
VW LR
TEMP.SENSOR
3 K17 V
LR
(CN.D6)
Sb
BLOWER-OFF RELAY. 7
BG
Sb
BG
WG
R4
3W
SHUNT RESISTOR
GW GR
GR 6
M
(CN.D8)
3WG
G
GW 7
LY 2
G
GL 3
GL LY
B 1
9
B
MOTOR ACT
B
(CN.D3)
LR M7 (AIR MIX)
4 M8
LR
RL
M 2 RL
YW YR
YR 6
BLOWER MOTOR
(CN.D9)
Y 4
YW
LY 2
Y
RL
YL 3
YL LY
B
5 A6 1 BrY
B 1 10
5
B
MOTOR ACT
BLOWER AMPLIFIER M6 (MODE)
LW LR
LR
M
(CN.D10)
LG 4
1 BrR LW 7
(CN.D1)
BrW LgR
R BrR
BrW
LG
15 K6 R 3
LgR
g
M5 1 11
COMPRESSOR RELAY E52 MOTOR ACT
AIR CONDITIONER UNIT (RECYCLE / FRESH)

Copyright ©
9006-10
Air conditioner circuit diagram (refer to the previous page)
Item Description
A6 BLOWER (AMP) CONTROLLER
A9 AIR CONDITIONER CONTROLLER
B5 EVA SENSOR
B61 SUNLOAD SENSOR
E52 AIR CONDITIONER UNIT
F5 FUSE 10A; AIR CONDITIONER CONDENSER FAN
F12 FUSE KEY SWITCH
F13 FUSE 5A; HEATER / AIR CONDITIONER
F14 FUSE 5A; AIR CONDITIONER COMPRESSOR
F23 FUSE 65A
G1 BATTERY
K6 RELAY-AIR CONDITIONER CONDENSER FAN
K7 RELAY BATTERY
K10 RELAY WORKING LIGHT (UPPER)
K17 BLOWER OFF RELAY
M5 MOTOR (AIR CHANGING)
M6 AIR VENT DIRECTION CONTROL MOTOR
M7 MOTOR ACT (AIR-MIX)
M8 BLOWER MOTOR
P6 AIR CONDITIONER CONTROL PANEL
R4 THERMISTOR INNER TEMPERATURE
S1 KEY SWITCH
S52 AIR CONDITIONING COMPRESSOR CLUTCH SWITCH
S53 DOOR LIMIT SWITCH
S54 FRONT WINDOW LIMIT SWITCH
Y8 AIR CONDITIONER MAGNET CLUTCH
1 CONNECTOR (CN.29)
2 CONNECTOR (CN.28
3 CONNECTOR (CN.D2)
4 CONNECTOR (CN.D3)
5 CONNECTOR (CN.D4)
6 CONNECTOR (CN.D5)
7 CONNECTOR (CN.D6)
8 CONNECTOR (CN.D11)
9 CONNECTOR (CN.D8)
16 CONNECTOR (CN.26)
17 CONNECTOR (CN.27)

Copyright ©
9006-11
EXPLANATION OF CONTROL
Back-up function
Even when air conditioner operation is stopped (switched OFF) with the ignition key power supply or operation
panel ON/OFF switch, the set temperature and all the other setting states are stored in memory, so the next
time air conditioner operation starts, it goes into the same state as before it was stopped.
When the ignition key power supply is cut off, the data is backed up by storing it in the internal EEPROM.
However, if the main key power supply is cut off within 0.5 seconds of switch input, that switch input is not
stored into memory. Also, the data read out from EEPROM when the power is switched ON is judged to see if
it is within the valid range. If data outside the valid range was written into memory, for example due to noise,
then operation starts from the default settings to avoid abnormal operation.
Fahrenheit temperature display

To switch, hold down both the temperature setting UP and DOWN switches for 5 seconds. The display toggles
between Celsius and Fahrenheit display each time the switches are both held down for five seconds.
The Fahrenheit display is a two-digit integer and below the decimal point is not used, so "F" is displayed.
However, in case of trouble, this display takes priority.
When this display is switched, the new status is backed up in memory, so even if the main key power supply is
switched OFF, the display status is retained. Internal calculations are all done in Celsius. Only the operation
panel display is in Fahrenheit. Therefore, the display may differ slightly from the exact Fahrenheit temperature.
Below is shown the Fahrenheit temperature and the corresponding Celsius temperature used in internal
processing.
CAUTION: These specifications are written with Celsius as the standard. Therefore, if the temperature is
displayed in Fahrenheit, convert the temperature to centigrade by using the table below.
Fahrenheit and Celsius correspondence

Fahrenheit display [F] Interior recognition set temperature
(Celsius) [°C]
63 18.0
64 18.5
65 19.0
77 25.0
91 32.0

Copyright ©
9006-12
1. Air Mix Motor Actuator Control

1) Summary explanation
The provisional target degree of opening is determined from the target blow temperature and the current blow
mode, various restrictions are applied, and the target degree of opening is calculated. Then drive is output to
move the motor actuator position to the target degree of opening.
Below are the details.
2) Restrictions on operation angle according to the blow mode
When the blow mode motor actuator is in the B / L, FOOT, or DEF position, it is prohibited for this motor
actuator degree of opening to be less than 20°C.
3) Heater unit hysteresis correction operation (motor actuator one-direction stop)
After the actuator moves to the target degree of opening, it returns to the specified position. However, if the
target degree of opening is less than 0°C, the actuator is treated as having reached the target degree of
opening when it reaches 0°C, then it moves to the specified position.
(A stop in the fully-open direction is used as the standard.)
4) Operation start / stop judgment
1) The operating motor actuator stops when the current position comes within the target position.
2) The stopped motor actuator operates when the current position goes beyond the target position.
5) Motor actuator operation priority order
The operation priority for this motor actuator is No. 1. This means that if the target degree of opening for this
motor actuator changes and operation becomes necessary, even if some other motor actuator is operating,
that other motor operation is paused, and this motor actuator operates.
2. Blow Mode Motor Actuator Control

The blow mode is switched by rotating the diffuser switching damper with the motor actuator. There are two
types of control: auto and manual.
2) Auto control
When the AUTO blow mode signal is recognized, the blow mode changes to auto control. During auto control,
the diffuser is switched according to the target blow temperature Auto control continues until operation of the
blow mode select switch is recognized.
Blow mode
MODE 2
MODE 3
MODE 4
Target blow temperature
AUTO blow mode

Copyright ©
9006-13
3) Manual control
a) When operation of the blow mode select switch is recognized, the motor actuators are driven to attain the output
shaft angle below and the display is switched too. Each time operation of the switch is recognized, the display
switches MODE1 => MODE2 => MODE3 => MODE4 => MODE1 => ... However, if this switch is pressed during
auto control, auto control is ended and the diffuser is fixed at its current position.
b) MODE5 in the table below only occurs when operation of the DEF select switch is recognized. After that, when
operation of the blow mode select switch is recognized, the blow mode becomes the one that was in effect just
before operation of the DEF switch was recognized.
Blow mode and display and motor actuator angle

Blow mode MODE 1 MODE 2 MODE 3 MODE 4 MODE 5
Blow mode motor actuator degree of opening 90° 65.5° 46.5° 26.6° 0°
Panel display FACE VENT B/L FOOT DEF
4) Mode unit hysteresis correction operation (motor actuator one-direction stop)

After the actuator moves to the target degree of opening (a), it returns to the specified position. However, if (a)
is less than 0°C, the actuator is treated as having reached the target degree of opening (a) when it reaches
0°C, then it moves to the specified position.
(A stop in the VENT or FACE direction is used as the standard.)
5) Operation start / stop judgment
a) The operating motor actuator stops when the current position comes within the target position.
b) The stopped motor actuator operates when the current position goes beyond the target position.
6) Blow mode control priority order
The priority order for auto control and manual control is as follows.
Control priority order

Priority order Control
1 Manual control
2 Auto control
3. Refresh / Recirculate Switch Motor Actuator Control

1) Recirculate mode
In refresh mode, when it is recognized that the refresh / recirculate switch on the operation panel has been
closed, the system goes into recirculate mode. At this time, the display switches to recirculate and the refresh
/ recirculate switch motor actuator operates to the recirculate angle.
2) Refresh mode
In recirculate mode, when it is recognized that the recirculate / refresh select switch on the operation panel
has been closed, the system goes into refresh mode. At this time, the display switches to refresh and the
refresh / recirculate switch motor actuator operates to the refresh angle.
3) Operation stop judgment
When one of the limiters is detected, operation stops.
Refresh / recirculate mode and refresh / recirculate display and motor actuator angle
Refresh / recirculate mode Recirculate Refresh
Refresh / recirculate motor actuator degree of opening 0° 90 °
Panel display

Copyright ©
9006-14
4. Blower Amp Control

The air flow is controlled by outputting to the blower amp connected in series with the blower motor. The air
flow is switched by varying the analog voltage output by changing the PWM output duty ratio and increasing or
decreasing the blower motor speed.
There are two types of air flow control: auto air flow control and manual air flow control. Also, in auto air flow
control, the air flow is restricted by the cold blast prevention control etc.
Auto air flow control has no levels and manual control has four levels.
2) Manual air flow control
Each time it is recognized that the air flow UP switch has been closed, Lo => M1 => M2 => HI the air flow is
fixed to the next higher level of air flow. When Hi is already displayed, the air flow is not changed.
In the same way, each time it is recognized that the air flow DOWN switch has been closed, HI => M2 => M1
=> Lo the air flow is fixed to the next lower level of air flow. When Lo is already displayed, the air flow is not
changed.
The same is true when air flow control is switched from auto to manual. For example, when AUTO M1 is
displayed, if it is recognized that the air flow DOWN switch has been closed, the display becomes Lo and
AUTO is no longer displayed.
Also, the change speed for air flow output switch over is the same as discussed for auto below.
Relationship between air flow and PWM output

Air flow Display Target % (approx.)
Hi (maximum air flow) 100%
M2 75%
M1 59%
Lo (minimum air flow) 40%

Copyright ©
9006-15
3) Auto air flow control

When it is recognized that the AUTO switch has been closed, the air flow is controlled automatically and AUTO
is displayed.
a) During auto air flow control, the air flow is set according to the target blowing temperature as in Figure 3.
b) Auto air flow control continues until closing of either the air flow UP or air flow DOWN switch is recognized.
c) The auto air flow amount calculation results are continuous, not divided into levels.
d) When it is recognized that the AUTO switch has been closed, the display becomes as in Table 10 according to
the results of the auto air flow amount calculation.
e) The normal auto air flow output change is roughly 5 V / second.
f) Auto air flow control is restricted by the cold blast prevention control described in (4), which is the next item.
Air Flow
Hi
M2
M1
Lo
Relationship between air flow and target blow temperature
Display refreshing and air flow output correspondence table

Current display Item Target% (approx.)
Lo display Output range changed to M1 When 53% or higher
M1 display Output range changed to Lo When 46% or lower
Output range changed to M2 When 70% or higher
M2 display Output range changed to M1 When 64% or lower
Output range changed to Hi When 92% or higher
Hi display Output range changed to M2 When 83% or lower

Copyright ©
9006-16
4) Cold blast prevention control

The air flow is restricted according to the value of the coolant temperature and other parameters sent from the
vehicle side. The air flow restriction has two levels - air flow 0 and air flow Lo. Whether or not to use the
restriction is determined from the judgment results.
a) Conditions under which cold blast prevention control is used
1. Auto air flow
2. When set temperature - inside air sensor temperature > 11°C
3. When the coolant temperature signal from vehicle is the less than 35°C signal or the 35°C or higher but
less than 45°C signal
Under the condition above, the inside air sensor temperature is the value immediately after the ignition key
power is switched ON and AUTO and Test are according to the current switch states. Therefore, when the
AUTO switch is pressed after the air flow has been set manually, if the coolant temperature is within the cold
blast prevention range, the air flow is restricted. In the same way, even if the set temperature is changed, if
the conditions are met, the air flow is restricted.
While cold blast prevention control is being executed, the display corresponds to the restricted air flow.
b) Air flow 0 control
When the coolant temperature signal from vehicle is the less than 35°C signal, the air flow is set to 0. This
continues until a coolant temperature signal of 30°C or higher is received. Once a coolant temperature
signal of 30°C or higher is received and these conditions are no longer met, air flow 0 is ended.
c) Air flow Lo control
When the coolant temperature signal from vehicle is the 35°C or higher but less than 45°C signal, the air
flow is set to Lo. This continues until a coolant temperature signal of 45°C or higher is received. Also, the
same as for (b), this shift is irreversible. Once a coolant temperature signal of 45°C or higher is received,
control is normal.
Coolant temperature signal sent from the vehicle (one cycle)

* Finalized by the same waveform for three cycles. However, for the first combustion after the
ignition switch is switched ON, judged with the latest one cycle.
* The default state for the coolant temperature signal when the ignition is switched ON is 45°C or
higher.
100 100 100 100 100 100 100 100 100 100 100 100 100
ms ms ms ms ms ms ms ms ms ms ms ms ms
5V
Coolant temperature < 30°C
0V
5V
30°C < Coolant temperature < 45°C
0V
5V
45°C < Coolant temperature
0V

Copyright ©
9006-17
5) Air flow control priority order

The priority order for auto air flow control, manual air flow control, and cold blast prevention control is as
follows.
Control priority order

Priority order Control
1 Blower air flow control when mode motor actuator angle switched
2 Manual air flow control
3 COOLMAX control
4 Cold blast prevention control
5 HOTMAX control
6 Auto air flow control
5. Compressor Clutch Control

The compressor clutch is controlled by the power to the clutch coil being switched ON / OFF by an external
relay. This control is executed by thermo operation, the condensation prevention function, and the fretting
prevention function. Thermo operation has control mode 1 and control mode 2. These modes are applied
according to the blow mode and other conditions. However, for blower air flow 0, the compressor clutch is
switched OFF. The operation temperature does not include the thermistor variation.
2) Thermo operation (AC switch ON)
a) Control mode switch over
• When the blow mode is B / L and the target blow temperature is as in the figure below, control mode 2 is
used.
As the figure shows, there is hysteresis between control modes 1 and 2.
• Other than the above is all control mode 1.
Control mode 1
Control mode 2
Relationship between control mode

and target blow temperature for B / L
b) Control mode 1
• OFF temperature: 5 ± 1°C
When this temperature or lower is detected, the compressor clutch is switched OFF.
(It is kept OFF until a temperature at or above the ON temperature is detected.)
• ON temperature: OFF temperature + 2 ± 0.5°C
When this temperature or higher is detected, the compressor clutch is switched ON.
(It is kept ON until a temperature at or below the OFF temperature is detected).
c) Control mode 2
• OFF temperature: 5 ± 1°C
• ON temperature: OFF temperature + 2 ± 0.5°C.

Copyright ©
9006-18
3) Condensation prevention function

a) Timer set temperature: 8 ± 2°C
When this temperature or lower is detected, the timer is set and starts counting.(It is not reset until a
temperature at or above the timer cancel temperature is detected.)
b) Timer cancel temperature: Timer set temperature + 1 ± 1°C
When this temperature or higher is detected, the timer is reset.
c) Count-up time: 10 ± 1 minutes
When the timer count reaches this time, the compressor clutch is switched OFF. After this, when the timer
recovery temperature or higher is detected, the compressor clutch is switched ON and timer setting is
prohibited.
d) Timer recovery temperature: Timer set temperature + 2 ± 1°C
When this temperature or higher is detected, the compressor clutch is switched ON and timer setting is
permitted.
4) Fretting prevention function
Compressor main shaft has a possibility to suffer by corrosion as fretting corrosion according to the engine
vibration mainly. To avoid this corrosion, this system has fretting prevention function.
a) Operation conditions
After the end of initial operation, if 5 ± 1 minutes continue with the air flow M2 or higher and the compressor
clutch not coming ON even once, the compressor clutch is switched ON one time.
This control is cleared by the ignition key power being switched OFF and this control starts again when this
power supply is switched ON again.
Compressor clutch ON time: 1 ± 0.6 seconds
b) This control takes priority over all other control.
5) AUTO switch link function
When operation of the AUTO switch is recognized, compressor clutch control comes ON and AUTO is
displayed.
a) Compressor clutch control is the same control as for the AC switch being switched ON.
b) When it is recognized that the AC switch has been switched OFF, the AUTO display goes out. Even when it is
recognized that the AC switch has been switched ON again, AUTO is not displayed.
However, at this time, if the main key power is switched OFF, then ON again, since the AC ON, air flow AUTO,
and blow mode AUTO conditions are all met, AUTO is displayed.
6. COOLMAX Control and HOTMAX Control

1) When the set temperature is 18.0°C [COOLMAX] (or 18. E)
a) The air mix motor actuator is set to the 0° limiter position (fully closed).
b) For auto air flow control, the air flow is set to Hi.
c) For AUTO blow mode control, the blow mode is set to VENT.
2) When the set temperature is 32.0°C [HOTMAX]
a) The air mix motor actuator is set to the 90° limiter position (fully open).
b) For auto air flow control, the air flow is set to M2.
c) For auto blow mode control, the blow mode is set to FOOT.

Copyright ©
9006-19
7. Trouble Detection and Control after Trouble Detected

If there is trouble in a motor actuator drive line or sensor controller input circuit, the trouble is detected and
control from then on changed as described below.
In any of these cases, once trouble has been detected, even when that location is returned to normal, trouble
control is not ended. Trouble control is only ended when the ignition key power supply is switched OFF or
when air conditioner operation is stopped with the ON / OFF switch on the operation panel. However, motor
actuator restriction is only ended by switching OFF the main key power supply.
2) Trouble in a motor actuator and its input / output circuits
a) Disconnection detection
Immediately after the main key power supply is switched ON, if a motor actuator potentiometer line is
disconnected or shorted, the display in the table below for that motor actuator is carried out and that motor
actuator is not driven until the main key power is switched OFF, then ON again.
Disconnection detection display

Trouble location Trouble display
Air mix motor actuator HL.E is displayed on the set temperature display
LCD. (See the figure below.)
Blow mode motor actuator The passenger icon display flashes.
Refresh / recirculate motor actuator Potentiometer line not used
b) Motor lock detection

If the output shaft rotation angle for a motor actuator does not reach its target value within 15 seconds, this
is treated as lock detection, output to that motor is stopped, and trouble is displayed on the controller
according to the trouble location.
Motor lock detection display

Trouble location Operation panel trouble display
Air mix motor actuator HL.E is displayed on the set temperature display
LCD. (See the figure below.)
Blow mode motor actuator The passenger icon display flashes.
R e f r e s h / r e c i r c u l a t e sw i t c h m o t o r The refresh / recirculate mark flashes.
actuator

Copyright ©
9006-20
3) Trouble in a sensor or its input / output circuits (disconnection or short)

a) Disconnection or short in the inside air sensor or its input / output circuits
1. Operator compartment temperature control end
• All control related to the operator compartment temperature (target blow temperature) is stopped and
the air mix degree of opening is directly adjusted according to the temperature adjustment switch input.
• Accompanying this, the operation panel set temperature display changes as H L . * ,
* is a value from 0 to 9. Each time the DOWN switch is closed, this value decreases by 1; each time the UP
switch is closed, this value increases by 1.
For any blow mode other than FACE or VENT, the minimum value is set to 1.
Display and control for inside air sensor trouble

* value Motor actuator degree of opening (°)
0 0°
1 to 8 * value X 10 °
9 90 °
2. Auto air flow control end

• The air flow is temporarily fixed at that in effect when the inside air temperature sensor trouble was
detected.
• The AUTO display is set flashing.
• After this, the air flow is switched by the manual air flow switch.
3. AUTO blow mode control end
• The blow mode is temporarily fixed at that in effect when the inside air temperature sensor trouble was
detected.
• The AUTO display is set flashing.
• After this, the blow mode is switched by the manual blow mode switch.
4. Air mix damper degree of opening display priority
• Even if the trouble shown by one of the items below occurs during inside air sensor trouble, E is not
displayed in the * section below the decimal point and the air mix damper degree of opening display is
given priority.
• HL.E is only displayed for air mix motor actuator trouble.
5. Thermo operation control mode fixed
• Switching of the control mode according to the blow mode and target blow temperature is stopped and
the control mode is fixed at control mode 1.
b) Disconnection or short in evaporator sensor or its input / output circuits
1. Compressor control is not executed and the compressor clutch is always OFF. However, fretting
prevention control is executed.
2. E is displayed in the first fraction position of the set temperature display LCD (See the figure below).
(The temperature setting is in 1°C steps.)
However, E is not displayed for inside air sensor trouble.
3. The AC mark flashes.
The AC mark flashes

E is not displayed
c) Disconnection or short in solar radiation sensor or its input / output circuits

1. The solar radiation compensation data is set to 0.
2. E is not displayed in the first fraction position of the set temperature display LCD as it is for other sensors.
d) Coolant temperature signal trouble
Cold blast prevention control does not work and normal control is used.

Copyright ©
9006-21
8. Monitor Mode
Monitor mode is a mode for understanding trouble in the controller itself or in other control. The system goes
into monitor mode when there is the special switch input below on the operation panel.
2) Starting monitor mode
When the air conditioner is operating with basic control, if the operation panel ON / OFF switch closed path
continues for one second while the refresh / recirculate switch closed path is ongoing, monitor mode is
started.
3) Monitor contents
a) LCD segment diagnosis
When monitor mode is entered, the target LCD lights up for one second. An LCD with trouble does not light
up.
b) Sensor diagnosis
The detection value (AD value or °C) for each sensor is displayed.
c) Coolant temperature signal recognition value
This displays the reception status for the coolant temperature signal sent from the vehicle.
4) Monitor contents
a) LCD segment diagnosis
When monitor mode is entered, the target LCD lights up for one second. An LCD with trouble does not light
up.
b) Sensor diagnosis
The detection value (°C) for each sensor is displayed.
5) Display contents in monitor mode
In monitor mode, the data (detection value for each sensor, coolant temperature signal recognition, etc.) is
displayed in the three digits of the 7-segment display for the temperature setting. The data displayed is
selected with the blower UP / DOWN switches and AUTO switch. The blower UP / DOWN switches move the
display on the dedicated monitor mode 7-segment display through 16 displays, 0 to F, and the corresponding
data is displayed (Table A on next page). Hexadecimal data display and decimal data display can be selected
with the AUTO switch. Only for the coolant temperature signal recognition value, the value detected
immediately before entry into monitor mode is displayed.
The difference between hexadecimal data and decimal data is indicated by the third digit of the 7-segment
display. For hexadecimal data, "H" is displayed there and for decimal data, numbers (0 to 9) are displayed
there.
a) Hexadecimal display
AD values 00H through FFH are displayed. When the AD value corresponds to that in Table B on the next
page (or Table C for the solar radiation sensor), this indicates a disconnection or short. In the hexadecimal
display, when the value of a sensor changes in monitor mode, the hexadecimal display changes with it. If
the display before entering monitor mode was H L . * , the error judgment value is displayed (In other
words, the value detected before the trouble was detected). In the same way, if the display before entering
monitor mode was * *. E , the display becomes **.E and the error judgment value is displayed.
b) Decimal display
From -99.9°C to 99.9°C is decimal display. Also, the "-" minus display displays the arrow mark for FOOT
mode.
6) Air conditioner operation in monitor mode
When the system enters monitor mode, all output (operation) through control is stopped and until monitor
mode is ended, operations and settings of basic control through all the switches are not possible.

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9006-22
7) Ending monitor mode

In monitor mode, if the operation panel ON / OFF switch closed path continues for one second while the
refresh / recirculate switch closed path is ongoing, monitor mode is ended and the system returns to the basic
control state. The same also occurs if the ignition key power supply is switched OFF.
Table A
Dedicated monitor mode Display contents
7-segment display
0 Inside air sensor temperature data
1 Evaporator sensor temperature data
2 Solar radiation compensation data
C Coolant temperature signal status data
Trouble Lower than 30°C 30°C or higher 45°C or higher
and lower than
45°C
4 1 2 3
3 to 9 and B to F Data (sensor diagnosis etc.)
Table B
Sensor name Short Disconnection
Inside air sensor F6H 0CH
Evaporator sensor F6H 0CH
Table C
Sensor name 5 V short Ground short
Solar radiation sensor C7H 0CH

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9006-23
9. Door Switch Control

This control adds a restriction to air conditioner operation with the door switch or front window switch. Its
purpose is to prevent overheating of the ignition unit. Concretely, it suppresses condenser heating and
controls in a way restricted in order to obtain a feeling of comfort.
2) Door switch / front window switch signal
The signal input into the controller is as follows for both the door and front window switches.
a) When door / front window open
Contact closed, the control controller input is at ground level.
b) When door / front window closed
Contact open, pulled up to 5 VDC inside the control controller
3) Control restricted by door switch / front window switch
a) Starting restricted control
When either the door or front window is open continuously for one second or longer, it is recognized that the
switch is open. At the count of 60 seconds, the buzzer buzzes the same way as for switch input to tell the
operator that restricted control is starting and that control starts.
b) Restricted control
1. For both auto and manual blow mode control:
Even if auto or manual blow mode is selected, unless the blow mode is FACE, the following air flow
restriction is executed.(If the blow mode is FACE, the air flow is not restricted.)
I. If the target blow temperature < 20°C, the air flow upper limit is set to M1.
II. If the target blow temperature > 25°C, the air flow restriction in I is ended.
2. When the current blow mode control is AUTO
Auto control with the AUTO blow mode VENT changed to FACE is used.
3. When the current blow mode control is manual selection
Only if the blow mode is VENT immediately after the open switch is recognized, that mode is changed to
FACE. After this, all the blow modes can be selected with manual operation.
c) Ending the restriction
When both the door and front window are closed continuously for one second or longer, it is recognized that
the switches are closed. After a count of 1 second, the buzzer buzzes the same way as for switch input to
tell the operator that restricted control has been ended.
When the restricted control is ended, the restriction on the air flow discussed in 1. above and the change
from VENT to FACE in 3. are ended and control returns to normal. However, if the blow mode has been
manually selected, even if the mode was changed from VENT to FACE by the above restriction, it does not
return to VENT when the restricted control is ended.

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9006-24
10. Inside Air Filter Clogging Detection Control

This control recognizes the blower current with the dedicated shunt resistor voltage input, judges from that
value whether or not the AC unit inside air filter is clogged and if it judges that filter is clogged, it issues a
warning to encourage the operator to replace the filter.
2) Filter detection control
a) Starting detection control (detection timing)
Five seconds after the end of initial operation, if the air conditioner is operating and the cold blast prevention
conditions are not present, this control is started. Also, this control is executed every 50 hours of air
conditioner (blower) operation. However, during a temporary filter clog or filter clog, it is executed every
time.
b) Detection method
Cooling / heating is judged from the operation mode and in this way the air mix motor actuator target
position is determined. Also, the mode motor actuator target value is set to FOOT, the blower air flow target
value is set to M1, and output is made to attain the target values. When all the target values are attained,
the blower current from the shunt resistor voltage is recognized, and the filter clog is judged by comparing
this current with the default current value.
(Cooling / heating judgment)

When the operation mode is FACE or VENT, : Cooling (COOLMAX)
When FOOT or DEF : Heating (HOTMAX)
When B / L: Final inside air temperature If < 22°C, heating
When B / L: Final inside air temperature If > 22°C, cooling
(Detection current threshold)
Relative to the default current value For cooling : 0.37 ± 0.02 A min.
For heating : 0.51 ± 0.03 A min.
If the value is below this three times in a row, it is judged that there is a clog.
(Default current value)
Current found in the initialization operation described below.
3) Clog warning
(Buzzer)
The buzzer buzzes intermittently at 1 Hz for 10 seconds.
(Display)
"FIL" is displayed on the 7-segment display for the set temperature for 10 seconds. Other marks go out.
However, if there is any switch input, the "FIL" display is ended immediately.
4) Alarm reset
If a reset detection value is recognized during the clog state, the clog state is reset.
The reset detection value is 50% of the clog detection threshold.
5) ON / OFF switching
This function is switched ON / OFF by pressing the [Refresh / Recirculate], [MODE], and [DEF] switches at the
same time. The factory setting for this function is OFF. This function does not come ON until the initialization
operation discussed below is executed.
(Buzzer)
When operation of this switch is recognized, there is the normal switch input sound.
(Display)
ON or OFF is displayed on the set temperature 7-segment display, whichever is the state after switching.
Other marks go out.

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9006-25
6) Initialization operation
When the [Refresh / Recirculate] and [DEF] switches are pressed at the same time, the default current value is
detected and all the data for filter detection is initialized. Before executing this operation, make sure that the
air conditioner unit (with a new inside air filter installed), ducts, and grilles (with all grilles fully open) are all
installed in their normal states on the vehicle. If initialization is carried out in any other state, there is a danger
of the clog detection judgment control making an incorrect judgment. Immediately after replacing the inside air
filter with a new one, execute the initialization operation.
(Buzzer)
When operation of the switch is recognized, the buzzer buzzes with the normal switch input sound. When the
detection ends, the buzzer buzzes for 3 s.
7) Detection processing avoidance
• When the inside / outside air damper is not at the recirculate position immediately before the current
value is read
• When the power supply voltage is not in the tolerance range for the voltage during the initialization
operation
• Trouble in any of the motor actuators

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9006-26
ACTUATOR INSPECTION
Air Mix Motor Actuator Inspection
1 2
G/W G/W
G
G/R
B G
3
G/L
L/Y 4 M
G/R
G/L
L/Y
Air mix damper operation defect
See the Chart.
Specifying the trouble location
1 Control panel
2 Air mix motor actuator
3 Connector 1
4 Connector 9

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9006-27
Chart
IGN OFF¨ON (when the engine starts)
Does Is an error
the actuator operate at all in NO displayed after the end of NO
initial operations? initial operation?
Control panel defect

YES YES
Does it Is there
operate according to the NO conductance in the harness NO
initial operation table below? between the actuator and
controller amp?
Harness defect
YES YES
Actuator defect or damper

Is an error lock or link defect
displayed after the end of NO
initial operation
Damper lock or link

defect
Disconnect the actuator connector (9)
Is the resistance NO
between L/Y and B of the
actuator about 4 k Ohms
Initial operation table

Actuator position before Air mix motor actuator
YES initial operation start
(1) COOLMAX position (0°) 0° => 90° => 0°
(2) HOTMAX position (90°) 90° => 0°
Is there (3) Other than the above Current position => 90° => 0°
conductance between the G / NO
L and L / Y of the actuator
and between G / L and B?
YES Actuator defect

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9006-28
Refresh / recirculate Motor Actuator Inspection
1 2
L/W L/W
3 L/G
5 M
L/R L/R
L/G
4
Refresh/recirculate operation defect
See the Chart.
1 Control panel
2 Air mix motor actuator
3 Connector 1
4 Connector 2
5 Connector 11

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9006-29
Chart
Switch the ignition OFF=>ON (to start the engine) and

complete the air mix and mode initial operation.
Press the refresh /

recirculate switch. Does the NO
actuator operate at all?
YES
Switch the
setting to recirculate. Does NO
the actuator become about
0°?
YES
Switch the
setting to refresh. Does the NO
actuator become about 90°?
NO
Is a refresh/recirculate error
Damper lock or link displayed?
defect
YES
Is there
conductance in the harness NO
between the actuator and
controller amp?
Harness defect
YES

lock or link defect

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9006-30
Mode Motor Actuator Inspection
1 2
Y/W Y/W
Y
Y/R
B Y
3
Y/L
L/Y 4 M
Y/R
Y/L
L/Y
Inside / outside air mix damper operation defect
See the Chart.
1 Control panel
2 Mode motor actuator
3 Connector 1
4 Connector 10

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9006-31
Chart
IGN OFF¨ON (when the engine starts)
Does Is an error
the actuator operate at all in NO displayed after the end of NO
initial operations? initial operation?

YES YES
Does it Is there
operate according to the NO conductance in the harness NO
initial operation table below? between the actuator and
controller amp?
Harness defect
YES YES

Is an error
lock or link defect
displayed after the end of NO
initial operation
Damper lock or link

defect
Disconnect the actuator connector (10)
Is the resistance NO
between L/Y and B of the
actuator about 4 k Ohms
Initial operation table

Actuator position before Air mix motor actuator
YES initial operation start
(1) COOLMAX position (0°) 0° => 90° => 0°
(2) HOTMAX position (90°) 90° => 0°
Is there (3) Other than the above Current position => 90° => 0°
conductance between the Y/ NO
L and L/Y of the actuator and
between Y/L and B?
Actuator defect
YES

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9006-32
SELF-DIAGNOSIS FUNCTION WITH PANEL DISPLAY
Trouble Display and Self-Check Procedure

Motor actuator and sensor troubles can be checked on the panel display.
1) Trouble Display Position
• Error is displayed on 3 digit 7-segment display.

2) Explanation of Trouble Display
a) Motor actuator trouble
1. HL.E displayed on three-digit 7-segment display
Check the air mix damper motor actuator for
harness disconnection or disconnected
connector.
2. MODE flashes.
Check the blow mode damper motor actuator for

connector.
3. The R / F flashes.
Check the refresh / recirculate motor actuator for

connector.
CAUTION: With the panel ON / OFF switch

ON, the above display and flashing does
not function even if a har ness
disconnection or disconnected connector
occurs.
After trouble occurs, when the panel ON /
OFF switch is switched ON, the function is
displayed.
After trouble occurs, the trouble display
and flashing are not ended until the main
switch is switched OFF=>ON.

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9006-33
b) Sensor trouble
1. HL.* displayed on three-digit 7-segment display
Check the inside air sensor and check its harness

for disconnection, short, or connector connection
defect.
(* is any number 0 to 9)
(*)
2. **.E and the mark flashing display are displayed on the three-digit 7-segment.
(** displays the set temperature value at that time still remaining.)
Check the evaporator sensor and its harness for

** disconnection, short, or connector connection
defect.
CAUTION: The display in [1] and [2] above is displayed on the three-digit 7-segment display when trouble
occurs with the panel ON / OFF switch ON.
After the trouble section is repaired, end the trouble display by switching the panel ON / OFF switch
OFF=>ON.

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9006-34
3) Explanation of Monitor Mode

When sensor trouble is displayed, the sensor status (disconnection, short) can be checked in monitor mode.
a) Monitor mode display position
• (25.5) = Three-digit 7 segment (°) = 7 segment dedicated to monitor display

b) Monitor mode display operation method
1 2
3 1 Refresh / recirculate switch

2 Blower switch UP / DOWN switch
3 ON / OFF switch
1. Hold down the refresh / recirculate switch and the ON / OFF switch at the same time for one second or
longer.
2. Press the AUTO switch.
(All the segments light up for one second, then the system enters monitor mode.)
3. Numbers 0 to 9 or letters A to F are displayed in the first and second digit of the three-digit 7-segment
display.
"H" is displayed in the third digit.
4. The 0 to 2 display on the dedicated 7-segment display is carried out with the blower UP / DOWN
switches. The necessary sensor is selected from the table below.
7-segment display table indicated to monitor
0 Inside air sensor

1 Evaporator sensor
2 Solar radiation sensor
(Display other than the above (3 to 9, B to F) is not

used during service)
5. To end the monitor display, either hold down the refresh / recirculate switch and the ON / OFF switch at
the same time for one second or longer or switch the vehicle main switch OFF.
CAUTION:
1. During monitor mode, operations and settings of basic control through all the switches are not possible
until the air conditioner control operation is stopped and monitor mode ended.
2. During monitor mode, even if a sensor is repaired, the trouble display is recorded in memory, and until
the ON / OFF switch is switched OFF, then ON again, the trouble display is not ended.

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9006-35
c) Display contents in monitor mode
See the dedicated monitor 7-segment display table and three-digit 7-segment table.
1. Display example 1
The dedicated monitor 7-segment display is 0

(indicates the inside air sensor state).
0 From the three-digit 7-segment table 3F=>The
sensor is normal.
=>The inside air sensor is normal.

(indicates the evaporator sensor state).
1 From the three-digit 7-segment table 00=>The
sensor is disconnected.
=>The evaporator sensor is disconnected.

(indicates the solar radiation sensor state).
2 From the three-digit 7-segment table FF => The
sensor is shorted.
=>The solar radiation sensor is shorted.
Three-digit 7-segment table
Second digit of 7-segment display

0 1 2 3 4 5 6 7 8 9 A B C D E F
Inside air sensor disconnection OCH0 display
0 Evaporator sensor disconnection OCH1 display
Solar radiation sensor short OCH2 display
1
2
3
4 1 0
3rd-digit of 7-segment display
5 Sensors normal
6
7
8
9
A
B
C
D 2
Solar radiation sensor 5V side short C7H2 display
E
F Inside air sensor short F6H0 display

Evaporator sensor short F6H1display

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9006-36
Air Conditioning troubleshooting
The blow temperature does not go down

When the AUTO switch or AC switch is pressed, HL. E is displayed in
the panel set temperature display section.
YES
NO
“HL.*” is displayed on the panel set
temperature display section. 1) The air mix motor actuator connector is
(*) is a number 0 to 9. disconnected or has a contact defect.
2) Air mix motor actuator defect.
NO YES 3) E Main harness conduction defect.
The panel snow mark The panel snow mark
flashes. flashes. Inspect and repair or replace the
parts
NO
YES
1) Inside air sensor or harness
1) Inside air sensor and evaporator
disconnection or short
sensor simultaneous disconnection or
2) The inside air sensor connector is
short.
disconnected or has a contact defect
2) Computer breakdown.
See the «Monitor Mode» item too. See the «Monitor Mode» item too.
Inspect and repair or replace the

parts
NO YES
When the setting temperature is set to 18.0 and the blow 1) The evaporator sensor connector is
mode is set to vent mode, the blow temperature drops. disconnected or there is a contact defect
2) Evaporator sensor simultaneous
disconnection or short
NO See the «Monitor Mode» item too.

YES
The air mix damper is at the Cool air is blowing into the Inspect and repair or replace the
COOLMAX position. inside air sensor section parts
NO YES NO
Switch compressor clutch ON/ Computer breakdown

If motor actuator operation or inside air sensor
OFF and inspect and repair the
stops midway, find the cause defect
power supply circuit
and correct it, measure the
operating force. Is it 1.5 kgf or
less? See the cooling cycle Inspect and replace
troubleshooting.
YES
NO YES Inspect the duct or
Motor actuator or computer eliminate the cause of the
1) Inspect, repair, or replace the cool air infiltration.
breakdown
motor actuator lever link section.
2) Clean the lever link section, then
apply grease. Replace

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9006-37
The blow temperature does not go up
HL.E is displayed on the panel set temperature
display section.
YES
NO
“HL.*” is displayed on the panel set
temperature display section. 1) The air mix motor actuator
(*) is a number 0 to 9. connector is disconnected or has a
contact defect.
2) Air mix motor actuator defect.
3) E Main harness conduction
defect.
YES
NO
1) Inside air sensor or harness disconnection
or short
2) The inside air sensor connector is Inspect and repair or
disconnected or has a contact defect replace the parts
See the «Monitor Mode» item too.

parts
When the setting temperature is set to 32.0 and the

blow mode is set to foot mode, the blow temperature
rises.
NO YES
The air mix damper is at the Warm air is flowing into the
HOTMAX position. inside air sensor section
NO YES NO
Inspect the warm
If motor actuator operation YES
coolant lines Control panel
stops midway, find the cause
and correct it, measure the breakdown or inside Inspect the duct or
operating force. Is it 1.5 kgf or air sensor defect eliminate the cause of
less? the warm air infiltration.
Inspect and replace
NO
1) Inspect, repair, or replace YES

the motor actuator lever link Motor actuator or computer
section. breakdown
2) Clean the lever link
section, then apply grease.
Replace

Copyright ©
9006-38
The blower motor does not rotate
With the flow set to HI, battery voltage is applied to
both terminal(+ and -) of the blower motor. (See the
“Note 1”).
NO YES
The battery voltage is applied between the blower Replace the

motor (+) power supply red/blue and the body. blower motor
YES
NO
Voltage of about 10 V is applied between the
1) Inspect the blower motor relay blower amp brown / yellow line and ground.
2) When the blower motor relay white/red
and blue/ red are directly connected, the
blower motor rotates. (See the “Note 2”).
NO YES
There is conductance between

Replace control
brown/yellow and black.
panel
NO YES
Inspect, replace or The voltage is applied between

repair the wire NO YES
the blower motor relay white/
harness red and the body.
Eliminate the cause of Inspect, replace or
the trouble, then repair the wire
replace the blower harness
amp.
YES
NO
When the blower motor relay
Inspect, replace or purple/white is dropped to ground,
repair the wire the blower motor rotates.
harness.
NO YES
Replace the relay. Inspect, replace or repair

the wire harness or
replace the control panel
(Note 1) measure with the connector connected

(Note 2) For the sake of safety, have the air conditioner, vehicle key, and light
switches all OFF when working with direct connections in place.

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9006-39
The blower motor speed does not change
(1)
“HL.*” is displayed on the panel set temperature display section.
(*) is a number 0 to 9.
YES
1) Inside air sensor or harness

NO disconnection or short
2) The inside air sensor connector is
Replace the blower amp disconnected or has a contact defect
or control panel
See the «Monitor Mode» item too.

parts
(2)
Does the blower motor fail to change speed when the mode is other
than face?
YES
Is the door or front window open?
NO
YES
While operating under restrictive control See (1)

by door switch or front window switch.

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9006-40
The magnetic clutch does not engage
When the AUTO switch or AC switch is pressed, the
snow mark lights up.
NO YES
The snow mark flashes and E is displayed Voltage is applied to the clutch.
on the panel display section.
YES
1) The evaporator sensor connector is
connected or there is a contact defect Clutch defect. Replace the
2) Evaporator sensor simultaneous compressor.
disconnection or short NO
See the «Monitor Mode» item too. Voltage is applied to the

harness for the pressure
Inspect and repair or replace the switch.
parts
NO YES
Voltage is applied between the vehicle side Pressure switch defect or coolant pressure
harness connector brown/red and ground abnormally high or low.
(black)
See the cooling cycle

NO YES troubleshooting.
Inspect the clutch fuse Is there trouble in the air
conditioner harness?
NO YES
Replace the harness. Replace control panel.
Refresh/recirculate mode does not switch

The refresh/recirculate mode display on the operation panel
LCD display section is flashing.
NO
YES
There is foreign matter on the motor actuator The refresh / recirculate motor actuator
lever or the motor actuator lever section is connector is disconnected, there is a contact
broken. defect, or there is trouble with the motor
actuator or the main.
YES
NO
Remove the foreign matter or replace
Replace the motor actuator. the part.

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9006-41
The mode is not switched
The passenger icon display on the operation panel LCD
display section flashes.
NO YES
The inside/outside air motor actuator
Inspect or replace connector is disconnected or has a contact
defect or the motor actuator is broken or the
main harness is broken.
NO YES
Repair Is a damper lever out of place?

Inspect or replace
NO NO
Repair When the cam with the rod removed is

moved by hand, it is sluggish (2 kgf or
more)
NO YES
1) Foreign matter or breakage at cam

section or damper shaft section.
Replace the motor actuator or
2) Operation defect due to soiling with
control panel.
grease or the like
1) Eliminate the foreign matter or replace

the part.
2) Clean the cam section, then apply
grease.

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9006-42
PART FUNCTION
Control Panel and Control Unit

The control panel and control unit are formed into one piece. The operation of its built-in microcomputer compares,
operates on, and processes the sensor input signals and control panel switch input signals, switches the output side
actuators (refresh / recirculate switching, air mix) and comprehensively controls the fan motor and compressor.
It is equipped with self-diagnosis functions to make trouble diagnosis easier.
(For details see the control specifications.)
Blower Amp
The blower amp receives the control signals from the control unit and changes the speed of the blower motor.
Terminal
number
Conductance
1 2 3
+ - Conductance (4.7 k Ohms ±5%)

- + No conductance
Tester
Conductance
+ -
(diode parallel forward direction)
1) Remove the blower amp connector.

2 2) Check the conductance between the blower amp side terminals.
* The installation position is on the left side of the air conditioner

3 unit.

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9006-43
Relay
4-pole relays are used for the blower OFF relay and compressor relay.
Blower OFF relay

This relay receives the signal from the control amp and switches the blower OFF relay ON.
When the blower OFF relay is switched ON, the power supply voltage is fed to the blower motor via the
blower amp and the blower motor is started.
Compressor relay
The compressor relay is switched ON / OFF by the control amp compressor control;
Relay inspection contents
1. Relay
2. Coil resistor: 320
3. Specification voltage: 20 to 30 VDC
4. Be careful. The coil side of this relay must be installed with the poles facing correctly.
5. Inspection: Inspect the conductance between 3 and 4 under the conditions below.
20 - 30 V applied between Terminals 1 and 2 : Conductance

No voltage applied between Terminals 1 and 2 : No conductance
Air Mix Actuator

The air mix actuator is installed at the center of the air conditioner unit. It opens and closes the air mix damper via the
link.
Built into the air mix actuator is the potentio-meter which varies linked with the actuator shaft.
When the target air mix door position is determined by the temperature control switch, the control unit reads in the
potentio-meter position in the actuator and determines whether the motor turns forward or reverse.The contacts move
linked with the motor. When the contacts move open or the target potentio-meter position is reached, the control unit
output signal goes OFF and the motor stops.
(See "Air Mix Motor Actuator Inspection".)

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9006-44
Refresh / Recirculate Actuator
The refresh/recirculate switch actuator is installed on the blower intake unit. It opens and closes the refresh/recirculate
damper via the link.
Built into the refresh/recirculate switch actuator is the position detection switch that changes linked with the actuator
shaft.
When the refresh/recirculate damper position is determined by the refresh / recirculate switch on the control panel, the
control unit reads in the signal of the position detection switch in the actuator and determines whether the motor turns
forward or reverse.The contact moves linked with the motor and when the contact reaches the position detection switch
and separates, the motor stops.
(See "Refresh / Recirculate Motor Actuator Inspection".)
Blow Mode Actuator

The blow mode actuator is installed on the back surface of the air conditioner unit. It opens and closes the blow damper
via the link.
Built into the blow mode actuator is the potentio-meter which varies linked with the actuator shaft.
When the blow mode position is determined by the temperature control switch, the control unit reads in the potentio-
meter position in the actuator and determines whether the motor turns forward or reverse.The contacts move linked with
the motor. When the contacts move open or the target potentio-meter position is reached, the control unit output signal
goes OFF and the motor stops.
(See "Mode Motor Actuator Inspection".)
Evaporator Sensor
In order to prevent the evaporator freezing, the evaporator blow temperature is detected and the compressor ON / OFF
controlled.
Evaporator sensor inspection method

(specifications value)
Disconnect the evaporator connector from the main harness and measure the resistance between the sensor
side connector terminals using the tester.
Resistance between When the sensor section detection temperature is 0°C : 7.2 kW
terminals
When the sensor section detection temperature is 25°C : 2.2 kW

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9006-45
Dual Pressure Switch
The dual pressure switch is installed on the receiver drier. When there is pressure trouble in the coolant high-pressure
side line (abnormally high pressure or abnormally low pressure), the dual pressure switch contacts open up to cut off the
compressor power and protect the cooling cycle.
Dual pressure switch specifications
0.02 MPa, 0.59 MPa,

(0.2 bar, 2.9 Psi) (5.9 bar, 85 Psi)
ON
OFF
0.20 MPa, 3.14 MPa,
(2 bar, 29 Psi) (31.4 bar, 455 Psi)
(Low pressure side) (High pressure side)
Simple inspection method for dual pressure switch:

1. With the cooling cycle stopped, disconnect the connector from the switch and check the conductance
between the switch side connector terminals using the tester. If there is conductance, the switch is
normal (When the outside air temperature is 0°C or higher).
2. Connect the gauge manifold high-pressure side hose to the high-pressure side charge port. With the
cooling cycle operating, the condenser front surface is covered with the plate top and the high-pressure
rises.If the compressor stops around 3.14 MPa (31.4 bar, 455 Psi), the switch is normal.
3. With the coolant removed, check the conductance between the switch side connector terminals using the
tester. If there is no conductance, the switch is normal.
Solar Radiation Sensor

This is the air conditioner solar radiation correct sensor. It detects the strength of sunlight with a photo diode, converts it
into current and sends that to the control panel.
Solar radiation sensor inspection method:

• Disconnect the solar radiation sensor connector from the harness and measure the resistance between
the sensor side connector terminals using the tester's voltage measurement mode.
• The voltage must be different when light is striking the photo receiver section and when it is not. (The
voltage is 0 V when absolutely no light is striking the photo receiver.)
CAUTION:
Always measure with the tester in voltage measurement mode (V mode).
Measuring with the tester in resistance mode (mode) would destroy the sensor.
Motor actuator and sensor troubles can be checked on the panel display.

Copyright ©
9006-46
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Section
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Printed in France
Contents
Contents
SH330-5 Copyright ©
Contents
Engine Section
Procedures for Replacing Consumable Parts
Engine Oil ................................................................................................................... 1
Removal and Installation of Engine Oil Filter Element................................................ 4
Fuel Filter.................................................................................................................... 5
Charge Fuel Pump Filter ............................................................................................ 9
Removal and Installation of Fan Belt ........................................................................ 11
Removal and Installation of Air Conditioner Belt ...................................................... 14
Assembly and Disassembly

Removal and Installation of Engine Hood................................................................. 15
Removal and Installation of Engine Assembly.......................................................... 17
Removal and Installation of Alternator...................................................................... 30
Removal and Installation of Supply Pump ................................................................ 32
Removal and Installation of Common Rail................................................................ 42
Removal and Installation of Injector.......................................................................... 44
Removal and Installation of Muffler .......................................................................... 56
Removal and Installation of Turbo Charger .............................................................. 58
Removal and Installation of EGR Cooler and EGR Valve......................................... 62
Removal and Installation of Engine Sensors ............................................................ 66
Removal and Installation of Fuel Cooler................................................................... 68
Removal and Installation of Engine Inter Cooler ...................................................... 69
Air Conditioner Section

Removal and Installation of Compressor.................................................................... 1
Removal and Installation of Condenser...................................................................... 3
Removal and Installation of Receiver Dryer ............................................................... 6
Assembly and Disassembly of Unit ............................................................................ 8
Gas Filling Procedures

Work Precautions ..................................................................................................... 13
Work Procedures ...................................................................................................... 14
Filling Procedures ..................................................................................................... 16
Maintenance Section
Electrical Equipment Judgment Procedures
Electricity Measurement Procedures.......................................................................... 1
Maintenance Standards
Check Sheet ............................................................................................................... 3
1 SSM-00-00-004EN
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Contents
Assembly and Disassembly Section
Track Shoe
Removal and Installation of Shoe Assembly .............................................................. 1
Removal and Installation of Shoe Plate...................................................................... 6
Travel Unit
Removal and Installation of Travel Motor.................................................................... 7
Assembly and Disassembly of Travel Motor ............................................................. 15
Take-up Roller
Removal and Installation of Take-up Roller .............................................................. 63
Assembly and Disassembly of Take-up Roller.......................................................... 66
Upper Roller
Removal and Installation of Upper Roller ................................................................. 76
Assembly and Disassembly of Upper Roller............................................................. 79
Lower Roller
Removal and Installation of Lower Roller ................................................................. 90
Assembly and Disassembly of Lower Roller............................................................. 93
Swing Unit
Removal and Installation of Swing Unit .................................................................. 103
Assembly and Disassembly of Swing Unit.............................................................. 108
Assembly and Disassembly of Swing Motor........................................................... 114
Assembly and Disassembly of Swing Reduction Gear........................................... 134
Planetary Carrier No.1 Assembly Diagram............................................................. 155
Planetary Carrier No.2 Assembly Diagram............................................................. 155
Center Joint
Removal and Installation of Center Joint ................................................................ 156
Counterweight
Removal and Installation of Counterweight ............................................................ 161
Hydraulic Pump
Removal and Installation of Hydraulic Pump .......................................................... 163
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit............. 171
Pump Main Unit Maintenance Standards ............................................................... 179
Procedures for Assembly and Disassembly of Regulator....................................... 190
Remote Control Valve

Removal and Installation of Operation Remote Control Valve................................ 199
Procedures for Assembly and Disassembly of Operation Remote Control Valve... 208
Removal and Installation of Travel Remote Control Valve ...................................... 221
Procedures for Assembly and Disassembly of Travel Remote Control Valve ......... 224
SSM-00-00-004EN 2
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Contents
Control Valve
Removal and Installation of Control Valve .............................................................. 244
Procedures for Assembly and Disassembly of Control Valve ................................. 250
Other Valves
Removal and Installation of 5 Stack Solenoid ........................................................ 276
Removal and Installation of Cushion Valve............................................................. 280
Assembly and Disassembly of Cushion Valve ........................................................ 284
Radiator and Oil Cooler

Removal and Installation of Radiator...................................................................... 291
Removal and Installation of Oil Cooler .........................................................................
Tank
Removal and Installation of Hydraulic Oil Tank....................................................... 304
Removal and Installation of Fuel Tank..........................................................................
Attachments
Removal and Installation of Bucket......................................................................... 316
Removal and Installation of Bucket Link .......................................................................
Removal and Installation of Bucket Cylinder ................................................................
Removal and Installation of Arm Cylinder.....................................................................
Removal and Installation of Arm...................................................................................
Removal and Installation of Boom Cylinder..................................................................
Removal and Installation of Boom ................................................................................
Removal and Installation of Arm HBCV........................................................................
Removal and Installation of Boom HBCV .....................................................................
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder ..............
Lights
Removal and Installation of Boom Light ................................................................. 376
Removal and Installation of Tool Box Light ...................................................................
Procedures for Removal and Installation of Cab Inner and Outer Parts
Removal and Installation of Cab Assembly ............................................................ 378
Removal and Installation of Operator's Seat ................................................................
Removal and Installation of Wiper ................................................................................
Removal and Installation of Wiper Controller ...............................................................
Removal and Installation of Wiper Motor......................................................................
Removal and Installation of Monitor .............................................................................
Removal and Installation of Cab Front Glass ...............................................................
Window Lock Adjustment Procedures ..........................................................................
3 SSM-00-00-004EN
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Contents
Hydraulic Equipment-related Parts
Accumulator............................................................................................................ 399
Suction Filter.................................................................................................................
Return Filter..................................................................................................................
Pilot Filter......................................................................................................................
Other
Removal and Installation of Side Door ................................................................... 405
Draining Oil from Hydraulic Oil Tank.............................................................................
SSM-00-00-004EN 4
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Engine

Engine Oil
Warning ・ Keep away from fire.
Caution ・ Be sure to stop the engine before beginning work.
Items to prepare
• Wrench (19 mm)
• Specialty plug (drainer plug)
• Waste oil can
• Rag
• Cleaning fluid
1. Engine Oil Draining
[1] Use a wrench (19 mm) to loosen the 2 bolts (1),
and then move the under cover (2) in the direc-
tion of the arrow.
[2] Remove the drain cap (3).

• The diagram on the right has the cover removed
so that the layout can be understood.
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[3] Prepare the waste oil can (4).
[4] When the drainer plug (5) is screwed in, engine
oil will drain.
2. Engine Oil Filling

[1] Remove the drainer plug used for draining oil.
[2] Attach the drain cock cap removed when oil was
drained.
[3] Fill at the feed port (2) with new engine oil. Next,
wait about 15 min. for the oil to completely travel
down to the oil pan, remove the oil level gauge
(1), and wipe the tip of the gauge off with a rag
before fully inserting the gauge again.
[4] Gently pull out the oil level gauge (1). If oil is
adhered to the area between the "upper limit
(3)" and "lower limit (4)", this indicates the oil
volume is correct (5).
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3. Inspection After Engine Oil and Element Replacement
Oil leak inspection
[1] Start the engine.
Slowly raise the rotation from idling rotation.
[2] Check the oil pan drain cock and each installation section of the oil filter for oil leaks.
Rechecking the engine oil volume
Stop the engine and wait 10 - 20 min. to recheck the engine oil volume. If the volume is low, fill up
with oil to the stipulated level.
The oil level will decrease due to engine oil entering the oil filter and oil path when the engine is
started.
Refill with oil if the oil level is low.
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Removal and Installation of Engine Oil Filter Element
Items to prepare
• Filter wrench
• Rag
• Cleaning fluid
1. Removal of Oil Filter Element
[1] Use a filter wrench (1) to remove the oil filter
element (2).
2. Installation of Oil Filter Element

Use the following procedure to install a new car-
tridge.
[1] Apply a thin layer of engine oil to the cartridge
gasket.
[2] After the cartridge is screwed in and the gasket
is touching the seal surface, use the filter
wrench to tighten the cartridge 1 rotation.
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Fuel Filter
・ When the fuel tank has been emptied, water drained from the fuel, the filter or element
Caution replaced, or other such work carried out, always bleed the air.
・ Be sure to stop the engine before beginning work.
Items to prepare
• Wrench (10 mm)
• Filter wrench
• Waste oil can
• Rag
• Cleaning fluid
[1] Tighten the cock (1).

[3] Use a wrench (10 mm) to loosen the air bleed
plug (3).
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[4] Remove the drain plug (4).
[5] Drain the fuel.
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[6] Use the filter wrench (5) to remove the cover
(6).
[7] Replace the element (7) and O-ring (8).

The O-ring cannot be reused. Always replace it
with a new one.
[8] After replacing the filter, use the filter wrench (5)
to attach the cover (6).
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plug (3).
[10] When the filter case priming pump (9) is turned
in the direction of the arrow, the knob pops out.
[11] Move the priming pump in and out until the fuel
filter is filled with fuel (more than 10 times).
When fuel appears inside the filter case, lightly
tighten the air bleed plug (3). Press the knob a
few times in this state.
Finally, hold the knob pressed in and slightly
loosen the air bleed plug.
Fuel oozes out from the hose (10) like bubbles.
[12] Repeat the operation in [11] until no more bub-
bles appear.
[13] Tighten the air bleed plug, and then turn the
knob and lock it.
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Charge Fuel Pump Filter
Items to prepare
• Box wrench (19 mm)
• Wrench (10 mm)
• Pliers
• Cap
• Rag
• Cleaning fluid
[1] Use a box wrench (19 mm) to remove the 2

bolts (1) and washer (2), and then remove the
cover (3).
[2] Remove the connector (4).
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[3] Use pliers or another tool to loosen the hose
bands (5), and then remove the hoses (6) and
(7).
• Use caps to cover the charge fuel pump filter
and hoses to prevent the entry of water, dust or
dirt.
[4] Use a wrench (10 mm) to remove the 2 installa-

tion bolts (8), and then turn the filter cover (9) to
the left and remove the element (10).
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Removal and Installation of Fan Belt
Items to prepare
• Wrenches (14 mm, 17 mm)
• Rag
• Cleaning fluid
[1] Remove the air conditioner belt.

(For details, see "Removal and Installation of Air
Conditioner Belt".)
[2] Use a wrench (14 mm) to remove the 3 bolts
(1).
[3] Use a wrench (14 mm) to remove the bolt (3),

and then remove the bracket (4).
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[4] Remove the fan guard (2).
[5] Use a wrench (17 mm) to loosen the nut (5).
[6] Use a wrench (17 mm) to loosen the tension

bolt (6).
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[7] Use a wrench (17 mm) to remove the nut (5),
and then remove the tension bolt (6).
[8] Pass the fan belt (7) over each of the fans and
remove it.
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Removal and Installation of Air Conditioner Belt
Items to prepare
• Wrench (19 mm)
• Rag
• Cleaning fluid

(2), and then remove the under cover (1).
[2] Use a box wrench (14 mm) to loosen the nut (3).
[3] Use a box wrench (14 mm) to loosen the ten-

sion bolt (4), and then remove the air condi-
tioner belt (5).
SSM-06-10-004EN 14
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Engine

Removal and Installation of Engine Hood
・ Do not perform this operation in strong wind.
Caution ・ Be sure to inspect the nylon sling and other lifting equipment before beginning work.
・ Do not stand or pass under the suspended load.
Items to prepare
• Wrench (19 mm)
• Nylon sling (with the required breaking load)
• Liftcrane (with the required lifting capacity)
[1] Open the engine hood, and then remove the
Matsuba pin (1) and the flat washer (2).
[2] Pull out the lock arm (4) from the engine hood
(3).
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[3] After closing the engine hood, use a wrench (19

mm) to remove the 9 bolts (5) from the engine
hood.
[4] Wrap the nylon sling (6) around the engine

hood, and then use the liftcrane to lift the engine
hood (7).
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Removal and Installation of Engine Assembly
・ Keep away from fire.
・ Be sure to release hydraulic pressure before beginning work.
Warning ・ The air conditioner circuit is filled with high-pressure gas, so there is the danger of gas spray-
ing out when loosening lines.
・ Do not use open flames and do not allow sparks near the battery.

Caution ・ Be sure to inspect the wire rope and other lifting equipment before beginning work.
Items to prepare
• Wrenches (7 mm, 8 mm, 13 mm, 14 mm, 17 mm, 19 mm, 36 mm)
• Shackle (with the required lifting capacity) × 2
• Wire ropes (with the required breaking load)
• Marking pen
• Cap
• Plug
• Waste oil can
• Rag
• Cleaning fluid
• Wood planks, etc.
[1] Drain the engine oil.

(For details, see "Engine Oil".)
[2] Drain the coolant from the radiator.
(For details, see "Removal and Installation of
Radiator".)
[3] Remove the engine hood.
Engine Hood".)
[4] Remove the hydraulic pump.
Hydraulic Pump".)
(1).
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(2), and then remove the bracket (3).
[8] Use a wrench (19 mm) to remove the 4 bolts,

and then remove the fan guide rubber (5).
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[9] Use a wrench (8 mm) to loosen the hose band
(6) on the radiator, and then remove the upper
hose (7).

(6) on the radiator, and then remove the lower
hose (8).
• Use caps to cover the radiator and hoses to pre-
vent the entry of water, dust or dirt.
• Before removing the radiator hoses, completely
drain the coolant.
[11] Use a wrench (13 mm) to loosen the line bolts

(9) in 2 locations, and then remove the 2 lines
(10) and (11) from the compressor.
• Always remove the low-pressure (suction side)
line (10) first.
• Attach caps or plugs to the compressor and
lines to prevent any entry of water, dust or dirt.
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(12) on the inter cooler, and then remove the
hose (13).
• Use caps to cover the lines and hoses to pre-

• Use caution when removing as the parts are
heavy.

• Drain the engine oil before removing the engine
oil hose.
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[15] Use a wrench (36 mm) to remove the 2 engine
oil remote hoses (17).
• Mark the engine and hoses so that the connec-
tors match at the time of assembly.
• Attach caps or plugs to the engine and hoses to
prevent any entry of water, dust or dirt.
• Clean the engine and hoses by spraying them
with a parts cleaner to prevent scratches and
prevent dirt from accumulating on the connec-
tors.

and then remove the battery cable (19) on the
negative side.
• When removing the terminal and harness,
secure them so that they do not interfere with
the frame.
Also, cover with a rubber cap to protect against
sparks.

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[18] Use a wrench (8 mm) to remove the 2 nuts (22),
and then remove the wiring (23) from the starter
motor.
[19] Remove the hose band (24), and then remove

the fuel hose (25).
[20] Remove the hose band (26), and then remove

the fuel hose (27).
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(28), and then remove the box cover (29).
[22] Remove the connectors (30) in the box.

• Wrap the removed connectors in plastic after
tying them together to prevent any entry of
water, dust or dirt.

(31), and then remove the heater hose (32).
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(33), and then remove the heater hose (34).

(35), and then remove the radiator hose (36).
vent any entry of water, dust or dirt.

(37), and then remove the air hose (38).
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(39), and then remove the air hose (40).
[28] Remove the connectors (41) from the alternator.
[29] Remove the cap (42), use the wrench (10 mm)
to remove the nut (44), and then remove the
alternator wiring (43).
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[30] Install the 2 shackles (45), and then use the
wire rope (46) and liftcrane to secure the engine
main unit.

bolts (47) from the mount.
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[32] Use the wire rope (48) and liftcrane to lift the
engine main unit.
[33] Thoroughly check that the location is safe
before lowering the engine on wood planks, etc.
[34] To install the engine, perform the reverse of the removal procedure.
After installing the engine, resupply coolant and engine oil, perform fuel line air bleeding, and per-
form filling for the air conditioner gas.
For details, see the individual explanations for each procedure.
[35] Run the engine at no-load idling and check for any water or oil leaks.
[36] Attach the hydraulic pump, covers, and counterweight.
For details, see the individual explanations for each procedure.
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Removal and Installation of Starter Motor
Warning ・ Do not use open flames and do not allow sparks near the battery.
Items to prepare
• Wrenches (8 mm, 14 mm, 17 mm, 19 mm)
• Rag
• Cleaning fluid

negative side.
the frame.
sparks.

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and then remove the wiring (6).

and then remove the wiring on the ground side
(8).

and then remove the starter motor (10).
[6] To install, perform the reverse of the removal

procedure.
Mount nut tightening torque: 82.4 N•m
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Removal and Installation of Alternator
Warning ・ Do not use open flames and do not allow sparks near the battery.
Items to prepare
• Wrenches (10 mm, 17 mm, 20 mm)
• Rag
• Cleaning fluid
[1] Remove the fan belt.

Fan Belt".)
negative side.
the frame.
sparks.
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[4] Remove the cap (5), use the wrench (10 mm) to
remove the nut (6), and then remove the wiring
(4).

and then remove the alternator (8).
[6] To install, perform the reverse of the removal

procedure.
Adjust the fan belt according to the tension
adjustment procedures.
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Removal and Installation of Supply Pump
Warning ・ Be sure to release hydraulic pressure before beginning work.
Each part of the fuel system is a high-precision part.

Caution Damage may result if foreign matter, etc. enters the fuel system, so use extreme caution when
handling these parts.
When high-pressure lines in the fuel system are removed, replace them with new lines.
Replace gaskets or O-rings with new ones.
Warning Fuel leaks may cause fires. Thoroughly wipe off fuel after work is completed, and carefully
check for any leaks after starting the engine.
Items to prepare
• Wrenches (10 mm, 14 mm, 17 mm, 19 mm, 22 mm)
• Gear puller
• Cap
• Plug
• Rag
• Cleaning fluid
1. Removal of Supply Pump
and then remove the hole cover (2).
[2] Turn the crankshaft in the correct rotation direc-

tion and align the reference mark of the 1st or
4th cylinder with the compression top dead cen-
ter position.
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[3] Use a wrench (19 mm) to remove the sleeve nut
(3), and then remove the injection pipe (4).
• Use caps and plugs to cover the lines to prevent
any entry of water, dust or dirt.
• Clean the line by spraying with a parts cleaner
to prevent scratches and prevent dirt from accu-
mulating on the connectors.
[4] Remove the fuel hose (5).

[5] Use a wrench (14 mm) to remove the 3 eyebolts

(6), and then remove the leak-off pipe (7).
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[6] Remove the connectors (8) and (9).
[7] Use a wrench (22 mm) to remove the eyebolt
(10) on the fuel pipe (11).

[9] Use a wrench (17 mm) to remove the bolts (13)
and (14).
[10] Remove the supply pump assembly (15).
• Use caps and plugs to prevent any entry of
• Clean the assembly by spraying it with a parts
cleaner to prevent scratches and prevent dirt
from accumulating on the connectors.
[11] Remove the nut securing the supply pump gear

(18) and use the gear puller (17) to remove the
gear from the supply pump assembly (19).
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[12] Remove the 3 bolts (21), and then remove the
supply pump (22) from the bracket (20). Also
remove the O-ring (23) at the same time.
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2. Installation of Supply Pump
[1] Install the O-ring (2) on the supply pump (1).
Install the pump on the bracket (3) and tighten
the 3 bolts (4) to the specified torque.
Tightening torque: 19 N•m
[2] Align the key of the supply pump shaft with the
gear (5), install the gear, and tighten the nut (6)
to the specified torque.
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[3] A reference mark circle has been stamped onto
the end face surface of the gear.
Paint the upper part of the gear tooth just above
the stamped "0" mark white.
This paint is very important for checking the cor-
rect position.
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[4] Install the O-ring (7) on the supply pump
assembly (8).
Align the supply pump gear position with the ref-
erence mark (0 mark) on the gear end face sur-
face and the slit on the pump bracket side.
Install the supply pump assembly on the engine
so that the alignment position is correct.
Temporarily tighten the bolts (10) and (11) and
the nut (9).
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[5] When looking from the plug hole, check that the
gear tooth with the white paint reference mark
(0 mark) and white paint is at the center of the
hole and in the position shown in the diagram.
If alignment is not correct, adjust the gear posi-
tion again and install the pump on it.
Temporarily tighten bolts (10) and (11) and nut
(9) to the specified torque.
Tightening torque
Nut: 50 N•m
Bolt: 76 N•m
[6] Install the hole cover (13) in the plug hole.

Tighten the bolt (12) to the specified torque.
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[7] Connect the connectors (14) and (15).
Install the line (17) with the eyebolt (16).
[8] Install the leak-off pipe (18) with the 3 eyebolts

(19).
• Be careful not to allow entry of any water, dust
or dirt.
Always replace seals.
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[9] Install the fuel hose (20).
or dirt.
[10] Install the injection pipe (22). This injection pipe

cannot be reused, so always replace it with a
new one.
Tighten the sleeve nut (21).
or dirt.
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Removal and Installation of Common Rail
Items to prepare
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
See Removal and Installation of Supply Pump for procedures for removal and installation of the oil level
gauge pipe, intake hose, manifold, etc.
[2] Use a wrench (14 mm) to remove the 3 eyebolts

(2) and (3) on the leak-off pipe (4), and then
remove the leak-off pipe.
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and then remove the fuel pipe (5).
[4] Use a wrench (17 mm) to remove each sleeve
nut (6) in the 6 locations.
• Replace the removed line in the same way as
the common rail.

and nuts (9).
[6] Remove the common rail (10).
[7] To install the common rail, perform the reverse of the removal procedure.
High-pressure lines that have been removed cannot be reused.
Always replace them with new ones.
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Removal and Installation of Injector
Warning Do not use open flames and do not allow sparks near the battery.
Warning Injector wiring is high voltage wiring, so make sure to remove the battery.
Caution ・ Be careful not to drop any removed parts inside the engine.
Items to prepare
• Pliers
• Marking pen
• Torx wrench (T40)
• Cap
• Plug
• Waste oil can
• Rag
• Cleaning fluid
1. Removal of Injector
Removal and installation of the No. 1 injector is explained here as a representative example. Use
the same procedure for other cylinder injectors.
Be extremely careful when handling injectors. The nozzle tips are especially delicate. Hitting the
nozzles or wiping them with a rag may cause the hole to clog. Also, injector wiring use high voltage,
so make sure to remove the battery terminals before beginning work.
High-pressure lines, seals, and packing that have been removed cannot be reused, so always
replace them with new parts.
negative side.
the frame.
sparks.
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(3), and then remove the step (4).
[3] Use pliers to loosen the hose band, and then

remove the blow-by hose (5).
• Use caps and plugs to cover the hoses and
[4] Remove the connectors (6) in the 2 locations.
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(7) on the cylinder head cover (8), and then
remove the cylinder head cover.
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[7] Use a wrench (7 mm) to remove the 2 nuts (11)
at each of the 6 injector terminal locations.
[8] Use a wrench (14 mm) to loosen the 4 bolts
(10), and then remove the harness bracket (12).
• When removing the nuts, loosen them equally a
little bit a time to simultaneously remove them.
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[9] Use wrenches (12 mm, 17 mm) to remove the 7
bolts (13) and (14) and the 7 gaskets (15) and
(16), and then remove the nozzle leak-off pipe
(17).
[10] Use a wrench (10 mm) to remove the bolt (18)

on the line clamp (21).
(19) of the injector-side line.
(20) of the common rail-side line.
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[13] Use a Torx wrench (T40) to remove the bolt (22)
on the injector clamp (24).
[14] Remove the injector (23).
[15] Use the injector remover (26) when it is difficult

to remove the injector (27).
Install the injector remover on the injector line
connection section. Also connect the sliding
hammer (25) and then remove the injector.
1) Sliding hammer
Isuzu part No.: 5-8840-0019-0
2) Injector remover
Isuzu part No.: 5-8840-2826
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2. Installation of Injector
[1] Record the "QR code" (2) that appears on the
top of the QR plate (1) of the replacement injec-
tor (3).
The "QR code" is different for each injector, so
match the cylinder to be installed with the injec-
tor and record the code.
[2] Always replace the gasket (5) and O-ring (7).

Apply Molybdenum to the threaded section of
the bolt (4) on the injector clamp (6) and seating
surface.
Install the injector (3) on the cylinder head. As
shown in the diagram, insert the injector by
pressing it in with the clamp. Temporarily tighten
the bolt on the injector clamp.
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[3] Apply a small amount of engine oil to the out-
side surface of the injector-side sleeve nut (10).
Install the line.
Carefully tighten each of the sleeve nuts (9) and
(10) until the line is touching the common rail
and injector.
Tighten the bolt (8) on the line clamp (11) to the
specified torque.
Fully tighten the bolt (4) on the injector clamp to
the specified torque.
Tighten the line sleeve nuts to the specified
torque.
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[4] Install the nozzle leak-off pipe (16) with the bolts
(12) and (13).
Replace the gaskets (14) and (15).
Tighten each of the lines to the specified torque.
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[5] Secure the harness bracket (19) with the bolts
(17).
Secure the bolts in sequence from the inside to
the outside.
[6] Install the injector terminal nuts (18) on each
injector.
Tighten to the specified torque.
Be careful not to tighten the nuts too much.
Tightening all at once with a ratchet wrench,
etc. may cause damage to the terminal stud.
[7] Connect the injector harness connector (20).
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[8] Install the head gasket (24) on the cylinder head
cover (23) and tighten with each of the bolts
(21) and nuts (22).
Tighten in the order shown in the diagram.
Specified torque: 13 N•m
[9] Connect the connectors (25).
[10] Install the blow-by hose (26).
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[11] Install the negative-side battery cable (28) ter-
minal.
Be careful of shorts with the terminal and har-
ness.
27 Bolt
[12] When replacing an injector (3) with a new one, make sure to enter the QR code of the replaced
injector into the ECM.
[13] See the Service Text for this procedure.
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Removal and Installation of Muffler
・ The engine is extremely hot just after stopping. Wait for it to sufficiently cool before beginning
Warning work.
Items to prepare
• Wrench (14 mm)
• Cap
• Rag
• Cleaning fluid
1. Removal of Muffler
[1] Use a wrench (14 mm) to loosen the nut (2) to
remove the 2 bolts (1), remove the seal clamp
from the exhaust pipe, and then remove the line.
• Use caps to cover the lines to prevent any entry
of water, dust or dirt.
[2] Use a wrench (14 mm) to remove the 2 nuts (3).
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[3] Remove the U-bolts (4), and then remove the
muffler (5).
2. Installation of Muffler
Perform the reverse of the removal procedure.
After installation, check for any leaks or vibration.
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Removal and Installation of Turbo Charger
The engine is extremely hot just after stopping.
Warning Wait for them to sufficiently cool before beginning work.
Items to prepare
• Cap
• Plug
• Rag
• Cleaning fluid
1. Removal of Turbo Charger
The engine oil line and coolant line will be removed, so either drain the engine oil and coolant
beforehand or use caps on the ends of the lines to prevent leaking.
(1), and then remove the intake hose (2).
• Use caps to cover the turbo charger and hoses
to prevent any entry of water, dust or dirt.

(3), and then remove the hose (4).
• Use caps to cover the turbo charger and hoses
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[3] Use a wrench (14 mm) to remove the eyebolt
(5), and then remove the oil feed pipe (6).
• Use caps and plugs to cover the turbo charger
and oil feed pipe to prevent any entry of water,
dust or dirt.
• When removing the oil feed pipe, take care not
to damage or lose the packing.

(7), and then remove the oil return pipe (8).
Use caps and plugs to cover the turbo charger
and oil return pipe to prevent any entry of water,
dust or dirt.

and then remove the turbo charger (10).
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[6] Use a wrench (13 mm) to remove the 8 nuts
(11), and then remove the line (12) from the
turbo charger main unit.
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2. Installation of Turbo Charger
To install, perform the reverse of the removal procedure. During installation, replace each gasket
and the packing with new ones.
Make sure to check the engine oil and coolant levels and resupply as necessary.
Each of the installation tightening torque values are indicated below.
Check carefully for exhaust leaks, water leaks, and oil leaks.
1 Oil feed pipe -

2 Exhaust manifold -
3 Turbo charger assembly 52 N•m
4 Exhaust adapter 32.4 N•m
5 Oil return pipe 17.6 N•m
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Removal and Installation of EGR Cooler and EGR Valve
The engine is extremely hot just after stopping.
Warning Wait for them to sufficiently cool before beginning work.

Caution ・ Be sure to drain coolant before beginning work.
Items to prepare
• Wrench (12 mm)
• Pliers
• Cap
• Plug
• Rag
• Cleaning fluid
1. Removal of EGR Cooler and EGR Valve
(1).
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(2).

and (4).
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[4] Use pliers to loosen the hose band (5) to
remove the hose (6), and then remove the EGR
cooler (7).
• Use caps and plugs to cover the lines and
hoses to prevent any entry of water, dust or dirt.
[5] Use a wrench (12 mm) to remove the nuts (9),

and then separate the manifold (8) and the EGR
cooler (7).

Use a wrench (12 mm) to remove the bolts (11),
and then remove the EGR valve (12).
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2. Installation of EGR Cooler and EGR Valve
To install, perform the reverse of the removal procedure. During installation, replace gaskets with
new ones.
Check that there is sufficient coolant and resupply as necessary. Each of the installation tightening
torque values are indicated below.
Check carefully for exhaust leaks and water leaks.
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Removal and Installation of Engine Sensors
Sensor name Bolt or nut Tool size Remarks
1 Engine coolant temperature sensor Lock nut × 1 Wrench (19 mm)
Bolt × 2 Wrench (10 mm)
2 Boost pressure sensor
Clip × 1 Pliers
Lock nut × 1 Wrench (22 mm)
3 Overheat switch
Wiring fastener nut Wrench (7 mm)
4 Common rail pressure sensor Lock nut × 1 Wrench (27 mm)
Installation screw
5 EGR valve DC motor Phillips screwdriver
×4
Tightening torque:
6 Boost temperature sensor Lock nut Wrench (19 mm)
82.4 N•m
7 Starter motor Installation nut × 2 Wrench (17 mm)
8 Engine hydraulic pressure sensor Lock nut × 1 Wrench (27 mm)
Hexagon wrench
9 Suction control valve Installation bolt × 2
(5 mm)
10 Fuel temperature sensor Lock nut × 1 Wrench (19 mm)
11 Cam position sensor Installation bolt × 1 Wrench (10 mm)
12 Crank position sensor Installation bolt Wrench (10 mm)
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Removal and Installation of Fuel Cooler
Caution ・ As the fuel hose will be removed, strictly prohibit open flames.
Items to prepare
• Wrench (12 mm)
• Screwdriver
• Pliers
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
• Drip pan
1. Removal of Fuel Cooler
[1] Mark the fuel cooler (5) and hoses (1) and (2)
so that the connectors match at the time of
assembly.
• Use pliers to loosen the hose bands (3) and (4),
and then remove the hoses.
• Fuel will spill out, so place a drip pan directly
below the area.
• Attach caps or plugs to the fuel cooler and

(6), and then remove the fuel cooler (5).
2. Installation of Fuel Cooler

[1] After connecting the hoses, carefully check for any fuel leaks.
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Removal and Installation of Engine Inter Cooler
Caution ・ As the fuel hose will be removed, strictly prohibit open flames.
Items to prepare
• Flathead screwdriver
• Wire cutters
• Cap
• Rag
• Cleaning fluid
1. Removal of Inter Cooler
[1] Remove the fuel cooler.
Fuel Cooler".)
(1), and then remove the bracket (2) from the
fuel cooler.
[3] Use a wrench (8 mm) or flathead screwdriver to

loosen the hose bands (3) in the 2 locations,
and then remove the 2 hoses (4) and (5).
• Use caps to cover the inter cooler and hoses to
prevent the entry of water, dust or dirt.
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(6), and then remove the inter cooler (7).
2. Installation of Inter Cooler

Check for any air leaks.
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Air Conditioner

Removal and Installation of Compressor
・ Be careful when loosening the lines. The air conditioner circuit is filled with high-pressure
Warning gas, so there is the danger of gas splaying out.

Caution ・ When removing and installing the compressor, check the compressor oil quantity.
Items to prepare
• Wrench (13 mm)
• Rag
• Cleaning fluid
1. Removal of compressor
[2] Use a box wrench (13 mm) to loosen the bolts

(2) on the lines in the 2 locations, and then
remove the 2 lines (3) and (4).
• Always remove the low-pressure side line (3)
first.
• Attach caps or plugs to the compressor and
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(5), and then remove the compressor (6).
2. Installation of compressor
[1] The installation procedure is the reverse of the removal procedure.
Compressor installation bolt tightening torque: 19.6 - 29.4 N•m
[2] Check the compressor oil quantity.
The compressor contains 135 cc of oil.
The oil quantity being low will cause compressor seizing and a reduction in durability. The oil
quantity being high will cause a reduction in cooling capabilities.
Make sure to check the oil quantity and adjust if needed.
Measure the oil quantity of the removed compressor. Only this oil quantity is necessary, so sub-
tract this quantity from 135 cc to determine the amount by which the oil quantity of the new com-
pressor should be reduced.
Example)
If the remaining oil quantity of the removed compressor is 30 cc:
Remove 135 cc - 30 cc = 105 cc from the new compressor to be installed.
Resupply oil: SP-10 or SP-20 (P.A.G. oil)
[3] Perform air conditioner gas charging.
For details, see "Gas Filling Procedures".
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Removal and Installation of Condenser
Caution ・ When removing and installing the condenser, resupply and check the compressor oil quantity.
Items to prepare
• Cap
• Plug
• Rag
• Cleaning fluid
1. Removal of condenser
[1] After opening the engine hood (1), use a

wrench (19 mm) to remove the top covers (2)
and (3).
5)

and then remove the center bar (5).
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[4] Use a wrench (17 mm) to press the lower line
on the condenser side (7), and then use a
wrench (19 mm) to loosen and remove the
sleeve nut of the low-pressure side line (6).
• Always remove the low-pressure side line first.
• Attach caps or plugs to the condenser and line
[5] Use a wrench (22 mm) to press the upper line

on the condenser side (9), and then use a
wrench (22 mm) to loosen and remove the
sleeve nut of the high-pressure side line (8).
• The "H" cap indicates the high-pressure side
line.
• Attach caps or plugs to the condenser and line

(10), and then remove the condenser (11).
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2. Installation of condenser
[1] To install, perform the reverse of the removal procedure.
High-pressure side line tightening torque: 19.6 - 24.5 N•m, Low-pressure side line tightening
torque: 11.8 - 14.7 N•m
[2] Make sure to resupply and check the compressor oil quantity.
Resupply quantity: 40 cc
For details, see "Procedures for Gas Filling".
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Removal and Installation of Receiver Dryer
Caution ・ When replacing the receiver dryer, resupply and check the compressor oil quantity.
Items to prepare
• Cap
• Plug
• Rag
• Cleaning fluid
1. Removal of receiver dryer
(1), and then remove the stay (2).
(1), and then remove the top cover (3).
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[4] Use a wrench (10 mm) to remove the 2 bolts (5)
from the line (6).
• Attach caps or plugs to the receiver dryer and
line to prevent any entry of water, dust or dirt.
• Clean the receiver dryer and line by spraying
them with a parts cleaner to prevent scratches
and prevent dirt from accumulating on the
connectors.
[5] Use a wrench (10 mm) to remove the 1 bolt (7),

and then remove the receiver dryer (8).
2. Installation of receiver dryer

[1] To install, perform the reverse of the removal procedure.
Receiver dryer installation bolt tightening torque: 19.6 - 24.5 N•m
[2] Check the compressor oil quantity.
Resupply quantity: 20 cc
For details, see "Procedures for Gas Filling".
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Assembly and Disassembly of Unit
Caution ・ When replacing the evaporator, resupply and check the compressor oil quantity.
1. Removal of blower unit

[1] Remove the connectors connected
to the refresh/recirculate motor
actuator, blower motor, blower con-
troller, and inside air sensor, and
also the harness installed on the
blower case.
[2] Remove the inside air filter (8) from

the intake duct (12), and remove the
3 T4 × 14 (T1) Phillips screws (16)
to remove the intake duct.
[3] Remove the filter clog sensor (11)
along with the nylon clip (17) from
the intake case (13).
[4] Remove the 4 T5 × 14 (T1) Phillips
screws (14) and remove the intake
case (13).
[5] Remove the 3 T5 × 14 (T1) Phillips
screws (18) and separate the blower
case (10) and air conditioner unit.
1 Evaporator sensor connector

2 Blower controller connector
3 Blower motor connector
4 Harness
5 Filter clog sensor
6 Refresh/recirculate motor actuator connector
7 Inside air sensor connector
9 Unit
15 Inside air sensor
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2. Replacement of blower motor
[1] Remove the coolant hose (4) connecting the
blower motor (5) and the blower case (6).
[2] Remove the 3 N5 × 16 (W) Phillips screws (3)
installed at the bottom of the blower unit case
and remove the blower motor (5).
[3] The installation procedure is the reverse of the
removal procedure.
Do not remove the fan from the
Caution blower motor.
3. Replacement of blower controller
[1] Remove the 2 T4 × 14 (T1) Phillips screws (2)
installed at the bottom of the blower case and
remove the blower controller (1).
[2] The installation procedure for the new blower
controller (1) is the reverse of the removal pro-
cedure.
Never disassemble the blower con-
Caution troller.
4. Removal of heater core
[1] Drain the coolant.
[2] Remove the 1 N5 × 16 (T2) Phillips screw (2),
and remove the pipe clamp (3) fixing the heater
core (4) to the unit (1) to remove the heater core
from the unit.
[3] The installation procedure is the reverse of the
removal procedure.
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5. Removal of air conditioner unit case front, rear and bottom
[1] Remove the mode motor actuator (4) and evap-
orator sensor connector.
[2] Remove the mode rod (1) from the rod holder
installed on the mode motor actuator (4) lever
MAL 1 (3).
[3] Remove the 3 N4 × 30 (T1) Phillips screws (6)
and remove the mode motor actuator (4)
installed on the bottom (5) and rear (7) of the
unit case.
[4] Remove the 11 N5 × 16 (T2) Phillips screws (8)

and remove the bottom (5) and front (12) of the
unit case.
While being careful not to let the evaporator
sensor cord get caught by the case, pull the
front of the unit case upwards to remove it.
At this time, perform work with the
Caution heater core removed from the unit
case.
2 Rod holder
9 Evaporator sensor
10 Expansion valve
11 Evaporator
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6. Replacement of evaporator and expansion valve
[1] Remove the evaporator assembly from the bot-
tom of the case with the case heat insulating
material and expansion valve attached to the
evaporator.
[2] After removing the case heat insulating material
from the top and bottom of the evaporator
assembly, remove the evaporator sensor (1) as
one piece with the sensor holder.
[3] Use a hexagon wrench (4 mm) to remove the 2
M5 × 40 hexagon socket head bolts (2), and
remove the expansion valve (3) from the evapo-
rator (5).
[4] Install O-rings (4) on the new evaporator (5) (1
NF O-ring 5/8 and 1 NF O-ring 1/2).
(Tightening torque 6.9 N•m)
Be careful of the O-rings getting
Caution caught, etc. when installing the
expansion valve.
7. Installation of evaporator sensor

[1] Make sure to install the evaporator sensor (1) in
the original position of the evaporator (2), as in
the diagram.
Be careful that the sensor cord does
Caution not get squeezed in the case when
the case is assembled.
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8. Replacement of motor actuator
[1] Replacement of mode motor actuator
Remove the connector connected to the motor
actuator (4).
Remove the mode rod (1) connecting the motor
actuator and mode cam from the rod holder (2).
Remove the 3 N4 × 30 (T1) Phillips screws (6)
that are used to install the motor actuator,
remove the motor actuator from the unit with the
rod holder and lever MAL 1 (3) attached to the
actuator, remove the rod holder and lever MAL 1
from the motor actuator, and then install the
new motor actuator. The installation procedure
is the reverse of the removal procedure.
[2] Replacement of air mix motor actuator
actuator (11).
Remove the AM rod (9) connecting the motor
actuator and lever AM (8) from the rod holder
(10).
that are used to install the motor actuator,
rod holder and lever MAL 1 (12) attached to the
actuator, remove the rod holder and lever MAL 1
from the motor actuator, and then install the
5 Unit case bottom
7 Unit case rear
[3] Replacement of refresh/recirculate motor actua-

tor
actuator (15).
that are used to install the motor actuator and
lever MAL 2 (14) attached. Remove the lever
MAL 2 from the motor actuator and install the
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Air Conditioner

Work Precautions
・ Refrigerant gas filling involves handling dangerous high-pressure gas, so make sure that a
experienced and qualified worker with the procedure performs this operation.
・ Always wear protective eyewear.
Warning ・ Gas entering the eyes may cause blindness.
・ Refrigerant in the liquid state is very cold (about -26 ℃ , so be very careful during handling.
・ Refrigerant coming in contact with skin may cause frostbite.
Always use R134a refrigerant.

• Storage
Keep service cans (hereinafter, cans) with refrigerant in them at 40 ℃ or below.
The insides of the cans are highly pressurized and filled with refrigerant, so if the temperature rises
there is the danger of internal pressure rising sharply and an explosion occurring.
Never store in direct sunlight, in a closed vehicle, or near open flames.
Be careful not to drop cans or have them collide with other objects.
• Filling operation
When cans are heated in order to fill them with refrigerant, make sure that the service can valve and
gauge manifold low-pressure valve are open and heat with water at 40 ℃ or below.
Direct heating or heating to 40 ℃ or higher may cause explosions, so use caution.
If refrigerant filling is done after the engine is started, never open the gauge manifold high-pressure
valve.
This is very dangerous, as the high-pressure gas will flow in the opposite direction and may cause a
can or charging hose explosion.
Be careful not to allow the entry of dust or dirt into the air conditioner circuit.
Air, moisture and dirt are very bad for the cooling cycle.
Perform work quickly and accurately, and be especially careful to prevent the entry of foreign matter.
Be careful not to overfill with gas.
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Work Procedures
1. Air conditioner refrigerant filling is divided into the "vacuum operation" and "gas filling oper-
ation".
[1] The "vacuum operation" consists of eliminating moisture in the air conditioner circuit.
If there is any moisture left inside the air conditioner circuit, various problems may occur during
operation such as freezing in the small hole of the expansion valve causing the circuit to clog and
rust developing in the circuit.
For this reason, perform vacuuming before filling the circuit with refrigerant. This operation con-
sists of eliminating moisture inside the circuit through boiling and evaporation.
[2] The "gas filling operation" consists of filling the circuit with refrigerant after the vacuum operation.
Gas filling does not only affect the cooling capabilities of the air conditioner, it also affects the life
of the parts which make up the circuit.
Severely overfilling the circuit will cause pressure inside the circuit to be abnormally high, and
this will cause reductions in the cooling ability of the air conditioner.
Additionally, if pressure is extremely low, the circulation of lubricating oil within the compressor
will be poor and this will cause seizing with sliding parts of the compressor.
Because the gas filling operation itself involves handling high-pressure gas, performing the oper-
ation using an incorrect procedure is very dangerous.
Follow the operation and observe all precautions indicated in this text to correctly perform refrig-
erant filling.
2. Operation chart
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3. Tools
No. Part name Q'ty Shape Application
1 Gauge manifold 1
Red: high-pressure side

2 Charging hose 3 Blue: low-pressure side
Yellow: vacuum pump side
3 Quick joint 1
4 Quick joint 1 Low-pressure side
5 T joint 1 For service can valve
6 Service can valve 2 For service can
7 Vacuum pump adapter 1 For vacuum pump
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Filling Procedures
・ Because gauge manifold specifications such as hose color are different depending on the
Caution manufacturer, read the Operator's Manual for the gauge manifold to be used for details.
1. Charging hose connection positions
1 High-pressure side (DIS) service valve

2 Low-pressure side (SUC) service valve
3 Air conditioner compressor
4 Condenser
5 Receiver dryer
6 Air conditioner unit
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2. Gauge manifold connection
[1] Close the high-pressure valve (HI) (8) and low-pressure valve (LO) (7) of the gauge manifold (9).
[2] Connect the charging hoses (red and blue) to the service valve.
Red hose (10): Gauge manifold high-pressure side (HI) → compressor high-pressure side (DIS)
service valve (1)
Blue hose (11): Gauge manifold low-pressure side (LO) → compressor low-pressure side (SUC)
service valve (2)
Push in the connections for the high-pressure and low-pressure sides until a "click" is heard to
make sure they are secure and in the correct position.
[3] Connect the charging hose (yellow) (3) to the vacuum pump (4).
5 Low-pressure gauge
6 High-pressure gauge
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3. Vacuuming
[1] Open the high-pressure valve (HI) (8) and low-
pressure valve (LO) (7) of the gauge manifold
(9).
[2] Turn the vacuum pump (4) switch on and vac-
uum for at least 30 min.
[3] After the prescribed vacuuming time has
elapsed (degree of vacuuming achieved: -750
mmHg or less), close the gauge manifold (9)
high-pressure valve (8) and low-pressure valve
(7).
[4] Next, turn the vacuum pump (4) switch off.
[5] Perform a check of air-tightness.
Let the gauge manifold (1) sit for at least 5 min.
with the high-pressure valve (3) and low-pres-
sure valve (2) closed, and check that the gauge
indicator does not go back to 0.
If the gauge indicator starts to swing back to 0,
this indicates there is a leak. Tighten the line
connections, perform vacuuming again, and
check to see if there is still a leak.
4. Gas filling operation, high-pressure side
First, start the filling operation from the high-pressure side.
[1] After repeating vacuuming, switch the charging
hose (yellow) (3) of the gauge manifold (9) from
the vacuum pump to the service can (12).
[2] Air purging
Open the valve for the service can (13). (How-
ever, keep the gauge manifold high-pressure
and low-pressure valves closed.) Next, press
the air purge valve (14) of the side service port
on the gauge manifold low-pressure side with a
screwdriver to discharge the air inside the
charging hose using the refrigerant pressure.
(Complete after the swooshing sound stops.)
[3] Open the high-pressure valve (8) of the gauge
manifold (9), and fill with coolant.
(Fill with refrigerant gas up to a gauge pressure
of 0.098 MPa.)
After filling, close the gauge manifold high-pres-
sure valve and valve for the service can (13).
Never operate the compressor. (This is very
dangerous, as the refrigerant will flow in the
opposite direction and may cause a service can
or hose explosion.)
[4] Gas leak check
Check for gas leaks in the cycle using the gas
leak tester.
If there are leaks, eliminate them through tight-
ening.
Always use the tester for R134a.
SSM-07-08-004EN 18
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5. Gas filling operation, low-pressure side
・ Never open the gauge manifold high-pressure valve.
Caution ・ Never tip over the service can. This may cause damage to the compressor.
After finishing the high-pressure side filling operation, perform the operation for the low-pressure
side.
[1] Check that the high-pressure valve (8) and low-
pressure valve (7) of the gauge manifold (9) and
the valve for the service can (13) are closed.
[2] Start the engine, increase speed to 1500 ± 100
min.-1, and completely open the cab door and
window.
[3] Turn the air conditioner switch on, move the fan
switch to the maximum position, and move the
temperature adjustment switch to the maximum
cooling position.
[4] During filling, set the degree of discharge for the
compressor at 1.37 - 1.57 MPa.
[5] Open the low-pressure valve (7) of the gauge
manifold (9) and valve for the service can (13),
and fill with refrigerant until the air bubbles in
the receiver sight glass (15) are gone.
・ Judging the amount of refrigerant from the receiver dryer sight glass
After the AC is turned ON, a few air bub-
When the amount is bles are visible. The glass then becomes
correct transparent and turns to a pale, milky-
white color.
When overfilling After the AC is turned ON, no air bubbles

occurred at all are visible.
When filling was After the AC is turned ON, air bubbles

insufficient are seen continuously.
(Total gas filling amount: 950 ± 50 g)
19 SSM-07-08-004EN
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[6] After refrigerant filling is complete, close the low-pressure valve (7) of the gauge manifold (9) and
the valve for the service can (13), and stop the engine.
• If the air conditioner is operated with very little refrigerant (R134a), this will have a damaging
effect on the compressor.
• If the air conditioner is filled with too much refrigerant (overcharge), this will actually cause insuf-
ficient cooling and there is the danger of pressure in the circuit becoming abnormally high.
Be sure to use an appropriate amount of refrigerant.
• Never open the gauge manifold high-pressure valve (8).
• Never invert the service can.
(Gas is suctioned in liquid form, so this may cause damage to the compressor valve.)
[7] After refrigerant filling and inspection, remove the gauge manifold and hoses.
Quickly remove the low-pressure side charge hose (blue) (11) from the low-pressure side (SUC)
service valve.
Do not do anything on the high-pressure side until the high-pressure gauge indicator falls to 0.98
MPa or below.
After confirming that the indicator has fallen below this point, quickly remove the high-pressure
side charge hose (red) (10) from the high-pressure side (DIS) service valve.
SSM-07-08-004EN 20
8

Electricity Measurement Procedures
Items to prepare
• Service connector
• Tester
[1] Use service connector (female) (1) and service
connector (male) (2) for voltage measurement.
[2] Remove the connector (3) in which voltage is to

be measured.
[3] Connect the service connector (female) (1) to

the removed connector, and attach the tester (4)
to measure voltage.
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[4] Also attach the service connector (male) (2) to
the removed connector on the opposite side
and measure voltage with the tester (4).
SSM-09-13-004EN 2
2
Maintenance
Check Sheet
1. Drive Sprocket
* See the gauge list for measurement gauges.

* Use the maintenance standard table for judgment.
Measured
Standard
dimen- Usage
Part name Code value Judgment Solution
sions limit (mm)
(mm)
(mm)
Acceptable/
a 83 73
Unacceptable
Acceptable/
b φ φ660.7 φ649.2
Unacceptable
Acceptable/
c φ φ748 φ738
Unacceptable Cladding by welding or
Drive sprocket
Acceptable/ replacement
d φ φ732.5 -
Unacceptable
Acceptable/
e 40 45
Unacceptable
Acceptable/
p 215.9 -
Unacceptable
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2. Take-up roller

Measured
Standard
dimen- Usage
sions limit (mm)
(mm)
(mm)
Acceptable/
a φ φ560 φ550
Unacceptable
Acceptable/ Cladding by welding or
Take-up roller b 22.5 -
Unacceptable replacement
Acceptable/
c 102 92
Unacceptable
Acceptable/
Shaft d φ φ85 φ84 Replacement
Unacceptable
Acceptable/
d φ φ85 φ86
Unacceptable
Bushing Replacement
Acceptable/
e 82 81
Unacceptable
Acceptable/
Hub f 24 23.6 Replacement
Unacceptable
SSM-09-14-004EN 4
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3. Upper roller

Measured
Standard
dimen- Usage
sions limit (mm)
(mm)
(mm)
Acceptable/
a φ φ150 φ140
Unacceptable
Carrier roller b 15 -
Acceptable/
c 104 -
Unacceptable
Acceptable/
Shaft d φ φ65 φ64 Replacement
Unacceptable
Acceptable/
Bushing d φ φ65 φ66 Replacement
Unacceptable
Acceptable/
Bushing e 69 68 Replacement
Unacceptable
Acceptable/
Thrust plate f 9 8.5 Replacement
Unacceptable
Acceptable/
Cover g 15 - Replacement
Unacceptable
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4. Lower roller

Measured
Standard
dimen- Usage
sions limit (mm)
(mm)
(mm)
Acceptable/
a φ φ180 φ170
Unacceptable
Track roller b 25 20
Acceptable/
d 216 224
Unacceptable
Acceptable/
Shaft e φ φ75 φ74 Replacement
Unacceptable
Acceptable/
e φ φ75 φ76
Unacceptable
Bushing Replacement
Acceptable/
f φ82 φ81
Unacceptable
Acceptable/
Collar g 17.5 17.0 Replacement
Unacceptable
SSM-09-14-004EN 6
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5. Track shoe (grouser shoe)
Measured Standard Usage

dimensions (mm) limit (mm)
(mm)
Acceptable/
Shoe plate a 49 34
Unacceptable Replacement
Link b 129 124
Acceptable/
c φ φ71 φ67 Unacceptable
Master bushing Replacement
Acceptable/
d φ φ47 -
Unacceptable
Acceptable/
Master pin e φ φ46.83 - Unacceptable Replacement
Acceptable/
f 215.9 220.2
Unacceptable
Link pitch Replacement
Acceptable/
f' 863.6 880.8 Unacceptable
Acceptable/
c' φ φ71 φ67 Unacceptable
Track bushing Replacement
Acceptable/
d' φ φ47 -
Unacceptable
Acceptable/
Track pin e' φ φ47 -
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6. Attachment (backhoe)

① Boom and swing frame installation section
Measured Standard Usage limit
Part name Code Judgment Solution
dimensions (mm) value (mm) (mm)
Acceptable/
Swing frame a 860 868
Unacceptable －
Acceptable/
Boom b 857 855 Replacement
Unacceptable
Shim adjust- Acceptable/
Clearance c (a - b) 3.0 - 5.5 Adjust with shims
ment Unacceptable
Acceptable/
Pin d φ φ110 φ109 Unacceptable
Replacement
Acceptable/
Bushing (boom) e φ φ110 φ111.5 Unacceptable
Replacement
② Boom cylinder and swing frame installation section
Part name Code Measured Standard Usage limit Judgment Solution

dimensions (mm) value (mm) (mm)
A c c e p t a bl e /
Swing frame a 131 137
Unacceptable －
Boom cylinder A c c e p t a bl e /
b 130 127 Replacement
(foot section) Unacceptable
Clearance c (a - b) 1.0 - 3.5 Shim adjust- Acceptable/ Adjust with shims
ment Unacceptable
Acceptable/
Replacement
Bushing (boom Acceptable/
cylinder) e φ φ90 φ91.5 Unacceptable
Replacement
SSM-09-14-004EN 8
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③ Boom and boom cylinder installation section

dimensions (mm) (mm)
(mm)
Boom cylinder (top Acceptable/
a 123 120 Replacement
section) Unacceptable
Acceptable/
Boom b 669 665 Unacceptable Replacement
Clearance c 2.0 - 3.0 ment Unacceptable Adjust with shims
Acceptable/
Replacement
Bushing (boom cyl- Acceptable/
inder)
e φ φ110 φ111.5 Unacceptable Replacement
④ Boom and arm cylinder installation section

Standard
Measured Usage limit
(mm)
Acceptable/
Boom a 146 152 Unacceptable Replacement
Boom cylinder (foot Acceptable/
b 145 143 Replacement
ment Unacceptable
Acceptable/
Replacement
Bushing (arm cylin- Acceptable/
der) e φ φ100 φ101.5 Unacceptable
Replacement
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⑤ Boom and arm installation section
Measured
Standard
dimen- Usage
sions limit (mm)
(mm)
(mm)
Acceptable/
Boom a 392 395 Replacement
Unacceptable
Acceptable/
Arm b 387.7 389 Replacement
Unacceptable
Shim
Acceptable/
Clearance c (a - b) 4.3 - 4.9 adjust- Adjust with shims
Unacceptable
ment
Acceptable/
Pin d φ φ115 φ114 Replacement
Unacceptable
Acceptable/
Bushing (arm) e φ φ115 φ116.5 Replacement
Unacceptable
Acceptable/
Boom f φ φ115 φ116.5 Replacement
Unacceptable
Acceptable/
Boom g 89 87 Replacement
Unacceptable
SSM-09-14-004EN 10
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⑥ Arm and arm cylinder installation section

(mm)
Acceptable/
Arm a 146 151
Arm cylinder (top Acceptable/
b 145 143
section) Unacceptable Replacement
Clearance c (a - b) 0.5 - 2.5
ment Unacceptable Adjust with shims
Acceptable/
Pin d φ φ100 φ99 Unacceptable Replacement
Bushing (arm cylin- Acceptable/
der)
⑦ Arm and bucket cylinder installation section
Standard
(mm)
A c c e p t a bl e / Replacement
Arm a 146 152
Unacceptable
Bucket cylinder A c c e p t a bl e / Replacement
b 145 143
(foot section) Unacceptable
Clearance c (a - b) 1.0 - 2.5
ment Unacceptable Adjust with shims
Acceptable/
Pin d φ φ95 φ94 Unacceptable Replacement
Bushing (bucket Acceptable/
cylinder)
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⑧ Arm and arm link installation section
Standard
(mm)
Acceptable/
Arm link a 50 47 Replacement
Unacceptable
Acceptable/
Arm b 375 371 Replacement
Unacceptable
Clearance c 1.0 - 1.5 Adjust with shims
ment Unacceptable
Acceptable/
Replacement
Acceptable/
Bushing (arm) e φ φ85 φ86.5 Unacceptable
Replacement
⑨ Bucket and bucket link installation section

Standard
(mm)
Acceptable/
Bucket a 401 406 Replacement
Unacceptable
Acceptable/
Bucket link b 400 397 Replacement
Unacceptable
Clearance c(a-b) 1.0 - 3.5 Shim adjust- Acceptable/ Adjust with shims
ment Unacceptable
Acceptable/
Replacement
link)
e φ φ90 φ91.5 Unacceptable
Replacement
SSM-09-14-004EN 12
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⑩ Bucket link and bucket cylinder installation section
Standard
(mm)
Acceptable/
Arm link a 50 48 Replacement
Unacceptable
Acceptable/
Bucket link b 375 371 Replacement
Unacceptable
Clearance c 1.0 - 1.5 Adjust with shims
ment Unacceptable
Acceptable/
Bucket link d 121 123 Replacement
Unacceptable
Bucket cylinder (top Acceptable/
e 120 118 Replacement
Clearance f (d - e) 1.0 - 2.0 Adjust with shims
ment Unacceptable
Acceptable/
Pin g φ φ105 φ104 Replacement
Unacceptable
h φ φ105 φ106.5 Replacement
link) Unacceptable
i φ φ105 φ106.5 Replacement
cylinder) Unacceptable
13 SSM-09-14-004EN
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⑪ Bucket and arm installation section
Standard
(mm)
Acceptable/
Bucket a 401 406 Replacement
Unacceptable
Acceptable/
Arm b 400 397 Replacement
Unacceptable
ment Unacceptable
Acceptable/
Bushing (bucket) d 16 10 Replacement
Unacceptable
Acceptable/
Pin e φ φ90 φ89 Replacement
Unacceptable
Acceptable/
Bushing (arm) f φ φ90 φ91.5 Replacement
Unacceptable
Acceptable/
Bushing (bucket) g φ φ90 φ91.5 Replacement
Unacceptable
SSM-09-14-004EN 14
12
Track Shoe
Track Shoe
Track Shoe
Removal and Installation of Shoe Assembly
・ When loosening the grease cylinder check valve, loosen it a little bit at a time.
・ The pressure inside the cylinder is very high, so there is the danger of grease being expelled
and the plug flying off. The check valve adjustment procedure should not be done in front of
Warning the check valve.
・ Do not get under the main unit when it is jacked up.
Make sure to place the main unit on crossties to prevent falling.
Caution ・ Make sure to stop the engine for loosening shoes and when removing master pins.
Items to prepare
• Wrench (19 mm)
• Hammer
• Striking jig
• Crowbar
• Rag
• Lifting equipment (with the required breaking load)
1. Removal of Shoe Assembly
[1] Rotate the shoe and align it so that the master
pin (1) is next to the idler.
[2] Use a box wrench (19 mm) to loosen the check

valve (2) to release grease, and then loosen the
track shoe tension.
Do not loosen the check valve all at once.
Loosen it slowly while monitoring the grease
output and shoe loosening.
Use a rag to catch grease that trickles out of the
check valve.
If the check valve is loosened too much at this
time, it may fly off. Be careful not to work in front
of the check valve.
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Track Shoe
and then remove the check valve stopper (4).
• If the check valve is removed, it is easier to
loosen the track shoe tension.
[4] Straighten out the S-pin (5) attached to the

master pin by striking one side of it with a ham-
mer, and use a crowbar, etc. to remove it.
[5] Use a hammer (6) and striking rod (7) to push

the master pin (1) out.
[6] Remove the track shoe (8).

At this time, place a wood plank (9) under the
bottom track shoe so that it does not fall.
SSM-13-01-004EN 2
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Track Shoe
[7] Start the engine, raise the lower side frame of
the track shoe removal side about 20 cm, slowly
set the travel lever to backwards, and move the
track shoe to remove it from the lower frame.
3 SSM-13-01-004EN
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Track Shoe
2. Installation of Shoe Assembly
[1] Raise the lower side frame about 20 cm.
Lift the track shoe (1) and align it with the
sprocket (2).
Pay attention to the backwards and forward
direction of the track shoe.
[2] Slowly set the travel lever to forward and feed

the track shoe to the take-up roller side as
shown in the diagram.
In the middle of this procedure when the track
shoe passes the upper roller, use a crowbar,
etc. to lift the track shoe while it is being fed.
Lower the lower side frame after the shoe has
reached position A shown in the diagram.
[3] Wrap the edge of the track shoe (4) onto the
take-up roller (3).
Place a wood plank (5) on the ground and lift
the bottom-side link to align the position where
the master pin is inserted.
[4] Insert the master pin (7).

Insert the S-pin (6) and bend it so that it cannot
slip out.
SSM-13-01-004EN 4
4
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Track Shoe
[5] Tighten the check valve (8).
While monitoring the track shoe tension, inject
grease into the grease cylinder.
[6] To adjust the track shoe tension, raise the lower

side frame as shown in the diagram.
Adjust the tension so that the distance indicated
with A between the frame bottom (9) of the cen-
ter area of the lower side frame and the lowest
hanging part of the top of the shoe plate (10) is
340 - 360 mm.
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Track Shoe
Removal and Installation of Shoe Plate
Items to prepare
• Grease
• Rag
• Cleaning fluid

shoe bolts (1), and then remove the shoe plate
(2).
SSM-13-01-004EN 6
6
Travel Unit
Travel Unit
Removal and Installation of Travel Motor
・ When loosening the check valve, loosen it a little at a time and stop when any grease
Warning appears. The pressure inside the cylinder is very high, so there is the danger of grease being
expelled and the plug flying off if the check valve is loosened too much.
・ Before removing the shoes, be sure to bleed off any air in the hydraulic circuits.
Items to prepare
• Box wrenches (19 mm, 36 mm)
• Hammer (to remove the master pin)
• Striking jig (to remove the master pin)
• Wire rope (with the required breaking load)
• Loctite #262
• Rag
• Cleaning fluid
1. Removal of Travel Motor
[1] Allow the bucket (1) to touch the ground so as to
elevate the side with the shoe (2) to be removed
as in the diagram on the right.
[2] Slowly rotate the shoe so that the shoe joint

section (3) is aligned as in the diagram on the
right.
[3] Place wood planks (4) under the shoe and
return the bucket to its original position.
[4] Perform air bleeding for the hydraulic line.
For details, see Air Bleed Procedures.
7 SSM-13-02-004EN
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Travel Unit
[5] Use a box wrench (19 mm) to rotate the grease
cylinder check valve (5) and loosen the shoe
tension.
• Grease will flow out, so have rags ready. If the
check valve is loosened too much at this time, it
may fly off. Be careful not to work in front of the
check valve.
[6] Pull out the S-pin (6) from the rear of the joint
section.
[7] Place a striking jig (9) against the master pin (7)
and hit it with a hammer (8) to push the master
pin out.
SSM-13-02-004EN 8
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Travel Unit
[8] Open the shoe (2) to the rear.

(10), and then remove the cover (11).
[10] Use wrenches (27 mm for drain hose, 41 mm for

high-pressure hose) to remove the drain hose
(13) and 3 high-pressure hoses (12).
• Be sure to use plugs on the removed drain and
high-pressure hoses.
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Travel Unit
[11] Use a wrench (19 mm) to remove the pilot hose
(15) and a wrench (27 mm) to remove the elbow
(14).
[12] Attach the wire rope (17) to the travel motor (16)
as in the diagram.
Adjust the wire rope so that it is located at the
center of mass and lift it with the liftcrane so that
it is slightly tensed.
[13] Use a box wrench (36 mm) to remove all 18

bolts (18).
SSM-13-02-004EN 10
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Travel Unit
[14] Remove the travel motor (16).
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Travel Unit
2. Installation of Travel Motor
[1] Attach the travel motor to the lower frame as in
the diagram.
• Be careful of the installation angles.
[2] Apply Loctite #262 to the installation bolt (2)

threaded sections and temporarily tighten them.
Tighten top and bottom alternately to the speci-
fied torque so that an even tightening force acts
on opposing corners as shown in the diagram
below.
[3] Use a wrench (27 mm) to remove the elbow (3)

and a wrench (19 mm) to install the pilot hose
(4).
SSM-13-02-004EN 12
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Travel Unit
[4] Use wrenches (27 mm for drain hose, 36 mm for
high-pressure hose) to install the drain hose (6)
and high-pressure hoses (5).

(7), and then install the cover (8).
[6] Wrap the shoe (9).
13 SSM-13-02-004EN
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Travel Unit
[7] Insert the master pin (11).
Insert the S-pin (10) and bend it so that it can-
not slip out.

[9] When adjusting the track shoe tension, raise the

lower side frame as shown in the diagram.
Place a wood plank (13) under the lower frame
to prevent falling.
with A between the frame bottom (14) of the
center area of the lower side frame and the low-
est hanging part of the top of the shoe plate (15)
is 340 - 360 mm.
SSM-13-02-004EN 14
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Travel Unit
Assembly and Disassembly of Travel Motor
1. To Ensure Safe Use
Please follow these precautions.

When transporting the motor with a liftcrane, do not use the tap on top of the base plate to sus-
pend the motor.
The motor falling may cause personal injury or damage the machine.
When disassembling the motor for transport, installation or maintenance inspection, make sure
to wear a helmet, protective shoes, gloves and safety goggles.
When there is little hydraulic oil in the hydraulic tank and the oil surface is near the inlet port or
there is no hydraulic oil, do not run the motor.
The motor will take in air and may run out of control, which could cause personal injury or dam-
age the machine.
Warning
Do not operate the motor when there is no hydraulic oil in the lines.
The motor will take in air and may run out of control, which could cause personal injury or dam-
age the machine.
For 1 hr. after operating the motor, do not remove the plugs for the oil fill, oil drain and oil check
ports for reduction gear lubrication oil.
Hot lubricating oil may spray out and cause burns.
Hot lubricating oil spraying out and entering the eyes may cause blindness.
15 SSM-13-02-004EN
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Travel Unit

When pressure is applied inside the lines, do not remove the motor pressure detection port
plug or the drain port plug.
Pressurized oil spraying out and entering the eyes may cause blindness.
When removing plugs, always let out the pressure inside the lines.
Do not remove the reduction gear cover with the motor left installed in the machine main unit.
Fingers or hands may get caught in gears and this could result in injury.
Warning
Do not disassemble the motor with the motor left installed in the machine main unit.
The machine may run out of control, which could result in personal injury.
For motor disassembly, be sure to remove the motor from the machine main unit.
Do not remove the spool of the double counter balance valve with the motor left installed in the
machine main unit.
The motor may run out of control, which could cause personal injury or damage the machine.
SSM-13-02-004EN 16
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Travel Unit

Do not tamper with the relief valve adjuster.
The set pressure of the relief valve may change and cause the motor to run out of control,
which could cause personal injury or damage the machine.
Warning
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Travel Unit

Do not operate the motor at settings beyond its specified range.
This could cause damage to the machine.
Do not touch the motor for 1 hr. after operation.
The surface of the motor is very hot due to operation. Touching the surface could cause burns.
Do not suddenly remove the plugs for the oil fill, oil drain and oil check ports on the reduction gear.
A plug may fly off and cause injury.
Align the port positions with the specified positions and slowly loosen the plug for each port,
starting with oil fill port on top, to release air inside the reduction gear.
Caution
When handling lines, make sure to confirm the input and output flow of the hydraulic oil and the
motor rotation direction.
It is extremely dangerous if the motor rotates in the opposite direction.
Do not use hydraulic oil other than the type specified.

Doing so could cause damage to the machine.
SSM-13-02-004EN 18
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Travel Unit

Do not use reduction gear lubricating oil other than the type specified.
Doing so could cause damage to the machine.
Do not let foreign matter into the motor.
This will damage the machine.
Caution Perform motor maintenance and inspection after the motor has cooled down.
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Travel Unit
2. Tools for Assembly and Disassembly
Use the tools indicated below for assembly and disassembly of the motor.
(1) Standard tools
The necessary standard tools for assembly and disassembly of this motor are indicated in Table 1.
1) Required tools for motor
Tool name Specifications
Hexagon wrench Bolt width 5, 6, 8, 10, 14 mm
Pliers for snap rings φ32 - φ58, φ60 - φ80 for hole
Plastic hammer 1
Screwdriver Flathead (medium-sized) 2
Torque wrench For 98.1 N•m, 324 N•m, and 441 N•m
Gear (bearing) puller Maximum diameter of 75 mm and maximum width of 45 mm (e.g., GP75 made by Asahi Tools) of removed item
Other Seal tape, cleaning oil (white kerosene), grease, hydraulic oil, rag, compressed air
Table 1
SSM-13-02-004EN 20
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Travel Unit
2) Required tools for reduction gear
Tool name Specifications
Hexagon wrench Bolt width 8, 14 mm
Torque wrench For 490 N•m
Receiving platform
Micro depth gauge 0 - 15 mm

Caliper 0 - 150 mm
For inserting spring pins (14, 21)
Pin
φ5.5 × 80 φ9.5 × 60
Eyebolt M10, M20 (3 bolts each)
For inserting angular bearing and installing lock washers
Pressing machine
(3-ton press capacity)
Cleaning oil (white kerosene), solvent, gear oil, grease, Loctite #242 and #515,
Other
rag, etc.
Table 1
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Travel Unit
(2) Secondary materials
The necessary secondary materials for assembly and disassembly of this motor are indicated in
Table 2.
Table 2. Secondary materials
Secondary mate- Standardized number

No. Type and dimensions Part used with
rials name Manufacturer name
1 Seal tape
2 Adhesive Loctite 271
3 Gear oil GL-4#90 equivalent
4 Hydraulic oil ISO VG46 equivalent
5 Grease Lithium-series
6 White kerosene No.2 equivalent oil
7 Liquid packing ThreeBond 1211
8 Lapping plate For sliding surface repair
9 Lapping agent #1000 For sliding surface repair
10 Copper plate
11 Tube brush For cleaning
12 Bamboo brush For cleaning
13 Oil pan For receiving oil
14 Plastic container For filling grease
15 Rag
(3) Special tools

The necessary special tools for assembly and disassembly of this motor are indicated in Table 3.
Table 3. Special tools
Standardized number Type and dimen-

No. Tool name Part used with
Manufacturer name sions
1 Pulley remover
2 Bearing press-fit jig
3 Bearing press-fit jig
4 Floating seal mounting jig
5 Rod
6 Angular bearing press-fit jig
7 Shim thickness adjustment jig
8 Rod
10 Thrust plate selection jig
11 Oil seal press-fit jig
12 Brake piston positioning jig
13 Snap ring removal jig
14 Poppet seat removal jig
SSM-13-02-004EN 22
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Travel Unit
(4) Measurement device
The necessary measurement devices for assembly of this motor are indicated in Table 4.
Table 4. Measurement devices
Standardized number Type and

No. Tool name Part used with
Manufacturer name dimensions
1 Dial gauge JIS B7503
2 Micrometer caliper JIS B7502
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3. Disassembly of Motor
(1) Precautions before motor disassembly
Begin motor disassembly only after thoroughly reading the precautions below.
[1] When performing disassembly, always wear protective devices such as a helmet, goggles
and safety shoes.
[2] Use the specified tools when performing disassembly.
[3] Remove all lines connected to the motor and remove the motor from the mother machine
only after making sure that the machine is on a level surface and there are no external forces
acting on rotating parts so that the mother machine does not operate uncontrollably when
the motor is removed.
[4] To prevent foreign matter from entering the lines and motor when removing the motor from
the mother machine, sufficiently clean off mud and dirt adhered around the motor before
removing lines connected to the motor.
[5] When removing lines connected to the motor, hydraulic oil from inside the lines will spray
out. For this reason, remove these lines only after removing pressure from inside the lines
and preparing an oil pan. To prevent injuries due to the motor falling when transporting it by
lifting the motor with a liftcrane, lift the machine with the eyebolts mounted in the positions
indicated in the diagram below.
[6] The motor is filled with hydraulic oil. Before disassembling the motor, prepare an oil pan and
drain the hydraulic oil from the motor.
[7] To prevent injuries during disassembly, prepare a waist-high, stable work platform to perform
work on.
[8] The motor comprises high-precision parts. For this reason, foreign matter adhering to parts
can be damaging. Motor disassembly should be done in an inside space without dust, and
mud and dirt should be prevented from adhering to parts.
[9] The motor comprises high-precision parts. For this reason, dents and scratching on part sur-
faces can be damaging. Be very careful when handling parts during disassembly and do not
create any dents or scratching.
[10] To prevent personal injury and damage to parts during disassembly, do not force disassem-
bly of parts which are especially tight to disassemble.
Motor lifting positions
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Travel Unit
(2) Tightening torque
Table 5 indicates tightening torque for each fastening section.
Table 5. Tightening torque for each section
Code Part name Dimensions Tightening torque (N•m)

378± 37.8 N•m
(4) Hexagon socket head bolt M18 × 110
(Loctite #242 coating)
68.6±6.9 N•m
(25) Hexagon socket head bolt M10 × 30
(Loctite #242 coating)
(26) Hexagon socket head plug G3/4 147± 14.7 N•m
(29) Plug M42 441 - 461
(35) Pilot valve plug G3/8 49.0 - 58.8
(38) Plug G1/4 29.4
(42) Plug G1/8 14.7
(56) Hexagon socket head bolt M18 324 ± 32.4
(57) Overload relief valve M27 98.1 - 118
(60) Plug G1/2 98.1
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Travel Unit
(3) Disassembly procedure
1) Disassembly of motor
Perform disassembly by observing the safety precautions listed in "1. To Ensure Safe Use" and
following the procedure indicated below.
a) Removal of supplied valves
Remove the supplied valves before disassembling the motor parts.
• It is recommended not to remove any supplied valves other than those required for disassembly.
However, the motor cannot be disassembled if the overload relief valve (57) is not removed
first.
Perform the disassembly procedure after the motor has reached its normal temperature, other-
Caution wise burns can occur.
Removal of supplied valves

[1] Remove the M42 plug (29) and O-ring (30).
[2] Remove the spring (28), spring receiver (27), and spool assembly (26).
• Make reference marks on the spool assembly (26) and rear cover (24), and when reas-
sembling the parts, make sure that the assembly direction does not go in the opposite
left-right direction.
• Adhesive is applied to the thread sections to fix the spool assembly (26), so no further
disassembly is possible.
[3] Remove the plug (42), O-ring (43), orifice spring (41), and orifice (40).
[4] Remove the overload relief valve (57).
• When removing the overload relief valve (57), the valve seat (57-3) can easily come off,
so be careful not to let it fall inside the rear cover (24), and check that it is not lost.
[5] Loosen the pilot valve plug (35), and remove the O-ring (36), spring (34), spring receiver
(33), pilot valve spool (31), and pin (32).
[6] Remove the coupling (58).
Caution Be very careful not to get hands stuck between parts or drop the carried parts on feet.
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b) Disassembly of motor
[1] Place the motor shaft horizontally and
pull it out while leaving the 2 vertically-
opposite hexagon socket head bolts
M18 × 50 (56) in place.
[2] Install guide pins at the 2 vertically-
opposite locations.
(Purpose: This prevents the rear cover
from falling when removed and acts as a
guide during assembly.)
[3] Slowly loosen the remaining 2 hexagon
socket head bolts M18 × 50 (56) at the
same time.
[4] Remove the rear cover (24) and brake
spring (55) while making sure that the
cylinder block (13) does not come out
together with the rear cover (24).
Be very careful not to get hands stuck

Caution between parts or drop the carried parts
on feet.
• Be careful not to drop the valve plate
(54), brake spring (55), rear bearing (51)
outer race, shim (52), and O-rings (50),
(47), (49).
• There is a shim (52) under the rear
bearing (51) outer race. Be very careful
not to lose this during disassembly.
[5] Remove the valve plate (54) while mak-
ing sure that the cylinder block (13) does
not come off.
• Make reference marks on the valve
plate (54) and rear cover (24), and when
reassembling the parts, be sure not to
reverse the front and rear.
[6] Using the removed hexagon socket
head bolt M18 × 50 (56), press the
holder fitting so as not to scratch the
sliding surface of the cylinder block (13),
and let the rear bearing (51) inner race
come out.
• Insert a rubber plate between the sliding
surface and the holder fitting so as not
to scratch the sliding surface of the cyl-
inder block (13).
[7] Attach the gear (bearing) puller to the
rear bearing (51) inner race and remove
it.
Removal of rear bearing
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[8] While holding the brake piston (21) with
the hand, fill compressed air from the
brake release oil hole and push out.
Be very careful as the air pressure can

Caution cause the brake piston (21) to fly off.
• When using a removal jig, install the
removal jig to the M6 taps (2 locations)
on the end of the brake piston (21), and
pull out the brake piston (21).
[9] Insert a rod that will not scratch the cyl-
inder block (13) (such as rolled-up cylin-
drical paper) into the piston (18) hole,
and make a reference mark on the outer
circumference of the cylinder block (13)
for reference.
[10] Remove the rotary group (cylinder block
(13), piston assembly (18), shoe retainer
(17), spherical joint (16), spring receiver
(15), and cylinder spring (14)).

on feet.
[11] Remove the separator plate (19) and
friction plate (20).
[12] Remove the 9 piston assemblies (18),
shoe retainer (17), and spherical joint
(16) from the rotary group at the same
time.
[13] Remove the spring receiver (15) and
cylinder spring (14) from the cylinder
block (13).
• With the piston assembly (18) and shoe
retainer (17) removed, align the align-
ment mark and the reference mark and
insert them into the cylinder block (13).
The purpose is to house the pistons into
the same holes before disassembly
when reassembling.
• Be careful not to scratch each of the
sliding surfaces. If the sliding surface is
scratched, the part cannot be reused.
• The piston and shoe are caulked and
cannot be disassembled.
[Tip]
The preceding described how to disassemble the motor unit, but the disassembly is also
the same if it comes with a reduction gear. Disassembling a motor with a reduction gear
may be easier because the shaft does not swing as much.
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[14] Remove the shoe plate (12).
[15] Do not remove the tilting piston assemblies (6), (7), (8). If these parts must be removed,
hold the tilting piston (6) with the hand and fill air from the tilting path hole and push out
the parts.
Caution Be very careful as the air pressure can cause the tilting piston (6) to fly off.
[16] The shaft (9) can be pulled out.

[17] When replacing the front bearing (10),
remove the inner race from the shaft (9)
with the bearing puller, and replace with
a new bearing.
• When replacing parts related to the
clearance of the bearing, such as the
bearings (10) and (51), shaft (9), casing
(1), and rear cover (24), the thickness of
the shim (52) needs to be adjusted. Cor-
rectly measure the shim gap when the
shim is lightly positioned, replace with a
shim (52) that matches the gap, and
adjust the bearing gap to 0 - 0.1 mm.
(See page 24.)
A separate jig or other tool is needed to
determine the jig thickness.
Contact us for details.
• Do not remove the pivot (11). If remov-
ing the part, make a reference mark on
the area aligned with the shoe plate
(12).
• Do not remove the oil seal (3). If the part
is removed, always replace with a new
part.
If removing the oil seal, remove the
retaining ring (4), and then remove the
oil seal (3).
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[18] Determining the thickness of the taper roller bearing shim (52)
Determining the shim thickness

• This needs to be performed when replacing the motor casing (1), rear cover (24), shaft
(9), or bearings (10), (51).
1) Measure dimension E in the assembled condition indicated in the above diagram.
• Be careful not to allow the shaft (9) to fall.
2) Measure dimension F on the rear cover side.
• Use the average of the measurements of the 4 orthogonally intersecting points on the
circumference.
3) When the thickness of the used shim (52) is "S," gap "Y" is as follows.
Y = F - (E + S)
4) In the case of this motor, select 1 or 2 shims (52) so that gap Y is 0 - 0.1 mm.
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c) Disassembly of overload relief valve
• The overload relief valve (57) is an important part in terms of performance and safety.
Because resetting the pressure of this part is extremely difficult, the overload relief valve
assembly should be replaced without disassembling if a problem occurs.
• The valve seat (57-3) fits into the socket (57-1) internal hole by a clearance fit and can easily come
off, so when removing the overload relief valve (57) from the rear cover (24), be careful not to drop
or lose the valve seat (57-3). When installing the overload relief valve (57) to the rear cover, apply
grease to the bonding section and install in a way that the valve seat (57-3) does not come off.
Valve seat bonding section
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2) Reduction gear disassembly procedures
a) Disassembly preparations
[1] The unit removed from the actual machine is dirty with dirt and debris.
Clean the exterior of the unit and let it dry.
Perform the disassembly procedure after the reduction gear has sufficiently cooled down, oth-
Caution erwise burns can occur.
[2] Loosen the drain and the feed plug G3/4 (26) to drain the gear oil inside the reduction
gear.
Caution When the gear oil is still hot, the pressure inside can cause the oil to spray out.
[3] Make reference marks to the outside of each alignment surface so that the part can be
assembled in its original form.
b) Installation to receiving platform of reduction gear (unit)
[1] Remove 3 hexagon socket head bolts
M10 × 30 (25) screwed into the cover
(24) at approximately the same distance
apart, and instead, install and suspend
the M10 eyebolts, and install the receiv-
ing platform with the cover in the raised
position and the motor in the lowered
position.
・ Be very careful not to get hands stuck

between parts or drop the suspended
Caution parts on feet.
・ Lift the part in a horizontal position.
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c) Removal of reduction gear cover
[1] Remove the remaining hexagon socket
head bolts M10 × 30 (25).
[2] The contact surfaces of the cover (24)

and ring gear (3) are coated with seal-
ant, so place a metal pin against the
projected part of the cover and use a
hammer to strike it obliquely upward to
remove the cover.

Caution between parts or drop the suspended
parts on feet.
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d) Removal of carrier 1 assembly
[1] Remove the thrust plate (23).
[2] Install 3 M10 eyebolts to the carrier 1
(16), and then remove the carrier 1
assembly (16, 17, 18, 19, 20, 21).

[3] Remove the sun gear 1 (22).

Caution between gears.
e) Removal of carrier 2 assembly

[1] Remove the sun gear 2 (15).

[2] Install 3 M10 eyebolts to the carrier 2
(9), and then remove the carrier 2
assembly (9, 10, 11, 12, 13, 14).

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f) Removal of housing assembly
[1] Remove the support ring (8).
[2] Place a screwdriver or other tool on the

divided surface of the lock washer (7)
and strike the tool with a hammer to
remove the lock washer (7).
[3] Install 3 M10 eyebolts into the M10

threaded holes on the ring gear (3) at
approximately the same distance apart,
and remove the housing assembly (ring
gear (3), housing (1), bearing (2), float-
ing seal (5), hexagon socket head bolt
M18 × 110 (4)) while lifting it in a hori-
zontal position.

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g) Disassembly of housing assembly
[1] Install 3 M20 eyebolts into the M20
threaded holes on the housing (1) at
approximately the same distance apart,
and place it on the receiving platform
with the ring gear (3) in the lowered
position and the housing (1) in the
raised position.
Make reference marks to the outer cir-
cumference of the housing and ring
gear.

[2] Remove the floating seal (5) from the

housing (1).
[3] Remove the hexagon socket head bolts
M18 × 110 (4) while leaving 2 diagonally
opposite bolts.
[4] With the remaining 2 hexagon socket
head bolts M18×110 (4) loosened, tap
the heads of the bolts with a hammer to
easily remove the ring gear (3) from the
housing (1).

parts on feet.
Removal of floating seal
• Be careful not to scratch the sliding surface of the floating seal (5) and its O-ring.
• The bearing (2) outer race and housing (1) inner diameter form a very tight fit. Do not dis-
assemble this unless it is necessary to replace the bearing (2). When removing the bear-
ing (2) from the housing (1), replace with a new part instead of reusing the part.
h) Removal of floating seal from motor
[1] Remove the floating seal (5) on the motor.
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i) Disassembly of carrier 1 assembly
• When reusing the carrier pin 1 (20), place codes on the carrier 1 (16) hole and carrier pin 1
(20) so that the parts can be reassembled in the same combination as before disassembly,
and store the parts.
[1] Push the spring pin 6 × 36 (21) into the
carrier pin 1 (20).
[2] Remove the carrier pin 1 (20) from the

carrier 1 (16).
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[3] Remove the thrust washer 1 (18), plane-
tary gear 1 (17), and needle bearing
(19) from the carrier 1 (16).

Caution between the gear and carrier.
[4] Pull out the spring pin 6 × 36 (21) from
the carrier pin 1 (20).
• When replacing the carrier pin 1 (20) or
planetary gear 1 (17), be sure to replace
with 1 set of 3 parts.
j) Disassembly of carrier 2 assembly

• When reusing the carrier pin 2 (13), place codes on the carrier 2 (9) hole and carrier pin 2
(13) so that the parts can be reassembled in the same combination as before disassembly,
and store the parts.
[1] Push the spring pin 10 × 50 (14) into the
carrier pin 2 (13).
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[2] Remove the carrier pin 2 (13) from the
carrier 2 (9).
[3] Remove the thrust washer 2 (11), plane-

tary gear 2 (10), and needle bearing
(12) from the carrier 2 (9).

[4] Pull out the spring pin 10 × 50 (14) from
the carrier pin 2 (13).
• When replacing the carrier pin 2 (13) or
planetary gear 2 (10), be sure to replace
with a set of 3 parts.
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4. Maintenance standards
(1) Motor parts maintenance standards
The reference values indicating whether or not a part can be reused are indicated using the mea-
surement values at the time a part is disassembled. However, this is a general reference, and
when determining whether a part should be replaced, priority is given to performance prior to dis-
assembly, the purpose of disassembly and the expected remaining life of the part if there is any
damage or discoloration that significantly affects the part appearance.
Measurement item and measurement method
[1] Sliding surfaces: cylinder block, valve plate, and shoe plate
Judgment criteria and solution
• Use a surface roughness gauge to measure the roughness of the sliding surfaces of these
parts.
Part name and inspection item Reference value Permissible limit value Solution
Surface roughness
・ Cylinder block
0.4 Zμ or lower 3.0 Zμ or lower Repair or replace.
・ Valve plate
・ Shoe plate
Table 1
(Perform common lapping to correct the surface roughness of the cylinder block and valve
plate. (Lapping material #1200))
• Use a hardness gauge to measure the hardness of the shoe plate sliding surface.
Shoe plate
HS78 or higher HS74 Replacement
・ Sliding surface hardness
Table 2
[2] Clearance of piston and cylinder block
• Use a micrometer caliper to measure the
piston outer diameter and cylinder bore
inner diameter at at least 3 locations in the
longitudinal direction.
Maximum outer diameter value (piston) = d maximum
Minimum outer diameter value (piston) = d minimum
Minimum inner diameter value (cylinder
bore) = D minimum
Maximum inner diameter value (cylinder
bore) = D maximum Measurement locations
Piston outer diameter d maxi-
0.01 mm 0.05 mm
mum - d minimum
Replace the piston or
Cylinder bore inner diameter
0.01 mm 0.022 mm cylinder block.
D maximum - D minimum
Clearance D - d 0.037 - 0.047 mm 0.065 mm
Table 3
(Piston replacement should be performed 9 pistons at a time.)
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[3] Piston and shoe backlash
• Use a jig (See "Measurement jig".) to press the shoe on the surface plate, slide the pistons
in an upward direction, and measure the piston and shoe backlash δ. (See "Caulking sec-
tion backlash" and "Measuring backlash".)
Permissible
Part name and inspection item Reference value Solution
limit value
Piston and shoe backlash 0 - 0.1 mm 0.3 mm Replace piston.
Table 4
Caulking section backlash Measuring backlash Measurement jig
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[4] Parking brake force
• After completing assembly, tighten the torque of the output shaft end with a torque wrench,
and measure the torque when starting rotation.
Part name and inspection Permissible

Reference value Solution
item limit value
Replace all parts.
・ Separator plates
Parking brake torque 1171 N•m 1055 N•m
・ Friction plates
・ Springs
Table 5
Guidelines for replacing the friction plates and partner plates
To measure the brake torque, the motor must be separated to a single unit.
It is extremely difficult to separate the motor by removing it from the mother machine or dis-
assembling the reduction gear.
Use the following method to determine whether to replace these parts when inspecting the
parts during maintenance.
(Replacement guidelines)
Measure the pack length of the 6 friction plates and 7 separator plates, and if the value is
less than the permissible value indicated below, replace all friction plates, separator plates,
and springs.
Reference value: 33.04 mm (nominal dimensions in the diagram)
Permissible value: 31.5 mm
[5] Shaft
• Use a roughness gauge to measure the wear on the oil seal contact areas of the shaft.
The parts can be reused with a stepped wear of up to 0.05 mm.
(When replacing the shaft (9), replace the oil seal (3) at the same time.)
[6] Bearing
• Replace the bearings.
Replace the bearings (10) (51) before the hour meter on the mother machine reaches 10000
hr.
(When replacing the bearings (10) (51), replace the inner race and outer race at the same
time. Also, when replacing the shaft (9) or bearings (10) (51), the shim (52) thickness must
be adjusted.)
[7] Spline
• Replace the spline when the spline wear exceeds the permissible limit value.
The parts can be reused with a stepped wear of up to 0.3 mm on the contact surface.
[8] Overload relief valve
• Pressure inspection and adjustments cannot be performed without a speciality test bench.
Replace as a valve assembly every time the hour meter on the mother machine reaches
10000 hr.
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(2) Reduction gear parts maintenance standards
1) Inspection prior to reassembly
a) Thrust washer
[1] Inspect for seizing, abnormal wear, and uneven wear.
[2] Inspect for wear that exceeds the permissible value.
b) Gears
[1] Inspect for pitching or seizing on the tooth surfaces.
[2] Perform a color check for cracks in the tooth base.
c) Bearing
Rotate by hand and inspect for abnormal noise or catching.
d) Floating seal
[1] Inspect for damage on the sliding surfaces and O-rings.
[2] Perform a color check for cracks in the tooth base.
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2) Parts maintenance
The reference values indicating whether or not a part can be reused are indicated below using
the measurement values at the time a part is disassembled. However, this is a general refer-
ence, and when determining whether a part should be replaced, priority is given to perfor-
mance prior to disassembly, the purpose of disassembly and the expected remaining life of the
part if there is any damage or discoloration that significantly affects the part appearance.
Parts with specified maintenance standards
See the above diagram for the corresponding codes.
Permissible limit
Code Item Reference value Solution
value
Smooth with no
Replace using a set of
A Planetary shaft wear abnormal wear or ← 3 parts.
seizing
No pitching of φ1.6
Smooth with no Replacement
Tooth surface and tooth base mm or more, or no
B abnormal wear or (Replace using a set of
condition cracks in the tooth
seizing 3 planetary gears.)
base.
Angular bearing (2) Inner race - 0.08 mm or more Shim adjustment (See
C
thrust gap 0.02 mm or less ← section e) on page 43.)
D Thrust washer 1 (18) thickness 3.5± 0.2 mm Wear of 0.1 mm Replacement
E Thrust washer 2 (11) thickness 5.5± 0.2 mm Wear of 0.1 mm Replacement
F Thrust plate (23) thickness 4.5± 0.16 mm Wear of 0.15 mm Replacement
G Gear oil 2000 operating hr. (hour meter) Replacement
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5. Assembly of motor
(1) Precautions before motor assembly
Begin motor assembly only after thoroughly reading the precautions below.
[1] When performing assembly, always wear protective devices such as a helmet, goggles and
safety shoes.
[2] Use the specified tools when performing assembly.
[3] To prevent injuries during disassembly, prepare a waist-high, stable work platform to perform
work on.
[4] The motor comprises high-precision parts. For this reason, foreign matter adhering to parts
can be damaging. Motor assembly should be done in an inside space without dust, and mud
and dirt should be prevented from adhering to parts.
[5] The motor comprises high-precision parts. For this reason, dents and scratching on part sur-
faces can be damaging. Be very careful when handling parts during assembly and do not
create any dents or scratching.
[6] Be sure to repair any damage discovered during disassembly, and prepare replacement
parts before beginning assembly.
[7] Remove metal fragments and foreign matter from all parts, and check that there are no burrs
or dents on parts before beginning assembly. If there are burrs or dents, use a whetstone to
remove them.
[8] When performing assembly, apply clean hydraulic oil to each sliding and rotating section
before assembly.
[9] Thoroughly degrease areas where Loctite and liquid packing is used, and remove oil and
water before assembly.
[10] Replace all seal parts such as O-rings and backup rings with new parts.
[11] Be careful not to damage O-rings and backup rings during assembly. When assembling O-
rings and backup rings, apply a small amount of grease for assembly.
[12] It is recommended that petroleum jelly or grease be used to prevent parts from falling during
assembly.
[13] Tighten each type of bolt at the fastening sections to the tightening torque indicated in Table
5 in 3. (2). Tightening torque should be controlled with a torque wrench.
[14] After assembly is complete, plug all ports leading into the motor to prevent dirt from entering.
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(2) Assembly procedures
Perform assembly by observing the precautions listed in "(1) Precautions before motor assembly"
and following the procedure indicated below.
1) Reduction gear assembly procedure
a) Assembly of the carrier 2 assembly
[1] Insert the planetary gear 2 (10), needle
bearing (12), and thrust washer 2 (11)
into the carrier 2 (9).

[2] Align the carrier pin 2 (13) with the
spring pin hole and insert it into the car-
rier 2 (9).
[3] Insert the spring pin 10 × 50 (14) into

the carrier pin 2 (9) and carrier pin 2
(13). (Hammer it 1 - 2 mm deeper than
the striking surface.)
[4] Caulk at 2 opposing 180° locations.

• For the direction of inserting the spring
pin and the caulking method, see
"Spring pin and caulking details".
Spring pin and caulking details
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b) Assembly of the carrier 1 assembly
[1] Insert the planetary gear 1 (17), needle
bearing (19), and thrust washer 1 (18)
into the carrier 1 (16).

[2] Align the carrier pin 1 (20) with the
spring pin hole and insert it into the car-
rier 1 (16).
[3] Insert the spring pin 6 × 36 (21) into the

carrier pin 1 (16) and carrier pin 1 (20).
(Hammer it 1 - 2 mm deeper than the
striking surface.)
[4] Caulk at 2 opposing 180° locations.

• For the direction of inserting the spring
pin and the caulking method, see "Dia-
gram 1 Spring pin and caulking details".
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c) Installation of bearing and floating seal
[1] Install the bearings (2) in the inner diam-
eter of the housing (1).
[2] Install the floating seals (5) on the motor
and housing (1).
• Clean the floating seal installation sec-
tion of any oil, dirt, paint, or other foreign
matter.
• Lightly apply gear oil to the sliding sec-
tions of the floating seals (5). (Do not
coat the O-rings with gear oil.)
• Install in such a way that the O-rings do

not become twisted. Check that the
floating seal (5) is correctly installed
between the housing (1) and motor in a
parallel direction, as shown in the dia-
gram. (Use of an insertion jig is recom-
mended.)
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d) Assembly of the housing assembly
[1] Thoroughly coat the housing (1) surface
that matches with the ring gear (3) with
Loctite #515.
[2] Install 3 housing (1) M20 eyebolts and
lift with a wire, and install onto the ring
gear (3) while aligning the reference
marks.

[3] Coat the 25 hexagon socket head bolts
M18 × 110 (4) with Loctite #242, and
tighten the bolts to the tightening torque
of 378 ± 38 N•m.
• For details on applying Loctite #242 to
the bolts, see "Method of applying Loc-
tite #242".
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Travel Unit
e) Determining the thickness of the angular bearing shim
• This needs to be performed when replacing the motor (casing), housing (1), (angular) bearing (2), or
lock washer (7). Otherwise use the previous shim (6) as is.
[1] Press the outer races of the 2 bearings (2) into the housing (1).
[2] Press the inner races of the 2 bearings (2) evenly and measure the inner race installation
width (A).
• Before measuring the inner race installation width, rotate the bearings at least 5 times to
stabilize them.
[3] Measure the bearing installation width (B) of the motor casing.
[4] Measure the lock washer groove width (C) of the motor casing.
[5] Measure the lock washer (7) thickness (D).
• Use the average of the measurements of the 4 orthogonally intersecting points on the cir-
cumference. Measure the dimensions with a precision of 0.01 mm.
[6] When the thickness of the used shim (6) is S, gap X is as follows. X = (B + C) - (A + D +
S)
[7] In the case of this unit, select 1 shim so that gap X is -0.08 - 0.02 mm. ((+) indicates a gap
and (-) indicates pressing.)
Determining the angular bearing shim thickness
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Travel Unit
f) Installation of housing assembly
[1] Place the motor shaft upwards on the
work platform, and place the shim (6)
selected by item e) (Determining the
thickness of the angular bearing shim) on
page 42 on the end surface of the bear-
ing insertion part of the motor casing.

[2] Install and suspend 3 M10 eyebolts to the
ring gear (3), slowly lower it vertically
while aligning it with the motor core, and
insert the bearings (2) installed in the
inner diameter of the housing (1) into the
motor. Use a pressing machine to press
the inner race parts of the bearings (2),
and insert them completely to the bottom.
Press fitting of the housing assembly
[3] Insert the lock washer (7) into the
groove while pressing the flange part of
the housing (1).
[4] Insert the support ring (8) into the out-

side of the lock washer (7).
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Travel Unit
g) Installation of the carrier 2 assembly
[1] Insert the carrier 2 assembly into the
ring gear (3) so that the 3 planetary
gears 2 (10) are at the position indicated
in "carrier 2 installation direction," and
have the gears mesh with the spline of
the motor casing.
Installation of the carrier 2 assembly

[2] Insert the sun gear 2 (15).

• The carrier 2 assembly is assembled at
the position indicated in "carrier 2 instal-
lation direction" to improve oil lubrica-
tion, so be sure to observe this
procedure.
Carrier 2 installation direction

h) Installation of the carrier 1 assembly
[1] Install and suspend 3 M10 eyebolts to
the carrier 1 assembly, insert it into the
ring gear (3), rotate the planetary gear 1
(17) by hand to align it, and then have
the gear mesh with the sun gear 2 (15).

[2] After making sure that the coupling (See
the motor parts Operator's Manual.) is at
the end of the motor shaft, insert the sun
gear 1 (22).
Be very careful not to get hands stuck Installation of the carrier 1 assembly
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Travel Unit
[3] Install the thrust plate (23) on the carrier 1 (16).
• Face the sharp edge toward the cover (24) side.
Thrust plate installation direction

i) Cover attachment
• The gear oil can be filled before installing the cover (24).
[1] Coat the cover (24) surface that
matches with the ring gear (3) with Loc-
tite #515, and install the cover (24) on
the ring gear (3).

parts on feet.
[2] Coat the 18 hexagon socket head bolts
M10 × 30 (25) with Loctite #242 sealant, Applying Loctite to the cover end surface
and tighten the bolts to the tightening
torque of 68.6 ± 6.9 N•m.
• For details on applying Loctite #242 to
the bolts, see "Method of applying Loc-
tite #242".
j) Gear oil filling
[1] Fill the gear oil (SAE90, API GL-4 or GL-
5, 9.5 L) into the filling port G3/4.
[2] Install the hexagon socket head plug
G3/4 (26) to the cover (24) at a tighten-
ing torque of 147.1 ± 14.7 N•m.
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Travel Unit
2) Motor assembly procedure
[1] Apply grease to the oil seal (3) outer cir-
cumference and casing (1) inner circumfer-
ence, and use a insertion jig to tap the oil
seal (3) into the casing (1) evenly so that it
does not fall down.
[2] Use a retaining ring (4) to fasten the oil seal
(3).
[3] Insert the front bearing (10) outer race into
the casing (1). (Clearance fit)
Press fit the inner race into the shaft (9).
(Tight fit)
• Heating the inner race to 100 ℃ or lower
provides for easier press fitting.
Caution Use caution to prevent burns.
[4] Install the shaft (9) into the casing (1).

Apply grease to the surface contacting the
oil seal (3).
[5] Install the tilting piston set.
• Insert the tilting piston (6) so that it is not
tilted.
• When installing the tilting piston (6), apply
grease to the seal parts and insert the pis-
ton carefully so as not to cut anything.
[6] Install the pivot (11). Install it to the side
matching the reference mark on the shoe
plate (12).
When operated for a long period of time,
install it in the direction in which the slide
imprints of the spherical section match the
contact imprints of the shoe plate (12).
[7] Thoroughly grease the 3 spherical sections
of the shoe plate (12) before installation.
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Travel Unit
[8] After sub-assembling piston assembly (18),
shoe retainer (17), spherical joint (16),
spring receiver (15), cylinder spring (14),
and cylinder block (13), insert the entire
assembly into the shaft (9).

on feet.
• The piston assembly (18) must be inserted
into the same holes of the cylinder block
(13) used before disassembly.
[9] Use a specialty insertion jig (A1, A2) to

insert the rear bearing (51) inner race into
the shaft (9).
[10] Alternately install all of the separator plates
(19) and friction plates (20) in turn.
The separator plate (19) should be the first
and last parts.
[11] Use an insertion jig (B) to insert the brake
piston (21) installed with D-rings (22) and
(23) to the casing (1).
• Apply grease to the D-rings (22) and (23).
• Use the insertion jig to make sure the brake
piston (21) is inserted evenly.
The brake piston is equipped with 2 large
and small D-rings (22) and (23). First, the
large-diameter D-ring (23) is inserted into
the hole, and then the small-diameter D-
ring (22) is inserted. The insertion condi-
tion of the small-diameter D-ring (22) can-
not be visually checked, so do not forcefully
insert this D-ring.
This can cause chipping by the casing (1)
hole.
• The shim must be adjusted when replacing parts related to the shim adjustment.
Perform the assembly after determining the shim thickness in advance by using the proce-
dure in "Determining the thickness of the taper roller bearing shim (52)" (page 24) in the dis-
assembly procedure.
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Travel Unit
[12] Install guide pins at 2 vertically-opposite
locations on the casing (1).
[13] Install the valve plate (54) to the rear cover
(24) according to the reference mark made
at the time of disassembly, and then mount
the shim (52), rear bearing (51) outer race,
brake spring (55), and O-rings (50), (47),
(49).
[14] Insert the rear cover (24) into the casing (1)
according to the guide pins, and tighten
with hexagon socket head bolts M18 × 50
(56) at 2 vertically-opposite locations so
that the rear cover is installed in a parallel
orientation. After tightening the bolts,
tighten with hexagon socket head bolts
M18 × 50 (56) at the locations excluding
the 2 locations with installed guide pins.
After tightening the bolts, remove the guide
pins and tighten the remaining 2 locations
with hexagon socket head bolts M18 × 50
(56).

on feet.
• If the outer race of the rear bearing (51) is
removed, do not forget to install the shim
(52). Check whether the O-rings (47), (49),
(50) are installed to the rear cover (24).
• The tightening torque for the hexagon
socket head bolts M18 × 50 (56) is 324 ±
32.4 N•m.
[15] Install the coupling (58).
[16] Install the spring (34), spring receiver (33),
pilot valve spool (31), and pin (32) to the
rear cover (24), and tighten with the pilot
valve plug (35) installed with the O-ring
(36).
• The tightening torque for the pilot valve plug (35) is 49.0 - 588 N•m.
[17] Install the overload relief valve (57).
• The valve seat (57-3) is fit with a clearance fit, so during installation, install the valve seat
after making sure that it will not come off by applying grease to the fitting sections so that the
valve seat does not fall off or become lost.
• The tightening torque for the overload relief valve (57) is 98.1 - 118 N•m.
[18] Install the orifice (40) and orifice spring (41) to the rear cover (24), and tighten with the plug
(42) installed with the O-ring (43).
• The tightening torque for the plug (42) is 14.7 N•m.
• When using a new orifice (40), adjust the seat section.
(With a hammer, tap the orifice installed to the rear cover.)
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Travel Unit
[19] Insert the spool assembly (26) to the rear cover (24) according to the the reference mark
made at the time of disassembly, and then install the spring receiver (27) and spring (28) in
order.
• The spool assembly (26) is directional, so insert it in the correct direction.
[20] Tighten the M42 plug (29) installed with the O-ring (30).
• The tightening torque for M42 plug (29) is 441 - 446 N•m.
(3) Initial pre-conditioning operation
a) Drain charge
After disassembly and assembly, completely fill the case of the motor casing with hydraulic oil.
This motor has 2 drain ports (G1/2). Perform air bleeding from the port on the side without a
line (top side).
b) Performing initial operation (pre-conditioning operation)
Perform a pre-conditioning operation for about 5 min. at the motor tilting 1st speed and engine
low idle, and check for abnormalities, such as abnormal noise or external leaks.
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Travel Unit
6. Troubleshooting
See the troubleshooting section below to perform checking, countermeasures and to solve prob-
lems when any kind of problem occurs in the motor during operation.
(1) General cautions
1) Think before attempting to fix a problem.
Determine the nature of the abnormality before beginning work, and think whether this same
kind of problem has occurred before.
Also, reconfirm whether the motor is the source of the problem.
2) Be careful about dust and dirt.
The cause of wear is very often dust and dirt. So take measures to prevent dust or dirt from
entering the parts during disassembly.
3) Parts handling
Handle parts carefully, be especially careful with the drive section, and do not scratch the slid-
ing sections.
4) Seals handling
Do not damage the seat surfaces of O-rings while performing work.
Also, it is recommended that O-rings be replaced with new ones during disassembly.
(2) Causes of troubles and countermeasures
1) Hydraulic motor does not operate.
Symptom Cause Countermeasure
No pressure rise Operation problem with internal relief valve Repair or replace the relief valve.
1. The parking brake cannot be released. 1. Check the orifice clog, and
(Orifice of release pressure path is then clean or replace the part.
clogged.)
2. The parking brake cannot be released. 2. Install the spool in the correct
(The spool assembly is inverted.) direction.
3. The friction plate or separator plate of 3. Replace the friction plate or
the parking brake section is sticking. separator plate.
Pressure rises.
4. The brake piston of the parking brake 4. Repair or replace the brake
section is sticking. piston outer diameter.
5. Seizing of sliding sections 5. Inspect and then repair or
replace the sliding parts (pis-
ton, shoe, shoe plate, cylinder
block, valve plate, etc.)
6. Spool operation problem 6. Repair or replace.
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Travel Unit
2) Weak startup of the hydraulic motor
The set pressure is normal, but
Spool operation problem
there is a delay in the release of Repair or replace.
(Spool sticking)
the parking brake.
The parking brake is released,
The hydraulic oil viscosity is too high. Raise the oil temperature.
but startup is delayed.
1. The parking brake is not fully released.
(Orifice of release pressure path is 1. Check the orifice clog.
clogged.)
The parking brake is released, 2. Clean the relief valve, and then
but startup is weak. 2. Debris is caught in the relief valve. inspect or replace the seat sur-
face.
3. Inspect and repair or replace
3. Seizing of sliding sections
the sliding parts.
3) Rotation speed does not reach the setting value.

1. Check the pump discharge vol-
1. Insufficient oil flow amount ume and the oil pressure path
Rotation speed does not reach up to the motor.
the setting value. 2. The shoe, cylinder block, or valve plate
2. Inspect and repair or replace
shows signs of wear or serious dam-
the part (s).
age.
4) The brake does not operate.

Parking brake operation problem Inspect and repair or replace the
The brake does not operate. a) Wear on the friction plate brake piston, friction plate, and
b) Broken spring spring(s).
a) Sticking of the spool and main unit
The reverse brake works. b) Sticking of the check valve or debris is Repair or replace.
caught in the check valve
c) Orifice hole is clogged.
5) Oil leak
1. Retighten to the specified
1. Bolt and plug loosening
torque.
Oil leak
2. Gouging of O-ring(s) 2. Replace O-ring(s).
3. Leak inside gear casing 3. Replace the oil seal(s).
6) Cannot shift from high speed to low speed.

Cannot shift from high speed to Inspect and repair or replace the
The pilot valve spool is sticking.
low speed. pilot valve spool.
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Travel Unit
7) Abnormal noise emitted
When braking slowly or braking Spool operation problem
at the same time as operating a Air is remaining in the circuit or valve sec- Air bleeding implementation
circuit other than the motor cir- tion.
cuit, a noise is emitted along
with a strong vibration. Spool sticking Repair or replace.
8) Hunting occurs when lowering the plate.

a) Sticking of the spool and main unit Repair or replace.
Strong hunting occurs during b) Orifice seating problem
inching operation. Interference with parking brake
The springs in the spool end section are Repair or replace.
worn or broken.
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Travel Unit
7. Structural diagram
(1) Travel motor
Diagram 1 Travel motor structural diagram
Code Part name Code Part name Code Part name

1 Casing 21 Brake piston 41 Orifice spring (brake valve)
2 NPT 1/16 plug 22 D-ring (small diameter) 42 G1/8 plug
3 Oil seal 23 D-ring (large diameter) 43 O-ring 1B P8
4 Circle R retaining ring IRTW68 24 Rear cover 44 Check valve
5 Expansion plug 25 NPT 1/16 plug (mec) 45 Check valve spring
6 Tilting piston 26 Spool assembly 46 M6 orifice (φ0.6)
7 Tilting piston seal 27 Spring receiver 47 O-ring 1B P12.5
8 Steel ball 28 Spring 48 M6 orifice (φ0.8)
9 Shaft 29 M42 plug 49 O-ring 1B P15
10 Bearing HR32209J 30 O-ring 1B G40 50 O-ring 215.57 × 2.62
11 Pivot 31 Pilot spool 51 Bearing HR32207C
12 Shoe plate 32 Pin 52 Shim
13 Cylinder block 33 Spring receiver 53 Parallel pin
14 Cylinder spring 34 Spring 54 Valve plate
15 Spring receiver 35 Pilot valve plug G3/8 55 Brake spring
16 Spherical joint 36 O-ring 1B P14 56 Hexagon socket head bolt M18 × 50
17 Shoe retainer 37 Joint 57 Overload valve
18 Piston assembly 38 G1/4 plug 58 Coupling
19 Separator plate 39 O-ring 1B P11 59 C retainer ring 40 for hole
20 Friction plate 40 Orifice (brake valve) 60 G1/2 plug
61 O-ring 1B P18
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Travel Unit
(2) Reduction gear
Diagram 2 Reduction gear structural diagram

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
4 Hexagon socket head bolt M18 × 110 14 Spring pin 10 × 50 24 Cover
5 Floating seal 368 15 Sun gear 2 25 Hexagon socket head bolt M10 × 30
6 Shim 16 Carrier 1 26 Plug G (PF) 3/4
7 Lock washer 17 Planetary 1 27 O-ring 1B P24
8 Support ring 18 Thrust washer 1
9 Carrier 2 19 Needle bearing FBNP-406040
10 Planetary 2 20 Carrier pin 1
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Take-up Roller
Take-up Roller
Removal and Installation of Take-up Roller
・ When loosening the grease cylinder check valve, loosen it a little at a time.
・ The pressure inside the cylinder is very high, so there is a danger of grease being expelled
and the plug flying off. The check valve adjustment procedure should not be done in front of
Warning the check valve.
・ Do not get under the machine when the main unit is jacked up.
・ Make sure to place the main unit on wood planks or the like to prevent falling.
・ Align the shoe assembly feed location and stop the engine except when working.
Items to prepare
• Wrench (24 mm)
• Hammer
• Lifting equipment
• Loctite #262
• Striking jig
• Liftcrane
• Crowbar
• Rag
1. Removal of Take-up Roller
[1] Remove the shoe assembly.
See the "Removal and Installation of Shoe
Assembly" procedure.
[2] Use a crowbar (3) to pull off the take-up roller
(1) and recoil spring assembly from the side
frame (2).
[3] Install the lifting equipment (5) on the take-up

roller (1) and recoil spring assembly (4) and
hang them from the side frame (2) with the lift-
crane.
5 Lifting equipment
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Take-up Roller
[4] Place the take-up roller (1) and recoil spring
assembly (4) onto wood planks (7) as in the dia-
gram. Use a wrench (24 mm) to remove the
take-up roller bolt (6) and separate the roller
and the recoil spring assembly.
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Take-up Roller
2. Installation of take-up roller
[1] Use a wrench (24 mm) to fasten the take-up
roller (1) and recoil spring assembly (2) with the
bolt (3).
At this time, be sure to coat the bolt with Loctite
#262.
[2] Install the lifting equipment (6) on the take-up

roller and recoil spring assembly (2) as in the
diagram, lift them up with the liftcrane, and
insert them into the side frame (5).
Push in with the crowbar until the recoil spring
assembly contacts the grease cylinder.
4 Wood plank
[3] Install the shoe assembly.

For details on installation, see the "Removal and Installation of Shoe Assembly" procedure.
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Take-up Roller
Assembly and Disassembly of Take-up Roller
・ To ensure safe operations, wear protective devices before beginning work and follow all pre-
cautions.
・ When removing devices or positioning devices at the time of installation, use a removal jig
and a hammer or steel rod.
・ Follow the precautions below when suspending the load.
・ The liftcrane must be operated by a qualified operator.
・ Check the weight of the roller to determine whether it can be carried by hand or whether a
liftcrane must be used.
・ Fix the roller to a level surface so it does not roll.
・ Be sure to repair any parts damaged during disassembly, and prepare replacement parts in
advance.
・ If any parts are significantly rusted or dirty, clean them before disassembling.
Caution
・ Any foreign matter entering the equipment during assembly can create a malfunction. There-
fore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and
assemble in a clean location.
・ When assembling sliding (5) parts, be sure to coat them with new hydraulic oil.
・ As a rule, replace all O-rings and other seal parts with new parts.
・ The take-up roller is a heavy object and requires at least 2 workers to handle.
General cautions
・ Be careful not to drop precision parts or let bump them with other parts during work.
・ Do not forcefully open or hit parts in an effort to speed up operations. Pay careful attention
and proceed with caution so as not to damage any parts, create any oil leaks, or compromise
the efficiency of the equipment.
・ Disassembled parts can easily rust or collect dust. Therefore, immediately after disassem-
bling parts, take precautions to prevent the parts from rusting or collecting dust.
Items to prepare
• Hexagon wrench (6 mm)
• Hammer
• Wire clip
• Pliers
• Gear puller
• Screwdriver
• Engine oil (Shell Rimula Oil #30)
• Specialty jigs
• Pressing machine
• Loctite
• Special fiber cloth (Kimwipe)
• Micrometer caliper
• Caliper
• Cylinder gauge
• Seal tape
• Oil pan (drip pan)
• Water container for inspection
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Take-up Roller
Configuration diagram
Code Part name

1 Take-up roller
2 Wrapping bearing
3 Floating seal
4 O-ring
5 Roller shaft
6 Pin hub
7 Hub (with plug)
8 Plug
9 Hub (without plug)
Dimension diagram
Jig dimension diagram

120 145.5
90 152 142
.5 .5
C0 C0
89
70
85
1.0
40
30 X
19
10
5
20 131
C3
A Bushing removal jig

B Bushing press-fit jig
C Floating seal installation jig
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Take-up Roller
Disassembly procedures
[1] After cleaning the roller with kerosene, use the
hexagon wrench (1) to remove the plug (2) from
the hub (3).
• The plug is coated with seal nylon, which comes
off when the plug is removed. Seal tape is nec-
essary for reusing.
[2] Face down the part of the roller from which the
plug was removed and empty the oil from within
the roller.
• It may take a few hours to completely empty the
oil.
• Place an oil pan (4) underneath to catch the oil.
[3] Remove the pin hub (6) from the hub (3), and
remove the hub (3) from the shaft (5).
• Only remove on one side.
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Take-up Roller
[4] After removing the O-ring (7) on the shaft (8),
pull the shaft (6) out from the roller (9).
• The O-ring cannot be reused. Replace them
with new parts.
[5] Remove the pin hub (6) from the hub (3). Next,
after removing the hub (3) from the shaft (8),
remove the O-ring (7) from the shaft (8).
[6] Remove the floating seals (10) from the hub (3).
[7] Remove the floating seals (10) from the roller

(9).
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Take-up Roller
[8] Use a micrometer caliper (11), cylinder gauge
(12), and caliper (13) to measure the roller (with
bushing) (9), hub (3), and shaft (8) for wear and
deformation. Replace with new parts as neces-
sary.
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Take-up Roller
[9] When replacing the bushing (14), remove it by
placing a striking rod (15) against the end sur-
face and striking that with a hammer (16) uni-
formly left and right as in the diagram.
• Do not disassembly the bushing (14) as long as
use has not yet been made impossible due to
wear, etc.
• Be careful not to scratch the inside of the roller
when striking the end of the bushing.
[10] Invert the roller (9), use jig A (17) to push up

against the bushing (14). Pressing with a rod-
shaped object (18) (shaft can be used) will
make the bushing come off.
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Take-up Roller
Assembly procedures
[1] Clean all parts.
• Find a clean location.
• Place a rubber plate or cloth on the work plat-
form so as not to damage the parts.
• In order to clean off adhered matter that forms
sharp points and causes scratches, immerse
parts in cleaning fluid (1) until dirt and grease
float to the top.
[2] After cleaning the parts, air blow them to

remove any remaining cleaning fluid or debris.
• If the parts are to be left as is for a long time
after drying them, apply engine oil.
[3] If the bushing (3) was removed during disas-

sembly, put it into the roller (2). Use a pressing
machine (4) to press in both the left and right
sides.
[4] Use the jigs (5) and (6) attached to the pressing
machine to attach the bushing (3). Use the
pressing machine to press from the opposite
side. Next, use a special fiber cloth to remove all
dust and debris.
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Take-up Roller
[5] Attach the floating seal (8) to the hub (7). Use
jig C (9) to press it into position.
[6] Use jig C (9) to attach the floating seal (8) to the
roller (2) side.
[7] Use a special fiber cloth to thoroughly wipe the

sliding surface of the floating seal to prevent any
dust or scratches.
[8] Apply engine oil to the floating seals (8) on the

hubs.
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Take-up Roller
[9] After attaching the O-ring (12) to the shaft (11),
attach the shaft to the hub (10) and fasten it with
the pin hub (13).
[10] Attach the shaft (11) to the roller (2).
[11] After attaching the O-ring (12) to the shaft (11),

attach the hub and fasten it with the pin hub
(13).
[12] Inject compressed air (0.2 MPa) from the oil fill
port and immerse in water to check that there
are no leaks.
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Take-up Roller
[13] Fill engine oil (120 cc) into the roller main unit.
• The roller main unit can be very unstable, so
give consideration to securing it.
[14] After filling the oil, use a hexagon wrench (6

mm) to tighten the plug (17) with the nylon seal
applied.
• To reuse a plug, wrap it with seal tape.
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Upper Roller
Upper Roller
Removal and Installation of Upper Roller
・ When loosening the check valve, loosen it a little at a time and stop when any grease
appears. The pressure inside the cylinder is very high, so there is the danger of grease being
Warning expelled and the plug flying off if the check valve is loosened too much.
The check valve adjustment procedure should not be done in front of the check valve.
Items to prepare
• Jack (That meets the lifting weight.)
• Rag
• Cleaning fluid
1. Removal of Upper Roller
[1] Use a box wrench (19 mm) to loosen the grease
cylinder check valve (1), then loosen the shoe
tension.
• Grease drains out, so provide rag (2) close to
the drain port.
[2] Use a jack (3) to lift the top of the shoe, and
then insert wood planks (4) to separate the
shoe (5) and upper roller (6) by about 10 mm.
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Upper Roller
bolts (7), and then remove the upper roller (6).
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Upper Roller
2. Installation of Upper Roller
[1] Perform the reverse of the removal procedure.
Apply Loctite to the bolts and tighten them to the
specified torque.
Installation specified tightening torque: 521 -
608 N 疥
[3] To adjust the track shoe tension, raise the lower

side frame as shown in the diagram.
Place a wood plank (2) under the lower frame to
prevent falling.
with A between the frame bottom (3) of the cen-
ter area of the lower side frame and the lowest
hanging part of the top of the shoe plate (4) is
340 - 360 mm.
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Upper Roller
Assembly and Disassembly of Upper Roller
cautions.
advance.
Caution ・ If any parts are significantly rusted or dirty, clean them before disassembling.
・ When assembling touching parts, be sure to coat them with new hydraulic oil.
General cautions
Items to prepare
• Hammer
• Screwdriver
• Engine oil (Shell Rimula Oil #30)
• Specialty jigs
• Loctite 262
• Marking pen
• Caliper
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Upper Roller
Configuration Diagram
4, 5
1
2 4, 5
3 6
8
7
Code Part name
1 Cover
10
2 O-ring
9
3 Plug
11
4 Hexagon bolt
12 5 Loctite
6 Thrust plate
7 Bushing
8 Shaft
9 Bushing
10 Roller
11 Floating seal
12 Bracket
Dimension Diagram
11 12
4 5
6 7 8 9 10
Jig Dimension Diagram

B1 Bushing press-fit jig (10)
B2 Bushing press-fit jig (9)
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Upper Roller
Disassembly Procedures
[1] Stand the roller vertically and use a hexagon
wrench (6 mm) (1) to remove the plug (2).
off when the plug is removed. To reuse the plug,
using seal tape is necessary.
the roller.
oil.
• Place an oil pan (3) under the roller to catch the
oil.

from the cover (5), and then remove the cover.
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Upper Roller
bolts (6) inside the roller, and then remove the
thrust plate (7).
[5] Lift the roller (8) and remove the shaft (9).
[6] Remove the floating seal (10) on the roller.

Check whether the sliding surface has rusted or
is damaged.
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Upper Roller
[7] Remove the floating seal (10) on the shaft (9).
[8] Remove the O-ring (11) on the cover (12) side.

• Check whether the O-ring is twisted. If it is
twisted, replace it with a new one.
[9] Use a micrometer caliper to measure the roller

(with bushing) (8), bracket (14), and shaft (9) for
wear and deformation. Replace with new parts
as necessary.
16 Caliper
17 Micrometer caliper
18 Cylinder gauge
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Upper Roller
[10] When replacing a bushing (19) and (20), use jig
A (15) to restrain it from the side where the shaft
(9) was removed and press it out with a press-
ing machine (13).
8 Roller
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Upper Roller
Assembly Procedures
[1] Clean all parts.
• Find a clean location.
1 Cleaning fluid


sembly, put it into the roller (5). Face up the
thrust plate installation side, restrain from above
using jig B2 (3), and push in with the pressing
machine (4).
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Upper Roller
[4] Invert the roller (5) and insert the bushing (6).
Restraining from above using jig B1 (7), push in
with the pressing machine (4).
Push in all the way to the position where jig B1
stops.
[5] Insert the floating seal (8) into the roller (5) and
bracket (10). Use jig C (9) to press the floating
seal into position.
[6] Use a special fiber cloth to wipe the surfaces of

the floating seals so as to increase adhesion
and prevent dust from entering.
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Upper Roller
[7] Apply hydraulic oil to the roller (5).
[8] Attach the shaft (11) to the roller (5).
[9] Use a special fiber cloth to thoroughly wipe the

surface of the thrust plate (12) to prevent any
dust or scratches.
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Upper Roller
[10] Install the thrust plate (12) with 2 bolts (13).
Degrease the bolts well, apply Loctite (14) to the
bolt openings, and tighten the bolts. After tight-
ening the bolts, mark them (15).
[11] Install the cover (18) with 3 bolts (17). Degrease

the bolts, apply Loctite (14) to the bolt openings,
and tighten the bolts. After tightening the bolts,
mark them (16).
[12] Rotate the roller in the direction of the arrow and

check that it rotates smoothly.
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Upper Roller
are no leaks.
[14] Inject engine oil (50 - 55 cc) into the roller. After
filling the engine oil, use a hexagon wrench (20)
to tighten the plug (21) (coated with seal nylon).
After tightening the bolts, mark them (19).
This completes the assembly.
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Lower Roller
Lower Roller
Removal and Installation of Lower Roller
・ Do not get under the main unit when it is jacked up.
Make sure to place the main unit on wood planks to prevent falling.
Warning ・ When loosening the grease cylinder check valve, loosen it a little at a time and stop when any
grease appears. The pressure inside the cylinder is very high, so there is the danger of
grease being expelled and the plug flying off if the check valve is loosened too much.
Items to prepare
• Rag
• Cleaning fluid
1. Removal of Lower Roller
[1] Use a box wrench (19 mm) to loosen the check
valve (1), and then loosen the shoe tension.
• Grease drains out, so provide rag (2) close to
the drain port.
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Lower Roller
[2] Jack up the side frame on the side where the
roller is being replaced, as shown in the dia-
gram.
Jack up so that the shoe is floating about 5 cm,
and insert wood plank (3) under the lower frame
to prevent falling.
[3] If it is impossible to insert wood plank (3) under

the lower frame, insert wood planks (4) between
the side frame and the link shoe (5) to separate
the link shoe and lower roller (6) by about 15
mm.

bolts (7), and then remove the lower roller (6).
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Lower Roller
2. Installation of Lower Roller
Apply Loctite to the bolts and tighten them to the
specified torque.
Tightening torque: 902 - 1049 N•m
[3] When adjusting the track shoe tension, raise the

lower side frame as shown in the diagram.
Place a wood plank (2) under the lower frame to
prevent falling.
with A between the lower frame (3) of the center
area of the lower side frame and the lowest
hanging part of the shoe plate (4) is 340 - 360
mm.
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Lower Roller
Assembly and Disassembly of Lower Roller
cautions.
advance.
Caution ・ If any parts are significantly rusted or dirty, clean them before disassembling.
・ When assembling sliding parts, be sure to coat them with new hydraulic oil.
General cautions
Items to prepare
• Hammer
• Wire clip
• Pliers
• Gear puller
• Screwdriver
• Gear oil (Mobile Gear Oil SHC320)
• Specialty jigs
• Loctite
• Caliper
• Cylinder gauge
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Lower Roller
Configuration Diagram
Part name
1 Roller
2 Shaft
3 Bushing
4 Floating seal
5 O-ring
6 Collar (with plug)
7 Wire clip
8 Plug
9 Collar (without plug)
Dimension diagram
9 1 2 3 4 5 6
Jig dimension diagram

B Bushing press-fit jig
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Lower Roller
Disassembly procedures
[1] Stand the roller vertically and use a hexagon
wrench (6 mm) (1) to remove the plug (2).
off when the plug is removed. To reuse the plug,
using seal tape is necessary.
the roller.
oil.
• Place an oil pan (3) underneath to catch the oil.
• Securely fasten so that the roller does not fall
over.
[3] Remove the wire clip (4). Tap another wire (5)
with the hammer (6) from the outside to push
out the wire clip that is already in the roller.
• Place the roller horizontally and secure it so it
does not roll before doing this work.
• The wire in the roller is very securely fixed, so
prepare several wire clips. Also be sure to coat
with lubricant.
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Lower Roller
[4] Use pliers (7) to remove the pushed out wire
clip (4).
[5] Use a gear puller (8) to remove the collar (9). If

the collar is difficult to remove, hook the collar
on the bolt and catch the puller on that part.
• If the collar has rusted or is difficult to remove
due to an accumulation of debris, subject it to a
shock, for example by hitting it with a hammer,
to make it easier to move.
• When hitting the collar with a hammer, be care-
ful not to dent it.
[6] Check whether the surface of the floating seal

(10) sliding against the removed collar has
rusted or is damaged. Also check whether the
O-ring (11) is twisted.
• The O-ring cannot be reused. Replace it with
new part.
12 Ring
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Lower Roller
[7] Remove the floating seal (10) on the roller. As
described in step [6] above, check whether the
sliding surface has rusted or is damaged. Also
check whether the O-ring is twisted.
[8] Remove the O-ring (13) on the shaft (14).

• The O-ring cannot be reused. Replace it with
new part.
[9] Remove the shaft (14).
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Lower Roller
[10] As described in Step [7], remove the floating
seal (10) on the opposite side.
[11] Use a caliper (19), micrometer caliper (20), and

cylinder gauge (21) to measure the roller (with
bushing) (17), collars (9) and (18), and shaft
(14) for wear and deformation. Replace with
new parts as necessary.
[12] When replacing a bushing, insert jig A (15) into

the bushing (16), and use a cylindrical object
(such as a shaft) (14) to push from the top.
The bushing comes off.
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Lower Roller
Assembly procedures
[1] Clean all parts by immersing them in cleaning
fluid (1).
• Select a clean location.


sembly, put it into the roller (5). Restraining from
above using jig B (3), push in with the pressing
machine (4).
Invert the roller and insert the bushing on the
opposite side in the same manner.
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Lower Roller
[4] Use jig C (8) to push the floating seal (6) into the
collar (7) and roller (5) by hand.
[5] Use a special fiber cloth to wipe the surfaces of

the floating seals so as to increase adhesion
and prevent dust from entering.
[6] Apply gear oil to the floating seals (6) on the col-
lars (7) and (9).
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Lower Roller
[7] Attach O-rings (11) to the shaft (10) and mount
into the roller (5).
[8] Install the collars (7) and (9) on both sides.
[9] Attach the wire clip (12).

• When attaching the wire clip, secure the roller
main unit so that it does not roll.
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Lower Roller
[10] Turn the main unit and check that the roller
rotates properly.
are no leaks.
[12] Fill gear oil (125 cc) into the roller. Use a hexa-
gon wrench (6 mm) (14) to tighten the plug (13)
with the nylon seal applied.
• Mobile Gear Oil SHC320 is recommended for
use.
• The plug tightening torque is 24.5 N 疥 .
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Swing Unit
Swing Unit
Removal and Installation of Swing Unit

・ Be sure to inspect the wire rope and other lifting equipment before beginning work.
・ When removing this product from the equipment it is mounted on, stop that equipment sys-
Caution
tem and wait for the surface temperature of this product to fall to about 40 ℃ or below before
removing it. Working on this product while it is still hot can cause burns. Additionally, always
bleed out the pressure before removing any line from this product. Removing a pressurized
line can result in oil spraying out and causing injury or oil leak.
Items to prepare
• Wrenches (14 mm, 19 mm, 22 mm, 27 mm, 36 mm, 41 mm)
• Hexagon wrenches (5 mm, 8 mm, 17 mm)
• Pliers
• Hammer
• Grease
• Specialty adapter for vacuum pump connection
• Vacuum pump (vacuum pump power supply)
• Extension cable
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of Swing Unit
bolts (1), and then remove the air breather (2)
on the hydraulic oil tank.
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Swing Unit
[2] Attach the specialty adapter (3) to the area
where the air breather was removed, and set
the vacuum pump.
Create negative pressure in the hydraulic oil
tank using the vacuum pump (4).

(5), and then remove the center cover (6).

hexagon bolts, and then remove the hoses (8)
and (9). Next, use a wrench (41 mm) to remove
the hose (7), use a wrench (36 mm) to remove
the hoses (10) and (11), and use a wrench (22
mm) to remove the hose (12).
• Mark the swing motor and hoses so that the
connectors can be matched during assembly.
• Attach caps or plugs to the swing motor and
• Clean the swing motor and hoses by spraying
them with a parts cleaner to prevent scratching
and prevent dirt from accumulating on the con-
nectors.
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Swing Unit

on the clamp (16) for the hose.

bolts (18) from the swing unit.
17 Drain hose
19 Knock pin
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Swing Unit
[8] Wrap the wire rope (20) around the swing motor
and lift it with a liftcrane.
• A knock pin (19) is driven into the installation
section of the swing unit. Apply lubricating oil to
the knock pin and pull it out together with the
main unit of the swing motor while hitting with a
hammer.

before lowering the swing unit on wood planks
(21).
• Thoroughly secure the swing unit so that it does
not fall over.
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Swing Unit
2. Installation of Swing Unit
When installing the swing unit, be careful with the position of the knock pin.
The tightening torque for the bolts for installing the swing unit on the swing frame is 900 - 1050
N•m.
[2] Before driving, be sure to fill the inside of the motor casing with hydraulic oil from the drain port
(1).
Thoroughly perform air bleeding from the air bleed port (2).
Use the level gauge (3) to check that gear oil for the reduction gear is filled to the stipulated vol-
ume.
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Swing Unit
Assembly and Disassembly of Swing Unit
1. Read and understand the contents of this Maintenance Manual before performing disas-
sembly, reassembly, inspection, repair, or other such work of this product.
2. Handle this product according to the separate "Usage Precautions".
3. When removing this product from the equipment it is mounted on, stop that equipment sys-
4. Use the specialty tools and measurement instruments for disassembly, reassembly, inspec-
tion, and repair, etc. of this product. Using an inappropriate tool may result in injury or prod-
Caution uct damage.
5. Be careful of parts falling when performing disassembly, reassembly, inspection or repair,
etc. of this product. This may result in injury or parts damage.
6. Do not directly touch with bare hands the machined edges or threaded sections of parts
during disassembly, reassembly, inspection, or repair etc. of this product. This may result in
injury.
7. Check performance after reassembly. Do not resume use unless performance is fully recov-
ered. Use may result in damage to product.
8. The cautions (mark !) listed in this Maintenance Manual do not cover all possible dangers.
Always think of safety first during disassembly, inspection, reassembly, repair, or other such
work.
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Swing Unit
1. Disassembly
[1] Making a reference mark on the unit matching
surface
It is useful to place a reference mark (*1) on the
matching surface of the housing (1) and ring
gear (2) with paint, etc.
[2] Removal of level gauge assembly

Remove the level gauge assembly (3) and cap
(4) (27 mm hexagon diameter).
[3] Gear oil draining

Loosen the drain hose (*2) end plug, and then
drain the gear oil.
• Gear oil cannot be reused.
5 Reduction gear
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Swing Unit
[4] Removal of hose
Remove the drain hose (*2).
[5] Removal of motor

Use the hexagon wrench (17 mm) to loosen and
remove the 12 hexagon socket head bolts (6).
Use the make-up port (G1) to raise the motor
and remove it.
• Liquid packing has been applied to the match-
ing surfaces of the housing (7) and ring gear (8),
so use the notch sections (*3) in the diagram on
the right to remove the motor.
5 Reduction gear
This completes the disassembly.
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Swing Unit
2. Assembly
[1] Application of liquid packing
After cleaning and degreasing the reduction
gear ring gear (1) and the motor housing match-
ing surfaces, apply liquid packing (ThreeBond
Co.,Ltd. "1215" gray or the equivalent) as shown
in the diagram on the right (*1).
[2] Motor installation

Lift the motor and gently install it in the reduc-
tion gear, and use the hexagon wrench (17 mm)
to tighten the hexagon socket head bolts (2) to
the tightening torque of 568 N•m.
• Align the housing (3) and ring gear (4) accord-
ing to the reference mark (*2) made before dis-
assembly.
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[3] Gear oil filling
Install a plug in the female side of the hose, and
install a hose (*3) in the drain port on the side of
the gear case.
Fill with gear oil (6 L) from the housing (3) gear
oil fill port.
[4] Installation of level gauge assembly

Install the cap (5) (27 mm hexagon diameter)
into the housing by tightening it to a torque of 49
N•m, and insert the level gauge assembly (6).
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Swing Unit
[5] Grease-up
Remove the plug (8) (5 mm hexagon socket
diameter) from the gear case (7) and inject
grease (1 L) from the grease fill port.
• When injecting grease, there is the possibility of
the reduction gear oil seal being damaged by
internal pressure, so remove the air bleed port
plug before injecting grease.
Tighten the plug to the gear case to a tightening
torque of 20 N•m.
After injecting grease, install the grease hose in
the grease fill port.
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Swing Unit
Assembly and Disassembly of Swing Motor
Caution uct damage.
injury.
ered. Using this product at a sub-par performance level may result in product damage.
work.
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Swing Unit
1. Causes of Trouble and Solutions
This list consists of actions to be taken when an abnormality is sensed or there are problems with
functions during use of the hydraulic motor. Additionally, details concerning disassembly inspection
and reassembly are listed after this, but sufficient caution should be exercised in handling during
these actions so as to prevent scratching of sliding parts of the motor.
[1] General cautions
This list consists of actions to be taken when an abnormality is sensed during use of the hydrau-
lic motor.
General cautions are listed below.
1) Think before attempting to fix a problem.
Determine the nature of the abnormality before beginning work and think whether this same
kind of problem has occurred before.
Also, reconfirm whether the motor is the source of the problem.
2) Be careful about dust and dirt.
The cause of wear is very often dust and dirt. So be careful that dust and dirt do not get into
parts during disassembly.
3) Parts handling
Parts are manufactured with a high degree of precision, so be careful not to scratch them dur-
ing handling.
4) Do not damage O-rings or gasket surfaces while performing work. Also, it is recommended that
O-rings are replaced for new ones during disassembly.
[2] Investigating abnormalities in the motor main unit
It is very difficult to search for the source of troubles in the hydraulic circuits. Inspect the following
items and thoroughly investigate whether the motor is the source of troubles.
1) Inspecting oil within the casing
Remove the drain plug and inspect the hydraulic oil within the casing. If a large amount of metal
particles come out at the same time as oil, it is very likely that there is damage with parts within
the motor.
2) Existence of abnormal noise
Check whether abnormal noise is coming from the motor main unit.
3) Measure pressure for each part.
Do not perform disassembly inspection carelessly. Measure pressure for each part and look for
abnormalities in each area.
4) Measure the amount of oil drained from the motor.
1. Operation is normal if about 30 L/min or less of oil drains from the motor when pressurized
oil is applied after the swing is locked.
2. 2 L/min or less of drained oil at constant swing is normal.
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[3] Trouble conditions and countermeasures
1) Hydraulic motor does not rotate.
Symptom Cause Solution

Pressure does not 1. Incorrect setting of the circuit safety 1. Reset safety valve correctly.
rise. valve 2. Disassemble and inspect.
2. Operation problems with relief valve ① Repair or replace sticking sec-
① Plunger sticking tion(s).
② Clogged plunger orifice ② Disassemble and clean.
3. Plunger seating problem 3. Check seating sections and replace
scratched part(s).
Pressure rises. 1. Overload 1. Eliminate load.
2. Seizing of driving part 2. Inspect and repair piston/shoe, cylin-
3. No release pressure acting on the der/valve plate, etc.
brake 3. Inspect and repair circuit.
4. Piston sticking to the brake 4. Disassemble and inspect.
5. Spool for brake release sticking 5. Disassemble and inspect.
6. Friction plate seizing 6. Disassemble and inspect. Replace
seizing part(s).
2) Rotation direction is reversed.

Reversed rotation 1. Motor rotation direction reversed. 1. Check the rotation direction and
direction 2. Input and output for line reversed. assemble correctly.
2. Correct line configurations.
3) Motor speed is not reaching the set value.

Rotation speed does 1. Insufficient oil flow amount 1. Check the pump discharge volume
not reach the setting 2. High temperature and severe leak of and the circuit up to the motor.
value. oil 2. Lower the temperature of the oil.
3. Wear or damage on each sliding 3. Replace part(s).
section
4) Hydraulic motor does not rotate.

Insufficient braking 1. Wear on the friction plate 1. Disassemble and inspect. Replace
torque 2. Brake piston sticking parts worn beyond the limit.
3. Brake release pressure cannot be 2. Disassemble and inspect.
released. 3. Inspect and repair circuit.
4. Spool for brake release sticking 4. Disassemble and inspect.
5. Damaged friction plate spline 5. Disassemble and inspect. Replace
damaged part(s).
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5) Severe hydraulic motor slipping
Investigate the amount of oil drained from the hydraulic motor. Motor operation is normal if the
amount is 500 cc/min or less.

1. Disassemble and inspect.
Slipping is severe 1. Operation problems with relief valve ① Repair or replace sticking sec-
when an external
① Plunger sticking tion(s).
driving torque acts
on the hydraulic ② Clogged plunger orifice ② Disassemble and clean.
motor. 2. Plunger seating problem 2. Check seating sections and replace
scratched part(s).
6) Oil leak
1) Oil leak from oil seal

Oil leak from oil seal 1. Debris lodged in lip causing scratch- 1. Replace oil seal(s).
ing. 2. Stagger the position(s) of the lip and
2. Shaft scratched or worn shaft(s) or replace it (them).
3. Pressure within the casing becoming 3. Repair any clogged drain line(s).
abnormally high caused oil seal lip to 4. Disassemble and repair.
turn up.
4. Shaft rusted.
2) Oil leak from matching surface

Oil leak from match- 1. O-ring has not been inserted. 1. Insert O-ring(s) and assemble.
ing surface 2. Scratched O-ring 2. Replace part(s).
3. Scratched seal surface 3. Disassemble and repair.
4. Loosened or damaged bolt 4. Tighten to the specified torque or
replace.
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2. Maintenance procedures
[1] Replacement standards for worn parts
If wear on any part exceeds the standard values below, replace or readjust that part.
However, parts should be replaced regardless of these standards if they appear to be extremely
damaged based on appearance.
Table 1. Part replacement standards
Standard Value at which replace-

Item dimensions ment is recommended Solution
(mm) (mm)
Clearances between piston and cylinder Replace the piston(s) or cylin-
0.028 0.058
bore (D-d) der(s).
Piston and shoe caulking section back- Replace the piston and shoe
0 0.3
lash (δ) assemblies.
Replace the piston and shoe
Shoe thickness (t) 5.5 5.3
assemblies.
Friction plate thickness 2.0 1.6 Replace the part(s).
Clearance (D-d) Piston and shoe backlash (δ)
Shoe thickness (t)
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[2] Sliding surface repair standards
If the roughness of the sliding surface in any section exceeds the standard values below, repair or
replace that part.
Table 2. Sliding surface repair standards
Standard surface Surface roughness requiring

Part name
roughness repair
0.8 - Z (Ra = 0.2)
Shoe 3 - Z (Ra = 0.8)
(Lapping)
0.4 - Z (Ra = 0.1)
Shoe plate 3 - Z (Ra = 0.8)
(Lapping)
1.6 - Z (Ra = 0.4)
Cylinder 12.5 - Z (Ra = 3.2)
(Lapping)
0.8 - Z (Ra = 0.2)
Valve plate 6.3 - Z (Ra = 1.6)
(Lapping)
Note:
1) Using lapping, make the degree of surface roughness of each sliding surface equal to or lower
than the standard value.
2) If the plate spring and cylinder spherical surface sliding section are rough, these should be
replaced as a set.
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3. Disassembly
[1] Wrap the wire rope around the outer circumfer-
ence of the motor, lift the motor with a liftcrane,
and clean with white kerosene. After cleaning,
dry the motor using compressed air.
• To prevent foreign matter from entering the
motor, mask each port with tape, etc. and clean
off adhered dirt and dust.
[2] From the drain plug, drain the oil inside the
housing.
[3] Point the shaft end of the drive shaft downwards
and place a reference mark (*1) on the match-
ing surface of the cover (1) and housing (2) with
paint, etc.
• Select a clean location. Place a rubber plate or
cloth on the work platform so as not to damage
the parts.
[4] Loosen the relief valves (3) and remove them

from the cover (1).
• Be sure to replace the O-rings. The O-rings are
damaged when the relief valves are loosened.
[5] Remove the plug (4) from the cover (1) and take
out the spring and plunger.
Be careful not to scratch the plunger seating
sections.
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[6] Loosen the bolts (5) and remove the cover (1)
from the housing (2).
• The cover will rise up from the housing when
the bolts are removed due to the force of the
brake springs.
[7] Remove the valve plate from the cover.
• Do this carefully so as not to let the valve plate
fall from the cover. (The valve plate may be
attached to the cylinder side.)
• When prying open the matching surface with a
screwdriver, be careful not to scratch the sur-
face.
[8] Take out the brake springs (6) from the brake
piston (7).
[9] Use a jig and remove the brake piston (7) from
the housing (2).
• Apply the tips of the jig to the grooves of the
brake piston, and pull straight up.
[10] Reposition the motor on its side, and remove

the cylinder (8) from the drive shaft. Next,
remove the piston, holder plate, plate spring,
and shoe plate.
• Be careful not to scratch the sliding surfaces of
the cylinder, shoe, etc.
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[11] Remove the friction plate and separator plate
(9) from the housing (2).
[12] Take out the drive shaft (11) and shoe plate
(10).
• The spline will damage the oil seal (12) when
the drive shaft is removed, so wrap the spline
section of the drive shaft with vinyl tape, etc.
(*2).
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[13] Perform the following as necessary. Do not
reuse a removed bearing.
• Use a press to remove the inner race of the
roller bearing (13) from the drive shaft (14).
When using a steel rod to hit the inner race of
the roller bearing, hit the inner race evenly while
being careful not to damage the bearing.
• Using a steel rod, tap from the housing section
side of the oil seal, and pull out the outer race of
the roller bearing from the housing.
• Use a slide hammer bearing puller (*3) to
remove the roller bearing (13) from the cover
(1).
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4. Assembly
(1) Preparation before operation
Execute the following preparations before reassembly.
1) Check each part for scratches from use or from disassembly. If there are any scratches,
remove them with a whetstone or sandpaper of the necessary grain, clean with pure cleaning
oil, then dry off with an air blower.
2）Replace seal parts with new ones.
3）Thoroughly clean all parts with cleaning fluid and dry with compressed air.
4）When assembling sliding sections, apply clean hydraulic oil before assembling.
[1] Place the housing on an appropriate plat-
form with the cover on top.
[2] If the roller bearing (1) was removed, shrink
fit the inner race of the roller bearing to the
drive shaft (2).
• Be careful with the direction of the flange of
the roller bearing.
[3] Use a jig to insert the oil seal (4) into the
housing (3).
• Be careful with the direction of the oil seal.
• Apply a thin layer of grease to the oil seal
lip section.
• Be careful to evenly hit it without scratching
the outer circumference.
[4] Use a steel rod to install the outer race of

the roller bearing (1) into the housing (3).
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[5] Mount the drive shaft (2) in the housing (3).
• Carefully insert it so as not to scratch the
lip section of the oil seal.
• Wrap vinyl tape, etc. around the shaft
spline section to protect it.
[6] Lay the housing on its side and insert the

shoe plate (5).
• Install with the larger chamfered side of the
shoe plate on the housing side.
• Apply a thin layer of grease to the matching
surface to prevent it from falling out.
[7] Set the plate spring (7) on the holder plate

(6), and then set the pistons (8).
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[8] Install the piston assembly (9) to the cylin-
der (10).
[9] Align the piston assembly (9) and cylinder

(10) with the drive shaft spline and insert
into the housing.
[10] Set the housing down with the oil seal side
facing downwards, and alternately install
separator plates (12) and friction plates
(11) in that order to the housing. Install the
4 separator plates and 3 friction plates.
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[11] Mount the O-ring (13) to the housing.
• If grease is applied to the O-ring, it will not
break easily when inserting the brake pis-
ton.
[12] Install the brake piston (14) into the hous-

ing.
[13] Install the brake springs (15) into the brake

piston (14).
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[14] If the roller bearing (17) was removed, use
a hammer and steel rod to insert it into the
cover (16).
[15] Install the valve plate (18) on the cover

(16).
• Apply a thin layer of grease to the matching
surface (*1) of the valve plate.
[16] Mount the O-ring (19) to the cover.

• Apply grease to the O-ring.
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[17] Install the cover (16) to the housing and
secure with the bolts (20).
• Be careful with the installation direction of
the valve.
• Make sure that the valve plate does not fall
over.
• Make sure that the brake springs (21) do
not fall over.
[18] Insert the plunger (22) and spring to the

cover (16) and tighten the ROMH plug with
the O-ring.
• Check that the plunger moves smoothly.
[19] Mount the relief valve (23) on the cover

(16).
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[20] Assembly confirmation
Open the input/output ports, apply 3.2 - 4.9
MPa of pilot pressure to the brake release
port to check if the output shaft rotates
smoothly for at least 1 rotation with about
30 - 40 N•m of torque. There is an assem-
bly problem if it does not rotate, so disas-
semble again and adjust it.
• At this time, have the drain port open.
• Check that the set pressure of the relief assembly is at the correct pressure after the hydraulic
motor is installed in the actual machine.
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Brake piston removal jig
1 Brake piston removal jig

2 Brake piston
3 Casing
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Swing motor internal structural diagram
No. Part name Qty No. Part name Qty No. Part name Qty No. Part name Qty
052 valve assyprevention
Reversal 051 Relief valve 2set 303 Valve casing H2 1 702 Brake piston 1
1set
051-1 O-ring 2 351 Plunger H2 2 706 O-ring 1
100 Casing 1 010 Piston subassy 1set 355 Spring H2 2 707 O-ring 1
151 ROH plug 2 101 Drive shaft 1 390 Name plate 1 712 Brake spring 14
161 O-ring 2 111 Cylinder 1 391 Pin 2 742 Friction plate 3
162 O-ring 2 114 Plate spring 1 401 Hex.socket head bolt 4 743 Separator plate 4
163 O-ring 2 121 Piston 9 443 Roller bearing 1 983 Plug 2set
171 Hex.socket head bolt 4 122 Shoe 9 444 Roller bearing 1 984 Plug 1set
400 Reversal prevention 2set 123 Retainer 1 451 Pin 2 985 Plug 1set
valve
124 Shoe plate 1 469 ROMH plug 2 986 Plug 1set
400-1 O-ring 2
131 Valve plate B 1 472 O-ring 1 994 Plug 1set
400-2 Backup ring 2
020 Valve casing H2 subassy 1set 488 O-ring 2
301 Casing K1 1 491 Oil seal 1
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Relief internal structural diagram
1 Seat
2 Poppet
3 Spring
4 Spring seat
5 Shim
6 Liner
7 Piston
8 Cap
9 Backup ring
10 O-ring
11 Holder
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Assembly and Disassembly of Swing Reduction Gear
Caution uct damage.
injury.
ered. Using this product at a sub-par performance level may result in product damage.
work.
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1. Disassembly
(1) Disassembly of swing reduction gear
[1] Remove the plug (11), and then drain the
gear oil.
[2] Remove all bolts (23).
[3] Use a liftcrane to carefully suspend and
remove the swing motor.
[4] Remove the sun gear No.1 (1) and the

planetary carrier No.1 assembly (3).
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[5] Use 2 lifting taps (M10) of the carrier No.2
(29) to remove the planetary carrier No.2
assembly (4) while lifting gently with a lift-
crane.
[6] Remove the sun gear No.2 (5) remaining
on the shaft.
(2) Disassembly of the planetary carrier No.1 assembly

This part cannot disassembled because it has
been caulked.
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(3) Disassembly of the planetary carrier No.2 assembly
[1] Use a jig to insert the spring pins (33) all
the way to the back of the planetary carrier
No.2 (29).
• Do not forcefully insert the parts, as this
can scratch the inner diameter of the pin
holes of the planetary carrier No.2 (29).
[2] Tap from the casting hole on the bottom of

the planetary carrier No.2 (29) and pull out
the planetary pin No.2 (31).
• Be careful not to drop the planetary gear
No.2 (30) and side plate No.2 (32).
[3] Pull out the spring pin (33) from the spring
hole of the planetary pin No.2 (31).
• When securing the planetary pin No.2 (31)
in a vise, use a rag so as not to scratch the
pin.
[4] Perform steps [1] to [3] for 4 locations.
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(4) Disassembly of the case subassembly
[1] Reverse the case subassembly.
[2] Remove the wire (18).
[3] Use 2 lifting tap holes (M16) on the gear
shaft end section (20) to pull out the shaft
subassembly.
(5) Disassembly of shaft subassembly

This part cannot be disassembled.
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2. Assembly
(1) Assembly of subassemblies
1) Assembly of the planetary carrier No.1 assembly (3)
• This part cannot reassembled because it has been caulked. Be careful when assembling.
[1] Insert the planetary gear No.1 (26) and 1
side plate No.1 (28) in order into the plane-
tary pin No.1 (27).
[2] Face the surface with the counterbore of
the internal teeth gear of planetary carrier
No.1 (25) upward, and place on top of the
jig.
[3] Face the notch with the planetary pin No.1

(27) flange section toward the side of the
outside of the circumference of the plane-
tary carrier No.1 (25), and press fit the
planetary carrier No.1 assembly. Be careful
not to pinch side plate No.1 (28). After con-
tinuing to apply press-fit force for about 5 or
6 sec. after press fitting, release the press-
fit force and remove the jig. Do not insert by
striking with a hammer or other tool, as this
can cause the inner diameter of the plane-
tary carrier hole to stick, reducing the pin
holding force and resulting in damage.
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[4] Invert the planetary carrier No.1 assembly.
Caulk using the following procedure.
Rotate the planetary gear No.1 (26) by
hand and check that there is no rotation
unevenness or catching.
[5] Use a caulking jig (*1) to caulk the plane-

tary pin No.1 (27) end section by opening
the end section.
If linear chips form during caulking, be sure
to remove the chips.
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[6] Rotate the planetary gear No.1 (26) by
hand and check again that there is no rota-
tion unevenness or catching. If there is any
rotation unevenness or catching, reassem-
ble using a new part.
Perform steps [1] - [6] at 3 locations to complete operations.
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2) Assembly of the carrier No.2 subassembly (4)
[1] Slide the planetary gear No.2 (30) and side
plate No.2 (32) from the side of the plane-
tary carrier No.2 (29), and place at the
specified position.
[2] Insert the planetary pin No.2 (31) from the

pin hole on the upper side of planetary car-
rier No.2 (29). Insert while being careful
with the insertion direction of the planetary
pin No.2 (31) and the planetary carrier No.2
(29) spring pin (See 3) Assembly of shaft
subassembly.).
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[3] Check that the spring pin insertion holes of
the planetary carrier No.2 (29) and plane-
tary pin No.2 (31) match, and then use a jig
to hammer the part while paying attention
to the direction (joint facing upward) and
depth (1 mm) of the spring pin 10 × 40 (33).
After hammering, use a punch to punch at
a position about 1 mm from the spring pin
hole, and then perform caulking by deform-
ing the spring pin hole.
[4] Rotate the planetary gear No.2 (30) by

hand and check that there is no rotation
unevenness or catching. If there is any
rotation unevenness or catching, disas-
semble according to "1. (3) Disassembly of
the planetary carrier No.2 assembly" and
reassemble using this procedure.
When reassembling, assemble using a new
pin for the spring pin 10 × 40 (33). (Using
the spring pin prior to disassembly can
reduce the holding force and result in dam-
age.)
Perform steps [1] - [4] at 4 locations to complete operations.
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3) Assembly of shaft subassembly
This describes how to assemble the subassembly of this part by shrink fitting it.
[1] Use a roller bearing (16) and pipe spacer
(19) to warm up to a temperature about 50
℃ warmer than the outside air. The roller
bearing (16) retainer is made of plastic, so
be careful not to deform the part with
excessive temperature. (Less than the
maximum temperature of 120 ℃ )
[2] Place the gear shaft (20) on the platform

with the 2 end surfaces with tapping facing
up.
[3] Be careful to insert the pipe spacer (15) in
the correct up-down direction.
[4] Remove the roller bearing (16) from the
bearing heater and insert.
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[5] When the temperature of the roller bearing
(16) reaches to about the temperature of
the outside air, grease up the inside of the
roller bearing (16).
[6] Be careful to insert the bearing cover (17)
in the correct up-down direction.
[7] Remove the pipe spacer (19) from the
bearing heater, and be careful to insert the
pipe spacer (19) in the correct up-down
direction.
[8] When the temperature of the pipe spacer

(19) reaches to about the temperature of
the outside air invert the pipe spacer,
grease up the inside of the roller bearing
(16), and place additional grease (*1) on
top of the roller bearing (16).
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4) Assembly of the case subassembly
[1] Turn the gear case (8) upside-down (with
the large flange up) and place on a surface
plate.
[2] Use lifting taps (M16, 2 locations) of the
gear shaft (20) to insert the shaft subas-
sembly (1) - 3) into the gear case (8) while
lifting with a liftcrane.
[3] Install the wire (18). If not installed suffi-

ciently, the shaft subassembly (1) - 3) can
come off and result in damage, so make
sure that it is properly installed.
[4] Invert the case subassembly being oper-

ated and place it on the jig.Be careful not to
allow the shaft end section to touch the
ground, as the shaft can fall out.
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[5] Coat the outer circumference of the oil seal
(12) with liquid packing (13) and press fit
with a jig. Apply a thin coat of grease to the
seal lip section and be careful to press fit
without scratching the lip.
[6] Be careful to insert the pipe spacer (10) in

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[7] Use a jig to press fit the roller bearing (9)
into the gear case (8).
[8] Hammer in the 4 knock pins (7).

[9] Degrease the gear case (8) end surface
and apply the liquid packing (22) evenly.
[10] Install while paying attention to the up-

down orientation of the ring gear (6) and
position of the knock pins (7), and tighten
the jig bolts (M20 × 200 hexagon socket
head bolt) and spacers (outer diameter:
φ27.2, inner diameter: φ21.6, height: 20)
at each of the 3 locations.
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[11] Screw in the plugs (11) and (14) in the
drain port on the gear case (8) side.
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(2) Assembly of the swing reduction gear
[1] Set the case subassembly (1) - 4) on the
jig.
[2] Use lifting taps (M10, 2 locations) of the
planetary carrier No.2 (29) to install the
case subassembly (1) - 4) while lifting the
planetary carrier No.2 subassembly (4)
with a liftcrane. (Picture 27) If installation is
difficult, rotate the carrier a little to make
installation easier.
[3] Insert the sun gear No.2 (5).
[4] Insert the thrust plate (2) into the grooves

on the sun gear No.2 (5) end surface.
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[5] Insert the planetary carrier No.1 subas-
sembly (3).
[6] Be careful to insert the sun gear No.1 (1) in

[7] Check that the distance between the end

surfaces of the sun gear No.1 (1) and ring
gear (6) is 1.04 - 3.70 mm (sun gear No.1
(1) is lower than ring gear (6)).
If the distance is less than 1.04 mm
• The gear shaft (20) and roller bearing (16)
are shifted.
• The roller bearing (9) is not inserted all the
way to the back.
• Foreign matter is caught inside.
If the distance is greater than 3.70 mm
• The wire (18) installation is insufficient.
• The ring gear (6) is not tightened all the
way on the gear case (8).
• Foreign matter is caught inside.
These are possible causes, so disassem-
ble and reassemble the part.
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[8] After removing the spacer and jig bolt used
to assemble the case subassembly (1) - 4)
and degreasing the ring gear (6) end sur-
face, apply the liquid packing (22) evenly.
[9] After degreasing the screw section of the

hexagon socket head bolt M20 × 200 (23)
attaching the swing motor, apply the liquid
packing (24) to the screw section, and
tighten to a tightening torque of 568.4 -
649.7 N•m at 12 locations.
[10] Fill with 6 liters of gear oil (viscosity classifi-

cation: GL-4 L or greater).
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Jig 1
(For assembly of oil seal (70))
Jig 2
(For assembly of pinion shaft (61))
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SH330-5 Swing reduction gear internal structure diagram
Code Part name Code Part name

1 Sun gear No.1 13 Liquid packing
2 Thrust plate 14 Plug with seal nylon
3 Planetary carrier No.1 assembly 15 Pipe spacer
4 Planetary carrier No.2 assembly 16 Roller bearing
5 Sun gear No.2 17 Bearing cover
6 Ring gear 18 Wire
7 Knock pin D16 × 40 19 Pipe spacer
8 Gear case 20 Gear shaft
9 Roller bearing 21 Grease (Lithium-series, consistency number: 2)
10 Pipe spacer 22 Liquid packing
11 Plug with seal nylon 23 Hexagon socket head B M20 × 200
12 Oil seal 24 Liquid packing
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Planetary Carrier No.1 Assembly Diagram
KSC0245X-B00
Planetary Carrier No.2 Assembly Diagram
KSC0246X-B00
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Center Joint
Center Joint
Removal and Installation of Center Joint
Items to prepare
• Hexagon wrenches (5 mm, 8 mm)
• Specialty adapter for vacuum pump connection
• Vacuum pump (vacuum pump power supply)
• Extension cable
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
1. Removal of center joint
bolts (1), and then remove the air breather (2)
on the hydraulic oil tank.

the vacuum pump (4).
tank using the vacuum pump.
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Center Joint
bolts (5), and then remove the lower under cov-
ers (6).
[4] Prepare a waste oil can (7) to receive the oil that
spills out under the center joint.
[5] Use a wrench (41 mm) to remove the travel

hoses (8) and a wrench (27 mm) to remove the
drain hoses (9).
• Mark the center joint and hoses so that the con-
nectors match at the time of assembly.
• Attach caps or plugs to the center joint and
• Clean the center joint and hoses by spraying
nectors.
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Center Joint
[6] Use a wrench (19 mm) to remove the pilot hose
(10) and a wrench (27 mm) to remove the drain
hose (11).
• Attach caps or plugs to the center joint and
• Clean the center joint and hoses by spraying
nectors.

(12), and then remove the center joint lock bar
(13).
[8] Use a hexagon wrench (8 mm) to remove each

group of 4 hexagon bolts, and then remove the
4 travel hoses (14).
• Mark the hoses so that the connectors can be
matched during assembly.
• Attach caps or plugs to the hoses to prevent any
entry of water, dust or dirt.
• Clean the hoses by spraying them with a parts
cleaner to prevent scratches and prevent dirt
from accumulating on the connectors.
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Center Joint
[9] Wrap a wire ropes (15) around the center joint
and suspend it with a liftcrane so that the center
joint does not fall during removal and installation
operations.

(16) from the center joint.
[11] Use the wire rope (15) and liftcrane to lift the
center joint (17).
before lowering the center joint on wood planks.
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Center Joint
2. Installation of center joint
The tightening torque for the center joint bolts
(1) is 109 - 127 N•m.
[2] The tightening torque for the lock bar (2) bolts
(3) is 267 - 312 N•m.
Also, apply Loctite #262 to the bolts.
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Counterweight
Counterweight
Removal and Installation of Counterweight
・ Be sure to inspect the wire rope and other lifting equipment before beginning work.
Caution ・ Do not stand or pass under the suspended load.
・ Thoroughly secure the removed counterweight with the wire ropes and liftcrane so that it
does not fall over.
Items to prepare
• Balance lifting device
• Wire rope (with the required breaking load × 4)
• Rag
• Cleaning fluid
1. Removal of counterweight
[1] Install the shackles (1), and then use the wire
ropes (2) and liftcrane to secure the counter-
weight so that it does not fall during removal and
installation operations.

bolts (3) at the bottom section of the counter-
weight.
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Counterweight
[3] Use the wire ropes and liftcrane to lift and
remove the counterweight.
• Move the counterweight about 50 cm to the rear
while lifting it so that it does not interfere with
the housing, engine parts and pipes.

before lowering the counterweight on wood
planks (8).
• Thoroughly secure the counterweight with the
wire ropes and liftcrane so that it does not fall
over.
2. Installation of counterweight
The tightening torque for the counterweight bolts is 1862 - 2058 N•m.
Do not apply oil, etc. to the bolts.
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Hydraulic Pump
Hydraulic Pump
Removal and Installation of Hydraulic Pump

Items to prepare
• Wrenches (10 mm, 13 mm, 17 mm, 19 mm, 27 mm, 30 mm, 36 mm, 41 mm)
• Nylon sling (with the required breaking load)
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of hydraulic pump
[2] Remove the engine hood. For the procedure,

see "Removal and Installation of Engine Hood".
[3] Tighten the cock (3).
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Hydraulic Pump
plug (5).
[6] Remove the drain plug (6).
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Hydraulic Pump
[7] Drain the fuel.
[8] Loosen the hose bands (8), and then remove

the 2 hoses (7).
(9), and then remove the fuel filter (10).
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Hydraulic Pump
[10] Remove the charge fuel pump filter.
For the procedure, see "Charge Fuel Pump Fil-
ter in Procedures for Replacing Consumable
Parts".
plug (12) of the fuel pre-filter (11).
[12] Loosen the cap (13) at the bottom and drain out
any remaining fuel.
* Put a waste oil case (14) underneath.
[13] Remove the 2 hoses (15).

and then remove the fuel pre-filter (11).
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[15] Remove the engine oil filter hoses (17).
[16] Use a wrench (13 mm) to remove the bolts (18),
and then remove the engine oil filter (19).
[17] Remove the 3 pilot filter (20) hoses (21).

(22), and then remove the pilot filter (20).

(23), and then remove the 4 covers (24), (25),
(26), and (27).
[20] Use a wrench (19 mm) to remove the bolts, and
then remove the right housing frame (28).
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[21] Remove the hoses and connectors that are con-
nected to the pump.
• Use a hexagon wrench (10 mm) to remove the 8
hose bolts (29), and remove the pressure hoses
(30).
• Use a wrench (41 mm) to remove the drain hose
(31).
• Use a wrench (27 mm) to remove the pilot hose
(32).
• Use a wrench (36 mm) to remove the suction
hose (33).
• Remove the connectors (34).
• Use a wrench (19 mm) to remove the hydraulic
pilot hoses (35).
• Use a hexagon wrench (14 mm) to remove the
suction line bolt and remove the suction line
(36).
• Mark the pump and hoses so that the connec-
• Attach caps or plugs to the pump and hoses to
• Clean the pump and hoses by spraying with a
parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.
[22] Secure the pump with a liftcrane and nylon sling
(37) so that it does not fall during removal and
installation operations.
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(38) from the pump.
[24] Use a liftcrane and the nylon sling (39) to pull

the pump out from the shaft and lift the pump.

before lowering the pump on wood planks (40).
• Thoroughly secure the pump so that it does not
fall over.
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Hydraulic Pump
2. Installation of hydraulic pump
The tightening torque for the pump bolt (38) is 63.7
- 73.6 N•m.
Fill the pump case with hydraulic oil from the drain
port so that no air remains in the pump case.
Additionally, when there is a 2nd option gear pump,
bleed off air from the air bleed port on the top sur-
face of the power take-off case.
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Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit
1. Tools
The table below shows the tools required for assembly and disassembly of the K3V/K5V pump. The
bolts and plugs may vary by pump type.
Tool name Tools dimensions

Hexagon wrench 4, 5, 6, 8, 14, 17 (B dimension, mm)
Socket wrench, double-head (single-head) wrench 19, 27 mm
Monkey wrench Medium-sized
Screwdriver Flathead screwdriver (medium-sized) × 2
Plastic hammer
Torque wrench With adjustable specified torque tightening
Snap ring pliers For stop ring, TSR-160
Steel rod Key material steel rod, 10 × 8 × 200
Tweezers
Bolt M8, L = about 50
2. Disassembly procedures
When disassembling the pump, read the disassembly procedures all the way to the end before dis-
assembling according to the sequence below.
The numbers in the parentheses after the part names indicate part numbers in the pump structural
diagram.
This manual lists the disassembly procedures for the tandem pump. Perform disassembly using the
type column as reference.
Also, be careful that parts from the front pump and rear pump do not get mixed together.
[1] Select a location for disassembly.
[2] Use cleaning oil to remove any dirt or rust from
the surface of the pump.
[3] Remove the drain port plugs (468) and drain the
oil from the pump casing.
• Remove the plugs from both the front and rear
pumps.
[4] Remove the hexagon socket head bolts (412,
413), and remove the regulator.
• See the manual for the regulator for how to dis-
assemble the regulator.
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[5] Loosen the hexagon socket head bolts (401)
that fasten together the swash plate support
boards (251), pump casings (271), and valve
block (312).
• When a gear pump, etc. is attached to the pump
rear surface, remove the gear pump, etc. first
before performing work.
[6] Face down the pump regulator installation sur-
face horizontally on the work platform, and sep-
arate the pump casing (271) and valve block
(312).
• When placing the regulator with the installation
surface facedown, be sure to place a rubber
plate or similar material on the work platform so
as not to damage the regulator installation sur-
face.
• When separating the pump casings and valve
block, remove the 1st gear at the same time.
[7] Remove the cylinder blocks (141) out from the
pump casings (271) in a straight line in relation
to the drive shafts (111), and remove the pis-
tons (151), holder plates (153), spherical bush-
ings (156), and cylinder springs (157) at the
same time.
• Be careful not to damage the sliding surfaces of
the cylinders, spherical bushings, shoes, and
swash plates.
[8] Remove the hexagon socket head bolts (406)

and remove the seal cover (F) (261).
• Removal can be performed easily by inserting a
bolt into the hole on the seal cover (F) and then
pulling the bolt out.
• The seal cover (F) has an oil seal, so be careful
not to damage the oil seal when removing the
seal cover.
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[9] Tap the installation flange section of the swash
plate support board (251) on the pump casing
side, and separate the swash plate support
board and the pump casing.
[10] Remove the shoe plates (211) and swash plates

(212) from the pump casings (271).
[11] Lightly strike the shaft end sections of the drive

shafts (111, 113) with a plastic hammer, etc. to
remove the drive shafts from the swash plate
support board.
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[12] Remove the valve plates (313, 314) from the
valve block (312).
• These can also be removed in Step [6].
[13] If necessary, remove the stopper (L) (534), stopper (S) (535), servo piston (532), and tilting pin
(531) from the pump casing (271), and remove the needle bearing (124) and 1st gear (116) from
the valve block (312).
• To avoid damaging the heads of the tilting pins, use a jig when removing them.
• Loctite has been applied to the sections where the tilting pins and servo pistons are bonded, so
be careful not to damage the servo pistons.
• Try to avoid removing the needle bearings unless they are at the end of their service life.
• Do not loosen the hexagon nuts of the valve block or swash plate support boards. This changes
the flow volume setting.
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3. Assembly procedures
The assembly procedure is the reverse of the disassembly procedure. However, follow the precau-
tions below.
[1] Be sure to repair any parts damaged during disassembly, and prepare replacement parts in
advance.
[2] Thoroughly clean all parts with cleaning oil and air blow them before assembly.
[3] Be sure to apply clean hydraulic oil to sliding parts and bearings before assembly.
[4] As a rule, replace all O-rings, oil seals, and other seal parts with new parts.
[5] Use a torque wrench to tighten all installation bolts and plugs to the torque specified in "Mainte-
nance Standards."
[6] Be careful not to mix up the pump parts for the front and rear.
[1] Install the swash plate support board (251) on
the pump casing (271) by lightly striking it with a
hammer.
• If the servo pistons, tilting pin, stoppers (L), and
stoppers (S) have been removed, assemble
these parts on the pump casings in advance.
• To avoid damaging the heads of the tilting pins
and the feedback pins, use a jig when tightening
the servo pistons and tilting pins. Also be sure
to apply Loctite (moderate strength) to the
threaded sections.
[2] Face down the regulator installation surface of

the pump casing, insert the tilting bushing of the
swash plate onto the tilting pin (531), and cor-
rectly mount the swash plate (212) and swash
plate support board (251).
• Use the fingertips of both hands to check that
the swash plates move smoothly.
• Coat the swash plates, swash plate support
boards, and all sliding sections with grease for
easier installation of the drive shaft.
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[3] Install the drive shaft (111) with a bearing (123),
bearing spacers (127), and stop ring (824)
attached to the swash plate support board
(251).
• Do not strike the drive shaft with a hammer, etc.
• Lightly strike the outside ring of the bearing with
a plastic hammer to install it, and use a steel
rod, etc. to tightly insert it all the way in.
[4] Attach the seal cover (F) (261) to the pump cas-
ing (271), and secure with the hexagon socket
head bolts (406).
• Apply a thin layer of grease to the oil seal inside
the seal cover (F).
• Be careful not to damage the oil seal when
attaching it.
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[5] Assemble the piston cylinder subassembly [cyl-
inders (141), pistons (151, 152), holder plates
(153), spherical bushings (156), spacers (158),
cylinder springs (157)], and insert it into the
pump casing in alignment with the phase of the
splines of the spherical bushings and cylinders.
[6] Install into the valve block (312) while aligning

the valve plate (313) with the pin (885).
• Be careful not to mistake the suction and dis-
charge directions of the valve plates.
[7] Install the valve block (312) into the pump cas-
ing (271) and tighten it with the hexagon socket
head bolts (401).
• Assembly is easier when starting with the rear
side pump.
• Install the valve block in the correct direction.
(Install the valve block with the regulator facing
up and the suction flange facing to the right
when looking at the valve block from the front.))
• Insert the 1st gear into the valve block before-
hand and couple it with the drive shaft joint sec-
tion spline.
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[8] Insert the feedback pins of the tilting pins into
the feedback lever of the regulators, install the
regulators, and tighten the hexagon socket head
bolts (412, 413).
• Install the regulator, making sure not to mistake
the front and the rear of the regulator.
[9] Attach the drain port plugs (468) to finish

assembly.
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Pump Main Unit Maintenance Standards
1. Standards for replacing worn parts
If any part exceeds the standard values below and is worn, replace or readjust that part. If, however,
the appearance of the part shows significant damage, replace that part.
Standard dimensions/
Part name and inspection item recommended replace- Solution
ment value
Piston and cylinder bore clearance
0.038/0.065 Replace the piston or cylinder.
(D-d)
Piston, shoes, and caulking section
0 ～ 0.1/0.3 Replace piston and shoe assembly.
backlash (δ)
Shoe thickness (t) 5.4/5.0 Replace piston and shoe assembly.
Free height of cylinder springs (L) 40.9/40.1 Replace cylinder springs.
Assembled height of holder plate
23.8/22.8 Replace holder plate or spherical bushing.
and spherical bushing (H-h)
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2. Standards for repairing cylinders, valve plates, and swash plates (shoe plates)
Valve plate (sliding section) Surface roughness requiring
3-Z
Swash plate (shoe plate section) repair
Cylinder Standard surface roughness
0.4 Z or lower (lapping)
Surface roughness (repair value)
3. Tightening torque
Tightening torque Tool name
Part name Size
(N•m) (mm)
M5 6.9 B=4
M6 11.8 5
M8 29.4 6
M10 56.9 8
Hexagon socket head bolt M12 98.1 10
M14 156.9 12
M16 235.4 14
M18 333.4 14
M20 431.5 17
R 1/16 70 4
R 1/8 105 5
Rc plug
Note: Wrap seal tape around the R 1/4 175 6
Hexagon
plug 1.5 - 2 times
R 3/8 350 8 wrench
R 1/2 500 10
G1/4 300 6
G1/2 1,000 10
G3/4 1,500 14
PO plug
G1 1,900 17
G1 1/4 2,700 17
G1 1/2 2,800 17
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Overall view
Attached diagram 1. pump assembly cross-section diagram
Drive shaft front side Drive shaft rear side
Drive shaft front side
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Part table
Code Part name Q'ty Component part no. (quantity) or type Code Part name Q'ty Code Part name Q'ty
04 Gear pump 1 set ZX15LHRZ2-07A-V 111 Drive shaft (F) 1 531 Tilting pin 2
011 Piston subassembly 2 set 151 (9PC), 152 (9PC) 113 Drive shaft (R) 1 532 Servo piston 2
013 Cylinder subassembly (R) 1 set 141 (1PC), 313 (1PC) 114 1 set gear 1 534 Stopper (L) 2
014 Cylinder subassembly (L) 1 set 141 (1PC), 314 (1PC) 123 Cylinder roller bearing 2 535 Stopper (S) 2
030 Swash plate subassembly 2 set 212 (1PC), 214 (1PC) 124 Needle roller bearing 2 541 Seat 4
041 Check valve 1 subassembly 2 set 541 (1PC), 543 (1PC), 545 (1PC) 127 Bearing spacer 4 543 Stopper 1 2
042 Check valve 2 subassembly 2 set 541 (1PC), 544 (1PC), 545 (1PC) 141 Cylinder block 2 544 Stopper 2 2
Electromagnetic proportional 151 Piston 18 545 Steel ball 4
079 pressure reducing valve and 1 set KDRDE5KR-V3-V 152 Shoe 18 548 Feedback pin 2
casing subassembly
153 Holder plate 2 702 O-ring 2
530 Tilting pin subassembly 2 set 531 (1PC), 548 (1PC)
156 Spherical bushing 2 710 O-ring 1
1 Adhesive (ThreeBond No. 130SN) coating 157 Cylinder spring 18 714 O-ring 1
Oil seal outer circumference Lubricant (SEALUB L101) 211 Shoe plate 2 717 O-ring 2
1 coating 212 Swash plate 2 724 O-ring 16
3 Right rotation valve plate 214 Tilting bushing 2 725 O-ring 6
4 Left rotation valve plate 251 Swash plate support board 2 728 O-ring 4
5 Tightening torque Flange socket (4-M10 × 1.5) 33 N•m 261 Seal cover (F) 1 732 O-ring 2
6 Tightening torque Hexagon bolt (3-M6 × 1.0) 12 N•m 271 Pump casing 2 774 Oil seal 1
312 Valve block 1 789 Backup ring 2
313 Valve plate (R) 1 792 Backup ring 2
314 Valve plate (L) 1 808 Hexagon nut 2
326 Cover 1 824 Stop ring 2
401 Hexagon socket head bolt 8 885 Valve plate pin 2
406 Hexagon socket head bolt 4 886 Spring pin 4
414 Hexagon socket head bolt 4 901 Eyebolt 2
466 VP plug 2 Hexagon socket head locking
953 2
screw
467 VP plug 2
954 Locking screw 2
468 VP plug 4
981 Nameplate 1
490 Plug 27
983 Driving tack 2
492 Plug 12
Drive shaft rear side
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4. Operation explanation
[1] Flow control
The pump discharge flow is controlled as desired with the pilot pres-
sure Pi as in the diagram on the right.
1) Flow reduction operation
When the pilot pressure Pi increases, the pilot piston (643) moves
to the right and stops at the location where the pilot spring (646)
force and hydraulic pressure force balance each other.
The pin (875) fixed to lever 2 (613) fits into the crimped groove sec-
tion [A section] of the pilot piston, so lever 2 rotates through the
movement of the pilot piston with point B [fastened by the fulcrum
plug (614) and pins (876)] as the fulcrum. The pin (897) fixed to the
feedback lever (611) projects into the large opening [C section] of lever 2, so as lever 2 rotates,
the pin (897) moves to the right. The pin (548) fixed to the tilting pin (531) that shakes the
swash plate is bonded to the 2-side width section [D section] of the feedback lever. Therefore,
as the pin (897) moves, the feedback lever rotates with section D as the fulcrum. Since the
spool (652) is linked to the feedback lever via the pin (874), the spool moves to the right.
When the spool moves, the discharge pressure P1 is led to the servo piston large-bore cham-
ber via the spool and port. The discharge pressure P1 is always led to the servo piston
small-bore chamber, but the servo piston is moved to the right due to the surface area differ-
ence and the tilting angle is reduced.
When the servo piston moves to the right, point D also moves to the right. The return spring
(654) is mounted on the spool. Since force pulling the spool to the left is always acting, the pin
(897) is pressed into the large opening (C section) of lever 2. Because of this, accompanying
the point D movement, the feedback lever rotates around the point C as the fulcrum and the
spool moves to the left.
This movement causes the open section between the sleeve (651) and the spool (652) to begin
to close, and the servo piston stops at the point the open section fully closes.
2) Flow increase operation
When the pilot pressure Pi decreases, the pilot piston (643) is moved to the left by the pilot
spring (646) force and lever 2 (613) rotates with point B as the fulcrum. The pin (897) is pressed
in the large opening [C section] of lever 2 by the return spring (654) via the spool (652), pin
(874), and feedback lever (611), so accompanying rotation of lever 2, the feedback lever rotates
with point D as the fulcrum and the spool moves to the left.
When the spool moves, the port opens to the tank port, so the pressure in the large-diame-
ter section of the servo piston drains out, the servo piston is moved to the left by the discharge
pressure P1 of the small-diameter section and the flow increases.
Accompanying the movement of the servo piston, point D moves to the left, the feedback lever
rotates with point C as the fulcrum, and the spool moves to the right. This operation continues
until the open section between the spool and sleeve closes, and then the servo piston stops at
the point the open section fully closes.
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[2] Horsepower control
As in the diagram on the right, the pump tilting angle decreases
when the load pressure increases and overload of the power
source is prevented and overload of the self pump is prevented.
The regulator utilizes a method to control horsepower in which a
hydraulic force that is the sum of the self pump pressure multiplied
by 1.33 and the counterpart pump pressure multiplied by 0.67 is
transmitted as a signal.
Compensation piston surface area
　Self pump pressurized area: counterpart pump pressurized area = 2 : 1
1) Overload prevention operation

When the self pump discharge pressure P1 or the counterpart pump discharge pressure P2
rises, since P1 and P2 act on the stepped section of the compensation piston (621), the com-
pensation rod (623) is pressed to the right and moves to the location where the force of the
outer spring (625) and inner spring (626) balance out the hydraulic pressure force. The move-
ment of the compensation rod is transmitted to lever 1 through the pin (875) and lever 1 rotates
around the pin (876) (point E) fastened to the casing (601). The pin (897) fixed to the feedback
lever (611) projects into the large opening [F section] of lever 1, so as lever 1 rotates, the feed-
back lever rotates with point D as the fulcrum and the spool (652) moves to the right.
When the spool moves, the discharge pressure P1 is led to the large-bore chamber of the servo
piston via the port, the servo piston is moved to the right, and the pump discharge flow is
decreased to prevent overload of the power source.
The servo piston movement is transmitted to the feedback lever via point D. The feedback lever
rotates with point F as the fulcrum and the spool moves to the left. The spool moves until the
open section with the sleeve (651) closes, and then the servo piston stops at the point the open
section closes.
2) Flow return operation
If the self pump discharge pressure P1 or the counterpart pump discharge pressure P2
decreases, the compensation rod (623) is pressed back by the springs (625, 626) and lever 1
rotates about point E. Accompanying the lever 1 rotation, the feedback lever rotates around
point D as the fulcrum and the spool moves to the left. Because of this, the port opens to
the tank port, the servo piston large-diameter section pressure drains off, the servo piston
moves to the left and the pump discharge flow increases.
The movement of the servo piston is transmitted to the spool by the feedback mechanism, and
this operation continues until the open section between the spool and the sleeve closes.
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[3] Low tilting (low flow) command priority mechanism
As above, the flow control and the horsepower control tilting command is transmitted to the feed-
back lever and spool via the large openings [C and F sections] of lever 1 and lever 2, but since
the C and F sections have a structure in which a pin (φ4) projects into a large hole (φ8), the pin
(897) only contacts the lever that makes the tilting smaller and the φ8 hole for the lever on the
side that has the larger tilting command state is free rather than being in contact with the pin
(897). This type of mechanical selection method gives priority to flow control and horsepower
control commands with low tilting.
[4] Power shift control (decreased horsepower control)
Use the power shift pressure Pf to arbitrarily control the pump set
horsepower as in the diagram on the right. When the power shift
pressure Pf increases, the compensation rod (623) is moved to the
right via the pin (898) and the compensation piston (621), so the
pump tilting angle and the horsepower setting are reduced in the
same way as was explained with the overload prevention operation
of horsepower control. By contrast, as the power shift pressure Pf
decreases, the horsepower setting increases.
5. Regulator adjustment
The adjusting screws on this regulator can be used to adjust the maxi-
mum flow, minimum flow, horsepower control properties, and flow control properties. (Each of the
adjustment amounts is shown in "6. (1) Regulator adjustment amount list".)
[1] Maximum flow adjustment
Loosen the hexagon nut (808) and tighten (or loosen) the locking
screw (954) to adjust the maximum flow. This only changes the max-
imum flow. It does not change the other control properties.
[2] Minimum flow adjustment

Loosen the hexagon nut (808) and tighten (or loosen) the hexagon
socket head locking screw (953) to adjust (or tighten) the minimum
flow. Similar to the maximum flow adjustment, this does not change
other control properties. However, if the hexagon socket head locking
screw is tightened too much, the required power may increase at the
time of maximum discharge pressure (during relief), so adjust this
carefully.
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[3] Input horsepower adjustment
This regulator uses the simultaneous full-horsepower method. Therefore, when changing the
horsepower setting, adjust the adjusting screw of both the front and rear pumps to the same
amount.
The pressure change value resulting from adjustment is the value when pressure boost is simul-
taneously performed with both pumps.
1) Outer spring adjustment
Loosen the hexagon nut (630) and tighten (or loosen) the adjusting
screw (C) (628) to adjust the outer spring. As the adjusting screw is
tightened, the control diagram shifts to the right as in the diagram
on the right and the input horsepower increases. When the adjust-
ing screw (C) is rotated N times, the inner spring setting also
changes. Therefore, return the adjusting ring (C) (627) by rotating it
N × A times in the opposite direction.
2) Inner spring adjustment

Loosen the hexagon nut (802) and tighten (or loosen) the adjusting
ring (C) (627). As the adjusting screw is tightened, the flow
increases as in the diagram on the right and the input horsepower
increases.
[4] Flow control properties adjustment

Loosen the hexagon nut (801) and tighten (or loosen) the hexagon
socket head locking screw (924) to adjust the flow control properties.
As the hexagon socket head locking screw is tightened, the control
diagram shifts to the right as in the diagram on the right.
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6. Tables and diagrams
[1] Regulator adjustment amount table
Speed (min-1) 2,030

Adjusting screw (954) tightening amount (rotation) +1/4
Maximum flow adjustment
Flow change volume (L/min) 6.3
Minimum flow adjustment
Outer spring Compensation control start pressure change volume (MPa) 1.75
adjustment Input torque change volume (N•m) 71.6
Input horsepower
A 1.9
adjustment
Inner spring
adjustment
Input torque change volume (N•m) 63.7
Adjusting ring (627) tightening amount (rotation) +1/4
Flow control properties adjustment Flow control start pressure change volume (MPa) 0.15
Flow change (L/min) 16.4
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[2] Regulator operation explanation diagram
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[3] Regulator breakdown
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Procedures for Assembly and Disassembly of Regulator
1. Cautions for disassembly
[1] These regulators comprise small precision parts, so disassembly and assembly operations are
somewhat complex. Accordingly, it is recommended that replacement be performed by replacing
the whole assembly as long as there are no special circumstances requiring disassembly. If dis-
assembly is unavoidable, read this entire manual before performing disassembly.
[2] The numbers in the parentheses after the part names indicate codes in the structural diagram.
2. Tools
Tool name Tools dimensions
Hexagon wrench 4, 5, 6 (B dimension, mm)
Socket wrench, double-head (single-
head) wrench
Monkey wrench Small-sized (maximum 36 mm)
Screwdriver
Plastic hammer
Torque wrench
Pliers For stop ring, × 2
Steel rod Diameter φ4 or less, L = 100
Tweezers
Bolt M4, L = about 50
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[1] Select a location for disassembly.
[2] Use cleaning oil to remove any dirt or rust from
the surface of the regulator.
413), and remove the regulator from the pump
main unit..
• Be careful not to lose the O-rings.
[4] Remove the hexagon socket head bolts (438),

and remove the cover (C) (629).
• The cover (C) is assembled with an adjusting
screw (C) (628), adjusting ring (C) (627), lock
nut (630), hexagon nuts (801, 802), and hexa-
gon socket head locking screw (924). Do not
loosen these screws and nuts. Loosening
causes the adjusted pressure and flow setting
to change.
[5] After removing the cover (C) (629) subassem-

bly, remove the outer spring (625), inner spring
(626), and spring seat (C) (624) from the com-
pensation section, and pull out the adjusting
ring (Q) (645), pilot spring (646), and spring
seat (644) from the pilot section.
• The adjusting ring (Q) (645) can be easily
removed by pulling it out with an M4 bolt.
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438), and remove the pilot cover (641). When
the pilot cover is removed, remove the set
spring (655) from the pilot section.
[7] Remove the stop ring (814), and remove the

spring seating (653), return spring (654), and
sleeve (651).
• The sleeve (651) is assembled with a retaining
ring (836).
• When removing the stop ring (814), the return
spring (654) will fly out, so be careful not to lose
it.
[8] Remove the locking rings (858), and remove the

fulcrum plug (614) and adjusting plug (615).
• The fulcrum plug (614) and adjusting plug (615)
can be easily removed by pulling them out with
an M6 bolt.
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[9] Remove lever 2 (613). Do not pull out the pin
(875).
• It can be easily removed by using a pair of twee-
zers.
[10] Pull out the pin (874), and remove the feedback
lever (611).
• Use a fine steel rod to push out the pin (874)
(pin diameter φ4) from above without touching
lever 1 (612).
[11] Remove lever 1 (612). Do not pull out the pin

(875).
[12] Pull out the pilot piston (643) and spool (652).
[13] Pull out the piston case (622), compensation
piston (621), and compensation rod (623) to
complete disassembly of the regulator.
• The piston case (622) can be removed by push-
ing out the compensation rod (623) from the
opposite side of the piston case.
The component parts are small, so be very careful not to lose them.
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The assembly procedure is the reverse of the disassembly procedure. However, follow the precau-
tions below.
[1] Be sure to repair any parts damaged during disassembly, and prepare replacement parts in
advance.
[2] Any foreign matter entering the equipment can create a malfunction. Therefore, after thoroughly
cleaning the equipment with cleaning oil, air blow the equipment, and perform assembly in a
clean location.
[3] Make sure to tighten bolts and plugs of each section to the specified torque.
[4] Be sure to apply clean hydraulic oil to sliding sections before assembly.
[5] As a rule, replace all seals such as O-rings with new parts.
[1] Install the compensation rod (623) into the com-
pensation hole on the casing (601).
[2] Insert the pin press fit in lever 1 (612) into the
groove on the compensation rod, and install
lever 1 on the pin press fit in the casing.
[3] Install the spool (652) and sleeve (651) in the
casing spool hole.
• Check that the spool and sleeve slide smoothly
in the casing without catching.
• Be careful to assemble the spool in the correct
direction.
[4] Install the feedback lever (611), and insert the

pin (874) in alignment with the pin hole on the
feedback lever.
• This is easier to assemble by inserting the pin
into the feedback lever to a small degree in
advance.
• Be careful to assemble the feedback levers in
the correct direction.
[5] Install the pilot piston (643) into the flow control
hole on the casing.
• Check that the pilot piston slides smoothly with-
out catching.
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[6] Insert the pin press fit in lever 2 (613) into the
groove on the pilot piston, and assemble lever
2.
[7] Assemble the fulcrum plug (614) and install the

locking ring (858) so that the pins press fit in the
fulcrum plug are inserted into the pin holes on
lever 2.
[8] Insert the adjusting plug (615), and install the

locking ring.
• Be careful to insert the fulcrum plug and adjust-
ing plug into the correct openings.
• At this time, check that the backlash from the
movement of the feedback lever is not too great
and that the feedback lever does not catch on
anything.
[9] Install the return spring (654) and spring seating
(653) into the spool hole, and install the stop
ring (814).
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Hydraulic Pump
[10] Assemble the set spring (655) into the spool
hole, assemble the compensation piston (621)
and piston case (622) into the compensation
hole, install the pilot cover (641), and tighten the
hexagon socket head bolts (436, 438).
[11] Install the spring seating (644), pilot spring

(646), and adjusting ring (645) into the pilot
hole, and install the spring seating (624), inner
spring (626), and outer spring (625) into the
compensation hole.
• Be careful to install the spring seating in the cor-
rect direction.
[12] Assemble the cover (C) (629) set with the

adjusting screw (628), adjusting ring (C) (627),
lock nut (630), hexagon nuts (801, 802), and the
hexagon socket head locking screw (924), and
tighten the hexagon socket head bolts (438).
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Hydraulic Pump
5. Regulator assembly structural diagram
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Hydraulic Pump
Code Part name Q'ty
496 Plug 5
601 Casing 1
611 Feedback lever 1
612 Lever (1) 1
613 Lever (2) 1
614 Fulcrum plug 1
615 Adjusting plug 1
621 Compensation piston 1
622 Piston case 1
623 Compensation rod 1
624 Spring seating (C) 1
625 Outer spring 1
626 Inner spring 1
627 Adjusting ring (C) 1
628 Adjusting screw (C) 1
629 Cover (C) 1
630 Lock nut 1
631 Pf sleeve 1
641 Pilot cover 1
643 Pilot piston 1
644 Spring seating (Q) 1
645 Adjusting ring (Q) 1
646 Pilot spring 1
651 Sleeve 1
652 Spool 1
653 Spring seating 1
654 Return spring 1
655 Set spring 1
656 Blind cover 1
708 O-ring 1
722 O-ring 3
724 O-ring 9
725 O-ring 1
728 O-ring 1
730 O-ring 1
732 O-ring 1
733 O-ring 1
734 O-ring 1
735 O-ring 1
753 O-ring 2
755 O-ring 2
756 O-ring 1
763 O-ring 1
801 Hexagon nut 1
802 Hexagon nut 1
814 Stop ring 1
836 Retaining ring 1
Tightening torque
858 Locking ring 2
Code Screw size Tightening torque (N•m) 874 Pin 1
412, 413 M8 29 875 Pin 2
436, 438 M6 12 876 Pin 2
496 NPTF1/16 8.8 887 Pin 1
630 M30 × 1.5 160 897 Pin 1
801 M8 16 898 Pin 1
802 M10 19 924 Hexagon socket head locking screw 1
198 SSM-13-09-004EN
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Removal and Installation of Operation Remote Control Valve
Items to prepare
• Phillips screwdriver
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of operation remote control valve (left side)
[1] Roll up the boot (1) of the control lever and use
the Phillips screwdriver or box wrench (10 mm)
to remove the 2 bolts (2) of the console top
cover.
[2] Use the Phillips screwdriver to remove the 2

screws (3), and then remove the handle of the
tilt lever (4).
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bolts (5), and remove the grip (6) of the gate
lock lever.

screws (7) of the console top cover.
[5] Remove the 3 connectors (8) and remove the

console top cover (9).
[6] Use the Phillips screwdriver or box wrench (10

mm) to remove the 5 bolts (10).
[7] Remove the cover (11).
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[8] Roll up the boot (12) of the control lever, remove
the connector (13) of the horn switch, and cut
the wire band (14).
[9] While securing the nut (15) with a wrench (22

mm), use another wrench (19 mm) to remove
the lock nut (16) and remove the control lever
(17).
[10] Roll back the hose cover (18).
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[11] Use a wrench (22 mm) to remove the 6 hoses
(19).
• Mark the joystick remote control valve and
hoses so that the connectors match at the time
of assembly.
• Use caps and plugs to cover the joystick remote
control valve and hoses to prevent any entry of
• Clean the joystick remote control valve and
hoses by spraying them with a parts cleaner to
prevent scratches and prevent dirt from accu-
[12] Use the hexagon wrench (5 mm) to remove the

4 bolts (20).
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[13] Remove the joystick remote control valve (21).
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2. Removal of operation remote control valve (right side)
[1] Roll up the boot (1) of the control lever and use
the Phillips screwdriver or box wrench (10 mm)
to remove the 2 bolts (2) of the console top
cover.

screws (3), and then remove the handle of the
tilt lever (4).

screws (5) of the console top cover.
[4] Remove the 3 connectors (6) and remove the

console top cover (7).
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mm) to remove the 5 bolts (8).
[7] Roll up the boot (10) of the control lever, remove

the connector (11) of the horn switch, and cut
the wire band (12).
[8] While securing the nut (13) with a wrench (22

mm), use a wrench (19 mm) to remove the lock
nut (14) and remove the control lever (15).
[9] Roll back the hose cover (16).
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(17).
• Mark the joystick remote control valve and
hoses so that the connectors match at the time
of assembly.
• Use caps and plugs to cover the joystick remote
control valve and hoses to prevent any entry of
• Clean the joystick remote control valve and
hoses by spraying them with a parts cleaner to
prevent scratches and prevent dirt from accu-
[11] Use the hexagon wrench (5 mm) to remove the
4 bolts (18) and 4 washers (19).
[12] Remove the joystick remote control valve (20).
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3. Installation of operation remote control valve
To install, perform the reverse of the removal procedure.
Be careful not to connect the hydraulic hoses in incorrect locations.
Before installing the hoses, check that the hose adapters are not loose and retighten them to the
specified torque.
P port
Hose adapter tightening torque : 28.4 ± 2.9 N•m
Hydraulic hose tightening torque : 49 ± 4.9 N•m
T port, 1 - 4 ports
Hose adapter, hydraulic hose tightening torque : 49 ± 4.9 N•m
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Procedures for Assembly and Disassembly of Operation Remote Control Valve
(1) Required tools and tightening torque
Dimension Tightening
Tool Part number Part name Screw size
(mm) torque (N•m)
22 312 Adjusting nut M14 68.6 ± 4.9
Wrench
32 302 Disk M14
Special jig
(diagram on 24 301 Joint M14 47.1 ± 2.9
page 220)
Other
· Vapor corrosion inhibitor · Sandpaper (#1000, #2000)
· White kerosene · Whetstone
· Heat-resistant grease · Vice
(2) Maintenance standards
Maintenance
Standard Remarks
inspection item
Leak amount When handle is in neutral1000 cc/min or more Conditions
During operation2000 cc/min or more Primary pressure 2.94 MPa
If either condition occurs, replace the remote con- Oil viscosity 23 mm2/s
trol valve as one unit.
Spool When wear on the sliding sections exceeds wear The same approximate condi-
on the non-sliding sections by 10 μm or more, tions as those listed above for
replace the remote control valve as one unit. leak amount are expected when
the condition on the left occurs.
Push rod If the end section is worn by 1 mm or more, perform replacement.
Operation section Replace the operation section disk (302) and joint Make adjustments if the backlash
backlash section (301) if there is backlash of 2 mm or more is due to looseness in the tighten-
due to wear. ing sections.
Operation stability If abnormal noise, hunting, or a drop in primary
pressure occurs and the problem cannot be
resolved with "4. Causes of trouble and counter-
measures", replace the remote control valve as
one unit.
Note:
It is desirable for seal materials such as O-rings to be replaced with each disassembly, but it is
acceptable to reuse these after it is confirmed that they are not damaged.
SSM-13-10-004EN 208
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[1] Preparations
1) Prepare a sufficiently spacious, solid and stable work platform so that parts will not fall or move
during work.
2) Prepare the tools and materials indicated in "1. Maintenance procedures (1) Required tools
and tightening torque".
3) When disassembling the valve, read the disassembly procedures thoroughly before following
the sequence below.
The numbers in the parentheses after the part names indicate codes in "Attached diagram 1.
Remote control valve assembly cross-section diagram".
[2] General work precautions
1) Each part has been manufactured with a high degree of precision, so be careful not to let parts
bump each other or fall when handling them.
2) If parts are struck or pulled with excessive force during work because they are tight, this may
cause burrs or damage which lead to faulty assembly causing reduction in performance or oil
leak. Perform work carefully and thoroughly.
3) Rust may form on parts due to moisture or debris if the valve is left disassembled or if work is
abandoned in the middle of disassembly. If work must be halted, be careful about preventing
rust from forming and dust settling on parts.
[3] Disassembly procedure
1) Clean the remote control valve with white ker-
osene.
• Place plugs in each port.
2) Use copper plate (or lead plate) to secure the
remote control valve in a vise.
3) Remove the bellows (501).
• Be careful not to tear the bellows.
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4) Use a wrench on the bolt width of the adjust-
ing nut (312) and disk (302) to loosen them,
and remove the adjusting nut and disk.
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5) Use a jig to rotate the joint (301) to the left and
loosen it.
• The diagram shows the jig installed.
• If the return springs (221) are strong, the
plate (151), plugs (211), and push rods
(212) will rise at the same time the joint is
loosened, so be careful of parts flying off
when removing the joint.
6) Remove the plate (151).
7) If the return springs (221) are weak, the plugs

(211) will remain in the casing (101) due to the
sliding resistance of the O-rings (214), so use
a flathead screwdriver to remove them.
• Use the groove in the outer circumference of
the plugs and remove them while making
sure they are not damaged by an unbal-
anced load.
• Use caution as plugs may fly off when they
are being removed due to the return springs.
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8) Remove the push rods (212), plugs (211),
pressure reducing valve assemblies and the
return springs (221) from the casing (101).
• Record the relation of parts to the casing
hole positions through marking, etc.
9) For disassembly of pressure reducing valves,

press in the spring seatings, move the spring
seatings (216) to the side while bending the
secondary pressure springs (241), and
remove the springs from the spools (201) by
passing the springs through the larger hole of
the spring seatings.
Next, separate the spools, spring seatings, sec-
ondary pressure springs, and washers (217).
• Be careful not to scratch the surface of the
spools.
• Do not lower the spring seatings by 6 mm or more.
• Handle these parts as assemblies until
assembly of the remote control valve.
10)Remove push rods (212) from the plugs (211).
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11)Remove O-rings (214) and seals (213) from
the plugs (211). Use a small flathead screw-
driver, etc. to remove seals.
• O-rings and seals cannot be reused.
Replace them with new parts.
12)Cleaning parts
1. Clean each part by placing it in a rough cleaning container filled with white kerosene. (rough
cleaning)
2. Clean each part by placing it in a finish cleaning container filled with white kerosene, and
thoroughly clean each part, including the interior, while slowly rotating it. (finish cleaning)
Use a rag to thoroughly remove white kerosene adhered to parts.
• Scratching can easily occur if cleaning of a part is begun just after parts are immersed in
white kerosene, so let each part sit in white kerosene until debris and grease sufficiently
loosen from the surface of the part and float to the surface.
• If the white kerosene is dirty, this will encourage damage to parts and result in reduced
performance after reassembly. Thoroughly manage the level of cleanliness of the white
kerosene.
• Do not dry parts with compressed air, as this will damage parts and cause rust to form
due to debris and moisture being dispersed into the atmosphere.
13)Preventing rust on parts
Apply an anti-rust agent to each part.
• Rust will form on parts if they are left as is after cleaning, and this will cause reduced perfor-
mance of functions after reassemly.
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[1] Preparations
1) As with disassembly, prepare a work platform, tools and materials.
[2] General work precautions
1) Observe the same general work precautions as with disassembly.
2) When performing assembly, remove metal fragments and foreign matter from all parts, and
check that there are no burrs or nicks on parts. If there are burrs or nicks, use a whetstone to
remove them.
3) As a rule, replace all O-rings and backup rings with new parts.
4) When installing O-rings and backup rings, be careful not to damage them. (Apply a thin layer of
grease to ensure smooth installation.)
5) When installing parts, using grease is good for preventing parts from falling.
6) Tighten bolts, etc. to the torque values indicated in "Attached diagram 1. Remote control valve
assembly cross-section diagram" on page 219. Use the torque wrench to measure the tighten-
ing torque.
7) After assembly is complete, place plugs in all of the ports to prevent entry of debris.
[3] Assembly procedures
1) Insert washers (217), secondary pressure
springs (241) and spring seatings (216) onto
each of the spools (201) in that order.
Then, press in the spring seatings and move

them to the side while bending the secondary
pressure springs to pass the seatings over the
larger holes and install them on each of the
spools.
• Do not lower the spring seatings by 6 mm or
more.
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2) Install the return springs (221) in the casing
(101).
Install the pressure reducing valve assemblies
in the casing.
• Install them in the positions they were in
before disassembly.
3) Install O-rings (214) on the plugs (221).
4) Install seals (213) on the plugs (211).

• Install so that the seal lips are as shown in
the diagram below.
*1 Seal
*2 Plug
*3 Push rod
*4 Hydraulic oil application
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5) Install push rods (212) into the plugs (211).
• Apply hydraulic oil to surface of the push
rods.
6) Install the plug assemblies into the casing

(101).
If the return springs (221) are weak, they will
be stopped by the sliding resistance of the O-
rings (214).
• Be careful not to scratch the casing holes by
forcing in the spools (201).
If the return springs are strong, use the plate

(151) to install all 4 plug assemblies at the
same time and temporarily tighten them with
the joint (301).
• Be careful of the plug assemblies and plate
flying off.
7) Install the plate (151).

8) Use a jig, and tighten the joint (301) to the
casing (101) to the specified torque.
Tightening torque: 47.1 ± 2.9 N•m
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9) Install the disk (302) onto the joint (301).
• Screw the disk in until it is equally touching
each of the 4 push rods (212).
Secondary pressure will cause faulty opera-
tion of the machine if the disk is screwed in
too much, so pay attention to adjustment of
the tightening position.
10)Install the adjusting nut (312), use a wrench

on the bolt width of the disk (302) to secure it,
and tighten the adjusting nut to the specified
torque.
• During tightening, do not move the disk posi-
tion.
11)Apply grease to the rotating section of the joint

(301) and to the top of the push rods (212).
12)Install the bellows (501).

• Be careful not to tear the bellows.
13)Inject vapor corrosion inhibitor into each port, and then place plugs in the ports.
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4. Causes of trouble and countermeasures
It is not always easy to find where the source of trouble is located. A few problems that may some-
times occur are listed in the table below. Repair of these problems can be difficult, so see the sug-
gested causes and solutions in the table for assistance.
The table below shows general symptoms, suggested causes and also solutions. However, the
cause of machine problems are often not rooted in just a single part. Problems are often due to the
relationship of one part with another. Also keep in mind that solutions other than those listed in the
table may sometimes be necessary.
The table below does not include all possible causes and countermeasures. Accordingly, further
investigation of problems and causes should be done by an experienced and qualified repair per-
son, as necessary.

Secondary pressure is 1. Insufficient primary pressure 1. Maintain primary pressure.
not rising. 2. Secondary pressure spring(s) (241) is 2. Replace it (them) with new
(are) broken or worn. part(s).
3. The gap between spool(s) (201) and the 3. Replace the remote control valve
casing (101) is abnormally large. as one unit.
4. There is backlash in the handle section. 4. Disassemble and assemble and
replace the handle section.
Secondary pressure is 1. Sliding parts are sticking. 1. Repair the sticking sections.
unstable. 2. Tank line pressure is variable. 2. Return directly to the oil tank.
3. Air is getting into lines. 3. Perform operation several times
and let out air.
Secondary pressure is 1. Tank line pressure is high. 1. Return directly to the oil tank.
high. 2. Sliding parts are sticking. 2. Repair the sticking sections.
SSM-13-10-004EN 218
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Attached diagram 1. Remote control valve assembly cross-section diagram
Code Part name Q'ty Code Part name Q'ty

101 Casing 1 217 Washer 4
151 Plate 1 221-1 Return spring (port 1) 1
201 Spool 4 221-2 Return spring (port 3) 1
211 Plug 4 221-3 Return spring (ports 2, 4) 2
212-1 Push rod (ports 1, 3) 2 241-1 Secondary pressure spring (ports 1, 3) 2
212-2 Push rod (ports 2, 4) 2 241-2 Secondary pressure spring (ports 2, 4) 2
213 Seal 4 301 Joint 1
214 O-ring 4 302 Disk 1
216-1 Spring seating (ports 1, 3) 2 312 Adjusting nut 1
216-2 Spring seating (ports 2, 4) 2 501 Bellows 1
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Attached diagram 2. Joint disassembly jig
SSM-13-10-004EN 220
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Removal and Installation of Travel Remote Control Valve
Items to prepare
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of travel remote control valve
[1] Remove the 3 screws (1) on the cover (2) and
remove the cover.
[2] Remove the floor mat (3).
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bolts (4) on both the left and right sides, and
then remove the left and right travel pedals (5).

bolts (6) on both the left and right sides of the
lever, and then remove the levers (7).


(10).
• Mark the valve and hoses so that the connec-
• Attach caps or plugs to the valve and hoses to
• Clean the valve and hoses by spraying with a
parts cleaner to prevent scratches and prevent
dirt from accumulating on the connectors.
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[7] Use a wrench (19 mm) to remove the 2 hose
adapters (11).

bolts (12) on both the left and right sides of the
travel lever .
[9] Pull up the travel remote control valve (13) into

the cab, and then remove the travel remote con-
trol valve.
2. Installation of travel remote control valve

Be careful not to connect the hydraulic hoses in incorrect locations.
Before installing the hoses, check that the hose adapters are not loose and retighten them to the
specified torque.
Hose adapter, hydraulic hose tightening torque: 36.3 ± 2.0 N•m
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Procedures for Assembly and Disassembly of Travel Remote Control Valve
When disassembling the valve, read the disassembly procedures thoroughly before following the
sequence below. The numbers in the parentheses after the part names indicate codes in "Attached
diagram 1. Remote control valve assembly cross-section diagram" on page 242.
(1) Disassembly procedures
1) Preparations
• Prepare a sufficiently spacious, solid and stable work platform so that parts will not fall or
move during work.
• Prepare tools and materials.
2) General work precautions
• Each part has been manufactured with a high degree of precision, so be careful not to let
parts bump each other or fall when handling them.
• If parts are struck or pulled with excessive force during work because they are tight, this may
cause burrs or damage which may then cause reductions in performance or oil leak due to
faulty assembly. Perform work carefully and thoroughly.
• Rust may form on parts due to moisture or debris if the valve is left disassembled or if work is
abandoned in the middle of disassembly. If work must be halted, be careful about preventing
rust from forming and dust settling on parts.
3) Disassembly procedure
[1] Clean the remote control valve with white
kerosene.
• Place plugs in each port.
[2] Use shock plate to secure the remote con-
trol valve in a vise.
• Remove the bellows (501) from the covers
(201) and remove the bellows by pulling
upwards.
4/
[3] Use a hexagon wrench on the hexagon

socket head locking screws (423) to loosen
them.
• Be careful, as application of Loctite #241
makes the loosening torque high.
4/
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[4] Place a round rod (φ8 mm or less) against
one end of the cam shafts (413) and lightly
strike it with a hammer to remove the
shafts.
4/
[5] Remove the cams (420) as an assembly

with the locking screws (471) and lock nuts
(472) left attached.
Record the positions of the cams in relation
to the covers (201).
• Be careful when removing, as the push
rods (214) may fly off.
4/

socket head bolts (271) to loosen and
remove them.
4/
[7] Remove the covers (201).

• Record the positions of the covers in rela-
tion to the casing (101).
• Be careful when removing, as the push
rods (214) or plugs (202) may fly off due to
the damping springs (336) and (337). (The
plugs are only kept in the casing by the
sliding resistance of the O-rings (212).)
4/
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[8] Remove push rods (214) from the plugs
(202).
• Record the positions of the plugs in relation
to the push rods.
push rods.
• Be careful when removing, as plugs may fly
off.
4/
[9] Remove the plugs (202) with the grease

caps (203) and NHU packings (210) left
attached.
Record the positions of the plugs in relation
to the casing holes.
• Be careful when removing, as the pistons
(224) may fly off due to the damping
springs (336) and (337).
4/
[10] Remove the pistons (224).

• Record the positions of the pistons in rela-
tion to the casing holes.
4/
[11] Remove the damping springs (336) and

(337) from the casing (101).
• Record the positions of the damping
springs in relation to the casing holes.
4/
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[12] Remove the spring seatings (218) from the
casing (101).
• Record the position of the spring seatings
in relation to the casing holes.
4/
[13] Use a magnet, etc. to remove steel balls

(225).
• Be careful not to lose steel balls.
4/

socket head bolts (220) to loosen and
remove them.
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[15] Remove the damper casing (102) and
remove the O-rings (211) and (213) from
the casing.
• Record the position of the damper casing in
relation to the casing (101).
• Be careful when removing, as the pressure
reducing valve assembly may fly off due to
the return springs (335).
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[16] Remove the pressure reducing valve
assemblies and return springs (335) from
the casing (101).
• Record the positions of these parts in rela-
tion to the casing holes.
4/
4/
[17] Lay the covers (201) on their sides on a

level surface, place the special tool 1
against the bushings (412), and remove the
bushings by lightly strike them with a ham-
mer.
4/
[18] Secure each cam assembly in a vise, use a

wrench to loosen the lock nuts (472), and
remove the lock nuts and locking screws
(471).
• As neutral adjustment of locking screws is
necessary during assembly, handle them
as part of the cam assembly as long as
replacement of locking screws is not nec-
essary.
4/
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[19] For disassembly of the pressure reducing
valve assemblies, place the bottom end of
the spools (301) perpendicular on a level
work platform, lower the spring seatings
(311), and use the end of a small flathead
screwdriver to remove the 2 half-circle
washers 1 (215).
spools.
• Do not lower the spring seatings by 4 mm
4/
or more.
[20] Separate the spools (301), spring seatings
(311), secondary pressure springs (324),
washers 2 (217), and washers 3 (313).
• Handle as an assembly until assembly is
performed.
• Washers 2 are used for pre-set adjustment
of the secondary pressure springs, so
thickness is different for each spool assem-
bly. Additionally, these are sometimes not
used, so record the status for each assem-
4/
bly.
[21] Remove the grease cups (203) from the
plugs (202).
4/
[22] Remove the NHU packings (210) from the

plugs (202). Use a small flathead screw-
driver, etc. to remove.
• Be careful not to scratch the inner surface
of the plugs.
4/
SSM-13-10-004EN 230
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[23] Remove the O-rings (212) from the plugs
(202).
4/
[24] Cleaning parts

• Clean each part by placing it in a rough cleaning container filled with white kerosene. (rough
cleaning)
[25] Scratching can easily occur if cleaning of parts is begun just after parts are immersed in
white kerosene, so let each part sit in white kerosene until debris and grease sufficiently
loosen off from the surface of parts and float to the surface.
• If the white kerosene is dirty, this will encourage damage to parts and result in reduced per-
formance after reassembly. Thoroughly manage the level of cleanliness of the white kero-
sene.
• Clean each part by placing it in a finish cleaning container filled with white kerosene, and
thoroughly clean each part, including the interior, while slowly rotating it (finish cleaning).
Use a rag to thoroughly remove white kerosene adhered to parts.
[26] Do not dry parts with compressed air, as this will damage parts and cause rust to form due
to debris and moisture being dispersed into the atmosphere.
[27] Preventing rust on parts
Apply an anti-rust agent to each part.
• Rust will form on parts if they are left as is after cleaning, and this will cause reduced perfor-
mance of functions after reassemly.
231 SSM-13-10-004EN
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1) Preparations
• As with disassembly, prepare a work platform, tools and materials.
2) General work precautions
• Observe the same general work precautions as with disassembly.
• When performing assembly, remove metal fragments and foreign matter from all parts, and
check that there are no burrs or nicks on parts. If there are burrs or nicks, use a whetstone to
remove them.
• As a rule, replace all O-rings and NHU packings.
• When installing O-rings and NHU packings, be careful not to damage them. (Apply a thin layer
of grease to ensure smooth installation.)
• When installing parts, using grease is good for preventing parts from falling.
• Tighten bolts, etc. to the torque values indicated in the assembly cross-section diagram.
• After assembly is complete, place plugs in all of the ports to prevent entry of debris.
3) Assembly procedures
[1] Install the washers 3 (313), washers 2
(217), secondary pressure springs (324),
and the spring seatings (311) onto each of
spools (301) in that order.
Washers 2 are used for pre-set adjustment
of the secondary pressure springs, so
thickness is different for each spool assem-
bly. Additionally, these are sometimes not
used.
• Check the status recorded during disas-
sembly and attach parts accordingly. 4/
[2] Place the bottom end of the spools (301)

perpendicular on a level work platform,
push the spring seatings (311) down, and
install the 2 half-circle washers 1 (215) onto
the spring seatings in such a way that they
are not on top of each other.
4/
• Install the washers 1 so that the sharp

edge side faces up and the washer catches
the head of the spool.
• Do not lower the spring seatings by 4 mm
or more.
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[3] Install the return springs (335) in the casing
(101).
before disassembly.
4/
[4] Install the pressure reducing valve subas-

semblies assembled in the previous steps
1) and 2) into the casing (101).
before disassembly.
4/
• When installing the pressure reducing

valve subassemblies, be careful not to
strongly strike the casing corners with the
bottom ends of the spools.
[5] Install O-rings (211) and (213) on the cas-

ing.
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[6] Tighten the damper casing (102) and cas-
ing (101) with the hexagon socket head
bolts (220) to the specified torque.
before disassembly.
• Tighten the 2 hexagon socket head bolts
(220) evenly, and tighten the damper cas-
ing (102) in a parallel orientation.
[7] Install the steel balls (225) into the bush-

ings (412).
4/
[8] Install the spring seatings (218) into the

bushings (412).
before disassembly.
4/
[9] Install the damping springs (336) in the

casing (101).
before disassembly.
4/
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[10] Install the damping springs (337) in the
casing (101).
before disassembly.
• Be careful that they do not become entan-
gled with damping springs (336).
4/
[11] Install the pistons (224).

before disassembly.
4/
[12] Install O-rings (212) on the plugs (202).
4/
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[13] Install NHU packings (210) into the plugs
(202).
• When installing the NHU packings, be
careful of the installation direction. (See the
diagram.)
• Before installing NHU packings, apply a
thin layer of grease.
4/
NHU packing
[14] Install grease cups (203) into the plugs

(202).
4/
[15] Install push rods (214) into the plugs (202).

• Before installing push rods, apply hydraulic
oil to the rod surfaces.
• Do not press the rods in strongly, as this
may damage the NHU packing lip sections.
4/
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[16] Install the push rod subassemblies assem-
bled in the previous steps [13], [14], [15],
and [16] into the casing (101).
4/
[17] Use special tool 1 on the covers (201) to

press down the bushings (412), and lightly
strike the bushings with a hammer to press
fit them.
• Be careful that the ends of the bushings do
not stick out from within the cover.
4/
[18] Install the covers (201) on the casing (101).

before disassembly.
• Be careful of the cover rising up due to the
damping springs (336) and (337).
4/
[19] Tighten the hexagon socket head bolts

(271) to the specified torque.
• Be careful that the covers are horizontal.
4/
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[20] Temporarily install the locking screws (471)
and lock nuts (472) on the cams (420).
4/
[21] Install the cams (420) on the covers (201).

before disassembly.
4/
[22] While holding the cams (420), insert the

cam shafts (413) from the outside.
4/
[23] Apply Loctite #241 or the equivalent to the

surfaces of the hexagon socket head lock-
ing screws (423).
4/
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[24] Tighten the hexagon socket head locking
screws (423) to the specified torque.
Tightening torque: 6.9 ± 1 N•m
4/
[25] Adjust the height of the locking screws

(471) so that the top surface of the cams
(420) and the bottom surface of the covers
(201) are parallel, and tighten the lock nuts
(472) to the specified torque after rotating
the cams left and right to check if there is
any neutral backlash.
• Even if the push rods (214) are pressed in
too much by the locking screws, backlash
during neutral will occur. Use caution as 4/
this may cause the sudden movement

when starting the engine.
[26] Tilt the cams (420) and fill the grease cups
(203) of the plugs (202) with grease while
filling grease to the top of the push rods
(214).
• For grease application and filling, use a flat
object made of soft material so as to not
scratch the push rod or plug surfaces.
4/
[27] After mounting the top end of the bellows

(501) on the cams (420), mount the bottom
end into the grooves on the covers (201).
• Before mounting the bottom end of the bel-
lows into the grooves of the covers, spray
anti-rust oil on the parts within the bellows.
4/
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• Be careful that the bellows are properly
mounted in the grooves and not twisted, as
this may reduce anti-rust and anti-moisture
protection.
4/
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2. Causes of trouble and countermeasures
It is not always easy to find where the source of trouble is located. A few problems that may some-
times occur are listed in the table below. Repair of these problems can be difficult, so see the sug-
gested causes and solutions in the table for assistance.
The table below shows general symptoms, suggested causes and also solutions. However, the
cause of machine problems are often not rooted in just a single part. Problems are often due to the
relationship of one part with another. Also keep in mind that solutions other than those listed in the
table may sometimes be necessary.
The table below does not include all possible causes and countermeasures. Accordingly, further
investigation of problems and causes should be done by an experienced and qualified repair per-
son, as necessary.

1. Insufficient primary pressure 1. Maintain primary pressure.
2. Secondary pressure spring(s) (324) is 2. Replace it (them) with new part(s).
(are) worn.
Secondary pressure is
not rising. 3. The gap between spool(s) and the cas- 3. Replace spool(s) and casing assembly.
ing is abnormally large.
4. There is backlash in the operation sec- 4. Disassemble and assemble or replace
tion. operation section parts.
1. Sliding parts are sticking. 1. Repair the sticking sections.
Secondary pressure is 2. Tank line pressure is variable. 2. Return directly to the oil tank.
unstable. 3. Air is getting into lines. 3. Perform operation several times and let
out air.
Secondary pressure is 1. Tank line pressure is high. 1. Return directly to the oil tank.
high. 2. Sliding parts are sticking. 2. Repair the sticking sections.
1. Air is gathering in the piston chamber. 1. Perform operation several times and let
out air.
3. Damping spring(s) (336) and/or (337) 3. Replace it (them) with new part(s).
are worn.
Damping is not work-
ing. 4. The gap between piston(s) (224) and 4. Replace piston(s) and casing assembly.
the casing is abnormally large.
5. There are check valve operation prob- 5. Disassemble and adjust the check valve
lems. section(s).
6. The piston metering hole(s) is (are) 6. Replace piston(s).
abnormally large.
Damping torque is high.
2. Piston metering hole(s) is (are) clogged. 2. Repair or replace piston(s).
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Note
1. Apply anti-rust oil to the inside of the bellows with a spray.
Attached diagram 1. Remote control valve assembly cross-section diagram
Tightening torque list Code Part name Q'ty Code Part name Q'ty
Code Screw size Tightening torque 101 Casing 1 271 Hexagon socket head bolt 2
151 NPTF1/16 6.9 ± 1 N•m 151 Plug 2 301 Spool 4
271 M12 78.5 ± 9.8 N•m 201 Cover 2 311 Spring seating 4
6.9 ±1 N•m 202 Plug 4 313 Washer 3 4
423 M6
(Loctite coating) 203 Grease cup 4 324 Secondary pressure spring 4
472 M10 33.3 ± 3.4 N•m 210 NHU packing 4 335 Return spring 4
212 O-ring 4 336 Damping spring 4
214 Push rod 4 337 Damping spring 4
215 Washer 1 8 412 Bushing 4
217 Washer 2 4 413 Camshaft 2
218 Spring seating 4 420 Cam 2
221 Locking ring 4 423 Hexagon socket head locking screw 2
223 Bushing 4 471 Locking screw 4
224 Piston 4 472 Lock nut 4
225 Steel ball 12 501 Bellows 2
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[1] Special jig 1 (for bushing removal)
[2] Special jig 2 (for locking ring installation)
Attached diagram 2. Jig for assembly and disassembly
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Control Valve
Control Valve
Removal and Installation of Control Valve

Items to prepare
• Wire cutters
• Eyebolts (M10 × 2)
• Wire ropes (with the required lifting capacity)
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of Control Valve
[1] Extend the attachment and bring in contact with
the ground.
[2] Drain the oil from the hydraulic oil tank.

(For details, see "Draining Oil from Hydraulic Oil
Tank")
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[3] After opening the engine hood (1), use a
wrench (19 mm) to remove the bolts (2), and
then remove the top covers (3) and (4).


(7), and then remove the bracket (8).
(9), and then remove the center bar (10).
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[7] Remove the connectors (11) and (12) from the
pressure sensor.
[8] Use a wrench (7 mm) to remove the hose band

(13), and then remove the low-pressure hose
(14).

and then remove the clamp (16).
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[10] Use wrenches (19 mm, 22 mm) and hexagon
wrenches (8 mm, 10 mm) to remove the control
valve lines and hoses.
• Mark the lines and hoses so that the connectors
match at the time of assembly.
• Use caps or plugs to cover the lines and hoses
• Clean the lines by spraying with a parts cleaner
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Control Valve
(17) from the control valve.
[12] Install the 2 eyebolts (18) (M10) on the control

valve.
[13] Install the shackles (19) on the eyebolts, then

use the liftcrane and wire ropes (20) to lift the
control valve (21).
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Control Valve
[14] Place the control valve (21) on wood planks
(22).
2. Installation of Control Valve

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Control Valve
Procedures for Assembly and Disassembly of Control Valve
1. Disassembly
(1) Cautions for disassembly
[1] On level ground, bring all the operating machines into contact with the ground. When doing
this, have the main machine in a horizontal position.
Check that the machine is in such a state that it will not travel or swing on its own.
Then stop the engine and bleed out the pressure from each actuator.
Do not replace a valve assembly or disassemble a valve with pressure remaining in the system.
This would be dangerous. High-pressure oil might spray out or parts might suddenly come out.
Caution For disassembly, bring the bucket to the ground and adequately bleed out any pressure in the
circuits.
[2] Bleed the air pressure from the tank.
[3] Clean well around the location to be disassembled and keep foreign matter from getting into
the valve during disassembly.
[4] Identify disassembled parts with shipping tags to show their position for re-assembly.
[5] Do not reuse any disassembled seals (O-rings, backup rings). Replace them with new ones.
[6] The spool was selected to fit with the valve housing and sleeve, so do not replace the spool.
(2) Disassembly procedure (The reference numbers are from the parts list.)
a) Removal of long cap and pull out of main spool
[1] Loosen the hexagon socket head bolts (74) (8 mm hexagon socket diameter) for the 9
caps (8) and the 1 cap (9), and remove them. When pulling out the spool only, do not
loosen the M6 screws on the plate except for the 4 hexagon socket head bolts (75) and
the 1 hexagon socket head bolt (94) fastening the plate assemblies.
[2] Loosen and remove the plugs (91) (19 mm hexagon diameter) attached to the ports as
necessary.
[3] Remove the O-rings (7) (1 in each section) from the plate assemblies (10) and (11).
[4] Pull out each spool from the valve housing still in the sub-assembly state.
1. When pulling out the spool, be careful not to cause any dents or scratches.
Caution 2. Identify each spool with a shipping tag so that there will be no mistake about their positions
when they are re-assembled.
[5] Loosen and remove the hexagon socket head bolts (75) (8 mm hexagon socket diameter)
and hexagon socket head bolts (94) (5 mm hexagon socket diameter) those fastens the
plate assemblies (10), (11), (28) and (29) to the housing.
Remove the plate assemblies still in the assembly state. Do not disassemble them.
[6] Loosen and remove the plugs (91) (19 mm hexagon socket diameter) as necessary.
[7] Remove the O-rings (7) and (41) from the valve housings (1) and (13).
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[8] Disassembly of spool assembly
1. In order to avoid damaging the outer edge of the spool,

sandwich the spool with wooden blocks (as in the dia-
gram on the right) and fasten with a vise before starting
the work.
2. Since adhesive is applied to the spool end thread section,
heat up the outer edge of the spool thread section to
break down the adhesive.
Caution
3. Heat so that the spool heating temperature is 200 - 250 ℃
. Heat until the spool end loosens easily immediately after
the heating.
4. If overheating occurs, replace the spring with a new one.
(Wooden blocks for spool
assembly/disassembly)
1) Loosen the spool assembly (2) - (6) and (14) - (17) spool ends (8 mm hexagon socket
diameter) and disassemble the spring seat and spring.
2) The spools in spool assemblies (3), (4), (6) and (14) have poppets, springs, plugs, and
filters in the spools, but do not disassemble them unless necessary.
When disassembly is required, heat up the outer edge of the spool to break down the
adhesive on the thread section, then remove the plug. When assembling, always
replace O-rings and backup rings with new ones.
b) Disassembly of arm 1 parallel-tandem spool, neutral cut spool section
for the caps (18) and (86).
[2] Remove the O-ring (23) from the cap (18). Remove the O-rings (65) from the housing (1).
[3] Pull out the spools (19) and (84) from the valve housing still in the sub-assembly state.
[4] Disassembly of spool assembly
1. In order to avoid damaging the outer edge of the spool, sandwich the spool with wooden
blocks for assemble (as in the diagram) and fasten with a vise before starting the work.
2. Since adhesive is applied to the spool end thread section, heat up the outer edge of the
Caution spool thread section to break down the adhesive.
3. Heat so that the spool heating temperature is 200 - 250 ℃ . Heat until the spool end loosens
easily immediately after the heating.
4. If overheating occurs, replace the spring with a new one.
1) Loosen the spool (19) spool end (22) (5 mm hexagon socket diameter) and disassem-
ble the spring seat (20) and spring (21).
c) Disassembly of arm regeneration release valve section (Sub-parts in the assembly are
expressed as [main number - sub-number].)
1. When removing the plug, pressure left within can make parts fly out dangerously.
Caution 2. Slowly loosen the plug to check that there is no resistance due to residual pressure, then
disassemble.
[1] Loosen and remove the plug (24) (32 mm hexagon diameter) and remove the O-ring (25).
[2] Remove the spring (26) and spool (27-1) from the sleeve (27-2).
[3] Pull out the sleeve (27-2) from the valve housing.
[4] Remove the piston (27-3), O-ring (30), and backup ring (31) from the sleeve (27-2).
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Control Valve
d) Disassembly of load check valve section
1. When removing the plug, pressure left within can make parts fly out dangerously.
Caution 2. Slowly loosen the plug to check that there is no resistance due to residual pressure, then
disassemble.
[1] Loosen and remove the hexagon socket head bolts (75) (4 in each section, 8 mm hexa-
gon socket diameter) for the flanges (37) (6 locations) and (61) (1 location). Only (61) has
a different shape from the others, so keep it separate from (37).
[2] Remove the spring (35), poppets (34) and (51) and O-ring (36) from the valve housing.
Remove the arm 2 (E-E cross section) poppet (59), spring (60), and sleeve (58).
for the flanges (52) (2 locations) .
[4] Remove the spacer (53) from the valve housing and remove the O-ring (54) and backup
ring (55) from the spacer (53).
[5] Remove the spring (35) and poppet (34) from the valve housing.
[6] Loosen and remove the plug (72) (8 mm hexagon socket diameter). (D-D cross section)
[8] Loosen and remove the plug (72) (8 mm hexagon socket diameter). (D-D cross section)
[9] Remove the spacer (57), spring (33), and poppet (32) from the valve housing.
[10] Loosen and remove the plug assembly (92) (36 mm hexagon diameter). (P4 section,
cross section H-H )
[11] Loosen and remove the hexagon socket head bolts (74) (4 locations, 8 mm hexagon
socket diameter) for the flange (43) .
[12] Remove the spring (45), poppet (44), and O-ring (36) from the valve housing.
[13] Loosen and remove the plug (46) (27 mm hexagon diameter) and remove the O-ring (47).
(H-H cross section)
e) Disassembly of antidrift valve section (Sub-parts in the assembly are expressed as [main
number - sub-number].)
1. When removing the antidrift valve assembly, pressure left within can make seals and other
parts fly out dangerously.
Caution 2. Slowly loosen the hexagon socket head bolt to check that there is no resistance due to
residual pressure, then disassemble.
[1] Loosen and remove the hexagon socket head bolts (74) (4 in each section, 8 mm hexa-
gon socket diameter) for the 2 antidrift valve assemblies (67).
[2] Remove the O-rings (36) and (41) from the valve housing.
[4] Disassembly of antidrift valve assembly
1. If parts inside the antidrift valve are disassembled with the antidrift valve installed in the
valve housing, pressure left within can make parts fly out dangerously.
Caution 2. Slowly loosen the plug assembly (67-12) to check that there is no resistance due to residual
pressure, then disassemble.
1) Loosen and remove the plug assembly (67-14) (38 mm hexagon diameter) and remove
the O-ring.
2) Remove the piston (67-3), spool (67-4), and spring (67-6).
3) Loosen and remove the plug (67-14) (12 mm hexagon diameter).
4) Remove the sleeve (67-5) and poppet (67-2) from the body and remove the O-rings
(67-8) and (67-9), backup rings (67-10) and (67-11) from the outer edge of the sleeve.
5) Remove the spring seat (67-13) and spring (67-7) from deep in the hole.
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f) Disassembly of relief valve
1. When removing the relief valve, loosen and remove the main unit installation section plug.
2. Do not loosen the set pressure adjustment plug or lock nut.
Caution 3. Doing so would be dangerous because the set pressure changes if the set pressure adjust-
ment plug turns.
[1] Loosen and remove the overload relief valve (69) (32 mm hexagon diameter).
[2] Loosen and remove the main relief valve (68) (32 mm hexagon diameter).
[3] Loosen and remove the 2 relief valve assemblies (70) (32 mm hexagon diameter).
Remove the O-rings (70-5) and (70-8).
g) Disassembly of option section
for the 2 caps (88), and remove the O-rings (89).
[2] Loosen and remove the 2 plug assemblies (93) (24 mm hexagon diameter), and remove
the O-rings and backup rings.
h) Disassembly of straight travel signal control valve
[1] Remove the hexagon socket head bolts (83) (5 mm hexagon socket diameter) and
remove the body assembly (42).
[2] Loosen and remove the plug assembly (42-5) (5 mm hexagon socket diameter) and
remove the O-ring.
[3] Pull out the spools (42-2) and (42-3) and spring (42-4).
[4] Loosen the orifice plug (42-7) (36 mm hexagon diameter) and remove it from the body (42-1).
i) Disassembly of other plugs
[1] Loosen and remove the plug assembly (71) (10 mm hexagon socket diameter) and
remove the O-ring.
[2] Loosen and remove the plug assembly (72) (8 mm hexagon socket diameter) and remove the O-ring.
[3] Loosen and remove the orifice plug (40) (5 mm hexagon socket diameter). (D-D cross section)
[4] Loosen and remove the plug assembly (92) (36 mm hexagon diameter) and remove the
O-ring.
[5] Loosen and remove the plug assembly (73) (6 mm hexagon socket diameter) and remove
the O-ring.
j) Disassembly of add-on section
[1] Loosen and remove the 4 hexagon nuts (97) (22 mm hexagon diameter).
[2] Remove the outlet housing (95).
Execute Steps [3] - [5] below as necessary.
[3] Remove the spool section assembly (98) and remove the matching surface O-rings (98-
10) and (98-11).
[4] Remove the inlet section assembly (99) and remove the matching surface O-rings (99-3)
and (99-4).
[5] Remove the spool section assembly (111) and remove the matching surface O-rings
(110-10) and (110-11).
[6] Remove the main unit body matching surface O-rings (56) and (64).
[7] Loosen the tie rod (96) and remove it from the main unit valve housing (1).
(Use a pipe wrench.)
When removing the add-on section, be careful not to cause any dents, scratches, or the like on
matching surfaces. Any dents, scratches, or the like on matching surfaces have a danger of
allowing oil to leak from those surfaces and causing malfunction.
Caution Also, be careful not to let any foreign matter enter the oil path. Such foreign matter has a dan-
ger of the spool sticking due to biting of the spool sliding section or a load check seat defect
making the actuator run wild or stop disabled.
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Control Valve
k) Disassembly of valve housing union bolt
1. Do not disassemble the union bolt (77) unless necessary.
Caution 2. If such disassembly is necessary, place the main unit on a flat table to do the work.
3. Prepare the replacement O-rings (65) and (66).
[1] Loosen and remove the 8 hexagon socket head bolts (77) (14 mm hexagon socket diam-
eter).
[2] Remove the valve housing matching surface O-rings (65) and (66).
(3) Cleaning
Completely clean all the disassembled parts with clean mineral oil.
Dry with compressed air and place each part on clean paper or vinyl for inspection.
(4) Inspection
Inspect all surfaces of each part for burrs, scratches, gouges, and other defects.
[1] Inspect the valve housing load check seat surface for scratches, gouges, and also for debris,
dents, rust. Repair any minor scratches with an oilstone.
[2] Check that there are no scratches, dents, etc. on the outer edge of the spool.
Repair any small scratches with an oilstone.
[3] Sliding parts must all move easily.
Also, all grooves and paths must be free of foreign matter.
[4] If a spring is broken or extremely deformed or worn, replace it.
[5] If relief valve operation is poor, inspect according to "Troubles and countermeasures Relief
valve".
[6] Replace all O-rings and backup rings from disassembled parts.
[7] After removing caps or plugs, check for any paint fragments around the body opening or
plug seating surface. (If paint fragments were to get inside the valve, they could jam up or
clog up the valve, resulting in operation defects and oil leaks.)
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(5) Assembly
1) Cautions for assembly
a) Cautions for O-Ring handling
[1] Do not use any O-ring with a molding defect or damage caused by handling.
[2] Apply enough grease or hydraulic oil to the O-ring and the section where it is mounted so
that it can be mounted smoothly.
[3] Do not stretch an O-ring so far that this causes permanent deformation.
[4] When assembling an O-ring, be careful not to roll the O-ring into place.
(If an O-ring is mounted twisted, it is difficult for it to naturally recover to its normal state
and that twist causes oil leaks.)
b) Cautions for spool handling
[1] Excessive torque on thread sections causes spool operation defects, so always tighten to
just the specified torque.
[2] Be careful to assemble all spools, springs, and spool ends in the same combinations as
before disassembly.
c) Adhesive application method (for male thread section and female thread section of parts
requiring adhesion)
[1] Cleaning (degreasing)
Either use vapor degreasing with acetate, ether or clean with an alkali cleaning agent.
[2] Drying
Dry the surface to be glued, either by blowing clean air on it or letting it dry naturally.
Inadequate drying reduces the effectiveness of the adhesive.
[3] Applying the adhesive
Apply a small amount of adhesive (equivalent to Loctite #638) to the first 2 - 3 threads at
the entrance of the spool female threads.
At this time, install being careful that the application section does not touch the spring
seat.
Caution Do not use "Loctite Primer T" hardening accelerator. It causes insufficient adhesion strength.
[4] Adhesive hardening time

In order to ensure the hardening of the adhesive, after fastening the spool end, leave the
part out in the air for the following period of time.
- Ambient temperature around 22 ℃ : 8 hr. or longer
If the parts are not left out in the air for the above period, adequate adhesive strength may not
Caution be achieved.
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2) Procedure for assembly of sub-assembly
Before starting the assembling, check the quantity of each part, the installation location, the
Caution required tools, etc.
a) Assembly of spool assembly (main spool)
[1] Apply adhesive to the thread sections of the spools (2) - (6), (14) - (17) and assemble the
spring seat, spring, and spool end.
[2] Sandwich the spool with the wooden blocks (the same ones used for disassembly), fas-
ten in place with a vise, then tighten the spool ends to the specified torque.
[3] For spools (3), (4), and (14), insert the poppets and springs from the end opposite from
the spool end, then apply adhesive to the thread sections of the plugs with the O-rings
and backup rings mounted, and tighten.
Also, for spool (5), the plug with filter is mounted at this location.
1. Be careful not to apply so much adhesive that it drips into the spool.
2. Be careful not to tighten any spool end with excessive torque. Excessive torque there would
Caution deteriorate spool operation.
3. There are 2 types of spring. Be careful to assemble each in its correct location. (only boom
2 different)
b) Assembly of arm 1 parallel-tandem spool assembly
[1] Apply adhesive to the thread sections of the spool (19) and assemble the spring seat
(20), spring (21), and spool end (22).
Caution 2. Be careful not to tighten any spool end with excessive torque. Excessive torque there would
deteriorate spool operation.
c) Assembly of neutral cut spool assembly
[1] Apply adhesive to the thread sections of the spool (84-1) and assemble the spring seat
(84-2), spring (84-3), and spring end (84-4).
Caution 2. Be careful not to tighten any spool end with excessive torque. Excessive torque there would
deteriorate spool operation.
d) Assembly of antidrift valve assembly
[1] Assemble the O-rings (67-8) and (67-9) and backup rings (67-10) and (67-11) into the
grooves on the outer edge of the sleeve (67-5).
1. Be careful to assemble O-rings and backup rings in the correct locations.

Caution 2. If they are assembled backwards, there is a danger of an O-ring being damaged and the
drop of the actuator from its own weight increasing.
[2] Insert the poppet (67-2) and spool (67-4) in the sleeve hole. Be careful to assemble the
spool in the correct direction.
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[3] Install the spring seat (67-13) at the small-diameter section at the tip of the poppet, mount
on the spring (67-7), and insert into the body (67-1) together with the sleeve.
Apply grease to the poppet seat so that the spring and spring seat can be installed correctly on
Caution the poppet seat.
[4] Screw the plug (67-14) into the body (67-1) and tighten it.
[5] Assemble the spring (67-6) and piston (67-3) on the plug (67-14).
[6] Tighten the plug assembly (67-12) with O-ring mounted to the body (67-1).
3) Procedure for assembly of control valve main unit
a) Assembly of relief valve
1. When installing the relief valve, be sure to tighten the main unit installation section plug.
2. Do not tighten the set pressure adjustment plug or lock nut.
Caution 3. Doing so would be dangerous because the set pressure changes if the set pressure adjust-
ment plug turns.
[1] Screw in and tighten the main relief valve (68).
[2] Screw in and tighten the 6 overload relief valves (69) at each section.
[3] Screw in and tighten the 2 relief valve assemblies with O-rings mounted (70).
b) Assembly of load check valve
[1] Mount the O-rings (36) in the arm 1 section (E-E cross section), Boom 1 and 2 sections
(F-F cross sections), swing section, and bucket section (G-G cross sections) and assem-
ble the poppets (34) and springs (35).
Mount the flanges (37) and tighten with the hexagon socket head bolts (75).
[1]For the arm 2 section (E-E cross section), assemble the sleeve (58), poppet (59) and
spring (60), mount the flange (61), and tighten with the hexagon socket head bolts (75).
[2] Mount the O-ring (36) in the travel section (I-I cross section) and assemble the poppet
(51) and spring (35). Tighten the flange (37) with the hexagon socket head bolt (75).
[3] Assemble the poppet (34) and spring (35) on the common check section (J-J cross sec-
tion), then insert the spacers (53) with the O-ring (54) and backup ring (55) mounted.
Tighten the flange (52) with the hexagon socket head bolt (75).
1. Be careful to assemble O-rings and backup rings in the correct locations.

Caution 2. If they are assembled backwards, there is a danger of an O-ring being damaged and caus-
ing external leaks.
[4] Mount the O-ring (36) in the option section (H-H cross section) and assemble the poppet
(44) and spring (45). Mount the flange (43) and tighten with the hexagon socket head
bolts (74).
[5] Assemble the poppet (49) and spring (48) in the travel section (H-H cross section).
Screw in and tighten the plug (46) with O-ring (47) mounted.
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[6] Assemble the poppet (32) and spring (33) in the arm 1 parallel-tandem section (D-D
cross section).
Screw in and tighten the plug assembly (72) with O-ring mounted.
[7] Assemble the poppet (32), spring (33), and spacer (57) in the arm 2 parallel-tandem sec-
tion (D-D cross section).
Screw in and tighten the plug assembly (72) with O-ring mounted.
c) Assembly of antidrift valve
[1] Mount the O-rings (36) and (41) on the antidrift valve installation surfaces in the arm 1
section (E-E cross section) and boom 1 section (F-F cross section).
[2] Assemble the poppet (38) and spring (39).
[3] Install the 2 antidrift valve assemblies (67) and tighten with the hexagon socket head
bolts (74).
d) Assembly of option section
[1] Install the 2 caps (88) with O-rings (89) mounted and tighten with the hexagon socket
head bolts (75).
[2] Screw in and tighten the 2 plug assemblies (93) with O-rings and backup rings mounted.
e) Assembly of arm regeneration release valve
[1] Mount the O-ring (30) and 2 backup rings (31) in the sleeve (27-2).
[2] Assemble the piston (27-3) and spool (27-1) in the sleeve and insert into the valve hous-
ing.
[3] Put the spring (26) into the plug (24) with O-ring (25) mounted, then screw into the valve
housing and tighten.
f) Assembly of arm 1 parallel-tandem spool
[1] Assemble the spool (19) in the sub-assembly state into the valve housing.
Caution After inserting the spool, slide it to check for any sticky or rough feeling.
[2] Mount the cap (18) with O-ring mounted (23) and tighten with the hexagon socket head
bolt (78).
Tightening torque: 8.8 - 10.8 N•m
g) Assembly of neutral cut spool
[1] Assemble the spool assembly (84) into the valve housing.
Caution After inserting the spool, slide it to check for any sticky or rough feeling.
[2] Mount the O-ring (65) into the housing and tighten the cap (86) with the hexagon socket
head bolt (78).
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h) Assembly of main spool
[1] Mount the O-rings (7) and (41) on the valve housing cap matching surface.
[2] Assemble the spool assemblies (2) - (6), (14) - (17) in the sub-assembly state into the
same location as before disassembly.
1. Line up the spool straight with the opening and insert it slowly.
2. After inserting the spool, slide it to check for any sticky or rough feeling.
Caution 3. If a spool is left inserted that feels sticky or rough, there is a danger of a spool operation
defect.
[3] Install the plate assemblies (28) and (29) and tighten the hexagon socket head bolts in
the order (75), (94). Be careful not to apply excessive tightening torque to (94).
Tightening torque: (75) 39 - 44 N•m, (94) 8.8 - 10.8 N•m
[4] Install the plate assemblies (10) and (11), and tighten with the hexagon socket head bolts (75).
[5] Install the caps (8) and (9), and tighten with the hexagon socket head bolts (74).
[6] Screw in the plug assembly (110) with O-ring mounted into the option section (H-H cross
section) short cap and tighten it.
[7] Screw in the plugs (91) with O-rings (90) mounted into the option section (H-H cross sec-
tion) and straight travel section (I-I cross section) long caps and tighten them.
1. Be careful not to apply excessive torque when tightening a plug to a cap.

Caution 2. Applying excessive torque could crush the cap threads.
i) Assembly of straight travel signal control valve
[1] Screw the orifice plug (42-7) (36 mm hexagon diameter) into the body (42-1) and tighten
it.
[2] Being careful about the insertion orientation, assemble the spools (42-2) and (42-3) and
spring (42-4).
[3] Tighten the plug assembly (42-5) (5 mm hexagon socket diameter) with O-ring mounted
to the body.
[4] Install the body assembly (42) with the hexagon socket head bolts (83) (5 mm hexagon
socket diameter).
j) Assembly of add-on section
[1] Screw the tie rod (96) into the main unit valve housing (1).
[2] Install the main unit body matching surface O-rings (56) and (64).
Execute Steps [3] - [5] below as necessary.
[3] Remove the spool section assembly (111) and remove the matching surface O-rings
(110-10) and (110-11).
[4] Remove the inlet section assembly (99) and remove the matching surface O-rings (99-3)
and (99-4).
[5] Remove the spool section assembly (98) and remove the matching surface O-rings (98-
10) and (98-11).
[6] Install the outlet housing (95).
[7] Tighten the 4 hexagon nuts (97) (22 mm hexagon diameter).
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k) Assembly of other plugs
[1] Screw in and tighten the plug assembly (71) with O-ring mounted.
[3] Screw in and tighten the orifice plug (40).
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Internal structure diagram
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Part list
Code Part name Q'ty Code Part name Q'ty

1 Valve housing 1 48 Spring 1
2 Spool assembly 1 49 Poppet 1
3 Spool assembly 1 51 Poppet 1
4 Spool assembly 1 52 Flange 2
5 Spool assembly 2 53 Spacer 2
6 Spool assembly 1 54 O-ring 2
7 O-ring 20 55 Backup ring 2
8 Cap 9 56 O-ring 1
9 Cap 1 57 Spacer 1
10 Plate assembly 1 58 Sleeve 1
11 Plate assembly 1 59 Poppet 1
13 Valve housing 1 60 Spring 1
14 Spool assembly 1 61 Flange 1
18 Cap 1 67 Antidrift valve assembly 2
19 Spool 1 68 Relief valve kit 1
20 Spring seat 2 69-1 Relief valve kit 5
21 Spring 1 69-2 Relief valve kit 1
22 Spool end 1 70 Relief valve assembly 2
23 O-ring 1 71 Plug assembly 3
24 Plug 1 72 Plug assembly 10
26 Spring 1 74 Socket head bolt 32
27 Spool assembly 1 75 Socket head bolt 66
28 Plate assembly 1 77 Socket head bolt 8
29 Plate assembly 1 78 Socket head bolt 4
30 O-ring 1 79 Name plate 1
31 Backup ring 2 80 Drive screw 2
32 Poppet 2 82 Metal plug 5
33 Spring 2 83 Socket head bolt 4
34 Poppet 7 84 Spool assembly 1
35 Spring 8 86 Cap 1
36 O-ring 10 88 Cap 2
37 Flange 6 89 O-ring 2
38 Poppet 2 90 O-ring 2
39 Spring 2 91 Plug 2
40 Orifice plug 1 92 Plug assembly 2
42 Body assembly 1 94 Socket head bolt 2
43 Flange 1 95 Outlet housing 1
44 Poppet 1 96 Tie rod 4
45 Spring 1 97 Nut 4
46 Plug 1 110 Plug assembly 1
47 O-ring 1
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(6) Relief valve
1) Procedures for assembly and disassembly of main relief valve
1 Plug (32 mm hexagon diameter) 7 Hexagon nut (30 mm hexagon diameter)

2 O-ring 8 Plug (27 mm hexagon diameter)
3 O-ring 9 1-1/16-12UN-2A
4 Hexagon nut (36 mm hexagon diameter) 10 Piston
5 O-ring 11 PF1/4 JIS O-ring type
6 Plug (27 mm hexagon diameter)
[1] Disassembly
This part is replaced as an assembly.
When replacing, loosen the plug (1) (32 mm diameter) with a wrench and remove the O-ring
(2).
If oil leaks from the nut (4) (36 mm hexagon diameter), loosen the nut (4) (36 mm hexagon
diameter) and the plug (1) (32 mm hexagon diameter), and replace the O-ring (3).
If oil leaks from the nut (7) (30 mm hexagon diameter), loosen the nut (7) (30 mm hexagon
diameter) and the plug (8) (27 mm hexagon diameter), and replace the O-ring (5).
[2] Assembly
Carefully check to make sure there is no debris, paint fragments around the thread sections
of the plugs (1) (32 mm hexagon diameter), (6) (27 mm hexagon diameter), (8) (27 mm
hexagon diameter) and nuts (4) (36 mm hexagon diameter), (7) (30 mm hexagon diameter)
and assemble the new O-rings.
Also clean the valve housing relief valve installation section well, install the relief valve, and
tighten the plug (1) (32 mm hexagon diameter).
[3]When the plug has been disassembled, adjust the pressure according to the Main relief
valve item in 5).
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2) Procedures for assembly and disassembly of overload relief valve
1 Cap 6 Spring
2 O-ring 7 1-1/16-12UN-2A
3 Adjuster kit section 8 Cap (31.75 mm hexagon diameter)
4 O-ring 9 Lock nut (17 mm hexagon diameter)
5 Poppet 10 Adjuster (6 mm hexagon diameter)
[1] Disassembly
When replacing, loosen the cap (1) (31.75 mm hexagon diameter) with a wrench and
remove the O-ring (2).
Also, if oil leaks from the adjuster kit section, loosen the adjuster kit and replace the O-ring
(4).
Be careful disassembling the adjuster kit. The spring may make parts fly out and the poppet
Caution could be lost.
[2] Assembly
Check carefully that there is no debris, paint fragments around the thread section of the cap
and assemble a new O-ring (2).
Also clean the valve housing relief valve installation section well, install the relief valve, and
tighten the cap (1) (31.75 mm hexagon diameter).
[3]When the adjuster kit has been disassembled, clean around the thread sections well and
adjust the pressure according to the Overload relief valve item in 5).
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3) Procedures for assembly and disassembly of low-pressure relief valve
1 Plug 7 Plug
2 Poppet 8 O-ring
3 Plug 9 PF1/4
4 Spring 10 PF3/4
5 O-ring 11 1 3/16-12UN-2A
6 Piston
[1] Disassembly
Fasten the assembly with a vise, loosen the plug, and remove the piston (6), spring (4), and
poppet (2). Then loosen the plug and take out the O-rings (5) and (8) from each part.
[2] Assembly
Check carefully that there is no debris, paint fragments around the thread section of the plug
and assemble a new O-ring. Install new O-rings (5) and (8) on the plug and install the plug.
Assemble the poppet (2), spring (4), and piston (6) and screw in and tighten the plug.
[3]Also clean the valve housing relief valve installation section well and tighten the relief
assembly plug (1) (36 mm hexagon diameter).
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4) Procedures for assembly and disassembly of add-on main relief valve
1 Plug (32 mm hexagon diameter) 6 Spring

2 O-ring 7 1-5/16-12UN-2A
3 Adjuster kit section 8 Plug (24 mm hexagon diameter)
4 O-ring 9 Lock nut (17 mm hexagon diameter)
5 Poppet 10 Adjuster (6 mm hexagon diameter)
[1] Disassembly
When replacing, loosen the plug (1) (32 mm hexagon diameter) with a wrench and remove
the O-ring (2).
Also, if oil leaks from the adjuster kit section, loosen the adjuster kit and replace the O-ring
(4).
Be careful disassembling the adjuster kit. The spring may make parts fly out and the poppet
Caution could be lost.
[2] Assembly
Check carefully that there is no debris, paint fragments around the thread section of the plug
and assemble a new O-ring (2).
Also clean the valve housing relief installation section well, install the relief valve, and tighten
the plug.
[3]When the adjuster kit has been disassembled, clean around the thread sections well and
adjust the pressure according to the Add-on main relief valve item in 5).
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5) Relief valve adjustment
This part is neither disassembled nor adjusted. (It is replaced as an assembly.) Therefore, be
Caution aware that proper operation is not guaranteed if pressure is adjusted.
a) Main relief valve
[1] Install an accurate pressure gauge in the entry circuit.
[2] Run the pump at its rated rotation rate.
[3] Switch the control valve spool and read the pressure gauge at the cylinder stroke end.
Switch the spool for the actuator with the overload relief valve set pressure higher than the
Caution main relief valve set pressure.
[4] High-pressure setting (1st stage) (See the diagram on page 268.)
1) Tighten the plug (8) until the piston (10) touches the plug (6) end surface (section
marked *). At this time, the plug (8) (27 mm hexagon diameter) tightening torque must
be 19.6 N•m or less.
However, when tightening the plug (8), be careful that the plug does not turn too. (The A
dimension must be at least 4 mm.)
2) With the plug (6) in the state in [4] 1), tighten and adjust the pressure. (While watching
the pressure gauge, tighten in the plug (6) gradually: 1 turn of the plug raises the pres-
sure 28.4 MPa.)
After setting the pressure, lock with the hexagon nut.
[5] Low-pressure setting (2nd stage)
With the high-pressure set in 4), loosen the plug (8) and adjust the pressure.
(When the plug is loosened, the piston moves to the right in the diagram and the spring
load drops: 21.3 MPa pressure drop per one rotation.)
After setting the pressure, lock with the hexagon nut (7).
[6] Again raise the pressure and check that it reaches the specified pressure.
b) Overload relief valve
If the set pressure is higher than the main relief valve, when adjusting as below, the main relief
valve operates, so the overload relief valve cannot be adjusted. That is why the relief valve is
Caution not disassembled and adjusted but is replaced as an assembly with an assembly that has
already been set.
[2] Turn the adjuster clockwise until the required pressure is obtained.
[3] Reference number 69, total of 6 locations: The pressure rises 21.2 MPa for one rotation
of the adjuster.
[4] When the specified pressure is reached, restrain the adjuster so that it does not turn,
then tighten the lock nut.
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c) Add-on main relief valve
[1] Install an accurate pressure gauge in the entry circuit.
[2] Run the pump at its rated rotation rate.
Switch the spool for the actuator with the overload relief valve set pressure higher than the
Caution main relief valve set pressure.
[4] Turn the adjuster clockwise until the required pressure is obtained.
The pressure rises 17.8 MPa for one rotation of the adjuster.
[5] When the specified pressure is reached, restrain the adjuster so that it does not turn,
then tighten the lock nut.
(7) Installation
[1] Be careful that the line does not apply excessive force to the valve.
[2] Tighten all the bolts the same.
[3] Be careful. Welding close to a valve can damage its seal due to excess heat and sputter.
[4] In order to keep out debris, do not remove the cap for a port until it is time to work on the
line.
(8) Operation
[1] Check that the hydraulic circuits and hydraulic oil are clean, then gradually raise the pres-
sure (inch the operating machine in low idle) and check that no oil leaks to the outside.
[2] For the oil, use hydraulic oil with an aniline point of 82 - 113 ℃ .
[3] Do not raise the relief valve above the specified set pressure.
[4] Set a difference of at least 2.0 MPa between the set pressure for the main relief valve and for
the overload relief valve.
[5] Warm up the machine adequately before starting the actual work.
Pay attention to the following points in order to avoid sticking due to spool heat shock partic-
ularly when starting up with the hydraulic oil temperature or valve temperature low.
• Do not operate the main relief valve and overload relief valve right too suddenly after each
other. Raise the temperature of each section uniformly and operate in such a way that the
hydraulic oil circulates within each actuator.
• Fine operations and compound operations generate heat locally due to throttling of individ-
ual sections, so do not suddenly perform these operations with the machine still at low tem-
perature.
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(9) Troubles and countermeasures
Control valves overall
Trouble content Conceivable cause Countermeasure

The spool does not 1. The oil temperature is abnormally Eliminate the section that is providing resis-
move through its stroke. high. tance to the oil flow in the line.
2. Dirty hydraulic oil Replace the hydraulic oil and at the same
time, clean the circuits.
3. Line port joint tightened too much Check the torque.
4. The valve housing was warped dur- Loosen the installation bolts and check.
ing installation.
5. The pressure is too high. Attach a pressure gauge to the pump and the
cylinder port and check the pressure.
6. The spool is bent. Replace the spool as an assembly.
7. Return spring damage Replace the damaged part.
8. The spring or cap is out of place. Loosen the cap, center it, then tighten it.
9. The temperature distribution within Warm up the circuits as a whole.
the valve is not uniform.
10. Debris is clogging inside the valve. Remove (flush out) the debris.
11. Pilot pressure insufficient Inspect for the pilot valve and pilot relief pres-
sure.
The load cannot be 1. Oil leak from cylinder Check the cylinder seal section.
held.
2. Oil from the spool is bypassing. Check for spool damage.
3. Oil leak from overload relief valve Clean the valve housing seat section and relief
valve seat section.
4. Oil leak from antidrift valve Disassemble the antidrift valve and clean the
seat section for each part.
If a seat section is damaged, replace the pop-
pet or lap the poppet and seat section.
If the antidrift valve spool is abnormal, since
the spool and the sleeve are mating parts,
replace them both at the same time.
When the spool is 1. There is debris jammed in the load Disassemble and clean the check valve.
switched from the neu- check valve.
tral to the raise position,
2. The check valve poppet or seat sec- Replace the poppet or lap the poppet and seat
the load falls.
tion is damaged. section.
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Relief valve

Pressure does not rise 1. Either the main poppet, sleeve, or Replace the relief valve.
at all. pilot poppet is stuck open or there is
debris jammed in the valve seat
section.
The relief pressure is 1. The pilot poppet seat section is
unstable. damaged.
2. The piston or main poppet is stuck.
The relief pressure is 1. Seat section worn by debris
wrong.
2. The lock nut and adjuster are loose. Set the pressure again, then tighten the lock
nut to the specified torque.
Oil leak 1. Relief valve seat section damage Replace the relief valve.
2. Each part is stuck due to debris.
3. An O-ring is worn. Replace the adjuster or installation section O-
ring.
Hydraulic system overall

The hydraulic system is 1. Pump trouble Check the pressure or replace the pump.
not working properly or
2. Relief valve trouble Replace the relief valve.
is not working at all.
3. Cylinder trouble Repair or replace.
4. Pump load pressure is high. Check the circuit pressure.
5. There is a crack in the valve. Replace the valve as an assembly.
6. The spool does not move through Check the spool movement.
its full stroke.
7. The tank oil level is too low. Fill the hydraulic oil.
8. The filter in the circuit is clogged. Clean or replace the filter.
9. The circuit line is throttled. Check the line.
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Removal and Installation of 5 Stack Solenoid
Items to prepare
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of 5 stack solenoid valve
[2] Use a wrench (13 mm) to remove the 2 cover

bolts (3), and then remove the cover (4).
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[3] Remove the 5 connectors (5).
[4] Use wrenches (19 mm, 22 mm) to remove the

hoses (6), (7) and (8).
• Mark the solenoid valve and hoses so that the
connectors match at the time of assembly.
• Use caps or plugs to cover the solenoid valve
and hose to prevent any entry of water, dust or
dirt.
• Clean the solenoid valve and hoses by spraying
nectors.
[5] Use a wrench (22 mm) to remove the hoses (9)

and (10).
and hoses to prevent any entry of water, dust or
dirt.
nectors.
6 Pilot hose (use 22 mm wrench)

10 Drain hose (use 22 mm wrench)
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hoses (11), (12) and (13).
dirt.
nectors.

(14), and then remove the 5 stack solenoid
valve (15).

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2. Installation of 5 stack solenoid valve
The hose connections and electrical connector connections are indicated below.
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Removal and Installation of Cushion Valve
Items to prepare
• Marking pen
• Caps
• Plugs
• Waste oil can
• Rag
• Cleaning fluid
1. Removal of cushion valve

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[5] Use wrenches (17 mm, 19 mm, 22 mm) to
remove each hose and line.
• Mark the cushion valve, hoses and lines so that
the connectors match at the time of assembly.
• Use caps or plugs to cover the cushion valve,
hoses and lines to prevent any entry of water,
dust or dirt.
• Clean the cushion valve, hoses and lines by
spraying them with a parts cleaner to prevent
scratches and prevent dirt from accumulating on
the connectors.
6 Pilot hose
7 Line
9 Use 17 mm wrench
10 Use 19 mm wrench
11 Use 22 mm wrench
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(12) on the cushion valve bottom, and then
remove the cushion valve.
2. Installation of cushion valve

The connections are as follows.
1 Arm in 7 Boom down

2 Boom up 8 Swing left
3 Swing right 9 Bucket open
4 Bucket close 10 Pressure sensor (swing)
5 Heat circuit line 11 Swing priority switching pilot line
6 Arm out 12 Drain line
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Assembly and Disassembly of Cushion Valve
This valve has a structure that forms small gaps. It is precision processed and the parts are carefully
selected and fit together, so do not disassemble it as much as possible. If assembly and disassem-
bly is unavoidable, pay attention to the following. (Failure to follow these instructions may invalidate
the product warranty.)
[1] Only disassemble in a clean location with minimal dirt.
[2] Use only clean tools and cleaning oil and handle them with care.
[3] Use plugs, caps to cover ports to prevent any entry of dirt and clean the outside of the assembly.
[4] Check the internal structure before starting work, and carefully study the disassembly objective
and scope.
(1) Reverse operation spool section
[1] Remove the plugs (1) and O-rings (2).
[2] Remove the springs (3).
[3] Remove the spools (4) with the cap screws and O-rings assembled in them.
Diagram 1
[4] Use a vise to fasten the spool (4) assemblies taken out in [3].
[Caution] Use a piece of wood (jig) to prevent scratches.
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[5] Remove the cap screw (1) and O-ring (2).
3 Spool
4 Piece of wood (jig)
Diagram 2
(2) Check plunger section with throttle

[1] Remove the plugs (1) and O-rings (2).
[2] Remove the springs (3) and remove the check plungers (4).
[Caution] The check plungers have similar shapes, so identify them in such a way that no
one will mix them up with each other.
Diagram 3
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Other Valves
(3) Shuttle valve section
[1] Remove the plugs (1) and O-rings (2) and (3).
[2] Remove the steel balls (4).
Diagram 4
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Other Valves
This valve has a structure that forms small gaps. It is precision processed and the parts are carefully
selected and fit together, so do not disassemble it as much as possible. If assembly and disassem-
bly is unavoidable, pay attention to the following. (Failure to follow these instructions may invalidate
the product warranty.)
[1] Only assemble in a clean location with minimal dirt.
[2] Use only clean tools and cleaning oil and handle them with care.
[3] Clean the disassembled parts and prepared parts.
[4] Study the internal structure before starting the work and prepare the parts required by the disas-
sembly objective and scope.
(1) Reverse operation spool section
[1] Assemble on the spool (3) the cap screw (1) with O-ring (2) attached.
[1][Caution] Use a piece of wood (jig) (4) to prevent scratches.
Diagram 5
[2] Insert the spool assembly (1) assembled in [1] into the body.
[Caution] The spool assembly is symmetrical left/right, so the insertion direction does not matter.
[3] Insert the springs (2) and assemble the plugs (3) with the O-rings (4) attached.
Diagram 6
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Other Valves
(2) Check plunger section with throttle
[1] Insert the check plungers (1).
[Caution] The check plungers have similar shapes, so be careful to insert each one in its cor-
rect position.
[2] Insert the springs (2) and assemble the plugs (4) with the O-rings (3) attached.
Diagram 7
(3) Shuttle valve section

[1] Insert the steel balls (1).
[2] Assemble the plugs (2) with the O-rings (3) and (4) attached.
Diagram 8
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Other Valves
3. Written materials
[1] Check plunger table
Part No. Name Orifice diameter (φ) Remarks

65301-11705 Check plunger 0.5
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Other Valves
[2] Cushion valve assembly diagram
External shape diagram
Cross-section diagram

1 Body 9 Check plunger 17 Plug
2 Spool 10 Check plunger 18 O-ring
3 Spring 11 Check plunger 19 Name plate
4 Plug 12 Check plunger 20 Drive screw
5 O-ring 13 Spring 21 Plug
6 Cap screw 14 Plug 22 Plug
7 O-ring 15 O-ring
8 Plug 16 Steel ball
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Removal and Installation of Radiator
・ Do not remove the radiator cap when the radiator coolant temperature is high. Hot liquid
Warning could spray out.

Items to prepare
• Pliers
• Caps
• Plugs
• Drain tank
• Drain hose
• Rag
• Cleaning fluid
1. Removal of radiator
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[2] Install the drain hose (3), and then prepare the
drain tank (4).
[3] To make it easier to drain the coolant, remove

the radiator cap (5).
[4] Loosen the drain plug (6), and then drain the
coolant.
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(10), and then remove the seal bracket (11).
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bolts (12) from the radiator cover.

(13), and then remove the upper hose (14) and
lower hose (15) from the radiator.
• Use caps to cover the radiator and hoses to pre-
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[10] Remove the drain plug (16), loosen the hose
band (17), and then remove the hose (18).
[11] Loosen the hose band (20), and then remove

the hose (19) from the radiator cap.
• Attach caps or plugs to the hoses to prevent any
entry of water, dust or dirt.

(21).
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[15] Remove the fan guide rubber (25).
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[16] Remove the 2 butterfly bolts (26), and then
remove the front anti-insect net (27).
[17] Install the 2 shackles (28) to the top of the radia-

tor, and then use the wire rope (29) and liftcrane
to lift the radiator.
[18] Lift the radiator together with the radiator cover

(31) until the fixtures (30) at the bottom of the
radiator become disconnected.
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before lowering the radiator on square wooden
pieces.
When laying down the radiator, be careful not to
bend or crush the bottom fixtures (30).
2. Installation of radiator
For details on the method for coolant filling, see the Engine Shop Manual.
Coolant capacity is 30 L.
Finally, check that the level of coolant is correct.
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Removal and Installation of Oil Cooler

Items to prepare
• Pliers
• Screwdriver
• Caps
• Waste oil can
• Rag
• Cleaning fluid
1. Removal of oil cooler
[1] Drain the hydraulic oil from the hydraulic oil
tank.
See "Draining Oil from Hydraulic Oil Tank" for
details of the procedure.
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[4] Remove the 2 butterfly bolts (4), and then

remove the anti-insect net (5).
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upper hexagon socket head bolts (6) and 2
lower bolts (6), and then remove the lines (7)
and (8).
• Use caps to cover the oil cooler and lines to pre-
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(9).
[7] Install the 2 eyebolts (M12) (10) on the top of

the oil cooler.
• Fully tighten the eyebolts, and then loosen them
by a half turn.
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[8] Install the 2 shackles (11) to the eyebolts, and
then use the wire rope (12) and liftcrane to lift
the oil cooler main unit.

before lowering the oil cooler on wood planks,
etc.
2. Installation of oil cooler

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Tank
Tank
Removal and Installation of Hydraulic Oil Tank
・ Bleed off the pressure in the hydraulic oil tank before beginning work.
Warning ・ The temperature of the hydraulic oil is high immediately after stopping the engine. Wait until
the hydraulic oil temperature has decreased (to 40 ℃ or less) before beginning work.

Items to prepare
• Marking pen
• Caps
• Plugs
• Waste oil can
• Rag
• Cleaning fluid
1. Removal of Hydraulic Oil Tank
[1] Drain the oil from the hydraulic oil tank. (For
details, see "Draining Oil from Hydraulic Oil
Tank".)
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Tank
[3] Prepare a waste oil can (3) under the hydraulic
oil tank.

and then remove the seal washer (5).
• Cover the seal washer to prevent the entry of
[5] After closing the engine hood (9), use a wrench

(19 mm) to remove the 9 bolts (6), and then
remove the top covers (7) and (8).
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Tank
(10), and then remove the drain hoses (11) and
(12).
• Use caps to cover the lines to prevent any entry
of water, dust or dirt.
[7] Use wrenches (19 mm, 22 mm, 27 mm, 36 mm)

to remove the drain hoses (13).
• Mark the hydraulic oil tank and hoses so that
the connectors match at the time of assembly.
• Attach caps or plugs to the hydraulic oil tank
dirt.
• Clean the hydraulic oil tank and hoses by spray-
ing them with a parts cleaner to prevent
scratches and prevent dirt from accumulating on
the connectors.

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Tank
(16), and then remove the top cover (17) from
the hydraulic oil tank.

(18) and 6 spacers (19) from the bottom of the
hydraulic oil tank.
• Depending on the machine, there may be height
adjustment shims between the tank and the
frame. Do not lose them.
Also, mark or write down the locations where
they are and how many.

(20) from the fuel tank front cover (tank) (21),
and then remove the cover (tank).
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Tank
(22) from the fuel tank side cover, and then
remove the side cover (23).

(24), and then remove the side covers (tank)
(25).
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Tank
[14] Connect the 2 eyebolts (M12) (26) to the top of
the hydraulic oil tank, and then use the shackles
(27), wire rope (28) and liftcrane to lift the
hydraulic oil tank (29).
• When lifting, be careful that the level gauge (30)
does not interfere with the frame at the side of
the hydraulic oil tank.
by a half turn.

before lowering the hydraulic oil tank on wood
planks (31).
• Thoroughly secure the hydraulic oil tank so that
it does not fall down.
2. Installation of Hydraulic Oil Tank

For the tightening torque, check the "Bolt tightening torque list" in the Service Text .
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Tank
Removal and Installation of Fuel Tank

Items to prepare
• Caps
• Plugs
• Drum can (for draining fuel)
• Rag
• Cleaning fluid
Removal of Fuel Tank
[1] Remove the cap (1) and filter (2).
[2] Drain out all the fuel from the fuel tank into a
drum can.
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Tank

(3), and then remove the top cover (5).

from the fuel tank front cover (tank) (7), and
then remove the cover (tank).
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Tank
and clamps (9), and then remove the handle
(10).

(11) from the fuel tank side cover (12), and then
remove the side cover.
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Tank
[9] Loosen the hose band (15), and then remove

the hose (16).
• Mark the fuel tank and hose so that the connec-
• Attach caps or plugs to the fuel tank and hoses
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Tank
(18) and 6 spacers (19) from the bottom of the
fuel tank.
• Depending on the machine, there may be height
adjustment shims between the tank and the
frame. Do not lose them.
Also, mark or write down the locations where
they are and how many.

(20), and then remove the side covers (tank)
(21).
[13] Install the 4 eyebolts (M12) (22) on top of the

fuel tank.
by a half turn.
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Tank
[14] Connect the 4 shackles (23) to the eyebolts,
then use the wire ropes (24) and liftcrane to lift.
before lowering the fuel tank (25) on wood
planks.
Installation of fuel tank

Finally, carefully check for any fuel leaks.
For the tightening torque, check the "Bolt tightening torque list" in the Service Text .
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Attachments
Removal and Installation of Bucket
・ Stop the machine on a level location with good footing.
・ When working together with others, always be sure to exchange signals and pay adequate
Caution attention to safety.
・ Always wear protective devices (protective eyewear and safety shoes, etc.) when working
with a hammer.
Items to prepare
• Hammer
• Striking rod
• Screwdriver
• Grease
• Rag
• Cleaning fluid
1. Removal of bucket
[1] Place the back of the bucket parallel to the
ground.
[2] Remove the bolts and nuts (1), and then remove
the bucket side and boom side pins.
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the bucket side pin (6) and arm side pin (5) out,
and then remove the bucket (2).
• If a pin is hard to remove, there is a load on the
pin.
Do not force it. Adjust the bucket position.
• When removing the pins, be careful not to dam-
age the installed O-rings or dust seals.
2. Installation of bucket
• Clean each pin and pin hole.
• If a pin is hard to insert, do not force it. Adjust the bucket position.
• When insetting pins, be careful not to damage the O-rings or dust seals.
• As the final step, always grease up.
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Removal and Installation of Bucket Link
Caution attention to safety.
・ Always wear protective devices (protective eyewear and safety shoes, etc.) when working
with a hammer.
Items to prepare
• 2 wrenches (36 mm)
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
1. Removal of bucket link
[1] Remove the bucket. (For details, see "Removal
and Installation of Bucket".)
[2] Place the bucket link (1) parallel to the ground.
[3] Use 2 wrenches (36 mm) to remove the double

nuts (2), and then pull out the bolts (3) and (4).
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the pin (7) out and remove the bucket link (8).

the pin (9) out and remove the arm links (10)
and (11).
pin.
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2. Installation of bucket link
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Removal and Installation of Bucket Cylinder
attention to safety.
Caution ・ Always wear protective devices (protective eyewear and safety shoes, etc.) when working
with a hammer.
・ Be sure to inspect the nylon sling and other lifting equipment before beginning work.
Items to prepare
• Hammer
• Striking rod
• Nylon sling (with the required lifting capacity)
• Grease
• Rag
• Cleaning fluid
• Crossties
• Wire
1. Removal of bucket cylinder
[2] Remove the bucket link. (For details, see
"Removal and Installation of Bucket".)
[3] Bring the arm (1) top in contact with the ground.
Retract the bucket cylinder rod.
[4] Tie the cylinder rod with wire (2) so that it can-
not come out.
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[5] Switch the key switch (3) OFF to stop the
engine. Switch the key switch ON again, and
then turn the control lever (4) about 10 times to
bleed off any pressure.
Note:
Do not operate the bucket at this time.
[6] Move the travel lever (5) back and forth about 5
times to bleed out the pressure.
[7] Return the key switch to OFF.
[8] Press the air breather button (6) on top of the

hydraulic oil tank to release the pressure inside
the tank.
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[9] Use 2 wrenches (36 mm) to remove the hoses
(7) and (8).
• Use caps or plugs to cover the hoses and lines
• Clean the hoses and lines by spraying them
tors.
[10] Use a liftcrane and nylon sling (9) to secure the

bucket cylinder (10).
• Wrap the nylon sling to the inside of the line so
that it is not crushed.

and washer (12).

the pin (15) out.
pin.
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[13] Lift the bucket cylinder (10) and remove it.
[14] Place the bucket cylinder on crossties.
2. Installation of bucket cylinder

• When inserting pins, be careful not to damage the dust seals.
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Removal and Installation of Arm Cylinder
with a hammer.
Items to prepare
• Wrench (19 mm)
• Caps
• Plugs
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Crossties
• Wire
1. Removal of arm cylinder
arm cylinder (2).

and washer (4).
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[3] Use a hammer (5) and striking rod (6) to remove
the pin (7). Be careful. The arm and arm cylin-
der rod may come out of place.
[4] Start the engine, move the arm out at idle, and
retract the arm cylinder (2) rod.
not come out.
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Do not operate the arm at this time.
[8] Switch the key switch OFF.

the tank.
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[10] Use a hexagon wrench (12 mm) to remove the
hexagon bolts, and then remove the hoses (13)
and (14).
tors.
[11] Use a wrench (19 mm) to remove the grease

hose (15).
• Use caps or plugs to prevent any entry of water,
dust or dirt.

and washer (17).
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the pin (20) out.
pin.
[14] Lift the arm cylinder (2).

[15] Place the arm cylinder (2) on crossties.
2. Installation of arm cylinder

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Removal and Installation of Arm
with a hammer.
Items to prepare
• Wrench (19 mm)
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Crossties
1. Removal of arm
[2] Remove the bucket cylinder. (For details, see
"Removal and Installation of Bucket Cylinder".)
[3] Remove the arm cylinder. (For details, see
"Removal and Installation of Arm Cylinder".)
[4] Bring the arm (1) top in contact with the ground
and use a liftcrane and nylon sling (2) to secure
it.
At this time, insert the arm cylinder pin (3) and
secure with the nylon sling.

and washer (5).
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the pin (8) out and remove the arm (9).
pin.
• Be very careful. When the pin is removed, the
arm may fall slightly.
• Be very careful. The arm may fall over to the
side.
[7] Lift the arm.

[8] Place the arm on crossties.
2. Installation of arm
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Removal and Installation of Boom Cylinder
with a hammer.
Items to prepare
• Crowbar
• Wire rope (with the required lifting capacity)
• Nylon sling
• Marking pen
• Caps
• Plugs
• Hammer
• Striking rod
• Grease
• Rag
• Cleaning fluid
• Crossties
• Wire
1. Removal of boom cylinder
• When removing only the boom cylinder, put the attachments in the temporary decommissioning
posture.
• When removing as far as the boom, first remove the bucket, bucket cylinder, arm, and arm cylinder
according to their respective removal procedures.
Bring the boom top in contact with the ground.
right boom cylinder (2).
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hose (4).
dust or dirt.
[3] Use 2 wrenches (30 mm) to remove the 2 dou-

ble nuts (5) and bolt (6), and then remove the
fastening ring (7).

the pin (10) out.
[5] Start the engine, lower the boom at idle, and
retract the boom cylinder rod.
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not come out.

[9] Switch the key switch OFF.
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the tank.
[11] Use a wrench (36 mm) to remove the hoses

(16).
• Mark the lines and hoses so that the connectors
tors.

and washer (18).
[13] Use a crowbar to remove the pin (19).
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[14] Use a liftcrane and nylon sling (1) to lift the right
boom cylinder (2) and remove it.
[15] Place the right boom cylinder (2) on crossties.
[16] Remove the left boom cylinder (3) with the
same procedure.
2. Installation of boom cylinder

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Attachments
Removal and Installation of Boom
with a hammer.
Items to prepare
• Slide hammer (24 mm)
• Marking pen
• Caps
• Plugs
• Rag
• Striking rod
• Cleaning fluid
• Batten
• Square wooden pieces
• Wire
1. Removal of boom
[2] Remove the bucket cylinder. (For details, see
"Removal and Installation of Bucket Cylinder".)
[3] Remove the arm cylinder. (For details, see
"Removal and Installation of Arm Cylinder".)
[4] Remove the arm. (For details, see "Removal
and Installation of Arm".)
[5] When removing the boom cylinder too, see
"Removal and Installation of Boom".
[6] This section explains the procedure for when
not removing the boom cylinder.
Bring the boom (1) top in contact with the
ground.
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hose (2).
dust or dirt.
[8] Use a wrench (30 mm) to remove the double

nuts (3) and bolt (4), and then remove the fas-
tening ring (5).

the pin (8) out.
Use a liftcrane and nylon sling (9) to hold the
boom cylinder so that it does not fall.
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not come out.
[11] Secure the base of the boom cylinder with the

batten (11).
[12] Lower the boom cylinder and let it rest on the

batten (11).
[13] Remove the cab side boom cylinder from the
boom in the same way.
[14] Install the pin (8) removed in Step [9].

Use a wrench (30 mm) to install the bolt (4) with
the 2 double nuts (3), and then install the fasten-
ing ring (5).
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[15] Wrap the nylon sling (9) around the pin installed
in Step [14] and secure with the liftcrane.
[16] Use wrenches (22 mm, 36 mm, 41 mm) to

remove the hoses (13), (14), (15), (16), (17) and
(18).
• Mark the hoses and lines so that the connectors
tors.
13 Bucket hose (use 36 mm wrench)

14 Bucket hose (use 36 mm wrench)
15 Arm hose (use 36 mm wrench)
16 Arm hose (use 41 mm wrench)
17 2nd option hose (use 22mm wrench)
18 2nd option hose (use 22mm wrench)

and washer (20).
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[18] Use a slide hammer (21) (24 mm) to remove the
pin (12).
[19] Back up the machine and remove the boom (1).
2. Installation of boom cylinder

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Removal and Installation of Arm HBCV
・ Stop the machine in the temporary decommissioning posture on a level location with good
footing.
Caution ・ When working together with others, always be sure to exchange signals and pay adequate
Items to prepare
• Wrench (22 mm)
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
1. Removal of arm HBCV
[1] Use a wrench (22 mm) to remove the hoses (1)
and (2).
• Mark the HBCV and hoses so that the connec-
• Use caps or plugs to cover the hoses and
HBCV to prevent any entry of water, dust or dirt.
• Clean the hoses and HBCV by spraying them
tors.

hexagon socket head bolts (3), and then remove
the line (4).
• Use caps or plugs to cover the HBCV and line to
• Clean the HBCV and line by spraying them with
a parts cleaner to prevent scratches and pre-
vent dirt from accumulating on the connectors.
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the arm HBCV (6).
2. Installation of arm HBCV

The tightening torque for line installation and HBCV installation is 92.4 ± 17.5 N•m.
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Removal and Installation of Boom HBCV
Caution ・ When working together with others, always be sure to exchange signals and pay adequate
Items to prepare
• Marking pen
• Caps
• Plugs
• Rag
• Cleaning fluid
• Crossties
1. Removal of boom HBCV
hoses from the tool box side boom HBCV (1),
(2), (3) and (4).
• Use caps or plugs to cover the HBCV and lines
• Clean the HBCV and lines by spraying them
tors.

the line (6).
tors.

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the boom HBCV (8).

hoses (1), (3), (4) and (9) from the cab side
boom HBCV in Step [1].
[5] Use a wrench (27 mm) to remove the boom bot-
tom pressure sensor (10).
tors.
hexagon socket head bolts (11), and then
remove the line (12).
• Use caps or plugs to cover the HBCV and line to
• Clean the HBCV and line by spraying them with
a parts cleaner to prevent scratches and pre-
vent dirt from accumulating on the connectors.

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hexagon socket head bolts (13), and then
remove the boom HBCV (14).
2. Installation of arm HBCV

The tightening torque for line installation and HBCV installation is 92.4 ± 17.5 N•m.
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Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder
1. Specifications and structure diagram (including the assembly diagram and parts table)
In this manual, explanation is done using a product with a representative structure for a construction
machine hydraulic cylinder (KCH-6 model).
For details on the specifications and structure of the product being used, see the delivery diagram
(including the assembly diagram and parts table) given separately.
2. Explanation of functions
(1) Basic functions
Hydraulic cylinders are a type of hydraulic actuator. A hydraulic cylinder converts the energy of
pressure supplied from the hydraulic pump into a large force of linear motion. By operating the
hydraulic pressure direction switchover valve, one can switch the direction of operation between
extension and retraction. This linear motion with large force and the switchover of the operation
direction are the basic functions.
(2) Function of each location
This manual explains the functions of each section of the cylinder using one of our products with
a typical structure. There may be some slight differences with the product being used, but the
functions are the same.
1) Cylinder head assembly
The cylinder head assembly has the function of bearing the piston rod (2) by the bushing (4)
press fit into the inner diameter of the cylinder head (3). The seal system of the inner diameter
of the cylinder head prevents oil from leaking to the outside and prevents foreign matter from
getting into the cylinder. The cylinder head assembly also has the function of supplying and dis-
charging high-pressure oil from inside the cylinder tube to the retraction side port.
1 Cylinder tube 7 U-ring

2 Piston rod 8 Backup ring
3 Cylinder head 9 Wiper ring
4 Bushing 10 O-ring
5 O-ring 11 Backup ring
6 Buffer ring 12 Installation bolt
• Bushing
The bushing is press fit to the inside surface of the cylinder head (3) and touches the piston
rod (2). Together with the slide rings (18) and (19) on the outer circumference of the piston,
the bushing divides the lateral load applied to the cylinder and moves linearly relative to the
piston rod. Furthermore, it supports one end of the piston rod and has the function of minimiz-
ing eccentricity which has a negative impact on the sealing.
• Buffer ring
The buffer ring (6) has the function of buffering the pressure and heat applied on the U-ring (7)
by the hydraulic oil to improve durability.
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• U-ring and backup ring
The U-ring (7) seals the pressurized oil within the cylinder. The U-ring also has the function of
forming an appropriate oil film on the surface of the piston rod in order to prevent rust of the
piston rod (2). The backup ring (8) has the function of suppressing extrusion of the U-ring into
the gap between the piston rod and the cylinder head (3) when the pressure operates and of
improving durability.
• Wiper ring
The wiper ring (9) is positioned in the opening where the piston rod (2) comes out from and
goes into the cylinder and prevents dust and water from getting into the cylinder from the out-
side. It also has the function of wiping off any mud sticking to the surface of the piston rod as
the piston rod moves.
2) Piston assembly
The piston assembly has the function of transmitting the propulsion of the cylinder. A seal ring
(16) is mounted on the center of the piston (15) to prevent the flow of pressurized oil from either
the left or right chamber to the other chamber. There are slide rings (18) and (19) mounted at
each end of the seal ring. They have the function of a bearing to receive the cylinder lateral
load.
1 Cylinder tube 19 Slide ring

2 Piston rod 20 Locking screw
13 Cushion ring 21 Steel ball
14 Cushion seal 22 Cushion ring
15 Piston 23 Cushion seal
16 Seal ring 24 Stopper
17 Backup ring 25 Snap ring
18 Slide ring
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For some cylinder sizes, the piston (15) and nut (21) are separate.
1 Cylinder tube 20 Shim

2 Piston rod 21 Nut
13 Cushion ring 22 Locking screw
14 Cushion seal 23 Steel ball
15 Piston 24 Cushion ring
16 Seal ring 25 Cushion seal
17 Backup ring 26 Stopper
18 Slide ring 27 Snap ring
19 Slide ring
Example of parts numbers for separated piston and nut

• Seal ring and backup ring
The seal ring (16) is positioned at the center of the piston (15) and uses the tension force of
the O-ring to seal the ring-shaped gap between the piston and the cylinder tube (1) and form
chambers with a high-pressure side and a low-pressure side with the piston as the boundary.
The backup ring (17) has the function of suppressing extrusion of the seal ring into the gap
between the piston and the cylinder tube when the pressure operates and of improving dura-
bility.
• Slide ring
Slide rings are positioned at both ends of the seal ring (16) and contact the inside surface of
the cylinder tube (1). Together with the bushing (4) positioned on the inside surface of the cyl-
inder head (3), the slide ring divides the lateral load applied to the cylinder and moves linearly
relative to the inside surface of the cylinder tube.
Furthermore, it supports one end of the piston rod (2) and has the functions of minimizing
eccentricity, which has a negative impact on the sealing, and buries and captures any impuri-
ties trapped between the cylinder tube and the slide rings (18) and (19).
• Cushion ring
When the cylinder is fully extended, the cylinder head (3) and the cushion ring (13) fit together.
When it is fully retracted, the cylinder bottom and the cushion ring fit together. In both cases,
this forms a ring-shaped gap and squeezes the oil to reduce the cylinder collision speed at full
extension or full retraction and thus soften the impact.
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3) Pipe assembly
The pipe assembly is mounted on the extension side and retraction side ports of the cylinder
tube assembly. It has the function of supplying and discharging high-pressure oil by connecting
with the hydraulic circuits of the machine body.
28 Pipe assembly
29 Pipe assembly
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3. Handling precautions
(1) Precautions for installing the cylinder on the machine body
• When installing the cylinder on the machine body or removing it from the machine body, secure
the piston rod at the fully retracted position, check safety, and suspend.
Never suspend the cylinder from the line section. This would not only pose the danger of falling
but could also damage the cylinder.
Use a band to secure the piston rod in the fully retracted state. If the piston rod is not in the fully
Caution retracted state, it could be easily damaged. This could create the need for repair or make the
piston rod unusable. Also, not securing the piston rod is dangerous because the piston rod
might fly out unexpectedly.
• Do not weld after the cylinder has been mounted on the machine body.
Electric welding on the cylinder or even at a position separated from the cylinder can generate
Caution a spark within the cylinder and damage parts. This could cause extensive damage, making it
necessary to replace parts or replace the cylinder.
• When painting the machine body, mask the piston rod and wiper ring.
If the cylinder is operated with paint sticking to the piston rod surface and the wiper ring, the
wiper ring does not function adequately, greatly interfering with cylinder functions. For example,
Caution dirt and paint from the outside may get into the cylinder easily and damage seal parts and
cause an oil leak.
• Clean the cylinder before installing it.

(2) Usage cautions
• Use under the determined conditions.
Use of hydraulic oil other than that specified can cause rapid deterioration of and damage to
seal parts. If the relief valve is set to a value higher than that on the assembly diagram, there is
a danger of this leading to cylinder damage.
General sealing materials cannot handle high ambient temperature (about 100 ℃ or higher) or
low ambient temperature (-20 ℃ or lower), so the cylinder would be damaged if used at such
Caution temperatures. Such temperatures require special seal materials, so check if the cylinder being
used complies with this requirement.
The number one cause of cylinder trouble is oil leaks due to piston rod scratches. Operate very
carefully to avoid scratching.
If the piston rod is scratched, take the measures according to "Trouble diagnostics".
• Warm up the equipment adequately before work.

After the cylinder has been stopped for a long time, the seal parts inside the cylinder are stuck
to the metal of sliding surfaces, so do not suddenly pressurize or operate such a cylinder.
A new cylinder or one that has been left unused for a long time has much air built up inside, so
it does not operate smoothly. Also, if the cylinder is suddenly operated or pressurized without
Caution bleeding out the air, the adiabatic compression of the air generates high temperatures, which
may burn and carbonize seal parts, leading to a drastically reduced functionality.
Before starting work, always warm up the cylinder by moving slowly through a few full strokes
under no load to bleed off any air in the cylinder.
• For stopping the machine temporarily or storing it, always have the machine in a safely secure
posture.
When extended, the cylinder cannot hold a load for a long time in a fixed position. This is
because the cylinder is extended and retracted by very minor oil leaks from hydraulic circuits
and from inside the cylinder and changes in the volume of the hydraulic oil due to oil tempera-
Caution ture variation. This results in the danger of machine moving unexpectedly, which can lead to
serious accidents.
For stopping the machine temporarily or storing it, always have the machine in a safely secure
position.
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(3) Maintenance and inspection cautions
• Always carry out daily maintenance inspections.
The most important point for realizing the cylinder functions for a longer time is "daily mainte-
nance inspections". In order to ensure adequate functioning, execute "4. Maintenance inspec-
tion and service".
Caution Constantly clean off any mud, water, dust, oil or grease stuck to the piston rod and keep the
piston rod in a clean state. However, do not use water or the like to clean the wiper ring section
and seal section. Wipe with a rag. When leaving the machine unused for a week or longer,
apply anti-rust oil to the surface of the piston rod in order to prevent rusting.
• Use genuine KYB parts for replacement parts.

If replacement parts are used that are not genuine KYB parts, adequate functioning cannot be
attained. Always use genuine KYB parts.
Caution Specialty jigs have been produced so that assembly work and disassembly work can be done
safely and quickly, so order them.
• Be careful about assembly and disassembly too.

Disassembling a cylinder still installed on the machine body is extremely dangerous because it
can cause unexpected movement of the machine body. Always remove the cylinder from the
machine body before disassembling it.
Caution Assembling with dirty hands can get dirt inside the cylinder and not only reduce the cylinder
service life but also damage other hydraulic equipment. Assemble under clean conditions.
Use the thread part tightening torque indicated in the diagram. If the torque is either too low or
too high, this can cause thread damage.
• Strictly observe the cylinder storage standards.
Caution Execute according to "7. Assembly and disassembly procedures".
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4. Maintenance inspection and service
In order to ensure a hydraulic cylinder functions properly for a long time, periodically carry out main-
tenance inspection and service based on the "Autonomous inspection table". Repair any trouble
locations quickly based on the trouble diagnostics.
For periodic inspection and service, first work to prevent any hazard to operators. Strive to pre-
Caution vent hazards by working with an attitude based on good sense.
Inspection and
Inspection and service detail Daily Monthly Yearly Remarks
service location
Is the cylinder clean
(especially rod sliding sections)? ○
Appearance Is any oil leaking from line installation sections

or other fixed sections? ○
Is there missing or peeling paint, or rust? ○

Is operation smooth and free of abnormal
noise and any other abnormality? ○
Is the responsiveness good? ○

Is any oil leaking from sliding sections? ○
Operation
Are there internal leaks? ○
Is the operating pressure normal? ○
Is the overload relief valve set pressure nor-
mal? ○
Is hydraulic oil dirty or deteriorated? ○

Hydraulic oil Is hydraulic oil replaced periodically? ○
Are filters inspected periodically? ○
Is the supply of grease to pins adequate? ○
Do pin sections have any abnormal noises or
seizing? ○
Section for instal-
lation with main Do pin sections have any backlash or wear? ○
unit Are pin seals normal? ○
Are any installation screws loose or fallen out? ○
Retighten installation screws. ○
Are sliding sections worn? ○
Are sliding sections scratched or dented? ○ When leaving piston
rod sliding sections
Piston rod sec- Is sliding section plating peeling off? ○ exposed for long peri-
tion
Are sliding sections bent? ○ ods, apply anti-rust oil
to the piston rod.
Are there any welding section cracks or dam-
age? ○
Are there any loose bolts or nuts (threaded

parts)? ○
Cylinder tube Retighten threaded installation parts (bolts

and nuts (threaded parts)). ○
section (including
line sections) Are there any welding section cracks or dam-
age? ○
Are there large dents on the tube? ○
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5. Trouble diagnostics
Hydraulic cylinder trouble, countermeasure and solution
It is not easy to discover trouble locations. The table below shows general symptoms, suggested
causes and also solutions.
For repairs, see the suggested causes and solutions in the table.
The cause of machine problems are often not rooted in just a single part. Problems are often due to
the relationship of one part with another. In some cases, solutions are required other than those
given in the table. In such a case, contact with our company to investigate the problem and its cause
further and take appropriate measures.
Item Symptom
Piston rod sliding section oil leak (For determining the values, see "7. (4)
1
Inspection after assembly".)
2 Cylinder head matching section oil leak
3 Pipe and cylinder tube welding section oil leak
4 Operation defect
Item Symptom Related part Symptom Countermeasure and solution

① Remove the scratches with a whetstone to make the
sliding surface smooth (1.5 s or lower). If the oil leak
A sliding surface has continues, the rod scratches may have damaged the
rust and scratches U-ring or other seal, so disassemble and inspect.
that catch on a fin- ② If the scratches or rust cover too large an area to be
Piston rod gernail. repaired with a whetstone, replace the piston rod and
the U-ring, wiper ring, or other seal and the piston
rod bearing part.
① Replate or replace the piston rod.
Plating is peeling off. ② At this time, inspect the seals and piston rod bearing
part as well and replace any that are damaged.
There is foreign mat-
ter caught in the ① Remove the foreign matter.
inner or outer diam- ② If the packing is damaged, replace it.
eter section.
There are scratches
on the inner or outer Replace the part.
Piston rod diameter section.
sliding
1 ① This may be scorching due to adiabatic compression
section oil The lips and groove
leak of air remaining in the cylinder.
section are locally
carbonized ② When operating the cylinder for the first time after
(scorched). replacing a packing, run at low pressure and low
speed to adequately bleed off the air.
Rod packing
(Buffer ring The packing has lost ① Replace the part.
and U-ring) its rubber elasticity ② This may be the end of the packing service life, dete-
and is in tatters. rioration of the hydraulic oil, or high temperature of
the hydraulic oil.
The lip section is a. Replace the hydraulic oil.
defective all the way b. Check the temperature of the hydraulic oil. (The
around. oil temperature should be no higher than 80 ℃ .)
c. Check for local high temperature.
① Replace the part.
There is major extru- ② Abnormally high pressure may be operating on the
sion of the packing packing.
heel section. a. Check the pressure during operation.
b. There may be trouble with the buffer ring section.
Inspect the buffer ring section.
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① As a rule, replace the rod packing too at the same
time.
The part is greatly
Backup ring
deformed. ② Abnormally high pressure is often the cause. The
check items for this are the same as those given
above for packing heel section extrusion.
There is foreign mat-
Remove the foreign matter.
ter caught in the lip.
Wiper ring The lip is damaged.
There is other Replace the part.
abnormal damage.
Piston rod
sliding There is major wear
1 of the bushing and
section oil
leak the gap with the pis-
ton rod exceeds the Replace the part.
Bearing part limit on inner diame-
(bushing) ter wear in "7. (9)
Usage limits".
There are large ① Replace the part.
scratches on a slid- ② Inspect the piston rod sliding surfaces for scratches
ing surface. and rust.
A seal mounting ① Remove the scratches or rust with a whetstone.
Cylinder head section has ② If the repair does not solve the problem, replace the
scratches and rust. cylinder head.
① Remove the foreign matter.
② If the O-ring is damaged, replace it.
③ Tube interior surface inspection: If there are any
There is foreign mat- scratches or rust, use a whetstone to make the sur-
ter caught in the face smooth.
O-ring inner or outer diam-
eter. There is dam- ④ Cylinder head O-ring groove inspection: Same as
age to the O-ring. above
⑤ Backup ring inspection: If the backup ring is
deformed or extruded, replace it.
Check the above and replace the O-ring.
The part is
Backup ring deformed or Replace the backup ring together with the O-ring.
Cylinder extruded.
head
2 matching ① Disassemble the cylinder head and inspect the O-
section oil ring and backup ring. If there is damage, replace.
leak ② Check the tube and cylinder head threads for dam-
Cylinder
A part is loose. age and if there is any damage, replace.
head
③ When the inspection is complete, tighten to the spec-
ified torque. See "7. (7) Assembly procedures.
④ Stop rotation.
There is looseness,
Bolt stretching or break- Replace all the bolts and tighten to the specified torque.
age.
① Replace with a new one.
There is abnormal ② Oil leaks at matching sections may be caused by
Cylinder tube abnormally high pressure (including cushion pres-
swelling.
sure), so if the tube is swollen or deformed, replace it
with a new one. Also inspect the circuit pressure.
Replace with a new one.
Pipe and
cylinder Caution (See page 356.)
tube weld- Pipe and cyl- There are cracks on
3 The crack progresses and ultimately the part fractures.
ing sec- inder tube the welding section.
tion oil A fracture is extremely dangerous, so if a crack is seen,
leak quickly stop work and replace that part.
Welding over a crack is ineffective.
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Oil leak Line fastening bolt is Tighten to the specified torque according to the work
from cylin- loose. procedure.
der line Pipe assem- The line is bent. Replace with a new one.
3
connec- bly There are scratches
tion sec- ① Use a whetstone to make the surface smooth.
on a contact sur-
tion face. ② If the oil leak does not stop, replace.
The bending is large and
exceeds the stipulated ① Replace with a new one.
Piston rod bend warp. ② There may also be damage to seals and sliding
Cylinder tube (Bend warp: See "7. (3) parts, so inspect them. If there is any abnormality,
Operation Maintenance stan- replace.
defect dards".)
Move- Replace with a new one. Inspect the seal and sliding
Cylinder tube There are dents.
ment is not parts the same as above.
smooth.
Abnormal wear of sliding ① Replace with a new one.
Piston rod parts and damaged pis- Inspect the seal and sliding parts the same as above.
Cylinder tube ton section or foreign
Sliding part matter caught at the cylin- ② Remove the foreign matter.
der head sliding section Inspect the seal and sliding parts the same as above.
There are scratches,
Internal oil Replace with a new one.
Piston seal wear, or other dam-
leak Also inspect the cylinder tube interior surfaces.
age.
The piston
rod extends ① Use honing or a whetstone to eliminate the scratches and rust and
There are scratches
and retracts Cylinder tube make the surface smooth. If the scratches cover too large an area
and rust on interior
on its own to be repaired, replace the cylinder tube with a new one.
surface.
and drops ② Replace with a new piston seal.
abnormally ① Tighten to the specified torque. See "7. (7) Assembly proce-
during opera- dures".
tion. Tightening is insuffi-
Piston nut
cient. ② The piston rod thread section could be stretched. Measure the
Also, the stip- diameter where the rod and piston fit together and if this area is
ulated speed tapered, replace the piston rod assembly.
is not output.
Valves Leak from valve. Inspect the amount of valve leakage and service.
4 Bleed out the air.
a. Cylinder with no air bleeding
Bleed out the air by moving the cylinder back and forth at
few times at low pressure and low speed.
b. Cylinder with air bleeding (air breather)
Operation
There is air remain- After securing the machine so that the cylinder does not
is Air
ing in the cylinder. move, bleed the air from the air breather.
unsteady.
[Tip]
The cylinder extends or retracts somewhat when the cylin-
der stops suddenly. This phenomenon occurs due to the
compressibility of the hydraulic oil. This occurs particularly
easily for cylinders with long strokes.
The impact is
high when The gap between
switching Pin bushing the installation sec- Measure the pin and pin bushing dimensions and
over between Pin tion and the pin replace any part that exceeds its stipulated dimension.
extension bushing is enlarged.
and retrac-
tion.
Cylinder slid- The oil or grease
Apply oil or grease.
ing opera- Pin bushing feed is inadequate.
tions make Pin There is seizing at
sounds. Replace with a new part and apply oil or grease.
matching section.
Caution
The hydraulic oil expands and contracts with changes in temperature and pressure.
This causes the cylinder to extend and retract too, so it can be mistaken for an internal oil leak.
For internal oil leaks, always check the temperature and pressure under the same conditions.
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6. Storage standards
When a hydraulic cylinder is shipped from the plant, every measure is taken, but in order to prevent
trouble during storage and to extend the product service life, pay attention to the following items.
1) Storing parts individually (In principle, store indoors.)
• Store parts off the floor and do not store in any location with high temperature and humidity,
corrosive gas or liquids.
• Before shipment, we operates the cylinder with hydraulic oil to which a fixed quantity of vapor-
izing anti-rust agent has been added (in order to prevent rust within the cylinder), carries out
the pre-shipping inspection, then retracts the piston rod with ultra-dry air (condensation point -
35 ℃ or lower) (in order to prevent condensation due to temperature difference), and then puts
caps on the ports and line joints before shipping the cylinder.
• Any product that has been storage in our product warehouse longer than the standard storage
period is disassembled and inspected before being shipped. Therefore, do not store or leave a
cylinder unused with a cap removed or with the remaining oil in the cylinder drained.
Storage for 6 months or longer
Storage for 1 month or longer Storage for 1 year or longer
(3 months for cylinder alone)
Operate the cylinder back and
Clean any dust from the cylin- Since there is a danger of pack-
forth with clear hydraulic oil, and
der, and then apply anti-rust ing deterioration, disassemble,
then pour anti-rust oil into the cyl-
① oil to the pin bushings, flange
inder and store in compliance
inspect, and replace packings.
sections, piston rod, and other Also, check for rust inside the cyl-
with the items on the left for stor-
sections that rust easily. inder.
age of 1 month.
If a cylinder that has been stored
If the cylinder cannot be oper- for a long time is used as is, oil
② -
ated, seal in anti-rust oil. may leak due to temporary run-
ning-in defects of seals.
When storing, be extremely careful not to let parts drop, let them collide with anything, or let anything
③ strike them.
2) Mounted on vehicle body

① Operate the cylinder at least once per month
② Retract the cylinder so that as much as possible outside air does not touch the piston rod and apply anti-
rust oil at least once per month to the exposed part of the piston rod.
③ Handle carefully to absolutely avoid scratching the piston rod.
④ When putting the cylinder into an environment where rust occurs particularly easily, for example due to
exposure to sea breezes during export, always apply anti-rust oil to the piston rod and as much as possi-
ble protect with polyethylene sheets or VCI paper (vaporizing anti-rust paper).
⑤ Anti-rust oil and other solvents can have negative impacts on seals, so select anti-rust oil carefully and as
much as possible keep it off dust seals etc. (For details on anti-rust oil to select, see "6.3) Recommended
anti-rust oil".)
3) Recommended anti-rust oil

Vaporizing anti-rust oil
a. Ferro Gard #1009 (from USC Limited)
a. Knuckle Oil #105S (from Parker Industries, Inc.)
For inside cylinder For both a. and b., add 3 - 5 % of the hydraulic oil.
By volume,
Ferro Gard: 5/100
Knuckle Oil: 3/100
For piston rod Anti-rust P-1300 (from the Nippon Oil Corporation)
For machine worked surfaces
other than parts with oil Select from JIS K 2246 (anti-rust oil) NP-1 through NP-6.
sealed in
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7. Assembly and disassembly procedures
(1) Preparations.........repare the following before starting disassembly.
[1] Work platform preparation
Prepare a sufficiently spacious, solid and stable work surface so that parts will not fall or
move during work.
[2] Tool and materials preparation
Prepare the tools and materials shown on the following pages.
(2) General work precautions
[1] Thoroughly clean any dirt or mud from the outside walls of the cylinder before starting disas-
sembly.
[2] Each part has been manufactured with a high degree of precision, so be careful not to let
parts bump each other or fall when handling them.
[3] If parts are struck or pried off with excessive force during work because they are tight, this
may cause burrs or damage which causing reduction in performance or oil leaking. Perform
work carefully and thoroughly.
[4] If a cylinder is left disassembled, humidity and dirt can cause rust on parts. If a pause in the
work is unavoidable, be careful to prevent rust and keep off dust.
(3) Maintenance standards
Replace sliding parts and seal parts as follows.
[1] Bushing .........................When 1/4 of the circumference is worn brown over the entire length
[2] Seals and slide rings .....Replace with new parts when the cylinder is disassembled.
[3] Pin bushing....................When there is severe seizing
[4] Piston rod ......................When the piston rod is bent more than 0.5 mm/1 m
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(4) Inspection after assembly
Dimension
Check the fully retracted length and stroke as instructed on the diagram.
inspection
Pressure with- Check for looseness, permanent deformation, and external leaks when the test pres-
stand inspection sure instructed on the diagram is applied to each stroke end for at least 3 min.
Check the amount of oil leak at the rod section.
・ Judgment value for rod section oil leak
Move the piston rod back and forth 20 times with the oil at a temperature from 20 ℃
to 40 ℃ , and then judge by the state of the oil ring formed on the rod surface. If the
oil ring is in a broken down A state, this is judged to be trouble.¢5.See "Trouble
diagnostics" for information on how to solve this.
External leak
inspection
Oil leak unit: ml/10 min. (For judgment, see the following page.)
Inner diam- Oil leak Inner diam- Oil leak Inner diam- Oil leak
eter mm amount eter mm amount eter mm amount
32 0.4 160 10.0
Internal leak
inspection 40 0.6 100 4.0 180 12.6
50 1.0 125 5.6 200 15.6
63 1.6 140 6.0 220 20.0
80 2.3 250 22.0
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(5) Required tools
1) General tools
No. Tool name Q'ty
1 Screwdriver (flathead screwdriver) 1
2 Hexagon wrench 1 set
3 Vise 1
4 Wrench (for piston nuts) 1 set
5 Punch 1
6 Torque wrench 1 set
7 Hammer (plastic hammer) 1
8 Monkey wrench 1
9 Scoop 1 set
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2) Special jig
Cylinder assembly requires the following special jigs.
Jig name Sketch
For bushing removal and

press fitting
For wiper ring press fitting
Seal ring insertion jig
Seal ring calibration jig
For cylinder head insertion
For piston insertion
Consult with our company about jigs.

(The following page has a list of jig part numbers.)
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3) Special jigs part number list
[1] Select jigs for the cylinder head according to the rod diameter.
[2] Select jigs for the piston according to the cylinder bore.
Applicable rod diameter Set part No.

65 3006J-56001
70 3007J-06001
75 3007J-56001
80 3,008J-06001
85 3008J-56001
Cylinder head
assembly and disas- 90 3,009J-06001
sembly jig
95 3009J-56001
100 3,010J-06001
105 3010J-56001
110 3,011J-06001
115 3011J-56001
120 3012J-06001
Applicable cylinder bore Set part No.
95 3009J-51001
100 3010J-01001
105 3010J-51001
110 3011J-01001
115 3011J-51001
120 3012J-01001
Seal ring insertion
125 3012J-51001
and calibration jig
130 3013J-01001
135 3013J-51001
140 3014J-01001
145 3014J-51001
150 3015J-01001
160 3016J-01001
170 3017J-01001
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(6) Disassembly procedures
1) Drain the oil.
2) Secure the cylinder.
Secure the cylinder in a vertical or horizontal
position. A vertical position makes assembly
and disassembly easier. Secure the cylinder
using the bottom pin hole and stop rotation
and secure the direction of the axis.
(When securing the cylinder, if a line or the
like interferes, remove it.)
3) Removal of cylinder head
Use a hexagon wrench to loosen the cylinder
head tightening bolts and remove them.
Passing a pipe through the hexagon wrench
as in the diagram below makes the work eas-
ier.
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4) Pull out the piston rod.
[1] Check that the line caps are removed.
[2] Put the oil pan at the retraction side (cylinder head side) port.
[3] With the piston rod pulled out all the way, slowly pull out the cylinder head and remove it.
[4] Pull out the piston rod together with the cylinder head and place them on crossties.
・ When assembling and disassembling with the cylinder

secured vertically, work paying particular attention to the fol-
lowing points.
In the work of removing the piston rod, the cylinder head may
come out of the cylinder tube ahead of the piston due to fric-
Caution tion with the packing, creating a condition in which there is
space between the cylinder head and the piston.
If the work is done in that state, the cylinder head may sud-
denly slip out and injure the operator. Always work with the
cylinder head touching the piston.
Working in the vertical state
・ When assembling and disassembling with

the cylinder secured horizontally, work pay-
ing particular attention to the following
points.
In the work of removing the piston rod,
Caution there is a danger of the piston rod falling
and damaging parts right after it is
removed.
Work carefully while holding the rod hori-
zontal and in contact with the crossties.
5) Secure the piston rod.

Use the rod head bolt width or pin hole to set
up a rotation stopper.
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Attachments
6) Remove the piston nut.
[1] Remove the locking screw (3).
Locking screw is caulked in with a punch at
2 locations on the outer circumference.
Cut away the caulked sections with a hand
drill (1), and then loosen the locking screw.
[2] Remove the steel ball (2) at the bottom of
the locking screw (3).
[3] Remove the piston nut.

• The piston nut is tightened with the torque
specified in the assembly diagram.
• Loosening a piston nut requires about 1.5
times that torque. Prepare the power
wrench (6) that uses the hydraulic jack (4)
and hydraulic cylinder (5).
* For a one-piece type piston and nut,
apply the wrench to the hexagonal sec-
tion of the piston and loosen the piston
directly.
7) Removal of piston etc.

Remove the piston (9), cushion ring (8), and cylinder head (7) in that order.
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Attachments
8) Retraction side cushion ring disassembly
[1] Remove the piston nut. Disassembly cannot be done with the nut attached.
[2] Remove the snap ring (12). Remove by gently tapping with a plastic hammer in such a way
as to not scratch the piston rod (11) or cushion ring (14).
[3] When the cushion ring (14) is slid to the piston rod thread (11) side, the stopper (split in two)
(15) can be removed.
[4] Remove the cushion ring (14).
[5] The cushion seal (13) has a split opening, so spread the opening wide and remove the cush-
ion seal.
9) Remove the piston seal.

[1] The slide rings (22) and backup ring (20)
can be removed easily by hand.
[2] Stand up a flathead screwdriver (23) as in
the diagram on the right and tap with a
hammer to cut through the seal ring (16),
and then remove the seal ring.
[3] Pull out the O-ring (19) with a scoop.
* The removed seal parts cannot be
reused.
10 Screw
17 Piston
18 Vise
21 Hardwood
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Attachments
10)Disassembly of buffer ring
[1] The buffer ring (27) is mounted in the
groove on the inner diameter of the cylinder
head. When removing this seal, stick in a
sharp tool and lift it up, and then insert a
scoop and take it out.
* The removed seal parts cannot be
reused.
11)Disassembly of U-ring and wiper ring

[1] Use a screwdriver to remove the U-ring (26) and backup ring (25).
[2] The wiper ring (24) is press fit.
Stick a screwdriver straight down into the rubber and tap it to remove the wiper ring.
* The removed seal parts cannot be reused.
12)Removal of O-ring and backup ring
[1] Pull out the O-ring (29) and backup ring
(30) with a scoop.
13)Disassembly of bushing
[1] Raise the snap ring (28) with a screwdriver,
and then remove it from the cylinder head.
[2] For the bushing (33), use the bushing
removal jig (32) as in the diagram on the
right and press out the bushing with a
press.
31 Bushing
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Attachments
14)Removal of pin bushing
[1] Remove the wiper ring (24) from the tube
and piston rod. Remove it by using a
screwdriver in the same manner as for the
cylinder head.
[2] Use the metal block (35) to remove the pin
bushing (37).
34 Press
36 Jig
15)Cleaning and storage

Clean the removed parts with white kerosene, and then apply hydraulic oil, cover the parts, and
store them.
If they are left disassembled, there is a danger of their collecting rust and dust and not being
able to function adequately after they are assembled again.
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Attachments
If a part with peeling paint is assembled, the peeled off paint can get inside the cylinder.
Caution This causes oil leaks, so work being very careful to prevent this.
1) Installation of pin bushing

[1] Use the installation jig to press fit onto the piston rod (4) and into the tube.
(Apply hydraulic oil in advance.)
[2] Use the metal block (5) to install the wiper ring (6).
2) Replacement of seal
[1] When reassembling the cylinder, replace
all the seals.
[2] O-rings
• Clean the mounting groove well, and then
mount the backup ring (7) and O-ring (8).
Foreign matter in the grove section would
cause an oil leak.
• Be careful about the location of the backup
ring.
• Apply grease or hydraulic oil to the backup
ring and O-ring so that they slide easily,
and then assemble them. If they are sliding 1 Press
poorly, O-ring may become twisted during 2 Installation jig
assembly, which causes oil leaks. 3 Pin bushing
9 Cylinder head
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Attachments
3) Assembly of cylinder head assembly
[1] Use the bushing press fit jig (10) to press fit the bushing (11).
Apply hydraulic oil to the inside surface of the cylinder head in advance and after press fit-
ting, check that there is no level difference at the bushing.
[2] Use the wiper ring press fit jig (15) to press fit the wiper ring (16).
[3] Mount the backup ring (18) and U-ring (19) in the U-ring groove (17) in that order.
• Check the assembly direction of the U-ring and mount it carefully so as not to scratch it.
Installing backwards can cause an oil leak.
• After mounting, check that there are no wrinkles or other permanent deformation remaining
in the U-ring.
[4] Mount the buffer ring (20).

Be careful with the attachment directions of the seals.
If the seal is attached backwards, extraordinarily high pressure will be generated between
the seal and the U-ring (19), causing deformation and breakage of the cylinder.
[5] Assemble the bushing retainer snap ring (21).
12 Cylinder head
13 Pressing base
14 Press
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Attachments
4) Assembly of piston assembly
[1] Attach the seal ring (24).
• Attach the back-up ring (23) for one side
and the O-ring (25) on the piston (26) in
advance, place on the press platform, and
use the seal ring insertion jig (22) as in the
diagram to assemble the seal ring.
[2] Correct the seal ring.
• Mount the seal ring (24) and the other
backup ring (23), and then immediately
correct with the seal ring calibration jig (27)
so that the seal ring does not remain
expanded. (Strictly observe this instruc-
tion.)
Since the seal ring is stretched when it is
mounted, if it is not calibrated, "6) Insertion
of piston rod into the tube" is not possible.
[3] Assemble the slide ring.
• Spread the cut section of the slide ring the
minimum with both hands and install from
the axial direction.
If it is spread too wide, it cannot be
mounted.
* Consult with our company about jigs.
5) Assembly of piston rod assembly
[1] Secure the piston rod (31).
[2] Assemble the cylinder head (32) on the pis-
ton rod (31).
Be careful that the wiper ring and U-ring
lips do not catch on the stepped section.
Use the cylinder head insertion jig (30) as
in the diagram on the right to assemble the
cylinder head on the piston rod.
• Apply grease or oil and assemble being
careful not to scratch the packing.
28 Metal block
29 Press
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Attachments
[3] If there is a cushion on the extension side,
assemble the cushion ring (33) and cush-
ion seal (34) with the following procedure.
1) Insert into the groove with the side of the
cushion seal with the slit (*2) facing the
piston side.
2) Assemble with the part of the cushion
ring processed to be flat facing as in the
diagram.
[4] When there is a cushion on the retraction

side
Assemble the cushion ring (39) and cush-
ion seal (38) with the following procedure.
1) Assemble the cushion ring before assem-
bling the piston nut.
The cushion ring cannot be assembled
with the piston nut attached.
2) Mount in the groove with the side of the
cushion seal with the slit (*4) facing the
thread side.
3) Assemble with the part of the cushion
ring processed to be flat facing as in the
diagram below.
4) Insert the stopper (40) into the groove.
Press the cushion ring (39) all the way to *1 Flat surface processing
the stopper and strike in the snap ring *3 Face the slit to the thread side.
(37). Strike gently with a plastic hammer 35 Piston
in such a way as to not scratch the piston 36 Screw
rod (4) or cushion ring.
Make sure that the cushion seal and cushion ring face the correct direction.
If they are installed backwards, the cushion will not be effective.
Caution After installing the cushions, check that the extension and retraction cushion rings move up and
down and left and right.
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Attachments
[5] Tighten the piston nut.
• Always tighten the piston nut to the specified torque given on the assembly diagram.
• If the tightening torque is insufficient, this causes internal leaks, nut looseness, and thread
cutting
• Also, if the tightening torque is excessive, extension side cushion ring swelling and piston
contact surface deformation occur.
• In order to tighten correctly, clean and degrease the piston and nut and piston rod thread
section adequately (with paint thinner) before tightening the nut.
[6] Stop the piston from turning.
• After tightening the piston nut, put in the
steel ball (43), tighten the locking screw
(42) to the specified torque given on the
assembly diagram, and then caulk (41) with
the punch (44) at 2 locations on the outer
circumference.
6) Insertion of piston rod into the tube

[1] Secure the tube (47) vertically or horizon-
tally.
[2] Insert the piston rod (4) into the tube (47).
• If the tube is secured vertically, the piston
rod enters the tube due to its own weight.
• When the piston section is entering the
tube, be careful that the slide rings (46) do
not fall out.
45 Jig (nylon pipe (split in two))

Slide ring (Shift the abutment phase
46
180°rom one ring to the next.)
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Attachments
7) Cylinder head tightening
Align the cylinder head with the position on the assembly diagram, and then tighten the bolts to
the specified torque given on the assembly diagram in the order shown in the diagram below.
Bolt tightening order
8) Installation of line
[1] Check that the O-ring is in the groove correctly.
[2] Tighten the port section bolts to the specified torque given on the assembly diagram.
[3] Tighten the line bands to the torque on the assembly diagram, the same on both sides, so
that no abutment gap occurs.
*5 Tighten the bolts. *8 Normal: OK

*6 Be careful about the O-rings. *9 There is a gap: Not OK
*7 No abutment opening gap *10 Band for securing the line
When installing the cylinder lines and the machine body rubber hoses, nipples, etc., assemble
Caution securing the cylinder line port section with a wrench. If one tightens without securing the port
section, the line may bend, oil may leak, and the machine body may get in the way.
(8) Test operation

[1] In order to fill the inside of the cylinder with oil, after it is installed on the machine body, move
the cylinder through its full stroke slowly 8 times or more. If the cylinder is suddenly moved
from the start, the hydraulic oil may be aerated.
[2] If the cylinder has air bleeding, pressurize so that the air bleed side is the pressure side
(return oil side) and bleed off the air.
[3] Apply oil and grease to the pins at both ends.
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Attachments
(9) Usage limits
Below are the usage limits for the main sliding sections. Use them for reference for maintenance.
• Piston rod outer diameter wear limit
Nominal diameter Minimum outer diameter
Solution
(mm) (mm)
65 - 80 -0.023 Replace or replate.
85 - 120 -0.027 Replace or replate.
• Rod bushing inner diameter wear limit

Nominal diameter Standard inner diameter Maximum inner diameter
Solution
(mm) (mm) (mm)
55 - 75 +0.060 - +0.190 +0.30 Replace the bushing.
80 - 120 +0.060 - +0.195 +0.30 Replace the bushing.
• Piston slide ring thickness wear limit

Nominal diameter
Standard thickness (mm) Minimum thickness (mm) Solution
(mm)
95 - 160 t 2.42 - 2.48 t 2.37 Replace the slide ring.
165 - 250 t 2.92 - 2.98 t 2.87 Replace the slide ring.
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Lights
Lights
Removal and Installation of Boom Light
Items to prepare
• Wrench (19 mm)
• Rag
• Cleaning fluid

spring washer (3), and washer (4), and then
remove the boom light (5).
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Lights
Removal and Installation of Tool Box Light
Items to prepare
• Wrench (13 mm)
• Rag
• Cleaning fluid
[1] Open the tool box (1).

and then remove the tool box light (4).
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Removal and Installation of Cab Assembly
Items to prepare
• Box wrenches (10 mm, 13 mm, 19 mm)
• Eyebolt (M24) × 4
• Chains (wire ropes) (with the required breaking load)
• Lubricating oil
• Rag
• Cleaning fluid
1. Removal of cab assembly
[1] Remove the operator's seat.
Operator's Seat".)
bolts (1) and a box wrench (13 mm) to remove
the 2 bolts (2), and then remove the rear cover
(3).

bolts (4), and then remove the air conditioner
ducts on both sides (5).
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[4] Remove the air conditioner ducts (6) and (7) by
pulling them forward.

(8), and then remove the brackets (9).
[6] Remove the air conditioner duct (10).
[7] Remove the radio antenna (11).
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for the ground wire (13) connecting the cab and
frame.
[9] Remove the connectors (14) and (15).
[10] Remove the washer fluid hose (16).

(17) each, and then remove the rear brackets
(right and left) (18) and (19).
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[12] Remove the 3 butterfly screws (20), and then
remove the cover (21).
[13] Remove the 2 butterfly screws (22), and then

open the cover (23) of the outside air filter.
[14] Remove the outside air filter (24).

Slide the suction duct connected with the air
conditioner unit in the cab from the duct flange
and remove it.
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[15] Remove the 4 caps (25) from the top of the cab.
[16] Install the 4 eyebolts (M24) (26) in place of the

removed caps.
by a half turn.
[17] Use chains (27) and liftcrane to secure the cab.
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[18] Use a Phillips screwdriver to remove the 3
screws (28), and then remove the cover (29).

(30) from the cab.
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[20] Use chains (32) and liftcrane to remove the cab
(31).

before lowering the cab on wood planks (33).
• Thoroughly secure the cab with the chains and
liftcrane so that it does not fall down.
2. Installation of cab assembly

The tightening torque for the cab assembly installation bolts is 157 N•m.
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Removal and Installation of Operator's Seat
Items to prepare
• Wrench (13 mm)
1. Removal of operator's seat
[1] Pull the slide lever (1) to slide the seat (2) to the
rear.
from the front of the seat.
[3] Pull the slide lever (1) to slide the seat forward,
and then pull the reclining lever (4) to fold the
seatback forward.

from the rear of the seat.
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[5] Remove the operator's seat (6).
2. Installation of operator's seat

The tightening torque for the seat installation bolts is 19.6 N•m.
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Removal and Installation of Wiper
Items to prepare
• Wrench (17 mm)
1. Removal of wiper
and then remove the wiper arm (2).
[2] Use the Phillips screwdriver to remove the

screw (3), and then remove the wiper (4).
2. Installation of wiper
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Removal and Installation of Wiper Controller
Items to prepare
• Wrench (10 mm)
• Flathead screwdriver
1. Removal of wiper controller
installation screws (2) for the side upper trim (1).
[2] Lift the side upper trim (1), remove the connec-
tors (3), and then remove the side upper trim.
Some models have no connector.
[3] Use a box wrench (13 mm) to remove the 2 turn

clips (4) and the 4 bolts (5), and then remove
the side rear cover (6).
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mm) to remove the 4 bolts (7), and then remove
the side rear B trim (8).

(9), and then remove the side lower trim (10).

mm) to remove the 4 bolts (11), and then
remove the side rear A trim (12).
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[7] Remove the connector (14) from the wiper con-
troller (13).
[8] Use a flathead screwdriver to slightly bend the 4

installation clips (15), and then remove the
wiper controller (13).
2. Installation of wiper controller

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Removal and Installation of Wiper Motor
Items to prepare
• Flathead screwdriver (longnose pliers)
1. Removal of wiper motor
(1), and then remove the side lower trim (2).
[2] Use a flathead screwdriver or longnose pliers to

remove the clip pins (3), and then remove ducts
B (4).
[3] Use a Phillips screwdriver or box wrench (10

mm) to remove the 3 bolts (5). Use a hexagon
wrench (4 mm) to remove the 3 bolts (6).
Remove the front upper trim assembly (7).
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[4] Lift the front upper trim assembly (7), and then
remove the connector (8).

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and then remove the wiper arm (13).
[8] Use a wrench (17 mm) to remove the 1 nut (14).

bolts (15) and 2 nuts (16), and then remove the
wiper motor assembly (17).
2. Installation of wiper motor

• Be careful about the wiper link and wiper arm installation location.
• Check the wiper arm wipe location and stop location.
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Removal and Installation of Monitor
Items to prepare
• Wrench (10 mm)
on the monitor (2).
[2] Lift the monitor main unit (2), and then remove
the connector (3) underneath.
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Removal and Installation of Cab Front Glass
Reinforced glass is used for the front window.
Caution Be extremely careful not to damage it when touching it during removal or installation.
Items to prepare
• Wrench (10 mm)
• Rag
• Cleaning fluid
each, and then remove the brackets (2) and (3).
[2] Remove the covers (4) and (5) for the bracket.

(6), and then remove the front glass left lower
bracket (7).
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(8), and then remove the front glass right lower
bracket (9).
[5] Move the front glass right upper bracket (11) to

a position where the wire (10) is not pulled on.
[6] Remove the cab front glass (12).
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Window Lock Adjustment Procedures
Items to prepare
• Wrench (10 mm)
• Rag
• Cleaning fluid

(2).
[3] Set the cab front glass (3) in place.
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[4] Use a wrench (10 mm) to retighten the 3 bolts
(2).
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Accumulator
Warning ・ Be sure to release the hydraulic pressure in the circuits.
Items to prepare
• Wrench (30 mm)
• Rag
• Cleaning fluid
[1] Use a wrench (30 mm) to remove the accumula-

tor (1).
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Suction Filter
・ Be careful to keep dirt, water, sand, and all other foreign matter out of the tank.
Caution ・ When replacing the hydraulic oil, always replace with new oil.
Items to prepare
• Wrench (17 mm)
• Rag
• Cleaning fluid

the tank.

(2), and then remove the feed port cover (3).
[3] Drain the oil from the hydraulic oil tank. (For
details, see "Draining Oil from Hydraulic Oil
Tank".)
[4] Remove the O-ring (4).
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[5] Remove the suction filter (5).
[6] Clean the suction filter (5) with pure cleaning

fluid, dry it well, and then inspect it. If there is
any damage on the surface, replace the suction
filter with a new one.
• If the O-ring on the rear of the cover is worn or
damaged, replace it.
• The installation procedure is the reverse of the
removal procedure.
• Always replace the suction filter with a new one
every 5000 hr. and when replacing the hydraulic
oil.
5 Suction filter
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Return Filter
・ Be careful to keep dirt, water, sand, and all other foreign matter out of the tank.
Caution ・ When replacing the hydraulic oil, always replace with new oil.
Items to prepare
• Wrench (17 mm)
• Rag
• Cleaning fluid

the tank.

• There is a spring inside the cover, so restrain
the spring by hand and remove the cover.
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[3] Remove the O-ring (4).
Take the spring (5) and valve (6) out from the
tank.
[4] Take the return filter (7) out from the tank and
replace it.
• If the O-ring on the rear of the cover is worn or
damaged, replace it.
• The installation procedure is the reverse of the
removal procedure.
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Pilot Filter
Warning ・ Be sure to release the hydraulic pressure in the circuits.
Items to prepare
• Wrench (19 mm)
• Rag
• Cleaning fluid
[1] Use a wrench (19 mm) to remove the pilot filter

(1).
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Other
Other
Removal and Installation of Side Door
Items to prepare
• Wrench (19 mm)
(1), and then remove the side door (left front)
(2).

(1), and then remove the side door (left rear)
(3).

(1), and then remove the side door (right) (4).
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Other
Draining Oil from Hydraulic Oil Tank
Warning ・ The temperature of the hydraulic oil is high immediately after stopping the engine. Wait until
the hydraulic oil temperature has decreased (to 40 ℃ or less) before beginning work.
Items to prepare
• Feed pump (power source for feed pump)
• Extension cable
• Waste oil tank
• Waste oil can
• Rag
• Cleaning fluid
hydraulic oil tank to bleed off the pressure in the
tank.

(2), and then remove the feed port cover (3).
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Other
[3] Insert the feed pump (4) into the feed port.
[4] Transfer the oil inside the hydraulic oil tank to

the waste oil tank (5).

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Other
[6] Prepare a waste oil can (8) under the hydraulic
oil tank.
[7] Use a wrench (36 mm) to remove the drain plug

(9).
[8] Drain any remaining oil that has settled at the

bottom of the hydraulic oil tank.
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NOTES
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Copyright ©
26 25 28 83
Notes:
27
21 1) ON MARK , UPPER VALUES SHOW THE CONNECTIVE POINTS AND
L2 LOWER VALUES SHOW THE ZONE NUMBER OF THIS DRAWING.

L1
2) Parts marked , , , , , , , and are optional.
B45 : Single Acting Circuit

30 29 29
: Multi_Purpose + 3 Way Valve
: HBCV
: Second W_Acting Circuit
D1 W4 : 1 Pedal Travel (North America)
83 : Double Acting Circuit (North America)
: Single Acting Circuit (North America)
: Multi_Purpose + 3 Way Valve (North America)
23 23
J I K1 B2
16 21 B1 xx For components description see section 8020
K2 72 132
CX350B - CX370B EXCAVATOR

22
Y27
HYDRAULIC SCHEMATIC
Y9
83
85
Y26 P 73
B25
134
45 O
Y25 15
R
N1
44 42
2 S71
N2
31 D
43 32
C
1 E
5
B
133
4 6
F
Y2 141
83 75 Y4
90 132 Y24 Y9
76 Y23
G
Y23 Y24 Y27 Y9
Y5
Y6 140 60
108 51
139 82
W4 Y3
A
B44 86
B42
58 B27 B26 10
B43 B40
71
55 Y7
62
54 85 85
53
59
57 85
85
H
85 85 B85
B28
63
B22

HYDRAULIC SCHEMATIC
Number KSJ12480-E01 EN
Copyright ©
F34 F1 F2
B81 G2
K2 K34 K10 K11 K32 K9 B81 H2

X3 K33
F6 F4 F3 F5
M1
A4 M4
E3
S54 R1 M15
K7
A1
E3 S55
G1
K35 K36 K37 K38 K39 K5 K51
B53
M20 K8
X15
M3
B52
M9
S62
P1 Y2 B50
P5 P9
W1 X2
X8 Y3 B49
R3
Y4
K30 K31 B21
H1
P4 Y5
S61
S53 S1
B61 B47
P10 S11 Y6
S12
S10
S2
S4
S70 E51
P3 B1
S16
Y18 B82
E4 B51
E2
S14 M14
S35
E1 B3
Y35
S71
Y7
X6 S6
R5
Y11
B2
B42
U1
Y27
Y9
B44
S28 S13 S22

Y23
B43
Y24
B6
P2
S15
S9 B43 Y25
NOTES
S69
1) THE MARKS ARE INDICATED AS BELOW IN THIS DRAWING.
Y26
S33 : OPTION PARTS
: FOR LBX
B22 : FOR CASE NORD AMERICA
S34 : FOR CASE EUROPA
S51
E52 2) EARTH LINE SYMBOLS AND CROSS POINT OF LINES IN THIS DRAWING
SHOWS THE FOLLOWING.
Y27 CONNECTED NOT CONNECTED

M7 B26 EACH OTHER
EACH OTHER
X9 Y9
B5 BODY EARTH EARTH WITH CABLE
K6
X5 B27
B23 SINGLE WIRE CONNECTOR HARNESS
M6 C
B48 K17 3) THE SYMBOL AT EACH LINE SHOWS COLOR OF CABLE.
B28
K17 R4 THE FIGURE BEFORE THE SYMBOL SHOWS THE AREA OF CABLE.
THE AREA OF CABLE NOT INDICATED IS 0,5 mm²
X24 THE FIGURE AFTER THE SYMBOL SHOWS CIRCUIT N°.
M8 M5 B45 60 B 001
AREA CIRCUIT NUMBER

COLOR
4) THE SYMBOL OF CONNECTOR IN THIS DRAWING SHOS THE FOLLOWING:

X23 P6 A9
A6
CONNECTOR (MALE) CONNECTOR (FEMALE)
XX For components description see section 4020 CONNECTOR' S NAME

YAZAKI
SWP CONNECTOR. No
(CN. xx)
S52
X4
Y8 CX350B-CX370B EXCAVATOR
ELECTRICAL SCHEMATIC
A2
Pub. Number KSR11440-E02 EN
Copyright ©
26 25 28 83
Notes:
27
21 1) ON MARK , UPPER VALUES SHOW THE CONNECTIVE POINTS AND
L2 LOWER VALUES SHOW THE ZONE NUMBER OF THIS DRAWING.

L1
2) Parts marked , , , , , , , and are optional.
B45 : Single Acting Circuit

30 29 29
: Multi_Purpose + 3 Way Valve
: HBCV
D1 W4 : 1 Pedal Travel (North America)
83 : Double Acting Circuit (North America)
: Single Acting Circuit (North America)
: Multi_Purpose + 3 Way Valve (North America)
23 23
J I K1 B2
16 21 B1 xx For components description see section 8020
K2 72 132

22
Y27
HYDRAULIC SCHEMATIC
Y9
83
85
Y26 P 73
B25
134
45 O
Y25 15
R
N1
44 42
2 S71
N2
31 D
43 32
C
1 E
5
B
133
4 6
F
Y2 141
83 75 Y4
90 132 Y24 Y9
76 Y23
G
Y23 Y24 Y27 Y9
Y5
Y6 140 60
108 51
139 82
W4 Y3
A
B44 86
B42
58 B27 B26 10
B43 B40
71
55 Y7
62
54 85 85
53
59
57 85
85
H
85 85 B85
B28
63
B22

HYDRAULIC SCHEMATIC
Number KSJ12480-E01 EN
Copyright ©
F34 F1 F2
B81 G2
K2 K34 K10 K11 K32 K9 B81 H2

X3 K33
F6 F4 F3 F5
M1
A4 M4
E3
S54 R1 M15
K7
A1
E3 S55
G1
K35 K36 K37 K38 K39 K5 K51
B53
M20 K8
X15
M3
B52
M9
S62
P1 Y2 B50
P5 P9
W1 X2
X8 Y3 B49
R3
Y4
K30 K31 B21
H1
P4 Y5
S61
S53 S1
B61 B47
P10 S11 Y6
S12
S10
S2
S4
S70 E51
P3 B1
S16
Y18 B82
E4 B51
E2
S14 M14
S35
E1 B3
Y35
S71
Y7
X6 S6
R5
Y11
B2
B42
U1
Y27
Y9
B44
S28 S13 S22

Y23
B43
Y24
B6
P2
S15
S9 B43 Y25
NOTES
S69
1) THE MARKS ARE INDICATED AS BELOW IN THIS DRAWING.
Y26
S33 : OPTION PARTS
: FOR LBX
B22 : FOR CASE NORD AMERICA
S34 : FOR CASE EUROPA
S51
E52 2) EARTH LINE SYMBOLS AND CROSS POINT OF LINES IN THIS DRAWING
SHOWS THE FOLLOWING.
Y27 CONNECTED NOT CONNECTED

M7 B26 EACH OTHER
EACH OTHER
X9 Y9
B5 BODY EARTH EARTH WITH CABLE
K6
X5 B27
B23 SINGLE WIRE CONNECTOR HARNESS
M6 C
B48 K17 3) THE SYMBOL AT EACH LINE SHOWS COLOR OF CABLE.
B28
K17 R4 THE FIGURE BEFORE THE SYMBOL SHOWS THE AREA OF CABLE.
THE AREA OF CABLE NOT INDICATED IS 0,5 mm²
X24 THE FIGURE AFTER THE SYMBOL SHOWS CIRCUIT N°.
M8 M5 B45 60 B 001
AREA CIRCUIT NUMBER

COLOR
4) THE SYMBOL OF CONNECTOR IN THIS DRAWING SHOS THE FOLLOWING:

X23 P6 A9
A6
CONNECTOR (MALE) CONNECTOR (FEMALE)
XX For components description see section 4020 CONNECTOR' S NAME

YAZAKI
SWP CONNECTOR. No
(CN. xx)
S52
X4
Y8 CX350B-CX370B EXCAVATOR
ELECTRICAL SCHEMATIC
A2
Pub. Number KSR11440-E02 EN

Manual de Excavadores Case Cx350b y Otros, Hidráulico

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Copyright ©

Copyright © 2008 CNH France S.A.

Lep SMCX350B370BTOC-0EN Issued 07-08

SAFETY, GENERAL INFORMATION

Copyright © 2006 CNH France S.A.

Lep 7-27691EN Issued 02-06

Lep 7-27691EN Issued 02-06

To prevent injury always follow the Warning, Caution

WARNING: If you wear clothing that is too

WARNING: When working in the area of the

WARNING: When doing checks and tests

WARNING: When putting the hydraulic

Lep 7-27691EN Issued 02-06

WARNING: When the battery electrolyte is

WARNING: Use suitable floor (service)

Lep 7-27691EN Issued 02-06

STANDARD TORQUE DATA FOR CAP SCREWS AND NUTS

Lep 7-27691EN Issued 02-06

AND SPECIAL TORQUE SETTINGS

Copyright © 2008 CNH France S.A.

TYPE, SERIAL NUMBER

FLUIDS AND LUBRICANTS ............................................................................................................................................ 4

SPECIAL TORQUE SETTINGS..................................................................................................................................... 20

MACHINE OVERALL DIMENSIONS ............................................................................................................................. 24

Lep SM350B370B1002-0EN Issued 07-08

(1) Type .......................................................................................................................................................................

Serial numbers of the components

Lep SM350B370B1002-0EN Issued 07-08

Transmission component oil

Lep SC350B370B1002-0EN Issued 07-08

Oil viscosity / Oil range

1) With mineral base

Lep SC350B370B1002-0EN Issued 07-08

Applicable Standard Recommendation

JIS (Japanese Industrial Standard) NO.2

DIN (Deutsche Industrie Normen) DIN 51601

SAE (Society of Automotive Engineers)

Based on SAE-J-313C NO. 2-D

Based on BS/2869-197 Class A-1

Lep SC350B370B1002-0EN Issued 07-08

Lep SC350B370B1002-0EN Issued 07-08

Plastic and resin parts

Lep SC350B370B1002-0EN Issued 07-08

Main body dimensions

Lep SM350B370B1002-0EN Issued 07-08

Capacity of coolant and lubricants

Hydraulic oil filter

Lep SM350B370B1002-0EN Issued 07-08

Horn: electric horn (x2)

Lep SM350B370B1002-0EN Issued 07-08

Lep SM350B370B1002-0EN Issued 07-08

Secondary pressure (MPa)

Lep SM350B370B1002-0EN Issued 07-08

Secondary pressure (MPa)

Travel lower body

Boom 6450 mm (253.93 in)

Lep SM350B370B1002-0EN Issued 07-08

Boom 6450 mm (253.93 in)

Lep SM350B370B1002-0EN Issued 07-08

Lep SM350B370B1002-0EN Issued 07-08

Lep SM350B370B1002-0EN Issued 07-08

Lep SM350B370B1002-0EN Issued 07-08

Lep SM350B370B1002-0EN Issued 07-08